Service Manual
Service Manual
Exprelia Series
Service
Service Manual
Revision 00 June 2010
Table of contents Page Table of contents Page
1. Introduction 4.7. Coffee grinder 7
1.1. Documentation required 1 4.8. Low bean level detection, dose quantity adjustment,
1.2. Tools and equipment required 1 coffee grinder blocked 8
1.6.1. External machine parts 3 4.12. Water level detection (drip tray) 11
2. Technical specifications
2.1. Technical specifications 1 5. Troubleshooting
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 authorisation has been provided in writing or through a contractual agreement.
Table of contents Page
7.6. Coffee pump 4
7.7. Turbine 4
7.8. Power card 4
7.9. Steam boiler 4
7.10 Coffee boiler 5
7.11 Gearmotor: 5
7.12. Multi-way valve 6
7.13 Frother unit valve assembly 6
7.14 Door tube coupling 6
7.15 Dispenser assembly 7
7.16 Steam pipe assembly 7
7.17 General carafe card assembly 8
7.18 Teflon pipe support and carafe attachment assembly
7.19 CPU and display card 8
7.20. Fitting and removing Oetiker clamps 8
8. Notes
10 Electrical diagram
Qty. Description Notes
1 Screwdriver Torx T 8 - T 10 - T 20
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
We recommend you consult the technical manual of the machine before performing any
maintenance 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.
Exprelia Exprelia
CLASS SS
Display interface X X
With satin-finished steel parts X
With ABS parts X
Milk carafe X X
Clean (automatic milk circuit washing) X X
Automatic dosing (SAS) X X
Dispensed coffee memory capacity X X
Dispensed milk memory capacity X X
Automatic shutdown
X X
(after 60' inactivity)
SBS X X
Ground coffee well X X
Automatic descaling cycle X X
Control
panel Grinding
adjustment
Service
hatch Milk carafe
SBS attachment
Hot water/steam
dispensing pipe
Dreg drawer
Power cable
connector and main
switch
Drip tray
Brewing unit
Saeco International Group Rev. 00 / June 2010 Page 03 / 04
EXPRELIA 01 INTRODUCTION
Coffee grinder
Water tank Ground coffee
present/missing tab channel
Steam pump
Water level
Power card capacitive sensor
Water pump
** The machine switches on at the TimerOn (Timer) value and switches off when the
“Standby time” (Delay – Time) has elapsed
MENU
OK ESC
BEVERAGE MENU The machine allows custom settings for dispensing each beverage
GENERAL MENU
To change the appliance operating settings
GENERAL MENU
ON To disable buzzers
ECOMODE This function governs activation of the boilers in the appliance for energy saving
OFF When the appliance is switched on all the boilers (coffee/steam) are activated.
When the appliance is switched on, only the coffee boiler is activated. The appliance consumes less
ON
power but takes longer to dispense milk beverages because the steam boiler is needed
This function is used to set the time since the last beverage dispensing when the machine will go onto
GENERAL STANDBY
standby. The default time setting is 60min
15 MINUTES
After the set time the machine will go onto standby.
30 MINUTES To reactivate the machine, press any button.
After running function diagnosis and the heating phase, the machine is again ready for use
60 MINUTES
180 MINUTES
DISPLAY MENU
This function is used to set the menu language and the display brightness
DISPLAY MENU
This setting is vital for correctly setting the parameters of the appliance for the user's country
LANGUAGE
WATER MENU
This menu is used to set the parameters for correct water management
WATER MENU
To change the setting of the hardness of the water in the appliance, adjusting it to the one used, so it
HARDNESS will request descaling at the right time
To activate/deactivate the water filter replacement warning. When this function is active the appliance
ACTIV. FILTER 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)
ENABL. FILTER To activate the filter after it has been installed or replaced.
This function lets you set all the functions so that machine maintenance is managed better
MAINTENANCE
This function is used to view how many products have been prepared for each single type of beverage
METERS FOR
since the last reset
UNIT CLEANING This function is used to run the washing cycle for the brewing unit
This function lets you run the washing cycle for the carafe used for making beverages containing milk
CARAFE CLEANING
This function is used to set the time since the last beverage dispensing when the machine will go onto
CLEAN CARAFE standby. The default time setting is 60min
FACTORY SETTINGS
This function allows the factory values to be reset.
