Bkon Craft Brewer Service Manual

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SERVICE MANUAL

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Page 1 SERVICE MANUAL...
Page 2: Safety
SAFETY IMPORTANT SAFETY INSTRUCTIONS - READ, UNDERSTAND AND SAVE This operation manual contains important instructions and safety information about the BKON™ Craft Brewer. Observe the following dangers, warnings, cautions and notices when operating the BKON™ Craft Brewer. Explanation of safety symbols...
Page 3 Safety Risk of injury and / or damage to the equipment! WA R N I N G Making improper changes in the form of modiﬁ cations or unauthorized repairs can lead to injury or damage to the equipment. - Programming and settings may only be preformed by authorized service technicians.
Page 4: Table Of Contents
Table of Contents Safety Table of Contents Service Prerequisites Removal / Installation of Parts - Tower Removal / Installation of Parts - WVSC Programming Testing and Adjustments Troubleshooting Water / Air Diagram Electrical Diagram Sequence of Operations of 86...
Page 5: Service Prerequisites
SERVICE PREREQUISITES Purge Water System If the BKON unit is powered ON upon the service technician’s arrival, the water WA R N I N G system will be ﬁ lled with hot water under pressure. Utilize the Cool Down function within the service menu before making any repairs or disconnecting any water lines.
Page 6 Service Prerequisites Protect Air and Water Line and Connections Remove the water, air and drain Place a piece of tape over the Before reconnecting the water, lines if the repair requires their water, air and drain tubing to air and drain tubing ensure any removal.
Page 7 of 86...
Page 8: Removal / Installation Of Parts - Tower
REMOVAL / INSTALLATION OF PARTS - TOWER Top Cover (Tower) Procedure Remarks Disassembly Order Assembly is in the reverse order of disassembly Electrical connection Unplug at wall from WVSC Screw (Phillips) End cover Top cover of 86...
Page 9 Removal / Installation of Parts - Tower Locking Lever Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Procedure Remarks Disassembly Order Assembly is in the reverse order of disassembly Screw Axel Clamp Axis Locking lever of 86...
Page 10 Removal / Installation of Parts - Tower Plunger Assembly Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Locking Lever - Page 8 Procedure Remarks Disassembly Order Assembly is in the reverse order of disassembly Screw (Phillips) Valve Cylinder Remove the silicone water and air lines and microswitch connections Plunger of 86...
Page 11 Removal / Installation of Parts - Tower Micro Switch Plunger Assembly Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Locking Lever - Page 8 Plunger Assembly - Page 9 Procedure Remarks Disassembly Order Assembly is in the reverse order of disassembly Screw Washer Spring...
Page 12 Removal / Installation of Parts - Tower Logo LEDs Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screws LED Board Disconnect wiring connection of 86...
Page 13 Removal / Installation of Parts - Tower Tower Solenoid Valves Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Solenoid Valves Disconnect silicone tubing and voltage connectors of 86...
Page 14 Removal / Installation of Parts - Tower Tower Left Side Panel Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Side Panel of 86...
Page 15 Removal / Installation of Parts - Tower Temperature Sensors - Thot and Tmix Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Tower Left Side Panel - Page 13 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly NTC Tmix sensor Ensure water supply is turned off.
Page 16 Removal / Installation of Parts - Tower Tower LED Left Side Lights Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Tower Left Side Panel - Page 13 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly LED strip (Upper) Disconnect wire connections LED strip (Lower)
Page 17 Removal / Installation of Parts - Tower Tower Right Side Panel Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Right Side Panel Disconnect (6) wire connections before lifting side panel Thot sensor wires are green Tmix sensor wires are grey of 86...
Page 18 Removal / Installation of Parts - Tower User Interface Display Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Cover Screws PCB Board Disconnect wire connections before removing boards Stand off Touch screen User Interface mounting screws User Interface gasket of 86...
Page 19 Removal / Installation of Parts - Tower Tower LED Right Side Lights Requisite Service Removal / Installation: Top Cover (Tower) - Page 7 Tower Right Side Panel - Page 16 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly LED strip (Upper) Disconnect wire connections LED strip (Lower)
Page 20 Removal / Installation of Parts - Tower Drain Pan Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Drain Pan Cover Screws Drain Pan Seal Not shown of 86...
