Preface General Nespresso technical website Content updates The purpose of this service manual is to Visit the Nespresso technical website periodi The version number of this service provide the service personnel with all neces cally to check for upgrades, technical modifi manual is printed on the lower right sary information with regards to correct cations, counter measures etc. for this coffee corner of the page. handling, maintenance and repair of the coffee machine: https://business.nespresso.com machines C91 and D91. Version 1.0 Access is restricted and can be This manual should be used by the techni Nespresso obtained by asking your First released service manual version. cians as a valuable aid to guarantee the technical contact person. permanent readiness for use of the machine. In order to take full advantage of all the func tions, it is absolutely necessary to follow the Please keep this manual together with the instructions in this manual. corresponding service documentation. This way you are assured to have the necessary information. 3 Service Manual C91 / D91 ...
General Safety Notes Risk of fatal electrical shock and fire! Example illustrations of typical devices: 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. This device does not protect against electrical shock due to contact with both circuit conductors. Use a GFCI with a trip level of 4 6 mA (USA) resp. a RCD with a trip level of 15 30 mA (Europe). A trip level above 30 mA provides only very limited protection against harm from an electric shock. Danger of burns! Hot parts and water under pressure 1) RCD protected socketoutlet inside the coffee machine (particu 2) Plugin RCD unit larly in the thermoblock). 3) GFCI socket • ...
Main Components Overview of rating plates The rating plate can be found at the underside of the coffee machine. It is of varying design depending on the brand and carries the following information: • Machine type • Voltage and power rating • Manufacturing country • Conformity with RoHS guidelines • Special disposal icon • Sign of conformity (CE) • Bar code • Serial number This overview shows examples of various brands and is subject to alterations. Serial number codification Example: 10190C91x0002782090 th 10190 production date: 190 day of year 2010 C91 machine type x production site 0002 incremental number per production day 7 machine partner codification 8 voltage ...
Main Components Water circuit 1) Water tank 2) Water tank valve and connector 3) Pump 4) Thermoblock 5) Compact brewing unit (TCBU) 6) Coffee outlet 7 Service Manual C91 / D91 Version 1.0 en ...
Main Components Technical data Mains Energy consumption (CECED / FEA 2009 method) EUR 230V / 50 Hz Approvals CEconform Energy efficiency class level A C91 Cable length approx. 1.1 m Daily energy consumption 129 Wh Annual energy consumption 47.09 kWh Pump data Various data Pump pressure max. permissible 19 bar ± 2 bar Preheating time approx. 50 sec. during coffee preparation 9 13 bar (depending on brand of coffee) Safety temperature (thermal cutoff) 167° C Coffee temperature at outlet 86° C ± 3° C Flow performance 120 240 ml/min. at 12 bar Weight of machine approx. 3 kg (without water) Capacities Water tank 0.9 l Drip tray ...
Operation Preparation 1 1. Fill tank with water. 2. Insert water tank in coffee machine. 3. Switch on machine by pressing the On/Off button. 3 4. Position receptacle with a capacity of min. 100 ml under coffee outlet. Do not insert a capsule yet. 2 5. Wait until machine is ready (coffee button 4 stops blinking). 6. Press coffee button to rinse coffee outlet. 7. Press coffee button again to stop rinsing when receptacle is filled. 5 6 9 Service Manual C91 / D91 Version 1.0 en ...
Operation Fill water system 4 2 If the coffee machine cannot pump water although there is water in the tank, the water circuit may be empty. Procedure to fill water system: 1. Perform steps 1 to 5 for preparation (see page 9). 2. Open closing handle in vertical position. 3 3. Press coffee button. 4. Press and hold closing handle to rear end position. 5. Observe capsule inlet for appearing water. 6. Press down closing handle immediately when first droplets are visible. 6 7. Press coffee button again to stop water flow. 7 10 Service Manual C91 / D91 Version 1.0 en ...
Operation Making coffee 1 3 1. Open closing handle. 2. Insert capsule. 2 3. Press down closing handle completely. 4. Position cup under coffee outlet. 5. Press coffee button. 6. Press button again to stop coffee flow when cup is full. 5 4 7. Briefly open closing handle after coffee preparation and eject capsule into capsule container. 6 11 Service Manual C91 / D91 Version 1.0 en ...