FACTORY SETTINGS
Restoring the factory parameters deletes all the personal parameters set beforehand.
3.2. Machine indications
INSERIRE GRUPPO Insert the brewing unit RIEMPIRE Take out the tank and fill it with
SERBATOIO ACQUA
in its correct location fresh drinking water
HOT WATER
STEAM
-
-
-
-
Steam outlet
DC2
Steam outlet Steam solenoid valve
Hot water/steam
inlet Hot water /steam
DC5
solenoid valve
Hot water/steam
outlet
Drain protecting
frother unit valve Drain solenoid valve
DC1
5
3
STEAM FROTHED HOT MILK
(CAPPUCCINO)
AIR
VENTURI
PIPE
MILK FROM
CARAFE
STEAM HOT MILK
VENTURI
PIPE
MILK FROM
CARAFE
CLEAN / RINSE
STEAM
VENTURI
PIPE
MILK IN
CARAFE
(steam)
hot water /
steam DC5
to steam pipe
Drain
Wa m th
fro
ter e b
en oile
ter r
ing
Functions:
Safety valve: functions as a safety valve by opening towards the drain in the event that the pressure rises above
16-19 bar
Filling the circuit: the solenoid valve opens (drain position) and the pump is activated, automatically refilling the
circuit by expelling the air in the pipe
Unit discharge: before the unit descends it opens briefly, discharging the pressure created to prevent spraying and
making the pad drier
Coffee beverage: when a coffee beverage is selected, the pump is charged briefly during the grinding process and
the valve assumes the drain position in order to fill the pipes with hot water.
Heating approx.
45 sec.
Status
Microswitch OFF ON
Switching on
When the machine is switched on, the gearmotor repositions itself as follows:
- It acts on microswitch 1 (see following chapter)
- The gearmotor changes its rotation direction and moves upwards again by approx. 1-2 mm
-T he boiler begins to heat the water for approx. 45 sec., at full power, in order to reach the
optimal temperature. The temperature will then remain at a constant level.
Coffee cycle
1. The coffee grinder starts the grinding process (controlled by pulses generated by a sensor)
2. The gearmotor (brewing unit) moves to the dispensing position
3. Preliminary dispensing phase (short pump activity, short pause)
4. Product dispensing (the pump operation period is defined by the amount of product dispensed)
5. The gearmotor moves to its home position (the dregs are expelled automatically)
- Standby position: 1
- Dispensing position: 2
An NTC is used as a temperature sensor; in the event of overheating this reduces boiler
element power consumption.
The electronic system detects the current boiler temperature from the drop in voltage of the
sensor and adjusts it accordingly.
Heating element values and corresponding temperatures: see table
6 4
1 2
3
The coffee grinder is driven by a direct current motor (1) using a worm screw helicoidal wheel
transmission (2).
The worm screw (2) drives a plastic gear wheel (3), which turns the lower grinder (4) and the
increment pin (5)
There are two magnets (6) in the gear wheel; at every rotation these induce two pulses to a Hall
sensor, which in turn transmits them to the electronic system.
4.8. Low bean level detection, dose quantity adjustment, coffee grinder
blocked
No coffee
Without beans n=100%
V t1 A low coffee bean level is detected by the Hall sensor,
after variations in the pulse frequency (with or without
coffee).
If there are no coffee beans (operation while empty),
the number of rotations – and therefore the number of
pulses – will be greater
t2 With beans n=100%
t1 = no coffee indication
The algorithm compares the maximum average value of the power consumed by the group motor
with the value listed in the table for the selected aroma, in order to calculate the new grinding
pulse value for the next coffee produced.
If the value of the power consumed is lower than the value of the min. current, the grinding
pulses will be increased by 2.
If the power consumption value is greater than the maximum current value, the grinding pulses
will be decreased by 4.
If the power consumption value falls within the “over-torque” interval, the product will be
dispensed and the grinding pulses will be decreased by 10.
