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Operating, Service, SINGLE TF 1.75 Gallon Operating

1. BLU to Ready Light BLU to RED Lead From Liquid Level Switch BLK to BLK Lead on Contactor Coil L BLK to Ready Light 2 118 100400 SERVICE cont DISPENSE VALVE Location Dispense valve is located inside the hood directly above the sprayhead Test Procedures 1 Disconnect the brewer from the power source NOTE ECA MODELS ONLY Brewer must be at operating temperature to perform step 2 or brew lock must be bypassed To bypass brew lock disconnect white yellow and orange wires from interlock of ECA and connect leads together 2 Disconnect the wires from the dispense valve and check the voltage across the white violet wire and white green wire Connect brewer to the power source Place the ON OFF switch in the position press and release the start switch The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 3 Disconnect brewer from the power source If voltage is present as described in step 2 proceed to 4 22 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness 4 Check for continuity across the dispense valve coil terminals If continuity is present as described reconnect the wires to the dispense valve brew loc
2. 0 A WHI ORA 615 GRINDER 200 240 VOLTS AC Page 44 27118 100400 SCHEMATIC WIRING DIAGRAM SINGLE BREWER ATF OR W SERVER SENSOR GRN LIMIT a ur Ya dl h BLK 12 TANS NENER RED 12 1 RED 12 5 ipi OVERFLOW PROTECTION SW BLK RED RED RED e N C RED RED BLK RED 3 SET SELECTOR SWITCH WITH GRINDER INTERFACE OPTION 1 4 BATCH E 19 BATCH mi 2 3 BATCH ORAS FULL BATOH SERVER 2 NO CONNECTION PNK 3 4 BATCH 4 SENSOR a BATCH COMMON 15 NI BYPASS jim 619 WHI VIO 25 WHI GRN s 5 WHI RED WU YEL YEL DISPENSE WHI ORA WHI ORA R Si GRINDER INTERFACE Page 45 2 118 100400
3. 7 Reconnect the pink wire to terminal 5 of the electronic control assembly 1 9 Remove the liquid level probe 7 from the tank lid and inspect it for mineral deposits Replace it if necessary Keep the exposed ends of the probe away from any metal surface of the dispenser 9 Check the voltage across terminals 1 amp 4 of the electronic control assembly 1 with a voltmeter Connect the brewer to the power source The indication must be 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models after a delay of approximately 1 sec ond b 200 to 240 volts ac for two wire 208 or 240 volt models after a delay of approximately 1 second 10 Touch the screw head end of the probe to the brewer housing The indication must be 0 11 Move the probe away from the brewer housing The indication must again be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models after a delay of approximately 1 sec ond b 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second Page 24 12 Disconnect the brewer from the power source If voltage was present as described reinstall the probe the sensing function of the system 15 operating properly If voltage was not present as described checkthe pink probe wire and the green ground wire for continuity and or replace the probe PROBLEM
4. If continuity is not present as described replace the safety overflow switch Page 32 Removal and Replacement 1 Disconnect the red leads from the overflow pro tection switch from the black wire from the termi nal block and the blue wire from the thermostat or black wire from electronic control assembly 2 Removethe nut beneath the copper overflow cup 3 Remove the entire switch assembly from the cup 4 Placethe new switch assembly into the cup wires first Make sure that a gasket is in place around the threaded switch stem NOTE The magnets must be at the top of float and there must be NO adjusting washers installed for the overflow protection switch to operate prop erly 5 Install the nut beneath the copper overflow cup Be sure not to overtighten 6 Referto the illustration below when reconnecting wires RED to BLK Wire from t RED to BLU Lead from Thermostat or to BLK Wire from Electronic Control Assy Terminal Block P1065 2 118 100400 SERVICE cont SERVER SENSOR Location The server sensor is attached to the bottom side of the server platform With brew selector switch in the 1 2 gallon position the server sensor will allow a brew cycle to start with a 1 2 gallon server only With brew selector switch in the 1 gallon or 1 3 4 gallon position the server sensor will allow a brew cycle to Start with a 1 3 4 gallon server only If the correct server is used for t
5. SINGLE TF 1 79 GALLON po Fal SE DISCONTINUED VERSION The information in this manual is no longer current OPERATING amp SERVICE MANUAL BUNN O MATIC CORPORATION POST OFFICE BOX 3227 SPRINGFIELD ILLINOIS 62708 3227 PHONE 217 529 6601 FAX 217 529 6644 2 118 0000C 10 00 1996 Bunn O Matic Corporation INTRODUCTION This equipment will brew a half gallon gallon or gallon and a three fourths batch of coffee into an awaiting server at the push of a button and includes a hot water faucet for allied beverage use The brewer is specifically designed for use with a BUNNS 5 gallon and 1 75 gallon server It is only for indoor use on a sturdy counter or shelf WARRANTY Bunn O Matic Corp Bunn warrants the equipment manufactured by itto be commercially free from defects in material and workmanship existing at the time of manufacture and appearing within one year from the date of installation In addition 1 Bunn warrants electronic circuit and or control boards to be commercially free from defects in material and workmanship for two years from the date of installation 2 Bunn warrants the compressor on refrigeration equipment to be commercially free from defects in material and workmanship for two years from the date of installation 3 Bunn warrants thatthe grinding burrs on coffee grinding equipment will grind coffee to meet original factory screen sieve analysis forthree years fro
6. LIQUID LEVEL CONTROL OVERFLOWS DEAN CUP RETRY DRAIN CUP 4 DISCONNECT PROBE IRE FROM PROBE 7 SHORT PROBE WIRE TO CHASSI RETRY Z O REPLACE PROBE 7 D lt lt e m o 42 lt m 42 DRAIN CUP 4 DISCONNECT WIRE FROM SOLENOID VALVE 12 RETRY YES REPLACE SOLENOID VALVE 12 NO REPLACE CONTROL ASSEMBLY 1 27118 100400 SERVICE cont ELECTRONIC CONTROL ASSEMBLY cont PROBLEM WATER NOT HOT ENOUGH NO TURN TEMPERATURE PED EN CONSTANTLY ADJUSTING SCREW 14 C CLOCKWISE CONTINUOUSLY MEASURE VOLTAGE AT TANK HEATER 5 lt m o n n 2 REPLACE CONTROL ASSEMBLY 1 VOLTAGE PRESENT REPLACE TANK 2 I m 2 o m REPLACE LIMIT LIMIT THERMOSTAT 6 OK THERMOSTAT 6 2 5 REPLACE CONTROL ASSEMBLY 1 MEASURE VOLTAGE AT TANK HEATER 5 REPLACE TRIAC 15 NO CHECK FOR SPLIT TANK HEATER 5 REINSTALL ORIGINAL CONTROL ASSEMBLY 1 VOLTAGE PRESENT YES RECHECK WATER TEMPERATURE PROBLEM WATER BOILS DRAIN CUP 4 RETRY REPLACE CONTROL ASSEMBLY 1 LED 11 13 ON WHILE BOILING NO DISCONNECT BLUE WIRE FROM CONTROL BOARD PIN RETRY CHECK FOR SPLIT TANK HEATER 5 STILL BOILING REPLACE TRIAC 15 NO REPLACE CONTROL ASSEMBLY 1 YES ADJUST FOR CORRECT WATER TEMPERARURE 844 P845 Temperature Control Test Procedure 3 Disconnect the brewer fr
7. 18 a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 5 Disconnect the brewer from the power source If voltage is present as described proceed to 6 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness 6 Check for continuity between the two black wires of the contactor coil If continuity is present as described reconnect one black wire to the white wire or red wire from the terminal block and the other black wire to the black wire from the control thermostat Reinstall capillary tube into tank to line 7 above the bulb and proceed to 1 If continuity is not present as described replace the contactor 7 Locate the white wire or red wire on L1 terminal and black wire on the L2 terminal on the contactor 8 Carefully check the voltage across the white or red and black wires with a voltmeter The indication must be a 120 volts ac for two wire 120 volt models 208 volts ac for three wire 120 208 volt models and 240 volts ac for three wire 20 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 9 Disconnect the brewer from the power source If voltage is present as described proceed to 710 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness 10 Check for conti
8. Brewer must be at operating temperature to perform step 3 or brew lock must be bypassed To bypass brew lock disconnect white yellow and orange wires from interlock of ECA and connect harness leads to gether 3 Check the voltage across the white green and the white violet wires with a voltmeter Connect the brewer to the power source With the ON OFF switch in the position the selector switch in the 1 or 1 3 4 gallon position press the start Switch The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 4 Disconnect the brewer from the power source If voltage is present as described proceed to 5 If voltage is not present as described refer to the wiring Page 15 diagrams and check the brewer wiring harness 5 Check for continuity across the bypass valve coil terminals If continuity is present as described reconnect the white green and white violet wires to the bypass valve brew lock wires if necessary and proceed to 6 If continuity is not present as described replace the bypass valve 6 Check the bypass valve for coil action Connect brewer to the power source With the ON OFF switch in the ON position press the start switch Listen carefully in the vicinity of the by pass valve fora clicking sound as the coil attracts and repels the plunger If the s
