P200E Shuttle & RAPS200E
Airpot/Shuttle Brewer Series
Operation and Instruction Manual
Table of Contents
Installation and Start-up ......................................1-2
Operation ............................................................3
Adjustments ..........................................................4-5
Installation
! WARNING: ELECTRIC SHOCK HAZARD!
INSTALLATION OF THIS APPLIANCE SHOULD BE PERFORMED BY
QUALIFIED SERVICE PERSONNEL ONLY. IMPROPER
INSTALLATION COULD RESULT IN ELECTROCUTION.
Cleaning
Service
..........................................................5-6
............................................................7
Troubleshooting
Filling Problems .................................... 8
See rough-in drawings in this manual for dimensions and locations of
electric and water input.
Heating Problems ................................. 9
Brewing Problems ................................ 10
Set-Up/Position
Exploded View for P200-E ....................................11
Exploded View for P200 (G version)......................12
Exploded View for RAPS200-E..............................13
Exploded View for RAPS200 (G version) ..............14
Rough-In Drawing for P200-E................................15
Rough-In Drawing for RAPS200-E........................16
Wiring Diagram for P200E/RAPS200-E ..........17
1) Remove the brewer from the packing material and attach its legs.
2) Position the brewer on a strong, stable table or counter. Check
the level front to back and side to side. Adjust the legs to the
correct level.
IMPORTANT:
THE PERSON INSTALLING THIS APPLIANCE IS RESPONSIBLE
FOR ENSURING THAT ELECTRIC AND WATER CONNECTIONS
MEET THE REQUIREMENTS OF THE NATIONAL ELECTRIC
CODE, NATIONAL PLUMBING CODE, AND ANY LOCAL
ORDINANCES.
Prior authorization must be obtained from
Grindmaster for all warranty claims.
Water Hook-up
1) Water inlet (supply) fitting is located at rear of unit.
2) Use 1/4" copper or flexible water line to prevent strain. Do not use low temperature plastic tubing. The connection
is 1/4" flare.
3) Water line pressure must be from 30 to 70 psi.
4) Hot (up to 160F) or cold water may be used. Hot water offers faster recovery between brews, (Use cold water only
if in-line water filters are implemented before the brewer).
5) Install a shut-off valve near the brewer.
6) Installing a filtering system can improve the taste of brewed coffee and extend the life of the brewer. If your water
has high calcium (lime), chlorine, or iron content, this is especially important. The filter should be the lime inhibiting
type if cold water is used. Contact our Customer Service Department to select the filter for your conditions.
Grindmaster Corporation™
4003 Collins Lane
Louisville, KY 40245 USA
(502) 425-4776
(800) 695-4500
(800) 568-5715 (Technical Service Only)
FAX (502) 425-4664
1004 FORM # AM-308-06
Part # A090-085
© Grindmaster Corporation, 1996
Printed in the U.S.A.
Installation (con't.)
Electric hook-up
1)
2)
3)
The electric ratings for your brewer are printed on its nameplate. Typical electric ratings
are: 120V, 1.65 kW, 15 Amp, 1 phase.
The brewer should be connected to its own circuit with a fused disconnect switch or a
circuit breaker near the brewer.
Electrical connection is made with power cord with NEMA 5-15P grounded plug (supplied) to
120V, 15 Amp wall socket. Certain models may be equipped with a NEMA 5-20P cordset and
plug.
WARNING
WARNING
ELECTROC
ELECTROCUTION HAZARD
!
NEVER USE THE GROUND CONDUCTOR AS A NEUTRAL. DO NOT USE GROUND
ELIMINATING ADAPTORS. UNIT MUST BE PROPERLY GROUNDED.
Start-up
Connect water line and turn water valve on. Check for leaks. Plug in power cord (supplied) to 120,
15 Amp (20 Amp for some models, see rating plate on unit) wall outlet.
Once the brewer is full of water, it will take 15 to 35 minutes to heat. The “READY” LAMP will light when
water has reached the set temperature.
