Bunn Dual, Dual DUAL010000 Operating & Service Manual

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ANY COMPONENT!

DISCONNECT FROM POWER SOURCE

BEFORE REMOVAL OF ANY PANEL OR

REPLACEMENT OF

™

DUAL

(Serial # DUAL010000 - Up)

gal

2 ⁄

1 gal

2 ⁄ 1

DER

G H T

L E F T

START

2 ⁄

1 ga

gal

2 ⁄ 1

ON / WARMER

SELECTOR

READY

CAUTION

DISCARD DECANTER

IF:

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FLAM

ILE

. S

D W

. B

. H

. U

EN M

. O

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N IO T

R O P

ENTS

OR C

IC T A

-M

-O N N

OMPLY RISKS INJURY

5 8 9

FUNNEL CONT

ARE HOT

FAILURE TO C

8 5 6 :

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HOT WATER

START

CAUTION

READY

SELECTOR

ON / WARMER

OPERATING & SERVICE MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

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

CAUTION:

WARMERS

AND

URFACES ARE HOT

www.bunnomatic.com

Page 2

INTRODUCTION

This equipment will brew two half-gallon, gallon, or gallon and a half batches of coffee into awaiting servers at the push of a button. The brewer is also equipped with a hot water faucet for allied beverage use and is designed to interface with a BUNN® Grinder. The brewer is specifically designed for use with a BUNN® 1.5 GPR server. It is only for indoor use on a sturdy counter or shelf.

BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY

Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:

1) All equipment other than as specified below: 2 years parts and 1 year 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.

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USER NOTICES

The notices on this brewer should be kept in good condition. Replace unreadable or damaged labels.

00658.0000

00831.0000

20201.5600

00656.0000

12364.0000

ELECTRICAL REQUIREMENTS

CAUTION - The brewer must be disconnected from the power source until specified in

L2 RED

200 or 240V A.C.

L1 BLACK

L2 RED

WHITE

NEUTRAL

L1 BLACK

120V A.C.

208 or 240V A.C.

120V A.C.120V A.C.

Initial Set-Up.

Requires 2-wire, grounded service rated 200 to 240 volts ac, 30 amp, single phase 50 or 60 Hz.

Requires 3-wire, grounded service rated 120/208 or 120/ 240 volts ac, 30 amp, single phase, 60 Hz.

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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. Remove the front panel beneath the sprayheads.

Models with electronic control assemblies:

Place the tank heater switch at the top of the control assembly in the “OFF” position.

Models with electro/mechanical thermostats:

Rotate the control thermostat knob fully counterclockwise to the “OFF” position.

4. Feed the cord through the strain relief and connect it to the terminal block.

5. Connect the brewer to the power source and verify the voltage at the terminal block before proceeding. Replace

the front panel.

6. If plumbing is to be hooked up later be sure the brewer is disconnected from the power source. If plumbing

has been hooked up, the brewer is ready for Initial Set-Up.

PLUMBING REQUIREMENTS

This brewer must be connected to a cold water system with operating pressure between 20 and 90 psi (138 and 620 kPa) from a 1⁄2" or larger supply line. A shut-off valve should be installed in the line before the brewer. 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 is 1⁄4" flare.

NOTE – Bunn-O-Matic recommends 1⁄4" copper tubing for installations of less than 25 feet and 3⁄8" for more than 25 feet from the 1⁄2" water supply line. A tight coil of copper tubing in the water line will facilitate moving the brewer to clean the countertop. Bunn-O-Matic does 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).

PLUMBING HOOK-UP

1. Flush the water line and securely attach it to the flare fitting on the strainer/flow control located on bottom of

brewer.

2. Turn on the water supply.

INITIAL SET-UP

CAUTION – The brewer must be disconnected from the power source throughout the initial set-up, except when

specified in the instructions. NOTE: ECA Models Only -This brewer is equipped with a temperature sensor that indicates when to brew and, when selected, locks-out the start of a brew cycle until the water has heated to the optimum brewing temperature.

1. Remove the front panel beneath the sprayhead.

Models with electronic control assemblies:

Place the tank heater switch at the top of the control assembly in the “OFF” position.

Replace the front panel.

Models with electro/mechanical thermostats:

Rotate the control thermostat knob fully counterclockwise to the “OFF” position.

Replace the front panel.

2. Connect the brewer to the power source. Water will begin flowing into the tank.

3. When water stops flowing into the tank, remove the front panel and proceed as directed:

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INITIAL SET-UP (cont.)

Models with electronic control assemblies:

Place the tank heater switch at the top of the control assembly in the “ON” position and replace the front panel.

Models with electro/mechanical thermostats:

Rotate the control thermostat knob fully clockwise to the “ON” position and replace the front panel.

4. Wait approximately twenty minutes for the water in the tank to heat to the proper temperature.

5. Place an empty server beneath either brew station and the ON/OFF switch in the upper ("ON") position.

6. Triple-set Timers only: Place the brew station Selector switch in the 1

7. (A) Initiate a brew cycle; after water has stopped flowing from the funnel, place the ON/OFF switch in the lower ("OFF") position and check the water volume in the server. It should be 192 ounces (5.7 L) for 1 1/2 gallons. If not, adjust the timer as required. Refer to

Adjusting Brew Volumes

NOTE: Each batch setting must be adjusted individually, if they are not correct. Volumes are as follows:

1 gallon - 128 ounces (3.8L)

.5 gallon - 64 ounces (1.9L) (B) If necessary adjust the needle valve to achieve desired water volume to be bypassed around the coffee filter in the funnel. NOTE: To increase the water bypass turn the needle valve counterclockwise, to decrease the water bypass turn the needle valve clockwise. An adjustment of the needle valve will require a timer adjustment for volume. To determine how many turns must be performed to achieve the desired volume, use the chart below.

⁄2 gallon position.

% BYPASS

REFERENCE CHART

MECHANICAL BYPASS WITH ADJUSTABLE NEEDLE VALVE

BYPASS PERCENTAGE VS NUMBER OF FULL TURNS FROM

MAXIMUM CLOCKWISE POSITION

SINGLE & DUAL BREWERS

012345678

NOTE: The factory bypass is set at 20%

NUMBER OF FULL TURNS

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INITIAL SET-UP (cont.)

8. Repeat step 7 until the proper water volume is achieved.

9. Repeat steps 5 through 8 for the remaining brew station.

10. The brewer is now ready for use in accordance with the coffee brewing instructions.

ADJUSTING BREW VOLUMES

CAUTION - Disconnect the power source from the brewer prior to the removal of any panel for the replacement

or adjustment of any component. NOTE: Prior to setting or modifying batch sizes, check that the brewer is connected to water supply, the tank is properly filled, and a funnel and server are in place.

1. Modifying batch sizes. To modify a batch volume, first check that the SET/LOCK switch is in the “SET” position on the circuit board. To increase a batch size. Press and hold the START or BREW switch until three clicks are heard. Release the switch (Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory) and press it again one or more times. Each time the switch is pressed, two seconds are added to the brew time period. Allow the brew cycle to finish in order to verify that the desired volume has been achieved. To decrease a batch size. Press and release the START or BREW switch once for every two-second interval to be removed from the total brew time period; then immediately press and hold down the START or BREW switch until three clicks are heard. Release the switch. (Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory). Allow the brew cycle to finish in order to verify that the desired volume has been achieved.

2. Setting batch sizes. To set a batch volume, first check that the SET/LOCK switch is in the “SET” position on the circuit board. Press and hold the START or BREW switch until three distinct clicks are heard, and then release the switch. (Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory). View the level of the liquid being dispensed. When the desired level is reached, turn the ON/OFF switch to “OFF” (lower). The brewer remembers this volume and will continue to brew batches of this size until the volume setting procedure is repeated.

NOTE: When brewing coffee, batch volumes will decrease due to absorption by the coffee grounds.

3. Setting programming disable feature. If it becomes necessary to prevent anyone from changing brew times once programmed, you can set the SET/LOCK switch to the “LOCK” position. This will prevent any programming to be done until switch is once again placed in the “SET” position.

OPERATING CONTROLS

BREW SELECTOR SWITCH (Triple - set timer models only)

Placing the switch in the 1⁄2 Gal, 1 Gal, or 11⁄2 Gal position selects the amount of coffee to be brewed in

subsequent brew cycles. Repositioning this switch after a brew cycle has been initiated does not change the brew batch in progress.

ON/OFF SWITCH

Placing the switch in the unlighted lower position cuts power to the brew station warmer and stops brewing.

Stopping a brew cycle after it has been started will not stop the flow of water from the funnel. Placing the switch in the lighted upper position supplies power to the brew station warmer and enables the brew circuit.

START SWITCH

Momentarily pressing and releasing this switch starts a brew cycle when the On/Off switch is in the lighted

upper position.

GRINDER SELECTOR SWITCH

Pressing the right or left side of the switch selects the corresponding brew station.

NOTE – The On/Off switch must be in the lighted upper position to initiate and complete a brew cycle.

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INITIAL SET-UP (cont.)

COFFEE BREWING

1. Select the desired batch size.

2. Insert a BUNN

filter into the funnel.

3. Pour the proper amount of fresh ground coffee into the filter and level the bed of grounds by gently shaking.

4. Slide the funnel into the funnel rails.

5. Place an empty server under the funnel. 6 Place the On/Off switch in the lighted upper position. Momentarily press and release the start switch.

7. When brewing is completed, simply discard the grounds and filter.

CLEANING

1. 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.

2. Check and clean the sprayhead. The sprayhead holes must always remain open. NOTE – In hard water areas, this may need to be done daily. It will help prevent liming problems in the brewer and takes less than a minute.

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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 - 240 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 avoid twists and kinks in the tubing.

• Make certain that all plumbing connections are sealed and electrical connections tight and isolated.

• This brewer is heated at all times. Keep away from combustibles.

WARNING

• Exercise extreme caution when servicing electrical equipment.

• Disconnect the brewer from the power source when servicing, except when electrical tests are specified.

• Follow recommended service procedures.

• Replace all protective shields or safety notices.

Problem

Equipment will not operate.

Probable Cause

1. No power or incorrect voltage.

1. No waterBrew cycle will not start.

2. Water strainer/flow control (.750 GPM)

Remedy

(A1) Check the terminal block for 120 volts across the red and white terminals and the black and white terminals on 120/208 or 120/240 volt brewers.

(A2) Check the terminal block for 200 volts on "B Series" brewers or 240 volts on "A Series" brewers across the red and black terminals.

(B) Check circuit breakers or fuses.

Check plumbing and shut-off valves

(A) Direction of flow arrow must be pointing towards brewer.

(B) Remove the strainer/flow control and check for obstructions. Clear or replace.

27040 041100

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TROUBLESHOOTING (cont.) Problem

Probable Cause

Remedy

Brew cycle will not start (cont.)

Automatic refill will not operate

3. ON/OFF switch

4. Start switch

5. Timer

6. Dispense Valve

7. Control Assembly (Electronic)

1. No water

2. Water strainer/flow control (.750 GPM)

Refer to

Service

- ON/OFF switch for

testing procedures. See page 32

Refer to

Service -

Start switch for

testing procedures. See page 37

Refer to

Service -

Timer for testing

procedures. See page 39 or 42

Refer to

Service -

Dispense valve for

testing procedures. See page 22

Refer to

Service

- Control assembly for testing procedures. See pages 23 thru 28

Check plumbing and shut-off valves.

