Grindmaster 815 User's Manual
Contents
1. pup e 3 Cj x5 T 385 9 L V 250 jJ 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 Page 11 10 11 May 1983 Supd s 3 80 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 Direction of flow must correspond to flow Direction Schematics 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 Prolonged use in excessive ambient temperature or humidity may damage coils Do not dent or bend or use enclosing tube as lever A damaged enclosing tube may result in coil burnout or inoperative valve Foreign matter in the valve may result in seat leakage sticking open or closed or coil burnout To prolong valve life and ensure system cleanliness use a strainer Coil Installation Instructions 1 Before removing coil from valve disconnect electrical power 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 ove2. eoejdeJ Jo pue 1no uee8 9 Suonoeuuoo Jedoud pue syeaJq sseuesoo JO DUU xoeuo 3o ulooul JO Buissiuu eBejyoA J JeuieJjs JOJEM ui pejeooj Jet ueeJos useuloJoiu ULAJ pue SAOWSY AQ3IN3H S EUIUJ9 H PUB IN HO pe1oeuuoosip Sal pO1 29 UI IH JOU SBOP HUEL SALA je 9JIM 9JIUM Je ineu H98U9 OSIV TI SE aw se seule eqoud IH pue 9 10 Oo EnSIA jeur IH WO p o uuooSsip 9JI pOo1 2 UUM SIII Xue p lJeuiuu9 JH WO pey euuoosip 9JI pO1 29 YUM l Jou Seop HUEL eue JH WO pojoeuuoosip 9JIM po1o l u SII JUEL Il uejs jou seop jeur H O euru TI Wor sedunr eiquiessesiq S euluJJ9 N pue H ssoJoe OV AOZ JO YO9UD Jaye jou pue Jeuies 9J0Jeq eunsseJd JejeM MOAHO 291A43S Aynej JOlJUOD 348 enq Uonoouuoo 25007 Apueniuuejul Jo jejejduuoo punoJ6 o Bunuous epoJjo9 3 ynej 041002 8497 enq punoJ6 o Buoys sepoJi29 3 eAneJedoul I09 BABA pIOUSJOS ll4 pesoj uezoJ Jo je s ui peBDojo SAIRA pIOU9JOS IL JOJ4u02 9 91 eng uo amod oN pe6Bojo 1eureugs Jop ASNVO 318lSSOd OEMS SI Wu oiny q penunuoo HUE JSJEM WU 9 SEL US o3ny O W3140 d penunuoo uu s sS 101jU09 J349 JENG pue yong JEM MOT Hua ojny Bunoous jqnoiu Al American Metal Ware Hot Water Boiler Page 9 Sulle o AJUELIEM UE Joj jueuniedeq SS9IA8S eoiuuoe s uoneJodio 1eyseuupuuc WO peurejqo eq 1snui UOUSZUOUID
3. until water shows in gauge glass approximately 6 min utes When water shows remove adhesive WARNING label from thermostat knob Turn thermostat knob maximum clockwise to BREW position Pilot light over knob should light showing heater power on Water compartment will fill automatically to stop full level and should reach operating temperature approximately 45 minutes later When the pointer on thermometer approaches the W in the blue BREW zone unit is ready for operation 5 REFILL RATE ADJUSTMENT To gain maximum capacity of the boiler and shorten heat recovery time adjust the water inlet flow regulator located inside the control box according to the chart provided Turning the threaded adjustment shaft clockwise increases the flow rate counterclockwise will decrease it Page 1 American Metal Ware Hot Water Boiler Installation cont 5 TO CHECK REFILL RATE allow water to fill to stop full level automatically then turn off master switch Draw off 1 gallon of water from faucet Turn master switch back on and time how long it takes for the water level to come up to stop full mark again Compare time with chart provided and adjust accordingly HEATER SIZE COLD WATER HOT WATER OR EQUIV STEAM USE CONNECTION CONNECTION 7KW 240 Volt 3min 30sec 1min 25sec m m Factory setting American Metal Ware Hot Water Boiler Page 2 Saeg AS o Rp OCF SA Se OE JOJ OILY a Eer PRP NOY Ee See 3 099 NMONHS RE
4. 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 sever al 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 obstructions Repair kits The following Repair Kits are available VALVE KIT VALVE KIT SERIES PART NO SERIES PART NO 202CB B K 1063 204CD B K 1072 202CB E K 1066 204CD _ F K 1075 VALVE KIT SERIES PART NO or 1 4 Orifice Only K 1162 K 1164 K 1167 K 1166 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 113 Leads AML d Spade Connection AMS 3 Use only Alco coils on
