Nespresso ZN100 PRO User manual

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

CONTENTS
2
1GENERAL SAFETY NOTES 5
2 MAIN COMPONENTS 6
2.1 Overview - front side 6
2.2 Overview - removable parts 7
2.3 Overview - left side and bottom 8
2.4 Overview - operating elements and display 9
2.5 Interior view 10
2.6 Type plate 12
2.7 Fluid system 13
2.8 Technical data 15
3 OPERATION 16
3.1 General information 16
3.2 Preparation 16
3.3 Preparing coffee 17
3.4 Coffee machine displays 18
3.4.1 Button colors 18
4 PROGRAMMING 20
4.1 Programming the cup volume by push-button 20
4.2 Programming the coffee temperature 21
4.3 Programming the water hardness settings 22
4.4 Programming the energy saving settings 23
4.5 Descaling alarm on/off 24
4.6 Reset to factory settings 24
4.7 Water level calibration 25
5 MAINTENANCE 26
5.1 Daily maintenance and cleaning 26
5.2 Change water filter 27
5.2.1 Accessory 27
5.2.2 Filter cartridge exchange procedure 28
5.3 Descaling 30
5.3.1 Accessory 31
5.3.2 Safety instructions 32
5.3.3 Descaling and rinsing procedure 33
5.4 mpty fluid system 35
6 TROUBLESHOOTING 36
6.1 Check list 36
6.2 Diagnostic with USB Dongle 37
6.3 Coffee capsule falls through 38
6.4 Only hot water during coffee preparation 38
6.5 Wrong water empty signal 38
7 REPAIRS 39
7.1 Safety instructions 39
7.2 General 40

3
7.2.1 Repair and mounting tips 40
7.2.2 Tools and accessories 41
7.2.3 Overview of plug-in modules 41
7.3 General disassembly 42
7.3.1 Handle 43
7.3.2 Side panels 44
7.3.3 Removing the front cover 45
7.3.4 Removing the top cover 46
7.3.5 Removing the rear panel 47
7.3.6 Removing the front panel 48
7.4 Replacing plug-in modules 49
7.4.1 Replacing lectronic board 49
7.4.2 Replacing thermoblock with add-on pieces 51
7.4.3 Replacing pump 53
7.4.4 Replacing extraction unit 54
7.5 Appliances with GSM module 56
7.6 Solenoid valves 57
7.7 Flowmeter 58
7.8 Coffee buttons 59
7.9 Replacing Illumination components 60
7.10 Change Power socket 61
7.11 xchanging the coffee capsule seal 62
7.12 PCB and Wiring diagram 64
7.13 Wiring schematic drawing 65
8 FUN TION TESTS 66
8.1 Safety instructions 66
8.2 Required equipment 67
8.3 Measure coffee temperature 68
8.4 Protective earth (P ) continuity test 69
8.4.1 What is the protective earth continuity test about? 69
8.4.2 General 69
8.4.3 Test sequence 70
8.4.4 What to do if the protective earth continuity test fails 71
8.5 Protective insulation test 72
8.5.1 What is the protective insulation test about? 72
8.5.2 General 72
8.5.3 Test sequence 73
8.6 Pressure test 74
8.6.1 Preparation 74
8.6.2 Test run 75
8.7 Leakage check 77
9 EXPLODED DRAWINGS 78
9.1 Spare parts for repair 78
9.2 Wiring diagram VD 80
9.3 Wiring diagram UL/JP 81
10 NOTES 82

