Coffee Machine
RI 9933
Gaggia Unica
Service
Service Manual
Revision 01 December 2012
Table of contents
Page
Table of contents
Page
1.
Introduction
4.7.
Dose self-learning (SAS)
5
1.1.
Documentation required
1
4.8.
Water level detection (water tank)
6
1.2.
Tools and equipment required
1
4.9.
Water level detection (drip tray)
6
1.3.
Material
1
4.10.
Descaling request
7
1.4.
Safety warnings
1
4.11.
Water filter
7
1.5
Service POLICY
2
1.6.1.
External machine parts
3
5.
Troubleshooting
1.6.2.
Internal machine parts
4
5.1.
Test mode
1
5.2.
Error messages
3
2.
Technical specifications
2.1.
Technical specifications
1
6.
Standard checks
2.2
Specification for the measurement of the coffee
products temperature.
2
6.1.
Repair schedule
1
6.2.
Service schedule
1
2.3.
Machine parameters and performance
3
6.3.
Final test
2
3.
User instructions
7.
Disassembly
3.1.
Customer and programming menu
1
7.1.
Outer elements
1
3.2.
Machine indications
2
7.2.
Coffee grinder
1
3.3.
Operation, cleaning and maintenance
3
7.3.
Grinder blades
2
4.
Operating logic
7.4.
Coffee grinder adjustment
3
7.5.
Pump
4
7.6
Turbine
4
7.7
Power card
4
7.8
Caldaia
4
7.9
Gearmotor
5
4.1.
Water circuit
1
4.2.
Coffee cycle
2
4.3.
Single microswitch
3
4.4.
Temperature sensor
3
4.5.
Coffee grinder
4
4.6.
Low bean level detection, dose quantity adjustment,
coffee grinder blocked
4
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
2011-June-08
Subject to modification
EN 4219 400 00012
Table of contents
Page
7.10.
Cock card and hot water/steam cock
6
7.11.
Dispenser assembly
6
7.12.
CPU and display card
6
7.13.
Fitting and removing Oetiker clamps
7
8.
Notes
9.
Water circuit diagram
10
Electrical diagram
Saeco International Group
Rev. 01
GAGGIA UNICA
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
1.1
01 INTRODUCTION
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.
1
1
1
1
1
Description
Screwdriver
Pliers for Oetiker clamps
CC -A - Vdc tester
Digital thermometer
SSC (Saeco Service Center)
1.3
Scale limit > 150°C
Programmer
(for programming and diagnostics mode)
Material
Description
Thermal paste
Descaler
Grease solvent
Silicone grease
1.4
Notes
Torx T 8 - T 10 - T 20
Notes
Heating element > 200°C
Saeco descaler
Personal choice
Safe to use with food
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.
Saeco International Group
Rev. 01
Page 01 / 04
GAGGIA UNICA
1.5
01 INTRODUCTION
Service POLICY grid as used for coffee machine
For IN WARRANTY repairs is mandatory to use the single components (not the assembly) available in the exploded views of the coffee machines or of the specific components. If you find the
information “SEE THE EXPLODED VIEW E........” in the assembly description field, it means that
the single components of the assembly are available in the other pages of the exploded view. It’s
possible to use the assembly only if there is a specific Symptom Cure that include this possibility
or when the single components are not available for the order.
