BRAVILOR BONAMAT Bolero Series User manual

Original document by manufacturer
version 1.0
Technical manual - English
TECHNICAL MANUAL
Bolero

Original document by manufacturer
version 1.0
All rights reserved.
No part of this document may be copied and/or published by means of printing, photocopying, microlming or by any other means whatsoever 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 are merely a guideline for the installation, maintenance and repair of the machine shown on the front cover.
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.

Original document by manufacturer
version 1.0
Table of contents
1. Installation requirements .....................................................1
2. Spare parts replacement ......................................................2
2.1 Remove the door safety switch ................................................. 2
2.2 Remove the service panel - HMI board (Bolero 32, 33, 42 and 43) ................... 3
2.3 Remove the service panel - HMI board (Bolero 11 and 21) .......................... 3
2.4 Remove the fan motor ........................................................ 4
2.5 Remove the mixer motor ...................................................... 5
2.6 Remove the canister motor .................................................... 6
2.7 Remove the I/O board (Bolero 32, 33, 42 and 43) .................................. 7
2.8 Remove the inlet valve ........................................................ 7
2.9 Reset the temperature safety switches (Bolero 32, 33, 42 and 43) ................... 7
2.10 Reset the temperature safety switches (Bolero 11 and 21) ......................... 7
2.11 Remove the temperature sensor (NTC resistor) ................................... 8
2.12 Remove the boiler ............................................................ 8
2.13Removethepumpoattank ................................................... 9
2.14 Remove the water selector .................................................... 9
3. Warningsanderrors ........................................................ 10
3.1 Warnings ................................................................... 10
3.2 Errormessages ............................................................. 11
3.3 Other problems (user) ....................................................... 14
3.4 Other problems (dealer) ...................................................... 16
4. Special functions ........................................................... 18
4.1 Interrupt the descale program ................................................ 18
4.2 Master PIN-code ............................................................ 18
4.3 Savesettingsasdefaultandexportle ......................................... 19
4.4 Importleandsavesettingsasdefault ......................................... 21
4.5 Reset the machine counter (for refurbishment) .................................. 23
5. Additionaloptions.......................................................... 25
5.1 MDB service set ............................................................. 25
5.1.1 Installation for the Bolero 11 and 12........................................ 25
5.1.2 Installation for the Bolero 32, 33, 42 and 43 ................................. 27
5.2 Installationofacoldwaterkit ................................................. 29

6. Recipes.................................................................... 32
6.1 General volume ranges....................................................... 32
6.2 Bolero11(3kw) ............................................................. 32
6.2.1 Standardconguration ................................................... 32
6.2.2 Standard available beverages.............................................. 32
6.3 Bolero21(3kw) ............................................................. 33
6.3.1 Standardconguration ................................................... 33
6.3.2 Standard available beverages.............................................. 33
6.4 Bolero 32 and 33 ............................................................ 34
6.4.1 Standardconguration ................................................... 34
6.4.2 Standard available beverages.............................................. 34
6.5 Bolero 42 and 43 ............................................................ 35
6.5.1 Standardconguration ................................................... 35
6.5.2 Standard available beverages.............................................. 35
6.6 Available beverages of all libraries ............................................. 36
6.7 Building a recipe ............................................................ 40
6.7.1 1 sequence, 1 ingredient .................................................. 40
6.7.2 1 sequence, 2 ingredients ................................................. 41
6.7.3 2 sequences, 3 ingredients ................................................ 42
6.7.4 2 sequences, 2 ingredients ................................................ 43
6.7.5 3 sequences, 3 ingredients ................................................ 44
7. Additionalinformation ..................................................... 45
7.1 Identicationoftheappliance ................................................. 45
7.2 Replacing HMI board......................................................... 46

