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Bunn FMD-4 manual

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Table of contents for the manual

  • Page 1

    OPERA TING & SERVICE MANUAL BUNN-O-MA TIC CORPORA TION POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227 PHONE: (217) 529-6601 FAX: (217) 529-6644 www .bunnomatic.com FMD-4 FMD-5 35135.0000 03/03 ©2003 Bunn-O-Matic Corporation BUNN ® PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE RELEASE BUTT ON WHEN CUP IS 2/3[...]

  • Page 2

    2 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-O-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 la[...]

  • Page 3

    3 00656.0000 00831.0000 28368.0000 USER NOTICES (Cont.) FMD-5 28964.0003 FMD-4 28964.0004 35135 012103[...]

  • Page 4

    4 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 sour ce until specified in Initial Set-Up. The 120 volt version of this dispenser has an attached cordset and requires [...]

  • Page 5

    5 INITIAL FILL & HEA T CAUTION - The dispenser must be disconnected from the power sour ce 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 [...]

  • Page 6

    6 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,[...]

  • Page 7

    7 DRAINING THE HOT W A TER T ANK CAUTION - The dispenser must be disconnected from the power sour ce throughout these steps. 1. Disconnect the dispenser from the power source. 2. Place the tank heater switch in the “OFF” position. 3. Shut-off and disconnect the incoming water supply. 4. Remove the front, lower access panel. 5. Pull out drain tu[...]

  • Page 8

    8 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 qual[...]

  • Page 9

    9 TROUBLESHOOTING (cont.) PROBLEM Product will not dispense (cont.) Water is not hot PROBABLE CAUSE 5. Solenoid Valve (Inlet) 6. Control Board #1 and Probe 7. Auger Drive 8. Water Strainer 9. 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 [...]

  • Page 10

    10 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 dependi[...]

  • Page 11

    11 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 7. Auger Motor 8. Rinse/Run Switch 9. Rinse Timer 10. Relay (120V versions only) 11. Control Board #2 (120[...]

  • Page 12

    12 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. Fan 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) W[...]

  • Page 13

    13 J4 J1 J2 J3 J4 J1 J2 J3 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 b[...]

  • Page 14

    14 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 [...]

  • Page 15

    15 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) 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 BLK to GRN from Control Board J3-4 P1639 FIG. 3 AUGER MOTOR TERMINALS FIG. 4 AUGER DRIVE COMPONENTS Location The auger components are locat[...]

  • Page 16

    16 SERVICE (cont.) AUGER DRIVE COMPONENTS - FMD-4 & 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 Repla[...]

  • Page 17

    17 SERVICE (cont.) AUGER DRIVE COMPONENTS - FMD-4 & FMD-5 (cont.) Auger Drive Motor (Refer to Fig. 5) 1. Remove all hopper assemblies (20) and set aside for reassembly. 2. Remove the four #8-32 screws securing the hop- per support plate (19), remove plate and set aside for reassembly. 3. Remove the four #8-32 locking screws, located inside the [...]

  • Page 18

    18 J4 J1 J2 J3 J4 J1 J2 J3 Location The front door lamp ballast is located behind the front access panel on the left front side of the compo- nent bracket. T est Procedure 1. Disconnect the dispenser from the power source. 2. Disconnect the two black lead on the ballast from the main harness. 3. Check for continuity between the two black leads on t[...]

  • Page 19

    19 J1 J2 CONTROL THERMOST A T - FMD-4 & FMD-5 FIG. 9 CONTROL THERMOST A T P2635 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. R[...]

  • Page 20

    20 J4 J1 J2 J3 J4 J1 J2 J3 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. Check the voltage across pins 1 & 4 of the four pin connector on the wiring harness with a voltmeter. Connect the dispenser to the power source. The indication must [...]

  • Page 21

    21 SERVICE (cont.) 16. Reconnect the ten pin connector of the wiring harness to J2 of control board #1. 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 termina[...]

  • Page 22

    22 J4 J1 J2 J3 J4 J1 J2 J3 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 #2. 3. Check the voltage across pins 5 & 6 of the six pin connector on the wwiring harness with a voltme- ter. Connect the disp[...]

