Grindmaster AMERICAN METAL WARE 87710 Installation And Operation Manual

American Metal Ware

®

Installation, Operation & Service Manual

For

High Speed Brewing Urn (Top Line)

TABLE OF CONTENTS

General Description.................................3

Roughing-In Drawing...............................4

Installation...............................................5

Spray-Over Time/Volume/Rate................6

How To Brew............................................7

Thermostat/Adjustments/Timer...............8

Care and Cleaning..................................9

Explanation of Agitation System............10

Operation Malfunction and Service........11

Dual Lever Control................................12

Troubleshooting Level Control...............14

Service/Troubleshooting Agitation.........18

Installation/Service for Solenoid Valve...18

Sprayover Pump Breakdown.................20

Illustrated Parts Breakdown...................21

List of Illustrated Parts...........................22

Parts List...............................................23

Wiring Diagram - Controls.....................24

Heater Wiring Diagram - 208V/240V......25

Heater Wiring Diagram - 480V..............26

Model 87710

Dual Wall Insulated

X

Electric Steam

Special Features

After completing installation and set-up, the

equipment owner should keep this manual for

future reference.

© Grindmaster Corporation™, 1995
PRINTED IN USA

Grindmaster Corporation™

4003 Collins Lane
Louisville, Kentucky 40245 USA
[phone]
[phone] (USA and Canada only)
[phone] (technical service only)
FAX: [phone]
www.grindmaster.com

1104 Form # AM-307-02

General Description

This urn is an automatic, push button operated, volume brewing unit. It consists of a non­pressure vented water compartment of large capacity into which two stainless steel coffee
liners are inserted. Also installed within this water compartment are electric immersion
heaters thermostatically controlled through a contactor relay, to keep the water always at
the desired temperature. Measurement of water quantity sprayed over coffee is by push
button start, electric reset timer, timing a constant water flow rate to the spray nozzle.

Hot water from the water compartment is pumped to the spray nozzle, controlled by the
reset timer. Automatic refill maintains water level in water compartment. Control system
components are enclosed in stainless steel housings on both ends of the urn for the 87710
urn.

Air agitation of coffee mixes the brew with compressed air automatically at the end of the
brew cycle or, if desired, manually at any time with a push button.

American Metal Ware 87710E Coffee Urn Page 3

Page 4 American Metal Ware 87710E Coffee Urn

Installation

IMPORTANT TO ALLOW 6” CLEAR SPACE FOR ACCESS TO CONTROL BOX.

1.
Urn should be level, both front to back and left to right.

CONNECT WATER LINE. 3/8” NPT water inlet located at left end and provide shutoff

2.
valve and union in supply line near urn. 140

mum - 70PSI maximum. We strongly recommend the use of copper or aluminum tub­ing to provide flexibility and avoid strain on the urn. 3/8” O.D. minimum tubing is rec­ommended.

Model No. 87710
Actual Coffee Capacity Each Liner 10 Gal.
Water Compartment Capacity 24 Gal.
Brew Capacity, Gals. per Hour 80
Electric Supply Voltage 240V/208V
1 Phase Heater Size 15KW / 15KW
1 Phase Amperes 63 / 72
3 Phase Heater Size 15KW / 15KW
3 Phase Amperes 36 / 42

O

F. hot water must be used, 30PSI mini-

CONNECT URN TO ELECTRIC POWER. Check to be sure that the nameplate mark-

3.
ing of voltage, phase and the number of wires matches supply lines. Remove cover on

control housing. The terminal block for the line connections is located in the housing
on the left end. See drawing, as required. It is recommended that a fused disconnect
switch be installed near urn. The urn body must be grounded either through metallic
conduit or else by means of ground wire. An experienced electrician should be respon­sible for the installation of the urn, and its associated supply line. NOTE: Neutral wire
required on all single phase and on 208 volt 3 phase power supplies to operate 120 volt
AC control circuit.

On single phase, 2 wire service (no neutral) or 3 phase 3 wire service (no neutral) 120
volt AC power to operate control circuit must be supplied as circuit. Do not replace
cover until completing installation start-up.

FILL WATER COMPARTMENT. Turn on water supply and electric service to urn.

4.
Water compartment should fill to stop-full level in approximately 10 minutes.

Turn thermostat knob to BREW position. Pilot light over knob should light showing
heater power on. Water compartment should reach operating temperature approxi­mately 45 minutes later. When the pointer on thermometer approaches the “W” in the
blue BREW zone, urn is ready for automatic operation.

American Metal Ware 87710E Coffee Urn Page 5

Spray-Over Time - Volume - Rate

Timer and spray-over rate are factory set as per information below. If other volumes of
water or a faster or slower spray-over rate is desired, see following instructions:

Timer Adjustment

Turn adjustment knob clockwise to decrease time, counterclockwise to increase time.

Operation Start-Up Checks/Brew Cycle Adjustments

1.

Turn thermostat dial to BREW position. Pilot light at top of thermostat bezel should light
up when thermometer pointer is at “W” in BREW zone, this pilot light should go out.
Water in urn tank is now at brew temperature. NOW and ONLY at initial start-up, we
advise checking time of flow of hot water to spray nozzle.

