BRAVILOR BONAMAT Bolero Turbo Instruction sheet

ECopyright Bravilor Bonamat B.V.
Bolero Turbo (XL)
OPERATING PRINCIPLE

ECopyright Bravilor Bonamat B.V.
©2011 Bravilor®Bonamat®
All rights reserved.
No part of this document may be copied and/or published by means of printing, photocopying, microfilming
or by any other means whatsoever without the prior written consent of the manufacturer. This applies equally
to the associated drawings and/or diagrams.
The information contained in this document is based on general data concerning the construction,
materials characteristics and working methods known to us at the time of publication, so we reserve the right
to make changes without notice. For this reason the instructions contained in this document should be
treated as a guide to the installation, use and maintenance and repair, of the machines indicated on the front
cover.
This document applies to the machines in its standard form. The manufacturer therefore accepts no
liability for any damage or injury arising from specifications that deviate from the standard form of the
machines as supplied to you.
Every possible care has been taken in the production of this document but the manufacturer accepts no
liability for any errors in this document or for any consequences arising therefrom.

ECopyright Bravilor Bonamat B.V.
1. OPERATING PRINCIPLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General operation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Water dosing system 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Start−up 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Initialisation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Filling 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Heating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.4 Dosing 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Powder dosing system 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Mixing system 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Ventilation system 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 Operating system 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.1 Keyboard 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.2 Main board 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Hardware protections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.1 Overflow protection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.2 Back−flow protection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.3 Boiling protection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.4 High temperature safety switch 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9 Software protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 Programming 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ECopyright Bravilor Bonamat B.V.
Fig. 1 The water dosing system 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 2 Float tank, complete 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 3 Water selector, complete 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 4 Pump motor + rotor 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 5 Pump housing 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 6 Encoder 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 7 Water selector 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 8 Water selector internal 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 9 Water distribution disc 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 10 Water distribution disc 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 11 Water distribution disc with wide cam 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 12 Water selector components 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 13 Mixing unit 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 14 Exhaust hood 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 15 Exhaust system for three mixing systems 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 16 Ventilation system 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 17 Drip tray water selector 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 18 LCD display with error message 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 19 Door open 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 20 Programming key 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 21 Total counter 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 22 Separate counter contents 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 23 Day counter 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 24 Day counter to zero 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 25 General selection screen 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 26 Default setting of the Timer (CL) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 27 Set current time 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 28 Descaling symbol 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 29 First switching on time (P1) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 30 Set time (ON) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 31 First switching off time (P1) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 32 Set time (OFF) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 33 Programming key / Door closed 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ECopyright Bravilor Bonamat B.V.
1. OPERATING PRINCIPLE
1.1 General operation
The machine works according to a pump system
developed by Bravilor Bonamat. This system has
the following advantages:
DThe components that are responsible for the
correct dosing of the water are housed in a cold
water unit. As a result, the largest cause of faults
with machines, the formation of scale on the
dosing valves, is limited to a minimum.
DThe float that regulates the water level is also
located in the cold−water circuit. This is another
reason why the formation of scale is limited to a
minimum.

ECopyright Bravilor Bonamat B.V.
1.2 Water dosing system
After a selection key is pressed, the pump motor is
driven with a controlled time and speed. The pump
rotor displaces a certain amount of cold water from
the cold water reservoir to the bottom of the boiler.
As a result, the hot water in the boiler is pushed
upwards towards a water selector. This selector
uses a rotating movement to select its position
(beverage−dependent). Depending on the selected
beverage, an ingredient is dosed which, together
with the dosed water, is or is not mixed and poured
into a cup.
The water dosing system consists of the following
main components:
1. Magnetic valve
2. Float tank
3. Boiler
4. Element
5. Temperature sensor (NTC)
6. Hot water selector
7. Protection float tray
8. Drain hose
Fig. 1 The water dosing system
Á
C
ÁÁ
ÁÁ
ÁÁ
Á
Á
A
B
Á
Á
D
E
ÁÁ
ÁÁ
F
Fig. 2 Float tank, complete
A. Float
B. Pump motor
C. Pump rotor
D. Pump housing
E. Encoder
Á
Á
A
ÁÁ
ÁÁ
B
ÁÁ
ÁÁ
C
ÁÁ
D
ÁÁ
ÁÁ
E
Fig. 3 Water selector, complete
A. Water selector motor
B. Top cover of water selector
C. Light sensor
D. Water rotation disk
E. Water distributor

