Gaggia Brera User manual

SERVICE
MANUAL
Revision 00
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.
Rev. 00 / OCTOBER 2009

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 Brera 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 1
3. Brief instructions
3.1 Customer and programming menu 1
3.2 Operation, cleaning and maintenance 3
4. Operating logic
4.1. Water circuit 1
4.2 Control ringnut and valve 2
4.3 Coffee cycle operating diagram 3
4.4 Single microswitch 4
4.5 Temperature sensor 4
4.6 Coffee grinder operation 5
4.7 Detection of low bean level, dose adjustment, 5
coffee grinder blockage
4.8 Dose self-learning 6
Table of contents
Rev. 00 OCTOBER 2009

Table of contents
Page
5. Service mode
5.1. Test mode 1
6. Servicing & Maintenance
6.1 Repair schedule 1
6.2 Service schedule 1
6.3 Final test 2
7. Disassembly
7.1 Outer elements disassembly 1
7.2 Dispensing spout disassembly 1
7.3 Keypad card and valve card disassembly 2
7.4 Power/CPU card disassembly 3
7.5 Gearmotor disassembly 3
7.6 Boiler disassembly 4
7.7 Valve disassembly 4
7.8 Pump and turbine disassembly 5
7.9 OETIKER clamps assembly and disassembly 6
7.10 Coffee grinder disassembly 7
7.11 Grinder adjustment / assembly and disassembly 8
8. Notes
9. Water circuit diagram
9.1. Water circuit diagram
10. Electrical diagram
10.1 Wiring diagram
Rev. 00 OCTOBER 2009

Rev. 00 OCTOBER 2009 Page / 04
GAGGIA 01 INTRODUCTION
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 10
1 Pliers for Oetiker clamps
1 CC -A - Vdc tester
1 Digital thermometer Scale limit > 150°C
1 SSC (Saeco Service Center) Programmer
1.3 Material
Description Notes
Thermal paste Heating element > 200°C
Descaler Saeco Entkalker
Grease solvent Personal preference
Silicone grease Safe to use with food
1.4 Safety warnings
We recommend you consult the technical manual of the machine before performing any mainte-
nance 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

Rev. 00 OCTOBER 2009 Page / 04
GAGGIA 01 INTRODUCTION
1.5. Brera range
Led interface X
Painted details X
Water/steam valve X
Alarm LED X
Automatic rinse X
Automatic dosage X
Pannarello (frother) X
Dispensed coffee memory capacity X
Automatic shutdown
(after 60' inactivity) X
02

Rev. 00 OCTOBER 2009 Page / 04
GAGGIA 01 INTRODUCTION
1.6.1 External machine parts
03
Power cord
LED display
selector switch
Hot water/steam selector switch
STAND-BY Button
Brew group Service door
Grinder adjustment knob
compartment
Cup stacking surface
Dispensing spout
Cup holder grill
ON-OFF power button
Full drip tray indicator
Drip tray
Water tank
Hot water/steam wand
Wand protective gripper
Control panel

Rev. 00 OCTOBER 2009 Page / 04
GAGGIA 01 INTRODUCTION
1.6.2 Internal machine parts
04
Card -
PWR/CPU
boiler
Pump
Temperature sensor
Side door
microswitch
Coffee grinder
Turbine
Coffee grinder
motor

Rev. 00 OCTOBER 2009
CHAPTER 2
TECHNICAL SPECIFICATIONS

Rev. 00 OCTOBER 2009 Page / 04
GAGGIA 02 TECHNICAL SPECIFICATIONS
2.1. Technical specications
2.2. Machine parameters and performance
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 heating element sensor (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
(230/120 V~) 1300 W - (100 V~) 1100W
for coffee, hot water and steam dispensing
Gearmotor: 33VC with 2 rotation directions; power supply 24VC
Pump: Ulka with reciprocating piston and 120°C cutout 48 W, 230V,
50 Hz, Type EP5 approx. 13-15 bar 120V, 60Hz 100V, 50/60 Hz
Overpressure valve: Opens at approx. 16-18 bar
Water lter: In tank
Coffee grinder: Direct current motor with at ceramic grinder blades
Hot water/steam valve Presblock
Automatic dosage Dose adjustment controlled by the electronic system
Power consumption: During the heating phase - approx. 5,6 A
Dimensions: W x H x D in mm: 256x315x410
Weight: 9 kg
Water tank capacity: 1l.
Coffee bean hopper capacity 200 gr. coffee beans
Dreg drawer capacity 8
Heat exchanger capacity: Approx. 10 cc
Water circuit lling time: Approx. 15 seconds for rst lling cycle
Heating time: Approx. 45 seconds
Dispensing temperature: Approx. 84°± 4°
Grinding time: Approx. 8-10 seconds
AMOUNT
OF PRODUCT
Minimum
amount
(Puls.)
Default
amount
(Puls.)
Maximum
amount
(Puls.)
Programm.
by the user
Programm. by
Production/Service
department
Espresso 70 165 600 Yes No
Medium coffee No No No No No
Long coffee 70 440 600 Yes No
Pre-ground Yes
Hot water Continues until the water supply has been exhausted (capacitive sensor)
Steam pannarello
(frother)
Continues until the water supply has been exhausted (capacitive sensor)
01

Rev. 00 OCTOBER 2009 Page / 04
GAGGIA 02 TECHNICAL SPECIFICATIONS
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’, after having
dispensed at least one coffee,
before switching off
No. of pulses 180 80
Stopping option Yes, by pressing any key Yes, by pressing any key
User disable option No No
Disabling by
Production/Service department No No
No. of pulses user adjustment
option No No
No. of pulses adjustable by
Production/Service department No No
Pulse range
(Min. - Max.) No No
WATER HARDNESS CANNOT BE SET
DREG DRAWER Description and values
Time-out for dreg drawer 5 sec.
Empty dreg drawer alarm after
(double coffee is the last product dispensed)
8 lots of dregs
(9 lots of dregs)
Warning to empty dreg drawer after No
Reset dreg counter Every time the dreg drawer is removed for at
least 5 seconds, even if the "empty dregs" alarm
has not been activated
POWER/OFF Description and values
Inlet time (min. - max.) 60 minutes
Inlet time (default) No
Inlet time prog. by the user No
Inlet time prog. by Production / Service departments No
WATER TANK Description
Level sensor Yes
Water reserve (pulses) with water lter 200
Water reserve (pulses) with no water lter 200
Water reserve modiable by Production/Service departments No
"Fill tank" alarm Yes
"No tray" alarm No
Water mains No
02