2.

CHECKING SPRAYOVER VOLUME AND RATE (REPEAT FOR EACH SPRAYARM)
Remove cover from brew basket over one liner. Position spray nozzle over this brew
basket. Liner should be empty and faucet shut off. Push in timer start button and brew
pilot should light up. Hot water should start to spray into brew basket. Allow to spray until
brew pilot light goes out and sprayover stops.

Measure amount sprayed over by drawing off into a calibrated one gallon measure. If
amount is more or less than desired, reset timer. Longer time, more sprayover, shorter
time - less sprayover. Each 1/4 minute increase or decrease adds or subtracts about 1/4
gallon to sprayover total. Note that setting of sprayover bypass valve (on sprayarm)
affects amount of sprayover.

Further adjustment of sprayover volume can be made using the internal
located in the side pump housing. Screwdriver adjustment is under the hole plug closest
to the urn body. Open the valve for less sprayover, close for more. Valve is wide open
when screwdriver slot is horizontal. It is closed when slot is vertical; i.e., pointing towards
sprayarm for maximum sprayover. The purpose of the internal bypass valve is to direct
excess discharge from the sprayover pump back into the urn water compartment.

Factory setting is 10 gallons sprayover water in 10 minutes (1 gallon/60 seconds) and
sprayover
or 3 gallons.

Before actual use of urn, it should be thoroughly cleaned and washed. It is also
recommended that a batch of coffee be brewed in each liner based on a final brewing
cycle timer setting and actual muslin bag or filter be used. We recommend that these first
batches be thrown out and not used. Strength of brew may be checked by hydrometer
or evaporation tests but flavor test might be poor on the first batch.

bypass valve wide open. Bypass volume is about 30% of the total sprayover,

bypass valve

Page 6 American Metal Ware 87710E Coffee Urn

How To Brew In An Automatic Urn

1.

Place filter in brew basket with designated amount of ground coffee (automatic urns are
designed to use 1, 2, 3 or 4 lbs. of coffee). Make certain you have a level bed of coffee.
Consult your coffee supplier for exact brewing specifications. (C.B.C. recommendation
is 1 lb. of coffee to each 2 1/2 gallons water).

2.

Replace cover and move spray head over center of coffee grounds.

3.

Check thermometer to make certain urn is at brewing temperature. Press timer button.

4.

When brew cycle is completed (brew light shuts off), remove brew basket and dispose of
spent grounds.

5.

Mixing of finished brew is accomplished automatically at the end of the brew cycle if the
urn has an air agitation option. Additional mixing can be performed at later time by
pressing manual air agitation push button.

Where urn is not equipped with air agitation, draw one gallon for each three gallons of
finished brew from coffee faucet, and pour over top into coffee liner.

The coffee is ready to serve.

6.

Hold coffee at 185

O

- 190OF. or HOLD setting on thermostat knob. Brewed coffee can be

held at this temperature for up to one hour with minimal deterioration of flavor and body.

Explanation Of Brewing Cycle

1.

When timer button is pushed, the timer is activated.

2.

The timer completes the circuit to the sprayover pump which delivers hot water through
the spray arm to the spray nozzle.

3.

The hot water from the spray nozzle is sprayed over the coffee grounds. The finished
brew collects in the coffee liner.

4.

As the pump delivers hot water from the water compartment through spray nozzle into
brew basket, the water level in the water compartment lowers.

5.

Drop in water level in water compartment below sensing probes activates liquid level
control which opens the refill solenoid valve, refilling the water compartment with cold
water.

6.

The entry of the cold water activates the thermostat, which allows power to go to the
heating element to maintain the brewing temperature

NOTE: Some urns may be equipped with an optional adjustable bypass valve on the spray
arm. Adjustment of this valve will allow some spray water to bypass the brewing basket for
additional control of the water/coffee brewing formula and the extraction percentage from
the coffee.

American Metal Ware 87710E Coffee Urn Page 7

Thermostat

The thermostat is factory set so that the knob on the BREW setting holds the urn at
brewing temperature toward the HI end of brew zone on the thermometer dial. Then, if
turned back to HOLD position, the thermostat should cycle on and off and hold at the LO
end of the BREW zone on the thermometer.

Thermostat Adjustment

If the water temperature is below the HI end of the BREW zone on the thermometer dial

1.

with the knob on BREW setting, remove the knob by pulling it straight outward. Using a
small screwdriver, insert in the hole in the center of the shaft, turn slotted screw counter­clockwise until the red pilot light goes on. Check to see that water in the urn holds at the
HI end of the BREW zone on the thermometer and does not

If the water boils with the thermostat knob set at the BREW position, remove the knob by

2.

pulling it straight outward. Using a small screwdriver, insert into the hole in the center of
the shaft, turn slotted screw clockwise until the red pilot light goes out. Hold shaft so it
does not turn while adjusting screw. Add cold water and check that the heat comes back
on (pilot light glows), and that the thermostat cycles at temperature at HI end of the
BREW zone on thermometer dial.

boil.

If the thermostat will not cycle, replace the entire control.