5. Alco valves H Page 12 Parts List 815 830 850 Electric Gas or Steam Heat AMW Part Description 522004 Aluminum Gauge Shield Only for 815 5 8 x 13 522006 Aluminum Gauge Shield Only for 830 5 8 x 16 522010 Aluminum Gauge Shield Only for 850 5 8 x 20 522034 Gauge Glass Only for 815 5 8 x 13 522036 Gauge Glass Only for 830 5 8 x 16 522129 Gauge Glass Only for 850 5 8 x 20 522030 Aluminum Bracket for Gauge Shield 522026 Upper Gauge Glass Washer 522027 Lower Gauge Glass Washer A 682 Gauge Shield Cap for Plug in Cleanout Cap A 1132 Plug in Cleanout Cap w Vent Hole 522094 Water Faucet 522102 Silicone Seat Cup for Faucet 532064 Water Line Strainer 506001 Thermometer 549 000 Dual Liquid Level Control 712 017 Electrode Assembly for 815 830 712 007 Electrode Assembly for 850 505021 Adjustable Water Flow Regulator 1 4 NPT 504001 Thermostat 515017 Red Pilot Light 537 060 Solenoid Valve Water Inlet 537 061 Repair Kit for Solenoid 515012 On Off Master Switch Electric Heat Only 514009 Heater Contactor 3 Pole 514005 Heater Contactor 4 Pole Control 515043 Control Circuit Transformer 515072 Circuit Breaker 535 Heater specifiy model and serial number voltage watts and phase Steam Heat Only 506009 Steam Solenoid Valve 10 40 PSI 506014 Repair Kit for Steam Solenoid 506016 Replacement Coil Only for Steam Solenoid 532027A Steam Strainer Gas Heat Only 504002 Gas Sole
6. American Metal Ware Hot Water Boiler Installation Operation amp Service Manual For Models 815 830 850 Gas TABLE OF CONTENTS X Electric Steam General Description Installation Thermostat Adjustment Service Instructions Dual Level Control Special Featu res Troubleshooting Solenoid Valve Safety Instructions Installation Disassembly Assembly Troubleshooting Cleaning Testing Repair Kits After completing installation and set up the equipment owner should keep this manual for future reference 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 Grindmaster Corporation 1995 1104 Form AM 324 03 PRINTED IN USA Electric Models 815 830 850 Equipped with Option 46 Automatic Refill Option 39 Low Water Cut Off System General Description This unit is a high temperature hot water boiler It consists of a non pressure vented water compartment into which is installed an electric immersion heater thermostatically controlled through a contactor relay to keep the water always at the desired brewing temperature Automatic refill maintains water level in water compartment All control system components are enclosed in a stainless steel housing on the right end of the urn A master ON OFF switch shuts o
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8. TI at AO SHD Ne FT Los Z Latro sv 6n og s 1100815 otre Sion CET per gt LITAI LAT HOLT ree ric l aes l LNG ur TRT Aa 3 lt Si bei 709 OISd SZ o St n S LIOS HLIM SIRCOS PSSYd WORLS ONLLEXI PO ATE S oe p o lel oe laas EZ E PTT Leg er EAE wars L Tn Sw9 ane LAUS NO 9074 702 mpn A OZI 10059 EU c AZ American Metal Ware Hot Water Boiler Page 3 Thermostat Factory set so that knob on BREW setting holds unit at brewing temperature toward HIGH end of brew zone on thermometer dial Then if turned back to HOLD position thermostat should cycle on and off and hold at LOW end of BREW zone on thermometer Thermostat Adjustment 1 If water temperature is below HIGH end of BREW zone on thermometer dial with knob on BREW setting remove knob by pulling straight outward Using a small screwdriver insert in hole in center of shaft turn slotted screw counter clockwise until red pilot light goes on Check to see that water in unit holds at HIGH end on BREW zone on thermometer and does not boil 2 If water boils with thermostat knob set at the BREW position remove knob by pulling straight outward Using a 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 thermo stat cycles at tempe
9. d Using small screwdriver in center of shaft turn slotted screw clockwise until pilot light goes out Check holding temperature by adding cold water Red light should come on and water heat up to HI 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 Relay must click on and off If it sticks replace American Metal Ware Hot Water Boiler Dual Level Control Auto Refill And Low Water Cutoff System 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 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 I Description and Operation of Dual Level Control System A Components 1 DUAL LEVEL CONTROL switches power to both the thermostat and water inlet solenoid valve by sensing c
