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

Rev. 00 OCTOBER 2009
CHAPTER 3
BRIEF INSTRUCTIONS

Rev. 00 OCTOBER 2009 Page / 03
GAGGIA 03 BRIEF INSTRUCTIONS
3.1. Customer and programming menu
01
Indications Causes Solutions
Machine at correct temperature
- for coffee bean dispensing
- for hot water dispensing Proceed with the dispensing process
Machine at correct temperature
- for ground coffee dispensing
(pre-ground) Proceed with the dispensing process
Machine dispensing steam
Proceed with steam dispensing
Machine dispensing
hot water Proceed with hot water dispensing
Machine dispensing
a coffee Wait for the dispensing process to end
(dispensing stops when you press the
key again)
Machine dispensing
two coffees Wait for the dispensing process to end
(dispensing stops when you press the
key again)
The machine is being programmed with
the coffee cup ll level Stop dispensing as desired
Machine in pre-heating phase for coffee,
hot water and steam dispensing Wait until heated
(see bar)
Steady on
Steady on
Steady on
Steady on
Steady on
Steady on
Blinking
Blinking

Rev. 00 OCTOBER 2009 Page / 03
GAGGIA 03 BRIEF INSTRUCTIONS
02
Indications Causes Solutions
Machine in rinsing phase
- wait for the machine to complete
the procedure Wait until end of procedure
The appliance requires a
descaling cycle
Perform the descaling cycle
To enter the descaling cycle press the
aroma/pre-ground coffee key for 5
sec.
No coffee beans inside hopper After lling the coffee bean hopper, start the
cycle again
No water Fill the water tank
Service door open: Close it
If the service door is opened while product is being dispensed, the appliance stops
dispensing and starts a 30 sec. countdown before cancelling the dispensing process.
The countdown can be stopped by closing the service door and operation will resume
from its stopping point.
Turn the hot water/steam valve knob to the correct position.
If the knob is turned (open) while product is being dispensed, the appliance stops
dispensing and starts a 30 sec. countdown before cancelling the dispensing process.
The countdown can be stopped by closing the knob and operation will resume from
its stopping point.
No brew group
If the brew group is removed while product is being dispensed, the appliance stops
dispensing and starts a 30 sec. countdown before cancelling the dispensing process.
The countdown can be stopped by re-inserting the brew group and closing the
service door; operation will resume from its stopping point.
Rell circuit Turn the knob to the cup
Empty the dreg drawer To reset the dreg counter, wait for the
icon to ash (5 sec.)
Insert dreg drawer When the dreg counter is reset, the icon
ashes
Blinking
Blinking
Blinking
Blinking
Cyclic blinking
Steady on
Steady on
Steady on
Steady on
Steady on

Rev. 00 OCTOBER 2009 Page / 03
GAGGIA 03 BRIEF INSTRUCTIONS
03
3.2. Operation, cleaning and maintenance
Operating the machine
1 Fill water tank
2 Fill the coffee bean hop-
per
3 Switch on the appliance
4 Fill the circuit Place a container under the steam wand and turn the selector
to the ” “ symbol
and wait for the appliance to return to coffee ready status.
5 Press the coffee key Press once for one coffee; twice for two coffees
CLEANING AND TECHNICAL SERVICING
A Empty the dreg drawer When indicated or every three (3) months which-
ever occurs rst
B Empty the drip tray As necessary
C Clean the water tank Weekly
D Clean the coffee bean hopper As necessary
E Clean the casing As necessary
F
Clean the brew group
Every time the coffee bean hopper is lled or weekly
Lubricate the brew group Once a month or every 500 dispensing procedures
Clean the group housing Weekly
H Descaling When indicated or every three (3) months, which-
ever occurs rst
Descaling cycle frequency
Hard-
ness Water hardness Without water lter With water lter
1Soft water (up to 7°dH) Approx. every 3 months /
120 litres
Approx. every 6 months /
240 litres
2Medium water (7° - 14°dH) Approx. every 2 months /
90 litres
Approx. every 4 months /
180 litres
3Hard water (15° - 21°dH) Approx. every 6 weeks or
60 litres
Approx. every 3 months /
120 litres
4Very hard water
(over 21°dH)
Approx. every 4 weeks or
30 litres
Approx. every 6 weeks or
60 litres

Rev. 00 OCTOBER 2009
CHAPTER 4
OPERATING
LOGIC

Rev. 00 OCTOBER 2009 Page / 06
GAGGIA 04 OPERATING LOGIC
4.1. Water circuit
01
• Traditional water system
• Turbine - Amount of coffee dispensed into the cup
• Reciprocating piston type pump (13 - 15 bar)
• Compensation valve (opening pressure 16 - 18 bar)
• Boiler - 1400 W
• Presblok valve - select coffee - hot water - steam
WATER TANK
COMPENSATION VALVE
VALVE
TURBINE
BOILER
HOT WATER/STEAM
PUMP
RINGNUT
OPERATION
DISPENSING
SPOUT

Rev. 00 OCTOBER 2009 Page / 06
GAGGIA 04 OPERATING LOGIC
4.2. Control ringnut and valve
No. DESCRIPTION
1Mushroom valve cap
2Spring for mushroom valve
3Mushroom valve support
4Mushroom valve
5Sealing OR
1
234
5
When dispensing coffee the mushroom valve opens at 4 bar +/- 0.5
Manual opening when dispensing water
Manual opening when dispensing steam
02
TOTAL STROKE
COFFEE CLOSED
-30° + 30°
Valve opening
stroke
Valve closing
stroke
STEAM
OPEN
WATER
OPEN
Extra stroke Extra stroke

Rev. 00 OCTOBER 2009 Page / 06
GAGGIA 04 OPERATING LOGIC
Notes: * Only with Prebrewing
4.3. Coffee cycle operating diagram
MS status 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 section)
- The gearmotor changes its rotation direction and moves upwards again by approx. 1-2 mm
- The boiler begins to heat water for approx. 45 seconds. It absorbs all the available heating
power in order to reach the optimal temperature. The temperature will then remain at a con-
stant level.
Coffee cycle
1. The coffee grinder starts the grinding process (controlled by pulses generated by a sensor)
2. The gearmotor (brew group) moves to the dispensing position
3. Preliminary dispensing phase (short pump activity, short pause)
4. Product dispensing (the pump operation period is dened by the amount of product dispensed)
5. The gearmotor moves to its home position (the dregs are expelled automatically).
Main
switch ON
START STOP
Time
Coffee grinder
Heating
Pump
Gearmotor
Brew group
Status Heating Ready Coffee cycle
Pulses
(Dosage)
Pump activity
(turbine pulses)
depending on the
product quantity
selected
approx.
45 sec.
*
03

Rev. 00 OCTOBER 2009 Page / 06
GAGGIA 04 OPERATING LOGIC
Temperature sensor
An NTC is used as a temperature sensor; in the event of overheating this reduces boiler ele-
ment 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: see table
4.5. 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
4.4. Single microswitch
The gearmotor is powered by a direct
current motor that engages with the smaller
double toothed wheel using a worm screw.
The brewing 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
2
1
04

Rev. 00 OCTOBER 2009 Page / 06
GAGGIA 04 OPERATING LOGIC
4.6. Coffee grinder operation
2
3
4
5
6
1
4.7. Low bean level detection, dose quantity adjustment,
coffee grinder blocked
t1
V
t2
t3
t4
t
Without beans n=100%
With beans n=100%
Without beans n=50%
With beans n=50%
Ceramic coffee grinder
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.
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 rota-
tions will be lower due to the force created by the grinding
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
05