1
1. Installation requirements
To enable a smooth and simple installation of the Bolero machines please ensure the customer has the
following prepared:
• Ensure the electrical supply is situated within 1 meter of the machines proposed location.
• Ensure the power supply is correct for the ordered machines:
• Bolero 11 / 21 / 32 / 33 / 43
» 230V, 2230W, 13amp (or higher).
• Bolero 11 / 21 3KW
» 230V, 3100W, 14amp (or higher).
• Ensurethatthemachinetstheproposedlocation.
• Thewatersupplymustbecoldpotable(drinking)waterterminatinginashutovalvewithamale3/4”
connection. This must be within 1 meter of the machines proposed location.
• The water pressure must be between 1 - 10 bar.
NOTE:WaterpressuremustbemeasuredasstandingpressureAFTERanyttedwaterltration.
What the engineer can do:
• Upon arrival the fully trained engineer will complete the following;
• Unpackthemachineandinspectfortransitdamage.
• Install the machine in the proposed location.
• Connect the power and water supply to the machine.
• Connectawaterltrationsystemifordered.
• Commission the machine and complete a function test ensuring full operation.
• Setthemachineuptoastandardrecipeifnopresetrecipehasbeenspeciedinadvance.
• Makeadjustmentstobeveragestasteandsize(basedonthepersononsitepresentedasthemanagement
representative).
• Checkifthewatervolumedosageiscorrect,ifnot,acalibrationmustbeperformed.
• Trainstaonmachinemaintenance,cleaningandoperation.
• Leave the area tidy .
Ingredients you may need:
» Ingredientsshouldbeselectedbasedontasteprolesandsiterequirements.
» Onlyuseinstantingredientsthataresuitableforvendingmachines(containsaowingagent).
» Usetherecommendeddosageasindicatedonthepackaging.
►Always follow the local and national safety regulations and standards for electrical devices during installation.
►The contents of the safety booklet supplied with the machine must be known to both the engineer and the customer.
►The operator instructions can be downloaded from the Bravilor Bonamat website.

2
2. Spare parts replacement
►Precautionary measures
» Alwaysunplugthemachinetoturnothepowerbeforeopeningit.
» Turnothewatertapanddisconnectthewatersupplyhose.
» The service area can have sharp edges, wear gloves and long sleeves.
» WhentheBoleroisdrained,wateroutofthedrainhosescanbehot,thereforetakeprotectivemeasures.
Necessities:
• Philips screwdriver
• screwdrivers torx 10 and 15
• curved nose pliers
Reassembly remarks:
• see the exploded views for the service part numbers
• see the electric diagram for the wiring connections
►This chapter is based on the Bolero 43, the same procedures can be used for the Bolero 11, 21, 33 and 42 as well.
Should the procedure be dierent for another type such as the Bolero 43, it is indicated separately
Step1
• open the door
• remove the 4 screws Aof the print cover
• remove the cover of the print B
• remove the 2 screws Cofthesafetyswitchbracket
• remove the safety switch D
• disconnect the connector of the wiring
2.1 Removethedoorsafetyswitch
A
B
C
D
A
A
A

3
2.2 Removetheservicepanel-HMIboard(Bolero 32, 33, 42 and 43)
Step1
• open the door
• remove the print cover, see section2.1
• remove the wiring
• carefullydisconnecttheatcableofthetouchscreen
A
►Do not remove at cable of the display B
Step2
• remove the 2 screws of the service panel C
• pull the service panel towards you D
►See also the additional information in section 7.2
Replacing HMI boardonp.46
A
B
C
D
C
2.3 Removetheservicepanel-HMIboard(Bolero 11 and 21)
Step1
• open the door
• remove the print cover
• remove the wiring
• carefullydisconnecttheatcableofthetouchscreen
A
►Do not remove at cable of the display B
Step2
• remove the screw of the service panel C
• pull the service panel towards you D
►See also the additional information in section 7.2
Replacing HMI boardonp.46
B
A
C
D

4
2.4 Remove the fan motor
Step1
• remove the 6 screws Aofthebackpanel
• removethebackpanel B
Step2
• disconnect the connector from
the I/O board C
Step3
• open the fan grid D
• remove the fan rotor E
• disconnect the fan grid from the fan housing by
pressing the fastening together F
• lead the wiring with the connector through the
opening to the outside G
• remove the fan motor H
B
A
A
A
C
D
F
E
G
H

5
2.5 Remove the mixer motor
Step1
• closethe“yellow”sliderofthecanisteroutlets A
Step2
• remove the hose outlet Bfromthebracket
• turnthexationring Ccounter-clockwise
• remove the mixing unit D
Step3
• remove the screw Eof the mixer motor plate
• detach the mixer motor plate Fand carefully and
pull it towards you
Step4
• disconnect the wiring
• remove the mixer G
• remove both seals Hand seal holder I
►Consider to exchange the seals.
Step5
• remove the 2 screws J
• remove the mixer motor K
►Consider to exchange the O-ring L
F
E
F
G
H
K
J
L
C
B
A
D

6
2.6 Remove the canister motor
Step3
• removethebackpanelasinStep1 of section2.4
►If necessary, loosen the hoses to make room.
Step4
• pushthelockingpawlforward D
• move the complete canister drive/motor Eupward to
unlockit
• removethepumpoattank
►The drive shaft will stay in place.
• disconnect the wiring
E
D
E
Step1
• closethe“yellow”sliders Aof the canister outlets
• remove the canisters B
Step2
• remove the gear wheel Cfrom the canister motor to
be replaced
B
B
B
B
A
A
A
A
C

