Gaggia Brera Service Manual Download Page 6

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Rev. 00 OCTOBER 2009

Page / 04

GAGGIA

01 INTRODUCTION

1.6.1 External machine parts

Power cord

LED display

selector switch

Hot water/steam selector switch

STAND-BY Button

Brew group

Service door

Grinder adjustment knob

compartment

Cup stacking surface

Dispensing spout

Cup holder grill

ON-OFF power button

Full drip tray indicator

Drip tray

Water tank

Hot water/steam wand

Wand protective gripper

Control panel

Summary of Contents for Brera

Page 1: ... 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 Rev 00 OCTOBER 2009 ...

Page 2: ... 2 Machine parameters and performance 1 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 Detection of low bean level dose adjustment 5 coffee grinder blockage ...

Page 3: ...pad card and valve card disassembly 2 7 4 Power CPU card disassembly 3 7 5 Gearmotor disassembly 3 7 6 Boiler disassembly 4 7 7 Valve disassembly 4 7 8 Pump and turbine disassembly 5 7 9 OETIKER clamps assembly and disassembly 6 7 10Coffee grinder disassembly 7 7 11Grinder adjustment assembly and disassembly 8 8 Notes 9 Water circuit diagram 9 1 Water circuit diagram 10 Electrical diagram 10 1 Wir...

Page 4: ...nter Programmer 1 3 Material Description Notes Thermal paste Heating element 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...

Page 5: ... 01 INTRODUCTION 1 5 Brera range Led interface X Painted details X Water steam valve X Alarm LED X Automatic rinse X Automatic dosage X Pannarello frother X Dispensed coffee memory capacity X Automatic shutdown after 60 inactivity X 02 ...

Page 6: ...y selector switch Hot water steam selector switch STAND BY Button Brew group Service door Grinder adjustment knob compartment Cup stacking surface Dispensing spout Cup holder grill ON OFF power button Full drip tray indicator Drip tray Water tank Hot water steam wand Wand protective gripper Control panel ...

Page 7: ...Rev 00 OCTOBER 2009 Page 04 GAGGIA 01 INTRODUCTION 1 6 2 Internal machine parts 04 Card PWR CPU boiler Pump Temperature sensor Side door microswitch Coffee grinder Turbine Coffee grinder motor ...

Page 8: ...Rev 00 OCTOBER 2009 CHAPTER 2 TECHNICAL SPECIFICATIONS ...

Page 9: ...ect current motor with flat ceramic grinder blades 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 256x315x410 Weight 9 kg Water tank capacity 1l Coffee bean hopper capacity 200 gr coffee beans Dreg drawer capacity 8 Heat exchanger capacity Approx 10 cc Water circ...

Page 10: ... Min Max No No WATER HARDNESS CANNOT BE SET DREG 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 dreg 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 Des...

Page 11: ...Rev 00 OCTOBER 2009 CHAPTER 3 BRIEF INSTRUCTIONS ...

Page 12: ...ed with steam dispensing Machine dispensing hot water Proceed with hot water dispensing Machine dispensing a coffee Wait for the dispensing process to end dispensing stops when you press the key again Machine dispensing two coffees Wait for the dispensing process to end dispensing stops when you press the key again The machine is being programmed with the coffee cup fill level Stop dispensing as d...

Page 13: ...stopping point Turn the hot water steam valve knob to the correct position If the knob is turned open while product is being dispensed the appliance stops dispensing and starts a 30 sec countdown before cancelling the dispensing process The countdown can be stopped by closing the knob and operation will resume from its stopping point No brew group If the brew group is removed while product is bein...

Page 14: ...ank Weekly D Clean the coffee bean hopper As necessary E Clean the casing As necessary F Clean the brew group Every time the coffee bean hopper is filled or weekly Lubricate the brew group Once a month or every 500 dispensing procedures Clean the group housing Weekly H Descaling When indicated or every three 3 months which ever occurs first Descaling cycle frequency Hard ness Water hardness Withou...