Push Button Timer For Spray Over Control

The function of the timer is to start the pump and run it for a preset period of time and upon
lapse of this time, to stop the pump, thereby completing the spray over cycle.

This urn is equipped with an electric reset timer. Pushing in the START button will start the
flow of water. The timer will complete the time cycle for which it has been programmed and
on completion, the flow will be stopped and the timer will reset itself, ready for the next
brewing cycle.

If electric power is cut off anywhere in the service coming to the urn during the timer
operating cycle, the timer will reset. When the power is restored, the timer must be
restarted by pushing the START button.

Spray Rinse Of Liner

To rinse the liner after brewing coffee, swing the spray arm over the desired liner and push
START button. Allow hot water to spray from the spray arm for approximately 30 to 60
seconds and then push STOP button and drain the liner.

Page 8 American Metal Ware 87710E Coffee Urn

Care and Cleaning of Coffee Urn

1.

Always rinse the urn immediately after each use.

2.

Add small quantity of hot water, brush sides and rinse with hot water until it runs clean.
Urn is now ready for next batch.

3.

At end of each day clean and brush urn several times, then rinse thoroughly with hot
water.

4.

Remove clean-out cap at the end of the coffee faucet (or take apart faucets which have
no caps) and scrub pipe leading to center of urn. Clean urn gauge glass with brush and
urn cleaner. Rinse!

5.

Scrub the faucet, then rinse it thoroughly with hot water.

6.

Place a gallon or more of fresh water in the urn until next use.

7.

Remove cover and clean. Replace cover, and leave partly open.

8.

ALWAYS REMEMBER TO EMPTY, AND RINSE THE URN WITH HOT WATER BEFORE
USING AGAIN.

NOTE

: On automatic urns, use brew start and stop switches, or the rinse switch, to spray
scalding hot water into liner for cleaning and rinsing. On pourover urns, draw hot water
directly from urn. Make sure urn water tank is kept near full, and heat is on.

Semi-Weekly Cleaning Procedure

1.

Be sure that the outer jacket is full of water.

2.

Turn on the heat and fill the urn liner 3/4 full of water; use only urn cleaning compounds,
following manufacturer’s directions; mix thoroughly and let stand about 30 minutes.

3.

Clean the gauge glass, faucet pipe, plugs, etc. using long thin brush. Use urn cleaning
solution for scrubbing. Take faucet valve apart and clean thoroughly. Clean all tubes
well.

4.

Scrub inside of urn and inside of cover with long handled brush. Be sure to clean the
“lug nut” in the base of urn liner.

5.

Rinse the inside of the urn three or four times with hot water - scrubbing each time. Also
rinse parts well. Repeat until all traces of foreign odor and cleaning solution are
removed.

6.

Leave a gallon or more of fresh water in the urn with the cover partly open until the next
use. If cold water is used, allow urn to cool to prevent cracking liner.

7.

The urn baskets may be cleaned by immersing them in urn cleaner solution and scrub­bing with a stiff brush. Rinse thoroughly and let dry. Sprayheads should be checked to
see that all holes are open. If any are clogged, remove sprayhead and use stiff wire to
open.

8.

Don’t use soap, scouring powders, or abrasives to clean coffee brewing equipment.

WARNING: Cleaner used can affect taste of coffee if not thoroughly flushed out as covered above.

NOTE: Coffee system 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

TEMP-KLEEN manufactured by Caddy Corp. of America, Pitman, NJ 08071

American Metal Ware 87710E Coffee Urn Page 9

Solid State Coffee Agitation System

Coffee agitation is accomplished with low pressure air, bubbling up through the coffee in
liner. Air enters at the top coffee gauge elbow fittings and forces coffee down out of sight
in gauge glasses during the agitation period. Air continues through into the liner connection
elbow, and bubbles up from this center fitting. The rich, heavy portion of brew is carried up
to the top and thoroughly mixed with weaker top level coffee.

Automatic Program - End of Brew and Delayed Types

At the end of the spray cycle, the air pump turns itself on for about 30 seconds automatical­ly. This automatic agitation program is either built into the solid state spray cycle (brew)
timer or is provided by a separate solid state agitation relay on equipment with mechanical
timers. Urns with delayed air agitation (Option 43D) have a two minute delay after the end
of the brew cycle before the 30 second agitation cycle starts for improved mixing. This
delayed program is provided by a separate delay solid state relay. Whenever power to the
urn has been off, such as upon installation, the automatic agitation program will begin as
soon as the power is turned on. Otherwise, it operates only after the end of spray.

Manual Agitation

At any desired time, holding in the “manual agitation” black push button switch will blend
stored coffee.

: The plug in the cleanout cap at the top of the coffee gauges must be pushed in

Note
completely to avoid air leaks. Gauge glasses are cleaned with a gauge brush by first lifting
out the top cap. (A slight twist will release a tightly sealed cap). Be sure to replace the cap
properly so that the agitation system can operate.

WARNING: Overfilling coffee liners may damage air pumps. Never

overfill liners at any

time.

Page 10 American Metal Ware 87710E Coffee Urn

Operation Malfunction and Service

Problem - Thermostat dial turned to brew and water in tank remains cold.

