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

03

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.

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

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

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 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

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

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)

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

- COLD WATER

- HOT WATER / STEAM

- STEAM

- HOT WATER

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

01

EXPRELIA 04 OPERATING LOGIC

4.2. Frother unit valve assembly

Air inlet

Air solenoid valve

Clean solenoid

valve (steam)

DC3

DC4

Steam outlet

Steam outlet

DC2

Steam solenoid valve

Hot water/steam

inlet

DC5

Hot water /steam
solenoid valve

Hot water/steam

outlet

Drain protecting

frother unit valve

DC1

Drain solenoid valve

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

4

3

7

1

2

5

1 Cappuccino valve body

2 Milk suction pipe and attachment
3 Venturi pipe

4 Milk dispenser pipe

5 Upper attachment of drain pipe

for carafe

6 Lower attachment of carafe drain

pipe

7 Levers, springs and pin for carafe

present/missing indication and
dispenser positioning

6

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

02

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

AIR

VENTURI

PIPE

MILK FROM

CARAFE

STEAM

FROTHED HOT MILK
(CAPPUCCINO)

HOT MILK

STEAM

Clean

(steam)

Milk-based

beverages

(steam)

DC4

DC3

DC2

Air

MILK FROM

CARAFE

MILK IN

CARAFE

VENTURI

PIPE

CLEAN / RINSE

VENTURI

PIPE

DC1 = pressure relief valve assembly
DC2 = steam valve
DC3 = air valve
DC4 = clean valve (steam)
DC5 = hot water/steam valve

AIR or STEAM

STEAM

hot water /

steam

PRESSURE RELIEF VALVE

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

DC5

DC1

to steam pipe

HOT WATER - STEAM

CARAFE ATTACHMENT

03

EXPRELIA 04 OPERATING LOGIC

4.3. Multi-way valve

Needle

Drain to drip tray

Drain

Water entering

from the boiler

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 relling the
circuit by expelling the air in the pipe

Unit discharge: before the unit descends it opens briey, discharging the pressure created to prevent spraying and

making the pad drier

Coffee beverage: when a coffee beverage is selected, the pump is charged briey during the grinding process and
the valve assumes the drain position in order to ll the pipes with hot water.

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

04

EXPRELIA 04 OPERATING LOGIC

4.4. Coffee cycle

Main

START STOP

switch ON

Time

Coffee grinder

Heating

Pump

approx.
45 sec.

Pulses

(Dosage)

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

Single microswitch gearmotor

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

- The 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

The coffee grinder starts the grinding process (controlled by pulses generated by a sensor)1.
The gearmotor (brewing unit) moves to the dispensing position2.
Preliminary dispensing phase (short pump activity, short pause)3.
Product dispensing (the pump operation period is dened by the amount of product dispensed)4.
The gearmotor moves to its home position (the dregs are expelled automatically)5.

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05

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

1

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

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06

EXPRELIA 04 OPERATING LOGIC

t1

V

t2

t3

t4

t

4.7. Coffee grinder

5

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

Without beans n=100%

With beans n=100%

No coffee

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

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

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

Without beans n=50%

With beans n=50%

t2 = no indication

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

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
system and the grinder will come to a stop

07

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 (SELF­LEARNING); 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” avour is selected by the user, no modication 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.

Setting/Status

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

Power consumption

in mA

Pulses corrected in the next grinding process

Exceeded by Decient by

Important:

For perfect operation, machine adjustment should take place in the area of the elds
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 insufcient 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 / 11

08

EXPRELIA 04 OPERATING LOGIC

4.10. SBS

SBS - Saeco Brewing System - Principle

Controlling the ow speed, which inuences

the contact time between the coffee and

water, changes the extraction and therefore

the taste intensity and strength of the coffee.

Slower ow: strong extraction•
Fast ow: lighter extraction•

SBS / dispensing valve

Turning the SBS control knob leads to brewing

taking place inside the brewing unit, where
the ow speed is adjusted using a cream

valve.

Cream valve control

Fastow(slightextraction)

If the SBS valve is open, the coffee ows

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 ow is not diminished.

Cream valve control

Slowow(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 ow.

