Saeco New Royal HD 8930 User manual

ServiceManual
Revision 01 December 2012
Service
Coee Machine HD 8930
New Royal
Table of contents Page
1. Introduction
1.1. Documentation required 1
1.2. Tools and equipment required 1
1.3. Material 1
1.4. Safety warnings 1
1.5 Service Policy 2
1.6. External machine parts 3
1.6. Internal machine parts 4
2. Technical specications
2.1. Technical specications 1
2.2 Specication for the measurement of the coee
products temperature.
2
2.3. Machine parameters and performance 3
3. User instructions
3.1. Customer and programming menu 1
3.2. Machine indications 3
3.3. Operation, cleaning and maintenance 4
4. Operating logic
4.1. Water circuit 1
4.2. Frother unit valve assembly 2
4.3. Cappuccino maker assembly 2
4.4. Relief valve 3
4.5. Coee cycle 4
4.6. Single microswitch 5
4.7 Temperature sensor 5
Table of contents Page
4.8. Water level detection (water tank) 6
4.9. Descaling request 6
4.10. Water lter 7
5. Troubleshooting
5.1. Test mode 1
5.2. Diagnostics mode 5
5.3 Error messages 7
6. Standard checks
6.1. Repair schedule 1
6.2. Service schedule 1
6.3. Final test 2
7. Disassembly
7.1. Outer elements 1
7.2. Coee grinder 1
7.3. Grinder blades 2
7.4. Coee grinder motor 3
7.5. Doser hatch, coil and microswitch 3
7.6. Doser hopper 3
7.7. Coee boiler and steam boiler 4
7.8. Boiler pin 4
7.9. Coee pump and steam pump 4
7.10. Flow meter 5
All parts of this document are the property of Saeco International Group.
All rights reserved. This document and all the information herein is provided without liability deriving from any errors or omissions. Furthermore, no part may be reproduced,
used or collected, except where express authorization has been provided in writing or through a contractual agreement.
Published by Saeco International Group Subject to modication EN 4219 400 013
2011-July-08
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Extensive Calcium deposits are seen in almost every espresso machine we open for repairs.
"Gamea Revo"
As Good As it Gets
Have questions? E-mail inquiries. [email protected]
Having problems steaming Milk hot?
Use Milk flow restrictor Click Here to order to steam Milk Hotter
Eliminate Milk Carafe. They are expensive and need frequent refilling, intense cleaning
and replacement of damaged or lost rubber connectors. Use of Milk flow restrictor with
15" Silicone tube Order part # 26151-S15
The restrictor is used on frothers that draw milk from a Milk container. Cannot be used
for straight Pannarello frothers.
Filter cartridges are preventative, expensive & ineffective as descaler.
The Brita filter installed on the kitchen faucet works better.
Calcium sediment inside the machine causes the following problems:
(1) reduces internal flow of water with full or partial clogging.
(2) generates back pressure in the Hydraulic system & causes internal leaks.
(3) reduces pump pressure, reduced flow of coffee & internal leakage reduces
programmed coffee in the cup (4) Error codes "Fill water" or Ventilate will display.
This will shut the machine down & force expensive repairs.
Descaling is best done manually, every two or three months.
Order Best descaler (#DSC-6) from our online store for effective & authentic Descaling
Learn about our New FULLY AUTOMATIC espresso maker GAMEA REVO for better tasting &
hot Espresso & steaming of milk at the touch of your finger tip
Return in 30 days for Full refund if not satisfied. Standard 1-year
warranty for labor & electrical parts
Extended 3-year warranty for purchase with one Kg. bag of
espresso Beans every month package.
NEW MACHINE AT AFFORDABLE PRICE EVERY COFFEE
LOVER CAN ENJOY.
Fully automatic home espresso machine with LED display
1- Convenient to operate
2- Easy to Program drinks
3- Easy access to brew group for cleaning
4- Easy to maintain
Trade in for any Jura, Delonghi or Gaggia espresso machine.
YOU WILL BE HAPPY YOU DID.
It is worth it

Table of contents Page
7.11. Gear motor 5
7.12. Relief valve 6
7.13. Solenoid valve assembly 6
7.14. Steam pipe assembly 7
7.15. Dispenser assembly 7
7.16. Power board 7
7.17. Display, keypads and control board 8
7.18. Fitting and removing Oetiker clamps 9
8. Notes
9. Water circuit diagram
10 Electrical diagram
Saeco International Group Rev. 01 NEW ROYAL
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Saeco International Group Rev. 01 NEW ROYAL
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NEW ROYAL 01 INTRODUCTION
Saeco International Group Rev. 01 Page / 04
1.1. Documentation required
The following documentation is needed for repair procedures:
• Instruction booklet for specific model.
