Saeco Estrosa, Carezza User Manual

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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 with the exception
of that authorised in writing or in accordance with a contractual agreement.

Service Manual

Revision 01 Jan 2013

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 Service Policy 2

1.6.1 External machine parts in manual machine 3

1.6.2 Internal machine parts in manual machine 4

1.7.1 External machine parts in Estrosa and Carezza 5

1.7.2 Internal machine parts in Estrosa and Carezza 6

2. Technical specifi cations

2.1 Technical specifi cations 1

2.2 Descaling frequency 1

2.3 Specifi cation for the measurement of the coffee products temperature. 2

3. User instructions

3.1 Operation, cleaning and maintenance 1

4. Operating logic

4.1.1 Water circuit 1

4.1.2 Exploded view of a water circuit in Estrosa and Carezza 2

4.1.3 Exploded view of a water circuit 3

4.1.4 Hydraulic diagram in Estrosa and Carezza 4

4.1.5 Hydraulic diagram 5

4.2.1 Wiring diagram in Estrosa and Carezza 6

4.2.2 Wiring diagram 7

4.2.3 Electrical diagram 7

4.3 Filter holder 8

4.4 Spherical cappuccino maker and nozzle 8

4.5 Flow meter 9

4.6 Anti-scale fi lter 9

5. Troubleshooting

5.1. Test Mode in Estrosa and Carezza 1

5.2. Causes and solutions 2

6. Standard inspections

6.1 Repair schedule 1

6.2 Service schedule 1

6.3 Final inspection 2

Contents

SAECO MANUAL MACHINES

Page

7. Disassembly

7.1.1. Outer elements 1

7.1.2 Controls support 2

7.1.3 Boiler support 2

7.1.4 Pump 2

7.1.5 Boiler thermostats 3

7.1.6 Boiler 3

7.1.7 Shower and valve 3

7.1.8 Steam pipe 3

7.2.1 Outer elements Carezza/Estrosa 4

7.2.2 Pump Estrosa/Carezza 5

7.2.3 Boiler support assembly Estrosa/Carezza 5

7.2.4 Steam knob Estrosa/Carezza 5

7.2.5 Steam pipe Estrosa/Carezza 5

7.2.6 CPU/power card Estrosa/Carezza 6

7.2.7 Keyboard card Estrosa/Carezza 6

7.2.8 Filterholder locking ring Estrosa/Carezza 7

7.3 Un/installing Oetiker clamps 8

8. Notes

SAECO MANUAL MACHINES

SAECO MANUAL MACHINES

CHAPTER 1

INTRODUCTION

MANUAL MACHINES 01 INTRODUCTION

SAECO Page / 06

1.1 Documentation required

The following documentation is required for repairs:

• Instruction booklet of the specifi c model

• Technical documentation for specifi c model (diagrams, exploded view, sympton cure and
service manual)

1.2 Tools and equipment required

Besides standard equipment, the following tools are required:

Qty. Description Notes

1 Screwdriver
1 Pliers for Oetiker clamps
1 AC - DC - Vdc tester
1 Digital thermometer Scale Limit > 150°C
1 SSC (Saeco Service Center) Programmer

(for programming and diagnosis mode)
1 Allen wrench
1 Hexagonal spanner

1.3 Material

Description Notes

Thermal grease Thermal resistance > 200°C
Descaler Saeco descaler
Degreaser Personal choice
Silicone grease Safe to use with food

1.4 Safety warnings

It is recommended to consult this Service manual of the machine before implementing any opera­tion.
Comply with all applicable standards relating to the repair of household appliances.

Always disconnect the power plug from the mains before beginning repairs on the machine.

Simply turning off the main switch is not suffi ciently safe to prevent electrical discharges.

This household appliance is rated as insulation class I.
On completion of the repairs, insulation and dielectric rigidity tests must be performed.

