Page 1
0205 Form # AM-321-04
American Metal Ware Volume Banquet Brew Systems
Installation, Operation & Service Manual
For
Models AMV-60, AMV-80, AMV-120 & AMV-160
Electric Steam
Special Features
After completing installation and set-up, the
equipment owner should keep this manual for
future reference.
© Grindmaster Corporation™, 1996
PRINTED IN USA
Grindmaster Corporation™
4003 Collins Lane
Louisville, Kentucky 40245 USA
(502) 425-4776
(800) 695-4500 (USA and Canada only)
(800) 568-5715 (technical service only)
FAX: (502) 425-4664
www.grindmaster.com
X
TABLE OF CONTENTS
General Description.................................1
Utility Data...............................................2
Performance Chart..................................5
Brew Urn Installation...............................6
Holding Urn Installation...........................8
Pre-Rinse Hose & Spray..........................9
Start Up : Brew Urn................................10
Holding Urn................................11
How to Brew..........................................12
Solid State Coffee Agitation...................16
Care & Cleaning of Coffee Urn..............18
Cleaning Transfer System.....................19
Space Saver Urn Service......................21
Operation Malfunction...........................23
Dual Level Control.................................25
Troubleshooting.......................27
Pre-Rinse Valve Unit Repair..................30
Parts List...............................................34
Page 2
Page 3
American Metal Ware Volume Banquet Brew Systems Page 1
AMERICAN METAL WARE
HIGH VOLUME COFFEE BREWING/HOLDING SYSTEM
GENERAL DESCRIPTION
American Metal Ware’s high volume coffee brewing/holding systems provide advantages to the
user in the three functions of 1) brewing, 2) holding, 3) transfer/fill operation. Each coffee urn is
equipped to brew both sides at one time; 20 gallons of coffee can be brewed within 15 minutes, 10
gallons on each side. The basic brewing urn is of the Space Saver type, electric or steam heat. It
requires connection to a source of 140
0
F. potable hot water, 3/8" NPT. Each urn uses a pump-type
brewing system, with a separate sprayover pump and spray arm for each coffee liner. Additional
equipment and options included on each brewing urn:
• Two all stainless steel coffee liner filter screens.
• Two Model BB810 brew baskets for use with paper filters.
• Low water cutoff system to protect the urn and immersion heater.
• Automatic refill of the water compartment.
• Adjustable bypass on each spray arm.
• Start/Stop pushbutton brewing timers, one for each coffee liner.
• Automatic air agitation of the coffee, programmed to operate only when not using
the transfer pump system.
• Two coffee transfer pumps with NSF approved stainless steel braid covered teflon
lined hoses to connect the brewing urn liners to a holding urn. The transfer pumps
are mounted in stainless steel housings located on the left and right ends of the
coffee brewing urn.
• Easy access for service is provided from the front of the housings, which also
contain the sprayover pumps.
• Sanitary teflon sealed ball valves connect the transfer system to the coffee brewing
liners. When the valves are closed, the liners are isolated from the transfer system
and holding urn.
Thus, the automatic coffee brewing urn may be used as a normal coffee urn and 10 gallons can be
brewed as an individual batch at any time.
Also included in the high volume coffee brewing system is one special coffee holding urn. The
gallon capacity is listed in the table that follows. Coffee is held at 180° F. to 190
0
F. by externally
mounted electric heaters underneath the stainless steel bottom. Thermostatic control is provided.
This holding unit has 4 coffee faucets, as shown on the layout drawing, with approximately 10"
clearance under the faucet spouts. This arrangement of faucets allows a very rapid transfer/fill of
64 oz. coffee serving pots. One 64 oz. pot can be filled within 15 seconds from any one of the 4
faucets. One operator can operate (2) of the coffee drawoff faucets and fill (6) 64-oz. coffee pots
per minute. Two operators can fill (12) 64-oz. coffee pots per minute. This enables very high
volume use of the coffee with a minimum amount of labor cost.
Page 4
Page 2 American Metal Ware Volume Banquet Brew Systems
ALL AMV 60 AND 80 SYSTEMS ARE DUAL WALL INSULATED.
BREW URN: MODEL 91119 ELECTRIC OR STEAM HEAT.
WITH (2) 10 GAL. LINERS; (2) BBS19 BREW BASKETS
FOR (25-11) PAPER FILTERS OR (17-9) MUSLIN BAG;
(2) BOTTOM LINER FILTER SCREENS.
HOLDING URN: ELECTRIC HEAT ONLY.
40 GAL. MODEL 99040E FOR AMV 60, 450 LBS.
WHEN FULL, OR 80 GAL. MODEL 99060E FOR AMV 80,
625 LBS. WHEN FULL.
COFFEE TRANSFER HOSES
(1) 3 FOOT
(1) 6 FOOT
J B NPT HOT WATER INLET
(140
O
F)
UTILITY CONNECTIONS
ARE FLUSH WITH BOTTOM
ELECTRIC INPUT
PUMP HOUSING HAS
REMOVABLE SIDE - FRONT
COVER TO PROVIDE EASY
SERVICE ACCESS
TRANSFER BALL VALVE
TRANSFER TIMER
STOP/START
SWITCHES
SPRAYOVER PUMP
BREW AND HEAT CONTROLS
6 FOOT, 120V AC, 3 WIRE CORD & PLUG ON EACH URN
ON-OFF
SWITCH
CC
CC
W
T
T
CC
FALSE BOTTOM
EXTERNALLY MOUNTED BLANKET
HEATER WITH BUILT-IN THERMOSTAT
C = COFFEE FAUCT
W = WATER FAUCET
T = THERMOMETER
CALIBRATED GAGE
OVERFLOW STANDPIPE
INSULATED COVERS
HOT WATER
SPRAY RINSE HOSE
LEG LOCATIONS SIMILAR
ON BREW URN
32
1
/4” for AMV 60
40
1
/2” for AMV 80
10
1
/2”
8
3
/4”
4”
12”
30”
45”
35”
5”
81”
35”
1”
27”
15”
6”
13
3
/4”
5
1
/4” ALL FAUCETS 1
2”
6”
10”10
1
/4”
8
5
/8”
1”
5”
4”
31” 2”
1”
17
3
/4”
17
1
/2”
3
/8” NPT HOT WATER CONNECTION AT BOTTOM
8
5
/8”
5”
CC
W
T
45”
35”
5”
10”10
1
/4”
8
5
/8”8
5
/8”
5”
37”
3
/8”
NPT
HOT
WATER
INLET
TRANSFER PUMP
1/2 “ NPT STEAM OUTLET
1/2” NPT STEAM INLET
AMERICAN METAL WARE
HIGH VOLUME/BANQUET COFFEE BREWING/HOLDING
SYSTEM. MODELS AMV 60 AND AMV 80
DRAWN BY
R.8 LRO
1
2
3
4
5
REVISIONS
DATE BYNO.
LRO
11-23-81
5 1/4 WAS 6
CHK’D
LRO,GRM
TRACES
SCALE
N.T.S.
DATE
8-5-81
APPS
.
DRAWING NO.
B-290
MATERIAL
UTILITY DATA AMV 60/80
1. BREW URN AND HOLDING URN REQUIRE
CONNECTION TO HOT WATER (140
O
F) SUPPLY, 3/8” NPT.
2. SEPARATE 120V. SINGLE PHASE, 3 WIRE, 20 AMP OUTLET
REQUIRED FOR BREW URN AND FOR HOLDING URN. USE
NEMA RECEPTACLE NO 5-20R, 3 WIRE CORD AND PLUG SUP-
PLIED ON EACH URN
A) TOTAL PUMP/CONTROL LOAD FOR BREW
URN = 15 AMP, FOR EACH SYSTEM = 30 AMP.
