BrewZilla 65L - Gen 4 Instruction Manual

Important Warnings

• Please read this ENTIRE instruction sheet before using the BrewZilla unit. If unsure, refer to YouTube videos or contact your local distributor.
• Do not use the BrewZilla if it is damaged. Contact your local distributor.
• NEVER turn on the pump or energize the device without the recirculation arm securely connected. Failure to do so risks spraying hot wort, causing injury.
• Do not run the pump dry for extended periods, as this can damage the pump.
• NEVER lift the BrewZilla when it is completely full. Use a hose to fill the unit. Use the pump or ball valve to transfer wort. Lifting a heavy/hot BrewZilla may result in serious injury.
• If the recirculation arm is removed, always ensure the ball valve is turned off.
• Do not boil dry. Do not energize the device or start a profile if there is less than 4 litres of liquid in the boiler (minimum fill level).
• NEVER direct a garden hose or mains water down the pump inlet or recirculation pipe, as this risks rupturing the silicone hosing.
• Use only recommended cleaners and sanitizers listed in the accessories section. Using unapproved chemicals can cause permanent damage and void the warranty.

Parts Checklist

The BrewZilla Gen 4.0 package includes the following components:

• 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
• 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 (Body, reinforced bottom screen, reinforced top screen)
• Malt Pipe Handle
• BrewZilla Gen 4 RAPT Wi-Fi Controller
• 8 pin power cable for BrewZilla Wi-Fi controller

Product Overview

The Gen 4.0 BrewZilla is a complete all-in-one system for all-grain home brewing. It offers full control over the brewing process, with Wi-Fi connectivity for remote monitoring and operation via the RAPT Portal. The system can also be operated manually using the detachable digital controller.

RAPT Portal Integration

To utilize the Wi-Fi capabilities, you need to register your BrewZilla with the RAPT Portal. This allows for remote control, recipe import, and brew monitoring.

1. Sign Up for a RAPT Account

Create an account at https://app.rapt.io/ and log in.

2. Connect your BrewZilla to your Wi-Fi Network

1. Plug the BrewZilla Gen 4.0 boiler into power using the detachable cable.
2. Connect the BrewZilla Wi-Fi controller to the boiler using the 8-pin power cable.
3. On your smartphone or tablet, connect to the "Kegland RAPT Wi-Fi" Access Point displayed on the controller.
4. Follow the prompt to sign into the network, which opens the RAPT Captive Portal. If no prompt appears, select the RAPT Wi-Fi network again in your Wi-Fi settings.
5. Select your home Wi-Fi network, enter your password, and select "Join".

A Wi-Fi symbol on the top left of the controller display indicates a successful connection.

3. Register your BrewZilla to your Account on the RAPT Cloud

1. On the controller, navigate to Settings > Register Device. Note the displayed MAC Address and Validation Code.
2. Log in to the RAPT Portal (https://app.rapt.io/) on a device connected to the same Wi-Fi network.
3. In the RAPT Portal, select "Add New Device", choose "BrewZilla" from the dropdown, and click "Next".
4. Enter the MAC Address and Validation Code when prompted, then click "Next".

Your BrewZilla is now connected and registered. You can control it via the RAPT Portal.

Remote Operation via the RAPT Portal

Create brewing profiles in the RAPT Portal (Profiles > Create New Profile) with steps like strike, mash, boil, etc. You can then "Send Profile to Device" or "Start Profile Session" from the Dashboard. The device will energize and begin the profile automatically. Manual adjustments for pump on/off, heating power, and pump duty cycle may still be required on the controller.

Digital Controller Assembly

The digital controller is mounted at the top of the boiler with a tilting frame for ergonomic adjustment. Slide the controller onto the mounting bracket using the grooves on its rear housing.

Adjusting the Angle of the Digital Controller

To adjust the screen angle, loosen the two bolts holding the bracket to the boiler. Adjust to your desired angle and retighten the bolts. The bracket can also be rested on its bolt for a greater angle.

Perforated False Bottom Installation

The false bottom prevents the pump from drawing in solids like hop pellets. It has legs that suspend it approximately 14mm above the boiler base, reducing dead space to 3.5L. It is recommended to keep this screen in place whenever the pump is used.

The Gen 4 includes an extra eye bolt kit for easier lifting. One eye bolt is on the outer rim, and one is in the center. Lift from the outer eyebolt first, then the middle one.

Boiler Assembly and Tap Installation

The tap is shipped unassembled to prevent transport damage. Unscrew the hex nut and retaining nut from the tap. Insert the barb with seal into the tap, ensuring the silicone seal is on the tap body. Turn the BrewZilla upside down and insert the tap's thread through the pre-drilled hole in the boiler. Secure the tap inside the boiler with the hex nut and tighten the retaining nut onto the tap's thread to secure the barb.

