KegLand BrewZilla 35L Gen 4 User manual

BrewZilla 35L - Gen 4 Instruction Manual
Page 1of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
BrewZilla 35L –Gen 4
Instruction Manual
KegLand Distribution PTY LTD
www.KegLand.com.au

BrewZilla 35L - Gen 4 Instruction Manual
Page 2of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
WARNING IMPORTANT INFORMATION!
1. Please read this ENTIRE instruction sheet before using the BrewZilla unit. If you are
unsure about any part of using this brewery, please refer to the YouTube videos that
we have made or contact your local distributor.
2. If the BrewZilla is damaged in any way do not use it. Contact your local distributor.
3. NEVER turn on the pump or energise the device without attaching the recirculation
arm shown in step 4 of the instructions. If you do not fit this arm, you could be at risk
of spraying hot wort into the air causing injury.
4. Do not run the pump dry for extended periods. This can damage the pump.
5. NEVER lift the BrewZilla when it is completely full, we strongly urge you to use a hose
to fill your unit. Use the pump or ball valve to transfer your wort. Lifting a heavy /
hot BrewZilla may result in serious injury.
6. If at any stage the recirculation arm is not fitted and/or needs to be removed always
ensure the ball valve is turned off (see instructions under the heading
7. NEVER clear a blocked pump by spraying water down the recirculation arm or
directly into the pump inlet. 8. Do not boil dry. Do not turn on the elements
8. Do not boil dry. Do not energise the device or begin a profile from the RAPT Portal if
there is less than 4 litres of liquid in the boiler. This is the minimum fill level.
9. Never direct a garden hose or mains water down the pump inlet or recirculation pipe
as you risk rupturing the silicone hosing on the underside of the brewery.
10. Use only the recommended cleaners and sanitiser products listed in the
recommended accessories section (p.20-22). Using chemicals not tested or
recommended on the BrewZilla can result in permanent damage and void warranty.
If you require further assistance with chemical compatibility please contact

BrewZilla 35L - Gen 4 Instruction Manual
Page 3of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Parts Checklist
Main BrewZilla Gen 4 Unit with Pump
Ball Valve Assembly
Detachable Boiler Power Cable
Glass lid with recirculation hole
2 x Stainless Steel Lid Handles
Immersion Chiller
Male Camlock Recirculation Arm Extension
White camlock silicone washer for female Camlock
0.5m Silicone hose for recirculation arm
Brewzilla Gen 4 Boiler Perforated False Bottom
Eye bolt assembly for boiler false bottom –1 x nut and 1 x washer
Malt Pipe Assembly
Malt Pipe Body
Malt Pipe Handle
Malt Pipe reinforced bottom screen (no hole and no seal required)
Malt Pipe reinforced top screen (no hole and no seal required)
BrewZilla Gen 4 RAPT Wi-Fi Controller
8 pin power cable for BrewZilla Wi-Fi controller

BrewZilla 35L - Gen 4 Instruction Manual
Page 4of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
The Gen 4.0 BrewZilla is a complete all in one, all grain home brewing system for those who
want to take the first step in all-grain brewing or simply want to upgrade their system
allowing them full control of their batch from start to finish using Wi-Fi connectivity.
The Gen 4.0 BrewZilla can be used with no Wi-Fi connection using the detachable controller
allowing temperature steps to be set and the pump operated manually through the
controller. However, to utilise the full range of functions of the Gen 4.0 BrewZilla we would
suggest connecting your controller to your Wi-Fi and registering it on the RAPT Portal.
This portal allows you to track, record and monitor your brews online and control your
brewery remotely through a Wi-Fi connected device.
The RAPT Portal gives you complete remote control over your brewery and makes the whole
brewing process easier with the ability to pre-heat your strike water remotely or set up push
notifications for hop or adjunct additions, no more phone timers or hand written notes.
Everything controlled and logged easily through the portal.
Registering your BrewZilla Gen 4.0 to the RAPT Portal is quick and easy and requires the
steps below to be followed. If you intend to only use the controller manually skip ahead to
the assembly instructions.
BrewZilla Digital Temperature Controller

