Newco FRESH CUP User Manual

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SINGLE SERVING AUTOMATIC POD MACHINE
NEWCO ENTERPRISES INC, 3650 NEW TOWN BLVD SAINT CHARLES, MO 63301
1-800-325-7867 FAX 1-636-925-0029
AUTOMATIC POD REMOVAL
FLOWMETER OPTION
20 OZ TRAVEL MUG
LARGE POD WASTE TRAY / THRU COUNTER OPTION
ADJUSTABLE DRINK STRENGTH
ADJUSTABLE DRINK VOLUME
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TABLE OF CONTENTS
SPECIFICATIONS ………………………………………………………………………………………….. 3
NEWCO PRODUCT WARRANTY ………………………………………………………………………... 4
MACHINE SET-UP …………………………………………………………………………………………. 5
MACHINE OPERATION …………………………………………………………………………………… 6
MACHINE PROGRAMMING & CALIBRATION ………………………………………………………… 7
SERVICING THE MACHINE ………………………………………………………………………………. 11
TANK REMOVAL …………………………………………………………………………………………… 12
POD BREWING MECHANISM ……………………………………………………………………………. 13
ELECTRICAL COMPONENTS ……………………………………………………………………………. 17
ERROR MESSAGES ……………………………………………………………………………………… 18
FLOW ADJUSTMENT CONTROL ………………………………………………………………………... 19
WIRING DIAGRAM …………………………………………………………………………………………. 20
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SPECIFICATIONS
TANK WATTAGES
US 1700W 120V- CANADA 1400W 120V- INTERNATIONAL 1700W 220V
TANK CAPACITY-1 US GALLON
DRIP TRAY CAPACITY 8 OUNCES
POD WASTE TRAY CAPACITY 80 PODS-
PN
780306 FOR THRU-COUNTER USE
UP TO 20 OZ CUP SIZE
USE WASTE TRAY
SHIPPING WT-APPROX 35 LBS
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NEWCO PRODUCT WARRANTY
Newco warrants equipment manufactured by it for 1 Year Parts & Labor
These warranty periods run from the date of installation Newco warrants that the equipment manufactured by it will be commercially free of defects in material and workmanship existing at the time of manufacture and appearing within the applicable warranty period. This warranty does not apply to any equipment, component or part that was not manufactured by Newco or that, in Newco’s judgment, has been affected by misuse, neglect, alteration, improper installation or operation, improper maintenance or repair, damage or casualty. This warranty is conditioned on the Buyer 1) giving Newco prompt notice of any claim to be made under this warranty by telephone at (800) 556-3926 or by writing to PO Box 852, Saint Charles, MO 63302; 2) if requested by Newco, shipping the defective equipment prepaid to an authorized Newco service location; and 3) receiving prior authorization from Newco that the defective equipment is under warranty.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The
agents, dealers or employees of Newco are not authorized to make modifications to this warranty or to make additional warranties that are binding on Newco. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon.
If Newco determines in its sole discretion that the equipment does not conform to the warranty, Newco, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the applicable parts and labor warranty periods specified above) to repair the defective components, provided that this repair is done by a Newco Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for the equipment.
THE BUYER’S REMEDY AGAINST NEWCO FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AT NEWCO’S SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND.
In no event shall Newco be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.
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MACHINE SET-UP
NOTE: The FRESH KUP machine weighs approximately 35 LBS. Use CAUTION when unpacking and lifting machine. LIFT MACHINE FROM MACHINE BOTTOM ONLY. DO NOT MOVE
MACHINE UNLESS THE HOT WATER TANK IS DRAINED AND EMPTY.
1. Open and install the drip tray grill and place drip tray into pod tray
2. Connect water fitting with strainer on the rear of machine under the power switch.
Plumber's Installation Instructions
1) Brewer must be installed to comply with all applicable federal, state and local plumbing codes and ordinances.
2) Plumb brewer in to water supply using 1/4 inch copper tubing. Flush water line before installing brewer to remove sediment. Brewer should be connected to COLD WATER LINE for best operation.
