MANUAL. North America Issue No.7 July, Simply consistent, Consistently simple Bodecker Brewed. All Rights Reserved. 1

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Coleen Terry
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2 TABLE OF CONTENTS INTRODUCTION UNPACKING AND INSPECTING SPECIFICATIONS PLUMBER S INSTALLATION SET UP PROGRAMMING TROUBLESHOOTING PARTS AND SETTINGS POUR OVER ATTACHMENT BASE UNIT FREE STANDING BASE UNIT VENDING APPLICATION SPACE SAVER CARE AND CLEANING PARTS LIST WARRANTY Bodecker Brewed. All Rights Reserved. 2

4 Thank you for choosing the Bodecker concept for your single service coffee program. Today we are going to explain to you the features of the Bodecker machine, its general construction and how to utilize these features. In observing the brewer you will note its low profile and compact design of The Display Unit. We have a convenient shuttle and simplicity of inserting the Bob cup. Once in place we simply push the shuttle to the loaded position and the ready light will display green. You may now select from the 3 cup sizes, short, tall, or regular. The illuminated panel will now tell you the duration of the brew cycle and count down to the completion of the cycle. If, during the cycle, you press the button again the extraction cycle will stop. By pressing the button again the cycle will start over again. This feature has been installed for those who like steeped tea or a stronger brewed coffee. The second cycle allows for longer extraction. Since the brewer will deliver an additional amount of liquid than possibly required due to the second cycle, push the brew button again once the desired amount of beverage has been delivered and it will stop. After a few uses the custom brew feature will become second nature to the user resulting in more satisfaction with your custom brew Bodecker Brewed. All Rights Reserved. 4

5 You will notice that after each brewing cycle is completed air pump is engaged. Enough air must be injected into the cup to dry the coffee, if it is not adequately dried the ability to recycle the product is inhibited. This cycle may be adjusted as to time or pressure thru the programming. For those requiring hot water, it can be activated by pressing the red button. Hot water will come out the red nozzle located in the center of the machine. Hot water will continually be delivered as long as the red button is depressed. The brewer is equipped with a drip tray designed to accommodate different sizes of cups. If required the top portion may be slid from left to right to accommodate different sizes of cups or may be removed entirely. The lower level may also be conveniently removed for cleaning or to accommodate a coffeepot for larger consumption. After a pre-determined number of brews have been completed (35 is the recommended factory setting) the empty bin light will come on to indicate that no more product can be made until such time as the refuse bin has been emptied. The bin may be emptied by simply sliding the drip tray out of the way and pulling the bin from its position by pulling on its handle located at the center top of the bin. Having emptied the bin the limit switch will reset the brewer to the predetermined level upon inserting the bin back into its proper position. The adjoining display stand will hold 20 sleeves of coffee and associated products as chosen by the user. The sleeves are designed to slip in and out, as replacements are required and to assure fresh products at all times Bodecker Brewed. All Rights Reserved. 5

7 CAUTION Do Not connect the machine power cord or attempt to operate the Bodecker Brewed System before it is completely inspected and the power supply is checked for proper voltage and grounding. UNPACKING AND INSPECTING Verify the model and part numbers with the Bodecker Brewed System invoice or freight bill; immediately report any shortage or discrepancy with the carrier. Remove all shipping and packing materials. Save all shipping and packing materials until a thorough inspection has been completed. Examine the Bodecker Brewed System for dents, scratches or other damage resulting from improper handling. If any shipping damage is detected, file an immediate claim with the carrier. ELECTRICAL PROVISIONS A wall outlet, capable of delivering 120-volts, 60 Hz, single phase must be available within six feet of the Bodecker Brewed System. Check the outlet for proper grounding and breaker to be at least 15 Amps. WARNING Bodecker Brewed System is intended for indoor use only Bodecker Brewed. All Rights Reserved. 7

12 1) Plumb brewer in to water supply using 1/4 inch copper tubing. Flush water line before installing brewer to remove sediment. Brewer should be connected to COLD WATER LINE for best operation. 2) Water pressure should be at least 20 lbs. For less than a 25 ft run, use 1/4" tubing and connect to 1/2" or larger water line. The inlet water fitting on the back of the brewer is a 1/4" flare fitting. 3) If installed with saddle valve, the valve should have a minimum of 1/8" port hole for up to 25 ft run, and 5/16" port hole for over 25 ft runs. 4) Connect incoming water line to the elbow extending from the solenoid water valve at the back of the brewer. 5)An approved water filter is recommended for all installations 2007 Bodecker Brewed. All Rights Reserved. 12

