BRAVILOR BONAMAT Aurora Single Low Instruction sheet

OPERATING PRINCIPLE
Thermal brewers
Aurora
SINGLE LOW (SGL) TWIN LOW (TWL)
SINGLE HIGH (SGH) TWIN HIGH (TWH)

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No part of this document may be copied and/or published by means of printing, photocopy, microlm or by any
other means without the prior written consent of the manufacturer. This also applies to the included drawings and/or
diagrams.
The information in this document is based on data that was available at the time the design, the material
characteristics and the operating methods were published, meaning that this document is subject to change. For
this reason the instructions given only serve as a guideline for installation, maintenance and repair of the machine
mentioned on the cover of this document.
This document applies to the standard version of this machine. The manufacturer therefore declines all liability for
any damage arising from specications that deviate from the standard version of the machine delivered to you.
This document has been compiled with the utmost care. However, the manufacturer cannot be held liable for any
errors it contains or the consequences thereof.

Table of Contents
1. General operation .......................................................1
2. Water dosing system .....................................................2
3. Start up ................................................................4
3.1 Initialisation ...........................................................4
3.2 Installation............................................................4
3.3 Fill ..................................................................4
3.4 Boiling point determination programme .....................................5
3.5 Heating ..............................................................6
3.6 Dosing...............................................................6
4. Extract .................................................................9
5. Recipes ...............................................................10
5.1 Recipe settings .......................................................10
5.2 Recipe build-up .......................................................11
5.3 Default recipes .......................................................11
5.4 Programme recipes....................................................12
5.5 Adjust recipes ........................................................12
5.6 Upload/download recipes ...............................................12
6. RFID..................................................................13
7. Hot water tap ..........................................................14
7.1 Tap hot water while making coffee ........................................14
8. Descaling signal........................................................15
8.1 Descaling signal set based on the hardness of the water.......................15
8.2 Active descaling signal .................................................15
9. Switched-mode power supply ............................................16
9.1 Operation of switched-mode power supply..................................16
10. Operating system.......................................................17
10.1 Touch screen display ..................................................17
10.2 Mainboard ...........................................................17
11. Hardware protection ....................................................18
11.1 Overow protection ....................................................18
11.2 Back-ow protection ...................................................18
11.3 Boiling protection .....................................................18
11.4 Boil-dry protection .....................................................18
12. Software protection .....................................................19
13. Programming ..........................................................21
13.1 User menu ..........................................................21
13.2 Chief menu ..........................................................22

Table of Figures
Fig.1 Water dosing system ....................................................2
Fig.2 Hot water outlet.........................................................2
Fig.3 Float tank .............................................................3
Fig.4 Boiler.................................................................3
Fig.5 Hot water selector.......................................................3
Fig.6 Boiling point determination programme ......................................5
Fig.7 Pump motor + rotor......................................................6
Fig.8 Pump housing..........................................................6
Fig.9 Encoder ..............................................................7
Fig.10 Water selector intern.....................................................7
Fig.11 Water distribution disc with magnets ........................................7
Fig.12 Bypass ...............................................................7
Fig.13 Position for coffee .......................................................8
Fig.14 Water selector components ...............................................8
Fig.15 Recipe build-up........................................................11
Fig.16 Place for holding the RFID card ...........................................13
Fig.17 Hot water tap .........................................................14
Fig.18 Hot water hose connections ..............................................14
Fig.19 Descaling setting table ..................................................15
Fig.20 Water hardness conversion table ..........................................15
Fig.21 Switched-mode power supply.............................................16
Fig.22 Touch screen display ...................................................17
Fig.23 Display with error message ..............................................19

1
1. General operation
The machine works according to a pump system developed by Bravilor Bonamat.
This system has the following advantages:
• Many of the parts ensuring correct dosing of the water are in a cold water circuit.
This minimises the main cause of failures, being the forming of scale on the dosing valves.
• The oat regulating the water level is also in the cold water circuit.
This also minimises scaling.