Operation Empty water system 5 After operation, residual water remains in the water circuit. 1 This residual water can be removed before a longer period of nonuse, 2 for frost protection, 4 before repair and following shipping. 3 1. Empty water tank. 2. The machine is switched off: Press and hold On/Off button. 3. Simultaneously press coffee button three times. 4. Release both buttons. The coffee button starts blinking fast and 6 the thermoblock heats up, evaporating the residual water. 5. Open closing handle and hold it in opened position. 6. After coffee button stops blinking, press down closing handle completely. 7. Empty drip tray. After this procedure the machine is blocked for approx. 10 minutes (till thermoblock temperature < 100° C). 12 Service Manual C91 / D91 Version 1.0 ...
Operation Coffee machine status ( 1 H z ) Operating mode Coffee button LED signal After pressing the On/Off button, an automatic Off off self test is performed to check if the NTC is connected, Heat up (coffee) blinking slow the NTC is short circuited, the thermoblock reaches the standby temperature within 2 minutes in brewing Ready on mode. A detected failure is indicated by the back System too hot blinking fast lighted coffee button as well as the operating modes listed in the following table. Brew coffee / rinse blinking slow Heat up (descaling) blinking fast Descaling ready blinking fast Pump on (while descaling) blinking fast Emptying water system blinking fast ...
Troubleshooting Checking the machine on receipt Repair any faults found and check if the appropriate repair action. The receipt check enables you to rapidly machine is operating perfectly. Follow the check procedure. locate faults on the machine and to initiate Check procedure Symptoms Action / repair work Further action / repair work YES Replace parts if necessary 1.1 Parts of housing broken or damaged NO Go to point 1.2 1 Check appliance for visible damage YES Replace mains cable 1.2 Mains cable damaged NO Plug machine to the mains and go to point 2.1 YES Go to point 2.2 YES Screw on closing handle screws at defined 2.1 Closing handle works correctly NO It is hard or impossible to close the closing handle torque or replace CBU (see page 22) 2 Check mechanical elements NO Replace the CBU YES Go to point 3 2.2 Is the capsule correctly ejected? NO Replace TCBU YES Replace water tank 3 Fill water tank 3.1 Water tank is leaking NO Go to point 4 YES Go to point b) YES a) Check if mains cable is functional NO Replace it YES Go to point c) YES b) Check if On/Off button is functional NO Replace it YES c) Check if pump is working (press coffee ...
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5.1 No coffee at outlet NO Go to point c) YES c) Machine is blocked by scale YES Descale machine (see page 36) 5 Check coffee temperature while preparing a coffee (see page 29) NO Go to point 5.2 YES Descale the machine (see page 36) 5.2 Temperature is too low (less than 83°C) NO Go to point 5.3 YES Change NTC (see page 18) 5.3 Temperature is too high (more than 89°C) NO Go to point 6 YES Replace TCBU (see page 22) 6.1 Leakage at extraction system NO Go to point 6.2 YES Replace defective tube and seal 6.2 Leakage at tubes connection NO Go to point 6.3 6 Check for leaks and check flow rate (see pages 25 and following) YES Descale machine (see page 36) YES Machine is scaled NO Replace pump 6.3 Flow rate out of range Contact Nespresso Technical Correspondant for NO No trouble found during the check procedure. further details in order to take decision YES Descale machine (see page 36) 7 Descaling process (if needed) 7.1 Machine scaled NO Go to point 8 8 Final cleaning (see page 38) End of check procedure 15 Service Manual C91 / D91 Version 1.0 en ...
Repair Safety instructions Risk of fatal electrical shock! Mains voltage inside the coffee machine. Disconnect the mains plug before disassembly the coffee machine must be free of voltage. Danger of burns! Hot parts and water under pressure inside the coffee machine (ther moblock in particular). Let coffee machine cool down before disassembly. General disassembly Tool: Torx screwdriver for security screws, PinTX 10 Procedure: 3. Place machine on the repairing/service holder device (see page 42). 1. Remove water tank (15) and drip tray (5) 4. Remove 6 screws (20) on the bottom of together with drip grid (4) and capsule the machine. container (6). Illustration of a PinTX screw head 5. Swing out and remove both side panels (1). 2. Remove 2 screws (20) on the front side of Empty water system if necessary the machine. 6. Remove lower chassis (2). (see page 12). 16 ...
Repair Replacing NTC Tools: Torx screwdriver PinTX10 Openended spanner 9 mm AF Torque wrench Procedure: 1. Follow general disassembly (see page 17). 2. Remove PCB housing (301). 3. Unplug NTC connector from electronic control board (300). 4. Remove defective NTC temperature sensor (219) from thermoblock (215) and replace it with a new one. 5. Assemble in reverse sequence. Reuse spring lock washer (220) and tighten new NTC temperature sensor (219) with torque wrench (140 160 Ncm). 17 Service Manual C91 / D91 Version 1.0 en ...
