Nespresso ZENIUS ZN 100 PRO Service Manual
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Nespresso ZENIUS ZN 100 PRO Service Manual

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S E R V I C E M A N U A L
C O F F E E M A C H I N E
ZN 100 PRO
Service manual ZN100 V 6.0

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  • Page 1 S E R V I C E M A N U A L C O F F E E M A C H I N E ZN 100 PRO Service manual ZN100 V 6.0...

  • Page 2: Table Of Contents

    CONTENTS GENERAL SAFETY NOTES MAIN COMPONENTS Overview - front side Overview - removable parts Overview - left side and bottom Overview - operating elements and display Interior view Type plate Fluid system Technical data OPERATION General information Preparation Preparing coffee Coffee machine displays 3.4.1 Button colors...
  • Page 3 7.2.1 Repair and mounting tips 7.2.2 Tools and accessories 7.2.3 Overview of plug-in modules General disassembly 7.3.1 Handle 7.3.2 Side panels 7.3.3 Removing the front cover 7.3.4 Removing the top cover 7.3.5 Removing the rear panel 7.3.6 Removing the front panel Replacing plug-in modules 7.4.1 Replacing Electronic board...
  • Page 4 In order to take full advantage of all the functions, it is absolutely necessary to follow the instructions in this manual. Visit the Nespresso technical website periodically to check for upgrades, technical modifications, counter measures etc. for these coffee machines: https://business.nespresso.com...

  • Page 5: General Safety Notes

    G E N E R A L S A F E T Y   N O T E S GENERAL SAFETY NOTES Risk of fatal electrical shock and fire! Mains voltage inside the coffee machine. • Unplug appliance before cleaning. •...

  • Page 6: Main Components

    M A I N   C O M P O N E N T S MAIN COMPONENTS 2.1 Overview - front side 1) Water tank 7) Handle 2) Water tank cover 8) Capsule container 3) Power on switch 9) Drip grid (movable) 4) Capsule slot with safety lid 10) Drip grid 5) Coffee (MMI) buttons...

  • Page 7: Overview - Removable Parts

    M A I N   C O M P O N E N T S 2.2 Overview - removable parts 1) Water tank 2) Water tank handle 3) Water tank cover 4) Water filter (optional) 5) Capsule container 6) Drip grid (movable) 7) Drip grid 8) Float drip tray 9) Drip tray...

  • Page 8: Overview - Left Side And Bottom

    M A I N   C O M P O N E N T S 2.3 Overview - left side and bottom 1) PC connector (with dongle) 3) Mains connector 2) Type plate 4) Mains cable Service manual ZN100 V 6.0...

  • Page 9: Overview - Operating Elements And Display

    M A I N   C O M P O N E N T S 2.4 Overview - operating elements National science foundation USA Food safety certification NSF version 1) Ristretto button 3) Lungo button 2) Espresso button 4) Hot water button 5) Coffee outlet NSF version 6) Hot water outlet...

  • Page 10: Interior View

    M A I N   C O M P O N E N T S 2.5 Interior view NSF version 1) Solenoid valve (hot water) 2) Solenoid valve (drain) 3) Pump CP4-SP C2 4) Power socket Service manual ZN100 V 6.0...
  • Page 11 M A I N   C O M P O N E N T S NSF version 5) Extraction unit 6) Thermoblock TB 7) Water tank connector 8) Flow meter 9) Power pcb Service manual ZN100 V 6.0...

  • Page 12: Type Plate

    M A I N   C O M P O N E N T S 2.6 Type plate The type plate can be found at the bottom side of the coffee machine, carries the following information: Coffee Machine Type 9737/ZENIUS/ZN100 PRO 220-240V 50/60Hz 1560-1860W 110 59Z N1M 0395 78G 0SC 1) Brand name...

