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REFILL
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BUNN
AF PR-2
AF PR-3
OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
28791.0001B 1/00 ©1998 Bunn-O-Matic Corporation
INTRODUCTION
This equipment supplies a premixed liquid product to the hoppers on the CDS-2 or 3 dispensers. It is for indoor
use only on a sturdy counter or shelf.
WARRANTY
Bunn-O-Matic Corp. (“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)
529-6601 or 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
28791.1 011500
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, clamps and product container connectors are not supplied. Fittings and labels are supplied. Make
hose assemblies as required.
1. Assemble hoppers with probe housing assemblies to CDS-2, CDS-3 or 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...ect.
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.
NOTE: Make sure all connections are made before connecting the auto refill box to the power source.
6. 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.
7. Place the main ON/OFF switch and ON/OFF refill switches in the “OFF” position.
8. Make sure all hoses are connected. Connect the dispenser to the power source and place the main ON/OFF
switch in the “ON” position.
9. 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.
10. To test refill circuit short out probes on one of the hoppers with a screwdriver, 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.
ELECTRICAL REQUIREMENTS
CAUTION - The dispenser must be disconnected from the power source until specified in
The 120 volt version of this dispenser has an attached cordset and requires 2-wire, grounded service rated 120
volts ac, 15 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-15R.
The 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.)
Initial Set-Up.
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.
3
28791.1 011500
CLEANING
RECOMMENDED WEEKLY CLEANING:
This should be done in conjunction with the recommended weekly cleaning of your CDS-2 or CDS-3 machine. 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.
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
4
28791.1 011500
OPERATING CONTROLS
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 of the other.
5
TROUBLESHOOTING (cont.)
PROBLEM
Product will not dispense
PROBABLE CAUSE REMEDY
1. Empty product container
2. No power or incorrect voltage to
the dispenser
Replace or refill
(A1) Check the outlet for 120 volts
on two wire 120 volt dispenser.
(A2) Check the outlet for 200 volts or
240 volts ac for two wire 200 volt or
240 volt dispensers.
(B) Check circuit breakers or fuses.
3. Signal cable unplugged
4. Hopper is full
Signal cable must be plugged in.
Product must not be touching probes
to fill.
5. Fuse and fuse holder
Refer to
Holder for test procedures. See page
8
Service
- Fuse and Fuse
Motor thermal cutout (motor stops
running)
6. Main ON/OFF switch
7. Probe box LOW/OFF/HIGH
switches
8. Circuit board
9. Vacuum switches
10. Vacuum/Supply pump
1. Motor over heats
Refer to
Service
- Main ON/OFF
Switch for testing procedure. See
page 9
Refer to
Service
- Probe System. See
page 10
Refer to
Service
- Circuit Board for
testing procedures. See page 7
Refer to
Service
- Vacuum Switches
for testing procedures. See page 14
Refer to
Service
- Vacuum/ Supply
Pump for testing procedures. See
page 12
The thermal switch will reset, but
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.
6
28791.1 011500
1
2
FLA
OR
INPUT
MIXED PR
ODUCT OUTPUT
TER
INPUT
REFILL
MAIN
PO
WER
SERVICE
This section provides procedures for testing and
replacing various major components used in this
dispenser should service become necessary. Refer to
Troubleshooting
cause of any problem.
WARNING - Inspection, testing, and repair of electri-
cal equipment should be performed only by qualified
service personnel. The dispenser should be unplugged when servicing, except when electrical tests
are required and the test procedure specifically states
to plug-in the dispenser.
COMPONENT ACCESS
for assistance in determining the
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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. Refer to Fig. 1
Refer to the contents listing for component location.
Contents
Circuit Board........................................................... 8
Fuse & Fuse Holder ................................................9
Main ON/OFF Switch.............................................10
Probe LOW/OFF/HIGH Switches ...........................11
Refill ON/OFF Switches ........................................ 12
Vacuum/Supply Pump Assembly.......................... 13
Vacuum/Supply Pump Tubing Installation............14
Vacuum Switches .................................................15
Wiring Diagrams.............................................. 16,17
FIG. 1 COMPONENT ACCESS
P1561
7
28791.1 011500
CIRCUIT BOARD
OFF
OFF
OFF
OFF
FIG. 2 CIRCUIT BOARD
Removal and Replacement:
1. Disconnect the ten pin plug from the main wiring
harness to the circuit board.
2. Remove the six #4-40 screws and spacers securing the circuit board to the solenoid mounting
bracket. Remove circuit board and discard.
3. Install new circuit board using #4-40 screws and
spacers to secure the circuit board to the vacuum
switch mounting bracket. The spacers must be
OFF
N
O
OFF
N
O
OFF
N
O
OFF
N
O
between the solenoid mounting bracket and the
circuit board.
