Saeco Aulika Sup 040R Service Manual
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Saeco Aulika Sup 040R Service Manual

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Coffee Machine
Service
S e r v i c e M a n u a l
Contents
1.
1.1.
1.2.
1.3.
1.4.
1.5
1.6.
1.7.
2.
2.1.
Technical data
2.2.
3.
3.1.
3.2.
3.3.
4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7
All parts included in this document are property of Saeco International Group
All rights reserved. The company waives all liability for any damages arising out of any errors or omissions in this document and the information contained herein, and no part of
this document can be copied, used or noted down without a written authorisation or a specific contractual clause.
Revision 00 July 2012
Page
Contents
4.8.
1
4.9.
1
4.10.
1
1
5.
2
5.1.
3
5.2.
4
5.3
6.
1
6.1.
2
6.2.
6.3.
1
7.
2
7.1.
7
7.2.
7.3.
7.4.
1
7.5.
2
7.6.
2
7.7.
3
7.8.
4
7.9.
5
7.10.
5
Sup 040R
Aulika
Page
6
6
7
1
6
1
1
2
1
1
2
3
3
3
4
4
4
5

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  • Page 1: Table Of Contents

    Temperature sensor All parts included in this document are property of Saeco International Group All rights reserved. The company waives all liability for any damages arising out of any errors or omissions in this document and the information contained herein, and no part of this document can be copied, used or noted down without a written authorisation or a specific contractual clause.
  • Page 2 Contents Page 7.11. Gearbox 7.12. Discharge valve 7.13. Solenoid valves assembly 7.14. Steam tube assembly 7.15. Dispenser assembly 7.16. Power Card 7.17. Display, keypads and CPU board 7.18. Assembly and disassembly of Oetiker clamps 7.19 Connection to the water supply system Notes Hydraulic diagram Electric diagram...
  • Page 3 Rev. 00 / July 2012 AULIKA...

  • Page 4: Introduction

    (for programming and diagnostic mode) 1.3. Materials Description Notes Thermal paste Thermal resistance > 200°C Descaler Saeco Descaler Degreaser Customer choice Silicone grease Food grade 1.4. Safety cautions We strongly suggest to consult the machine's technical manual before working on it. Compliance with all the relevant regulations for the servicing of appliances is required.

  • Page 5: Aulika Range

    AULIKA 01 INTRODUCTION 1.5. Aulika range Aulika Aulika Mains Display interface Satin-finished steel details ABS details Removable Cappuccinatore Stored dispensed coffee quantity Stored dispensed milk quantity Automatic shutdown (after 30’ of inactivity) Automatic descaling cycle Connection to the water supply system Conical steel burrs Rev. 00 / July 2012 Page / 04...
  • Page 6 AULIKA 01 INTRODUCTION 1.6. Componenti macchina esterni Container lid lock Container lid Coffee beans container Water tank Service door lock Coffee grinder adjustment Cappuccinatore (removable) Hot water dispenser tube Grid Drip tray Service drawer Dose Brewing unit adjustment Full tank floater Dregs drawer Main switch 0/I Cup connector...

  • Page 7: Machine External Hardware

    AULIKA 01 INTRODUCTION 1.7. Machine internal hardware CPU board Power Card Display Solenoid valves assembly Steam boiler Doser assembly Coffee boiler Turbine Coffee grinder assembly Gearbox assembly Coffee pump Rev. 00 / July 2012 Page / 04...
  • Page 8 Rev. 00 / July 2012 AULIKA...

  • Page 9: Technical Data

    AULIKA 02 TECHNICAL DATA 2.1. Technical data Power supply and absorption power 240 V~ 50 Hz 1500 W - 230 V~ 50/60 Hz 1400 W Temperature control: Variable resistance sensors (NTC) sends the values to the electronic card Safety cautions: 2 thermostats one shot at 190°C Coffee heat exchanger power: (230 V~) 1300 W Stainless steel for coffee delivery Steam heat exchanger power: 230 V~) 1300 W Stainless steel for water/steam delivery Gearbox:...

