RealCup RC400 User manual

MODEL: RC400
Single Cup Brewer
Service Manual
Model RC400
Prior authorization must be obtained from
GMCW for all warranty claims.
GMCW
4003 Collins Lane
Louisville, KY 40245 USA
[phone]
[phone] (USA & Canada only)
FAX [phone]
www.gmcw.com
1213 Form # BW-306-01
Part # 390-00021
GRINDMASTER ®
BY GMCW ™
© GMCW, 2013
Printed in Thailand
Table of Contents
Safety Precautions ……………………...2
Installation…………... …………………..3
Power Supply ……..…………………….4
Set –up …………….…………………….4
Advance Settings …….………………...5
Servicing. ……………………………….10
Cleaning and Maintenance …………...21
Troubleshooting………………………...21
QR Codes ……..………………………..24
Spare Parts List..……………………….25
Plumbing diagram ……………………..27
Wiring diagram …………………………28
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Safety Precautions Important Safety Information

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
For your safety and the safety of others, read all warnings and the operator’s manual before installing or using the
product.
DANGER: This term warns of imminent hazard that will result in serious injury or death.
WARNING: This term refers to a potential hazard or unsafe practice, which could result in serious injury.
CAUTION: This term refers to a potential hazard or unsafe practice, which could result in minor or moderate injury
or property damage.
NOTICE: This term refers to information that needs special attention or must be fully understood.
DANGER
To prevent the possibility of electrocution, burns, or other injuries and to prevent damage to your brewer, do not
immerse in water or any cleaning liquids.
Do not operate a damaged brewer. Inspect the power supply cord and water supply often. If cord or plug is
damaged or worn, do not use your brewer. Turn off the water supply and disconnect the electrical power.
Turn off and unplug the brewer before cleaning or maintenance.
Risk of suffocation. The product packaging contains a plastic bag. Keep plastic bags away from children.
Disconnect power if the machine functions abnormally and notify qualified service personnel for repairs. Do not
permit non-qualified service personnel to attempt repairs. No user serviceable components inside the brewer. Do
WARNING
Brew probes are sharp. To prevent injury, do not place fingers inside the brew chamber.
The brewer must only be connected to a three wire 120 VAC, 60 Hz, 15 Amp, electrical circuit.
Allow brewer to cool before cleaning or maintaining.
CAUTION
Risk of burns. The brewer uses 185°F- 200°F water that, if not properly handled, could cause burns. Do not
permit children to use this appliance unless there is direct adult supervision. Keep away from pets and other
animals.
For indoor use only. Do not install or use outdoors, in moving equipment, or watercraft.
Use the product for its intended purpose only. Any other usage is inappropriate and may be dangerous. The
manufacturer assumes no responsibility for injury, loss or damage resulting from improper machine use.
To avoid the risk of burns, do not operate without bezel installed.
Hot surfaces may cause burns. Do not touch the brewer while in operation.
To prevent scalding by hot water, do not open brew chamber while brewing. 
To prevent scalding by hot water, do not move or tilt the brewer. Moving or tilting the brewer could result in water
spilling from the reservoir. Internal boiling is possible at high elevations. You must reduce temperature set point
below boiling point for your elevation.
To avoid scalding, use appropriate cup rest to minimize splash. Allow a minimum of 1/2” clearance between cup
rim and brewer dispense spout to prevent spills when removing a full cup. Center cup with dispense spout while
brewing and allow brewer cycle to complete before opening brew chamber or removing cup.
To avoid pinching, keep fingers clear of brew chamber when closing.
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Installation
Where to Install
Brewer should be installed on a firm, stable, level surface. Keep away from pets. Provide supervision for
unattended children and assistance for others that require help to operate the brewer.
Drain Tube
Power Switch
Power Cord
Water and Power Water Inlet
Adapter (Auto-Fill ONLY)
Valve Cap (Pour-Over ONLY)
Water Supply
NOTICE: The brewer is designed to operate with water pressures from 10 psig up to 100 psig. Grindmaster
requires the use of an external water filter such as Water Filter Kit P/N 250-00034. The filter mounts on the rear
surface of the brewer.
NOTICE
For best results, remove used Real Cup™ capsule from brew chamber when brewing is complete.
Avoid spills by not removing the reservoir while Auto-Fill unit is filling; allow complete filling cycle before removing
reservoir.
A qualified professional should perform installation, maintenance and repairs.
