COFFEtek NEVA 4 User manual

NEVA 4
BEVERAGE MACHINE
TECHNICAL MANUAL

COFFEtek LTD
NEVA 4 Issue 1 22/02/08 2
NEVA 4 BEVERAGE MACHINE
TECHNICAL MANUAL
CONTENTS
FOREWORD..................................................................................................................................... 4
SECTION 1 TECHNICAL INFORMATION ....................................................................................... 6
INTRODUCTION ................................................................................................................................................6
SPECIFICATIONS .............................................................................................................................................7
SERVICES REQUIRED .....................................................................................................................................7
Electrical Supply.............................................................................................................................................7
Water Supply..................................................................................................................................................7
GENERAL DESCRIPTION ................................................................................................................................8
Cabinet Front..................................................................................................................................................8
Cabinet Interior...............................................................................................................................................8
Water System.................................................................................................................................................8
ELECTRICAL AND ELECTRONIC SYSTEM..................................................................................................10
Functional Description..................................................................................................................................10
Circuit Description ........................................................................................................................................11
SECTION 2 PROGRAMMING ........................................................................................................ 14
INTRODUCTION ..............................................................................................................................................14
INTERNAL KEYPAD LAYOUT .......................................................................................................................15
KEYPAD FUNCTIONS.....................................................................................................................................15
OPERATORS PROGRAM ...............................................................................................................................16
ENGINEERS PROGRAM.................................................................................................................................17
Program Options ..........................................................................................................................................17
SECTION 3 INSTALLATION AND MAINTENANCE...................................................................... 26
INTRODUCTION ..............................................................................................................................................26
SAFETY WARNINGS ......................................................................................................................................27
FROST WARNING...........................................................................................................................................27
Location........................................................................................................................................................28
Levelling .......................................................................................................................................................28
Securing .......................................................................................................................................................28
CONNECTING THE WATER SERVICES........................................................................................................29
CONNECTING THE ELECTRICAL SERVICES ..............................................................................................30
DESCALING THE TANK .................................................................................................................................31
COMMISSIONING............................................................................................................................................32
FAULT FINDING GUIDE ................................................................................................................ 34
SECTION 4 EXPLODED PARTS DIAGRAM ................................................................................. 36

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NEVA 4 Issue 1 22/02/08 4
FOREWORD
1. The information contained in this technical manual is applicable to the Neva 4 Beverage
Machine. Due to customer requirements some units may vary from the one described in
the manual.
2. Personnel who have undergone relevant equipment training must only undertake
maintenance of the beverage machine.
3. The Manufacturer reserves the right to make changes, without notice, to the design of the
beverage machine, which may affect the information contained in this manual.
4. The Neva 4 Beverage Machine is designed for indoor use, in an environment with an
ambient temperature range of between 0°C and 40°C.

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Section 1
Technical Information
INTRODUCTION
1. The Neva 4 Beverage Machine dispenses hot beverages in response to a simple keypad
selection. All beverages are dispensed in cup measures. All operations are
microprocessor controlled.
2. A cup is placed under the dispense head and the selection is made on the keypad. The
drink is then dispensed in the required quantity. The machine does not accept money,
but a feature such as this can be added.
3. The status of the machine may be monitored, and the configuration altered, by accessing
a program using an internal keypad and display. The program offers a menu of options,
each consisting of a number of sub-options which can be altered.
Programming is accomplished using a dedicated programming keypad and display
mounted on the rear side of the machines door.
4. The Neva 4 Beverage Machine requires a 230V, 13A single-phase supply.
FIG 1.1 NEVA 4 BEVERAGE MACHINE.