9. Remedy Equipment will not operate Brew 1 No power or incorrect voltage A1 Check the terminal block for cycle will not start 120 volts across the black and white terminals on 120 volttwo wire brew ers A2 Check the terminal block for 120 volts across the red and white terminals and the black and white terminals 120 208 or 120 240 volt brewers A3 Check the terminal block for 200 volts on Series brewers or 240 volts on A Series brewers across the red and black terminals B Check circuit breakers or fuses Brew cycle will not start 1 Server Make sure server size agrees with batch selection 2 No water Check plumbing and shut off valves Page 8 27118 100400 TROUBLESHOOTING cont Problem Brew cycle will not start cont Automatic refill will not operate Probable Cause 3 Water strainer flow control 500 GPM 4 ON OFF switch 5 Start switch 6 Timer 7 Dispense Valve 8 Control Assembly Electronic 9 Brew selector switch 10 Server sensor 1 No water 2 Water strainer flow control 500 GPM Page 9 Remedy A Direction of flow arrow must be pointing towards brewer B Remove the strainer flow con troland check for obstructions Clear or replace Refer to Service ON OFF switch for testing procedures See page 31 Refer to Service Start switch for testing procedures See page 35 Refer to Service Timer for testing procedures See page 38 o
10. be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models after a delay of approximately 1 sec ond b 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second 8 Touch the free end of jumper wire to the brewer housing The indication must be 0 9 Move the jumper wire away from the brewer housing The indication must again be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models after a delay of approximately 1 sec ond b 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second 10 Disconnect the brewer from the power source and remove the jumper wire from terminal 4 59 If voltage is present as described the level control board is operating properly proceed to 711 If voltage is not present as described replace the level control board 11 Reconnect the pink wire to terminal 4 12 Gently pull the probe out of the tank lid and inspect for corrosion Replace it if necessary 13 Place the probe so that neither end is in contact with any metal surface of the brewer 14 Check the voltage across terminals 1 amp 3 with a voltmeter Connectthe brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models after a delay of ap
11. check that the SET LOCK switch is in the SET position on the circuit board Place the ON OFF switch in the ON position press and hold the START switch until three distinct clicks are heard and then release the switch Failure to release the Switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory Page 41 20 L _ wn 8 I f MOO1 13S TIMER WIRING WHI YEL wire to TL5 WHI GRN wire to TL4 WHI ORA wire to TL3 WHI wire to TL2 120V Two Pole 120 208V or 120 240V Three Pole Terminal Block RED wire to TL2 200V or 240V Two Pole Terminal Block WHI VOI wire to TL1 View the level of the liquid being dispensed When the desired level is reached turn the ON OFF switch to OFF NOTE Several ounces of water will continue to syphon from the tank after turning the switch OFF The brewer remembers this volume and will continue to brew batches of this size until the volume setting procedure is repeated NOTE When brewing coffee volumes will de crease due to absorption by the coffee grounds Setting programming disable feature If it be comes necessary to prevent anyone from chang ing brew time once p
12. funnel over the server entrance with ON OFF switch in the ON position press the start switch and release it Check the water tem perature immediately below the sprayhead with a thermometer The reading should not beless than 195 F The nut on back of the solenoid must be tight or it will vibrate during op eration Plumbing lines should not be rest ing on the counter top A The brewer must be connected to a cold water line B Water pressure to the brewer must not be higher than 90 psi 620 kPa Install a regulator if necessary to lower the working pressure to approximately 50 psi 345 kPa Remove and clean lime off the tank heater Check for low voltage 27118 100400 SERVICE This section provides procedures for testing and replacing various major components used in this brewer should service become necessary Refer to Troubleshooting for assistance in determining the cause of any problem WARNING Inspection testing and repair of electri cal equipment should be performed only by qualified Service personnel The brewer should be unplugged when servicing except when electrical tests are re quired and the test procedure specifically states to plug in the brewer COMPONENT ACCESS WARNING Disconnect the brewer from the power source before the removal of any panel or the replace ment of any component All components are accessible by the removal of the top cover front inspection panel and warmer bas
13. remedies for the most likely problems encountered If the problem remains after exhausting the troubleshooting steps contact the Bunn O Matic Technical Service Department WARNING Problem Inspection testing and repair of electrical equipment should be performed only by qualified service personnel All electronic components have 120 240 volt ac and low voltage dc potential on their terminals shorting of terminals or the application of external voltages may result in board failure Intermittent operation of electronic circuit boards is unlikely Board failure will normally be permanent If an intermittent condition is encountered the cause will likely be a switch contact or loose connection at a terminal or crimp solenoid removal requires interrupting the water supply to the valve Damage may result if solenoids are energized for more than ten minutes without a supply of water The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened This will help avoid twists and kinks in the tubing Make certain that all plumbing connections are sealed and electrical connections tight and isolated This brewer is heated at all times Keep away from combustibles Exercise extreme caution when servicing electrical equipment Disconnect power source when servicing except when electrical tests are specified Follow recommended service procedures Replace all protective shields or safety notices Probable Cause
14. 0V 200V and 240V Red Insert BLU to Tank Heater BLU to Electronic Control 7 TAN to Tank Heater Switch 2 118 100400 SERVICE cont LEVEL CONTROL BOARD AND LEVEL PROBE Electro mechanical only Location The level control board is located inside the front in center of the brewer on the component bracket The level probe is located inside the hood on the center rear of the tank lid Test Procedure 1 Disconnect the brewer from the power source 2 Remove the violet wire from terminal 1 amp pink wire from terminal 4 of the circuit board 3 Check the voltage across terminals 2 amp 3 witha voltmeter Connectthe brewerto the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 4 Disconnect the brewer from the power source If voltage is present as described proceed to 5 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness Page 28 en Reconnect the violet wire to terminal 1 Carefully connect a piece of insulated jumper wire to terminal 4 Keep the other end of this wire away from any metal surface of the brewer Check the voltage across terminals 1 amp 3 with a voltmeter Connectthe brewertothe power source The indication must
15. 40 compound or equivalent It can be purchased direct from Bunn O Matic part number M2522 0002 1 Place the tank heater switch on the electronic control assembly in the OFF position 2 Completely drain the tank 3 Place a stryofoam or wood block between the center of the tank and the rear of the brewer 4 Disconnect triac wires white violet from terminal block blue from tank heater blue from electronic control and tan from tank heater switch Carefully set the brewer on its back 6 Remove the 2 dia hole plug from the bottom COVer d 10 11 12 13 14 15 16 Page 27 Remove the two 78 32 keps nuts securing tank to tank mounting bracket Remove the twelve 78 32 slotted head screws securing the bottom cover Remove the bottom cover with the four feet the tank mounting brackets triac heat sink as an assembly Remove triac heat sink from tank mount ing bracket and discard Install new triac heat sink assembly on tank mounting bracket Route the wires up around the rear of the brewer Reinstall the bottom cover four feet tank mounting brackets and triac heat sink to the bottom of the tank using two 8 32 keps nuts secure bottom cover to brewer base with twelve 8 32 slotted head screws otand the brewer upright Reconnect the wires of the new triac assembly Refer to the illustration below when reconnect ing wires WHIWIO to Terminal Block 120V White Insert 120 208V 120 24
16. CTION SW BLK RED RED BLU WHI U N C WHI WHI BLK pue WHI WHI 3 SET SELECTOR SWITCH WITH 3 Eau GRINDER INTERFACE OPTION 1 J See I WHI VIO GRY 1 4 1 AI WHI CBS AS REQUIRED 2 3 BATCH 3 SERVER FULL BATCH PLU NO CONNECTION 3 4 BATCH 4 SENSOR T PNK BATCH COMMON 15 16 RE I BYPASS in y WHINIO er WV WHUGRN m WHI RED i WHI RED YEL YEL DISPENSE WHI ORA WHI ORA 120 VOLTS AC 2 WIRE GRINDER 120 208 VOLTS AC OR INTERFACE 120 240 VOLTS AC 2 CONNECTOR 3 WIRE Sn mo comnmrrmc Page 43 27118 100400 SCHEMATIC WIRING DIAGRAM SINGLE BREWER ECA ATF amp W SERVER SENSOR GRN YEL 12 LIMIT pus MIeeer TANK HEATER BLCI2 de fep Buc SEP 7 E WHI BRN 20 Jmm __ WHUYEL 1 ELECTRONIC i GRN REFILL OVERFLOW CONTROL ASSY i WHI BLU 0 RED BLK RED RED N C BLK WHI VIO ue X RED RED y RED 2 1 4 WHINIO 1 3 BATCH FRACTIONAL BATCHES CONNECT 1 2 BATCH 5 REQUIRED FULL BATCH NO CONNECTION 2 3 BATCH PNK A 710 1 z 2 3 WHI GRN K gt 4 SENSOR PNK 1 earch common WHU YEL 5 5 cane 619 4 WHI VIO on WHI GRN WHI GRN S Es YEL VEL ORA ORA DISPENSE
