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Service Manual

This document provides service information for the Exprelia Series coffee machine, including: 1. An introduction section describing the documentation, tools, materials, and safety warnings required for service and repairs. 2. An overview of the Exprelia range of coffee machines and their key features. 3. Diagrams labeling the external parts of the coffee machine. 4. The document continues with sections covering technical specifications, operating instructions, operating logic, troubleshooting, maintenance procedures, and diagrams of the water and electrical systems.
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© © All Rights Reserved
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Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
388 views56 pages

Service Manual

This document provides service information for the Exprelia Series coffee machine, including: 1. An introduction section describing the documentation, tools, materials, and safety warnings required for service and repairs. 2. An overview of the Exprelia range of coffee machines and their key features. 3. Diagrams labeling the external parts of the coffee machine. 4. The document continues with sections covering technical specifications, operating instructions, operating logic, troubleshooting, maintenance procedures, and diagrams of the water and electrical systems.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 56

Coffee Machine

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

1.3. Material 1 4.9. Dose self-learning (SAS) 9

1.4. Safety warnings 1 4.10. SBS 10

1.5 Exprelia Range 2 4.11. Water level detection (water tank) 11

1.6.1. External machine parts 3 4.12. Water level detection (drip tray) 11

1.6.2. Internal machine parts 4 4.13. Descaling request 12


4.14. Water filter 12

2. Technical specifications
2.1. Technical specifications 1 5. Troubleshooting

2.2. Machine parameters and performance 2 5.1. Test mode 1


5.2. Diagnostics mode 5
3. User instructions 5.3 Error messages 7
3.1. Customer and programming menu 1
3.2. Machine indications 3 6. Standard checks
3.3. Operation, cleaning and maintenance 5 6.1. Repair schedule 1
6.2. Service schedule 1
4. Operating logic 6.3. Final test 2
4.1. Water circuit 1
4.2. Frother unit valve assembly 2 7. Disassembly
4.2.1 General carafe assembly 2 7.1. Outer elements 1
4.3. Multi-way valve 4 7.2. Coffee grinder 1
4.4. Coffee cycle 5 7.3. Grinder blades 2
4.5. Single microswitch 6 7.4. Coffee grinder adjustment 3
4.6 Temperature sensor 6 7.5. Steam pump 4

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

9. Water circuit diagram

10 Electrical diagram

Saeco International Group Rev. 00 /June 2010 EXPRELIA


Saeco International Group Rev. 00 / June 2010 EXPRELIA
EXPRELIA 01 INTRODUCTION

1.1 Documentation required

The following documentation is needed for repair procedures:

• Instruction booklet for specific model


• Technical documentation for specific model (diagrams, exploded drawings)

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 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 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.

This domestic appliance is rated as insulation class I.


On completion of the repair work, insulation and dielectric rigidity tests must be performed.

Saeco International Group Rev. 00 / June 2010 Page 01 / 04


EXPRELIA 01 INTRODUCTION

1.5. Exprelia Range

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

Saeco International Group Rev. 00 / June 2010 Page 02 / 04


EXPRELIA 01 INTRODUCTION

1.6.1 External machine parts


Coffee bean hopper
Water tank with lid
Compartment for
pre-ground coffee

Control
panel Grinding
adjustment
Service
hatch Milk carafe
SBS attachment
Hot water/steam
dispensing pipe

Drip Milk carafe


tray+grille

Full tray floating


indicator

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

1.6.2 Internal machine parts

Water tank connection

Coffee grinder
Water tank Ground coffee
present/missing tab channel

Steam pump

Frother unit Turbine


valve assembly
Multi-way valve

Water level
Power card capacitive sensor

Steam boiler Coffee boiler

Water pump

Saeco International Group Rev. 00 / June 2010 Page 04 / 04


Saeco International Group Rev. 00 / June 2010 EXPRELIA
EXPRELIA 02 TECHNICAL SPECIFICATIONS

2.1. Technical specifications
Power supply and output: 240 V~ 50 Hz 1400 W - 230 V~ 50/60 Hz 1400 W -
120 V~ 60 Hz 1500 W - 100 V~ 50/60 Hz 1300 W