Page 15: ...Rev 00 OCTOBER 2009 CHAPTER 4 OPERATING LOGIC ...

Page 16: ... Turbine Amount of coffee dispensed into the cup Reciprocating piston type pump 13 15 bar Compensation valve opening pressure 16 18 bar Boiler 1400 W Presblok valve select coffee hot water steam WATER TANK COMPENSATION VALVE VALVE TURBINE BOILER HOT WATER STEAM PUMP RINGNUT OPERATION DISPENSING SPOUT ...

Page 17: ...hroom valve 3 Mushroom valve support 4 Mushroom valve 5 Sealing OR 1 2 3 4 5 When dispensing coffee the mushroom valve opens at 4 bar 0 5 Manual opening when dispensing water Manual opening when dispensing steam 02 TOTAL STROKE COFFEE CLOSED 30 30 Valve opening stroke Valve closing stroke STEAM OPEN WATER OPEN Extra stroke Extra stroke ...

Page 18: ...ch the optimal temperature The temperature will then remain at a con stant level Coffee cycle 1 The coffee grinder starts the grinding process controlled by pulses generated by a sensor 2 The gearmotor brew group 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 dispense...

Page 19: ...erature 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 gearmotor is powered by a direct current motor that engages with the smaller double toothed wheel using a worm screw The brewing unit is mounted on the axle of the large gear wheel and when a coffee is reques...

Page 20: ...tronic system No coffee A low coffee bean level is detected by the Hall sensor after variations in the pulse frequency with or without coffee If there are no coffee beans operation while empty the number of rotations and therefore the number of pulses will be greater t1 no coffee indication If however there are coffee beans the number of rota tions will be lower due to the force created by the gri...

Page 21: ...t absorbed by the gearmotor is lower than the value of the minimum cur rent the grinding pulses will be increased by 2 If the value of the power consumed by the gearmotor is greater than the value of the maximum current the grinding pulses will be decreased by 4 If the pre ground aroma is selected by the user no modification will be made Min current mA Max current mA Aroma pulses 200 300 Mild 10 o...

Page 22: ...Rev 00 OCTOBER 2009 CHAPTER 5 SERVICE MODE ...

Page 23: ...presso coffee key Operational check keys PRESS No key SETTINGS PRESS THE ON OFF KEY TO ACCESS THE NEXT LEVEL UP Operational check microswitches and sensors PRESS Control knob in water pos Control knob in coffee pos Control knob in steam pos No water SETTINGS PRESS RHS service door open No dreg drawer No unit SETTINGS PRESS THE ON OFF KEY TO ACCESS THE NEXT LEVEL UP 01 Steady on Steady on Steady on...

Page 24: ...trol knob is set to hot water or steam and the key pressed water is dispensed from the steam wand Return to the previous level set the brew group to its work position up return to this level set the control knob to coffee and press the button water will be dispensed from the dispensing spout FUNCTION Pump operation the turbine monitors the water flow and the icon begins to flash PRESS THE ON OFF K...

Page 25: ...Rev 00 OCTOBER 2009 CHAPTER 6 SERVICING AND MAINTENANCE ...

Page 26: ... appliance is open 12 Assembly 13 Final inspection test 14 Draining the circuit in winter 15 External cleaning 16 Lubricating the brew group with suitable grease 17 Insulation test HG 701 dielectric 18 Documentation S Replacement P Cleaning ES Visual inspection TR Noise test D Descaling R Adjustment Component Action Support tool Water filter P S Water tank lip seal S Boiler pin O ring S Brew group...

Page 27: ...up until the cream separates The cream should come together again to form a complete layer Cream colour Hazel brown Temperature Reading taken while dispensing Thermometer 84 C 4 C Grinding level Check the grain size of the ground coffee Hot water Dispense water Steam Dispense steam Dreg drawer missing indication Remove the dreg drawer Dreg drawer missing indication Missing indication coffee beans ...

Page 28: ...Rev 00 OCTOBER 2009 CHAPTER 7 DISASSEMBLY ...