Page 21 Removal / Installation of Parts - Tower Communication / Power Connector Requisite Service Removal / Installation: Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Image not available of 86...
Page 22: Axel Clamp
Removal / Installation of Parts - Tower Locking Handle Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Handle Cover Screws Axel Clamp Locking Handle of 86...
Page 23 Removal / Installation of Parts - Tower Actuator Switch Requisite Service Removal / Installation: Locking Handle - Page 21 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Bolts Springs Holding frame Screws Limit housing Micro Switch Disconnect wiring of 86...
Page 24 Removal / Installation of Parts - Tower Locking Handle Bushing Requisite Service Removal / Installation: Locking Handle - Page 21 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Brass bushing of 86...
Page 25 of 86...
Page 26: Removal / Installation Of Parts - Wvsc
REMOVAL / INSTALLATION OF PARTS - WVSC WVSC Covers Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screws Top cover Screw Right cover Screw Left cover of 86...
Page 27 Removal / Installation of Parts - WVSC Air / Water Separator Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Air / Water Separator Disconnect silicone tubing of 86...
Page 28 Removal / Installation of Parts - WVSC Vacuum Pump Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screws Washer Vacuum pump Disconnect silicone tubing and wiring of 86...
Page 29 Removal / Installation of Parts - WVSC Power Switch Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly DANGER: Disconnect main power before removing power switch Knob Set Screw ON / OFF face plate Screws...
Page 30 Removal / Installation of Parts - WVSC Power Supply Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly DANGER: Disconnect main power before removing power supply Screws NEVER remove the mesh cover Power supply bracket Disconnect wiring...
Page 31 Removal / Installation of Parts - WVSC Secondary Board Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly DANGER: Disconnect main power before removing power supply Screw High voltage board bracket Disconnect wiring Screws...
Page 32 Removal / Installation of Parts - WVSC Command Board Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly DANGER: Disconnect main power before removing power supply Screw Low voltage board bracket Disconnect wiring Screws...
Page 33 Removal / Installation of Parts - WVSC Communication / Power Connection Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Communication / Power Connection Ensure the largest notch is orientated to the operator side of the WVSC.
Page 34 Removal / Installation of Parts - WVSC Communication Port Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Washer Communication Connector of 86...
Page 35 Removal / Installation of Parts - WVSC Flow Meter Shelf Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Flow meter shelf Disconnect silicone tubing and wiring of 86...
Page 36 Removal / Installation of Parts - WVSC Flow Meter Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Flow meter Disconnect silicone tubing and wiring of 86...
Page 37 Removal / Installation of Parts - WVSC Mixing Valve Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screws Mixing valve Disconnect silicone tubing and wiring of 86...
Page 38 Removal / Installation of Parts - WVSC Water Pump Motor Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Bolt Washer Water pump motor Disconnect silicone tubing and wiring Capacitor Secured by one nut (see detail below) Capacitor mounting detail.
Page 39 Removal / Installation of Parts - WVSC Rotary Pump Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly of 86...
Page 40 Removal / Installation of Parts - WVSC Thermal Block Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Bolt Washer Thermoblock Disconnect silicone tubing and wiring Tubing Spacer Sensor NTC Safety Thermostat of 86...
Page 41 Removal / Installation of Parts - WVSC Solenoid Valves Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screw Solenoid valve holder Screws Solenoid valve Disconnect silicone tubing and wiring of 86...
Page 42 Removal / Installation of Parts - WVSC Descaling Valve Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screws Descaling valve Disconnect silicone tubing and wiring of 86...
Page 43 Removal / Installation of Parts - WVSC Water Inlet Valve Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Screws Water inlet valve Disconnect silicone tubing and wiring of 86...
Page 44 Removal / Installation of Parts - WVSC Water Pressure Regulator Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Water pressure regulator Disconnect silicone tubing of 86...
Page 45 Removal / Installation of Parts - WVSC Air Pressure Regulator Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Air pressure regulator Disconnect silicone tubing of 86...