4. Refer to Fig. 3 for circuit board ten pin connector.
4
P1556
J
1
J
2
J
3
J
P1528
FIG. 3 CIRCUIT BOARD CONNECTOR LOCATION
8
1
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FLA
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INPUT
MIXED PR
ODUCT OUTPUT
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INPUT
REFILL
MAIN
PO
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SERVICE
FUSE AND FUSE HOLDER
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FIG. 4 FUSE HOLDER
Location:
The fuse holder is located on the lower right
front of the autofill box just to the left of the power
cord.
2
3
P1561
Removal and Replacement:
Fuse:
1. Remove the cap from the fuse holder.
2. Remove fuse from the fuse holder, inspect, if
blown discard.
3. Install new 10 amp fuse in the fuse holder.
4. Reinstall fuse holder cap.
Fuse Holder:
1. Disconnect the wires from the rear of the fuse
holder.
2. Remove the nut securing the fuse holder to the
front of the main mounting panel.
3. Push the fuse holder through the hole in the panel.
4. Install new fuse holder and fuse through the hole
in the panel.
5. Secure the fuse holder to the panel.
6. Refer to Fig 5 and reconnect the wires.
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 as described, reinstall the fuse,
the fuse is operating properly.
If continuity is not present as described, replace the
fuse.
WHI/GRN from Main
BLK from Main
Harness/ON/OFF Switch
Wiring Harness
WHI/GRN from Main
BLK to Main
Harness/Control Board
ON/OFF Switch
FIG. 5 FUSE HOLDER TERMINALS
P1331
9
28791.1 011500
1
2
FLA
OR
INPUT
MIXED PR
ODUCT OUTPUT
TER
INPUT
REFILL
MAIN
PO
WER
SERVICE (cont.)
MAIN ON/OFF SWITCH
If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the
wiring diagrams and check the dispenser wiring harness.
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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.
FIG. 6 MAIN ON/OFF SWITCH
P1561
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 to
the main ON/OFF switch. Disconnect the white
wire from pump #1.
3. Check for voltage across the black wires removed
from the switch and the white wire removed from
pump #1. Connect the dispenser to the power
source. 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.
4. Disconnect the dispenser from the power source.
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 Pump Switch #2
FIG. 7 MAIN ON/OFF SWITCH TERMINALS
P1522
10
28791.1 011500
PROBE SYSTEM
FIG. 8 PROBE SWITCHES
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. 8B.
11
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FLA
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INPUT
MIXED PR
ODUCT OUTPUT
1
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REFILL
MAIN
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1
2
FLA
OR
INPUT
MIXED PR
ODUCT OUTPUT
TER
INPUT
REFILL
MAIN
PO
WER
SERVICE (cont.)
VACUUM/SUPPLY PUMP ASSEMBLY
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ODUCT OUTPUT
MIXED PR
3
INPUT
3
1
2
REFILL
3
MAIN
WER
PO
WATER
UT
INP
1
2
P1560
FIG. 16 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. Check the voltage across the white wire and yellow, orange or red wire with a voltmeter. Connect
the dispenser to the power source. 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.
If voltage is present as described, replace the pump.
If voltage is not present as described, refer to the
wiring diagrams and check the main wiring harness.
Pump Removal and Replacement:
1. Disconnect the wires from the pump leads.
2. Disconnect the input and output tubes.
3. Remove the four thumb screws securing the pump
head to the pump body, discard pump head with
tubes.
4. Remove the two #8-32 keps nuts securing the
pump to the main mounting panel.
5. Remove the two #6-32 screws securing the pump
body to the mounting bracket.
6. Remove pump body and discard.
7. Install new pump assembly on the pump mount-
ing bracket and secure with two #6-32 screws.
8. Remove the four thumb screws securing the new
pump head with hoses to the new pump body.
9. Using two #6-32 screws mount the pump body on
the pump mounting bracket.
10. Using two #8-32 keps nuts mount the pump body
and bracket to main panel.
11. Install new pump head with hoses to the rear of the
pump body and secure with four thumb screws.
12. Connect the input and output tubes using new
hose clamps.
13. Refer to Fig 17 and reconnect the wires.
13
SERVICE (cont.)
VACUUM/SUPPLY PUMP TUBE INSTALLATION
ROLLERS
PUMP
HEAD
TUBING
KEY
EXIT
PORT
ENTRY
PORT
FIG. 18 TUBING START POSITION
P1542
1. Separate the pump head from the pump body.
Hold pump head as shown in Fig. 18, with roller in
the 2, 6 10 o’clock positions.
2. Wrap tubing around rollers and hold as shown in
Fig. 18.
3. Insert the slot of the tubing key (supplied), as
shown in Fig. 18 on the rotor so the bottom edge
of the key is pressing the tubing into the pump
head cavity.
4. Push down and turn the key counterclockwise to
guide the tubing deep into the pump head cavity as
shown in Fig. 19.
5. Hold the tubing and rotor in the pump head and
remove key carefully.