BrewZilla 35L - Gen 4 Instruction Manual
Page 5of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Registering your BrewZilla to the RAPT Portal
To utilise the Wi-Fi connectivity of the BrewZilla RAPT controller you will need to sign up for
an account on the RAPT Portal. This will allow you to import recipes from the RAPT portal
directly on to your BrewZilla RAPT controller and control the BrewZilla directly from the
RAPT portal using your Wi-Fi enabled device.
Sign up for a RAPT Account
1. Sign up for an account on the RAPT Portal at the following address:
https://app.rapt.io/
2. Once signed up log in to your account on the RAPT Portal
Connect your BrewZilla to your Wi-Fi and register the device
How to connect your BrewZilla RAPT Wi-Fi Controller to your Wi-Fi
1. Plug your BrewZilla Gen 4.0 boiler into power using the supplied detachable 240V
plug power cable.
2. Plug your BrewZilla Wi-Fi controller into the boiler using the provided 8-pin power
cable
3. On your smart phone or tablet, open your Wi-Fi setting and connect to the Kegland
RAPT Wi-Fi Access Point using the Wi-Fi name and password displayed on the
BrewZilla Wi-Fi controller.
4. Your device should automatically open a browser to the KegLand RAPT Access Portal.
5. Select your home Wi-Fi network, enter your Wi-Fi password and select Join. This will
connect your BrewZilla controller to your Wi-Fi network.
6. Once your BrewZilla controller is connected to your Wi-Fi network then on the
BrewZilla Controller enter the settings by pressing Select and select Register Device.
A Mac Address a Validation Code will then be displayed on the device. Write both of

BrewZilla 35L - Gen 4 Instruction Manual
Page 6of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
these down. You will need to enter the MAC address and Validation Code later on
the RAPT Cloud to register your device.
How to register a BrewZilla controller to the RAPT Cloud
1. Ensure your BrewZilla controller is connected to your Wi-Fi (see above).
2. Ensure you are logged in to the RAPT Portal (www.app.rapt.io) on a device that is
connected to the same Wi-Fi network as the BrewZilla controller you are registering.
3. In the RAPT Portal select Add New Device. Select BrewZilla from the drop down.
Select Next after ensuring that your BrewZilla Controller is connected to your Wi-Fi
network as above.
4. Enter the MAC address and Validation Code when prompted in the required fields,
then select Next.
5. Congratulations! Your BrewZilla controller is connected to Wi-Fi and registered to
your RAPT Portal and your BrewZilla can now be controlled through the RAPT Portal.

BrewZilla 35L - Gen 4 Instruction Manual
Page 7of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Assembling the Digital Controller
The BrewZilla Digital Controller is mounted in a higher position with a tilting frame so you
can adjust the angle of the screen depending on how tall you are improving the overall
ergonomics of the system.
To mount the Digital Controller onto the boiler, slide the controller
onto the bracket using the grooves which are moulded into the
rear of the controllers housing.
Adjusting the Angle of the Digital Controller
To adjust the angle of the screen, loosen the two bolts which hold the bracket in place on
the boiler. Then adjust the angle of the bracket to your desired angle and tighten the bolts
to hold the bracket in this position.
Tip: if you require a greater angle for the Digital Controller the mounting bracket can be
rested on the bolt as shown below to the right.

BrewZilla 35L - Gen 4 Instruction Manual
Page 8of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Assembling the Boiler –Perforated False Bottom
The BrewZilla Gen 4.0 includes a perforated false bottom.
This false bottom is designed to protect your pump from
solids and prevent your pump drawing in more than 95% of
solids such as hop pellets. This false bottom has NOT been
designed so you can place grain directly onto this screen and
is not designed to hold the weight of a grain bill. This false
bottom adds significantly to the reliable operation of the
BrewZilla and it’s recommended that this screen is always in
place if the pump is going to be used.
The false bottom has legs that suspend it about 14mm above
the base of the dome of the boiler so all liquid that exits in
the pump or out via the ball valve will be filtered by this
screen.
To aid in lifting out the false bottom install the eye bolt
assembly, washers and locking nut onto the false bottom.
These parts are included in your BrewZilla kit.

