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Bunn FMD-5 Espresso Machine

1. OPERATING amp SERVICE MANUAL BUNN O MATIC CORPORATION POST OFFICE BOX 3227 SPRINGFIELD ILLINOIS 62708 3227 PHONE 217 529 6601 FAX 217 529 6644 35135 0000 03 03 2003 Bunn O Matic Corporation www bunnomatic com INTRODUCTION This equipment dispenses hot beverages or soups on demand from powdered product It is for indoor use only on a sturdy counter or shelf BUNN 0 MATIC COMMERCIAL PRODUCT WARRANTY Bunn O Matic Corp BUNN warrants equipment manufactured by it as follows 1 All equipment other than as specified below 2 years parts and 1 year labor 2 Electronic circuit and or control boards parts and labor for 3 years 3 Compressors on refrigeration equipment 5 years parts and 1 year labor 4 Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis parts and labor for 3 years or 30 000 pounds of coffee whichever comes first These warranty periods run from the date of installation BUNN 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 BUNN or that in BUNN s judgment has been affected by misuse neglect alteration improper installation or operation improper maintenance or repair
2. 26 4 Disconnect the dispenser from the power source If voltage is present as described replace the motor If voltage is not present as described refer to the wir ing diagrams and check the dispenser wiring harness FIG 18 MIXING WHIPPER CHAMBER COMPONENTS 1 Steam Collector 8 Nut 2 Mixing Chamber 9 Slinger 3 Dispense Tip 10 Motor Assy 4 Whipper Chamber 11 Fan 5 O Ring 12 Vacuum Hose 6 Frother 13 Baffle 7 Receptacle w Seal Removal Cleaning amp Replacement Refer to Fig 18 1 Open the dispenser door and raise the top front COVer 2 Lift the front edge of the each hopper assembly over the tab on the hopper support panel and slide each hopper assembly out the front of the dispenser Set aside for reassembly 3 Remove the four 78 32 screws securing the hop per support panel to auger motor mounting panel and the whipper motor mounting panel Set aside for reassembly 35135 012103 SERVICE cont FROTHER AND WHIPPER MOTOR FMD 4 shown amp FMD 5 cont 4 5 6 10 11 12 13 Disconnect vacuum hose 12 from fan baffle 13 Remove the steam collector 1 by pulling it for ward and at the same time twisting it clockwise Pull the mixing chamber 2 out of the whipper chamber 4 Remove the two 74 40 x 25 screws securing the fan baffle 13 to the whipper motor mounting panel and remove fan baffle Set aside for reas sembly Remove dispense tip 3 and t
3. CONTROL LIMIT SNITCH THERMOSTAT TANK HEATER n BLK 16 reo 0 BLK 16 BLK 16 RED 16 M44 REFILL VALVE 120V 24V AC LORD TRANSFORMER HOPPER 1 HOPPER 2 HOPPER 3 BLK RED BLK LwHvoRN amp 5 STATION 1 STATION 2 STATION 3 STATION 4 STATION 5 WHIPPER WHIPPER WHIPPER WHIPPER WHIPPER HOPPER 5 RED RINSE PROGRAM py RUN SWITCH STATION 1 DISPENSE STATION 2 DISPENSE STATION 3 DISPENSE VALVE STATION 4 STATION 5 DISPENSE DISPENSE VALVE VALVE TION LEFT ONLY HOT COLD SWITCH WHI YEL BRN RED a JUMPER PLUG MUST BI USED WHEN COLD DRINK FEATURE NOT INSTALLED WHUBED BED WHURED 120 208 240 VOLTS AC 3 WIRE BLK RED BLK BLK ge ORN BLK ee TT SINGLE PHASE 60HZ 45 35135 012103
4. 1D m L 1 WHINIO T 1 OVERFLOW PROTECTION SWITCH NO joi BLK RED RED LB L 1 C J8 41 ol B 1 Err 1T 35 WHVBLK ell c 1B 10 T 1 10 1 42 5 11 1 1 1 pao fof ENE 1 m HOPPER 1 HOPPER 2 HOPPER 3 HOPPER 5 1 m Ws 1 4 1 rrace STATION 1 STATION 2 STATION 3 STATION 4 WHIPPER WHIPPER WHIPPER WHIPPER PROBE RINSE PROGRAM BLK BLK BLK ed BLK py RUN SWITCH STATION 1 DISPENSE STATION 2 DISPENSE VALVE STATION 3 STATION 4 DISPENSE DISPENSE VALVE VALVE QD DRINK OPTION LEET ONLY IOT COLD SWITCH _ WHI YEL a LD JUMPER PLUG MUST BE E USED WHEN COLD E DRINK FEATURE NOT E INSTALLED PNK 4 i RED WHI RINSE 1 3 L E D PNK WHUREDS BLWHIJ pp BED WHURED amp 1 WHURED 4 WHURED BLU 120 VOLTS AC 2 WIRE BLK WHIBLK BLK PBED BLK BLK RORN BLK BLU BLK SINGLE PHASE 60HZ 44 STATION 5 WHIPPER STATION 5 DISPENSE VALVE 35135 012103 4 4 rosazoo o oTa PNK S RED WI Be RINSE 1 3 L E D OH RINSE 4 amp 5 L E D WHYRED p BLK WHI BLK gj SCHEMATIC WIRING DIAGRAM FMD 5 MA
5. 7 Connect the transformer to the main wiring har ness see Fig 42 8 Place the component bracket into position and tighten the three 78 32 screws Main Harness WHI GRN from Main Harness Main Harness WHI BLK from Main Harness P2640 FIG 42 TRANSFORMER TERMINALS 35135 012103 RINSE 4 amp 5 L E D SCHEMATIC WIRING DIAGRAM FMD 4 Hi GRN N TANK HEATER CONTROL SWITCH THERMOSTAT TANK HEATER K i a r BLK 18 BLK 16 BLK 16 op py BLK 16 WHI 16 Teen GR 120V 24VAC TRANSFORMER re WHIO MY 1 4 oroo 4 WORN isi PNK HOPPER 1 HOPPER 2 HOPPER 43 BLK lu E 1 STATION 1 STATION 2 STATION 3 STATION 4 PROBE WHIPPER WHIPPER WHIPPER WHIPPER STATION 1 DISPENSE BLK BLK STATION 2 DISPENSE VALVE BLK BLK BLK STATION 3 STATION 4 DISPENSE DISPENSE VALVE VALVE ORN DRINK OPTION LECT ONLY HOT COLD SWITCH WHI YEL S COLD n E JUMPER PLUG MUST BI USED WHEN COLD DRINK FEATURE NOT INSTALLED PNK D RED WHI SLU WHL RINSE 1 3 L E D RED B
6. Connectthe dispenser to the power supply The indication must be a 120 volts ac for two wire 120 volt models b 120 volts ac for three wire 120 208 volt or 120 240 volt models Disconnect the dispenser from the power source If voltage is present as described proceed to 6 If voltage is not present as described refer to the wir ing diagram and check the dispenser wiring harness 6 With a voltmeter check the voltage across the remaining two wires of the dispense switch being tested from the door interconnect wiring harness Connect the dispenser to the power source The indication must be 5 volts dc If voltage is present as described proceed to 77 If voltage is not present as described refer to the wiring diagram and check the dispenser wiring har ness 35135 012103 SERVICE cont DISPENSE SWITCHES cont T Check for continuity across the terminals top right to top left bottom right to bottom left of the dispense switch with the switch in the ON posi tion Continuity must not present when the switch is in the OFF released position If continuity is present as described reconnect the connector to the door interconnect wiring harness the switch is operating properly If continuity is not present as described replace the switch Removal and Replacement 1 2 3 Open the dispenser door Remove the six 78 32 screws securing the bot tom door cover and remove cover Disconnect
7. HOT COLD SWITCH Optional FIG 27 HOT COLD SWITCH Location The hot cold switch is located on the left side of the whipper motor mounting panel Test Procedure 1 Disconnect the dispenser from the power source 2 Disconnect the four pin plug from the hot cold switch and the four pin connector on the main wiring harness 3 Press the left dispense switch on the door and with a voltmeter check the voltage across the white wire pin 4 and red wire pin 2 in the four pin connector on the main wiring harness Con nect the dispenser to the power source The indi cation must be a 120 volts ac for two wire 120 volt models and three wire 120 208 volt and 120 240 volt models b 240 volts ac for two wire 240 volt models 4 Disconnect the dispenser from the power source If voltage is present as described reconnect the four pin plugs and proceed to 75 If voltage is not present as described refer to the Wiring Diagrams and check the main wiring harness 5 Disconnect the wires from the switch terminals 6 With the switch in the Cold upper position check for continuity between the center terminal and the bottom terminal With the switch in the Hot lower position check for continuity be tween the center terminal and the upper terminal If continuity is present as described the hot cold switch is operating properly If continuity is not presen
8. motor mounting panel Test Procedures 1 Disconnect the dispenser from the power source 2 Check for continuity between the center left ter minal and left bottom terminal also between the center right terminal and the right bottom termi nal with the switch in the rinse position upper Check for continuity across the center left termi nal and the top left terminal also between center right terminal and the top right terminal with the switch in the run position lower Continuity must not be present when the switch is in the center position 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 Open the dispenser door 2 Removethe facenut securing the run rinse switch to the whipper motor mounting panel 3 Remove switch with wires attached from the back side of the whipper motor mounting panel 4 Disconnect the wires from the switch and dis card the switch 5 Refer to Fig 26 when connecting the wires to the new switch 6 Install new switch with wires attached through the hole in the whipper motor mounting panel and secure with facenut GRY to Control Board J2 2 BRN BLK to Main Harness _ __ GRN to Control Board J2 9 BLK from Main Harness BRN BLK to Main Harness WHI GRY to Control Board J2 3 P1644 FIG 26 RINSE RUN SWITCH TERMINALS 35135 012103 SERVICE cont
