Bunn AFPO-3 SL User Manual.pdf

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AFPO-3 SL

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SERVICE & REPAIR MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227

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

41093.0000A 04/08 ©2008 Bunn-O-Matic Corporation

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 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, 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 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, 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.

BrewWISE, BUNN Gourmet Ice, BUNN Pour-O-Matic, BUNN, Bunn-OMatic, Bunn-O-Matic, BUNNlink, BUNNserve, BUNN Espress, DBC, Dr. Brew, Dual, EasyClear, EasyGard, Easy Pour, FlavorGard, Gourmet Ice, Gourmet Juice, High Intensity, IMIX, Infusion Series, Legendary for Quality, The Mark of Quality in Beverage Equipment Worldwide, My Café, PowerLogic, Safety-Fresh, Scale-Pro, Single, Smart Funnel, Smart Hopper, SmartWAVE, Soft Heat, SplashGard, System III, ThermoFresh, 392, AXIOM, Beverage Profit Calculator, Beverage Bar Creator, BrewLOGIC, BrewMETER, BrewWIZARD, BUNNSERVE, BUNNsource, Coffee At Its Best, Cool Froth, Digital Brewer Control, Intellisteam, Nothing Brews Like a BUNN, Pouring Profits, Pulse Wave, Quality Beverage Equipment Worldwide, , Signature Series, Silver Series, Smart Heat, Tea At Its Best, The Horizontal Red Line, Titan, Ultra, are either trademarks or registered trademarks of Bunn-O-Matic Corporation.

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CONTENTS

User Notices...............................................................................................................................

3

Preventive Maintenance

 

Cleaning......................................................................................................................................

4

Adjustments...............................................................................................................................

4

Operating Controls.....................................................................................................................

6

Troubleshooting..........................................................................................................................

7

Service.......................................................................................................................................

9

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

USER NOTICES

All notices on the equipment are written for your protection. All notices are to be kept in good condition. Replace any unreadable or damaged labels.

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CLEANING

RECOMMENDED WEEKLY CLEANING:

This should be done in conjunction with the recommended weekly cleaning of your machine. The 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 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-cup container 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.

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.

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MIX RATIO ADJUSTMENTS(cont.)

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 a one-cup container 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 when one-half cup 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 dispense one-half cup 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-half cup 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

 

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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 auto-fill

 

 

box just below the top access cover. For setting flow

 

rates and mix ratios for flavors, place the TEST/OPER-

 

ATE switch in the “TEST” position. This allows the op-

D

erator 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.

P1951

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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 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 notbe touchingprobes

 

 

to fill.

 

5. Fuse and fuse holder

Refer to Service - Fuse and Fuse

 

 

Holder for test procedures. See

 

 

page 12

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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 13

 

7. Probe box LOW/OFF/HIGH switch-

Refer to Service - Probe system.

 

es

See page 14

 

8. Circuit board

Refer to Service - Circuit Board for

 

 

testing procedures. See page 11

 

9. Vacuum switch

Refer to Service - Vacuum switch for

 

 

testing procedures. See page 22

 

10. Vacuum/Supply pump

Refer to Service - Vacuum/Supply

 

 

pump for testing procedures. See

 

 

page 20

 

11. Pump (flavor) start switches

Refer to Service - Pump (flavor)

 

 

start switches for test procedures.

 

 

See page 15

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 5

 

3. Solenoids

Refer to Service - Solenoids for test

 

 

procedures. See page 17

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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41093 040408

 

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

 

 

 

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FIG. 1 COMPONENT ACCESS

 

 

P1521

 

 

 

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SERVICE

CIRCUIT BOARD

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 #8-32 keps 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 #4-40 screws and spacers securing the circuit board to the solenoid mounting bracket. Remove circuit board and discard.

5.Install new circuit board using #4-40 screws 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 #8-32 keps nuts.

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

 

J4

 

J1

 

J2

 

J3

 

P1528

 

FIG. 3 CIRCUIT BOARD CONNECTOR LOCATION

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SERVICE

FUSE AND FUSE HOLDER

3

MAINER

 

POW

WATER

 

INPUT

 

FIG. 4 FUSE HOLDER

P1516

 

Location:

The fuse holder is located on the lower right front of the autofill box just to the left of the power cord.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Remove cap and fuse from fuse holder.