• Technical documentation for specific model (diagrams, exploded view, sympton cure and
service manual).
1.2. Tools and equipment required
As well as the standard equipment, the following is required:
Qty. Description Notes
1 Screwdriver Torx T 8 - T 10 - T 20
1 Screwdriver Cross-head
1 Pliers for Oetiker clamps
1 CC -A - Vdc tester
1 Digital thermometer Scale limit > 150°C
1 SSC (Saeco Service Center) Programmer
(for programming and diagnostics mode)
1.3. Material
Description Notes
Thermal paste Heating element > 200°C
Descaler Saeco descaler
Grease solvent Personal choice
Silicone grease Safe to use with food
1.4. Safety warnings
We recommend you consult this Service Manual of the machine before performing any mainte-
nance work.
Observe all applicable standards relating to the repair of electrical appliances.
Always disconnect the power plug from the mains before beginning repair work.
Simply turning off the main machine power switch is not an adequate safety precaution.
This domestic appliance is rated as insulation class I.
On completion of the repair work, insulation and dielectric rigidity tests must be performed.
01
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NEW ROYAL 01 INTRODUCTION
Saeco International Group Rev. 01 Page / 04
02
Components Assembly use Single components available
COFFEE
GRINDER Only for OOW repairs YES, to consult the specific exploded-view of the machine or of the Coffee Grinder on website
BREWING
UNIT Only for OOW repairs YES, to consult the specific exploded-view of the machine or of the Brewing unit on website
BOILER Only for OOW repairs YES, to consult the specific exploded-view of the
machine on website
GEAR
MOTOR Only for OOW repairs YES, to consult the specific exploded-view of the machine on website
FILTER
HOLDER Only for OOW repairs YES, to consult the specific exploded-view of the machine on website
MILK
CARAFE Only for OOW repairs YES, to consult the specific exploded-view of the machine on website
THERMAL
CARAFE Only for OOW repairs YES, to consult the specific exploded-view of the Thermal Carafe on website
MILK ISLAND Only for OOW repairs YES, to consult the specific exploded-view of the
Milk Island on website
List of principal assembly present in all our coffee machines
1.5 Service POLICY grid as used for coffee machine
For IN WARRANTY repairs is mandatory to use the single components (not the assembly) avail-
able in the exploded views of the coffee machines or of the specific components. If you find the
information “SEE THE EXPLODED VIEW E........” in the assembly description field, it means that
the single components of the assembly are available in the other pages of the exploded view. It’s
possible to use the assembly only if there is a specific Symptom Cure that include this possibility
or when the single components are not available for the order.
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NEW ROYAL 01 INTRODUCTION
Saeco International Group Rev. 01 Page / 04
1.6. External machine parts
03
Grille
Water tank
Cappuccino maker (removable)
Coffee bean hopper
Hot water dispensing pipe
Full tray floating indica-
tor
Drip tray
Brewing unit
Pre-ground coffee compart-
ment
Dreg drawer
Service hatch
Cup heater plate
Grinding adjust-
ment
Coffee dose adjustment
MENU OK ESC
Cappuccino maker “Clean” button or used to scroll
through the menu (Page Up )
Special Drinks selection button or used to exit the
menu (ESC)
ON/OFF button
Cappuccino dispensing button or used to scroll through
the menu (Page Down )
Coffee dispensing button or used to con-
firm selection (OK)
Pre-ground coffee button or (MENU) to
access programming mode
Espresso dispensing button
Latte macchiato dis-
pensing button
Power cable connector
Main switch 0/I
IRDA for SW programation
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NEW ROYAL 01 INTRODUCTION
Saeco International Group Rev. 01 Page / 04
1.7. Internal machine parts
04
Coffee grinding assembly
Ground coffee hop-
per
Power board
Control board
Doser assembly
Coffee boiler Gear motor assembly
Relief valve assembly
Steam boiler
Solenoid valve assembly
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NEW ROYAL 02 TECHNICAL SPECIFICATIONS
Saeco International Group Rev. 01 Page / 03
2.1. Technical specifications
Power supply and output: 240 V~ 50 Hz 1500 W - 230 V~ 50/60 Hz 1400 W
Temperature monitoring: (NTC) variable resistor sensor - transmits the value to the
electronic card
Safety system: 2 thermostats at 190°C one shot
Coffee heat exchanger output:
Stainless steel (230 V~) 1300 W for coffee dispensing
Steam heat exchanger output:
Stainless steel (230 V~) 1300 W for water/steam dispensing
Gear motor: 2 rotation directions; power supply 24VC
Coffee pump Ulka Type EP5/S GW approx. 13-15 bar with reciprocating
piston and thermal switch 120°C 48 W, 230V, 50 Hz,
Steam pump Ulka HF with reciprocating piston 230V, 50 Hz and thermal
switch 120°C - 22W
Overpressure valve:
(multi-way valve) Opening at approx. 19-23 bar
Water filter: In tank
Coffee grinder: Direct current motor with conical steel grinder blades
Power consumption: During heating phase- approx. 5.6 A
Consumption in Standby <0.3 W
Dimensions: W x H x D in mm: 336x380x450
Weight: 16 kg
Water tank capacity: 2.2 l
Coffee bean hopper capacity: 320 g. of coffee beans
Dreg drawer capacity: 19 (18+1)
Heat exchanger capacity: Approx. 10 cc
Water circuit filling time: Approx. 50 sec Max. on first filling cycle including rinsing
Heating time: Approx. 25 sec. Max. in stand-by
Grinding time: Approx. 4-7 sec.