(A) Direction of flow arrow must be pointing towards brewer.

3. Solenoid Valve

4. Limit thermostat (Electro/ mechanical and Electronic)

5. Overflow protection switch

6. (A) Level control board & level probe. (Electro/mechanical controlled)

(B) Electronic controls

(B) Remove the strainer/flow control and check for obstructions. Clear or replace.

Refer to

Service

- Solenoid valve for testing procedures. See page 36

Refer to

Service

- Limit thermostat for testing procedures. See page 31

Refer to

Service -

Overflow protection switch for testing procedures. See page 33

Refer to

Service

- Level control board

for testing procedures. See page 29

Refer to

Service

- Electronic controls for testing procedures. See page 23 thru 28

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TROUBLESHOOTING (cont.) Problem

Probable Cause

Remedy

Beverage level will not adjust (Selector switch in any position)

Water flows into tank continuously .

Water flows into tank continuously (ON/OFF switch "ON").

Water from tank is not hot

1. Brew Selector switch

1. Solenoid valve

2A. Level control board and level probe (Electro/mechanical)

2B. Control assembly (Electronic)

1. Timer

2. Overflow protection switch

1. Limit thermostat

CAUTION - Do not eliminate or bypass limit thermostat. Use only replacement part #23717.0001

Refer to

Service

- Selector switch for

testing procedures. See page 16

Refer to

Service

- Solenoid valve for

testing procedures. See page 36

Refer to

Service

- Level control board

for test procedures. See page 29

Refer to

Service

- Control assembly for testing procedures. See page 23 thru 28

Refer to

Service

- Timer for testing

procedures. See page 39 or 42

Refer to

Service

- Overflow protection switch for testing procedures. See page 33

Refer to

Service

-Limit thermostat

for testing procedures. See page 31

2A. Control Thermostat (Electro/mechanical)

2B. Control assembly (Electronic)

3. Contactor (Brewers with Recovery Booster)

4. Tank heaters

5. Triac assembly (Electronic)

Refer to

Service

- Control Thermostat for testing procedures. See page 20

Refer to

Service

- Control assembly for testing procedure. See page 23 thru 28

Refer to

Service

- Contactor for test-

ing procedures. See page 18

Refer to

Service

- Tank heaters for

testing procedures. See page 38

Refer to

Service

- Triac assembly for testing procedures. See page 23 thru 28

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TROUBLESHOOTING (cont.)

Problem

Water from tank is not hot (cont.).

Server warmer is not hot.

Spitting or unusual steaming from sprayhead or airvents.

Probable Cause

6. Relay (Brewers with Recovery Booster)

1. ON/OFF switch

2. Warmer element

1A. Control thermostat (Electro/mechanical)

1B. Control assembly (Electronic)

2. Triac assembly (Electronic)

3. Lime build-up

CAUTION - Tank and tank components should be delimed regularly depending on local water conditions. Excessive mineral build-up on stainless steel surfaces can initiate corrosive reactions resulting in serious leaks.

Remedy

Refer to

Service

- Relay for testing

procedures. See page 34

Refer to

Service

- ON/OFF switch for

testing procedures. See page 32

Refer to

Service

- Warmer element

for testing procedures. See page 44

Refer to

Service

- Control thermostat for testing procedures. See page 20

Refer to

Service

- Control assembly for testing procedures. See page 23 thru 28

Refer to

Service

- Triac assembly for testing procedures. See page 23 thru 28

Inspect the tank assembly for excessive lime deposits. Delime as required.

Inconsistent beverage level in server.

1. Strainer/flow control (.750 GPM) (A) Direction of flow arrow must be

pointing towards the brewer.

(B) Remove the strainer/flow control and check for obstructions. Clear or replace.

2. Improper water pressure Check operating water pressure to

the brewer. It must be between 20 and 90 psi (138 and 620 kPa) .

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TROUBLESHOOTING (cont.)

Problem

Inconsistent beverage level in server (cont.).

Consistently high or low beverage level in server.

Dripping from sprayhead.

Water overflows filter.

Probable Cause

3. Dispense valve

1. Timer adjustment

1. Dispense valve

1. Bypass valve

2. Needle Valve

3. Type of paper filters

Remedy

Refer to

Service -

Dispense valve for

testing procedures. See page 22

Adjust the timer as required to achieve the recommended volume for each brew cycle.

Refer to

Service

- Dispense valve

for testing procedures. See page 22

Refer to

Initial Set-Up

on page 5 step

#7. For test procedures see page 15

Refer to

Initial Set-Up

on Page 5

step #7

BUNN® paper filters should be used for proper extraction.

Beverage overflows server.

Weak beverage.

4. No sprayhead

1. Beverage left in server

2. Timer adjustment

3. Dispense valve

1. Type of paper filters

2. Coffee

Check sprayhead

The brew cycle should be started only with an empty server under the funnel.

Adjust the timer as required to achieve the recommended volume for each brew cycle. Refer to

Service

- Timer for testing

procedures. See page 39 or 42

Refer to

Service

- Dispense valve for

testing procedures. See page 22

BUNN

paper filters should be used

for proper extraction.

A sufficient quantity of fresh drip or regular grind should be used for proper extraction.

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TROUBLESHOOTING (cont.)

Problem

Weak beverage (cont.)

Probable Cause

3. Sprayhead

4. Funnel loading

5. Water temperature

Remedy

A clean sprayhead should be used to properly wet the bed of ground coffee in the funnel.

The BUNN® paper filter should be centered in the funnel and the bed of ground coffee leveled by gentle shaking.

Empty the server, remove its cover, and place the server on the warmer. Place empty funnel over the server entrance, with ON/OFF switch in the "ON" position press the start switch and release it. Check the water temperature immediately below the sprayhead with a thermometer. The reading should not be less than 195˚F(91˚C).

Brewer is making unusual noises.

1. Solenoid (Inlet)

2. Plumbing lines

3. Water supply

4. Tank Heaters

5. Contactor

The nut on back of the solenoid must be tight or it will vibrate during operation

Plumbing lines should not be resting on the counter top.

(A) The brewer must be connected to a cold water line.

(B) Water pressure to the brewer must not be higher than 90 psi (620 kPa). Install a regulator if necessary to lower the working pressure to approximately 50 psi (345 kPa).

Remove and clean lime off tank heaters.

Check for low voltage

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SERVICE

This section provides procedures for testing and replacing various major components used in this brewer 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 brewer should be unplugged when servicing, except when electrical tests are required and the test procedure specifically states to plug in the brewer.

COMPONENT ACCESS

WARNING - Unplug the brewer before the removal of

any panel or the replacement of any component.

All components are accessible by the removal of the top cover, front inspection panel and warmer base plate.

l a

⁄2 1

1 l a g

2 1⁄

Y D A

R E D

N I

G H T

L E F T

l a

⁄2 1

1 l a g

1 l a

2 ⁄ 1

LE E S

Y D

A E R

R E

N A C

S I

F I

RY D

SCR

G I

ELEC

HEA

TIO

O C

U B

E R U

L I A

658 : N P

HOT WATER

T R A

T S

CAUTI

E M R A

W /

O T C

L E S

R E M

A W /

N O

T R A

T S

The top cover is attached with four #4-40 slotted

head screws.

The front inspection panel is attached with five #6-

32 slotted head screws.

The warmer base is attached with four #6-32

slotted head screws.

Contents

Brewer Selector Switch......................................... 16

Bypass Valve ........................................................15

Contactor Assembly.............................................. 18

Control Thermostat............................................... 20

Dispense Valve ..................................................... 22

Electronic Control .................................... 23 thru 28

Grinder Selector Switch ........................................ 28

Level Control Board and Level Probe ....................29

Limit Thermostat .................................................. 31

ON/OFF Switch (Warmer) .....................................32

Overflow Protection Switch .................................. 33

Relay .................................................................... 34

Solenoid ...............................................................36

Start Switches (Brew) ...........................................37

Tank Heaters......................................................... 38

Timers (Early Models) .......................................... 39

Digital Timer (Late Models) .................................. 42

Warmer Elements .................................................44

Wiring Diagrams................................................... 45

S E C

F R U

D N A

S R E

M R A

: N

IO T U

A C

O H E

R A

P772

27040 011904

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SERVICE (cont.)

BYPASS VALVE

gal 1

A N I

O-

N-

0 2

2 N /

C I

A N I

O-

0 2

6 2

N / P

T O H

E R A

E C A

UR S D

N A

S R E

I T

IO T

AU C

P773

FIG. 1 BYPASS VALVES

Location:

The bypass valves are located inside the right front

and the center front of the hood.

Test Procedures:

1. Disconnect the brewer from the power source and place a server beneath the funnel.

2. Check the water level in the tank to confirm that it is within 1/2" from the top of the tank.

3. Connect the brewer to the power source.

4. Check the bypass valve for coil action. Place the ON/OFF switch in the "ON" position, press and release the BREW switch. Listen carefully in the vicinity of the bypass valve for a "clicking" sound as the coil magnet attracts and repels the plunger.

5. Disconnect the brewer from the power source.

6. Connect the voltmeter lead ends to the bypass valve coil terminals. Connect the brewer to the power source. With the selector switch in the 1 or 1-1/2 gallon position, place "ON/OFF" Switch in the "ON" position. Press and release the brew switch. The indication must be: a.) 120 volts ac for three wire 120/208 volt and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

7. Disconnect the brewer from the power source.

If voltage is present as described, but no coil action is observed, nor "clicking" heard, bypass valve is defective. Replace valve and test again to verify repair. If voltage is not present as described, refer to

Diagrams

and check the brewer wiring harness. Also

Wiring

check the control board for proper operation. See Pages 22 through 27.

Removal and Replacement:

1. Remove the wires from the bypass valve.

2. Drain enough water from the tank so bypass valve is above the water line.

3. Remove water lines from bypass valve.

4. Remove the two nuts retaining the bypass valve inside the hood and remove bypass valve.

5. Remove hose barb fitting and attach to new bypass valve.

6. Install new bypass valve with hose barb fitting.

7. Reconnect the water tubes and the wires to the bypass valve.

8. Refer to Fig. 2 when reconnecting the wires.

WHI/GRN To Dispense Valve

If the sound is heard as described, there may be a blockage in the bypass valve or the water line to the sprayhead. Remove the bypass valve and inspect for wear, and remove waterborne particles. If the sound is not heard as described, proceed to #6.

WHI/VIO to Brew Selector Switch

LEFT AND RIGHT VALVE

P774

FIG. 2 BYPASS VALVE TERMINALS

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Page 16

SERVICE (cont.)