2
2. Water dosing system
After having started a selection, the pump motor is controlled with a regulated time and speed.
The pump rotor moves a certain amount of cold water from the cold water reservoir to the bottom
of the boiler. This pushes the hot water in the boiler up towards the water selector. This selector
chooses its position by means of a rotating movement. Dependent on the recipe, the water
selector will also dose through the bypass and therefore choose a different position.
5
4
3
2
1
Fig.1 Water dosing system
C
B
A
Fig.2 Hot water outlet

3
The water dosing system consists of the following main components:
1. Magnetic valve
2. Hot water outlet (Fig.2)
2a. Hot water outlet
2b. Tap including switch
2c. Hot water valve
3. Float tank (Fig.3)
3a. Float
3b. Pump motor
3c. Pump rotor
3d. Encoder
4. Boiler (Fig.4)
4a. Element
4b. Temperature sensor (NTC)
4c. Clixon
5. Hot water selector (Fig.5)
5a. Water selector motor
5b. Water distribution disc
5c. Hall sensor
5d. Top cover water selector (including
electrodes for scaling detection)
D
A
B
C
Fig.3 Float tank
A
C
B
Fig.4 Boiler
D
C
B
A
Fig.5 Hot water selector

4
3. Start up
3.1 Initialisation
The machine is switched on using the main switch. The display shows the version number of
the software downloaded in the factory and after this the display will show all symbols and “init”
to indicate that the machine starts initialisation. During this initialisation, the machine will run a
standard routine to make sure that a number of essential components have been connected and
are operating correctly. The machine will generate an error when a component has not been
connected for any reason or is defective. When everything goes well, this process will take about
15 seconds.
3.2 Installation
When switching on the machine for the rst time, the installation programme “rst start” must be
run. The machine will have to run its boiling point determination programme and while running
this programme, hot water can come out of the outlet (see 3.4). Calibrate the pump motor after
having run the boiling point determination programme.
This calibration will take place in 2 steps:
1. The machine will calibrate the pump motor for dosing on the coffee.
The machine will dose through the lter pan. Collect the quantity of water to be dosed and
enter this into the display.
Repeat the procedure when the quantity deviates too much.
2. The machine will now calibrate the pump motor for dosing on the coffee and tapping hot
water at the same time.
The machine will now dose through the lter pan as well as through the hot water tap.
Collect the quantity dosed through the lter pan and enter this quantity in the display.
Repeat the procedure when the quantity deviates too much.
When both calibrations have been done, the machine is ready for use.
3.3 Fill
The oat tank and the boiler are connected by a siphon hose. Together they form communicating
vessels.
When the machine is switched on for the rst time, the oat tank is (Fig.3) empty and the oat
(Fig.3,A) is its low.
• The magnetic valve (Fig.1) is opened and lls the oat tank with a pressure-independent
speed with water. This lling speed is type-dependent, being 5 litres per minute for the Twin
version and 6 litres per minute for the Single version.
• The water in the oat tank runs through the hose below the oat tank to the boiler.
• After the water level has pushed up the oat, the water level in the oat tank is equal to that of
the boiler. The magnetic valve is switched off.
If the machine is a Twin version, the other side will now be lled following the same procedure.
Note:
► As the oat tank lls up faster than the water ‘drops’ into the boiler, the lling process will
take place with short intervals.

5
3.4 Boiling point determination programme
Hot water may come out of the lter pan while running this programme.
The machine automatically only runs the boiling point determination programme when using the
machine for the rst time. The boiling point of the water is now determined. This is necessary
because the boiling point depends on the local atmospheric pressure. The boiling point at sea
level will be about 100°C, whereas the boiling will drop to about 97°C at an altitude of 2000m.
After having switched on the mains voltage, the water in the boiler will rst be heated to about
75°C at full power (Fig.6,A).
Then the water in the boiler will be heated with reduced power to 85°C. During this period, the
software will measure how quickly the water is heated.
Based on this measurement, the machine will heat up with a certain power until the temperature
sensor on the outside of the boiler has not detected a temperature change for some minutes
(Fig.6,B). After this period, the boiling point has been reached and the measured value is saved in
the software.
The nal operating temperature in the boiler will be 3°C below this point. Because the boiling
point of water depends on the atmospheric pressure, it is necessary to run this programme at the
location where the machine will be used. During the boiling programme, the display shows the
current temperature with below this a ashing thermometer and a changing, increasing volume.
After a certain period (dependent on the power the machine has been connected to), the
thermometer stops ashing to indicate that the boiling point has been determined.
Note:
► While running the boiling point determination programme, it is very important that no
panels have been removed from the machine.
The fact is that this may inuence the measurement and so cause a deviation in the
temperature during normal use.
0
10
20
30
40
50
60
70
80
90
100
110
T (ºC)
t
B
A
Fig.6 Boiling point determination programme

