Saeco Xsmall Plus User manual

XSMALL
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.
Saeco Int. Rev. 00 / Jul. 2008 XSMALL

Saeco Int. Rev. 00 / Aug. 2008 Xsmalll
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 Xsmall range 2
1.6.1 External machine parts 3
1.6.2 Internal machine parts 4
2. Technical specifications
2.1 Technical specifications 1
2.2 Machine parameters and performance 2
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 Low bean level detection, dose quantity adjustment,
coffee grinder blocked 5
4.8 Dose self-learning 6
Contents

Saeco Int. Rev. 00 / Jul. 2008 XSMALL
Contents
Next
5. Troubleshooting
5.1. Test mode 1
5.2. Draining the boiler (Steam Out) 2
6. Servicing & Maintenance
6.1 Repair schedule 1
6.2 Service schedule 1
6.3 Final test 2
7. Disassembly
7.1 Disassembling the outer elements 1
7.2 Disassembling the electronics 2
7.3 Disassembling the control knob and coffee keys 3
7.4 Disassembling the boiler pin 3
7.5 Disassembling the gear motor 4
7.6 Disassembling the boiler 5
7.7 Disassembling the valve 5
7.8 Disassembling the pump and turbine 6
7.9 Disassembling and fitting OETIKER clamps 7
7.10 Disassembling the coffee grinder 8
7.11 Grinder adjustment/assembly and disassembly 9
8. Notes
9. Water circuit diagram
9.1. Water circuit diagram
10. Electrical diagram
10.1 Wiring diagram

Saeco Int. Rev. 00 / Jul. 2008 XSMALL
CHAPTER 1
INTRODUCTION

XSMALL 01 INTRODUCTION
Saeco Int. Rev. 00 / Jul. 2008 Page 1 / 4
1.1 Documentation required
The following documentation is needed for repair procedures:
Instruction booklet for specific model.•
Technical documentation for specific 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 Heat resistance > 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.

Page 2 / 4 Rev. 00 / Jul. 2008 Saeco Int.
01 INTRODUCTION XSMALL
1.5. Xsmall range
Xsmall
Plus Xsmall Steam
Painted details X
Water/steam valve XX
Alarm LED XX
Automatic rinse XX
Automatic dosage XX
Frother X
Dispensed coffee memory capacity XX
Automatic shutdown
(after 60’ inactivity) XX
Xsmall Plus Xsmall Steam

XSMALL 01 INTRODUCTION
Saeco Int. Rev. 00 / Jul. 2008 Page 3 / 4
15 1817
24
1.6.1 External machine parts
Coffee bean tank lid
Coffee bean tank
Dreg
drawer
Coffee
dispenser
Cup rack
Drip tray full
indicator
Drip tray
Brewing
unit
Service hatch
13
Water
tank
Hot water/steam
dispensing hose
Steam hose
protection
Control panel
Frother
(Plus)
Small coffee
Large coffee Alarm
LED
Double
coffee LED
Selector
- coffee
- hot water
- steam
Temperature LED
On/Off
21
15 1817

Page 4 / 4 Rev. 00 / Jul. 2008 Saeco Int.
01 INTRODUCTION XSMALL
1.6.2 Internal machine parts
Turbine
Pump
Boiler
PW/CPU
P.C.B.
Power cable connector
Valve
Coffee grinder
motor
Coffee grinder

Saeco Int. Rev. 00 / Jul. 2008 XSMALL
CHAPTER 2
TECHNICAL
SPECIFICATIONS

Saeco Int. Rev. 00 / Jul. 2008 Page 1 / 4
XSMALL 02 TECHNICAL SPECIFICATIONS
2.1. Technical specifications
2.2. Machine parameters and performance
Power supply and output: 230 V~ 50/60 Hz 1500 W - 120 V~ 60 Hz 1500 W - 100 V~
50/60 Hz 1300 W
Temperature monitoring: Variable resistor sensor (NTC) - transmits the value to the
electronic P.C.B.
Safety system: 2 manual reset or one-shot thermostats (175°C)
Coffee heat exchanger output:
Stainless steel
(230/120 V~) 1300 W - (100 V~) 1100 W
for coffee, hot water and steam dispensing
Gear motor: 33VC with 2 rotation directions; power supply 24VC
Pump: Ulka with reciprocating piston and 100°C cutout 48 W, 230 V, 50
Hz, Type EP5 approx. 13-15 bar 120 V, 60 Hz 100 V, 50/60 Hz
Overpressure valve: Opens at approx. 16-18 bar
Water filter: In tank
Coffee grinder: Direct current motor with flat ceramic grinders
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: 295x325x420
Weight: 6.9 kg
Water tank capacity: 1.0 litres
Coffee container capacity 185 g coffee beans
Coffee dreg drawer capacity 08
Heat exchanger capacity: Approx. 10 cc
Water circuit filling time: Approx. 15 seconds for first filling cycle
Heating time: Approx. 45 seconds
Dispensing temperature: Approx. 84 ± 4°C
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/Serv-
ice department
Espresso 70 165 600 Yes No
Medium coffee No No No No No
Large coffee 70 440 600 Yes No
Pre-ground No
Hot water Continues until the water supply has been exhausted (fill circuit
status)
Steam for frother Continues until the water supply has been exhausted (fill circuit
status)
Steam for Milk-
Island No

