NEWCO KP3AF K Line Automatic and Tea Brewer Instruction Manual

NEWCO KP3AF K Line Automatic and Tea Brewer

K-LINE AUTOMATIC & FAUCET MODELS

WARNING
DISCARD GLASS DECANTER IF

• CRACKED
• SCRATCHED
• BOILED DRY
• USED ON HIGH FLAME OR
• OPEN ELECTRIC ELEMENTS.

FAILURE TO DO SO MAY RESULT IN BODILY INJURY

PLUMBER’S INSTALLATION INSTRUCTIONS

CAUTION: Power to brewer must be OFF before proceeding with plumbing installation.

1. Flush water line before installing brewer. Brewer should be connected to COLD WATER LINE for best operation.

2. Water pressure should be at least 20 Ibs. For less than a 25 ft. run, use 1/4″ copper tubing & connect to 1/2″ or larger water line.
   For more than 25 ft. run, use 3/8″ copper tubing & connect to 1/2″ or larger water line, and provide an adapter fitting for connection to the brewer.

3. If installed with saddle valve should have minimum of 1/8″ port hole for up to 25 ft., and 5/16″ port hole for over 25 ft.

4. Connect incoming water line to the incoming male fitting on the back of brewer. Manufacturer recommends connecting to copper tubina.

INITIAL OPERATION INSTRUCTIONS

WARNING: – Read & follow initial operation instructions before plugging or wiring in machine to electrical circuit. Warranty will be void if machine is connected to any voltage other than that specified on the serial plate.
Newco automatic coffee brewers are designed with the feature of brewing as a pour over, except models K3A, KAF, K5A and K5AF.

ALL MODELS (EXCEPT KT-3 TEA BREWER)

1. BEFORE PLUGGING OR WIRING BREWER INTO PROPER VOLTAGE CIRCUIT: Place empty decanter under brew basket. For airport brewers, open airpot lid and remove stem from airpot. Place airpot under brew basket. Brewer must be manually filled by pouring three decanters (180 oz.) of water into top pour-in assembly. Water should come through brew basket as third decanter drains out of pour in basin. if brewer does not have pour in dish, models KA, KAF, K5A and K5AF remove top cover of brewer and pour 3 decanters of water into pour in basin.

2. Adjust timer to deliver desired amount of water. To brew into a regular 60 oz. decanter little adjustment should be needed. For brewing with the airpot brewer into a 72 oz. airpot the adjustment should be increased. To increase amount of water, increase time of water flow by turning timer dial slightly clockwise. To decrease amount of water, decrease time of water flow by turning time dial slightly counter clockwise.

3. Return power to the brewer.

4. Allow 10-15 minutes for water in tank to heat to brewing temperature. (Additional water may drip from brew basket on initial expansion of water in tank, this will not occur thereafter.) If brewer has ready light, brewer is ready when light is on.

5. After water has reached brewing temperature (thermostat will click off and heating noise will stop), place empty decanter under brew basket. Depress start switch & run a cycle of water to remove expanded water from tank.

6. Run one cycle to check for proper temperature with an accurate thermometer. Take the temperature of this water at a point below the brew basket opening, at the start of the cycle and when the decanter is half full. Recommended temperature of the water is
   approximately 195 degrees Fahrenheit.

7. Due to higher altitude locations (5,000 ft. above sea level) – thermostat may have to be re-adjusted to prevent boiling.

8. CAUTION: On faucet models the water faucet will dispense hot water when handle is depressed. The faucet system is independent of the brewing system and can be operated during the brew cycle. Once brewer is pressurized operate faucet until water flows smoothly.

MODEL KT-3 (TEA BREWER)

1. Remove back panel from brewer.
2. Place tea urn under brewer.
3. Fill tank with water by pouring 3 decanters (180 oz.) of water into receiving pan. Some water will flow through sprayhead. Empty tea urn.
4. Plug in brewer. Close needle valve (Fig. 5A) in tea brewer control panel by turning clockwise.
5. Set timer (Fig. 5B) to 180 seconds. Start brew cycle by pressing start switch.
6. Tea urn should fill with one brew cycle. If not, adjust timer until desired level in tea urn is achieved (3 gallons).
7. Open needle valve by turning counter clockwise 3 to 4 full revolutions. This will give 2 gals. of cold water flowing through dilution tube and 1 gal. of hot water concentrate through sprayhead.
8. Replace back panel.

