American Metal Ware 7443 Manual

[ SGML Version See Change Record ]
TECHNICAL MANUAL
INSTALLATION, OPERATION &
SERVICE MANUAL
SINGLE OR TWIN
AUTOMATIC
COUNTER MOUNTED
MID LINE COFFEE URNS
DISTRIBUTION STATEMENT E: DISTRIBUTION AUTHORIZED TO DOD COMPONENTS
ONLY; CRITICAL TECHNOLOGY; DATE OF PUBLICATION. OTHER REQUESTS SHALL
BE REFERRED TO THE NAVAL SEA SYSTEMS COMMAND (SEA-09B2).
WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS
RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22. U.S.C. SEC. 2751 ET.
SEQ.) OR EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE
SUBJECT TO SEVERE CRIMINAL PENALTIES.
DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-
SURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.
S6161-JB-FSE-010
0910-LP-641-2046
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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND
JUN 30, 1990

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CHANGE NO. DATE TITLE OR BRIEF DESCRIPTION ENTERED BY
NOTE
THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC
SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO
LOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT
MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS
EXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT
IN THIS PAGINATED VERSION.
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TABLE OF CONTENTS
Chapter/Paragraph Page
GENERAL DESCRIPTION ................................ 1-5
INSTALLATION ...................................... 1-5
OPERATION START-UP ................................. 1-6
HOW TO BREW IN AN AUTOMATIC URN ..................... 1-8
CARE AND CLEANING OF COFFEE URNS ..................... 1-9
QUICK SERVICE CHECK OF LIQUID LEVEL CONTROL SYSTEM ....... 1-22
REPAIR/REPLACEMENT INSTRUCTIONS FOR ELECTRICAL AND
MECHANICAL COMPONENTS ........................... 1-23
PART NUMBERS & QUANTITY REQUIRED FOR 1 YEAR ............ 1-29
VALVE DISASSEMBLY ................................. 1-39
DIRECTORY ........................................ 1-39
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LIST OF TABLES
Table Title Page
Roughing-In Data Parts List ................................ 1-2
Brew Baslet Selection Chart ................................ 1-3
PRODUCTION-ENGINEERING DATA ......................... 1-3
Standard Voltage ...................................... 1-4
Standard Voltage (cont’d) ................................. 1-4
IV. Trouble Shooting Auto Refill, Low Water Cutoff, and Liquid Level Control
System. .......................................... 1-17
Part Numbers and Quantities ............................... 1-30
Manufacturers/Suppliers for Component Parts ...................... 1-39
Recommended Coffee Urn Cleaners ........................... 1-40
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LIST OF ILLUSTRATIONS
Figure Title Page
Roughing-In Data ..................................... 1-2
(3) ROUGH-IN SPECS. FOR AUTO URNS ........................ 1-11
(4) 7400E URN CONTROL CIRCUIT WIRING HARNESS DIAGRAM: NCC TIMER,
AUTO REFILL, LOW WATER CUTOFF, OPT. 43 (AIR AGITATION) ...... 1-13
(5) TAB TERMINAL HEATER WIRING - URNS WITHOUT PUMP .......... 1-15
(6) ILLUSTRATED PARTS BREAKDOWN 7400 SERIES ................ 1-28
(11) 507028 NCC Timer .................................... 1-33
(12) 505002 Liquid Level Control ............................... 1-33
(13) 521021- Urn Elastomer Kit ................................ 1-34
(14) Seal Kit P/N 521028 .................................... 1-34
(15) Option 43 Outside Tube Kit P/N 512015 When Supplied. ............... 1-35
(19) .5CC Disposable Tube of Loctite 271 Cover Handle Kit for Automatic Urns P/N
513001 .......................................... 1-36
S301 Standard Open Frame Solenoid Valve ....................... 1-38
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CHAPTER 1
SECTION
ELECTRIC, STEAM, GAS
TWIN MODELS:
7443
7446
74410
SINGLE MODELS:
7413
7416
74110
MID LINE AUTOMATIC COFFEE URNS FRESH WATER BREWING SYSTEM THE MID LINE
URN...American’s Budget Cutter, completely automatic coffee urn. When a basic, no trills, nothing added urn is
needed, this is it! Then build by adding what you want - such as air agitation for mixing of coffee, or any other
of the many extras found in the OPTIONS SECTION of this catalog.