3) Water pressure should be at least 20 lbs. For less than a 25 ft run, use 1/4" tubing and connect to 1/2" or larger water line. The inlet water fitting on the back of the brewer is a 1/4" flare fitting. It may be necessary to remove the plumbing cover box on the rear of brewer to access water connection point.
4) If installed with saddle valve, the valve should have a minimum of 1/8" porthole for up to 25 ft run, and 5/16" porthole for over 25 ft runs.
5) Turn on water supply and check for leaks.
WARNING: - Read and follow installation instructions before plugging or wiring in machine to electrical circuit. Warranty will be void if machine is connected to any voltage other than that specified on the serial tag.
Turn the power switch to the “OFF “ position and plug the machine into a properly installed and grounded electrical circuit. Turn on power switch to start the initial
WATER FILL CYCLE.
When tank is filled, the heater circuit will turn on-allow up to 20 min for the tank to reach brewing temperature. Machine is now ready for programming or operation.
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MACHINE OPERATION
BREWING
INDICATOR
LIGHT
DRAWER OPEN
BUTTON
PUSH & HOLD FOR HOT WATER
DISPENSE WHEN DRAWER IS CLOSED
READY
TO BREW
INDICATOR LIGHT
TEMPERATURE RANGE IS 170-203 DEGREES
POWER SAVE OR POWER FEATURE AVAILABLE
BEEPER VOLUME CAN BE ADJUSTED OR BEEPER CAN BE SHUT OFF
AIR PUMP POD DRYING TIME & PUMP STRENGTH CAN BE ADJUSTED
POD COUNT TO EMPTY POD WASTE BIN AJDUSTABLE OR CAN BE
TURNED OFF IF USING THROUGH THE COUNTER WASTE BIN
COFFEE OR TEA PRE-INFUSTION, BREW TIME & BREW VOLUME ADJUSTABLE FOR EACH OF 3 CUSTOMIZABLE DISPENSE BUTTONS
PROGRAMMABLE
BREW BUTTONS (CUP
STRENGTH OR CUP
SIZE, TEA, ETC
PUSH TO RETURN BREW
MECHANISM TO HOME POSITION
WHEN DRAWER IS OPEN
BREW OPERATION
1. PLACE CUP UNDER BREW NOZZLE ON DRIP TRAY
2. PRESS THE DRAWER OPEN BUTTON
3. UNWRAP THE POD & PLACE IN CENTER OF BREW CHAMBER
4. PRESS THE DESIRED BREW BUTTON-DRAWER WILL CLOSE & BREW CYCLE WILL START
5. ONCE THE POD DRYING CYCLE IS COMPLETE, THE POD WILL EJECT & THE CUP CAN BE REMOVED
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MACHINE PROGRAMMING AND CALIBRATION
MACHINES EQUIPPED WITH A FLOWMETER- Please run your Fresh Cup pod brewer a
few times. If the volume dispensed is comparable to the amount expected from your Button Settings (which are set in the programming menu as described BELOW) and consistent and the pulsing is acting as expected you are done. However, if your dispensed calibration volume is larger or smaller than the volume setting for each brew button, then adjust the “OZ Per tick” until volumes match. For example, calibration volume delivers 6.5 oz, but the volume setting on a brew button is 7 oz, adjust the Oz Per tick until 7 oz is delivered in the calibration volume.
To enter the maintenance menu turn the unit off then hold the Hot Water (Reset) key and the Open key (Button A) while turning on the power to the Fresh Cup pod brewer. Hold both keys down until “DRAIN LINE” scrolls across the display. Press the Mild key (Button B) until “OZ PER TICK” is scrolling across the display.
Press the Hot Water (Reset) key to enter. A number will be displayed, 43 is the default value. Pressing the Open key (Button A) will decrease the number. Pressing the Mild key (Button B) will increase the number. A change of one number (example; 43 to 44) will alter the dispensed volume by approx. 0.2 oz for a 7oz dispense. If you want more in your cup decrease the number and if you want less in your cup increase the number. (Example; 43 to 44 will reduce your cup volume and 43 to 42 will increase your cup volume.) Press the Hot Water (Reset) key to exit. The display will show “END”. Press the Hot Water (Reset) key again to save your changes and to exit to the normal Run mode.