LIMING
To prevent liming problems in tank fittings remove sprayhead and insert deliming spring ali the way into the tank. When inserted into tank properly, no more than ten inches of the spring should be visible at the sprayhead fitting. Saw back and forth five or six times. This will keep fittings open and clear of lime. In hard water areas this should be done every day; this takes less than a minute. In all areas sprayhead should be cleaned at least once a week.
Time involved is about thirty seconds. Where bad liming has already occurred, a new complete tank assembly can be installed in five minutes.

WARRANTY

Newco Coffee Brewers are warranted against defects in worksmanship or materials, under normal use, for 90 days from the date of purchase. Brewer parts are warranted against defect for 12 months from date of purchase. Liability in all events is limited to the purchase prioc paid and liability under the aforesaid warranty is limited to replacing or repairing any part or parts which are defective in material or workmanship, and returned to our factory, shipping cost prepaid. No warranty expressed or implied, other than the aforesaid is made or authorized by Newco Enterprises, Inc. Prompt disposition will be made if item proves to be defective, within warranty. Before returning any item, write or call Newco, or the Dealer from whom the product was purchased, giving model number, serial number, and date of purchase, and describe the nature of the defect. If damage was incurred during transit to you, file a claim with the carrier.

TROUBLESHOOTING GUIDE

MODELS KP1A, KP2A, KP3A, KP4A, KSP1A, KSP2A, KSP3A, KSP4A, KP1AF, KP2AF, KP3AF, KP4AF, KSP1AF, KSP2AF, KSP3AF, KSP4AF, K3A, KAF, KPPA, KPPAF AND KT-3

CAUTION: Disconnect brewer cord from electrical outlet before removal of any panel or replacement of any component.

COMPONENT REPLACEMENT INSTRUCTIONS

To access tank assembly; limit thermostat; control thermostat; tank heating element; switches; faucet, & hot water coil, proceed as follows:

1. Remove sprayhead & sprayhead nut (Fig. 1 No. 12) by unscrewing in counter clockwise direction.
2. Remove brewer lid. For models with upper warmer, disconnect electrical plug (Fig. 4A) from upper warmer.
3. Unscrew inlet/discharge tube (Fig. 2 O) from upper right hand side of automatic control panel then remove inlet/ discharge tube from receiving pan.
4. Remove pour-in basin assy (Fig. 2 N).

TANK ASSEMBLY, AUTOMATIC (704124)

1. Disconnect polarized plug (Fig. 3 B) connected to tank.
2. Lift tank completely out of brewer. Replace with new tank assembly by following reverse procedures.

TANK ASSEMBLY, FAUCET (704125)

1. Disconnect polarized plug (Fig. 4 B) connected to tank.
2. Disconnect flex tubing from hot water coil elbows (Fig. 4, E & F).
3. Lift tank completely out of brewer. Replace new tank assembly by following reverse procedures

THERMOSTAT, HI LIMIT (1000174) (Fig. 4 1)

1. Remove wires from limit thermostat.
2. Lift retaining spring slightly to remove old limit thermostat.
3. Check continuity of the new limit thermostat before installing.
4. Slide new limit thermostat into place under the retaining spring. Reconnect wire leads to new limit thermostat.
5. Make sure the limit thermostat is securely mounted & that all electrical connects are tight & isolated.

THERMOSTAT, MAIN (704227) (Fig. 3 Y)

1. Remove the two screws (Fig. 3 Z) from the back of bracket.
2. Remove grommet (Fig. 1 No. 13) from top of tank lid by pressing up with thumbs. Pull capillary bulb (Fig. 1 No. 14) out through hole.
3. Unplug thermostat black & blue wires from tank lid harness.
4. Replace thermostat by following reverse procedures.
5. To calibrate thermostat, rotate pin wheel adjustment (Fig. 3 P) counter clockwise to increase temperature.