9. terminals of the tank heater relay The indication must be open circuit If continuity is absent as described the relay is func tioning correctly If continuity is present replace the relay Removal and Replacement 1 Loosen the three 78 32 screws securing the com ponent bracket to the dispenser housing base 2 Pull component bracket out the front of the dis penser far enough so the tank heater relay can be disconnected from the main wiring harness 3 Disconnect the tank heater relay from the main wiring harness 4 Remove the two 78 32 screws securing the tank heater relay to the rear of the component bracket 5 Remove and discard the tank heater relay 6 Install new tank heater relay on the rear of the component bracket and secure with two 78 32 SCrews 7 Connect the tank heater relay to the main wiring harness see Fig 40 8 Place the component bracket into position and tighten the three 78 32 screws BLK from Main Harness BRN BLK from WHI from Main Harness Main Harness BLK from No Connection Main Harness P2639 FIG 40 TANK HEATER RELAY TERMINALS 35135 012103 SERVICE cont TRANSFORMER FIG 41 TRANSFORMER Location The transformer is located behind the lower front access cover mounted on the right rear side of the component bracket Test Procedure 1 Disconnect the dispenser from the power sour
10. the indication must be 4 0 to 24 5 volts dc 35135 012103 SERVICE cont AUGER DRIVE COMPONENTS FMD 4 amp FMD 5 cont 4 Disconnect the dispenser from the power supply If voltage is present as described and the auger does not turn replace the auger motor If voltage is not present as described refer to the wir ing diagrams and check the dispenser wiring harness Removal Cleaning and Replacement Hopper amp Auger 1 2 ps 10 11 12 13 14 Open the dispenser door and raise the top front COVer Lift the front edge of hopper assy 20 over the tab on hopper support plate 19 and slide hop per assembly out the front of the dispenser Remove hopper lid 1 and empty product Pull off the ejector elbow 13 Remove agitator disc assy 2 by pulling agitator support rod 4 towards agitator disc assy and lifting agitator disc assy from hopper 10 Remove auger 12 by pulling it out the front of the hopper 10 Remove auger drive shaft 5 by removing the retaining clip 6 from auger drive shaft Slide washer 8 and auger drive shaft bracket 7 off of the auger drive shaft 5 Slide auger drive shaft 5 from auger drive shaft bushing 3 and remove from hopper 10 Remove locknut 9 from auger drive shaft bush ing 3 and remove auger drive shaft bushing from hopper 10 Wash components in a mild solution of dish de tergent using a bristle brush when needed R
11. voltage requirement ELECTRICAL HOOK UP CAUTION Improper electrical installation will damage electronic components An electrician must provide electrical service as specified Using a voltmeter check the voltage and color coding of each conductor at the electrical source Open the front door of the dispenser and place the heater switch in the OFF upper position Connect the dispenser to the power source If plumbing is to be hooked up later be sure the dispenser is disconnected from the power source If plumb ing has been hooked up the dispenser is ready for nitial Fill amp Heat Cp po No PLUMBING REQUIREMENTS This dispenser must be connected to a cold water system with operating pressure between 20 and 100 psi 138 and 690 kPa This water source must be capable of producing a minimum flow rate of 4 5 fluid ounces 133 1 ml per second A shut off valve should be installed in the line before the dispenser Install a regulator in the line when pressure is greater than 100 psi 690 kPa to reduce it to 50 psi 345 kPa The water inlet fitting is amp flare NOTE At least 18 inches of an FDA approved flexible beverage tubing such as reinforced braided polyethylene or silicone before the dispenser will facilitate movement to clean the countertop It can be purchased direct from Bunn O Matic part number 00327 0000 0 does not recommend the use of a saddle valve to install the dispenser The size and sha
12. wiring harness with a voltmeter Connect the dispenser to the power source The indication must be 120 volts ac for two wire 120 volt models three wire 120 208 volt models three wire 120 240 volt models 8 Disconnect the dispenser from the power source If voltage is present as described proceed to step 9 If voltage is not present as described refer to the wiring diagram and check the dispenser wiring har ness 9 Reconnect the four pin connector of the wiring harness to J4 of control board 1 Disconnect the ten pin connector from J2 of control board 1 Carefully connect a piece of insulated jumper wire to pin 10 top right of J2 on the control board Keep the other end of this wire away from any metal surfaces of the dispenser Check the voltage across the terminals of the inlet solenoid valve with a voltmeter Connect the dis penser to the power source The indication must be 120 volts ac fortwo wire 120 volt models three wire 120 208 volt models three wire 120 240 volt models after a delay of approximately 10 seconds Touch the free end of the jumper wire to the dispenser housing The indication must be 0 Move the jumper wire away from the housing The indication must again be 120 volts ac for two wire 120 volt models three wire 120 208 volt models three wire 120 240 volt models after a delay of approximately 5 seconds Disconnect the dispenser from the power source and remove the jumper wire
13. 1 1 1 n2 13 14 1 If voltage is present as described proceed to step 16 If the voltage is not present as described replace control board 1 35135 012103 SERVICE cont CONTROL BOARD CONT 16 Reconnect the ten pin connector of the wiring harness to J2 of control board 71 17 Gently pull the liquid level probe out of the tank lid and inspect for corrosion Replace it if necessary 18 Place the probe so that neither end is in contact with any metal surface of the dispenser 19 Check the voltage across the terminals of the inlet solenoid valve with a voltmeter Connect the dis penser to the power source The indication must be 120 volts ac fortwo wire 120 volt models three wire 120 208 volt models three wire 120 240 volt models after a delay of approximately 10 seconds Move the probe s flat end to the dispenser hous ing The indication must be 0 21 Move the probe s flat end away from the housing The indication must again be 120 volts ac for two wire 120 volt models three wire 120 208 volt models three wire 120 240 volt models after a delay of approximately 5 seconds 22 Disconnect the dispenser from the power source 20 If the voltage is present as described re install the probe The liquid level control circuitry is operating properly If the voltage is not present as described check the pink probe wire and green tank wire for continuity 21 Hopper Moto
14. 135 012103 SERVICE cont TANK HEATER RELAY 120V Dispensers only FIG 39 TANK HEATER RELAY Location The tank heater relay is located behind the lower front access cover mounted on the left rear side of the component bracket Test Procedure 1 Disconnect the dispenser from the power source 2 Placethe tank heater switch in the OFF upper position 3 With an ohmmeter check for continuity between normally closed NC 5 and common COM 3 terminals of the relay The indication must be less than 1 ohm If continuity is present as described proceed to step 4 If continuity is not present as described replace the relay 4 With an ohmmeter check the resistance across the coil terminals 1 amp 2 of the relay The indica tion must be approximately 4 000 ohms 4kQ If the resistance measures as described proceed to step 5 If the resistance does not measure as described replace the relay 5 Disconnect the wires from the normally closed NC 5 and common COM 3 terminals of the relay 40 6 With an ohmmeter check for continuity between the normally closed NC 5 and common COM 3 terminals of the relay 7 Placecontainers below any three dispense nozzles 8 Connect the dispenser to the power source 9 Simultaneously initiate dispenses at each of the selected dispense stations while monitorintg con tinuity across the referenced
15. 2 3 Check the voltage across pins 5 amp 6 of the six pin connector on the wwiring harness with a voltme ter Connect the dispenser to the power source the indication must be 24 volts ac 4 disconnect the dispenser from the power source If voltage is present as described proceed to step 5 If voltage is not present as described refer to the wiring diagram and check the dispenser wiring har ness 5 Reconnect the six pin connector of the wiring harness to J3 of control board 2 6 Disconnect the four pin connector from J4 of control board 2 7 Checkthe voltage across pins 1 amp 4 of the four pin connector on the wiring harness with a voltmeter The indication must be 120 volts ac 8 Disconnect the dispenser from the power source If voltage is present as described proceed to step 9 If voltage is not present as described refer to the wiring diagram and check the dispenser wiring har ness 9 Reconnect the four pin connector of the wiring harness to J4 of control board 72 10 Check the voltage across the coil terminals of the tank heater relay with a voltmeter Connect the dispenser to the power source The indication must be 0 volts ac 22 If voltage is absent as described proceed to step 11 If voltage is present replace the control circuit board 2 11 Placecontainers below any three dispenser nozzles 12 Simultaneously initiate dispenses at each of the selected dispense stations while mo