01
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NEW ROYAL 02 TECHNICAL SPECIFICATIONS
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02
2.2. Specification for the measurement of the coffee products temperature.
The temperature is influenced by the flow from the dispenser and stratification of temperatures in
the glass. In order to consider these phenomena and to introduce measures that allow compari-
sons in controlled conditions, below guidelines must be followed:
Conditions:
a) Water temperature in tank: 23°C (+/-2°C).
b) It must be used a plastic cup (see picture N°1).
c) It must be used a thermocouple thermometer (e.g. type K - see picture N°2).
d) The coffee machine is tested without any change of parameters or calibrations, which may
affect the temperature of products, so the measurement of temperature must be done with
machine in default factory setting.
Procedure:
1. The temperature must be measured in the cup, immediately after dispensing. Cup has to be
placed on a non-metal surface using a thermocouple thermometer.
2. The temperature in the cup is measured by immersing the probe of the thermometer up to
touch the bottom.The probe then must be moved in a circular motion for 5/6 rotations. At the
of the rotations, stop in the center of the cup.
3. The highest temperature measured during the rotations is the value we are searching for, and
that must be reported;
4. Test measurement: from end of dispensing to the end of rotations must be completed within 12
seconds.
Limits of acceptability
The acceptance limits are divided by features and products and are the following:
Espresso Coffee Italy Q.ty 25/40 gr.
Temperature of 1st product 69°C ≤ 85°C
Temperature of 2nd product 72°C ≤ 85°C
Coffee Q.ty 70/120 gr.
Temperature of 1st product 69°C ≤ 85°C
Temperature of 2nd product 72°C ≤ 85°C
Picture 1 Picture 2
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NEW ROYAL 02 TECHNICAL SPECIFICATIONS
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2.3. Machine parameters and performance
PRODUCT
QUANTITY
Minimum
quantity
(Puls.)
Default
quantity
(Puls.)
Maximum
quantity
(Puls.)
User pro-
grammable
Programm. by
Production / Service
Espresso 90 130 - 170 *200 Yes No
Coffee 100 200 -280*600 Yes No
Long coffee 70 330 - 440 *600 Yes No
American
coffee 300 -600 Yes No
Pre-ground Yes
Hot water Continues for 400 pulses
* Depends on the language selected by the user
RINSE Initial rinse Final rinse
When performed When the machine is
switched on and the boiler
temperature is ≤ 50°C
When the machine is switched off elec-
tronically, manually or automatically after
30', if at least one coffee has been dis-
pensed, before switching off
No. of pulses 130 100
Stopping option Yes, by pressing any key Yes, by pressing any key
User disable option No No
Production/Service de-
partment disable option No No
No. of pulses user ad-
justment option No No
No. of pulses Produc-
tion/Service department
adjustment option
No No
Pulse range
(Min. – Max.) No No
03
Descaling cycle frequency
Hard-
ness Water hardness Without water filter With water filter
1Soft (up to 7°dH) 240 litres (480,000 pulses) 480 litres (960,000 pulses)
2Medium (7° - 14°dH) 120 litres (240,000 pulses) 240 litres (480,000 pulses)
3Hard (15° - 21°dH) 60 litres (120,000 pulses) 120 litres (240,000 pulses)
4Very hard
(over 21°dH) 30 litres (60,000 pulses) 60 litres (120,000 pulses)
The default water hardness level is 4. Each litre of water corresponds to approximately
2,000 pulses.