7
2.7 RemovetheI/Oboard(Bolero 32, 33, 42 and 43)
Step1
• removethebackpanelasinStep1 of section2.4
• disconnect the wiring
• remove the mainboard A
2.8 Remove the inlet valve
Step1
• removethebackpanelasinStep1 of section2.4
Step2
►Be careful some boiler parts can be hot.
• push both red switches Ato reset
A
2.9 Resetthetemperaturesafetyswitches(Bolero 32, 33, 42 and 43)
AA
AA
Step1
• removethebackpanel
Step2
►Be careful some boiler parts can be hot.
• push both red switches Ato reset
►If necessary, loosen the hoses to make room.
Step1
• removethebackpanelasinStep1 of section2.4
Step2
• disconnect the wiring
• disconnect the hoses
• remove the 2 screws Aofthevalvebracket
• remove the inlet valve B
B
A A
2.10 Resetthetemperaturesafetyswitches(Bolero 11 and 21)

8
2.12 Remove the boiler
Step2
• removethebackpanelasinStep1 of section2.4
Step3
• remove the temperature sensors from the boiler A
• remove the wiring of the temperature safety switches
B
• remove the hose on top of the boiler C
• remove the 2 screws Dofthemountingbrackets
• disconnect wiring of the element Eunderneath the
boiler
• pull the boiler supply Fout of the boiler
• remove the boiler
Step4
• pull the silicone ring Gout of the boiler
• remove the temperature safety switches H
• remove the isolation parts I
A
B
A
C
D
EE
F
H
G
I
H
I
Step1
• remove the drip tray
• pull out the draining hose A
• place a container under the drain hose B
• remove the tightening plug C
• wait until all the water has drained out of the boiler
• replace the tightening plug
A
B
C
B
D
2.11 Remove the temperature sensor (NTC resistor)
A
A
B
B
Step1
• removethebackpanelasinStep1 of section2.4
Step2
►Be careful some boiler parts can be hot.
• disconnect the wiring from the I/O board
• remove the bolt Aof the temperature sensor
• remove the temperature sensor B
►See the electric diagram for the connection on the I/O
board.

9
2.13 Removethepumpoattank
Step1
• drain the hot water boiler as in Step1 of section2.12
Step2
• removethebackpanelasinStep1 of section2.4
Step3
• disconnectthewiringofthepumpandoftheoat
(abovethepumpoattank)
• remove the descaler inlet cap
• disconnectthe3hosesunderneaththeoattank A
• disconnect the aeration hose Bontopoftheoat
tank
• disconnect the wiring from the pump
Step4
• pushthelockingpawl Cforward
• movethepumpoattank Dto the left and then
downtounlockit
• removethepumpoattank
►To remove the pump, rst remove the positioning disc
to take out the pump motor.
B
A
AA
D
C
Step4
• pushthelockingpawl Dforward
• move the water selector Eto the right and then up to
unlockit
• disconnect the aeration hose F
►Maintenance can be carried out without disconnecting
the hoses from the water selector outlet.
►Consider greasing the notch Gin
the lid, where the rotating disc
rotates, with food-grade silicone
grease.
F
D
E
G
2.14 Removethewaterselector
Step1
• drain the hot water boiler as in Step1 of section2.12
Step2
• removethebackpanelasinStep1 of section2.4
Step3
• disconnect the wiring from the motor A
• disconnect the wiring from the light sensor B
• disconnect the hot water supply hose C
A
B
C

10
3. Warningsanderrors
3.1 Warnings
code description action
W001 temperature sensor out of range • no action required, disappears after a few seconds, becomes
after 3 incidents E002
W002 temperature too high • no action required, disappears after a few seconds
W003 temperature not rising while
relay engaged
• no action required, disappears after a few seconds, becomes
E004 after 3 incidents within certain time
W004 canister motor not detected • reset the message on the screen
» if the warning persists, contact your dealer
W005 not used
W006 mixing cups must be rinsed • reset the message on the screen
» rinsethemixingsystem,see”Rinsemixingsystem”inde
user manual
W007 machine must be descaled soon • reset the message on the screen
» schedule the descaling procedure soon
W008 machine must be descaled now • reset the message on the screen
(the warning will pop-up after every dispensed beverage)
» descalethemachine,see”Descale”indeusermanual
W009 water filter must be changed
soon
• reset the message on the screen
» schedulewaterlterreplacementsoon
W010 water filter must be changed now • reset the message on the screen
(the warning will pop-up after every dispensed beverage)
» replacethewaterlterandconrmin”Waterlter
management”indeusermanual
M011 payment device connection
successful
• no action required, disappears after a few seconds
W012 payment device connection failed • no direct action required, disappears after a few seconds
» checktheconnectionsandrestartthepaymentdevice
» if the error persists, contact your dealer
W013 -
W019 not used
W020 A message that shows up when
relay life (integrated on the I/O
board) is almost over.
• reset the message on the screen, the message will recur
several times after which it becomes E026
►Using the Energy control function (Eco mode) will reduce the amount of switching of the relay and will
extend the life time.