Installation, maintenance or repairs by unqualified personnel may damage the brewer and void the manufacturer’s
warranty.
This equipment must be installed in accordance with the appropriate national and local codes of the country and/or
region in which the appliance is installed.
Contact the manufacturer to report any malfunction of or damage to the brewer.
When turning the machine off for an extended period, be sure to evacuate the water inside the piping completely,
otherwise the water inside the machine could freeze and lead to damage or cause mold to appear.
To reduce foreign material from entering the brewer, keep brew chamber and reservoir lids closed.
Flare Washer
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Installation (continued)
Power Supply
WARNING
Disconnect power if the machine functions abnormally and notify qualified service personnel for repairs. Do not
permit non-qualified service personnel to attempt repairs.
No user serviceable components inside the brewer. Do not disassemble brewer.
Notice
This appliance is equipped with a three wire power cord. A dedicated three wire 120V, 15A NEMA 5-15 electrical
circuit must be used.
1. A dedicated 120 VAC, 60 Hz, 15 Amp, type 5-15, electrical circuit is required for proper operation.
2. Always unplug machine before servicing or maintaining the machine.
3. Place power switch in OFF position and plug power cord into the dedicated three wire 120V, 15A, NEMA
5-15 electrical circuit
Set-Up
Priming the internal hot water tank
NOTE: The brewer will not operate until the hot water tank is primed.
Please follow these procedures to ensure proper installation.
Pour- Over version Auto-Fill version
1. Ensure that the water inlet valve cap supplied with
the machine is installed on the water inlet valve to
prevent leaking.
1. Plumb water to the fill valve located on the back of
the brewer. A ¼” female flare x ¼” tube adapter as well
as a ¼” flare x hose adapter provided with the brewer.
Do not use reverse osmosis water.
2. Open reservoir lid. 2. Open water service valve.
3. Fill reservoir with tap or bottled water to the level
indicated on reservoir. Do not use distilled water. 3. Plug unit into a 120V/15 amp receptacle. Turn main power switch to ON.
4. Plug unit into a 120V/15 amps receptacle. Turn main
power switch to ON. 4. Reservoir will automatically fill.
5. Place a cup in the drip tray of the unit to collect the
water from the priming operation. 5. Place a cup in the drip tray of the unit to collect the water from the purging operation.
6. The screen will display "Prime Brewer", press BREW
button continue until screen displays "Lift to Brew”. 6. The screen will display "Prime Brewer", press BREW button continue until screen displays "Lift to Brew".
7. Refill the reservoir to the appropriate level. 7. Allow brewer to reach brewing temperature.
8. Allow brewer to reach brewing temperature.
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Note: Auto-Fill ONLY:
The water is supplied directly to the unit and
the water fill level marking is not used.
Operation is not affected by the water being
below the fill line.
Fill Level
Advance Settings:
The advance setting feature is available to authorized service agents only. It allows changes beyond the skills of the
regular end user. It is only accessible via a passcode and allows the technician to change the passcode, change
beverage options, beverage size options, water temperature, brew count, review error messages, modify service
contact information, and adjust dispense volumes.
This icon allows
to enter the ad-
vanced settings
This icon allows
to go back to the
“Lift to Brew”
screen.
To access the advanced settings screen, type in the factory default passcode: 0400
The brewer brings you to
the Advance Settings
screen
There are eight options within the
Advance Settings Menu:
 Set passcode
 Beverage Type Options
 Beverage Size Options
 Water Temperature
 Brew Count
 Error Messages
 Service Contact
 Adjust Dispense Volumes
Allows to go back to main set up
screen, on previous page, without
saving changes.
Allows to go back to main set up
screen, on previous page, and save
changes.
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This selection takes
you back to the basic
settings screen.
Setting a new passcode:
Select “Set
Passcode”
Enter new
Passcode
Re-Enter new
Passcode
Changing Beverage Type: NOTE: Factory Default beverage is COFFEE
Depicts selected beverages.
Unselected beverages will not
show on Beverage selection
To set default beverage, select the
one of choice. The selection will
remain highlighted to indicate it
being the default.
Note that if you had unselected “Ice
Tea” the selection would not show
up on the Select Your Beverage
screen.
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Select or deselect a
size to enable/
disable
Select a size to set as default
size. The selection will remain
highlighted to indicate it being
the default.