Push the unconnected silicone hose from the pump over the barb on the tap and secure it with the wire clamp.

Plumbing Configuration

The plumbing can be altered so that wort flows to the tap before entering the pump. This allows draining the boiler even if the pump is blocked. To achieve this, reposition the pump and change the pipework so the tee piece from the boiler outlet splits to the tap before reaching the pump inlet.

Ensure there are no kinks or twists in the silicone hosing, as this can impede flow and potentially cause the hose to split due to pressure buildup.

Malt Pipe Assembly

The malt pipe is a basket for grain during mashing and sparging. It consists of the malt pipe body, a perforated bottom screen, and a perforated top screen. The Gen 4 screens do not have holes for overflow pipework.

Insert the perforated bottom screen into the malt pipe body until flush with the bottom. The top screen is added after grain is added during mashing. The top screen is optional but recommended for sparging to disperse water and prevent channeling.

Fitting the Malt Pipe Handle

Install the malt pipe handle before adding grain. Feed one end through a hole in the malt pipe, push it through until there's enough clearance on the other side to feed it into the opposing hole. This allows for easy lifting and maneuvering of the malt pipe.

The Gen 4 Malt Pipe features stepped lautering capability with added feet mounts halfway up.

Operation of the BrewZilla using the Digital Controller

The BrewZilla can be controlled via the digital controller or the RAPT Portal. To use only the controller, disable Wi-Fi in the Settings menu (Settings > Disable Wi-Fi) to remove RAPT Portal prompts.

Enable/Disable Graph

By default, the controller displays a temperature vs. time graph. This can be changed to a numerical display by unselecting "Show graph" in the Settings.

Adjusting Target Temperature

Press "Return" until "Target Temperature" is highlighted. Use the up/down arrows to set the temperature. Press the play button (▶️) to energize the device and begin heating. Warning: Do not press play if there is no liquid in the vessel.

Turning the Pump On/Off

Press the pump button (▶️) to toggle the pump. The "Pump" text will be light blue when ON and grey when OFF. The pump only runs after the device is energized by pressing play. Warning: Do not press play with an empty vessel, as this will run the pump dry and can cause damage.

Adjusting the Pump Duty Cycle (Percentage)

Control pump output for repeatability by adjusting the duty cycle. Press "Return" until the pump percentage is highlighted, then use up/down arrows. Alternatively, hold the pump button while using up/down arrows. Reducing the percentage cycles the pump on/off.

Adjusting the Heating Power

Press "Return" until "Heat percentage" is highlighted, then use up/down arrows to change heating power. With PID disabled, setting heating power between 30-40% during mash is recommended to prevent temperature overshoot.

Out of the Box Care

KegLand recommends running 20L of water with 3 scoops of StellarOxy at 80°C (176°F) for 15 minutes on a new unit to clean any machining oil. Wipe internal surfaces with a microfiber cloth.

Mashing

After assembling the boiler, controller, and malt pipe, you are ready to add grains. Ensure the correct volume of strike water is heated to the recipe's strike temperature (usually a few degrees above the desired mash temperature).

Place the malt pipe with the bottom screen installed into the boiler, resting its top lip on the wire supports. Pour grain into the malt pipe (capacity up to 18.5kg, typically 10-14kg used). Stir the grain periodically while pouring to break up dough balls. Once all grain is added, stir thoroughly for 2-5 minutes.

Insert the top screen lightly onto the grain. Assemble the recirculation arm to recirculate wort during the mash.

To maintain a stable mash temperature, reduce heating power to 30-40% if 100% causes overshoot. The exact power setting depends on variables like grain bill, jacketing, and heat loss.

Recirculation Arm Assembly

Warning: The recirculation arm must be fitted whenever the pump is in use.

Recirculation ensures a homogenous mash mixture and even temperature throughout the grain bed, aiding mash efficiency.

Before attaching, check that the silicone washer is in place in the female camlock. Lift the arms on the female camlock, insert the male camlock, and engage the female camlock to its locked position.

To rotate the arm, switch off the pump, readjust the camlock, and re-lock it before restarting the pump.

Important: If mashing without the top screen, ensure the recirculation arm's silicone hose is elevated above the grain bed when the pump duty cycle is below 100% and before turning the pump off. This prevents grain from being sucked back into the pump.

Mash Temperature Reading

The temperature displayed on the controller is read near the heating elements at the bottom of the boiler. This is not the core mash temperature. With sufficient recirculation, the mash temperature will approach the controller's reading. For faster temperature increases, it's recommended to overshoot the target mash temperature slightly and monitor the core temperature with a calibrated thermometer.

If overshooting occurs, adjust the heating power. The probe placement is designed to prevent element scorching by measuring wort closest to the elements, hence the importance of accurate strike temperature.

The BrewZilla uses Ultra Low Watt Density Elements (ULWD) to minimize the risk of scorching and off-flavors.