14 WARNING: - Read and follow installation / setup instructions before plugging or wiring in machine to electrical circuit. Warranty will be void if machine is connected to any voltage other than that specified on the name plate. Initial Setup Instructions 1) Plug or wire brewer to the appropriate voltage circuit as indicated on the serial tag. Depress the "On/Off" (power) switch to supply power to the control board and the tank will begin to fill, segments of display will cycle in an hourglass pattern to indicate brewer is operational. The tank lid has a probe in it to signal the control board when the water has reached the appropriate level to begin heating cycle. If this probe does not see water for 3 minutes the control board will interpret this as an error. It will shutoff the solenoid valve, disable the control board and display H20. After supplying water to the brewer you have to power it off and on to clear error message. NOT READY CONDITIONS While the tank is filling it is a good time to see display of Not Ready Messages. Depress one of the brew buttons. CUP will be displayed momentarily in the display window. This indicates that a Bob cup must be put in place before brewing can begin. Install a Bob cup to overcome this error. Depress one of the brew buttons again. H20 is displayed indicating that the water level in the tank is too low to brew (assuming that tank has not finished filling already). Wait until solenoid shuts off to overcome this error Bodecker Brewed. All Rights Reserved. 14

15 Depress one of the brew buttons again. Htr is displayed indicating that the brewer needs to heat before it is able to begin a brew cycle (assuming that tank has not finished heating already). When tank finishes heating, this error will be corrected. For purposes of brewing, the temperature is considered ready when it is within 10 degrees of set point. Temperature still regulates at the set value however, a brew cycle can be started regardless of water temperature by holding in the brew button for several seconds to over ride temperature condition. Note that all other ready conditions must be met. While waiting for the heater to finish heating, remove bin from brewer and push a brew button. bin will display to indicate that a brew cycle will not take place because bin is missing. Replace bin in brewer to overcome this error. A message of UPS is also possible if the up switch is not depressed, indicating that the brew mech is in the retracted position. This error should never be seen, if this does happened refer to programming section. These are some of the ready conditions that must be met in order for the ready light to come on and a brew cycle to be started. These messages will be displayed for two seconds whenever a brew cycle is attempted if the error noted exist. If multiple errors exist, the error condition will display one at a time with the 2nd error condition appearing after the 1st condition is resolved. For instance if you walk up to the Bodecker and try to brew without 1st putting a Bob cup in place it will prompt you to insert a cup. Once that is done it may then prompt you to wait for it to finish heating if it has just experienced heavy use or faucet activity. If no other errors exist, the ready light will come on when unit reaches temperature. On the next page we are showing proper placement of the roller bearing in the down position. It should be slightly to the right of centre (about 1/32 ) to lessen the amount of torque required to start the up cycle. Failure to properly position roller bearing may result in E6 error and requirement for service call Bodecker Brewed. All Rights Reserved. 15

18 These items apply to all programming functions: Programming is entered on power up while holding hot water button. Top brew button increments value. Middle brew button decrements value. Lower brew button advances to next parameter to set within a function. Global programming functions Hold faucet button on power up. Settings apply to all brews. Bin counter setting Determines how many Bob cups can be brewed before the bin must be removed and emptied to reset counter. May be turned off (if storage bin is not used) or set from 20 to 500 in increments of 5. Air pump run time Determines how long air pump runs after brew to remove excess liquid from system. Set from 1 to 30 seconds. Air pump speed Sets the air pump speed. Set from 1 to 10 with 10 being the maximum. Calibration mode This sequence is used to calibrate the electronics to the liquid flow rate through the brew system. It DOES NOT set the flow rate. It simply tells the control what the flow rate is. To calibrate the unit when CAL is displayed: Place a graduated container in place below coffee dispense point, Place a Bob cup in place, Press either of the two upper brew buttons, Brewer will dispense for 30 seconds, set display to the volume in ounces delivered. Volume can be set in 1/10th oz increments. Brew Button Programming Hold brew button to set up while powering up unit. Brew volume Set the desired product volume. Valid values are between 4 and 14 oz. Service mode (you can enter it on power up while holding hot water button) and scroll to service mode (tall button). Display shows SRV. Press either of the two upper brew buttons to enter service mode. Service mode Display shows Srv. This mode is used to monitor temperature and verify functionality of thermistor, switches and probe system. Service sub functions are as follows: 2007 Bodecker Brewed. All Rights Reserved. 18

