BODECKER BREWED BREWER User manual

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MANUAL
North America
Issue No.7
July, 2007
…Simply consistent,
Consistently simple…

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TABLE OF CONTENTS
• INTRODUCTION 3 - 5
6 - 7
8 - 10
11 - 12
13 - 16
17 - 20
21 - 25
26 - 42
43 - 45
46 - 48
49 - 51
52 - 61
62 - 63
64 - 68
69 - 70
71 - 72
• UNPACKING AND INSPECTING
• SPECIFICATIONS
• PLUMBER’S INSTALLATION
• SET UP
• PROGRAMMING
• TROUBLESHOOTING
• PARTS AND SETTINGS
• POUR OVER ATTACHMENT
• BASE UNIT
• FREE STANDING BASE UNIT
• VENDING APPLICATION
• SPACE SAVER
• CARE AND CLEANING
• PARTS LIST
• WARRANTY

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INTRODUCTION

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Thank you for choosing the Bodecker concept for your single service coffee program.
Today we are going to explain to you the features of the Bodecker machine, its general
construction and how to utilize these features.
In observing the brewer you will note its low profile and compact design of The Display
Unit. We have a convenient shuttle and simplicity of inserting the Bob cup. Once in
place we simply push the shuttle to the loaded position and the ready light will display
green. You may now select from the 3 cup sizes, short, tall, or regular. The
illuminated panel will now tell you the duration of the brew cycle and count down to
the completion of the cycle.
If, during the cycle, you press the button again the extraction cycle will stop. By pressing
the button again the cycle will start over again. This feature has been installed for
those who like steeped tea or a stronger brewed coffee. The second cycle allows for
longer extraction. Since the brewer will deliver an additional amount of liquid than
possibly required due to the second cycle, push the brew button again once the
desired amount of beverage has been delivered and it will stop. After a few uses the
custom brew feature will become second nature to the user resulting in more
satisfaction with your custom brew.

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You will notice that after each brewing cycle is completed air pump is engaged. Enough
air must be injected into the cup to dry the coffee, if it is not adequately dried the
ability to recycle the product is inhibited. This cycle may be adjusted as to time or
pressure thru the programming.
For those requiring hot water, it can be activated by pressing the red button. Hot water
will come out the red nozzle located in the center of the machine. Hot water will
continually be delivered as long as the red button is depressed. The brewer is
equipped with a drip tray designed to accommodate different sizes of cups. If
required the top portion may be slid from left to right to accommodate different sizes
of cups or may be removed entirely. The lower level may also be conveniently
removed for cleaning or to accommodate a coffeepot for larger consumption.
After a pre-determined number of brews have been completed (35 is the recommended
factory setting) the empty bin light will come on to indicate that no more product can
be made until such time as the refuse bin has been emptied. The bin may be emptied
by simply sliding the drip tray out of the way and pulling the bin from its position by
pulling on its handle located at the center top of the bin. Having emptied the bin the
limit switch will reset the brewer to the predetermined level upon inserting the bin
back into its proper position. The adjoining display stand will hold 20 sleeves of
coffee and associated products as chosen by the user. The sleeves are designed to
slip in and out, as replacements are required and to assure fresh products at all
times.

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UNPACKING AND INSPECTING

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CAUTION
Do Not connect the machine power cord or attempt to operate the Bodecker
Brewed System before it is completely inspected and the power supply is
checked for proper voltage and grounding.
UNPACKING AND INSPECTING
Verify the model and part numbers with the Bodecker Brewed System invoice or freight
bill; immediately report any shortage or discrepancy with the carrier. Remove all
shipping and packing materials. Save all shipping and packing materials until a
thorough inspection has been completed. Examine the Bodecker Brewed System for
dents, scratches or other damage resulting from improper handling. If any shipping
damage is detected, file an immediate claim with the carrier.
ELECTRICAL PROVISIONS
A wall outlet, capable of delivering 120-volts, 60 Hz, single phase must be available
within six feet of the Bodecker Brewed System. Check the outlet for proper grounding
and breaker to be at least 15 Amps.
WARNING
Bodecker Brewed System is intended for indoor use only.