01

MANUAL MACHINES 01 INTRODUCTION

SAECO Page / 06

02

Components Assembly use Single components available

COFFEE

GRINDER

Only for OOW repairs

YES, to consult the specifi c exploded-view of the

machine or of the Coffee Grinder on website

BREWING

UNIT

Only for OOW repairs

YES, to consult the specifi c exploded-view of the

machine or of the Brewing unit on website

BOILER Only for OOW repairs

YES, to consult the specifi c exploded-view of the

machine on website

GEAR

MOTOR

Only for OOW repairs

YES, to consult the specifi c exploded-view of the

machine on website

FILTER

HOLDER

Only for OOW repairs

YES, to consult the specifi c exploded-view of the

machine on website

MILK

CARAFE

Only for OOW repairs

YES, to consult the specifi c exploded-view of the

machine on website

THERMAL

CARAFE

Only for OOW repairs

YES, to consult the specifi c exploded-view of the

Thermal Carafe on website

MILK ISLAND Only for OOW repairs

YES, to consult the specifi c exploded-view of the

Milk Island on website

1.5 Service POLICY grid as used for coffee machine

List of principal assembly present in all our coffee machines

For IN WARRANTY repairs is mandatory to use the single components (not the assembly) avai-

lable in the exploded views of the coffee machines or of the specifi c components. If you fi nd the

information “SEE THE EXPLODED VIEW E........” in the assembly description fi eld, it means that

the single components of the assembly are available in the other pages of the exploded view. It’s
possible to use the assembly only if there is a specifi c Symptom Cure that include this possibility
or when the single components are not available for the order.

MANUAL MACHINES 01 INTRODUCTION

SAECO Page / 06

03

1.6.1 External machine parts in manual machine

Water tank

ON/OFF switch

Hot water/steam
dispensing pipe

Hot water/steam
dispensing knob

Nozzle

Drip tray+grille

Pressurised
fi lter holder

Selection
knob

Some machines have the spherical

cappuccino maker instead of the

nozzle

Spherical

Cappuccino maker

MANUAL MACHINES 01 INTRODUCTION

SAECO Page / 06

1.6.2 Internal machine parts in manual machine

04

Boiler assembly

Pump assembly

Overpressure
valve

Hot water/Steam
opening - closing
knob rod

Thermal protector

Overpressure
relief valve

Thermostats

Selection knob

Filter holder ring

MANUAL MACHINES 01 INTRODUCTION

SAECO Page / 06

05

1.7.1 External machine parts in Estrosa and Carezza

Control panel

Hot water /steam

dispensing pipe

1/2 cup fi lter

Coffee measure

Power cable

connector

Water temperature

thermometer

Steam button

Rinsing button

Led “Allarm”

Led “Descaling”

On/Off button

Coffee button

Led machine “ON”

Led “Temperature”

Led “Rinsing”

Led “Steam”

Knob
Hot water /steam

Support for cups

Drip-tray

Water

tank

Cappuccinatore

Grille

Filter holder

pressurised

Led

“Descaling”

Led

“Steam”

Led

“Rinsing”

Led

““Alarm”

Led

“Temperature”

Coffee button

Rinsing button

Steam button

ON/OFF button

Knob
Hot water /steam

MANUAL MACHINES 01 INTRODUCTION

SAECO Page / 06

BOILER

FLOW SELECTOR

FAUCET

Filter holder

pressurised

Boiler

1.7.2 Internal machine parts in Estrosa and Carezza

Coffee

Hot water/steam

Water

tank

Pump

Boiler

Hot water/steam

Cold water

Diagram hydraulic circuit

06

SAECO MANUAL MACHINES

CHAPTER 2

TECHNICAL SPECIFICATIONS

MANUAL MACHINES 02 TECHNICAL SPECIFICATIONS

SAECO Page / 02

2.1. Technical specifi cations

Technical specifi cations Estrosa and Carezza

2.2. Descaling frequency

Safety system: 2 one-shot thermostats (127°C and 95°C) 1 thermal protector >

184°C
Coffee heat exchanger
output: Stainless steel

(230/120 V~) 1000 W – for coffee, hot water and steam

dispensing
Pump Ulka Type EP5/S GW approx. 13-15 bar with reciprocating piston

and 120°C cutout 48 W, 230V, 50 Hz, 120V, 60Hz 100V, 50/60 Hz

and Defond A2P03 220-240V 53W
Overpressure valve: Opening at approx. 16-18 bar
Water fi lter: In tank
Flow meter assembly Only in the single versions with the coffee amount setting
Consumption: During the heading phase of 8,2A, during the brewing phase 8,5A