If the power consumption value falls within the “abort cycle” interval, the pad will be expelled and
the grinding pulses will be decreased by 10.
This guarantees that, regardless of the coffee type used, the grinding level setting
and the wear on the grinders always remains constant.
Important:
For perfect operation, machine adjustment should take place in the area of the fields
highlighted in green (A, B, C). When the type or brand of coffee is changed, there may be
variations in the size of the beans and their stickiness or roasting level. This leads to variations
in power consumption (mA), with resulting excessive or insufficient doses (until the necessary
adjustments have been made to compensate for this change).
Caution: In the case of excessive dosage, powder may be expelled into the dreg
drawer. This is not a fault, but can occur during preliminary operation or after a
service.
4.10. SBS
Function:
Water tank The water level is monitored by a capacitative sensor, located one
third of the way up the water tank wall.
If the electronics assembly detects, by means of the sensor,
that the amount of water in the tank has dropped below the
Sensor above mentioned level, a water reserve remains available for the
dispensing process underway (this will cover 200 turbine pulses).
The product dispensing process will then come to an end.
If a dispensing cycle ends after the sensor has been triggered (in
200 puls. the reserve) then the display “Water low” continues to be displayed
during the following dispensing cycle.
Function:
The residual water level is monitored using a capacitive
sensor. The sensor is located approximately halfway up the
Drip tray
upper edge of the drip tray. To ensure the best possible
use of the drip tray capacity, the sensor is located near to
Sensor a dam. Therefore, the drip tray fills up to the upper edge
of the dam and overflows inside, triggering the sensor and
thus the “Empty drip tray” message.
Total
Switching
capacity
level sensor
Filter off:
If the function is turned off the electronics
assembly monitors the turbine pulses, recording
one pulse each turn.
Filter
off
Filter on:
If the function is turned on the electronics
assembly monitors the turbine pulses, recording
one pulse every two turns.
Number of pulses
“Change water filter” message
The electronics assembly uses the turbine impulses
360°
1 rev to keep track of the amount of water which has
flowed through; after the specified amount (set
in accordance with the water hardness level), the
“Replace filter” message appears.
Function:
• Reduced limescale deposits which take longer to
form.
• Improved water quality.
• Improved taste due to the ideal water hardness
2 3
MENU
4 1 OK ESC
Entry into Test Mode results in a screen divided into sections, as illustrated in the diagram below
A B E
Software XX.YY.ZZ
A B E
C D F G
C D * * * * F G
MENU
OK ESC
The sectors highlighted in red on the following screens represent the various loads that can be
activated by pressing the corresponding keys on the keypads.
This load is deactivated by pressing the same key once more.
Other conditions in which a load can be automatically deactivated are:
- If a work cycle is defined and ends (e.g., coffee grinder or brewing unit)
- A time-out is reached (e.g.: 5 sec for the boiler test)
The 4 buttons highlighted in yellow under the display can be used for navigating within Test Mode.
The remaining four dashed sectors are used to indicate the status of the sensors, microswitches or
control variables.
If present, the asterisk symbol (*) in a sector indicates that no function is associated with that
sector on that particular screen.
Keyboard
KEYBOARD *
Espr Caf Cappucc This is the button test page: each beverage corresponds to a box on the
display that changes colour when the corresponding button is pressed (e.g.:
ESPRESSO)
Long Spec Clean Stdby
* * * *
Brew Unit
This screen corresponds to the management of the area inside the front hatch.
