Grindmaster RAP400E, RAPS300E, RAP300E, P400E, P300E User Manual

...
4 (1)

Shuttle Brewer & Airpot/Shuttle Brewers

Operation and Instruction Manual

For Models P300E, P400E, RAP300E,

RAP400E, RAPS300E, RAPS400E

Table of Contents

Installation and Start-up .......................................

1-2

Operation ..........................................................

 

3

Adjustments ........................................................

 

4-7

Care and Cleaning ...............................................

8-9

Service ...............................................................

 

9-10

Troubleshooting

 

 

Filling Problems ....................................

11

Heating

Problems .................................

12

Brewing

Problems ................................

13

Parts Illustrations

 

 

Models P300E & P400E .......................

14

Model RAP400E .....................................

15

Model RAPS400E ...................................

16

VSB-400

................................................

17

Shuttle CS-LL ..........................................

18

Rough-In Drawings

 

 

Model P-300..........................................................

19

Model P-400 .........................................

20

Model RAP-300 .........................................

21

Model RAP-400 ........................................

22

Model RAPS-300 .......................................

23

Model RAPS-400 .....................................

24

VSB-300

..................................................

25

VSB-400

................................................

26

Wiring Diagrams

 

 

P300E/P400E with 1 Batch Timer .........

27

P300E/P400E with 2 Batch Timer........

28

RAP300E/RAP400E................................

29

RAPS300E/RAPS400E........................

30

Drawing

#091-548 .................................

31

Drawing #091-182 ....................................

32

Warranty ...................................................................

 

36

Installation:

WARNING

ELECTRIC SHOCK HAZARD!

Installation of this appliance should be performed by qualified service personnel only. Improper installation could result in electrocution.

See rough-in drawings in this manual for dimensions and locations of electric and water input.

Set-Up/Position

1)Remove the brewer from the packing material and attach its legs.

2)Position the brewer on a strong, stable table or counter. Check the level front to back and side to side. Adjust the legs to the correct level.

IMPORTANT:

THE PERSON INSTALLING THIS APPLIANCE IS RESPONSIBLE FOR ENSURING THAT ELECTRIC AND WATER CONNECTIONS MEET THE REQUIREMENTS OF THE NATIONAL ELECTRIC CODE, NATIONAL PLUMBING CODE, AND ANY LOCAL ORDINANCES.

The electric and water hook-up locations are behind the front panel. Remove the four screws fastening this panel for access to these connections.

Water Hook-up

1)The water line may enter through holes on the rear or the bottom of the brewer. Use the right hand opening for water.

2)Use 3/8" copper or flexible water line to prevent strain. Do not use low temperature plastic tubing. The connection to the fill valve is 3/8" flare.

3)Water line pressure must be from 30 to 70 psi.

4)Hot (up to 160°F) or cold water may be used. Hot water offers faster recovery between brews.

5)Install a shut-off valve near the brewer.

6)Installing a filtering system can improve the taste of brewed coffee and extend the life of the brewer. If your water has high calcium (lime), chlorine, or iron content, this is especially important. The filter should be the lime inhibiting type if cold water is used. Contact our parts department to select the filter for your conditions.

Prior authorization must be obtained from Grindmaster Corporation for all warranty claims.

Grindmaster Corporation

4003 Collins Lane

Louisville, KY 40245 USA (502) 425-4776

(800) 695-4500 (USA & Canada only)

(800) 568-5715 (Technical Service Only)

FAX (502) 425-4664 www.grindmaster.com

© Grindmaster Corporation, 1998

0306 FORM # AM-309-06

PRINTED IN U.S.A.

Part # 090-077

Installation (con't)

Electric Hook-up

1)The electric ratings for your brewer are printed on its nameplate. Typical electric ratings are:

P300, P400, RAP300, RAP400

 

Optional

120/208V, 3.8kW, 18A or 120/240V

5.0kW, 21A, 1 phase

Standard

120/208V, 5.0kW, 24A or 120/240V

6.6kW, 28A, 1 phase

RAPS300, RAPS400

 

Standard

120/208V, 4.4KW 21A or 120/240V, 5.6KW 24A, 1 phase

If the brewer includes the three heater tank option C21A, the ratings will be different. Always see the nameplate for correct ratings.

2)The brewer should be connected to its own circuit with a fused disconnect switch or a circuit breaker near the brewer.