BrewZilla 35L - Gen 4 Instruction Manual
Page 9of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Assembling the Tap
The BrewZilla is shipped with the tap assembled but not fitted to the boiler to minimise the
risk of damage in transport.
Unscrew the hex nut and retaining nut from the tap. Push the barb with seal into the tap
and ensure the silicone seal is on the tap body prior to installation.
Then turn the BrewZilla upside down and insert the thread of the tap through the pre-drilled
hole in the boiler. Secure the tap on the inside of the boiler using the hex nut and secure the
barb in place by tightening the retaining nut onto the taps thread.

BrewZilla 35L - Gen 4 Instruction Manual
Page 10 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Push the unconnected silicone hose from the pump over the barb on the tap and secure in
place with the wire clamp.
Plumbing the Tap to Bypass the Pump (optional)
The plumbing on the underside of the BrewZilla Gen
4.0 can be altered so that the wort runs to the tap
before it enters the pump. This is handy as it allows
the boiler to be drained through the tap even if you
have a blockage in the pump. To achieve this, you
will first need to move the position of the pump as
shown to the right.

BrewZilla 35L - Gen 4 Instruction Manual
Page 11 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Then change the pipe work to the following such that the tee piece from the boiler outlet
splits to the tap before it reaches the pump inlet.

BrewZilla 35L - Gen 4 Instruction Manual
Page 12 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Assembling the Malt Pipe
The malt pipe is the basket which sits inside the boiler and contains your grain during
mashing and sparging.
The malt pipe is made up of the malt pipe body, a perforated bottom screen and a
perforated top screen. The BrewZilla gen 4 does not require any overflow pipework and
hence the malt pipe bottom and top screens do not have any holes for pipework.
Simply insert the perforated bottom screen into your malt pipe body until it is flush with the
bottom of the malt pipe. The perforated top screen is added to the malt pipe after all of
your grain has been added to your malt pipe during the mashing step.
Please note: Use of the perforated top screen is optional. The system can be used without it
if you prefer to gently stir the mash.

BrewZilla 35L - Gen 4 Instruction Manual
Page 13 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Fitting the Malt Pipe Handle
We recommend installing the malt pipe handle before you add your grain and malt pipe into
your BrewZilla.
To fit the handle feed one end of the handle through one hole in the malt pipe. Push the
handle in on one side far enough so you have enough clearance on the other side to feed
the handle into the opposing hole.
Once the handle has been fitted you can lift/manoeuvre the malt pipe easily.
Operation of the BrewZilla using the Digital Controller
The Gen 4.0 BrewZilla can be controlled using the buttons on the digital controller or
through the RAPT Portal.
If you do not intend to connect your device to the RAPT Portal and hence do not want to
utilise the Wi-Fi functionality of the controller you can choose to control the brewery using
only the digital controller. To remove the prompts requesting you to register your device to
the RAPT Portal you will need to disable the Wi-Fi in the settings of the controller. To do this
press select to enter the menu, then select settings, then navigate using the arrows to the
Disable Wi-Fi settings, press select to disable Wi-Fi and the controller will then restart.

BrewZilla 35L - Gen 4 Instruction Manual
Page 14 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Enable/Disable Graph
By default, the BrewZilla Gen 4.0 controller will display a graph of temperature vs time. If
you prefer instead for a numerical old school interface than this can be easily changed by
unselecting the Show graph checkbox in the Settings.
Manually Adjusting Target Temperature
Press the Return button until the Target Temperature is highlighted then use the up or
down arrows to change the target temperature. The BrewZilla will only begin heating once
the device has been energised by pressing the play button. Warning: Do not press play to
energise the device if there is no liquid in the vessel.
Manually Turning the Pump On/Off
Press the pump button to turn the pump on/off. The Pump text will be coloured light blue
when the pump is set to ON and coloured grey when set to OFF. The pump will only begin
running once the device has been energised by pressing the play button. Warning: Do not
press play to energise the device if there is no liquid in the vessel, this will result in the
pump running dry which can damage the pump
Adjusting the Pump Duty Cycle (Percentage)
For greater repeatability of your mash schedule, you can control the pump output by
adjusting the duty cycle of the pump rather than using the ball valve on the recirculation
arm to adjust the output of the recirculating wort.
To adjust the duty cycle of the pump, press the Return button until the pump percentage is
highlighted then use the up or down arrows to change the pump percentage. If the pump
percentage is reduced then the pump will cycle on/off to reduce the output.
Alternatively, you can hold the pump button while pressing the up or down arrows to adjust
the duty cycle.
Adjusting the heating power