B) TOTAL HEATER LOAD FOR HOLDING
URN = 3 KW/16.5 AMP
3. BREW URN - ELECTRIC HEAT
A) SPECIFY SERVICE: 208 VOLT - 1 PH. 2 WIRE
240 VOLT - 1 PH. 2 WIRE
208 VOLT - 3 PH. 3 WIRE
240 VOLT - 3 PH. 3 WIRE
480 VOLT - 3 PH. 3 WIRE
B) TOTAL HEATER LOAD FOR EACH BREW URN
4. EACH BREW URN - STEAM HEAT
A) STANDARD OPERATING STEAM
PRESURE = 10 - 25 PSI
B) MAXIMUM STEAM DEMAND LBS. PER HOUR
TOTAL = 70
C) TOTAL BOILER HORSEPOWER = 2.3
KW Heater Size 15KW
Elec. Supply Volts 208 240 480V
Amps Drawn 1 Ph. 72 63 --
Amps Drawn 3 Ph. 42 36 18
Page 5
American Metal Ware Volume Banquet Brew Systems Page 3
UTILITY DATA AMV 120/160
1. BREW URN AND HOLDING URN REQUIRE
CONNECTION TO HOT WATER (140
O
F) SUPPLY, 3/8” NPT.
2. SEPARATE 120V. SINGLE PHASE, 3 WIRE, 20 AMP OUTLET
REQUIRED FOR BREW URN AND FOR HOLDING URN. USE
NEMA RECEPTACLE NO 5-20R, 3 WIRE CORD AND PLUG
SUPPLIED ON EACH URN
A) TOTAL PUMP/CONTROL LOAD FOR BREW
URN = 15 AMP
B) TOTAL HEATER LOAD FOR HOLDING
URN = 2 KW/16.5 AMP
3. BREW URN - ELECTRIC HEAT
A) SPECIFY SERVICE: 208 VOLT - 1 PH. 2 WIRE
240 VOLT - 1 PH. 2 WIRE
208 VOLT - 3 PH. 3 WIRE
240 VOLT - 3 PH. 3 WIRE
480 VOLT - 3 PH. 3 WIRE
B) TOTAL HEATER LOAD FOR EACH BREW URN
C) TOTAL HEATER LOAD FOR SYSTEM = 20KW
4. EACH BREW URN - STEAM HEAT
A) STANDARD OPERATING STEAM
PRESURE = 10 - 25 PSI GAUGE
B) MAXIMUM STEAM DEMAND LBS. PER HOUR
TOTAL = 70
C) TOTAL BOILER HORSEPOWER = 2.3
D) TOTAL STEAM DEMAND FOR
SYSTEM = 140 LBS. PER HOUR REQUIRING
4.6 BOILER HORSEPOWER
KW Heater Size 15KW
Elec. Supply Volts 208 240 480V
Amps Drawn 1 Ph. 72 63 --
Amps Drawn 3 Ph. 42 36 18
AMERICAN METAL WARE
HIGH VOLUME/BANQUET COFFEE BREWING/HOLDING
SYSTEM. MODELS AMV 60 AND AMV 80
DRAWN BY
R.8 LRO
1
2
3
4
5
REVISIONS
DATE BYNO.
LRO
11-23-81
5 1/4 WAS 6
CHK’D
LRO,GRM
TRACES
SCALE
N.T.S.
DATE
8-5-81
APPS
.
DRAWING NO.
B-290
MATERIAL
ALL AMV 120 AND 160 SYSTEMS ARE DUAL WALL INSULATED.
BREW URN: MODEL 91119 ELECTRIC OR STEAM HEAT.
WITH (2) 10 GAL. LINERS; (2) BBS19 BREW BASKETS
FOR (25-11) PAPER FILTERS OR (17-9) MUSLIN BAG;
(2) BOTTOM LINER FILTER SCREENS.
HOLDING URN: ELECTRIC HEAT ONLY.
80 GAL. MODEL 99040E FOR AMV 120, 850 LBS.
WHEN FULL, OR 120 GAL. MODEL 99060E FOR AMV 160,
1200 LBS. WHEN FULL.
TRANSFER
BALL VALVE
TRANSFER TIMER
STOP/START
SWITCHES
COFFEE TRANSFER HOSE (1) 4 FOOT, (2) 7 FOOT, (1) 11 FOOT
3/8” NPT HOT WATER
INLET (140
O
F)
PUMP HOUSING
HAS REMOVABLE
SIDE-FRONT COVER
TO PROVIDE EASY
ACCESS FOR
SERVICING
1”
6”
4”
C
C
W
T
C
C
W
T
C
CCC
T
45”
35”
45”
6” 6”
5
1
/4”
17
3
/4”
13
3
/4”
2”
2”
1”
2”
31”
33”
44”
96
1
/2””
20”
1”
1”
37”
20”
12”
4”
148
1
/2”
35”
5”
10”
10
1
/4”
8
5
/8”8
5
/8”8
5
/8”8
5
/8”
5”
5”5”
EXTERNALLY MOUNTED
BLANKET
HEATER WITH BUILT-IN
THERMOSTAT
FALSE BOTTOM
ON-OFF SWITCH
6 FOOT
120V AC
CORTD & PLUG
ON EACH URN
BREW AND
HEAT CONTROLS
C=COFFEE FAUCET
W-WATER FAUCET
T=THERMOMETER
NOTE: UTILITY CONNECTIONS ARE
SAME FORE ACH BREWING URN AND
ARE FLUSH WITH BOTTOM
STEAM OUTLET
1
/2” NPT
STEAM INLET
1
/2” NPT
ELECTRIC INPUT
SPRAYOVER PUMP
TRANSFER PUMP
CALIBRATED
GAGE
OVERFLOW STANDPIPE
INSULATED COVERS
3/8” NPT HOT WATER CONNECTION AT BOTTOM
HOT WATER
SPRAY RINSE HOSE
LEG LOCATIONS
ALL FAUCETS 1
36
1
/2” for AMV 120
46
1
/4” for AMV 160
10
1
/2”
8
3
/4”
3
/8” NPT
HOT WATER
INLET
Page 6
Page 4 American Metal Ware Volume Banquet Brew Systems
UTILITY DATA AMV 60/80, 120/160
1. Brew urn(s) and holding urn require connection to hot water (1400F) supply,
3/8" NPT.
2. Separate 120V, single phase, 3 wire 20 amp outlet required for each brew urn
and for holding urn. Use nema receptacle no. 5-20R. 3 wire cord and plug
supplied on each urn.
A) Total pump/control load
1) for each brew urn = 15 amp
2) for AMV 60/80 system = 15 amp
3) for AMV 120/160 system = 30 amp
B) Total heater load for holding urn = 2KW/16.5 amp
3. Each brew urn - Electric heat
A) Specify service: 208Volt-1Ph. 2Wire
240Volt-1Ph. 2Wire
208Volt-3Ph. 3Wire
240Volt-3Ph. 3Wire
480Volt-3Ph. 3Wire
B) Total heater load for each brew urn
KW Heater Size 150KW
Elec. Supply Volts 208 240 480V
Amps Drawn 1 Ph. 72 63 Amps Drawn 3 Ph. 42 36 18
C) Total heater load for AMV 60/80 system = 15KW
D) Total heater load for AMV-120/160 system = 30KW
4. Each brew urn - Steam heat
A) Standard operating steam pressure = 10-25 PSI gage
B) Maximum steam demand-lbs. per hour total = 70
C) Total boiler horsepower 2.3
D) Total steam demand for AMV 60/80 system = 70 lbs./hr. (2.3BHP)
E) Total steam demand for AMV 120/160 system = 140 lbs./hr. (4.6BHP)
Page 7
American Metal Ware Volume Banquet Brew Systems Page 5
HIGH VOLUME COFFEE BREWING/HOLDING SYSTEM
PERFORMANCE CHART
Based on spraying over 10.5 gallons water each batch.