3)Attach the appropriately sized cord to the brewer with a cord grip for the 1 1/2" electric input opening. The cord may enter through the rear or bottom on the left side of the brewer. Use an oil resistant cord such as type SO, SOO, SAO, STOO, SEO, SJO, SJOO, SJTO, SJTOO, SJEO, HSO, HSOO, HSJO, or HSJOO. Alternatively, flexible conduit and type THHN wires may be used. Use only copper conductors.

4)Standard connection is 1 phase 3 wire. Connect the two lines to L1 and L2 on the terminal block. If the brewer is wired for three phase, a lug, L3, is provided on the terminal block. A neutral line must be connected to the N terminal.

WARNING

Never use the ground conductor as a neutral. This could cause electrocution.

5)The body of the brewer must be grounded. A ground lug is provided for this purpose.

Start-up

1)Turn on the water supply to the brewer. Check for leaks.

2)Turn on the electric supply. The brewer will begin to fill.

3)Replace the front access panel.

4)Once the brewer is full, it will take 15 to 35 minutes to heat. The water hot light will turn on when up to temperature.

5)Insert the brew baskets and place a shuttle or airpot under the baskets. Brew at least one batch from each side. Check the level in the container to be sure the brew volume is correct. Remember that when using coffee, the level will be lower. Do this for both batch sizes when provided. The water must be hot to check the levels. If adjustments are needed, see the adjustments section of this manual.

Shuttle Brewers & Airpot/Shuttle Brewers

Page 2

Grindmaster RAP400E, RAPS300E, RAP300E, P400E, P300E User Manual

Operation

CAUTION

HOT LIQUID HAZARD!

Water used for brewing coffee is very hot. Use caution when brewing, pouring, or transporting coffee. Accidental spills may result in severe burns.

1)RAPS Brewers require the accessory warmer base placed over the pegs on the brew shelf before brewing into a shuttle. Plug the base into the receptacle on the side of the brewer. The receptacle is only energized when a shuttle is in place.

2)Place an empty, warm shuttle or airpot on the shelf, counter, or accessory base (depending on model) under the brew head. Turn on the warmer if a shuttle is used.

3)If the shuttle is not warm, allow the warmer to heat the shuttle. Only a short brew of water will speed this. A cold shuttle will significantly lower the temperature of the brewed coffee.

4)Remove the filter basket and line with a filter paper. Paper size is 13 x 5 for the smaller basket, BB1.5, and 14 x 5 for the larger, BB2.0.

5)Place ground coffee in the filter basket. Your coffee supplier can help you select the right amount of coffee and grind. Coffee brewing experts recommend between 6.5 and 8 ounces of coffee per gallon of water for most applications. A full shuttle is 1.4 gallons and a full airpot is 0.80 gallon.

6)Slide the basket into the brewer making sure the spout lines up with the top of the shuttle or airpot.

7)Check that the correct batch size is selected. Check the WATER HOT light. If lit, press start.

8)Brew time is about 4 minutes for a full shuttle, less for airpots and half batches. After the brew, allow the coffee to drip for 1 to 2 minutes.

CAUTION

Coffee basket contains very hot water until the drip is completed. Early removal of a dripping basket could result in burns.

9)Dump the grounds from the basket and rinse for the next brew. Coffee is ready to serve.

10)The shuttle may be placed on remote warming stations. Use caution when moving a full shuttle.

Shuttle Brewers & Airpot/Shuttle Brewers

Page 3

Adjustments

WARNING

Electrical Shock Hazard!

Dangerous electric voltages are present near adjustable components. All adjustments should be performed by qualified service personnel only.

All adjustable components are located under the top cover. To access these parts:

1)Shut off the electric line to the brewer or unplug the brewer.

2)Remove the single screw fastening the top cover. Remove the top cover.

3)Pull forward and lift off the top cover.

Brew Volume, Brew Timer

The brew volume of the brewer is controlled by its timer. The batch size is directly proportional to the timer setting. The timer adjustment is located under the top cover. On twin brewers, there is one timer for each brew head.

Depending on the model, American Metal Ware offers three types of timer adjustments. Look at the instructions for the type of timer you have. There will always be a small variation (+ 5%) in level from batch to batch.

Note: Always adjust bypass before adjusting timer because bypass affects brew rate.

Before making the timer adjustment, do the following:

1)Brew a batch of water to determine where the level falls. Using a stop watch, determine the current brew volume.