  • Page 13: Fluid System

    M A I N   C O M P O N E N T S 2.7 Fluid system Hot water E-valve Check Valve Thermoblock Y-connector T-connector Piston Venting Pump E-valve Pressure Valve Flowmeter Brewing unit Water tank Color of tube number indicate temperature (blue/cold - red/hot) Water flowing through machine keep fluid system (illustrate blue and red water flow)
  • Page 14 M A I N   C O M P O N E N T S NSF version A) Water tank I) Brewing unit B) Water tank connector J) Thermoblock C) Flow meter K) T-connector D) Pump L) Hot water E-valve E) Y-connector M) Pressure valve F) Venting E-valve...

  • Page 15: Technical Data

    Pump CP4 SP ..........60 W Flow performance ....= > 180 ml/min. at 12 bar Solenoid Valve..........10 W Machine versions Technical version Machine version (Voltage/Hz/power) Nespresso Professional Zenius ZN100/AR 220-240V/50-60Hz/1560-1860W Nespresso Professional Zenius ZN100/BR 120-127V/60Hz/1610-1810W Nespresso Professional Zenius ZN100/BR3 220-240V/50-60Hz/1560-1860W Nespresso Professional Zenius ZN100/CN...

  • Page 16: Operation

    O P E R A T I O N OPERATION 3.1 General information For an overview of the operational controls see "Overview - operating elements" on page 9. Preset filling amounts Coffee-, portion- and fill up buttons have preset filling amounts that can be modified (see "Programming the cup volume by push-button"...

  • Page 17: Preparing Coffee

    O P E R A T I O N Start-up 35 sec 1. Connect coffee machine to 2. Wait (approx. 35 sec.) till coffee 3. …and button illumination turns main. Switch on mains switch. machine is heated up… to white. 3.3 Preparing coffee Coffee preparation can be aborted by pressing the same coffee button again (e.g.

  • Page 18: Coffee Machine Displays

    O P E R A T I O N 3.4 Coffee machine displays 3.4.1 Button colors 1) White, blinking backlight..........coffee machine is heating up 2) White backlight ................ready for operation 3) Red, blinking backlight ..........water tank empty or missing 4) Red backlight ........
  • Page 19 (even if there are no more Descale machine water, the sensor don’t - If alarm is repeated after detect an empty water tank) descaling: Call Nespresso - machine scaled B2B service centre Fatal defect Reasons for alarm: - Thermoblock defective...

  • Page 20: Programming

    P R O G R A M M I N G PROGRAMMING 4.1 Programming the cup volume by push-button 15 s 1 1 5 15 s 1. Switch off coffee machine. 2. Press and hold Lungo and Hot water buttons while turning on the machine.

  • Page 21: Programming The Coffee Temperature

    P R O G R A M M I N G 4.2 Programming the coffee temperature 15 s 1 1 5 15 s 1. Switch off coffee machine. 2. Press and hold all 3 coffee 3. To programm coffee tempera- buttons while turning on the ture, press during blinking cycle.

  • Page 22: Programming The Water Hardness Settings

    P R O G R A M M I N G 4.3 Programming the water hardness settings 15 s 1 1 5 15 s 1. Switch off coffee machine. 2. Press and hold Ristretto and 3. To select water hardness setting, Espresso buttons while turning press during blinking cycle.

  • Page 23: Programming The Energy Saving Settings

    P R O G R A M M I N G 4.4 Programming the energy saving settings 15 s 1 1 5 15 s 1. Switch off coffee machine. 2. Press and hold Espresso 3. To select auto power off setting, button while turning on the press during blinking cycle.

  • Page 24: Descaling Alarm On/Off

    P R O G R A M M I N G 4.5 Descaling alarm on/off 15 s 1 1 5 15 s 1. Switch off coffee machine. 2. Press and hold Ristretto and 3. To select alarm ON or alarm Lungo buttons while turning on OFF, press during blinking cycle.

  • Page 25: Water Level Calibration

    M A I N T E N A N C E 4.7 Water level calibration Calibration is needed after exchanging of the back panel (with water level PCBA). (See page 47, 7.3.5 Remove the rear panel). 360 ml 1. Fill the water tank with 360 ml 2.

