Bunn AFPO-2 User Manual

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OPERATING & SERVICE MANUAL

BUNN-O-MATICCORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

PHONE: (217) 529-6601FAX: (217)529-6644

28791.0000E 4/01 ©1998 Bunn-O-MaticCorporation

www.bunnomatic.com

INTRODUCTION

This equipment supplies a liquid concentrate mixed with water at various ratios to the hoppers on the CDS-2orCDS-3dispensers. It is for indoor use only on a sturdy counter or shelf.

WARRANTY

Bunn-O-MaticCorp. (“Bunn”) warrants the equipment manufactured by it to be commercially free from defects in material and workmanship existing at the time of manufacture and appearing within one year from the date of installation. In addition:

1.) Bunn warrants electronic circuit and/or control boards to be commercially free from defects in material and workmanship for two years from the date of installation.

2.) Bunn warrants the compressor on refrigeration equipment to be commercially free from defects in material and workmanship for two years from the date of installation.

3.) Bunn warrants that the grinding burrs on coffee grinding equipment will grind coffee to meet original factory screen sieve analysis for three years from date of installation or for 30,000 pounds of coffee, whichever comes first.

This warranty does not apply to any equipment, component or part that was not manufactured by Bunn or that, in Bunn’s judgement, has been affected by misuse, neglect, alteration, improper installation or operation, improper maintenance or repair, damage or casualty.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of Bunn are not authorized to make modifications to this warranty or to make additional warranties that are binding on Bunn. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon.

The Buyer shall give Bunn prompt notice of any claim to be made under this warranty by telephone at (217) 529-6601or by writing to Post Office Box 3227, Springfield, Illinois,62708-3227.If requested by Bunn, the Buyer shall ship the defective equipment prepaid to an authorized Bunn service location. If Bunn determines, in its sole discretion, that the equipment does not conform to the warranty, Bunn shall repair the equipment with no charge for parts during the warranty period and no charge for labor by a Bunn Authorized Service Representative during the warranty period. If Bunn determines that repair is not feasible, Bunn shall, at its sole option, replace the equipment or refund the purchase price for the equipment.

THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AS SPECIFIED HEREIN, TO REPAIR OR, AT BUNN’S SOLE OPTION, REPLACEMENT OR REFUND.

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.

00656.0000

00986.0002

2

28791 051599

 

ELECTRICAL REQUIREMENTS

CAUTION - The dispenser must be disconnected from the power source until specified inInitial 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 NEMA5-15R.

The 230 volt CE version requires 2 wire, grounded service rated 230V ac, single phase, 50 Hz.

The 200 volt or 240 volt versions require 2 wire, grounded service rated 200 volts ac or 240 volts ac, single phase, 50 Hz.

(Refer to the dispenser’s data plate for exact voltage requirement.)

Electrical Hook-Up

CAUTION – Improper electrical installation will damage electronic components.

1.An electrician must provide electrical service as specified.

2.Using a voltmeter, check the voltage and color coding of each conductor at the electrical source.

3.Connect the dispenser to the power source.

PLUMBING REQUIREMENTS

This dispenser must be connected to a cold water system with operating pressure between 20 and 90 (138 and 620 kPa) psi from a12" or larger supply line. Ashut-offvalve should be installed in the line before the dispenser. Install a regulator in the line when pressure is greater than 90 psi (620 kPa) to reduce it to 50 psi (345 kPa). The water inlet fitting is14" flare.

NOTE - Bunn-O-Maticrecommends14" copper tubing for installations of less than 25 feet and38" for more than 25 feet from the12" water supply line. At least 18 inches of an FDA approved flexible beverage tubing, such as reinforced braided polyethylene or silicone, before the brewer will facilitate movement to clean the countertop. Tubing is supplied byBunn-O-Matic(part number00326-0000).Bunn-O-Maticdoes not recommend the use of a saddle valve to install the brewer. The size and shape of the hole made in the supply line by this type of device may restrict water flow

This equipment must be installed to comply with the Basic Plumbing Code of the Building Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the Food and Drug Administration (FDA).

INITIAL SET-UP

NOTE: This refill unit should not be used to initially fill the hopper. Running the motor for extended periods will trip the thermal switch. The thermal switch will reset, but requires up to 30 minutes of cooling time.

