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Bunn JDF-4S manual

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Table of contents for the manual

  • Page 1

    JDF-2S, JDF-4S JDF-4D, JDF-4SB SER VICE & REP AIR MANU AL BUNN-O-MA TIC CORPORA TION POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227 PHONE: (217) 529-6601 F AX: (217) 529-6644 T o ensure you have the latest revision of the Operating Manual, or to view the Illustrated Parts Catalog, Programming Manual, or Service Manual, please visit the B[...]

  • Page 2

    2 BUNN-O-MA TIC COMMERCIAL PRODUCT WARRANTY Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows: 1) Airpots, thermal carafes, decanters, GPR servers, iced tea/coffee dispensers, MCP/MCA pod brewers thermal ser vers and Thermofresh servers (mechanical and digital)- 1 year parts and 1 year labor . 2) All other equipment -[...]

  • Page 3

    3 USER NOTICES All notices on this equipment are written for your protection. All notices are to be kept in good condition. Replace any unreadable or damaged labels. CONTENTS Warranty ................................................................................................................................... 2 User Notices ...................[...]

  • Page 4

    4 Recommended Daily Cleaning Instructions The use of a damp cloth rinsed in any mild, non-abrasive, liquid detergent is recommended for cleaning all surfaces on Bunn-O-Matic equipment. Do NOT clean this equipment with a water jet device. 1. Open dispenser door . Lift up on product containers to discon- nect them from the machine in- let. 8. Dispens[...]

  • Page 5

    5 REQUIRED REGULAR MAINTENANCE: When performing Daily-Weekly Cleaning procedures, inspect o-rings, seals, and bushings for signs of wear or damage and replace immediately . Check and/or replace every 6 months or as required: 39690.0000 Pump T ube Replacement Kit (Includes items indented below) 28755.1011 T ube, Norprene .25" ID x 17.0" lg[...]

  • Page 6

    6 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 T echnical Ser vice Department. • Inspection, testing, andrepair of electrical equipment should?[...]

  • Page 7

    7 PROBLEM PROBABLE CAUSE REMEDY TROUBLESHOOTING (Continued) Check for "ON" position or no continu - ity - replace switch. Clean filter and fins or replace con- denser filter . (Filter not supplied on some machines). A) Check for 120V or 230V AC. Re- place fan motor or check fan blades for obstructions. B) Check compressor LED on circui[...]

  • Page 8

    8 PROBLEM PROBABLE CAUSE REMEDY TROUBLESHOOTING (Continued) Dispense station not working All stations dispense concentrate only 1. Dispense Lockout switch set to OFF position. 2. Dispense switch failed Main water supply Frozen bath Inlet water valve failed Place switch in ON position. Check switch and harness for proper continuity . Check for ON po[...]

  • Page 9

    9 PROBLEM PROBABLE CAUSE REMEDY TROUBLESHOOTING (Continued) Dispense station concentrate only Dispense station water only Replace solenoid (24vdc) or check wire connection between water valve and main control board. Replace refill concentrate container or BIB Check for proper counterclockwise rotation of pump rollers. If coun- terclockwise, replac[...]

  • Page 10

    10 PROBLEM PROBABLE CAUSE REMEDY TROUBLESHOOTING (Continued) Water leak filling drip tray or around dispense deck area Water leaking beneath machine Erratic spray during dispense Dispense nozzle dripping water 1. Initial fill/setup 2. Dispense deck 3. Water pressure greater than 100psi 1. Bath tank overflow . 2. Condensation from cabinet cool- i[...]

  • Page 11

    11 PROBLEM PROBABLE CAUSE REMEDY TROUBLESHOOTING (Continued) Unit is not working Difficulty brixing and/or weak bever - age Difficulty brixing and/or weak bever - age Difficulty brixing bag-in-box 1. Step-down transformer . 2. Main control board. 1. Product viscosity or too cold. 2. Low water pressure. 3. High water pressure. 4. Dispense valve a[...]

  • Page 12

    12 SERVICE This section provides procedures for testing and replacing various major components used in this dispenser should service become necessar y . Refer to T roubleshooting for assistance in determining the cause of any problem. WARNING - Inspection, testing, and repair of electrical equipment should be performed only by qualified ser vice p[...]

  • Page 13

    13 SERVICE(CONT .) ACCESS P ANELS Location: All access panels are similar through the whole JDF family (JDF-4S shown). Before removing panels, make sure power is OFF to the machine and water is disconnected accept where indicated in testing procedures. Retain all screws and other attaching hardware for re-assembly . FIG. 1 ACCESS P ANELS JDF-4S sho[...]