Based on simultaneous 2-side brewing.
Based on connection to 140
0
F. hot water supply.
Model No.
Total Coffee
Capacity Held
Brewing Urn(s)
Brewing Urn
Holding Capacity
Holding Urn
Capacity
Total Capacity
Brew Time
Transfer Time
Total Preparation
Time (No Heat Up)
Equivalent No.
5 oz. servings
Equivalent No.
6 oz. servings
AMV-60
60 Gals.
One
Twin 10 Gal.
20 Gals.
40 Gals.
45 Min.
10 Min.
55 Min.
1500
1250
AMV-80
80 Gals.
One
Twin 10 Gal.
20 Gals.
60 Gals.
60 Min.
15 Min.
75 Min.
2000
1700
AMV-120
120 Gals.
Two
Twin 10 Gal.
40 Gals.
80 Gals.
45 Min.
10 Min.
55 Min.
3000
2500
AMV-160
160 Gals.
Two
Twin 10 Gal.
40 Gals.
120 Gals.
60 Min.
15 Min.
75 Min.
4000
3300
Page 8
Page 6 American Metal Ware Volume Banquet Brew Systems
Brew Urn Installation
1. Position urn so that the faucets drip into a drain trough or drain receptacle of some type.
2. Level urn both front to back and left to right. The feet are adjustable for this purpose.
Utility Connections
IMPORTANT: DO NOT RUN TUBING, PIPES, CONDUIT OR CABLE UNDER CENTER
PORTION OF URN. THIS AREA MUST
BE KEPT CLEAR FOR SERVICING URN CONTROLS.
Water
1. 1400F. hot water must be used.
2. Provide shutoff valve and union in supply line near urn.
3. Minimum operating pressure at urn should be 30 PSI.
4. Maximum pressure recommended at urn
is 75 PSI.
5. Copper or aluminum tubing should be used for flexiblity and avoiding strain on the urn.
6. To insure pressure at the urn of at least 30 PSI, use 3/8" O.D. tubing for short runs, 1/2" O.D.
tubing for longer runs, and larger size tubing for unusually long runs.
Electric
1. An experienced electrician should be responsible for connecting urn to electric power.
2. Check rating marking on urn to be sure supply lines match voltage and phase requirements.
3. Neutral wire normally required on all single phase and on 208 Volt three phase power supplies
to operate 120 Volt AC control circuit. If single phase, 2 wire service (no neutral) or 3
phase 3 wire service (no neutral), a 3-wire cord and plug is supplied on the urn for
120 Volt AC 15 amp power connection to the pump and control circuit.
4. A fused disconnect switch should be installed near urn.
5. Urn body must be grounded. A grounding conductor terminal is provided for this purpose.
Other means of positively grounding urn may be used.
6. Use only copper wire to connect this urn.
Electric Field
Terminal Block
3
/8” NPT
Water Inlet
Page 9
American Metal Ware Volume Banquet Brew Systems Page 7
Installation
1. Position urn so that the faucets drip into a drain trough or drain receptacle of some type.
2. Level urn both front to back and left to right. The feet are adjustable for this purpose.
Utility Connections
IMPORTANT: DO NOT RUN TUBING, PIPES, CONDUIT OR CABLE UNDER CENTER
PORTION OF URN. THIS AREA MUST BE KEPT CLEAR FOR SERVICING URN CONTROLS.
Water
1. Cold or hot water may be used. Heat input capacity is ample for the coldest water, and
cold water should be used for best results.
2. Provide shutoff valve and union in supply line near urn.
3. Minimum operating pressure at urn should be 30 PSI.
4. Maximum pressure recommended at urn
is 75 PSI.
5. Copper or aluminum tubing should be used for flexibility and avoiding strain on the urn.
6. To insure pressure at the urn of at least 30 PSI, use 3/8" O.D. tubing for short runs, 1/2"
O.D. tubing for longer runs, and larger size tubing for unusually long runs.
Steam
1. Steam supply line should have a shut-off valve ahead of urn. (A steam strainer and
solenoid valve are located in the urn controls compartment.)
2. Steam return line should be connected to a high quality steam trap. Also, including a
bypass and test valve to check trap operation while in service is recommended.
3. Use unions and/or copper tubing on both the supply and return connections to avoid
strain on urn.
Electric
Plug 3-wire cord into nearby 120V AC outlet to provide power for urn controls. Note: Outlet must
be a grounding-receptacle type.
3
/8” NPT
Water Inlet
1
/2” NPT
Steam Outlet
1
/2” NPT
Steam Inlet
Plug Into
120V AC
Grounded
Outlet
Page 10
Page 8 American Metal Ware Volume Banquet Brew Systems
Holding Urn Installation
1. Position urn on a sufficiently braced and reinforced stand or counter--a full 120 gallon holding
urn weighs more than 1200 pounds.
2. Locate urn so faucets drip into a drain trough or drain receptacle of some type.
3. Level urn both front to back and left to right. The feet are adjustable.
4. Bolt feet to counter.
Utility Connections
Water
1. Connect 1400F. or hotter water to the spray rinse unit. Connection is 3/8"NPT, located
center rear just below the bottom of the urn body.
2. Provide shutoff valve and union in supply line near urn.
3. Minimum operating pressure at urn
should be 30 PSI.
4. Maximum pressure recommended at urn is 75 PSI.
5. Copper or aluminum tubing should be used for flexibility and avoiding strain on the urn.
6. To insure pressure at the urn of at least 30 PSI, use 3/8" O.D. tubing for short runs, 1/2" O.D.
tubing for longer runs, and larger size tubing for unusually long runs.
Electric
1. Holding urn must have its own 120V, single phase, 3 wire (grounded) 20 amp circuit. Heater
load = 16.5 amp.
2. Connect provided 3-wire cord and plug into NEMA style 5-20R receptacle.
3. A fused disconnect switch should be installed near urn.
Transfer Hose Connections
Stainless steel braided, teflon lined hoses connect the holding urn to the brew urn(s). Hose
fittings are located on the top rear of each brew urn side pump housing and on the top of the
holding urn. The hoses have different lengths--connect the shortest to the pump housing nearest
to the holding urn, longest to the furthest away.
Page 11
American Metal Ware Volume Banquet Brew Systems Page 9
For 919-S Pre-Rinse R1SEK, Hose & Spray
1. Assemble body adapter ‘A’ to body
with Loctite or adhesive.
2. Remove insulated handle & spray ‘B’
from hose assembly.
3. Assemble pipe support ‘D’ and hose hook ‘E’ to riser ‘C’.
4. Install riser ‘C’ to body adapter ‘A’.
5. Assemble hose ‘F’ to riser coupling.
6. Slip gooseneck spring ‘G’ over hose ‘F’.
NOTE: Top of spring has short radius bend.
7. Reconnect spray valve and insulated handle ‘B’ to hose ‘F’.
The Chicago Faucet Company
T-90
l ’77
F
F
E
C
A
D
G
Page 12
Page 10 American Metal Ware Volume Banquet Brew Systems
Operation Start-Up: Brew Urn
1.
2.
Operation Start-Up Checks/Brew Cycle Adjustments
1.
2.
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 to 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 first batch.
Turn on power supply to urn. Open water supply line valve to urn. Water compartment
will fill automatically. In case of failure to fill, refer to Automatic Refill service instructions page.