Temperature monitoring: Variable resistance sensors (NTC)


transmits the value to the electronic card
Safety system: 2 manual reset or one-shot thermostats (175°C)
Coffee heat exchanger output: (230/120 V~) 1300 W – (100 V~) 1100W
Stainless steel for coffee, hot water and steam dispensing
Steam heat exchanger output:
As above
Stainless steel
Gearmotor: 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, 120V,
60Hz 100V, 50/60 Hz
Steam pump Ulka MF with reciprocating piston 230V, 50 Hz, 120V, 60Hz
100V, 50/60 Hz
Overpressure valve: Opening at approx. 17-23 bar
(multi-way valve)
Water filter: In tank
Coffee grinder: Direct current motor with flat ceramic grinder blades
Automatic dosage Dose adjustment controlled by the electronic system
Power consumption: During heating phase- approx. 5.6 A
Consumption in Standby <1W
Dimensions: W x H x D in mm: 245x360x420
Weight: 14 kg
Water tank capacity: 1.5 l.
Coffee bean hopper capacity 300 g. of coffee beans
Dreg drawer capacity 11
Heat exchanger capacity: Approx. 10 cc
Water circuit filling time: Approx. 15 sec Max. on first filling cycle
Heating time: Approx. 45 sec.
Dispensing temperature: Approx. 84°± 4°
Grinding time: Approx. 8-10 sec.

Saeco International Group Rev. 00 / June 2010 Page 01 / 03


EXPRELIA 02 TECHNICAL SPECIFICATIONS

2.2. Machine parameters and performance

Minimum Default Maximum


AMOUNT User Programm. by
amount amount amount
OF PRODUCT programmable Production / Service
(Puls.) (Puls.) (Puls.)
Espresso 50 130 - 170 * 600 Yes No
Long coffee 70 200 - 230 * 600 Yes No
Pre-ground Yes
Hot water Continues for 400 pulses
Steam for
Continues until the water supply has been exhausted (capacitive sensor)
frother
* Depends on the language selected by the user

RINSE Initial rinse Final rinse


When performed When the machine is switched When the machine is switched
on and the boiler temperature is off electronically, manually or
≤ 50°C automatically after 60', if at least
one coffee has been dispensed,
before switching off
No. of pulses 130 100
Stopping option Yes, by pressing any key Yes, by pressing any key
User disable option Yes No
Disabling by Production/
No No
Service department
No. of pulses user
No No
adjustment option
No. of pulses adjustable
by Production/Service No No
department
Pulse range
No No
(Min. – Max.)

Descaling cycle frequency


Hardness Water hardness Without water filter With water filter
1 Soft (up to 7°dH) 240 litres (480,000 pulses) 480 litres (960,000 pulses)
2 Medium (7° - 14°dH) 120 litres (240,000 pulses) 240 litres (480,000 pulses)
3 Hard (15° - 21°dH) 60 litres (120,000 pulses) 120 litres (240,000 pulses)
4 Very hard
30 litres (60,000 pulses) 60 litres (120,000 pulses)
(over 21°dH)
The default water hardness level is 3. Each litre of water corresponds to approximately 2,000
pulses

Saeco International Group Rev. 00 / June 2010 Page 02 / 03


EXPRELIA 02 TECHNICAL SPECIFICATIONS
DREG DRAWER Description and values
Time-out for dreg drawer 5 sec.

Warning to empty dreg drawer after Yes, after 12 lots of dregs

Shutdown alarm to empty dreg drawer after 15 lots of dregs


(double coffee as last product dispensed) (16 lots of dregs)

The dreg drawer must be emptied only


when prompted by the machine ensuring
Reset dreg counter
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) 60 minutes
Inlet time programmed by user Yes
Inlet time programmed by Production/ Yes
Service
Boiler temperature during Standby Boiler OFF
Cup heater during Standby Cup heater OFF
Timer and Standby Yes **

** The machine switches on at the TimerOn (Timer) value and switches off when the
“Standby time” (Delay – Time) has elapsed

WATER TANK Description


Water reserve (pulses) with water filter 200
Water reserve (pulses) with no water filter 200
Water reserve modifiable by Production/Service No
departments
"Fill tank" alarm Yes
"No tray" alarm No
Water mains No

Saeco International Group Rev. 00 / June 2010 Page 03 / 03


CHAPTER 3

USER INSTRUCTIONS

Saeco International Group Rev. 00 / June 2010 EXPRELIA


EXPRELIA 03 USER INSTRUCTIONS

3.1. Customer and programming menu
Key used to dispense an espresso Key used to dispense a cappuccino
Key used to dispense a coffee Key used to select "MENU"
Key used to select aroma

MENU
OK ESC

Key used to dispense Key used to set the


a long coffee Function keys machine on standby
Key used to select aroma
Key used to carry out a
Key used to access
carafe cleaning cycle
special beverages