17. FF position Models with electro mechanical thermostats Rotate the control thermostat knob fully counterclockwise to the OFF position 4 Feed the cord through the strain relief and connect it to the terminal block 5 Connectthe brewer to the power source and verify the voltage at the terminal block before proceeding Replace the front panel 6 If plumbing is to be hooked up later be sure the brewer is disconnected from the power source If plumbing has been hooked up the brewer is ready for Initial Set Up PLUMBING REQUIREMENTS This brewer must be connected to a cold water system with operating pressure between 20 and 90 psi 138 and 620 kPa from a or larger supply line A shut off valve should be installed in the line before the brewer Install a regulator in the line when pressure is greater than 90 psi 620 kPa to reduce it to 50 psi 345 kPa The water inlet fitting is 1 4 flare NOTE Bunn O Matic recommends 74 copper tubing for installations of less than 25 feet and for more than 25 feet from the gt water supply line A tight coil of copper tubing in the water line will facilitate moving the brewer to clean the countertop Bunn O Matic does not recommend the use of a saddle valve to install the brewer The size and shape of the hole made in the supply line by this type of device may restrict water flow This equipment must be installed to comply with the Basic Plumbing Code of the Building Officials and Code Administr
18. FUNNEL CONTENTS e USED ON HIGH FLAME OR EXPOSED ELECTRIC ARE HOT ELEMENTS 00658 0000 THIS APPLIANCE IS HEATED WHENEVER CONNECTED TO A POWER SOURCE A WARNING HOT WATER 00831 0000F 3 98 1988 BUNN O MATIC CORPORATION 00831 0000 20201 5600 This equipment is to be installed to comply with the Basic Plumbing Code of the Building Officials and Code Administrators International Inc BOCA and the Food Service Sanitation Manual of the Food and Drug Administration FDA 00656 0000 ELECTRICAL REQUIREMENTS CAUTION The brewer must be disconnected from the power source until specified in nitial Set Up NEUTRAL n AC 200 o 240V A C Y 205 or 240V A C T Y Requires 2 wire grounded ser Requires 3 wire grounded ser amp B models require 2 wire vice rated 120 volts ac 20 amp vice rated 120 208 volts or 120 240 grounded service rated 200 volts ac single phase 60 Hz volts 20 amp single phase 60 20 amp single phase 50 Hz Hz Page 3 27118 100400 Electrical Hook Up CAUTION Improper electrical installation will damage electronic components 1 electrician must provide electrical service as specified 2 Using a voltmeter check the voltage and color coding of each conductor at the electrical source 3 Remove the front panel beneath the sprayhead Models with electronic control assemblies Place the tank heater switch at the top of the control assembly in the O
19. Referto Service Dispense valve for testing procedures See page 22 Adjust the timer as required to achieve the recommended volume for each brew cycle Referto Service Dispense valve for testing procedures See page 22 Referto Adjustments on page 5 step For test procedures see page 15 BUNN paper filters should be used for proper extraction Check sprayhead The brew cycle should be started only with an empty server under the funnel Adjust the timer as required to achieve the recommended 224 07 for each 1 3 4 gallon brew cycle Refer to Service Timer for testing procedures See page 38 or 40 Refer to Service Dispense valve for testing procedures See page 22 27118 100400 TROUBLESHOOTING cont Problem Weak beverage Brewer is making unusual noises Probable Cause 1 Type of paper filters 2 Coffee 3 Sprayhead 4 Funnel loading 5 Water temperature 1 Solenoid Inlet 2 Plumbing lines 3 Water supply 4 Tank heater 5 Contactor Page 13 Remedy BUNN paper filters should be used for proper extraction A sufficient quantity of fresh drip or regular grind should be used for proper extraction sprayhead 01082 0002 Should be used to properly wet the bed of ground coffee in the funnel The BUNN paper filter should be centered in the funnel and the bed of ground coffee leveled by gentle shak ing Empty the server remove its cover Place empty
20. Valve p WHI GRN to Dispense Valve ORA toServer Sensor and Bypass Valve Pin 3 e WHI ORA to Start Switch E To Timer Electro mechanical e WHI ORA to Interlock Assy ud Electronic 7 E TAN GRY to GRY Lead on Interface Socket PNK to PNK Lead on Interface Socket TAN to TAN Lead on Interface Socket YEL to Server Sensor Pin 4 1 7 27118 100400 SERVICE cont CONTACTOR ASSEMBLY W MECHANICAL THER MOSTAT ONLY Location The contactor assembly is located inside the hood just behind the dispense valve Test Procedures Mechanical Thermostat 1 Disconnect the brewer from the power source 2 Disconnect the white wire of the two pole 120V terminal block white wire of the three pole 120 208V or 120 240V or the red wire of the two pole 200V or 240V terminal block and the black wire of the contactor coil and disconnect the black wire of the control thermostat from the remaining black wire of the contactor coil 3 Gently remove the capillary bulb and grommet from the tank 4 Check the voltage across the white wire from the terminal block on 120 120 208 120 240 volt units or the red wire from 200 240 volt units and the black wire from the control thermostat with a voltmeter when the thermostat is turned clock wise to the FULL ON position Connectthe brewer to the power source The indication must be Page
21. ators International Inc BOCA and the Food Service Sanitation Manual of the Food and Drug Administration FDA Plumbing Hook Up 1 Attachthe quickconnect fitting fromthe tubing supplied to the water inlet fitting on the bottom of the brewer 2 Flush the water line and securely attach it to the flare fitting on the tubing supplied 3 Turn on the water supply Page 4 2 118 100400 INITIAL SET UP CAUTION The brewer must be disconnected from the power source throughout the initial set up except when Specified in the instructions NOTE Models Only This brewer is equipped with a temperature sensor that indicates when to brew and when Selected locks out the start of a brew cycle until the water has heated to the optimum brewing temperature 1 Remove the front panel beneath the sprayhead Models with electronic control assemblies Place the tank heater switch at the top of the control assembly in the OFF position Models with electro mechanical thermostats Rotate the control thermostat knob fully counterclockwise to the OFF position Connect the brewer to the power source Water will begin flowing into the tank When water stops flowing into the tank remove the front panel and proceed as directed Models with electronic control assemblies Place the tank heater switch at the top of the control assembly in the ON position and replace the front panel Models with electro mechanical thermostats Ro
22. ble Bunn shall at its sole option replace the equipment or refund the purchase price for the equipment THE BUYER S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT WHETHER DERIVED FROM WARRANTY OR OTHERWISE SHALL BE LIMITED AS SPECIFIED HEREIN TO REPAIR OR AT BUNN S SOLE OPTION REPLACEMENT OR REFUND Inno event shall Bunn 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 Page 2 27118 100400 USER NOTICES The notices on this brewer should be kept in good condition Replace unreadable or damaged labels A warnne AWARNING Fill water tank before turning on thermostat or connecting appliance to power source Use only on a properly protected circuit capable of the rated load Electrically ground the chassis Follow national local electrical codes READ THE ENTIRE OPERATING MANUAL BEFORE USING THIS PRODUCT Do not use near combustibles FAILURE TO COMPLY RISKS INJURY FAILURE TO COMPLY RISKS EQUIPMENT DAMAGE FIRE OR SHOCK HAZARD READ THE ENTIRE OPERATING MANUAL BEFORE BUYING OR USING THIS PRODUCT DISCARD DECANTER 21 CRACKED SCRATCHED 41 BOILED DRY a HEATED WHEN EMPTY
23. bracket 1 Disconnect the brewer from the power source 2 Locate the blue wires on the control thermostat 3 Check the voltage across the blue wires on the control thermostat and the white insert on the two or three pole 120V 120 208V 120 240V terminal block and the red insert ontwo pole 200V or 240V terminal blocks with a voltmeter Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 4 Disconnect the brewer from the power source If voltage is present as described reconnect the wire and proceed to 5 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness 5 Locate the black wires on the control thermostat 6 Gently remove the capillary bulb and grommet from the tank 7 Check the voltage across the black wires of the control thermostat and the white insert on the two pole or three pole 120V 120 208V or 120 240V terminal blocks and the red insert on two pole 200V 240V terminal blocks with a voltmeter when the control thermostat is turned ON fully clock wise Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200
24. cks in the sheath 2 118 100400 SERVICE cont TANK HEATER cont Electronic Control Models 1 Disconnect the brewer from the power source 1 2 2 Disconnect wires from heater 3 Check for continuity across the tank heater ter minals 3 4 If continuity is present as described the tank heater is operating properly 2 If continuity is not present as described replace the tank heater NOTE If the tank heater remains unable to heat remove and inspectthe heater for cracks in the sheath BLK to Contactor T2 RED to Contactor T1 ELECTRO MECHANICAL Page 37 Removal and Replacement Remove wires from tank heater Remove the four 78 32 nuts securing tank heat to tank lid Remove tank heater and gasket Install new tank heater and gasket with four 8 32 nuts on tank lid Refer to the illustration below when reconnect ing the wires LY LY BLK to Limit Thermostat BLU Lead from Triac Assy ELECTRONIC 27118 100400 SERVICE cont TIMER First Type Location The timer is located inside the left front of the brewer on the upper part of the component bracket Test Procedures 1 Disconnect the brewer from the power source 2 Disconnect the wires from the timer terminals TL3 TL4 and TL5 and rotate the dial s fully counterclockwise 3 Check the voltage across ter