6
3.5 Heating
Now the system has been completely lled with water, a relays will enable the element.
The machine has been provided with a smart boiler routine, which basically works as follows:
• The lower temperature sensor measures the current temperature of the water.
The temperature sensor makes sure that the water in the boiler is heated to the desired nal
temperature.
• The centre temperature sensor is responsible for releasing or not releasing the selections
volume 2 and volume 3 for dosing.
• The upper temperature sensor is responsible for releasing or not releasing the volume 1
selection for dosing (if set, the airpot selection will be released as well).
• The heating switches off when the set temperature has been reached. Hot water has a lower
specic weight than cold water. As a result, the hot water in the boiler will not ow back to the
oat tank through the siphon hose at the bottom. Therefore this part of the system will remain
cold. This is very important because the parts in the oat tank are sensitive to scaling.
3.6 Dosing
Dosing takes place when:
• The oat is in the upper position.
• The uppermost temperature sensor measures a temperature higher than the blocking
temperature.
• After having started a recipe, the pump motor (Fig.7) will for a certain period be controlled with
a set speed (rpm), dependent on the programmed recipe.
Fig.7 Pump motor + rotor Fig.8 Pump housing
• The pump rotor rotates in the pump chamber that has been lled with water.
This is formed by the bottom of the oat tank and the bottom of the pump housing (Fig.8).
• The pump rotor pumps the water out of the pump chamber through the siphon hose at the
bottom of the boiler.
• This presses the hot water out of the boiler.
• The oat and the magnetic valve make sure that the correct level of water in the oat tank is
maintained and so water remains in the pump chamber.

7
The volume of moved liquid (output) is mainly determined by the time and speed of the pump
motor. The software controls the time that the motor is on and this is very precise. The rotational
speed of the motor is measured by an active revolution counter. Fig.9 shows that a disc has been
mounted on the shaft of the pump motor (A=Encoder). This disc rotates at the same speed as the
pump rotor. The encoder rotates between a light sensor (B) and interrupts a light beam each time.
The interruption of the light beam is converted into electronically readable pulses.
A
B
Fig.9 Encoder Fig.10 Water selector intern
This actively controls the rotational speed in order to guarantee that the rotational speed and
therefore the water output remains constant during the time that the pump motor is on.
Select the dosed hot water:
• This machine has a hot water selector (Fig.10).
• This part is responsible for distributing the dosed water from the boiler in 2 directions, through
the lter (for the coffee) or through the bypass (passing by the lter and the coffee).
Fig.11 Water distribution disc with magnets Fig.12 Bypass
After the machine has been switched on, the water selector will go to the home position following
the procedure below:
• The water selector motor is controlled.
• This motor drives the water distribution disc with a plastic worm (Fig.10).
• The water distribution disc has 3 magnets (Fig.11) 2 of which are close together. The hall
sensor detects all these magnets (Fig.5,C).
• The water distribution disc will always rotate min. 360 degrees to determine its position.
The position for dosing through the bypass during the start-up of the machine is the home
position (Fig.10).

8
B
A
Fig.13 Position for coffee
Operation of the water selector when starting to make coffee:
• When a selection is made, the water selector motor is controlled. When the hall sensor
(Fig.13,A) detects the magnets that are close together (Fig.13,B), the position for dosing on
the coffee is determined.
• After the position has been determined, the pump motor is controlled.
• The dosed hot water is pumped into the top of the water selector (Fig.14,A).
• The water runs through the central hole of the distribution disc (Fig.14,B). Then it exits through
the oblique hole at the bottom (Fig.14,C).
• Dependent on the recipe settings, the water selector can switch between dosing on the coffee
and dosing through the bypass. This can be done several times while making coffee.
Note:
► As soon as the water selector switches between dosing on the coffee or through the
bypass, the pump will be switched off until the water selector has determined its position
again.
A
C
B
Fig.14 Water selector components

9
4. Extract
The water that is pumped through the spray head falls on the coffee. This water seeps down
through the coffee and the lter paper. The basket in the lter pan prevents the lter paper from
sticking to the bottom and the coffee from owing to the outlet. The extraction of the coffee takes
place during this process.
The extraction can be inuenced in various ways. See the following chapter for this.