NOTE: Factory default size is 8 oz
Changing Beverage Size:
Changing Water Temperature:
NOTE: Factory default of water temperature is 195 °F
Press “+” or “-”
to increase/
decrease water
temperature
Changing Brew Count:
Allows to reset
the counter
Error Messages:
Returns to “Error Messages”
Allows to go back to advance
settings menu without saving
changes.
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Edit Service Contact
A series of screens (with different characters
that may be required) will allow you to change
Service Contact information. There are two
lines for name and address and one line for
phone number.
By selecting this
icon, you switch
from upper case
to lower case.
By selecting
this icon, you
switch from
English to
French/Spanish
characters.
Upper case Lower case
Upper case Lower case
Once you are in
the French/
Spanish screen,
if you press this
symbol, you will
go to the number
screen.
By selecting this
icon, you switch
from upper case
to lower case.
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Edit Service Contact Name (continued):
Once you are in
the number
screen, if you
press this symbol,
you will go to the
character screen.
Once you are in the char-
acter screen, if you press
this symbol, you will go to
the English characters
screen.
Editing Service Contact Number:
Input new number
using numeric
screen
Reset Factory Default:
RED-BLUE-GREEN: The initial start does a
RED-BLUE-GREEN sequence.
GREEN: When in the brew selection screen
AND the hot tank is at temperature, it is
steady green. It is also steady green at the
end of a dispense. It pulses green during a
dispense.
Brew Button Color Indications:
ORANGE: When in “Lift to Brew”, the instructions
screens, the basic settings screens or the More
Options screen AND the hot tank is at
temperature, it is steady Orange.
YELLOW: If the brew chamber is open
or the display is in the advance settings,
the brew button will show yellow.
RED: When the brew is heating in many
screens, it will pulse red. If there is a
fault, it will flash red.
AQUA: When the hot tank is low, it is
steady on. When the reservoir is low or
removed, it flashes.
When in Restore Factory Default, if
you select reset, the brewer will ask
you to confirm. If you confirm, the
brewer will display a screen indicating
that the reset is complete.
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Adjusting Brew Volumes:
This option will allow you to change Brew Volumes factory
default as much as ten percent. You will be able to go up ten
percent or down ten percent.
Example: For 10 oz, if you adjust to +10, it will set the vol-
ume to 11 oz. If on the other hand, you adjust to –10, then
the volume will be 9 oz.
Servicing:
This section covers basic instructions for replacing normally serviceable parts.
1) Replacing inlet or outlet probe seals.
Warning
Brew probes are sharp. To prevent finger injury be careful when servicing inlet and outlet probe seals.
Open brew chamber, pull inlet probe seal (located on underside of brew chamber and surrounding the inlet probe)
away from probe. Replace seal by carefully pushing the new one onto the probe. Push on sides of seal to prevent
finger injury.
To replace outlet seal, reach into the brew cup with needle nose pliers, pull seal away from the probe. To replace,
gently push on edges of seal (care should be taken not to push on probe) with needle nose pliers until seal bottoms
out on cup.
2) Replacing drip tray assembly:
Pull drip tray assembly away from brewer. To
replace, line up drip tray with internal walls of
brewer and slide into until tray hit rear wall of
cavity.
(See figure below for items 1 and 2)
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Servicing (continued):
4) Replacing reservoir components.
To replace reservoir components, first remove reservoir from brewer. Follow the steps as outlined below.
3) Replacing flip down Grid assembly.
To replace the grid sub-assembly, follow the steps as outlined below with the use of a small flat head screwdriver.
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Servicing (continued):
Warning
The next section covers instructions for replacing internal components in the brewer. Always unplug machine before
servicing any internal parts.
5) Servicing internal brewer components. In order to service any of the components in the following section, you will
first have to gain access to the interior of the brewer. Follow the instructions below to gain access. Remove the
panels following the sequence outlined below. For reassembly, execute the sequence in reversed order. You will
need a Phillips screw driver.
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Servicing (continued):
5a) Servicing check valve or 3-way valve. These two components are located on the upper rear section of the
brewer.
 To replace the check valve:
1. Cut strain relief straps using wire cutters.
2. Pull inner and outer tubes away from check valve using needle nose pliers.
Follow the sequence in reverse when replacing. Make sure tubing is secured and new straps are installed.
Check for leaks by running brewer.
 To replace 3-way valve:
1. Disconnect the two black wires on the solenoid from the main wire harness. You may have to
cut the strain relief strap.