Operation:
• WORK: if pressed, switches the unit into its work position
• STOP: if pressed, stops the unit instantly
BREW UNIT • HOME: if pressed, switches the unit into its Home position
• DREG UP: increases the coffee dregs counter
Work Home mA: xx • DREG DOWN: decreases the coffee dregs counter
Indicators:
• mA: indicates moment by moment the maximum current (in mA)
Stop 10 Dreg- Dreg+
consumed by the unit when moving. Its value must not exceed 300 mA
• H/W: becomes active (illuminated) when the unit reaches a “Work”
DDr H/W Door Pres position
• Pres: if active, this indicates that the unit is inserted
• DDr: if active, this indicates that the dregs counter is inserted
• Door: if active, this indicates that the front hatch is closed
Operation:
• Boil1: if pressed, this activates the coffee boiler. The boiler is deactivated
HYDR CIRCUIT 2/2 either by pressing the button again or automatically after 5 seconds. The
temperature is indicated in the corresponding window at the bottom
Boil1 Boil2 p/s 0 • Boil2: if pressed, activates the steam/hot water boiler. The boiler is
deactivated either by pressing the button again or automatically after 5
seconds. The temperature is indicated in the corresponding window at
Pmp1 Pmp2 * * the bottom
• Pmp1: activates the hot water dispensing pump. The pump is
22.6 23.4 DTrav 50 Hz switched off by pressing the button once more
• Pmp2: activates the hot water/steam dispensing pump. The pump is
switched off by pressing the button once more
Indicators
• p/s: indicates moment by moment the water flow rate in the turbine, expressed in pulses per second. When
coffee pump 1 is switched on and the coffee solenoid valve is on (AcV on the previous screen) the value must be
no lower than 10 p/sec. When hot water/steam pump 2 is switched on and the drain solenoid valve is on (DcV5
on the previous screen) the value must be no lower than 5 p/sec.
• 50 Hz: indicates the mains electricity voltage frequency.
• DTray: indicates the status of the tray level sensor. If activated, the sensor signals that the level has been reached
Grinder
Operation:
GRINDER * • Grind: if pressed, activates the coffee grinder. To stop it, press the
button again. If the coffee grinder is not stopped, it will grind for 200
Grind BTest Pls: 0 pulses; the corresponding countdown appears in the window.
• BTEST: if pressed, activates the coffee grinder. To stop it, press the
button again. If stopped, the no-coffee test is run. At the end of
A+ A- 34 17 the test, 2 values will appear in the "instantaneous threshold" and
"reference threshold" windows: if “instantaneous threshold” is less
100 DDoor BLess Z-Cr than the “reference threshold” the system considers that the coffee
grinder is empty
Display
Operation:
SETTINGS * • C+: increases the contrast of the display
• C-: decreases the contrast of the display
C+ C- * • L+: increases the brightness of the display
• L-: decreases the brightness of the display
L+ L- * * Indicators
• The values at the bottom are indices representing the
brightness and contrast: in this case these values are not
52 40 * * saved to eeprom as they have solely a test function
Steam Out
This is the last screen of the Test Mode. Press to go back to the previous screens.
On each screen, pressing ESC exits the TEST mode and restarts the appliance in normal mode.
1 2
3 4
MENU
OK ESC
Entering Diagnosis Mode shows a screen like the one in the following diagram and pressing
scrolls through all the menus present
MENU
PRODUCT COUNTER
ERROR COUNTER
WATER COUNTER
MENU
OK ESC
MENU DESCRIPTION
PRODUCT
PRODUCT COUNTERS
COUNTER This represents the number of times the C:A: has dispensed each beverage
This displays the total number of “out of order” (fail) errors occurring in the
ERROR
ERROR COUNTERS
COUNTER system and enables resetting. The max number of counted “fails” is 20
This shows the water consumption (in pulses) after dispensing beverages,
WATER
WATER COUNTERS
COUNTER for the descaling cycle, the unit cleaning cycle and filter activation
This shows the water consumption after the last unit cleaning cycle and
BREWING
BREWINGUNIT
UNITCLEANING
RINSING the number of times cleaning has been performed
This is used to select the highest dose threshold the coffee grinder can
MAX GRINDER DOSE accommodate
This is used to select the maximum delay between two water pulses in the
HOTWATER FLOWRATE flow meter
1. PRODUCT COUNTERS
2. ERROR COUNTERS
• ERRORS LOG • ERROR CODE ERROR CODE - the code representing the type of error that
• (default 0) has occurred (see Tab. 5.3 Error messages)
• ERROR INDEX NUMERICAL POSITION - represents the numerical position
• (default 0) of the error in the internal list for a max no. of 20
• ERROR TEXT ERROR DESCRIPTION - a text description of the type of
• (default 0) error that has occurred
3. WATER COUNTERS
• DESCALING CYCLES • WATER SINCE LAST Represents the consumption of water since the last
CYCLES descaling cycle
• WATER SINCE SECOND As above but for the penultimate descaling cycle
• WATER SINCE THIRD As above but for the third last descaling cycle
• WATER SINCE LAST CYCLE total no. of descaling cycles performed
• BREWING UNIT CLEANING • SINCE LAST Represents the consumption of water since the last unit
• (default 0) cleaning cycle. When performed it goes back to 0.