List of principal assembly present in all our coffee machines
Components
COFFEE
GRINDER
BREWING
UNIT
BOILER
GEAR
MOTOR
FILTER
HOLDER
MILK
CARAFE
THERMAL
CARAFE
MILK ISLAND
Assembly use
Only for OOW repairs
Only for OOW repairs
Only for OOW repairs
Only for OOW repairs
Only for OOW repairs
Only for OOW repairs
Only for OOW repairs
Only for OOW repairs
Saeco International Group
Single components available
YES, to consult the specific exploded-view of
machine or of the Coffee Grinder on website
YES, to consult the specific exploded-view of
machine or of the Brewing unit on website
YES, to consult the specific exploded-view of
machine on website
YES, to consult the specific exploded-view of
machine on website
YES, to consult the specific exploded-view of
machine on website
YES, to consult the specific exploded-view of
machine on website
YES, to consult the specific exploded-view of
Thermal Carafe on website
YES, to consult the specific exploded-view of
Milk Island on website
Rev. 01
the
the
the
the
the
the
the
the
Page 02 / 04
GAGGIA UNICA
01 INTRODUCTION
1.6.1 External machine parts
Coffee bean hopper
with lid
Grinding
adjustment
Service
hatch
Hot water/steam
dispensing pipe
Dispensing pipe
protection
Brewing unit
Drip
tray+grille
Hot water/steam
dispensing knob
Dreg drawer
Control panel
Coffee
dispenser
Water tank
Power supply socket
LED display
Espresso
dispensing button
ON/OFF button
Long coffee
dispensing button
steam selection
button
Saeco International Group
Rev. 01
Page 03 / 04
GAGGIA UNICA
01 INTRODUCTION
1.6.2 Internal machine parts
Safety valve
Grinding
adjustment insert
Coffee grinder
Turbine
Pump
Power cable connector
Steam pipe
Power card
Hot water/steam valve
Hot water /steam cock card
Thermostats
Boiler
Saeco International Group
Rev. 01
Page 04 / 04
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
2.1.
02 TECHNICAL SPECIFICATIONS
Technical specifications
Power supply and output:
Temperature monitoring:
Safety system:
Coffee heat exchanger output:
Stainless steel
Steam heat exchanger output:
Stainless steel
Gearmotor:
Pump
Overpressure valve:
Water filter:
Coffee grinder:
Automatic dosage
Power consumption:
Dimensions: W x H x D in mm:
Weight:
Water tank capacity:
Coffee bean hopper capacity
Dreg drawer capacity
Heat exchanger capacity:
Water circuit filling time:
Heating time:
Grinding time:
Saeco International Group
240 V~ 50 Hz 1400 W - 230 V~ 50/60 Hz 1400 W 120 V~ 60 Hz 1500 W - 100 V~ 50/60 Hz 1300 W
(NTC) variable resistor sensor - transmits the value to the
electronic card
2 thermostats at 175°C one shot
(230/120 V~) 1300 W – (100 V~) 1100W
for coffee, hot water and steam dispensing
As above
2 rotation directions; power supply 24VC
Ulka Type EP5/S GW approx. 13-15 bar with reciprocating
piston and thermal switch 100°C 48 W, 230V, 50 Hz, 120V,
60Hz 100V, 50/60 Hz
Opening at approx. 18-20 bar
In tank
Direct current motor with flat ceramic grinder blades
Dose adjustment controlled by the electronic system
During heating phase- approx. 5.6 A
320x372x461
9 kg
1.7 l.
250 g. of coffee beans
14
Approx. 10 cc
Approx. 15 sec Max. on first filling cycle
Approx. 45 sec.
Approx. 8-10 sec.
Rev. 01
Page 01 / 04
GAGGIA UNICA
02 TECHNICAL SPECIFICATIONS
2.2. Specification for the measurement of the coffee products temperature.
The temperature is influenced by the flow from the dispenser and stratification of temperatures in
the glass. In order to consider these phenomena and to introduce measures that allow comparisons in controlled conditions, below guidelines must be followed:
Conditions:
a) Water temperature in tank: 23°C (+/-2°C).
b) It must be used a plastic cup (see picture N°1).
c) It must be used a thermocouple thermometer (e.g. type K - see picture N°2).
d) The coffee machine is tested without any change of parameters or calibrations, which may
affect the temperature of products, so the measurement of temperature must be done with
machine in default factory setting.
Procedure:
1. The temperature must be measured in the cup, immediately after dispensing. Cup has to be
placed on a non-metal surface using a thermocouple thermometer.
2. The temperature in the cup is measured by immersing the probe of the thermometer up to
touch the bottom.The probe then must be moved in a circular motion for 5/6 rotations. At the
of the rotations, stop in the center of the cup.
3. The highest temperature measured during the rotations is the value we are searching for, and
that must be reported;
4. Test measurement: from end of dispensing to the end of rotations must be completed within 12
seconds.
Limits of acceptability
The acceptance limits are divided by features and products and are the following:
Espresso Coffee Italy Q.ty 25/40 gr.
