Thermoplan AGUILA AG220 User manual

© 2015 by Thermoplan AG, Subject to change 6.1
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AG220 / AG420
SECTION VI
Service and Technical Manual
Troubleshooting

6.2 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual
Modication journal
Revision: Date: Modications Inicials:
0 2011-10-06 Basic document, rst edition SO
1 2011-11-21 Various changes SO
2 2012-01-31 Added Machine Intervention form RZ
3 2015-04-07 Complete revision; added model AG220 RZ
4 2015-06-15 Various changes RZ
5 2015-07-06 Added safety note regarding neglecting preparatory actions RZ
6
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NOTICE
Country-specic rules are to be followed and complied with.
National rules and directives may force you to perform a ground continuity and insulation test. The ground continuity and insulation tests
have to be performed every time the machine has been disassembled or reassembled in any way. This applies after installation, performing a
PM (preventive maintenance) or if the machine has been opened for repairs or troubleshooting.
Thermoplan recommends to use the test device "IR4056" from company HIOKI. In section 2, on the pages 2.8 - 2.11 “Ground continuity
and insulation test”, you will nd instructions, on how to perform these tests using the mentioned test device.
WARNING
Risk of scalding and electric shock by neglecting preparatory actions
• Empty all boilers before performing preventive maintenance or troubleshooting inside the machine to avoid scalding from hot water:
Choose “General Settings ►Emptying Sequence” in the service menu and follow the instructions on the display.
All boilers will be emptied. Once reassembled, the machine will perform a cold start (to ll the boilers with water).
• Always disconnect the machine from the power plug socket before opening!
WARNUNG
Verbrennungen oder Stromschlag durch Unterlassung von Vorbereitungsmassnahmen
• Entleeren Sie alle Boiler bevor Sie Wartungsarbeiten oder eine Fehlersuche im Innern der Maschine vornehmen, um Verbrühungen durch
heisses Wasser zu vermeiden:
Wählen Sie im Servicemenü “Allg. Einstellungen ►Entleerungs-Sequenz” und folgen Sie den Anweisungen auf dem Display.
Alle Boiler werden anschliessend entleert. Nach dem Zusammenbau der Maschine wird darüber hinaus ein Kaltstart der Maschine verlangt.
• Die Maschine vor dem Öffnen immer vom Stromanschluss trennen.

© 2015 by Thermoplan AG, Subject to change 6.3
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SECTION VI
Service and Technical Manual
Index
Machine Intervention form .................................................................................................................................................6.4
Service menu: Input and output test ...........................................................................................................................6.5 - 6.9
Access to service menu ...........................................................................................................................................................6.5
Output test .....................................................................................................................................................................6.6 - 6.7
Input test ........................................................................................................................................................................6.8 - 6.9
Housing...................................................................................................................................................................6.10 - 6.21
Views AG220 ..............................................................................................................................................................6.10 - 6.15
Views AG420 ..............................................................................................................................................................6.16 - 6.21
Coffee and water part.............................................................................................................................................6.22 - 6.29
Possible problems .......................................................................................................................................................6.22 - 6.23
Water way to the pump ........................................................................................................................................................ 6.25
Detailed view Manometer / Bypass ........................................................................................................................................ 6.25
AG220 Components / Flow of coffee ...........................................................................................................................6.26 - 6.27
AG420 Components / Flow of coffee ...........................................................................................................................6.28 - 6.29
AG220 Flow of tea ............................................................................................................................................................... 6.30
AG420 Flow of tea ............................................................................................................................................................... 6.31
Brew unit ................................................................................................................................................................6.32 - 6.37
Possible problems .......................................................................................................................................................6.32 - 6.33
AG220 Overview brew unit / Brew unit view from back / Detailed prole view brew unit ..............................................6.34 - 6.35
AG420 Overview brew unit / Brew unit from bottom view / Detailed prole view brew unit ..........................................6.36 - 6.37
Milk part .................................................................................................................................................................6.38 - 6.57
Possible problems .......................................................................................................................................................6.38 - 6.39
Tea / milk boiler .................................................................................................................................................................... 6.41
AG220 Milk inlet ..................................................................................................................................................................6.42
AG420 Milk inlet ..................................................................................................................................................................6.43
AG220 Milk pump ................................................................................................................................................................ 6.44
AG420 Milk pump ................................................................................................................................................................ 6.45
AG220 Cold / hot milk way .........................................................................................................................................6.46 - 6.51
AG420 Cold / hot milk way .........................................................................................................................................6.52 - 6.57
Cleaning..................................................................................................................................................................6.58 - 6.63
Possible problems ................................................................................................................................................................. 6.58
AG220 Cleaning way ..................................................................................................................................................6.60 - 6.61
AG420 Cleaning way ..................................................................................................................................................6.62 - 6.63
Electronics...............................................................................................................................................................6.64 - 6.69
Possible problems ........................................................................................................................................................6.64- 6.65
AG220 Overview electronics ................................................................................................................................................. 6.66
AG420 Overview electronics ................................................................................................................................................. 6.67
AG220 Overview plugs control board (CPU) / power board ..........................................................................................6.68 - 6.69
AG220 Overview LEDs control board (CPU) / power board ...........................................................................................6.70 - 6.71
AG420 Overview plugs control board (CPU) / power board ..........................................................................................6.68 - 6.69
AG420 Overview LEDs control board (CPU) / power board ...........................................................................................6.70 - 6.71
Display messages..............................................................................................................................................................6.76
Nespresso Aguila Phone-Fix-List .............................................................................................................................6.77 - 6.81