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

09

EXPRELIA 04 OPERATING LOGIC

4.11. Water level detection (water tank)

“Water low” message (water reserve)

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

Function:

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)

Total
capacity

Drip tray

Switching
level sensor

Sensor

“Empty drip tray” - message

Function:

The residual water level is monitored using a capacitive

sensor. The sensor is located approximately halfway up the

upper edge of the drip tray. To ensure the best possible

use of the drip tray capacity, the sensor is located near to
a dam. Therefore, the drip tray lls up to the upper edge
of the dam and overows inside, triggering the sensor and

thus the “Empty drip tray” message.

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

10

EXPRELIA 04 OPERATING LOGIC

4.13. Descaling request

Filter

on

Filter

off

Flow meter pulses

360°

1 rev

“Descaling”–messagewithwaterlter

inserted

(appliances with display only)

The water hardness is set on the basis of the
regional water hardness analysis

(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 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lter”message

The electronics assembly uses the turbine impulses
to keep track of the amount of water which has

owed through; after the specied amount (set
in accordance with the water hardness level), the
“Replace lter” message appears.

4.14. Waterlter

Bypass

Waterlter

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•

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

4

3

1

OK

MENU

ESC

Entry into Test Mode results in a screen divided into sections, as illustrated in the diagram below

A

C

B

D

Software

A

B

DC

XX.YY.ZZ

E

* * * *

GF

E

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 dened 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 / 07

01

EXPRELIA 05 TROUBLESHOOTING

Software version

Software

D:64

*

* *

KEYBOARD

Espr

Long

E:8

P Off

Caf

Spec

xx.yy.zz

Debug msg

*

* *

*

Cappucc

Clean Stdby

* * * *

*

(xx.yy.zz)• software version loaded onto the machine
(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
machine is switched on
Debug msg:• if active it enables the automatic dosing debug messages

for the next restart only

Keyboard

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)

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

Work

Stop

Home

10

DDr H/W

UNIT

mA: xx

Dreg- Dreg+

Door Pres

HOME• : if pressed, switches the unit into its Home position
DREG UP• : increases the coffee dregs counter
DREG DOWN• : decreases the coffee dregs counter

Indicators:

mA• : indicates moment by moment the maximum current (in mA)

consumed by the unit when moving. Its value must not exceed 300 mA
H/W• : becomes active (illuminated) when the unit reaches a “Work”

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 / 07

02

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

DcV 1

DcV 2

DcV 3

Tank Clean

HYDR

Boil1

Pmp1

Boil2

Pmp2

22.6 23.4

CIRCUIT 1/2

DcV 5

Ac V DcV 4

*

Milk Pres

CIRCUIT 2/2

p/s 0

*

*

DTrav 50 Hz

Dc V2• : activates the 24V steam dispensing solenoid valve
Dc V3• : activates the 24V milk frothing solenoid valve
Dc V4• : activates the 24V solenoid valve for milk circuit cleaning
Dc V5• : activates the 24V hot water dispensing solenoid valve

Indicators

Tank• : indicates the status of the water tank level sensor. If activated,

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

either by pressing the button again or automatically after 5 seconds. The
temperature is indicated in the corresponding window at the bottom

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
the bottom
Pmp1• : activates the hot water dispensing pump. The pump is
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 ow 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

BTest

A +

100 DDoor

*

Pls: 0

34A -

BLess Z-Cr

17

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

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
the test, 2 values will appear in the "instantaneous threshold" and

"reference threshold" windows: if “instantaneous threshold” is less
than the “reference threshold” the system considers that the coffee
grinder is empty

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

03

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modiedmanuallywiththe

“A+” and “A-" keys or automatically by the automatic dosing algorithm

Display

SETTINGS

C +

L +

C -

L -

52 40

STEAM OUT

Boil1

Boil2

*

54.8 50.2

*

*

*

*

* *

*

Start

**

*

*

T .0

Operation:

C+• : increases the contrast of the display
C-• : decreases the contrast of the display
L+• : increases the brightness of the display
L-• : decreases the brightness of the display

Indicators

The values at the bottom are indices representing the •
brightness and contrast: in this case these values are not
saved to eeprom as they have solely a test function

Steam Out

Operation:

Boil1• : illuminates when the coffee boiler is powered
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
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 / 07