10
5. Recipes
With the Aurora it is possible to create own recipes for the extraction and strength of the coffee to
your own taste.
For example, with these recipes you can vary the contact time, the strength and the temperature
of the coffee. It is also possible to vary the dosing of water in different quantities and phases with
various intervals.
• The contact time of the water with the coffee can be inuenced by making the pump dose
slowly (20ml/sec) or quickly (30ml/sec).
• The boiler temperature can be set separately for each recipe between 85°C and 97°C.
• Water dosing quantities and waiting times can be entered by means of “pre-infusion” and
different “Pulse Brew” programmes.
It is also possible to dose water outside the lter (also called bypass). This water will therefore
be mixed with the made coffee and in this way the solution and strength of the coffee can be
inuenced.
All these variables have their inuence on the nal result.
In the machine a total of 25 recipes can be stored and each recipe can be given its own name.
Each recipe consists of 3 volumes that can be selected for making coffee. For the low version of
the Aurora also a fourth volume can be selected, being the airpot (2,2 litres).
5.1 Recipe settings
The variables that can be programmed in each recipe are:
• Coffee volume.
• The quantity of lost water in percentages (this refers to the water that remains behind in the
coffee).
• The temperature of the water.
• The pump speed with which the water is dosed on the coffee. The speed can be set
separately for the various programmes between low (20ml/sec) and high (30ml/sec).
• Pre-infusion, the rst dosing programme for dosing the water on the coffee. This function is
optional and the volume can be set between 100ml and 1000ml as well as the waiting time
before the start of the next dosing.
• Various water dosing programmes PB1, PB2 and PB3 (also called the “Pulse Brew”
programmes). For these pulse brew programmes different settings can be used for the volume
and the waiting times. For each pulse brew programme 1 dosing volume can be set, but this
can be dosed several times with waiting times between the dosings.
• It is possible, though, to use other volumes between the various pulse brew programmes.
• Drip time in seconds.
The bypass is not a variable that is to be entered, but the quantity of water that is to be dosed for
this depends on the other settings. After having entered each dosing programme, the display will
show how much water will be dosed through the bypass. If another dosing programme is entered
as well, the quantity for the bypass will be adjusted again. The quantity of water for the bypass
will always be dosed during the waiting times.
Eventually, the settings mentioned above will more or less inuence the taste of the coffee.

11
5.2 Recipe build-up
Below an example is given of how a recipe can be built up:
Fig.15 Recipe build-up
The above-mentioned recipe can be fully calculated. See below for an example:
• The coffee volume has been set to 2000ml.
• The quantity of lost water has been set to 10% (the percentage may differ for each coffee
type or the ground of the coffee).
• The machine will now dose a total volume of 2200ml water (2000ml + 10% = 2200ml).
Now it is known how much water the machine will dose and the various programmes can be used
for this.
• Pre-infusion has been set to 500ml.
• P1 has been set to 400ml and to 4x dosing (therefore here 4 x 400ml = 1600ml will be dosed
with a set interval of 10 seconds between the 4 dosings).
The machine will now dose 500ml (Pre-infusion) + 1600ml (P1) = 2100ml water on the coffee.
In this example also 100ml will be dosed through the bypass.
2200ml (total volume) – 2100ml (set dosed volume) = 100ml.
The 100ml. (for the bypass) will be dosed in the waiting times.
The water dosing time can also be calculated based on the pump speed and the waiting times.
The correct drip time is to be determined by experience.
The total set time for the coffee = water dosing time + drip time.
5.3 Default recipes
A number of default recipes have been programmed in the factory.
These recipes can be used for making coffee immediately after installation.
3 different volumes have been programmed for each recipe.
Of course, the results of these recipes depend on various factors, such as the ground of the
coffee, the quantity of coffee, the roasting of the coffee, etc.
If required, these recipes can be adjusted using the programme “change recipe”.