BREW SELECTOR SWITCH

FIG. 3 BREW SELECTOR SWITCHES

12. Reconnect the pink wire to the grind switch.

13. Disconnect the tan wire from the left or right selector switch and tan wire from interface socket.

14. Check for continuity across the tan wires.

15. Reconnect the tan wires.

16. With the selector switch set at 1 and 1-1/2 gallon, disconnect the white/violet from the bypass valve.

17. Check for continuity across the white/violet wire and terminal on bypass valve.

l a g

2 ⁄ 1

l a g 1

l a g

2 ⁄ 1

D A E

O CT E

L E S

R E

M R A

W /

R A T

l a g

2 ⁄ 1

1 l a

1 l a g

2 ⁄ 1

E RM A

/ N O

T C E

L E S

R A T

18. Reconnect the white/violet wire to the terminal on the bypass valve.

19. Disconnect the white/red wire from the dispense valve.

20. Check for continuity across white/red wire and terminal on dispense valve.

21. Reconnect white/red wire to the terminal on the

P775

dispense valve.

Location:

The brew selector switches are located in the front

left and right side of the hood.

Test Procedure:

1. Disconnect the brewer from the power supply.

2. Separate the connector on the selector switch harness from the brew timer circuit board.

3. Carefully slide the plastic cover off of the connector from the switch harness.

4. Check for continuity across the pink and tan wires on the connector when the switch is in the 1/2 gallon position. Continuity must not be present in any other switch position.

5. Check for continuity across the pink wire and gray wire when the switch is in the 1 gallon position. Continuity must not be present in any other position.

6. Reattach the connector to the brew timer circuit board.

7. Disconnect the gray wire from the left or right selector switch and gray wire from the interface socket.

8. Check for continuity across the gray wires.

9. Reconnect the gray wires from the selector switches and the interface socket.

10. Disconnect the pink wire from the left or right selector switch to the grinder switch.

11. Check for continuity across the pink wire and the terminal on the grind switch.

If continuity is present as described the switch is operating properly. If continuity is not present as described replace switch assembly.

Removal and Replacement:

1. Disconnect the connector on the selector switch harness from the brewer timer circuit board.

2. Disconnect wires from the selector switch, interface socket, dispense valve and bypass valve.

3. Loosen the set screw on the switch knob.

4. Remove the 9/16" nut and washer holding the switch to the hood.

5. Remove the switch.

6. Install the new switch. The positioning tab must be in the hole in the hood for proper switch and knob alignment.

7. Install the knob so that the arrow lines up in the 11/2 gallon position when the switch is turned to the full right position.

8. Reattach the connector to the brew timer circuit board.

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

27040 032201

Page 16

Page 17

SERVICE (cont.)

WHI/VIO to Left or Right By-Pass Valve

WHI/RED to Left or Right Dispense Valve

To Left or Right Timer

GRY to Left or Right Selector Switch to GRY Lead on Interface Socket

PNK from Left Switch to Grinder Switch (Lower Left) PNK from Right Switch to Grinder Switch (Lower Right)

TAN to Left or Right Selector Switch to TAN Lead on Interface Socket

TAN

GRY

PNK

FIG. 4 BREW SELECTOR SWITCH TERMINALS

P776

27040 032201

Page 17

Page 18

SERVICE (cont.)

CONTACTOR ASSEMBLY

C I

-M

2 6

2 N / P

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

5. Disconnect the brewer 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

l a g

⁄ 1

1 l a

1 g l a g

2 ⁄ 1

READY

ELECTOR S

/ W

LECTO

REA

l a g

2 ⁄ 1

1 l a g

1 l a

2 ⁄ 1

C I

2 6

2 N /

START

ER M R A

ness.

6. Check for continuity between the two black wires of the contactor coil.

and check the brewer wiring har-

If continuity is present as described, reconnect one black wire to red or white wire from the terminal block and the other black wire to the black wire from the control thermostat. Reinstall capillary tube into the

T O

E H S AR E

AC RF U

AND S

ERS

T O H

TIO

CAUTION:

U A C

tank to a line 7" above the bulb and proceed to #7. If continuity is not present as described, replace the contactor.

P796

FIG. 5 CONTACTOR ASSEMBLY

Location:

The contactor assembly is located inside the hood

just to the rear of the right dispense valve.

Test Procedures: Mechanical Thermostat (Brewers with or without Recovery Booster)

1. Disconnect the brewer from the power source.

2. Disconnect the red wire of the two pole 200V or 240V terminal block or the white wire of the three pole 120/208V or 120/240V terminal block and the black wire of the contactor coil. Disconnect the black wire of the control thermostat from the remaining black wire of the contactor coil.

3. Gently remove the capillary bulb and grommet from the tank.

4. With a voltmeter, check the voltage across the white wire from the terminal block on 120/208, 120/240 volt units or the red wire from 200 or 240 volt units and the black wire from the control thermostat when the thermostat is turned clockwise to the "FULL ON" position. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models.

7. Locate the red wire on the L1 terminal and black wire on the L2 terminal on the contactor.

8. With a voltmeter, carefully check the voltage across the red and black wires. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

9. Disconnect the brewer from the power source.

If voltage is present as described, proceed to #10. If voltage is not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

10. Check for continuity across the terminals on the left side of the contactor by manually closing the contacts. Continuity must not be present when the contact is released.

11. Check for continuity across the terminals on the right side of the contactor by manually closing the contacts. Continuity must not be present when the contact is released.

If continuity is present as described, the contactor is operating properly. If continuity is not present as described, replace the contactor.

27040 032201

Page 18

Page 19

SERVICE (cont.)

CONTACTOR ASSEMBLY (cont.)

Test Procedures : Electronic Control (Brewers w/Recovery Booster)

1. Disconnect the brewer from the power source.

2. Disconnect the gray wire from the black wire on the rear of the contactor coil and white /brown wire from the black wire on the front of the contactor coil.

3. With a voltmeter, check the voltage across the gray wire and white/brown wire with both "ON/OFF" switches in the "ON" position. Connect the brewer to the power source and press both start switches. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

4. Disconnect the brewer from the power source.

RED L1 to Terminal Block (Red Insert)

BLK L2 to Terminal Block (Black Insert)

BLK to WHI Lead from the Three Pole 120/208V or 120/240V Terminal Block BLK to RED Lead from the Two Pole 200V or 240V Terminal Block

MECHANICAL THERMOSTAT W/RECOVERY BOOSTER

BLU L1 to Left Tank Heater

BLK to GRY on Relay

BLK T2 to Left Tank Heater BLK T2 to Right Tank Heater

RED T1 to Left Tank Heater RED T1 to Right Tank Heater

BLK to BLK Lead from Thermostat

RED T1 to Terminal Block (Red Insert)

BLK to WHI/BRN to Left Dispense Valve

If voltage is present as described, proceed to #5. If voltage is not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

5. Disconnect the blue and red wires from the contactor terminals. Check for continuity across the terminals of the contactor by manually closing the contacts. Continuity must not be present when the contact is released.

If continuity is present as described, reconnect the blue and red wires to the contactor terminals. Connect one black lead from the contactor coil to the gray wire and the white/brown wire to the remaining black lead of the contactor coil. The contactor is operating properly. If continuity is not present as described, replace the contactor.

Removal and Replacement:

1. Remove all wires from the contactor.

2. Remove the two #10-32 slotted head screw securing contactor to the inside of the hood.

3. Securely install the new contactor inside the hood.

4. Refer to Fig. 6 when reconnecting the wires.

ELECTRONIC CONTROL W/RECOVERY BOOSTER

FIG. 6 CONTACTOR TERMINALS

P778

27040 032201

Page 19

Page 20

SERVICE (cont.)

CONTROL THERMOSTAT

l a

2 ⁄ 1

1 l a g

2 ⁄ 1

AD E R

R O T

SEL

ARM

W / N

T R

O-MA

N N

6 2

N / P

RM WA /

T C E

Y D A

l a g

2 ⁄

l a g 1

l a

2 ⁄

O-

6 2 N

RT A T

OT RE H A

FAC R U

S D

ER M R

AT W OT

CAUTION:

CAUTION

P779

FIG. 7 CONTROL THERMOSTAT

Location:

The control thermostat is located inside the lower

left front of the brewer on the component bracket.

1. Disconnect the brewer from the power source.

2. Locate the blue wire on the control thermostat.

3. With a voltmeter, check the voltage across the blue wire on the control thermostat and the white insert on three pole 120/208V, 120/240V terminal block and the red insert on two pole 200V, 240V terminal block. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models.

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

4. Disconnect the brewer 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 brewer wiring harness.

5. Locate the black wires from the control thermostat.

6. Gently remove the capillary bulb and grommet from the tank.

7. With a voltmeter, check the voltage across the black wires of the control thermostat and the white insert on the three pole 120/208V, 120/240V terminal blocks and the red insert on two pole 200V, 240V terminal blocks when the control thermostat is turned "ON" (fully clockwise). Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models. Voltage must not be indicated across these terminals when the thermostat is turned "OFF" (fully counterclockwise).

8. Disconnect the brewer from the power source.

If voltage is present as described, reinstall the capillary tube into the tank to the line 7" above the bulb, the control thermostat is operating properly. If voltage is not present as described, replace the thermostat.

27040 032201

Page 20

Page 21

SERVICE (cont.)

CONTROL THERMOSTAT (cont.)

Removal and Replacement:

1. Remove wires from the control thermostat.

2. Remove the thermostat capillary bulb by firmly pulling up on the capillary tube at the tank lid. This will disengage the grommet from the tank lid.

3. Remove the #8-32 slotted head screw holding the control thermostat to the component bracket.

4. Slide the grommet to the line 7" above the bulb on the new capillary tube.

5. Insert the capillary bulb through the hole in the tank lid and press the grommet firmly and evenly so that the groove in the grommet fits into the tank lid.

6. Carefully bend the capillary tube so that the tube and bulb inside the tank are in the vertical position.

BLU to Left & Right Ready Lights BLU to RED Lead from Liquid Level Switch

BLK to BLK Lead of Contactor Coil BLK to Left & Right Ready Lights

FIG. 8 CONTROL THERMOSTAT

TERMINALS

P780

NOTE - The capillary tube must be clear of any electrical termination and not kinked.

7. Using a #8-32 slotted head screw fasten the control thermostat to the component bracket.

8. Refer to Fig. 8 when reconnecting the wires.

9. Adjust the control thermostat as required.

27040 032201

Page 21

Page 22

SERVICE (cont.) DISPENSE VALVE

2 N /

A N I

O-

6 2

N / P

ART T

R E

RM WA /

N O

R O T

ADY E

l a g

2 ⁄

l a g

1 l a

2 ⁄ 1

O-MA

FIG. 9 DISPENSE VALVE

Location:

Dispense valves are located inside the hood in the

center of each sprayhead panel.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the wires from the right dispense valve and check the voltage across the white/violet wire and white/green wire. Connect brewer to the power source. Place the "ON/OFF" switch in the "ON" position, press and release the start switch. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

3. Disconnect brewer from the power source.

4. Disconnect the wires from the left dispense valve and check voltage across the white/red wire and the white/brown wire. Connect the brewer to the power source. Place the "ON/OFF" switch in the "ON" position and press and release the start switch. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

5. Disconnect brewer from power source.

If voltage is present as described in steps 2 & 4 proceed to #6. If voltage is not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

6. Check for continuity across the dispense valve coil terminals.

If continuity is present as described, reconnect the wires to the dispense valve and proceed to #7 If continuity is not present as described, replace the dispense valve.

l a g

2 ⁄ 1

1 l a g

l a g

2 ⁄ 1

Y AD E

R O T

EC EL S

ARM W /

ART O T

7. Check the dispense valve for coil action. Connect the brewer to power source. Place the ON/OFF" switch in the "ON" position, press and release the start switch. Listen carefully in the vicinity of the dispense valve for a "clicking" sound as the coil magnet attracts and repels the plunger.