16. 240 volt models 4 BDisconnectthedispenserfromthe power source 35 If voltage is present as described proceed to 5 If voltage is not present as described refer to wiring diagram and check dispenser wiring harness 5 Check for continuity across the solenoid valve coil terminals If continuity is present as described reconnect the wires to the solenoid see Fig 32 proceed to 76 If continuity is not present as described replace the solenoid valve 6 Check the solenoid valve for coil action Connect the dispenser to the power source With RINSE RUN switch in the RINSE upper position press the dispense switch and listen carefully in the vicinity of the solenoid valve for a clicking sound as the coil magnet attracts 7 Disconnect the dispenser from the power source If the sound is heard as described and water will not pass through the solenoid valve there may be a block age in the water outlet before 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 35135 012103 SERVICE cont SOLENOID VALVE DISPENSE FMD 4 amp FMD 5 cont Removal and Replacement 1 Remove the four 78 32 screws securing the side access panel to the housing Remove panel and set aside 2 Remove the wires from the solenoid valve 3 Turn off the water supply to the dispenser 4 Usi
17. 5 012103 SERVICE cont LAMP HOLDERS FIG 22 LAMP HOLDERS 1 Door Assy 4 Upper Panel 2 Lamp Holders 5 Lower Panel 3 Lamp 6 Starter W Socket Location The lamp holders are located on the front of the upper panel behind the display panel Test Procedure 1 Disconnect the dispenser from the power source 2 Remove upper door panel 4 and disconnect the door wiring harness from the leads on the lamp holders Remove lamp from lamp holders 4 Check for continuity on each lead of the lamp holders If continuity is present as described lamp holders are operating properly If continuity is not present as described replace the lamp holder 29 Removal and Replacement 14 Open dispenser door 1 Remove the six 8 32 screws securing lower door panel 5 to the door 1 and remove cover Disconnect the door wiring harness from the door interconnect wiring harness Remove three 78 32 screws securing the upper door panel 4 to the door Remove the upper door cover 4 lamp 3 lamp holders 2 and door wiring harness as an assem bly Disconnect the wires from the lamp holder to be replaced from the door wiring harness Rotate lamp 3 90 and remove from lamp hold ers 2 Remove the 26 32 screw securing the lamp holder 2 to be removed remove lamp holder 2 and discard Install new lamp holder 2 and secure with a 6 32 screw Connect the wires on the n
18. LK gy ap HEK BLKA BED BLK 120 VOLTS 2 WIRE pp ENEL SINGLE PHASE 60HZ 42 35135 012103 SCHEMATIC WIRING DIAGRAM FMD 4 GRN N CONTROL LIMIT SWITCH THERMOSTAT TANK HEATER n BLK 16 ie e 0 e BLK 16 16 J44 43 1 fe WBUORN GEN TEUER 25 5 REFILL VALVE 120 24VAC LOAD TRANSFORMER OVERFLOW PROTECTION SWITCH BLK RED RED WHUVIO 4 4 coms o rozsazoo 1 HOPPER 2 STATION 1 STATION 42 STATION 3 STATION 4 WHIPPER WHIPPER WHIPPER WHIPPER RINSE PROGRAM BLK od BLK BLK BLK BLK py RUN SWITCH STATION 1 DISPENSE STATION 2 DISPENSE STATION 3 STATION 4 DISPENSE VALVE DISPENSE VALVE COLD DRINK OPTION LEFT ONLY HOT COLD SWITCH WHI YEL D BRN RED COLI JUMPER PLUG MUST USED WHEN COLD DRINK FEATURE NOT INSTALLED RINSE 4 amp 5 L E D WHURED BN 120 208 240 VOLTS AC 3 WIRE Ere ORNBLK SINGLE PHASE 60HZ a BLK WHI S WHUBLK 43 35135 012103 RINSE 4 amp 5 L E D SCHEMATIC WIRING DIAGRAM FMD 5 TANK HEATER CONTROL LIMIT SWITCH THERMOSTAT teeters K d H BLK 16 i ig Fee ei E iE BLK 16 WHI 16 pp m ds 1 ua uuo
19. LS 21 35135 012103 SERVICE cont INCREASE DECREASE SWITCH FIG 20 INCREASE DECREASE SWITCH Location The increase decrease switch is located on the lower left front of the whipper motor mounting panel Test Procedure 1 2 3 Disconnect the dispenser from the power source Disconnect the wires from the switch terminals Check for continuity between the center terminal and upper terminal with switch in the decrease position lower Check for continuity between the center terminal and the lower terminal with the switch in the increase position upper 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 Open the dispenser door 2 Remove the facenut securing the increase de crease switch to the whipper motor mounting panel 3 Remove switch with wires attached from the back side of the whipper motor mounting panel 4 Disconnect the wires from the switch and discard the switch 5 Referto Fig 21 when connecting the wires to the new switch 6 Install new switch with wires attached through the hole in the whipper mounting panel and secure with facenut RED BLK from Control Board J2 6 GRN from Control Board J2 9 WHI VIO from Control _ SJ Board J2 1 FIG 21 INCREASE DECREASE SWITCH TERMINALS 28 3513
20. PROGRAMING The hopper dispense rate is preset at the factory With 22 tooth gear and auger wire the preset dispense rate is approximately to 5 grams per second With 30 tooth gear and auger wire the preset dispense rate is approximately 5 to 7 grams per second The hopper dispense rate can be adjusted to produce a wide range of dispense rates as follows 1 Place the rinse run switch in the center program position 2 Place the increase decrease switch in the desired increase or decrease position 3 Press and release the dispense switch for the chamber you wish to adjust Each time the dispense switch is pressed the rinse L E D will flash and the motor speed for that hopper will be increased decreased by approximately 2 1 2 4 Return the rinse run switch to the run position after hopper motor speed adjustments are complete 6 35135 012103 DRAINING THE HOT WATER TANK CAUTION The dispenser must be disconnected from the power source throughout these steps Disconnect the dispenser from the power source Place the tank heater switch in the OFF position Shut off and disconnect the incoming water supply Remove the front lower access panel Pull out drain tube to empty into a sink or a container with a minimum of 6 1 2 gallon capacity Make sure drain clamp is closed Then remove drain plug Direct tube into sink or container and open drain clamp Continue draining tank until ALL of the water is out WARNING Be very care
21. ST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT WHETHER DERIVED FROM WARRANTY OR OTHERWISE SHALL BE LIMITED AT BUNN S SOLE OPTION AS SPECIFIED HEREIN TO REPAIR REPLACEMENT OR REFUND In no 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 USER NOTICES Carefully read and follow all notices on the equipment and in this manual They were written for your protection All notices are to be kept in good condition Replace any unreadable or damaged labels LIQUID RELEASE BUTTON WHEN CUP IS 2 3 FULL FMD 4 28328 0008 PLACE PLACE PLACE PLACE CUP HERE CUP HERE CUP HERE CUP HERE wagNING LIQUID RELEASE BUTTON WHEN CUP IS 2 3 FULL M M M FMD 5 28328 0009 PLACE PLACE CUP HERE CUP HERE 2 35135 012103 USER NOTICES Cont 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 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 A
22. an 1 Lamp 2 Lamp Holder 3 Starter Lamp 4 Ballast REMEDY Plumbing lines should not be rest ing on the counter top A The dispenser must be connected to a cold water line B Water pressure to the dispenser must not exceed 100 psi 690 kPa Install a regulator if necessary to lower the working pressure to ap proximately 50 psi 345 kPa Remove and clean lime off the tank heater See page 38 Refer to Service Fan for testing procedures See page 25 Refer to Service Lamp see page 29 for lamp replacement Refer to Service Lamp Holder for testing procedures See page 29 Refer to Service Starter for testing procedures See page 30 Refer to Service Ballast for testing procedures See page 18 35135 012103 SERVICE This section provides procedures for testing and replacing various major components used in this dispenser 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 dispenser should be un plugged when servicing except when electrical tests are required and the test procedure specifically states to plug in the dispenser COMPONENT ACCESS WARNING Disconnectthe dispenser from the power source before the removal of any panel or the replace ment of any component All components are accessible b
23. as described replace the tank heater NOTE If the tank heater remains unable to heat remove and inspect heater for cracks in the sheath Removal and Replacement 1 Disconnect the dispenser from the power source 2 Disconnect the water supply tube on the tank lid 3 Disconnectthe black wires on the limit thermstat 4 Disconnectthe black wire and the white or red wire from the tank heater terminals 5 Disconnect the pink wire from the liquid level probe and the green wire from the tank 6 Remove the thermostat capillary bulb by firmly pulling up on the capillary at the tank lid This will disengage the grommet from the tank lid 7 Remove the ten 78 32 nuts securing the tank lid to the tank 8 Remove tank lid with limit thermostat liquid level probe and tank heater as an assembly 9 Remove the two hex nuts securing the tank heater to the tank lid Remove tank heater with gaskets and discard Install new tank heater with gaskets on the tank lid and secure with two hex nuts Install tank lid with limit thermostat liquid level probe and tank heater on the tank and secure with ten 8 32 hex nuts 12 Connect water inlet line to the tank lid 13 Reconnect the black wires to limit thermostat the pink wire to the liquid level probe and the green wire to the tank Refer to the limit thermostat and the liquid level board and probe sections in this manual when reconnecting wires Refer to Fig 36 when reconnect