AMERICAN STANDARD FEATURES
•FRESH WATER BREWING Special large area heat exchange coil resists scale problems. Heats water for
brewing/sprayover as it travels through coil, fresh for each batch brewed.
•FULLY AUTOMATIC ONE TOUCH BREWING TIMER Most foolproof for operator. No dial or knob to
turn. Concealed setting. Adjust with screwdriver through front panel. Stop sprayover with one touch. Use for
spray rinse of coffee liner.
•AUTOMATIC REFILL OF WATER COMPARTMENT Saves time and attention required to manually fill.
Unlimited supply of hot water for tea, etc. always available.
•ADJUSTABLE BYPASS ON SPRAY ARM Enables proper brew extraction even with variations caused by
soft or treated water.
•DIAL THERMOMETER WITH MARKED BREW ZONE
•ALL A.I.S.I. TYPE 304 18-8 stainless steel construction.
•ONE ALL STAINLESS STEEL BREW BASKET With 25 filter papers.
•CONTROL BOX ON RIGHT HAND END If requested, the control box can be located on left hand end
of urn at no additional cost.
•LOW WATER CUTOFF SYSTEM Solid state probe sensor system provides positive protection against
heater burnout, at start-up or in operation.
•GREATEST SAFETY FOR OPERATOR (OSHA) All controls operate on 120 Volt.
•SPECIAL PINPOINT CONTROL THERMOSTAT Super sensitive, highest accuracy and reliability, lowest
service cost. Includes marked ″Nite Standby″position for energy savings.
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•CLOSED CHAMBER BREWING Brews with NSF approved cover on brew basket. Prevents costly steam/
moisture loss to room. Saves energy with savings of air conditioning load.
•EASY ADJUSTMENT OF SPRAYOVER RATE Simple screwdriver adjustment. No awkward changing of
parts. Improved two stage flow regulator system gives same volume time after time.
•VELVET SMOOTH SPRAY ARM Special teflon coating on spray arm piston prevents liming and insures
smooth operation. Positive ″stops″on spray arm for operator safety.
•DRAIN IN BOTTOM
•OPTIONS AVAILABLE Select from Options Section of this catalog.
•DOUBLE SERVICE (SELF SERVICE) FAUCETS Available on both twin and single urns. Choose from
Options Section of this catalog.
•MILITARY SPECIFICATIONS-MARINE MODIFICATIONS Twin and single automatic urns MIL-U-
43263D or latest specification.
Available modified for marine (shipboard) use; no spillage of liquid with 15° list in any plane, and other
requirements. Contact factory for detailed quotation and data.
Roughing-In Data Parts List
Model No. A
*
BCD
+
Work Height
+
Overall Height
7443 30-1/2 15-1/4 7-5/8 7-3/4 21-5/8 27-1/8
7446 34 16-3/4 8-3/8 8-5/8 27-5/8 33-1/8
74410 34 16-3/4 8-3/8 8-5/8 27-5/8 34-5/8
7413 18 15-1/4 7-5/8 5-1/2 21-5/8 27-1/8
Roughing-In Data
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Roughing-In Data Parts List - Continued
Model No. A
*
BCD
+
Work Height
+
Overall Height
7416 21 16-3/4 8-3/8 7-5/8 27-5/8 33-1/8
74110 21 16-3/4 8-3/8 7-5/8 27-5/8 34-5/8
*
Add 2-1/4″for flue on gas-allow additional 6″wall clearance.
+
Add 2-1/2″on gas.
Brew Baslet Selection Chart
Brews 3 Gal. 6 Gal. 10 Gal. 1/2 Batch on 6 Gal. 1/2 Batch on 10 Gal.
Part No. BB3 BB6 BB810 BB6-3 BB810-6
NOTE
All SS Permanent Filter Brow Basket with SS woven wire cloth bottom is avail-
able. Filter paper is available from our stock. See price list.
TWIN MODELS: 7443 • 7446 • 74410
SINGLE MODELS: 7413 • 7416 • 74110
PRODUCTION-ENGINEERING DATA
MODEL NO. 7443 7446 74410 7413 7416 74110
Coffee Capacity Each Liner 3 Gal. 6 Gal. 10 Gal. 3 Gal. 6 Gal. 10 Gal.
*
Gals. Per Hour (Up To)
Electric, Steam 25 30 42 15 18 20
Gas 18 24 28 9 16 19
No. of 5 Oz.