Possible Cause

1. No power at urn.

2. Power at urn, but no power

at heater terminals.

3. Power at heater terminals,

but no heat.

Service Checks and Cures
Check main switch. Check main fuses.

(Three on 3 phase power, two on single
phase power). Check that pilot light at top
of thermostat bezel is ON.

Check urn control circuit breaker or fuse,
reset or replace if needed. Check that water
level is at STOP mark on gauge. Check that
power contractor has power at coil, and
clicks open and closed at thermostat dial is
turned off and to BREW position. Check
control transformer, if supplied. It may be
burned out. Lastly, check for voltage at
heater terminals. If voltage at heater is
O.K., check for broken or loose wire. Water
must be showing in center gauge glass 2” if
Opt. 39 equipped.

Check heater for an open circuit with
ohmmeter or continuity tester. If necessary,
replace heater. (It is necessary to remove
coffee liner to replace electric heater).

PROBLEM: Water boils continuously with thermostat dial on position

“BREW” or “HOLD.”

Possible Cause

1. Thermostat out of calibration.

Service Checks and Cures

Set knob on “BREW” and remove knob by
pulling outward. Using small screwdriver in
center of shaft, turn slotted screw clockwise
until pilot light goes out. Check holding
temperature by adding cold water. Light
should come on and water heat up to high
end of “BREW” zone on thermometer dial

2. Thermostat is inoperative.

Fluid has leaked out of
diastat assembly of thermostat.

and then shut off. NO

If impossible to get control to cycle on and
off and control temperature, replace entire
control. Be sure to drain water in urn below

BOILING.

level at which bulb enters urn. Also, shut off
all power before service is attempted.

3. Contractor sticking in

closed position.

Contactor must click on and off. If it sticks,
replace.

American Metal Ware 87710E Coffee Urn Page 11

Dual Level Control Auto Refill And Low Water Cutoff System

1. Dual Level Control: What it does:

A.

AUTO REFILL of the water compartment to keep the tank filled with water. When
water is used, the fill valve opens automatically to let more in. The fill valve
closes when the water level reaches full.

B.

LOW WATER CUTOFF to prevent burn out of the electric immersion heater when
there is not enough water to cover it. When low water occurs, the heat automati­cally switches off. The heat stays off until more water is added.

C.

A device called a DUAL LEVEL CONTROL keeps the tank filled with water and
turns off the heat when water is low by simultaneously monitoring two different
water levels.

2. Description and Operation of the Dual Level Control System:

A.

Components

1. Dual Level Control - switches power to both the thermostat and water inlet
solenoid valve by sensing changes in water level.

H

120 VAC

N

Transformer

Printed Circuit

Relays

Fill Heat

Probes

HI XL C

2. Electrode Assembly - consists of a high (short) and a low (extra long) sensing
electrode, or probe, molded in an epoxy body.

Red Wire

Green Wire

High

Red Wire

Low

Side Mounted ProbesTop Mounted Probes

High

Green Wire

Low

3. Metal Enclosure (tank body)- provides a common (ground) connection for the

electrode circuit.

Page 12 American Metal Ware 87710E Coffee Urn

2. Description and Operation of Dual Level Control System (continued):

B.

Operation
W

ater Level

1) Below both electrodes

Action

1) Both “HI” and “XL” electrode circuits
open. Dual Level Control turns power on to
fill valve and keeps power off to thermostat.

2) Rises to low electrode above

above heater coils

3) Rises to high electrode

4) Falls below high electrode only

Fill Solenoid

Valve

ON

OFF

Thermostat

2) “XL” electrode circuit closes. Power to
thermostat turned on. Power to fill valve
remains on.

Fill Solenoid

Valve

ON

ON

Thermostat

3) “HI” electrode circuit closes. Dual Level
Control turns power off to fill valve and con­tinues power to thermostat.

Fill Solenoid

Valve

OFF

ON

Thermostat

4) “HI” electrode circuit opens. “XL” circuit
stays closed. After a few seconds delay,
power to fill valve is turned on.

Fill Solenoid

Valve

Thermostat

ON

5) Falls below low electrode.

(Same as condition no. 1)

ON

5) “XL” electrode circuit now opens. Power
to thermostat is turned off. Power to fill
valve remains on.

3. Quick Service Check of Dual Level Control System:

1) All

wire secure and properly connected.

2) Clean the electrodes. Lime (mineral scale) build-up can interfere with the
operation of any liquid level control system.

3) Check the common (ground) connection. A little looseness or dirt can cause
erratic operation.

American Metal Ware 87710E Coffee Urn Page 13

IV) Trouble Shooting Auto Refill, Low Water Cutoff, and Dual Level Control System

direction of tank, away from fresh

connected to outside fresh water

supply.

Disassemble and clean out. May

require new plunger assembly.

Caution is advised to avoid damage

to valve. See valve instruction

sheet.

Install so that port marked “IN” is

On valves without integral strainer:

On valves with integral strainer:

Install so that arrow points in

water supply.

Remove electrode assembly. Clean

both electrodes. If still no remedy

and connections are good, replace

assembly.

Make good secure connection. May

require cleaning or replacement.

Connect “BLACK” wire lead to “FILL”

terminal.