After “READY” LAMP is lit, portion volume may now be checked. Insert the brew basket and place
Shuttle/Airpot under the brew basket. Brew at least one batch at half and full volume to check for
proper volumes. Remember that when brewing coffee, the level will be lower. The water must be hot
to check for proper levels.
If adjustments are needed, see the Adjustments section of this manual.
!
WARNING: HOT LIQUID HAZARD
DO NOT TRANSPORT BREWER WITHOUT DRAINING WATER TANK FIRST.
Page 2
P200/RAPS200 Brewers
Operation
CAUTION: HOT LIQUID HAZARD
WATER USED FOR BREWING COFFEE IS VERY HOT. USE CAUTION
WHEN BREWING, POURING, OR TRANSPORTING COFFEE. ACCIDENTAL
SPILLS MAY RESULT IN SEVERE BURNS.
1)
Place an empty, warm Shuttle under the brew head. Turn on the warmer once a Shuttle is
in place, or place an empty 1.9L to 3.0L airpot under the brewing head. Choose one size airpot
to minimize risk of brewing too large of volume in smaller container.
2)
3)
Remove the brew basket and line it with a paper filter. Paper size is 13 x 5 (Filter # BB1.5WP).
Place ground coffee in the filter basket. Your coffee supplier can help you select the right
amount of coffee and grind. Coffee brewing experts recommend between 6.5 and 8 ounces
of coffee per gallon of water for most applications. A full Shuttle is 1.5 gallons.
4)
5)
6)
Slide the basket into the brewer, making sure the spout lines up with the top of the Shuttle or
Airpot.
Check that the correct batch size is selected. Check the “READY” light. If lit, press
START.
Brew time is about 5 minutes for Shuttles and 4 minutes for 3.0L Airpots. After the brew, allow
the coffee to drip for 1 to 2 minutes.
CAUTION: HOT LIQUID HAZARD
COFFEE BASKET CONTAINS VERY HOT WATER UNTIL THE DRIP IS
COMPLETED. EARLY REMOVAL OF A DRIPPING BASKET COULD RESULT IN
BURNS.
7)
8)
Dump the grounds from the basket and rinse for the next brew. Coffee is ready to serve.
The Shuttle may be placed on remote warming stations. Use caution when moving a
full Shuttle or Airpot.
Page 3
P200/RAPS200 Brewers
Adjustments
WARNING: ELECTRIC SHOCK HAZARD
!
DANGEROUS ELECTRIC VOLTAGES ARE PRESENT NEAR ADJUSTABLE
COMPONENTS. ALL ADJUSTMENTS SHOULD BE PERFORMED BY
QUALIFIED SERVICE PERSONNEL ONLY.
All adjustable components are located under the top cover. To access these parts:
1)
2)
Unplug the brewer.
Remove the screw fastening the top cover. Remove the top cover.
Brew Volume Adjustment
The brew volume of the P200/RAPS200 brewer is controlled by its timer. The batch size is directly
proportional to the timer setting. The timer adjustment is located under the top cover.
There will always be a small variation (+/- 5%) in level from batch to batch.
Before making the timer adjustment, do the following:
1)
Brew a batch of water to determine where the level falls. Using a stop watch, determine
the current brew time. Measure the volume of water.
2)
To determine the desired time setting, use the following formula:
desired brew volume
desired brew time
=
_________________ X current brew time
current brew volume
Timer Adjustment
Two Batch Timer with Knob Adjustment, See Figure A:
1)
This timer is adjustable from 15 seconds to 5 minutes. Locate the
adjustment knobs under the top cover.
2)
Set this timer by adjusting the knob. The batch selector switch
picks the adjustment potentiometer which the timer will see.
A
Page 4
P200/RAPS200 Brewers
Thermostat Adjustment
The thermostat controls the water temperature in the tank. Factory setting is 195 degrees F. This
is the ideal temperature for brewing coffee. Water should never boil in the tank. If water is
boiling in the tank, adjust the temperature appropriately.
Standard Mechanical Thermostat:
1)
2)
3)
Shut off power and unplug brewer.
Open cover, locate thermostat mounted on tank. (Refer to Figure B).
Turn the shaft counter clockwise to increase temperature,
clockwise to decrease temperature.