NOTE: Hoses and product container connectors are not supplied. Fitting, clamps and labels are supplied. Make hose assemblies as required. Refer toPIPING DIAGRAM on page 22.

1.Assemble hoppers with probe housing assemblies to CDS-2,CDS-3or modify existing hoppers using template provided.

2.Make sure probe housing assembly is pushed down into slots on back of hoppers.

3.Install cable assembly to the lower right front of the auto refill box and the probe housing assemblies on the hoppers. The connectors on the cable pushes in and cap rotates 1/4 turn to lock into position.

4.Run output tubes from auto refill box to the quick disconnects in the hoppers.

NOTE: Make sure numbers on the labels match up. Cable#1 with Hose#1, Cable#2 with Hose#2,....etc.

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INITIAL SET-UP(cont.)

5.Connect one end of input hoses to the auto refill box and the other end to the product container. Product container connectors (BIB) are not supplied. Install your own interface.

6.Connect water line to auto refill box. A minimum of 20 psi (138 kPa) is required.

NOTE: Make sure all connections are made before connecting the auto refill box to the power source.

7.Each product container has an ON/OFF refill switch located on the front of the auto refill box. A second switch for each hopper is at the probe housing assembly. These are 3 position switches, high level, low level and a center “OFF” position.

8.Place the main ON/OFF switch and ON/OFF refill switches in the “OFF” position.

9.Make sure all hoses are connected. Place the main ON/OFF switch in the “ON” position.

10.Place one of the ON/OFF refill switches in the “ON” position, after a four second delay product will begin to flow through the hoses into the hopper. Be sure the switch selected is filling the correct hopper, if not, check the labels. See NOTE in step #4.

11.To test refill circuit short out probes on one of the hoppers with a screwdriver, so that hopper should shut off. Remove the screwdriver and the hopper will start to fill again after a four second delay. If hopper does not start to fill, check labels, refer to NOTE in step #4.

12.To change mix ratio refer to MIX RATIO ADJUSTMENTS.

CLEANING

RECOMMENDED WEEKLY CLEANING:

This should be done in conjunction with the recommended weekly cleaning of your CDS-2orCDS-3machine. The CDS Hoppers must be empty before starting.

1.Prepare a 1 gallon cleaning solution consisting of 1 gallon of hot water and a sanitizing cleaner which contains 3-5%chlorine based sanitizer. Mix per manufacturers instructions

2.Remove connectors from each concentrate container and place them directly into the cleaning solution.

3.Energize each refill station and allow the cleaning solution to pump through the system into the hoppers. The cleaning procedure should remove the color stains from the tubing. If not, prepare another gallon of cleaning solution and repeat.

4.After the cleaning solution has been pumped into the hoppers, rinse the cleaning solution container with hot water.

5.Fill the cleaning solution container with hot water. Energize each refill station and rinse thoroughly. The amount of clean hot rinse water should equal the amount of cleaning solution pumped through the system.

6.Empty the hoppers of your CDS machine and follow the recommended cleaning instructions.

NOTE: The hoses should be checked monthly for deterioration, cracks and possible discoloration from some concentrates. Replace the tubing when necessary.

MIX RATIO ADJUSTMENTS

1.Remove the top access panel.

2.Connect the test hose to the “WATER OUTPUT” to be adjusted.

3.Connect the provided hose (or other suitable water hose) to the “WATER INPUT”.

4.Ensure water regulator is set at 20 psi(137.9 kPa). Press the “TEST OUTPUT” switch and while water is flowing from the test hose, check that the gauge reads 20.

5.Place a one-cupcontainer under the test hose. Press the “TEST OUTPUT” switch, and carefully measure and note the elapsed time from when water first flows form the test hose to when one cup of water has been dispensed. Hoses and tubing should be primed and free of substantial air spaces and/or bubbles prior to calibration.

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MIX RATIO ADJUSTMENTS(cont.)

6.Compare results with chart or formula below.

7.If the time observed is too short or long, turn the needle valve clockwise or counterclockwise, respectively, a little at a time. Repeat from the preceding step until correct.

