COFFEtek BEAN TO CUP User manual

BEAN TO CUP
BEVERAGE MACHINE
TECHNICAL MANUAL

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 2
BEAN TO CUP BEVERAGE MACHINE
TECHNICAL MANUAL
FOREWORD......................................................................................................................................4
SECTION 1 TECHNICAL INFORMATION ........................................................................................6
INTRODUCTION ................................................................................................................................................6
SPECIFICATIONS..............................................................................................................................................7
SERVICES REQUIRED......................................................................................................................................8
Electrical Supply.............................................................................................................................................8
Water Supply..................................................................................................................................................8
GENERAL DESCRIPTION ................................................................................................................................9
Cabinet Front..................................................................................................................................................9
Cabinet Interior...............................................................................................................................................9
WATER SYSTEM.............................................................................................................................................10
Heater Control and Boosting ........................................................................................................................10
Tank Filling & Overflow Protection ...............................................................................................................11
ELECTRICAL AND ELECTRONIC SYSTEM..................................................................................................12
Functional Description..................................................................................................................................12
Circuit Description ........................................................................................................................................13
SECTION 2 PROGRAMMING........................................................................................................14
INTRODUCTION ..............................................................................................................................................14
INTERNAL KEYPAD LAYOUT........................................................................................................................15
KEYPAD FUNCTIONS.....................................................................................................................................15
OPERATOR PROGRAM..................................................................................................................................16
ENGINEER PROGRAM ...................................................................................................................................17
Accessing the Engineers Mode....................................................................................................................17
Program Options ..........................................................................................................................................18
SECTION 3 INSTALLATION AND MAINTENANCE ......................................................................26
INTRODUCTION ..............................................................................................................................................26
SAFETY WARNINGS.......................................................................................................................................27
FROST WARNING ...........................................................................................................................................27
INSTALLATION ...............................................................................................................................................28
Location ........................................................................................................................................................28
Levelling .......................................................................................................................................................28
Securing .......................................................................................................................................................28
CONNECTING THE WATER SERVICES........................................................................................................29
CONNECTING THE ELECTRICAL SERVICES ..............................................................................................30
DESCALING THE TANK .................................................................................................................................32
COMMISSIONING............................................................................................................................................33

COFFEtek LTD
3 01/12/2005 Issue 1 BEAN TO CUP
DAILY HYGIENE..............................................................................................................................................35
Cleaning .......................................................................................................................................................35
Filling ............................................................................................................................................................37
Flushing ........................................................................................................................................................37
WEEKLY HYGIENE .........................................................................................................................................38
Cleaning .......................................................................................................................................................38
Filling Procedure ..........................................................................................................................................39
FAULT FINDING GUIDE .................................................................................................................40
SECTION 4 EXPLODED PARTS DIAGRAM ..................................................................................42

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 4
FOREWORD
1. The information contained in this technical manual is applicable to the Bean To Cup
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 Bean To Cup Beverage Machine is designed for indoor use, in an environment with an
ambient temperature range of between 0ºC and 40ºC.

COFFEtek LTD
5 01/12/2005 Issue 1 BEAN TO CUP
This page is intentionally blank.

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 6
Section 1
Technical Information
INTRODUCTION
1. The Bean To Cup Beverage Machine dispenses hot beverages in response to a pushbutton
selection. All beverages are dispensed in cup measurements. A liquid crystal display
provides status indications and operational information. All operations are microprocessor
controlled.
2. A cup is placed under the dispense head and the selection is made via a pushbutton. 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 the keypad and display. The program offers a menu of options; each
consisting of a number of sub-options which can be altered.
4. The Bean To Cup Beverage Machine has a feature, which heats the water in the boiler very
quickly, with one heater connected, from a 230V, 16A single-phase supply.
FIG 1.1 BEAN TO CUP BEVERAGE MACHINE