24. ated on the outside rear of the hopper base The auger motor is located on the lower right rear of the motor mounting panel Refer to Fig 2 for disassembly and assembly Test Procedures Auger Motor 1 Disconnect the dispenser from the power source 2 Disconnect the white red wire and the white wire from the hopper speed control board 3 Check the voltage across the white red wire and the white wire with a voltmeter With the rinse run switch in the run lower position connect the dispenser to the power supply The indica tion must a 120 volts ac for two wire 120 volt models b 120 volts ac for three wire 120 208 volt or 120 240 volt models 4 Disconnect the dispenser from the power sup ply If voltage is present as described proceed to 5 If voltage is not present as described refer to the wir ing diagram and check the dispenser wiring harness 35135 012103 SERVICE AUGER DRIVE COMPONENTS FMD 4 CONT 5 Check the voltage across the positive red wire terminal and the negative black wire terminal on the auger motor with a voltmeter With the rinse run switch in the run lower position press and hold the dispense switch Connect the dispenser to the power supply After a 6 second delay the indication must be 4 0 to 24 5 volts dc If voltage is present as described the auger motor drive is operating properly If auger does not turn replace the auger motor If voltage is not present as desc
25. ce 2 Disconnect the four wires of the main harness from the transformer 3 Check the voltage across black wire and the white wire on the main harness Connect the dispenser to power source The indication must be a 120 volts ac for two wire 120 volt models b 120 volts for three wire 120 208 volt models and three wire 120 240 volt models 4 Disconnect the dispenser from the power source If voltage is present as described reconnect the wires and proceed to 5 If voltage is not present as described refer to the wiring diagrams and check the main wiring harness 5 Check the voltage between J3 5 and J3 6 on the six pin connector at either control board Connect the dispenser to the power source The indication must be 24 volts ac If voltage is present as described the transformer is operating properly If voltage is not present as described replace the transformer Removal and Replacement 1 Loosen the three 28 32 screws securing the com ponent bracket to the dispenser housing base 2 Pull component bracket out the front of the dis penser far enough so the transformer can be disconnected from the main wiring harness 3 Disconnect the transformer from the main wiring harness 4 Remove the two 78 32 screws securing the trans former to the rear of the component bracket 5 Remove and discard the transformer 6 Install new transformer on the rear of the compo nent bracket and secure with two 78 32 screws
26. damage or casualty This warranty is conditioned on the Buyer 1 giving 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 2 if requested by BUNN shipping the defective equipment prepaid to an authorized BUNN service location and 3 receiving prior authorization from BUNN 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 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 If BUNN determines in its sole discretion that the equipment does not conform to the warranty BUNN 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 BUNN Authorized Service Representative or 2 shall replace the equipment or refund the purchase price for the equipment THE BUYER S REMEDY AGAIN
27. dministration FDA Follow national local electrical codes Do not use near combustibles 00656 0000 FAILURE TO COMPLY RISKS EQUIPMENT DAMAGE FIRE OR SHOCK HAZARD CONTROL THERMOSTAT ADJUSTMENT READ THE ENTIRE OPERATING MANUAL BEFORE BUYING OR USING THIS PRODUCT od Se oO Ce am e THIS APPLIANCE IS HEATED WHENEVER CONNECTED TO A POWER SOURCE 00831 0000F 3 98 1988 BUNN O MATIC CORPORATION 200 F 190 180 APPROXIMATE THERMOSTAT TEMPERATURE SETTINGS 00831 0000 sick ture iiu e 28368 0000 RINSE PUSH and HOLD BUTTON UNTIL CUP IS 2 3 FULL THEN RELEASE FMD 4 28964 0004 e e RINSE RINSE PUSH and HOLD BUTTON UNTIL CUP IS 2 3 FULL THEN RELEASE FMD 5 28964 0003 3 35135 012103 INITIAL SET UP 1 Locate the drip tray assembly inside the dispenser door 2 Remove the drip tray and the drip tray cover and set them aside ELECTRICAL REQUIREMENTS CAUTION The dispenser must be disconnected from the power source until specified in nitial Set Up The 120 volt version of this dispenser has an attached cordset and requires 2 wire grounded service rated 120 volts ac 15 amp single phase 60 Hz The mating connector must be a NEMA 5 15R The 120 208 and the 120 240 versions of this dispenser has an attched cordset The mating connector must be a NEMA 14 20R Refer to the dispenser s dataplate for exact
28. e 18 Dust Seal 14 Install hopper assy 15 the dispenser by sliding Washer 19 Auger Motor Mounting hopperassy on the hopper support plate 11 until 0 Retainer Clip panel the slot in the rear of the hopper base 8 seats against the pins in the hopper support plate 11 14 35135 012103 SERVICE cont AUGER DRIVE COMPONENTS FMD 4 cont Auger Drive Motor Refer to Fig 2 1 Remove hopper assy 15 and set aside for reas sembly 2 Remove the four 78 32 screws securing the hop per support plate 11 remove plate and set aside for reassembly Remove the four 28 32 screws located inside the dispenser housing on the lower right front of the auger motor mounting panel 19 securing auger motor mounting bracket 16 and auger motor 17 to the rear of the auger motor mounting panel 19 4 Disconnectthe wires from the hopper drive board 5 Remove auger motor mounting bracket 16 au ger motor 17 and dust seal 18 as an assembly 6 Remove dust seal 18 from auger motor 17 T Disconnect the wires from the auger motor 17 8 Remove the four 78 32 screws securing the auger motor 17 to the auger motor mounting bracket 16 Remove auger motor 17 and discard Using four 78 32 screws install new auger motor 17 on mounting bracket 16 Install dust seal 18 on auger motor shaft and align notch in seal with motor casting Reconnect the wires to the terminals on the hop per drive board Refe
29. e sealed and electrical connections tight and isolated This unit is heated at all times Keep away from combustibles WARNING Exercise extreme caution when servicing electrical equipment Unplug the dispenser when servicing except when electrical tests are specified Follow recommended service procedures Replace all protective shields or safety notices PROBLEM PROBABLE CAUSE REMEDY Product will not dispense 1 No water Water lines and valves to the dis penser must be open 2 No power or incorrect voltage to Check for 120 volts across the the dispenser black and white wires on two wire 120 volt dispensers A2 Check for 120 volts across the red and white wires and the black and white wires 208 volts across the red and black wires on three wire 120 208 volt dispensers and 240 volts across the red and black wires on three wire 120 240 volt dispens ers B Check circuit breakers or fuses 3 Dispense Switch Refer to Service Dispense Switch for testing procedure See page 23 4 Dispense Solenoid Valve Referto Service Dispense Solenoid Valve for testing procedures See page 35 8 35135 012103 TROUBLESHOOTING cont PROBLEM Product will not dispense cont Water is not hot PROBABLE CAUSE 5 Solenoid Valve Inlet 6 Control Board 1 and Probe T Auger Drive 8 Water Strainer 9 Lime build up CAUTION Tank and tank compo nents should be delimed regularly depending on local water condi
30. efully bend the capillary tube so that the tube and bulb inside the tank are in the vertical position and away from any electrical connections 11 Refer to Fig 10 and reconnect the wires NOTE The capillary tube must be clear of any electri cal termination and not kinked BLK from Limit Thermostat Heater Switch P1668 FIG 10 THERMOSTAT TERMINALS 35135 012103 SERVICE cont CONTROL BOARD FIG 11 CONTROL BOARD Location The Control Boards are located behind the lower frontaccess cover mounted on the component bracket Test Procedure Liquid Level Control Circuitry Control Board 71 1 Disconnect the dispenser from the power source 2 Disconnect the six pin connector from J3 of the control board 3 Checkthe voltage across pins 5 amp 6 of the six pin connector on the wiring harness with a voltmeter Connect the dispenser to the power source The indication must be 24 volts ac 4 Disconnect the dispenser from the power source If voltage is present as described proceed to step 5 If voltage is not present as described refer to the wiring diagram and check the dispenser wiring har ness 20 5 Reconnect the six pin connector of the wiring harness to J3 of the control board 6 Disconnect the four pin connector from J4 of control board 1 7 Checkthe voltage across pins 1 amp 4 of the four pin connector on the
31. ew lamp holder to the door wiring harness Install lamp 3 into lamp holders 2 and turn 90 until the pins snap in place Install upper door panel 4 lamp 3 lamp hold ers 2 and door wiring harness as an assembly using three 28 32 screws Reconnect the plug on the door wiring harness to the connector on the door interconnect wiring harness Install the door lower panel 5 using six 78 32 screws LAMP REPLACEMENT Refer to Fig 22 1 2 3 Open dispenser door 1 Remove the six 8 32 screws securing lower door panel 5 to the door 1 and remove cover Disconnect the door wiring harness from the door interconnect wiring harness Remove three 78 32 screws securing the upper door panel 4 to the door Remove the upper door cover 4 lamp 3 lamp holders 2 and door wiring harness as an assem bly Rotate lamp 3 90 and remove from lamp hold ers 2 Install lamp 3 into lamp holders 2 and turn 90 until the pins snap in place Install upper door panel 4 lamp 3 lamp hold ers 2 and door wiring harness as an assembly using three 28 32 screws 35135 012103 SERVICE cont LAMP REPLACEMENT Refer to Fig 22 cont 9 Reconnect the plug on the door wiring harness to the connector on the door interconnect wiring harness 10 Install the door lower panel 5 using six 48 32 screws LAMP STARTER and SOCKET Refer to Fig 22 Location The lamp starter 6 is located
