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Saeco Intelia Service Manual
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Saeco Intelia Service Manual

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Coff ee Machine
Service
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Table of contents

1.
1.1.
1.2.
1.3.
1.4.
1.5
1.6.1.
1.6.2.
2.
2.1.
Technical specifi cations
2.2.
3.
3.1.
3.2.
3.3.
3.4
3.5
4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6
adjustment, coff ee grinder blocked
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.
Published by Saeco International Group
Service
Service
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Subject to modifi cation
Manual
Manual
Rev. 02 September 2012
Table of contents
4.7.
4.8.
4.9.
4.10.
4.11
5.
5.1.1.
5.1.2.
5.1.3.
Intelia Latte test mode
5.1.4
Intuita test mode
5.2.
Error messages
6.
6.1.
6.2.
6.3.
7.
7.1.
7.2.
7.3.
7.4.
7.5.
7.6
7.7
7.8
7.9
Intelia
Page
EN 4219 400 00014
2012-Sept-07
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  • Page 1: Table Of Contents

    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.
  • Page 2 Water sensor control board 7.13. Gear motor 7.14. Boiler 7.15. Dispenser assembly 7.16. Valve disassembly 7.17. Control board and display 7.18. Fitting and removing Oetiker clamps Notes Water circuit diagram Electrical diagram Saeco International Group INTELIA Rev. 02 / September 2012...
  • Page 3 CHAPTER 1 INTRODUCTION Saeco International Group Rev. 02 / September 2012 INTELIA...

  • Page 4: Introduction

    Screwdriver Torx T 8 - T 10 - T 20 Pliers for Oetiker clamps CC -A - Vdc tester Digital thermometer Scale limit > 150°C SSC (Saeco Service Center) Programmer (for programming and diagnostics mode) Material Description Notes Thermal paste Heating element >...

  • Page 5: Service Policy

    YES, to consult the specifi c exploded-view of the Thermal Carafe on Only for OOW repairs CARAFE website YES, to consult the specifi c exploded-view of the Milk Island on MILK ISLAND Only for OOW repairs website Saeco International Group Rev. 02 / September 2012 Page / 05...

  • Page 6: External Machine Parts

    INTELIA 01 INTRODUCTION Coffee bean hopper 1.6.1 External machine parts with lid Intelia Cappuccino Grinding adjustment Coffee dispenser Water dispenser (removable) Service hatch Drip tray+grille Pre-ground coffee Brewing unit compartment Dreg drawer Control panel Milk carafe Power cable socket and...
  • Page 7 INTELIA 01 INTRODUCTION Coffee bean Intelia Class e Focus Hot water/steam hopper with lid dispensing pipe Pannarello (Intelia Focus) Service hatch Cappuccino valve (Intelia Class) Power cable socket and main switch Drip tray+grille Pre-ground coffee Brewing unit compartment Dreg drawer...

  • Page 8: Internal Machine Parts

    1.6.2 Internal machine parts Coffee grinder Grinding adjustment insert 2-way solenoid valve KYB Interface card Power board Steam pipe Safety valve Boiler cover and boiler Power cable connector Flow-meter Pump Boiler pin Saeco International Group Rev. 02 / September 2012 Page / 05...

  • Page 9: Technical Specifi Cations

    CHAPTER 2 TECHNICAL SPECIFICATIONS Saeco International Group Rev. 02 / September 2012 INTELIA...
  • Page 10 Espresso coffee Italy 25/40 grTemperature of 1st product ≥ 69°C ≤ 85°C Temperature of 2nd product ≥ 72°C ≤ 85°C Coffee 70/120 grTemperature of 1st product ≥ 69°C ≤ 85°C Temperature of 2nd product ≥ 72°C ≤ 85°C Saeco International Group Rev. 02 / September 2012 Page / 03...