COFFEtek LTD
7 01/12/2005 Issue 1 BEAN TO CUP
SPECIFICATIONS
5.
DESCRIPTION DETAILS
HEIGHT/CM 64(78 Inclusive Bean Canister)
WIDTH/CM 42
DEPTH/CM 51
WEIGHT/KG 26
TANK CAPACITY/LITRE 2.5
CANISTER CAPACITY - GRAM DETAILS
FRESH COFFEE BEANS 1.5Kg
CHOCOLATE 1500g
TOPPING 1000g
MENU OPTIONS/SELECTIONS 8
DISPENSE TIME PER CUP/SEC
POWER 3KW
CUP SERVING/HOUR 180
MAINS WATER/PORTABLE YES/YES
MAX/MIN PRESSURE-BAR MIN-1/MAX-8
ILLUMINATED BUTTONS YES
BACK PANEL YES
SELF CLEANING BUTTON YES

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 8
SERVICES REQUIRED
Electrical Supply
6.
(a) Single Heater Operation
Supply voltage : 230V, 50Hz, single phase, fused supply
Current rating : 10A/16A
(b) The fused electrical supply should terminate at an appropriate isolator located within
1m of the beverage machine.
Water Supply
7.
(a) 15mm dia. Water mains supply, terminating at a convenient stop tap located within
1m of the beverage machine.
(b) Water pressure : 1 bar minimum, 8 bar maximum
(c) A 15mm double backcheck valve, with inspection port, should be fitted prior to the
flexible hose.

COFFEtek LTD
9 01/12/2005 Issue 1 BEAN TO CUP
GENERAL DESCRIPTION
8. The Bean To Cup Beverage Machine is a free-standing unit which may be mounted on a
secured table, bench, cabinet or food and drink counter.
Cabinet Front
9. The cabinet front door has a large picture panel area and located beneath this 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 and
Engineer Program. The panel can, when unscrewed, be hinged to give access to the MPU
and keyboard PCB.
Cabinet Interior
10. A swivel open door provides access to the two plastic product containers, each fitted with a
gear driven worm screw located in the base of each canister to dispense ingredients in
exact amounts.
The ingredients are mixed with hot water in mixing bowls prior to the beverage being
poured from the dispense head.
A plastic agitator is located inside of the milk topping and chocolate canister to ensure free and
consistent flow of product. Additionally a whipper unit, located beneath the mixing bowls,
ensures that the product and water are correctly mixed.
The ingredient canisters must be removed for filling of the products and when all four canisters
are removed and steam hoods of the mixing bowls are removed the extract chamber can be
removed for cleaning.
11. Located on the upper left hand panel is the machine on/off switch, which controls the power
to the MPU, power supply. Access to all other components is either by removal of the lid
assembly/boiler cover and motor shelf.
12. Further access to the inner components is achieved by removing the left-hand side panel
by unscrewing the location screw and then the panel will drop down clear of its keyhole
slots. Removing this panel gives access to all internal components.
13. 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. The supply is then connected via
the terminal block, line filter to the on/off switch on the front of the machine.

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 10
WATER SYSTEM
14. 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.
15. 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 via overtemp safety
thermostats to the waste tray.
16. The cold water mains supply enters the machine at the base of the cabinet and connects
with a dual chamber solenoid operated inlet valve, which controls the flow of water to the
boiler. The water is maintained at a constant level in response to signals from a water level
probe which is connected to the Controller Board.
17. The water is heated to the required temperature by a single or up to 3 heating elements
subject to configuration. The Controller Board ensures that the temperature is maintained
to a predetermined level by controlling the supply to the heater in response to signals from
the N.T.C. temperature sensor which forms part of the level/temperature probe assembly.
18. 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.
19. The temperature of the water, is monitored by the Controller Board via a sensor inserted
into the tank, thus causing the supply to the heater to be removed when the water in the
boiler reaches its required temperature setting. If the temperature in the boiler increases
causing the water to boil over, the water will flow down the overflow pipe over the overtemp
sensors which will cut off the electrical supply to the heating elements. These sensors are
mounted on the cabinet rear and are re-settable.
Heater Control and Boosting
20. The heating control system employs an intelligent algorithm to obtain maximum
performance as follows:-
Boost operation takes place when the inlet valve opens following a selection being taken. The
heater control algorithm is instructed to turn on both SSR’s for the duration specified in the
variable CUP BOOST referred to Section 2 paragraph 24.
If the temperature is 50 more than the DESIRED TEMPERATURE, set in the CHANGE
SETTING MENU (see Section 2 paragraph 24) all boosting operations are disabled.
If the actual temperature is between 0 – 35 less than the DESIRED TEMPERATURE one SSR
is OFF and the other one toggles ON & OFF unless a boost operation is in progress then both
SSR are ON.
If the actual temperature is between 35 - & 50 less than the desired temperature one SSR is
ON and the other is OFF. Boost operations are as above.
If the actual temperature is more than 50 below the desired temperature both SSR’s are ON.