BEVERAGE MENU The machine allows custom settings for dispensing each beverage

MENU BEVERAGE MENU


BEVERAGE MENU ESPRESSO
MACHINE MENU COFFEE
LONG COFFEE
MENU MENU MENU
OK ESC OK ESC 1 2 OK 3 ESC 4
1. Scroll/select key
Press the "MENU" button to go Press the "OK" button to go to 2. Select/confirm key
to the machine's main menu the BEVERAGE MENU 3. Exit key
4. Scroll/select key

• Quantity of Coffee: this section enables programming the quantity of coffee


to be ground for making the beverage; this setting will affect the aroma of the
coffee. GROUND - LIGHT - MEDIUM - STRONG
• Pre-brewing: the coffee is slightly moistened before brewing to enhance the
ESPRESSO aroma of the coffee. OFF - LOW - HIGH
AMOUNT OF COFFEE • Coffee temperature: LOW - NORMAL - HIGH
• Coffee size: Used to program the quantity of coffee to dispense.
PREBREWING
• Amount of milk: (only for cappuccino, latte macchiato and hot milk) Used to
COFFEE TEMPERATURE program the quantity of milk to dispense.
MENU • Amount of water: (only for HOT WATER) Used to program the quantity of
OK ESC
water to dispense.
• Default: The standard values set as default by the manufacturer are
reprogrammed.
• SPECIAL BEVERAGES: This function includes
LATTE MACCHIATO, HOT MILK and HOT WATER

Saeco International Group Rev. 00 / June 2010 Page 01 / 05


EXPRELIA 03 USER INSTRUCTIONS
MACHINE MENU Used to customize the machine's operational settings

MENU MACHINE MENU


Press the "OK" button Press the "OK" button to
BEVERAGE MENU to go to the MACHINE GENERAL MENU go to the submenus
MACHINE MENU MENU DISPLAY MENU
WATER MENU
MENU MENU
OK ESC OK ESC

GENERAL MENU
To change the appliance operating settings
GENERAL MENU

SOUND This function permits activating/deactivating audible warnings

OFF To enable buzzers

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

ENGLISH The currently selected language is shown

BRIGHTNESS To set the correct brightness

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.

Saeco International Group Rev. 00 / June 2010 Page 02 / 05


EXPRELIA 03 USER INSTRUCTIONS
MAINTENANCE

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

DESCALING This function is used to run the descaling cycle

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

OFF The self-cleaning function is disabled

ON The self-cleaning function is enabled

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

Remove the dregs drawer.


Close the coffee bean hopper Note: The dregs drawer must
INSERIRE SVUOTARE
COPERCHIO CHICCHI
lid to enable delivery of any only be emptied when requested
CONTENITORE FONDI
beverage by the machine and with the
machine on.

For the machine to become


ADD COFFEE Fill the coffee CHIUDERE SPORTELLO
operative, the service hatch
FRONTALE
container must be closed

INSERIRE GRUPPO Insert the brewing unit RIEMPIRE Take out the tank and fill it with
SERBATOIO ACQUA
in its correct location fresh drinking water

Saeco International Group Rev. 00 / June 2010 Page 03 / 05


EXPRELIA 03 USER INSTRUCTIONS

Open the front hatch and empty


the drip tray underneath the
INSERIRE Insert the dregs SVUOTARE VASCA brewing unit. You should also
CONTENITORE FONDI drawer GRUPPO
empty the dreg drawer, as the
dregs counter will also be reset
when the machine is switched on.

A beverage containing milk has The appliance requires a descaling


RUOTARE CARAFFA been selected. The machine asks cycle.
IN EROGAZIONE you to place the carafe handle With this message you can keep on
spout in its dispensing position. using the machine but there is the
ESC
Press “ESC” to cancel the risk it will not work properly.
procedure

The machine requires replacement


RUOTARE CARAFFA The carafe rinse function has been
of the "Intenza" filter with a new
IN RISCIACQUO selected.
one.
Press “ESC” to cancel the
ESC The alarm is displayed only if the
procedure
"enable filter" function is ON.

An operation has been selected An even has occurred that requires


INSERIRE CARAFFA RIAVVIARE PER
that requires dispensing from the RISOLVERE IL restarting the appliance.
milk container. PROBLEMA
Take note of the code (E xx) shown
ESC Insert the milk container. Press at the bottom
“ESC” to cancel the procedure

Red LED blinking Machine on Standby.