  • Page 14

    14 SERVICE(CONT .) DISPENSE PLA TFORM REMOV AL 1. Remove concentrate dispense tips by turning 1/4 turn to the left, then pull straight down. 2. Lift and remove product shelf to access dispense platform(s). 3. Remove front thumb screw holding dispense platform(s). 4. Disconnect 12 pin connector above dispense platform in rear . 5. Disconnect 3/8” [...]

  • Page 15

    15 SERVICE (CONT .) Ballast (JDF-2S,4S) P1684.40 FIG. 3 BALLAST Location: The door lamp ballast is located inside the dispenser door mounted in the center of the door rear cover . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect a black and blue wire from one set of lamp sockets. 3. Connect an ohmmeter to the end of[...]

  • Page 16

    16 SERVICE (CONT .) Cabinet Fan (all Models) P1684.40 FIG. 5 CABINET F AN Location: The cabinet fan is located inside the dispenser cabinet mounted in the center behind the fan guard cover . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Remove the four screws attaching the fan and cover assembly . 3. Gently pull the cover f[...]

  • Page 17

    17 SERVICE (CONT .) LG Compressor (JDF-2S,4S,4D) P1684.40 FIG. 7 COMPRESSOR Location: The compressor is located at the top of the dispenser frame. T est Procedures: Compressor Relay: Refer to FIG. 8 1. Disconnect the dispenser from the power source. 2. Remove compressor terminal cover retainer (1). 3. Connect a voltmeter across the white wire and t[...]

  • Page 18

    18 SERVICE (CONT .) Compressor (Cont.) Removal and Replacement: Compressor Relay: Refer to FIG. 8 1. Remove the terminal cover (1) 2. Disconnect the white wire from the compressor relay . 3. Pull relay (2) off of the compressor pins and discard. 4. Push new relay onto the compressor pins. 5. Refer to Fig. 9 and reconnect the wires. 6. Reinstall ter[...]

  • Page 19

    19 SERVICE (CONT .) GD Compressor (JDF-2S,4S,4D) P1684.40 FIG. 11 COMPRESSOR Location: The compressor is located at the top of the dispenser frame. T est Procedures: Compressor Start Relay: Refer to FIG. 12 WARNING: The compressor capacitor must be properly discharged before proceeding. This is most commonly done on low voltage capacitors by shorti[...]

  • Page 20

    20 SERVICE (CONT .) Compressor (Cont.) Removal and Replacement: Compressor Start Relay: Refer to FIG. 12 1. Remove the terminal cover (4) 2. Disconnect the wires from the compressor start relay . 3. Pull relay (1) off of the compressor pins and dis- card. 4. Push new relay onto the compressor pins. 5. Refer to Fig. 26 and reconnect the wires. 6. Re[...]

  • Page 21

    21 SERVICE (CONT .) Compressor (JDF-4SB) P1684.40 FIG. 15 COMPRESSOR Location: The compressor is located at the top of the dispenser frame. T est Procedures: Compressor Start Relay: Refer to FIG. 16 WARNING: The compressor capacitor must be properly discharged before proceeding. This is most commonly done on low voltage capacitors by shorting acros[...]

  • Page 22

    22 SERVICE (CONT .) Compressor (Cont.) Removal and Replacement: Compressor Start Relay: Refer to FIG. 16 1. Remove the terminal cover (4) 2. Disconnect the wires from the compressor start relay . 3. Pull relay (1) off of the compressor pins and dis- card. 4. Push new relay onto the compressor pins. 5. Refer to Fig. 16 and reconnect the wires. 6. Re[...]

  • Page 23

    23 SERVICE (CONT .) Compressor Switch (all Models) P1684.40 FIG. 19 COMPRESSOR SWITCH Location: On models JDF-2S and 4S, early models had the switch located on the back of the dispenser next to the water inlet. On later models JDF-2S, 4S, 4D and 4SB, the switch is located on the front left of the dispenser behind the splash panel. T est Procedure: [...]

  • Page 24

    24 SERVICE (CONT .) Condenser Fan (all Models) P1684.40 FIG. 21 CONDENSER F AN Location: The condenser fan is located inside the main frame below the compressor assembly . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the 2-pin from the fan to the main wiring harness. 3. Check for continuity across the fan termin[...]

  • Page 25

    25 SERVICE (CONT .) Control Board, Main (all Models) FIG. 23 CONTROL BOARD P3250.25 Location: The Main Control Board is located on the electrical component enclosure behind the splash panel. T est Procedure: Power Supply Circuitry: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , back probe check the voltage across pins 1 &a[...]