  • Page 26: Maintenance

    M A I N T E N A N C E MAINTENANCE 5.1 Daily maintenance and cleaning This chapter contains basic maintenance work done by the customer as well Inform customer that daily cleaning and maintenance of the coffee as special maintenance machine is very important to obtain the best coffee quality in cup and instructions for the avoid bad smells.

  • Page 27: Change Water Filter

    Life-time of the Nespresso “Aqua Clarity” filter is 4 months. 15 s 1 1 5 15 s 1.

  • Page 28: Filter Cartridge Exchange Procedure

    1. Empty water tank. 3. Clean and flush watertank with 2. Remove used filter cartridge and a soft towel. discard it. Life-time of the Nespresso “Aqua Clarity” filter is 4 months. 17 5 2011 A new filter cartridge must be rinsed for faultless function.
  • Page 29 M A I N T E N A N C E 3 3 3 x 15 s 1 1 5 15 s 13. To select new filter, press Ri- 14. Confirmation of selection: stretto button during blinking cycle. New filter is selected. About 150 ml cold water flows out of the hot water outlet within approx.

  • Page 30: Descaling

    M A I N T E N A N C E 5.3 Descaling The coffee machine displays this alarm, if descaling is necessary. 15 s 1 1 5 15 s This alarm appears only, if the descaling alarm is ON. (See page 24) Performance Service life Instruct the customer to call the service partner or to perform descaling...

  • Page 31: Accessory

    M A I N T E N A N C E 5.3.1 Accessory Two descaling kits are available for this coffee machine: Stock number 5035/CS100 Stock number 5034 Both descaling packages are needed for one descaling process. This kit contains 2 descaling packages and a descaling manual.

  • Page 32: Safety Instructions

    If swallowed, seek medical advice immediately and show decalcifier package for countermeasures. The decalcifier is aggressive to surfaces. Protective measures • Only use Nespresso decalcifier - never use vinegar! • Wipe off decalcifier splashes with a wet cleaning rag immediatley. Service manual ZN100 V 6.0...

  • Page 33: Descaling And Rinsing Procedure

    M A I N T E N A N C E 5.3.3 Descaling and rinsing procedure 1. Switch off coffee machine. 2. Remove and empty water tank. 3. Remove filter. 1,5 L 4. Fill water tank with indicated 5. Insert water tank into the coffee 6.
  • Page 34 M A I N T E N A N C E 13. Place receptable (1,5 l) under 14. To start rinsing procedure, outlets. Fill the water tank with press Lungo button. fresh, potable water (2 l). Insert it to the coffee machine. 17.

  • Page 35: Empty Fluid System

    M A I N T E N A N C E 5.4 Empty fluid system After operation, residual water remains in the fluid system of the coffee machine. This residual water can be removed before a longer period of non-use, for frost protection, before repair and following shipping.

  • Page 36: Troubleshooting

    T R O U B L E S H O O T I N G TROUBLESHOOTING This chapter gives useful hints and information for fault finding. It is not intended as a complete list of possible errors and malfunctions. 6.1 Check list adapt to zenius machine With an acceptance check in accordance with this checklist, common errors are quickly found and corrected.

  • Page 37: Diagnostic With Usb Dongle

    T R O U B L E S H O O T I N G 6.2 Diagnostic with USB Dongle With the help of the service software, a quick and simple function test of the operating elements is possible, statistic data can be retrieved and displayed.

  • Page 38: Coffee Capsule Falls Through

    T R O U B L E S H O O T I N G 6.3 Coffee capsule falls through An inserted new coffee capsule falls through the brewing unit into the capsule container immediately. Possible reasons: • The used capsule has a deformed border. •...

  • Page 39: Repairs

    These repair instructions: help to localize components of the Zenius coffee machine with general drawings, are based on exploded drawings combined with repair and mounting tips, presuppose basic knowledge in repairing Nespresso coffee machines. 7.1 Safety instructions Danger of electrocution! Mains voltage inside the coffee machine.