6.4 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Machine intervention form
1 / 1
Aguila Machine Intervention
CSP
Company Name Market / Country
Technician Name
Complaint
Name Customer
NN affiliate
Other
Date Time
Description
Intervention
Customer Name Customer Location
Date Arrival Time Departure Time
Machine Serial Number (19 digit)
A G
Situation / Findings
Actions / Work
Used Parts
Additional Comment
If you have any questions regarding...
...the Aguila Campus, please contact: [email protected]
...spareparts orders and warranty claims, please contact: [email protected]
Please send the completely filled out file to: [email protected]
Should you call our Service Team under [phone] please have the information below always ready!

© 2015 by Thermoplan AG, Subject to change 6.5
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SECTION VI
Service and Technical ManualService menu: Input and output test
Access to service menu
1. Remove the used capsule drawer
(AG420: remove used capsule
drawer from left module).
2. Insert programming key in the
back of the drawer and turn it
clockwise.
3. In the service menu, navigate to
„INPUT TEST“ or „OUTPUT TEST“.
1. Up (cleaning key): Next menu
2. Down (rinse key): Previous menu
3. Standard (ristretto key):
No function
4. Enter (espresso key): Check valve / check state / activate function
5. Cancel (lungo key): Exit menu
Overview of the keys and their function in the menues „Input Test“ and „Output Test“
TECHNICIAN MENU
<OUTPUT TEST>
TECHNICIAN MENU
<INPUT TEST>
Follow these steps to access the In- and Output Tests in the service menu:
The In- and Output Tests will help nding a possible source of malfunctioning part. All assembled valves, sensors etc.
can be checked for functionality.
If the valve you have chosen to test (press the enter key to test the components) is connected and working you will hear
a click noise. If the component is not a valve you can see the state of the component on the display.
Note: On model AG420 the In- and Output Tests are divided into „Left“ and „Right“ to check the components
either in the left or right machine module.

6.6 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Service menu: Input and output test
Output test
In this menu all the electrical components can be tested for function.
Menu Description
OUTPUT TEST LEFT / RIGHT
Water Inlet Valve
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Chamber Release Valve 1
Press the Enter-key to open the valve.
If the brew chamber is closed, a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Chamber Release Valve 2
Press the Enter-key to open the valve.
If the brew chamber is closed, a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Brew Valve 1
Press the Enter-key to open the valve.
If the brew chamber is closed, a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Brew Valve 2
Press the Enter-key to open the valve.
If the brew chamber is closed, a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Tea Valve
The Tea Valve opens the water way from the tea / milk boiler through
the cleaning tablet valve to the tea valve 2.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Tea Valve 2
(only available for model AG220)
The Tea Valve 2 opens the water way from the coffee boiler to the tea
outlet.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Exhaust Valve
(only available for model AG220)
The Exhaust Valve adds air to exhaust the milk way.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Milk Clean Valve
The Milk Clean Valve opens the rinse way to the refrigerator.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Milk Rinse Valve
The Milk Rinse Valve opens the rinse way to the milk pump.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Cold Milk Valve
The Cold Milk Valve is switching between cold and warm milk respec-
tively cold and warm foam.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.