3.Remove fuse from the cap.

4.Check for continuity through the fuse.

If continuity is present, reinstall the fuse, the fuse is operating properly.

If continuity is not present, replace the fuse.

Removal and Replacement:

Fuse:

1.Remove the cap from the fuse holder.

2.Remove fuse from the fuse holder and inspect. If blown, discard.

3.Install new 10 amp fuse in the fuse holder.

4.Reinstall fuse holder cap.

Fuse Holder:

1.Disconnect the dispenser from the power source.

2.Disconnect the wires from the rear of the fuse holder.

3.Remove the nut securing the fuse holder to the front of the main mounting panel.

4.Push the fuse holder through the hole in the panel.

5.Install new fuse holder and fuse through the hole in the panel.

6.Secure the fuse holder to the panel.

7.Refer to Fig. 5 and reconnect the wires.

BLK from Main

Wiring Harness

BLK to Main

ON/OFF Switch

P1331

FIG. 5 FUSE HOLDER TERMINALS

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41093 040408

 

SERVICE (cont.)

MAIN ON/OFF SWITCH

3

N

MAIER

 

POW

WATER

 

INPUT

 

FIG. 6 MAIN ON/OFF SWITCH

P1516

 

Location:

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

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect the black wire from the fuse holder and the white wire from pump #1.

3.Connect the dispenser to the power source. Check for voltage across the black wire removed from the switch and the white wire removed from pump #1. The indication must be:

a)120 volts ac for 2 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, proceed to #5.

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

5.Check for continuity across the switch terminals with the switch in the “ON” position. Continuity must not be present when the switch is in the “OFF” position.

If continuity is present as described, reconnect the wires to the switch terminals.

If continuity is not present as described, replace the switch.

Removal and Replacement:

1.Remove the wires from the switch terminals.

2.Compress the clips inside the autofill box and gently push the switch through the opening

3.Push the new switch into the opening and spread the clips to hold switch in the autofill box.

4.Refer to Fig. 7 when reconnecting the wires.

BLK from Fuse Holder

BLK to Solenoid (Water)

Switch #2 AFPO-2 & 3

FIG. 7 MAIN ON/OFF SWITCH TERMINALS P1522

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SERVICE (cont.)

PROBE SYSTEM

BU

NN

 

 

P1523

FIG. 8 PROBE SWITCHES

Location

The probe switches are located on the rear of each hopper, mounted in the probe housing cover.

Test Procedure

Probe System

1.Disconnect the dispenser from the power source.

2.With the probe boxes connected to the signal cable, remove connector from refill box.

3.Place the switch on the probe box in the “HIGH” position.

AFPO-2

AFPO-3

P1538

FIG. 9 SIGNAL CABLE PINS

 

4.Check resistance across pins as shown in Fig. 9.

5.With the probe box switch in “LOW” position check the resistance across the signal cable pins, see Fig. 9.

6.If readings match values indicated, the probe system is functioning properly. If not, check the probe boxes.

Probe Boxes:

1.Disconnect the signal cable from the probe boxes.

2.Remove probe box from CDS hopper.

3.Place the switch on the probe box in the “HIGH” position.

4.Check the resistance across the box cable pins, see Fig. 10.

AFPO-2 & 3

 

P1539

FIG. 10 PROBE BOX CABLE PINS

 

5.With the probe box switch in the “LOW” position check the resistance across the pins, refer to Fig. 10.

6.If readings match the values indicated, the probe system is functioning properly.

Switch Removal and Replacement:

1.Remove the #6 thread cutting screw securing the probe housing cover to the probe housing.

2.Remove the wires from the switch terminals.

3.Compress the clips inside the probe box and gently push the switch through the opening

4.Push the new switch into the opening and spread the clips to hold switch in the autofill box.

5.Refer to Fig. 11 when reconnecting the wires.