32. ful with the draining water because it can be very hot 8 Close drain clamp insert drain plug place drain tube back into machine and replace lower access panel NOTE The dispenser must be refilled using the NITIAL FILL amp HEAT steps before reconnecting to the power source Sho oe Ne 7 35135 012103 TROUBLESHOOTING A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems encountered If the problem remains after exhausting the troubleshooting steps contact the Bunn O Matic Technical Service Department Inspection testing and repair of electrical equipment should be performed only by qualified service personnel All electronic components have 120 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 a 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 to avoid twists and kinks in the tubing Make certain that all plumbing connections ar
33. gh the hole in the lower door panel 5 and releasing spring tabs Connect the sockets leads to the door wiring harness Install doorlower panel 5 with starter and starter socket on door assy 1 using four 78 32 screws 35135 012103 SERVICE cont LIMIT THERMOSTAT FIG 23 LIMIT THERMOSTAT Location The limit thermostat is located in the center of the tank lid Test Procedures 2 3 Disconnect the dispenser from the power source Disconnect both black wires from the limit ther mostat Check for continuity across the limit thermostat terminals If continuity is present as described the limit thermo stat is operating properly If continuity is not present as described replace the limit thermostat Removal and Replacement Remove all wires from the limit thermostat ter minals Carefully slide the limit thermostat out from un der the retaining clip and remove the limit ther mostat Carefully slide the new limit thermostat into the retaining clip Refer to Fig 24 when reconnecting the wires BLK to Tank Heater BLK to Control Thermostat FIG 24 LIMIT THERMOSTAT TERMINALS 35135 012103 SERVICE cont RINSE RUN SWITCH FIG 25 RINSE RUN SWITCH Location Therinse run switch is located on the lower center of the whipper
34. her 6 onto the motor shaft making sure the flat in the frother 6 lines up with the flat on the motor shaft 23 Install whipper chamber 4 on the whipper cham ber receptacle 7 by twisting counterclockwise until the tabs on the whipper chamber 4 lock with the tabs on the whipper chamber receptacle 7 Be sure dispense port is pointing down 24 Install dispense tip 3 into the bottom of the whipper chamber 4 25 Using two 4 40 screws secure the fan baffle to the whipper motor mounting panel 26 Install vacuum hose 12 on fan baffle 13 27 Install hopper support panel using four 8 32 screws 28 Slip the mixing chamber 2 onto the mixing chamber water inlet tube far enough so the mixing chamber 2 will seat inside the whipper chamber 4 Install the steam collector 1 onto the mixing chamber 2 by pushing down and toward the dispenser while twisting until the flange on the steam collector lines up with the slot in the front panel Install hopperassembly inthe dispenser by sliding hopper assembly on the hopper support panel until the slot in the bottom rear of the hopper seats against the shoulder screw in the hopper support panel Co 2 co 3 BLK to Main Harness WHI BLK to Main Harness BRN Station 71 BLK to Main Harness RED Station 72 BLK to Main Harness ORN Station 3 BLK to Main Harness YEL Station 4 BLK to Main Harness BLU Station 5 P1221 FIG 19 WHIPPER MOTOR TERMINA
35. ing the wires to the tank heater 1 1 1 WHI or RED to es BLK to Limit E 5 Thermostat Main Harness CS FIG 36 TANK HEATER TERMINALS 35135 012103 SERVICE cont TANK HEATER SWITCH FIG 37 TANK HEATER SWITCH Location The tank heater switch located inside the dispenser on the upper right of the front panel Test Procedure 1 Disconnect the dispenser from the power source 2 Disconnect the black wires from the main wiring harness 3 With the switch in the ON lower position check for continuity between the center and the upper terminal With the switch in the OFF upper posi tion no continuity should be present between center and upper terminals If continuity is present as described the tank heater ON OFF switch is operating properly If continuity is not present as described replace the switch 39 Removal and Replacement 1 Remove the switch mounting nut on the front of the front panel 2 Remove switch with wires attached from the rear of the front panel 3 Remove the wires from the switch terminals and discard switch 4 Connect the wires to the new switch refer to Fig 38 5 Push new switch through hole in the front panel and secure with facenut BLK to Main Harnesss BLK from Main ae Harness M 219 FIG 38 TANK HEATER SWITCH TERMINALS 35
36. inse and dry each item thoroughly Check for damaged or broken components re place any if necessary and reassemble hopper assy Install hopper assy 20 in the dispenser by sliding hopper assy in the guides on the hopper support plate 19 until the slot in the bottom rear the hopper seats against the pin 18 in the hopper support plate Beo 9 o9 14 15 16 12 13 P2634 FIG 5 AUGER DRIVE amp HOPPER DISASSEMBLY Hopper Lid Mixing Blade Agitator Disk Auger Drive Shaft Bushing Auger Drive Shaft Locknut Auger Drive Bracket Hopper 9 Auger Wire 10 Ejector Elbow 11 Hopper Assy 12 Auger Motor Mounting Panel 13 Hopper Support Plate 14 Auger Motor Bracket 15 Auger Motor 16 Dust Seal 35135 012103 SERVICE cont AUGER DRIVE COMPONENTS FMD 4 amp FMD 5 cont STATIONS 1 5 Auger Drive Motor Refer to Fig 5 RED to BRN WHI from 1 Remove all hopper assemblies 20 and set aside Control Board 1 J3 3 for reassembly RED to WHI RED from 2 Remove the four 78 32 screws securing the hop Control Board 71 J3 2 per support plate 19 remove plate and set aside RED to WHI ORN from for reassembly Control Board 71 J3 1 3 Remove the four 78 32 locking screws located RED to WHI YEL from inside the dispenser housing on the front of the Control Board 2 J3 3 auger motor mounting panel 14 securing auger RED to WHI BLU from a motor mounting bracket 15 and auger motor Control Boa
37. inside the door assy 1 on the top of the door lower panel 5 Test Procedures 1 Disconnect the dispenser from the power source 2 Disconnect the starter leads from the door wiring harness 3 Remove lamp starter from starter socket 4 Check for continuity on each lead of the starter socket If continuity is present as described the starter socket is operating properly If continuity is not present as described replace the starter socket 5 Remove starter 6 from starter socket 6 Check for continuity across the pins on the bottom of the starter 6 If continuity is presentas described replace the starter If continuity is not present as described starter is operating properly Note If continuity tests are both as described and lamp does not light replace the starter 30 Removal and Replacement Refer to Fig 22 1 2 3 1 Open dispenser door assy 1 Remove the four 78 32 screws securing the door lower panel 5 to the door assy 1 Disconnectthe leads onthe starter socket from the door wiring harness Remove lower door panel 5 and starter w socket 6 as assembly Compress the spring tabs on the socket and re move socket from the door bottom cover 5 Rotate starter 90 and remove from the starter socket Insert new starter 6 into socket and turn 90 until the pins snap in place Install new socket by compressing spring tabs on the socket and pushing the socket up throu
38. ispensed LIQUID LEVEL CONTROL The system automatically maintains the hot water tank s level by energizing the refill solenoid when the water level drops below the liquid level probe Ifthe system has not successfully refilled in 15 minutes a refill error occurs When a refill error occurs the refill solenoid is de energized and the left rinse L E D will flash about once every 5 seconds Once the cause of the refill error has been investigated see the troubleshooting guide in the Operating and Service Manual and cured the system can be reset by placing the Rinse Run switch in the programming center position momentarily RINSE TIMERS The dispenser is shipped from the factory with the rinse timers disabled To enable the rinse timers remove power from the dispenser remove the lower access panel and remove the jumper from J1 of the control boards Replace the lower access panel and return power to the dispenser When enabled the rinse timers automatically keep track of the time since the dispenser was last run through a rinse sequence If the dispenser detects that a rinse sequence has not been run for 8 hours the appropriate rinse L E D will flash continually If afteran additional 4 hours 12 hours total a rinse sequence has still not been run the appropriate rinse L E D will light continuously and the appropriate hopper drives will be disabled until a rinse sequence has been run RUNNING A RINSE SEQUENCE 1 Place the rinse run s