10. ff entire unit including heater circuit Separate low water cutoff system protects heater and entire unit from damage Installation 1 IMPORTANT TO ALLOW 6 CLEAR SPACE TO RIGHT ON CONTROL BOX FOR ACCESS Urn should be level both front to back and left to right 2 CONNECT WATER LINE 3 8 NPT water inlet located at right end Provide shutoff valve and union in supply line near urn Cold or hot water may be used but hot water will give greater gal lon per hour capacity We strongly recommend the use of copper or aluminum tubing to provide flexibility and avoid strain on the unit 3 8 O D Tubing is recommended 3 CONNECT URN TO ELECTRIC POWER Check to be sure that name plate marking of voltage phase and number of wires matches supply lines Remove cover on control housing Terminal block for line connections located in housing on right end See drawing as required It is rec ommended that a fused disconnect switch be installed near urn 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 unit and its associated supply line NOTE Neutral wire required on all single phase and on 208 volt 3 phase power supplies to operate 120volt AC control circuit Do not replace cover until completion of installation 4 FILL WATER COMPARTMENT Turn on water supply and electric service to urn Turn master switch on Do NOT turn on thermostat
11. ge or personal injury Use of solenoid valves on applications not specifically 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 Do not exceed MOPD Maximum Operating Pressure Differential or valve may fail to open when energized Installation Valve and Solenoid Position 1 For ease of installation an Alco solenoid valve can be installed in any position gravity does not affect its operation NOTE 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 The solenoid coil can be rotated 360 for ease of wiring If possible do not reduce thelength 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 from its piping allow at least 2 inches of clearance above the solenoid Be sure valve is installed so that its flow arrow on valve body corre sponds to direction of flow through piping FLUID TEMPERATURE RATING F Elastomer Coil Code Code AMG AMC AHG AHC B J 4 4185 JXJh L p 1 25 C x N 10 X
12. hanges in water level TRANSFORMER PRINTED CIRCUIT RELAYS PROBES 2 ELECTRODE ASSEMBLY consists of a high short and a low extra long sensing electrode or probe molded in an epoxy body M LOW TOP MOUNTED PROBES SIDE MOUNTED PROBES 3 METAL ENCLOSURE provides a common ground connection for the TANK BODY electrode circuit American Metal Ware Hot Water Boiler Page 6 I Description and Operation of Dual Level Control System continued B Operation Water Level 1 Below both electrodes 2 Rises to low electrode above heater coils es a 3 Rises to high electrode Td 4 Falls below high electrode only 5 Falls below low electrode Same as condition no 1 III Quick Service Check of Dual Level Control System Action 1 Both HI and XL electrode circuits open Dual Level Control turns power on to fill valve and keeps power off to thermostat Fill Solenoid Valve Zei ON OFF 2 XL electrode circuit closes Power to thermostat turned on Power to fill valve remains on Fill Solenoid LA Valve Thermostat ON ON 3 HI electrode circuit closes Dual Level Control turns power off to fill valve and continues power to thermostat Fill Solenoid 1 5 Valve ol Thermostat OFF ON 4 HI electrode circuit opens XL circuit stays closed After a few seconds delay power to fill valve is turned on Fill Solenoid Le Va
13. lve ol Thermostat ON ON 5 XL electrode circuit now opens Power to thermostat is turned off Power to fill valve remains on Thermostat 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 Page 7 American Metal Ware Hot Water Boiler u do ag seA eA eui Ajddns sejyem WE euns op UO SI pepi oJd JI yoyms J8MOd pue YO SI JexXeaeJq yno s euiuoeui zey JUN 0 Je od epi oJd s uexeeuq naia s asny se uoiws urew eins op 01U09 242 enq eoe des leuiuue 1 1143 0 PES SIM MOV Ig HEUUOD jueujeoe deu 10 Buiueejo euinboeJ fe uonoeuuoo eJnoes poo sen quiesse eoe deJ poof eje suonoeuuoo pue p w ou IS J sepouoelje Ujoq ue8 9 Ajquiesse polno eAoules Addns Joe used Wo Aeme yuez JO uomnoauip ul SJUIOd MOJE jeu OS ejsu JeureJis IEIDa YM SONIEN UO A ddns Ja eEM US9JJ pis no o pejoeuuoo SI NL Depu uod jeu os j ejsu JeureJjs IEIDou NOUJIM SONIEN UO Jeeus uononu su SA EA BBS eA EA 0 eDeuiep PIOA 0 pesi pe SI uonne Ajqwesse jeBunj d meu eJinboJ e N no uea pue e quiessesiq 4o9uo a1nsseJd JO 1 u 18J2M je Buy 9612 Gui uo euy uo seje1edo BUIUJON II dois jou seop D O JH UO Jedunf TENSIA ll Sdojs a