  • Page 10: Machine Behaviour And Parameters

    AULIKA 02 TECHNICAL DATA 2.2. Machine behaviour and parameters Default menu values 1. CREDIT MENU 1.1 Add Credit 1.2 Clear Credit (OK/ESC) 1.3 Display Credit = OFF 1.4 Check Credit = OFF 2. DRINK MENU 2.1. Espresso 2.6. Special drinks * 2.1.1. Pre-infusion = Low 2.6.1. Caffè lungo 2.1.2. Coffee temperature = Normal 2.6.1.1. Pre-infusion = Low 2.1.3. Coffee quantity = 35 g 2.6.1.2 Coffee temperature = Normal 2.1.4. Default (OK/ESC) 2.6.1.3. Coffee quantity = 130 g 2.2.
  • Page 11 AULIKA 02 TECHNICAL DATA 3. MACHINE MENU 3.1 General menu 3.3. Water menu 3.1.1. Sound = ON 3.3.1. Hardness = 4 3.1.2. Ecomode = ON 3.3.2. Filter enabl. = OFF 3.1.3. Stand-by sett. = 30 min 3.3.3. Filter Activ. (OK/ESC) 3.1.4. Self learning = OFF 3.3.4. Water mains = OFF 3.1.5. Set password 3.4 Maintenance 3.2 Display menu 3.4.1. Assembly cleaning (OK/ESC) 3.2.1. Language = Italian 3.4.2.1. Start Descaling (OK/ESC) 3.2.2. Brightness = 8th graphic level 3.4.2.2. Descaling warning = OFF 3.2.3. Contrast = 8th graphic level 3.4.3. Cappuccinatore cleaning 3.4.3.1. Start Cleaning (OK/ESC) 3.4.3.2. Cleaning warning = ON 3.5 Factory settings (OK/ESC) Minim.
  • Page 12 AULIKA 02 TECHNICAL DATA RINSE Initial rinse Final rinse When it occurs When the machine is turned on When the machine is turned off and the boiler temperature is ≤ electronically, manually by the user 50°C or automatically after 30’ , provided that at least one coffee has been dispensed prior to the turning off.
  • Page 13 Rev. 00 / July 2012 AULIKA...

  • Page 14: User Guide

    AULIKA 03 USER GUIDE 3.1. Machine warnings The machine requests a descaling cycle. CHIUDERE LO In order for the machine to When this message appears, the machi- SPORTELLO operate, close the service door ne can be used but its performance can LATERALE be compromised.

  • Page 15: Operator Guide

    AULIKA 03 USER GUIDE 3.2. Operator guide To enter the menu, turn the machine back on and press the following keys in sequence - Cappuccino If the sequence is correct, - Stand-By the programming menu is - Milk coffee accessed. - Clean Menus must be PASSWORD-protected. The PASSWORD is not requested if it is set to the default value (0000). The password must be changed upon first starting the machine, so as to prevent access by unauthorised staff.
  • Page 16 AULIKA 03 USER GUIDE BEVERAGES MENU This menu makes it possible to manage and customise the settings for each beverage To manage the delivery of beverages BEVERAGES MENU To manage the delivery parameter of espresso ESPRESSO To manage the delivery parameter of coffee COFFEE To manage the delivery parameter of cappuccino CAPPUCCINO...
  • Page 17 AULIKA 03 USER GUIDE BEVERAGE PARAMETERS This paragraph describes the various parameters that can be changes. Note: not all parameters are present for all programmable items. Pre-infusion: coffee is wet before infusion, so as to highlight the full aroma of coffee, with excellent results. OFF: pre-infusion does not occur. PRE-INFUSION LOW: enabled HIGH: longer, to enhance the taste of coffee. This section can be used to program the quantity of milk delivered every time the beverage is selected. The bar makes it possible to fine-tune the quantity of milk to be used (unit of measure in seconds) MILK QUANTITY These settings are valid only to program the delivery of beverages containing milk.
  • Page 18 AULIKA 03 USER GUIDE MACHINE MENU Makes it possible to customise the machine functions settings To change the operating settings of the machine GENERAL MENU This function makes it possible to enable/disable the audible warnings SOUND To disable the audible warnings To enable the audible warnings This function manages the activation of the machine boilers, to save energy.
  • Page 19 AULIKA 03 USER GUIDE WATER MENU This menu can be used to set the parameters for the correct management of water used to brew WATER MENU coffee. To change the water hardness setting of the machine. Thanks to the "Hardness" function, it is possible HARDNESS to adapt the machine to the level of hardness of the water used, so that the machine can signal the need for a descaling cycle at the correct time.