  • Page 11: Machine Parameters And Performance

    120 litres (240,000 pulses) Very hard (over 21°dH) 30 litres (60,000 pulses) 60 litres (120,000 pulses) The default water hardness level is 4. Each litre of water corresponds to approximately 2,000 pulses. Saeco International Group Rev. 02 / September 2012 Page / 03...
  • Page 12 Water reserve (pulses) with water fi lter Water reserve (pulses) with no water fi lter Water reserve modifi able by Production/Service departments "Fill tank" alarm "No tray" alarm Yes (Fill tank) Water mains Saeco International Group Rev. 02 / September 2012 Page / 03...

  • Page 13: User Instructions

    CHAPTER 3 USER INSTRUCTIONS Saeco International Group Rev. 02 / September 2012 INTELIA...

  • Page 14: Intelia Cappuccino Customer And Programming Menu

    INTELIA 03 USER INSTRUCTIONS 3.1. Intelia Cappuccino customer and programming menu ON/OFF button espresso dispensing Aroma button / Pre-ground button button Long espresso button MENU dispensing button special beverages cappuccino dispensing button selection button Machine ready signals (GREEN) Machine at correct temperature...

  • Page 15: Factory Settings

    For details see the paragraph concerning the fi lter management. Descaling Cycle This function lets you execute a descaling cycle. Factory settings DEFAULT SETTINGS This function allows the factory values to be reset. Saeco International Group Rev. 02 / September 2012 Page / 10...

  • Page 16: Intelia Latte Customer And Programming Menu

    INTELIA 03 USER INSTRUCTIONS 3.2. Intelia Latte customer and programming menu Espresso coffee brew Latte Macchiato brew button button Long espresso brew Display Cappuccino brew button button “Aroma” - Pre-ground Hot Milk brew button coffee button SON/OFF button “MENU” button...
  • Page 17 “ button to go on using the machine. Please bear in mind that failure to descale your machine will prevent it from working properly. Repair is not covered by warranty. Saeco International Group Rev. 02 / September 2012 Page / 10...
  • Page 18 2 or 3 times. If the machine does not start, contact the consumer care help line at the phone number listed on the last page of this document. Saeco International Group Rev. 02 / September 2012 Page / 10...

  • Page 19: Intelia Focus And Class Customer And Programming Menu

    INTELIA 03 USER INSTRUCTIONS 3.3. Intelia Focus and Class customer and programming menu ON/OFF button espresso dispensing button Aroma / Pre-ground button Long espresso dispensing button Descaling button Hot water/steam (Focus) selection button Machine ready signals (GREEN) Machine at correct temperature...
  • Page 20 For details see the paragraph concerning the fi lter management. Descaling Cycle (Focus and Class) This function lets you execute a descaling cycle. Factory settings (only Class) DEFAULT This function allows the factory values to be reset. SETTINGS Saeco International Group Rev. 02 / September 2012 Page / 10...

  • Page 21: Intuita Customer And Programming Menu

    STEADY ON The machine needs a descaling cycle. Please bear in mind that failure to descale your machine will prevent it from working properly. Repair is not covered by warranty. Saeco International Group Rev. 02 / September 2012 Page / 10...
  • Page 22 Turn off the coffee machine. After 30 seconds, turn it on again. Try this 2 or 3 times. If the machine does not start, contact the consumer care help line at the phone number listed on the last page of this document. Saeco International Group Rev. 02 / September 2012 Page...

  • Page 23: Operation, Cleaning And Maintenance

    120 litres (240,000 pulses) Very hard 30 litres (60,000 pulses) 60 litres (120,000 pulses) (over 21°dH) The default water hardness level is 3. Each litre of water corresponds to approximately 2,000 pulses Saeco International Group Rev. 02 / September 2012 Page / 10...

  • Page 24: Operating Logic

    CHAPTER 4 OPERATING LOGIC Saeco International Group Rev. 02 / September 2012 INTELIA...

