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Saeco Intelia Service Manual

Other manuals for Intelia: Service Manual

Summary of Intelia

  • Page 1

    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 authorisati...

  • Page 2

    Saeco international group rev. 02 / september 2012 intelia table of contents page 7.10. Flow-meter 6 7.11. Power board 6 7.12. Water sensor control board 6 7.13. Gear motor 7 7.14. Boiler 9 7.15. Dispenser assembly 9 7.16. Valve disassembly 9 7.17. Control board and display 10 7.18. Fitting and remo...

  • Page 3: Chapter 1

    Saeco international group rev. 02 / september 2012 intelia chapter 1 introduction.

  • Page 4

    Intelia 01 introduction saeco international group rev. 02 / september 2012 page / 05 1.1 documentation required the following documentation is needed for repair procedures: instruction booklet for specifi c model • technical documentation for specifi c model (diagrams, exploded view, sympton cure an...

  • Page 5

    Intelia 01 introduction saeco international group rev. 02 / september 2012 page / 05 02 1.5 service policy grid as used for coffee machine components assembly use single components available coffee grinder only for oow repairs yes, to consult the specifi c exploded-view of the machine or of the coff...

  • Page 6

    Intelia 01 introduction saeco international group rev. 02 / september 2012 page / 05 03 1.6.1 external machine parts intelia cappuccino intelia latte grinding adjustment control panel milk carafe pre-ground coffee compartment water tank drip tray release button display espresso coffee brew button la...

  • Page 7

    Intelia 01 introduction saeco international group rev. 02 / september 2012 page / 05 04 coffee bean hopper with lid hot water/steam dispensing pipe pannarello (intelia focus) cappuccino valve (intelia class) dreg drawer service hatch brewing unit drip tray+grille intuita “coffee grounds drawer” ligh...

  • Page 8

    Intelia 01 introduction saeco international group rev. 02 / september 2012 page / 05 1.6.2 internal machine parts 05 boiler pin pump flow-meter power cable connector safety valve boiler cover and boiler power board grinding adjustment insert steam pipe kyb interface card 2-way solenoid valve coffee ...

  • Page 9: Chapter 2

    Saeco international group rev. 02 / september 2012 intelia chapter 2 technical specifications.

  • Page 10

    Intelia 02 technical specifications saeco international group rev. 02 / september 2012 page / 03 2.1. Technical specifi cations power supply and output: 240 v~ 50 hz 1850 w - 230 v~ 50/60 hz 1850 w temperature monitoring: (ntc) variable resistor sensor - transmits the value to the electronic card sa...

  • Page 11

    Intelia 02 technical specifications saeco international group rev. 02 / september 2012 page / 03 2.2. Machine parameters and performance product quantity minimum quantity (puls.) default quantity (puls.) maximum quantity (puls.) user programmable programm. By production / service espresso 50 165 600...

  • Page 12

    Intelia 02 technical specifications saeco international group rev. 02 / september 2012 page / 03 water tank description water reserve (pulses) with water fi lter 200 water reserve (pulses) with no water fi lter 200 water reserve modifi able by production/service departments no "fill tank" alarm yes ...

  • Page 13: Chapter 3

    Saeco international group rev. 02 / september 2012 intelia chapter 3 user instructions.

  • Page 14

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 3.1. Intelia cappuccino customer and programming menu 01 if this screen appears after you switch the machine on, it means that you must run a descaling cycle. Press “ ” to access the descaling menu and consult ...

  • Page 15

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 02 alarm signals ( red ) menu (commands and programming) close the service door. No beans inside the coffee container. After fi lling the container, the cycle can be restarted. The brewing unit must be inserted...

  • Page 16

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 3.2. Intelia latte customer and programming menu ready signals (green colour) display espresso coffee brew button latte macchiato brew button long espresso brew button cappuccino brew button “menu” button speci...

  • Page 17

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 warning signals (yellow colour) the machine is programming the amount of milk to be dispensed in order to prepare a latte macchiato. The machine is programming the amount of coffee to be brewed in order to prep...