It is possible to change the Standby settings
Press the button to exit Standby

Saeco International Group Rev. 00 / June 2010 Page 04 / 05


EXPRELIA 03 USER INSTRUCTIONS

3.3. Operation, cleaning and maintenance

Operating the machine


1 Fill water tank
2 Fill the coffee bean hopper
3 Switch on the appliance
Press the button to start the
4
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

CLEANING AND TECHNICAL SERVICING


A Empty the dregs 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
Clean the brewing unit Every time the coffee bean hopper is filled or weekly
Lubricate the brewing unit After 500 dispensing cycles or when the grease is no
F
longer present on the brewing unit
Clean the unit housing Weekly
H Descaling When indicated

Descaling cycle frequency


Hardness Water hardness Without water filter With water filter
1 Soft (up to 7°dH) 240 litres (480,000 pulses) 480 litres (960,000 pulses)
2 Medium (7° - 14°dH) 120 litres (240,000 pulses) 240 litres (480,000 pulses)
3 Hard (15° - 21°dH) 60 litres (120,000 pulses) 120 litres (240,000 pulses)
4 Very hard
30 litres (60,000 pulses) 60 litres (120,000 pulses)
(over 21°dH)
The default water hardness level is 3. Each litre of water corresponds to approximately 2,000 pulses

Saeco International Group Rev. 00 / June 2010 Page 05 / 05


Saeco International Group Rev. 00 / June 2010 EXPRELIA
EXPRELIA 04 OPERATING LOGIC

4.1. Water circuit

HOT WATER / STEAM


COLD WATER

HOT WATER
STEAM
-
-
-
-

Saeco International Group Rev. 00 / June 2010 Page 01 / 11


EXPRELIA 04 OPERATING LOGIC

4.2. Frother unit valve assembly
Air solenoid valve
Air inlet
Clean solenoid
DC3 DC4 valve (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

Features and requirements


Maximum operating pressure 3 bar
Maximum pressure in the water/steam circuit does not exceed 4.5 bar 0/+1
Hot water temperature 90°
Steam temperature 125°

4.2.1 General carafe assembly

5
3

1 Cappuccino valve body


7 2 Milk suction pipe and attachment
1 3 Venturi pipe
4 Milk dispenser pipe
5 Upper attachment of drain pipe
for carafe
6 Lower attachment of carafe drain
pipe
2 7 Levers, springs and pin for carafe
present/missing indication and
dispenser positioning

Saeco International Group Rev. 00 / June 2010 Page 02 / 11


EXPRELIA 04 OPERATING LOGIC
Functional method for the production of milk-based beverages and circuit cleaning
When the solenoid valves open and let air or hot water/steam through, the following situations
occur:
• DC3+DC2 STEAM + AIR = Frothing and heating of frothed milk
• DC2 STEAM FROM CENTRAL HOLE = Heating of non-frothed milk
• DC4 STEAM FROM LOWER HOLE = Cleaning of milk circuits


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

DC1 = pressure relief valve assembly


DC2 = steam valve
Clean DC3 = air valve
(steam) DC4 = clean valve (steam)
DC4 DC5 = hot water/steam valve
Air AIR or STE
AM
DC3
Milk-based
beverages DC2 STEAM

(steam)
hot water /
steam DC5
to steam pipe

HOT WATER - STEAM

PRESSURE RELIEF VALVE


DC1 CARAFE ATTACHMENT

Saeco International Group Rev. 00 / June 2010 Page 03 / 11


EXPRELIA 04 OPERATING LOGIC

4.3. Multi-way valve

Needle Drain to drip tray

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.

Saeco International Group Rev. 00 / June 2010 Page 04 / 11


EXPRELIA 04 OPERATING LOGIC

4.4. Coffee cycle

Main START STOP


switch ON
Time

Coffee grinder Pulses


(Dosage)

Heating approx.
45 sec.

Pump Pump activity


(turbine pulses)
depending on the
product quantity
selected
*
Gearmotor:
Brewing unit

Status Heating Ready Coffee cycle

Notes: * Only with Pre-brewing

Status
Microswitch OFF ON

Single microswitch gearmotor

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)

Saeco International Group Rev. 00 / June 2010 Page 05 / 11


EXPRELIA 04 OPERATING LOGIC
4.5. Single microswitch

The gearmotor is powered by a direct current


2 motor that engages with the smaller double
toothed wheel using a worm screw. The
unit is mounted on the axle of the large
gear wheel and when a coffee is requested,
it moves from the standby position to the
dispensing position, and then back to the
standby position again.