Electric, Steam 625 750 1050 375 450 500
Cups Per Hour
Gas 450 600 700 225 400 475
Max. Steam Demand
Lbs. Per Hour 50 70 70 30 70 70
Gas Consumption
BTU Per Hour 35,000 35,000 35,000 18,000 24,000 24,000
*
Based on spraying over amount of water equal to capacity of liner.
ELECTRIC HEAT Specify electric service desired. Standard is dual voltage 120/240 Volt or 120/208 Volt
single phase 3 wire (neutral wire required). Watts and amps as shown.
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Standard Voltage
120/240 Volt 120/208 Volt
1-PH. 3 WIRE 1-PH. 3 WIRE
MODEL KW AMPS KW AMPS
7443 8 34 6 29
7446 11.5 48 8.5 41
74410 15 63 15 72
7413 7 29 5.5 25
7416 11.5 48 8.5 41
74110 15 63 15 72
Standard Voltage (cont’d)
+
240 Volt 120/108 Volt
+
480 Volt
3-PH. 3 Wire 3-PH. 4 Wire 3PH. 3 Wire
Specify Opt. 21B Specify Opt. 21A Specify Opt. 21C
MODEL KW AMPS KW AMPS KW AMPS
7443 10.5 25 8 22 12 14
7446 12 29 11.5 31 12 14
74410
*
15 36
*
15 42 15 18
7413 10.5 25 8 22 12 14
7416 12 29 11.5 31 12 14
74110
*
15 36
*
15 42 15 18
+
Control transformer (Option 22) included when no 120 Volt in the field.
*
No extra charge.
STEAM HEAT Specify operating steam pressure. Standard is 10 to 25 PSI Gage. 1/2″FPT steam inlet and
outlet. Requires plug-in of 3 wire cord to 120 Volt AC outlet. Steam trap to be supplied by others.
GAS HEAT Specify Natural or L.P. gas. Standard includes thermostat with 100% safety pilot shutoff,
stainless steel flue on rear and combustion chamber with aluminum heat shield under gas burner. Requires plug-in
of 3 wire cord to 120 Volt AC outlet. Six and ten gallon models require connection to 160°F hot water line.
OPTIONAL ONE YEAR SERVICE Covers service/labor and parts for one year from date of installation
(maximum of 18 months from date of shipment). See price list.
SECTION
ELECTRIC HEATED MODELS
7443
7446
74410
7413
7416
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GENERAL DESCRIPTION
This urn is an automatic, pushbutton operated, volume brewing unit. It consists of a non-pressure, vented
water tank of large capacity into which two stainless steel liners are inserted.
Electric heat is used to keep water in the tank always at the desired temperature. For this type of heat, a ther-
mostat, sensing the water temperature and controlling a contactor, switches on and off the electric immersion
heater found inside.
Also in this tank is a heat exchange coil that carries fresh (cold) water up to a top mounted, swivelly attached
sprayarm for discharging a hot water spray over ground coffee during brow. A pushbutton start, electric reset
timer measures the quantity of water sprayed over by timing a constant water flow. The flow of sprayover water
is maintained accurately by a two-stage, adjustable regulator system. Flow through the heat exchange coil starts
and stops as the timer opens and closes a water (brew) solenoid valve. Whenever this brow process is going on
in the urn, an orange pilot light also lights up.
Automatic refill is provided to keep the tank always full of water. Whenever the level drops, a built-in con-
trol causes water to enter the tank by opening a second water solenoid valve. This refill valve closes when ″full″
is reached.
Low water cutoff is included to prevent damage to the urn or heater that can be caused by a low water level.
Even at initial start-up, no heat can come on until a safe water level is reached in the tank.
Air agitation, If provided, blends the brewed coffee by allowing low pressure air to bubble up through the
coffee in the coffee liner. Programmed agitation is automatic at the end of each brew cycle. Depressing a manual
agitation switch provides further mixing between brews.
All components of the control system are enclosed in a stainless steel housing on one end of the 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
Water
1. 3/8″NPT water inlet located beneath control box.
2. Cold or hot water may be used. Heat input capacity is ample for cold water, and cold water should be used
for best results.
3. Provide shutoff valve and union in supply line near urn.
4. Minimum operating pressure at urn should be 30 PSI.
5. Maximum pressure recommended at urn is 75 PSI.
6. Copper or aluminum tubing should be used for flexibility and avoiding strain on the urn.
7. 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. Field terminal block located inside control box.
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2. An experienced electrician should be responsible for connecting urn to electric power.