FOR OTHER ITEMS IN THE MAINTENANCE MENU, SEE ‘MAINTENANCE MENU”, BELOW
NOTE: THE MACHINE HAS BEEN CALIBRATED AT THE FACTORY AND HAS BEEN ADJUSTED TO BREW INTO AN 8 OUNCE CUP WITH APPROX 7 OUNCES OF COFFEE FOR BREW STRENGTHS OF MILD, REGULAR AND BOLD. NO FURTHER ADJUSTMENTS ARE NECESSARY IF THE FACTORY DEFAULTS ARE USED.
The Fresh Kup pod brewer has a menu that consist of scrolling menu entries that can be scanned through backward and forward using button A and button B (see Fig 1). To enter a programming record, press and hold the Reset Key when powering up machine (see Fig 1) then use button A and button B (see Fig 1) to change the entry. Pressing the Reset key (see Fig 1) will exit the entry, saving the entire Parameter structure to memory upon exiting the programming
menu using the which is accessed through the
are as follows:
END entry. There are nine entries on the Main menu and four on one sub menu,
BUTTON SET UP entry. The current entries in the Main menu
Fig 1: Fresh Kup Keys
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PROGRAMMING AND CALIBRATION CONT’D
TEMPERATURE
degrees Fahrenheit with the default at 200 degrees F. Pressing button D (see Fig 1) will toggle the display so the user may view the real tank temperature. The real temperature display has all three decimal points illuminated. Pressing button D (see Fig 1) again will switch the display back to show the current set point. As with most of the entries, button A and button B (see Fig 1) will change the set point, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit.
: In this entry the user may set the tank temperature in the range of 170 to 205
POWER SAVE: This entry allows the user to select the Power Save mode. Use button A and
button B (see Fig 1) to change the entry then press the Reset key to exit.
Off (default) – Turns Power Save function off. Prt – Partial Power Save Mode. After the user selectable time out the tank temperature set
point is set to 180 until a key is pressed. When this mode is selected the right most decimal point in the display is on.
FuL – Full Power Save Mode. After the user selectable time out the tank heater is disabled until a key is pressed. When this mode is selected the left most decimal point in the display is on.
POWER SAVE TIME: This entry will not be displayed if the Power Save function
has been turned off. This entry sets the time the machine will operate normally until the power save function is activated. The user can choose 1 through 4 hours in 1-hour increments with the default set to 4 hours. As with most of the entries, button A and button B (see Fig 1) will change the time, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit.
BEEPER VOLUME
: The range is from 1 to 24. The default is 13.
AIR PUMP SPEED: In this entry the user may set the air pump strength in the range of 5 to 10
strength with the default at 9. As with most of the entries button A and button B (see Fig 1) will change the Air Pump Strength, incrementing or decrementing by one. Pressing Reset (see Fig 1) key will exit.
AIR PUMP TIME: In this entry the user may set the air pump time in the range of 2 to 10
seconds with the default at 5. As with most of the entries button A and button B (see Fig 1) will change the Air Pump Time, incrementing or decrementing by one. Pressing Reset (see Fig 1) key will exit.
POD COUNT: In this entry the user may set the number of pods the brewer will hold before
signaling that the bin is full. The range is 10 to 100 pods, with the default at 40. Setting the pod count under 10 turns off the count so the bin full alarm will never go off. As with most of the entries button A and button B (see Fig 1) will change the Pod Count threshold, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit.
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PROGRAMMING AND CALIBRATION CONT’D
CALIBRATION*: (NON-FLOWMETER MACHINES ONLY) This entry shows the amount of
water the brewer dispenses in 30 seconds with no pauses. To run calibration, place a container able to hold at least 10 oz preferably greater. Press button D (see Fig 1) and the brewer will enter a brew cycle. The door will open to allow the user to place a beverage pod in the drawer. After the pod has been placed press the button D button (see Fig 1) again to start the brew cycle.