11
3.2 Errormessages
code description Detected Suspectedcomponents
E001 temperature
rise while relay
disengaged
temperature sensors measure a
certain temperature rise when
power should not be converted
to the heating element
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» I/Oboard(heatingrelay)
» all associated wiring
E002 temperature sensor
out of range
the temperature sensor (NTC)
measures a value that is outside
itsrange(0OhmorinnityOhm)
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» temperature sensor
» I/Oboard
E003 magnetic valve
unexpectedly
opened
machinells‘x’timeswithouta
beverage selection for dispensing.
• without manual tap : x = 3
• with a manual tap : x = 99
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» leakagewatersystem
» temperature sensor
» oat
E004 temperature not
rising while relay
engaged
the heating relay is activated and
no temperature rise is measured
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» high temperature safety device
» I/Oboard(heatingrelay)
» all associated wiring
E005 water selector
malfunction
the light sensor of the water
selector does not measure
pulsesorcannotndthestarting
position
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» scale
» light sensor
» motor
» atcable
» all associated wiring
» rotation disc
» I/Oboard
E006 water supply failure theoatdidnotrisewithina
certaintimeduringlling
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» water tap not opened
» kinkedhose
» waterpressure/owtolow
» inlet valve
» oat
» all associated wiring
E007 not used

12
code description Detected Suspectedcomponents
E008 bus system
communication error
no communication • reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» all associated wiring of the
underneath parts
» I/Oboard
» HMI board
» MDB board (if present)
E009 pump motor
malfunction
no or too few pulses during start-
up or operation of the pump
motor
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» pump motor
» encoder not properly inserted
» all associated wiring
» I/Oboard
E010 mixer motor not
detected
mixer motor not detected during
start-up
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» mixer motor
» all associated wiring
» I/Oboard
E011 canister motor
malfunction
the canister motor runs too
heavily
• reset the message on the screen,
• iftheerrorpersists,checkthefollowing
parts:
» canister
» canister motor
» I/Oboard
» all associated wiring
►E011 cannot be detected by the hardware when the canister motor is running at low speed, i.e. when
small amounts of ingredients are dispensed, which is usually the case for recipes with a very low
ingredient/water ratio.
E012 coin mechanism
missing
coin mechanism is no longer
detected
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» all associated wiring
» MDB board
E013 coin mechanism
defective
message send from the coin
mechanism to the machine
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» coin mechanism
» all associated wiring
» MDB board
E014 coin mechanism
blocked
message send from the coin
mechanism to the machine
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» coin mechanism (consult the
manufacturer’smanual)

13
code description Detected Suspectedcomponents
E015 coin mechanism
sabotaged
message send from the coin
mechanism to the machine
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» coin mechanism (consult the
manufacturer’smanual)
E016 coin mechanism
communication error
message send from the coin
mechanism to the machine
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» all associated wiring
» coin mechanism (consult the
manufacturer’smanual)
E017 coin mechanism
general error
message send from the coin
mechanism to the machine
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» all associated wiring
» coin mechanism (consult the
manufacturer’smanual)
E018 cashless device
general error
message send from the cashless
device to the machine
• reset the message on the screen
• iftheerrorpersists,checkthefollowing
parts:
» all associated wiring
» cashless device (consult the
manufacturer’smanual)
E019 -
E025 not used
E026 contact your dealer
for necessary
maintenance
A message that shows up when
relay life is over. The amount of
switching that a heating relay
does during the life time of
the machine is calculated very
accurately. The heating relay on
theI/Oboardcandoacertain
extra amount of switching
in relation to the calculated
number, however if the machine
is used excessively it could be
that the relay life is shorter than
the machine life time.
• replaceI/Oboard
The relay switching counter is in the
memoryoftheI/Oboard,whenthe
I/Oboardisreplacedforanewonethe
message is automatically reset as the
relayswitchingcounteriszero.
►Using the Energy control function (Eco mode) will reduce the amount of switching of the relay and will
extend the life time.