• NUMBER OF EXECUTION Represents the number of unit cleaning cycles carried out
• (default 0) on the C.A.
• WATER FILTER
• SINCE LAST RESET Represents the consumption of water since the last filter
• (default 0) activation cycle. When performed it goes back to 0
• NUMBER OF RESET total no. of filter activation cycles performed.
• (default 0)
11 Coffee boiler in open circuit Coffee boiler temperature sensor in open circuit
13 Steam boiler in open circuit Steam boiler temperature sensor in open circuit
17 Not used
20 Not used
Action
1 Visual inspection (transport damage)
2 Machine data check (rating plate)
3 Operational check / problem analysis
4 Opening machine
5 Visual inspection
6 Operational tests
7 Repairing the faults encountered
8 Checking any modifications (view info, new sw, etc.)
9 Service activities in accordance with the operating schedule
10 Internal cleaning
11 Operational test while the appliance is open
12 Assembly
13 Final inspection test
14 Draining the circuit (in winter)
15 External cleaning
16 Lubricating the brewing unit with suitable grease
17 Insulation test HG 701 (dielectric)
18 Documentation
S Replacement P Cleaning
ES Visual inspection TR Noise test
D Descaling R Adjustment
CF Operative check
D
A B
C
Loosen the screws as Unscrew the screws as indicated under the water container cover
indicated and remove the rear (A) and the coffee bean hopper (B). Unhook and gently raise the
frame casing cover (C) by a few cm. Go onto the opposite side and raise
the cover as shown in the photo (D)
Loosen the screws as Raise the coffee When reassembling the coffee
illustrated and remove the grinder and remove the grinder, make sure the spring is
sound insulating cover of the connections repositioned correctly (see photo)
coffee grinder
Saeco International Group Rev. 00 / June 2010 Page 01 / 09
EXPRELIA 07 DISASSEMBLY
The grinding adjustment can be set by the user (only with the coffee grinder in operation) by
pressing and turning (only by one click at a time) the knob inside the coffee bean hopper
Adjuster knob
+
-
+
-
A
B
-
7.7. Turbine
Lift the turbine out of the casing assembly and remove the electrical and
water circuit connections
1 2
1 2 3
1 2 3
7.11. Gearmotor:
B Replace the gear (B), making sure that the imprint of the
arrow is aligned with the opening containing the pin (P).
Unscrew the screws anchoring the Unscrew the screws Unhook the support for
valve support to the housing and shown and pull out coupling the drain (A) and
to the horizontal plate as shown the valve assembly extract the three Teflon tubes
as shown
Loosen the screws as Extract the coupling Unhook the coupling (A) and
illustrated guard extract the three Teflon tubes
as shown
Saeco International Group Rev. 00 / June 2010 Page 06 / 09
EXPRELIA 07 DISASSEMBLY
Loosen the screws as illustrated to Remove the fork spring and the steam pipe washer, disconnect the pipe
remove the inner front panel cover from the Teflon by removing the fork
Loosen the screw as shown 1) Magnet to improve carafe adherence to the door
2,3,4) for the carafe presence and position sensors
5) Carafe card
Loosen the screws as illustrated to Remove the screws shown and pull the Teflon pipe support cover
remove the inner front panel cover away from the carafe
Extract the connections and flat Extract the display and the
cable. keypad
1
1) Boiler connection
2
2) Other connections
Use a suitable pair of pliers to remove the Tighten the clamp as illustrated
clamp (as illustrated)