3. Check rating marking on urn to be sure supply lines match voltage and phase requirements.
4. 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
transformer is installed to supply 120 volt AC power to control circuit.
5. A fused disconnect switch should be installed near urn.
6. Urn body must be grounded. A grounding conductor terminal is provided for this purpose. Other means of
positively grounding urn may be used.
7. Use only copper wire to connect this urn.
OPERATION START-UP
1. Turn power on to urn. Have spray arm in ″Park″position, with nozzle in vent tube opening at center rear. Turn
on water supply to urn. With automatic refill, water compartment will fill automatically. Time required to fill
is 10 to 15 minutes. In case of failure to fill, refer to Automatic Refill Service Instruction page.
2. Turn thermostat knob to ″Brew″position. Pilot light at top of thermostat bezel should light up. Water in urn
should heal up, and rise to high end of ″Brew″zone on thermometer within approximately 55 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 fuses, switch off, or while urn is refilling.
OPERATION START-UP CHECKS
1. Turn thermostat dial to ″Brew″position. Pilot light at top of thermostat bezel should light up and when ther-
mometer pointer is in high ″Brew″zone, this pilot light should go out. Water in urn tank is now at brew tem-
perature. NOW and ONLY at initial start-up, we advise checking time of flow of hot water to spray nozzle.
2. Checking Spray-Over Volume and Rate 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, remove cover to reveal timer adjustment and reset timer using a screwdriver. Longer time-more
sprayover, shorter time-less sprayover. Each 1/4 minute increase or decrease adds or subtracts about 1/3 gallon
to sprayover total. Replace cover after setting.
Note that setting of sprayover bypass valve effects amount of sprayover. Set as desired.
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, actual muslin bag or filter to be
employed. 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.
COFFEE BREWING AND URN BREW CYCLE
Measurement of water quantity sprayed over is by a precision electric timer, controlling an electric solenoid
water valve. When timer is started, water solenoid valve opens, and water line pressure forces fresh water to flow
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through heat exchange coil and come out of the spray nozzle and spray over the coffee in the brew basket. The
rate at which the water flows is controlled by a two stage water flow regulator system designed to provide accu-
rate flow rate under all conditions.
All urns with coffee liner capacity of 6, 8, or 10 gallons have an adjustable bypass on the spray arm. (Some
3 gallon models may also be so equipped). This bypass allows some spray-over water to bypass the brew basket
and go directly into the coffee liner. By adjusting bypass valve, brew can be controlled for ideal extraction from
coffee.
Variable brewing factors which the coffee urn cannot control are:
1. The uniformity and type of grind on coffee supplied.
2. The uniformity and quality of roasting, and selection of blend and type of coffee beans used, and the fresh-
ness of ground coffee used in a brew.
3. Water chemistry - i.e., mineral content, taste factors (chlorine, fluorine, iron, etc.) and effects of any treatment
process occurring ahead of urn.
4. Uniformity and quality of filter paper is also important, and proper storage and handling of paper effects final
brew.
5. Proper and regular, frequent cleaning of all coffee brewing equipment is vital to insure the most delicious tast-
ing brew.
Figure (2)
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HOW TO BREW IN AN AUTOMATIC URN
1. Place filter in brew basket with designated amount of ground coffee (automatic urns are designed to use 1, 2,
or 3 lbs. of coffee). Make certain you have a level bed of coffee.
2. Replace cover and move spray head over center of coffee grounds.
3. Check thermometer to make certain urn is at brewing temperature. Press start button.
4. When brew cycle is completed (brew light shuts off), remove brew basket and dispose of spent grounds.
5. Mixing of finished brow is accomplished automatically at the end of the brow cycle if the urn has an air agi-
tation option. Where urn is not equipped with air agitation, draw one gallon for each three gallons of finished
brow from coffee faucet, and pour over top into coffee liner.
Coffee ready to serve.
Variable brewing factors which this coffee urn can control are:
1. Contact time of water with ground coffee.
2. Accuracy of water spray-over volume.
3. Temperature of water spray-over.
4. Holding temperature of finished brew.
5. Proper and uniform extraction over coffee brew basket bed area.
6. Proper coffee bed depth in brew basket.
7. Proper and thorough mixing of first rich brew with later, weaker brew for uniform final brew.
Final decision of brewing formula and brewing cycle adjustments rests with the operator and the coffee sup-
plier.
COMPLETE URN BREW CYCLE ADJUSTMENT PROCEDURE
See charts on page following and also Parts Breakdown drawing, following service section of this manual.