4)
5)
If the maximum temperature adjustment needs to be increased,
insert a small flat screwdriver into the shaft.Turn the calibration
screw counter clockwise to increase the maximum temperature.
Reinstall top cover with screw then plug unit in, return to use.
Figure B
Cleaning
!
WARNING: BURN HAZARD
HOT LIQUIDS AND SURFACES ARE PRESENT IN THIS EQUIPMENT. TO
AVOID BURNS, USE CAUTION WHEN CLEANING. RINSE HOT PARTS
WITH COLD WATER BEFORE CLEANING. USE GLOVES OR A HEAVY
CLOTH WHEN REMOVING HOT PARTS FROM BREWER.
After Each Brew:
1)
2)
Dispose of grounds and rinse brew basket.
Rinse Shuttles and Airpots before reuse.
Every Day:
1)
2)
Wash brew basket with warm soapy water.
Remove spray head located above brew basket, using gloves or a heavy towel. Wash off coffee
oils and clean any plugged holes.
3)
4)
5)
Clean Shuttles and Airpots with warm soapy water and a brush or towel.
Wipe exterior of brewer with a damp cloth. Do not use abrasives which will scratch surface.
If the Shuttle is to be left on the warmer all night, fill it with water to avoid coffee oil burn-in.
Page 5
P200/RAPS200 Brewers
Weekly or Bi-Weekly, Depending on Use (P200 Only):
1)
2)
Fill Shuttle with one gallon of hot water.
Pour the recommended concentration of urn cleaner into the Shuttle liners (Excessive amounts
of cleaner will attack the stainless steel).
Urn 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
3)
4)
Scrub the liner interior with a plastic bristle brush.
Remove the knurled nut at the top of the gauge glass and clean the glass with a small
bottle brush.
5)
6)
7)
8)
9)
Pour out the contents of the Shuttle.
Remove the handle assembly of the Shuttle faucet by unscrewing the plastic bonnet.
Gently wash the faucet seat cup with a soft cloth and warm soapy water.
Wash the faucet shank with a bottle brush.
Clean the warmer and bottom of Shuttle surfaces. These surfaces must be clean for
proper heat transfer.
10)
Polish the exterior of the brewer with stainless steel cleaner. Use the appropriate
cleaner for brass, copper, or vinyl if these optional finishes are provided.
Page 6
P200/RAPS200 Brewers
Service
The rest of this manual contains information to help the service person who is working on this
equipment. This section has information on performing common service tasks.
To Drain The Water Tank
CAUTION: HOT LIQUIDS / BURN HAZARD
WATER IN TANK IS VERY HOT. USE CAUTION WHEN DRAINING TANK.
ACCIDENTAL SPILLS MAY RESULT IN SEVERE BURNS.
1)
2)
3)
4)
5)
6)
7)
Shut off power to brewer.
Remove the top panel.
Remove the warmer shelf.
Pinch or clamp the tube from fill valve to tank (near tank entry on bottom).
Disconnect rubber tube from outlet barb on fill valve.
Pull tube through the brewer body so that it exits at the bottom.
Place tube over drain and release clamp.
To Remove The Heater
1)
2)
3)
4)
Disconnect power and remove top cover of brewer.
Disconnect wire leads to heater.
Remove tank cover by loosening retaining nuts. Remove heater from cover.
Replace heater with sealing washers in same configuration. When tightening nuts, hold
element so it does not twist.
5)
6)
7)
Replace tank cover.
Replace heater wires. Be sure all electrical connections are secure.
Replace top cover of brewer and connect power cord to outlet.
Page 7
P200/RAPS200 Brewers
Troubleshooting: Filling, Heating, and Brewing
Filling Problems
The filling system consists of the following components:
• Liquid Level Control, located behind the brewer front panel.
• Liquid Level Probes, located on the tank top, secured by wing nut, under the top cover
• Fill Valve, located behind the front panel.
Problem
Possible Cause
Service Check
Remedy
Fill valve not sealing
properly.
Water entering tank
continuously, usually
slowly.
Disassemble valve and clean out
dirt. Valve may need new plunger
if seal is worn.