After the cycle has completed, measure the amount of water dispensed and adjust the Calibration number shown in tenths of an ounce to match the amount dispensed by using button A and button B (see Fig 1) to increment or decrement by one. Press the Reset key (see Fig 1) to advance to the brew button programming selections. Range for the calibration volume
is 10 to 320 tenths of an ounce. The default is 100 tenths of an ounce.
BUTTON SET UP: This entry takes the user into a sub menu to program the parameters
unique to each key. When this entry is accessed the display will change to SELECT BUTTON indicating that the user should press the brew key (button B, C or D (see Fig 1)) to be programmed. When a brew key is selected the display will show the first entry in the Button Set up sub menu, PRE-INFUSION. While SELECT BUTTON is displayed the user may exit back to the Main menu by pressing the Reset key (see Fig 1).
With these four entries in the BUTTON SET UP sub menu:
PRE-INFUSION: This entry sets the time of the pre-infusion pulse of water in tenths of a
second. Range is 1 to 30, the default is 15 tenths of a seconds.
BREW VOLUME: This entry sets the volume in tenths of an ounce for this key to dispense.
The Range is from 20 to 160 tenths of an ounce with the default set to 70 tenths of an ounce
BREW TIME: This entry sets the brew time in seconds for a 7-ounce cup of coffee with
on/off pulses. The range is from ~30 to 99 seconds with the default being 35 seconds.
RETURN: Exit to Main Programming Menu.
FILTER SELECT: This entry allows the user to select the filter size for the filter used on the
inlet for the water. Choices include OFF, 500 GAL, 1000 GAL and 1500 GAL. These set the counter for the filter warning. Whenever water is dispensed the counter is incremented to account for the water dispensed. When the counter is above 90% of the capacity of the chosen filter a warning message, “REPLACE WATER FILTER”, is displayed in place of the “READY” message. To reset the counter the user must enter the programming menu and enter the RESET FILTER entry described below. The following entries are only shown when a filter is selected. If the filter selection is OFF then following entries are not available. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu.
FILTER REMAINING: This entry scrolls the number of Gallons left before the filter should be
replaced. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu.
RESET FILTER: When in this entry the message “PRESS OPEN TO RESET’. Press the Open
Door key will reset the Filter Use counter to the value chosen in the FILTER SELECT entry above. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu.
END – Exit to Main and save parameters.
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“MAINTENANCE” MENU
The Fresh Cup pod brewer has a maintenance menu that consist of scrolling menu entries that can be scanned through, backward and forward, using button A and button B (see Fig 1). The letter to the right of the button is the buttons letter assignment. To enter the maintenance menu, hold Button A (Open) and the Reset key (Hot Water) down while turning on the Fresh Cup machine. Hold the keys down until the Drain Line message appears on the display. This is the first entry of the maintenance menu. Until the Drain Line message appears on the display the current version will be displayed. To enter a maintenance record, press the Reset key (see Fig 1) then use button A and button B (see Fig 1) to change the entry.
The current entries in the Main menu are as follows:
FLOWMETER ADJUST: This entry displays the value used to represent the amount
of liquid in thousandths of an ounce seen for one tick of the flow meter count. While in this entry, pressing the A key will decrement and the B key will increment this value. This can be used to fine-tune the amount of liquid that is dispensed. The default value is 43.
CYCLE COUNT: This entry shows the number of brew cycles that has occurred on this machine since the last time the count was cleared. To clear the count hold button C down for 10 seconds while in this entry.
RESET TO FACTORY DEFAULTS: When in this option, pressing the “OPEN” key
resets the unit to its factory defaults then exits to the Maintenance Menu. To exit to the Maintenance Menu without resetting press the “HOT WATER” key.
