Thermoplan Aguila AG440 User manual

Troubleshooting
Technical Manual AG440
© Thermoplan AG | 07/04/2022

Change Log Troubleshooting - Aguila - 440 - B - en
2 / 52 © Thermoplan AG
Change Log
Revision Date Proof of Change Initials
A 2017-07-07 First release, basic document ZV
B 2022-03-01 Various changes ZV

Troubleshooting - Aguila - 440 - B - en Table of Contents
© Thermoplan AG 3
Table of Contents
1 Access to Service Menu................................................................................................................. 5
1.1 Overview of the Button Functions in the "Input Test" and "Output Test" Menus ........................................... 6
2 Service Menu: Input and Output Test............................................................................................. 7
2.1 OUTPUT TEST ............................................................................................................................................... 7
2.2 INPUT TEST................................................................................................................................................. 10
3 Chassis....................................................................................................................................... 12
3.1 Front view .................................................................................................................................................. 12
3.2 Rear View................................................................................................................................................... 13
3.3 Left View .................................................................................................................................................... 14
3.4 Right View.................................................................................................................................................. 15
3.5 View from Above ........................................................................................................................................ 16
3.6 View from Below/Drain System.................................................................................................................... 17
4 Coffee/Water Part....................................................................................................................... 18
4.1 Possible Problems ....................................................................................................................................... 18
4.2 Water Channel to the Pump........................................................................................................................ 19
4.3 Detailed View of Pressure Gauge/Bypass ..................................................................................................... 20
4.4 Components............................................................................................................................................... 21
4.5 Flow Coffee Channel................................................................................................................................... 22
4.6 Tea Channel ............................................................................................................................................... 23
5 Brewing Unit .............................................................................................................................. 24
5.1 Possible Problems ....................................................................................................................................... 24
5.2 Brewing Unit Overview ............................................................................................................................... 26
5.3 View of Brewing Unit from Behind .............................................................................................................. 26
5.4 Detailed View of Brewing Unit Cross Section ............................................................................................... 27
6 Milk Component......................................................................................................................... 28
6.1 Possible Problems ....................................................................................................................................... 28
6.2 Tea/milk boiler............................................................................................................................................ 30
6.3 RF Box Refrigerator..................................................................................................................................... 31
6.4 Milk Pump and Proportional Valve .............................................................................................................. 32
6.5 Cold Milk Channel ...................................................................................................................................... 33
6.6 Hot Milk Channel........................................................................................................................................ 34
7 Cleaning..................................................................................................................................... 35
7.1 Possible Errors ............................................................................................................................................ 35
7.2 Cleaning Channel ....................................................................................................................................... 36
8 Electronics .................................................................................................................................. 37
8.1 Possible Problems ....................................................................................................................................... 37

Table of Contents Troubleshooting - Aguila - 440 - B - en
4 © Thermoplan AG
8.2 Connector Overview of Control Board (CPU)................................................................................................ 39
8.3 LED Overview of Control Board (CPU).......................................................................................................... 41
8.4 Connector Overview of Power Board (power PCB) ....................................................................................... 43
8.5 LED Overview of Power Board (power PCB) ................................................................................................. 45
8.6 Connector Overview of Control Board (CPU) America .................................................................................. 47
8.7 LED Overview of Control Board (CPU) America ............................................................................................ 49
8.8 Display Messages........................................................................................................................................ 50

Troubleshooting - Aguila - 440 - B - en Access to Service Menu
© Thermoplan AG 5 / 52
1 Access to Service Menu
The input and output tests help when searching for an error source. The functionality of all valves, sensors
etc. installed in the coffee machine can be tested.
If the part concerned is not a valve, the status of the selected part can be seen on the display or its function is
activated (e.g. the heater).
To call up the input and output test in the service menu, proceed as follows:
uRemove capsule container on the left module.
uInsert programming key in the rear area of the
drawer and turn clockwise.
ðService menu was entered as technician and
the water inlet valve was opened.
Upon exiting the technician menu, the water
inlet valve is closed again.
uIn the service menu, navigate to the menu item
"Input test left/right" or "Output test left/right".
TECHNICIAN MENU
<INPUT TEST LEFT>
TECHNICIAN MENU
<OUTPUT TEST LEFT>

Access to Service Menu Troubleshooting - Aguila - 440 - B - en
6 / 52 © Thermoplan AG
uTurn programming key anticlockwise and remove.
ðStart display ("Ready") appears again.
ðService menu was exited as technician.
<- Ready
Ready ->
1.1 Overview of the Button Functions in the "Input Test" and "Output Test"
Menus
<- Ready
Ready ->
1
2
34 5
1 Up (Cleaning button): next menu 4 Input (Espresso button): non-return valve/
check status/activate function
2 Down (rinse button): Previous menu 5 Cancel button
3 Standard (Ristretto button): No function