The purpose of this service manual is to provide the service personnel with all
necessary information with regards to correct handling, maintenance and repair of the
coffee machines ZN100 PRO.
This manual should be used by the technicians as a valuable aid to guarantee the
permanent readiness for use of the machines. 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
PREFACE
DOCUMENT CHANGE HISTORY
A movie is available
for dismantling and
test explanation..
4Service manual ZN100 V 6.0
Date Edition Modification(s) Pages
11.09.2013 V 2.0 Y- to T-connector changed 13, 14, 51, 54
11.09.2013 V 2.0 Button message 19
11.09.2013 V 2.0 Repair and mounting tips 40
11.09.2013 V 2.0 Handle mounting 43
11.09.2013 V 2.0 Antenna guiding modified 46
11.09.2013 V 2.0 Replacing electronically board 49-50
11.09.2013 V 2.0 Triac connector added 51, 52, 54
11.09.2013 V 2.0 F P Tube 230 mm (pump-evalve lower) 77, 81 (Pos. 41)
11.09.2013 V 2.0 xploded drawings updated 76 to 77
11.09.2013 V 2.0 Wiring diagrams VD and UL/JP added 78 to 79
11.09.2013 V 2.0 Spare parts list updated 80 to 83
20.06.2014 V 3.0 Water level sensor calibration 25
20.06.2014 V 3.0 Removing the front panel 48
20.06.2014 V 3.0 Spare parts list updated 80 to 83
23.09.2015 V 4.0 Neslink module removed from current appliances 44 to 79
23.09.2015 V 4.0 Replacement of O-rings on solenoid valves 57
23.09.2015 V 4.0 Spare parts list updated 80 to 83
26.10.2016 V 5.0 Different dismantling of metal or plastic housing parts 44 to 45
26.10.2016 V 5.0 Different protective tests of metal or plastic housing 68 to 71
26.10.2016 V 5.0 Spare parts list removed from the manual 80 to 83
21.11.2018 V 6.0 New solenoid valves added 10 to 81
21.11.2018 V 6.0 Instructions for brewing capsule replacement added 62 to 63

Risk of fatal electrical shock and fire!
Mains voltage inside the coffee machine.
• Unplug appliance before cleaning.
•Never clean wet or immerse plug, cord or appliance in any fluid.
• Disconnect the mains plug before disassembly - the appliance
must be free of voltage.
As an additional safety measure, the use of a residual current device (RCD), also called
a ground fault circuit interrupter (GFCI), in the repair centre is highly recommended.
Danger of burns!
Hot parts and water under pressure inside the coffee machine
(particularly in the thermoblock).
• Let coffee machine cool down before cleaning or disassembly.
1 GENERAL SAFETY NOTES
This device does
not protect
against electrical shock
due to contact with both
circuit conductors.
xample illustrations
of typical devices.
Use a GFCI with a
trip level of 4 - 6 mA
(USA) resp. a RCD
with a trip level of
15 - 30 mA ( urope).
A trip level above 30
mA provides only
very limited
protection against
harm from an
electric shock.
1) RCD protected socket-outlet
2) Plug-in RCD unit
3) GFCI socket 4) Plug-in GFCI
5
Service manual ZN100 V 6.0
GN R A L S A F T Y N O T S

9
8
7
5
4
3 2
1
6
10
11
1) Water tank
2) Water tank cover
3) Power on switch
4) Capsule slot with safety lid
5) Coffee (MMI) buttons
6) Hot water button
7) Handle
8) Capsule container
9) Drip grid (movable)
10) Drip grid
11) Drip tray opening with support
2 MAIN COMPONENTS
MA I N C O M P O N N T S
6Service manual ZN100 V 6.0
2.1 Overview - front side

8
9
5
6
7
1
2
3
4
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
7
Service manual ZN100 V 6.0
MA I N C O M P O N N T S
2.2 Overview - removable parts

3
1
2
xxx xxx xxx xxxx xxx xxx
Coffee Machine
Type 9737/ZENIUS/ZN100 PRO
220-240V 50/60Hz 1560-1860W
4
2.3 Overview - left side and bottom
Service manual ZN100 V 6.0
8
MA I N C O M P O N N T S
1) PC connector (with dongle)
2) Type plate
3) Mains connector
4) Mains cable

MA I N C O M P O N N T S
Service manual ZN100 V 6.0 9
2.4 Overview - operating elements
1) Ristretto button
2) spresso button
3) Lungo button
4) Hot water button
31
4
2
5
6
7
5) Coffee outlet
6) Hot water outlet
7) Cup lighting
6
5
7
NSF version
NSF version
NSF -
National science
foundation USA
Food safety
certification

3
1
2
2.5 Interior view
Service manual ZN100 V 6.0
10
MA I N C O M P O N N T S
3
4
1) Solenoid valve (hot water)
2) Solenoid valve (drain)
3) Pump CP4-SP C2
4) Power socket
NSF version