Repair Replacing thermoblock Tools: Torx screwdrivers PinTX10, TX20 Openended spanner 9 mm AF Torque wrench Procedure: 1. Follow general disassembly (see page 17). 2. Remove 3 screws (19) and separate ther moblock assembly from upper chassis (3). 3. Remove screw (222) and separate ther moblock from its support (216 + 217). 4. Remove 2 screws (224) and separate thermal fuses (parts of cord set 304) from thermoblock. 5. Remove PCB housing (301). 6. Unplug NTC connector from electronic control board (300). 7. Remove NTC temperature sensor (219) from thermoblock. 8. Remove clips (228) and 2 hose connec tors (211+212) from thermoblock. 9. Remove ground wire and electrical connections from thermoblock. 10. Replace thermoblock (215). 11. Assemble in reverse sequence. Use a torque wrench (140 160 Ncm) ...
Repair Replacing pump Tools: Torx screwdriver PinTX10 Longnose pliers Blade screwdriver, no. 7 Procedure: 1. Follow general disassembly (see page 17). 2. Remove clip (227), hose (205) and Oring (206). 3. Remove angled hose (204). 4. Release pump (208) first from rubber strap (213) at the side of the angled hose. 5. Remove electrical connections from pump. 6. Release pump from second rubber strap (213). 7. Replace defective pump (208). 8. Attach new pump (208) to one rubber strap with corner connector (209) first. 9. Plug in electrical connections on pump. Check for correct wiring of pump. 10. Attach pump to second rubber strap. 11. Insert new Oring (226), mount hose (205) and clamp (227). 12. ...
Repair Replacing electronic control board with button prints Tools: Torx screwdriver PinTX10 The service engineer must be earthed using an earthing strap! Only touch button prints with dedi cated gloves to avoid oxydation. Procedure: 1. Follow general disassembly (see page 17). 2. Detach prints of On/Off button (13) and coffee button (14) from upper chassis (3). 3. Remove 2 screws (19) and lift cover (7) at the front side to threadout cables with button prints. 4. Remove housing (301) from electronic control board (300). 5. Unplug NTC connector and all wires from electronic control board (300). 6. Remove 2 screws (20) and replace defect electronic control board with button prints. 7. Assemble in reverse sequence. Check for correct wiring of electronic control board (see page 23). 20 Service Manual C91 / D91 Version 1.0 en ...
Repair Replacing compact brewing unit Tools: Torx screwdriver PinTX10 Blade screwdriver no. 4 Longnose pliers Torque wrench Procedure: 1. Remove water tank (15) and drip tray (5) together with drip grid (4) and capsule container (6). 2. Place machine on the repairing/service holder device (see page 42). 3. Remove 4 screws (20) on the bottom of the machine. 4. Swing out and remove both side panels (1). 5. Remove 2 screws (21) and pull off closing handle (8). 6. Remove 2 screws (19) at the front and 1 screw (19) at the back to detach cover (7). C91 machine: All screws have the same lenght. D91 machine: The screw at the back Tighten new closing handle screws 9. Remove clip (227) and hose (206) with O is longer than those at the front. (21) with a torque of 200 Ncm. ring (226) from compact brewing unit. 7. Unlatch coffee outlet (9) from compact 10. ...
Repair Wiring diagram Europe (230V / 50 Hz) 1) Heat sink 2) Print for On/Off button 1 3) Print for coffee button with LED 4) NTC temperature sensor 5) Thermal fuses on thermoblock 3 2 6) Thermal fuse on pump 5 6 22 Service Manual C91 / D91 Version 1.0 en ...
Function Tests Measuring flow rate (1) 2 1 Procedure: 3 1. Fill and insert water tank. 2. Open closing handle. 3. Insert connecting unit of pressure adapter into capsule bay. 4. Push back sealing cone into capsule cage. 5. Insert fixation unit of pressure adapter into capsule bay. 6. Press down operating lever. Continued on next page. 23 Service Manual C91 / D91 Version 1.0 en ...
Function Tests Measuring flow rate (2) 13 Procedure (continued): 7 7. Connect pressure hose to pressure tester. 8. Position measuring beaker underneath exit tube of pressure tester. 9. Switch on machine. 10. Press coffee button after heatingup. 12 9 11. Open valve fully till water begins to flow. 12. Close valve slowly until 12 bar are indi cated. The manometer must be observed 8 continuously and the pressure regu lated using the valve if necessary. With increasing temperature the pressure also increases, if neces sary readjust the pressure to 12 bar. 13. Perform measurement for approx. 30 sec. 14. There must be at least 60 120 ml water in the measuring beaker. Notice: With a flow of < 60 ml the pump is defective or there is a leak in the system. ...