- Standby position: 1

- Dispensing position: 2

4.6. Temperature sensor (adjustment)

Temp. (°C) R nom (kΩ) ΔR (+/- %)


20 61.465 8.6
50 17.599 5.9
75 7.214 4.1
80 6.121 3.7
85 5.213 3.4
90 4.459 3.1
100 3.3 2.5
125 1.653 3.9
150 0.893 5.1

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

Saeco International Group Rev. 00 / June 2010 Page 06 / 11


EXPRELIA 04 OPERATING LOGIC
4.7. Coffee grinder

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

If, however, there are coffee beans, the number of rotations


will be lower due to the force created by the grinding
t2 = no indication
t3 Without beans n=50%
t3 and t4 = this measurement is taken at the end of
each grinding cycle
Dose quantity adjustment
The dose quantity is adjusted in accordance with the
t4 With beans n=50% pulses detected (number of rotations proportional to the
weak/medium/strong aroma setting)
Coffee grinder blockage
If the coffee grinder becomes blocked for any reason,
pulses will no longer be transmitted to the electronic
t system and the grinder will come to a stop

Saeco International Group Rev. 00 / June 2010 Page 07 / 11


EXPRELIA 04 OPERATING LOGIC

4.9 Dose self-learning (SAS)
The aim of this function is to automatically regulate the average dose of ground coffee (SELF-
LEARNING); this takes place with an algorithm based on three pieces of data that the machine
receives via the card:

1. Number of coffee grinder pulses during the grinding cycle


2. Max. average value of the power consumed by the group motor during the coffee brewing cycle
3. Aroma selected by the user

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.

If the “pre-ground” flavour is selected by the user, no modification will be made.

This guarantees that, regardless of the coffee type used, the grinding level setting
and the wear on the grinders always remains constant.

Power consumption Pulses corrected in the next grinding process


Setting/Status
in mA Exceeded by Deficient by
A Mild aroma 200 - 300 mA -4 +2
B Medium Aroma 301 - 450 mA -4 +2
C Strong Aroma 451 - 600 mA -4 +2
D Over-limit 601 - 800 mA -4

E Overwork 801 - 1000 mA - 10

F Pad expulsion > 1000 mA - 10

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.

Saeco International Group Rev. 00 / June 2010 Page 08 / 11


EXPRELIA 04 OPERATING LOGIC

4.10. SBS

SBS - Saeco Brewing System - Principle


Controlling the flow speed, which influences
the contact time between the coffee and
water, changes the extraction and therefore
the taste intensity and strength of the coffee.
• Slower flow: strong extraction
• Fast flow: lighter extraction

SBS / dispensing valve


Turning the SBS control knob leads to brewing
taking place inside the brewing unit, where
the flow speed is adjusted using a cream
valve.

Cream valve control


Fast flow (slight extraction)
If the SBS valve is open, the coffee flows
more easily because the pressure is lower
and the membrane, with the support of
the spring, remains almost in its original
position.
The control needle does not close off the
opening and the flow is not diminished.

Cream valve control


Slow flow (strong extraction)
The coffee can only be dispensed slowly with
a closed SBS valve – a pressure is created
which forces the membrane to the side,
pushing it against the spring force.
In the next stage, the valve needle closes off
the opening, thus reducing the flow.

Saeco International Group Rev. 00 / June 2010 Page 09 / 11


EXPRELIA 04 OPERATING LOGIC

4.11. Water level detection (water tank)

“Water low” message (water reserve)

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.

4.12. Water level detection (drip tray)

“Empty drip tray” - message

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

Saeco International Group Rev. 00 / June 2010 Page 10 / 11


EXPRELIA 04 OPERATING LOGIC

4.13. Descaling request

Flow meter pulses “Descaling” – message with water filter


inserted
(appliances with display only)

The water hardness is set on the basis of the


regional water hardness analysis
Filter
on
(1, 2, 3, 4).

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.

4.14. Water filter


Water filter

Function:
• Reduced limescale deposits which take longer to
form.
• Improved water quality.
• Improved taste due to the ideal water hardness

Life span / descaling performance:


• - 10 ° dH
• 60 litres
• 2 months

Bypass To achieve the best possible operating mode consistency


over the total life span, the water is channelled using
a 3-stage bypass (A, B, C) depending on the degree of
hardness.
See small image.

Saeco International Group Rev. 00 / June 2010 Page 11 / 11


Saeco International Group Rev. 00 / June 2010 EXPRELIA
EXPRELIA 05 TROUBLESHOOTING
5.1. Test mode

To enter Test Mode:


- Switch on the machine
- Press the four function keys in the sequence indicated below (1,2,3,4) before the heating bar is
completed

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.