19 Display shows SRV. Press either of the two upper brew buttons to enter service mode (Regular or Short). This mode is used to monitor temperature and verify functionality of thermistor, switches and probe system. Once in the service mode display will show current temperature of water (not programmed temperature). If there is the problem with temperature probe you will see following messages (instead of current temperature) displayed. Temperature monitor Shr Shorted Thermistor Opn Open Thermistor --- Out of Range xxx (degrees F) By pressing (Regular or Short) buttons you will be able to monitor motor switches Use increment (Regular) and decrement (Short) buttons to control motor for testing. You will notice that brewing chamber is moving up and down activating upper and lower limit switches which govern the position of the brewing chamber at the same time display will change indicating current position as follows: 1:- - Neither switch closed 1:U- Up switch closed 1:-d Down switch closed 1:Ud Up and down switches closed Pressing Tall button will allow you to monitor waste bin and Bob cup switches depending if they are activated or not following message will be displayed: 2:- - Neither switch closed 2:b- Bin switch closed 2:-C Cup switch closed 2:bC Bin and cup switches closed With Next service future (just press Tall button) is monitoring low and high water level probes in water tank. They are sending command to open or close water solenoid. Depending on current water level in the tank display will read: 3:- - Neither probe active 3:L- Low probe active closed 3:-H High probe active 3:LH Low and high probes active Press Tall button (enter) to return to Service mode Bodecker Brewed. All Rights Reserved. 19

20 ERROR CODES E-1 Open thermistor E-2 Shorted thermistor E-3 Heater timeout E-4 Fill timeout E-5 Up switch timeout E-6 Down switch timeout E-7 Cup switch opened during brew cycle Recommended programming settings: Bin 35 Air pump time 5 Air pump speed 6 Calibration 7.5 for strong coffee (default setting) 10 for weaker coffee (flow regulator must be adjusted to compensate for shorter brewing time) Regular 8.0 Short 7.0 Tall 9.0 Set PDF valve to give out 8.0 fluid ounces of coffee when using Regular selection 2007 Bodecker Brewed. All Rights Reserved. 20

22 MOST PROBLEMS CAN BE RESOLVED BY SHUTTING OFF THE POWER AND TURNING BACK ON. TURN OFF THE POWER BEFORE PROCEEDING WITH ANY TROUBLE- SHOOTING ACTIVITY 1. Review shuttle staying in position 2. Possible spring out 3. Facial plate not in place 4. Corner of facial plate loose 5. Guillotine too low, preventing shuttle from sliding in 6. Pull coffee outlet to ensure it s free 7. Place bob-cup in shuttle; observe green ready light on. If it goes off, review steps 1-3 and check limit setting for cup switch. 8. Review service LED panel. 9. To check shuttle operation, place a screwdriver between bearing and shuttle to see if it slides in and out easily. 10. Enter service mode with shuttle out by scrolling down to SERVICE. Now press SHORT. The current temperature will appear. Now press TALL. IU will appear. By pressing the REGULAR button the guillotine will start to operate. To get out of the program press HOT WATER button, then REGULAR button. This will engage the guillotine. To ensure it is functioning properly allow it to return to HOME. Install shuttle repeat process. If it jams, the pitchforks are hitting either the side rails or the bearing, OR the shuttle is jammed with hot chocolate. Remove the guillotine and move up and down by hand to observe the problem. Adjust pitchforks or shuttle stop accordingly. 11. Roller bearing on guillotine should always be in its resting position: 1/32 of an inch to the right of center on the injector pin in the upper position. The roller bearing should be within 1/32 of an inch of the center. If either is out, reset limits. If shuttle does not go in all the way the guillotine is too low OR the horseshoe needs adjusting. Observe shuttle wear spots for possible clues. 12. Notes: TALL to service, then SHORT, current temperature, then TALL, then REGULAR. IU will give motor action Bodecker Brewed. All Rights Reserved. 22

23 Problem: Shuttle cannot be withdrawn from the inserted position Turn power off and back on. This will remedy most service problems. Go to programming (you can enter it on power up while holding hot water button) and scroll to service mode (tall button). Display shows SRV. Press either of the two upper brew buttons to enter service mode. You can raise the guillotine by pressing Regular button. Then press Hot Water to return. Shut off power. Remove cover. Observe position of cam on drive motor. The location should be as per diagram. If not, manually turn rotor in a clockwise motion until cam is located as per diagram. Shuttle will now withdraw. Check wiring and limit switch operation. Make sure limit switch screws are tight and secure Bodecker Brewed. All Rights Reserved. 23