25. ctronic controlled 200 or 240 volt brewers If continuity is not present as described replace the Page 34 4 Disconnect the brewer from the power source If voltage is present as described proceed to 75 If voltage is not present as described refer to the wiring diagrams and check brewer wiring harness 5 Check for continuity across the solenoid valve coil terminals solenoid valve 6 Check the solenoid valve for coil action Connect the brewer to the power source Listen carefully in the vicinity of the solenoid valve for a clicking sound after approximately 1 second as the coil magnet attracts 7 Disconnect the brewer from the power source If the sound is heard as described and water will not pass through the solenoid valve there may be a blockage in the water line before or after the solenoid valve or the solenoid valve may require inspection for wear and removal of waterborne particles If the sound is not heard as described replace the solenoid valve Removal and Replacement Remove all wires from the solenoid valve coil Turn off the water supply to the brewer Disconnect the water lines to and from the sole noid valve 4 Remove the two 710 32 slotted head screws and lockwashers holding the solenoid valve to the upper component bracket 5 Lift out the solenoid valve 6 Securely install the new solenoid valve to the upper component bracket 7 Securely fasten the water lines to and from the solen
26. e plate The top cover is attached with one 4 40 slotted head screw The front inspection panel is attached with four 6 32 slotted head screws The server plateform is attached with seven 6 32 Slotted head screws Page 14 Contents Brewer Selector 16 15 Contactor 0 18 Control Thermostat ness 20 Dispense Valve 22 Electronic Control 23 thru 27 Level Control Board and Level Probe 26 Limit 200 30 ON OFF Switch 31 Overflow Protection Switch 32 Proximity Sensor 33 34 vitz udi cm 35 Tank 2 2 2 0 0021 36 30 40 Wiring 42 thru 45 27118 100400 SERVICE cont BYPASS VALVE Location The bypass valve is located inside the right front of the hood Test Procedures 1 Disconnect the brewer from the power source and place a 1 3 4 gallon server under funnel 2 Disconnect the white green wire and the white violet wire from the bypass valve NOTE ECA MODELS ONLY
27. ee wire 120 208 volt models and 240 volts ac for three wire 120 240 volt models while the red indicator on the circuit board is on or blinking b 200 to 240 volts ac for two wire 200 or 240 volt models while the red indicator on the circuit board is on or blinking Disconnect the brewer from the power source 2 118 100400 SERVICE cont ELECTRONIC CONTROL ASSEMBLY cont If voltage was present as described the temperature control of the system is operating properly If voltage was not present as described contact Bunn O Matic to order an electronic control assembly 1 temperature sensor 8 and triac assembly 15 for revaluation and proceed to 79 9 Replace the electronic control assembly 1 and temperature sensor 8 NOTE each electronic control assembly is calibrated to atemperature sensor Both components MUST be replaced as a set 10 Checkthe voltage across the tank heater terminals 5 with a voltmeter Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models 208 volts ac for three wire 120 208 volt models and 240 volts ac for three wire 120 240 volt models while the red indicator on the circuit board is on or blinking b 200 to 240 volts ac for two wire 200 or 240 volt models while the red indicator on the circuit board is on or blinking 11 Disconnect the brewer from the power source If voltage was present as described return the new triac as
28. electthe 1 gallon or 1 3 4 gallon setting on the brew selector switch 8 Check for continuity between the white yellow wire disconnected from timer terminal TL5 and the orange wire pin 3 on the server sensor terminal plug of the wiring harness and the start switch depressed 9 Reconnect the white yellow to timer terminal TL5 and brew lock if necessary 10 Disconnect the pink wire from timer terminal TL3 11 Check continuity between the pink wire removed from timer terminal TL3 and the pink wire pin 5 on the server sensor terminal plug of the wiring harness 12 Reconnect the pink wire to timer terminal TL3 If continuity is present as described the server sensor wiring is operating properly Replace the server sensor If continuity is not present as described refer to the wiring diagrams and check brewer wiring harness Removal and Replacement 1 Remove the four 76 32 slotted head screws securing the server platform to the brewer base 2 Liftserver platform high enough to be able to discon nect the server sensor terminal plug from the terminal plug on the wiring harness Disconnect the plugs 3 Turn the server platform over and remove the two 8 32 Keps nuts securing the server sensor to the weld stud on the server platform 4 Remove the server sensor leaving the two spacers in place 5 Install new server sensor on the weld studs and secure with two 78 32 Keps nuts 6 Reconnect the terminal plug on the server sens
29. eter Connect brewer to power source The indication must be 120 volts ac for two wire 120 volt models 208 volts ac for three wire 120 208 volt models and 240 volts ac for three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 3 Disconnect brewer from the power source If voltage was present as described proceed to 4 If voltage was not present as described refer to the wiring diagrams and check the brewer wiring harness 4 Remove the pink wire from terminal 5 of the electronic control assembly 1 5 Check the voltage across terminals 1 amp 4 of the electronic control assembly 1 with a voltmeter Connect brewer to the power source The indica tion must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 2 118 100400 SERVICE cont ELECTRONIC CONTROL ASSEMBLY cont 120 240 volt models after a delay of approximately 1 second 0 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second 6 Disconnect the brewer from the power source If voltage was present as described the liquid level control system is operating properly proceed to If voltage was not present as described replace the electronic control assembly 1 and temperature sensor 8 in the tank lid NOTE Each electronic control assembly is calibrated to atemperature sensor Both components MUST be replaced as a set
30. g harness 15 Check for continuity across the white orange and yellow wires on the selector switch when the switch is in the 1 2 gallon position Continuity must not be present in any other position 16 Check for continuity across the white orange and Orange wires on the selector switch when the switch is inthe 1 gallon and 1 3 4 gallon position Continuity must not be present in any other posi tion 17 Reconnect the yellow white orange and orange wires If continuity is present as described the switch is operating properly If continuity is not present as described replace the switch Removal and Replacement 1 Disconnect the connector on the selector switch harness from the brewer timer circuit board 2 Disconnect wires from the selector switch inter face socket dispense valve bypass valve and proximity sensor harness 3 Loosen the set screw on the switch knob 4 Remove the 9 16 nut and washer holding the switch to the hood 2 118 100400 SERVICE cont 8 Reattach the connector to the brew timer circuit board 9 Refer to the illustration below when reconnecting 5 Remove the switch the wires 6 Install the new switch The positioning tab must be in the hole in the hood for proper switch and knob alignment 7 Install the knob so that the arrow lines up in the 1 3 4 gallon position when the switch is turned to the full right position WHI RED to Dispense Valve WHI VIO to By Pass
31. h terminals 2 Compress the clips inside the hood and gently push the switch through the opening Page 35 2 118 100400 SERVICE cont TANK HEATER Location The tank heater is located inside the hood on the right rear of the tank lid Test Procedure Electro Mechanical Models 1 Disconnect the brewer from the power supply 2 Checkthe voltage across the black and the red wire on 120V 208 or 240V models on the tank heaters With the control thermostat turned to the ON position fully clockwise connect the brewer to the power supply and checkthe voltage across the wires with a voltmeter The indication should be 120 volts ac for two wire 120 volt models 208 volts ac for three wire 120 208 volt models and 240 volts ac for three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 3 Disconnect the brewer from the power supply Page 36 If voltage is present as described proceed to 74 If voltage is not present as described refer to the wiring diagrams and check the wiring harness 4 Disconnect wires from the tank heater 5 Check for continuity across the terminals of the tank heater If continuity is present as described reconnect the wires the tank heater is operating properly If continu ity is not present as described replace the tank heater NOTE If the tank heater remains unable to heat remove and inspect the heater for cra
