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

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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.

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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

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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

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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.

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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.

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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.