Troubleshooting - Aguila - 440 - B - en Service Menu: Input and Output Test
© Thermoplan AG 7 / 52
2 Service Menu: Input and Output Test
2.1 OUTPUT TEST
In this menu the functionality of all electrical components in the machine can be tested.
uPress input button.
ðWater inlet valve is closed.
• If a "click" sound can be heard when releasing the
button, the valve works.
OUTPUT TEST LEFT
Water Inlet Valve
uPress input button.
ðBrewing chamber valve 1 is opened.
• If the brewing chamber is closed, a "click" sound
should be heard.
OUTPUT TEST LEFT / RIGHT
Chamber Release Valve 1
uPress input button.
ðBrewing chamber valve 2 is opened.
• If the brewing chamber is closed, a "click" sound
should be heard.
OUTPUT TEST LEFT / RIGHT
Chamber Release Valve 2
uPress input button.
ðBrewing valve 1 is opened.
• If the brewing chamber is closed, a "click" sound
should be heard.
OUTPUT TEST LEFT / RIGHT
Brew Valve 1
uPress input button.
ðBrewing valve 2 is opened.
• If the brewing chamber is closed, a "click" sound
should be heard.
OUTPUT TEST LEFT / RIGHT
Brew Valve 2
uPress input button.
ðTea valve on the boiler is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Tea Valve 1
uPress input button.
ðTea valve 2 (on the machine module chassis at
the front) is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Tea Valve 2
uPress input button.
ðVenting valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Exhaust Valve
uPress input button.
ðMilk cleaning valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Milk Clean Valve

Service Menu: Input and Output Test Troubleshooting - Aguila - 440 - B - en
8 / 52 © Thermoplan AG
uPress input button.
ðMilk rinsing valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Milk Rinse Valve
uPress input button.
ðCold milk valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Cold Milk Valve
uPress input button.
ðMilk discharge valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Milk Outlet Valve
uPress input button.
uMilk outlet valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Milk Drain Valve
uPress input button.
ðMilk air valve is opened.
OUTPUT TEST LEFT / RIGHT
Milk Air Valve
uPress input button.
ðCleaning tablet valve is opened.
• If a "click" sound can be heard, the valve works.
OUTPUT TEST LEFT / RIGHT
Cleaning Tablet Valve
uPress and hold down the input button to test the
water pump.
ðThe LED "LD2" illuminates on the Power PCB.
ðIf the pump in the output test left is activated,
water comes out of the left tea outlet. If the
pump in the output test right is activated,
water comes out of the right tea outlet.
OUTPUT TEST LEFT / RIGHT
Water Pump
uPress and hold down the input button to test the
milk pump.
ðFresh water runs through the pump/milk outlet.
uStart internal rinsing sequence by briefly pressing
the input button (5 min).
OUTPUT TEST LEFT / RIGHT
Milk Pump
uPress and hold down the input button to test the
fan in the refrigerator.
OUTPUT TEST RIGHT
Refrigerator fan

Troubleshooting - Aguila - 440 - B - en Service Menu: Input and Output Test
© Thermoplan AG 9 / 52
• Displays the current temperature of coffee boiler 1.
uPress input button.
ðBoiler heater is switched on.
ðThe LED "LD5" illuminates on the Power PCB.
• ATTENTION: The controller is not active, the boiler
could overheat!
OUTPUT TEST LEFT / RIGHT
Coee boiler 1 = xx.x °C
• Displays the current temperature of coffee boiler 2.
uPress input button.
ðBoiler heater is switched on.
ðThe LED "LD6" illuminates on the Power PCB.
• ATTENTION: The controller is not active, the boiler
could overheat!
OUTPUT TEST LEFT / RIGHT
Coee boiler 2 = xx.x °C
• Displays the current temperature of the tea/milk
boiler.
uPress input button.
ðBoiler heater is switched on.
ðThe LED "LD4" illuminates on the Power PCB.
• ATTENTION: The controller is not active, the boiler
could overheat!
OUTPUT TEST LEFT / RIGHT
Tea/Milk boiler = xx.x °C
uPress input button to switch on the cup heater.
uCheck cup heater on the Power PCB by
meansofthe LED.
ðThe LED "LD1" illuminates on the Power PCB.
OUTPUT TEST LEFT / RIGHT
Cup Heater