BLU (HIGH) from Probe

Box Cable

GRN (OFF) from Probe

Box Cable

TAN (LOW) from Probe Box Cable

FIG. 11 PROBE LOW/OFF/HIGH SWITCH P1540

TERMINALS

13

41093 040408

 

SERVICE (cont.)

PUMP (FLAVOR) ON/OFF SWITCHES

1

2

3

P1521

FIG.12 PUMP (FLAVOR) START SWITCHES

Location:

The pump (flavor) START switches are located on the switch mounting plate inside the autofill box on the right side.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect the wires from the switch to be tested.

3.Check for continuity across the terminals on the switch when it is held in the on position. Continuity must not be present across these terminals in the released position.

If continuity is present as described, reconnect the wires to the switch.

If continuity is not present as described, replace the switch.

Removal and Replacement:

1.Disconnect the dispenser from the power source.

2.Remove the wires from the switch terminals.

3.Compress the clips inside the autofill box and gently push the switch through the opening.

4.Push the new switch into the opening and spread the clips to hold switch in the autofill box.

5.Refer to Fig. 13 when reconnecting the wires.

#1 AFPO-2 & 3

BLK from Solenoid Switch #1 BLK to Test/Operate Switch RED/BLK to Test/Operate Switch

YEL to Pump #1

#2 AFPO-2 & 3

BLK from Solenoid Switch #1 BLK to Solenoid Switch #2 BRN/BLK to Test/Operate Switch

ORN to Pump #2

#3 AFPO-3 ONLY

BLK from Solenoid Switch #2

BLK to Solenoid Switch #3

WHI/RED to Test/Operate Switch

RED to Pump #3

P1524

FIG. 13 PUMP (FLAVOR) SWITCH TERMINALS

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SERVICE (cont.)

REFILL SWITCHES

3

 

FIG. 14 REFILL SWITCHES

P1516

 

Location:

The refill switches are located on the upper right front of the autofill box.

Test Procedures:

1.Disconnect the dispenser from the power source.

2.Disconnect the two white/red, brown/black or red/black wires from the switch terminals.

3.Connect the dispenser to the power source. Check for voltage across the white/red, brown/black or red black wires from the test/operate switch and the white wire on solenoid #2 or #3. 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, proceed to #5.

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

5.Check for continuity across the switch terminals with the switch in the “ON” position. Continuity must not be present when the switch is in the “OFF” position.

If continuity is present as described, reconnect the wires to the switch terminals.

If continuity is not present as described, replace the switch.

Removal and Replacement:

1.Remove the wires from the switch terminals.

2.Compress the clips inside the autofill box and gently push the switch through the opening in the front of autofill box.

3.Push the new switch into the opening and spread the clips to hold switch in the autofill box.

4.Refer to Fig. 15 when reconnecting the wires.

#1 AFPO-2 & 3

RED/BLK from Test/

Operate Switch

RED/BLK to Vacuum

Switch #1

#2 AFPO-2 & 3

BRN/BLK from Test/

Operate Switch

BRN/BLK to Vacuum

Switch #2

#3 AFPO-3 ONLY

WHI/RED from Test/

Operate Switch

WHI/RED to Vacuum

Switch #3

P1522

FIG. 15 REFILL SWITCH TERMINALS

15

41093 040408

 

SERVICE (cont.)

SOLENOIDS

 

 

1

 

2

 

3

FIG. 16 SOLENOIDS

P1521

 

Location:

The solenoids are located inside the autofill box.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect the white/violet, violet or blue wire and the white wire from the solenoid.

3.Connect the dispenser to the power source. Press the solenoid (water) switch, and with a voltmeter, check the voltage between the white wire, and either the blue, violet, or white/violet wire. 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, proceed to #5.

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

5.Check for continuity across the solenoid valve coil terminals.

If continuity is present as described, refer to Fig. 17 and reconnect the wires to the solenoid.

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. Press the solenoid (water) 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 blockage in the water inlet 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, rebuild or replace the solenoid valve.

Solenoid Valve Repair:

1.Remove the wires from the solenoid valve to be repaired.

2.Turn off the water supply to the dispenser.