COFFEtek LTD
11 01/12/2005 Issue 1 BEAN TO CUP
Tank Filling & Overflow Protection
21. The control system will only open the inlet valve for a maximum of 40 seconds. If the tank
is not full at the end of this time the machine will enter a fault condition. The internal display
will read “TANK FILL FAULT CALL OPERATOR”. This fault can be cleared by switching the
machine off and on.
Note: An empty tank may take several cycles to fill completely.
22. The second protective mechanism is designed to act as a fail-safe in the event that a slow
leak occurs which does not result in the liquid entering the drip tray. The machine will
cease all attempts to fill the tank after 20 tank top ups have been made, if no selections
have been taken in the meantime.
FIG 1.2 WATER SYSTEM – FUNCTIONAL DIAGRAM
Inlet Valve
Overtemp
Cutout 1
Overflow
Valves
A
COFFEE
BREWER
A
Boiler
B
C
Mixe
r
HOT WATER

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 12
ELECTRICAL AND ELECTRONIC SYSTEM
Functional Description
23. 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.
24. 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.
25. 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 signalling 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.
26. 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.
HEATER SSR'S
VALVES
MOTORS/FAN
CONTROLLER
BOARD
WATER LEVEL
KEY PAD
TEMP SENSOR
DISPLAY
PUSHBUTTONS
FIG 1.3 ELECTRICAL & ELECTRONIC SYSTEM – FUNCTIONAL DIAGRAM

COFFEtek LTD
13 01/12/2005 Issue 1 BEAN TO CUP
Circuit Description
27. If the beverage machine is supplied by a 230V single-phase supply from a 10A or 16A
outlet (or from a 13A domestic outlet), only heater 1 can be connected in circuit a 15A fuse
protects the heater circuit, a solid state relay (SSR) contact and high temperature cut-out is
placed in the circuit of heater
28. The SSR switches the supply to the heaters 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-outs remove the supply to the heaters. Reset
buttons for cut-out 1 is accessible at the top of the machine.
29. A 230V ac main supply is taken from 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, extract fan, SSR and solenoid
operated valves. The 12V-dc output supplies the MPU Controller Board and operational
coin acceptor (if fitted).
30. 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 signalling 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.
31. 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. Operator data information is
sent in parallel form to the (LCD) Display.

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 14
Section 2
Programming
INTRODUCTION
1. The Bean To Cup 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
store in NVRAM (non-volatile random access memory).
3. Settings are maintained, with out the need for back-up battery, when the power supply is
removed.

COFFEtek LTD
15 01/12/2005 Issue 1 BEAN TO CUP
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
dispensed counters if applicable. Additionally, the operator can set the machine to Out of
Service if required.
5. Keypad functions when used in the Operator’s programming mode, are as follows:-
(1) Key (ENTER) used to access a function.
(2) Key (PROG) used to access the operators program, then used to change menu
functions.
(3) ARROWS UP (¿), DOWN (À), LEFT (½), RIGHT (¾) are used for adjustments when
in program mode.
(4) key is used for selecting option when in output test mode.
FLUSH PROG
ESC ENTER