  • Page 25: Water Circuit

    INTELIA 04 OPERATING LOGIC 4.1. Water circuit Intelia Cappuccino Saeco International Group Rev. 02 / September 2012 Page / 08...
  • Page 26 INTELIA 04 OPERATING LOGIC Intelia Focus e Class Saeco International Group Rev. 02 / September 2012 Page / 08...

  • Page 27: Coffee Cycle

    Product dispensing (the pump operation period is defi ned by the amount of product dis- pensed). The gear motor moves to its home position (the dregs are expelled automatically). Saeco International Group Rev. 02 / September 2012 Page / 08...

  • Page 28: Single Microswitch

    The electronic system detects the current boiler temperature from the drop in voltage of the sensor and adjusts it accordingly. Heating element values and corresponding temperatures: see table. Saeco International Group Rev. 02 / September 2012 Page / 08...

  • Page 29: Coffee Grinder

    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. Saeco International Group Rev. 02 / September 2012 Page / 08...

  • Page 30: Dose Self-Learning (Sas)

    Caution: In the case of excessive dosage, powder may be expelled into the dreg drawer. This is not a fault, but can occur during preliminary operation or after a service. Saeco International Group Rev. 02 / September 2012 Page / 08...

  • Page 31: Water Level Detection (Water Tank)

    360° 1 rev which has fl owed through; after the specifi ed amount (set in accordance with the water hardness level), the “Replace fi lter” message appears. Saeco International Group Rev. 02 / September 2012 Page / 08...

  • Page 32: Water Fi Lter

    3-stage bypass (A, B, C) depending on the degree of hardness. See small image. 4.11. Intelia Cappuccino milk carafe 1) Steam input 2) Cappuccino maker 3) Bring the cappuccino maker into dispensing position before...

  • Page 33: Troubleshooting

    CHAPTER 5 TROUBLESHOOTING Saeco International Group Rev. 02 / September 2012 INTELIA...

  • Page 34: Intelia Cappuccino Test Mode

    INTELIA 05 TROUBLESHOOTING 5.1.1. Intelia Cappuccino test mode To enter Test Mode Hold down the buttons Espresso and Menu. Turn on the main switch at the rear of the machine Entry into Test Mode results in a screen divided into sections, as illustrated in the diagram below.
  • Page 35 Press STAND_BY “ Press STAND_BY “ ” to move to the next screen ” to move to the next screen Operational check – brewing unit Initial status Initial status Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 36 Press STAND_BY “ Press STAND_BY “ ” to move to the next screen ” to move to the next screen Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 37 Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 38 Above this temperature the boiler is always off, avoiding the risk of dan- Above this temperature the boiler is always off, avoiding the risk of dan- gerously high temperatures. gerously high temperatures. Saeco International Group Rev. 02 / September 2012 Page / 22...