2)To determine the desired time setting, use the following formula:

desired brew time

=

desired brew volume

_________________ X current brew

 

 

current brew volume

Adjusting the Timer

Standard single batch timer: RAP and P models without half batch include this timer, (see Figure 1). This timer is adjustable from 1 to 8 minutes. After removing the cover, do the following:

1)Use the timer label to make an approximate adjustment

of the timer.

Figure 1

 

Single Batch Timer

2)After adjusting the timer, brew a batch of water to check the volume. Repeat adjustment, tweaking the timer knob until the volume is correct.

Shuttle Brewers & Airpot/Shuttle Brewers

Page 4

Two Batch Timer with Knob Adjustment, See Figure 2:

This timer is adjustable from 15 seconds to 5 minutes.

Locate the adjustment knobs under the top cover.

Set this timer by adjusting the knob. The batch selector switch picks the adjustment potentiometer which the timer will see.

Figure 2

Two Batch Timer

Two Batch Timer with Counter Adjustment, See Figure 3:

The two batch size timer may also be used with optional counter potentiometer to ease adjustments. Each batch size is adjustable from 00 to 99. The timer settings for this timer are tabulated on the table below. This chart is for making an approximate setting. You may need to click up or down to make fine adjustments to volume. Each number

is about 3 seconds.

 

 

 

 

 

 

Figure 3

 

 

 

 

 

Two Batch Timer

 

 

 

 

 

w/Counter Adjustment

Counter Settings for NCC Q4F-0300-341AM Timers

 

 

 

 

 

 

 

 

 

 

Counter

Time

Counter

Time

Counter

Time

 

Setting

(min:sec)

Setting

(min:sec)

Setting

(min:sec)

 

 

 

 

 

 

 

 

00

0:15

35

2:03

65

3:26

 

10

0:46

40

2:17

70

3:39

 

15

1:01

45

2:31

75

3:53

 

20

1:17

50

2:45

80

4:06

 

25

1:32

55

2:59

85

4:20

 

30

1:47

60

3:13

99

5:00

Bypass Adjustment

The bypass valve adjusts the amount of water which bypasses coffee grounds and dilutes the final brew (see Figure 4). The factory setting is no bypass.

Bitter coffee results when the amount of ground coffee is too small. Therefore, if your coffee is brewing too strong, it is better to adjust the bypass valve instead of reducing the amount of coffee.

BYPASS VALVEE

Figure 4

Bypass Valve

Shuttle Brewers & Airpot/Shuttle Brewers

Page 5

To Adjust the Bypass:

1)Shut off and open brewer as described at the beginning of the adjustments section.

2)Locate the bypass valve for the brew head you wish to adjust. Valve is on the right and front of the BREW valve.

3)Open the valve (counter clockwise) to the desired setting. Use the table below as a guide:

BYPASS SETTING

BYPASS: % OF TOTAL BREW

closed

0

1 turn

8

2 turns

12

3 turns

22

4 turns

33

 

 

4)Measure the bypass setting:

a)Remove the brew basket.

b)Place an empty shuttle without its lid under the spray head.

c)Place a measuring cup under the bypass nozzle.

d)Press START and brew water for about thirty seconds or until measuring cup is almost full. Press STOP.

e)Record the amount of water in the bypass measuring cup.

f)Add this to the water in the shuttle and record, measure the total amount of water.

g)The bypass percent is calculated as:

Bypass % = (Bypass Volume/Total Volume) X 100

5)Tweak the valve adjustment until the bypass is set as desired.

Note: The bypass is accurate to + 4%.

Thermostat Adjustment

The main thermostat adjusts the water temperature in the tank. Factory setting is 200°F. This is the ideal temperature for brewing most coffee. Water should never boil in the tank. If water is

boiling, adjust the thermostat. There are two types of thermostats available. Mechanical is standard and solid state is optional. See the adjustment instructions for the thermostat in your brewer.

Standard Mechanical Thermostat:

1)Shut off power and open cover.

2)Locate thermostat mounted on tank. See Figure 5.

3)Turn the shaft counter clockwise to decrease temperature, opposite to increase temperature.

Figure 5

Mechanical Thermostat

Shuttle Brewers & Airpot/Shuttle Brewers

Page 6

4)If the maximum temperature adjustment needs to be increased, insert a small flat screwdriver into the shaft. Turn the calibration screw counter clockwise to increase the maximum temperature.

Optional Solid State Thermostat: This control maintains range is from 155°F to 205°F.

See Figure 6.

1)Shut off power and open top cover.

2)Locate thermostat on bracket mounted to front panel.