3.Remove the nut securing solenoid valve coil to the base.

4.Remove guide, washer, o-ring, plunger/spring and inspect for wear. Replace parts as required.

5.Install new o-ring in the solenoid valve base.

6.Install plunger/spring in the guide with spring to the bottom of the guide.

7.Installguidewiththeplunger/springintothesolenoid valve base.

8.Install washer on guide.

9.Install coil with retainer on guide and secure with nut.

10.Refer to Fig. 17 and reconnect the wires.

WHI from Main Harness WHI to Solenoid #2 BLU from Solenoid Switch #1

#1 AFPO-2 & 3 #2 AFPO-2

&3 #3 AFPO-3 ONLY

WHI to Solenoid #1 WHI to Pump #1 VIO from Solenoid Switch #2

WHI/VIO from Solenoid Switch #3

WHI to Main Harness

WHI to Pump #3

FIG. 17 SOLENOID TERMINALS

P1544

 

16

41093 040408

 

SERVICE (cont.)

SOLENOID (WATER) ON/OFF SWITCHES

1

2

3

P1521

FIG.18 SOLENOID (WATER) ON/OFF SWITCHES

Location:

The solenoid (water) ON/OFF switches are located on the switch mounting plate inside the autofill box on the right side.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect the wires from the switch to be tested.

3.Check for continuity across the terminals on the switch when it is held in the on position. Continuity must not be present across these terminals in the released position.

If continuity is present as described, refer to Fig. 19 and reconnect the wires to the switch.

If continuity is not present as described, replace the switch.

Removal and Replacement:

1.Remove the wires from the switch terminals.

2.Compress the clips inside the autofill box and gently push the switch through the opening.

3.Push the new switch into the opening and spread the clips to hold switch in the autofill box.

4.Refer to Fig. 19 when reconnecting the wires.

#1 AFPO-2 & 3

BLK from Pump Switch #2 BLK to Pump Switch #1

BLU to Test/Operate Switch BLU to to Solenoid #1

#2 AFPO-2 & 3

BLK from Main ON/OFF Switch

BLK to Pump Switch #2

VIO to Test/Operate Switch

VIO to Solenoid #2

#3 AFPO-3 ONLY

BLK from Pump Switch #3

WHI/VIO to Test/Operate Switch

WHI/VIO to Solenoid #3

P1524

FIG. 19 SOLENOID (WATER) SWITCH TERMINALS

17

41093 040408

 

SERVICE (cont.)

TEST/OPERATE ON/OFF SWITCH

 

 

1

 

2

3

 

FIG. 20 TEST/OPERATE SWITCH

P1521

 

Location

The test/operate switch is located inside the autofill box on the right side.

Test Procedures:

1.Disconnect the dispenser from the power source.

2.Remove the black wire from the top center switch terminal.

3.Connect the dispenser to the power source. With a voltmeter, check the voltage across the black wire removed from the test/operate switch and the white wire from one of the solenoids. 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.

5. 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 Wiring Diagrams and check the wiring harness.

6.Disconnect the wires from the left and center terminals.

7.Check for continuity across the left and center terminals in rows one, two, three and four with the switch in the “operate” position. Continuity should not be present across the left and center terminals with the switch in the “center” or “Test” position.

If continuity is present as described, replace the wires. The switch is operating properly.

If continuity is not present as described, replace the switch.

Removal and Replacement:

1.Disconnect the dispenser from the power source.

2.Remove the wires from the switch terminals.

3.Compress the clips inside on the back of the switch panel and gently push the switch through the opening.

4.Push the new switch into the opening and spread the clips to hold the switch in the switch panel.

5.Refer to FIG. 21 when reconnecting the wires.

BLK to Circuit

 

BLK from Main

 

Board J4-3

 

ON/OFF Switch

 

BLU from Solenoid Switch #1

 

RED/BLK from Pump Switch #1

 

 

RED/BLK to Refill Switch #1

 

 

 

 

VIO from Solenoid Switch #2

 

BRN/BLK from Pump Switch #2

 

 

BRN/BLK to Refill Switch #2

 

 

 

 

WHI/VIO from Solenoid Switch #3

 

WHI/RED from Pump Switch #3

 

 

WHI/RED to Refill Switch #3

 

 

 

 

FIG. 21 TEST/OPERATE SWITCH TERMINALS

P1525

 

 

18

41093 040408

 

 

 

SERVICE (cont.)