Page 2 / 4 Rev. 00 / Jul. 2008 Saeco Int.
02 TECHNICAL SPECIFICATIONS XSMALL
RINSE Initial rinse Final rinse
When performed When the coffee maker is
activated When the boiler
temperature is ≤50°C
When the machine is switched off
electronically, manually or auto-
matically after 60’, if at least one
coffee has been dispensed, 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
Production/Service
department disable option
No No
No. of pulses user adjust-
ment option
No No
No. of pulses Produc-
tion/Service department
adjustment option
No No
Pulse range
(Min. - Max.)
No No
WATER HARDNESS CANNOT BE SET
DREGS 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 dregs 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 department No
WATER TANK Description
Level sensor No
Water reserve (pulses) with water filter No
Water reserve (pulses) with no water filter No
Water reserve modifiable by Production/Service departments No
“Fill tank” alarm No
“No tray” alarm No
Water mains No

Saeco Int. Rev. 00 / Jul. 2008 XSMALL
CHAPTER 3
BRIEF INSTRUCTIONS

XSMALL 03 BRIEF INSTRUCTIONS
Saeco Int. Rev. 00 / Jul. 2008 Page 1 / 3
Indications Causes Solutions
Fixed
Machine at correct temperature
- for coffee dispensing
- for hot water dispensing
- for steam dispensing
Blinks slowly Machine in pre-heating phase for coffee,
hot water and steam dispensing.
Blinks quickly
Machine overheated; the machine cannot
dispense coffee in this mode.
The water must be drained out
into a recipient by turning the se-
lector clockwise to the “ ” point,
until the green correct temperature
LED remains lit in a fixed manner.
The flow of water dispensed should
then be stopped.
Blinks slowly The machine is being programmed
with the coffee cup fill level
Fixed Machine dispensing coffee
3.1. Customer and programming menu
On/Off
Small coffee (press twice
for double coffee)
Large coffee (press twice
for double coffee)
Alarm LED
Double coffee LED
Selector
- coffee
- hot water
- steam
Temperature LED
21
1817

Page 2 / 3 Rev. 00 / Jul. 2008 Saeco Int.
03 BRIEF INSTRUCTIONS XSMALL
Indications Causes Solutions
Fixed
Coffee bean container empty
Dreg drawer full
Fill the coffee bean tank.
Empty the dreg drawer while the
machine is switched on.
If the drawer is emptied before the
indication appears and the drawer
remains out of position for at least
5 seconds, the dregs counter will
still be reset.
Blinks quickly
Water circuit drain Fill the tank with fresh drinking wa-
ter and fill the water circuit of the
machine by turning the selector to
the “ ” point; wait for a continu-
ous jet of water to come out of the
steam hose.
Blinks slowly
Brewing unit not present
Dreg drawer not present
Service hatch open
Valve position NOT suitable for machine
operation
To stop the red blinking light, make
sure that all components are insert-
ed or closed correctly.
Blinking in an anti-
clockwise sequence
(cyclically)
The machine is performing its rinse /
automatic cleaning cycle
- When the machine is switched on (the
boiler is cold)
- After filling the circuit (the boiler is
cold)
- Before the machine enters Standby
mode (if it has dispensed a coffee)
- During the shutdown phase, after the
ON/OFF key has been pressed (if the
machine has dispensed a coffee)
The machine ends the cycle auto-
matically.
The cycle may be stopped by press-
ing one of the two coffee keys.
Blinking simultaneously The machine is experiencing a fault and
will not dispense coffee, water or steam
Switch the machine off, wait for
30 seconds and switch it back on
again.
Repeat 2 or 3 times.
If the machine does not start, enter
test mode.
Blinking in
alternating
fashion
The brewing unit has experienced a fault Try to carry out a coffee dispensing
cycle again.
+
+