2. Cut strain relief straps located on inlet and outlet tubing using wire cutters
3. Remove tubing from the inlet and two outlet ports.
4. Unscrew the valve from the base.
Follow the same sequence in reverse to reassemble. Please make sure new strain relief straps are installed
on inlet, outlet ports, and main wire harness. Check for leaks by running the brewer.
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Servicing (continued):
5b) Servicing air pump and relief valve. These two components are located on the upper rear section of the brewer,
to the left of the 3-way valve when viewed from rear.
 To replace the air pump:
1. Cut the strain relief on the top of the air pump.
2. Disconnect tubing going to check valve.
3. Lift air pump from its grommet.
Follow the sequence in reverse when replacing. Make sure tubing is secured and new straps are installed.
 To replace the relief valve:
1. Cut the strain relief on the side of the relief valve going to the 3-way valve.
2. Disconnect tubing going to 3-way valve.
3. Gently lift the relief valve from its cradle. Cut the strain relief on the lower tube.
4. Disconnect the lower tube and raise valve away from home base.
5. Cut the strain relief on the upper tube.
6. Disconnect upper tube.
Follow the same sequence in reverse to reassemble. Please make sure new strain relief straps are installed
on all three tubes. Check for leaks by running the brewer.
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Servicing (continued):
5c) Servicing flow meter and water pump. These two components are located on the lower left area of the brewer
when viewed from rear.
 To replace the flow meter:
1. Disconnect wire connector on the top of the flow meter.
2. Cut the strain reliefs on both inlet and outlet of flow meter.
3. Disconnect the tubing from both inlet and outlet ports.
4. Pull up on flow meter to remove from cradle.
Follow the sequence in reverse when replacing. Make sure tubing is secured and new straps are installed.
Check for leaks.
 To replace the water pump:
1. Disconnect wire connector on the top of the water pump.
2. Cut the strain reliefs on both inlet and outlet of water pump.
3. Disconnect the tubing from both inlet and outlet ports.
4. Remove water pump.
Follow the same sequence in reverse to reassemble. Please make sure new strain relief straps are
installed. Check for leaks by running the brewer.
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Servicing (continued):
5d) Servicing Bezel and Capsule Holder. These two components are located in the brew chamber.
 To replace the Bezel. Pull on one of the rear corners and pull part away from the lip of the carrier. To
replace, line up the slot on the bezel with the lip of the carrier, rotate, and snap into position.
 To replace the Capsule holder. Push the base of the capsule holder with one of your index fingers to
unsnap the part from the carrier. To replace, place in carrier and snap the part into the carrier.
5e) Servicing Probe Holder assembly. This assembly is also located in the brew chamber. Follow the directions
below to service:
 Cut the strain relief straps from inlet and outlet
 Remove both tubes from inlet and outlet
 Remove the two screws that secure probe holder assembly to carrier.
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Servicing (continued):
The sketch below shows the bypass kit on the probe holder assembly. To service by pass on probe holder
assembly:
 Pull the Manifold Fitting away from the probe holder.
 Remove the bypass parts.
 Replace the spring, ring, and ball as shown. Please make sure that the spring is sitting properly inside
of the manifold fitting. If is not, the bypass will not operate properly.
5f) Servicing the Linear Damper and the Interlock Switch. This assembly is located behind the brew chamber.
Follow the directions below to service:
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5g) Access to the electronics module:
a) Loosen the upper screw (pointing to 1) and pull the clamp up. This will allow you to remove the clamp
and the electronic housing.
b) Remove the four screws on the back of the electronics module. This will give you access to all the
components in this module.
Reverse sequence to reassemble unit.
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Servicing (continued):
6) Servicing the water inlet valve, the USB board, and the power cord.
In order to gain access to these parts, you will have to follow the sequence below:
6a) Servicing the water inlet valve, the USB board, and the power cord.
Follow the sequence outlined below to gain access to these components. Reverse order for reassembly.
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Servicing (continued):
6b) Servicing the Triac assembly and the Transformer
Follow the sequence outlined below to gain access to these components. Reverse order for reassembly.
6c) Servicing the Tank Assembly
Follow the sequence outlined below to gain access to the Tank Assembly. Cut the strain relief straps on the
upper and lower hoses, pull hoses from tank, and disconnect all wiring. Reverse order for reassembly.
Replace all strain relief straps. Turn brewer on, purge, and check for leaks.
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