  • Page 26

    26 SERVICE (CONT .) Portion Control Board (JDF-2S,4S) FIG. 25 PORTION CONTROL BOARD P4034.25 Location: The Portion Control Board is located inside the door cover mounted on the bracket. T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , back probe check the voltage across pins 1 & 5 of the J6 connector on [...]

  • Page 27

    27 SERVICE (CONT .) Push Button Control Board (JDF-4D) FIG. 27 PUSH BUTTON CONTROL BOARD P4081.25 Location: The Push Button Control Board is located inside the door cover mounted on the bracket. T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , back probe check the voltage across pins 1 & 5 of the J6 conn[...]

  • Page 28

    28 POWE R C O O L ING SERVICE (CONT .) Portion Control Board (JDF-4D) FIG. 29 PORTION CONTROL BOARD Location: The Portion Control Board is located inside the door cover mounted on the bracket. T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , back probe check the voltage across pins 1 & 5 of the J6 connec[...]

  • Page 29

    29 SERVICE (CONT .) Circulation Pump (all Models) FIG. 31 CIRCULA TION PUMP Location: The Circulation Pump is located on top of the water bath tank cover . T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter . If voltage is present as described, proceed to step 4. If voltage is not present as described, refer to [...]

  • Page 30

    30 SERVICE (CONT .) Dispense Platform Switch (all Models) FIG. 33 DISPENSE PLA TFORM SWITCH Location: The Dispense Platform Switch is located below the dispenser in the front center and is mounted on the component mounting bracket. T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , back probe check across the [...]

  • Page 31

    31 SERVICE (CONT .) Dispense Pump (all Models except JDF-4D) FIG. 35 DISPENSE PUMP Location: The Dispense Pumps are located on the platform assembly . Removal, Inspection, and Replacement: 1. Loosen the four #8-32 x 2.45 screws securing the pump assembly to the platform. 2. Pr y the two halves of the pump housing apart to reveal the pump tube and t[...]

  • Page 32

    32 SERVICE (CONT .) Dispense Motor (all Models) FIG. 37 DISPENSE MOTOR Location: The Dispense Motors are located on the rear of the platform assembly . T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , check the voltage across the two wire terminals of the motor assembly . Connect the dispenser to the power s[...]

  • Page 33

    33 SERVICE (CONT .) Dispense Valve (all Models) FIG. 39 DISPENSE V AL VE Location: The Dispense Valves are located at the front of the platform assembly . T est Procedure: 1. Disconnect the dispenser from the power source. 2. With a voltmeter , check the voltage across the two wire terminals of the valve solenoid. Connect the dispenser to the power[...]

  • Page 34

    34 SERVICE (CONT .) Dispense Switches (JDF-2S, JDF-4S) FIG. 41 DISPENSE SWITCHES P1449 FIG. 42 DISPENSE SWITCH TERMINALS Station #1 Station #2 Station #3 BLK RED BLK GRN Location: The dispense switches are located on the lower outside of the dispenser door . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Remove the five scr[...]

  • Page 35

    35 SERVICE (CONT .) Cold Water Dispense Switch (JDF-4S only) FIG. 43 COLD WA TER DISPENSE SWITCH P1449 FIG. 44 COLD WA TER SWITCH TERMINALS BLK BLU Location: The cold water dispense switch is located on the lower outside of the dispenser door . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Remove the five screws attaching [...]

  • Page 36

    36 COLD WA TER SERVICE (CONT .) Dispense Membrane Switch (all Models) FIG.45 MEMBRANE SWITCHES Location: The dispense buttons are located on the lower outside of the dispenser door and actuate switches on the dispense switch board located on the inside of the door . T est Procedures: NOTE : Before continuing, check that the ribbon cable is properly[...]

  • Page 37

    37 SERVICE (CONT .) Cold Water Dispense Membrane Switch (all Models) FIG.47 MEMBRANE SWITCHES Location: The dispense buttons are located on the lower outside of the dispenser door and actuate switches on the dispense switch board located on the inside of the door . T est Procedures: NOTE : Before continuing, check that the ribbon cable is properly [...]

  • Page 38

    38 SERVICE (CONT .) EMI Filter (all Models) FIG. 49 EMI FIL TER Location: The EMI Filter is located on the electrical component mounting bracket on the lower front of the dispenser behind the splash panel. T est Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the two black wires and two white wires on the EMI Filter from[...]