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SPECIFICATIONS

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PLUMBER'S INSTALLATION
INSTRUCTIONS

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1) Plumb brewer in to water supply using 1/4 inch copper tubing. Flush
water line before installing brewer to remove sediment. Brewer
should be connected to COLD WATER LINE for best operation.
2) Water pressure should be at least 20 lbs. For less than a 25 ft run,
use 1/4" tubing and connect to 1/2" or larger water line. The inlet
water fitting on the back of the brewer is a 1/4" flare fitting.
3) If installed with saddle valve, the valve should have a minimum of
1/8" port hole for up to 25 ft run, and 5/16" port hole for over 25 ft
runs.
4) Connect incoming water line to the elbow extending from the
solenoid water valve at the back of the brewer.
5)An approved water filter is recommended for all installations

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SET UP

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WARNING: - Read and follow installation / setup instructions before plugging or wiring in
machine to electrical circuit. Warranty will be void if machine is connected to any
voltage other than that specified on the name plate.
Initial Setup Instructions
1) Plug or wire brewer to the appropriate voltage circuit as indicated on the serial tag.
Depress the "On/Off" (power) switch to supply power to the control board and the
tank will begin to fill, segments of display will cycle in an hourglass pattern to indicate
brewer is operational. The tank lid has a probe in it to signal the control board when
the water has reached the appropriate level to begin heating cycle. If this probe does
not see water for 3 minutes the control board will interpret this as an error. It will
shutoff the solenoid valve, disable the control board and display “H20”. After
supplying water to the brewer you have to power it off and on to clear error message.
NOT READY CONDITIONS
While the tank is filling it is a good time to see display of “Not Ready Messages”. Depress
one of the brew buttons. “CUP” will be displayed momentarily in the display window.
This indicates that a Bob cup must be put in place before brewing can begin. Install a
Bob cup to overcome this error. Depress one of the brew buttons again. “H20” is
displayed indicating that the water level in the tank is too low to brew (assuming that
tank has not finished filling already). Wait until solenoid shuts off to overcome this
error.

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Depress one of the brew buttons again. “Htr” is displayed indicating that the brewer
needs to heat before it is able to begin a brew cycle (assuming that tank has not
finished heating already). When tank finishes heating, this error will be corrected. For
purposes of brewing, the temperature is considered ready when it is within 10
degrees of set point.
Temperature still regulates at the set value however, a brew cycle can be started
regardless of water temperature by holding in the brew button for several seconds to
over ride temperature condition. Note that all other ready conditions must be met.
While waiting for the heater to finish heating, remove bin from brewer and push a
brew button. “bin” will display to indicate that a brew cycle will not take place because
bin is missing. Replace bin in brewer to overcome this error. A message of “UPS” is
also possible if the up switch is not depressed, indicating that the brew mech is in the
retracted position. This error should never be seen, if this does happened refer to
programming section. These are some of the ready conditions that must be met in
order for the ready light to come on and a brew cycle to be started. These messages
will be displayed for two seconds whenever a brew cycle is attempted if the error
noted exist. If multiple errors exist, the error condition will display one at a time with
the 2nd error condition appearing after the 1st condition is resolved. For instance if
you walk up to the Bodecker and try to brew without 1st putting a Bob cup in place it
will prompt you to insert a cup. Once that is done it may then prompt you to wait for it
to finish heating if it has just experienced heavy use or faucet activity. If no other
errors exist, the ready light will come on when unit reaches temperature.
On the next page we are showing proper placement of the roller bearing in the down
position. It should be slightly to the right of centre (about 1/32”) to lessen the amount
of torque required to start the up cycle. Failure to properly position roller bearing may
result in E6 error and requirement for service call.