Temperature of 1st product 69°C ≤ 85°C
Temperature of 2nd product 72°C ≤ 85°C
Coffee Q.ty 70/120 gr.
Temperature of 1st product 69°C ≤ 85°C
Temperature of 2nd product 72°C ≤ 85°C
Picture 1
Saeco International Group
Picture 2
Rev. 01
Page 02 / 04
GAGGIA UNICA
2.3.
02 TECHNICAL SPECIFICATIONS
Machine parameters and performance
Minimum Default Maximum
User
Programm. by
quantity quantity quantity
programmable Production / Service
(Puls.)
(Puls.)
(Puls.)
Espresso
50
130 - 170
600
Yes
No
Long coffee
70
200 - 230
600
Yes
No
Pre-ground
No
Hot water
Continues for 400 pulses
Steam for
Continues until the water supply has been exhausted (capacitive sensor)
frother
PRODUCT
QUANTITY
RINSE
When performed
Initial rinse
When the machine is switched
on and the boiler temperature is
≤ 50°C
No. of pulses
Stopping option
User disable option
Production/Service
department disable option
No. of pulses user
adjustment option
No. of pulses Production/
Service department
adjustment option
Pulse range
(Min. – Max.)
130
Yes, by pressing any key
No
Final rinse
When the machine is switched
off electronically, manually or
automatically after 60', if at least
one coffee has been dispensed,
before switching off
100
Yes, by pressing any key
No
No
No
No
No
No
No
No
No
Hardness
1
2
3
4
Descaling cycle frequency
Without water filter
240 litres (480,000 pulses)
120 litres (240,000 pulses)
60 litres (120,000 pulses)
Water hardness
With water filter
Soft (up to 7°dH)
480 litres (960,000 pulses)
Medium (7°-14dH)
240 litres (480,000 pulses)
Hard (15°-21°dH)
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. 01
Page 03 / 04
GAGGIA UNICA
02 TECHNICAL SPECIFICATIONS
DREG DRAWER
Time-out for dreg drawer
Description and values
5 sec.
Warning to empty dreg drawer after
Yes, after 14 lots of dregs
Reset dreg counter
The dreg drawer must be emptied only
when prompted by the machine ensuring
the machine is switched on and removing
the drawer for more than 5 seconds.
STANDBY
Inlet time (default)
Inlet time programmed by Production/
Service department
Boiler temperature during Standby
Description and values
60 minutes
Yes
Boiler OFF
WATER TANK
Water reserve (pulses) with water filter
Water reserve (pulses) with no water filter
Water reserve modifiable by Production/Service
departments
"Fill tank" alarm
"No tray" alarm
Water mains
Saeco International Group
Rev. 01
Description
200
200
No
Yes
Yes
No
Page 04 / 04
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
3.1.
03 USER INSTRUCTIONS
Customer and programming menu
Espresso dispensing button
ON/OFF button
Long coffee
Lo
offe
of
fe di
dispensing
si b
but
button
utto
to
Steam selection button
Machine ready signals
Machine ready for dispensing
coffee with coffee beans and hot
water
STEADY
Fisso
Machine dispensing steam
BLINKING
Lampeggiante
Machine dispensing hot water
STEADY
Fisso
Machine dispensing espresso or
long coffee
STEADY
Fisso
Machine dispensing two espressos
or two long coffees
STEADY
Fisso
The machine is being
programmed with the coffee cup
fill level
BLINKING
Lampeggiante
Notice signals
The appliance requires a descaling
cycle
Machine in pre-heating phase
for coffee, hot water and steam
dispensing.
BLINKING
Lampeggianti
STEADY
Fissi
Machine in rinsing phase. Wait for
the machine to end the operation
BLINKING
Lampeggianti
INinCYCLE
ciclo
The machine requires a water
circuit filling cycle
BLINKING
Lampeggianti
Machine in steam heating phase
BLINKING
Fisso
Saeco International Group
BLINKING
Lampeggiante
FAST
veloce
Rev. 01
Machine overheated.
Dispense water to take the
machine to the ideal temperature
for dispensing coffee and hot
water
Page 01 / 03
GAGGIA UNICA
3.2.