Sparging

After mashing for 60-90 minutes, it's time to sparge. Sparging rinses the grain bed with warm water to extract sugars without undesirable tannins.

Lift the malt pipe out of the boiler using the handle and rotate it 90 degrees until its feet are located near the halo ring (wire supports). The Gen 4 BrewZilla has a two-stage malt pipe, allowing it to be supported halfway up the halo ring for easier lifting, especially for smaller batches.

Ensure the top screen is inserted into the malt pipe during sparge to prevent channeling.

With the malt pipe suspended, pour warm water (approx. 75-80°C) onto the top screen to rinse remaining sugars. This typically requires 5-15 liters, depending on the recipe and desired gravity.

A secondary vessel (e.g., a 35L DigiBoil) is recommended for holding hot water for sparging. Hot water directly from a faucet can also be used.

Boiling

To boil, set heating power to 100% and target temperature above 100°C to ensure continuous heating. If set to exactly 100°C, elements might briefly turn off.

Once boiling, add hops and boil for the duration specified in your recipe (typically 60 minutes).

Boil Temperature Reading

At sea level, water boils at 100°C. If the controller displays a different temperature during a boil, calibration may be needed. If boiling below 100°C at high altitude, correlate the displayed temperature with the local boiling point of water.

Cooling

The BrewZilla includes an immersion cooling coil. An optional counter-flow chiller can be purchased separately.

The immersion chiller is easy to use: connect a garden hose to both ends and run cold water through it while immersed in the wort. For water conservation, connect the chiller to the BrewZilla pump and immerse it in a bucket of ice water.

Optional fittings are available for easier garden hose or pump connections.

Connecting the immersion chiller to a garden hose (recommended)

Push the garden hose over the immersion chiller and secure with a hose clamp. For a more ergonomic solution, use compression fittings (12.7mm) and garden hose fittings (male) purchased separately.

Connecting the immersion chiller to your BrewZilla pump – Ice Bath (optional)

Connect the chiller to the BrewZilla pump using 12.7mm compression fittings and camlock fittings. Run silicone hosing from the recirculation arm to the chiller, and from the chiller outlet back into the BrewZilla. These fittings and extra hosing can be purchased separately.

To sanitize the chiller using this method, recirculate boiling wort through it for at least 5 minutes. Then, place the chiller in a bucket of ice water. Use the ball valve on the recirculation arm to adjust the flow rate and achieve the desired wort temperature for fermentation.

Hot Cubing

Hot cubing is a time-saving cooling method. Fill a HDPE Cube or Bladder with hot wort, seal it quickly to maintain a sanitary environment, purge air, and leave at ambient temperature for 24 hours to cool (out of direct sunlight).

Cleaning

The Gen 4.0 BrewZilla has a domed bottom and central pump inlet, allowing easy draining. After draining, rinse to remove trub. Tipping the unit upside down may help remove stubborn residue.

Fill the brewery with water and an approved cleaner (e.g., StellarClean) according to package instructions. Set the boiler temperature to 55°C, attach the camlock recirculation arm, press play (▶️) to energize, and recirculate for 10 minutes. Use a sponge or cloth to remove particulates. Turn off the pump, connect the chiller (if needed), and recirculate for another 5 minutes.

Empty the cleaning liquid. Rinse thoroughly by filling with clean water, attaching the recirculation arm, pressing play (▶️), and running the pump. Repeat rinsing if necessary.

Fill again with water and an approved sanitizer (e.g., StellarSan) per package instructions. Acidic sanitizers like StellarSan help dissolve minerals and passivate stainless steel. Recirculate the sanitizer solution through the recirculation arm and chiller (if required). StellarSan does not require rinsing and can be emptied, ready for the next brew day.

Pump Cleaning and Maintenance

Generally, the pump does not require disassembly after each brew day. Recirculating cleaner and sanitizer breaks down proteins, minerals, and contaminants. The pump is accessible by flipping the brewery over for thorough cleaning if needed.

If the pump is blocked, detach all hosing, unscrew the pump from the brewery, remove screws holding the pump head, and check for debris. Inspect the impeller for damage or blockages and clear the impeller housing.

Note: Never direct a garden hose down the pump inlet or recirculation arm due to high mains water pressure, which can rupture silicone hosing.

Troubleshooting

No Telemetry Displayed on RAPT Portal

First, verify your BrewZilla controller is connected to your Wi-Fi network.

Determine Wi-Fi connection and signal strength

On the controller, press 'Select', navigate to Settings > Diagnostics. The Wi-Fi strength (0 to -100dbm) and connected network (wifi AP) will be displayed. Signal strength interpretation:

Re-register your BrewZilla Controller

If telemetry is still not sending despite a good Wi-Fi signal, re-register the controller. Do not delete the device from the RAPT Portal.