VACUUM/SUPPLY PUMP ASSEMBLY

1 2

3

P1521

FIG. 22 VACUUM/SUPPLY PUMP ASSEMBLY Location:

The vacuum/supply pumps are located inside the autofill box.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect the white wire from the pump lead and the yellow, orange or red wire from the other lead.

3.Connect the dispenser to the power source. With a voltmeter, check the voltage across the white wire and yellow, orange or red wire. Push the pump (flavor) switch for the pump to be tested. 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 dispenser from the power source.

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

Pump Motor Removal and Replacement:

NOTE: Do not disconnect or damage tubing. Tubing is not replaced when pump is replaced.

1.Disconnect the pump motor leads.

2.Remove the four thumb screws securing the pump head to the pump body.

3.Remove the two #8-32 keps nuts securing the pump motor/bracket assembly to the refill unit.

4.Remove the two #6-32 screws securing the pump motor to its mounting bracket.

5.Reattach this bracket to the new motor, and reinstall the assembly in the refill unit.

6.Reattach the pump head to the rear of the pump motor with the four thumbscrews.

7.Reconnect the pump motor leads. Refer to Fig. 23 to reconnect the wires.

Pump Removal and Replacement:

NOTE: Do not disconnect or damage tubing. Tubing is not replaced when pump is replaced.

1.Remove the four thumb screws securing the pump head to the pump body.

WHI from Solenoid #2

 

YEL from Pump Switch #1

 

WHI from Pump #1

 

ORN from Pump Switch #2

 

WHI from Solenoid #3

 

RED from Pump Switch #3

 

FIG. 23 VACUUM/SUPPLY PUMP TERMINALS

P1526

 

19

41093 040408

 

SERVICE (cont.)

VACUUM/SUPPLY PUMP TUBE INSTALLATION

2.Separate the two halves of the pump and carefully remove the tubing from within.

3.Hold the new pump head as shown in Fig. 24, with rollers in the 2, 6, and 10 o’clock positions.

4.Reinstall tubing in the new pump head by wrapping the tubing around the rollers as shown in Fig. 24.

5.Insert the slot of the tubing key (supplied), as shown in Fig. 24, on the rotor so the bottom edge of the key is pressing the tubing into the pump head cavity as shown in Fig. 25.

6.Hold the tubing and rotor in the pump head and remove key carefully.

7.Squeeze the pump body and pump heads together simultaneously until pump body and pump head are touching on all sides. Be careful not to pinch the tubing between the pump body and the pump head.

8.Place the new pump body on the rotor shaft.

9.Replace the four thumbscrews to secure the pump to the motor assembly. Finger-tighten only.

ROLLERS

 

 

PUMP

 

HEAD

 

TUBING

 

KEY

 

EXIT

ENTRY

 

PORT

PORT

 

 

FIG. 24 TUBING START POSITION

P1542

 

 

 

ROTOR

 

ROTOR

 

 

SHAFT

 

 

FIG. 25 TUBING LOADED

P1541

 

20

41093 040408

 

SERVICE (cont.)

VACUUM SWITCHES

 

1

 

2

FIG. 26 VACUUM SWITCHES

P1521

 

Location:

The vacuum switches are located inside autofill box, mounted on the left side of the solenoid mounting bracket just below the needle valves.

Test Procedure:

1.Disconnect the dispenser from the power source.

2.Disconnect flavor input lines.

3.Disconnect white/red, red/black or the brown/black wires on the vacuum switch.

4.Check for continuity across the switch leads.

If continuity is not present as described, the vacuum switch is operating properly.

If continuity is present as described, without a vacuum generated by an empty product concentrate, replace the vacuum switch.

Removal and Replacement:

1.Disconnect dispenser from the power source.