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SPECIFICATIONS
5.
(a) Weight: 26kg
(b) Height: 68cm
(c) Width: 32cm
(d) Depth: 47cm
(e) Temp. Range: 0ºC to 55ºC (ambient)
SERVICES REQUIRED
Electrical Supply
6. Single Heater Operation
(a) Supply voltage: 230V, 50-60Hz, single phase fused supply
(b) Current rating: 13A
(c) Connection to the domestic mains supply is via a factory fitted mains lead
incorporating a moulded domestic plug suitable for connection to a switched
socket. The socket should be located within 1m of the beverage machine.
7. 6kW Model for fused 30 Amp supply.
(a) as above
(b) Current Rating 23A
(c) The fused electrical supply must be terminated at a safety isolator switch, which
provides a contact separation of at least 3mm. The isolator should be located within
1m of the beverage machine. Note the mains lead appropriate to the 6kW heater
load is not suitable for use with a rewireable domestic plug and no attempt should
be made to fit one.
Water Supply
8.
(a) 15mm dia. water mains supply, terminating at a convenient stop tap located within
1m of the beverage machine.
(b) Water Pressure
Minimum: 1 bar
Maximum: 8 bar
(c) A 15mm double backcheck valve with inspection port should be fitted prior to the
flexible hose.

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GENERAL DESCRIPTION
9. The Neva 4 Beverage Machine is a free-standing unit which may be mounted on a
secure table, bench, cabinet or food and drink counter.
Cabinet Front
10. The cabinet front door has a large picture panel area and located within this area are 8
pushbuttons, which have removable front covers to enable fitting of individual selection
labels. On the rear of the door is the display for accessing product information and
machine settings plus the internal keypad, which provides access to the Operator’s and
Engineer’s Program.
11. The panel can, when unscrewed, be hinged to give access to the MPU, display lamps
and keyboard PCB.
12. A gear driven worm screw located in the base of each canister dispenses ingredients in
exact amounts. The ingredient is then mixed with hot water in a mixing bowl prior to the
beverage being poured from the dispense head. A plastic agitator, located inside the
canisters, ensures a free and consistent flow of powder. Additionally, a whipper unit,
located beneath the mixing bowls, ensures that the product and water are properly
blended.
13. The machine On/Off switch is located on the lower panel. Access to all other components
is either by removal of the motor shelf or side panels.
Cabinet Interior
14. Further access to the inner components is achieved by removing the left-hand side panel
by lifting it upwards, clear of its keyhole shifts. Removing this panel gives access to all
internal components.
15. The mains electricity supply cable enters the machine via a cable gland on the base
panel of the machine, where it terminates in a terminal block.
Water System
16. The main water supply enters the machine via a double chamber inlet valve, which is
mounted in the cabinet base panel. A length of tube then takes the water supply into the
top of the water boiler via an air break into a channel, which is directed to the bottom of
the heater tank.
17. Hot water is dispensed from the boiler, via the appropriate solenoid operated valve, to the
mixing bowl. A length of tube directs any overflow from the boiler to the waste tray.
18. The water is maintained at a constant level in response to signals from a water level
probe, which is connected to the Controller Board.
19. The water is heated to the required temperature by one or two heating element(s),
depending on the model. The Controller Board ensures that the temperature is
maintained to a predetermined level by controlling the supply to the heater(s) in response
to signals from the N.T.C. temperature sensor which forms part of the level/temperature
probe assembly. Safety cut-out switches mounted on the front of the boiler ensure that
power is removed from the heaters in the event that a fault with the control system leads
to the water in the tank beginning to boil.

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20. Hot water from the boiler is fed directly to the mixing bowls, where it mixes with the
dispensed ingredient to produce the selected beverage. Solenoid operated valves
distribute the hot water to the selected mixing bowl, the amount of water being
determined by the program setting.
A
BOILER
OVERTEMP
CUTOUT 1
D C
VALVES INLET
VALVE
B A
MIXERS
B
D
C
OVERTEMP
CUTOUT 2
6kW ONLY
OVERFLOW
FIG 1.2 WATER SYSTEM – FUNCTIONAL DIAGRAM