1. On the BrewZilla controller, go to Settings > Clear Registration and press Select.
2. Log in to the RAPT Portal (https://app.rapt.io/) and click the edit button for the BrewZilla controller.
3. Go to the Troubleshooting tab and select "Reset Device Authentication".
4. When prompted, enter the new Validation Code generated on the BrewZilla Controller and click Save.

BrewZilla Controller Stopped Sending Telemetry

Check Wi-Fi connection, router range, and network/internet interruptions. Unusual network setups or security settings can also cause issues. Contact beer@kegland.com.au for further assistance.

Updating Firmware

Firmware updates are checked and installed automatically when the BrewZilla is powered on and connected to Wi-Fi. To check the current version, go to Settings > Diagnostics. To manually check for updates, go to Settings > Check for OTA Update.

Temperature Probe Calibration

If the temperature probe is inaccurate (e.g., reading over 100°C when boiling at sea level), a 2-point calibration can be performed.

To enter calibration mode: Settings > 2 point calibration. Fill the boiler with ice water, measure its temperature with a calibration thermometer, wait for the ADC reading to stabilize, and input the measured temperature for Calibration point 1. Press Select. Empty and refill with hot/boiling water, wait for stabilization, and input the measured temperature for Calibration point 2. Press Select.

Note: If above sea level, water boils below 100°C; calibration may not be required. Refer to local boiling point data.

PID Temperature Control

The Gen 4.0 BrewZilla has a PID Temperature Control setting. Default coefficients are provided for a 23L fermenter volume. For different batch sizes or high-gravity beers, PID coefficients may need tuning.

Display Icons Legend

Default Settings

Recommended Accessories

Silicone Tubing

Heavy-duty silicone tubing (12.5mm ID, 18.5mm OD) is recommended for transferring wort. It is plasticizer-free, BPA-free, and suitable for temperatures up to 200°C. (Part No. KL06873)

StellarClean (Powerful Brewery Wash - PBW)

A buffered alkaline detergent that effectively cleans carbon or protein soils. Safe for skin and soft metals. Works best in warm to hot water and requires rinsing. (Part No. KL05494)

StellarSan

A phosphoric acid blend sanitizer that passivates stainless steel. Apply undiluted to a rag, rub internals, leave for 30 minutes, and rinse thoroughly. It's also a great sanitizer for other brewing equipment. (Part No. KL05494)

Stainless Mash Paddle

Long-handled paddle for removing dough balls and equalizing mash heat. (Part No. KL03810)

Refractometer with Light

A tool for instant gravity readings of hot wort, aiding in optimizing sparging. Faster and more convenient than hydrometers. (Part No. KL07344)

Extra Long Heavy Duty Brewery Cleaning Gloves

Heavy-duty gloves with long sleeves for handling chemicals and hot wort. (Part No. KL05289)

Hop Scales / Brewing Salt Scales

Jewellery scales are recommended for accurately measuring small amounts of hops or brewing salts. (Part No. KL20114)

A BrewFather Subscription

Brewing software for recipe inspiration, creation, water chemistry, and brew day logging. (Part No. brewfather-subscription)

Intermediate / Advanced Users Accessories

35L DigiBoil Hot Liquor Tank (HLT)

Primarily used for sparging. Allows rinsing mash with 76°C to 80°C water. (Part No. KL07252)

Digital pH Meter

For monitoring mash pH and final beer pH, especially for sour beers. (Part No. KL04169)

Phosphoric Acid 85%

Used with a pH meter and calculators to adjust brewing water pH. (Part No. KL05364)

Reverse Osmosis Filter

For starting with pure water, useful if water supply quality varies. (Part No. KL15141)

Cooling Upgrades

Alternatives to the stock cooling coil include the Braided Counter Flow Chiller, The Chillout Plate Chiller, and the Coolossus Counter Flow Chiller.

Distillation Accessories

Distillation Lid for BrewZilla 65L (47mm hole)

Allows fitting an AlcoEngine Pot or Reflux still to the BrewZilla 65L or DigiBoil 65L. (Part No. KL10962)

AlcoEngine Pot Still

A pure pot still that allows flavors from the wash to come through in the distillate. Features all-copper construction and a digital thermometer. (Part No. KL04633)

AlcoEngine Reflux Still

Designed for pure neutral alcohol distilling, offering easy operation and reliability. Requires adequate water/coolant flow. (Part No. KL04640)

Support

Join the RAPT Users Group and KegLand Home Brew Community Group on Facebook for support, recipes, and tips. For hardware support, contact your nearest BrewZilla distributor.

Warranty (Australia)

The BrewZilla 35L & 65L Generation 4.0 comes with a 3-Year Warranty in Australia. To lodge a warranty claim, forward supporting information and a detailed description of the issue to the provided contact. For international purchases, follow the warranty process of the respective distributor. Full terms and conditions are available on the KegLand website.