© 2015 by Thermoplan AG, Subject to change 6.7
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SECTION VI
Service and Technical ManualService menu: Input and output test
Output test
OUTPUT TEST LEFT / RIGHT
Milk Outlet Valve
The Milk Outlet Valve opens the way to the milk outlet.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Milk Drain Valve
The Milk Drain Valve opens the way to the drain.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Milk Air Valve
The Milk Air Valve opens the air way on the milk pump.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Air Select Valve
(only available for model AG420)
The Air Select Valve opens the additional air way for cold foam.
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Cleaning Tablet Valve
(this valve is located in the right module of model AG420)
Press the Enter-key to open the valve.
The valve is functioning correctly if a „click“ noise is heard.
OUTPUT TEST LEFT / RIGHT
Water Pump
Press and hold the Enter-key to test the Water Pump.
The LED „LD2“ (AG220, on power board) resp. „LD12“ (AG420, on
CPU) willl glow on the power print.
OUTPUT TEST LEFT / RIGHT
Refrigerator Fan
(only available for model AG220)
Press and hold the Enter-key to test the fan inside the refrigerator.
OUTPUT TEST LEFT / RIGHT
Milk Pump
Press and hold the Enter-key to test the Milk Pump.
OUTPUT TEST LEFT / RIGHT
Coffee boiler 1 = xx.x °C
The display shows the current temperature of coffee boiler 1. By
pressing the Enter-key, the boiler will start heating up. The LED „LD5“
(AG220) resp. „LD2“ (AG420) willl glow on the power print.
ATTENTION: The regulation is not active, the boiler can overheat!
OUTPUT TEST LEFT / RIGHT
Coffee boiler 2 = xx.x °C
The display shows the current temperature of coffee boiler 2. By
pressing the Enter-key, the boiler will start heating up. The LED „LD6“
(AG220) resp. „LD3“ (AG420) willl glow on the power print.
ATTENTION: The regulation is not active, the boiler can overheat!
OUTPUT TEST LEFT / RIGHT
Tea/Milk boiler = xx.x °C
The display shows the current temperature of the tea / milk boiler. By
pressing the Enter-key, the boiler will start heating up. The LED „LD4“
(AG220) resp. „LD1“ (AG420) willl glow on the power print.
ATTENTION: The regulation is not active, the boiler can overheat!
OUTPUT TEST LEFT / RIGHT
Cup Heater
By pressing the Enter-key, the cup heater will either be switched on or
off, depending wether it was already activated before or not.
The LED „LD1“ (AG220) resp. „LD4“ (AG420) willl glow on the power
print.

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In this Menu all inputs (sensors) can be tested for functionality.
Menu Description
INPUT TEST LEFT / RIGHT
EAPB = detected
(only available for model AG420)
The display shows „detected“ if the CPU (EAPB) is correctly
connected.
INPUT TEST LEFT / RIGHT
Cleaning key = closed
The display shows the current state of the cleaning key.
„closed“: cleaning key is detected and mounted correctly (reed switch
closed).
„open“: cleaning key not detected (reed switch open).
INPUT TEST LEFT / RIGHT
Cleaning tablet = No
The display shows, if a cleaning tablet is detected in the cleaning key.
„No“: No tablet in the cleaning key detected (reed switch open).
„Yes“: Tablet detected in the cleaning key (reed switch closed).
INPUT TEST LEFT / RIGHT
Brewchamber 1 = open
The display shows the current state of brew chamber 1.
„open“: Brew chamber is open (micro switch is open)
„closed“: Brew chamber is closed (micro switch is closed).
INPUT TEST LEFT / RIGHT
Brewchamber 2 = open
(only available for model AG420)
The display shows the current state of brew chamber 2 (right module).
„open“: Brew chamber is open (micro switch is open)
„closed“: Brew chamber is closed (micro switch is closed).
INPUT TEST LEFT / RIGHT
NTC Boiler 1 = xx.x °C
The display shows the current water temperature of coffee boiler 1.
If a temperature of 3276.8 °C is shown, a cable is disconnected or a
short circuit occured on the NTC.
INPUT TEST LEFT / RIGHT
NTC Boiler 2 = xx.x °C
The display shows the current water temperature of coffee boiler 2.
If a temperature of 3276.8 °C is shown, a cable is disconnected or a
short circuit occured on the NTC.
INPUT TEST LEFT / RIGHT
NTC Boiler 3 = xx.x °C
The display shows the current water temperature of tea / milk boiler.
If a temperature of 3276.8 °C is shown, a cable is disconnected or a
short circuit occured on the NTC.
INPUT TEST LEFT / RIGHT
NTC Refrigerator = x.x °C
The display shows the current temperature of the refrigerator.
If a temperature of 3276.8 °C is shown, a cable is disconnected or a
short circuit occured on the NTC.
Input test
Service menu: Input and output test