Overfilling
watertank even
when power is off.
If arrow on valve is pointing toward
water inlet, remove valve and install
correctly.
Fill valve installed
backwards.
Look for direction of
arrow on valve body.
Overfilling
watertank only
when power is on.
High electrode coated Jumper HI terminal on Remove electrode assembly and
clean both probes. If this does not
work, replace assembly.
with lime or faulty.
level control to metal
enclosure stops fill.
Make secure connection of C to
metal body.
Missing or faulty
connection of C
terminal on level
control to metal
enclosure.
Jumper from C
terminal to metal body
stops fill.
Connect black lead for valve to
FILL on level control.
Fill valve connected to Check connections.
heat terminal on level
control.
Replace level control.
Liquid level control is Jumper from HI to C
faulty.
or metal enclosure
does not stop fill.
No power at
equipment.
Nothing operates.
Check main switch or circuit
breaker, brewer's circuit breaker or
power switch if provided.
Tank does not refill.
No water at
equipment.
Crack water inlet
fitting.
Make sure all water supply line
valves are open.
Water strainer
clogged.
Water pressure
before strainer but
not after.
Remove and clean or replace
strainer's mesh.
No power to level
control.
If no voltage, check for loose or
broken wires.
Check for 120V AC
across H and N
terminals on level
control
Disconnect probe
wire to HI terminal on
level control. Check
for 120V at FILL
terminal.
If no 120V at FILL terminal, replace
level control.
Level control faulty.
Tank fills only when
probe wire is
Replace electrodes. If no remedy,
check for improper wiring or level
probe tip touching metal.
Electrodes faulty.
Fill valve faulty.
disconnected from HI
terminal on level
control.
Disassemble valve and clean or
replace plunger if frozen. If plunger
is OK, coil may need replacement.
120V is across FILL
and N on level
control, but no fill.
Page 8
P200/RAPS200 Brewers
Troubleshooting: Filling, Heating, and Brewing (con’t.)
Heating Problems
The heating system consists of the following components:
• Thermostat, located on the tank or on the front of top control panel under top cover.
• Heating Element, located on top of tank under top cover.
Problem
Possible Cause
Service Check
Remedy
Tank does not
heat.
Thermostat faulty or
out of calibration.
Make sure thermostat Recalibrate thermostat. If no reme-
is turned on.
dy or thermostat does not cycle,
replace thermostat.
Heater faulty.
Check resistance
across elements with
wires disconnected.
If resistance is much different than 7
to 10 ohms, replace heater.
Recovery time is very Heater faulty.
long.
See above.
See above.
If you still need help, call our Service Department at (800) 568-5715, press 2 (Monday through
Friday, 8 a.m. - 6 p.m. EST) or an authorized service center in your area. Please have the model
and serial numbers ready so that accurate information can be given.
Prior authorization must be obtained from Grindmaster Technical Services Department for all
warranty claims.
Page 9
P200/RAPS200 Brewers
Troubleshooting: Filling, Heating, and Brewing (con’t.)
Brewing Problems
The brewing system consists of the following components:
• Start and Stop switches, located on the front control panel.
• Brew Timer, located in the top control section under the top cover.
Problem
Possible Cause
Service Check
Remedy
Brew volume too
large or too small.
Timer out of ad-
justment.
Compare timer setting Adjust timer.
to factory setting
chart.
Pressure not ad-
equate at brewer.
Check water flow before Clean or rinse strainer at fill valve.
removing strainer.
Spray head clogged.
Timer faulty.
Visual
Clean all holes.
Replace timer.
Check if brew time
matches timer setting
and if timer can be
adjusted.
Brew volume erratic. Timer faulty.
(there is always some
small variation from
Measure brew time for If time is different from batch to
inconsistencies.
batch, replace timer.
batch to batch)
Pressure fluctuations
at brewer.
Check pressure at
brewer inlet.
Plumb water line so its pressure is
not influenced by other appliances.
Brew will not
start.
Tripped circuit
breaker.
Check to see if circuit
breaker tripped or
popped out.
Reset or replace breaker.