ELEMENT, TANK HEATING (202067) (Fig. 1 No. 15)

1. Follow instructions for tank assembly removal.

2. Remove the 8 tank lid retaining nuts (Fig. 4 G).

3. Disconnect black & white wires from the tank heating element (Fig. 4 H).

4. Remove the 2 nuts holding the tank heating element.
   Remove element.

5. Install the new tank heating element. Replace tank heating element washers & tighten nuts securely to insure proper sealing

6. Inspect tank lid gasket & replace when necessary.

7. Reassemble by reversing steps 3 through 1.

ELEMENT, WARMING (100187) (Fig. 2 No. 16)

1. Remove screws holding warmer plate (Fig. 2 V)
2. Lift plate up & disconnect wire leads.
3. Remove 2 nuts holding the retaining plate & warmer element to plate.
4. Replace warmer element following reverse procedures.

SWITCH, BREW (201985) (Fig. 4 K) and SWITCH, LIGHTED ROCKER (100085) (Fig. 4 L)

1. Disconnect wires from switch, noting location of each wire.
2. Remove switch by compressing spring clip on top & bottom of switch, press forward.
3. Replace switch following reverse procedures.

FAUCET ASSEMBLY (100145) Fig. 4 M)

COIL, HOT WATER (771031)

1. Follow instructions for tank assembly removal.
2. Remove the 8 tank lid retaining nuts (Fig. 4 G).
3. Lift the tank lid assembly from tank.
4. Remove the 2 compression nuts from top of hot water coil. (Inspect tank lid gasket & replace if necessary)
5. Replace with new hot water coil by following reverse procedures

CONTROL PANELS

To gain access to the automatic control panel or tea brew control panel remove brewer lid. On models with an upper warmer disconnect electrical plug from upper warmer. Remove back panel. Disconnect 9 pin plug. Remove control panel by loosening the 2 knurled nuts.

COMPONENT REPLACEMENTS FOR AUTOMATIC CONTROL PANEL (781061)

TIMER ASSEMBLY (700062) (Fig. 3 No. 4)

1. Disconnect electrical plug (Fig. 3 No. 6) from timer.
2. Remove white & gray wire tabs from solenoid valve terminal tabs (Fig. 3 No. 7).
3. Remove screws from timer assembly bracket.
4. Replace new timer assembly by reversing procedure.

FLOW CONTROL ASSEMBLY (101190) (Fig. 3 No. 3)

1. For easy access remove timer assembly (see instructions).

2. Remove 1/4″ swivel nut (Fig. 3 No. 10) from flow control.
   From opposite end of L-shaped copper tubing disconnect 1/4″ flare nut. (Fig. 3 No. 9)

3. Remove 1/4″ swivel nut (Fig. 3 No. 11) from solenoid.
   Disconnect flow control from solenoid.

4. Replace with new flow control and follow reverse procedure (insuring all arrows on flow control & solenoid point the the right side of automatic control panel.)

SOLENOID (100250) (Fig. 3 No. 2)

1. Follow steps 1 through 3 of flow control replacement.
2. Unscrew 1/4″ swivel nut from solenoid. Replace solenoid following reverse procedure (insuring all arrows on flow control & solenoid point to the right side of automatic controi panel.)

STRAINER (202003) (Fig. 3 No. 5)

1. For easy access remover timer assembly (see instructions)
2. Remove 1/4″ flare nut from each side of strainer.
3. Remove strainer & replace new strainer following reverse procedure.

COMPONENT REPLACEMENTS FOR TEA BREWER CONTROL PANEL (781062)

TIMER ASSEMBLY (700062) (Fig. 5 No. 4)

1. Disconnect white & gray wires from solenoid terminal tabs. (Fig. 5 No. 7)
2. Disconnect electrical plug (Fig. 5 No. 6) to timer.
   Remove screws from timer assembly bracket. Replace with new timer assembly following reverse procedure.