32. h through the opening 3 Pushthe new switch into the opening and spread the clips to hold switch in the hood 4 Refer to the following below when reconnecting the wires BLK to Terminal WHI to Terminal Block Black Block White Insert Insert on 120V 120 208V or 120 240V Models RED to Terminal Block Red Insert on 200V 240V Models WHI VIO to Timer 1 2 118 100400 SERVICE cont OVERFLOW PROTECTION SWITCH Location The overflow protection switch is located inside the hood on the tank inside the copper overflow cup To test the overflow protection switch access will also be needed to the level control board or electronic control assembly and terminal block Test Procedure 1 Disconnect the brewer from the power source 2 Remove the wire nuts connecting the red wires from the overflow protection switch to the black wire from the terminal block and blue wire from the thermostat or the black wire from the electronic control assembly 3 Check for continuity across the safety overflow switch red wires only until the plastic float is raised and check that continuity returns when the plastic float is again lowered If continuity is present as described reconnect the red wires to the black wire from the terminal block and the blue wire from the thermostat or black wire from electronic control assembly
33. he selected batch size and the brew cycle will not start procede with the test procedures Test Procedures 1 Disconnect the brewer from the power source 2 Disconnect the terminal plug on the wiring harness from terminal plug on the server sensor 3 Check the voltage across the gray wire 1 and the white wire or red wire pin 2 on the wiring harness with a voltmeter and with the ON OFF switch in the ON position Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac on two wire 200 or 240 volt models 4 Disconnect the brewer from the power source If voltage is present as described proceed to 5 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness Page 33 NOTE ECA MODELS ONLY Brewer must be at operating temperature to perform step 5 or brew lock must be bypassed To bypass brew lock disconnect white yellow and orange wires from interlock of ECA and connect harness leads together 5 Disconnectthe white yellow wire from timer terminal TL5 6 Check for continuity between the white yellow wire disconnected from timer terminal TL5 and the yellow wire pin 4 on the server sensor terminal plug of the wiring harness with the brew selector switch in the 1 2 batch position and the start switch depressed S
34. k 9 Dispense Valve Timer 10 Bypass Valve Liquid Level Switch 11 Ready Light amp Overflow Cup 12 Solenoid Valve Tank Heater 13 LED Limit Thermostat 7 Liquid Level Probe Electronic Control pee Ds D 15 Assy 16 Server Sensor Location The electronic control assembly 1 is located inside the lower left front on the component bracket of the brewer Access will also be needed to the tempera ture sensor 8 liquid level probe 7 located on the tank lid and to the triac assembly 15 located beneath the tank General This system controls the liquid level and water temperature of the brewer These two functions act independently of each other and should be tested separately BREW START LOCK The water must be heated to the preset tempera ture indicated by the glowing ready light before a brew Page 23 14 Temperature Adjustment cycle can be initiated If the ready light goes out during a brew cycle the cycle will continue until it is completed You must wait until the ready light glows before starting another brew cycle PROBLEM LIQUID LEVEL CONTROL SYSTEM DOES NOT REFILL REMOVE POWER DRAIN CUP 4 RETRY VOLTAGE PRESENT AT SOLENOID VALVE 12 REPLACE CONTROL ASSEMBLY 1 Liquid Level Control Test Procedure 1 Disconnect brewer from the power source 2 Check the voltage across terminals 3 amp 4 of the electronic control assembly 1 with a voltm
35. k wires if neces sary and proceed to 75 If continuity is not present as described replace the dispense valve 5 Checkthe dispense valve for coil action Connect the brewer to power source Place the ON OFF switch in the ON position press and release the Start switch Listen carefully in the vicinity of the dispense valve for a clicking sound as the coil magnet attracts and repels the plunger 6 Disconnect the brewer from the power source If the sound is heard as described there may be a blockage in the dispense valve or the water line to the Sprayhead Remove the dispense valve and inspect for wear and remove waterborne particles If the sound is not heard as described replace the dispense valve Removal and Replacement 1 Disconnect wires from dispense valve 2 Drain enough water from the tank so the dispense valve is above the water line 3 Remove water lines and hose barb fitting from dispense valve 4 Remove dispense valve from the sprayhead panel 9 Install new dispense valve 6 Reconnect the water lines hose barb fitting and the wires to the dispense valve 7 Refer to the illustration below when reconnecting wires WHIIO to Timer WHI VIO to ON OFF Switch WHI RED to Brew Selector Switch WHI GRN to Timer TL4 gt WHI GRN to By Pass Valve 27118 100400 SERVICE cont ELECTRONIC CONTROL ASSEMBLY 8 Temperature Sensor Terminal Bloc
36. llon server under funnel Select a 1 gallon batch and repeat 6 The voltage indication should remain for approximately 40 seconds Select a 1 3 4 gallon batch and repeat 6 The indication should remain approximately 1 minute 9 Reconnect brew lock wires if necessary If voltage is present as described timer is operating properly If voltage is not present as described replace the timer Removal and Replacement 1 Remove all wires from the timer 2 Remove the four 76 32 slotted head screws hold ing circuit board and dial plate on to the compo nent mounting bracket 3 Remove circuit board nylon spacers and dial plate 4 Install new dial plate and circuit board with nylon Spacers to component mounting bracket 5 Refertothe illustration on the following page when reconnecting wires 6 Adjust timer dial s as required 27118 100400 SERVICE cont TIMER First Type cont WHI VIO TL1 to ON OFF Switch WHI VIO TL1 to Server Sensor WHI TL2 to Terminal Block and Server Sensor 120V Two Pole 120 208V or 120 240V Three Pole Terminal Block __ RED TL2 to Terminal Block and Server Sensor 200V or 240V Two Pole Terminal Block PNK to Server Sensor PNK Pin 5 WHI GRN TL4 to Dispense Valve WHI YEL TL5 to Start Switch Page 39 2 118 100400 SERVICE cont DIGITAL TIMER SecondType Location The time
37. m date of installation orfor 30 000 pounds of coffee whichever comes first This warranty does not apply to any equipment component or part that was not manufactured by Bunn or that in Bunn s judgement has been affected by misuse neglect alteration improper installation or operation improper maintenance or repair damage or casualty 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 Bunn are not authorized to make modifications to this warranty or to make additional warranties that are binding on Bunn Accordingly statements by such individuals whether oral or written do not constitute warranties and should not be relied upon The Buyer shall give Bunn prompt notice of any claim to be made under this warranty by telephone at 217 529 6601 or by writing to Post Office Box 3227 Springfield Illinois 62708 3227 If requested by Bunn the Buyer shall ship the defective equipment prepaid to an authorized Bunn service location If Bunn determines in its sole discretion that the equipment does not conform to the warranty Bunn shall repair the equipment with no charge for parts during the warranty period and no charge for labor by a Bunn Authorized Service Representative during the warranty period If Bunn determines that repair is not feasi
38. minals TL1 and TL2 with a voltmeter when the ON OFF switch is in the ON position Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 4 Disconnect the brewer from the power source If voltage is present as described reconnect pink wire to TL3 white green wire to TL4 white yellow wire to Page 38 TL5 and proceed to 75 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness NOTE ECA MODELS ONLY Brewer must be at operating temperature to perform step 5 or brew lock must be bypassed bypass brew lock discon nect white yellow and orange wires from interlock of ECA and connect harness leads together 5 Place 1 2 gallon server under the funnel and select 1 2 gallon position on selector switch 6 Check the voltage across terminals TL1 and TL4 with a voltmeter when the ON OFF switch is in the ON position Connect the brewer to the power source and press the start switch The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models for approximately 20 seconds for 1 2 gallon batch b 200 to 240 volts ac for two wire 200 or 240 volt models for approximately 20 seconds for 1 2 gallon batch Place 1 3 4 ga
39. nd stops brewing Stopping a brew cycle after it has been started will not stop the flow of water from the funnel Placing the switch the lighted upper position supplies power to the server sensor and enables the brew circuit START SWITCH Momentarily pressing and releasing this switch starts a brew cycle when the On Off switch is in the lighted upper position NOTE The On Off switch must be in the lighted upper position to initiate and complete a brew cycle COFFEE BREWING 1 Select the desired batch size 2 Insert a BUNN filter into the funnel 3 Pour the proper amount of fresh coffee into the filter and level the bed of grounds by gently shaking 4 Slide the funnel into the funnel rails 5 Place an empty server under the funnel Make sure server size agrees with batch selection 6 Place the On Off switch in the lighted upper position Momentarily press and release the start switch 7 When brewing is completed simply discard the grounds and filter CLEANING 1 he use of a damp cloth rinsed in any mild non abrasive liquid detergent is recommended for cleaning all surfaces on Bunn O Matic equipment 2 Checkand clean the sprayhead The sprayhead holes must always remain open NOTE In hard water areas this may need to be done daily It will help prevent liming problems in the brewer and takes less than a minute Page 7 27118 100400 TROUBLESHOOTING A troubleshooting guide is provided to suggest probable causes and