04

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

3

2

4

OK

MENU

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

MENU

PRODUCT COUNTER

PRODUCT COUNTERS

ERROR COUNTER

ERROR COUNTERS

WATER COUNTER

WATER COUNTERS

BREWING UNIT RINSING

BREWING UNIT CLEANING

MAX GRINDER DOSE

MAX GRINDER DOSE

MAX GROUND

MAX GROUND

HOTWATER FLOWRATE

HOTWATER FLOWRATE

CUP TEMPERATURE

CUP TEMPERATURE

DESCRIPTION

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
system and enables resetting. The max number of counted “fails” is 20

This shows the water consumption (in pulses) after dispensing beverages,
for the descaling cycle, the unit cleaning cycle and lter activation

This shows the water consumption after the last unit cleaning cycle and
the number of times cleaning has been performed

This is used to select the highest dose threshold the coffee grinder can
accommodate

This is used to select the maximum number of coffee grounds batches.

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
ow meter

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

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

05

EXPRELIA 05 TROUBLESHOOTING

Press the or buttons to move the cursor onto the desired beverage and
press to enter the submenu

1. PRODUCT COUNTERS

2. ERROR COUNTERS

OK

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.•

ERRORS LOG• ERROR CODE •

(default 0)•

ERROR INDEX •

(default 0)•

ERROR TEXT•

• (default 0)

ERRORS RESET• All the errors are reset

3. WATER COUNTERS

DESCALING CYCLES• WATER SINCE LAST •

CYCLES
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 •

(default 0)•

NUMBER OF EXECUTION •

(default 0)•

ERROR CODE - the code representing the type of error that
has occurred (see Tab. 5.3 Error messages)

NUMERICAL POSITION - represents the numerical position
of the error in the internal list for a max no. of 20

ERROR DESCRIPTION - a text description of the type of

error that has occurred

Represents the consumption of water since the last
descaling cycle

Represents the consumption of water since the last unit
cleaning cycle. When performed it goes back to 0.

Represents the number of unit cleaning cycles carried out
on the C.A.

WATER FILTER•

SINCE LAST RESET •

(default 0)•

NUMBER OF RESET •

(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 / 07

Represents the consumption of water since the last lter

activation cycle. When performed it goes back to 0

total no. of lter activation cycles performed.

06

EXPRELIA 05 TROUBLESHOOTING

5.3. Error messages

Code Brief description Description

01 coffee grinder blocked

03

Brewing unit blocked in ‘work’
position

04 Brewing unit blocked in ‘home’

position

05 Water circuit blocked

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

Descent time-out exceeded

Ascent time-out exceeded

No water in ow meter or ow meter not turning
(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

14

15

Various temperature errors
(in the coffee boiler)

Various temperature errors
(in the steam boiler)

Coffee boiler temperatures out of control

Steam boiler temperatures out of control

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

17 Not used

18 Clock error Memory fault or impossible to set

19 No zero crossing

No zero crossing on card, could be caused by power

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 modications (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 lter: 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 / 02

01

EXPRELIA 06 STANDARD CHECKS

6.3. Final test

Test Procedure Support/tool Standard Tolerance

Espresso

Coffee

2-3 Espressos for

adjustment purposes

2-3 Coffees for

adjustment purposes

Measuring scoop Same amount 15%

Measuring scoop Same amount 15%

Noise Standard

The cream

Amount of
cream

Blow into the cup until
the cream separates

should come
together again to
form a complete
layer

Cream colour Hazel brown

Temperature

Grinding level

Reading taken while
dispensing

Check the grain size of

the ground coffee
Hot water Dispense water
Steam Dispense steam
Dreg drawer
missing

Remove the dreg drawer
indication
Missing
indication
coffee beans

Start brewing a coffee

while the coffee bean

hopper is empty

Thermometer 84 ˚C ± 4 ˚C

Dreg drawer
missing indication

Missing indication
coffee beans

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

02

Saeco International Group Rev. 00 / June 2010 EXPRELIA

EXPRELIA 07 DISASSEMBLY

AA

BB

CC

DD

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

Loosen the screws as
indicated and remove the rear
frame

7.2. Coffee grinder

Unscrew the screws as indicated under the water container cover

(A) and the coffee bean hopper (B). Unhook and gently raise the
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