FLOW CONTROL ASSEMBLY (101100) (Fig. 5 No. 19)

1. Remove 1/4″ swivel nut (Fig. 5 No. 10) from each end of flow control.
2. Replace with new flow control insuring arrow on sticker points toward left hand side of control panel.

SOLENOID (100250) (Fig. 5 No. 2)

1. Disconnect gray & white wires from solenoid terminal tabs. (Fig. 5 No. 7)
2. Disconnect 1/4″ swivel nut from elbow.
3. Disconnect 1/4″ swivel nut from needle valve assembly.
4. Disconnect 1/4″ swivel nut from street tee.
5. Disconnect street tee from solenoid.
6. Disconnect elbow from solenoid.
7. Replace with new solenoid by following reverse procedure insuring arrow points to the right hand side of control panel.

CONVERSIONS

FRONT-TO-BACK to SIDE-TO-SIDE (or visa versa) SWITCH PLATES

1. Remove brewer lid. For models with upper warmer, disconnect electrical plug (Fig. 4 A) from upper warmer plate.
2. Remove pour in basin assy (Fig. 2 N).
3. Remove desired blank panel by unscrewing 4 nuts.
4. Remove knurled nuts (Fig. 2 W) on switch plate.
5. Slide switch plate panel through opening to inside of brewer by turning panel. Continue sliding switch panel through to desired opening.
6. Reassemble by reversing steps 4 through 1.

BREW RAILS

1. Loosen brew rail screws. DO NOT REMOVE. Slide off brew rails.
2. Reposition brew rails. The narrower part of brew rail denotes entrance of brew basket.
3. Slide brew rails under screws & tighten screws.

ROTATION OF WARMERS

UPPER STEP-UP WARMER (Two and four burner models)

1. Remove brewer lid. Disconnect electrical plug from upper warmer plate.
2. Turn brewer lid upside down. Remove screws.
3. While holding warmer to brewer lid turn lid right side up.
4. Reposition warmer by increments of 90 degree turns.
5. While holding warmer to brewer lid turn upside down.
6. Align 4 holes of brewer lid to the holes on warmer base.
7. Reassemble by reversing steps 2 and 1.

3-WARMER BASE WITH STEP UP WARMER (Three and four burner models)

1. Remove screws from porcelain plate.
2. Gently lift porcelain plate & place to side.
3. Remove the 2 screws from bracket.
4. Rotate step-up warmer to desired position & align bracket with 2 holes in the base
5. Reverse steps 3 through 1.

BASE CHANGES

1. Follow instructions for tank assembly removal.
2. Remove back panel. Unplug main wiring harness (Fig. 2 0)
3. Remove control panel by loosening the 2 knurled nuts. Lift control panel approx. 1″, puil the base out while pushing back & down on the top.
4. For all modeis (except Airpot & Tea) unplug red, white & black wire lead for base warmer.
5. Remove the 2 knurled screws & the 4 screws (Fig. 2 U) located on base of housing.
6. Remove housing from base. On all models (except Airpot and Tea puli warmer wires out through plate on base ofchousing.
7. Replace housing on new base. On all but airpot & tea bases pull red, white & black warmer wires through hole in base plate. Align holes of new base with holes on brewer housing. Align warmer wire hole on base with large hole in base plate (On all bases except airpot & tea).
8. Reassemble by reversing steps 6 through 1.

LID CHANGES

POUR-IN ONLY to POUR-IN WITH STEP-UP WARMER or 2 BURNER STEP-UP WARMER

1. Remove brewer lid. Replace with step-up warmer lid.
   Connect electrical plug for warmer.

2.  Replace 6 brewer lid screws & tighten.

POUR-IN WITH STEP-UP WARMER to POUR-IN ONLY

1. Remove brewer lid. Disconnect electrical plug for upper warmer.
2. Replace with pour-in only lid. Replace 6 brewer lid screws & tighten.