40. nuity across the terminals on the left side of the contactor by manualy closing the contacts Continuity must not be present when the contact is released 11 Check for continuity across the terminals on the right side of the contactor by manualy closing the contacts Continuity must not be present when the contact is released 2 118 100400 SERVICE cont CONTACTOR ASSEMBLY W MECHANICAL THER MOSTAT ONLY cont If continuity is present as described the contactor is operating properly If continuity is not present as described replace the contactor Removal and Replacement 1 Remove all wires from the contactor 2 Remove the two 710 32 slotted head screw secur ing contactor to the inside of the hood securely install the new contactor inside the hood 4 Refer to the illustration below when reconnecting the wires i WHI L1 to Terminal Block BLK 2 toTank Heater White Insert RED L1 to Terminal Block Red Insert BLK L2 to Limit Thermostat RED T1 to Tank Heater BLK to WHI Lead from the Two Pole 120V Terminal Block BLK to WHI Lead from the Three Pole 120 208V or 120 240V Terminal Block BLK to Red Lead from the Two Pole 200V or 240V Terminal Block EE MECHANICAL THERMOSTAT ONLY Page 1 9 2 118 100400 SERVICE cont CONTROL THERMOSTAT Location The control thermostat is located inside the lower left front of the brewer on the component
41. oid valve 0 Referto the illustration below when reconnecting the wires WHI to Level Control Board T3 120V 120 208V 120 240V Electro mechanical Whi to Control Assy 74 120V Electronic RED to Level Control Board T3 200 or 240V Electro mechanical or RED to Control Assy T4 200 or 240V Electronic VIO to Level Control Board 1 Electro mechanical WHI BLU to Control Assy 1 Electronic 27118 100400 SERVICE cont 3 Push the new switch into the opening and spread START SWITCH the clips to hold the switch in the hood 4 Refer to the following illustration when reconnect ing the wires WHI ORA to Brew Selector Switch Electro mechanical ORA to Interlock Assy Electronic WHI YEL to Timer TL5 Location The momentary start switch is located in front of hood just to the left of the ON OFF switch Test Procedure 1 Disconnect the brewer from the power source and remove the wires from both terminals of the switch 2 Check for continuity across the two terminals on the switch when it is held in the lower position Continuity must not be present across these ter minals in the upper position If continuity is present as described reconnect the wires the switch is operating properly If continuity is not present as described replace the switch Removal and Replacement 1 Remove all wires from the switc
42. ol assembly board 4 Remove the temperature sensor from the grom met in the tank lid 9 Install the new temperature sensor into the grom met on the tank lid Route the wires to the location of the new electronic control assembly 6 Attach the temperature sensor and ready indicator wires to the electronic control assembly 7 Fasten the new electronic control assembly to its bracket 9 Reconnect the wires 9 Referto the illustrationon next page when recon necting the wires 10 Review the initial set up procedures and adjust the control as required for the desired temperature 2 118 100400 SERVICE cont ELECTRONIC CONTROL ASSEMBLY cont GRY amp GRY to InterLock Assy WHI amp WHI to Temperature Sensor PNK Top amp GRY Bottom to Interlock Assy PNK Top amp GRY Bottom from LED ___ 7 BLU from Triac Assy ____ 6 WHI BRN to Tank Heater Switch TAN from Triac Assy to Tank Heater Switch 5 PNK to Liquid Level Probe 4 RED to Terminal Block Red Insert on 120 208 120 240 200 or 240 Volt Models Nate to Terminal Block White insert on 120V Models SN 3 VIO i RED Lead from Liquid Level Switch 2 GRN to Ground 1 WHI BLU to Solenoid Triac Assembly Removal and Replacement NOTE each triac installation requires the use of an approved silicone heat sink compound 0 Matic recommends the use of Dow Corning 3
43. olts If voltage indications are otherthan described discon nectthe brewer from the power source and replace the timer 6 Check the voltage across terminals TL1 and TL4 with a voltmeter when the ON OFF switch is in the ON position Connect the brewer to the power source and press the start switch The indication must be a 120 volts acfortwo wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models If voltage indications are otherthan described discon nect the brewer from the power source and replace the timer 7 Remove the test equipment and connect all wires as described below Removal and Replacement NOTE Do notremove or install wires whiletimer board is installed Pressure applied to one side may cause damage to the board 1 Remove the four 76 32 screws securing circuit board to component mounting bracket 2 Remove circuit board and nylon spacers 3 Remove all wires from the timer 4 Attach all wires to the replacement timer board prior to installation to the component mounting bracket Refer to illustration below when recon necting the wires 9 Install new circuit board with nylon spacers to component mounting bracket using two 76 32 screws 6 Adjust the timer as described below 27118 100400 SERVICE cont TIMERS Second Type cont Timer Setting NOTE Check that the brewer is connected to
44. om the power source Check the voltage across terminals 3 amp 4 of the electronic control circuit board with a voltmeter Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models 208 volts ac for three wire 120 208 volt models and 240 volts ac for three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models Disconnect the brewer from the power source If voltage was present as described proceed to 4 If voltage was not present as described refer to the wiring diagrams and check the brewer wiring harness 4 D 6 Connect the brewer to the power source and place the tank heater switch in the ON position Observe the red LED indicator on the electronic control circuit board 13 Disconnect the brewer from the power source If the indicator was on or blinking the temperature sensor is operating properly proceed to 77 If the indicator was off check the sensor connection on the electronic control circuit board and or replace the temperature sensor 8 and the electronic control assembly 1 NOTE each temperature sensor is calibrated to an Page 25 electronic control assembly Both components MUST be replaced as a set Checkthe voltage across the tank heater 5 termi nals with a voltmeter Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models 208 volts ac for thr
45. on 200V or 240V Brewers T2 BLU fromThermostat T1 VIO to Solenoid Coil Page 29 2 118 100400 SERVICE cont LIMIT THERMOSTAT Removal and Replacement 1 Remove all wires from the limit thermostat termi nals 2 Carefully remove the two 8 32 nuts securing the limit thermostat to tank lid and remove limit ther mostat 3 Carefully secure new limit thermostat to tank lid 4 Refer to the illustration below when reconnectng the wires BLK to Terminal BLK to Tank Heater Block Black Insert Left Terminal BLK to Contactor Terminal Location The limit thermostat is located inside the hood on the tank lid just to the left of the tank heater Test Procedure 1 Disconnect the brewer from the power supply 2 Disconnect both black wires from the limit ther mostat 3 Check for continuity across the limit thermostat terminals with a ohmmeter If continuity is present as described reconnect the black wires to the limit thermostat the limit thermo Stat is operating properly If continuity is not present as described press the reset button on the limit thermostat and repeat step 3 After repeating step 3 no continuity is shown replace the limit thermostat Page 30 27118 100400 SERVICE cont ON OFF SWITCH Location The ON OFF switch is located on the front of the hood in the center to the righ
46. or 240 volt models Voltage must not be indicated across these termi nals when the thermostat is turned OFF fully counterclockwise 8 Disconnect the brewer from the power source If voltage is present as described reinstall the capil lary tube into the tank to the line 7 above the bulb the control thermostat is operating properly If voltage is not present as described replace the thermostat Page 20 2 118 100400 SERVICE cont CONTROL THERMOSTAT cont Removal and Replacement 1 2 Remove wires from the control thermostat Remove the thermostat capillary bulb by firmly pulling up on the capillary tube at the tank lid This will disengage the grommet from tank lid Remove the 8 32 slotted head screw holding the control thermostat to the component bracket slide the grommet to the line 7 above the bulb on the new capillary tube Insert the capillary bulb through the hole in the tank lid and press the grommet firmly and evenly so thatthe groove in the grommet fits into the tank lid Carefully bend the capillary tube so that the tube and bulb inside the in the vertical position Page 21 NOTE The capillary tube must be clear of any electri cal termination and not kinked 7 Using a 78 32 slotted head screw fasten the con trol thermostat to the component bracket 0 Referto the illustration below when reconnecting the wires 9 Adjust the control thermostat as required