  • Page 18

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 05 warning signals (read colour) close the service door no coffee beans in the coffee bean hopper. After refi lling the hopper, the cycle can be restarted. Insert the coffee grounds drawer. Empty the coffee gro...

  • Page 19

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 3.3. Intelia focus and class customer and programming menu memo 06 on/off button espresso dispensing button long espresso dispensing button hot water/steam selection button descaling button (focus) aroma / pre-...

  • Page 20

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 07 esc - + display contrast esc - + max med min esc - + yes no default settings alarm signals ( red ) menu (commands and programming) close the service door. No beans inside the coffee container. After fi lling...

  • Page 21

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 08 “coffee grounds drawer” light “no water” light on/off button hot water dispensing button descaling button cappuccino brewing / steam dispensing button long espresso brew button “aroma” selector switch espres...

  • Page 22

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 blinking prime the circuit. Blinking insert the coff ee grounds drawer. Blinking close the service door. The brew group must be inserted into the machine. Fast blinking empty the coffee grounds drawer and the l...

  • Page 23

    Intelia 03 user instructions saeco international group rev. 02 / september 2012 page / 10 cleaning and technical servicing a empty the dregs drawer when indicated b empty the drip tray as necessary c clean the water tank weekly d clean the coffee bean hopper as necessary e clean the casing as necess...

  • Page 24: Chapter 4

    Saeco international group rev. 02 / september 2012 intelia chapter 4 operating logic.

  • Page 25

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 4.1. Water circuit 01 milk car af e compensation v alv e w ater outlet flow -meter 1900 w boiler w ater hot w ater /steam compensation v alv e w ater outlet pump w ater tank tr aditional w ater system • flow mete...

  • Page 26

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 steam pipe compensation v alv e w ater outlet flow -meter 1900 w boiler w ater hot w ater /steam two- w ay solenoid v alv e pompa w ater tank brewing unit tr aditional w ater system • flow meter – amount of cof f...

  • Page 27

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 notes: * only with pre-brewing 4.2. Coffee cycle switching on when the machine is switched on, the gear motor repositions itself as follows: - it acts on microswitch 1 (see following chapter). - the gear motor ch...

  • Page 28

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 an ntc is used as a temperature sensor; in the event of overheating this reduces boiler element power consumption. The electronic system detects the current boiler temperature from the drop in voltage of the sens...

  • Page 29

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 4.5. Coffee grinder 2 3 4 5 6 1 4.6. Low bean level detection, dose quantity adjustment, coffee grinder blocked t1 v t2 t3 t4 t without beans n=100% with beans n=100% without beans n=50% with beans n=50% the coff...

  • Page 30

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 4.7. Dose self-learning (sas) 06 the aim of this function is to automatically regulate the average dose of ground coffee (self- learning); this takes place with an algorithm based on three pieces of data that the...

  • Page 31

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 4.8. Water level detection (water tank) “water low” message (water reserve) function: the water level is monitored by a capacitative sensor, located one third of the way up the water tank wall. If the electronics...

  • Page 32

    Intelia 04 operating logic saeco international group rev. 02 / september 2012 page / 08 water fi lter function: reduced limescale deposits which take longer to • form. Improved water quality. • improved taste due to the ideal water hardness. • life span / descaling performance: • - 10 ° dh 60 litres...

  • Page 33: Chapter 5

    Saeco international group rev. 02 / september 2012 intelia chapter 5 troubleshooting.

  • Page 34

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 5.1.1. Intelia cappuccino test mode entry into test mode results in a screen divided into sections, as illustrated in the diagram below. Entry into test mode results in a screen divided into sections, as illustra...

  • Page 35

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 02 close the side door (the dreg drawer must already be in position) close the side door (the dreg drawer must already be in position) the door indicator must change from “n” to “y” the door indicator must change...

  • Page 36

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 03 press the espresso button to move the unit to work position. When press the espresso button to move the unit to work position. When the unit is in position, the work indication changes from “n” to “y”, the the...