6. Place pump body on the rotor shaft.
7. Squeeze the pump body and pump head 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.
ROTOR
SHAFT
ROTOR
FIG. 19 TUBING LOADED
P1541
14
28791.1 011500
L1
1
2
FLA
OR
INPUT
MIXED PR
ODUCT OUTPUT
TER
INPUT
REFILL
MAIN
PO
WER
S
C
H
E
M
B
LK
A
T
I
C
W
I
R
A
I
M
N
F
AIN O
G
B
P
L
N
S
K
/
D
W
OFF
R
ITCH
I
A
3
G
R
A
BLK
M
1
0
A
M
GRN
P
R
E
RED
D
N
R
EFIL
L
SWIT
ON
PU
/OFF
M
CH
P
#
#
3
3
W
HI
OR
ORN
W
N
H
I
/R
ED
R
E
FI
L
L
O
S
WITC
N/OFF
P
U
M
H
P
#
2
#2
W
HI
YE
BR
Y
L
E
N
L
/B
W
LK
H
I
RE
F
ILL
BLK
S
O
W
N
/
ITC
O
FF
H #1
PU
MP
#
1
RE
D/B
LK
V
AC
U
SW
C
U
M
ITC
I
H
#
J
3
4-
R
1
C
2
W
HI/R
U
3
E
B
4
D
LK
I
T
B
5
RN
/BLK
R
6
ED/
BLK
B
7
WH
I
O
8
OR
N
WHI
A
9
J
VACU
GRY
4
10
SW
R
U
V
M
I
IO
TCH
D
#2
Y
EL
V
A
C
UUM
SW
I
T
C
H #
1
120
V
1
O
LT
SI
G
RN
AC
N
2
G
4
2
2
2
L
8814.
R
E
E
W
D
P
0003E
I
3
RE
1
HA
3
S
7/
98 ©1
E
B
LK
4
998
BU
NN
O
W
-MAT
H
I
W
IC
H
I
CORPO
1
RA
T
IO
N
BL
K
1
2
GRN
1
B
L
K
1
2
G
B
RN
LK
1
2
2
BLK
G
RN
2
1
L
H
B
T
L
K
2
A
L
N
BL
H
U
T
A
PRO
N
CO
B
L
E
BL
NTRO
U
L
H
1
T
P
R
O
A
C
BE
O
N
TR
N
OL
BL
2
U
P
RO
C
BE
ON
T
R
OL
3
1
VOR
FLA
2
UCT OUTP
OD
IXED PR
M
3
INPUT
3
UT
1
2
REFILL
N
AI
3
M
ER
W
PO
WATER
INPUT
1
2
15
SCHEMA TIC WIRING DIAGRAM
AFPR-2
L1 N
BLK
MAIN ON/OFF
SWITCH
BLK
BLK
10
AMP
ORN
GRN
REFILL ON/OFF
SWITCH #2
BRN/BLK
T
C
I
R
C
U
I
B
O
A
R
D
BLK
J4-1
2
3
4
5
6
7
8
9
J4-10
BLK
BRN/BLK
RED/BLK
WHI
ORN
VIO
YEL
YEL
ORN
PUMP
#2
PUMP
#1
WHI
REFILL ON/OFF
YEL
GRN
RED
1
1
4
2
2
3
BLK
4
3
SWITCH #1
1
VACUUM
SWITCH #2
VACUUM
SWITCH #1
BLK
2
RED/BLK
WHI
WHI
1
2
120 VOLT AC 2 WIRE
SINGLE PHASE
28814.0002E 7/98 ©1998 BUNN-O-MATIC CORPORATION
16
1
GRN GRN
T
A
N
BLK
2
LH LH
T
A
N
PROBE
CONTROL
1
BLU
1
PROBE
CONTROL
2
BLK
2
BLU
28791.1 011500
L1
BLK
BLK
MAIN ON/OFF
SWITCH
BLK
SCHEMA TIC WIRING DIAGRAM
10
AMP
AFPR-3
RED
GRN
REFILL ON/OFF
SWITCH #3
N
WHI/RED
RED
PUMP
#3
ORN
PUMP
#2
YEL
PUMP
#1
BLK
C
J4-1
I
WHI/RED
2
R
C
U
T
B
O
A
R
D
I
3
4
5
6
7
8
9
J4-10
BLK
BRN/BLK
RED/BLK
WHI
ORN
GRY
VIO
YEL
120 VOLT AC 2 WIRE
SINGLE PHASE
28814.0003E 7/98 ©1998 BUNN-O-MATIC CORPORATION
WHI
WHI
REFILL ON/OFF
ORN
YEL
W
H
I
GRN
RED
1
423
1
2
BLK
4
3
WHI
SWITCH #2
REFILL ON/OFF
SWITCH #1
1
1
GRN
VACUUM
SW ITCH #3
VACUUM
SWITCH #2
VACUUM
SWITCH #1
BLK
2
BLK
2
GRN
RED/BLK
1
1
BRN/BLK
BLK
2
BLK
2
WHI
WHI
GRN
1
2
1
BLK
2
17
LH LH
T
A
N
PROBE
CONTROL
T
BLU
A
N
PROBE
CONTROL
1
2
BLU
LH
T
A
N
PROBE
CONTROL
3
BLU
28791.1 011500
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