8. Disconnect the brewer from the power source.

P796

If the sound is heard as described, there may be a blockage in the dispense valve or the water line to the dispense valve. Remove the dispense valve and inspect for wear, and remove waterborne particles. If the sound is not heard as described, replace the dispense valve.

Removal and Replacement:

1. Disconnect wires and water tubes from dispense valve.

2. Drain enough water from the tank so the dispense valves are above the water line.

3. Remove dispense valve from the sprayhead panel.

4. Install new dispense valve.

5. Reconnect the water lines and the wires to the dispense valve.

6. Refer to Fig. 10 when reconnecting wires.

WHI/VIO to Right Timer TL1 WHI/VIO to Right ON/OFF Switch WHI/RED to Right Brew Selector Switch

WHI/GRN to Right Timer TL4 WHI/GRN to Right By-Pass Valve

RIGHT

WHI/RED to Left Timer TL1 WHI/RED to Left Brew Selector Switch WHI/RED to Left ON/OFF Switch

WHI/BRN to Left Timer TL4 WHI/GRN to Left By-Pass Valve

LEFT

P782

FIG. 10 DISPENSE VALVE TERMINALS

27040 032201

Page 22

Page 23

SERVICE (cont.)

ELECTRONIC CONTROL ASSEMBLY

Location:

The electronic control assembly (1) is located inside the lower left front on the component bracket of the brewer. Access will also be needed to the temperature sensor (8), liquid level probe (7) located on the tank lid and to the triac assembly (17) located beneath the tank.

General:

This system controls the liquid level and water temperature of the brewer. These two functions act independently of each other and should be tested separately.

7 8 6 5 11

gal

2 ⁄

1 gal

gal

⁄2

TES

TIC

AC IN M

-O-M

BUN

P/N 2620- 120 V

TES

ATIC

INU

-M

20 VAC

N-O

0- 1

BU /N 262

TICE

OFF

READ NO

h c it

w S

! t

e t

e p

CAUTION

e u T

r e

t a

i t n U

Failure To Comply Voids Warranty!

HAZARDOUS

VOLTAG

NNECT FROM

ER SOURCE DISCO POW

RE REMOVING! BEFO

N / WARMER

SELECTOR

READY

START

U A

F R U

S D N

R E

T W

O H

IO T

N TIO U

A C

gal 1

gal

2 ⁄ 1

SELECTOR

/ WARMER

START

E C A

16 15

gal

⁄2

ADY

2 1

FIG. 11 ELECTRONIC CONTROL ASSEMBLY

1. Electronic Control

2. Terminal Block

3. Timers

4. Liquid Level Switch & Overflow Cup

5. Tank Heater

6. Limit Thermostat

7. Liquid Level Probe

8. Temperature Sensor

9. Dispense Valve

10. Recovery Booster Relay

11. Contactor Assembly

12. Bypass Valve

13. Ready Light

14. Solenoid Valve

15. LED

16. Temperature adjustment

17. Triac Assy

P783

27040 032201

Page 23

Page 24

SERVICE (cont.)

ELECTRONIC CONTROL ASSEMBLY (cont.)

BREW START- LOCK

The water must be heated to the preset temperature indicated by the glowing ready light before a brew cycle can be initiated.

PROBLEM:

LIQUID LEVEL CONTROL OVERFLOWS

DRAIN CUP

(4)

RETRY

If the ready light goes out during a brew cycle, the cycle will continue until it is completed. You must wait until the ready light glows before starting another brew cycle.

PROBLEM:

LIQUID LEVEL CONTROL SYSTEM DOES NOT REFILL

REMOVE POWER

OVERFLOW CUP FULL

(4)

DISCONNECT LEVEL PROBE

(7)

YES

DRAIN CUP

RETRY

(4)

OVERFLOW

YES

DRAIN CUP (4)

DISCONNECT PROBE

WIRE FROM PROBE (7)

SHORT PROBE WIRE

TO CHASSIS

RETRY

OVERFLOW

YES

DRAIN CUP (4)

DISCONNECT WIRE

FROM

SOLENOID VALVE (14)

RETRY

REPLACE PROBE (7)

VOLTAGE PRESENT AT

SOLENOID VALVE

(14)

REPLACE CONTROL

ASSEMBLY (1)

YES

DOES WATER FLOW

REPLACE

SOLENOID VALVE

(14)

YES

REPLACE PROBE

(7)

P808

Page 24

YES

OVERFLOW

REPLACE

CONTROL

ASSEMBLY (1)

REPLACE SOLENOID

VALVE (14)

P809

Liquid Level Control Test Procedure:

1. Disconnect brewer from the power source.

2. With a voltmeter, check the voltage across terminals 3 & 4 of the electronic control assembly (1). Connect brewer to power source. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

27040 041100

Page 25

YES

MEASURE VOLTAGE

AT TANK HEATER (5)

VOLTAGE PRESENT

REPLACE TANK

HEATER (5)

LIMIT THERMOSTAT (6)

REPLACE LIMIT

THERMOSTAT (6)

REPLACE CONTROL

ASSEMBLY (1)

MEASURE VOLTAGE AT TANK HEATER (5)

VOLTAGE PRESENT

REPLACE TRIAC (17)

CHECK FOR SPLIT

TANK HEATER (5)

REINSTALL ORIGINAL

CONTROL ASSEMBLY (1)

RECHECK WATER

TEMPERATURE

LED ON CONSTANTLY

TURN TEMPERATURE

ADJUSTING SCREW (16)

CLOCKWISE CONTINUOUSLY

LED ON

REPLACE CONTROL

ASSEMBLY (1)

ADJUST FOR CORRECT

WATER TEMPERARURE

SERVICE (cont.)

ELECTRONIC CONTROL ASSEMBLY (cont.)

3. Disconnect brewer from the power source.

If voltage was present as described, proceed to #4. If voltage was not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

4. Remove the pink wire from terminal 5 of the electronic control assembly (1).

5. With a voltmeter, check the voltage across terminals 1 & 4 of the electronic control assembly (1). Connect brewer to the power source. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models after a delay of approximately 1 second. b.) 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second.

6. Disconnect the brewer from the power source.

11. Move the probe away from the brewer housing. The indication must again be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire120/240 volt models after a delay of approximately 1 second. b.) 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second.

12. Disconnect the brewer from the power source.

If voltage was present as described, reinstall the probe, the sensing function of the system is operating properly. If voltage was not present as described, check the pink probe wire and the green ground wire for continuity and/or replace the probe.

Temperature Control Flow Charts

PROBLEM:

WATER NOT HOT ENOUGH

If voltage was present as described, the liquid level control system is operating properly, proceed to #7. If voltage was not present as described, replace the electronic control assembly (1) and temperature sensor (8) in the tank lid.

NOTE - each electronic control assembly is calibrated to a temperature sensor. Both components MUST be replaced as a set.

7. Reconnect the pink wire to terminal 5 of the electronic control assembly (1).

8. Remove the liquid level probe (7) from the tank lid, and inspect it for mineral deposits. Replace it if necessary. Keep the exposed ends of the probe away from any metal surface of the brewer.

9. With a voltmeter, check the voltage across terminals 1 & 4 of the electronic control assembly (1). Connect the brewer to the power source. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models after a delay of approximately 1 second. b.) 200 to 240 volts ac for two wire 208 or 240 volt models after a delay of approximately 1 second.

10. Touch the screw head end of the probe to the

brewer housing. The indication must be 0.

P810

27040 041100

Page 25

Page 26

SERVICE (cont.)

assembly (1).

ELECTRONIC CONTROLS (cont.)

PROBLEM:

WATER BOILS

DRAIN CUP (4)

RETRY

YES

REPLACE CONTROL

ASSEMBLY (1)

CHECK FOR SPLIT

TANK HEATER (5)

REPLACE TRIAC (17)

P811

LED (13)(15) ON

WHILE BOILING

DISCONNECT BLUE WIRE

FROM CONTROL BOARD PIN #7

RETRY

STILL BOILING

REPLACE CONTROL

ASSEMBLY (1)

Temperature Control Test Procedure

1. Disconnect the brewer from the power source.

2. With a voltmeter, check the voltage across terminals 3 & 4 of the electronic control circuit board. Connect the brewer to the power source. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

3. Disconnect the brewer from the power source.

If voltage was present as described, proceed to #4. If voltage was not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

NOTE - each temperature sensor is calibrated to an electronic control assembly. Both components MUST be replaced as a set.

7. With a voltmeter, check the voltage across the tank heater (5) terminals. Connect the brewer to the power source. The indication must be: a.) 208 volts for three wire 120/208 volt models and 240 volts for three wire 120/240 volt models while the red indicator on the circuit board is on or blinking. b.) 200 to 240 volts ac for two wire 200 or 240 volt models while the red indicator on the circuit board is on or blinking.

8. Disconnect the brewer from the power source.

If voltage was present as described, the temperature control of the system is operating properly. If voltage was not present as described, contact BunnO-Matic to order an electronic control assembly (1), temperature sensor (8), and triac assembly (17) for revaluation and proceed to #9.

9. Replace the electronic control assembly (1) and temperature sensor (8).

NOTE - each electronic control assembly is calibrated to a temperature sensor. Both components MUST be replaced as a set.

10. With a voltmeter, check the voltage across the tank heater terminals (5). Connect the brewer to the power source. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volt ac for three wire 120/240 volt models while the red indicator on the circuit board is on or blinking. b.) 200 to 240 volts ac for two wire 200 or 240 volt models while the red indicator on the circuit board is on or blinking.

11. Disconnect the brewer from the power source.

4. Connect the brewer to the power source and place the tank heater switch in the “ON” position.

5. Observe the red indicator on the electronic control circuit board (15).

6. Disconnect the brewer from the power source.

If the indicator was on or blinking, the temperature sensor is operating properly, proceed to #7. If the indicator was off, check the sensor connection on the electronic control circuit board and/or replace the temperature sensor (8) and the electronic control

If voltage was present as described, return the new triac assembly (17) to Bunn-O-Matic for credit. The temperature control of the system is operating properly. If voltage was not present as described, reinstall your existing electronic control assembly (1) and temperature sensor (8), and proceed to #12.

12. Replace the triac assembly (17).

13. With a voltmeter, check the voltage across the tank

27040 041100

Page 26

Page 27

SERVICE (cont.)

OFF

STOP

READ NOTICE

ELECTRONIC CONTROL ASSEMBLY (cont.)

heater terminals (5). Connect the brewer to the power source. The indication must be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models while the red indicator on the circuit board is on or blinking. b.) 200 to 240 volts ac for two wire 200 or 240 volt models while the red indicator on the circuit is on or blinking.