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ELECTRICAL AND ELECTRONIC SYSTEM
Functional Description
21. The MPU Controller Board employs microprocessor technology to monitor and control
the operation of the beverage machine. The board contains the main System Program,
the Operator's Program and the Engineer's Program, each stored in programmable read
only memory (EPROM).
22. Variables, such as the amount of ingredients dispensed, are stored in non-volatile
random access memory (NVRAM) and are called up by addressing either the Operator's
Program or the Engineer's Program as appropriate.
23. The main System Program tasks the microprocessor with continually checking the status
of the input devices (keypad, probe, etc) and responding to data received by signaling
the output devices (LCD display, motors, whippers, etc) to take the appropriate action.
The System Program also requests the microprocessor to interrogate the variable
settings in NVRAM and to modify its actions accordingly.
24. Output transistors and F.E.T. devices on the MPU Controller Board convert signals from
the Controller’s microprocessor circuit to the current drive necessary to operate output
devices, i.e. motors, whippers and inlet valve.
MOTORS / FAN
HEATER SSR'S
VALVES
KEY PAD
DISPLAY
CONTROLLER
BOARD
WATER LEVEL
TEMP SENSOR
PUSHBUTTONS
FIG 1.3 ELECTRICAL & ELECTRONIC SYSTEM – FUNCTIONAL DIAGRAM.

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Circuit Description
25. The beverage machine is connected to a 230V single-phase supply that terminates at a
terminal block (TBA). From here AC supplies are taken to the heater element(s) and
Power Supply PCB.
26. A 15A fuse(s) protect the heater circuit(s). A solid state relay (SSR) and high temperature
cut-out are also placed in each heater circuit. The SSR switches the supply to the heater
as directed by the MPU Controller in response to data received from the temperature
sensor part of the temperature/level probe, thus maintaining the water in the boiler at the
correct temperature. However, if the water in the boiler starts to boil, the high
temperature cut-out removes the supply to the heater. Once operated, the cut-out must
be reset manually. The reset buttons are located on the boiler cover behind the
ingredient canisters. On the 3kW model the single active element is designated as
HEATER 1.
27. A 230V AC main supply is taken from the terminal block to the Power Supply PCB via the
On/Off switch. The Power Supply PCB provides DC supplies of 24V, 12V and 5V. The
24V DC output supplies the ingredient motors, whipper motors, extraction fan, SSR and
solenoid operated valves. The 12V DC output supplies the MPU Controller Board and
operational coin acceptor (if fitted).
28. The MPU Controller Board continually checks the status of input devices connected to
plugs J1 and J3, and responds to any change of state by signaling the operation of the
relevant output devices via on-board current drive transistors. Thus, for example, the
water level probe controls the operation of the inlet valve and the temperature sensor
controls the operation of the SSR.
29. The dispensing of a beverage begins with the keypad selection, which is scanned by the
MPU Controller Board via a ribbon connector. Control signals corresponding to the
required actions are then generated by the MPU Controller to operate the relevant output
devices in the correct sequence and for the specified duration. User data information is
then sent in parallel form to the front panel (LCD) display.

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Section 2
Programming
INTRODUCTION
1. The Neva 4 Beverage Machine provides two discrete user programs: The Operator’s
Program and the Engineer’s Program. The Operator’s Program is available to both the
Operator and the Service Engineer, but the Engineer’s Program is only available to the
Service Engineer.
2. Both the programs are stored in programmable read only memory on the Controller
Board. The values and settings (Variables) which the program allows the programmer to
alter are stored in NVRAM (non-volatile random access memory).
3. Settings are maintained, without the need for back-up battery, when the power supply is
removed.

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INTERNAL KEYPAD LAYOUT
KEYPAD FUNCTIONS
4. The Operator’s Program is available to the Operator and Service Engineer.
The Program provides options for counting the number of drinks dispensed for each
beverage, monitoring the weight of ingredients used, showing the total vends dispensed
and resetting the drink counters if applicable. Additionally, the operator can set the
machine to “Out of Service” mode, if required.
5. Keypad key functions, when used in the operator’s programming mode, are as follows:
•Key (ENTER) used to access a function;
•Key (ESC) used to escape from the operators mode;
•Key (PROG) used to access the Operator’s Program, then used to change menu
functions;
•ARROWS UP (¿), DOWN (À), LEFT (½), RIGHT (¾) are used for adjustments
when in program mode;
•key is used for selecting option when in output test mode.
FLUSH PROG
ESC ENTER