03 USER INSTRUCTIONS
Machine indications
Alarm signals
Turn the hot water/steam valve
knob to the correct position
- The Brewing unit must be inserted
in the machine.
- Close the service door
BLINKING
Lampeggiante
STEADY
Fisso
Switch off the machine and
carefully clean the dispensing
unit.
- Empty the dregs drawer
- Empty the tray under the unit
BLINKING
Lampeggiante
FAST
veloce
STEADY
Fisso
Insert the dregs drawer
BLINKING
Lampeggiante
STEADY
Fisso
- No beans inside the coffee
container.
After filling the container, the cycle
can be restarted.
Fill the water tank
STEADY
Fisso
Saeco International Group
Rev. 01
Page 02 / 03
GAGGIA UNICA
3.3.
03 USER INSTRUCTIONS
Operation, cleaning and maintenance
Operating the machine
1
Fill water tank
2
Fill the coffee bean hopper
3
Switch on the appliance
4
Press the key to switch the
machine on
5
Heating
When the heating phase begins, wait for it to finish
6
Rinse
Carry out a rinse cycle for the internal circuits
7
Machine ready
The machine is ready to dispense beverages
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 necessary
Clean the brewing unit
Every time the coffee bean hopper is filled or weekly
Lubricate the brewing unit
After 500 dispensing cycles or when the grease is no
longer present on the brewing unit
Clean the unit housing
Weekly
Descaling
When indicated
F
H
Descaling cycle frequency
Hardness
Water hardness
Without water filter
With water filter
1
Soft (up to 7°dH)
240 litres (480,000 pulses)
480 litres (960,000 pulses)
2
Medium (7°-14dH)
120 litres (240,000 pulses)
240 litres (480,000 pulses)
3
Hard (15°-21°dH)
60 litres (120,000 pulses)
120 litres (240,000 pulses)
4
Very hard
(over 21°dH)
30 litres (60,000 pulses)
60 litres (120,000 pulses)
The default water hardness level is 3. Each litre of water corresponds to approximately 2,000 pulses
Saeco International Group
Rev. 01
Page 03 / 03
Saeco International Group
Rev. 01
GAGGIA UNICA
Saeco International Group
Rev. 01
WATER DESCHAGE IN THE WATER TANK
SAFETY VALVE
BOILER 1300W
STEAM/WATER DISPENSING
STEAM/WATER FAUCET
PIN FOR BOILER
HOT WATER
HOT WATER/STEAM
WATER
WATER DESCHAGE IN THE WATER TANK
4.1.
PUMP
WATER TANK
FLOW METER
GAGGIA UNICA
04 OPERATING LOGIC
Water circuit
Page 01 / 07
GAGGIA UNICA
4.2.
04 OPERATING LOGIC
Coffee cycle
Main switch ON
START
STOP
Time
Coffee grinder
Pulses
(Dosage)
Heating
approx. 45 sec.
Pump operation
(turbine pulses) in
accordance with the
amount of product
selected
Pump
*
Brewing unit gear
motor
Status
Heating
Ready
Coffee cycle
Notes: * Only with Pre-brewing
Status
Microswitch
OFF
ON
Single microswitch gearmotor
Switching on
When the machine is switched on, the gearmotor repositions itself as follows:
- It acts on microswitch 1 (see following chapter)
- The gearmotor changes its rotation direction and moves upwards again by approx. 1-2 mm
- The boiler begins to heat the water for approx. 45 sec., at full power, in order to reach the
optimal temperature. The temperature will then remain at a constant level.
1.
2.
3.
4.
5.
Coffee cycle
The coffee grinder starts the grinding process (controlled by pulses generated by a sensor)
The gearmotor (brewing unit) moves to the dispensing position
Preliminary dispensing phase (short pump activity, short pause)
Product dispensing (the pump operation period is defined by the amount of product dispensed)
The gearmotor moves to its home position (the dregs are expelled automatically)
Saeco International Group
Rev. 01
Page 02 / 07
GAGGIA UNICA
4.3.
04 OPERATING LOGIC
Single microswitch
The gearmotor 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 standby position to the
dispensing position, and then back to the
standby position again.
2
- Standby position: 1
- Dispensing position: 2
1
4.4.
