Newco Fresh Cup Manual

SINGLE SERVING AUTOMATIC POD MACHINE

NEWCO ENTERPRISES INC, 3650 NEW TOWN BLVD SAINT CHARLES, MO 63301

1-800-325-7867 FAX 1-636-925-0029

Features/ Specifications

• AUTOMATIC POD REMOVAL

• FLOWMETER OPTION

• 20 OZ TRAVEL MUG

• LARGE POD WASTE TRAY / THRU COUNTER OPTION

• ADJUSTABLE DRINK STRENGTH

• ADJUSTABLE DRINK VOLUME

1

TABLE OF CONTENTS

SPECIFICATIONS ………………………………………………………………………………………….. 3

NEWCO PRODUCT WARRANTY ………………………………………………………………………... 4

MACHINE SET-UP …………………………………………………………………………………………. 5

MACHINE OPERATION …………………………………………………………………………………… 6

MACHINE PROGRAMMING & CALIBRATION ………………………………………………………… 7

SERVICING THE MACHINE ………………………………………………………………………………. 11

TANK REMOVAL …………………………………………………………………………………………… 12

POD BREWING MECHANISM ……………………………………………………………………………. 13

ELECTRICAL COMPONENTS ……………………………………………………………………………. 17

ERROR MESSAGES ……………………………………………………………………………………… 18

FLOW ADJUSTMENT CONTROL ………………………………………………………………………... 19

WIRING DIAGRAM …………………………………………………………………………………………. 20

2

SPECIFICATIONS

TANK WATTAGES

US 1700W 120V- CANADA 1400W 120V- INTERNATIONAL 1700W 220V

TANK CAPACITY-1 US GALLON

DRIP TRAY CAPACITY 8 OUNCES

POD WASTE TRAY CAPACITY 80 PODSUSE WASTE TRAY

PN 780306 FOR THRU-COUNTER USE

UP TO 20 OZ CUP SIZE

SHIPPING WT-APPROX 35 LBS

3

NEWCO PRODUCT WARRANTY

Newco warrants equipment manufactured by it for 1 Year Parts & Labor

These warranty periods run from the date of installation Newco warrants that the equipment manufactured by it will be commercially free of defects in material and workmanship existing at the time of manufacture and appearing within the applicable warranty period. This warranty does not apply to any equipment, component or part that was not manufactured by Newco or that, in Newco’s judgment, has been affected by misuse, neglect, alteration, improper installation or operation, improper maintenance or repair, damage or casualty. This warranty is conditioned on the Buyer 1) giving Newco prompt notice of any claim to be made under this warranty by telephone at (800) 556-3926 or by writing to PO Box 852, Saint Charles, MO 63302; 2) if requested by Newco, shipping the defective equipment prepaid to an authorized Newco service location; and 3) receiving prior authorization from Newco that the defective equipment is under warranty.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY,

WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED

WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

The agents, dealers or employees of Newco are not authorized to make modifications to this warranty or to make additional warranties that are binding on Newco. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon.

If Newco determines in its sole discretion that the equipment does not conform to the warranty,

Newco, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the applicable parts and labor warranty periods specified above) to repair the defective components, provided that this repair is done by a Newco Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for the equipment.

THE BUYER’S REMEDY AGAINST NEWCO FOR THE BREACH OF ANY OBLIGATION ARISING

OUT OF THE SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR

OTHERWISE, SHALL BE LIMITED, AT NEWCO’S SOLE OPTION AS SPECIFIED HEREIN, TO

REPAIR, REPLACEMENT OR REFUND.

In no event shall Newco be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.

4

MACHINE SET-UP

NOTE: The FRESH KUP machine weighs approximately 35 LBS. Use CAUTION when unpacking and lifting machine. LIFT MACHINE FROM MACHINE BOTTOM ONLY. DO NOT MOVE

MACHINE UNLESS THE HOT WATER TANK IS DRAINED AND EMPTY.