  • Page 39

    39 SERVICE (CONT .) Lamps, Holders and Ballast(s) (Early Models) FIG. 51 LAMPS & HOLDERS Location: The lamps and lamp holders are located on the door light panel behind the door cover . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Remove the five #10-32 screws securing the door cover to the door and move the cover asi[...]

  • Page 40

    40 SERVICE (CONT .) LED Lamps (JDF-2S, JDF-4S) Removal and Replacement: 1. Disconnect power from the dispenser . 2. Remove the five #6-32 screws securing the door cover to the door . 3. Carefully lower the door cover and disconnect the lamp terminals from the LED regulator board. 4. Remove and discard the faulty LED board. 5. Install a new LED reg[...]

  • Page 41

    41 SERVICE (CONT .) Rectifier (JDF-2S, JDF-4S) Removal and Replacement: 1. Disconnect the wires from the rectifier . 2. Remove the #10-32 screw securing the rectifier . 3. Remove the rectifier and discard. 4. Secure new rectifier with #10-32 screw . 5. Refer to Fig. 56 and reconnect the wires. BLU from Door Harness (+) WHI/GRN to T ransformer [...]

  • Page 42

    42 12 11 9 8 7 SERVICE (CONT .) Relay (all Models) FIG. 57 RELA Y 4. Disconnect the blue/black wire and the red/black wires from relay terminals #4 and #6. 5. Connect the dispenser to the power source. 6. T urn on power and check for continuity across terminals on relay . If continuity is present as described, disconnect the dispenser from power so[...]

  • Page 43

    43 12 11 9 8 7 SERVICE (CONT .) Resistor (all 230V Models) Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Disconnect the resistor from the relay and discard. 3. Install new resistor to the relay as shown below . 4. Return power to the dispenser . FIG. 60 RESISTOR TERMINALS P3864 FIG. 59 RESISTOR Location: The resisto[...]

  • Page 44

    44 SERVICE (CONT .) Solenoid - Cold Water (JDF-4S only) FIG. 62 COLD WA TER SOLENOID TERMINALS FIG. 61 COLD WA TER DISPENSE SOLENOID Location: The Cold Water dispense solenoid is located at the inside rear of the chassis frame. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the two wires from the solenoid valve. [...]

  • Page 45

    45 SERVICE (CONT .) Solenoid - Inlet (all Models) FIG. 63 INLET SOLENOID V AL VE P1445.40 Location: The inlet solenoid is located inside on the rear of the dispenser base. T est Procedures: 1 . Disconnect the dispenser from the power source. 2 . Disconnect the two wires from the solenoid valve. 3. Check for continuity across the solenoid valve coil[...]

  • Page 46

    46 SERVICE (CONT .) T emperature Probe (all Models) FIG. 65 TEMPERA TURE PROBE FIG. 66 TEMPERA TURE PROBE Location: The temperature probe is located on the top of the tank assembly . T est Procedure: 1. Disconnect the dispenser from the power source. 2. Remove the top rear cover . 3. With a voltmeter , back probe the connector from the temperature [...]

  • Page 47

    47 SERVICE (CONT .) T emperature Sensor (all Models) FIG. 68 TEMPERA TURE SENSOR FIG. 67 TEMPERA TURE SENSOR Location: The T emperature Sensor is located inside the cabinet between the fan and the water coil. T est Procedures: 1. Remove the left side housing panel. 2. Connect a voltmeter across the two leads of the temperature sensor (leave plug co[...]

  • Page 48

    48 + A C A C SERVICE (CONT .) T ransformer (all Models) Removal and Replacement: 1. Loosen the two #8-32 screws securing the com- ponent bracket to the dispenser housing base. 2. Pull component bracket out the front of the dispenser far enough so the transformer can be disconnected from the main wiring harness. 3 Remove the two #6-32 keps nuts secu[...]

  • Page 49

    49 SERVICE (CONT .) T ransformer - Lited Doors (JDF-2S, JDF-4S) Removal and Replacement: 1. Loosen the two #8-32 screws securing the com- ponent bracket to the dispenser housing base. 2. Pull component bracket out the front of the dispenser far enough so the transformer connector can be disconnected from the main wiring harness. 3 Disconnect the tr[...]

  • Page 50

    50 T riac Map 49179 012214 1 2 3 4 5 6 7 8 9 10 1 1 1. Compressor Relay Q25 2. Station 2 Water Q27 3. Station 1 Water Q28 4. Station 1 Concentrate Q23 5. Station 2 Concentrate Q18 6. Station 3 Concentrate Q17 7. Station 4 Concentrate Q13 8. Station 3 Water Q7 9. Cold Water Valve Q11 10. Inlet Water V alve Q10 11. Station 4 Water Q8[...]

