Saeco Xsmall Series, Xsmall Plus, Xsmall Steam Service Manual

INTRODUCTION

Documentation required

The following documentation is needed for repair procedures:

• Instruction booklet for specific model.
• Technical documentation for specific model (diagrams, exploded drawings).

Tools and equipment required

As well as the standard equipment, the following is required:

Material

Product range

External machine parts

Internal machine parts

TECHNICAL SPECIFICATIONS

Technical specifications

Machine parameters and performance

BRIEF INSTRUCTIONS

Customer and programming menu

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 selector 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
Fixed	Coffee bean container empty	Fill the coffee bean tank.
	Dreg drawer full	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 water and fill the water circuit of the machine by turning the selector to the " " point; wait for a continuous 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 inserted or closed correctly.
Blinking in an anticlockwise 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 automatically. The cycle may be stopped by pressing 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.

Operation/cleaning and maintenance

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.
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
Hardness	Water hardness	Without limescale filter	With limescale filter
1	Soft water (up to 7°dH)	Approx. every 3 months / 120 litres	Approx. every 6 months / 240 litres
2	Medium water (7° - 14°dH)	Approx. every 2 months / 90 litres	Approx. every 4 months / 180 litres
3	Hard water (15° - 21°dH)	Approx. every 6 weeks or 60 litres	Approx. every 3 months / 120 litres
4	Very hard water (over 21°dH)	Approx. every 4 weeks or 30 litres	Approx. every 6 weeks or 60 litres

OPERATING LOGIC

Water circuit

• 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

Control ringnut and valve

When dispensing coffee the mushroom valve opens at 4 bar +/- 0.5
Manual opening when dispensing water
Manual opening when dispensing steam

Coffee cycle operating diagram

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 constant level.

Coffee cycle

1. The coffee grinder starts the grinding process (controlled by pulses generated by a sensor).
2. The gear motor (brewing unit) moves to the dispensing position.
3. Preliminary dispensing phase (short pump activity, short pause).
4. Product dispensing (the pump operation period is defined by the amount of product dispensed).
5. The gear motor moves to its home position (the dregs are expelled automatically).

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 dispensing position, and then back to the home position again.

• Home position: 1
• Dispensing position: 2

Temperature sensor adjustment

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

Coffee grinder function

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 transmit two pulses to a Hall sensor, which in turn transmits them to the electronic system.

Low bean level detection/dose quantity adjustment/coffee grinder blocked

Dose self-learning

The aim of this modification process is to ensure that, with an algorithm based on three pieces of information (listed below) detected by the machine P.C.B., the average dose is adjusted automatically (SELF-LEARNING).

1. Number of coffee grinder pulses taking place during the grinding cycle
2. Max. average value of the power consumed by the gear motor during the coffee brewing cycle
3. Flavour selected by the user

The algorithm compares the maximum average value of the power consumed by the unit with the value listed in the table for the selected flavour, in order to calculate the new grinding pulse value for the next coffee produced.
If the value of the power consumed by the gear motor is lower than the value of the min. current, the grinding pulses will be increased by 2.
If the value of the power consumed by the gear motor is greater than the value of the maximum current, the grinding pulses will be decreased by 4.
If the "pre-ground" flavour is selected by the user, no modification will be made

If the value of the power consumed by the gear motor falls within the "overwork" interval, the grinding pulses will be decreased by 10 and the product will be dispensed.
If the value of the power consumed by the gear motor falls within the "expulsion" interval, the grinding pulses will be decreased by 10 and the pad will be dispensed.

TROUBLESHOOTING

Test mode

To enter TEST MODE, proceed as follows:
MAKE SURE THE MACHINE IS UNPLUGGED.

• Turn the selector to the water position and press and hold the espresso coffee key while you plug the machine in.

Confirmation that the machine is in TEST MODE is signalled by LEDs 1, 2 and 3 lighting up in a cyclical manner.
Release the espresso key; LEDs 1 and 2 will remain lit.

There are four LEVELS of checking (to move to a higher level, press the (on/off) key

L0	MICROSWITCHES OPERATIONAL CHECK (unit, dreg drawer, hatch)
L1	BREWING UNIT OPERATIONAL CHECK (power consumption and stroke limit microswitch)
L2	PUMP AND TURBINE OPERATIONAL CHECK
L3	BOILER AND COFFEE GRINDER OPERATIONAL CHECK
lev.	pos. selector	LED	key	function	notes
L0 Operational check - microswitches		ON
	OR	ON
		OFF		Microswitch: dreg drawer unit hatch
		blinks once		insert unit	When the unit is removed and replaced, wait for at least 5 sec.
		blinks once		insert dreg drawer	Always insert the components in this sequence
		blinks once		close hatch
		ON		check keys	By pressing espresso or coffee
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
L1 Operational check - brewing unit		ON		brewing unit microswitch	Gear motor rises (brewing unit in work position)
		ON		brewing unit microswitch	Gear motor falls (brewing unit in home position)
		OFF		power consumption of the unit in mA	OK
		Blinks			Between 200 and 300 mA OK with unit inserted
		ON			KO over 300 mA
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
L2 Operational check - pump and turbine		Blinks		pump operation	Make water come out of the steam hose
				turbine operation	Each blink corresponds to one turbine rotation
				coffee pipe operation	Return to L1 and switch the unit to Work, return to L2 and make water come out of the dispenser
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
L3 Operational check - boiler coffee grinder				power consumption of the boiler	Use an ammeter to check the power consumption is between 5.3 and 6.1 mA
		Blinks		coffee grinder operation
				coffee grinder sensor	Each blink corresponds to one coffee grinder rotation