1. Open and install the drip tray grill and place drip tray into pod tray

2. Connect water fitting with strainer on the rear of machine under the power switch.

Plumber's Installation Instructions

1) Brewer must be installed to comply with all applicable federal, state and local plumbing codes and ordinances.

2) Plumb brewer in to water supply using 1/4 inch copper tubing. Flush water line before installing brewer to remove sediment. Brewer should be connected to COLD WATER

LINE for best operation.

3) Water pressure should be at least 20 lbs. For less than a 25 ft run, use 1/4" tubing and connect to 1/2" or larger water line. The inlet water fitting on the back of the brewer is a

1/4" flare fitting. It may be necessary to remove the plumbing cover box on the rear of brewer to access water connection point.

4) If installed with saddle valve, the valve should have a minimum of 1/8" porthole for up to

25 ft run, and 5/16" porthole for over 25 ft runs.

5) Turn on water supply and check for leaks.

WARNING: - Read and follow installation 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 tag.

Turn the power switch to the “OFF “ position and plug the machine into a properly installed and grounded electrical circuit. Turn on power switch to start the initial

WATER FILL CYCLE .

When tank is filled, the heater circuit will turn on-allow up to 20 min for the tank to reach brewing temperature. Machine is now ready for programming or operation.

5

MACHINE OPERATION

BREWING

INDICATOR

LIGHT

DRAWER OPEN

BUTTON

PUSH & HOLD FOR HOT WATER

DISPENSE WHEN DRAWER IS CLOSED

READY

TO BREW

INDICATOR LIGHT

PROGRAMMABLE

BREW BUTTONS (CUP

STRENGTH OR CUP

SIZE, TEA, ETC

PUSH TO RETURN BREW

MECHANISM TO HOME POSITION

WHEN DRAWER IS OPEN

•

TEMPERATURE RANGE IS 170-203 DEGREES

•

POWER SAVE OR POWER FEATURE AVAILABLE

•

BEEPER VOLUME CAN BE ADJUSTED OR BEEPER CAN BE SHUT OFF

•

AIR PUMP POD DRYING TIME & PUMP STRENGTH CAN BE ADJUSTED

•

POD COUNT TO EMPTY POD WASTE BIN AJDUSTABLE OR CAN BE

TURNED OFF IF USING THROUGH THE COUNTER WASTE BIN

•

COFFEE OR TEA PRE-INFUSTION, BREW TIME & BREW VOLUME

ADJUSTABLE FOR EACH OF 3 CUSTOMIZABLE DISPENSE BUTTONS

BREW OPERATION

1. PLACE CUP UNDER BREW NOZZLE ON DRIP TRAY

2. PRESS THE DRAWER OPEN BUTTON

3. UNWRAP THE POD & PLACE IN CENTER OF BREW CHAMBER

4. PRESS THE DESIRED BREW BUTTON-DRAWER WILL CLOSE &

BREW CYCLE WILL START

5. ONCE THE POD DRYING CYCLE IS COMPLETE, THE POD WILL

EJECT & THE CUP CAN BE REMOVED

6

MACHINE PROGRAMMING AND CALIBRATION

MACHINES EQUIPPED WITH A FLOWMETER Please run your Fresh Cup pod brewer a few times. If the volume dispensed is comparable to the amount expected from your Button

Settings (which are set in the programming menu as described BELOW) and consistent and the pulsing is acting as expected you are done . However, if your dispensed calibration volume is larger or smaller than the volume setting for each brew button, then adjust the “OZ Per tick” until volumes match. For example, calibration volume delivers 6.5 oz, but the volume setting on a brew button is 7 oz, adjust the Oz Per tick until 7 oz is delivered in the calibration volume.

To enter the maintenance menu turn the unit off then hold the Hot Water (Reset) key and the

Open key (Button A) while turning on the power to the Fresh Cup pod brewer. Hold both keys down until “DRAIN LINE” scrolls across the display. Press the Mild key (Button B) until “OZ PER

TICK” is scrolling across the display.

Press the Hot Water (Reset) key to enter. A number will be displayed, 43 is the default value.