24 Problem: No hot water to Bob cup Check power source. Remove water line to injector pin. Place end of line in the drip tray. (Start cycle with Bob cup in place.) If there is still no water check pumps with a voltmeter during operation. If pumps are running and you get water remove the water injector pin for observation. If obstructed replace and clean with a 3/32 drill bit by inserting it into injector pin. Check for possible replacement of main board. Problem: Brewer dripping liquid. Remove cover. Make sure all water lines are secure and in place. Check coffee seal in shuttle to assure that it is in place and functioning. Check seal on guillotine to assure it is in good repair and functioning. Check guillotine to assure that it is in the down position and creates proper seal at the time of brewing. If not, adjust all cams and functions to assure that they are in the position as indicated in drawing and that limit switches are secure and functioning. Check if there are coffee grounds stuck to the seal. If so, clean them out, as they will create obstruction, preventing a proper seal Bodecker Brewed. All Rights Reserved. 24

25 Problem: Hot water dripping into tray Shut off power. Remove cover. Check the diaphragm in the hot water solenoid for obstruction or deformity in the diaphragm. Problem: Cup does not always lie flat in the shuttle Check to see the location of the coffee outlet pin in the shuttle. The pin should be located as per drawing. The pin may be adjusted by loosening Allen screw. See drawing. On the underside of the shuttle after resetting pin make sure that the pin is positioned so that the top portion enters the Bob cup first. Reset horse shoe elevation as it may be too high. Problem: Shuttle will not insert Forks on guillotine may be obstructing path. Shut power off, then turn on. Check to make sure that forks are above the roller bearings. Cam must be in the fully raised position and centered over roller bearings. Remove cover and check for cam location and limit switch operation. Turning rotor of motor counterclockwise, facing the front can activate resetting. This should not normally occur. Test cycle repeatedly for limit switch functions and mounting screws. Check passageway to see if Bob cup is stuck in loaded position Bodecker Brewed. All Rights Reserved. 25

Tip machine to your left to empty remainder of water. 7. Put plug back in the hose. 8.

29 DRAIN HOSE ACCESS PANEL 1. Remove screw in center of panel and remove access panel. 2. Pull out hose. 3. Remove drain plug. 4. Unlatch drain clump. 5. Drain until empty. 6. Tip machine to your left to empty remainder of water. 7. Put plug back in the hose. 8. Clamp hose again. 9. Store the hose back in its place. 10. Reinstall access panel Bodecker Brewed. All Rights Reserved. 29

42 TANK 1 Tank W/Blanket Warmer, 120V 3 Hot water connection 4 Grommet, Stud Retaining 5 Fastener, 1/4 Turn.250" Dia. 6 Gasket, Tank Lid 7 Tank Lid Weldment 8 Nut, Hex.50"-20 9 Gasket, Tank Heater 10 Tank Heater, 1850W 220V 11 Thermal Cut-Off W/ Double Terminal 12 Thermal Cut-Off W/Lead Assy 13 Lead, Electrical (Thermostat to Heater) 14 Bracket, Thermostat Mounting 15 Thermostat Assy 16 Grommet, Thermostat 17 Tube Kit 18 Gasket, Sprayhead Tube 19 Hub, Syphon 20 Wiring Harness 21 Nut, Hex.438" Sprayhead, 6-Hole 2007 Bodecker Brewed. All Rights Reserved. 42

44 A single cup brewing system that is designed for locations where no plumbing is available. This unit will brew 45 cups of coffee before there is any need to add water. The Brewer has a low water" notification on a digital display Bodecker Brewed. All Rights Reserved. 44

47 Bodecker also offers an alternative to the disposal bin. The High Volume Metal Base Unit rests on the counter allowing The Bodecker Brewer and the drip tray to be securely placed on top. The High Volume Base Unit is designed to be placed at high capacity stations and holds up to 175 spent Bobcups Bodecker Brewed. All Rights Reserved. 47

The Bodecker Brewer and the drip tray are securely placed on top.