  • Page 40: General

    R E P A I R S 7.2 General 7.2.1 Repair and mounting tips These general advices are completed with specific repair tips in this chapter. Additional information For components not mentioned in this repair chapter, refer to "Spare parts" on page 80. Screw connections Do not overtighten screws.

  • Page 41: Tools And Accessories

    R E P A I R S 7.2.2 Tools and accessories With the following assortment of tools, all repairs described can be made: • TORX-screwdriver set TX6, TX10, TX15, TX20, TX25, TX30 (can be substituted partly by torx bits of special mounting tool) •...

  • Page 42: General Disassembly

    R E P A I R S 7.3 General disassembly This subchapter gives information how to open the casing of the coffee machine for a basic inspection and leakage check, the parts of the casing are mounted. The following disassembly steps are required for most of the repair work.

  • Page 43: Handle

    R E P A I R S 7.3.1 Handle These general advices are completed with specific repair tips in this chapter. 1. Unscrew one of the screws on the handle. 2. Then unscrew both rear screws completely out of the unit. 3.

  • Page 44: Side Panels

    R E P A I R S 7.3.2 Side panels This disassembly step builds on the preceding step and is not feasible without it. If side panels are damaged, replace metal panel by metal panel spare parts. Replace plastic panels by plastic panels spare parts.

  • Page 45: Removing The

    R E P A I R S 7.3.3 Removing the front cover This disassembly step is feasible independent of the other steps. If front cover is damaged, replace metal cover by metal cover spare part. Replace plastic cover by plastic cover spare part.

  • Page 46: Removing The Top Cover

    R E P A I R S 7.3.4 Removing the top cover This disassembly step builds on the preceding step and is not feasible without it. 14. In the case of older models, use a suitable tool to unscrew the antenna cable from the GSM module and remove the cable ties of the antenna.

  • Page 47: Removing The Rear Panel

    R E P A I R S 7.3.5 Removing the rear panel This disassembly step builds on the preceding step and is not feasible without it. 18. With your fingers or an appropriate tool disconnect the water sensor PC board's connection cable connector from the mainboard.

  • Page 48: Removing The Front Panel

    R E P A I R S 7.3.6 Removing the front panel This disassembly step builds on the steps 7.3.1 to 7.3.4 and is not feasible without it. 23. Remove the plugs on the MMI. 24. Remove the light guide and the MMI. 25.

  • Page 49: Replacing Plug-In Modules

    R E P A I R S 7.4 Replacing plug-in modules This subchapter gives information how to open the casing of the coffee machine for a basic inspection and leakage check, the parts of the casing are mounted. 7.4.1 Replacing electronic board Bevor changing the electronic board, repairing operation 7.3.2 has to be completed.
  • Page 50 R E P A I R S For new BU, no need connect these 3 cables (red, blue, black). - Brewing unit (red) - Brewing unit (blue) - Brewing unit (black) 3. Repeat the process with the 3 connectors on the right-hand side of the mainboard.

  • Page 51: Replacing Thermoblock With Add-On Pieces

    R E P A I R S 7.4.2 Replacing thermoblock with add-on pieces Before changing the thermoblock, repairing operations 7.3.2, 7.3.4 and 7.3.5 have to be completed. 1. Unscrew completely the screw from the base of the thermoblock. 2. On the opposite side pull the clip out of the elbow to the left at the bottom with an appropriate pair of pliers.
  • Page 52 R E P A I R S Take care of the fuse position (between the thermoblock and the fix metal part) in order to ensure the correct temperature control. 9. Remove both foam insulators from the heater. 10. Make sure that the cables can be withdrawn via the gap on the side of the larger insulator piece.

  • Page 53: Replacing Pump

    R E P A I R S 7.4.3 Replacing pump Before changing the pump, repairing operations 7.3.2, 7.3.4 and 7.3.5 have to be completed. 1. Remove both connectors from the pump contacts. 2. Pull the thermostat off the housing. 3. With an appropriate pair of pliers remove both clips from the Y-connector.