Temperature sensor (adjustment)
Temp. (°C) R nom (kΩ)
20
61.465
50
17.599
75
7.214
80
6.121
85
5.213
90
4.459
100
3.3
125
1.653
150
0.893
ΔR (+/- %)
8.6
5.9
4.1
3.7
3.4
3.1
2.5
3.9
5.1
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
sensor and adjusts it accordingly.
Heating element values and corresponding temperatures: see table
Saeco International Group
Rev. 01
Page 03 / 07
GAGGIA UNICA
4.5.
04 OPERATING LOGIC
Coffee grinder
5
6
4
1
2
3
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 induce two pulses to a Hall
sensor, which in turn transmits them to the electronic system.
4.6.
Low bean level detection, dose quantity adjustment, coffee grinder
blocked
Without beans n=100%
With beans n=100%
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 rotations
will be lower due to the force created by the grinding
t2 = no indication
Without beans n=50%
t3 and t4 = this measurement is performed at the end
of each grinding process
Dose quantity adjustment
The dose quantity is adjusted in accordance with the
pulses detected
With beans n=50% (number of rotations proportional to the weak/medium/
strong aroma setting)
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. 01
Page 04 / 07
GAGGIA UNICA
4.7.
04 OPERATING LOGIC
Dose self-learning (SAS)
The aim of this function is to automatically regulate the average dose of ground coffee (SELFLEARNING); this takes place with an algorithm based on three pieces of data that the machine
receives via the card:
1. Number of coffee grinder pulses during the grinding cycle
2. Max. average value of the power consumed by the group motor during the coffee brewing cycle
3. Aroma selected by the user
The algorithm compares the maximum average value of the power consumed by the group motor
with the value listed in the table for the selected aroma, in order to calculate the new grinding
pulse value for the next coffee produced.
If the power consumption value is less than the minimum current value, the
grinding pulses will be increased by 2.
If the power consumption value is greater than the maximum current value, the grinding pulses
will be decreased by 4.
If the power consumption value falls within the “over-torque” interval, the product will be
dispensed and the grinding pulses will be decreased by 10.
If the power consumption value falls within the “abort cycle” interval, the pad will be expelled and
the grinding pulses will be decreased by 10.
If the “pre-ground” flavour is selected by the user, no modification will be made.
This guarantees that, regardless of the coffee type used, the grinding level setting
and the wear on the grinders always remains constant.
Setting/Status
Pulses corrected in the next grinding process
Power consumption
in mA
Exceeded by
Deficient by
A
Mild aroma
200 - 300 mA
-4
+2
B
Medium Aroma
301 - 450 mA
-4
+2
C
Strong Aroma
451 - 600 mA
-4
+2
D
Over-limit
601 - 800 mA
-4
E
Overwork
801 - 1000 mA
- 10
F
Pad expulsion
> 1000 mA
- 10
Important:
For perfect operation, machine adjustment should take place in the area of the fields
highlighted in green (A, B, C). When the type or brand of coffee is changed, there may be
variations in the size of the beans and their stickiness or roasting level. This leads to variations
in power consumption (mA), with resulting excessive or insufficient doses (until the necessary
adjustments have been made to compensate for this change).
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. 01
Page 05 / 07
GAGGIA UNICA
4.8.
04 OPERATING LOGIC
Water level detection (water tank)
“Water low” message (water reserve)
Water tank
Sensor
200 puls.
4.9.
Function:
The water level is monitored by a capacitative sensor, located one
third of the way up the water tank wall.
If the electronics assembly detects, by means of the sensor,
that the amount of water in the tank has dropped below the
above mentioned level, a water reserve remains available for the
dispensing process underway (this will cover 200 turbine pulses).
The product dispensing process will then come to an end.
If a dispensing cycle ends after the sensor has been triggered (in
the reserve) then the display “Water low” continues to be displayed
during the following dispensing cycle.
Water level detection (drip tray)
“Empty drip tray” - message
Drip tray
Sensor
Total
capacity
Switching
level sensor
Saeco International Group
Function:
The residual water level is monitored using a capacitive
sensor. The sensor is located approximately halfway up the
upper edge of the drip tray. To ensure the best possible
use of the drip tray capacity, the sensor is located near to
a dam. Therefore, the drip tray fills up to the upper edge
of the dam and overflows inside, triggering the sensor and
thus the “Empty drip tray” message.