BrewZilla 35L - Gen 4 Instruction Manual
Page 15 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Press the Return button until the Heat percentage is highlighted then use the up or down
arrows to change the heating power.
Operation of the BrewZilla through the RAPT Portal
The brewery can be controlled via a profile generated in the RAPT Portal. Once you have
registered your device on the RAPT Portal select Profiles and Create New Profile. Then add
your profile steps such as strike, mash, mash-out, sparge, boil etc. Once you have made your
profile then either select Send Profile to Device from the profile menu or Start Profile
Session on the Dashboard to send the profile to your BrewZilla controller. Once the profile
has been sent to the device it will automatically energise the device and begin the profile.
You will still need to turn the pump on/off on the controller and adjust the power and pump
output percentage (if required) manually on the controller.
Mashing
Once you have assembled your boiler, digital controller and malt pipe you are then ready to
add grains to begin mashing.
Ensure that you have added the correct volume of strike water and this water is heated up
to the correct strike temperature according to your recipe. Then add your malt pipe with the
bottom perforated screen installed into your boiler, such that the top lip of the malt pipe
rests on the wire supports which are nested in the groove at the top of the boiler.
You can then pour your grain into the malt pipe. The malt pipe is designed to take up to
11.5kg grain but in the majority of recipes you will probably only used 4-5kg.
It is best to stir the grain periodically while pouring it into your malt pipe to break up any
dough balls (dry spots). Once you have added all the grain thoroughly stir the grain to
ensure all the dough balls have been broken up. This will take about 2-5 minutes.
Then insert the top screen into the malt pipe so that it lightly rests on top of the grain. After
all the grain has been stirred in and the top screen inserted, you can then assemble the
recirculation pipe to recirculate during the mash.

BrewZilla 35L - Gen 4 Instruction Manual
Page 16 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Assembling the Recirculation Arm
WARNING: The recirculation arm must be fitted whenever the
pump is in use.
Recirculation assists in achieving high mash efficiency using your
system as it aids in producing a homogenous mixture ensuring the
temperature is even throughout the grain bed.
Before attaching your recirculation arm, please check to see if the
silicone washer is in place in the female camlock. If this seal has
rattled loose or fallen off, the male and female camlocks will not
make a good seal and it will leak when the pump is in use.
To fit the recirculation arm to the BrewZilla, lift the arms on the
female camlock, then insert the male camlock and engage the
female camlock into its locked position.
If you need to rotate the recirculation arm for any reason, please
switch off the pump and readjust the camlock to the position
required and then reengage the camlock into its locked position
before turning the pump back on.
Important: If you are mashing without the top perforated in place
in the malt pipe then always make sure to elevate the silicone hose
from the recirculation arm above the grain bed if running a pump
duty cycle below 100% and before turning the pump off. This
prevents grain being sucked back up the recirculation arm and back
into the pump when suction is generated when the pump is cycled off.

BrewZilla 35L - Gen 4 Instruction Manual
Page 17 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Temperature
The temperature on the digital controller reads the temperature at the bottom of the boiler
near where the elements are mounted. It is important to understand that this is not the
core temperature of the mash. If you recirculate long enough the mash temperature will
eventually be close the measured temperature displayed on the digital controller. With that
said if you want to increase the temperature of the mash it is normally fastest and easiest to
overshoot the desired mash temperature by a few degrees while using a secondary
calibrated thermometer in the mash to keep an eye on the core temperature of the mash.
The phot to the right shows the placement of the
probe. The probe placement has been designed like
this as it prevents the element from overheating and
scorching the wort by taking the temperature of the
wort closest to the elements. This is why your strike
temperature needs to be accurate!
The BrewZilla includes Ultra Low Watt Density
Elements (ULWD) meaning brighter beer can be
brewed with the fear of scorching and burnt off-
flavours.