47. or to the terminal plug on the wiring harness 7 Reinstall server platform on the brewer base using four 6 32 Slotted head screws 27118 100400 SERVICE cont SOLENOID VALVE Inlet Location The inlet solenoid valve is located inside the hood on the right side of the upper component bracket Test Procedure 1 Disconnect the brewer from the power source Remove both wires from the solenoid valve coil terminals 3 Check the voltage across the removed wires a White and violet wires on 120 120 208 and 120 240 volt electro mechanical controlled brew ers b White and white blue on 120 120 208 and 120 240 volt electronic controlled brewers c Redand violet wires on 200 or 240 volt electro mechanical control brewers d Red and white blue on 200 or 240 volt elec tronic controlled brewers with a voltmeter Connect the brewer to the power source The indication must be e 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models f 200 to 240 volts ac for two wire 200 or 240 volt models If continuity is present as described reconnect the white and violet wires on the electro mechanical con trolled 120 120 208 and 120 240 volt brewers white and white blue on electronic controlled 120 120 208 and 120 240 volt brewers red and violet on electro mechanical controlled 200 or 240 volt brewers and red and white blue on ele
48. ound is heard as described there may be a blockage in the water line before the bypass valve or the bypass valve may require inspection for wear and removal of waterborne particles If the sound is not heard as described replace the bypass valve Removal and Replacement 1 Remove the wires from the bypass valve 2 Drain enough water from the tank so bypass valve is above the water line 3 Remove water lines from valve 4 Removetwonuts retaining bypass valve inside the hood and remove bypass valve 5 Remove hose barb fitting and attach to new by pass valve 6 Install new bypass valve with hose barb fitting Reconnect the water tubes and the wires to the bypass valve 0 Referto the illustration below when reconnecting the wires WHI GRN to Dispense Valve WHI VIO to Brew Selector Switch 2 118 100400 SERVICE cont BREW SELECTOR SWITCH Location The brew selector switch is located in the front right side of the hood Test Procedure Timer 1 Disconnect the brewer from the power supply 2 separate the connector on the selector switch harness from the brew timer circuit board 3 Carefully slide the plastic cover off of the con nector from the switch harness 4 Check for continuity across the pink and tan wires on the connector when the switch is in the 1 2 gallon position Continuity must not be present in any other switch position 5 Check for continuity acro
49. procedures See page 28 Refer to Service Electronic con trols fortesting procedures See page 23 thru 27 Refer to Service Solenoid valve for testing procedures See page 34 Referto Service Selector switch for testing procedures See page 16 Refer to Service Timer for testing procedures See page 38 or 40 Referto Service Level control board for test procedures See page 28 Refer to Service Control assembly for testing procedures See page 23 thru 27 Refer to Service Overflow protec tion switch for testing procedures oee page 32 Refer to Service Solenoid valve for testing procedures See page 34 Refer to Service Limit thermostat for testing procedures See page 30 2 118 100400 TROUBLESHOOTING cont Problem Water from tank is not hot cont spitting or unusual steaming from Sprayhead or airvent Probable Cause 2 A Control Thermostat Electro mechanical B Control assembly Electronic 3 Contactor Electro mechanical 4 Tank heater Triac assembly Electronic 1 A Control thermostat Electro mechanical B Control assembly Electronic 2 assembly Electronic 3 Lime build up CAUTION Tank and tank compo nents should be delimed regularly depending on local water conditions Excessive mineral build up on stain less steel surfaces can initiate cor rosive reactions resulting in serious leaks Page 11 Remedy Refer to Service Cont
50. proximately 1 second b 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second 15 Move the probe s flat end to the brewer housing The indication must be 0 16 Move the probe s flat end away from the brewer 27118 100400 SERVICE cont LEVEL CONTROL BOARD AND LEVEL PROBE Electro mechanical only cont housing The indication should again be a 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second 17 Disconnect the brewer from the power source If voltage is present as described reinstall the probe the level control board and level probe are operating properly If voltage is not present as described check the pink probe wire for continuity Removal and Replacement 1 Remove all wires from the level control board 2 Remove two 78 32 slotted head screws and lockwashers holding level control board to com ponent bracket 3 Install the new level control board to the compo nent bracket Make certain that the lockwashers are between the level control board and the com ponent bracket 4 Referto the illustration below when reconnecting the wires T4 PNK to Probe T8 WHI to Terminal Block White Insert on 120V Two Wire 120 208V or 120 240V Three Wire Brewers T3 RED to Terminal Block Red Insert
51. r 40 Refer to Service Dispense valve for testing procedures See page 22 Refer to Service Electronic con trols for testing procedures See pages 23 thru 27 Refer to Service Brew selector switch for testing procedures See page 16 Refer to Service Server sensor for testing procedures See page 33 Check plumbing and shut off valves A Direction of flow arrow must be pointing towards brewer B Remove the strainer flow con troland check for obstructions Clear replace 27118 100400 TROUBLESHOOTING cont Problem Automatic refill will not operate cont Beverage level will not adjust Selec tor switch in any position Water flows into tank continuously ON OFF Switch ON Water flows into tank continuously ON OFF Switch OFF Water from tank is not hot Probable Cause 3 Overflow protection switch 4 A Level control board amp level probe Electro mechanical B Control Assembly Electronic 5 Solenoid Valve 1 Selector switch 1 Timer 1 A Level control board and level probe Electro mechanical B Control assembly Electronic 2 Overflow protection switch 3 Solenoid Valve 1 Limit thermostat CAUTION Do not eliminate or by pass limit thermostat Use only part 23717 0001 Page 10 Remedy Refer to Service Overflow protec tion switch for testing procedures see page 32 Referto Service Level control board for testing
52. r is located inside the left front of the brewer on the upper part of the component bracket Test Procedures NOTE Do not remove or install wires while timer board is installed Pressure applied to one side may cause damage to the board 1 Disconnect the brewer from the power source and remove the front panel 2 Check the voltage across terminals TL1 and TL2 with a voltmeter when the ON OFF switch is in the ON position Connect the brewer to the power source he indication must be 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 3 Disconnect the brewer from the power source If voltage is present as described proceed to 74 If voltage is not present as described refer to the wiring diagrams and check the brewer wiring harness 4 Disconnect the WHI ORA wire from terminal TL3 and the WHI YEL wire from terminal TL5 Check for continuity across the two wires when the start switch is pressed to the START position Page 40 If continuity is present as described reconnect the wires and proceed to 75 If continuity is not present as described refer to the wiring diagrams and check the brewer wiring harness 5 Check the voltage across terminals TL1 and TL4 with a voltmeter when the ON OFF switch is in the ON position Connect the brewer to the power source The indication must be zero v
53. rogrammed you can set the SET LOCK switch to the LOCK position This will prevent any further programming 2 118 100400 SCHEMATIC WIRING DIAGRAM SINGLE BREWER W SERVER SENSOR L1 Enn L2 N LIMIT 22452 RED 12 208 OR 240V ae 4922 DEDIZ 400 ON 4400 12 Sg BL 4 n HEATER 6 SW i PNK 20 PROBE 4 RED 208 OR 240V A ORA WHI 1200 WHUYEL ELECTRONIC GRN REFILL CONTROL ASSY i WHI BLU WHI PROTECTION SW BLK RED RED N C WHIANO A Pm FRACTIONAL BATCHES 13 BATCH Wi e WHI WHI 2 1 gt GRN CONNECT 1 2 BATCH 2L 02i2 itn AS REQUIRED 2 3 BATCH 3E PNK 54 lt ORA SERVER FULL BATCH WHI GRN F S TEL i SENSORS NO CONNECTION PNK 3 4 BATCH 4 i WHI YEL APP BYPASS E p WHI VIO WHI GRN WHI GRN 3 WHI RED WHI RED Mose EF YEL YEL ae DISPENSE T WHI ORA 0 120 VOLTS AC 2 WIRE GRINDER 120 208 VOLTS AC OR 120 240 VOLTS AC 2 CONNECTOR 3 WIRE Page 42 2 118 100400 SCHEMATIC WIRING DIAGRAM SINGLE BREWER W SERVER SENSOR GRN LIMIT THERMOSTAT RED 12 208 OR 240V ao LIMIT THERMOS TANK HEATER p puer e UR AUN BLK 12 ed BUT Ex a a ibi A OVERFLOW PROTE
54. rol thermo Stat for testing procedures See page 20 Refer to Service Control assembly for testing procedure See page 23 thru 27 Refer to Service Contactor for test procedures See page 18 Refer to Service Tank heater for testing procedures See page 36 Referto Service Triac assembly for removal and replacement See page 27 Refer to Service Control thermo Stat for testing procedures See page 20 Refer to Service Control assembly for testing procedures See page 23 thru 27 Refer to Service Triac assembly for testing procedures See page 2 Inspect the tank assembly for exces sive lime deposits Delime as re quired 2 118 100400 TROUBLESHOOTING cont Problem Inconsistent beverage level in server Consistently high or low beverage level in server Dripping from sprayhead Water overflows filter Beverage overflows server Probable Cause 1 Strainer flow control 500 GPM 2 Improper water pressure 3 Dispense valve 1 Timer adjustment 1 Dispense valve 1 Bypass valve 2 of paper filters 3 No sprayhead 1 Beverage left in server 2 Timer adjustment 3 Dispense valve Page 12 Remedy A Direction of flow arrow must be pointing towards the brewer B Remove the strainer flow con trol and check for obstructions Clear or replace Check the operating water pressure to the brewer It must be between 20 and 90 psi 138 and 620 kPa