  • Page 37

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 operational check - coffee grinder and boiler initial status initial status if the following screen appears it means that the dreg drawer is not if the following screen appears it means that the dreg drawer is no...

  • Page 38

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 05 error: error: if the number remains 0, the display turns red, and the motor is run- if the number remains 0, the display turns red, and the motor is run- ning, the problem lies in the hall sensors, or their wi...

  • Page 39

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 5.1.2. Intelia focus and class test mode 1 2 06 entry into test mode results in a screen divided into sections, as illustrated in the diagram below. Entry into test mode results in a screen divided into sections,...

  • Page 40

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 insert grounds drawer insert grounds drawer the dreg indicator must change from “n” to “y” the dreg indicator must change from “n” to “y” error condition: error condition: if the indication does not change, check...

  • Page 41

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 08 when the unit reaches the home position the indicator changes from “n” to when the unit reaches the home position the indicator changes from “n” to “y”, the absorbed current, without the brewing unit, must be ...

  • Page 42

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 09 operational check - coffee grinder and boiler initial status initial status press stand_by “ press stand_by “ ” to move to the next screen ” to move to the next screen press the aroma button to activate the co...

  • Page 43

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 steamout this procedure is carried out whenever you need to completely empty the residual water from this procedure is carried out whenever you need to completely empty the residual water from the boiler. The boi...

  • Page 44

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 5.1.3. Test mode intelia latte b 11 to enter test mode a) hold down the espresso and milk buttons. B) switch on the main switch at the back of the machine. Firmware software version firmware software version oper...

  • Page 45

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 insert grounds drawer insert grounds drawer the dreg indicator must change from “n” to “y” the dreg indicator must change from “n” to “y” error condition: error condition: if the indication does not change, check...

  • Page 46

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 operational check – brewing unit when the unit is in position, the work indication changes from “n” to “y”, when the unit is in position, the work indication changes from “n” to “y”, the absorption current must b...

  • Page 47

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 initial status initial status press the espresso button to activate the solenoid valve press the coffee button to activate the solenoid valve press the aroma button to activate the pump operational check - soleno...

  • Page 48

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 operational check - coffee grinder and boiler initial status initial status press the aroma button to activate the coffee grinder temperature control press the coffee button to activate the boiler the coffee grin...

  • Page 49

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 to enter test mode the machine enters in test mode by pushing the espresso and coffee buttons and then turn- the machine enters in test mode by pushing the espresso and coffee buttons and then turn- ing on the ac...

  • Page 50

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 the user can switch the level by pressing the on/off button, the machine shows the level of the user can switch the level by pressing the on/off button, the machine shows the level of the test: the test: a) level...

  • Page 51

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 level 0 (led) description : verify keyboard led action : led on/off always blink during the test. The others led blink once, then only one led is on starting from no water, error, double, no beans, dump box, calc...

  • Page 52

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 level 2 (switch) [led no water + error on] description: verify the security switch connection action: mechanical move the switch and verify the relative electrical feedback start condition (no water tank, no bu, ...

  • Page 53

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 level 4 (water circuit) [led no water + error + double + no beans on] description: verify the water circuit component: fl ux meter, pump, electro valve, brewing unit action: turn on and off actuators along water ...

  • Page 54

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 led on/off hot water espresso coffee steam calc clean ok off off off off off off start condition (water tank full, bu, dump box, door close) led on/off hot water espresso coffee steam calc clean during the test b...

  • Page 55

    Intelia 05 troubleshooting saeco international group rev. 02 / september 2012 page / 22 error error codes codes description description 01 01 the coffee grinder is blocked (grinder blades jammed or sensor not reading properly) 03 03 the brewing unit is blocked in work position (microswitch not relea...

  • Page 56: Chapter 6

    Saeco international group rev. 02 / september 2012 intelia chapter 6 standard checks.

  • Page 57

    Intelia 06 standard checks saeco international group rev. 02 / september 2012 page / 02 01 action 1 visual inspection (transport damage) 2 machine data check (rating plate) 3 operational check / problem analysis 4 opening machine 5 visual inspection 6 operational tests 7 repairing the faults encount...

