Philips Saeco Exprelia Series, Exprelia CLASS, Exprelia SS Service Manual

Coffee Machine

Exprelia Series

Service

Service Manual

Revision 00 June 2010

Table of contents Page

1. Introduction

1.1. Documentation required 1

1.2. Tools and equipment required 1

1.3. Material 1

1.4. Safety warnings 1

1.5 Exprelia Range 2

1.6.1. External machine parts 3

1.6.2. Internal machine parts 4

2. Technical specications

2.1. Technical specications 1

2.2. Machine parameters and performance 2

3. User instructions

3.1. Customer and programming menu 1

3.2. Machine indications 3

3.3. Operation, cleaning and maintenance 5

4. Operating logic

4.1. Water circuit 1

4.2. Frother unit valve assembly 2

4.2.1 General carafe assembly 2

4.3. Multi-way valve 4

4.4. Coffee cycle 5

4.5. Single microswitch 6

4.6 Temperature sensor 6

Table of contents Page

4.7. Coffee grinder 7

4.8. Low bean level detection, dose quantity adjustment,
coffee grinder blocked

4.9. Dose self-learning (SAS) 9

4.10. SBS 10

4.11. Water level detection (water tank) 11

4.12. Water level detection (drip tray) 11

4.13. Descaling request 12

4.14. Water lter 12

5. Troubleshooting

5.1. Test mode 1

5.2. Diagnostics mode 5

5.3 Error messages 7

6. Standard checks

6.1. Repair schedule 1

6.2. Service schedule 1

6.3. Final test 2

7. Disassembly

7.1. Outer elements 1

7.2. Coffee grinder 1

7.3. Grinder blades 2

7.4. Coffee grinder adjustment 3

7.5. Steam pump 4

8

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 Teon 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

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

1.1 Documentation required

The following documentation is needed for repair procedures:

Instruction booklet for specic model•
Technical documentation for specic 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.

01

EXPRELIA 01 INTRODUCTION

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

1.5. Exprelia Range

Exprelia

CLASS

Exprelia

SS

Display interface X X
With satin-nished 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

(after 60' inactivity)

X X

SBS X X
Ground coffee well X X
Automatic descaling cycle X X

02

EXPRELIA 01 INTRODUCTION

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

1.6.1 External machine parts

Coffee bean hopper

Water tank

with lid

Compartment for

pre-ground coffee

Control
panel

Grinding
adjustment

Service
hatch

SBS

Milk carafe
attachment

Hot water/steam
dispensing pipe

Drip
tray+grille

Full tray oating

indicator

Milk carafe

Dreg drawer

Power cable

connector and main

switch

Drip tray

Brewing unit

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EXPRELIA 01 INTRODUCTION

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

1.6.2 Internal machine parts

Water tank connection

Coffee grinder

Water tank
present/missing tab

Frother unit
valve assembly

Ground coffee
channel

Steam pump

Turbine

Multi-way valve

Water level

Power card

Steam boiler

capacitive sensor

Coffee boiler

Water pump

04

Saeco International Group Rev. 00 / June 2010 EXPRELIA

EXPRELIA 02 TECHNICAL SPECIFICATIONS

 2.1. Technicalspecications

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:

Stainless steel

Steam heat exchanger output:

Stainless steel

(230/120 V~) 1300 W – (100 V~) 1100W
for coffee, hot water and steam dispensing

As above

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 lter: In tank

Coffee grinder: Direct current motor with at ceramic grinder blades
Automatic dosage Dose adjustment controlled by the electronic system
Power consumption: During heating phase- approx. 5.6 A
Consumption in Standby < 1 W

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 lling time: Approx. 15 sec Max. on rst lling cycle

Heating time: Approx. 45 sec.
Dispensing temperature: Approx. 84°± 4°
Grinding time: Approx. 8-10 sec.

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01

EXPRELIA 02 TECHNICAL SPECIFICATIONS

2.2. Machine parameters and performance

AMOUNT

OF PRODUCT

Minimum

amount

(Puls.)

Default

amount

(Puls.)

Maximum

amount

(Puls.)