TO ACCESS INSIDE OF BREWER

1. Remove sprayhead & sprayhead nut (Fig. 1 No. 12) by unscrewing in counter clockwise direction.
2. Remove brewer lid. For models with upper warmer disconnect electrical plug (Fig. 4 A) from upper warmer.
3. Unscrew inlet/discharge tube (Fig. 2 0) from upper right hand side of automatic control panel. Then remove inlet/ discharge tube from receiving pan.
4. Remove pour in basin assy (Fig. 2 N).
5. Remove back panel.

AUTOMATIC TO POUR-OVER

1. Loosen 2 knurled nuts on automatic control panel (Fig. 2 R). Remove automatic control panel & replace with pour- over control panel.

2. Disconnect black & blue wires on start switch (Fig. 4 K).
   Refasten black & blue wires with a line splice connector.

3. Replace start switch with a blank dummy switch cover.
   Connect wires for start switch (now unused) together with line splice connector.

4. Plug receiving pan hole with screw & washer.

5. Reassemble by reversing “access” steps.

AUTOMATIC TO FAUCET

1. Remove plug (Fig. 2X) in switch panel to provide opening for faucet.

2. Remove brass nut & star washer from faucet assembly. Insert faucet through opening in switch panel. Position faucet then fasten with brass nut & star washer.

3. Remove tank assembly by unscrewing sprayhead & sprayhead nut (Fig. 1 No. 12). Unplug polarized plug (Fig.
   4 B) & lift tank assembly out of brewer. Place faucet tank assembly in brewer. Reconnect polarized plug, sprayhead nut & sprayhead.

4. Connect the 12″ flex tubing to faucet & to the hot water outlet (Fig. 4 F) on tank lid

5. Connect the 10″ flex tubing to cold water inlet on tank lid (Fig. 4 E) & to the top left hand fitting (Fig. 2 No. 8 B) on automatic control panel.

6. Replace pour in basin assy. Remove screw plugging hole in pour in basin.

7. Insert inlet/discharge tube into pour in basin. Slide gasket up to seal hole in basin. Tighten flare nut to top right hand fitting on automatic control panel.

8. Adjust water flow to water faucet by adjusting needle valve (Fig. 2 No. 1). (Turn counter-clockwise to open.)

9. Replace back panel. Reconnect electrical plug to warmer (on models with upper warmer). Replace brewer lid.

10. Refer to Plumber’s Installation Instructions.

AUTOMATIC to TEA BREWER

1. Follow instructions for base changes. Do not replace brewer lid, tank assembly, back panel and pour in basin.

2. Replace left hand track guide with tea brewer track guide.

3. Remove plug from sprayhead plate. Inset 1/4″ flared male connector, with longer side on inside of brewer. Fasten with star washer & nut.

4. Place tank assembly into brewer. Fasten sprayhead nut.

5. Replace 5 hole sprayhead with 6 hole sprayhead.

6. Insert tea brewer control panel and fasten knurled nuts.
   Reconnect polarized plug.

7. Connect int. dilution tube by connecting to fitting on top right hand side of tea brewer control panel & to 1/4″ flared male connector on sprayhead plate.

8. Replace pour in basin assy. Insert tea brewer inlet/ discharge tube through hole in basin (sliding gasket up to seal hole). Insert tea brewer inlet/discharge tube into basin. Connect opposite end of tea brewer inlet/discharge tube to fitting on top left hand side of tea brewer control panel.

9. Attach ext. dilution tube to 1/4″ flared male connector located on outside of brewer on sprayhead plate.

10. Refer to plumber’s installation instructions.

11. Refer to Tea Brewer initial operation instructions for dilution setting.

12. Replace back panel.

13. Replace step-up cover with “pour-in screen only” cover. (on models with upper step-up warmer).

WIRING SCHEMATIC – ALL MODELS

FIGURES 1, 2, 3, 4 & 5 PARTS LIST

K BREWER PARTS LIST

3650 New Town Blvd. St. Charles, MO 63301
Main Office: 800-325-7867 Technical Service: 800-556-3926 Fax: 636-925-0029
www.newcocoffee.com

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