AMW 815 Manual

1104 Form # AM-324-03

American Metal Ware®Hot Water Boiler

Installation, Operation & Service Manual

For

Models 815, 830, 850

Gas

Electric Steam

Special Features

After completing installation and set-up, the

equipment owner should keep this manual for

future reference.

PRINTED IN USA

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

TABLE OF CONTENTS

General Description.................................1

Installation...............................................1

Thermostat..............................................4

Adjustment..................................4

Service Instructions.................................5

Dual Level Control...................................6

Troubleshooting.......................................7

Solenoid Valve

Safety Instructions.....................11

Installation..................................11

Disassembly..............................12

Assembly...................................12

Troubleshooting.........................12

Cleaning....................................12

Testing.......................................12

Repair Kits.................................12

Coils..........................................12

Parts List...............................................13

Page 1 American Metal Ware Hot Water Boiler

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 off entire unit, including heater circuit: Separate low water cutoff

system protects heater and entire unit from damage.

Installation

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.

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.

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.

FILL WATER COMPARTMENT. Turn on water supply and electric service to urn. Turn master

switch on. Do NOT turn on thermostat 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.

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.

American Metal Ware Hot Water Boiler Page 2

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.

Installation (cont.)

*Factory setting

HEATER SIZE

(OR EQUIV. STEAM USE)

5.5KW/208 Volt or

7KW/240 Volt

12KW

15KW

COLD WATER*

CONNECTION

3min. 30sec.

1min. 50 sec.

1min. 25sec.

TIME TO REFILL 1 GALLON

HOT WATER

CONNECTION

1min. 25sec.

45sec.

35sec.

Page 3 American Metal Ware Hot Water Boiler

American Metal Ware Hot Water Boiler Page 4

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

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.

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 temperature at HIGH end of BREW zone on thermometer dial.

If thermostat will not cycle, replace entire control.

Page 5 American Metal Ware Hot Water Boiler

Service Instructions

PROBLEM: THERMOSTAT DIAL TURNED TO BREW AND WATER IN COMPARTMENT REMAINS COLD

POSSIBLE CAUSE

PROBLEM: WATER BOILS CONTINUOUSLY WITH THERMOSTAT DIAL ON POSITION BREW OR HOLD.

POSSIBLE CAUSE

Set knob on BREW and remove knob by pulling outward. 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.

Thermostat out of

calibration.

Thermostat is inoperative.

Fluid has leaked out of

diastat assembly of

thermostat.

Relay sticking in closed

position.

No power at urn.

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.

American Metal Ware Hot Water Boiler Page 6

Dual Level Control

Auto Refill And Low Water Cutoff System

II)

Dual Level Control: What it does:

Description and Operation of Dual Level Control System:

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.

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.

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.

Components

1. DUAL LEVEL CONTROL -

2. ELECTRODE ASSEMBLY -

3. METAL ENCLOSURE -

(TANK BODY)

switches power to both the thermostat and

water inlet solenoid valve by sensing changes

in water level.

consists of a high (short) and a low (extra long)

sensing electrode, or probe, molded in an epoxy

body.

provides a common (ground) connection for the

electrode circuit.

HIGH

RED WIRE

GREEN WIRE

TRANSFORMER

RELAYS

FILL HEAT

120VAC

PROBES

HI XL C

PRINTED CIRCUIT

RED WIRE

HIGH LOW

GREEN WIRE

LOW

SIDE MOUNTED PROBES

TOP MOUNTED PROBES

Page 7 American Metal Ware Hot Water Boiler

II)

III) Quick Service Check of Dual Level Control System:

Description and Operation of Dual Level Control System (continued)

B. Operation

Water Level Action

1) Below both electrodes 1)

2) Rises to low electrode 2)

above heater coils

3) Rises to high electrode 3)

4) Falls below high electrode only 4)

5) Falls below low electrode 5)

(Same as condition no. 1)

Both “HI” and “XL” electrode circuits open.

Dual Level Control turns power on to fill

valve and keeps power off to thermostat.

“XL” electrode circuit closes. Power to

thermostat turned on. Power to fill valve

remains on.

“HI” electrode circuit closes. Dual Level

Control turns power off to fill valve and

continues power to thermostat.

“HI” electrode circuit opens. “XL” circuit

stays closed. After a few seconds delay,

power to fill valve is turned on.