Saeco International Group Rev. 00 / June 2010 Page 01 / 07


EXPRELIA 05 TROUBLESHOOTING
Software version

Software xx.yy.zz • (xx.yy.zz) software version loaded onto the machine


D:64 E:8 Debug msg • (D and E) are values providing information on the memory settings
and must be 64 and 8.
• P OFF: if active it enables immediately going onto Standby when the
* P Off * * machine is switched on
• Debug msg: if active it enables the automatic dosing debug messages
for the next restart only
* * * *

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

Saeco International Group Rev. 00 / June 2010 Page 02 / 07


EXPRELIA 05 TROUBLESHOOTING
HydraulicCircuit
This screen corresponds to water circuit management.
Operation:
• Ac V: if pressed, activates the 230V solenoid valve
• Dc V1: activates the 24V solenoid valve for draining
HYDR CIRCUIT 1/2 • Dc V2: activates the 24V steam dispensing solenoid valve
• Dc V3: activates the 24V milk frothing solenoid valve
DcV 1 DcV 2 DcV 5 • Dc V4: activates the 24V solenoid valve for milk circuit cleaning
• Dc V5: activates the 24V hot water dispensing solenoid valve

DcV 3 DcV 4 Ac V * Indicators


• Tank: indicates the status of the water tank level sensor. If activated,
Tank Clean Milk Pres the sensor signals that the level has been reached
• Clean: if activated, it indicates that the milk carafe is in the CLEAN position.
• Milk: if activated, it indicates that the milk carafe is in the MILK
dispensing position
• Pres: if activated, it indicates that the milk carafe is inserted

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

Saeco International Group Rev. 00 / June 2010 Page 03 / 07


EXPRELIA 05 TROUBLESHOOTING
Indicators:
• Pls: indicates, during grinding, the real-time grinding pulse countdown
• BLess: This is activated when the system detects there is no coffee. To cancel the alarm you need to raise and
lower the bean cover to simulate coffee loading
• BDOOR: indicates the status of the bean hopper door sensor (if active, it indicates that the door is closed)
• A+: increases the number of pulses for a medium aroma
• A-: decreases the number of pulses for a medium aroma
• Z-cr:... not used
The value at bottom left is the number of pulses for a medium aroma: it is modified manually with the
“A+” and “A-" keys or automatically by the automatic dosing algorithm

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

STEAM OUT * Operation:


• Boil1: illuminates when the coffee boiler is powered
Boil1 Boil2 Start • Boil2: illuminates when the steam boiler is powered
• Start: starts the draining process
Indicators
* * * * • The values at the bottom are the temperatures of the two
boilers and the countdown (T.O) before the machine requests
54.8 50.2 * T .0 switching off.

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.

Saeco International Group Rev. 00 / June 2010 Page 04 / 07


EXPRELIA 05 TROUBLESHOOTING
5.2. Diagnostics mode
To enter Diagnostics mode:
- Switch on the machine
- Press the four function keys in the sequence indicated below (1,2,3,4) before the heating bar is
completed

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 number of coffee grounds batches.


MAX GROUND The range of the number of coffee grounds batches can vary from 10 to 20

This is used to select the maximum delay between two water pulses in the
HOTWATER FLOWRATE flow meter

This is used to select the average or normal temperature of the coffee in a


CUP TEMPERATURE cup

Saeco International Group Rev. 00 / June 2010 Page 05 / 07


EXPRELIA 05 TROUBLESHOOTING
Press the or buttons to move the cursor onto the desired beverage and
press OK to enter the submenu

1. PRODUCT COUNTERS

• ESPRESSO (default 0) • dispensing no.


• COFFEE (default 0) • dispensing no.
• LONG COFFEE (default 0) • dispensing no.
• HOT WATER (default 0) • dispensing no.
• CAPPUCCINO (default 0) • dispensing no.
• LATTE MACCHIATO (default 0) • dispensing no.
• HOT MILK (default 0) • dispensing no.

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

• ERRORS RESET All the errors are reset

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)

• WATER SINCE PRODUCT Total consumption of water in litres (default 0).