  • Page 23

    23 PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE RELEASE BUTTON WHEN CUP IS 2/3 FULL ! WARNING H O T L I Q U I D PUSH and HOLD BUTT ON UNTIL CUP IS 2/3 FULL, THEN R ELEASE RINSE RINSE PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE PLACE CUP HERE RELEASE BUTTON WHEN CUP IS 2/3 FULL ! WARNING H O T L I Q U I D PUSH and HOLD[...]

  • Page 24

    24 SERVICE (cont.) DISPENSE SWITCHES (cont.) 7. 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 conn[...]

  • Page 25

    25 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) FA N FIG. 15 F AN Location: The fan is located inside the dispenser housing on the center rear of the dispenser base plate. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the black and white wires from the fan terminals. 3. Check the voltage across the black and white wi[...]

  • Page 26

    26 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) FROTHER AND WHIPPER MOTOR - FMD-4 (shown) & FMD-5 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. T est Procedu[...]

  • Page 27

    27 SERVICE (cont.) FROTHER AND WHIPPER MOTOR - FMD-4 (shown) & FMD-5 (cont.) FIG.19 WHIPPER MOTOR TERMINALS P1221 4. Disconnect vacuum hose (12) from fan baffle (13). 5. Remove the steam collector (1) by pulling it for- ward and at the same time twisting it clockwise. 6. Pull the mixing chamber (2) out of the whipper chamber (4). 7. Remove the [...]

  • Page 28

    28 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) INCREASE/DECREASE SWITCH FIG. 20 INCREASE/DECREASE SWITCH P2635 Location: The increase/decrease switch is located on the lower left front of the whipper motor mounting panel. T est Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the switch terminals. 3. Check for [...]

  • Page 29

    29 PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEASE RINSE RINSE LAMP HOLDERS FIG. 22 LAMP HOLDERS P2638 3 4 6 5 1. Door Assy 2. Lamp Holders 3. Lamp 4. Upper Panel 5. Lower Panel 6. Starter W/Socket 2 1 Location: The lamp holders are located on the front of the upper panel behind the display panel. T est Procedure: 1. Disconnect the dispens[...]

  • Page 30

    30 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 #8-32 screws. LAMP ST AR TER and SOCKET (Refer to Fig. 22) Location: The lamp starter (6) is located inside the door assy (1) on the top of the door lower panel (5). T est Procedures: 1. Discon[...]

  • Page 31

    31 SERVICE (cont.) LIMIT THERMOST A T FIG. 23 LIMIT THERMOST A T P2635 Location: The limit thermostat is located in the center of the tank lid. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect both black wires from the limit ther - mostat. 3. Check for continuity across the limit thermostat terminals. If continuity[...]

  • Page 32

    32 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) P2635 RINSE/RUN SWITCH FIG. 25 RINSE/RUN SWITCH Location: The rinse/run switch is located on the lower center of the whipper motor mounting panel. T est Procedures: 1. Disconnect the dispenser from the power sour ce. 2. Check for continuity between the center left ter - minal and left bottom terminal, also[...]

  • Page 33

    33 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) FIG. 27 HOT/COLD SWITCH P2635 HOT/COLD SWITCH (Optional) Location: The hot/cold switch is located on the left side of the whipper motor mounting panel. T est 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 [...]

  • Page 34

    34 J4 J1 J2 J3 J4 J1 J2 J3 SOLENOID V AL VE (COLD WA TER - OPTIONAL) FIG. 29 COLD WA TER SOLENOID V AL VE P2635 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 wi[...]

  • Page 35

    35 J4 J1 J2 J3 J4 J1 J2 J3 SOLENOID V AL VE (DISPENSE) - FMD-4 & FMD-5 FIG. 31 DISPENSE SOLENOID V AL VE Location: The dispense solenoid is located on the upper left center of the tank. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the two wires from the solenoid valve that is being tested. With the “RINSE[...]

  • Page 36

    36 SERVICE (cont.) FIG. 32 DISPENSE SOLENOID V AL VE TERMINALS P1672 Removal and Replacement: 1. Remove the four #8-32 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. Using the tank drain tube, drain enough water from the[...]