Turn thermostat knob on front of housing to BREW position. Pilot light at top of thermostat
bezel should light up. Water in urn should heat up, and thermometer pointer rise to "W" in
the blue BREW zone on thermometer dial, within approximately 45 minutes, depending on
temperature of water in urn. Pilot light at top of thermostat bezel should go out when water
in urn is at brew temperature. This pilot light will also go out in case of dangerous low
water conditions, or no power at urn due to blown fuse, switch off, etc.
Turn thermostat dial to BREW position. Pilot light at top of thermostat bezel should light up
and 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.
Checkinq 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 bypass valve 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. 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 spray
-
over bypass valve wide open. Bypass volume is about 30% of the total sprayover, or 3 gallons.
Page 13
American Metal Ware Volume Banquet Brew Systems Page 11
Operation Start-Up: Holding Urn
1.
2.
3.
4.
Operation Start-Up Checks: Transfer System
1.
2.
3.
4.
Turn on power supply to urn. Open water supply line valve to urn.
Turn on master switch. Indicator light should be lit; if not, check power supply for blown fuse,
disconnect switch off, etc.
Remove cover and manually spray rinse water into urn. If spray is not hot, run water until it is,
then drain the initially cool water through the front faucets. (If this is not done, the urn will take
an abnormally long time to heat up.) Fill urn until water level rises above thermometer.
Urn should heat up until thermometer pointer reaches low end of blue Brew Zone. Internal
thermostatic control should maintain this setting of 180
0
-1900F.
With brew urn(s) up to temperature, spray full brew volume into each coffee liner.
When sprayover is complete, open transfer ball valve, located on urn front, by moving handle
to horizontal position.
Push start button on front of pump housing to begin timer-controlled transfer. The pilot light
should light up indicating transfer in process.
The transfer pump and pilot light should shut off soon after the full liner is empty. If too soon,
adjust timer for longer time. Factory setting is 4
1
/2 minutes for a full 10 gallon liner.
Page 14
Page 12 American Metal Ware Volume Banquet Brew Systems
How To Brew In An Automatic Urn
1.
2.
3.
4.
5.
6.
7.
8.
9.
Place filter in brew basket with designated amount of ground coffee (automatic urns are designated to use 1, 2, or 3 lbs. of coffee). Make certain the coffee has a level bed depth of at least
1 1/2" to 2".
Replace cover and move spray head over center of coffee grounds.
Check thermometer to make certain urn is at brewing temperature; pointer should be at high
end of brew zone. Press START button.
When brew cycle is completed, remove brew basket and dispose of spent grounds.
Mixing of finished brew is accomplished automatically at the end of the drip-through cycle.
When mixing of the finished brew is completed, open transfer ball valve, located on urn front,
by moving handle to horizontal position.
Push start button on front of the pump housing to begin timer-controlled transfer. The pilot light
should light up indicating transfer in process.
The transfer pump and the pilot light should shut off soon after the full liner is empty. If too
soon, adjust timer for longer time. Factory setting is 5 1/2 minutes for a full 10 gallon liner.
Coffee is ready to serve.
Thermometer
Pre-Rinse Hose
Brew Basket
Holding Tank
Jug Fill
Hose
Transfer
Timer
Brew Timers
Thermostat
Transfer
Ball Valve
Sprayarm
Cover
Page 15
American Metal Ware Volume Banquet Brew Systems Page 13
How To Brew In An Automatic Urn
1.
2.
3.
4.
5.
6.
7.
Explanation Of Brewing Cycle
1.
2.
3.
4.
5.
6.
NOTE: All urns are equipped with an 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.
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 gallson water).
Replace cover and move spray head over center of coffee grounds.
Check thermometer to make certain urn is at brewing temperature. Press timer button.
When brew cycle is completed (brew light shuts off), remove brew basket and dispose of
spent grounds.
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.
Coffee is ready to serve.
Hold coffee at 185
O
- 1900F. 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.
When timer button is pushed, the timer is activated.
The timer completes the circuit to the sprayover pump which delivers hot water through the
spray arm to the spray nozzle.
The hot water from the spray nozzle is sprayed over the coffee grounds. The finished brew
collects in the coffee liner.
As the pump delivers hot water from the water compartment through spray nozzle into brew
basket, the water level in the water compartment lowers.
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 fresh water.
The entry of the water activates the thermostat, which allows power to go to the heating
element to maintain the brewing temperature.
Page 16
Page 14 American Metal Ware Volume Banquet Brew Systems
Variable brewing factors which the coffee urn cannot control are:
1.
2.
3.
4.
5.
Variable brewing factors which this coffee urn can
control are:
1.
2.
3.
4.
5.
6.
7.
Final decision of brewing formula and brewing cycle adjustments rests with the operator and the
coffee suppliler.
OPT. 121 - Overfill protection
In the event of an operator errror to transfer coffee while the holding tank is full, this option will
disable the transfer timer which will shut off the pumps and prevent the holding tank from overfilling.
The uniformity and type of grind on coffee supplied.
The uniformity and quality of roasting, and selection of blend and type of
coffee beans used, and the freshness of ground coffee used in a brew.
Water chemistry - i.e., mineral content, taste factors, (chlorine, flourine,
iron, etc.) and effects of any treatment process occurring ahead of urn.
Uniformity and quality of filter paper is also important, and proper
storage and handling of paper affects final brew.
Proper and regular, frequent cleaning of all coffee brewing equipment is vital to insure the
most delicious tasting brew.
Contact time of water with ground coffee.
Accuracy of water spray-over volume.
Temperature of water spray-over.
Holding temperature of finished brew.
Proper and uniform extraction over coffee brew basket bed area.
Proper coffee bed depth in brew basket.
Proper and thorough mixing of first rich brew with later, weaker brew for uniform final brew.
Page 17
American Metal Ware Volume Banquet Brew Systems Page 15
Filter Screen For Coffee Grounds
This automatic urn includes 2 filter screens. They are located. inside the coffee liners, resting near
the bottom. Their purpose is to prevent blockage or clogging of coffee transfer pump hose system
caused by careless operator, torn or defective filter paper, or overfill of coffee brew basket. Filter
screen must be in position at all operatinq times in both liners.
Filter screen should be removed and rinsed after each batch brewed, at the same time that coffee
liner is rinsed out.
Daily rinse off advised.
Weekly wash through dishwasher cycle, or by cleaning with coffee removal compound such as:
Dip-It -- Economics Lab
Oxylite -- Avril, Inc. Syndet Division
Temp-Kleen -- Caddy Corp. of America
Transfer System Operation
1.
2.
3.
4.
5.
NOTE:
Coffee may be transferred from all brew liners at the same time provided that there is room left in
the holding urn. DO NOT overfill the coffee holding urn. Poushing the STOP button on the side
housing will shut off the transfer pump.
Whenever the coffee holding urn is to be used, switch it on while the first brewing operation(s)
are going on in the brew urn(s). This will allow the holding urn to be up to temperature for the
first transfer of freshly brewed coffee.
The sanitary, teflon-sealed, ball valves on the brew urn front must be kept closed (handle
down) except when transferring coffee, or cleaning the system. After completing a brew in one
liner, open its ball valve by moving the handle up to horizontal. This will feed coffee to the
transfer pump.
Before transferring coffee, check the calibrated gauge on the front of the holding urn. If the
coffee level is near full, do not transfer until coffee has been drawn off to a safe level. If okay
to transfer, push START button on front of side pump housing. The pilot light should light up
indicating transfer in process.
After the timer controlled transfer pump shuts off, and the pilot light goes out, close the ball
valve by moving its handle down. Rinse out the brew liner.
Ready for next brew.