14. Disconnect the brewer from the power source.

If voltage was present as described, the temperature control of the system is operating properly. Return the new electronic control assembly (1) and temperature sensor (8) to Bunn-O-Matic for credit.

Electronic Controls Removal and Replacement

NOTE - each electronic control assembly is calibrated to a temperature sensor. Both components MUST be replaced as a set.

1. Remove all wires from the electronic control as-

sembly terminals.

2. Remove the two 8-32 screws holding the elec-

tronic control assembly to the component bracket.

3. Disconnect the temperature sensor and ready

indicator wires from the left side of the electronic control assembly board.

4. Remove the temperature sensor from the grom-

met in the tank lid.

5. Install the new temperature sensor into the grom-

met on the tank lid. Route the wires to the location of the new electronic control assembly.

6. Attach the temperature sensor and ready indicator

wires to the electronic control assembly.

7. Fasten the new electronic control assembly to its

bracket.

8. Reconnect the wires.

9. Refer to Fig. 12 when reconnecting the wires.

10. Review the initial set-up procedures and adjust the

control as required for the desired temperature.

Triac Assembly Removal and Replacement

NOTE - each triac installation requires the use of an approved silicone heat sink compound. Bunn-OMatic recommends the use of Dow Corning 340 compound or equivalent. It can be purchased direct from Bunn-O-Matic (part number M2522.0002).

Page 27

GRY to GRY to InterLock Assy

WHI & WHI to Temperature Sensor

PNK (Top) & GRY (Bottom) to Interlock Assy

PNK (Top) & GRY (Bottom) from LED

DO NOT Turn On The Tank Heater Switch

CAUTION

Until Water Comes From Opened Faucet!

Hot Water Systems – Water Tank Will Fill

Automatically When Unit Is Connected To Power!

Coffee Brewers

Accordance W

Failure To Comply Voids Warranty!

– Fill The Water Tank In

ith T

he Installation Instructions!

DO NOT Turn On The Tank Heater Switch

Until Water Comes From Opened Faucet!

Hot Water Systems – Water Tank Will Fill

Automatically When Unit Is Connected To Power!

Coffee Brewers – Fill The Water Tank In

Accordance With The Installation Instructions!

Failure To Comply Voids Warranty!

#7 BLU from Triac Assy #6 WHI/BRN to Tank Heater Switch TAN from Triac Assy to Tank Heater

CAUTION

WARNING

HAZARDOUS

VOLTAGE

DISCONNECT FROM

POWER SOURCE

BEFORE REMOVING!

OFF

STOP

READ NOTICE

Switch

NIN

CT FR

URC

#5 PNK to Liquid Level Probe #4 RED to Terminal Block (Red Insert) #3 BLK to RED Lead from Liquid Level Switch #2 GRN to Ground #1 WHI/BLU to Solenoid

FIG. 12 ELECTRONIC CONTROL BOARD

P784

TERMINALS

1. Place the tank heater switch on the electronic control assembly in the “OFF” position.

2. Completely drain the tank.

3. Place a stryofoam or wood block between the center of the tank and the rear of the brewer.

4. Disconnect triac wires, white/violet from terminal block, blue from right tank heater, blue from electronic control and tan from tank heater switch.

5. Carefully set the brewer on its back.

6. Remove the two 2" dia. hole plugs from the bottom cover.

7. Remove the four #10-32 keps nut securing tank to tank mounting bracket.

8. Remove the twelve #8-32 slotted head screws securing the bottom cover.

9. Remove the bottom cover with the four feet, the tank mounting brackets, triac/heat sink as an assembly.

10. Remove triac/heat sink from right tank mounting bracket and discard.

27040 032201

Page 28

SERVICE (cont.) ELECTRONIC CONTROL ASSEMBLY (cont.)

11. Install new triac/heat sink assembly on right tank mounting bracket.

12. Route the wires up around the rear of the brewer.

13. Reinstall the bottom cover, four feet, tank mounting brackets and triac/heat sink to the bottom of the tank using four #10-32 keps nuts.

14. Secure bottom cover to brewer base with twelve #8-32 slotted head screws.

15. Stand the brewer upright.

16. Reconnect the wires of the new triac assembly. Refer to Fig. 13 when reconnecting wires.

WHI/VIO to Terminal Block (200V-240V Red Insert) BLU to Right Tank Heater (Left) BLU to Electronic Control #7

TAN to Tank Heater Switch

P785

FIG. 13 TRIAC TERMINALS

Test Procedure:

1. Disconnect the brewer from the power source.

2. Remove all wires from the switch terminals.

3. Place the selector switch in the left position. 4 Check for continuity across the center and right

terminals on the rear of the switch.

5. Continuity must not be present across the center and left terminals on the rear of the switch.

6. Check the bottom row, then the top row of terminals.

If continuity is present as described proceed to #7. If continuity is not present as described replace the switch.

7. Place the selector switch in the right position.

8. Check for continuity across the center and left terminals on the rear of the switch.

9. Continuity must not be present across the center and right terminals on the rear of the switch.

10. Check the bottom row, then the top row.

If continuity is present as described, reconnect the wires, the switch is operating properly. If continuity is not present as described, replace the switch.

GRINDER SELECTOR SWITCH

/ W N

R A T

gal

2 ⁄ 1

gal

⁄2 1

T S

E RM A

/ W N

ECTO

SEL

EAD

FIG. 14 GRINDER SELECTOR SWITCH

Location:

The grinder selector switch is located in the upper

center on the front of the hood.

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

gal1

2 ⁄

gal

2 ⁄

EADY

ECTO

SEL

PNK to PNK Lead from Right Brew Selector Switch

PNK to PNK Lead from Interface Socket

PNK to PNK Lead from

P786

Left Brew Selector Switch

P787

FIG. 15 GRINDER SELECTION

SWITCH TERMINALS

27040 032201

Page 28

Page 29

SERVICE (cont.)

LEVEL CONTROL BOARD AND LEVEL PROBE (Electro/ mechanical only)

al g

2 ⁄ 1

al g 1

al g

2 ⁄ 1

ADY

ECTO

EL S

AR W /

al g

2 ⁄

1 gal 1

gal

2 ⁄ 1

O-

N / P

O-M

N-

2 N /

R CTO E

READY

START

TART S

T O H

S E C

F R U

N A S

R E M

R E

U A

P796

FIG. 16 LIQUID LEVEL CONTROL BOARD

If voltage is present as described, proceed to #5. If voltage is not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

5. Reconnect the violet wire to terminal 1.

6. Carefully connect a piece of insulated jumper wire to terminal 4. Keep the other end of this wire away from any metal surface of the brewer.

7. With a voltmeter, check the voltage across terminals 1 & 3. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models after a delay of approximately 1 second. b.) 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second.

8. Touch the free end of jumper wire to the brewer housing. The indication must be 0.

9. Move the jumper wire away from the brewer housing. The indication must again be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models after a delay of approximately 1 second. b.) 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second.

10. Disconnect the brewer from the power source and remove the jumper wire from terminal 4.

Location:

The level control board is located inside the front of the brewer just left of center on the component bracket

Test Procedure:

1. Disconnect the brewer from the power source.

2. Remove the violet wire from terminal 1 & pink wire

from terminal 4 of the circuit board.

3. With a voltmeter, check the voltage across termi-

nals 2 & 3. Connect the brewer to the power

source. The indication must be:

a.) 120 volts ac for three wire 120/208 volt models

and three wire 120/240 volt models.

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

models.

4. Disconnect the brewer from the power source.

If voltage is present as described, the level control board is operating properly, proceed to #11. If voltage is not present as described, replace the level control board.

11. Reconnect the pink wire to terminal 4.

12. Gently pull the probe out of the tank lid and inspect for corrosion. Replace it if necessary.

13. Place the probe so that neither end is in contact with any metal surface of the brewer.

14. With a voltmeter, check the voltage across terminals 1 & 3. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models after a delay of approximately 1 second. b.) 200 to 240 volts ac for two wire 200 or 240 volt models after a delay of approximately 1 second.

27040 032201

Page 29

Page 30

SERVICE (cont.)

LEVEL CONTROL BOARD AND LEVEL PROBE (Electro/ mechanical only) (cont.)

15. Move the probe's flat end to the brewer housing. The indication must be 0.

16. Move the probe's flat end away from the brewer housing. The indication should again be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

17. Disconnect the brewer from the power source.

If voltage is present as described, reinstall the probe, the level control board and level probe are operating properly. If voltage is not present as described, check the pink probe wire.

Removal and Replacement:

1. Remove all wires from the level control board.

2. Remove two #8-32 slotted head screws holding level control board to component bracket.

3. Install the new level control board to the component bracket. Make certain that the lockwashers are between the level control board and the component bracket.

4. Refer to Fig. 17 when reconnecting the wires.

T4 PNK to Probe T3 WHI to Terminal Block (White Insert on 120V Two Wire, 120/208V or 120/240V Three Wire Brewers) T3 RED to Terminal Block (Red Insert on 200V or 240V Brewers)

T2 BLU to Overflow Protection Switch T1 VIO to Solenoid Coil

P789

FIG. 17 LIQUID LEVEL CONTROL BOARD

TERMINALS

27040 032201

Page 30

Page 31

SERVICE (cont.)

LIMIT THERMOSTAT

2 ⁄ 1

1 l a

g 1

2 ⁄

READ

O T C

L E S

/ WA

TART

l a

2 ⁄

l a g 1

l a g

2 ⁄

MINU

BUNN

2620- 120 VAC

P/N

TES

ATIC

-M

-O

REA

R TA S

R O

T C E

EL S

P790

FIG. 18 LIMIT THERMOSTAT

Location:

The limit thermostat is located inside the hood on

the tank lid just to the left of the right tank heater.

Test Procedure:

1. Disconnect the brewer from the power supply.

2. Disconnect the black wire from the limit thermostat to the terminal block.

3. With a voltmeter, check the voltage across the black wire removed from the limit thermostat and the black wires to the tank heater terminals.

4. Connect the brewer to the power supply.

5. The indication must be: a.) 208 or 240 volts ac on electronic three wire models. b.) 120 volts ac on eletro/mechanical brewers. c.) 200 or 240 volts ac on electro/mechanical or electronic control two wire "A" or "B" models.

6. Disconnect the brewer from the power supply.

If voltage is present as described, reconnect the black wire to the limit thermostat from the terminal block, the limit thermostat is operating properly. If voltage is not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

Removal and Replacement:

1. Remove all wires from the limit thermostat terminals.

2. Carefully remove the two #8-32 nuts securing the limit thermostat to tank lid and remove limit thermostat.

3. Carefully secure new limit thermostat to tank lid.

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

BLK to Terminal Block (Black Insert)

BLK to Tank Heater (Electronic) BLK to Contactor Terminal (Electro/mechanical)

P791

FIG. 19 LIMIT THERMOSTAT

TERMINALS

27040 032201

Page 31

Page 32

SERVICE (cont.)