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Cam on a brew motor must be set slightly to
the right. This is critical !

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PROGRAMMING

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These items apply to all programming functions:
Programming is entered on power up while holding hot water button. Top brew button
increments value. Middle brew button decrements value. Lower brew button
advances to next parameter to set within a function. Global programming functions –
Hold faucet button on power up. Settings apply to all brews. Bin counter setting –
Determines how many Bob cups can be brewed before the bin must be removed and
emptied to reset counter. May be turned off (if storage bin is not used) or set from 20
to 500 in increments of 5. Air pump run time – Determines how long air pump runs
after brew to remove excess liquid from system. Set from 1 to 30 seconds. Air pump
speed – Sets the air pump speed. Set from 1 to 10 with 10 being the maximum.
Calibration mode – This sequence is used to calibrate the electronics to the liquid
flow rate through the brew system. It DOES NOT set the flow rate. It simply tells the
control what the flow rate is. To calibrate the unit when CAL is displayed: Place a
graduated container in place below coffee dispense point, Place a Bob cup in place,
Press either of the two upper brew buttons, Brewer will dispense for 30 seconds, set
display to the volume in ounces delivered. Volume can be set in 1/10th oz
increments.
Brew Button Programming – Hold brew button to set up while powering up unit.
Brew volume – Set the desired product volume. Valid values are between 4 and 14 oz.
Service mode (you can enter it on power up while holding hot water button) and scroll to
service mode (tall button). Display shows “SRV”. Press either of the two upper brew
buttons to enter service mode. Service mode – Display shows “Srv”. This mode is
used to monitor temperature and verify functionality of thermistor, switches and probe
system. Service sub functions are as follows:

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•Display shows “SRV”. Press either of the two upper brew buttons to enter service mode (Regular or
Short).
•This mode is used to monitor temperature and verify functionality of thermistor, switches and probe
system.
•Once in the service mode display will show current temperature of water (not programmed temperature). If
there is the problem with temperature probe you will see following messages (instead of current
temperature) displayed.
•Temperature monitor
•“Shr” – Shorted Thermistor
•“Opn” – Open Thermistor
•“---“–OutofRange
•“xxx” – 150 – 225 (degrees F)
•By pressing (Regular or Short) buttons you will be able to monitor motor switches – Use increment
(Regular) and decrement (Short) buttons to control motor for testing. You will notice that brewing chamber
is moving up and down activating upper and lower limit switches which govern the position of the brewing
chamber at the same time display will change indicating current position as follows:
•“1:- -“ – Neither switch closed
•“1:U-“ – Up switch closed
•“1:-d” – Down switch closed
•“1:Ud“ – Up and down switches closed
•Pressing Tall button will allow you to monitor waste bin and Bob cup switches depending if they are
activated or not following message will be displayed:
•“2:- -“ – Neither switch closed
•“2:b-“ – Bin switch closed
•“2:-C” – Cup switch closed
•“2:bC“ – Bin and cup switches closed
•With Next service future (just press Tall button) is monitoring low and high water level probes in water
tank. They are sending command to open or close water solenoid. Depending on current water level in the
tank display will read:
•“3:- -“ – Neither probe active
•“3:L-“ – Low probe active closed
•“3:-H” – High probe active
•“3:LH“ – Low and high probes active
•Press Tall button (enter) to return to Service mode.

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ERROR CODES
E-1 Open thermistor
E-2 Shorted thermistor
E-3 Heater timeout
E-4 Fill timeout
E-5 Up switch timeout
E-6 Down switch timeout
E-7 Cup switch opened during brew cycle
Recommended programming settings:
Bin 35
Air pump time 5
Air pump speed 6
Calibration 7.5 for strong coffee (default setting) 10 for weaker coffee (flow regulator must be adjusted
to compensate for shorter brewing time)
Regular 8.0
Short 7.0
Tall 9.0
Set PDF valve to give out 8.0 fluid ounces of coffee when using Regular selection