Rev. 01
Page 06 / 07
GAGGIA UNICA
04 OPERATING LOGIC
4.10. Descaling request
Flow meter pulses
“Descaling” – message with water filter
inserted
(appliances with display only)
The water hardness is set on the basis of the
regional water hardness analysis
(1, 2, 3, 4).
Filter
on
Filter off:
If the function is turned off the electronics
assembly monitors the turbine pulses, recording
one pulse each turn.
Filter
off
Filter on:
If the function is turned on the electronics
assembly monitors the turbine pulses, recording
one pulse every two turns.
Number of pulses
360°
1 rev
“Change water filter” message
The electronics assembly uses the turbine impulses
to keep track of the amount of water which has
flowed through; after the specified amount (set
in accordance with the water hardness level), the
“Replace filter” message appears.
4.11. Water filter
Water filter
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
• 2 months
Bypass
Saeco International Group
To achieve the best possible operating mode consistency
over the total life span, the water is channelled using a
three-stage bypass (A, B, C) depending on the degree of
hardness.
See small image.
Rev. 01
Page 07 / 07
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
5.1.
05 TROUBLESHOOTING
Test mode
To enter Test Mode
1) turn the hot water/steam knob to the ON
position
2) switch on the machine by plugging it in
end push the espresso coffee button (3)
4) the icons will blink cyclically
1
3
release the espresso coffee button and turn
the hot water/steam knob back into the OFF
position
4
BLINKING
Lampeggianti
INinCYCLE
ciclo
2
Entry into Test Mode results in a screen divided into sections, as illustrated in the diagram below
Button functional test (level 01)
PRESS
No key
SETTINGS
STEADY
STEADY
STEADY
STEADY
Release the
ON/OFF
button to
move on to
level 2
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
Operational check on microswitches and sensors (level 02)
Hot water/steam knob OFF
Hot water/steam knob ON
Initial LED status
STEADY
STEADY
No water
STEADY
If the LED
does not turn
on, check the capacitive
sensor and the JP21 wiring
RHS service door open
or extracted water recovery tank open
STEADY
No dreg drawer
STEADY
does not turn
If the LED
on, check the knob card and
the JP21 wiring
does not turn
If the LED
on, check the microswitch of
the door or water recovery
tank and the JP16 wiring
No unit
If the LED
does not
does not turn
If the LED
turn on, check the drawer
on, check the brewing unit
microswitch and the JP16
microswitch JP14
STEADY
wiring
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
Saeco International Group
Rev. 01
Page 01 / 03
GAGGIA UNICA
05 TROUBLESHOOTING
Brewing unit functional test (level 03)
Press
Initial LED status
at level 3
STEADY
STEADY
Press
STEADY
to take the brewing unit on to Work
The brewing unit goes into the Work position
and the LED lights up
.
symbol turns on if strain is excessive.
The
Check operation of the gearmotor and
microswitch of the gear (broken or inserted
incorrectly). Check the JP16 wiring
to take the brewing unit on to Work
The brewing unit goes into the Home position
.
and the LED lights up
The
symbol turns on if strain is excessive.
Check operation of the gearmotor and
microswitch of the gear (broken or inserted
incorrectly). Check the JP16 wiring
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
Pump functional test (level 04)
Press
Initial LED status
at level 4
BLINKING
to activate the pump
The water is dispensed from the steam pipe and
symbol blinks. The
symbol turns on
the
if no water flows. Verify checks at the pump,
pump wiring and/or connection on the CPU/
Power card (JP24), turbine, turbine wiring and/
or connection on the CPU/Power card (JP5).
To check correct water flow from the coffee
duct, return to level 03 (brewing unit functional
check), put the unit in the “Work” position and
proceed as above.