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OPERATORS PROGRAM
ACCESSING THE OPERATORS MODE
6. Accessing the Operator’s Program is by pressing the PROG key on the internal
keyboard. The display will show:
PRESS DRINK TO DISPLAY COUNTER
DISPLAY COUNTER
7. The DISPLAY COUNTER option is accessed on entering the Operator’s Program.
The resettable vend counts may be viewed by pressing each drink key (as shown on the
keypad) in turn.
8. To access other options, press PROG on the internal keypad. The other options are as
follows:
TOTAL VENDS
RESET COUNTERS
DISABLE VENDS
VIEW INGREDIENT COUNTERS
TOTAL VENDS
9. Access the TOTAL VENDS COUNT option using PROG key, the display will show total
vend count.
RESET COUNTERS
10. Access RESET COUNTERS by using PROG key, to clear drink counters press ENTER.
The display will show:
ARE YOU SURE?
ENTER (Y), ESC (N)
DISABLE VENDS
11. The machine may be disabled without switching off the electrical supply by pressing
DISABLE VEND.
12. To enable vends, enter the Operator’s Program and press ENABLE VEND.
VIEW INGREDIENT COUNTERS
13. Access the VIEW INGREDIENT COUNTERS option by using PROG key. Press ENTER
to display the first counter, then press ¿to scroll through the others.

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ENGINEERS PROGRAM
ACCESSING THE ENGINEER’S PROGRAM
14. The Operator’s Program must be accessed before the Engineer’s Program can be
accessed, the operation is as follows:
(1) Press PROG to access the Operator’s Program, the display will show:
PRESS DRINK TO DISPLAY COUNTER
(2) Press PROG again , the display will show:
TOTAL VENDS
(3) Now, press the bottom left hand selection button on the front of the door.
The display will now show:
SELECT DRINK TO MODIFY
(4) The machine is now in engineer’s mode.
Program Options
15. Thirteen program options are available as follows:
SELECT DRINK TO MODIFY
SELECT DRINK TO TEST
OUTPUT TEST
CHANGE PRICE OF, OR INHIBIT DRINKS
SET INGREDIENT THROW RATE
TANK STATUS
INITIALISE
CHANGE SETTINGS
PRESS DRINK FOR FIXED COUNTERS
EDIT BIN NAMES
SAVE TO HIGH MEMORY BANK
SET FACTORY DEFAULTS
LEAVE ENGINEERS PROGRAM
16. Repeated pressing of PROG key causes the program to scroll through the options in the
above sequence. Therefore a specific option is accessed by pressing PROG key until
that option is displayed. To access any program press ENTER.

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SELECT DRINK TO MODIFY
Ingredient/Water/Whipper Adjustments Program concept
17. The central concept behind the Coffetek NewGeneration software is that each individual
drink button can be programmed to have any combination of ingredients present in the
machine in its recipe. Therefore scrolling down the list of settings for a given button, start
and run durations for each motor, mixer and valve will be seen. This can be disconcerting
to those unfamiliar with this approach. Since any button can be configured to produce
any drink, limited only by the available ingredients, a facility to change the name of the
drink displayed when the button is pressed is also included in this section. Other control
parameters that apply specifically to the beverage associated with each specific selection
button are included in these menus.
18. The SELECT DRINK TO MODIFY option allows modification of individual drink timings.
(1) First select the drink; e.g. Product A. The display will show:
DRINK 03 NAME IS
PRODUCT A
If name is correct move to step 4.
(2) Press ENTER. The display will show:
PRODUCT A
¿, ÀENTER OR ESC
(3) Press ¿to scroll other drink name options available or press Àto return to Product
A. Press ENTER to enter new option.
(4) If drink name is correct, use ¿, Àto step through program. The display will show:
USES NOZZLE
000
19. The machines software is capable of dispensing up to three beverages at one time.
Of course the mechanics of the machine must be such that this is possible. That is to
say, as a minimum it must have more than one dispense head! Otherwise several
beverages would emerge at the single dispense head at the same time with obviously
unsatisfactory results. The software allows for three dispense heads 0, 1 & 2. Only one
drink assigned to each nozzle will be allowed at any time. As the Neva 4 only has 1
nozzle, all drinks should be programmed to use Nozzle 0.