50 The High Volume Free Standing Base Unit is design for locations where counter space is not available. The Bodecker Brewer and the drip tray are securely placed on top. In addition this unit holds up to 175 spent Bob-cups Bodecker Brewed. All Rights Reserved. 50

The illuminated panel indicates the price at the top of the face plate on a digital display, allowing the operator or client to conveniently change the price in increments of 5 cents, thereby

53 The illuminated panel indicates the price at the top of the face plate on a digital display, allowing the operator or client to conveniently change the price in increments of 5 cents, thereby eliminating the need for printed sticker or price labels. When coins are added, the screen will show the amount remaining, similar to conventional vending machines Bodecker Brewed. All Rights Reserved. 53

55 COIN ATTACHMENT Coin attachment is fixed to the Bodecker and has a 3-Digit LED display to indicate the amount of money put in the coin acceptor. The Coin attachment has three interface points inside the Bodecker -Interface to the coin acceptor -Vending motor home position detector -Vending Switch detector Controller has a set of DIP switches to set the vend price from 0 to $2 in increments of 5 (See APPENDIX). The entire functionality of controller like price set, motor home position detection, vending switch control etc. are implemented in the CPU with firmware. It is designed to be Fixed Price Vend controller i.e. if customer pays exact money, vend starts once customer presses the vend switch. If customer pays more money, the leftover money is not paid back or used for next vend. OPERATION OF COIN ATTACHMENT The operator sets the vend price by setting the appropriate DIP switch. When the customer pays exact or more money in the vending machine, the Coin attachment directs the machine for vending coffee, green ready light is displayed. Coin attachment detects when brewing process is completed by sensing the motor home position. Brewer is ready for another cycle. For next cycle of vending, the customer has to pay again the exact or more amount Bodecker Brewed. All Rights Reserved. 55

56 OPERATING SPECIFICATION: If all DIP Switches are ON, there will be free vend and Coin Acceptor will not accept any coin. Displays will show 000. Normal case, Vend price (Price set by the DIP switches) will be displayed and every time a coin is accepted, the remaining money to vend will be displayed. Once coin accepted is more than or equal to the vend price, vending ready relay will be activated. Displays will blink 000 and also beeps once. When cup switch is activated and brew button is pressed, vending will start and during that time displays will steadily show 000 without any beep by the buzzer. When vending is over, vend price will be displayed and new cycle of vending can start over again. WHEN DIP SWITCH IS CHANGED WHILE THE MACHINE IS POWERED ON, THE MACHINE NEEDS TO BE RESTARTED TO TAKE THE NEW CHANGES INTO EFFECT OR ATLEAST ONE VEND WILL BE DONE WITH THE LAST SETTINGS. INSTALLATION: There are two sets of wires for installation from the Coin attachment. One is 4 wire shielded wire and another is two isolated wires. POWER WIRES: This is a pair of two wires, Red and Black. They are connected to the Transformer in parallel to the wires from the Vending Machine board. These wires can be interchanged. The following diagram shows the installation of those wires Bodecker Brewed. All Rights Reserved. 56

58 SHIELDED (4) WIRES: There are two pairs of wires in the shielded package; one pair is longer than the other. 1st Pair of Shielded wire is Longer and of Black and White color - Black wire is connected to the Lower Leaf Switch, where the other black wire of Coffee Machine Board is already connected. - White wire is connected to the Upper Leaf Switch, where the other Gray wire from the Coffee Machine Board is already connected. NOTE: These wires can t be interchanged. 2nd Pair of Shielded wire is shorter and of Red and Green color - Remove the Blue wire from the Cup Sensing Leaf Switch and proceed as follows - Green wire is connected to the coffee cup sensing leaf switch, where originally the blue wire from the Coffee Machine Board was connected. - Red wire is connected to the Blue wire with a Jumper. NOTE: These wires may be interchanged 2007 Bodecker Brewed. All Rights Reserved. 58

60 a.1: 1st Pair of Shielded wire is Longer and of Black and White color i) Black wire is connected to the Lower Leaf Switch, where the other black wire of Coffee Machine Board is already connected. ii) White wire is connected to the Upper Leaf Switch, where the other Gray wire from the Coffee Machine Board is already connected. NOTE: These wires can t be interchanged. a.1: 2nd Pair of Shielded wire is shorter and of Red and Green color Remove the Blue wire from the Cup Sensing Leaf Switch and proceed as follows i) Green wire is connected to the coffee cup sensing leaf switch, where originally the blue wire from the Coffee Machine Board was connected. ii) Red wire is connected to the Blue wire with a Jumper. NOTE: These wires may be interchanged 2007 Bodecker Brewed. All Rights Reserved. 60