User

programmable

Programm. by

Production / Service

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

frother

* Depends on the language selected by the user

Continues until the water supply has been exhausted (capacitive sensor)

RINSE Initial rinse Final rinse

When performed When the machine is switched

on and the boiler temperature is

≤ 50°C

When the machine is switched

off electronically, manually or

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/

Service department

No. of pulses user
adjustment option

No No

No No

No. of pulses adjustable

by Production/Service

No No

department
Pulse range

(Min. – Max.)

No No

Descaling cycle frequency

Hardness Water hardness Withoutwaterlter Withwaterlter

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

(over 21°dH)

30 litres (60,000 pulses) 60 litres (120,000 pulses)

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 / 03

02

EXPRELIA 02 TECHNICAL SPECIFICATIONS

DREG DRAWER Description and values

Time-out for dreg drawer

Warning to empty dreg drawer after

Shutdown alarm to empty dreg drawer after

(double coffee as last product dispensed)

Yes, after 12 lots of dregs

15 lots of dregs

(16 lots of dregs)

The dreg drawer must be emptied only

Reset dreg counter

when prompted by the machine ensuring

the machine is switched on and removing

the drawer for more than 5 seconds.

STANDBY Description and values

Inlet time (min. – max.) 15 minutes - 180 minutes

Inlet time (default) 60 minutes

Inlet time programmed by user Yes

Inlet time programmed by Production/

Service

Boiler temperature during Standby Boiler OFF

Cup heater during Standby Cup heater OFF

5 sec.

Yes

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lter 200

Waterreserve(pulses)withnowaterlter 200

WaterreservemodiablebyProduction/Service

No

departments

"Fill tank" alarm Yes

"No tray" alarm No

Water mains No

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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 coffee

Key used to select aroma

Key used to dispense
a long coffee

Key used to select aroma

Key used to access
special beverages

Key used to dispense a cappuccino

Key used to select "MENU"

MENU

OK

ESC

Function keys

Key used to carry out a
carafe cleaning cycle

Key used to set the
machine on standby

BEVERAGE MENU The machine allows custom settings for dispensing each beverage

MENU

BEVERAGE MENU

MACHINE MENU

ESC

MENU

1

MENU

OK

Press the "MENU" button to go

to the machine's main menu

ESC

ESPRESSO

AMOUNT OF COFFEE

PREBREWING

COFFEE TEMPERATURE

MENU

OK

ESC

OK

Press the "OK" button to go to

the BEVERAGE MENU

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

aroma of the coffee. OFF - LOW - HIGH

Coffee temperature:• LOW - NORMAL - HIGH
Coffee size:• Used to program the quantity of coffee to dispense.
Amount of milk:• (only for cappuccino, latte macchiato and hot milk) Used to

program the quantity of milk to dispense.

Amount of water:• (only for HOT WATER) Used to program the quantity of

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

BEVERAGE MENU

ESPRESSO

COFFEE

LONG COFFEE

OK

2 3 4

Scroll/select key1.

Select/conrm key2.
Exit key3.

Scroll/select key4.

ESC

MENU

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01

EXPRELIA 03 USER INSTRUCTIONS

MACHINE MENU Used to customize the machine's operational settings

MENU

BEVERAGE MENU

MACHINE MENU

OK

GENERAL MENU

GENERAL MENU

SOUND

OFF

ON

ECOMODE

OFF

ON

GENERAL STANDBY

Press the "OK" button
to go to the MACHINE
MENU

MACHINE MENU

GENERAL MENU

DISPLAY MENU

WATER MENU

MENU

ESC

To change the appliance operating settings

This function permits activating/deactivating audible warnings

To enable buzzers

To disable buzzers

This function governs activation of the boilers in the appliance for energy saving

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

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

standby. The default time setting is 60min

OK

ESC

Press the "OK" button to
go to the submenus

MENU

15 MINUTES

30 MINUTES

60 MINUTES

180 MINUTES

DISPLAY MENU

DISPLAY MENU

LANGUAGE

ENGLISH

BRIGHTNESS

WATER MENU

WATER MENU

HARDNESS

After the set time the machine will go onto standby.