Safety system: 2 one-shot thermostats 190°
Coffee heat exchanger
output: Stainless steel

1900 W 230V – for coffee, hot water and steam dispensing

Pump Ulka Type EP5/S GW approx. 13-15 bar with reciprocating piston

and 120°C cutout 48 W, 230V, 50 Hz, 120V, 60Hz 100V, 50/60 Hz

and Defond A2P03 220-240V 53W
Overpressure valve: Opening at approx. 16-18 bar
Water fi lter: In tank
Consumption: During the heading phase of 8,2A, during the brewing phase 8,5A

01

Descaling frequency

Hardness

Water hardness Without anti-scale fi lter With anti-scale fi 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)

MANUAL MACHINES 02 TECHNICAL SPECIFICATIONS

SAECO Page / 02

2.3. Specifi cation for the measurement of the coffee products temperature.

The temperature is infl uenced by the fl ow from the dispenser and stratifi cation of temperatures in
the glass. In order to consider these phenomena and to introduce measures that allow compari­sons in controlled conditions, below guidelines must be followed:

Conditions:

a) Water temperature in tank: 23°C (+/-2°C).

b) It must be used a plastic cup (see picture N°1).

c) It must be used a thermocouple thermometer (e.g. type K - see picture N°2).

d) The coffee machine is tested without any change of parameters or calibrations, which may
affect the temperature of products, so the measurement of temperature must be done with
machine in default factory setting.

Procedure:

1. The temperature must be measured in the cup, immediately after dispensing. Cup has to be
placed on a non-metal surface using a thermocouple thermometer.

2. The temperature in the cup is measured by immersing the probe of the thermometer up to
touch the bottom.The probe then must be moved in a circular motion for 5/6 rotations. At the
of the rotations, stop in the center of the cup.

3. The highest temperature measured during the rotations is the value we are searching for, and
that must be reported;

4. Test measurement: from end of dispensing to the end of rotations must be completed within 12
seconds.

Limits of acceptability

The acceptance limits are divided by features and products and are the following:

Espresso Coffee Italy Q.ty 25/40 gr.

Temperature of 1st product 69°C ≤ 85°C
Temperature of 2nd product 72°C ≤ 85°C

Coffee Q.ty 70/120 gr.

Temperature of 1st product 69°C ≤ 85°C
Temperature of 2nd product 72°C ≤ 85°C

Picture 1

Picture 2

02

SAECO MANUAL MACHINES

CHAPTER 3

USER INSTRUCTIONS

MANUAL MACHINES 03 USER INSTRUCTIONS

SAECO Page / 01

3.1 Operation, cleaning and maintenance

CLEANING AND TECHNICAL ASSISTANCE

A Empty the drip tray As necessary (fl oat)
B Clean the water tank Weekly
C Clean the fi lter holder As necessary
D Clean the casing As necessary
E Descaling cycle If signalled

01

Descaling frequency

Hardness

Water hardness Without anti-scale fi lter With anti-scale fi lter
1 Soft (up to 7°dH) 240 litres 480 litres
2 Medium (7° - 14°dH) 120 litres 240 litres
3 Hard (15° - 21°dH) 60 litres 120 litres
4 Very hard

(over 21°dH)