Page 46 Removal / Installation of Parts - WVSC Filter Holder Requisite Service Removal / Installation: WVSC Covers - Page 25 Procedure Remarks Removal Order Assembly is in the reverse order of disassembly Thumb Screw Filter Holder Disconnect silicone tubing of 86...
Page 47 of 86...
Page 48: Programming
PROGRAMMING Entering / Updating Time and Date User Interface Software Update Uploading Main board Software Uploading New Menu (Drink Recipes) Entering Time and Date 1. At the home screen, press the wrench icon button 2. Press the Time/Date button 3. Select the hour box, enter the current hour and press Ok - The time format used is the 24 hour clock, 16:30 is 4:30 PM 4.
Page 49 Programming Install new User Interface Software START Insert Select Wait Wait ca. 20 s approx. 20 sec. RESTART Select Remove Install new Mainboard Software Insert Enter Update MB Passcode Firmware 4576 Press & hold 5 seconds RESTART Restart Select file Machine Main Board FW Selection Remove...
Page 50: Testing And Adjustments
Coffee Spirits Coffee Spirits Counters < < Press and hold the BKON Enter PIN number 4576 and Select page 2 to enter the service dots for 5 seconds press Enter menu Use this function to check water ﬂ ow rate...
Page 51 Testing and Adjustments Water Calibration Check and Adjustment The BKON unit comes factory calibrated to the correct 17:30 17:30 water ﬂ ow rate. The following procedure can be used in the event the water ﬂ ow should need to be readjusted.
Page 52 Testing and Adjustments Water Pump Adjustment Remove the top and right side Locate the water pump. Loosen the locking nut (1) panels Turn the adjustment screw (2) - Clockwise to increase pressure. - Counterclockwise to decrease pressure - Turn adjustment screw in ¼ turn increments or less Tighten the locking nut.
Page 53 Testing and Adjustments Vacuum Calibration If the BKON unit is powered ON upon the service technician’s arrival, the water WA R N I N G system will be ﬁ lled with hot water under pressure. Utilize the Cool Down function (shown on page 4) before making any repairs or disconnecting any water lines.
Page 54 Testing and Adjustments Vacuum Calibration Ensure that a brew handle and 17:30 1 7: 1 7: 1 7: 1 7: basket are installed in the brew chamber. Move the locking handle down, to the locked position. Note: The calibration will not work Green Tea T ea T ea...
Page 55 of 86...
Page 56: Troubleshooting
TROUBLESHOOTING Error Messages on User-Interface Error Code Possible Cause Solution Brew Chamber Glass Brew Chamber not installed correctly 1. Remove and reinstall Brew chamber. 1. Poke purge valve with purge valve tool to make sure ball moves and is free of debris. Try a Purge valve may be stuck open or different purge valve or brew handle.
Page 57 Troubleshooting General Trouble Shooting Malfunction Possible Cause Solution Main power off 1. Check power cord and breaker User Interface not on Communication cable disconnected 2. Check connection on tower and WVSC Leak Between Tower and WVSC 1. Check water line connections Water leak Drain lines leak 2.
Page 58 Troubleshooting Temperature Sensor Error Codes Error Title Message TB1 Sensor Short WVSC - Temperature sensor of Thermal Block 1 is in short. TB2 Sensor Short WVSC - Temperature sensor of Thermal Block 2 is in short. TB3 Sensor Short WVSC - Temperature sensor of Thermal Block 3 is in short. TcoldWater Short WVSC - Cold Water Temperature sensor is in short.
Page 59 of 86...
Page 60: Water / Air Diagram
WATER / AIR DIAGRAM of 86...
Page 61 Water / Air Diagram of 86...
Page 62: Electrical Diagram
ELECTRICAL DIAGRAM Electrical Diagram Overview Water Vacuum Supply Center THERMOBLOCKS THERMOBLOCKS X400 X202 X801 V1 & V13 X701 To J1 X401 Tcold X203 X402 POWER SWITCH (EMPTY) X204 EMPTY X403 FM 1&2 X700 V2, V8, V7, X800 X200 X504 V9, V10 X301 X500 X702...