Pressing the Open key (Button A) will decrease the number. Pressing the Mild key (Button B) will increase the number. A change of one number (example; 43 to 44) will alter the dispensed volume by approx. 0.2 oz for a 7oz dispense. If you want more in your cup decrease the number and if you want less in your cup increase the number. (Example; 43 to 44 will reduce your cup volume and 43 to 42 will increase your cup volume.) Press the Hot Water (Reset) key to exit. The display will show “END”.

Press the Hot Water (Reset) key again to save your changes and to exit to the normal Run mode .

FOR OTHER ITEMS IN THE MAINTENANCE MENU, SEE ‘MAINTENANCE MENU”, BELOW

NOTE: THE MACHINE HAS BEEN CALIBRATED AT THE FACTORY AND HAS BEEN ADJUSTED TO

BREW INTO AN 8 OUNCE CUP WITH APPROX 7 OUNCES OF COFFEE FOR BREW STRENGTHS OF

MILD, REGULAR AND BOLD. NO FURTHER ADJUSTMENTS ARE NECESSARY IF THE FACTORY

DEFAULTS ARE USED.

Fig 1: Fresh Kup Keys

The Fresh Kup pod brewer has a menu that consist of scrolling menu entries that can be scanned through backward and forward using button A and button B (see Fig 1). To enter a programming record, press and hold the Reset Key when powering up machine (see Fig 1) then use button A and button B (see Fig 1) to change the entry. Pressing the Reset key (see Fig 1) will exit the entry, saving the entire Parameter structure to memory upon exiting the programming menu using the END entry. There are nine entries on the Main menu and four on one sub menu, which is accessed through the BUTTON SET UP entry. The current entries in the Main menu are as follows:

7

PROGRAMMING AND CALIBRATION CONT’D

TEMPERATURE : In this entry the user may set the tank temperature in the range of 170 to 205 degrees Fahrenheit with the default at 200 degrees F. Pressing button D (see Fig 1) will toggle the display so the user may view the real tank temperature. The real temperature display has all three decimal points illuminated. Pressing button D (see Fig 1) again will switch the display back to show the current set point. As with most of the entries, button A and button B (see Fig 1) will change the set point, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit.

POWER SAVE : This entry allows the user to select the Power Save mode. Use button A and button B (see Fig 1) to change the entry then press the Reset key to exit.

Off (default) – Turns Power Save function off.

Prt – Partial Power Save Mode. After the user selectable time out the tank temperature set point is set to 180 until a key is pressed. When this mode is selected the right most decimal point in the display is on.

FuL – Full Power Save Mode. After the user selectable time out the tank heater is disabled until a key is pressed. When this mode is selected the left most decimal point in the display is on.

POWER SAVE TIME: This entry will not be displayed if the Power Save function has been turned off. This entry sets the time the machine will operate normally until the power save function is activated. The user can choose 1 through 4 hours in 1-hour increments with the default set to 4 hours. As with most of the entries, button A and button B (see Fig 1) will change the time, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit.

BEEPER VOLUME : The range is from 1 to 24. The default is 13.

AIR PUMP SPEED : In this entry the user may set the air pump strength in the range of 5 to 10 strength with the default at 9. As with most of the entries button A and button B (see Fig 1) will change the Air Pump Strength, incrementing or decrementing by one. Pressing Reset (see Fig 1) key will exit.

AIR PUMP TIME : In this entry the user may set the air pump time in the range of 2 to 10 seconds with the default at 5. As with most of the entries button A and button B (see Fig 1) will change the Air Pump Time, incrementing or decrementing by one. Pressing Reset (see Fig 1) key will exit.

POD COUNT : In this entry the user may set the number of pods the brewer will hold before signaling that the bin is full. The range is 10 to 100 pods, with the default at 40. Setting the pod count under 10 turns off the count so the bin full alarm will never go off. As with most of the entries button A and button B (see Fig 1) will change the Pod Count threshold, incrementing or decrementing by one. Pressing Reset key (see Fig 1) will exit.