3)Adjust the knob to the temperature desired. This control cannot be set above 205°F.

Figure 6

Solid State Thermostat

Optional Brew Thermostat Adjustment: Your brewer may include the optional low temp/no brew thermostat, (see Figure 7). This will not allow a brew unless the water is up to temperature. The factory setting is 192°F. If you wish to adjust this, do the following:

1)Shut off power and remove top cover.

2)Locate the thermostat mounted on the water tank.

3)To increase the set point, turn the shaft clockwise. We do not recommend adjusting this above 192°F which may cause excessive delays between batches.

4)For accurate setting of the thermostat, remove the bulb from the brewer and immerse in water known to be 190°F. Adjust the

knob so the thermostat closes at this point.

Figure 7

Brew Thermostat

Shuttle Brewers & Airpot/Shuttle Brewers

Page 7

Cleaning

WARNING

Burn Hazard!

Hot liquids and surfaces are present in this equipment. To avoid burns use caution when cleaning. Rinse hot parts with cold water before cleaning. Use gloves or a heavy cloth when removing hot parts from brewer.

After Each Brew:

1)Dispose of grounds and rinse brew basket.

2)Rinse shuttle or airpot containers before reuse.

Every Day:

1)Wash brew basket with warm soapy water. The wire basket is removable to aid cleaning.

2)Remove spray head(s), located above brew basket(s), using gloves or a heavy towel. Wash off coffee oils and clean any plugged holes.

3)Clean shuttles with warm soapy water and a brush or towel.

4)Clean airpots with warm soapy water and bottle brush. Be careful, glass interior breaks easily. Use only a soft cloth and warm soapy water or stainless steel polish on the outside to avoid scratches.

5)Wipe exterior of brewer with a damp cloth. Do not use abrasives which will scratch surface.

6)If shuttles are to be left on warmer all night, fill with water to avoid coffee oil burn-in.

Shuttle Brewers & Airpot/Shuttle Brewers

Page 8

Weekly or Bi-Weekly, Depending on Use

1)Fill shuttles with one gallon, 2/3 full, of hot water.

2)Pour into the shuttle liners the recommended concentration of urn cleaner (excessive amounts of cleaner will attack the stainless steel).

Urn cleaners that have been used successfully:

DIP-IT, manufactured by Economics Laboratories, Inc. 4 Corporate Park Drive

White Plains, NY 10604

OXYLITE, manufactured by Avril, Inc., Syndet Division 601 N. Third Street

Reading, PA 19601

3)Scrub the liner interior with a plastic bristle brush.

4)Remove the knurled nut at the top of the gauge glass and clean the glass with a small bottle brush.

5)Pour out the contents of the shuttle.

6)Remove the handle assembly of the shuttle faucet by unscrewing the plastic bonnet.

7)Gently wash the faucet seat cup with a soft cloth and warm soapy water.

8)Wash the faucet shank with a bottle brush.

9)Soak airpot pick-up tube assembly in hot soapy water. Urn cleaner may be used for stronger cleaning.

10)Clean the warmer and bottom of shuttle surfaces. These surfaces must be clean for proper heat transfer.

11)Polish the exterior of the brewer with stainless steel cleaner. Use the appropriate cleaner for brass, copper, or vinyl if these optional finishes are provided.

Service

The rest of this manual contains information to aid the service person who is working on this equipment. This page has information on performing common service tasks. Following this is the Troubleshooting section which can help diagnose problems which are divided into three basic systems: filling, heating, and brewing.

Next is an illustrated parts breakdown which will help in the selection of repair parts. If further assistance is needed, call our Technical Service Department at (502) 425-2776 or 800-695-4500 (USA & Canada only) Monday -Friday between 8:00 am and 8:00 pm EST.

Wiring diagrams are also provided. Locate the basic diagram for the model you are working with. If there are any options, see Diagram #091-548 (page 31 of this manual) which shows the wiring alterations for Shuttle Brewer & Airpot/Shuttle Brewer options.

Shuttle Brewers & Airpot/Shuttle Brewers

Page 9

Service (con't)

Drain Water Tank

Always empty the tank before shipping.

WARNING

Draining of tank should be performed by a qualified service technician. The tank contains very hot water. May cause severe burns.

Note: Brewer may contain over 5 gallons of hot water.

1)Prepare a heat resistant container to drain tank water into.

2)Shut off power to the brewer.

3)Remove the front access panel.

4)Pinch or clamp the silicone hose connected to fill valve.

5)Disconnect hose from outlet barb on fill valve.

