Philips Saeco Exprelia Series User manual

Service Manual
Revision 00 June 2010
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
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Service
Coffee Machine
Exprelia Series
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 8
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

Saeco International Group Rev. 00 /June 2010 EXPRELIA
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

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
1CC -A - Vdc tester
1 Digital thermometer Scale limit > 150°C
1SSC (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
03
Full tray oating
indicator
Drip
tray+grille
Control
panel
Water tank
Coffee bean hopper
with lid
Compartment for
pre-ground coffee
Service
hatch
SBS
Milk carafe
attachment
Milk carafe
Hot water/steam
dispensing pipe
Grinding
adjustment
Brewing unit
Dreg drawer
Drip tray
Power cable
connector and main
switch

EXPRELIA 01 INTRODUCTION
Saeco International Group Rev. 00 / June 2010 Page / 04
1.6.2 Internal machine parts
04
Turbine
Multi-way valve
Coffee boiler
Water level
capacitive sensor
Power card
Steam boiler
Water pump
Steam pump
Frother unit
valve assembly
Coffee grinder
Ground coffee
channel
Water tank
present/missing tab
Water tank connection

Saeco International Group Rev. 00 / June 2010 EXPRELIA

EXPRELIA 02 TECHNICAL SPECIFICATIONS
Saeco International Group Rev. 00 / June 2010 Page / 03
 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
(230/120 V~) 1300 W – (100 V~) 1100W
for coffee, hot water and steam dispensing
Steam heat exchanger output:
Stainless steel 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:
(multi-way valve)
Opening at approx. 17-23 bar
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.
01

EXPRELIA 02 TECHNICAL SPECIFICATIONS
Saeco International Group Rev. 00 / June 2010 Page / 03
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 Continues until the water supply has been exhausted (capacitive sensor)
* Depends on the language selected by the user
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 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
02
Descaling cycle frequency
Hardness Water hardness Withoutwaterlter Withwaterlter
1Soft (up to 7°dH) 240 litres (480,000 pulses) 480 litres (960,000 pulses)
2Medium (7° - 14°dH) 120 litres (240,000 pulses) 240 litres (480,000 pulses)
3Hard (15° - 21°dH) 60 litres (120,000 pulses) 120 litres (240,000 pulses)
4Very 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

EXPRELIA 02 TECHNICAL SPECIFICATIONS
Saeco International Group Rev. 00 / June 2010 Page / 03
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
departments
No
"Fill tank" alarm Yes
"No tray" alarm No
Water mains No
DREG DRAWER Description and values
Time-out for dreg drawer 5 sec.
Warning to empty dreg drawer after Yes, after 12 lots of dregs
Shutdown alarm to empty dreg drawer after
(double coffee as last product dispensed)
15 lots of dregs
(16 lots of dregs)
Reset dreg counter
The dreg drawer must be emptied only
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
Yes
Boiler temperature during Standby Boiler OFF
Cup heater during Standby Cup heater OFF
Timer and Standby Yes **
** The machine switches on at the TimerOn (Timer) value and switches off when the
“Standby time” (Delay – Time) has elapsed
03

Saeco International Group Rev. 00 / June 2010 EXPRELIA
CHAPTER 3
USER INSTRUCTIONS

EXPRELIA 03 USER INSTRUCTIONS
Saeco International Group Rev. 00 / June 2010 Page / 05
3.1. Customer and programming menu
BEVERAGE MENU The machine allows custom settings for dispensing each beverage
OK ESC
MENU
Key used to dispense an espresso Key used to dispense a cappuccino
Key used to set the
machine on standby
Key used to carry out a
carafe cleaning cycle
Function keys
Key used to dispense a coffee
Key used to select aroma
Key used to select "MENU"
Key used to access
special beverages
Key used to dispense
a long coffee
Key used to select aroma
OK ESC
MENU
OK ESC
MENU
MENU
BEVERAGE MENU
MACHINE MENU
OK ESC
MENU
BEVERAGE MENU
ESPRESSO
COFFEE
LONG COFFEE
OK ESC
MENU
ESPRESSO
AMOUNT OF COFFEE
PREBREWING
COFFEE TEMPERATURE
Press the "MENU" button to go
to the machine's main menu 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
Scroll/select key1.
Select/conrm key2.
Exit key3.
Scroll/select key4.
12 3 4
01

