Saeco Estrosa User manual

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All rights reserved. This document and all the information herein is provided without liability deriving from
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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 specifications
2.1 Technical specifications 1
2.2 Descaling frequency 1
2.3 Specification 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 filter 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 specific model
• Technical documentation for specific 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 opera-
tion.
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 sufficiently 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 specific exploded-view of the machine or of the Coffee Grinder on website
BREWING
UNIT Only for OOW repairs YES, to consult the specific exploded-view of the machine or of the Brewing unit on website
BOILER Only for OOW repairs YES, to consult the specific exploded-view of the
machine on website
GEAR
MOTOR Only for OOW repairs YES, to consult the specific exploded-view of the machine on website
FILTER
HOLDER Only for OOW repairs YES, to consult the specific exploded-view of the machine on website
MILK
CARAFE Only for OOW repairs YES, to consult the specific exploded-view of the machine on website
THERMAL
CARAFE Only for OOW repairs YES, to consult the specific exploded-view of the Thermal Carafe on website
MILK ISLAND Only for OOW repairs YES, to consult the specific 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 specific components. If you find the
information “SEE THE EXPLODED VIEW E........” in the assembly description field, 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 specific 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
filter 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 filter
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 specifications
Technical specifications 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 filter: 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 filter: 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 filter With anti-scale filter
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)

MANUAL MACHINES 02 TECHNICAL SPECIFICATIONS
SAECO Page / 02
2.3. Specification for the measurement of the coffee products temperature.
The temperature is influenced by the flow from the dispenser and stratification of temperatures in
the glass. In order to consider these phenomena and to introduce measures that allow compari-
sons 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 (float)
B Clean the water tank Weekly
C Clean the filter holder As necessary
D Clean the casing As necessary
E Descaling cycle If signalled
01
Descaling frequency
Hardness Water hardness Without anti-scale filter With anti-scale filter
1Soft (up to 7°dH) 240 litres 480 litres
2Medium (7° - 14°dH) 120 litres 240 litres
3Hard (15° - 21°dH) 60 litres 120 litres
4Very hard
(over 21°dH) 30 litres 60 litres
Operating the machine
1 Fill the water tank
2Fill the coffee bean
container
3 Switch on the appliance
4Press to switch on the
machine /
5 Heating The heating phase begins, wait for it to finish
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 flow 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