XSMALL 03 BRIEF INSTRUCTIONS
Saeco Int. Rev. 00 / Jul. 2008 Page 3 / 3
3.2. Operation, cleaning and maintenance
CLEANING AND TECHNICAL SERVICING
A Empty the coffee dreg drawer When indicated
B Empty the drip tray As necessary or when indicated
C Clean the water tank Weekly
D Clean the coffee bean container As necessary
E Clean the casing As necessary
F
Clean the brewing unit Every time the coffee bean container is
filled, or weekly, or
Lubricate the brewing unit Once a month or every 500 dispensing
procedures
Clean the unit housing Weekly
H Perform descaling Every 1 or 2 months, or when you notice a
reduction in the water flow rate
Descaling cycle frequency
Hard-
ness Water hardness Without limescale filter With limescale filter
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
Operating the machine
1 Fill the water tank
2 Fill the coffee bean container
3 Switch on the appliance
4 Fill the circuit Place a recipient underneath the steam
hose and turn the selector towards the “
” symbol; wait until the LED stops
blinking.
5 Press the coffee key Press once for one coffee; twice for two
coffees.

Saeco Int. Rev. 0 / Jul. 2008 XSMALL
CHAPTER 4
OPERATING LOGIC

Saeco Int. Rev. 00 / Jul. 2008 Page 1 / 6
XSMALL 04 OPERATING LOGIC
4.1. Water circuit
Boiler
Turbine
Brewing unit
Coffee
dispenser
Water collection tank
Pump
Compensation
valve
Water tank
Water / steam
Control
ringnut
Presblock
valve
Compensation valve 16/18 bar
Steam hose connection
Steam hose
Compensation valve water outlet
Turbine
1300 W boiler
To brewing unit
Water tank rapid
connection
Steam
valve
Pump
Traditional water system•
Turbine - Amount of coffee dispensed into the cup•
Reciprocating piston type pump (13 - 15 bar)•
Compensation valve (opening pressure 17 - 19 bar)•
Boiler - 1300 W•
Presblok valve - select coffee - hot water - steam•

Page 2 / 6 Rev. 00 / Jul. 2008 Saeco Int.
04 OPERATING LOGIC XSMALL
4.2. Control ringnut and valve
No. DESCRIPTION
1Mushroom valve cap
2Spring for mushroom valve
3Mushroom valve support
4Mushroom valve
5Sealing OR
1234
5
CLOSED for
COFFEE
When dispensing coffee the mushroom valve opens at 4 bar +/- 0.5
Manual opening when dispensing water
Manual opening when dispensing steam
OPEN -
STEAM
OPEN -
WATER
TOTAL STROKE
EXTRA
STROKE
EXTRA
STROKE
VALVE OPENING
STROKE
VALVE OPENING
STROKE

Saeco Int. Rev. 00 / Jul. 2008 Page 3 / 6
XSMALL 04 OPERATING LOGIC
4.3. Coffee cycle operating diagram
Main switch
ON
START STOP
Time
Coffee grinder
Heating
Pump
Brewing unit
gear motor
Status Heating Ready Coffee cycle
approx.
45 secs.
Pulses
(Dosage)
Pump operation (tur-
bine pulses) in accord-
ance with the amount
of product selected.
*
Notes: * Only with Pre-brewing
MS status OFF
Single microswitch gear motor
ON
Switching on
When the machine is switched on, the gear motor repositions itself as follows:
- It acts on microswitch 1 (see following section).
- The gear motor 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
The coffee grinder starts the grinding process (controlled by pulses generated by a sensor).1.
The gear motor (brewing unit) moves to the dispensing position.2.
Preliminary dispensing phase (short pump activity, short pause).3.
Product dispensing (the pump operation period is defined by the amount of product dis-4.
pensed).
The gear motor moves to its home position (the dregs are expelled automatically).5.

Page 4 / 6 Rev. 00 / Jul. 2008 Saeco Int.
04 OPERATING LOGIC XSMALL
Temperature sensor
An NTC is used as a temperature sensor; in
the event of overheating this reduces resistor
consumption.
The electronic system detects the current
boiler temperature from the drop in voltage
and adjusts it accordingly.
Resistor 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 gear motor is powered by a
direct current motor that engages
with the smaller double toothed
wheel using a worm screw. The
unit is mounted on the axle of
the large gear wheel and when a
coffee is requested, it moves from
the home position to the dispens-
ing position, and then back to the
home position again.
- Home position: 1
- Dispensing position: 2
2
1