Service Menu: Input and Output Test Troubleshooting - Aguila - 440 - B - en
10 / 52 © Thermoplan AG
2.2 INPUT TEST
In this menu the functionality of all inputs (sensors) in the machine can be tested.
• Displays the current status of the grounds drawer.
INPUT TEST LEFT / RIGHT
Drawer = Open
• Displays the current status of the cleaning key.
• "closed" Cleaning key present and inserted/locked
correctly.
• "open": Cleaning key not present.
INPUT TEST LEFT
Cleaning key = closed
• Displays whether a cleaning tablet is in the
cleaning key.
• "No": No tablet is present in the key (reed switch
closed).
• "Yes": Tablet is present in the key (reed switch
open).
INPUT TEST LEFT
Cleaning tablet = No
• Displays the current status of brewing chamber 1.
• "open": Brewing chamber is opened (microswitch
is open).
• "closed": Brewing chamber is closed (microswitch
is pressed).
INPUT TEST LEFT / RIGHT
Brew Chamber 1 = open
• Displays the current status of brewing chamber 2.
• "open": Brewing chamber is opened (microswitch
is open).
• "closed": Brewing chamber is closed (microswitch
is pressed).
INPUT TEST LEFT / RIGHT
Brew Chamber 2 = open
• Displays the current temperature of coffee boiler 1.
• If a temperature of 3276.8 °C is displayed, either a
cable breakor short-circuit attheNTC has
occurred.
INPUT TEST LEFT / RIGHT
NTC Boiler 1 = xx.x °C
• Displays the current temperature of coffee boiler 2.
• If a temperature of 3276.8 °C is displayed, either a
cable breakor short-circuit attheNTC has
occurred.
INPUT TEST LEFT / RIGHT
NTC Boiler 2 = xx.x °C
• Displays the current temperature of the tea/milk
boiler.
• If a temperature of 3276.8 °C is displayed, either a
cable breakor short-circuit attheNTC has
occurred.
INPUT TEST LEFT / RIGHT
NTC Boiler 3 = xx.x °C

Troubleshooting - Aguila - 440 - B - en Service Menu: Input and Output Test
© Thermoplan AG 11 / 52
• Displays the current temperature inside the
refrigerator.
• If a temperature of 3276.8 °C is displayed, either a
cable breakor short-circuit attheNTC has
occurred.
INPUT TEST LEFT
NTC Refrigerator = x.x °C
• Displays the impulses of flowmeter 1.
uPress and hold down the input button to test the
flowmeter.
ðThe number of ticks is displayed (brewing
chamber must be closed).
INPUT TEST LEFT / RIGHT
Flowmeter 1 = x ticks
• Displays the impulses of flowmeter 2.
uPress and hold down the input button to test the
flowmeter.
ðThe number of ticks is displayed (brewing
chamber must be closed).
INPUT TEST LEFT / RIGHT
Flowmeter 2 = x ticks
• Displays the current milk temperature in the
refrigerator.
• If the temperature is above 12 °C, the preparation
of milk products is blocked.
• If a temperature of 3276.8 °C is displayed, either a
cable breakor short-circuit attheNTC has
occurred.
INPUT TEST LEFT / RIGHT
Milk temperature = x.x °C
• Displays the status of the upper milk level sensor.
• "Off": "Milk level low" not reached (continuity
exists), there is still sufficient milk in the container.
• "On": "Milk level low" reached, milk level is below
the sensor (no continuity), milk almost empty.
INPUT TEST LEFT / RIGHT
Milk Level Low = O
• Displays the status of the lower milk level sensor.
• "Off": "there is still milk in the container
(continuity exists).
• "On": Milk level is below the sensor (no
continuity), there is no more milk left.
INPUT TEST LEFT / RIGHT
Milk Container Empty = O
• Displays the current status of the energy standby
button.
uPress energy standby button.
ðDisplay changes to "On".
• "Off": Button is not pressed, standby mode is not
activated.
• "On": Button is pressed, standby mode is
activated.
INPUT TEST LEFT
Energy Save Button = O

Chassis Troubleshooting - Aguila - 440 - B - en
12 / 52 © Thermoplan AG
3 Chassis
3.1 Front view
1 1 12 1 23 4
6 5 78 6 5
1 Brewing Unit 5 Coffee boiler 2
2 CPU/power PCB 6 Coffee boiler 1
3 Milk cleaning key 7 Water inlet
4 RF Box 8 Water pump unit

Troubleshooting - Aguila - 440 - B - en Chassis
© Thermoplan AG 13 / 52
3.2 Rear View
44 3
1 22
1 Refrigerator compressor 3 Water pump unit
2 Milk pump unit 4 Tea/milk boiler