Mix ratio (water/flavor)

Time for FLAVOR OUTPUT (1/2 cup)

Time for WATER OUTPUT (1 cup)

 

 

 

1+1

assume 20 sec. or obtain time per note below

40 sec. or 2 times flavor output time

 

 

 

2+1

assume 20 sec. or obtain time per note below

20 sec. or equal to flavor output time

 

 

 

3+1

assume 20 sec. or obtain time per note below

13.3 sec. or 0.67 times flavor output time

 

 

 

4+1(see below)

assume 20 sec. or obtain time per note below

10 sec. or 0.5 times flavor output time

 

 

 

5+1

assume 20 sec. or obtain time per note below

8 sec. or 0.4 times flavor output time

6+1

assume 20 sec. or obtain time per note below

6.7 sec. or 0.33 times flavor output time

 

 

 

NOTE: For a typical adjustment, the time for flavor output in the center column above is assumed to be 20 seconds. A more specific flavor pump output time may be obtained prior to adjustment of the needle valve. To do so, connect the flavor to be tested to the “FLAVOR INPUT”, and the test hose to the corresponding “FLAVOR OUTPUT” (make no connection to the “WATER INPUT”). With aone-cupcontainer under the test hose press the corresponding “TEST OUTPUT” switch, and carefully measure and note the elapsed time from when the product first flows from the test hose to whenone-halfcup of the product has been dispensed. This value may then be used in the formula below. Following flavor pump output measurement, disconnect the flavor line from the “FLAVOR INPUT” and purge remaining product from the line.

Formula for setting mix ratio: To obtain the time for dispensing 1 cup of water, divide the time it takes to dispenseone-halfcup of product by the first number in the mix ratio and then multiply the result by two.

Example: W=2(F/X) Where W is the time it should take to dispense one cup of water, it took F seconds (20 here) to dispense 1/2 cup of flavor concentrate, we desire a mix ratio X of 4+1 (X will be the first number in the mix ratio, 4).

Therefore:

W = 2/(20/4)

 

W = 2/5

 

W = 10 seconds

So if it took 20 seconds to dispense one-halfcup of flavor concentrate, and a mix ratio of 4 to 1 is required, the needle valve should be adjusted to dispense 1 cup of water in 10 seconds.NOTE: Hoses and tubing should be primed and free of substantial air spaces and/or bubbles prior to calibration.

 

1

 

2

 

3

NEEDLE VALVE

P1521

 

5

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OPERATING CONTROLS

C

B

A

P1949

A. MAIN POWER ON/OFF

The main power ON/OFF switch is located on the right of the front panel just above the power cord.

B. REFILL CIRCUIT ON/OFF

The refill circuit ON/OFF switches are located on the right of the front panel just above the main power switch. These allow each circuit to operate independently.

C. TEST/OPERATE

The TEST/OPERATE switch is located inside the autofill box just below the top access cover. For setting flow rates and mix ratios for flavors, place the TEST/OPERATE switch in the "TEST" position. This allows the operator to run the water and flavor lines for each circuit depending on the requirements for the flavor recipe.

D. PROBE CONTROL BOX LOW/OFF/HIGH

On models equipped with a dual level probe, there is a LOW/OFF/HIGH switch located at the probe control box on the hopper. The "OFF" position allows the operator to disable the probe for that hopper only. THE "LOW" and "HIGH" positions allow the operator to select the level of product desired for that hopper.

D

P1951

6

28791

040501

 

 

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-MaticTechnical 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 are sealed and electrical connections tight and isolated.

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

(A1) Check the outlet for 120 volts

 

the dispenser

on two wire 120 volt dispensers.

 

 

(A2) Check the outlet for 200 volts

 

 

or 240 volts ac for two wire 200

 

 

volt or 240 volt dispensers.

 

 

(A3) Check the outlet for 230 volts

 

 

on two wire 230 volt dispensers.

 

 

(B) Check circuit breakers or fuses.

 

3. Signal cable unplugged

Signal cable must be plugged in.

 

4. Hopper is full

Product must not be touching

 

 

probes to fill.

 

5. Fuse and fuse holder

Refer to Service - Fuse and Fuse

 

 

Holder for test procedures. See

 

 

page 11

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28791 040501

 

TROUBLESHOOTING (cont.)

 

 

PROBLEM

PROBABLE CAUSE

REMEDY

Product will not dispense (cont.)