Draining the boiler

(Steam Out)
To drain the boiler, proceed as follows:
MACHINE UNPLUGGED

• Turn the selector to the water position , press and hold the large coffee key and plug the machine in.
• The three LEDs light up and remain lit.
• Release the large coffee key; the LEDs will begin to blink in an anti-clockwise cycle and boiler draining will commence (remember to place a recipient underneath the steam hose).
• When the draining process is complete, the double coffee and temperature LEDs will remain lit.
• Unplug the machine to end this procedure.
• Press on/off; the coffee maker will begin filling the circuit (red LED 3 blinks quickly).

SERVICING & MAINTENANCE

Repair schedule

Service schedule

S = Replacement
TR = Noise test
P= Cleaning
D = Descaling
ES = Visual inspection
R = Adjustment

Final test

DISASSEMBLY

Disassembling the outer elements

	Disassembling the Top cover
	1/2. Remove the dreg drawer, water tank, mushroom finger protection device on the coffee container lid and coffee container, then loosen the screws shown. 3/4. Slide out the steam hose protection, lift the cover at the rear by pressing down gently on the cooling vents to help detach the anchoring tabs, then pull it away from the steam hose, taking care not to scratch it.
	Disassembling the side cover
	Loosen the screws shown and slide out the side cover; be careful of the protrusions (A) on the base.
	Disassembling the hatch
	Detach the hatch by pressing the fastenings. Lift the fastenings shown. Slot for pins.

Disassembling the electronics

	Disassembling the CPU
	Remove the RHS and LHS light guide. Loosen the screws shown, detach the dispenser, then remove the circlip and gear as illustrated in the photograph. Slide out the control keypad. Remove the flat cable shown and slide out the P.C.B.
	Disassembling the power P.C.B.
	Loosen the screw shown and remove the P.C.B. protection. Slide out the P.C.B., removing all connections.

Disassembling the control knob and coffee keys

	Disassembling the Top cover
	To remove the coffee keys from the control keypad, detach them from the anchoring device on the back of it and take them out. To remove the knob, simply slide it out of its position.

Disassembling the boiler pin

	Disassembling the boiler pin
	Loosen the screws shown and remove the boiler pin.

Gear motor

Gear motor

Loosen the screws holding the boiler pin in place, remove it and loosen the other screws shown. The following are located inside the compartment protected by the casing: Electric motor (A) with gears (B) and (C) for transmission and timing of the brewing unit. Dreg drawer present microswitch (D). Brewing unit present microswitch (E). Microswitch (F) intercepting the brewing unit home and dispensing phases. Remove the gear (C) that meshes with the motor transmission shaft. Remove the large gear (B). Remove the motor (A), complete with transmission shaft. Replace the gear (B), making sure that the imprint of the arrow is aligned with the opening containing the pin (P). When replacing the motor and the transmission shaft, make sure the guide runners (L) are in the right position. Grease the shaft thoroughly and evenly.

Disassembling the boiler

Loosen the screws shown. Loosen the screw and remove the plastic support. Disconnect the hoses and the connections.

Disassembling the valve

Remove the boiler pin. Remove the boiler. Remove the gear. Loosen the screws shown.

Disassembling the pump and turbine

Slide out the support as shown. Remove connection silicone hoses 1, slide out the To prevent annoying vibrations when reassembling the pump, take extra care when positioning spring 2. At this point, the turbine may also be removed from its recess.

Fitting and removing OETIKER clamps

	Boiler connection. Other connections.
	Replacing the hoses
	Use a suitable pair of pliers to remove the clamp (as illustrated). Tighten the clamp as illustrated.

Disassembling the coffee grinder

To remove the coffee grinder, simply slide it out and remove its connections. When replacing it, make sure the spring (A) and the coffee pipe (B) are positioned correctly.

Grinder adjustment/assembly and disassembly

To remove the upper grinder support, use a hex key to exert pressure, turning it clockwise in order to release the grinder support from the bayonet coupling. To remove the grinder from the upper support, turn it anti-clockwise until it detaches from the bayonet coupling. To remove the lower grinder, keep the increment pin (A) locked in position and turn the grinder anti-clockwise, until it detaches from the bayonet coupling. When refitting the upper grinder support, make sure you reposition it so that the mark is as illustrated in the photo.

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.

Documents / Resources

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

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