Page 18
Page 16 American Metal Ware Volume Banquet Brew Systems
Solid State Coffee Agitation System
Coffee agitation is accomplished with low pressure air, bubbling up through coffee in liner. Air enters
at top coffee gauge elbow fittings and forces coffee down out of sight in gauge glasses during agitation period. Air continues through into 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 cyle, the air pump turns 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.
Note
: The plug in cleanout cap at the top of the coffee gages must be pushed in 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 19
American Metal Ware Volume Banquet Brew Systems Page 17
Coffee Agitation System (Automatically Programmed)
Coffee agitation is accomplished with low pressure air, bubbling up through coffee in liner. Air
enters at top coffee gauge elbow fittings and forces coffee down out of sight in gauge glasses
during agitation period. Air continues through into 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.
OPERATION
30 second agitation at end of spray cycle is automatic. At any additional time to agitate
stored coffee, push black button and hold as long as desired to agitate.
DELAYED AGITATION
Some urns are equipped with delayed automatic agitation. In these urns, agitation begins
1 1/2 to 2 minutes after spray cycle ends and continues for the normal 30 second coffee
blending period.
WARNING
OVERFILLING COFFEE LINERS MAY DAMAGE AIR PUMPS. NEVER overfill liners at
any time.
SERVICE - IF NO AIR
Make sure all tubes are tightly connected. Check pump. Check for leaks at gauge glass,
at top or bottom and at top cleanout caps. (May require new "O" ring on top cap.)
The top cap of the Deluxe Top Coffee Gauge Cleanout Fitting for Air Agitation MUST BE
COMPLETELY PUSHED INTO the upper gauge fittings. Gauge glasses can be cleaned
with gauge glass brush by first lifting out the top cap from the upper gauge fitting.
In operation, the top cap must be in place for agitation to operate.
TO CHECK TIMING
If timing is too short, or too long, check solid state timing relay.
Cleaning Urn
After emptying a liner of coffee, liner should be flushed out. Push start button. After 30 to 60
seconds, push red stop button switch. Spray will rinse liner very effectively with scalding hot
water. Thorough daily cleaning after last batch of coffee is brewed should be a must
procedure.
Use ample amount of hot water with brush, and clean draw-off tube ana faucets and gauge
glasses. At least once a week, use a good urn cleaner to clean urn. Be sure to thoroughly rinse
after any cleaning operation with several gallons of hot water.
Page 20
Page 18 American Metal Ware Volume Banquet Brew Systems
Care and Cleaning Of Coffee Urns
1.
2.
3.
4.
5.
6.
7.
8.
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.
2.
3.
4.
5.
6.
7.
8.
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
Always rinse urn immediately after each use.
Add small quantity of hot water, brush sides and rinse with hot water until it runs clean. Urn is
now ready for next batch.
At end of each day clean and brush urn several times, then rinse thoroughly with hot water.
Remove clean-out cap at end of 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!
Scrub the faucet, then rinse it thoroughly with hot water.
Place a gallon or more of fresh water in urn until next use.
Remove cover and clean. Replace cover, and leave partly open.
ALWAYS REMEMBER TO EMPTY, AND RINSE THE URN WITH HOT WATER BEFORE USING AGAIN.
Be sure outer jacket is full of water.
Turn on heat and fill urn liner 3/4 full of water; use only urn cleaning compounds, following
manufacturer's directions; mix thoroughly and let stand about 30 minutes.
Clean gauge glasses, 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.
Scrub inside of urn and inside of cover with long handled brush. Be sure to clean "lug nut" in
base of urn liner.
Rinse inside of 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.
Leave a gallon or more of fresh water in urn with cover partly open until next use. If cold water
is used, allow urn to cool to prevent cracking liner.
Urn baskets may be cleaned by immersing 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.
Don't use soap, scouring powders, or abrasives to clean coffee brewing: equipment.
Page 21
American Metal Ware Volume Banquet Brew Systems Page 19
Specific Instructions For Cleaning Transfer System
NOTE: A. These cleaning instructions are in addition to the regular care and cleaning of coffee
urn instructions found on another page in this manual.
B. These specific instructions must be followed after each use of the transfer system.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
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
Cleanout plugs are found on the elbows beneath the coffee brew liner faucet shanks. These
should be opened and liner rinse water allowed to flush out the fittings in front of the transfer
ball valves.
After flushing, open the ball valves and insert a gauge glass brush through the cleanouts to
scrub the transfer line up to the pump. Note that the brush can be shaped so that the bristles
reach all the way to the pump housing. Do not insert the brush too far as its tip may puncture
the flexible tubing inside the housing.
Plug the cleanouts. Keep the valves open. Make sure the urn is up to temperature. (The
holding urn need not be turned on.)
Spray over half volume of hot water into each liner. (Push BREW STOP button when water
reaches middle of gauge.) Add about 4 tablespoons of coffee system cleaner to each liner.
Transfer cleaning solution from each liner to holding urn.
After transfer is complete, open all liner and holding urn faucets to drain cleaning solution.
While cleaning solution is being drained, fill each liner halfway again.
Close faucets. Transfer hot rinse water from each liner to holding urn.
Repeat steps 6, 7, and 8.
Drain rinse water as before.
Close faucets. Close transfer ball valves.
Page 22
Page 20 American Metal Ware Volume Banquet Brew Systems
Service Instructions
Mineral or lime content of water is the major factor determining frequency of cleaning of water
heating circuit which includes solenoid water valve, strainer, spray arm, spray nozzle, bypass valve,
sprayover pump 'and water tank. We recommend that a Poly phosphate type of water treatment be
used where hardness of water is a problem. Such units are manufactured by: 'Ever Pure, Inc.,
Westmont, IL, Calgon Co., Pittsburgh, PA. Contact your equipment dealer, sales representative, or
a plumber to find out about this vital water treatment problem in your location. It may even be
necessary to consult a water treatment engineer to solve a difficult problem in particular areas.
Generally speaking, water over 7 or 8 grain hardness can cause trouble in this equipment. We
cannot guarantee urn against operational problems caused by liming or scaling.
We do provide a large capacity strainer on the water line to protect the water solenoid valve and
flow control valve from being affected by suspended particles. This strainer should be cleaned by
removing plug on screen and washing screen every 3-6 months or year, depending on local water
conditions.
Thermostat Adjustment
1.
2.
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.
If water temperature is below "W" in BREW zone on thermometer dial with knob on BREW
setting, remove knob by pulling straight outward. Using small screwdriver, insert in hole in
center of shaft, turn slotted screw counterclockwise until red pilot light goes on. Check to see
that water in urn holds at "W" in BREW zone on thermometer and does not boil.
If water boils with thermostat knob set at the BREW position, remove knob by pulling straight
outward. Using small screwdriver, insert into hole in center of shaft, turn slotted screw
clockwise until red pilot light goes out. Hold shaft so it does not turn while adjusting screw.
Add cold water and check that heat comes back on (pilot light glows), and that thermostat
cycles at temperature at HI end of BREW zone on thermometer dial.
If thermostat will not cycle, replace entire control.
Page 23
American Metal Ware Volume Banquet Brew Systems Page 21
Space Saver Urn Service Instructions
Electrode Assembly
The electrode assembly that is used to detect the water level for American Metal Ware auto refill
and low water cutoff systems is mounted through the center portion of the urn top, at the rear.
Remove the cover to gain access to the electrodes for cleaning off any mineral scale buildup. See
Service Bulletin 4 pages for further information.
Controls Compartment Servicing
The controls for the Space Saver urn are mounted on a drawer which drops down and pulls out for
complete access. This drawer is held up in the urn base by a rear support angle and mounting
screws in the front control panel face. Follow this procedure when performing any service of the
components located in the drawer compartment:
A.
B.
C.
D.
E.
TURN OFF POWER.