Function Tests Checking for leaks and pump pressure (1) 2 3 The following components are checked for 4 leaks: Compact brewing unit (TCBU) Hose connections Thermoblock Pump 1 Preparation (unplug machine from mains): 1. Remove right side panel. 2. Open closing handle. 3. Insert connecting and fixation unit of pres sure adapter into capsule bay (refer to page 25). 4. Press down operating lever. 6 5. Position pot underneath exit tube of pres sure plug. 6. Fill and insert water tank. 7. Connect mains cable. Dangerous voltage inside coffee machine! Do not touch any live part while performing checks. Hot, pressurized parts inside coffee machine! Do not touch any hot part ...
Function Tests Checking for leaks and pump pressure (2) 9 Procedure (continued): 8. Switch on machine. Press coffee button 10 after heatingup. 9. Open valve and leave water to run out for approx. 10 sec. 10. Fully close valve. The pressure will rise 8 rapidly initially and stabilise between 16 19 bar (check of pump pressure). 8 The pressure will rise slowly due to the temperature increase. If the pressure exceeds 23 bar, the machine has to be switched off and pressure released through the pres sure valve. 11. Perform visual and acoustic checks on all pressurized connections. The pump must not be in operation for longer than 50 sec. without water 11 flow. 12 12. Switch off machine. 13. Open valve to empty pressure gauge. 26 Service Manual C91 / D91 Version 1.0 en ...
Function Tests Measuring coffee temperature Procedure: 1. Press On/Off button to switch on machine. 1 2. Position measuring beaker underneath coffee outlet. 3. After warming up, press coffee button. 4. Preheat coffee outlet for 10 sec. with hot 3 4 water. 5. Empty measuring beaker. 6. Insert a capsule (Cosi is the most suit 2 able). 7. Press coffee button. 8. Wait until 20 ml coffee has flown in the measuring beaker. 9. Measure the coffee temperature approx. 5 10 mm below the outlet opening. 6 Coffee temperature should be approx. 86 °C ± 3 °C (187 °F ± 5.4 °F). 9 7 5 27 Service Manual C91 / D91 Version 1.0 en ...
200 mA DC). nuity test. General Read and observe safety instruc Test equipment tions in user manual of test equip Legal regulation Special test equipment is needed that ment. In case of a repair/modification of the coffee complies with the regulations to perform machine, the repair centre is bound by law to This test sequence is not applicable protective earth continuity measurements. protect the user/consumer by for coffee machines with twowire Detailed requirements and tolerances must be restoring the regular condition of the appli power cords (without ground pin). verified by your local authorities or measure ance and ment supplier in any case. performing the respective tests according Nespresso for recommenda Continued on next page. to EN/IEC 603351 “Safety of household tions about test equipment. and similar electrical appliances” and national regulations (e.g. DIN VDE 0701). 28 Service Manual C91 / D91 Version 1.0 en ...
Function Tests Protective earth continuity test (2) Test sequence (continued): 1. Connect black measuring cable to ground pin of power plug with an alligator clip 1 (example shown: Swiss power plug). 2. Switch on test equipment and select protective earth continuity test. Symbolic illustration of test equip ment. 3. Touch thermoblock through one of the marked holes with tip of red test probe. 4. Press "measure" button and read off displayed resistance. The resistance must be lower than 0.3 Ohm. 5. Fill in measured value in a test report. Proceed with protective insulation test before reassembling the housing of the coffee machine. 4 What to do if the protective earth continuity test fails Check ground wire connection on thermoblock 3 (refer to wiring diagrams on page 23). 29 Service Manual C91 / D91 Version 1.0 en ...
Ideally the test equipment has a national restoring the regular condition of the appli Danger of electrical shock! power socket for testing, so that the coffee ance and machine can plugged in directly. Otherwise a performing the respective tests according • Do not touch tip of test probes. special shunt is necessary to connect the to EN/IEC 603351 “Safety of household • Do not touch metallic parts of coffee phase and neutral pin of the coffee machine’s and similar electrical appliances” and machine during test. power plug. national regulations (e.g. DIN VDE 0701). • Read and observe safety instructions Nespresso for recommenda in user manual of test equipment. tions about test equipment. Description The insulation test Continued on next page. assures that wiring and insulation of the coffee machine fullfill the normative 30 Service Manual C91 / D91 Version 1.0 en ...