ON/OFF SWITCH (Warmers)

l a g

2 1⁄

1 l a

g 1

l a g

2 ⁄ 1

Y EAD R

TOR

SEL

R E M

A W /

T R A

l a

1⁄

l a g 1

l a g

2 ⁄ 1

A T S

ER M R

W / N

ECTO

SEL

Y EAD R

P792

FIG. 20 ON/OFF SWITCHES

Location:

The ON/OFF switches are located on the front of

the hood just to the left and right of the start switches.

6. Check for continuity across the center and lower left terminal with switch in the "ON" position. Continuity must not be present when switch is in the "OFF" position.

If continuity is present as described, reconnect the black wire to the center terminal and the white/red wire on the left switch or the white/violet on the right switch to the lower left terminal. If continuity is not present as described, replace the switch.

Removal and Installation:

1. Remove the wires from the switch terminals.

2. Compress the clips inside the hood 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 hood.

4. Refer to Fig. 21 when reconnecting the wires.

Test Procedure:

1. Disconnect the brewer from the power source.

2. Viewing the switch from the back remove the white or red wire from the upper right terminal and the black wire from the center terminal.

3. With a voltmeter, check the voltage across the white wire and the black wire or red and black wire. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

4. Disconnect the brewer from the power source.

If voltage is present as described, reconnect the white or the red wire, and proceed to #5. If voltage is not present as described, refer to the

Wiring Diagrams

and check the brewer wiring har-

ness.

BLK to Terminal Block (Black Insert)

WHI/RED to Left Timer TL1

LEFT

BLK to Terminal Block (Black Insert)

WHI/VIO to Right Timer TL1

RIGHT

FIG. 21 ON/OFF SWITCH TERMINALS

WHI to Terminal Block (White Insert on 120/ 208V or 120/240V Models)

RED to Terminal Block (Red Insert on 200V or 240V Models)

WHI to Terminal Block (White Insert on 120/ 208V or 120/240V Models)

RED to Terminal Block (Red Insert on 200V or 240V Models)

P793

5. With the black wire removed, remove the white/ red wire on the left switch or the white/violet wire on the right switch from the lower left terminal.

27040 032201

Page 32

Page 33

SERVICE (cont.)

OVERFLOW PROTECTION SWITCH

al g

⁄2 1

1 l ga

2 ⁄ 1

Y D A E

R TO C

LE E S

R E

/ WA N O

R A T

2 1⁄

l ga 1

2 1⁄

TL5

TL4

TL3

TL2

TL1

TL5

TL4

TL3

TL2

TL1

SET

S E

LOCK

L O C K

J 1

J 2

SET

S E T

LOCK

L O C

/ WARM N O

OR T C

LE E S

Y D A

FIG. 22 OVERFLOW PROTEC-

R TA S

P2194

TION SWITCH

Location:

The overflow protection switch is located inside the hood on the center of the tank inside the copper overflow cup.

To test the overflow protection switch, access will also be needed to the level control board or electronic control assembly and terminal block.

Test Procedure:

1. Disconnect the brewer from the power source.

2. Remove the wire nuts connecting the red wires

from the overflow protection switch to the black

wire from the terminal block and blue wire from the

thermostat or the black wire from the electronic

control assembly.

3. Carefully check the voltage across the violet wire

and the blue wire on electro/mechanical models or

the black wires on electronic models. Connect the

brewer to the power source. The indication must

be:

a.) 120 volts ac for electro/mechanical three wire

120/208 volt models and three wire 120/240 volt

models.

b.) 208 volts for electronic three wire 120/208 volt

models and 240 volts ac on 120/240 volt models.

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

models.

4. Disconnect brewer 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 brewer wiring harness.

5. Check for continuity across the overflow protection switch red wires only until the plastic float is raised and check that continuity returns when the plastic float is again lowered.

If continuity is present as described, reconnect the red wires to the blue wire from the thermostat or black wire from electronic control assembly and the black wire from terminal block. If continuity is not present as described, replace the overflow protection switch.

Removal and Replacement:

1. Disconnect the red leads from the overflow protection switch from the blue wire from the thermostat or black wire from electronic control assembly and the black wire from the terminal block.

2. Remove the nut beneath the copper overflow cup.

3. Remove the entire switch assembly from the cup.

4. Place the new switch assembly into the cup, wires first. Make sure that the gasket is in place around the threaded switch stem.

NOTE - The magnets must be at the top of float and there must be NO adjusting washers installed for the overflow protection switch to operate properly.

5. Install the nut beneath the copper overflow cup. Be sure not to overtighten.

6. Refer to Fig. 23 when reconnecting wires.

RED to BLK Wire form Terminal Block

FIG. 23 OVERFLOW PROTECTION

RED to BLU Lead from Thermostat

P795

SWITCH TERMINALS

27040 032201

Page 33

Page 34

SERVICE (cont.) RELAY (Brewers W/Recovery Booster)

NOTE - Electro/mechanically controlled brewers have

two relays and the electronically controlled have one.

l a

2 ⁄ 1

l a g 1

al g

2 ⁄

R O

T EC

R E

ARM

W / N

RT O

C I

A N I

O-

0 2

6 2 N /

O T C

AD E R

l a g

2 ⁄ 1

1 l a g

1 l a

2 ⁄

A N I

O-MA

1 NN

2 N /

RT A

T O H

E AR S

E C A

D N A

S R E

R E

IO T

U A

IO T

P796

a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

4. Disconnect brewer 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 brewer wiring harness.

5. Remove the white/green wire from the "A" terminal and white/violet wire from the "B" terminal on the right relay, the white/brown wire from the "A" terminal and white/red wire from "B" terminal on the left relay.

6. Check for continuity across the "A" and "B" terminals of each relay.

If continuity is present as described, reconnect the white/green wire and white/violet wire to the right relay or the white/brown wire and the white/red wire to the left relay and proceed to #7. If continuity is not present as described, replace the relay(s).

FIG. 24 RELAY

Location: Electro/mechanically Controlled Brewers

The relays are located inside the hood, the right relay just to the right of the contactor in front of the tank and left relay is just left of the component bracket in front of the tank. Electronically Controlled Brewers

The relay is located inside the hood just to the right of the contactor in front of the tank.

Test Procedures: Electro/mechanically Controlled Brewers.

1. Disconnect the brewer from the power source.

2. Locate the black wire on the left center relay

terminal and the blue wire on the right center relay

terminal.

3. With a voltmeter, check the voltage across the

black and blue wire. Connect the brewer to the

power source . The indication must be:

7. Remove the two blue wires from terminal 5 and the red wire from terminal 7 on the right relay, the black wires from terminal 5 and the red wire from terminal 7 on the left relay.

8. Check for continuity across terminals 5 and 7 of each relay by manually closing relay contact. Continuity must not be present when contact is released.

If continuity is present as described, reconnect blue wires to terminal 5 on the right relay, the black wires to terminal 5 on the left relay and the red wire to left and right terminal 7, the relays are operating properly. If continuity is not present as described, replace the relay(s).

Electronically Controlled Brewers

1. Disconnect brewer from the power source.

2. Locate the gray wire on terminal 7 and the white/ green wire on terminal B of the relay.

27040 032201

Page 34

Page 35

SERVICE (cont.) Relay (Brewers W/Recovery Booster) (cont.)

3. Check the voltage across the gray and white/green wire with left and right "ON/OFF" switch in the "ON" position. Connect the brewer to the power source and press the left and right start switch. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

4. Disconnect brewer 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 brewer wiring harness.

5. Locate the white/red wire on the relay terminal 5 and the gray wire relay terminal 7.

6. Check for continuity across the relay terminals 5 and 7 by manually closing relay contact. Continuity must not be present when contact is released.

If continuity is present as described, reconnect the wires, the relay is operating properly. If continuity is not present as described, replace the relay.

Removal and Replacement:

1. Remove all wires from relay terminals.

2. Remove the #8-32 slotted screw holding relay mounting bracket to the hood.

3. Remove the relay from the mounting bracket.

4. Securely install the new relay to the mounting bracket.

5. Install the relay mounting to the hood.

6. Refer to Fig. 25 when reconnecting the wires.

LEFT

WHI/BRN to Left Dispense Valve

MECHANICAL THERMOSTAT W/RECOVERY BOOSTER

GRY to BLK Lead from Contactor Coil

WHI/VIO to Right Dispense Valve

RED

BLK to BLK Lead on Contactor Coil

BLK to BLK Lead on Thermostat

WHI/RED to Left Dispense Valve

WHI/GRN to Right Dispense Valve

BLU to BLU Lead from Thermostat BLU to BLU Lead from Liquid Level Board

WHI/VIO to Right Dispense Valve

WHI/GRN to Right

Dispense Valve

RIGHT

ELECTRONIC CONTROL W/RECOVERY BOOSTER

FIG. 25 RELAY TERMINALS

Page 35

P797

27040 032201

Page 36

SERVICE (cont.)

SOLENOID VALVE (Inlet)

A N I

O-MA

2 N /

RM WA /

N O

R O

REA

l a g

2 ⁄ 1

l a g

1 l a

2 ⁄ 1

A N I

O-MA

0 2

2 N /

E AR S

E C A

SUR

D N A

R E M

R E

U A

P796

FIG. 26 SOLENOID VALVE

Location:

The solenoid valve is located inside the lower right

front of the brewer.

Test Procedure:

1. Disconnect the brewer from the power source.

2. Remove both wires from the solenoid valve coil terminals.

3. With a voltmeter, check the voltage across the removed wires: a.) Violet and white on 120/208 volt and 120/240 volt three wire electro/mechanical models. b.) Violet and red on 200 volt and 240 volt electro/ mechanical models. c.) White/blue and white on 120/208 volt and 120/ 240 volt electronic models. d.) White/blue and red on 200 volt and 240 volt electronic models. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for 120/208V and 120/240V three wire models. b.) 200 to 240 volts ac for 200V or 240V two wire models.

4. Disconnect the brewer 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 brewer wiring harness.

wires and proceed to #6. If continuity is not present as described, replace the solenoid valve.

6. Check the solenoid valve for coil action. Connect the brewer to the power source. Listen carefully in the vicinity of the solenoid valve for a "clicking" sound after approximately 1 second, as the coil magnet attracts.

7. Disconnect the brewer from the power source.

If the sound is heard as described and water will not pass through the solenoid valve, there may be a blockage in the water line before or after 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, replace the solenoid valve.

Removal and Replacement:

1. Remove all wires from the solenoid valve coil.

2. Turn off the water supply to the brewer.

3. Disconnect the water lines to and from the solenoid valve.

4. Remove the two #8-32 slotted head screws holding the solenoid valve and mounting bracket to the brewer trunk.

5. Lift out the solenoid valve.

6. Remove the two #10-32 slotted head screws holding the solenoid valve to the mounting bracket.

7. Securely install the new solenoid valve to its mounting bracket.

8. Attach the solenoid valve and mounting bracket to the brewer trunk.

9. Securely fasten the water lines to and from the solenoid valve.

10. Refer to Fig. 27 when reconnecting the wires.

WHI to Level Control Board T3 (120/208V or 120/ 240V Eletro/mechanical)

WHI to Terminal Block (120/208V or 120/240V Electronic)

RED to Level Control Board T3 (200 or 240V Electro/mechanical or Control Assy T4 Electronic)

VIO to Level Control Board T1 (Electro/ mechanical)

WHI/BLU to Control Assy #1 (Electronic)

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

If continuity is present as described, reconnect the

P799

FIG. 27 SOLENOID VALVE TERMINALS

27040 032201

Page 36

Page 37

SERVICE (cont.)