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NEW ROYAL 02 TECHNICAL SPECIFICATIONS
Saeco International Group Rev. 01 Page / 03
WATER TANK Description
Water reserve (pulses) 200
Water reserve modifiable by Production/Service
departments
No
"Fill tank" alarm Yes
"No tray" alarm No
Water mains No
DREG DRAWER Description and values
Time-out for dreg drawer 5 sec.
Warning to empty dreg drawer after Yes, after 15 lots of dregs
Empty dreg drawer blocking alarm after
(double coffee is the last beverage
dispensed)
18 lots of dregs
(19 lots of dregs)
Reset dreg counter
The dreg drawer must be emptied only
when prompted by the machine ensuring
the machine is switched on and removing
the drawer for more than 5 seconds.
STANDBY Description and values
Inlet time (min. – max.) 15 minutes - 180 minutes
Inlet time (default) 30 minutes
Inlet time programmed by user Yes
Inlet time programmed by Production/
Service
Yes
Boiler temperature during Standby Boiler OFF
Cup heater during Standby Cup heater OFF
04
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NEW ROYAL 03 USER INSTRUCTIONS
Saeco International Group Rev. 01 Page / 04
MENU OK ESC
3.1. Customer and programming menu
01
1
Pre-ground selection button - MENU
This button is used to select the possibility to
dispense the coffee with
pre-ground coffee.
2nd function - Press for 5 seconds to access
the machine programming menu.
2
Espresso dispensing button
3
Coffee button - OK
The button is used to select
the type of coffee dispensing.
2nd function - Press to select the heading
shown on the display.
4
Special Drinks selection button - ESC
The button is used to access the list of special
drinks the machine can dispense.
2nd function - Press to exit the selected
page and/or exit the programming mode and/
or stop the drink dispensing.
4
CLEAN button (washing) - Page UP
The button is used to carry out a cleaning cycle
of the cappuccino maker by dispensing steam
(for more details refer to the specifi
c paragraph).
2nd function - Press to scroll the selection in
the page upwards.
6
Cappuccino dispensing button - Page DOWN
The button is used to select cappuccino dispens-
ing.
2nd function - Press to scroll the selection in
the page downwards.
7
Latte Macchiato dispensing button
8
ON/OFF button
MENU
1 2 3 4 5 6 7 8
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NEW ROYAL 03 USER INSTRUCTIONS
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02
DISPLAY MENU
This function is used to set the menu language and the display brightness
This setting is vital for correctly setting the parameters of the appliance for the user's country
The currently selected language is shown. The language can be changed using the special com-
mands
To set the correct brightness on the display
To set the correct contrast on the display
DISPLAY MENU
BRIGHTNESS
CONTRAST
LANGUAGE
ENGLISH
MACHINE MENU Used to customize the machine's operational settings
ON
OFF
To change the appliance operating settings
This function permits activating/deactivating audible warnings
This function is used to set the time since the last beverage dispensing when the machine will go onto
standby. The default time setting is 30 min.
After the set time the machine will go onto standby.
To reactivate the machine, press any button.
After running function diagnosis and the heating phase, the machine is again ready for use
To enable buzzers
When the machine is switched on all the boilers (coffee/steam) come on to allow the immediate
preparation of all beverages.
When the appliance is switched on, only the coffee boiler is activated. The appliance consumes less
power but takes longer to dispense milk beverages
To disable buzzers
This function governs activation of the boilers in the appliance for energy saving
GENERAL MENU
SOUND
ECOMODE
GENERAL STANDBY
OFF
ON
OFF
ON
15 MINUTES
30 MINUTES
60 MINUTES
180 MINUTES
This function is used to enable/disable the cup heater on the top of the machine
To disable the cup heater
To enable the cup heater
CUP HEATER
WATER MENU
This menu is used to set the parameters for correct water management
To change the setting of the hardness of the water in the appliance, adjusting it to the one used, so it
will request descaling at the right time
To activate the filter after it has been installed or replaced.
To activate/deactivate the water filter replacement warning. When this function is active the appliance
warns the user when the water filter needs to be changed.
OFF: Warning disabled ON: Warning enabled
(this value is set automatically when the filter is activated)
WATER MENU
ACTIV. FILTER
HARDNESS
ENABL. FILTER
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NEW ROYAL 03 USER INSTRUCTIONS
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03
This function is used to run the washing cycle for the Brewing Unit
This function lets you set all the functions so that machine maintenance is managed better
This function is used to run the descaling cycle
This function lets you run the washing cycle for the cappuccino maker used for making beverages
containing milk
MAINTENANCE
DESCALING
UNIT CLEANING
CAPPUCCINO MAKER
CLEANING
MAINTENANCE
FACTORY SETTINGS
This function allows the factory values to be reset.