30 litres 60 litres

Operating the machine

1 Fill the water tank

2

Fill the coffee bean
container

3 Switch on the appliance

4

Press to switch on the
machine

/

5 Heating The heating phase begins, wait for it to fi nish
6 Machine ready The machine is ready to dispense beverages

SAECO MANUAL MACHINES

CHAPTER 4

OPERATING LOGIC

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

WATER TANK

FLOW METER

BOILER

STOPCOCK

THERMOSTATS

HOT WATER/STEAM

DISPENSING PIPE

DISPENSING COFFEE

FILTER HOLDER

PUMP

OVERPRESSURE VALVE

4.1.1 Water circuit

Various types for water circuit

01

- COLD WATER

- HOT WATER/STEAM

- HOT WATER

Coffee

Pump

Boiler

Hot water/steam

Water

tank

P.S.: Only the single coffee machines have a fl ow meter, which can set and save the amount

of dispensed coffee via the control board.

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

02

4.1.2 Exploded view of a water circuit in Estrosa and Carezza

THERMOSTATS

HOT WATER/STEAM

DISPENSING PIPE

PUMP

BOILER

OVERPRESSURE

VALVE

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

4.1.3 Exploded view of a water circuit

03

THERMOSTATS

HOT WATER/STEAM

DISPENSING PIPE

OVERPRESSURE

VALVE

PUMP

BOILER

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

4.1.4 Hydraulic diagram in Estrosa and Carezza

04

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

4.1.5 Hydraulic diagram

05

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

4.2.1 Wiring diagram in Estrosa and Carezza

06

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

07

4.2.2 Wiring diagram

4.2.3 Electrical diagram

MANUAL MACHINES 04 OPERATING LOGIC

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4.4 Spherical cappuccino maker and nozzle

08

HOT WATER/STEAM
PIPE FITTING

STEAM

STEAM

HOT WATER/STEAM
PIPE FITTING

AIR FLOW

ADJUSTMENT

NEEDLE

MILK

FROTHED

MILK

STEAM

4.3 Filter holder

Pressurised and mechanical
fi lter holder

Standard
fi lter holder

MANUAL MACHINES 04 OPERATING LOGIC

SAECO Page / 09

Anti-scale fi lter

Function:

• Reduced limescale deposits that take longer to form.

• Improved water quality.

• Better taste due to ideal water hardness

Descaling duration / effi ciency:

• - 10° dH

• 60 litres

• 2 months

To obtain a linear characteristic of its effectiveness,
throughout the duration of the descaling process, the
water is split according to the degree of hardness in a
three-phase by-pass (A, B and C).
See small picture.

Bypass

4.6 Anti-scale fi lter

09

4.5 Flow meter

1) upper body

2) fl ow meter

3) magnet

4) O-ring seal

5) lower body
A) Board

The water enters, hits against the blades of the fl ow
meter, causing it to turn.
The magnet passes beneath the board and transmits
the number of revs to it, which in turn transmits it to
the main board

Water inlet

Water outlet

1

4

5

3

A

2

SAECO MANUAL MACHINES

CHAPTER 5

TROUBLESHOOTING

MANUAL MACHINES 05 TROUBLESHOOTING

SAECO Page / 02

01

5.1 Test Mode in Estrosa and Carezza

ENTER IN TEST MODE:
The entering in Test mode is possible only disconnecting the machine from the main plug,
opening the steam knob and pressing the coffee button and the rinsing button at the

same time, connecting the machine to the main plug and keep pressed the buttons for 3

seconds.

After 3 seconds the Led Alarm and Led Descale turn on and the thermometer (only Gaggia

version)will move to reache the zero to confi rm the entering in TEST MODE.

TEST MODE:

At this point at every button presion will be associate the turning on of one Led and the turning
on of a load for 3 seconds. In this mode it is possible to do the machine steam out.

• ON/OFF button turn on Heater and Led ON for 3 seconds (only in Gaggia machine).

• Coffee button turn on Led coffee and move the Motor for 3 seconds.

• Rinsing button turn on Led Rinsing and Pump. Pressing again the Rinsing button the

pump will turn off.