Page 63 User Interface Box (Tower) Tower From X203 Brew Chamber LEDs Primary LED Primary LED Board Front Board Back Secondary LED Secondary LED J106 Board Front Board Back Left Upper Right Upper SENSORS Thot Thermostat Tmix Thermostat Brew Handle Microswitch Brew Cylinder Microswitch From X203 Left Lower Right Lower...
Page 64 Electrical Diagram Secondary Board Electrical Diagram Overview Thermoblocks X701-1 X701-4 2.0 kW X701-2 X701-5 2.0 kW X701-3 X701-6 2.0 kW NEMA L6-30R 208V-220/230V Main Power Switch Water Pump X702-1 X702-2 of 86...
Page 65 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage X700 Main Power 208V-220/230VAC Main Power 208V-220/230VAC Black Main Power 208V-220/230VAC Black Main Power 208V-220/230VAC X701 Blue Thermoblock 1 208V-220/230VAC Grey Thermoblock 1 208V-220/230VAC Blue Thermoblock 2 208V-220/230VAC Grey Thermoblock 2 208V-220/230VAC Blue...
Page 66 Electrical Diagram Secondary Board Electrical Diagram Overview (Continued) X801-2 Mains X801-4 X801-1 Descale X801-3 X800-3 Spare X800-9 X800-5 Leakage X800-11 X800-2 X800-8 Sanitize X800-6 Vacuum X800-12 X800-4 Blow Out X800-10 X800-6 Purge X800-12 X704-2 X704-4 Fill X704-1 X704-3 Rinse X705-1 Air valve X705-2 Command Board...
Page 67 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage X704 Yellow Rinse (V4) +24VDC Purple Fill (V3) +24VDC Yellow Rinse (V4) -24VDC Purple Fill (V3) -24VDC X705 Orange Air valve (V6) -24VDC Orange Air valve (V6) +24VDC X800 Yellow Spare Brown...
Page 68 Electrical Diagram Command Board Electrical Diagram Overview Thermoblocks Temperature Sensors X400-1 X400-4 X400-2 X400-5 X400-3 X400-6 Water Temperature Sensor X401-1 Tcold X401-2 Flow Meters X403-1 X403-2 X403-3 X403-4 X403-5 X403-6 Secondary Board of 86...
Page 69 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage X301 (Not Used) X302 (Not Used) X303 (Not Used) X304 (Not Used) X400 Brown NTC Thermoblock 1 Signal Yellow NTC Thermoblock 2 Signal Blue NTC Thermoblock 3 Signal Brown NTC Thermoblock 1 -24VDC Yellow...
Page 70 Electrical Diagram Command Board Electrical Diagram Overview (Continued) X202-1 Communication Port X202-2 X202-3 LIM Board X203-1 X203-2 X203-3 X203-4 X203-5 X203-6 X200-1 X200-2 X500-1 Cold Water ODE X500-2 X503-1 Vacuum Pump X503-2 X300-1 User Interface X300-2 Screen of 86...
Page 71 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage X200 Blue -24VDC +24VDC Empty X202 Brown Digital Ground Green Communication Port Orange Communication Port X203 Brown UI Communication Blue UI Communication White +24VDC Green LIM Communication LIM Communication Black Digital Ground -24VDC...
Page 72 Electrical Diagram User Interface Board Electrical Diagram Overview LIM Board J11-2 J11-1 3 2 1 Command Board J10-2 J10-1 of 86...
Page 73 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage Yellow User Interface Power -24VDC Orange User Interface Power +24VDC Brown Communication Blue Communication of 86...
Page 74 Electrical Diagram LIM Board Electrical Diagram Overview J2-1 J2-2 Thot J2-3 J2-4 Tmix J2-8 J2-9 Micro Switch Brew Handle J2-10 J2-11 Micro Switch Brew Cylinder J2-5 J2-6 Pressure Sensor J2-7 Primary LED Board Front J3-1 J3-2 J3-3 User Interface Board J1-1 J1-2 Command Board...