Replace Dual Level Control.

Make sure main switch(es), fuse(s),

circuit breaker(s), provide power to

unit, that machine’s circuit breaker is

OK and power switch, if provided, is

on.

Make sure all water supply line

valves are open.

Visual. Water entering

tank continuously, and

usually slowly.

1) Fill solenoid valve

leaking due to dirt or

scale holding valve

open, or worn plunger

seat.

Problem Possible Cause Service Check Remedy

A) Overfilling of water

tank when power is off.

Visual.

2) Fill solenoid valve

installed backwards.

Jumper from “HI”

terminal to metal

enclosure stops fill.

1) High electrode

coated with scale,

or faulty.

B) Overfilling of water

tank only when power

to unit is on.

Jumper for “C” terminal

(next to XL) to metal

enclosure stops fill.

2) Missing or faulty com-

mon connection for elec-

trode circuit (“C” terminal

to metal enclosure).

Visual.

3) Fill valve connected

Jumper from “HI” to “C”

does not stop fill.

Nothing operates on

machine.

to “HEAT” terminal.

4) Dual Level printed

circuit board faulty.

1) No power at

equipment.

C) Auto refill fails to

fill water tank.

“Crack” fitting at water

inlet for pressure check.

2) No water at

equipment

Page 14 American Metal Ware 87710E Coffee Urn

IV) Trouble Shooting Auto Refill, Low Water Cutoff, and Dual Level Control System (continued)

Remedy

Remove and clean micromesh

screen filter located in water strainer.

If voltage missing or incorrect, check

wiring for looseness, breaks, and

proper connections.

Clean out and/or replace plunger

assembly or entire valve. May

require new coil. Caution is advised

to avoid damage to valve. See valve

instruction sheet.

Replace coil. Also check for frozen

plunger. See valve instruction sheet.

Replace electrode assembly. If no

remedy, check for improper wiring

(cut insulation) or electrode tips

touching metal.

Replace Dual Level Control.

Replace electrode assembly.

Push wire lead connector securely

onto terminal(s). Replace connector

if wire is frayed or broken.

Replace Dual Level Control.

Service Check

Water pressure before

strainer and not after.

Check for 120V AC

across “H” and “N” ter-

Possible Cause

3) Water strainer

clogged.

4) No power on Dual

Level Control.

Problem

minals.

Disassemble.

5) Fill solenoid valve

clogged with scale or

frozen closed.

Jumper from “FILL” ter-

minal to “H” terminal

does not start fill.

Tank fills with electrode

wire disconnected from

“HI” terminal.

6) Fill solenoid valve

coil inoperative.

7) Electrodes shorting

to ground.

Tank does not fill with

electrode wire

disconnected from

“HI” terminal.

Tank fills with electrode

wire disconnected from

“HI” terminal.

8) Dual Level Control

faulty.

1) Electrode shorting to

ground completely or

intermittently.

Visual. Check “C” and

“HI” probe terminals as

well as “FILL”. Also

check neutral (white)

wire at valve.

Tank does not fill with

electrode wires discon-

nected from “XL” and

2) Loose connection.

3) Dual Level Control

faulty.

“H” terminals.

water tank (continued).

C) Auto refill fails to fill

American Metal Ware 87710E Coffee Urn Page 15

D) Auto Refill is erratic.

IV) Trouble Shooting Auto Refill, Low Water Cutoff, and Dual Level Control System (continued)

NOTE: The level control board works on the principle that water is conductive and with some pure water installations an increased sensitivity may be required in

the level control system. Consult factory if this be the case.

If you still need help, call our service department at [phone], Ext. 3 or [phone] (Monday through Friday, 8 am - 6 pm EST) or an authorized

service center in your area. Please have the model and serial number ready so that accurate information may be given.

Prior authorization must be obtained from Grindmaster Corporation’s Technical Service Department for all warranty claims.

F) No water in tank, but

heat comes on (heater

damage likely).

E) Tank fills with water,

but heat does not come

on.

Problem

2) Electrode(s) shorting

3) Dual Level Control

faulty.

tank fill.

Heat comes on with no

probe wires (HI, XL, C)

connected

Replace Dual Level Control.

to ground.

Disconnecting wire

(white) from “C” probe

terminal provides low

water heat cutoff and

Replace electrode assembly. If no

remedy, check for improper wiring

(cut insulation for instance), or elec-

trode tips touching metal inside tank.

5) Dual Level Control

1) Thermostat and fill

valve connected to

wrong terminals on

Dual Level Control.

Visual

Thermostat (brown wire) must be

connected to “HEAT” and fill valve

(black wire) to “FILL”.

faulty.

Jumper from “XL” termi-

nal to “C” does not

cause unit to heat

Replace Dual Level Control.

2) Thermostat inopera-

3) Power relay or con-

4) Low electrode faulty

or covered with lime

scale.

Jumper from “XL” termi-

nal to metal enclosure

allows unit to heat.

Clean electrodes. Check wiring. If

still no remedy, replace electrode

assembly.

tactor inoperative.

Check for voltage

(120V AC) across coil

terminals.