BrewZilla 35L - Gen 4 Instruction Manual
Page 18 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Sparging
Once you have mashed your grain for 60-90 minutes it’s then time to sparge the grain.
Sparging involves rinsing the grain bed with warm water to extract as much sugar as
possible without extracting undesirable tannins.
Using the malt pipe handle lift the malt pipe out of the boiler and rotate 90 degrees until
you see the feet of the malt pipe located near the halo ring (wire supports). See picture to
the right.
The Gen 4 BrewZilla includes a two-stage malt pipe. This gives you the option to lift the malt
pipe half way up and support it on the halo ring. This makes it more ergonomic, making it
easier to lift the heavy malt pipe out of the liquid. If you are making smaller batches only
raising the malt pipe up halfway may be preferable.
Note: The malt pipe of the March 2022 batch of Gen 4.0 BZ does not feature a perforated malt pipe
like the one shown above.

BrewZilla 35L - Gen 4 Instruction Manual
Page 19 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Once the malt pipe is suspended above the boiler and is
securely supported by the halo ring then pour warm
water (approximately 75-80°C) on top of the grain
inside the malt pipe to rinse the grain of the majority of
the remaining sugars. This process will probably require
5-15 liters of water depending on your recipe and
desired gravity that you are trying to achieve.
We highly recommend a secondary vessel to hold
hot/warm water for this process such as a 35L Digiboil.
If not, hot water directly from your faucet will do.
Boiling
Boiling is one of the final steps of making beer in the BrewZilla. Simply set the digital
controller to HH which will result in the elements remaining on continuously. Once you have
reached a boil make your hop additions and boil as long as required as per your recipe. A
normal boil length is 60 minutes however this can vary between beer styles.
Cooling
The BrewZilla includes an immersion cooling coil. An optional counter flow can be
purchased separately but these are complicated to use and it is sold as an optional extra.
The immersion chiller is easy to use and clean, simply connect your garden hose to each end
and run cold water through the chiller while it’s immersed in the wort inside the boiler.
If you were looking to save water you can also connect the immersion chiller to your pump
on your BrewZilla and then immerse your immersion chiller in a bucket of ice water.
There are a number of optional fittings which can be used to easily connect your garden
hose or pump to your immersion chiller which can be purchased separately.

BrewZilla 35L - Gen 4 Instruction Manual
Page 20 of 31 www.KegLand.com.au Last Updated 22/03/2022 16:53 PM
Connecting the immersion chiller to a garden hose (recommended)
The easiest way to connect a garden hose to the immersion chiller is to simply push the
garden hose over the immersion chiller and secure with a hose clamp.
For a more ergonomic solution you can install compression fittings and garden hose fittings
onto your immersion chiller. This will allow you to quickly connect and disconnect a garden
hose using female garden hose quick disconnect fittings.
12.7mm compression fittings (KL02004) and male garden hose fittings (KL09461) can be
purchased separately.
Connecting the immersion chiller to your BrewZilla pump –Ice Bath (optional)
If you were looking to save water you can easily hook your immersion chiller up to the pump
on your BrewZilla using 12.7mm compression fittings (KL02004) and camlock fittings
(KL04503 and KL04497). Run some silicone hosing (KL06873) from your recirculation arm to
your chiller and then run silicone hosing from the outlet of the chiller back into the
BrewZilla. These compression fittings, camlock fittings and extra silicone hosing can be
purchased separately.
If you prefer to use this method recirculate boiling wort through the chiller and back into
the boiler for at least 5 minutes to make sure the coil is hot and any potential contaminant
such as wild yeast or bacteria are killed by the boiling wort.
Once you have sanitised your chiller, place the chiller into a bucket of ice water and use the
ball valve on the recirculation arm to adjust the flow rate. Adjusting the flow rate on the
recirculation arm will change the temperature out of the output of the coil. So, use this
adjustment to achieve your desired wort temperature so the wort is at a suitable
temperature to put into your fermenter.
Hot Cubing
Another great method of cooling your wort that saves time is hot cubing. If you fill a HDPE
Cube or HDPE Bladder with hot wort then quickly fit the lid, this will keep your wort in a
sanitary environment. If you use this method, make sure to purge air out of the cube /