Page 29: ...nger protection device and coffee bean hopper 3 Lift and remove the top cover 4 Slide out the service door lifting it upwards 5 6 Unscrew the screws shown and slide out the rear cover side cover and coffee grinder sound insulating cover 7 Slide out the control knob cover un screw the screws shown and slide out the dispensing head cover 8 Unscrew the screws shown and slide out the dispensing head f...

Page 30: ...cable Slide out the front panel 3 Disconnect the connector shown and unscrew the CPU card support screws shown 4 5 Unscrew the screws shown 8 Unscrew the screws shown 9 Slide out the top cover knob support assembly gear and card support 10 Release the card from the support 7 Slide out the keys seal light guide and LED glass 1 2 1 2 3 3 4 4 5 5 7 7 8 8 9 9 10 10 ...

Page 31: ...g Brew drive A with gears B and C for trans mission and timing of the dispensing head Dreg drawer present microswitch D Dispensing head present microswitch E Microswitch F intercepting both the standby phase of the dispensing head and the dispensing phase Slide out the gear C that meshes with the brew drive Remove the large gear B Remove the brew drive A complete with trans mission shaft 3 Replace...

Page 32: ...es and the connections 7 6 Boiler disassembly 1 2 3 7 7 Valve disassembly 1 Remove the boiler pin 2 Remove the control knob cover and unscrew the screw as indicated 3 Lift and remove the dispenser as sembly slide out the fork shown and unscrew the screws holding the front piece 4 Unscrew the screws shown to remove the front piece support 5 Remove the spring washer and the control knob gear steam w...

Page 33: ...disconnect the valve from the water connections 7 Unscrew the screws shown and disconnect the valve from the mesh hoses 7 8 Pump and turbine disassembly 6 7 PUMP Remove the connection 1 disconnect the silicone hoses 2 Unscrew the safety valve and remove the pump from the two supports TURBINE Remove the connection and disconnect the silicone hoses 2 2 1 05 ...

Page 34: ...A 07 DISASSEMBLY 1 Boiler connection 2 Other connections Replacing the hoses 1 Use a suitable pair of pliers to remove the clamp as illustrated 2 Tighten the clamp as illustrated 7 9 Disassembling and fitting OETIKER clamps 1 1 2 2 06 ...

Page 35: ...AGGIA 07 DISASSEMBLY 1 To remove the coffee grinder simply slide it out and remove its connections 2 When replacing it make sure the spring A and the coffee pipe B are positioned correctly 7 10 Coffee grinder disassembly 1 2 A B 07 ...

Page 36: ...t coupling 2 To remove the grinder blade from the upper support turn it anti clockwise until it detaches from the bayonet coupling 3 To remove the lower grinder blade keep the increment pin A locked in position and turn the grinder blade anti clockwise until it detaches from the bayonet coupling 4 When refitting the upper grinder support make sure you reposition it so that the mark is as illus tra...

Page 37: ...Rev 00 OCTOBER 2009 CHAPTER 8 NOTES ...

Page 38: ...Rev 00 OCTOBER 2009 Page 01 GAGGIA 08 NOTES 01 ...

Page 39: ...Rev 00 OCTOBER 2009 CHAPTER 9 WATER CIRCUIT DIAGRAM ...

Page 40: ... silicone tube Tubo silicone retinato 5x8 9 11005599 190mm Safety valve Valvola di sicurezza 11010166 Linen faced silicone tube Tubo silicone retinato 5x8 9 11003557 260mm Water drain Scarico acqua T o t h e D i s p e n s i n g s p o u t A l l e r o g a t o r e c a f f è Linen faced silicone tube Tubo silicone retinato 5x8 9 11004050 165mm Water tank Water tank Flow meter Turbine Steam wand Tubo v...

Page 41: ...Rev 00 OCTOBER 2009 CHAPTER 10 ELECTRICAL DIAGRAM ...

Page 42: ...Rev 00 OCTOBER 2009 Page 01 GAGGIA 10 WATER CIRCUIT DIAGRAM 10 1 Wiring diagram 01 ...

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