4. MAX GRINDER DOSE 100 to 170 (default 170)

5. MAX GROUND 10 to 20 (default 10)

6. HOTWATER FLOWRATE 100 to 150 (default 120)

7. CUP TEMPERATURE 75 to 85 (default 78)

Saeco International Group Rev. 00 / June 2010 Page 06 / 07


EXPRELIA 05 TROUBLESHOOTING

5.3. Error messages

Code Brief description Description


The coffee grinder is blocked (grinder blades
01 coffee grinder blocked
jammed or sensor not reading properly)

Brewing unit blocked in ‘work’


03 Descent time-out exceeded
position

04 Brewing unit blocked in ‘home’


Ascent time-out exceeded
position

No water in flow meter or flow meter not turning


05 Water circuit blocked
(jammed)

06 Frother unit solenoid valve Frother unit solenoid valve short-circuit

10 Coffee boiler short-circuit Coffee boiler temperature sensor short-circuit

11 Coffee boiler in open circuit Coffee boiler temperature sensor in open circuit

12 Steam boiler short-circuit Steam boiler temperature sensor short-circuit

13 Steam boiler in open circuit Steam boiler temperature sensor in open circuit

Various temperature errors


14 Coffee boiler temperatures out of control
(in the coffee boiler)

Various temperature errors


15 Steam boiler temperatures out of control
(in the steam boiler)

16 Group motor short-circuit Brewing unit microswitch short-circuit

17 Not used

18 Clock error Memory fault or impossible to set

No zero crossing on card, could be caused by power


19 No zero crossing
card

20 Not used

Saeco International Group Rev. 00 / June 2010 Page 07 / 07


CHAPTER 6

STANDARD CHECKS

Saeco International Group Rev. 00 / June 2010 EXPRELIA


EXPRELIA 06 STANDARD CHECKS

6.1. Repair schedule


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

6.2. Service schedule

S Replacement P Cleaning
ES Visual inspection TR Noise test
D Descaling R Adjustment
CF Operative check

Component Action Support/tool


Water filter: P/S/CF
Water tank lip seal S/CF
Boiler pin O-ring S/CF
Brewing unit ES/P/CF Grease solvent / Grease
Hoses, attachments and Oetiker clamps ES/CF
Coffee circuit pump ES/TR/CF
Hot water/steam circuit pump ES/TR/CF
Gearmotor: ES/TR/CF
Coffee grinder P/R/CF Vacuum cleaner / brush
Water circuit D/CF Saeco descaler
Frothing valve assembly ES/S/CF
Multi-way valve (solenoid pilot) ES/S/CF

Saeco International Group Rev. 00 / June 2010 Page 01 / 02


EXPRELIA 06 STANDARD CHECKS

6.3. Final test

Test Procedure Support/tool Standard Tolerance


2-3 Espressos for
Espresso Measuring scoop Same amount 15%
adjustment purposes
2-3 Coffees for
Coffee Measuring scoop Same amount 15%
adjustment purposes
Noise Standard
The cream
should come
Amount of Blow into the cup until
together again to
cream the cream separates
form a complete
layer
Cream colour Hazel brown
Reading taken while
Temperature Thermometer 84 ˚C ± 4 ˚C
dispensing
Check the grain size of
Grinding level
the ground coffee
Hot water Dispense water
Steam Dispense steam
Dreg drawer
Dreg drawer
missing Remove the dreg drawer
missing indication
indication
Missing Start brewing a coffee
Missing indication
indication while the coffee bean
coffee beans
coffee beans hopper is empty

Saeco International Group Rev. 00 / June 2010 Page 02 / 02


Saeco International Group Rev. 00 / June 2010 EXPRELIA
EXPRELIA 07 DISASSEMBLY

7.1. Outer elements

Take off the caps


covering the screws
and unscrew them.
Raise the rear cover
and take it off

Remove the water tank,


coffee container cover and Extract the PWR cover
water drip tray

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)

Unscrew the screws shown and


pull out the RH and LH panel
assembly

7.2. Coffee grinder

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

7.3. Grinder blades

B To extract the top support of the appliance, press on the


A grinding adjustment spindle (A) and turn the support
anticlockwise until it unhooks.

Turn the grinder blades anticlockwise out of the


support.

Turn the grinder blades clockwise out of the support. The


bayonet connections can be accessed from the rear.

For a standard adjustment, both markings must be aligned.

Saeco International Group Rev. 00 / June 2010 Page 02 / 09


EXPRELIA 07 DISASSEMBLY

7.4. Coffee grinder adjustment

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

Coffee bean hopper

Coffee bean hopper


cover
Range of adjustment
with the knob

+
-
+
-

Adjustment by a service centre

To adjust grinding further, the engineer can work directly


on the coffee grinder by pressing and turning the ring nut
(C) shown. (clockwise + to increase the particle size of
the coffee and anticlockwise - to decrease it).