  • Page 39: Intelia Focus And Class Test Mode

    INTELIA 05 TROUBLESHOOTING 5.1.2. Intelia Focus and Class Test mode To enter Test Mode Hold down the Espresso and Menu buttons. Switch on the main switch at the back of the machine. Entry into Test Mode results in a screen divided into sections, as illustrated in the diagram below.
  • Page 40 If the absorbed current exceeds 300 mA the display turns red, check the brewing unit, the gears on the gear motor and the motor housing in its seat. brewing unit, the gears on the gear motor and the motor housing in its seat. Saeco International Group Rev. 02 / September 2012 Page...
  • Page 41 ERROR: If L / H is 0 or very low, the solenoid valve does not open. Check the solenoid valve and the wiring (JP3). solenoid valve and the wiring (JP3). Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 42 CPU/POWER in (JP19), also check the wiring on the and the connection to the CPU/POWER in (JP19), also check the wiring on the NTC (JP13). NTC (JP13). Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 43 When the procedure is completed, the message “COMPLETE” appears on the display, the solenoid valves close automatically and the machine may the display, the solenoid valves close automatically and the machine may be switched off. be switched off. Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 44 INTELIA 05 TROUBLESHOOTING 5.1.3. Test Mode Intelia latte To enter Test Mode A) Hold down the Espresso and Milk buttons. B) Switch on the main switch at the back of the machine. LATTE ESPRESSO MACCHIATO LONG COFFEE CAPPUCCINO AROMA MILK...
  • Page 45 Press STAND_BY “ ” to move to the next screen ” to move to the next screen Operational check - impuls Milk Operational check - impuls Milk NOT USED NOT USED Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 46 Press STAND_BY “ Press STAND_BY “ ” to move to the next screen ” to move to the next screen Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 47 (JP24). and the pump wiring (JP24). Press STAND_BY “ Press STAND_BY “ ” to move to the next screen ” to move to the next screen Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 48 CPU/POWER in (JP19), also check the wiring on the and the connection to the CPU/POWER in (JP19), also check the wiring on the NTC (JP13). NTC (JP13). Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 49 Level 5: The machine tests the coffee powder circuit: The machine tests the coffee powder circuit: a)Heater (plus NTC sensor) a)Heater (plus NTC sensor) b)Grinder (plus rotation pick up) b)Grinder (plus rotation pick up) Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 50 TEST MODE Level 4 Pressing botton ON/OFF TEST MODE Level 5 TEST MODE Level 5 Pressing botton ON/OFF TEST MODE Level 0 TEST MODE Level 0 Pressing botton ON/OFF Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 51 If you are not able to turn the LED OFF detects an error condition over the button switch Start condition All LED are OFF Pressing ON/OFF button moves to next level On ERROR verify: Cable connection Power supply Push button presence and welding Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 52 2 beans hot water + espresso 3 beans hot water + espresso + coffee Press ON/OFF button moves to next level On ERROR verify: Cable connection Power supply Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 53 Move BU to rest position. Press Calc Clean button to move BU to rest position ON/OFF Hot water Espresso Coffee Steam Calc clean BLINK BLINK Press ON/OFF button moves to next level On ERROR verify: Cable connection Power supply Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 54 Hot water Espresso Coffee Steam Calc clean During the test BLINK No grinder rotation Press ON/OFF button moves to next level (level 0) On ERROR verify: Cable connection Power supply Saeco International Group Rev. 02 / September 2012 Page / 22...
  • Page 55 The boiler temperature has not increased by x°C in y sec (boiler power supply disconnected, incorrect boiler fi tted must be a 1300W boiler, par- tial power supply to boiler, cut out thermostat tripped) Mains voltage trouble Saeco International Group Rev. 02 / September 2012 Page / 22...

  • Page 56: Standard Checks

    CHAPTER 6 STANDARD CHECKS Saeco International Group Rev. 02 / September 2012 INTELIA...

  • Page 57: Repair Schedule

    ES/P Grease solvent / Grease Hoses, attachments and Oetiker clamps Pump ES/TR Gear motor ES/TR Coffee grinder Vacuum cleaner / brush Water circuit Saeco descaler Hot water/steam valve ES/S Saeco International Group Rev. 02 / September 2012 Page / 02...

  • Page 58: Final Test

    Dreg drawer missing Remove the dreg drawer missing indication indication Start brewing a coffee Low bean level Low bean level while the coffee bean indication indication hopper is empty Saeco International Group Rev. 02 / September 2012 Page / 02...

  • Page 59: Disassembly

    CHAPTER 7 DISASSEMBLY Saeco International Group Rev. 02 / September 2012 INTELIA...

  • Page 60: Intelia Cappuccino Outer Shell

    INTELIA 07 DISASSEMBLY 7.1. Intelia Cappuccino outer Shell Remove the water tank, coffee con- tainer cover, drip tray, dreg drawer, brewing unit, carafe or hot water dispenser. Unscrew the screws shown Lift the top cover. Unscrew the screws shown Slide out the hatch.