If correct voltage, replace coil or

entire device. If not correct voltage,

check for loose wires, improper

wiring or other cause.

tive or out of calibration.

Jumper across thermo-

stat terminals causes

heat to come on.

Recalibrate thermostat. If no reme-

dy, or thermostat does not cycle,

replace.

1) Thermostat off.
Possible Cause

Visual.

Service Check

Make sure knob is turned fully

clockwise.

Page 16 American Metal Ware 87710E Coffee Urn

Remedy

Service/Troubleshooting Solid State Air Agitation

A vibrator air pump is located in the control box. This pump supplies the air to the coffee
liners. It is turned on directly by pushing the manual agitation switch, and automatically by
the brew timer or solid state relay in series with the brew timer.

The manual agitation switch is a momentary contact, normally open single pole black push
button switch. Depressing the button closes the switch contacts completing the circuit to
the air pump. It is wired parallel to the automatic agitation circuit.

The automatic 30-second (approx.) operation of the air pump is provided by the output of
the solid state brew timer or a separate solid state agitation relay in series with the brew
timer. The delayed automatic agitation program (2 minute off time between end of spray
and start of 30 second agitation) uses a delay solid state relay in series with the brew timer.

The following trouble shooting guide assumes that internal wiring is correct and 120V AC
power is provided.

1.

IF COFFEE LEVEL

DOES NOT RISE BACK IN GAUGE GLASS, or is unusually slow to
come back up, the very small vent hole in the clean out cap is clogged. Clear vent using
a straight pin or similar object.

2.

IF

AGITATION DOES NOT STOP, check for sticking manual agitation switch. Where
automatic agitation is built into timer, and manual switch checks okay, timer is defective
and should be replaced. Where automatic agitation is a separate solid state agitation
relay and manual switch checks okay, the relay is defective and should be replaced. If
there is a constant “low” air pump output, the solid state timer or relay is defective and
should be replaced.

3.

IF NO

AIR ENTERS LINER, check output of pump through outlet fittings on urn front. If
okay, then make sure all connections are tight. Check for leaks at gauge glass, at top,
bottom and at cleanout cap. May require new o-ring or silicone grease on top cap; upper
or lower gauge glass washer; or, if chipped or cracked, new gauge glass. Also, make
sure passageways through top cap and gauge base are clear.

4.

IF LITTLE OR NO

AIR COMES THROUGH FITTINGS ON URN FRONT, open control
box and check pump operation. If pump operates, but has weak output, replace it. If air
pump is okay, air lines between control box and front fittings are blocked or leak.
Blockage usually is caused by overfilling liners. Use stiff thin wire to clear. If air lines
leak, coffee liners are removed first, then tighten compression fittings at each end of
lines.

5.

IF NEITHER

AUTOMATIC NOR MANUALAGITATION OPERATES PUMP, pump is most

likely defective and should be replaced.

6.

IF

AUTOMATIC AGITATION IS OKAY, BUT MANUAL DOES NOT WORK, replace

manual agitation switch.

7.

IF MANUAL

AGITATION WORKS, BUT AUTOMATIC DOES NOT, replace the solid state

brew timer or separate solid state agitation relay.

American Metal Ware 87710E Coffee Urn Page 17

Installation and Service Instructions

For

53.20.10

202CB and 204CD Series

General Purpose Solenoid Valve

Safety Instructions

Attention: Read carefully before attempting to
install, operate or service your Alco solenoid
valve. Retain for future reference.

Read installation instructions - thoroughly. Failure to comply

1.
can result in valve failure or system damage or personal injury.

Do not use solenoid valves on applications or fluid media not

2.
specifically cataloged without prior approval of Alco
Engineering Department.

WARNING: DO NOT USE WITH FLAMMABLE OR
EXPLOSIVE FLUIDS OR GASES. DO NOT USE IN
EXPLOSIVE ATMOSPHERES.

Use on these elements can result in product damage or
personal injury.

Use of solenoid valves on applications not specifically

3.
cataloged can result in valve failure and/or system damage or
personal injury. Do not utilize a solenoid valve on any system
where the system pressure can exceed the safe working
pressure of the valve.

CAUTION: Do not utilize a solenoid valve as a safety shut off.

4.

May 1983

Supd’s 3-80

5.

Do not exceed MOPD (Maximum Operating Pressure
Differential) or valve may fail to open when energized.

6.

CAUTION: Always disconnect power source and
depressurize the system before working on solenoid valve
or system. If the power disconnect is out-of-sight, lock it
in the open position and tag to prevent unexpected
applications of power.

7.

Direction of flow must correspond to Flow Direction
Schematics.

8.

Before energizing valve, be sure source voltage and
frequency matches that on coil. Do not energize coil
unless coil is securely attached to valve. See Coil
Installation Instructions.

9.

Prolonged use in excessive ambient temperature or
humidity may damage coils.

10.

Do not dent or bend or use enclosing tube as lever. A
damaged enclosing tube may result in coil burnout or
inoperative valve.

11.

Foreign matter in the valve may result in seal leakage,
sticking open or closed, or coil burnout. To prolong valve
life and ensure system cleanliness use a strainer

Installation

Coil Installation Instructions

Valve and Solenoid Position

1.