START SWITCHES

M R

l a g

1⁄

l a g 1

l a g

2 ⁄ 1

W / N

TOR

SEL

READ

T R A

FIG. 28 START SWITCHES

Location:

The momentary start switches are located in front

of hood just left and right of center.

If continuity is present as described, reconnect the wires, the switch is operating properly. If continuity is not present as described, replace the switch.

Removal and Replacement:

1. Remove all wires from the switch terminals.

2. Compress the clips inside the hood and gently

l a

1⁄

1 l a

g 1

l a g

2 ⁄ 1

READ

ECTOR

SEL

push the switch through the opening.

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

4. Refer to Fig. 29 when reconnecting the wires.

ORN to Left Timer TL3 (Electro/

P792

mechanical)

RED/BLK to Interlock Assy (Electronic)

YEL to Left Timer TL5

Test Procedure:

1. Disconnect the brewer from the power source and remove the wires from both terminals of the switch.

2. Check for continuity across the two terminals on the switch when it is held in the lower position. Continuity must not be present across these terminals in the upper position.

WHI/ORN to Right Timer TL3 (Electro/ mechanical)

BRN/BLK to Interlock Assy (Electronic) WHI/YEL to Right Timer TL5

P801

FIG. 29 START SWITCH TERMINALS

27040 032201

Page 37

Page 38

SERVICE (cont.)

TANK HEATERS

l ga

2 1⁄

1 al g

l a g

2 1⁄

EC L E

N /

l a g

2 ⁄ 1

2 ⁄

U N I

-O N N

0 2 6

E T

I T A

0 2 1

Y D A

RMER

A W /

CT E L

FIG. 30 TANK HEATERS

Location:

The tank heaters are located on the left and right

side of the tank lid.

Test Procedure: Electro/Mechanical Models.

1. Disconnect the brewer from the power supply. 2 Check the voltage across the black and the red

wires on 120/208V or 120/240V models on the tank heaters. With the control thermostat turned to the "ON" position (fully clockwise), connect the brewer to the power supply and with a voltmeter, check the voltage across the wires. The indication should be: a.) 208 volts ac for three wire 120/208 volt models and 240 volts ac for three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

3. Disconnect the brewer from the power supply.

If voltage is present as described, proceed to #4. If voltage is not present as described, refer to the

Wiring Diagrams

and check the wiring harness.

4. Remove the black and red wires from the tank heaters.

5. Check for continuity across the terminals of the tank heaters.

STA

P790

tank heater(s). NOTE - If the tank heater remains unable to heat, remove and inspect the heater for cracks in the sheath.

Electronic Models:

1. Disconnect the brewer from the power source.

2. Disconnect wires from heater(s).

3. Check for continuity across the tank heater terminals.

If continuity is present as described, the tank heater is operating properly. If continuity is not present as described, replace the tank heater. NOTE - If the tank heater remains unable to heat, remove and inspect the heaters for cracks in the sheath.

Removal and Replacement:

1. Remove wires from tank heater.

2. Remove the four #8-32 nuts securing tank heater to tank lid.

3. Remove tank heater and gasket.

4. Install new tank heater and gasket with four #8-32 nuts on tank lid.

5. Refer to Fig. 31 when reconnecting the wires.

BLK to Contactor

RED to Contactor

LEFT & RIGHT

ELECTRO/MECHANICAL

BLU

BLK

BLK to Terminal Block (Black Insert)

BLU Lead from from Triac Assy.

If continuity is present as described, reconnect the wires, the tank heaters are operating properly. If continuity is not present as described, replace the

Page 38

LEFT

ELECTRONIC

RIGHT

FIG. 31 TANK HEATER TERMINALS

P803

27040 032201

Page 39

SERVICE (cont.)

TIMERS (Early Models)

C I

MAT

O-

62 2

N / P

NOTE: ECA MODELS ONLY - Brewer must be at operating temperature to perform step 5 or brew-lock must be bypassed. To bypass brew-lock disconnect white/orange wire and brown/black wire for right timer or orange wire and red/black wire for left timer from brew-lock of ECA and connect the harness leads together.

l ga

2 ⁄ 1

l a g

1 l ga

2 ⁄ 1

Y AD E

EC EL S

ARM W /

R E

A W /

N O

R O T

E EL S

ADY

al g

2 ⁄ 1

1 al g

1 l a g

⁄ 1

O-MA

120

UN B

620 2

RT A T

5. Check for continuity across the white/orange wire and white/yellow wire from the right timer or the orange wire and yellow wire on the left timer when the start switch is pressed.

If continuity is present as described, reconnect the wires to terminals TL3, TL4 and TL5 of the timer board and brew-lock wires if necessary, and proceed to #6.

EARLY MODELS

FIG. 32 TIMERS

Location:

The timers are located inside the left front of the

brewer on the upper part of the component bracket.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the wires from the timer terminals TL3, TL4 and TL5 and rotate the dial(s) fully counterclockwise.

3. With a voltmeter, check the voltage across terminals TL1 and TL2 when the "ON/OFF" switch is in the "ON" position. Connect the brewer to the power source. The indication must be: a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models. b.) 200 to 240 volts ac for two wire 200 or 240 volt models.

4. Disconnect the brewer 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 brewer wiring harness.

T O

E R A

CES A F

S D N

R E M

O H

U A

6. Check the voltage across terminals TL1 and TL4 with a voltmeter when the "ON/OFF" switch is in the "ON" position. Connect the brewer to the power source and press the start switch. The indication must be:

P796

a.) 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models for approximately 1 minute for 1-1/2 gallon batch. b.) 200 to 240 volts ac for two wire 200 or 240 volt models for approximately 1 minute for 1-1/2 gallon batch.

7. Select a 1 gallon batch and repeat #6. The indication should remain for approximately 40 seconds.

8. Select a 1/2 gallon batch and repeat #6. The indication should remain approximately 20 seconds.

Removal and Replacement:

1. Remove all wires from the timer.

2. Remove the four #6-32 slotted head screws holding circuit board and dial plate on to the component mounting bracket.

3. Remove circuit board, nylon spacers and dial plate.

4. Install new timer circuit board as described in

Digital Timer

section on the following pages.

5. Refer to Fig. 36 when reconnecting wires.

6. Install the timer setting decal provided with the replacement timer kit, on the inside of the front access panel.

7. Adjust timer as required. Refer to section on the following pages.

Digital Timer

27040 032201

Page 39

Page 40

MINUTES

P/N 24486-0000 120 VAC

BUNN-O-MATIC

SERVICE (cont.)

Timers (Early Models)(cont.)

BUNN-O-MATIC

2.5

1.5

P/N 24486-0000 120 VAC

MINUTES

BUNN-O-MATIC

P/N 2620- 120 VAC

WHI/RED TL1 to Left ON/OFF Switch WHI/RED TL1 to Left Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on 120/208V and 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

ORA TL3 to Left Start Switch WHI/BRN TL4 to Left Dispense Valve YEL TL5 to Left Start Switc

LEFT

MINUTES

BUNN-O-MATIC

P/N 2620- 120 VAC

WHI/VIO TL1 to Right ON/OFF Switch WHI/VIO TL1 to Right Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on 120/208V and 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

WHI/ORA TL3 to Right Start Switch WHI/GRN TL4 to Right Dispense Valve WHI/YEL TL5 to Right Start Switch

RIGHT

SINGLE BATCH MACHINE ONLY

1.5

P/N 24486-0000 120 VAC

BUNN-O-MATIC

2.5

WHI/RED TL1 to Left ON/OFF Switch WHI/RED TL1 to Left Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on120/208V and 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

ORA TL3 to Left Start Switch WHI/BRN TL4 to Left Dispense Valve YEL TL5 to Left Start Switch

LEFT

(120/208V AC or 120/240V AC 3 WIRE, 200V AC or 240V AC 2 WIRE)

ELECTRO/MECHANICAL

FIG. 33 TIMER TERMINALS

Page 40

WHI/VIO TL1 to Right ON/OFF Switch WHI/VIO TL1 to Right Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on 120/208V and 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

WHI/ORA TL3 to Right Start Switch WHI/GRN TL4 to Right Dispense Valve WHI/YEL TL5 to Right Start Switch

RIGHT

P805

27040 032201

Page 41

SERVICE (cont.)

1.5

2.5

MINUTES

Timers (Early Models)(cont.)

P/N 24486-0000 120 VAC

BUNN-O-MATIC

TIC

-M

N-O

2620- 120

WHI/RED TL1 to Left ON/OFF Switch WHI/RED TL1 to Left Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on 120/208V or 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

ORA TL3 toInterlock Assy WHI/BRN TL4 to Left Dispense Valve YEL TL5 to Left Start Switch

LEFT

-M

-O

2620- 120 V

SINGLE BATCH MACHINE ONLY

BUNN-O-MATIC

P/N 24486-0000 120 VAC

WHI/VIO TL1 to Right ON/OFF Switch WHI/VIO TL1 to Right Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on120/208V or 20/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

WHI/ORA TL3 to Interlock Assy WHI/GRN TL4 to Right Dispense Valve WHI/YEL TL5 to Right Start Switch

RIGHT

WHI/RED TL1 to Left ON/OFF Switch WHI/RED TL1 to Left Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on120/208V or 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

ORA TL3 to Interlock Assy WHI/BRN TL4 to Left Dispense Valve YEL TL5 to Left Start Switch

LEFT

(120/208V AC or 120/240V AC 3 WIRE, 200V AC or 240V AC 2 WIRE)

ELECTRONIC

FIG. 34 TIMER TERMINALS

Page 41

WHI/VIO TL1 to Right ON/OFF Switch WHI/VIO TL1 to Right Warmer Element

WHI TL2 To Terminal Block and Warmer Element (White Insert on 120/208V or 120/240V Three Pole Terminal Blocks) RED TL2 to Terminal Block (Red Insert on 200V or 240V Two Pole Terminal Blocks.

WHI/ORA TL3 Interlock Assy WHI/GRN TL4 to Right Dispense Valve WHI/YEL TL5 to Right Start Switch

RIGHT

P847

27040 032201

Page 42

SERVICE (cont.) TIMERS (Late Models)

l ga

2 ⁄ 1

l a g

1 l

2 ⁄

D A E

C LE E

E M R

W / N

T R

A T S

R A T

R E M

P2194

TL5

TL4

TL3

TL2

TL1

TL5

TL4

TL3

TL2

TL1

J 1

J 2

SET

S E T

LOCK

O C K

J 2

SET

S E

LOCK

O C K

0526.0750) .0000)

ating pressure

# 22300.0750

500 gpm FLOW

LATE MODELS

al g

2 ⁄ 1

1 l a g

1 l a

2 1⁄

A W /

OR T

LE E S

FIG. 35 DIGITAL TIMER

Location:

The timers are located inside the left front of the

brewer on the upper part of the component bracket.