  • Page 61: Intellia Class And Focus Outer Shell

    When reassembling the coffee grinder, Loosen the screws as illustrated and remove the sound make sure the spring is repositioned insulating cover. Raise the coffee grinder and remove correctly (see photo). the connections. Saeco International Group Rev. 02 / September 2012 Page / 11...

  • Page 62: Grinder Blades

    Turn the grinder blades anticlockwise out of the support. Turn the grinder blades clockwise out of the support. The bayonet connections can be accessed from the rear. For a standard adjustment, both markings must be aligned. Saeco International Group Rev. 02 / September 2012 Page / 11...

  • Page 63: Coffee Grinder Adjustment

    (B). 7.6. Intelia Cappuccino three-way solenoid valve 1) Loosen the screws holding the front plate to the upper plate 2) Remove the front plate, pressing it in the center and pulling the side walls outward...

  • Page 64: Intelia Class And Focus Two-Way Solenoid Valve

    INTELIA 07 DISASSEMBLY 7.7. Intelia Class and Focus two-way solenoid valve 1) Loosen the screws holding the front plate to the upper plate. 2) Remove the card support assembly. 3) Loosen the screws holding the solenoid valve to the upper plate.

  • Page 65: Pump

    Loosen the screw as illustrated and Slide out the pipe Slide the card off the remove the capacitive sensor glued to connecting the fl ow support. the seat. meter to the pump. Saeco International Group Rev. 02 / September 2012 Page / 11...

  • Page 66: Gear Motor

    Slide out the fork as illustrated. access the screws which fi x the dispenser cover into place. Only for Intelia Cappuccino remove the plug body along with pitcher Unscrew the screws in the front cover and lift it off the milk jug plug body from the place...
  • Page 67 (P). When replacing the motor and the transmission shaft, make sure the guide runners (L) are in the right posi- tion. Grease the shaft thoroughly and evenly. Saeco International Group Rev. 02 / September 2012 Page / 11...

  • Page 68: Boiler

    Loosen the screws as illustrated and remove the front panel to illustrated and remove the access the screws which fi x the dispenser cover into place boiler pin (A) Saeco International Group Rev. 02 / September 2012 Page / 11...

  • Page 69: Control Board And Display

    Loosen the screws as Remove the frame from illustrated. illustrated. the keypad and the display. Remove the electrical connections between the card and the display and release the card from the support. Saeco International Group Rev. 02 / September 2012 Page / 11...

  • Page 70: Fitting And Removing Oetiker Clamps

    7.18. Fitting and removing Oetiker clamps 1) Boiler connection. 2) Other connections. Use a suitable pair of pliers to remove the Tighten the clamp as illustrated. clamp (as illustrated). Saeco International Group Rev. 02 / September 2012 Page / 11...
  • Page 71 CHAPTER 8 NOTES Saeco International Group Rev. 02 / September 2012 INTELIA...
  • Page 72 INTELIA 08 NOTES Saeco International Group Rev. 02 / September 2012 Page / 01...
  • Page 73 CHAPTER 9 WATER CIRCUIT DIAGRAM Saeco International Group Rev. 02 / September 2012 INTELIA...
  • Page 74 INTELIA 09 WATER CIRCUIT DIAGRAM Intelia Cappuccino Saeco International Group Rev. 02 / September 2012 Page / 01...
  • Page 75 INTELIA 09 WATER CIRCUIT DIAGRAM Intelia Focus and Class Saeco International Group Rev. 02 / September 2012 Page / 01...

  • Page 76: Electrical Diagram

    CHAPTER 10 ELECTRICAL DIAGRAM Saeco International Group Rev. 02 / September 2012 INTELIA...
  • Page 77 INTELIA 10 WIRING DIAGRAM Intelia Focus and Class Saeco International Group Rev. 02 / September 2012 Page / 01...

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