Page 75 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage Yellow User Interface -24VDC Orange User Interface +24VDC Green Communication Communication White Communication +24VDC Black Digital Ground -24VDC Green NTC Thot Thermostat Signal Green NTC Thot Thermostat Signal Grey NTC Tmix Thermostat Signal Grey...
Page 76 Electrical Diagram LED Boards Electrical Diagram Overview Primary LED Board Front Secondary LED Board Front = Pin 1 LIM Board Brew Cylinder LEDs Primary LED Board Back Secondary LED Board Back J106 LED Strip Left Upper LED Strip Right Upper LED Strip Left Lower LED Strip Right Lower of 86...
Page 77 Electrical Diagram Connector Pin Number Wire Color Description / Function Voltage Primary LED Board J1 (Front) Blue Primary LED Board Power -24VDC White Primary LED Board Power +24VDC Yellow Primary LED Board Power Signal J3 (Front) Blue LED Strip Upper Right +24VDC LED Strip Upper Right Signal...
Page 78: Sequence Of Operations
SEQUENCE OF OPERATIONS The 9 Core Functions of the BKON Unit: 1. Fill 2. Rinse 3. Vacuum 4. Purge no water 5. Purge with water 6. Blowout 7. Drink Preparation a. Preparation Vacuum b. Preparation Water 8. Start / Initialization...
Page 79 Sequence of Operations Task Fill T(cold) T(hot) T(mix) Rinse T(cold) T(hot) T(mix) vacuum pump speed Vacuum (RAIN) modulation Purge (No Water) vacuum pump speed Drink Dispensing modulation Purge (With Water) vacuum pump speed Preheat Brew modulation Cylinder Blowout Air/Water Separator Drink Preparation Temp to sense...
Page 80 Sequence of Operations Sequence of operations for the core functions: Fill - 1. Activate (open) main water inlet valve (V1) 2. Activate (start) water pump (M1) 3. Cold water thermostat ((T)cold) measures the temperature of the cold water 4. Hot water ﬂ owmeter 2 (F2) measure the amount of hot water 5.
Page 81 Sequence of Operations Purge NO water - 1. Activate (open) vacuum pump (P4) 1. Activate (open) purge valve (V9) 2. Activate (open) atmosphere valve (V6) 3. Pressure sensor 1(P1) measures the vacuum pressure 4. Vacuum pump speed modulation 5. Vacuum pump speed modulation 6.
Page 82 Sequence of Operations Blowout - 1. Activate (open) purge valve (V9) 2. Activate (open) blowout valve (V8) 3. Activate (open) vacuum pump (P4) 4. Deactivate (Close) vacuum pump (P4) 5. Deactivate (Close) purge valve (V9) 6. Deactivate (Close) blowout valve (V8) Preparation vacuum - 1.
Page 83 Sequence of Operations of 86...
Page 84 Sequence of Operations The 5 Beverage Functions 1. Prewash 2. Fill 3. Infusion 4. Steep 5. Dispense Prewash - adding a small amount of water to wash the tea leaves (mostly darker teas) a. Preparation water b. Preparation vacuum c. Fill d.
Page 85 Sequence of Operations Brew Parameters Code Chart 205° of 86...
Page 86 Sequence of Operations The blue pie shapes represents a negative pressure inside the brew cylinder, a vacuum, also called an infusion cycle. Vacuum (Depth / Holding Time) The two numbers inside the blue box represents negative pressure amount and the time the pressure is held. In this example the unit decreases pressure inside the brew cylinder to -40 kPa for 17 seconds.
Page 87 Sequence of Operations Water Injection (Fill / Rinse) Water quantity is measured in milliliters (ml) In this example a total of 300 ml of water is injected into the brew cylinder. 250 ml of water is injected through the ﬁ ll valve (V3) and 50 ml through the rinse valve (V4) Atmosphere Pause This is the amount of time in seconds that the unit pauses to...
Page 88 (19006964 Rev. B, April, 2015) in any form of media without the express written permission of Franke. BKON, BKON Craft Brewer, RAIN, Reverse Atmospheric Infusion, and the red dot logo are trademarks of Bkon LLC. Franke mark used under license Franke Technology and Trademark Ltd., Switzerland. Due to continuous...