39. m the power source If voltage is present as described proceed to 5 If voltage is not present as described refer to the wiring diagram and check dispenser wiring harness 5 Checkfor continuity across the solenoid valve coil terminals If continuity is present as described reconnect the white and violet wires to the solenoid If continuity is not present as described replace the solenoid valve 37 6 Check the solenoid valve for coil action Connect the dispensertothe power source Listen carefully in the vicinity of the solenoid valve for a clicking sound as the coil magnet attracts 7 Disconnect the dispenser 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 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 1 Remove the white and violet wires from the sole noid valve 2 Turn off the water supply to the dispenser 3 Disconnect the water lines to and from the sole noid valve 4 Remove the two 78 32 screws securing the sole noid to the rear of the dispenser housing Remove solenoid 5 Remove the two 78 32 U Type fasteners from the solenoid bracket 6 Install the two 78 32 U Type fasteners and the two 8 32 screws on the new solenoid 7 n
40. ng the tank drain tube drain enough water from the tank so the water level is below the dispense valve mounting hole 5 Disconnectthe water line from the solenoid valve 6 Removethe 78 32 keps nut securing the solenoid valve bracket to side of the tank Remove solenoid valve 7 nstall new solenoid valve and o ring on side of the tank and secure in place with valve mounting bracket and 78 32 keps nut 8 Push the water line onto the tube on bottom of solenoid valve 9 Refer to Fig 32 and reconnect the wires 10 Reinstall side access panels 36 WHIto Main Harness TAN to Main Harness Station 1 RED to Main Harness Station 2 ORN to Main Harness Station 3 YEL to Main Harness Station 4 BLU to Main Harness Station 5 P1672 FIG 32 DISPENSE SOLENOID VALVE TERMINALS 35135 012103 SERVICE cont SOLENOID VALVE INLET e 1 pz FIG 33 INLET SOLENOID VALVE Location The inlet solenoid is located on the lower left side near the rear panel Test Procedures 1 Disconnect the dispenser from the power source 2 Disconnect the white and violet wires from the solenoid valve 3 Checkthe voltage across the white and violet wires with a voltmeter Connect the dispenser to the power source The indication must be 120 volts ac for two wire 120 volt models three wire 120 208 and 120 240 volt models 4 Disconnect the dispenser fro
41. nitoring the voltage across the coil terminals of the tank heater relay The indication must be 120V ac If voltage is present as described the control board 2 is functioning correctly If voltage is not present as described replace the control circuit board 2 Removal and Replacement 1 Disconnect the three plugs on the main wiring harness from the connectors on the control board 2 Remove the four 76 32 keps nuts securing the control board to the component bracket 3 Remove control board and discard 4 Installnew control board on the component bracket using four 76 32 keps nuts 5 Reconnectthe three plugs on the main harness to the connectors on the control board NOTE J4 is not connected on Control Board 2 on 120 208 240V dispensers CONTROL BOARD 1 J3 J1 CONTROL BOARD 72 J2 P2637 FIG 12 CONTROL BOARD CONNECTORS 35135 012103 SERVICE cont DISPENSE SWITCH S FMD 4 amp FMD 5 FIG 13 DISPENSE SWITCHES Location The dispense switches are located on the lower outside of the dispenser door 23 Test Procedure 5 Disconnect the dispenser from the power source Open the dispenser door and remove the bottom door cover Disconnect the wires from the door interconnect wiring harness to the dispense switch to be tested Check for voltage across the black and red white wires for the dispense switch to be teseted from the door interconnect wiring harness
42. pe 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 Administrators International Inc BOCA and the Food Service Sanita tion Manual of the Food and Drug Administration FDA PLUMBING HOOK UP 1 Flush the water line and securely attach it to the flare fitting on the bottom of the dispenser 2 Turn on the water supply 4 35135 012103 INITIAL FILL amp HEAT CAUTION The dispenser must be disconnected from the power source throughout the initial set up except when specified in the instructions 1 Turn on the water supply and connect the dispenser to the power source 2 Water will automatically flow into the tank to the proper level and then shut off This will take less than five minutes 3 When the tank is full of water open the front door and place the heater switch in the ON lower position A tank full of cold water will take approximately eighty minutes for the water to heat on 120 volt versions or forty minutes for 120 208 volt versions and 120 240 volt versions During this waiting period complete these dispenser set up steps a Place the drip tray in front of the dispenser Set the drip tray cover in place b Placeasetof keyholes in the cup locator plate over the screws beneath the hopper access door and push down gently c Fill the hoppers with the dry product to be d
43. r 8 Rinse Run Switch 9 Rinse Timer 10 Relay 120V versions only 11 Control Board 2 120V versions only 11 REMEDY Refer to Service Dispense Switch for testing procedures See page 23 Remove the solenoid valve and clear any obstructions Rebuild or replace the valve if necessary See page 35 Place an empty container beneath the dispense tip Initiate a dispense cycle and check the water tempera ture immediately below the dispense tip with a thermometer Reading should be 180 F to 200 F see ther mostat temperature settings decal in USER NOTICES on page 3 Referto Service Whipper Motor for testing procedure See page 27 Refer to Service Frother Compo nents See page 26 Referto Service Dispense Solenoid Valve for test procedures See page 35 Refer to Service Auger Drive Com ponents See page 13 amp 15 Refer to Service Auger Drive Com ponents See page 13 amp 15 Refer to Service Auger Drive Com ponents See page 13 amp 15 Refer to Service Rinse Run Switch for test procedures See page 32 Refer to Operation Rinse Timer See Page 5 Refer to Service Relay for testing procedures See page 40 Refer to Service Control Board 72 for testing procedures See page 22 35135 012103 TROUBLESHOOTING CONT PROBLEM Dispenser is making unusual noises Excess dust Display not lit PROBABLE CAUSE 1 Plumbing Lines 2 Water Supply 3 Tank Heater 1 F
44. r Control Circuitry Stations 1 3 Control Board 1 amp Stations 4 5 Control Board 2 1 Disconnect the dispenser from the power source 2 Disconnect the six pin connector from J3 of the appropriate control board 3 Checkthe voltage across pins 5 amp 6 of the six pin connector on the wiring harness with a voltmeter Connect the dispenser to the power source The indication must be 24 volts ac 4 Disconnect the dispenser from the power source If voltage is present as described proceed to step 5 If voltage is not present as described refer to the wiring diagram and check the dispenser wiring har ness 5 Reconnect the six pin connector of the wiring harness to J3 of the control board 6 Check that the rinse run switch is in the run position 7 Check the voltage across the red terminal and the black terminal of the auger motor with a voltmeter Connect the dispenser to the power source Press and hold the appropriate dispense switch After a delay of about 6 seconds the indication must be between 4 0 and 24 5 volts dc If the voltage is present as described the hopper motor control circuitry is operating properly If the voltage is not present as described replace the control circuit board 35135 012103 Tank Heater Relay Control Circuitry Control Board 2 120V dispensers only 1 Disconnect the dispenser from the power source 2 Disconnect the six pin connector from J3 of con trol board
45. r source 2 Disconnectthe black and white wires from the fan terminals 3 Checkthe voltage across the black and white wires onthe main harness with a voltmeter Connect the dispenser to the power source The indication must be a 120 volts ac for two wire 120 volts models b 120 volts ac for three wire 120 208 volt or 120 240 volt models If voltage is present as described replace the fan If voltage is not present as described refer to wiring diagram and check the dispenser wiring harness 25 35135 012103 SERVICE cont FROTHER AND WHIPPER MOTOR FMD 4 shown amp FMD 5 P2635 FIG 17 FROTHER AND WHIPPER MOTOR Location The frothers are located behind the dispenser door mounted on the front panel inside the whipper cham ber The whipper motors are located on the back side of the whipper motor mounting panel Test Procedure 1 Disconnect the dispenser from the power source 2 Disconnect the red and white wires FMD 1 amp FMD 2 left motor or orange and white wires FMD 2 right motor of the main harness from the black leads of the motor Press and hold the dispense switch and check the voltage across the disconnected harness wires with a voltmeter Connect the dispenser to the power source The reading must be a 120 volts ac for two wire 120 volt models b 120 volts ac for three wire 120 208 volt or 120 240 volt models