12
5.4 Programme recipes
There are 2 programmes for programming recipes, being build and program.
BUILD:
When using “build”, you can enter all variables yourself.
When all 3 volumes have been programmed, the recipe is saved.
Now coffee can be made using this recipe and you can determine if you like the recipe. After the
recipe has been saved, it can be adjusted in the programme “change recipe”.
PROGRAM:
When using “program” coffee will be actually made.
A limited number of settings is to be entered.
These settings are:
• Total quantity of water.
• The quantity of lost water in percentages (this refers to the water that remains behind in the
coffee).
• The temperature of the water.
• The pump speed for dosing.
• Pre-infusion (optional), the volume and the waiting time for this.
• Volume for the pulse brew programme.
The waiting times between the dosings and the drip time are determined by the creator of the
recipe. As soon as the machine has nished dosing, the waiting time starts. The waiting time is
determined by pressing the display and the next dosing will be started, if required.
Any dosing through the bypass will be dosed at the end of this programme.
This dosing through the bypass will with normal use just be given during the waiting times
between the various dosings.
If required, these recipes can be adjusted using the programme “change recipe”.
5.5 Adjust recipes
If required, saved recipes can at all times be adjusted using the programme “change recipe”.
The various settings can be given a different value.
5.6 Upload/download recipes
Recipes can be uploaded from a machine to an RFID card using “upload” and then you can
download this recipe using “download” to any other Aurora machine.
One single recipe can be uploaded from a machine to an RFID card, but it is also possible to
upload all recipes in one go to an RFID card. The latter is called “bulk recipes”.

13
6. RFID
RFID (Radio Frequency identication) is a wireless system that uses radio frequency and
electromagnetic elds to transfer data, without using any wires or batteries.
Settings and recipes can be transferred from a machine to an RFID card and vice versa. Recipes
and/or settings can be transferred and recipes can be overwritten.
The RFID print is found on the left side of the machine (Fig.16).
For transferring data, hold the RFID card against the machine at the place intended for this.
Fig.16 Place for holding the RFID card
Transferring data can only be done by going to the relevant setting in the programme.
Note:
► If several recipes are transferred at once using an RFID card (bulk recipes), all existing
recipes will be overwritten and be lost.
Before actually overwriting the existing recipes, the display shows a message that needs
conrmation. This message offers the possibility to cancel the overwriting of the existing
recipes.

14
7. Hot water tap
The Aurora has a hot water tap (Fig.17).
This tap can be found on the front side of the machine.
Fig.17 Hot water tap Fig.18 Hot water hose connections
The hot water tap has been connected to the same boiler as used for the coffee. With a Twin
version this will be connected to the left boiler. The temperature of the hot water is determined by
the setting of the used default recipe for coffee.
Operating the lever of the tap activates a switch behind the panel. This will generate a signal to
the mainboard which in its turn will open the hot water valve and control the pump motor. Then
hot water will ow out of the hot water outlet. The oat and the magnetic valve make sure that the
level in the oat tank is maintained, so there will always be water in the hot water hose. As soon
as the lever is released, the hot water valve will close and the pump motor will be switched off.
In order to make sure that the water in the hose between the boiler and the valve does not cool
down when no hot water is tapped for some time, 2 hoses have been connected from the boiler
(Fig.18) to a Y-piece for the hot water valve. The thickest hose is connected highest on the boiler;
the thin hose is connected to the boiler about 15cm lower. As soon as the hot water valve is
closed, the water will start circulating. This will happen because the colder surrounding air will
cool the water in the hose. The cooled water will ow back into the boiler and the hot water will
ow from the boiler into the other hose. In this way the temperature of the water will remain more
or less constant.
7.1 Tap hot water while making coffee
As for making coffee and for tapping hot water the same pump motor and boiler are used,
normally the dosing would deviate. Still it is possible to tap hot water while making coffee without
causing a deviation in the dosing.
While making coffee the pump motor runs at a certain speed.
When hot water is tapped and the pump motor maintains its speed, the dosing for the coffee
would change.
This problem is solved by simultaneous calibration of the dosing during the rst installation.
When the calibration has been performed correctly, the pump motor will start running faster at
the moment that simultaneous dosing takes place. When, for example, coffee is made, the pump
motor runs at a certain speed. When the hot water tap is operated too, the pump motor will start
running at a higher speed to make sure that no dosing deviations will occur. The pump motor will
start running at its lower speed again after the hot water tap has been released.