8

PROGRAMMING AND CALIBRATION CONT’D

CALIBRATION* : (NON-FLOWMETER MACHINES ONLY) This entry shows the amount of water the brewer dispenses in 30 seconds with no pauses. To run calibration, place a container able to hold at least 10 oz preferably greater. Press button D (see Fig 1) and the brewer will enter a brew cycle. The door will open to allow the user to place a beverage pod in the drawer. After the pod has been placed press the button D button (see Fig 1) again to start the brew cycle.

After the cycle has completed, measure the amount of water dispensed and adjust the

Calibration number shown in tenths of an ounce to match the amount dispensed by using button A and button B (see Fig 1) to increment or decrement by one. Press the Reset key (see

Fig 1) to advance to the brew button programming selections. Range for the calibration volume is 10 to 320 tenths of an ounce. The default is 100 tenths of an ounce.

BUTTON SET UP : This entry takes the user into a sub menu to program the parameters unique to each key. When this entry is accessed the display will change to SELECT BUTTON indicating that the user should press the brew key (button B, C or D (see Fig 1)) to be programmed. When a brew key is selected the display will show the first entry in the Button Set up sub menu, PRE-INFUSION. While SELECT BUTTON is displayed the user may exit back to the

Main menu by pressing the Reset key (see Fig 1).

With these four entries in the BUTTON SET UP sub menu:

PRE-INFUSION : This entry sets the time of the pre-infusion pulse of water in tenths of a second. Range is 1 to 30, the default is 15 tenths of a seconds.

BREW VOLUME : This entry sets the volume in tenths of an ounce for this key to dispense.

The Range is from 20 to 160 tenths of an ounce with the default set to 70 tenths of an ounce

BREW TIME : This entry sets the brew time in seconds for a 7-ounce cup of coffee with on/off pulses. The range is from ~30 to 99 seconds with the default being 35 seconds.

RETURN : Exit to Main Programming Menu.

FILTER SELECT : This entry allows the user to select the filter size for the filter used on the inlet for the water. Choices include OFF, 500 GAL, 1000 GAL and 1500 GAL. These set the counter for the filter warning. Whenever water is dispensed the counter is incremented to account for the water dispensed. When the counter is above 90% of the capacity of the chosen filter a warning message, “REPLACE WATER FILTER”, is displayed in place of the “READY” message. To reset the counter the user must enter the programming menu and enter the RESET

FILTER entry described below. The following entries are only shown when a filter is selected. If the filter selection is OFF then following entries are not available. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu.

FILTER REMAINING : This entry scrolls the number of Gallons left before the filter should be replaced. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu.

RESET FILTER : When in this entry the message “PRESS OPEN TO RESET’. Press the Open

Door key will reset the Filter Use counter to the value chosen in the FILTER SELECT entry above. Press the Reset key (see Fig 1) to leave the entry and return to the Main Programming menu.

END – Exit to Main and save parameters.

9

“MAINTENANCE” MENU

The Fresh Cup pod brewer has a maintenance menu that consist of scrolling menu entries that can be scanned through, backward and forward, using button A and button B (see Fig 1). The letter to the right of the button is the buttons letter assignment. To enter the maintenance menu, hold Button A (Open) and the Reset key (Hot Water) down while turning on the Fresh Cup machine. Hold the keys down until the Drain Line message appears on the display. This is the first entry of the maintenance menu. Until the Drain Line message appears on the display the current version will be displayed. To enter a maintenance record, press the Reset key (see Fig 1) then use button A and button B (see Fig 1) to change the entry.

The current entries in the Main menu are as follows:

FLOWMETER ADJUST: This entry displays the value used to represent the amount of liquid in thousandths of an ounce seen for one tick of the flow meter count.

While in this entry, pressing the A key will decrement and the B key will increment this value. This can be used to fine-tune the amount of liquid that is dispensed.

The default value is 43.

CYCLE COUNT: This entry shows the number of brew cycles that has occurred on this machine since the last time the count was cleared. To clear the count hold button C down for 10 seconds while in this entry.