2.Removal of the two #8-32 keps nuts securing the pump/motor assembly nearest the vacuum switches is required to access the lower vacuum switch.

3.Disconnect the input tubes from the vacuum switch to be replaced.

4.Disconnect the wires on the vacuum switch to be removed.

5.Removethetwo#4-40screwssecuringthevacuum switch to the solenoid bracket. Remove and discard switch.

6.Using two #4-40 screws secure the new vacuum switch to the solenoid bracket.

7.Refer to Fig. 27 and reconnect the wires.

8.Connect the input tubes to the new vacuum switch.

9.Restore the pump/motor assembly to its normal mounting position using the two #8-32 keps nuts.

 

WHI/RED from Refill ON/OFF Switch #3

 

 

WHI/RED to Circuit Board J4-2

 

 

RED/BLK from Refill ON/OFF Switch #1

 

RED/BLK to Circuit Board J4-5

 

#3

#1

 

 

BRN/BLK from Refill ON/OFF Switch #2

 

BRN/BLK to Circuit Board J4-4

 

 

#2

 

 

FIG. 27 VACUUM SWITCH TERMINALS

P1527

 

 

 

21

41093 040408

 

 

PIPING DIAGRAM (AFPO-2)

The only difference between the AFPO-2/3 and AFPO-2/3 SL is the SL models have a water output line and a flavor output line for each product. This allows the water and flavor to be mixed in the hoppers. Refer to the illustration below when connecting the lines.

22

41093 040408

 

SCHEMATIC WIRING DIAGRAM

AFPO-2

L1

 

 

 

 

 

 

 

 

 

 

 

GRN

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SW1D

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAIN ON/OFF

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

REFILL ON/OFF

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLK

10

 

 

 

 

 

T

SWITCH #2

 

 

 

 

 

 

 

 

 

BRN/BLK

 

BRN/BLK

 

 

 

 

 

AMP

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

SW1C

S

 

 

 

 

SOLENOID

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

/

 

 

 

 

SWITCH #2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

O

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VIO

 

SOL

WHI

 

 

 

P

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

#2

 

 

 

 

 

 

 

 

 

 

VIO

 

 

 

 

 

R

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

PUMP

 

 

 

 

 

 

 

A

REFILL ON/OFF

 

 

L

SW ITCH #2

BRN/BLK

 

 

 

 

 

T

SWITCH #1

 

 

K

 

 

ORN

 

 

 

W

RED/BLK

E

 

RED/BLK

 

 

 

 

 

PUMP

 

 

 

 

 

 

 

 

 

H

 

 

S

 

 

 

 

 

 

 

 

#2

 

 

 

 

 

 

 

 

 

 

 

W

I

 

 

 

 

 

B

 

 

 

 

 

 

SW1B

W

 

 

 

SOLENOID

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

I

 

 

 

L

 

 

 

 

 

 

 

 

 

SWITCH #2

 

 

 

I

 

 

 

T

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

BLU

 

SOL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

 

 

#1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

PUMP

BLU

 

 

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

SW ITCH #1

RED/BLK

 

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YEL

 

PUMP

 

 

 

 

 

 

WHI

 

 

 

 

 

 

#1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SW1A

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

VACUUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH #2

 

 

 

 

 

 

 

 

 

 

 

 

 

VACUUM

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH #1

 

C

J4-1

 

 

 

 

 

 

 

 

 

 

 

I

 

 

 

 

 

 

 

 

 

 

 

R

 

2

BLK

 

 

 

 

 

 

 

 

 

 

C

 

3

 

 

 

 

 

 

 

 

 

 

 

BRN/BLK

 

 

 

 

 

 

 

 

 

U

 

4

 

 

 

 

 

 

 

 

 

I

 

RED/BLK

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

T

 

WHI

 

 

 

 

 

 

 

 

 

WHI

 

6

 

 

 

 

 

 

 

 

 

 

 

ORN

 

 

 

 

 

 

 

 

 

 

B

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

O

 

8

VIO

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

R

 

YEL

 

 

 

 

 

 

GRN

 

 

J4-10

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

RED

 