  • Page 20: Operation, Cleaning And Maintenance

    AULIKA 03 USER GUIDE 3.3. Operation, cleaning and maintenance Operation Fill the water tank Fill the coffee container with beans. Turn the machine on Press the key to start the machine Select the desired language Save it Heating The heating phase starts, please wait until it is completed. Rinse The machine performs a rinsing cycle on the internal circuits.
  • Page 21 Rev. 00 / July 2012 AULIKA...

  • Page 22: Operating Logic

    AULIKA 04 OPERATING LOGIC 4.1. Hydraulic Circuit Aspiration Filter Valve Discharge Turbine Boiler Boiler Pump Elecrovalves Pump Discharge Rev. 00 / July 2012 Page / 07...

  • Page 23: Emulsifier Valve Assembly

    AULIKA 04 OPERATING LOGIC 4.2. Emulsifier valve assembly HOT WATER STEAM DISCHARGE 1 Output to the cappuccinatore for milk products 2 Output to the steam tube, only hot water is dispensed 3 Discharge used to reduce the inter- nal pressure in the conduits when the product ends 4 Safety valve protecting the valve assembly...

  • Page 24: Discharge Valve

    AULIKA 04 OPERATING LOGIC 4.4. Discharge valve Discharge to the liquids recovery tank Discharge Functions: Safety valve: serves as safety valve by opening towards the discharge when the pressure exceeds 16-19 bar. Circuit charging: the solenoid valve opens (discharge position), the pump is activated and automatically recharges the circuit, discharging any air out of the conduit. Assembly discharge: before the assembly comes down, it opens briefly to discharge the accumulated pressure and avoiding spraying from the assembly and keeping the plug nut drier Coffee product: when a coffee product is selected, the pump briefly charges during the grinding phase, the valve goes into discharge mode to bring hot water back into the conduits.

  • Page 25: Coffee Cycle

    AULIKA 04 OPERATING LOGIC 4.5. Coffee Cycle Main switch START Time Coffee grinder Pulses (Dosing) Heating ca.45 sec. Pump Pump activity (turbine pulses) based on the programmed product quantity Gearbox Brewing unit Status Heating Ready Coffee cycle Notes: * Only with pre-infusion Microswitch status Single micro gearbox...

  • Page 26: Single Microswitch

    AULIKA 04 OPERATING LOGIC 4.6. Single Microswitch The gearbox is operated by a direct current motor that acts on the smallest double too- thed wheel through a worm screw. The assembly is mounted on the axle of a large toothed wheel and, when a request for coffee must be addressed from idle mode, it moves to the delivery position and then goes back to the idling position.

  • Page 27: Water Level Detection (Water Tank)

    AULIKA 04 OPERATING LOGIC 4.8. Water level detection (water tank) Lack of water alarm (water reserve) Water tank Function: The water level is monitored by a capacitive sensor placed one third from the bottom of the tank. If the sensor records a lack of water in the tank at its level, this means that a water reserve of Sensor about 200 turbine pulses is still available for the product being...

  • Page 28: Water Softener

    AULIKA 04 OPERATING LOGIC 4.10. Water softener Water softener Function: • Reduction of and delay in the formation of limescale deposits. • Water quality improvement. • Taste improvement by finding the ideal water hardness Duration / results of descaling: • - 10 ° dH • 6 0 litres • 2 months Bypass In order for the operation to be as uniformly effective...
  • Page 29 Rev. 00 / July 2012 AULIKA...

