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

COFFEtek LTD
3 22/02/08 Issue 1 NEVA 4
This page is intentionally blank.

COFFEtek LTD
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.

COFFEtek LTD
5 22/02/08 Issue 1 NEVA 4
This page is intentionally blank.

COFFEtek LTD
NEVA 4 Issue 1 22/02/08 6
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.

COFFEtek LTD
7 22/02/08 Issue 1 NEVA 4
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.

COFFEtek LTD
NEVA 4 Issue 1 22/02/08 8
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.

COFFEtek LTD
9 22/02/08 Issue 1 NEVA 4
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

COFFEtek LTD
NEVA 4 Issue 1 22/02/08 10
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.