46. r to Fig 3 when reconnecting wires Using four 78 32 locking screws install auger motor dust seal and mounting bracket to the rear of the auger motor mounting panel 19 15 Install hopper assy 15 SIATONS 1 4 RED to BRN WHI from Control Board 1 J3 3 RED to WHI RED from Control Board 1 J3 2 RED to WHI ORN from Control Board 1 J3 1 RED to WHI YEL from Control Board 2 J3 3 1 12 13 14 Control Board J3 4 FIG 3 AUGER MOTOR TERMINALS AUGER DRIVE COMPONENTS FMD 4 amp FMD 5 FIG 4 AUGER DRIVE COMPONENTS Location The auger components are located inside the bottom part of the hopper except for the auger drive bracket washer and locknut which are located on the outside bottom rear of the hopper The auger motors are located on the rear of the auger motor mounting panel Refer to Fig 5 for disassembly and assembly Test Procedures Auger motors Disconnect the dispenser from the power source Disconnect the wires from the motor to be tested Check the voltage across the positive white or ange wire for the right motor or the positive white red wire for the left motor and the negative green wire with a voltmeter With the rinse run switch in the run lower position press and hold the appropriate dispense switch Connect the dis penser to the power supply After a 6 second delay
47. rd 2 J3 2 16 to the rear of the auger motor mounting panel 14 BLK to GRN from 4 ee Control Board J3 4 5 Remove auger motor mounting bracket 15 au ger motor 16 and dust seal 17 as an assembly 6 Remove dust seal 17 from auger motor 16 7 Remove the four 8 32 screws securing the auger motor to the auger motor mounting bracket 8 Remove auger motor and discard 9 Using four 8 32 screws install new auger motor 16 on mounting bracket 15 10 Install dust seal 17 on auger motor shaft 11 Using four 8 32 locking screws install auger motor dust seal and mounting bracket to the rear of the auger motor mounting panel 14 12 Reconnect the wires to the terminals on the auger motor 13 Install hopper support plate 19 and all hopper assemblies 20 14 Refer to Fig 6 when reconnecting wires FIG 6 AUGER MOTOR TERMINALS 17 35135 012103 SERVICE cont Removal and Replacement o TE 1 Loosen the three 78 32 screws securing the com ponent bracket to the dispenser housing base 2 Pull component bracket out the front of the dis penser far enough so the leads on each ballast can be disconnected from the main wiring harness and the door interconnect harness 3 Remove the two 78 32 screws securing each ballast to the rear of the component bracket 4 Remove and discard the ballast 5 Install new ballast on the rear of the component bracket and secure each wi
48. re 240 volt models 4 Disconnectthe dispenser from the power source If voltage is present as described proceed to 5 If voltage is not present as described refer to Wiring Diagrams and check dispenser wiring harness 5 Checkfor continuity across the solenoid valve coil terminals If continuity is present as described reconnect the white and white yellow wires to the solenoid If continuity is not present as described replace the solenoid valve 34 6 Check the solenoid valve for coil action Connect the dispenser to the power source With HOT COLD switch in the COLD upper position press the left dispense switch and listen carefully in the vicinity of the solenoid valve for a clicking sound as the coil magnet attracts 7 Disconnect the dispenser from the power source If the sound is heard as described and water will not pass through the solenoid valve there may be a block age in the water line before 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 1 Loosen the two screws securing the component bracket to the dispenser base Lift the component bracket off of the base and move to the right 2 Remove the white and white yellow wires from the solenoid valve Turn off the water supply to the dispenser 4 Disconnect the water lines to and from
49. ribed replace the auger hopper drive board Removal Cleaning and Replacement Hopper amp Auger 1 Open the dispenser door and raise the top front cover 2 Lift the hopper assy 15 over the pins on hopper support plate 11 and slide hopper assembly out the front of the dispenser Remove hopper lid 1 and empty product Pull off the ejector elbow 14 5 Remove retainer clip 10 and washer 9 from the bottom of the hopper base 8 6 Remove whipper shaft 3 wiper blade 4 and wiper drive gear 5 from the hopper base 8 7 Remove auger wire 13 by pulling it out the front Be ae of the hopper base 8 Lor 8 Remove auger drive bracket 6 by unscrewing left 16171819 11 9 hand threads from auger drive shaft 12 9 Slide spacer 7 and auger drive shaft bracket 6 FIG 2 AUGER DRIVE amp HOPPER DISASSEMBLY off of the auger drive shaft 12 pepe P2633 10 Remove auger drive shaft 12 from hopper base Hopper Lid 11 Hopper Support Plate 8 Hopper 12 Auger Drive Shaft 11 Wash components in a mild solution of dish deter Wiper Shaft 13 Auger Wire gent using a bristle brush when needed Wiper Blade 14 Ejector Elbow 12 Rinse and dry each item thoroughly 13 Check for damaged or broken components re Wiper Drive Gear 15 Hopper Assembly Auger Drive Bracket 16 Auger Motor Bracket ROO c4 OX Odo place any if necessary and reassemble hopper Spacer 17 Auger Motor assembly Hopper Bas
50. ss black wire on the control thermostat and the white or red wire on the tank heater with the tank heater switch in the ON lower position with a voltmeter Connect the dis penser to the power source The indication must be a 120 volts ac for two wire 120 volt models b 208 volts ac for three wire 120 208 volt models c 240 volts ac for three wire 120 240 volt models 5 Disconnect the dispenser from the power source If voltage is present as described the control thermo stat is operating properly Reinstall bulb into the tank If voltage is not present as described replace the thermostat Removal and Replacement 1 Remove the thermostat capillary bulb by firmly pulling up on the capillary at the tank lid This will disengage the grommet from the tank lid 2 Loosen the two 76 32 screws securing the ther mostat to the front tank mounting bracket 3 Disconnect the wires from the thermostat 4 Remove thermostat and remove the screws and spacers from the thermostat 5 Discard thermostat 6 Install two spacers and two 76 32 screws on the new thermostat T Position the thermostat on the botttom side of the front tank mounting bracket and tighten the two 6 32 screws 8 Slide the grommet to the line 4 5 above the bulb on the new capillary tube 9 Insert the capillary bulb through the hole in the tank lid and press the grommet firmly and evenly so that the groove in the grommet fits into the tank lid 10 Car
51. stall new solenoid on rear of dispenser housing and tighten the two screws 8 Securely fasten the water lines to and from the solenoid valve 9 Refer to Fig 34 and reconnect the wires WHI from Main Harness VIO from Main Harness P2641 FIG 34 INLET SOLENOID VALVE TERMINALS 35135 012103 SERVICE cont TANK HEATER FIG 35 TANK HEATER Location The tank heater is located inside the tank and se cured to the tank lid Test Procedure 1 Disconnect the dispenser from the power source 2 Checkthe voltage across the black and white wires 120volt models or blackand red wires for 120 208 volt models or 120 240 volt models with a voltme ter Connect the dispenser to the power source The indication must be a 120 volts ac for two wire 120 volt models b 208 volts ac forthree wire 120 208 volt models C 240 volts ac for three wire 120 240 volt models 3 Disconnect the dispenser from the power source If voltage is present as described proceed to 4 If voltage is not present as described refer to the dispenser wiring diagram and check the wiring har ness 4 Disconnect the black wire and the white or red wire from the tank heater terminals 5 Check for continuity across the tank heater termi nals If continuity is present as described reconnect the wires the tank heater is operating properly If continuity is not present
52. t as described replace the switch Removal and Replacement 1 Remove all wires from the switch terminals 2 Removethe mounting nut on the front of the whip per motor mounting panel 3 Remove the hot cold switch from the rear of the front panel and discard 4 Reconnect the wires to the terminals on the rear of the new switch 5 Push new hot cold switch through the hole on the left side of the whipper motor mounting panel and secure with mounting nut 6 Referto Fig 28 when reconnecting the wires TAN to Main Harness E RED to Main Harness WHI YEL to Cold Solenoid FIG 28 HOT COLD SWITCH TERMINALS 35135 012103 SERVICE cont SOLENOID VALVE COLD WATER OPTIONAL P2635 FIG 29 COLD WATER SOLENOID VALVE Location The cold water solenoid valve is located on the left side of the dispenser base just behind the compo nent bracket Test Procedures 1 Disconnect the dispenser from the power source 2 Disconnect the white and white yellow wires from the solenoid valve With the HOT COLD switch in the COLD upper position press the left dis pense switch on front of the door 3 With a voltmeter check the voltage across the white and white yellow wires Connect the dis penser to the power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 208 volt and 120 240 volt models b 240 volts ac for two wi