15
8. Descaling signal
The machine has 2 different descaling signals:
• Descaling signal set based on the hardness of the water (continuous descaling symbol).
• Active descaling signal (ashing descaling symbol).
8.1 Descaling signal set based on the hardness of the water
Bravilor Bonamat BV recommends to correctly set this setting using the table in the manual or the
table given below (Fig.19). The correct setting is to be set, because this can prevent excessive
scaling on parts as much as possible. For setting the descaling signal based on the hardness of
the water it is important to know the correct hardness of the water at the location the machine
is used. If necessary, ask the local water company for the hardness of the water supplied or
measure the harness of the water supplied on the spot. Enter the correct setting during the rst
installation. The registration of the number of litres running through the system is measured
as the machine continuously registers how long the inlet valve is open. The inlet valve has a
certain ow rate and this ow rate is independent of the pressure between 1 and 10 bar. This
ow rate multiplied by the time that the inlet valve has been open is the number of litres that
has run through the system. When the number of registered litres is higher than or equal to the
programmed value, the descaling symbol will light up continuously on the LCD.
18 - 30 °dH = 32 - 55 °TH 250 L. 66 Gal.
12 - 18 °dH = 22 - 32 °TH 500 L. 132 Gal.
8 - 12 °dH = 15 - 22 °TH 1000 L. 264 Gal.
4 - 8 °dH = 7 - 15 °TH 1500 L. 396 Gal.
0 - 4 °dH = 0 - 7 °TH 2000 L. 528 Gal.
Fig.19 Descaling setting table
°dH / dGh °e / °Clarck °fH / °TH ppm gpg mmol/l
1 °dH / dGh 1 1.253 1.78 17.8 1.04 0.179
1 °e / °Clarck 0.798 1 1.43 14,3 0.83 0.142
1 °fH / °TH 0.560 0.702 1 10 0.58 0.1
1 ppm 0.056 0.07 0.1 1 0.058 0.01
1 gpg 0.96 1.2 1,71 17,1 1 0.169
1 mmol/l 5.6 7.02 10 100 5.85 1
Fig.20 Water hardness conversion table
8.2 Active descaling signal
Depending on the use and water hardness, scale will be formed in the spray head in the course of
time. The more scale builds up, the slower the water ows out of the spray container. Eventually
the water will come into contact with the electrodes in the spray head.
A measurement will take place between these electrodes after each water dosing programme of a
recipe.
When the electrodes in the spray head make contact, the descaling symbol will start ashing in
the display after a water dosing programme.
When starting a new recipe, the descaling symbol will be reset until the electrodes make contact
again. When the machine has been descaled, the water level drops fast enough from the spray
container and the descaling signal will stop ashing.

16
9. Switched-mode power supply
The input voltage (mains voltage) supplied to the switched-mode power supply (Fig.21) may vary
between 115VAC and 240VAC.
The output voltage of the switched-mode power supply is about 24VDC and it is independent of
the input voltage as long as this is between 115VAC and 240VAC.
9.1 Operation of switched-mode power supply
The input voltage (mains voltage) is an alternating voltage, which is rectied and smoothed by the
switched-mode power supply.
This rectied voltage is supplied to the primary coil of the transformer by means of a high-
frequency pulsating electronic circuit.
The transformation ratio of this transformer determines the output voltage and the voltage coming
from the secondary coil will be a (lower) alternating voltage.
This (lower) alternating voltage is then rectied and smoothed again, making the output voltage of
the switched-mode power supply a rectied voltage.
However, by measuring the output voltage of the switched-mode power supply this can be
adjusted if necessary.
This adjustment is done by varying the high-frequency pulsating electronic circuit at the primary
coil of the transformer.
Due to this, it does not matter if the input voltage is 115VAC or 240VAC or somewhere in
between. The switched-mode power supply has been externally secured with two 4A fuses.
Fig.21 Switched-mode power supply