6
7
5
8
MA I N C O M P O N N T S
Service manual ZN100 V 6.0 11
9
6
5) xtraction unit
6) Thermoblock TB
7) Water tank connector
8) Flow meter
9) Power pcb
NSF version

2.6 Type plate
The type plate
- can be found at the bottom side of the coffee machine,
- carries the following information:
Service manual ZN100 V 6.0
12
MA I N C O M P O N N T S
1) Brand name
2) Machine type
3) Rated voltage and power consumption
4) Origin
5) Bar code
6) Serial number
7) Non-waste disposal symbols
8-10) Marks of conformity
Serial number codification
Example:
Coffee Machine
Type 9737/ZENIUS/ZN100 PRO
220-240V 50/60Hz 1560-1860W
110 59Z N1M 0395 78G 0SC
1
7
9
8
10
2
3
5
6
4
110 59Z N1M 0395 78G 0SC
Checksum value (based on module 35)
Color version
Mains plug version
Mains voltage
Machine partner codification
Incremental number per production day
Production site
Machine type
Day of production (59 = 28.2.)
Year of production (2011)

MA I N C O M P O N N T S
Service manual ZN100 V 6.0 13
2.7 Fluid system
Water flowing through machine keep fluid system (illustrate blue and red water flow)
Tube list
Flowmeter
Water tank
Pump
Venting
E-valve
Check Valve
Pressure
Valve
Brewing unit
Color of tube number
indicate temperature
(blue/cold - red/hot)
Cup
T-connector
Y-co nne cto r
Piston
Thermoblock
Hot water E-valve
8
6
7 9
54
2
1
3
10
11
Nr. Con A Con B Temperature
1. Water tank connector Flowmeter Cold
2. Flowmeter Pump Cold
3. Pump Y-connector Cold
4. Y-connector Check valve Cold
5. Check valve Thermoblock Cold
6. Thermoblock T-connector Hot
7. T-connector Pressure valve Hot
8. T-connector Hot water -valve Hot
9. Hot water -valve Hot water outlet Hot
10. Y-connector Venting -valve Cold
11. Venting -valve Water tank connector Cold

1
A
B
C
D
E
I
J
K
L
M
NO
F
G
H
3
11
4
8
9
7
6
5
10
2
MA I N C O M P O N N T S
14 Service manual ZN100 V 6.0
A) Water tank
B) Water tank connector
C) Flow meter
D) Pump
) Y-connector
F) Venting -valve
G) Piston
H) Check valve
I) Brewing unit
J) Thermoblock
K) T-connector
L) Hot water -valve
M) Pressure valve
N) Coffee outlet
O) Hot water outlet
ON
NSF version

2.8 Technical data
Main voltage versions.............. 220-240 V, 50/60 Hz
Approvals....... BSMI, CB, CCC, C , C-Tick,
C-Tick RCM, CSA; STI, Gost-r,
IRAM, KT , SASO, SABS, UL com
Consumption data
Preheating time aprrox. ................................... 35 s
Heating up ..................................................10.8 Wh
1 medium coffee cup (40 ml*) ......................2.7 Wh
1 large coffee cup (110 ml*) ............................9 Wh
Hot water (125 ml*) ..................................... 6.6 Wh
Standby (1 h) ................................................14 Wh
Auto power OFF (2 h*).....................................0 Wh
* Default settings
Power ratings
Thermoblock (230V) ............................... 1630 W
Thermoblock (120V) ............................... 1580 W
Thermoblock (100V) ............................... 1400 W
Pump CP4 SP ............................................ 60 W
Solenoid Valve.............................................10 W
Capacities
Watertank...........................................................2.2 l
Drip tray .........................................................350 ml
Capsule container ................................ 25 pcs. max.
Various data
Safety temperature (thermal cut-off) ............. 167°C
Coffee temperature at outlet ............... 86° C ± 3° C
Hot water temperature at outlet ................. > 90° C
Dimensions
(width x depth x height) ........ 19.0 x 39.8 x 31.5 cm
Cable length approx........................................ 1.2 m
Weight of coffee machine (without water) ......7.3 kg
Pump EP4GW
Pump pressure
- max. permissible .................................. 19 - 21 bar
- during coffee preparation
(depending on the type of coffee) .............. 9 -16 bar
Flow performance ............... =
>180 ml/min. at 12 bar
15
MA I N C O M P O N N T S
Machine versions
Machine version Technical 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 220-240V/50-60Hz/1560-1860W
Nespresso Professional Zenius ZN100/ UR 220-240V/50-60Hz/1560-1860W
Nespresso Professional Zenius ZN100/JP 100V/50-60Hz/1450W
Nespresso Professional Zenius ZN100/KR 220-240V/50-60Hz/1560-1860W
Nespresso Professional Zenius ZN100/SG 220-240V/50-60Hz/1560-1860W
Nespresso Professional Zenius ZN100/TW 100V/50-60Hz/1450W
Nespresso Professional Zenius ZN100/UL 120-127V/60Hz/1610-1810W
Nespresso Professional Zenius ZN100/ZA 220-240V/50-60Hz/1560-1860W