RESET TO FACTORY DEFAULTS: When in this option, pressing the “OPEN” key resets the unit to its factory defaults then exits to the Maintenance Menu. To exit to the Maintenance Menu without resetting press the “HOT WATER” key.

DRAIN LINES: In this entry the user may run the pump for 15 seconds in order to drain any water from the lines for transportation. This function runs similarly to the calibration function. The display will prompt “RUN PUMP” once the user has entered this entry. To run the pump first press the ‘D’ key. The drawer will go to the open position. At this point pressing any brew key (B, C, or D) will cause the drawer to go to the brew position and then, once the drawer is in position, run the pump for 15 seconds, then return the drawer to the home position. At this point pressing ‘RESET’ will exit to the menu and pressing the ‘D’ key will start the process again. Pressing any key while running will abort the process.

END – Exit to Main and save parameters.

10

DRAINING THE HOT WATER TANK

THE DRAIN TUBE IS CLIPPED TO THE TANK PLATE IN FRONT OF THE TANK.

THE HOT WATER TANK CAN BE DRAINED FROM THE FRONT OF THE MACHINE –

UNPLUG MACHINE FROM POWER SOURCE. REMOVE POD WASTE TRAY.

CAUTION-UNLESS THE TANK IS LEFT TO COOL THE WATER IS EXTREMELY HOT

AND CAN CUASE HARMFUL BURNS.

REPLACE DRAIN PLUG, ENSURE HOSE

CLAMP IS TIGHT AND REPOSITION DRAIN HOSE BEFORE RE-FILLING THE HOT

WATER TANK.

SERVICING THE MACHINE

The Fresh Kup machine has a modular Water Tank Assembly and Brew Mechanism.

These assemblies can be easily removed from the machine by removing or loosening

Machine nuts as noted in drawings below:

BREW MECHANISM

ACCESS SCREWS

(VIEW FROM BOTTOM FRONT OF MACHINE)

REMOVE

BRASS

KNURLED

NUTS

(2)

NOTE: TO REMOVE BREW

MECHANISM, UNSNAP WATER

& HARNESS FITTINGS

LOOSEN

ACORN

NUTS

(4)

Front Of Brewer

11

TANK REMOVAL & ACCESS AREAS

REMOVE (3) 8-32 NUTS TO

PREPARE TANK FOR

REMOVAL (TWO ON TOP

OF TANK & ONE ON

BOTTOM OF PUMP

BRACKET

LOOSEN SCREWS TO

REMOVE TOP & BACK

COVERS

LOOSEN BUT DO NOT

REMOVE THESE 2

SCREWS THEN LIFT &

PULL CONTROL BOARD &

BRACKET OUT OF

MACHINE TO ACCESS

TRANSFORMER

REMOVE (2) 6-32 SCREWS

TO REMOVE SIDE PANEL

FOR PUMP ACCESS

(REMOVE TOP COVER

BEFORE REMOVING

SIDE PANELS)