Giving temporary support underneath the front of the controls compartment (your hand
or fist will do), remove the mounting screws.
Carefully lower the drawer to the countertop and pull it completely forward for full
access to all components.
Note that some parts are attached to the actual urn bottom, in the upper area of the
controls compartment. These parts include: the water inlet assembly, thermostat bulb,
and steam solenoid assembly or electric heater terminals (depending if urn is steam or
electric heat).
When putting the drawer back in position, take care that all wires and the thermostat
capillary tube are free from being caught or pinched.
Page 24
Page 22 American Metal Ware Volume Banquet Brew Systems
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 troubleshooting guide assumes that internal wiring is correct and 120V AC power is
provided.
1.
2.
3.
4.
5.
6.
7.
IF COFFEE LEVEL DOES NOT RISE BACK IN GAUGE GLASS, or is unusually slow to come
backup, the very small vent hole in the clean out cap is clogged. Clear vent using a straight pin
or similar object.
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 defectiveand 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.
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.
IF LITTLE OR NO AIR COMES THROUGH FITTINGS ON URN FRONT, open the control box
and check the 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.
IF NEITHER AUTOMATIC'NOR MANUAL AGITATION OPERATES PUMP, pump is most likely
defective and should be replaced.
IF AUTOMATIC AGITATION IS OKAY, BUT MANUAL DOES NOT WORK, replace manual
agitation switch.
IF MANUAL AGITATION WORKS, BUT AUTOMATIC DOES NOT, replace the solid state brew
timer or separate solid state agitation relay.
Page 25
American Metal Ware Volume Banquet Brew Systems Page 23
Operation Malfunction and Service
PROBLEM - THERMOSTAT DIAL TURNED TO BREW AND WATER IN TANK REMAINS COLD
1.
2.
3.
PROBLEM - WATER BOILS CONTINUOUSLY WITH THERMOSTAT DIAL ON POSITION
“BREW” OR “HOLD”.
1.
2.
3.
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
contactor 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 ohmeter
or continuity tester. If necessary, replace heater.
(It is necessary to remove coffee liner to replace
electric heater).
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 cod water. Light should come on and
water heat up to high end of “BREW” zone on
thermometer dial and then shut off.
NO
BOILING.
If impossible to get control to cycle on and off
and control temperature, replace entire control.
Be sure to drain water in urn below level at which
bulb enters urn. Also shut off all power before
service is attempted.
Contractor must click on and off. If it sticks, replace.
POSSIBLE CAUSE
No power at urn.
Power at urn, but no power at
heater terminals.
Power at heater terminals,
but no heat.
POSSIBLE CAUSE
Thermostat out of calibration.
Thermostat is inoperative.
Fluid has leaked out of
diastat assembly of thermostat.
Contractor sticking in
closed position.
Page 26
Page 24 American Metal Ware Volume Banquet Brew Systems
Operation Malfunction and Service (cont’d)
PROBLEM - LINE OR CONTROL CIRCUIT BREAKER (OR FUSE) TRIPS FREQUENTLY
1.
2.
3.
4.
5.
6.
7.
PROBLEM - NO COFFEE TRANSFER
1.
2.
3.
4.
SERVICE CHECKS AND CURES
Install circuit protector with proper amp rating.
Replace push button switch. Check with
ohmeter.
Replace liquid level control.
Check coil for continuity and proper resistance
and short to ground with ohmeter.
Check coil for continuity and proper resistance
and short to ground with ohmeter.
Check pump motor for high operating
temperature. Check with ohmeter for
ground-out or burn-out.
Check with ohmeter to ground.
Replace defective unit.
SERVICE CHECKS AND CURES
Clean and/or open valve.
To prime, shut off coffee pump switch for 20
seconds. Restart and coffee should circulate
through lines. (Make sure transfer ball valve is
open.)
Clean lines - see “Cleaning Instructions”.
Check pump fuses. Check pump timer/switches. Check motor with live 120 volt test cord.
Replace pump if necessary. Note: Overload
protector thermostat on pump motor may cut off
and on, under overload conditions, pump binding or clogged, etc. If condition persists, replace
pump.
POSSIBLE CAUSE
Fuse or breaker undersized.
Manual agitation push button
grounds out intermittently.
Liquid level control malfunctioning.
Contractor coil defective.
Solenoid valve coil defective.
Pump motor defective.
Pump timer switch grounds out
intermittently.
POSSIBLE CAUSE
Transfer ball valve in supply line
clogged or shut off.
Needs priming.
Transfer lines blocked.
Pumps not working.
Page 27
American Metal Ware Volume Banquet Brew Systems Page 25
Dual Level Control Auto Refill and Low Water Cutoff System
I)
II)
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 in more. The fill valve
closes when 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.
Description and Operation of Dual Level Control System:
A. Components
Thermostat
To Thermostat
To Thermostat
Neutral
Neutral
Neutral
OrOr
Steam HeatElectric Heat
Electric Heat
L
1
T
1
L
2
T
2
L
3
T
3
L
4
T
4
Gas Heat
To Thermostat
Urn
Auto
Refill
Full
Low
N
Fill
Valve
Steam
Valve
Gas
Valve
Electrode
Assembly
H
H
White
Red
Green
XL HI C
HEAT FILL H N
Dual
Level
Contol
Auto Refill and Low
Water Cutoff
120V - AC
C2
C1
H
N
Power
Input
090-488
1-15-92 WK
Page 28
Page 26 American Metal Ware Volume Banquet Brew Systems
II) Description and Operation of Liquid Level Contol System (cont’d)
III) Quick Service Check of Dual Liquid Level Control System:
1) All
wires 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) connections. A little looseness or dirt can cause erratic
operation.
090-489
1-15-02 WK
ACTION
1. Electrode circuit open. Liquid level
control turns on power to fill valve
and turns off power to thermostat.
2. Electrode circuit stays open. Power to
fill valve remains on. Liquid level
control turns power on to thermostat.
3. Electrode circuit closes. Liquid level
control turns off power to fill valve and
leaves power on the thermostat.
4. Electrode circuit opens. Liquid level
control turns power on to fill valve.
Thermostat stays on.
5. SAME AS STEP ONE, ABOVE.
B. Operation
WATER LEVEL
1. Below both electrodes.
2. Rises to low electrode.
3. Rises to high electrode.
4. Falls to below high electrode only
5. Falls to below low electrode
Fill
Solenoid
Valve
ON OFF
Thermostat
ON ON
Thermostat
OFF ON
Thermostat
ON ON
Thermostat
Fill
Solenoid
Valve
Fill
Solenoid
Valve
Fill
Solenoid
Valve
Page 29
American Metal Ware Volume Banquet Brew Systems Page 27
090-805
3 of 5
Rev. 4/87
A)
B)
C)
Overfilling of water
tank when power is
off.
Overfilling of water
tank only when power
to unit is on.
Auto refill fails to
fill water tank.
PROBLEM
IV) Troubleshooting Auto Refill, Low Water Cutoff, and Dual Level Control System
POSSIBLE CAUSE SERVICE CHECK REMEDY
1)
2)
1)
2)
3)
4)
1)
2)
Fill solenoid valve leaking
due to dirt or scale holding
valve open, or worn
plunger seat.
Fill solenoid valve
installed backwards.
High electrode coated
with scale, or faulty.
Missing or faulty
common connection for
electrode circuit (“C”
terminal to metal
enclosure).
Fill valve connected to
“HEAT” terminal.
Dual Level printed
circuit board faulty.
No power at equipment.
No water at equipment.
Visual. Water entering
tank continuously, and
usually slowly.
Visual.
Jumper from “HI” terminal
to metal enclosure stops
fill.