14. nf sjeuiuuJe 109 ssojoe OV AOZL oDejoA JO 19809 UO BOO o jee sesneo sjeuluJe jeJSoueu ssoJoe Jedunp TENSIA Ajnej 01 U09 18497 jeng puno1B6 o Bunuious s epouos 3 o 3u02 9497 jeng uo sjeuiuue BuoJ 0 pajoeuuoo A EA Illy pue 3ejsouueu L Anez 041002 8497 jenq e eos OUI UJM P818A09 JO AUDEL anoeia MOT eAnjeJedoul 10 98 U09 Jo AER 18MOd uoneJgi eo Jo jno Jo eAneJedour jejsouueu L oesouueu Ajexi eBeuep Jojeou uo s wo9 jeeu inq uB u JejeM ON 4 uo wo jou seop jeeu 1nq JOJEM YUM SII HUEL 3 pA O3HO93O H3S 3snvO31sSsod CWO penunuoo uu 1s S Jo3uo2 J249 ENG pue Hona J9jeA MOT Ilay ony BuNOOUS jqnoul Al Page 10 American Metal Ware Hot Water Boiler INSTALLATION AND SERVICE INSTRUCTIONS FOR 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 can result in valve failure or system damage or personal injury Do not use solenoid valves on applications or fluid media not 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 dama
15. noid Valve 504024 Thermocouple 504038 TS11K Gas Safety Valve 504026 Coil for Gas Solenoid 504023 Pilot Burner with Orifice Natural Gas 504025 Pilot Burner with Orifice L P Gas 505007 Gas Pressure Regulator Natural Gas 505039 Gas Pressure Regulator L P Gas IMPORTANT Give Model Number and Serial Number when ordering Page 13 American Metal Ware Hot Water Boiler 120 VAC ILON ATNO 1Y3H 2109191 VANVIUS LINDY PE Z zB E de Pe Gg 53 8 American Metal Ware Hot Water Boiler Page 14 GRINDMASTER CORPORATION Grindmaster amp Coffee Grinders and Brewers e Espressimo Espresso Machines e Crathco Hot Beverage Dispensers Crathco Cold and Frozen Beverage Dispensers e American Metal Ware Coffee and Tea Systems Tel 502 425 4776 e Fax 502 425 4664 e 1 800 695 4500 P O Box 35020 e Louisville KY 40232 e USA www grindmaster com e email info grindmaster com
16. ol X11981 1 shown in Figure 1 Notes 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 amp COIL RETAINER amp gt NAME PLATE SERVICE TOOL K ee Q COIL ASSEMBLY J COLLAR o o RING K ENCLOSING TUBE PLUNGER AND SPRING ASSEMBLY K S GASKET K K INDICATES ITEMS INCLUDED IN REPAIR KIT ALCO CONTROLS American Metal Ware Hot Water Boiler ALCO CONTROLS DIVISION EMERSON ELECTRIC CO P O BOX 12700 ST LOUIS MISSOURI 63141 314 569 4500 CUSTOMER SERVICE 314 569 4666 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
17. r 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 American Metal Ware Hot Water Boiler Diassembly 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 to
18. rature at HIGH end of BREW zone on thermometer dial If thermostat will not cycle replace entire control American Metal Ware Hot Water Boiler Page 4 Service Instructions PROBLEM THERMOSTAT DIAL TURNED TO BREW AND WATER IN COMPARTMENT REMAINS COLD POSSIBLE CAUSE 1 No power at urn 2 Power at urn but no power at heater terminals Check main switch Check main fuses 3 on 3 phase power 2 on single phase power Check that Pilot Light by On Off switch is ON Check control circuit fuse Check that pilot light over thermostat dial is lighted with dial set to BREW Check that water level is at FULL mark on water gauge glass NOTE If urn is equipped with Option 39 Low Water Cut off System level in gauge glass should be minimum 2 inches showing to have power ON to control circuit Check low water cut off and auto refill system and replace if necessary Check that contactor clicks on and off as thermostat dial is turned from BREW to OFF Check control transformer if so equipped Lastly check for voltage at heater terminals If OK check for broken or loose wire on terminal If necessary replace heater PROBLEM WATER BOILS CONTINUOUSLY WITH THERMOSTAT DIAL ON POSITION BREW OR HOLD POSSIBLE CAUSE 1 Thermostat out of calibration 2 Thermostat is inoperative Fluid has leaked out of diastat assembly of thermostat 3 Relay sticking in closed position Page 5 Set knob on BREW and remove knob by pulling outwar
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