To reactivate the machine, press any button.
After running function diagnosis and the heating phase, the machine is again ready for use

This function is used to set the menu language and the display brightness

This setting is vital for correctly setting the parameters of the appliance for the user's country

The currently selected language is shown

To set the correct brightness

This menu is used to set the parameters for correct water management

To change the setting of the hardness of the water in the appliance, adjusting it to the one used, so it

will request descaling at the right time

To activate/deactivate the water lter replacement warning. When this function is active the appliance

ACTIV. FILTER

ENABL. FILTER

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

warns the user when the water lter needs to be changed.

OFF: Warning disabled ON: Warning enabled

(this value is set automatically when the lter is activated)

To activate the lter after it has been installed or replaced.

02

EXPRELIA 03 USER INSTRUCTIONS

MAINTENANCE

MAINTENANCE

METERS FOR

UNIT CLEANING

CARAFE CLEANING

DESCALING

CLEAN CARAFE

OFF

ON

FACTORY SETTINGS

This function lets you set all the functions so that machine maintenance is managed better

This function is used to view how many products have been prepared for each single type of beverage
since the last reset

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

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

standby. The default time setting is 60min

The self-cleaning function is disabled

The self-cleaning function is enabled

FACTORY SETTINGS

This function allows the factory values to be reset.
Restoring the factory parameters deletes all the personal parameters set beforehand.

3.2. Machine indications

INSERIRE

COPERCHIO CHICCHI

ADD COFFEE

Close the coffee bean hopper
lid to enable delivery of any
beverage

Fill the coffee
container

SVUOTARE

CONTENITORE FONDI

CHIUDERE SPORTELLO

FRONTALE

Remove the dregs drawer.
Note: The dregs drawer must
only be emptied when requested
by the machine and with the
machine on.

For the machine to become

operative, the service hatch

must be closed

INSERIRE GRUPPO

Insert the brewing unit
in its correct location

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

RIEMPIRE

SERBATOIO ACQUA

Take out the tank and ll it with

fresh drinking water

03

EXPRELIA 03 USER INSTRUCTIONS

Open the front hatch and empty
the drip tray underneath the
brewing unit. You should also

empty the dreg drawer, as the

dregs counter will also be reset
when the machine is switched on.

INSERIRE

CONTENITORE FONDI

Insert the dregs
drawer

SVUOTARE VASCA

GRUPPO

RUOTARE CARAFFA

IN EROGAZIONE

ESC

RUOTARE CARAFFA

IN RISCIACQUO

ESC

INSERIRE CARAFFA

ESC

A beverage containing milk has
been selected. The machine asks
you to place the carafe handle
spout in its dispensing position.
Press “ESC” to cancel the
procedure

The carafe rinse function has been
selected.
Press “ESC” to cancel the
procedure

An operation has been selected
that requires dispensing from the
milk container.
Insert the milk container. Press
“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

RIAVVIARE PER

RISOLVERE IL

PROBLEMA

The appliance requires a descaling
cycle.
With this message you can keep on
using the machine but there is the
risk it will not work properly.

The machine requires replacement

of the "Intenza" lter with a new

one.
The alarm is displayed only if the

"enable lter" function is ON.

An even has occurred that requires
restarting the appliance.

Take note of the code (E xx) shown

at the bottom

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

04

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

4

5 Select the desired language Store

6 Heating When the heating phase begins, wait for it to nish
7 Rinse Carry out a rinse cycle for the internal circuits
8 Machine ready The machine is ready to dispense beverages

A Empty the dregs drawer When indicated
B Empty the drip tray As necessary (oat indicator)

C Clean the water tank Weekly

D Clean the coffee bean hopper As necessary

E Clean the casing As necessary

F

H Descaling When indicated

Press the button to start the
appliance

CLEANING AND TECHNICAL SERVICING

Clean the brewing unit Every time the coffee bean hopper is lled or weekly

Lubricate the brewing unit After 500 dispensing cycles or when the grease is no

longer present on the brewing unit

Clean the unit housing Weekly

Descaling cycle frequency

Hardness Water hardness Withoutwaterlter Withwaterlter

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

(over 21°dH)

The default water hardness level is 3. Each litre of water corresponds to approximately 2,000 pulses

30 litres (60,000 pulses) 60 litres (120,000 pulses)

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05