Brew valve faulty.
Stop switch faulty.
Check 120V across
brew valve.
If 120V is across brew valve, but brew
valve doesn't open, replace coil or valve.
Check for continuity
across stop switch
when not pressed.
If no continuity, replace switch.
If start switch does not provide 120V
start signal, replace switch.
Check 120V between
S.S. and N on timer
when start is pressed.
Start switch faulty.
Timer faulty.
Check 120V between H
and N on timer. If OK,
check for 120V between
BREW and N on timer
after pressing start.
If no 120V BREW output from timer,
replace timer.
Spray head will not
stop dripping water.
(spray heads normally
drip slightly after
brew)
Boiling tank.
If drip is from right side, Turn down thermostat. If that doesn't
check for water from cure, check for faulty thermostat or
overflow outlet at top of heater relay.
tank.
Clean valve. Valve seal or entire
valve may need replacement.
Limed up Fill valve.
Visual check of valve.
Page 10
P200/RAPS200 Brewers
Exploded View for the P200-E
ITEM DESCRIPTION
PART #
Page 11
P200/RAPS200 Brewers
Exploded View for the P200 (G version only)
ITEM DESCRIPTION
PART #
Page 12
P200/RAPS200 Brewers
Exploded View for the RAPS200-E
ITEM DESCRIPTION
PART #
Page 13
P200/RAPS200 Brewers
Exploded View for the RAPS200 (G version only)
ITEM
DESCRIPTION
PART #
Page 14
P200/RAPS200 Brewers
Rough-In Drawing for the P200-E
Page 15
P200/RAPS200 Brewers
Rough-In Drawing for the RAPS200-E
Page 16
P200/RAPS200 Brewers
Wiring Diagram for P200-E/RAPS200-E
Page 17
P200/RAPS200 Brewers
WARRANTY
for P200/RAPS200 Series
EFFECTIVE MARCH 1, 1996
GENERAL WARRANTY INFORMATION
Grindmaster maintains the highest standard of quality control in the manufacturing of American Metal Ware
products. We use the finest components and materials, and employ quality engineering standards and
tests. The P200E Brewer is warranted for a period of one year from date of shipment. This warranty will
include parts and labor but will not cover transportation and shipping charges and will be limited to equip-
ment sold to commercial purchasers and installed in the continental U.S.A., Hawaii, Alaska and Canada.
EXCEPTIONS
Coverage is not included for labor needed or caused by:
• Adjustments of temperature or flow rates or timers. These adjustments are covered in
the technical manual provided and subject to user preferences.
• This warranty does not cover maintenance consumable parts such as o-rings, seat cups,
washers. These are subject to NORMAL wear or everyday usage and are a responsibility
of the user.
• Accident
• Improper installation
• Neglect or abuse
• Excessive lime/mineral content of water used
• Cleaning of any category. Cleaning is a user's responsibility.
• All warranties are null and void if muriatic or any other form of hydrochloric acid is used
for cleaning or deliming our equipment.
NOTE: THIS WARRANTY SUPERSEDES ANY OTHER WARRANTY. ALL OTHER WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES OR MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE OR USE, ARE HEREBY EXCLUDED AND DISCLAIMED.
HOW TO OBTAIN WARRANTY SERVICES
Call Grindmaster Service Department toll free at 1-800-695-4500 for technical services or write to:
Grindmaster Factory Service Center, P.O. Box 35020, Louisville, KY 40232. In order to receive warranty
service, you must provide the serial number of the machine requiring service along with a description of
the problem. Service will be arranged through one of our authorized local service centers or our factory
service center. Transportation is the user's responsibility. Should it become necessary to transport your
machine to a service center, make sure it is properly packaged to avoid in-transit damage, which is not
covered by this warranty.
No field, outside or service station work is covered by this warranty without prior authorization
by Grindmaster's Service Dept.
Grindmaster Corporation™
4003 Collins Lane
Louisville, KY 40245 USA
(800) 695-4500 • (502) 425-4776
FAX: (502) 425-4664
Printed in the U.S.A.
© Grindmaster Corporation, 1996
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