EXPRELIA 03 USER INSTRUCTIONS
Saeco International Group Rev. 00 / June 2010 Page / 05
MACHINE MENU Used to customize the machine's operational settings
GENERAL MENU
02
OK ESC
MENU
MENU
BEVERAGE MENU
MACHINE MENU
OK ESC
MENU
MACHINE MENU
GENERAL MENU
DISPLAY MENU
WATER MENU
Press the "OK" button
to go to the MACHINE
MENU
Press the "OK" button to
go to the submenus
To change the appliance operating settings
This function permits activating/deactivating audible warnings
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
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
To enable buzzers
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
To disable buzzers
This function governs activation of the boilers in the appliance for energy saving
GENERAL MENU
SOUND
ECOMODE
GENERAL STANDBY
OFF
ON
OFF
ON
15 MINUTES
30 MINUTES
60 MINUTES
180 MINUTES
DISPLAY MENU
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
DISPLAY MENU
BRIGHTNESS
LANGUAGE
ENGLISH
WATER MENU
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 the lter after it has been installed or replaced.
To activate/deactivate the water lter replacement warning. When this function is active the appliance
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)
WATER MENU
ACTIV. FILTER
HARDNESS
ENABL. FILTER

EXPRELIA 03 USER INSTRUCTIONS
Saeco International Group Rev. 00 / June 2010 Page / 05
03
This function is used to view how many products have been prepared for each single type of beverage
since the last reset
This function lets you set all the functions so that machine maintenance is managed better
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
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
The self-cleaning function is disabled
The self-cleaning function is enabled
This function is used to run the washing cycle for the brewing unit
MAINTENANCE
METERS FOR
CARAFE CLEANING
DESCALING
UNIT CLEANING
CLEAN CARAFE
OFF
ON
MAINTENANCE
FACTORY SETTINGS
This function allows the factory values to be reset.
Restoring the factory parameters deletes all the personal parameters set beforehand.
FACTORY SETTINGS
3.2. Machine indications
Close the coffee bean hopper
lid to enable delivery of any
beverage
Take out the tank and ll it with
fresh drinking water
Fill the coffee
container
Insert the brewing unit
in its correct location
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
COPERCHIO CHICCHI
INSERIRE GRUPPO
SVUOTARE
CONTENITORE FONDI
CHIUDERE SPORTELLO
FRONTALE
RIEMPIRE
SERBATOIO ACQUA
ADD COFFEE

EXPRELIA 03 USER INSTRUCTIONS
Saeco International Group Rev. 00 / June 2010 Page / 05
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
An operation has been selected
that requires dispensing from the
milk container.
Insert the milk container. Press
“ESC” to cancel the procedure
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
Red LED blinking Machine on Standby.
It is possible to change the Standby settings
Press the button to exit Standby
The carafe rinse function has been
selected.
Press “ESC” to cancel the
procedure
Insert the dregs
drawer
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
SVUOTARE VASCA
GRUPPO
RUOTARE CARAFFA
IN EROGAZIONE
ESC
RUOTARE CARAFFA
IN RISCIACQUO
ESC
INSERIRE CARAFFA
ESC
RIAVVIARE PER
RISOLVERE IL
PROBLEMA
04

EXPRELIA 03 USER INSTRUCTIONS
Saeco International Group Rev. 00 / June 2010 Page / 05
CLEANING AND TECHNICAL SERVICING
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
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
H Descaling When indicated
Descaling cycle frequency
Hardness Water hardness Withoutwaterlter Withwaterlter
1Soft (up to 7°dH) 240 litres (480,000 pulses) 480 litres (960,000 pulses)
2Medium (7° - 14°dH) 120 litres (240,000 pulses) 240 litres (480,000 pulses)
3Hard (15° - 21°dH) 60 litres (120,000 pulses) 120 litres (240,000 pulses)
4Very 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
3.3. Operation, cleaning and maintenance
Operating the machine
1 Fill water tank
2 Fill the coffee bean hopper
3 Switch on the appliance
4Press the button to start the
appliance
5 Select the desired language Store
6Heating When the heating phase begins, wait for it to nish
7Rinse Carry out a rinse cycle for the internal circuits
8Machine ready The machine is ready to dispense beverages
05

Saeco International Group Rev. 00 / June 2010 EXPRELIA

EXPRELIA 04 OPERATING LOGIC
Saeco International Group Rev. 00 / June 2010 Page / 11
4.1. Water circuit
- COLD WATER - HOT WATER / STEAM - STEAM - HOT WATER
01

EXPRELIA 04 OPERATING LOGIC
Saeco International Group Rev. 00 / June 2010 Page / 11
02
4.2.1 General carafe assembly
4
1
7
2
35
6
1 Cappuccino valve body
2 Milk suction pipe and attachment
3Venturi pipe
4 Milk dispenser pipe
5 Upper attachment of drain pipe
for carafe
6Lower attachment of carafe drain
pipe
7 Levers, springs and pin for carafe
present/missing indication and
dispenser positioning
4.2. Frother unit valve assembly
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°
DC3
DC1
DC2
DC4
DC5
Air inlet
Steam outlet
Steam outlet
Hot water/steam
inlet
Hot water/steam
outlet
Drain protecting
frother unit valve
Air solenoid valve
Steam solenoid valve
Clean solenoid
valve (steam)
Hot water /steam
solenoid valve
Drain solenoid valve