PRESS THE ON/OFF KEY TO ACCESS THE NEXT LEVEL UP
Saeco International Group
Rev. 01
Page 02 / 03
GAGGIA UNICA
05 TROUBLESHOOTING
Functional check on coffee grinder and boiler (level 05)
Press
to activate the coffee grinder
The brewing unit is activated and the
symbol starts blinking. If this does not occur
Initial LED status
at level 5
BLINKING
symbol turns on, check the sensor
and the
and/or the coffee grinder motor, the wiring of
the sensor and/or the connection on the CPU/
Power card (JP2), the wiring of the coffee
grinder motor and/or the connection on the
CPU/Power card (JP8)
Press
to activate the boiler
symbol appears, the boiler sensor
If the
is interrupted. Check the boiler sensor wiring
and/or the connection on the CPU/Power card
(JP13)
If you connect the machine to an ammeter and
on activating the boiler there is no power draw,
check the power supply wiring and/or the
connection on the CPU/Power card (JP17-3)
5.2. Error messages
ERROR
CODES
01
03
04
05
10
11
14
15
19
DESCRIPTION
The coffee grinder is blocked (grinder blades jammed or sensor not reading
properly)
The brewing unit is blocked in work position (microswitch not released in up
position after 3", torque error trying to move down, descent time out exceeded)
The brewing unit is blocked in home position (microswitch not released in down
position after 3", torque error trying to move up, ascent time out exceeded)
Water circuit / flow meter problems (water circuit blocked or no flow meter signal)
Boiler temperature sensor short circuited
Boiler temperature sensor open circuit
The boiler temperature has exceeded the maximum allowed value (165°c)
The boiler temperature has not increased by x°c in y sec (boiler power supply
disconnected, incorrect boiler fitted must be a 1300W boiler, partial power supply
to boiler, cut out thermostat tripped)
Mains voltage trouble
Saeco International Group
Rev. 01
Page 03 / 03
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
6.1.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
06 STANDARD CHECKS
Repair schedule
Action
Visual inspection (transport damage)
Machine data check (rating plate)
Operational check / problem analysis
Opening machine
Visual inspection
Operational tests
Repairing the faults encountered
Checking any modifications (view info, new sw, etc.)
Service activities in accordance with the operating schedule
Internal cleaning
Operational test while the appliance is open
Assembly
Final inspection test
Draining the circuit (in winter)
External cleaning
Lubricating the brewing unit with suitable grease
Insulation test HG 701 (dielectric)
Documentation
6.2.
Service schedule
S Replacement
ES Visual inspection
D Descaling
Component
Water filter
Water tank lip seal
Boiler pin O-ring
Brewing unit
Hoses, attachments and Oetiker clamps
Pump
Gearmotor
Coffee grinder
Water circuit
Hot water/steam valve
Saeco International Group
P
TR
R
Cleaning
Noise test
Adjustment
Action
P/S
S
S
ES/P
ES
ES/TR
ES/TR
P/R
D
ES/S
Rev. 01
Support/tool
Grease solvent / Grease
Vacuum cleaner / brush
Saeco descaler
Page 01 / 02
GAGGIA UNICA
6.3.
06 STANDARD CHECKS
Final test
Test
Espresso
Coffee
Procedure
2-3 Espressos for
adjustment purposes
2-3 Coffees for
adjustment purposes
Noise
Amount of
cream
Blow into the cup until
the cream separates
Support/tool Standard
Measuring
Same amount
scoop
Measuring
Same amount
scoop
Standard
The cream should
come together
again to form a
complete layer
Cream colour
15%
15%
Hazel brown
Reading taken while
Thermometer
dispensing
Check the grain size of
Grinding level
the ground coffee
Hot water
Dispense water
Steam
Dispense steam
Dreg drawer
missing
Remove the dreg drawer
indication
Start brewing a coffee
Low bean
while the coffee bean
level
hopper is empty
indication
Temperature
Saeco International Group
Tolerance
Rev. 01
84 ˚C
± 4 ˚C
Dreg drawer
missing indication
Missing indication
coffee beans
Page 02 / 02
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
7.1.
07 DISASSEMBLY
Outer elements
Remove the water tank, coffee container cover, water
recovery tray, dregs drawer, brewing unit, hot water/
steam knob.
Unscrew the marked
screws and remove the
finger protection
Firmly raise the top
cover
Unscrew the marked screws, remove the
fork and extract the front casing cover
Unhook the front panel, raising it and extract
the electric connections
To remove the front casing, unscrew the marked screws,
remove the fork spring and extract the cover and the
fitting of the steam pipe and extract it from the casing.