Jumper “C” terminal
(next to XL) to metal
enclosure stops fill.
Visual.
Jumper from “HI” to “C”
does not stop fill.
Nothing operates on
machine.
“Crack” fitting at
water inlet for pressure
check.
Disassemble and clean out. May
require new plunger assembly. Caution
is advised to avoid damage to valve.
See valve instruction sheet.
On valves without integral strainer:
Install so that port marked “IN” is connected to
outside fresh watersupply.
On valves with integral strainer:
Install so that arrow points in direction of tank,
away from fresh 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.
Page 30
Page 28 American Metal Ware Volume Banquet Brew Systems
090-805
4 of 5
Rev. 4/87
C)
D)
Auto refill fails to
fill water tank
(continued).
Auto Refill is erratic.
PROBLEM
IV) Troubleshooting Auto Refill, Low Water Cutoff, and Dual Level Control System (continued)
POSSIBLE CAUSE SERVICE CHECK REMEDY
3)
4)
5)
6)
7)
8)
1)
2)
3)
Water strainer clogged.
No power on Dual
Level Control.
Fill solenoid valve
clogged with scale
or frozen closed.
Fill solenoid valve
coil inoperative
Electrodes shorting to
ground.
Dual Level Control
faulty.
Electrode shorting to
ground completely or
intermittently.
Loose connection.
Dual Level Control
faulty.
Water pressure before
strainer and not after.
Check for 120V AC across
“H” and “N” terminals.
Disassemble.
Jumper from “FILL”
terminal to “H” terminal
does not start fill.
Tank fills with electrode
wire disconnected from
“HI” terminal.
Tank does not fill
with electrode wire
disconnected from “HI”
terminal.
Tank fills with
electrode wire
disconnected from “HI”
terminal
Visual. Check for “C” and
“HI” probe terminals as well
as “FILL.” Also check
neutral (white) wire at valve.
Tank does not fill with
electrode wires disconnected
from “XL” and “H” terminals.
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 forzen
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.
Page 31
American Metal Ware Volume Banquet Brew Systems Page 29
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 an authorized dealer in your area or Grindmaster Corporation’s Technical Service
Department. You can reach Technical Service at (800) 695-4500 (USA & Canada only) or (502) 425-4776
Monday-Friday, 8:00 AM - 6:00 PM Eastern Standard Time. Please have the model and serial number ready
so that accurate information can be given.
Prior authorization must be obtained from Grindmaster Corporation’s Technical Service Department for all warranty clamins.
090-805
5 of 5
Rev. 4/87
E)
F)
Tank fills with water,
but heat does not come
on.
No water in tank, but
heat comes on (heater
damage likely).
PROBLEM
IV) Troubleshooting Auto Refill, Low Water Cutoff, and Dual Level Control System (continued)
POSSIBLE CAUSE SERVICE CHECK REMEDY
1)
2)
3)
4)
5)
1)
2)
3)
Thermostat off.
Thermostat inoperative
or out of calibration.
Power relay or
contractor inoperative.
Low electrode faulty
or covered with lime
scale.
Dual Level Control
faulty.
Thermostat and fill
valve connected to
wrong terminals on
Dual Level Control .
Electrode(s) shorting
to ground.
Dual Level Control
faulty.
Visual.
Jumper across thermostat
terminals causes heat to
come on.
Check for voltage
(120V AC) across coil
terminals.
Jumper from “XL”
terminal to metal
enclosure allows unit
to heat.
Jumper from “XL”
terminal to “C” does not
cause unit to heat.
Visual
Disconnecting wire
(white) from “C” probe
terminal provides low
water heat cutoff and
tank fill.
Heat comes on with no
probe wires (HI, XL, C)
connected.
Make sure knob is turned fully clockwise.
Recalibrate thermostat. If no remedy, or ther-
mostat does not cycle, replace.
If correct voltage, replace coil or entire device.
If not correct voltage, check for loose wires,
improper wiring or other cause.
Clean electrodes. Check wiring. If still no
remedy, replace electrode assembly.
Replace Dual Level Control.
Thermostat (brown wire) must be
connected to “HEAT” and fill valve (black wire)
to “FILL”.
Replace electrode assembly. If no
remedy, check for improper wiring (cut insula-
tion for instance), or electrode tips touching
metal inside tank.
Replace Dual Level Control.
Page 32
Page 30 American Metal Ware Volume Banquet Brew Systems
Instructions For Repairing
Pre-Rinse Valve Unit
#80, 81, 82, 84, 502, 509, 509GC, 510, 510GC, 512, 512GC,
535, 536, 537, 538, 538WC, 549, 919, 919S, 920, 923, 923GC
Before beginning this procedure, turn water off at source.
Remove 80-13 allen screw from bottom of housing with #6 allen wrench.
Slip lower housing down
and pull forward with finger pressure only. This will clear the rear tongue
in the adapter and allow ther front end of the housing to go past the sprayhead, when pulling
forward.
The Chicago Faucet Co.
9/29/83 T-148
Rear Molded
Tongue
80-2 NF
‘C’ Ring
80-8 RBF
Cap-Retainer
Molded
Locator Stud
80-9 RBF
Nipple
Adapter
80-016
SO-1 RBF
Body
80-13 NF Flat HD
Socket Cap Screw
80-4 NF
‘O’ Ring
80-6 NF
Spring
80-7 NF
‘O’ Ring
80-13 NF Flat HD
Socket Cap Screw
919-29K
Asembly
Spray
Head
80-5 NF
Back-Up Ring
Rear Molded
Tongue
First -
Down
Second Forward
Page 33
American Metal Ware Volume Banquet Brew Systems Page 31
This procedure exposes the 80-008 retainer cap.
With a flat-faced wrench, remove the cap, turning counter-clockwise. Remove all parts as shown
and replace with identical parts from repair kit #80-5K. Note that stem seal 80-004 is at the top
and wiper 80-005 is at the bottom for proper seal wear on valve poppet.
After re-assembly tighten retainer cap against 80-007 body seal and test for proper function
before completing re-assembly.
Replace lower housing, sliding rear tongue into adapter and positioning molded locator stud into
hole in valve body, before inserting 80-013 screw. Tighten screw firmly. Do not overtighten as
allen head socket will strip on the allen wrench making further service difficult.
The Chicago Faucet Co.
9/29/83 T-148
80-008
SO-1 RBF
Body
SO-13 NF Flat HD
Socket Cap Screw
Valve Poppet
80-003
Locate on Top
80-4 NF ‘O’ Ring
Locate on bottom
SO-5 NF Backup Ring
80-002
‘O’ Ring
(Seat Seal)
80-006
Spring
80-007
‘O’ Ring
Body Seal
Page 34
Page 32 American Metal Ware Volume Banquet Brew Systems
AMERICAN METAL WARE
Hartell Sprayover Pump Parts Breakdown
DRAWN BY
MKG
1
2
3
4
5
REVISIONS
DATE BYNO.
SCALE
NONE
DATE
9-3-87
DRAWING NO.
093-011
MATERIAL
#8 - 32x3” Screws
539-213 (4 req’d)
Impeller Assembly
533-013
“O” Ring
544-009
Motor Assembly
533-014
Body
53-015
Complete Pump
Part # 533-012
Page 35
American Metal Ware Volume Banquet Brew Systems Page 33
AMERICAN METAL WARE
ILLUSTRATED PARTS BREAKDOWN LIST
FOR 81110 AMV BREW URN
DRAWN BY
WK
1
2
3
4
5
REVISIONS
DATE BYNO.
CHK’D
TRACES
SCALE
DATE
4-22-93
APPS
DRAWING NO.