6)Place hose over drain and release clamp.

7)Allow the tank to drain completely.

NOTE: It may be necessary to pinch the hose and stop the water before container is full. Carefully reinstall hose over fill valve outlet, then empty container. Repeat steps 4-7 completely to drain tank.

Remove Brew Valve

1)Disconnect electric power to machine.

2)Remove top cover and remove wires and small tube from valve.

3)Tilt inlet of valve down and pull sideways out of spray tee.

4)Clamp rubber tubing and disconnect valve from tubing.

Remove Heater

1)Disconnect power and remove top cover of brewer.

2)Disconnect wire leads to heater.

3)Remove tank cover by loosening retaining screw. Cover is lifted up with heater attached. Heater is then removed.

4)Replace heater with sealing washers in same configuration. When tightening nuts, hold element so it does not twist.

5)Replace tank cover ensuring O-ring seal is good.

6)Replace heater wires. Be sure all electrical connections are secure.

Shuttle Brewers & Airpot/Shuttle Brewers

Page 10

Troubleshooting: Filling, Heating, and Brewing

Filling Problems

The filling system consists of the following components:

 

Liquid Level Control, located behind the brewer front panel.

 

Liquid Level Probes, located on the tank top, secured by wing nut, under the top cover.

• Fill Valve, located behind the front panel.

 

 

 

 

 

 

Problem

 

Possible Cause

Service Check

Remedy

 

 

 

 

 

 

 

 

Overfilling water

Fill valve not sealing

Water entering tank

Disassemble valve and clean out

tank even when

properly.

continuously, usually

dirt. Valve may need new plunger

power is off.

 

 

slowly.

if seal is worn.

 

 

 

 

 

 

 

Fill valve installed

Look for direction of

If arrow on valve is pointing toward

 

 

water inlet, remove valve and install

 

 

backwards.

arrow on valve body.

 

 

correctly.

 

 

 

 

Overfilling water

High electrode

Jumper HI terminal on

Remove electrode assembly and

tank only when

coated with lime or

level control to metal

clean both probes. If this does not

power is on.

 

faulty.

enclosure stops fill.

work, replace assembly.

 

 

Missing or faulty con-

Jumper from C

Make secure connection of C to

 

 

nection of C terminal

terminal to metal body

 

 

on level control to metal

stops fill.

metal body.

 

 

 

 

 

 

 

 

 

 

Fill valve connected

Check connections.

Connect black lead for valve to

 

 

to heat terminal on

 

FILL on level control.

 

 

level control.

 

 

 

 

 

 

 

 

 

Liquid level control is

Jumper from HI to C

Replace level control.

 

 

faulty.

or metal enclosure

 

 

 

 

does not stop fill.

 

Tank does not

 

No power at

Nothing operates.

Check main switch or circuit

refill.

 

equipment.

 

breaker, brewer's circuit breaker or

 

 

 

 

power switch if provided.

 

 

 

 

 

 

 

No water at

Cracked water inlet

Make sure all water supply line

 

 

equipment.

fitting.

valves are open.

 

 

 

 

 

 

 

Water strainer

Water pressure before

Remove and clean or replace

 

 

strainer but not after.

 

 

clogged.

strainer's mesh.

 

 

 

 

 

 

 

 

 

 

No power to level

Check for 120V AC

If no voltage, check for loose or

 

 

across H and N ter-

broken wires.

 

 

control.

 

 

minals on level control.

 

 

 

 

 

 

 

 

 

 

 

 

Level control faulty.

Disconnect probe wire

If no 120V at FILL terminal,

 

 

 

to HI terminal on level

 

 

 

replace level control.

 

 

 

control. Check for

 

 

 

 

 

 

 

120V at FILL terminal.

 

 

 

 

 

 

 

 

Electrodes faulty.

Tank fills only when

Replace electrodes. If no remedy,

 

 

 

probe wire is discon-

 

 

 

check for improper wiring or level

 

 

 

nected from HI ter-

 

 

 

probe tip touching metal.

 

 

 

minal on level control.

 

 

 

 

 

 

 

 

 

 

 

Fill valve faulty.

120V is across FILL

Disassemble valve and clean or

 

 

 

and N on level control,

 

 

 

replace plunger if frozen. If plunger

 

 

 

but no fill.

 

 

 

is OK, coil may need replacement.

 

 

 

 

 

 

 

 

 

Shuttle Brewers & Airpot/Shuttle Brewers

Page 11

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