Undo the marked screws, remove the RH and LH side cover
7.2.
Coffee grinder
Loosen the screws as illustrated
and remove the sound insulating
cover of the coffee grinder
Saeco International Group
When reassembling the coffee
Raise the coffee grinder and
grinder, make sure the spring is
remove the connections
repositioned correctly (see photo)
Rev. 01
Page 01 / 07
GAGGIA UNICA
7.3.
07 DISASSEMBLY
Grinder blades
B
A
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 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. 01
Page 02 / 07
GAGGIA UNICA
7.4.
07 DISASSEMBLY
Coffee grinder adjustment
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 supplied.
+
-
Adjustment by a service centre
To adjust grinding further, the engineer can work directly
on the coffee grinder by pressing and turning the ring nut
(C) shown. (clockwise + to increase the particle size of
the coffee and anticlockwise - to decrease it).
+
Lastly, move the arrow (A) on the adjustment knob to the
centre of the adjustment dots on the cover (B).
-
C
If there are any remains of coffee powder between the
two grinding blades it is recommended to tighten by max.
two marks at a time.
Saeco International Group
Rev. 01
Page 03 / 07
GAGGIA UNICA
7.5.
07 DISASSEMBLY
Pump
Slide out the two pump supports (highlighted)
fixed to the housing, unhook the safety valve
outlet and disconnect the electrical and water
circuit connections
7.6.
Turbine
Lift the turbine out of the casing assembly and remove
the electrical and water circuit connections
7.7.
Power card
Loosen the screws as illustrated and remove the
PWR card extracting the electrical connections
7.8.
Boiler
Loosen the screws as illustrated
Unhook the boiler support
Unscrew the marked screw and disconnect the electrical and water circuit connections
Saeco International Group
Rev. 01
Page 04 / 07
GAGGIA UNICA
7.9.
07 DISASSEMBLY
Gearmotor
Loosen the screws as illustrated and remove
the boiler pin.
Loosen the screws as illustrated and
remove the gearmotor cover.
E
B
F
C
D
A
A
B
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 dispensing unit.
- Dreg drawer presence sensor (D).
- Dispensing head present microswitch (E).
- Microswitch (F) detecting brewing unit home and work
positions.
- 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).
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.
Saeco International Group
Rev. 01
Page 05 / 07
GAGGIA UNICA
07 DISASSEMBLY
7.10. Cock card and hot water/steam cock
Loosen the screw as illustrated to remove the cock card
Unscrew the marked screws and extract the hydraulic
connections to remove the hot water/steam cock
7.11. Dispenser assembly
Press, extract the front cover of the dispenser and
remove the movable part
7.12. CPU and display card
Loosen the screws as illustrated
Loosen the screws as illustrated
Saeco International Group
Rev. 01
Page 06 / 07
GAGGIA UNICA
07 DISASSEMBLY
7.13. Fitting and removing Oetiker clamps
1) Boiler connection
2) Other connections
Use a suitable pair of pliers to remove the
clamp (as illustrated)
Saeco International Group
Tighten the clamp as illustrated
Rev. 01
Page
07 / 07
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
Saeco International Group
08 NOTES
Rev. 01
Page 01 / 01
Saeco International Group
Rev. 01
GAGGIA UNICA
Saeco International Group
Safety valve
Water tank
Pump
Silicone tube
Silicone tube
Rev. 01
Linen-faced silicone tube
Boiler
Steam/Water dispensing
Steam
Water drain
Silicone tube
Pipe fitting for pin
Coffee dispensing
valve assy
To the coffee dispenser
Pin for boiler
Brew unit
Brew unit valve
Draining water tank
Discharging water 90° connector
Water outlet fitting
Linen-faced silicone tube
Water-Steam knob
Linen-faced silicone tube
Linen-faced silicone tube
Pipe fitting of water draining
Flow meter
GAGGIA UNICA
09 HYDRAULIC DIAGRAM
Page 01 / 01
Saeco International Group
Rev. 01
GAGGIA UNICA
GAGGIA UNICA
Saeco International Group
10 WIRING DIAGRAM
Rev. 01
Page 01 / 01