Breville 800 Series Service Manual - Comparison with my own and readers’ findings

In the summer of 2011, a kind reader provided me (and us all) with what appears to be the service manual for the Breville 800 series of machines, as of early 2008. The document explicitly lists the model 800ES for Australia and New Zealand, the 800ESXL for the United States, and the BRE800ESXL for Canada. There are also various notes for the “A” suffix models, which do indeed appear to be “new and improved” revisions.

I present the PDF file here for the benefit of Breville 800 series machine owners wishing to keep their own machines useful and running. Neither myself nor the person who provided it to me can find any copyright information on the PDF file. I do not intend to violate Breville’s copyright, and if contacted by the company and asked to remove the PDF, i will. I do hope that Breville will choose to allow the file to remain available for all our benefit, and especially to help keep as many of these machines as possible running well.

Had this been available to me when i first needed to work on our own machine here, it is unlikely that i would have gone to the time and trouble to draw out my own schematic. Comparing the two, there are some interesting differences. Open up the PDF in another window to the schematic (p. 6) and let’s compare it with my schematic, repeated here:

Revision History of my hand-drawn schematic

Before we get into comparisons, some notes on the revisions (to date) of my schematic:

Rev. 1 (initial release), 22 December 2009

GIF file format, for maximum compatibility with WWW browsers of the era. Missing details on Steam/Hot Water circuit board.

Rev. 2, 10 August 2013

Added R14 and R15 470Ω each Steam and Hot Water LED series resistors. Added C9 and C10, but not their capacitances

Rev. 3, 25 March 2024

The wiring around the Power switch and related LEDs/resistors was significantly incorrect on earlier revisions (appreciation to James L. for finding the error and alerting me). Carefully reviewed the wiring of the actual machine here, which matches what James L. sent, as well as better fitting the Breville service manual wiring diagram’s wiring.

Redrew schematic as a Scalable Vector Graphic (SVG) file, which will hopefully be sharper and clearer and scale better on various screen types and sizes

Added missing main board C8 across Power button contacts. Interestingly, there is a duplicate unstuffed C8 in electrically the same position over on the Power button/light P.C.B.

Added capacitances for C9 and C10

Redid coloring to hopefully make colored wires easier to see, and better differentiate between parts on the main P.C.B. and parts off of it

Schematic/Wiring Diagram Comparisons

At first, this looks like an entirely different circuit. Yet after careful study, it is mostly the same circuit, drawn differently. Some changes appear to be related to the difference between the 230-240V version, which appears to be what is shown in the service manual’s schematic, and the 120V U.S. version (i’d assume the Canadian model is the same, but i don’t know) in the schematic i drew. The changes i see which are apparently related to the voltage difference are:

• SCR Q1 is a 2P6M in the 240V model and a 2P4M in the 120V model
• There is no surge-suppressing varistor (MOV V1) shown in the service manual drawing
• C1, R1 (A and B), and R2 are doubled/halved in value as appropriate for each voltage

Then there are a group of differences which are likely errors on my part or whomever drew up the schematic in the service manual:

• P50 vs. P61 controlling Q2 for the heater relay and water tank illuminator vs. the T/F sense line

Carefully rechecked in late March 2024, and absolutely for sure IC pin 1 (P50) goes to R13 and pin 3 of the 5-contact plug leading to the power button P.C.B. on the unit here.

There’s another class which may be errors or may be production changes:

• C2 and C4 values swapped
• R24 (mine) at 1.5 kΩ 2W vs. R23 (manual) at 1.2 kΩ 1W
• R8 & R9 (mine) at 4.7 kΩ and R8 twice (manual) at 3.3 kΩ
• Diode D8 across the pump and its thermal fuse (in the manual and absent in my schematic and from the actual machine here)
• In the actual machine here and on my schematic, contact de-bounce capacitors C8-10 (all 10 nF) exist, each in parallel with one of the Power, Hot Water, and Steam buttons.

Another class are clearly production changes:

• Relay switching the heating element on the “high” (neutral) side (manual) vs. the “low” (line) side (mine)
• On/Off LED and water level (Tank Illuminator) LEDs swapped positions. Manual has the front panel Power LED in the emitter of Q2 and Water Level LED driven off the line driving Q2; mine has the opposite.
• R6 (SCR gate drive series resistor) 3.3 kΩ in the manual and 4.7 kΩ in the machine here

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