“XL” electrode circuit now opens. Power to

thermostat is turned off. Power to fill valve

remains on.

All wire secure and properly connected.

Clean the electrodes. Lime (mineral scale) build-up can interfere with the operation of any

liquid level control system.

Check the common (ground) connection. A little looseness or dirt can cause erratic

operation.

Thermostat

Fill Solenoid

Valve

OFF

Thermostat

Fill Solenoid

Valve

Thermostat

Fill Solenoid

Valve

OFF

Thermostat

Fill Solenoid

Valve

American Metal Ware Hot Water Boiler Page 8

Overfilling of water

tank when power is

off.

Overfilling of water

tank only when power

to unit is on.

Auto refill fails to

fill water tank.

PROBLEM

IV) Trouble Shooting Auto Refill, Low Water Cutoff, and Dual Level Control System

POSSIBLE CAUSE SERVICE CHECK REMEDY

Fill solenoid valve leaking

due to dirt or scale holding

valve open, or worn

plunger seat.

Fill solenoid valve

installed backwards.

High electrode coated

with scale, or faulty.

Missing or faulty

common connection for

electrode circuit (“C”

terminal to metal

enclosure).

Fill valve connected to

“HEAT” terminal.

Dual Level printed

circuit board faulty.

No power at equipment.

No water at equipment.

Visual. Water entering

tank continuously, and

usually slowly.

Visual.

Jumper from “HI” terminal

to metal enclosure stops

fill.

Jumper “C” terminal

(next to XL) to metal

enclosure stops fill.

Visual.

Jumper from “HI” to “C”

does not stop fill.

Nothing operates on

machine.

“Crack” fitting at

water inlet for pressure

check.

Disassemble and clean out. May

require new plunger assembly. Caution

is advised to avoid damage to valve.

See valve instruction sheet.

On valves without integral strainer:

Install so that port marked “IN” is

connected to outside fresh water

supply.

On valves with integral strainer:

Install so that arrow points in

direction of tank, away from fresh

water supply.

Remove electrode assembly. Clean both

electrodes. If still no remedy and

connections are good, replace assembly.

Make good secure connection. May

require cleaning or replacement.

Connect “BLACK” wire lead to “FILL”

terminal.

Replace Dual Level Control.

Make sure main switch(es), fuse(s),

circuit breaker(s) provide power to

unit, that machine’s circuit

breaker is OK and power switch, if

provided, is on.

Make sure all water supply line

valves are open.

Page 9 American Metal Ware Hot Water Boiler

Auto refill fails to

fill water tank

(continued).

Auto Refill is erratic.

PROBLEM

IV) Trouble Shooting Auto Refill, Low Water Cutoff, and Dual Level Control System (continued)

POSSIBLE CAUSE SERVICE CHECK REMEDY

Water strainer clogged.

No power on Dual

Level Control.

Fill solenoid valve

clogged with scale

or frozen closed.

Fill solenoid valve

coil inoperative

Electrodes shorting to

ground.

Dual Level Control

faulty.

Electrode shorting to

ground completely or

intermittently.

Loose connection.

Dual Level Control

faulty.

Water pressure before

strainer and not after.

Check for 120V AC across

“H” and “N” terminals.

Disassemble.

Jumper from “FILL”

terminal to “H” terminal

does not start fill.

Tank fills with electrode

wire disconnected from

“HI” terminal.

Tank does not fill

with electrode wire

disconnected from “HI”

terminal.

Tank fills with

electrode wire

disconnected from “HI”

terminal

Visual. Check for “C” and

“HI” probe terminals as well

as “FILL.” Also check

neutral (white) wire at valve.

Tank does not fill with

electrode wires disconnected

from “XL” and “H” terminals.

Remove and clean micromesh screen

filter located in water strainer.

If voltage missing or incorrect,

check wiring for looseness, breaks,

and proper connections.

Clean out and/or replace plunger

assembly or entire valve. May require

new coil. Caution is advised to avoid

damage to valve. See valve instruction

sheet.

Replace coil. Also check for frozen

plunger. See valve instruction sheet.

Replace electrode assembly. If no

remedy, check for improper wiring

(cut insulation) or electrode tips

touching metal.

Replace Dual Level Control.

Replace electrode assembly.

Push wire lead connector securely

onto terminal(s). Replace connector

if wire is frayed or broken.

Replace Dual Level Control.

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