If there are any remains of coffee powder between the


C two grinding blades it is recommended to tighten by max.
+ two marks at a time.
-
Lastly, move the arrow (A) on the adjustment knob to the
centre of the adjustment dots on the cover (B).

A
B
-

Saeco International Group Rev. 00 / June 2010 Page 03 / 09


EXPRELIA 07 DISASSEMBLY

7.5. Steam pump

Slide out the two pump supports (highlighted)


fixed to the housing and disconnect the electrical
and water circuit connections

7.6. Coffee pump

1) Loosen the screws as illustrated and remove all


electrical connections from the component support
2) Extract the pump from the supports and
disconnect it from the electrical and water circuit
1 connections

7.7. Turbine

Lift the turbine out of the casing assembly and remove the electrical and
water circuit connections

7.8. Power card

1)Remove the card cover by raising


it
2)Loosen the screws as illustrated
and remove the PWR card
extracting the electrical connections

1 2

7.9. Steam boiler

1-2)Unscrew the screws shown


3)Unhook the boiler, disconnect the
electrical and water circuit connections

1 2 3

Saeco International Group Rev. 00 / June 2010 Page 04 / 09


EXPRELIA 07 DISASSEMBLY
7.10. Coffee boiler

1-2)Unscrew the screws shown


3)Unhook the boiler, disconnect the
electrical and water circuit connections

1 2 3

7.11. Gearmotor:

Loosen the screws as Loosen the screws as Loosen the screws as


illustrated and remove the illustrated and remove illustrated and remove the
boiler pin the boiler pin gearmotor cover

The following are located inside the compartment


E protected by the casing:
- Electric motor (A) with gears (B) and (C) for transmission
and timing of the dispensing unit
- Dreg drawer presence sensor (D)
F B
- Dispensing head present microswitch (E)
- Microswitch (F) detecting brewing unit home and work
C positions
- Remove the gear (C) that meshes with the motor
D transmission shaft
A - Remove the large gear (B)
- Remove the motor (A), complete with transmission shaft

G - (G) Multi-way valve drain

B Replace the gear (B), making sure that the imprint of the
arrow is aligned with the opening containing the pin (P).

When replacing the motor and the transmission shaft, make


H sure the guide runners (L) are in the right position.
Grease the shaft thoroughly and evenly.
L

Saeco International Group Rev. 00 / June 2010 Page 05 / 09


EXPRELIA 07 DISASSEMBLY

7.1. Multi-way valve

Unscrew the screws as Loosen the screw as Disconnect the


indicated to reach the screw illustrated and remove electrical and water
anchoring the multi-way valve the clip circuit connections
to the support

7.13. Frother unit valve assembly

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

7.14. Door tube coupling

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

7.15. Dispenser assembly

Extract the dispenser assembly Loosen the screws as illustrated


to remove the inner front panel
cover A

Remove the dispenser (photo B);


Loosen the screws located inside the door and slide out the coffee when replacing it, make sure the
dispenser as shown spring highlighted is positioned
correctly

7.16. Steam pipe assembly

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

Saeco International Group Rev. 00 / June 2010 Page 07 / 09


EXPRELIA 07 DISASSEMBLY

7.17. General carafe card assembly

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

7.18 Teflon pipe support and carafe attachment assembly


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

Remove the Teflon pipe support assembly

7.19. CPU and display card

Loosen the screws as


illustrated and remove the
guard and the flat cable

Unscrew the screws of the


display support as shown

Saeco International Group Rev. 00 / June 2010 Page 08 / 09


EXPRELIA 07 DISASSEMBLY

Extract the connections and flat Extract the display and the
cable. keypad

CPU and display card assembly


7.20. Fitting and removing Oetiker clamps

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)

Saeco International Group Rev. 00 / June 2010 Page 09 / 09


CHAPTER 8

NOTES

Saeco International Group Rev. 00 / June 2010 EXPRELIA


EXPRELIA 08 NOTES

Saeco International Group Rev. 00 / June 2010 Page 01 / 01


CHAPTER 9

WATER CIRCUIT DIAGRAM

Saeco International Group Rev. 00 / June 2010 EXPRELIA


EXPRELIA 09 WATER CIRCUIT DIAGRAM

Saeco International Group Rev. 00 / June 2010 Page 01 / 01


CHAPTER 10

ELECTRICAL DIAGRAM

Saeco International Group Rev. 00 / June 2010 EXPRELIA


EXPRELIA 10 WIRING DIAGRAM

Saeco International Group Rev. 00 / June 2010 Page 01 / 01

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