Loosen the screws as
illustrated and remove the
sound insulating cover of the
coffee grinder

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

Raise the coffee
grinder and remove the
connections

When reassembling the coffee

grinder, make sure the spring is
repositioned correctly (see photo)

01

EXPRELIA 07 DISASSEMBLY

ABA

B

7.3. Grinder blades

To extract the top support of the appliance, press on the
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 / 09

02

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 / 09

03

EXPRELIA 07 DISASSEMBLY

11

22

11

33

7.6. Coffee pump

7.7. Turbine

7.5. Steam pump

Slide out the two pump supports (highlighted)
xed to the housing and disconnect the electrical

and water circuit connections

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
connections

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

7.8. Power card

7.9. Steam boiler

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

1-2)Unscrew the screws shown

3)Unhook the boiler, disconnect the

electrical and water circuit connections

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

04

EXPRELIA 07 DISASSEMBLY

11

22

33

E

B

C

A

D

F

E

B

C

A

D

F

HLH

L

B

G

P

B

G

P

7.11. Gearmotor:

7.10. Coffee boiler

Loosen the screws as
illustrated and remove the
boiler pin

1-2)Unscrew the screws shown

3)Unhook the boiler, disconnect the

electrical and water circuit connections

Loosen the screws as
illustrated and remove
the boiler pin

Loosen the screws as
illustrated and remove the
gearmotor cover

The following are located inside the compartment
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)

- Dispensing head present microswitch (E)

- Microswitch (F) detecting brewing unit home and work

positions

- Remove the gear (C) that meshes with the motor

transmission shaft

- Remove the large gear (B)

- Remove the motor (A), complete with transmission shaft

- (G) Multi-way valve drain

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

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

When replacing the motor and the transmission shaft, make
sure the guide runners (L) are in the right position.

Grease the shaft thoroughly and evenly.

05

EXPRELIA 07 DISASSEMBLY

AA

7.1. Multi-way valve

Unscrew the screws as
indicated to reach the screw

anchoring the multi-way valve

to the support

7.13. Frother unit valve assembly

Unscrew the screws anchoring the
valve support to the housing and

to the horizontal plate as shown

Loosen the screw as
illustrated and remove
the clip

Unscrew the screws
shown and pull out
the valve assembly

Disconnect the
electrical and water
circuit connections

Unhook the support for

coupling the drain (A) and
extract the three Teon tubes

as shown

7.14. Door tube coupling

Loosen the screws as
illustrated

Extract the coupling

guard

Unhook the coupling (A) and
extract the three Teon tubes

as shown

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

06

EXPRELIA 07 DISASSEMBLY

AA

BB

7.15. Dispenser assembly

Extract the dispenser assembly

Loosen the screws as illustrated
to remove the inner front panel
cover

Loosen the screws located inside the door and slide out the coffee

dispenser as shown

7.16. Steam pipe assembly

Remove the dispenser (photo B);
when replacing it, make sure the

spring highlighted is positioned
correctly

Loosen the screws as illustrated to
remove the inner front panel cover

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

Remove the fork spring and the steam pipe washer, disconnect the pipe
from the Teon by removing the fork

07

EXPRELIA 07 DISASSEMBLY

Loosen the screw as shown

7.17. General carafe card assembly

7.18 Teonpipesupportandcarafeattachmentassembly

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 inner front panel cover

Remove the Teon pipe support assembly

7.19. CPU and display card

Loosen the screws as
illustrated and remove the

guard and the at cable

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

Remove the screws shown and pull the Teon pipe support cover

away from the carafe

Unscrew the screws of the
display support as shown

08

EXPRELIA 07 DISASSEMBLY

121

2

Extract the connections and at

cable.

7.20. Fitting and removing Oetiker clamps

Extract the display and the

keypad

1) Boiler connection

2) Other connections

CPU and display card assembly

Use a suitable pair of pliers to remove the

clamp (as illustrated)

Tighten the clamp as illustrated

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

09

CHAPTER 8

NOTES

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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

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01

CHAPTER 10

ELECTRICAL DIAGRAM

Saeco International Group Rev. 00 / June 2010 EXPRELIA

EXPRELIA 10 WIRING DIAGRAM

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01