DRAIN LINES: In this entry the user may run the pump for 15 seconds in order to
drain any water from the lines for transportation. This function runs similarly to the calibration function. The display will prompt “RUN PUMP” once the user has entered this entry. To run the pump first press the ‘D’ key. The drawer will go to the open position. At this point pressing any brew key (B, C, or D) will cause the drawer to go to the brew position and then, once the drawer is in position, run the pump for 15 seconds, then return the drawer to the home position. At this point pressing ‘RESET’ will exit to the menu and pressing the ‘D’ key will start the process again. Pressing any key while running will abort the process.
END – Exit to Main and save parameters.
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DRAINING THE HOT WATER TANK
THE DRAIN TUBE IS CLIPPED TO THE TANK PLATE IN FRONT OF THE TANK. THE HOT WATER TANK CAN BE DRAINED FROM THE FRONT OF THE MACHINE – UNPLUG MACHINE FROM POWER SOURCE. REMOVE POD WASTE TRAY.
CAUTION-UNLESS THE TANK IS LEFT TO COOL THE WATER IS EXTREMELY HOT AND CAN CUASE HARMFUL BURNS. REPLACE DRAIN PLUG, ENSURE HOSE
CLAMP IS TIGHT AND REPOSITION DRAIN HOSE BEFORE RE-FILLING THE HOT WATER TANK.
SERVICING THE MACHINE
The Fresh Kup machine has a modular Water Tank Assembly and Brew Mechanism. These assemblies can be easily removed from the machine by removing or loosening Machine nuts as noted in drawings below:
BREW MECHANISM
ACCESS SCREW S
(VIEW FROM BOTTOM FRONT OF MACHINE)
NOTE: TO REMOVE BREW
REMOVE
BRASS
KNURLED
NUTS
(2)
LOOSEN
ACORN
NUTS
(4)
MECHANISM, UNSNAP WATER
& HARNESS FITTINGS
Front Of Brewer
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)
TANK REMOVAL & ACCESS AREAS
REMOVE (3) 8-32 NUTS TO
PREPARE TANK FOR
REMOVAL (TWO ON TOP
OF TANK & ONE ON
BOTTOM OF PUMP
BRACKET
LOOSEN SCREWS TO
REMOVE TOP & BACK
COVERS
LOOSEN BUT DO NOT
REMOVE THESE 2
SCREWS THEN LIFT &
PULL CONTROL BOARD &
BRACKET OUT OF
MACHINE TO ACCESS
TRANSFORMER
12
REMOVE (2) 6-32 SCREWS
TO REMOVE SIDE PANEL
FOR PUMP ACCESS
(REMOVE TOP COVER
BEFORE REMOVING
SIDE PANELS
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POD BREWING MECHANISM
780234-61MM and 780330 –56MM
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POD BREWING MECHANISM CONT’D
ITEM # NEWCO PN DESCRIPTION QTY/EA
1 780230 BREW MECH MOTOR 2
2 780231 DELTROL SOLENOID 1
3 780257
780329 4 773246 U-CUP SEAL RING 1 5 780262
780314 6 780418 EJECT SLOPE CAM ASS’Y 1
UPPER BREW CHAMBER-61MM UPPER BREW CHAMBER-56MM
LOWER BREW CHAMBER-61MM LOWER BREW CHAMBER-56MM
1
1
*MACHINE IS ORDERED FOR 56MM OR 61MM POD SIZE
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780234 TANK ASS’Y
110
2