ECopyright Bravilor Bonamat B.V.
1.3 Start−up
1.3.1 Initialisation
The machine is switched on with the main switch.
On the LCD (Liquid Crystal Display) the following
appear in succession:
Dall symbols that the display can show.
Dthe version number of the software
(microprocessor) loaded from the factory.
Dthe version of the software table (Eeprom), also
loaded from the factory.
This process takes approx. 3 seconds and ends with
the steaming cup in the LCD display to show that
this phase has successfully finished.
1.3.2 Filling
The float tank and the boiler are connected by a
siphon hose. Together, they form a communicating
vessel. When the machine is switched on for the
first time, the float tank will be empty and the float
will be low.
DThe magnetic valve is opened and fills water in
the float tank with a speed of 3,5 litres per minute,
depending on the pressure.
DThe water in the float tank flows to the boiler
through the hose under the float tank.
DAfter the water level has pushed the float
upwards, the water level in the float tank is the
same as that of the boiler. The magnetic valve is
switched off.
DA signal sounds when the level of the float is
reached.
Please note:
Because the float tank is filled faster than the water
”drops” to the boiler, the filling process will be made
with short intervals.
1.3.3 Heating
After the system is completely filled with water,
element is switched on by means of a relay in the
machine.
The lower temperature sensor measures the current
temperature of the water. This ensures that the
water in the boiler is heated to the required final
temperature. The upper temperature sensor
releases the machine for dosing or not. The heating
is switched off when the pre−set temperature has
been reached.
Hot water has a lower specific weight than cold
water. As a result, the hot water in the boiler will not
want to flow back to the float tank through the
siphon hose at the bottom. That part of the system
will therefore remain cold. The latter is very
important because precisely the parts of the float
tank are sensitive for scale.
1.3.4 Dosing
Dosing is allowed when:
DThe float is in the top position.
DThe second temperature sensor measures a
temperature higher than the blocking
temperature.
DAfter a selection key is pressed, the pump motor
(fig.4 ) is driven for a certain time, depending on
the programmed amount, with a certain speed
(number of revolutions).
Fig. 4 Pump motor + rotor
DThe pump rotor rotates in the pump chamber,
which is filled with water. This is formed by the
bottom of the float tank and the underneath of the
pump housing (fig.5 ).
Fig. 5 Pump housing
DThe pump rotor pumps the water out of the pump
chamber, through the siphon hose in the bottom
of the boiler.
DAs a result, the hot water in the boiler is pushed
out of the boiler.
DThe float and the magnetic valve ensure that the
level in the float tank is maintained and that water
remains in the pump chamber.

ECopyright Bravilor Bonamat B.V.
The volume of the displaced liquid (yield) is mainly
determined by the time and speed of the pump
motor.
The time that the motor is on is regulated from the
software and is very accurate.
The number of revolutions of the motor is measured
with an active revolution counter.
Figure 6 shows that a disc is 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. The interruption of the light
beam is converted to pulses that can be read by the
electronics.
AB
Fig. 6 Encoder
This forms an active revolution regulation that
guarantees that, during the time that the pump
motor is on, the speed and thus the water yield
remain constant.
Selection of the dosed hot water:
This machine is fitted with a hot water selector. This
component (fig.7 ) is responsible for the dosed water
from the boiler being dosed in a minimum of 3 and a
maximum of 6 directions (type−dependent).
Fig. 7 Water selector
Fig. 8 Water selector internal
Fig. 9 Water distribution disc
After the machine is switched on, the water selector
goes to the stand−by position according to the
following procedure:
DThe water selector motor is driven.
DThis motor uses a plastic worm to drive the water
distribution disc (fig.8 / 9 ).
DThe cams on the distribution disc interrupt the
light beam of the light sensor and pass these
pulses to the control (fig.10 ).
DWhen the light sensor observes the wide cam on
the distribution disc (fig.10 / 11 ), the initial
position is determined.
Fig. 10 Water distribution disc

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Fig. 11 Water distribution disc with wide cam
Operation of the water selector after a selection key
is pressed:
DDepending on the selected beverage, the water
selector determines its position.
DAfter the position is determined, the pump motor
is driven.
DThe dosed hot water is pumped into the top of the
water selector (fig.12 A).
DThe water runs through the central hole of the
distribution disc (fig.12 B). It comes out through the
slanted hole at the bottom (fig.12 C).
DAfter this, the water falls into one of the chambers
in the bottom of the water selector (fig.12 D).
DThe water runs to the relevant part through the
hoses that are connected to the water selector.
DThe water selector rotates back to its initial
position.
Please note:
The arrow in fig.12 A shows a small hole on the top
of the water selector cover. This is an aeration hole,
which prevents siphoning. A hose, which goes to the
top of the float tank, is connected to the tulle.
Please note:
Depending on the selected beverage, the water
selector can also rotate during the pumping. This is
done if water has to go to several mixing systems.
ABC
D
Fig. 12 Water selector components

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1.4 Powder dosing system
The powder dosing system consists of an ingredient
holder (canister) that is driven by a motor (canister
motor).
After the start key is pressed, the canister motor will
rotate after a certain delay. This motor drives a
worm, which transports the ingredient to the canister
outlet.
The control of the canister motor makes it possible
to regulate timing and dosing speed independently.
As a result, the ingredient can be poured into the
mixer at the same time that the water flows out.
However, the canister motor will stop slightly earlier
than the water, to rinse the mixing jug clean.
Depending on the type of ingredient, “beater
springs” are used in the canister. These springs
ensure that less tunnel formation occurs. This is the
caking of ingredient against the walls.