12

POD BREWING MECHANISM

780234-61MM and 780330 –56MM

13

POD BREWING MECHANISM CONT’D

ITEM # NEWCO PN DESCRIPTION

1 780230 BREW MECH MOTOR

4

780329

773246

UPPER BREW CHAMBER-56MM

U-CUP SEAL RING

QTY/EA

2

1

1

1

1

6

780314

780418

LOWER BREW CHAMBER-56MM

EJECT SLOPE CAM ASS’Y 1

*

MACHINE IS ORDERED FOR 56MM OR 61MM POD SIZE

14

780234 TANK ASS’Y

10

9

8

7

6

5

15

4

1

2

3

780234 TANK ASS’Y CONT’D

ITEM # NEWCO PN DESCRIPTION QTY/EA

1

2

110958

111593

RELAY, 12 VDC SPST 30A 1

1

3 706341 PUMP ASS’Y-120 VOLT 1

4 781772 PUMP ASS’Y W/ELBOW 1

5

6

7

8

9

10

780253

773056

108022

151677

110051

704166-10

PUNCHED TANK W/STUD

AIR PUMP, POD

LIQUID LEVEL PROBE

DUAL TEMP THERM PROBE

ELBOW ¼ TUBE X 1/8 NPT

TANK HEATING ELEMENT

1

1

1

1

1

1

16

ELECTRICAL COMPONENTS

17

ELECTRICAL COMPONENTS CONT’D

ITEM # NEWCO PN DESCRIPTION

2

3

110626

102383

SWITCH, DPST, ON/OFF

SOLENOID FILL VALVE

4 105115 TRANSFORMER

QTY/EA

1

1

1

1

ERROR MESSAGES

Message - "THERMISTOR ERROR"

THERMISTOR IS OPEN OR SHORTED-REPLACE PN 151677

Message - "HIGH TEMP ERROR"

RAPID TEMPERATURE RISE-HEATER ON WITH LOW WATER LEVEL-

CHECK FILL VALVE OR WATER SUPPLY LINE

Message - "UPPER/LOWER MOTOR ERROR"

BREW CHAMBER DRIVE MOTOR ERROR-CHECK FOR JAM OR

OBSTRUCTION IN BREW CHAMBER

Message - "BOARD ERROR"

CONTROL BOARD WRITE ERROR-REPLACE BOARD IF MESSAGE

DOES NOT CLEAR PN 780225

Message - "FILL TIMEOUT ERROR"

WATER NOT REACHING LEVEL PROBE-CHECK WATER SUPPLY OR

CHECK FOR WATER LEAK

Message - "HEATER TIMEOUT ERROR"

WATER NOT HEATED DURING TIMEOUT PERIOD-CHECK HEATER

RELAY PN 110958 OR HEATING ELEMENT PN 704166-10(1700W US) OR

704161-10 (1400W CANADA) OR HI-LIMIT THERMOSTAT PN 111593

18

FLOW ADJUSTMENT CONTROL

VIEW FROM TOP OF MACHINE

COVER REMOVED

ONLY USED FOR

ADJUSTING

WATER FLOW

RATE

(FACTORY SET)

CALIBRATION

PUMP FLOW

ADJUSTMENT

COUNTER

CLOCKWISE

INCREASE

FLOW

CLOCKWISE

DECREASE

FLOW

19

WIRING DIAGRAM

BK

RD

GY

BK 24 VDC

BK

RD

RD

BK

RD

UPPER

DRIVE

MOTOR

+ -

GY

+

LOWER

DRIVE

MOTOR

RD

RD

RD

24 VDC

GY

RD

BK

HOT

WATER

TANK

BK

BK

DUAL

THERMISTOR

LOWER

SOLENOID

OR

12 VDC

BR

GY

WH

BL

YL

GY

COFFEE

PUMP

HOT

WATER

PUMP

12 VDC

+

-

120 VAC

AIR

PUMP

12 VDC

+

-

OR

RD

FILL

SOLENOID

120 VAC

RD

BK

UPPER

SOLENOID

12 VDC

BK WH

VIO/BK

HI-LIMIT

THER-

MOSTAT

BK

BK

WASTE

BIN

REED

SWITCH

RD

GY

RD

780225

6

5

2

1

GY

VIO/BK

TANK

HEATER

ELEMENT

VIO/BK

WH

CN6

CN7

BK

SWITCH/DISPLAY BOARD

4

3

BK

WH

BR

CN8

GY

6

CN4

5 4

3 2 1

LEDs

VIO/BK

HEATER

RELAY

12 VDC

COIL

-

+

BK

WH

CN2

PROGRAMMING

HEADER

780224

CONTROL

BOARD

RD

BK

BR

TANK

GND

LIQUID

LEVEL

PROBE

VIO/BK

VIO/WH

YL

BK/WH

BK

8

4 3 2 1

BK/WH

BR

BK/WH

CENTER

TAP

12/24 VAC

BK

BR

CN5

120 VAC

DPST

SWITCH

BK

WH

WH

POWER

CORD

CN1

TRANS

FORMER

GN

20

21

22