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Drink Timings
20. For each ingredient motor, its associated valve and mixer there is a start and a run time.
These times are in tenths of a second.
(1) Press ¿, Àto show Ingredient Settings in turn. The display will take one of the
forms below as the list is scrolled through:
INGREDIENT ING
XXX (START)
INGREDIENT ING
XXX (DUR))
INGREDIENT WATER
XXX (START)
INGREDIENT WATER
XXX (DUR)
INGREDIENT WHIP
XXX (START)
INGREDIENT WHIP
XXX (DUR)
NUMBER OF CYCLES
001
Setting this to more than one causes the drink cycle to repeat however many times
this number is set to, e.g. set to 005 for ½ pot option.
SCALE FACTOR
%
This is a percentage scale factor in % applied to all DURation times for the
selection. Thus setting it to 125 will cause the selection to be 1 ¼ times its normal
size.
21. Example to adjust the strength of the Coffee drink.
(1) With the SELECT DRINK TO MODIFY menu displayed press the button on the
EXTERNAL keypad that is assigned to the Coffee drink. Then use the ¿, Àto
scroll through to the display that controls the coffee ingredient motor run time.
It will be of the form below.
COFFEE ING
(DUR)
Note: It is the DURation we want to change to adjust the strength, NOT the START
time which would only control when the ingredient starts being dispensed.
(2) Press ENTER - display will show:
COFFEE ING
VALUE = 012 (Flashing Digit)
(3) Press ¿to increase or Àto decrease. Press ENTER to accept the new value.
(4) Press ¿to step through program to adjust other value or press ESC to return to
SELECT DRINK TO MODIFY, then press ESC again to return to normal operating
mode.
Key:
INGREDIENT is one of the following:
MILK, CHOCOLATE, COFFEE, ESPRESSO
ING indicates that the display relates to the
timing of an ingredient motor.
WATER indicates that the display relates to the
timing of a dispense valve.
WHIP indicates that the value displayed relates
to a mixer.

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SELECT DRINK TO TEST
22. The SELECT DRINK TO TEST option allows any selected drink to be dispensed, while
still in the Engineer's Program, in order to be tested. This facility is useful for testing a
drink that has been modified.
23. Press DRINK A, for example, to test a change made to the selection in the SELECT
DRINK TO MODIFY option.
OUTPUT TEST
24. The OUTPUT TEST option allows an output device to be operated. All output devices are
described as Whipper A/B, C, D or Motor A, B, C D or Valve A/B, C, D. These
components correspond to the position the canisters are located, i.e. from right to left.
MOTOR MOTOR MOTOR MOTOR
A B C D
WHIPPER WHIPPER WHIPPER
A/B C D
(1) For example, to operate the Ingredient Motor C, select Motor C by pressing ¿until
it appears in the display window, then press to switch the motor ON, then press
to switch the motor OFF.
(2) To select other components, press ¿or Àto list all other components and repeat
the procedure above.
CHANGE PRICE OF,OR INHIBIT DRINK
25. The CHANGE PRICE OF, OR INHIBIT DRINK option allows individual drinks to be priced
or inhibited.
(1) Press the drink key (e.g. DRINK A). The display will show:
DRINK A
FREE
(2) To set DRINK A to FREE, press ENTER, otherwise press ¿and the display will
show:
DRINK A
PRICE 1
(3) To set PRICE 1, press ENTER, otherwise press ¿and the display will show:
DRINK A
PRICE 2
(4) To set PRICE 2, press ENTER, otherwise press ¿and the display will show:
DRINK A
INHIBITED
(5) To set DRINK A INHIBITED, press ENTER.