6. Main ON/OFF switch

Refer to Service - Main ON/OFF

 

 

Switch for testing procedure. See

 

 

page 12

 

7. Probe box LOW/OFF/HIGH

Refer to Service - Probe system. See

 

switches

page 13

 

8. Circuit board

Refer to Service - Circuit Board for

 

 

testing procedures. See page 10

 

9. Vacuum switch

Refer to Service - Vacuum switch for

 

 

testing procedures. See page 21

 

10. Vacuum/Supply pump

Refer to Service - Vacuum/Supply

 

 

pump for testing procedures. See

 

 

page 19

 

11. Pump (flavor) start switches

Refer to Service - Pump (flavor) start

 

 

switches for test procedures. See

 

 

page 14

Incorrect mix ratio

1. No water

Water lines and valves to the dis-

 

 

penser must be open.

 

2. Needle valve

Refer to Setup - Mix Ratio Adjust-

 

 

ments for adjustment. See page 4

 

3. Solenoids

Refer to Service - Solenoids for test

 

 

procedures. See page 16

Motor thermal cutout (motor stops

1. Motor overheat

The thermal switch will reset, but

running)

 

requires up to 30 minutes of cooling

 

 

time. See NOTE below

NOTE: This refill unit should not be used to initially fill the hopper. Running the motor for extended periods will trip the thermal switch. The thermal switch will reset, but requires up to 30 minutes of cooling time.

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28791 040501

 

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 electrical equipment should be performed only by qualified service personnel. The dispenser should be unplugged when servicing, except when electrical tests are required and the test procedure specifically states to plug in the dispenser.

COMPONENT ACCESS

WARNING - Disconnect the dispenser from the power source before the removal of any panel or the replacement of any component.

All components are accessible by removing the eight #8-32screws (five on the front and three on the rear) securing the main housing to the main mounting panel and the removal of the four#8-32nuts securing the pump/solenoid switch panel to the solenoid mounting bracket. Refer to Fig. 1

Refer to the contents listing for component location.

Contents

 

Circuit Board .........................................................

10

Fuse & Fuse Holder ..............................................

11

Main ON/OFF Switch .............................................

12

Probe LOW/OFF/HIGH Switches ...........................

13

Pump (Flavor) Start Switches ...............................

14

Refill ON/OFF Switches ........................................

15

Solenoid ...............................................................

16

Solenoid (Water) Start Switches ...........................

17

Test/Operate Switch..............................................

18

Vacuum/Supply Pump Assembly ..........................

19

Vacuum Switches .................................................

21

Piping Diagram .....................................................

22

Wiring Diagrams ...................................................

23

 

 

 

1

 

REFI

LL

2

3

 

 

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MAIER

 

 

 

POW

TER

 

 

WA

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FIG. 1 COMPONENT ACCESS

 

 

P1521

 

 

 

9

28791 040501

 

SERVICE

CIRCUIT BOARD

O

 

O

 

O

 

O

 

FIG. 2 CIRCUIT BOARD

P1520

 

Location:

The circuit board is located inside the autofill box, mounted on the right side of the solenoid mounting bracket under the switch panel.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect the ten pin plug on the main wiring harness from the connector on the circuit board.

3.Connect the dispenser to the power source. With a voltmeter, check the voltage across the black wire(#3) and the white wire (#6). The indication must be:

a)120 volts ac for two wire 120 volt models.

b)200 to 240 volts ac for two wire 200 or 240 volt models.

c) 230 volts ac for two wire 230 volt models.

4.Disconnect the dispenser from the power source.

If voltage is present as described, replace the circuit board.

If voltage is not present as described, refer to the Wiring Diagrams and check main wiring harness.

Removal and Replacement:

1.Remove the four #8-32keps nuts securing the switch mounting bracket. Set aside with the wires attached.

2.Remove the circuit board shield and set aside for reassembly.

3.Disconnect the ten pin plug from the main wiring harness to the circuit board.

4.Remove the six #4-40screws and spacers securing the circuit board to the solenoid mounting bracket. Remove circuit board and discard.

5.Install new circuit board using #4-40screws and spacers to secure the circuit board to the solenoid mounting bracket. The spacers must be between the solenoid mounting bracket and the circuit board.

6.Place circuit board shield over the circuit board.

7.Install switch panel assembly and secure with four #8-32keps nuts.

8.Refer to Fig. 3 for circuit board ten pin connector.

 

J4

 

J1

 

J2

 

J3

 

P1528

 

FIG. 3 CIRCUIT BOARD CONNECTOR LOCATION

10

28791 040501