61 DIP Switch settings Cents DIP7 DIP6 DIP5 DIP4 DIP3 DIP2 DIP1 5 ON ON ON ON ON ON ON 10 ON ON ON ON ON ON OFF 15 ON ON ON ON ON OFF ON 20 ON ON ON ON ON OFF OFF 25 ON ON ON ON OFF ON ON 30 ON ON ON ON OFF ON OFF 35 ON ON ON ON OFF OFF ON 40 ON ON ON ON OFF OFF OFF 45 ON ON ON OFF ON ON ON 50 ON ON ON OFF ON ON OFF 55 ON ON ON OFF ON OFF ON 60 ON ON ON OFF ON OFF OFF 65 ON ON ON OFF OFF ON ON 70 ON ON ON OFF OFF ON OFF 75 ON ON ON OFF OFF OFF ON 80 ON ON ON OFF OFF OFF OFF 85 ON ON OFF ON ON ON ON 90 ON ON OFF ON ON ON OFF 95 ON ON OFF ON ON OFF ON 100 ON ON OFF ON ON OFF OFF 105 ON ON OFF ON OFF ON ON 110 ON ON OFF ON OFF ON OFF 115 ON ON OFF ON OFF OFF ON 120 ON ON OFF ON OFF OFF OFF 125 ON ON OFF OFF ON ON ON 130 ON ON OFF OFF ON ON OFF 135 ON ON OFF OFF ON OFF ON 140 ON ON OFF OFF ON OFF OFF 145 ON ON OFF OFF OFF ON ON 150 ON ON OFF OFF OFF ON OFF 155 ON ON OFF OFF OFF OFF ON 160 ON ON OFF OFF OFF OFF OFF 165 ON OFF ON ON ON ON ON 170 ON OFF ON ON ON ON OFF 175 ON OFF ON ON ON OFF ON 180 ON OFF ON ON ON OFF OFF 185 ON OFF ON ON OFF ON ON 190 ON OFF ON ON OFF ON OFF 195 ON OFF ON ON OFF OFF ON 200 ON OFF ON ON OFF OFF OFF 2007 Bodecker Brewed. All Rights Reserved. 61

Where space is of a concern our display unit is designed to be

65 The shuttle or Bob Cup holder can be removed simply by first removing the drip tray and refuse bin. By now pulling down on the silver catch under the shuttle the shuttle may be removed. On each delivery the shuttle should be removed, cleaned, and examined for functionality. While rinsing the shuttle the bin should also be emptied and rinsed. Customers appreciate this attention to detail and should be encouraged in order to maintain a safe and clean refreshment area. To service any interior parts of the brewer the switch at the back of the brewer should be turned off. To remove the cover, first disconnect the water filter, if one has been installed. Next, remove the two screws at the topside of the faceplate, then the 6 screws at the base of the cover. You may now remove the shroud by pushing in ¾ of an inch back to clear the faceplate, and then lift off, being careful to place the cover in a location where it will not get damaged or interfere with your clients. The water inlet solenoid, you will observe, is a standard solenoid requiring normal service as recommended by the manufacturer. The hot water tank, although large for a single serve machine, is comprised of components most operators currently have in stock from Newco Bodecker Brewed. All Rights Reserved. 65

66 Deliming is accomplished by first engaging the hot water button with the inlet water connection removed. Once the water level has been lowered remove the tank installing a fresh recycled tank. We recommend that the tanks be replaced on location rather than removing the brewer and subjecting it to damage. The 2 solenoid pumps adjacent to the tank operate simultaneously. This feature creates the pulsating effects in conjunction with the spray injector that is critical to the quality of the product produced. The next item is the flow control valve. This valve, due to its unique features, ensures a consistent flow of hot water to the Bob cup regardless of the resistance created by different products in the Bob cup. The setting of the control valve will be covered under the set-up section. The hot water flows in the injection pin which has been designed to cause water to be injected upwards to the lid with a pulsating flow to increase infusion. The guillotine directs the injection pin into the Bob cup Bodecker Brewed. All Rights Reserved. 66