© 2015 by Thermoplan AG, Subject to change 6.9
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Service and Technical Manual
INPUT TEST LEFT / RIGHT
Milk temperature = x.x °C
(only available for model AG220)
The display shows the current temperature of the milk.
If a temperature of 3276.8 °C is shown, a cable is disconnected or a
short circuit occured on the NTC.
INPUT TEST LEFT / RIGHT
Flowmeter 1 = 0 ticks
The display shows the impulse of owmeter 1.
Press and hold the Enter-key to test the owmeter, the number of
ticks will be shown (brew chamber must be closed).
INPUT TEST LEFT / RIGHT
Flowmeter 2 = 0 ticks
(only available for model AG420)
The display shows the impulse of owmeter 2.
Press and hold the Enter-key to test the owmeter, the number of
ticks will be shown (brew chamber must be closed).
INPUT TEST LEFT / RIGHT
Milk Level Low = Aus
The display shows the status of the low milk level sensor.
„Off“: „Milk level low“ is not reached (passage open),
there is still enough milk available in the container
„On“: „Milk level low“ is reached, milk level is below the sensor
(no passage), milk is almost empty
INPUT TEST LEFT / RIGHT
Milk Container Empty = Aus
The display shows the status of the sensor.
„Off“: There is still some milk in the container (passage open)
„On“: Milk level is below the sensor (no passage), milk is empty.
INPUT TEST LEFT / RIGHT
Standby Button = Aus
The display shows the status of the standby button.
„Off“: Button is not pressed, Standby mode is not active.
„On“: Button is pressed, Standby mode is active.
Input test
Service menu: Input and output test

6.10 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Chassis
Aguila AG220 front view
Water pump unit Water inlet
Coffee boiler 1 Coffee boiler 2
Brew unit
CPU / power print
Milk cleaning key
RF-Box

© 2015 by Thermoplan AG, Subject to change 6.11
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SECTION VI
Service and Technical ManualChassis
Aguila AG220 back view
Milk pump unit
Tea / milk boilerRefrigerator
compressor
Water pump unitSupply terminal

6.12 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Chassis
Aguila AG220 view from left-hand side
Water pump unit
Manometer
Switching
power supply
Power print
CPU
Coffee boiler

© 2015 by Thermoplan AG, Subject to change 6.13
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SECTION VI
Service and Technical ManualChassis
Aguila AG220 view from right-hand side
Compressor fan
Refrigerator
compressor
Water pump unit

6.14 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Chassis
Aguila AG220 top view
Tea / milk boiler
Coffee boiler Compressor fan
Brew unit
Refrigerator

© 2015 by Thermoplan AG, Subject to change 6.15
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SECTION VI
Service and Technical ManualChassis
Aguila AG220 bottom view / drain system
1Drain from the drip tray
2Milk drain
3Drainage from over pressure valves
4To the drain

6.16 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Chassis
AG420 front view
Water pump unit Water inlet Brew unit
CPU / power print
Milk cleaning key
RF-Box
Coffee boiler 1 Coffee boiler 2 Air regulator
hot / cold milk foam

© 2015 by Thermoplan AG, Subject to change 6.17
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SECTION VI
Service and Technical ManualChassis
AG420 back view
Tea / milk boiler Transformator
(only US/CAN/JP)
Switching
power supply
GSM antenna
Milk pump unit
Milk pump unit
Tea / milk boilerRefrigerator
compressor
Water pump unit

6.18 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual Chassis
AG420 view from left-hand side
Water pump unit
Manometer
Milk pump unit
Power print
CPU
Coffee boiler

© 2015 by Thermoplan AG, Subject to change 6.19
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SECTION VI
Service and Technical ManualChassis
AG420 view from right-hand side
Power print
Milk outlet
valve
Tea / milk boiler
Coffee boiler
Transformator
(only 1Ph./JP)
Switching
power supply

6.20 © 2015 by Thermoplan AG, Subject to change
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SECTION VI
Service and Technical Manual
AG420 top view
Chassis
Tea / milk boiler
Coffee boiler Coffee boiler
Tea / milk boiler
Compressor fan
Brew unit Brew unit
Refrigerator
Transformator
(only US/CAN/JP)