Urn must be full of water, and heated to operating range (thermometer pointer at high end of ″Brew″zone)
before starting adjustment.
1. Set spray arm bypass valve.
2. Set timer for 2 minutes.
3. Remove cover from control housing. Remove cover and brew basket from left liner.
4. Measure one gallon of water and pour into left liner and mark level on gage shield with pencil. Drain liner.
Close faucet. Swing spray arm over left liner.
5. Push brew timer start button, and use second hand of watch or stop watch to time spray-over of one gallon
(to pencil line on gage shield). Then drain liner and close faucet.
6. Check number of seconds required for spray-over of one gallon, approximately 80 seconds recommended.
7. If spray-over time in seconds is too long, loosen lock nut and screw in adjusting screw (turn clockwise) on
flow regulator inside housing about 1/8 turn. Tighten lock nut. If spray-over time in seconds is too short,
loosen lock nut and screw in adjusting screw out (turn counter clockwise) on flow regulator about 1/8 turn.
Tighten lock nut. Recheck spray-over time as in Step 5.
8. Now set timer to quantity of water desired.
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9. Push brew timer start button and allow to spray-over full timer amount into liner. Check total spray-over
water by drawing off into one gallon measure, a gallon at a time. If spray-over is slightly over or under
desired amount, change timer setting; longer time to increase amount, shorter time to decrease amount
10. Replace cover on control housing and timer cover if applicable. No further adjustment of the flow regulator
should be necessary. Fine adjustments can be made at any time on the timer setting only.
NOTE
This urn has a two stage water flow regulator system. The first stage regulator,
located outside under the control housing is factory set at 25 PSI. Do not change
or adjust this regulator.
The second stage regulator, located inside the control housing is adjustable for
rate and amount of sprayover desired
HALF BATCH BREWING
Standard brew basket is designed for full batch brewing with proper bed depth. Half batch brew will result
in weak final brew, because of thin bed depth, unless half batch brew adaptor is used, or more than normal
amount of coffee is used. Half batch brew baskets are available for 6, 8, and 10 gallon models. They require using
a smaller filter paper size.
Occasional half batches can be brewed in standard full batch brew basket by using slightly more then half of
usual weight of coffee, and using an inverted soup bowl in the center of the brew basket to increase coffee bed
depth around the soup bowl and also reduce bottom filtration area.
CARE AND CLEANING OF COFFEE URNS
1. Always rinse urn immediately after each use.
2. Add small quantity of hot water, brush sides and rinse with hot water until it runs clean. Urn is now ready for
next batch.
3. At end of each day clean and brush urn several times, then rinse thoroughly with hot water.
4. Remove clean-out cap at end of coffee faucet (or take apart faucets which have no caps) and scrub pipe lead-
ing to center of urn. Clean urn gage glass with brush and urn cleaner. Rinse!
5. Scrub the faucet, then rinse it thoroughly with hot water.
6. Place a gallon or more of fresh water in urn until next use.
7. Remove cover and clean. Replace cover, and leave partly open.
8. ALWAYS REMEMBER TO EMPTY, AND RINSE THE URN WITH HOT WATER BEFORE USING
AGAIN.
NOTE
On automatic urns, use brew start and stop switches, or the rinse switch, to spray
scalding hot water into liner for cleaning and rinsing. On pourover urns, draw hot
water directly from urn. Make sure urn water tank is kept near full, and heat is
on.
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SEMI-WEEKLY CLEANING PROCEDURE
1. Be sure outer jacket is full of water.
2. Turn on heat and fill urn liner 3/4 full of water; use only urn cleaning compounds (See Note) following manu-
facturer’s directions; mix thoroughly and let stand about 30 minutes.
3. Clean gage 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.
4. Scrub inside of urn and inside of cover with long handled brush. Be sure to clean ″lug nut″in base of urn
liner.
5. 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.
6. 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.
7. Urn baskets may be cleaned by immersing in urn cleaner solution and scrubbing with a stiff brush. Rinse thor-
oughly and let dry. Sprayheads should be checked to see that all holes are open. If any are clogged, remove
sprayhead and use stiff wire to open.
8. Don’t use soap, scouring powders, or abrasives to clean coffee brewing equipment.
WARNING
Cleaner used can effect taste of coffee if not thoroughly flushed out as cov-
ered 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
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Figure (3) ROUGH-IN SPECS. FOR AUTO URNS
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