67 The guillotine cam is driven by the motor. As the guillotine is lowered the forks pull the shuttle roller bearings, causing the pull rods 1 and 2 to direct the coffee outlet pin into the Bob cup. When a Bob cup is placed in the shuttle, limit switch #1 is engaged through push rod #3 forced back into limit switch #1 as a result of the Bob cup being forced against it. Limit switch engages the ready light until such time as the pressure on push rod #3 is removed. The cam motor is engaged through limit switches #2 and #3, controlling the up and down cycles. This ensures that the Bob cup does not go up as the guillotine removes the injection pin. The retainer on the yoke prevents the cup from being impaled on the injection pin. Upon the removal or withdrawal of the shuttle for loading, the ejector plate pushes the Bob cup off the end of the shuttle, causing it to be ejected into the refuse bin. As the refuse bin is removed limit switch #4 resets the brew count. The control panel is located on the back of the faceplate. The faceplate conveniently stays in place upon the removal of the cover to facilitate testing Bodecker Brewed. All Rights Reserved. 67

68 Only non-acidic products should be utilized in cleaning any portion of the Bodecker Brewer. Periodically, you should visually inspect your machine s hot water tank for excessive lime and scale buildup. This buildup on the tank walls, water valves, and heater element will vary dramatically, depending upon water quality. You should develop a cleaning and deliming schedule based on the apparent local water quality. The hot water tank should be delimed with a solution of SCALEX 900. All other components should be cleaned with regular dish detergents with care. Take time to rinse all residues from surfaces that come in contact with consumable products. Only an approved stainless steel product should be used to polish any stainless steel components, with particular care taken never to use abrasive products on any Bodecker surfaces. Prior to any cleaning or sanitizing activities, make sure the brewer is disconnected from Hydro sources Bodecker Brewed. All Rights Reserved. 68

70 Part number Description Price Carry in Service truck How many Switch micro- Modified $2.20 yes Pump,Air $12.95 yes Switch,DP/ST,rect,rocker $ Relay,12V DC, SPST 30 Amp. $2.88 yes Drawer assembly $ Body plunger Assembly $ Tube,plunger, /481.0 $ Needle Horizontal $2.50 yes Seal Block $1.80 yes Retainer, spring, grooved $ Retainer, spring $0.10 yes Screw, set, 8-32x3/16 $ Body plunger, Rev, 2/06 $ Drawer handle and Cap Assembly $ Bar Assembly $ Stripper Assembly $ Motor $39.50 yes Motor Assembly $ Crank $ Pin,spring,.125x.625 $ Retainer,cup,polyprop $3.00 yes Wire,poly cup,retain $ Actuator Assembly $ "O" ring $0.20 yes Seal Ring $ Needle Vertical $ Micro switch $2.15 yes E-Clip $0.20 yes Faceplate Assembly $29.25 yes Faceplate $ Label overlay $ Label Switch $ Label Drawer $4.05 yes Thermostat,man/reset $3.00 yes Probe assembly Thermister $17.50 yes Element Main 1400 w, 120 V $9.00 yes Tank Assembly $ Board, Control $47.00 yes Valve, Check $6.18 yes Tee,Tube $ Pump PI $14.85 yes Tube, poly, Red,1" $0.10 yes Tube,poly,black,1" $0.10 yes Dump Valve Turned $22.20 yes Valve Assembly-Inlet $17.95 yes 1 Note: These parts were recommended based on you have at least 20 machines in the field Bodecker Brewed. All Rights Reserved. 70

72 Bodecker Brewed coffee brewers are warranted against defects in workmanship or materials, under normal use, for 90 days from the date of purchase. Brewer parts are warranted against defect for 12 months from date of purchase. Liability in all events is limited to the purchase price paid and liability under the aforesaid warranty is limited to replacing or repairing any part or parts which are defective in material or workmanship, and returned to our factory, shipping cost prepaid. No warranty expressed or implied, other than the aforesaid is made or authorized by Bodecker Brewed, Inc. Prompt disposition will be made if item proves to be defective, within warranty. Before returning any item, write or call Bodecker Brewed, or the dealer from whom the product was purchased, giving model number, serial number, and date of purchase, and describe nature of the defect. If damage was incurred during transit to you, file claim with the carrier Bodecker Brewed. All Rights Reserved. 72

E N T E R P R I S E S

N E W C O E N T E R P R I S E S P/N 110881 Issued 12/99 INSTALLATION and OPERATION MANUAL for OCS-16A BREWERS BREWER SPECIFICATIONS Model Width Length Height US 120V Amps CANADA 120V Amps OCS-16A 14 15-1/2