090-914
MATERIAL
1. ADJUSTABLE LEG
2. FAUCET
3. GAUGE GLASS ASSEMBLY
4. TRANSFER TIMER
5. AIR AGITATION TUBING
6. COVER HANDLE
7. ELECTRIC IMMERSION HEATING ELEMENT(S) (ELECTRIC HEAT ONLY)
8. COFFEE LINER COVER
9. SPRAY ARM ASSEMBLY
10. 3 AMP FUSE
11. REFlLL WATER INLET STANDPIPE
12. ELECTRODE ASSEMBLY
13. THERMOMETER
14. TRANSFER BALL VALVE
15. THERMOSTAT CAPILLARY BULB
16. POWER INPUT TERMINAL BLOCK (ELECTRIC HEAT ONLY)
17. TERMINAL BLOCK COVER
18. CONTROL SECTION CIRCUIT BREAKER
19. BREW TIMER
20. THERMOSTAT W/PILOT LIGHT
21. DUAL OUTPUT AIR PUMP
22. LIQUID LEVEL CONTROL
23. HEATER CONTACTOR (ELECTRIC HEAT ONLY)
24. WATER INLET FILL SOLENOID VALVE
25. WATER REGULATOR
26. INLET WATER-STRAINER
27. DRAIN
28. SPRAYOVER PUMP SILICONE TUBING
29. SPRAYOVER VALVE-DRAIN TUBING
30. TOP GAUGE CLEANOUT FlTTING FOR AIR AGITATION
31. DRIP CUP AND VENT TUBE DRAIN ASSEMBLY
32. SPRAYOVER PUMP
33. TRANSFER PUMP
34. TRANSFER PUMP SILICONE TUBING
35. BREW BASKET
36. VENT TUBE
37. BYPASS VALVE
38. SPRAYOVER VALVE
Control Panel Top View
Bottom View
Page 36
Page 34 American Metal Ware Volume Banquet Brew Systems
High Volume Coffee Brewing/Holding System
Parts List - Electric and Steam Heat
Important: Give serial no. and model no. when ordering parts
522005
522046
522035
522048
522030
522026
522027
A682
A689
A1132
521019
522094
522102
542023
542012
542052
532064
506001
531011
1214033
1214031
521014
508004
508015
508030
533-012
533-013
509003
513001
509001
509005
712-017
549-000
516007
515074
10 Gal. Coffee Gauge Shield, 15”
10 Gal. Water Gauge Shield, 14”
10 Gal. Coffee Gauge Glass 5/8” x 15”
10 Gal. Water Gauge Glass 5/8” x 14”
Gauge Shield Bracket
Upper Gauge Glass Rubber Washer
Lower Gauge Glass Rubber Washer
Gauge Shield Cap for Plug-In
Cleanout Cap
Plu-In Cleanout Cap w/O-rings for
Air Agitation
Plug-In Cleanout Cap w/Vent Hole
O-Ring for Cleanout Cap A689
Coffee or Water Faucet
Silicone Seat Cup for Faucet
BB810WP Filter Paper 25 x 11
10 Gal. Stainless Steel Bag Ring
10 Gal. Muslin Cloth Filter 17 x 9
Water Line Strainer 1/4”
Thermometer
Spray Nozzle
Spray Arm Handle
10 Gal. Spray Arm Assembly with
Nozzle and Bypass
O-Ring & Teflon Seal Kit for
Spray Arm
Air Pump (Agitation) (Dual)
Air Pump (Agitation) (Single)
Coffee Transfer Pump
Sprayover Pump Assembly w/Motor
Renewal Parts for 508016:
Pump Seal Assembly
Mushroom Knob w/Bolt for Cover
Cover Handle Kit
Cover Handle Spacer
Spray Opening Cover Knob
Electrode Assembly
Liquid Level Control (Dual)
120V, 3 wire, Cord & Plug for Brew Urn
120V, 3 wire, Cord & Plug for Holding
Urn
520001
530-007
516001
515001
515016
515017
515018
515003
515053
515065
504001
725-084
537-060
537-061
537-062
531-021
531-024
532097
542006
512018
151010
512012
515072
535-045
535-046
535-047
535-048
535-049
535-050
535-051
514009
514005
506009
506014
506016
532027A
712-051
712-052
- - - -
503060
515075
Liner Washer, Silicone
Timer, Brew or Transfer
RBM Control Relay
Manual Coffee Agitation Switch
5/16” Dia. Orange Pilot Light
1/2” Dia. Red Pilot Light
1/2” Dia. Amber Pilot Light,
Opt. 47 Low Temp No Brew
Fuseholder for Type 3AG Fuse
3 Amp, Type 3AG Fuse
On-Off Toggle Switch, DPST
Thermostat, Heater Circuit
Thermostat, Opt. 47 - Low Temp No Brew Kit
Fill Solenoid Valve
Repair Kit for 505023 Solenoid Valve
Renewal Coil for 505023 Solenoid Valve
Solid State Relay (Agitation) NC
Solid State Relay, Opt. 43D NO
Boiler Drain Valve
SS Worm Gear Hose Clamp
Pinch Clamp for 5/8” O.D. Silicone Tubing
Coffee Liner Filter Screen
Coffee Transfer SS Braided Teflon Lined Hose
w/JIC Swivel Fittings - Specify Length
Silicone Tubing 5/8” O.D. - Specify Length
ALL MODELS ELECTRIC HEAT ONLY
Circuit Breaker
HEATING ELEMENTS:
5.7 KW 240 Volt
3.5 KW 240 Volt
6.6 KW 240 Volt
5 KW 240 Volt
4 KW 240 Volt
5 KW 480 Volt
4 KW 480 Volt
Heater Contractor - 3 Pole
Heater Contractor - 4 Pole
ALL MODELS STEAM HEAT ONLY
Steam Solenoid Valve 10-50 PSI
Repair Kit for 506009
Replacement Coil for 506009
Steam Strainer 1/2” FPT “Y” Type
ALL MODELS - OPTION 121
Electrode Assm. 88040-60 Holding Urn
Electrode Assm. 88080-120 Holding Urn
Flashing Signal Light
490W, 120 Volt Contact Heater For
Holding Urn
Contact Thermostat For Holding Urn
Page 37
American Metal Ware Volume Banquet Brew Systems Page 35
AMERICAN METAL WARE
WIRING DIAGRAM AMV BREW URN W/NCC TIMER, AUTO REFILL/LOW
WATER CUTOFF, DELAYED AUTO AIR AGITATION, STEAM OR
ELECTRIC HEAT
DRAWN BY
WK
A
B
C
D
E
REVISIONS
DATE BYNO.
WK
11-29-93
ECN #972
CHK’D
TRACES
SCALE
DATE
5-1-91
APPS
DRAWING NO.
091-359
MATERIAL
Page 38
Page 36 American Metal Ware Volume Banquet Brew Systems
Page 39
American Metal Ware Volume Banquet Brew Systems Page 37
AMERICAN METAL WARE
AMV HOLDING URN HEATER SCHEMATIC
2 KW, 120V, 1O, 16.5 AMP LOAD
DRAWN BY
LRO
1
2
3
4
5
REVISIONS
DATE BYNO.
CHK’D
TRACES
SCALE74DATE
12-23-80
APPS
.
DRAWING NO.
A-1182
MATERIAL
Includes 6 foot long,
3 wire cord & plug.
Connect to 120V
AC, 20 amp circuit,
Use NEMA receptacle
No. 5-20R.
correct wire
Page 40
Page 18 American Metal Ware Volume Banquet Brew System
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 (502) 425-4776 • Fax (502) 425-4664 • 1-800-695-4500
P.O. Box 35020 • Louisville, KY 40232 • USA
www.grindmaster.com • email: info@grindmaster.com
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