  • Page 54: Replacing Extraction Unit

    R E P A I R S 7.4.4 Replacing extraction unit Before changing the extraction unit repairing operations 7.3.2, 7.3.3, 7.3.4, 7.3.5 and 7.3.6 have to be completed. 1. Disconnect the elbows from the two tubes on the thermoblock by pulling out the clips with an appropriate pair of pliers.
  • Page 55 R E P A I R S 5. Check whether all connectors are disconnected from the logicboards. For a new brewing unit, no need connect these 3 cables (red, blue, black) 6. You can now carefully remove Update the software the brewing unit, including all of machine to latest hoses and cables still...

  • Page 56: Appliances With Gsm Module

    R E P A I R S 7.5 Appliances with GSM module Appliances fitted with a GSM module: Do not dismantle the Neslink module, antenna and connecting cable or replace them with new parts. Service manual ZN100 V 6.0...

  • Page 57: Solenoid Valves

    R E P A I R S 7.6 Solenoid valves Before changing the solenoid valves repairing operation 7.3.2 has to be completed. 1. Pull both upper connectors and the double connector (ground) off the hot water solenoid valve contacts. 2. Disconnect both hoses on the valve by pulling out the retaining clips.

  • Page 58: Flowmeter

    R E P A I R S 7.7 Flowmeter Before changing the Flowmeter repairing operations 7.3.2, 7.3.4 and 7.3.5 has to be completed. To the watertank connector. To the pump. 1. Raise the flowmeter and remove the hoses that connect to the water tank connector and to the pump.

  • Page 59: Coffee Buttons

    R E P A I R S 7.8 Coffee buttons Before changing the coffee buttons/MMI PCB repairing operation 7.3.3 has to be completed. 1. Remove the buttonplate from the inside of the front cover. 2. Remove the plugs on the MMI. 3.

  • Page 60: Replacing Illumination Components

    R E P A I R S 7.9 Replacing illumination components Before changing the illumination components repairing operations 7.3.3 and 7.3.4 have to be completed. 1. Remove the plugs on the MMI. 2. Remove the light guide and the MMI. 3.

  • Page 61: Change Power Socket

    R E P A I R S 7.10 Change power socket Before changing the power socket, the pump should be removed. 1. Remove the power plugs from the socket. 2. Press the 4 clipping hooks on the socket with a suitable tool.

  • Page 62: Exchanging The Coffee Capsule Seal

    R E P A I R S 7.11 Exchanging the coffee capsule seal Before changing the illumination components repairing operations 7.3.2 to 7.3.4 and 7.3.6 have to be completed. 1. Please ensure that the connecting tube leading to the hot water valve is not subject to excess tension.
  • Page 63 R E P A I R S 6. Use a small set of pliers to grip the coffee capsule seal and pull it out. 7. A seal that has been soaked in water must then be taken out of its container. 8.

  • Page 64: Pcb And Wiring Diagram

    R E P A I R S 7.12 PCB and wiring diagram This drawing show the connections of the electric and electronic components. For new BU, no need connect these 3 cables (red, blue, black) 230V 1) Main PCB A) Brewing unit 2) MMI PCB B) Rear cover 3) Triac PCB...

  • Page 65: Wiring Schematic Drawing

    R E P A I R S 7.13 Wiring schematic drawing These compoments at the Triac_Board 4.7nF/1KV 4.7nF/ 1KV 4.7nF/ 1KV RA65 4.7nF/ 1KV RA66 4.7nF/ 1KV RA67 Remote_switch 4.7nF/ 1KV RA68...

  • Page 66: Funktion Tests

    F U N C T I O N T E S T S FUNCTION TESTS 8.1 Safety instructions Some function tests are performed with an energized, partly opened coffee machine. Danger of electrocution! Mains voltage inside the coffee machine. Do not touch any live part while performing tests. Danger of burns! Hot parts and water under pressure inside the coffee machine.