  • Page 51

    51 ELECTRICAL SCHEMA TIC DIAGRAM for JDF-2S (Models with LED Lited Doors) J6-1 J11-1 J11-5 J6-1 J6-5 J6-3 J5-1 J5-4 J2-1 J2-6 GRN WHI/ORN LEFT DISPENSE RIGHT DISPENSE LEFT DISPENSE RIGHT DISPENSE YEL YEL WHI/VIO RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK ORN WHI/VIO WHI/ORN VIO RED RED RED WHI/RED BLK WHI RED/BLK RED/BLK YEL WHI/BLU BL[...]

  • Page 52

    52 J6-1 J11-1 J11-5 J6-1 J6-5 J6-3 C O N T R O L P C B O A R D J5-1 J5-4 J2-1 J2-6 GRN WHI/ORN LEFT DISPENSE RIGHT DISPENSE LEFT DISPENSE RIGHT DISPENSE YEL YEL WHI/VI O RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK ORN WHI/VIO WHI/ORN VIO RED RED WHI/RED BLK WH IR ED/BLK RED/BLK YEL WHI/BLU BLU BLK RED BLU YEL ORN BLK RED BLU YEL ORN RED[...]

  • Page 53

    53 ELECTRICAL SCHEMA TIC DIAGRAM for JDF-4S (Models with LED Lited Doors) J6-1 J6-3 J5-1 J5-4 J2-1 J2-6 GRN WHI/ORN STA TION 1 DISPENSE STA TION 2 DISPENSE STA TION 1 DISPENSE STA TION 2 DISPENSE YEL YEL WHI/VIO RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK ORN WHI/VIO WHI/ORN VIO RED RED WHI/RED BLK WHI RED/BLK YEL WHI/BLU BLU RED MOTOR [...]

  • Page 54

    54 J6-1 J6-3 C O N T R O L P C B O A R D J5-1 J5-4 J2-1 J2-6 GRN WHI/ORN ST AT ION 1 DISPENSE ST AT ION 2 DISPENSE ST AT ION 1 DISPENSE ST AT ION 2 DISPENSE YE LY EL WHI/VIO RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK ORN WHI/VIO WHI/ORN VIO RED RED WHI/RED BLK WH IR ED/BLK YEL WHI/BLU BLU RED MOTOR CONDENSOR FA N RED/BLK BLU/BLK BLU/BL[...]

  • Page 55

    55 J6-1 J6-3 C O N T R O L P C B O A R D J5-1 J5-4 J2-1 J2-6 GRN ST AT ION 1 DISPENSE RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK RED RED WHI/RED BLK WHI RED/BLK RED/BLK WHI/BLU BLU MOTOR CONDENSOR FA N RED/BLK BLU/BLK BLU/BLK J7-1 J7-2 J9-1 J9-2 PUMP FA N t t WHI/BLK GRY BLK WHI CABINET THERMISTOR WA TER BA TH THERMISTOR WHI WHI BLK WH[...]

  • Page 56

    56 ELECTRICAL SCHEMA TIC DIAGRAM for JDF-4D (Portion Control Models) J6-1 J6-3 J5-1 J5-4 J2-1 J2-6 GRN STA TION 1 DISPENSE RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK RED RED WHI/RED BLK WHI RED/BLK RED/BLK WHI/BLU BLU MOTOR CONDENSOR FAN RED/BLK BLU/BLK BLU/BLK J7-1 J7-2 J9-1 J9-2 PUMP FAN t t WHI/BLK GRY BLK WHI CABINET THERMISTOR WA [...]

  • Page 57

    57 J6-1 J6-3 J5-1 J5-4 J2-1 J2-6 GRN WHI/ORN STA TION 1 DISPENSE STA TION 2 DISPENSE STA TION 1 DISPENSE STA TION 2 DISPENSE YEL YEL WHI/VIO RECIR. PUMP BRN WHI BLK J1-1 J1-5 WHI J3-1 J3-2 WHI/BLK ORN WHI/VIO WHI/ORN VIO RED RED WHI/RED BLK WHI RED/BLK YEL WHI/BLU BLU RED MOTOR CONDENSOR FAN RED/BLK BLU/BLK BLU/BLK J7-1 J7-2 J9-1 J9-2 PUMP PUMP FAN[...]