• Steam button turn on the Led Steam.

STEAM OUT:

• Push contemporarily ON/OFF button and STEAM button will turn on Led ON and the
Led Steam.

• Keep the button pressed for 3 seconds.at the end of this time the 2 led will turn off and

Led Steam starts blinking indicating that the heater is going in steam temperature.

• During the warming up some water will fl ows out from the steam tube.

• When the heater reach the steam temperature no more power is given to the heater.

The Led Steam stop blinking and stays on for 5 seconds to guarantee that the heater is

empty of water.

• At the end of the 5 seconds the Led Steam turn off to allow the user to test the next ma

chine.

• At the end of this action the machine is empty and at the fi rst power on, the circuit rechar
ge is needed.

EXIT FROM TEST MODE:

From the test mode is possible to exit only disconnecting the machine from the main plug.

MANUAL MACHINES 05 TROUBLESHOOTING

SAECO Page / 02

02

FAULT POSSIBLE CAUSES SOLUTION

The machine does not
switch on

No power supply Check the electrical circuit

The machine does not warm
up

The thermostats have intervened

The power supply does not reach
the boiler

Replace the thermostats (if of the
One shot type)
If they are manual, reset them
If they are automatic, they are
reset automatically
Check the electrical connections

The pump is very noisy

There is no water in the tank
The pump has disengaged from
the supports
The silicone pipe that carries the
water from the tank to the pump is
pinched or blocked

Fill the tank
Insert the pump into the supports
once again
Check the water circuit

The coffee is too cold

The fi lter holder is not inserted for
the pre-heating process
The cups are cold

Run hot water through the fi lter
holder
Pre-heat the cups with hot water

The milk does not froth

The milk is not suitable (powdered
or skimmed milk)
Dirty nozzle or Cappuccino maker

Use whole milk

Carefully clean the nozzle or the
cappuccino maker with water

The coffee flows too quickly
and does not form the cream

Little coffee in the filter holder
Grinding level too coarse
There is a missing component in
the filter holder

Increase the quantity
Use a different mixture
Verify that all the components are
in place and installed correctly

The coffee does not flow or
it flows in drops

Grinding level too fi ne
The coffee is pressed too much in
the fi lter holder
Too much coffee in the filter holder
Blocked water channels
Blocked filter in the filter holder

Use a different mixture
Agitate the coffee

Reduce the amount of coffee
Descale the machine
Carefully clean the fi lter

The coffee does not flow from
the edges

The fi lter holder has been
inserted incorrectly into the coffee
dispensing unit
The upper border of the fi lter
holder is dirty
The seal of the boiler is dirty or
worn
Too much coffee in the fi lter holder

Insert the fi lter holder correctly
Clean the edges of the fi lter holder

Clean or replace the seal
Reduce the amount of coffee

P.S.: Refi ll the water circuit when the machine is fi rst used as well as when the water in the tank

fi nishes.

5.2 Causes and solutions

SAECO MANUAL MACHINES

CHAPTER 6

STANDARD INSPECTIONS

MANUAL MACHINES 06 STANDARD INSPECTIONS

SAECO Page / 02

Action
1 Visual inspection (damage during transport)
2 Machine data check (plate)
3 Functional check / problem analysis
4 Opening the machine
5 Visual inspection
6 Functional tests
7 Repairing the faults encountered
8 Checking any modifi cations (view info, etc.)
9 Service activities in accordance with the operating schedule

10 Internal cleaning
11 Functional test with the machine open
12 Assembly
13 Final inspection test
14 Draining the circuit (in winter)
15 External cleaning
16 Insulation test HG 701 (dielectric)
17 Documentation

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

Component Action Support/tool

Water fi lter P/S/CF
Water tank lip seal S/CF
Pipes, fi ttings and Oetiker clamps ES/CF
Hot water/steam circuit pump ES/TR/CF
Water circuit D/CF Saeco descaler
Wiring ES/CF