  • Page 30: Fault Finding

    AULIKA 05 FAULT FINDING 5.1. Test mode Display MAIN FUNCTION SECONDARY FUNCTION Espresso Coffee Hot water Access to the Special menu Cappuccino Next page of the Test Mode menu Milk coffee Cleaning cycle Previous page of the Test Mode menu Access while in Stand-by Exit the Test Mode from page 1 To access the Test Mode: - Turn on the machine - Press the four function keys in sequence (SX4, SX1, SX2, SX3) before the initialization bar is complete.
  • Page 31 AULIKA 05 FAULT FINDING Description of the individual pages 1 Software 1 Software Swiss Pow Off Debug W.Net S W.Net A MV: xx xx.yy.zz B2B RI SECTOR TYPE DESCRIPTION Swiss can be used to activate or deactivate the ECO-MODE default setting. If Swiss is active, the Eco-Mode default setting is ON, while if Swiss is inac- tive, the Eco-Mode default setting is OFF. Swiss FUNCTION The hydraulic circuit emptying function brings the ECO-MODE back to the default value. This default value, as already mentioned, is a function of the Swiss setting It shows whether the machine, once turned on with the electromechanical switch (I/O), goes in Stand-By mode; if so, the “Pow Off” words are hi-...
  • Page 32 AULIKA 05 FAULT FINDING 2 Brew Unit 2 Brew Unit Work Home Dreg+ Stop m BU Dr Dreg- m Tray mA: xxxx m H/W m Door m Dreg m BU SECTOR TYPE DESCRIPTION Work If activated, it operates the gearbox to bring the brew unit in the Work position FUNCTION Home If activated, it operates the gearbox to bring the brew unit in the Home position FUNCTION Stop If activated, it stops the gearbox FUNCTION If activated, it increases the set maximum value of grounds before the alarm is Dreg+...
  • Page 33 AULIKA 05 FAULT FINDING 3 Hydraulic Circuit 3 Hydraulic Circuit EVsteam EVwater Pump1 EVdisch. EVcoffee Pump2 T1 xx T2 yy p/s: zz m Capp m Milk m Tank SECTOR TYPE DESCRIPTION If activated, it operates the 24 VDC solenoid valve of the steam circuit EVsteam (actual activation occurs only if: - the grounds drawer and the brew unit FUNCTION niche drawer are assembled and the side door is closed) If activated, it operates the 24 VDC solenoid valve of the hot water circuit EVwater (actual activation occurs only if: - the grounds drawer and the brew unit FUNCTION niche drawer are assembled and the side door is closed) If activated, it operates the 24 VDC solenoid valve of the steam circuit EVdisch. discharge (actual activation occurs only if: - the grounds drawer and the FUNCTION brew unit niche drawer are assembled and the side door is closed) EVcoffee...
  • Page 34 AULIKA 05 FAULT FINDING 4 Heaters & Grinder 4 Heaters & Grinder Heater1 Heater2 St. Out Grinder EVdose m Bean m Dose Grinder Block T1 xx T2 yy NoBean T. 0 DESCRIPTION SECTOR TYPE If on it activates the coffee boiler for the duration of T.O. (8 seconds). Heater 1 The boiler turns on only if the coffee boiler temperature is lower than FUNCTION 130°C If on it activates the water/steam boiler for the duration of T.O. (8 se-...

  • Page 35: Diagnostic Mode

    AULIKA 05 FAULT FINDING 5.2. Diagnostic mode Display To access the Diagnostic Mode: - Turn on the machine - Press the four function keys in the sequence shown below (SX1, SX2, SX3, SX4) before the initialization bar is complete Menu description in diagnostic mode MENU PRODUCT COUNTERS ERROR COUNTERS WATER COUNTERS HOTWATER FLOWRATE CUP TEMPERATURE 1. Product counters 2. Error counters 3.
  • Page 36 AULIKA 05 FAULT FINDING Press the DX1 or DX3 keys to move the cursor over the desired product and press SX2 to access the submenu 1. PRODUCT COUNTERS • ESPRESSO (default value 0) • n° of executions • COFFEE (valore di default 0) • n° of executions • CAFFE LUNGO (valore di default 0) • n° of executions •...

  • Page 37: Error Messages

    AULIKA 05 FAULT FINDING 5.3. Error messages code brief description description the coffee grinder is blocked (the burrs are stuck or coffee grinder blocked the sensor does not read accurately) brewing unit blocked in "work" the descent time out has been exceeded mode brewing unit blocked in "home" the ascent time out has been exceeded mode water circuit interrupted no water flows into the turbine emulsifier unit solenoid valve short circuit of a solenoid valve in the emulsifier unit doser microswitch blocked short circuit of the doser microswitch short-circuit in the temperature sensor of the coffee coffee boiler short-circuited boiler...
  • Page 38 Rev. 00 / July 2012 AULIKA...