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 16
OPERATOR PROGRAM
Accessing the Operators Mode
6. Accessing the Operator 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 VEND
VIEW INGREDIENT COUNTERS
RESET COUNTERS
TOTAL VENDS
9. Access the Total Vends Count option using PROG key, the display will show total vend
count.
VIEW INGREDIENT COUNTERS
10. Access the View Ingredient Counters option by using PROG key. Press ENTER to display
the first counter, then press the ¿UP arrow to scroll through the others.
RESET COUNTERS
11. Access Reset Counters by using PROG key, to clear drink counters press ENTER. The
display will show:
ARE YOU SURE
ENTER (Y) ESC (N)

COFFEtek LTD
17 01/12/2005 Issue 1 BEAN TO CUP
ENGINEER PROGRAM
Accessing the Engineer Program
12. The operator program must be accessed before the Engineer Program can be accessed,
the operation is as follows:
(1) Press PROG to access the Operator 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
Accessing the Engineers Mode
13.
(1) Gain access to the Operator mode.
(2) Press the PROG key until the display shows ‘TOTAL VENDS’.
(3) At this point, on the external keypad, press the bottom left hand key.
(4) The machine is now in engineer’s mode.

COFFEtek LTD
BEAN TO CUP Issue 1 01/12/2005 18
Program Options
14. Twelve program options are available as follows:
SELECT DRINK TO MODIFY
SELECT DRINK TO TEST
OUTPUT TEST
SELECT DRINK TO RESTORE PRESET
CHANGE PRICE OR INHIBIT DRINKS
SET INGREDIENT THROW RATE
TANK STATUS
.............................................................................................................................................................
INITIALISE
CHANGE SETTINGS
FLUSH SET UP
PRESS DRINK FOR FIXED COUNTERS
QUIT ENGINEER PROGRAM
15. 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.

COFFEtek LTD
19 01/12/2005 Issue 1 BEAN TO CUP
SELECT DRINK TO MODIFY
INGREDIENT/WATER ADJUSTMENTS PROGRAM
16. This program allows access to the specific variables that control each selection for the
purposes of configuring each drink to suit the customers precise requirements. Each drink
selection has it own unique set of control variables. The function of each variable is largely
self explanatory the values displayed represent start times and opening (valve) or running
(motors) times in units of one tenth of a second. The method of editing all variables is
identical.
(1) The SELECT DRINK TO MODIFY option allows modification of individual drink
timings. First select the drink. For example, let us choose the Freshbrew Coffee
Press the Coffee button. The display will show:
INGREDIENT DUR
50
This represents the run time for the coffee grinder in tenths of a second. In this case fifty
tenths of a second i.e. 5.0 seconds.
(2) Use ¿, Àto step through the remaining variables that control the operation of this
selection. The following displays will be visible in turn: -
WATER 1 DURATION
75
i.e. The valve time for the first delivery 7.5 seconds.
WATER 2 DELAY
0
i.e. The delay between the first and second deliveries.
WATER 2 DURATION
0
i.e. The valve time for the second delivery 0 seconds.
WHIPPER DELAY
0
i.e. The delay time which controls the start time of the
whipper.
WHIPPER DURATION
0
i.e. The length of time for which the whipper runs.
LOCK DELAY DEL
45
i.e. The delay time which controls the unlocking of the
brewer, 4.5 seconds.
PUMP 1 START DEL
0
i.e. The time delay in starting of the air pump.
PUMP 1 DURATION
20
i.e. The time for which the air pump is active,
2.0 seconds.
PUMP 2 START DEL
50
i.e. The time delay in starting the air for the second
time, 5 seconds.
PUMP 2 DURATION
35
i.e. The time for which the air pump is active for the
second stage, 3.5 seconds.
PUMP 3 START DEL
0
i.e. The time delay in starting the air for the third time.
PUMP 3 DURATION
0
i.e. The time for which the air pump is active.
DRAIN TIME
30
i.e. The time taken for the brewer to drain,3 seconds.