53. te corro sive reactions resulting in serious leaks 2 Control Thermostat 1 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 caninitiate corro sive reactions resulting in serious leaks 2 Dispense Solenoid Valve 1 Control Board 71 and Probe 2 Solenoid Valve Inlet REMEDY Referto Service Tank Heater Switch for testing procedures See page 39 Refer to Service Relay for testing procedures See page 40 Refer to Service Control Board 2 for testing procedures See page 22 Inspect the tank assembly for exces sive lime deposits Delime as re quired Refer to Service Control Thermo stat for testing procedures See page 19 Inspectthe tank assembly for exces sive lime deposits Delime as re quired Remove the dispense solenoid valve and clear any obstructions Rebuild or replace the valve if necessary See page 35 Refer to Service Control Board and Probe for testing procedures See page 20 Refer to Service Solenoid Valve Inlet for testing procedures See page 37 35135 012103 TROUBLESHOOTING cont PROBLEM Product overflows container Weak product PROBABLE CAUSE 1 Dispense Switch 2 Dispense Solenoid Valve 1 Water Temperature 2 Whipper Motor 3 Frother 4 Dispense Solenoid Valve 5 Auger Drive 6 Auger Spring T Auger Moto
54. th two 78 32 screws 6 Referto Fig 8 and reconnect the wires 7 Place the component bracket into position and tighten the two 8 32 screws securing the compo nent bracket to the dispenser housing base BLK to BLK from Main Wiring Harness Qr BLK to RED from Main Harness FIG 7 BALLASTS Location The front door lamp ballast is located behind the front access panel on the left front side of the compo FIG 8 BALLAST TERMINALS nent bracket Test Procedure 1 Disconnect the dispenser from the power source 2 Disconnect the two black lead on the ballast from the main harness Check for continuity between the two black leads on the ballast If continuity is present as described the ballast is operating properly If continuity is not present as described replace the ballast 18 35135 012103 SERVICE cont CONTROL THERMOSTAT FMD 4 amp FMD 5 2 X FIG 9 CONTROL THERMOSTAT Location The control thermostat is located at the upper left rear of the dispenser housing Test Procedure 1 Disconnect the dispenser from the power source 2 Disconnect the black wire of the control thermo stat from the black lead from the limit thermostat 3 Remove bulb from the tank 4 Checkthe voltage acro
55. the sole noid valve 5 Loosen the two 78 32 screws and washers se curing the solenoid mounting bracket to the base Remove solenoid bracket and solenoid valve as an assembly 6 Remove the two 710 32 screws and lockwashers securing the solenoid valve to the solenoid bracket 7 Using two 710 32 screws lockwashers install new solenoid valve on solenoid mounting bracket 8 Install the solenoid valve and bracket on the dis penser base and tighten the two 78 32 screws 9 Securely fasten the water lines to and from the solenoid valve 10 Refer to Fig 30 when reconnecting the wires WHI YEL to Hot Cold Switch WHI to Main Wiring Harness o P1215 FIG 30 COLD WATER SOLENOID TERMINALS 35135 012103 SERVICE cont SOLENOID VALVE DISPENSE FMD 4 amp FMD 5 P2635 FIG 31 DISPENSE SOLENOID VALVE Location The dispense solenoid is located on the upper left center of the tank Test Procedures 1 Disconnectthe dispenser from the power source 2 BDisconnectthetwo wires from the solenoid valve thatis being tested With the RINSE RUN switch inthe RINSE upper position press the dispense switch on front of the door 3 Check the voltage across the two wires with a voltmeter Connect the dispenser to the power source The indication must be 120 volts ac for two wire 120 volt models three wire 120 208 and 120
56. the wires on the dispense switch from the door interconnect wiring harness Compress the clips inside the door on the dis pense switch and gently push the switch through the opening Push the new switch into the opening and spread the clips to hold the switch in the door Reconnect the wires to the dispense switch from the door interconnect wiring harness Reinstall the door bottom cover using six 78 32 screws Refer to Fig 14 when reconnecting wires 24 STATIONS BLK WHI 1 WHI BLK RED 2 RED BLK ORN 3 ORN BLK GRN WHI 4 GRN BLK BLU 5 BLU BLK FIG 14 DISPENSE SWITCH TERMINALS P1449 35135 012103 SERVICE cont FAN Removal and Replacement 1 Disconnect the vacuum hose from the fan 2 Remove the two 78 32 locking screws securing the fan to the dispenser housing base plate 3 Disconnect the wires from the fan terminals and discard the fan 4 Referto Fig 16 and connect the wires to the new fan 5 Install new fan through the rear access hole and secure to the dispenser housing base plate using two 78 32 locking screws 6 Reconnect the vacuum hose to the fan BLK from Main Harness FIG 15 FAN Location WHI from Main Harness The fan is located inside the dispenser housing on the center rear of the dispenser base plate FIG 16 FAN TERMINALS Test Procedures 1 Disconnect the dispenser from the powe
57. tions Excessive mineral build up on stain less steel surfaces caninitiate corro sive reactions resulting in serious leaks 10 Transformer 1 Limit Thermostat CAUTION Do not eliminate or by pass limit thermostat Use only BOM replacement part 29329 1000 2 Control Thermostat 3 Tank Heater REMEDY Refer to Service Solenoid Valve Inlet for testing procedures See page 37 Refer to Service Control Board and Probe for testing procedures See page 20 Refer to Service Auger Drive See page 13 amp 15 Remove the strainer and check for obstructions Clear or replace Inspectthe tank assembly for exces sive lime deposits Delime as re quired Refer to Service Transformer for testing procedures See page 41 Refer to Service Limit Thermostat for testing procedures See page 31 Refer to Service Control Thermo stat for testing procedures See page 19 Refer to Service Tank Heater for testing procedures See page 38 35135 012103 TROUBLESHOOTING cont PROBLEM Water is not hot Cont Spitting or excessive steaming Dripping from dispense tip Water flows into tank continuously PROBABLE CAUSE 4 Tank Heater Switch 5 Relay 120V versions only 6 Control Board 2 120V versions only 1 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 caninitia
58. wist the whipper chamber 4 clockwise and pull it off the whipper chamber receptacle 7 Pull the frother 6 off the motor shaft Notice the flat side on the shaft and the matching flat inside the frother It is important that these two flats are lined up when reassembling Slip the O ring 5 off the whipper chamber recep tacle 7 Slide the receptacle w seal off of the motor shaft Slide the slinger 9 off of the motor shaft Remove the two nuts 8 securing whipper cham ber receptacle 7 and whipper motor 10 to the front panel NOTE To remove the receptacle only rotate clockwise 14 15 16 17 18 19 20 21 until the receptacle clears the nuts 8 and slide off of the motor shaft Disconnect the black leads on the motor 10 from the main wiring harness Remove motor and discard Install new motor 10 on rear of front panel and secure with two nuts 8 and connect black leads on the motor to the main wiring harness Refer to Fig 19 when reconnecting wires Slide slinger 9 onto the motor shaft flush against the front panel Wash remaining components in a mild solution of dish detergent using a bristle brush Rinse thoroughly and allow to dry before reinstall ing in the dispenser Slide whipper chamber receptacle w seal 7 and O ring 5 on to the motor shaft Rotate the receptacle w seal 7 counterclockwise until it snaps into place on the motor mounting nuts 8 22 Push frot
59. witch in the rinse position 2 Sequentially or simultaneously at each of the positions dispense for at least 10 seconds After the rinse L E D has extinguished the rinse timer is reset 4 Return the rinse run switch to the run position DISPENSER USE 1 Simply place a cup on the drip tray beneath the dispensing tip 2 Press the button and dispense the beverage 3 Release the button when the cup is approximately full and allow the whipper chamber to drain NOTE The whipper chamber must drain at the end of each dispense 5 35135 012103 COLD BEVERAGE SET UP OPTIONAL Cold beverages may be dispensed from the left dispense position Simply place the HOT COLD switch near the left whipper chamber in the COLD upper position CLEANING Refer to the decal on the rear of the dispenser door for cleaning recommendations and proccedures The use of a damp cloth rinsed in any mild non abrasive liquid detergent is recommended for cleaning all surfaces on 0 equipment ADJUSTMENTS The beverage solenoid is preset to dispense approximately 9 10 ounce per second This amount can be adjusted 1 Disconnect the dispenser from the power source 2 Remove product hopper s 3 Remove the hole plug s in the auger motor mounting panel 4 Rotatethecontrolatthe base ofthe solenoid clockwise to decrease or counterclockwise to increase the amount of water 5 Reinstall plug s and hopper s HOPPER MOTOR SPEED
60. y opening the door removal of the door panels dispenser top cov ers hopper s hopper support plate splash guard splash panel w drip tray lower front access panel and rear access cover Refer to the contents listing for component loca tion Contents Auger Drive Components FMD 4 13 Auger Drive Components FMD 5 15 Ballare ntes 18 Control Thermostat 19 Control BOB 20 Dispense Switch 23 25 RN 26 Increase Decrease Switch 28 Entum 29 EaD eee 29 Lamp Starter and Socket 5 nen 30 Limit Thermostat 91 Rinse Run Switch 32 Hot Cold Switch Optional 33 Solenoid Cold Water Optional 34 caesi 25 sini e n 37 Tank 38 Tank Heater Switch 2er teneri 39 Tank Heater emiten itta 40 IranStOr ME ennan 41 Whipper cn terii 27 Wiring NAGY AIM RENE 42 45 AUGER DRIVE COMPONENTS FMD 4 FIG 1 AUGER DRIVE COMPONENTS Location The auger components are located inside the bottom part of the hopper except for the auger drive bracket spacer and retaining clip which are loc

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