  • Page 58

    Intelia 06 standard checks saeco international group rev. 02 / september 2012 page / 02 02 test procedure support/ tool standard tolerance espresso 2-3 espressos for adjustment purposes measuring scoop same amount 15% coffee 2-3 coffees for adjustment purposes measuring scoop same amount 15% noise s...

  • Page 59: Chapter 7

    Saeco international group rev. 02 / september 2012 intelia chapter 7 disassembly.

  • Page 60

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 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 and remove the fi nger protection. Li...

  • Page 61

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 7.2. Intellia class and focus outer shell remove the water tank, coffee con- tainer cover, drip tray, dreg drawer, brewing unit, cappuccino maker or pannarello. Unscrew the marked screws and remove the fi nger protec...

  • Page 62

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 03 to extract the top support of the appliance, press on the grinding adjustment spindle (a) and turn the support anticlockwise until it unhooks. Turn the grinder blades anticlockwise out of the support. Turn the gri...

  • Page 63

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 04 the grinding adjustment can be set by the user (only with the coffee grinder in operation) by pressing and turning (only by one click at a time) the insert inside the coffee bean hopper with the aid of the wrench ...

  • Page 64

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 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. 4) disconnect all electrical and water circuit...

  • Page 65

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 7.9. Pump 7.10. Flow-meter lift the fl ow meter out of the casing assembly and remove the electrical and water circuit connections. Loosen the screws as illustrated, slide out the electrical connection and remove the...

  • Page 66

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 7.13. Gear motor only for intelia cappuccino remove the plug body along with pitcher unscrew the screws (highlighted) and release the milk jug plug body assembly unscrew the screws in the front cover and lift it off ...

  • Page 67

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 08 loosen the screws as illustrated and remove the gear motor cover. The following are located inside the compartment pro- tected by the casing: - electric motor (a) with gears (b) and (c) for trans- mission and timi...

  • Page 68

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 09 7.15. Dispenser assembly 7.16. Valve disassembly 7.14. Boiler unscrew the marked screw and disconnect the electrical and water circuit connections. Loosen the screws as illustrated and remove the front panel to ac...

  • Page 69

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 7.17. Control board and display loosen the screws as illustrated and remove the front panel. Disconnect the electrical connections and unhook the card support. Loosen the screws as illustrated. Remove the frame from ...

  • Page 70

    Intelia 07 disassembly saeco international group rev. 02 / september 2012 page / 11 use a suitable pair of pliers to remove the clamp (as illustrated). Tighten the clamp as illustrated. 1) boiler connection. 2) other connections. 7.18. Fitting and removing oetiker clamps 11.

  • Page 71: Chapter 8

    Saeco international group rev. 02 / september 2012 intelia chapter 8 notes.

  • Page 72

    Intelia 08 notes saeco international group rev. 02 / september 2012 page / 01 01.

  • Page 73: Chapter 9

    Saeco international group rev. 02 / september 2012 intelia chapter 9 water circuit diagram.

  • Page 74

    Intelia 09 water circuit diagram saeco international group rev. 02 / september 2012 page / 01 01 flow meter turbina w ater tank serbatoio acqua silicone tube tubo silicone silicone tube tubo silicone silicone tube tubo silicone silicone tube tubo silicone assy solenoid v alv e assieme elet tro valv ...

  • Page 75

    Intelia 09 water circuit diagram saeco international group rev. 02 / september 2012 page / 01 02 flow meter turbina w ater tank serbatoio acqua silicone tube tubo silicone silicone tube tubo silicone silicone tube tubo silicone silicone tube tubo silicone silicone tube tubo silicone silicone tube tu...

  • Page 76: Chapter 10

    Saeco international group rev. 02 / september 2012 intelia chapter 10 electrical diagram.

  • Page 77

    Intelia 10 wiring diagram saeco international group rev. 02 / september 2012 page / 01 01 intelia focus and class.