  • Page 39: Standard Checks

    Pipes, joints and Oetiker clamps ES/CF Coffee circuit pump ES/TR/CF Hot water/steam circuit pump ES/TR/CF Gearbox ES/TR/CF Coffee grinder P/R/CF Vacuum cleaner / brush Hydraulic Circuit D/CF Saeco Descaler Emulsion valve unit ES/S/CF Multiple-way valve (solenoid valve) ES/S/CF Rev. 00 / July 2012 Page / 02...
  • Page 40 AULIKA 06 STANDARD CHECKS 6.3. Final check Support / Test Procedure Standard Tolerance tool 2-3 espressos for Measuring Espresso Same quantity calibration 2-3 coffees for Measuring Coffee Same quantity calibration Noise Standard Cream Blow in the cup until the The cream must quantity cream separates merge back again Cream colour Nocciola Measuring during...
  • Page 41 Rev. 00 / July 2012 AULIKA...

  • Page 42: Disassembly

    AULIKA 07 DISASSEMBLY 7.1. Aesthetics Loosen the screws Remove the lid and the water tank, the be- Loosen the screws shown shown in the pictu- ans container lid, the grounds drawer, the in the picture drip tray, the brewing unit, the brewing unit re and remove the coffee container support plate and the coffee dispenser.

  • Page 43: Burrs

    AULIKA 07 DISASSEMBLY 7.3. Burrs Loosen the screws shown in To remove the upper support of the burr, rotate the metal the picture and remove the ring (A) counter-clockwise until it uncouples. calibration lever. In replacing the burrs, take care that the Lower burr (1) and upper burr (2) two references shown in the picture are aligned Removed the cover of the upper burr by pressing on the blades shown in the pic-...

  • Page 44: Coffee Grinder Motor

    AULIKA 07 DISASSEMBLY 7.4. Coffee grinder motor Unlock the motor support by Remove the three burr Remove the spheres shown in the lifting the stops shown in the dampers and the felt ring picture and the springs underneath picture and replace the motor. and lift the burr support 7.5.

  • Page 45: Coffee Boiler And Steam Boiler

    AULIKA 07 DISASSEMBLY 7.7. Coffee boiler and steam boiler Loosen the screws shown in the pic- Loosen the screw shown in the picture, remove the boiler ture and remove the boiler support support and slide the power and hydraulic connections out 7.8.

  • Page 46: Turbine

    AULIKA 07 DISASSEMBLY 7.10. Turbine to replace the turbine, loosen the screws inside to replace the turbine, loosen the screws inside the brewing unit niche shown in the picture the brewing unit niche shown in the picture 7.11. Gearbox Loosen the screws shown in the picture and remove the Loosen the screws shown in the gearbox assembly picture and remove the gearbox lid...

  • Page 47: Discharge Valve

    AULIKA 07 DISASSEMBLY 7.12. Discharge valve Loosen the screws shown in the picture to remove the To remove the discharge valve (A), lo- base and access the screw located under the chassis of osen the screws that fasten the cover the machine of the boiler pin and remove the valve. Disconnect the po- Loosen the screw wer and hydraulic...

  • Page 48: Steam Tube Assembly

    AULIKA 07 DISASSEMBLY 7.14. Steam tube assembly Loosen the screws shown in the picture and remove the card support for easier access to the steam tube assembly Loosen the screws shown in the picture and remove the yoke spring 7.15. Dispenser assembly Loosen the screws shown in the picture and remove the card support for easier access to the dispenser Loosen the screws shown in the picture, remove...

  • Page 49: Display, Keypads And Cpu Board

    AULIKA 07 DISASSEMBLY 7.17. Display, keypads and CPU Board Loosen the screws shown in the picture, Loosen the screws shown in the picture from the disconnect the power connections and back of the display assembly remove the display assembly Loosen the screws shown in the picture and remove the keypads Loosen the screws shown in the picture and disconnect the power connections 7.18.

  • Page 50: Connection To The Water Supply System

    AULIKA 07 DISASSEMBLY To remove the clamp use appropriate Fasten the clamp as shown pliers, as shown in the picture 7.19. Connection to the water supply system Loosen the screw shown in the Disconnect the power and Loosen the screws shown in picture and remove the back the picture and remove the hydraulic connections shown in...
  • Page 51 Rev. 00 / July 2012 AULIKA...
  • Page 52 AULIKA 08 NOTES Rev. 00 / July 2012 Page / 01...
  • Page 53 Rev. 00 / July 2012 AULIKA...
  • Page 54 AULIKA 09 HYDRAULIC DIAGRAM Rev. 00 / July 2012 Page / 01...
  • Page 55 Rev. 00 / July 2012 AULIKA...
  • Page 56 AULIKA 10 ELECTRIC DIAGRAM Rev. 00 / July 2012 Page / 01...

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