Function Tests Protective insulation test (2) Test sequence (continued): 1. Connect the phase and neutral pin of the power plug together with a test adapter 2 (procured by the repair centre). A Swiss power plug is shown here as an example. 1 2. Connect the black measuring cable to the test adapter (see image). Use a short circuit plug or special alligator clips etc. as substitute for this test adapter. 3. Switch on test equipment and select an insulation test voltage of 500 V DC. Symbolic illustration of test equip ment. 4. Touch thermoblock through one of the marked holes with tip of red test probe. 5 5. Press "measure" button and read off displayed insulation resistance or test result. Continued on next page. 4 31 Service Manual C91 / D91 Version 1.0 en ...
Function Tests Protective insulation test (3) Test sequence (continued): The insulation resistance must be higher than 300 kOhm (300,000 Ohm). S ome test equipment displays test 7 passed or failed instead of the insu lation resistance. 6. Fill in measured value in a test report. 7. Touch closing handle screw with red test probe. Do not scratch surface of closing handle with probe tip. 8. Press "measure" button. 9. Read off displayed insulation resistance or test result. The insulation resistance must be higher than 300 kOhm (300,000 Ohm). What to do if the insulation test fails 10. Fill in measured value in a test report. 11. Switch off test equipment. Risk of damage! 12. Short red with black test probe to make A sparkover can damage the elec sure that test voltage is discharged. tronic control board and sensors etc. Assume that the coffee machine is defect after a failed insulation test. Check wiring and locate fault. After fault clearance proceed with trouble shooting check list (see page 14). 32 ...
Maintenance Descaling (1) Only use Nespresso decalcifier 2 never vinegar! Decalcifier is aggressive to surfaces. Immediately clean drops of descaling solution. 3 Preparation: 1 1. Switch off machine. 2. Check that there is no capsule in inlet and close handle. 3. Remove drip grid. Empty drip tray and capsule container. 4. Reinsert drip tray and place a pot on it. Carefully read safety instructions on decalcifier package. 6 5. Fill measuring jug with 0.5 l fresh, potable water and pour 0.1 l descaling fluid in it. 6. Fill descaling solution in water tank. Reinsert water tank. 7. Press On/Off button and coffee button 7 simultaneously for at least 3 seconds to 5 switch on machine and start descaling 9 7 mode (fast blinking coffee button). Descaling: ...
Maintenance Descaling (2) 10. Fill water tank again with descaling solu tion from pot. 10 11. Repeat descaling procedure one more time: Press coffee button and let entire descaling solution run through. Rinsing: 12. Empty pot. 13. Rinse water tank thoroughly and fill it with 11 fresh water. 12 14. Place pot on drip tray. 15. Press coffee button to start pump. Let complete content of water tank run through coffee outlet. 16. Switch off machine. Descaling is completed. 17. Remove and empty pot. 13 18. Clean machine. 16 17 14 15 34 Service Manual C91 / D91 Version 1.0 en ...
Maintenance Daily care and final cleaning 1 Risk of fatal electrical shock and fire! 2 Never clean wet or immerse plug, cord or appliance in any fluid. Unplug appliance and let it cool down to avoid burns. Never use hard cleaning brushes and/or cleaning agents that contain aggressive or chemical components resp. solvents. Do not put any part in a dishwasher. Preferably use only a damp cloth or sponge and a mild cleaning agent if necessary. Do not use a brush to clean the water tank it could be scratched. Procedure: 1. Eject capsule. 2) Empty capsule container. 3) Empty water tank and drip tray. 3 4) Clean water tank and drip tray. 35 Service Manual C91 / D91 Version 1.0 en ...
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Maintenance 5 6 Procedure (continued): 5) Fill tank with fresh water. 6) Reassemble coffe machine. 7) Press On/Off button. Wait till coffee button stops blinking. 8) Press coffee button and rinse coffe outlet for 10 sec. 7 9. Clean coffee machine. 8 36 Service Manual C91 / D91 Version 1.0 en ...
Spare Parts Repair accessories Pos. EFR No. Component Repairing/service holder device 1 * (for C91or D91) 2 42213 Manometer 3 60460 Pressure adapter G4 1 3 64373 Spare part seal G4 * Repair accessories only available at Nespresso . Please ask your Nespresso technical contact person. Manometer and pressure adapter are avail able at Eugster Frismag AG 2 37 Service Manual C91 / D91 Version 1.0 en ...