6.2. Service schedule

6.1. Repair schedule

01

MANUAL MACHINES 06 STANDARD INSPECTIONS

SAECO Page / 02

Test Procedure

Support/
tool

Standard Tolerance

Coffee

2-3 Coffees for
adjustment purposes

Measuring
beaker

Noise Standard

Amount of
cream

Blow into the cup until
the cream separates

The cream should
come together

again completely
Cream colour Hazel brown
Hot water Dispense water

Steam Dispense steam

6.3. Final inspection

02

SAECO MANUAL MACHINES

CHAPTER 7

DISASSEMBLY

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

7.1.1. Outer elements

Upper cover

RIGHT and LEFT side covers

Remove the water tank, the water drip tray, the
grille and the steam knob.

Loosen the screws as shown on the front
and rear part of the machine

Lift the cover and loosen the screws as shown

Remove the side covers
by lifting them upwards

LEFT side cover
(note the hooks
of the cover)

RIGHT side cover. Remove the connection of the
on/off switch from the cover

01

RIGHT

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

02

Remove the knob by
pulling it outwards

Remove the electrical connections
and the two bright indicators

Loosen the overpressure valve

Remove the pump from the supports

Remove the water connections and loosen the screws as shown

Loosen the screws as shown
to remove the rotating switch

7.1.2 Controls support

7.1.3 Boiler support

7.1.4 Pump

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

03

Loosen the screw as shown

Loosen the screws as shown

Loosen the screw as shown

Loosen the
screw of the
valve holder

Check the condition of the
shower, valve holder screw,
channels (holes not blocked)
and verify there is no limescale
on any of the parts

Shower

Loosen the screws as shown

Check the internal condition of the boiler
(limescale, any breakages, condition of the
O-ring seal, etc.)

When putting back the thermostats,
always apply conductive paste for the
thermostat to adhere perfectly to the
boiler

7.1.8 Steam pipe

7.1.5 Boiler thermostats

7.1.6 Boiler

7.1.7 Shower and valve

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

04

7.2.1 Outer elements Carezza / Estrosa

Remove the water tank, the water drip
tray, the grille, the steam knob and pan­narello.

steam knob

pannarello

water tank

water drip tray
and grille

Upper cover

LEFT and RIGHT side covers

Loosen the screws as shown on the rear part of the
machine and lift the cover

Remove the posterior
cover lifting it upwards

Loosen the screws as shown

Remove the covers as in the pictures

Pump

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

Loosen the screws

Loosen the screws

Loosen the screws

Loosen the screws to remove the steam pipe

Remove the pump from the sup­ports as the picture

Remove the water and electric connections

Remove the water and
electric connections

Remove the water connections

7.2.2 Pump Esrosa/Carezza

7.2.3 Boiler support assembly Esrosa/Carezza

7.2.4 Steam knob Esrosa/Carezza

7.2.5 Steam pipe Esrosa/Carezza

05

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

7.2.6 CPU/power card Estrosa/Carezza

7.2.7 Keyboard card Estrosa/Carezza
Estrosa

Carezza

Loosen the screws as shown

Loosen the screws as shown

Loosen the screws as shown

Loosen the screws, the electric con­nection and remove front panel as
shown

Loosen the screws, the electric
connection and remove front
panel as shown

Remove the knob

Hot

water /steam

Remove the electric connections

06

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

7.2.8 Filterholder locking ring Estrosa/Carezza

Loosen the screws

Loosen the bolt

Remove the cover pulling
it down

Remove the water
connections

07

MANUAL MACHINES 07 DISASSEMBLY

SAECO Page / 08

1) Boiler connection

2) Other connections

Replacing the pipes

1) Use a suitable pair of pliers to

remove the clamp (as shown in the
picture)

2) Tighten the clamp as shown in the

pictures

7.3 Un/installing Oetiker clamps

1

1

2

2

08

SAECO MANUAL MACHINES

CHAPTER 8

NOTES

MANUAL MACHINES 08 NOTES

SAECO Page / 01

01