Setup & Assembly

Setup & Assembly | RAPT Gen4 BrewZilla

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  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

KegLand reserve the right to change inclusions as upgrades/model revisions are released

WARNING - IMPORTANT INFORMATION

Please read this ENTIRE instruction manual 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

If the BrewZilla is damaged in any way do not use it. Contact your local distributor

Ensure the IEC Cable has been firmly inserted into the socket on the BrewZilla base and ensure that the IEC cable doesn’t move once you power up the BrewZilla. If the cable moves or is not firmly connected it can cause an electrical arc to form between the male and female parts of the cable/socket. This arcing can cause heat, damage to the respective parts and possibly result in fire

NEVER turn on the pump or energise the device without the recirculation arm securely connected. If you do not fit this arm, you could be at risk of spraying hot wort into the air causing injury

Do not run the pump dry for extended periods. This can damage the pump

Do not use the lid clamps on the glass lid. This is only for metal distillation lids

Out of the box care instructions

This unit requires cleaning before use to remove any maching oils or factory residue.

Dissolve 2-3 scoops KL07405 StellarOxy or KL05494 StellarClean at 80°C (176°F) for 15 minutes in around 20L water. Use a mash paddle to stir the liquid and circulate using the pump. Once the unit is at a temperature that is tolerable to touch, use a set of heavy-duty brewing gloves and a microfibre towel to wipe down the internal surfaces. This includes the malt pipe and false bottom pieces.

This will wash away any left-over machining oils that could still be present.

General Information

The Gen 4 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 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 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 can be controlled and logged easily through the RAPT Portal.

Registering your RAPT BrewZilla Gen 4 to the RAPT Portal is quick and easy. If you intend to only use the controller manually skip ahead to the assembly instructions.

Digital Controller Assembly

The BrewZilla Digital Controller is mounted in a position at the top of the boiler with a tilting frame so you can adjust the angle of the screen depending on your height, 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.

The Digital Controller can also be wall mounted at any convenient height with the optional Screen Extension Cable and Screen Swivel Mounting Bracket

Perforated False Bottom Installation

The BrewZilla Gen 4 includes a perforated false bottom. This false bottom is designed to prevent your pump drawing in more than 95% of solids such as hop pellets. It 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. The 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 into 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.

Boiler Assembly

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.

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

The plumbing on the underside of the BrewZilla Gen 4 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.

Then change the pipe work as shown below such that the tee piece from the boiler outlet splits to the tap before it reaches the pump inlet.

NOTE: Pump model and mount postion varies between models

Malt Pipe Assembly

The malt pipe is the basket which sits inside the boiler and contains your grain during mashing and sparging.

It 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.

NOTE: Use of the perforated top screen is optional. The system can be used without it if you prefer to gently stir the mash but it should be reinstalled for sparging to disperse the sparge water and prevent channelling which can reduce your efficiency.

It is strongly recommended to use the top screen when reciculating during the mash however, as otherwise it is possible to have grain from the mash 'sucked back' to the pump which can cause blockages.

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.

The Gen 4 Malt Pipe now has a stepped lautering capability with added feet mounts* halfway up the malt pipe.

*Not available in all regions

Recirculation Arm Assembly

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.