 

 

 

 

 

 

 

 

 

1

2

2

1

 

 

 

 

 

 

 

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

3

3

4

1

1

 

 

 

 

 

 

 

 

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

2

120 VOLT AC 2 WIRE

GRN 1

BLK

GRN 1

BLK

 

 

 

SINGLE PHASE

 

2

 

2

28814.0000D 6/98 ©1998 BUNN-O-MATIC CORPORATION

 

 

 

 

 

L

H

L

H

 

T

BLU

T

BLU

 

A

 

A

 

 

N

 

N

 

 

PROBE

 

PROBE

 

CONTROL

CONTROL

 

 

1

 

2

 

23

 

 

41093 040408

 

 

 

 

24

41093 040408

 

SCHEMATIC WIRING DIAGRAM

AFPOA-2

L1

 

 

 

 

 

 

 

 

 

 

 

GRN

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SW1D

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAIN ON/OFF

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

REFILL ON/OFF

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLK

10

 

 

 

 

 

T

SWITCH #2

 

 

 

 

 

 

 

 

 

BRN/BLK

 

BRN/BLK

 

 

 

 

 

AMP

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

SW1C

S

 

 

 

 

SOLENOID

 

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

/

 

 

 

 

SWITCH #2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

O

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VIO

 

SOL

WHI

 

 

 

P

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

#2

 

 

 

 

 

 

 

 

 

 

VIO

 

 

 

 

 

R

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

PUMP

 

 

 

 

 

 

 

A

REFILL ON/OFF

 

 

L

SW ITCH #2

BRN/BLK

 

 

 

 

 

T

SWITCH #1

 

 

K

 

 

ORN

 

 

 

W

RED/BLK

E

 

RED/BLK

 

 

 

 

 

PUMP

 

 

 

 

 

 

 

 

 

H

 

 

S

 

 

 

 

 

 

 

 

#2

 

 

 

 

 

 

 

 

 

 

 

W

I

 

 

 

 

 

B

 

 

 

 

 

 

SW1B

W

 

 

 

SOLENOID

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

I

 

 

 

L

 

 

 

 

 

 

 

 

 

SWITCH #2

 

 

 

I

 

 

 

T

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

BLU

 

SOL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

 

 

#1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

PUMP

BLU

 

 

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

SW ITCH #1

RED/BLK

 

 

 

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YEL

 

PUMP

 

 

 

 

 

 

WHI

 

 

 

 

 

 

#1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SW1A

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

VACUUM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH #2

 

 

 

 

 

 

 

 

 

 

 

 

 

VACUUM

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH #1

 

C

J4-1

 

 

 

 

 

 

 

 

 

 

 

I

 

 

 

 

 

 

 

 

 

 

 

R

 

2

BLK

 

 

 

 

 

 

 

 

 

 

C

 

3

 

 

 

 

 

 

 

 

 

 

 

BRN/BLK

 

 

 

 

 

 

 

 

 

U

 

4

 

 

 

 

 

 

 

 

 

I

 

RED/BLK

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

T

 

WHI

 

 

 

 

 

 

 

 

 

WHI

 

6

 

 

 

 

 

 

 

 

 

 

 

ORN

 

 

 

 

 

 

 

 

 

 

B

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

O

 

8

VIO

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

R

 

YEL

 

 

 

 

 

 

GRN

 

 

J4-10

 

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

 

RED

 

 

 

 

 

 

 

 

 

 

1

2

2

1

 

 

 

 

 

 

 

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

3

3

4

1

1

 

 

 

 

 

 

 

 

 

 

 

 

BLK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

2

230 VOLT AC 2 WIRE

GRN 1

BLK

GRN 1

BLK

 

 

 

SINGLE PHASE

 

2

 

2

28814.0004A 11/99 ©1999 BUNN-O-MATIC CORPORATION

 

 

 

 

 

L

H

L

H

 

T

BLU

T

BLU

 

A

 

A

 

 

N

 

N

 

 

PROBE

 

PROBE

 

CONTROL

CONTROL

 

 

1

 

2

 

25

 

 

41093 040408