Chassis Troubleshooting - Aguila - 440 - B - en
14 / 52 © Thermoplan AG
3.3 Left View
1 2
5 4 3
1 Power PCB 4 Pressure gauge
2 CPU 5 Water pump unit
3 Coffee boiler

Troubleshooting - Aguila - 440 - B - en Chassis
© Thermoplan AG 15 / 52
3.4 Right View
1
2
3
1 Compressor fan 3 Water pump unit
2 Refrigerator compressor

Chassis Troubleshooting - Aguila - 440 - B - en
16 / 52 © Thermoplan AG
3.5 View from Above
1 1 2 1 1 23
5 5 5 54
1 Coffee boiler 4 Refrigerator
2 Tea/milk boiler 5 Brewing Unit
3 Compressor fan

Troubleshooting - Aguila - 440 - B - en Chassis
© Thermoplan AG 17 / 52
3.6 View from Below/Drain System
1
2
4
3
2
3
1 Drip tray outlet 3 Milk outlet
2 Outlet of overpressure valves 4 Into the drain

Coffee/Water Part Troubleshooting - Aguila - 440 - B - en
18 / 52 © Thermoplan AG
4 Coffee/Water Part
4.1 Possible Problems
Messages Possible Cause Solution
No product/display message
"Flowmeter # error"
• Hoses of the water circuit or
brewing unit not connected
correctly.
• Flowmeter plug oxidised.
• Microswitch inserted in reverse
on the brewing unit.
• No water supply.
• Filter in the water inlet/
flowmeter blocked.
• Water flow too low or
interrupted.
• Electrical circuit interrupted.
uConnect hoses of the water
circuit or brewing unit
correctly.
uCheck everything and replace if
necessary.
uConnect microswitch correctly.
uCheck water inlet valve.
uCheck filter.
uCheck water flow to brewing
group.
uCheck electrical circuit until the
flowmeter.
Display message
"Error: NTC # short-circuit"
• # = 1: Coffee boiler 1.
• # = 2: Coffee boiler 2.
• # = 3: Tea/milk boiler.
• NTC short-circuit.
• Short-circuit in the NTC circuit.
uCheck NTC of the
corresponding coffee boiler.
Measured value: 10 kΩ at 25
°C.
uCheck electrical circuit of the
NTC.
Display message
"Error: NTC # breakage"
• # = 1: Coffee boiler 1.
• # = 2: Coffee boiler 2.
• # = 3: Tea/milk boiler.
• Interruption of the NTC from
boiler.
• Interruption in the NTC circuit.
uCheck brewing unit for water
leakage.
uHoses from the 3rd channel
"outlet" not connected to
module; cracks in the hose;
check all hose connections.
uWhen after cold start rinsing:
Clean coffee outlet.
Water under the machine • Leak. uCheck brewing unit for water
leakage.
uHoses from the 3rd channel
"outlet" not connected to
module; cracks in the hose;
check all hose connections.
uWhen after cold start rinsing:
Clean coffee outlet.
Long heating up time/Display
message
"Heating up"/
"Please wait"
• The corresponding boiler has
not yet reached the operating
temperature.
• Defective NTC on the boiler.
• Defective component in the
corresponding heating circuit.
• Boiler has limescale.
uWait until operating
temperature is reached
("Ready").
uIn the "Input test" service
menu check the NTC.
uCheck complete heating circuit:
CPU/Powerprint/Triac;
temperature fuses; heating
element.

Troubleshooting - Aguila - 440 - B - en Coffee/Water Part
© Thermoplan AG 19 / 52
Messages Possible Cause Solution
uCheck boiler.
4.2 Water Channel to the Pump
Water channel until pump and detailed view of water connection with non-return valve:
1
10
9
8
2
3
4
5
6
6
7
1 Water inlet valve 2 Reducing nipple
3 Filter 4 O-ring 12x2
5 Reduction MW 6 Check valves
7 Elbow fitting 8 Water connection
9 Bottom plate 10 Water pump unit

Coffee/Water Part Troubleshooting - Aguila - 440 - B - en
20 / 52 © Thermoplan AG
4.3 Detailed View of Pressure Gauge/Bypass
The water inlet pressure must be between 2-4 bar when the machine is switched on.
During preparation of a coffee product and a correspondingly activated water pump, the brewing pressure
must increase to 14.5 bar.
To check the pressure during preparation of the product: Remove the capsule container on the left module
and dispense a product on the right module.
If the brewing pressure does not match the required values, the bypass can be adjusted as follows:
1
2
1 Bypass 2 Pressure gauge
uLoosen hexagon nut to adjust bypass.
uAdjust bypass:
• clockwise: increase pressure
• anticlockwise clockwise: decrease pressure
uTighten hexagon nut again.