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" on page 20).
Procurements
The coffee machine can perfom only one serving at the same time (coffee or hot water).
3.2 Preparation (for test in After Sales Center)
For a function control and some function tests (see "Function tests" on page 62) it is
necessary to make the coffee machine ready for operation.
Service manual ZN100 V 6.0
16
OP R A T I O N
1
2
1
2
A minimum water quantity is required to let the capacitive sensor detect water in
the tank. Otherwise the L D MMI will show “water tank empty” signal
(All 4 buttons blink red permanently)
3 OPERATION
2. Fill the water tank with fresh,
potable water.

OP R A T I O N
Service manual ZN100 V 6.0 17
Start-up
1
2
35 sec
1. Connect coffee machine to
main. Switch on mains switch.
2. Wait (approx. 35 sec.) till coffee
machine is heated up…
3. …and button illumination turns
to white.
3.3 Preparing coffee
Coffee preparation can be aborted by pressing the same coffee button again
(e.g. cup too small for preset filling amount).

3.4 Coffee machine displays
3.4.1 Button colors
Service manual ZN100 V 6.0
18
OP R A T I O N
A red backlight on
buttons locates the
error.
34
12
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 ...................................... error, user or service intervention necessary
Button colors for coffee and hot water preparation can be different, depending on oper-
ation mode.
Operation
Button message Reason Remedy
Fill water Water tank empty.
Floater in water tank stucked.
Water sensor defective.
xchange of the back panel
(Incl. water level PCBA).
Fill water tank.
Clean floater chamber in water
tank.
Replace water sensor.
Calibrate water sensor.

OP R A T I O N
Service manual ZN100 V 6.0 19
Button message Reason Remedy
Overheat Machine is too hot. This alarm is blocking the
machine (no machine usage
allowed when alarm is on),
machine is blocked during
about 10 minutes until the
temperature is again normal
Hot water button blinking red
(until the temperature is again
back at normal level), other
buttons Off.
All buttons are inactive.
Temporary defect Reasons for alarm:
- Flow-meter defective
- pump defective
- water tank sensor defective
(even if there are no more
water, the sensor don’t
detect an empty water tank)
- machine scaled
Indication in the user manual:
- Switch on/off the machine.
- If alarm is repeated after
switch on/off several times:
Descale machine
- If alarm is repeated after
descaling: Call Nespresso
B2B service centre
Fatal defect Reasons for alarm:
- Thermoblock defective
- NTC defective
- Newton defective
- Machine software not
updated, or no serial number
recorded
Check related parts and
change if defect.
Maintenance
Button message Reason Remedy
Change filter Preset service life of water
filter reached. Replace water filter in water tank.
.
Descaling needed Preset operating time reached
(depending on water hardness).
Perform descaling.
Some additional servings are
possible till coffee machine
locks up to prevent damage.
Errors
15 s1151515 s
15 s1151515 s

4.1 Programming the cup volume by push-button
20
PR O G R A M M I N G
To adjust hot water
cup volume no
capsule is necessary.
4 PROGRAMMING
OFF
ON
15 s1151515 s
1. Switch off coffee machine. 2. Press and hold Lungo and Hot
water buttons while turning on
the machine.
6. Press and hold cup button
during blinking cycle. Release
once desired volume is served.
7. Confirmation of selection.
xample for spresso new cup
volume setting.
3 x333 x
Service manual ZN100 V 6.0