  • Page 67: Required Equipment

    F U N C T I O N T E S T S 8.2 Required equipment 1) Pressure tester (EFR no. 42213) 2) Zenius pressure adapter (WIK 9310244000). This part is delivered together with the dummy capsule (pos. 6). 3) Electronic thermometer (or digital multimeter suitable for temperature measurement).

  • Page 68: Measure Coffee Temperature

    The programmed cup lenght should be 40 ml or more. 8. Press “Nespresso” button. 9. Then measure the coffee The coffee tempe- Wait until the measuring baker temperature approx. 5-10 mm rature should be contains 20 ml of coffee.

  • Page 69: Protective Earth (Pe) Continuity Test

    0.3 Ohms (with a test current of 200 mA DC). Test equipment Ask Nespresso for Special test equipment is needed that complies with the regulations to perform recommendations protective earth continuity measurements. Detailed requirements and tolerances must about test equipment.

  • Page 70: Test Sequence

    F U N C T I O N T E S T S 8.4.3 Test sequence This test sequence Danger of electrocution! is not applicable for Do not plug in the coffee machine during the protective earth coffee machines with two-wire power cords continuity test.

  • Page 71: What To Do If The Protective Earth Continuity Test Fails

    F U N C T I O N T E S T S 8.4.4 What to do if the protective earth test fails? • Check/measure ground wire connection of power cord; replace if necessary. • Check and retighten terminal screws on side panels if necessary. Service manual ZN100 V 6.0...

  • Page 72: Protective Insulation Test

    Test equipment Special test equipment is needed that complies with the regulations to perform insulation and withstanding voltage tests. Detailed requirements and tolerances must Ask Nespresso for recommendations be verified with your local authorities or measurement supplier in any case.

  • Page 73: Test Sequence

    F U N C T I O N T E S T S 8.5.3 Test sequence Danger of electrical shock/short circuit! Do not plug in the coffee machine during insulation test. Danger of electrical shock! Do not touch tip of test probes. Do not touch metallic parts of coffee machine during test.

  • Page 74: Pressure Test

    F U N C T I O N T E S T S 8.6 Pressure test Danger of electrocution! Mains voltage inside the coffee machine. Danger of electrical shock. ASC Maintenance pressure mode must be entered (button board). Static pressure can be measured. Fluid system tightness can be measured.

  • Page 75: Test Run

    F U N C T I O N T E S T S 10. Close the handle… 11. …and plug the cord. 12. Open the valve from the pressure gage and place a beaker below the exit. 8.6.2 Test run During the Mode: - the venting e-valve is open...
  • Page 76 F U N C T I O N T E S T S 10 s 4. Press a button to start the pump. 5. Let the flow run for 10 seconds 6. Once the max. pressure is and close the valve of the reached, press a button to stop manometer.

  • Page 77: Leakage Check

    F U N C T I O N T E S T S 8.7 Leakage check Search for leaks as 1. Prepare the machine according to menu 8.6.1. long as the water ciruit is under pressure. 2. Perform the test according to menu 8.6.2 (till point 6) a. If necessary put water circuit 3.

  • Page 78: Exploded Drawings

    E X P L O D E D D R A W I N G S EXPLODED DRAWINGS 9.1 Spare parts for repair...

  • Page 80: Wiring Diagram Vde

    E X P L O D E D D R A W I N G S 9.2 Wiring diagram VDE For new BU, no need connect these 3 cables (209, 210, 212) 207 (pos. 5) 211 (pos. 7) 203 (pos. 14) For Zenius plastic panels version, plastic side panels and plastic front cover are not connected to...

  • Page 81: Wiring Diagram Ul/Jp

    9.3 Wiring diagram UL/JP For new BU, no need connect these 3 cables (209, 210, 212) 207 (pos. 5) 211 (pos. 7) 203 (pos. 14) For Zenius plastic panels version, plastic side panels and plastic front cover are not connected to the ground wire Service manual ZN100 V 6.0...

  • Page 82: Notes

    N O T E S 10 NOTES Service manual ZN100 V 6.0...

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