  • Page 37

    37 J4 J1 J2 J3 J4 J1 J2 J3 P2641 FIG. 34 INLET SOLENOID V AL VE TERMINALS SERVICE (cont.) WHI from Main Harness 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 requi[...]

  • Page 38

    38 Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Disconnect the water supply tube on the tank lid. 3. Disconnect the black wires on the limit thermstat. 4. Disconnect the 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 fr[...]

  • Page 39

    39 J4 J1 J2 J3 J4 J1 J2 J3 SERVICE (cont.) FIG. 38 T ANK HEA TER SWITCH TERMINALS P1219 BLK to Main Harnesss BLK from Main Harness FIG. 37 T ANK HEA TER SWITCH T ANK HEA TER SWITCH P2635 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 sou[...]

  • Page 40

    40 J4 J1 J2 J3 J4 J1 J2 J3 TANK HEATER RELAY (120V Dispensers only) FIG. 39 TANK HEATER RELAY P2635 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. Place the tank heater switch in the “OFF?[...]

  • Page 41

    41 J4 J1 J2 J3 J4 J1 J2 J3 TRANSFORMER FIG. 41 TRANSFORMER P2635 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 source. 2. Disconnect the four wires of the main harness from the transformer. 3 Check the volt[...]

  • Page 42

    42 GRN GRY WHI/GRY BRN/BLK BRN/BLK BLK I N C D E C INCREASE/ DECREASE SWITCH RINSE/PROGRAM/ RUN SWITCH RUN RUN PGM PGM RINSE RINSE WHI/VIO RED/BLK GRN GRN GRN GRN GRY PNK WHI/ORN WHI/ORN WHI/RED WHI/RED WHI/GRY WHI/VIO GRY WHI/GRY WHI/VIO WHI/VIO WHI VIO WHI WHI/BLK WHI/GRN WHI/BLK WHI/BLK WHI/RED WHI/GRN WHI/BLK BRN/WHI RED/BLK RED/BLK BLU/BLK WHI[...]

  • Page 43

    43 GRN GRY WHI/GRY BRN/BLK BRN/BLK BLK I N C D E C INCREASE/ DECREASE SWITCH RINSE/PROGRAM/ RUN SWITCH RUN RUN PGM PGM RINSE RINSE WHI/VIO RED/BLK GRN PROBE GRN GRN GRN GRY PNK WHI/ORN WHI/ORN WHI/RED WHI/RED WHI/GRY WHI/VIO GRY WHI/GRY WHI/VIO WHI/VIO WHI VIO WHI WHI/BLK WHI/GRN WHI/BLK WHI/BLK WHI/RED WHI/GRN WHI/BLK BRN/WHI RED/BLK RED/BLK BLU/B[...]

  • Page 44

    44 GRN GRY WHI/GRY BRN/BLK BRN/BLK BLK I N C D E C INCREASE/ DECREASE SWITCH RINSE/PROGRAM/ RUN SWITCH RUN RUN PGM PGM RINSE RINSE WHI/VIO RED/BLK GRN GRN GRN GRN GRY PNK WHI/ORN WHI/ORN WHI/RED WHI/RED WHI/GRY WHI/VIO GRY WHI/GRY WHI/VIO WHI/VIO WHI VIO WHI WHI/BLK WHI/GRN WHI/BLK WHI/BLK WHI/RED WHI/GRN WHI/BLK BRN/WHI RED/BLK RED/BLK BLU/BLK WHI[...]

  • Page 45

    45 GRN GRY WHI/GRY BRN/BLK BRN/BLK BLK I N C D E C INCREASE/ DECREASE SWITCH RINSE/PROGRAM/ RUN SWITCH RUN RUN PGM PGM RINSE RINSE WHI/VIO RED/BLK GRN PROBE GRN GRN GRN GRY PNK WHI/ORN WHI/ORN WHI/RED WHI/RED WHI/GRY WHI/VIO GRY WHI/GRY WHI/VIO WHI/VIO WHI VIO WHI WHI/BLK WHI/GRN WHI/BLK WHI/BLK WHI/RED WHI/GRN WHI/BLK BRN/WHI RED/BLK RED/BLK BLU/B[...]