Before removing coil from valve, disconnect electrical power

For ease of installation, an Alco solenoid valve can be installed

1.
in any position. Gravity does not affect its operation.

NOTE:

The solenoid coil can be rotated 360

2.
If possible do not reduce the length of the solenoid coil wire leads,
so that if it becomes necessary to remove coil at a later date (for
valve cleanout, etc.) wire leads will not have to be disconnected.

To allow for removal of the solenoid coil without removing the valve

3.
from its piping, allow at least 2 inches of clearance above the solenoid.

4.

Be sure valve is installed so that its flow arrow on valve body
corresponds to direction of flow thru piping.

Identify valve elastomer code and coil code from valve model number
and reference rating from table.

Valves are rated for use on air or other non-hazardous, non-toxic fluids,
water and other aqueous, non-hazardous fluids, and steam.

Although all valves can be operated in any position,
by mounting the valve upright there is less chance of
malfunction caused by the collection of foreign material

O

for ease of wiring.

O

AHG, AHC

Elastomer

Code

B
P
N
F
T
V

FLUID TEMPERATURE RATING F

Coil Code

AMG, AMC

180
250
180
180

250

365

source. Failure to do so will cause coil to burn out.

2.

Verify coil type, voltage and frequency. This information
appears on the coil nameplate.

3.

Place coil over the enclosing tube. Coil may be rotated 360
for easy wiring. It is recommended that coil lead connections
be soldered on D.C. and 24V -50/60 Hz. applications.

4.

Install valve nameplate. Pull tab on valve nameplate and
peel off paper backing to expose adhesive. Stick nameplate
on top of coil housing and press nameplate down firmly. If
installing replacement coil, use valve nameplate supplied
with valve. Press nameplate down firmly.

5.

Install voltage nameplate and coil retainer. Press coil
retainer down firmly to secure coil.

Wiring

1.

Be sure your wiring conforms to all local and national
electric codes.

2.

For dual voltage coils, refer to the wiring schematic label on
side of coil.

3.

The coil circuit of each solenoid valve should be protected by
adequate fuses.

WARNING

If not properly grounded, a hazard of electrical shock may
exist. Install and ground unit in compliance with National,
state, and local electrical codes.

Page 18 American Metal Ware 87710E Coffee Urn

O

Disassembly

Disassemble in the same general order as indicated in exploded ­view illustrations except as noted in the following steps:

1.

De-pressurize valve and disconnect electrical power source.

2.

To remove solenoid coil:
Insert small screwdriver into gap in voltage nameplate. Slide
screwdriver tip under coil retainer and snap off. If replacing
coil, use knife to separate adhesive-backed valve nameplate
from coil. Keep valve nameplate.

3.

To remove collar, use service tool X11981-1 shown in Figure 1
Note: Do NOT lose nameplate, as it is extremely important

if it becomes necessary to order a parts kit, coil or
duplicate valve.

Assembly

1.

Assemble in the reverse general order of disassembly.

2.

Lubricate gasket and “O” ring sparingly with a compatible
lubricant such as a Silicon base lubricant.

3.

All moving parts must move freely over the full length of its
intended travel.

Troubleshooting

1.

Check system fuses, electrical wiring and system source
voltage as specified.

2.

Is flow direction arrow on valve the same as system flow
direction?

Cleaning

As with all valves, it may become necessary to clean them
periodically to keep them in peak operating condition. Any
cleaning methods or fluids used should be compatible with
valve materials.

Inspection

1.

All moving parts and elastomers should be clean in
appearance without permanent set; springs should be
free of corrosion. If any appear damaged, replace them
with a parts kit which contains all moving parts
necessary to rebuild valve to an “as new” condition.

2.

Inspect enclosing tube assembly for wear, exterior dents
or other conditions which would impair free movement of
the poppet and/or plunger assembly. Its interior should
be clean and free from any obstructions. Be especially
critical of its valve seat.

Testing

1.

Apply correct voltage to valve solenoid and cycle
solenoid several times. A distinct click should be heard
each time the solenoid is energized.

2.

Pressurize valve and check for leaks.
Note: Alco solenoid valves are equipped with a

continuous-duty solenoid coil, which when energized for
an extended period of time becomes hot to the touch.
This is a safe operating temperature. Any excessive
heating will be indicated by smoke and odor of burning
coil insulation.

3.

Are all system relays operating?

4.

Is system source pressure as specified?

5.

Are all system components free from obstruction?

Repair Kits - The following Repair Kits are available.

Valve

Series
202CB -B
202CB -F
202CB -N
202CB -P
202CB -T
202CB -V

Kit

Part No.

K-1063
K-1066
K-1067
K-1064
K-1068
K-1065

Valve

Series

For 1/4” Orifice Only
204CD -B
204CD -V
204CD -T
204CD -P

Valve

Series
204CD -B
204CD -F
204CD -N
204CD -P
204CD -T
204CD -V

Kit

Part No.

K-1162
K-1164
K-1167
K-1166

Kit

Part No.

K-1072
K-1075
K-1073
K-1076
K-1077
K-1074

Coils

1.

Junction box (AMG) is supplied as standard on all
valves.