Restoring the factory parameters deletes all the personal parameters set beforehand.
FACTORY SETTINGS
3.2. Machine indications
Close or correctly position the
coffee bean hopper lid to en-
able dispensing of any bever-
age
An operation has been selected
that requires the dispensing
of milk. Insert the valve in the
cappuccino maker.
Fill the coffee hopper with coffee
beans.
The appliance requires a descaling
cycle.
If this message appears you may
continue to use the machine but the
operations may be compromised. Re-
member that any damage caused due
to lack of de-scaling is not covered by
the warranty.
The machine requires replacement of
the "Intenza" water filter with a new
one. Proceed with the replacement of
the filter. The alarm is displayed only if
the "Enable Filter" function is ON.
The machine indicates that in a few
cycles' time the dreg drawer will need
emptying.
This message allows you to carry on
dispensing beverages.
An event has occurred that requires
restarting the appliance. Note the code
(E xx) shown at the bottom. Switch
off the machine and switch it back on
after 30 seconds. If the problem per-
sists, contact the assistance center.
Remove the dreg drawer and empty
out the dregs. Note: the dreg drawer
must only be emptied with the ma-
chine switched on. If the drawer is
emptied with the machine switched
off the machine cannot register the
emptying operation.
Take out the tank and fill it
with fresh drinking water
Insert the brewing unit in its
correct location
An operation has been select-
ed that requires the dispens-
ing of milk.
Insert the cappuccino maker
in the machine as specified in
the manual.
For the machine to become
operative, the service hatch
must be closed
CHIUDERE LO
SPORTELLO
LATERALE
INSERIRE VASCA
RACCOGLIGOCCE
INSERIRE
CONTENITORE FONDI
INSERIRE
COPERCHIO CHICCI
RIEMPIRE
SERBATOIO ACQUA
INSERIRE GRUPPO
INSERIRE IL
CAPPUCCINATORE
INSERIRE LA VALVOLA
NEL CAPPUCCINATORE
AGGIUNGERE CAFFE’
Insert the dreg drawer
Insert the drip tray
SVUOTARE
CONTENITORE FONDI
RIAVVIARE
PER RISOLVERE
IL PROBLEMA
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NEW ROYAL 03 USER INSTRUCTIONS
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CLEANING AND TECHNICAL SERVICING
A Empty the dreg drawer When indicated
B Empty the drip tray As necessary (float indicator)
C Clean the water tank Weekly
D Clean the coffee bean hopper As necessary
E Clean the casing As necessary
F
Clean the brewing unit Every time the coffee bean hopper is filled or weekly
Lubricate the brewing unit After 500 dispensing cycles
Clean the unit housing Weekly
H Descaling When indicated
I Cleaning the cappuccino maker with detergent Before redelivery
Descaling cycle frequency
Hardness Water hardness Without water filter With water filter
1Soft (up to 7°dH) 240 litres (480,000 pulses) 480 litres (960,000 pulses)
2Medium (7° - 14°dH) 120 litres (240,000 pulses) 240 litres (480,000 pulses)
3Hard (15° - 21°dH) 60 litres (120,000 pulses) 120 litres (240,000 pulses)
4Very hard
(over 21°dH) 30 litres (60,000 pulses) 60 litres (120,000 pulses)
The default water hardness level is 4. Each litre of water corresponds to approximately 2,000 pulses
3.3. Operation, cleaning and maintenance
Operating the machine
1 Fill water tank
2 Fill the coffee bean hopper
3 Switch on the appliance
4Press the button to start the
appliance
5 Select the desired language Store
6 Heating When the heating phase begins, wait for it to finish
7 Rinse Carry out a rinse cycle for the internal circuits
8 Machine ready The machine is ready to dispense beverages
04
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NEW ROYAL 04 OPERATING LOGIC
Saeco International Group Rev. 01 Page / 07
4.1. Water circuit
01
Acqua calda
Acqua
Vapore
Acqua calda o vapore
EROGAZIONE
ACQUA CALDA
AL CAPPUCCINATORE
ALLO SCARICO
ASSIEME GENERALE CALDAIA VAPORE
ALLO SCARICO
AL GRUPPO CAFFE’
ASSIEME GENERALE TURBINA
SERBATOIO ACQUA
ASSIEME POMPA VAPORE
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