9
8
7
6
3
4
5
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780234 TANK ASS’Y CONT’D
ITEM # NEWCO PN DESCRIPTION QTY/EA
1 110958 RELAY, 12 VDC SPST 30A 1
2 111593 HI-LIMIT THERMOSTAT 1
3 706341 PUMP ASS’Y-120 VOLT 1 4 781772 PUMP ASS’Y W/ELBOW 1 5 780253 PUNCHED TANK W/STUD 1 6 773056 AIR PUMP, POD 1 7 108022 LIQUID LEVEL PROBE 1 8 151677 DUAL TEMP THERM PROBE 1 9 110051 ELBOW ¼ TUBE X 1/8 NPT 1
10 704166-10 TANK HEATING ELEMENT 1
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ELECTRICAL COMPONENTS
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ELECTRICAL COMPONENTS CONT’D
ITEM # NEWCO PN DESCRIPTION QTY/EA
1 780225 CONTROL BOARD 1
2 110626 SWITCH, DPST, ON/OFF 1
3 102383 SOLENOID FILL VALVE 1 4 105115 TRANSFORMER 120VAC-24VAC 1 5 780224 DISPLAY BOARD 1
ERROR MESSAGES
Message - "THERMISTOR ERROR"
THERMISTOR IS OPEN OR SHORTED-REPLACE PN 151677
Message - "HIGH TEMP ERROR"
RAPID TEMPERATURE RISE-HEATER ON WITH LOW WATER LEVEL­CHECK FILL VALVE OR WATER SUPPLY LINE
Message - "UPPER/LOWER MOTOR ERROR"
BREW CHAMBER DRIVE MOTOR ERROR-CHECK FOR JAM OR OBSTRUCTION IN BREW CHAMBER
Message - "BOARD ERROR"
CONTROL BOARD WRITE ERROR-REPLACE BOARD IF MESSAGE DOES NOT CLEAR PN 780225
Message - "FILL TIMEOUT ERROR"
WATER NOT REACHING LEVEL PROBE-CHECK WATER SUPPLY OR CHECK FOR WATER LEAK
Message - "HEATER TIMEOUT ERROR"
WATER NOT HEATED DURING TIMEOUT PERIOD-CHECK HEATER RELAY PN 110958 OR HEATING ELEMENT PN 704166-10(1700W US) OR 704161-10 (1400W CANADA) OR HI-LIMIT THERMOSTAT PN 111593
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FLOW ADJUSTMENT CONTROL
VIEW FROM TOP OF MACHINE
COVER REMOVED
ONLY USED FOR
ADJUSTING
WATER FLOW
RATE
(FACTORY SET)
CALIBRATION PUMP FLOW ADJUSTMENT
COUNTER
CLOCKWISE
INCREASE
FLOW
CLOCKWISE
DECREASE
FLOW
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WIRING DIAGRAM
BK
BK
RD
RD
BK
RD
GY
LOWER
SOLENOID
12 VDC
24 VDC
UPPER DRIVE
GY
MOTOR
+
-
LOWER
DRIVE
MOTOR
-
+
BL
RD
OR
GY
BK
RD
UPPER
SOLENOID
12 VDC
BK
RD
WASTE
SWITCH
BK
RD
WHBKYLBR
24 VDC
RD
RD
THERMISTOR
DUAL
GY
RD
COFFEE
PUMP
120 VAC
BK
BK
BK
WH
GY
WATER
HOT
PUMP
12 VDC
AIR
PUMP
12 VDC
HI-LIMIT
THER-
MOSTAT
+
VIO/BK
HOT
WATER
TANK
FILL
SOLENOID
120 VAC
BK
BIN
REED
-
+
-
RD
GY
RD
OR
TANK
HEATER
ELEMENT
WH
780225
2 1
7 6 5 4 3 2 1
VIO/BK
VIO/BK
SWITCH/DISPLAY BOARD
BK
CN6
4 3
CN7
BK
GY
14 13 12 11 10
9 8
VIO/BK
BR
WH
GY BR
CN4
67568
LEDs
HEATER
RELAY 12 VDC
COIL
WH
BK
CN8
24153
RD
-
+
VIO/BK
CN2
PROGRAMMING
HEADER
780224
CONTROL
BOARD
BR
BK
YL
TANK
GND
LIQUID LEVEL
PROBE
VIO/WH
BK/WH
BK
BK/WH
CN3
214
3
CN5
4321
BK/WH
BR
CENTER
TAP
12/24 VAC
120 VAC
BK WH
DPST
SWITCH
WHBK
POWER
CORD
CN1
TRANS
FORMER
GN
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