14
3.3 Other problems (user)
In addition to the messages and errors present in the machine, a number of other problems may occur; these
problems are described below.
Problemdescription Possible cause Checkthefollowing
drinktoweak almost out of powder in
ingredient canister
• Ingredient container
strength not correct • adjustdrinksettingsintherecipeeditor
» if the error persists, contact your dealer
drinktostrong strength not correct • adjustdrinksettingsintherecipeeditor
» if the error persists, contact your dealer
no water dosed hoseblocked • contact your dealer
mixing unit clogs up mixing unit not cleaned • clean the mixing unit
to much powder • checktheadvisedosingofthepackagingofthe
powder, use a scale to weight the amount of
powder used
powder used which is not
applicable for vending
machines
• use powder that is applicable for vending
machines
pump calibration not
correct
• calibrate the pump (availability depends on PIN
setting)
• contact your dealer
mixer defect or missing • checkthemixer
mixing unit damaged • checkthemixingunit
fan rotor does not turn • clean the fan rotor and housing or remove any
blockage
» if the error persists, contact your dealer
mixing unit overflows
water
pump calibration not
correct
• calibrate the pump (availability depends on PIN
setting)
• contact your dealer
mixing bowl clogged up • mixing bowl, see previous descriped problem
» if the error persists, contact your dealer
mixingunitleaks mixingbowlsealleaks • clean the complete mixing unit
» if the error persists, contact your dealer
nofaomonthedrink mixer speed not correct • adjustthemixerspeed(availabilitydependson
PIN setting)
» if the error persists, contact your dealer
type of instant ingredient • tryadierentinstantingredient
tomuchfoamonthedrink mixer speed not correct • adjustthemixerspeed(availabilitydependson
PIN setting)
» if the error persists, contact your dealer
not enough water dosed scale in the water system • descale the machine
» if the error persists, contact your dealer

15
Problemdescription Possible cause Checkthefollowing
fan rotor does not run fan not cleaned • clean the fan rotor and housing or remove any
blockage
» if the error persists, contact your dealer
water dispensed in wrong
outlet
scale in water selector • descale the machine
» if the error persists, contact your dealer
machinedoesn’tturnon switch not turned on • turnontheswitchonthebackside
no power • checkthepowersupply
» if the error persists, contact your dealer
message safety circuit
interupted in the display
door and lid not closed • rstclosethelidandthenthedoor
servicekeynotplaced • placetheservicekey
» If the error persists, contact your dealer
touch screen display
sometimes not responsive
touch screen filthy • turnothemachineandcleanthetouchscreen
with a damp cloth
►Do not use agressive detergents.
» if the error persists, contact your dealer

16
3.4 Otherproblems(dealer)
Problemdescription Possible cause Checkthefollowing
beveragetoweak almost out of powder in ingredient
canister
• Ingredient container
strength not correct • adjustdrinksettingsintherecipe
editor
beverage to strong strength not correct • adjustdrinksettingsintherecipe
editor
cup to full drinkvolumenotsetupcorrect • adjustdrinksettingsintherecipe
editor
cup not full enough drinkvolumenotsetupcorrect • adjustdrinksettingsintherecipe
editor
no water dosed water level too low • oat
hoseblocked,scale • all related hoses
mixing chamber clogs up to much powder • checktheadvisedosingofthe
packagingofthepowder,usea
scale to weight the amount of
powder used
pump calibration not correct • calibrate the pump
mixer defect or missing • mixer
mixing chamber damaged • mixing chamber
hoseblocked • all related hoses
fan not running • fan
powder used which is not applicable for
vending machines
• use powder that is applicable for
vending machines
water selector gives water in wrong outlet
(only applicable on Bolero 32, 33, 42 and 43)
• water selector
mixing chamber
overflows water
pump calibration not correct • calibrate the pump
mixing chamber clogged up • mixing chamber
mixingchamberleaks mixingchambersealleaks • seal mixing chamber
mixing chamber defect • replace mixing chamber
not enough foam on the
beverage
mixer speed not correct • adjustmixerspeed
type of instant ingredient • tryadierentinstantingredient
mixer not on the mixer motor • place mixer
mixer motor defect • mixer motor
tomuchfoamonthedrink mixer speed not correct • adjustmixerspeed
In addition to the messages and errors present in the machine, a number of other problems may occur; these
problems are described below.