2.

The following coil housings are available:
a. Conduit Connection (AMC) c. Open Frame (AMF)
b. GROMMET 18” Leads (AML) d. Spade Connection (AMS)
Use only Alco coils on Alco valves.

3.

Alco Controls Division • Emerson Electric Co.

P.O. Box 12700 • St. Louis, Missouri 63141 • 314-569-4500

American Metal Ware 87710E Coffee Urn Page 19

Customer Service • 314-569-4666

093-011

Page 20 American Metal Ware 87710E Coffee Urn

American Metal Ware 87710E Coffee Urn Page 21

List of Illustrated Parts

(see page 21)

1. Dual Air Pump

2. Electrode Assembly

3. Timer

4. Thermostat

5. Cover

6. Air Agitation Tubing

7. Vent Tube

8. Spray Arm Assembly

9. Cover Handle

10. Brew Basket

11. Gauge Glass Assembly

12. Faucet

13. Leg

14. Shank with Wing Coupling Nut

15. Electric Immersion Water Heater

16. Thermometer

17. Circuit Breaker

18. Manual Agitation Switch

19. Fill Solenoid Valve

20. Sprayover Pump

21. Water Pressure Regulator

22. Heater Contactor

23. Liquid Level Control - Dual

24. Power Input Terminal Block

25. Solid State Relay - Automatic Air Agitation

26. Water Strainer

27. Start Push Button

28. Stop Push Button

29. Refill Water Inlet Standpipe

30. Boiler Drain Valve

31. Pump Silicone Tubing

Page 22 American Metal Ware 87710E Coffee Urn

87710E Parts

522005 Gauge Shield, Coffee, 15”
522046 Gauge Shield, Water, 14”
522035 Gauge Glass, Coffee, 15”
522048 Gauge Glass, Water, 14”
522026 Upper Gauge Glass Washer
522027 Lower Gauge Glass Washer
522030 Gauge Shield Aluminum

Bracket
522094 Coffee/Water Faucet
522102 Silicone Seat Cup for Faucet
522120 Stainless Steel Spring for

Faucet
A-682 Gauge Shield Cap for Plug-

In cleanout cap
A-689 Plug-in Cleanout Cap with

“O” Ring for Agitation
A-1132 Plug Cleanout Cap with vent

hole for Water
532064 1/4” FPT Water Strainer
506001 Dial Thermometer
531011 Spray Nozzle w/Body
1214031 10 Gallon Spray Arm

Assembly
521014 “O” Ring & Teflon Seal Kit

Spray Arm
513001 Cover Handle Kit
507003 ATC Timer, Standard
507011 ATC Timer w/Lock & 2 Keys
530-007 Half Batch Timer
531-012 Half Batch Selector Switch
549-000 Dual Liquid Level Control
515001 Black Start Push Button
515002 Red Stop Push Button
504019 KR48 Thermostat - Opt 47
504001 Thermostat, Heater Circuit
533-012 Sprayover Pump
533-004 Sprayover Pump Complete

Assembly
533-013 Pump Repair Kit
512012 Sprayover Pump Silicone

Tubing 5/8” O.D. x 3/8” I.D.
524006 Pinch Clamp for 5/8” O.D.

Tubing
712-017 Electrode Assembly - 6 & 10

Gallon Pump Urn
508004 Dual Air Pump

512011 Silicone Tubing 1/4” O.D. x

1/8” I.D. for Air Agitation

515001 Manual Agitation Push

Button

712-050 Solid State Delayed Air

Agitation Relay
Assembly - Complete

531-024 Solid State Delayed Air

Agitation Relay - Only
5220001 Urn Liner Washer
537-060 Alco Tank Refill Solenoid

Valve
537-061 Alco Valve Repair Kit
537-062 Alco Valve Replacement Coil
532068 Boiler Drain Valve
BB810 10 Gallon Brew Basket
BB810-6 1/2 Batch Brew Basket
BB810WP 10 Gallon Filter Paper
BB6WP 6 Gallon Filter Paper

Electric Heat Only

514005 4 Pole Heater Contactor
514009 3 Pole Heater Contactor
515072 Circuit Breaker
Heating Elements - Specify Volts, Watts &
Phase or Urn’s Serial Number

S

team Heat Only

506009 Steam Solenoid Valve -

0-50 PSI
506014 Repair Kit for Steam

Solenoid Valve 506009
506016 Replacement Coil for Steam

Solenoid Valve 506009
532027A Steam Strainer 1/2” FPT

American Metal Ware 87710E Coffee Urn Page 23

Page 24 American Metal Ware 87710E Coffee Urn

American Metal Ware 87710E Coffee Urn Page 25

Page 26 American Metal Ware 87710E Coffe Urn

Grindmaster® Coffee Grinders and Brewers • Espressimo® Espresso Machines • Crathco® Hot Beverage Dispensers

Crathco® Cold and Frozen Beverage Dispensers • American Metal Ware® Coffee and Tea Systems

Tel [phone] • Fax [phone] • 1-800-695-4500

P.O. Box 35020 • Louisville, KY 40232 • USA

www.grindmaster.com • email: [e-mail]