55. sembly 15 to Bunn O Matic for credit The temperature control of the system is operating prop erly If voltage was not present as described reinstall your existing electronic control assembly 1 and tempera ture sensor 8 and proceed to 712 12 Replace the triac assembly 15 13 Checkthe voltage across the tank heater terminals 5 with a voltmeter Connect the brewer to the power source The indication must be a 120 volts ac for two wire 120 volt models 208 volts ac for three wire 120 208 volt models and 240 volts ac three wire 120 240 volt models while the red indicator on the circuit board is on or blinking b 200 to 240 volts ac for two wire 200 or 240 volt models while the red indicator on the circuit is on or blinking Page 26 14 Disconnect the brewer from the power source If voltage was present as described the temperature control ofthe system is operating properly Return the new electronic control assembly 1 and temperature sensor 8 to Bunn O Matic for credit Electronic Controls Removal and Replacement NOTE each electronic control assembly is calibrated to atemperature sensor Both components MUST be replaced as a set 1 Remove all wires from the electronic control as sembly terminals 2 Remove the two 8 32 screws holding the elec tronic control assembly to the component bracket 3 Disconnect the temperature sensor and ready indicator wires from the left side of the electronic contr
56. ss the pink wire and gray wire when the switch is in the 1 gallon position Continuity must not be present in any other posi tion 6 Reattach the connector to the brew timer circuit board Grinder Interface 7 Disconnect the pink gray and tan wires on the Selector switch from the pink gray and tan wires on the interface socket 8 Check for continuity across the pink wire and tan wire on the selector switch when the switch is in the 1 2 gallon position Continuity must not be present in any other position Page 16 9 Checkfor continuity across the pink wire and gray wire on the selector switch when the switch in the 1 gallon position Continuity must not be present in any other position 10 Reconnect the pink gray and tan wires on the selector switch to the pink gray and tan wires on the interface Bypass Valve 11 Disconnect the white violet on the selector switch from the bypass valve coil and disconnect the white red from the dispense valve coil 12 Check for continuity across the white violet and the white red wires when the selector switch is in the 1 gallon and 1 3 4 gallon position Continuity must not be present in any other position 13 Reconnect the white violet to the bypass valve coil and the white red to the dispense valve coil Server Sensor 14 Disconnect the yellow white orange and the or ange wires of the selector switch from the yellow white orange and orange wires of the brewer wir in
57. t of the start switch Test Procedure 1 Disconnect the brewer from the power source 2 Viewing the switch from the back remove the red or white wire from the upper right terminal and the black wire from the center terminal 3 Checkthe voltage across the red or white wire and the black wire with a voltmeter Connectthe brewer to the power source The indication must be 120 volts ac for two wire 120 volt models three wire 120 208 volt models and three wire 120 240 volt models b 200 to 240 volts ac for two wire 200 or 240 volt models 4 Disconnect the brewer from the power source If voltage is present as described reconnect the red or white wire and proceed to 5 If voltage is not present as described refer to the Wiring Diagrams and check the brewer wiring har ness Page 31 5 With the black wire removed remove the white violet wire on the switch from the lower left terminal 6 Check for continuity across the center and lower left terminal with switch in the ON position Continuity must not be present when switch is in the OFF position If continuity is present as described reconnect the black wire to the center terminal and the white violet wire on the switch to the lower left terminal If continuity is not present as described replace the switch Removal and Installation 1 Remove the wires from the switch terminals 2 Compress the clips inside the hood and gently push the switc
58. tate the control thermostat knob fully clockwise to the ON position and replace the front panel Wait approximately twenty five minutes on 208V 240V Models or fifty minutes on 120V Models for the water in the tank to heat to the proper temperature Place an empty server beneath the brew station Place the Selector switch in the desired position the On Off Switch in the upper position and initiate a brew cycle Place the On Off switch in the lower OFF position after water has stopped flowing from the funnel and check the water volume in the server It should be 64 07 1 2 gallon 128 07 1 gallon or 224 oz 1 3 4 gallon NOTE Brewer will not operate if the server size does not match the selected batch size A If not disconnect the brewer from the power source remove the front panel and adjust the timer as required Refer to Adjusting Brew Volumes Replace the front panel connect the brewer to the power source allow the water to reheat start and measure another brew cycle B If necessary adjust the needle valve to achieve water volume to be bypassed around the coffee filter in the funnel NOTE To increase the water bypass turn the needle valve counterclockwise to decrease the water bypass turn the needle valve clockwise An adjustment to the needle valve will require a timer adjustment for volume Repeat step until the proper water volume is achieved The brewer is now ready for use in accordance with the coffee brewing ins
59. that the desired volume has been achieved Setting batch sizes To set a batch volume first check that the SET LOCK switch is in the SET position on the circuit board Press and hold the START or BREW switch until three distinct clicks are heard and then release the switch Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory View the level of the liquid being dispensed When the desired level is reached turn the ON OFF switch to OFF lower The brewer remem bers this volume and will continue to brew batches of this size until the volume setting procedure is repeated NOTE When brewing coffee batch volumes will decrease due to absorption by the coffee grounds 3 Setting programming disable feature If it becomes necessary to prevent anyone from changing brew times once programmed you can set the SET LOCK switch to the LOCK position This will prevent any program ming to be done until switch is once again placed in the SET position Page 6 2 118 100400 OPERATING CONTROLS BREW SELECTOR SWITCH Placing the switch in the 2 Gal 1 Gal 1 Gal position selects the amount of coffee to be brewed in Subsequent brew cycles Repositioning this switch after a brew cycle has been initiated does not change the brew batch in progress ON OFF SWITCH Placing the switch in the unlighted lower position cuts power to the server sensor a
60. tructions Page 5 2 118 100400 ADJUSTING BREW VOLUMES CAUTION Disconnect the power source from the brewer prior to the removal of any panel for the replacement or adjustment of any component NOTE Prior to setting or modifying batch sizes check that the brewer is connected to water supply the tank is properly filled and a funnel and server are in place 1 Modifying batch sizes To modify a batch volume first check that the SET LOCK switch is in the SET position on the circuit board To increase a batch size Press and hold the START or BREW switch until three clicks are heard Release the switch Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory and press it again one or more times Each time the switch is pressed two seconds are added to the brew time period Allow the brew cycle to finish in order to verify that the desired volume has been achieved To decrease a batch size Press and release the START or BREW switch once for every two second interval to be removed from the total brew time period then immediately press and hold down the START or BREW switch until three clicks are heard Release the switch Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory Allow the brew cycle to finish in order to verify
61. water Supply the tank 1 properly filled and a funnel and Server are in place prior to setting or modifying volumes NOTE All volume settings must be done with the Sprayhead installed 1 Modifying brew volumes To modify a brew vol ume first check that the SET LOCK switch Is inthe SET position on the circuit board To increase a brew volume place the ON OFF switch in the ON position press and hold the START switch until three clicks are heard Release the switch Failure to release the switch within two seconds after the third click causes the volume Setting to be aborted and previous volume setting will remain in memory and press it again one or more times Each time the switch is pressed two Seconds are added to the brew time period Allow the brew cycle to finish in order to verify that the desired volume has been achieved To decrease a brew volume place the ON OFF switch in the ON position press and release the START switch once for every two second interval to be removed from the total brew time period then immediately press and hold down the START switch until three clicks are heard Release the switch Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory Allow the brew cycle to finish in order to verify that the desired volume has been achieved 2 Setting brew volumes seta brew volume first

Operating, Service, SINGLE TF 1.75 Gallon Operating

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