Test Procedure. NOTE: Do not remove or install wires while timer board is installed. Pressure applied to one side may cause damage to the board.

1. Disconnect the brewer from the power source and remove the front access panel.

2. Remove the two #8-32 screws securing circuit board to the mounting bracket.

3. Remove circuit board and spacers (as required).

4. With a voltmeter, check the voltage across terminals TL1 and TL2 when the "ON/OFF" switch is in the "ON" position. Connect the brewer to the power source. The indication must be: a) 120 volts ac for two wire 120 volt models, three wire 120/208 volt models and 120/240 volt models. b) 200 to 240 volts ac on two wire 200 volt or 240 volt models.

5. Disconnect the brewer from the power source.

6. With a voltmeter, check the voltage across terminals TL1 and TL4 when the "ON/OFF" switch is in the "ON" position. Connect the brewer to the power source. The indication must be 0 volts.

If voltage is as described, proceed to #7. If voltage is not as described, disconnect the brewer from the power source and replace the timer.

7. With a voltmeter, check the voltage across terminals TL1 and TL4 when the "ON/OFF" switch is in the "ON" position. Connect the brewer to the power source and press the "START" switch. The indication must be as follows: a) 120 volts ac for two wire 120 volt models, three wire 120/208 volt models and 120/240 volt models. b) 200 to 240 volts ac on two wire 200 volt or 240 volt models.

If voltage is present as described, the brew timer is operating properly. Reset the timer as required, to obtain the desired brew volume. If voltage is not present as described, disconnect the brewer from the power source and replace the timer.

Removal and Replacement: NOTE: Do not remove or install wires while timer board is installed. Pressure applied to one side may cause damage to the board.

1. Remove the two #8-32 screws securing circuit board to the mounting bracket.

2. Remove circuit board and spacers (as required).

3. Remove all wires from the timer.

4. Attach all wires to the replacement timer board prior to installation to the component mounting bracket. Refer to FIG. 36 when reconnecting the wires.

5. Install new circuit board with spacers (as required) to the component mounting bracket.

6. Adjust the timer as described below.

If voltage is present as described, proceed to #6. If voltage is not present as described, refer to the

Wiring Diagrams

and check the brewer wiring har-

ness.

Timer Setting: NOTE: Prior to setting or modifying volumes, check that the brewer is connected to water supply, the tank is properly filled, and a funnel and server are in place. NOTE: All volume settings must be done with the sprayhead installed.

27040 032201

Page 42

Page 43

SERVICE (cont.)

TIMERS (Late Models)(cont.)

1. Modifying brew volumes. To modify a brew volume, first check that the SET/LOCK switch is in the “SET” position on the circuit board.

To increase a brew volume, place the ON/OFF switch in the “ON” position, press and hold the START switch until three clicks are heard. Release the switch and press it again one or more times. (Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory.) Each time the switch is pressed, two seconds are added to the brew time period. Allow the brew cycle to finish in order to verify that the desired volume has been achieved.

To decrease a brew volume, place the ON/OFF switch in the “ON” position, press and release the START switch once for every two-second interval to be removed from the total brew time period; then immediately press and hold down the START switch until three clicks are heard. Release the switch. (Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory). Allow the brew cycle to finish in order to verify that the desired volume has been achieved.

2. Setting brew volumes. To set a brew volume, first check that the SET/LOCK switch is in the “SET” position on the circuit board. Place the ON/OFF switch in the “ON” position, press and hold the START switch until three distinct clicks are heard and then release the switch. (Failure to release the switch within two seconds after the third click causes the volume setting to be aborted and previous volume setting will remain in memory.) View the level of the liquid being dispensed. When the desired level is reached, turn the ON/OFF switch to “OFF”. NOTE: Several ounces of water will continue to syphon from the tank after turning the switch “OFF”. The brewer remembers this volume and will continue to brew batches of this size until the volume setting procedure is repeated. NOTE: When brewing coffee, volume will decrease due to absorption by the coffee grounds.

LEFT TIMER RIGHT TIMER

YEL WHI/YEL wire to TL5 WHI/BRN WHI/GRN wire to TL4 ORA WHI/ORA wire to TL3 WHI WHI wire to TL2 (120V Two Pole,

120/208V or 120/240V Three Pole Terminal Block)

RED RED wire to TL2 (200V or 240V

Two Pole Terminal Block)

WHI/RED WHI/VIO wire to TL1

P2037

FIG. 36 DIGITAL TIMER TERMINALS

3. Setting programming disable feature. If it be- comes necessary to prevent anyone from changing brew time once programmed, you can set the SET/ LOCK switch to the “LOCK” position. This will prevent any further programming until switch is once again put into the “SET” position.

27040 032201

Page 43

Page 44

SERVICE (cont.)

WARMER ELEMENTS

O-M

6 2

FIG. 37 WARMER ELEMENTS

5. Check the continuity across the two terminals on the warmer element.

If continuity is present as described, reconnect the white or red and white/red wires on the left warmer element or the white or red and white/violet wires on the right warmer element.

⁄2

1 l ga

1 al g

2 ⁄ 1

ADY

CTO

E EL S

ARM W /

ER M R

WA /

CTO

READY

2 ⁄

1 l ga

2 ⁄

O-

0 2

2 N /

START

T TAR S

If continuity is not present as described, replace the warmer element.

Removal and Replacement:

1. Remove the three #4-40 slotted head screws securing the warmer assembly to the brewer base.

2. Lift the warmer assembly from the brewer base.

3. Disconnect the two wires from the warm element terminals.

4. Remove the two #8-32 nuts securing the warmer

E R A

E C A

F R

D N A

E M R

IO T

U A C

element to the warmer plate.

5. Securely install new warmer element.

6. Reconnect the two wires to warmer element terminals.

7. Securely install warmer assembly in brewer base.

P796

8. Refer to Fig. 38 when reconnecting wires.

Location:

The warmer elements are located in the base of the

brewer under the warmer plate.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Using the white wire in the terminal block and the white/red wire to left warmer or the white/violet wire to right warmer check the voltage. With a voltmeter, check voltage across the white and white/red wire or the white wire and white/violet wire with the "ON/OFF" switch in the "ON" position. The indication must be 120 volts ac for three wire 120/208 volt models and three wire 120/240 volt models.

3. With a voltmeter, check the voltage across the red wire and white/red wire or red wire and white/ violet wire with the "ON/OFF" switch in the "ON" position. The indication must be 200 to 240 volts ac for two wire 200 or 240 volt models.

4. Disconnect the brewer from the power source.

WHI/RED to Left Timer TL1

WHI to Terminal Block (White Insert on Three Pole Terminal Blocks or Red Insert on Two Pole Terminal Blocks) WHI or Red to Right Warmer Element

LEFT WARMER ELEMENT

WHI to Terminal Block (White Insert on Three Pole Terminal Blocks or Red Insert on Two Pole Terminal Blocks) WHI or Red to Left Warmer Element

WHI/VIO to Right Timer TL1

If voltage is present as described, proceed to #5. If voltage is not present as described, refer to the

Wiring Diagrams

and check brewer wiring harness.

Page 44

RIGHT WARMER ELEMENT

FIG. 38 WARMER ELEMENT TERMINALS

27040 032201

P807

Page 45

120/208 VOLTS AC OR

120/240 VOLTS AC

3 WIRE

R T

S E L E C T O R

VIO

PROBE

PIN-20

LIQUID LEVEL

BOARD

BLUBLK

WHI

LIMIT THERMOSTAT

SOL

WHI

OVERFLOW

PROTECTION SW

RED RED

SW. & THERMOSTAT

READY INDICATORS

OPTIONAL

RECOVERY BOOSTER

BLKBLU

K2 N.O. K3 N.O.

RED

SCHEMATIC WIRING DIAGRAM DUAL BREWER

(W/TWO-GRINDER INTERFACE)

BLU

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

TAN

GRY

PNK

GRINDER

INTERFACE

CONNECTOR

GRY

TAN

PNK

WHI/VIO

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH TWO-GRINDER INTERFACE OPTION

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

TAN

GRY

PNK

WHI/VIO

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

GRINDER

INTERFACE

CONNECTOR

GRY

TAN

PNK

L T

S E L E C T O R

WHI

WHI/ORA

WHI/VIO

WHI/GRN

WHI/YEL

WHI

WHI/RED

WHI/GRN

RIGHT BREW TIMER

4 5

SOL

WHI

ORA

WHI/RED

WHI/BRN

YEL

WHI

WHI/RED

WHI/GRN

SOL

WATER

BYPASS

WATER

BYPASS

LEFT BREW TIMER

4 5

LEFT SW.

RIGHT SW.

WHI/VIO

SOL

OPTIONAL

RECOVERY BOOSTER

WHI/RED

WHI/BRN

SOL

OPTIONAL

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

WHI/RED

WHI

WHI/VIO

BLK

WHI

GRN

RED-12

BLK-12 BLK-12

N.O.

RED-12

TANK HEATERS (TWO)

N.O.

BLK-12

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

START SW.

Page 45

27040 062200

Page 46

SCHEMATIC WIRING DIAGRAM DUAL-A & -B BREWER

LIMIT THERMOSTAT

(W/TWO-GRINDER INTERFACE)

BLK-12BLK-12

N.O.

OVERFLOW

PROTECTION SW

BLK

RED RED

BLK

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH TWO-GRINDER INTERFACE OPTION

TAN

R T

S E L E C T O R

TAN

L T

S E L E C T O R

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

GRY PNK TAN

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

PNK

GRINDER

INTERFACE

CONNECTOR

GRINDER

INTERFACE

CONNECTOR

PNK

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

BLK-12

TANK HEATERS (TWO)

READY INDICATORS

SW. & THERMOSTAT

BLU

OPTIONAL

RECOVERY BOOSTER

RED

K2 N.O. K3 N.O.

WHI/VIO

RIGHT

3 4 5

WHI/ORA WHI/GRN

WHI/YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

WHI/RED

RIGHT SW.

RED

WHI/VIO

LEFT SW.

WHI/RED

LEFT

3 4 5

ORA

WHI/BRN

YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

WHI/RED

200 OR 240 VOLTS AC

2 WIRE

BLKBLU

START SW.

RED-12

LIQUID LEVEL

BOARD

2 3 4

WHI/VIO

SOL

WHI/RED

SOL

GRN/YEL

N.O.

VIO

BLU

SOL

PIN-20

PROBE

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/RED WHI/BRN

RED-12

RED

RED RED

RED

27040 062200

Page 46

Page 47

SCHEMATIC WIRING DIAGRAM DUAL BREWER ECA

(W/TWO-GRINDER INTERFACE)

THERMOSTAT

BLK-12

BLK BLK

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH TWO-GRINDER INTERFACE OPTION

TAN

R T

S E L E C T O R

TAN

L T

S E L E C T O R

GRN

LIMIT

READY

L.E.D.

OVERFLOW

PROTECTION SW

RED RED

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

GRY PNK TAN

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

BLK-12

PNK

4 3 2

PNK

GRY

GRINDER

INTERFACE

CONNECTOR

GRINDER

INTERFACE

CONNECTOR

TANK HEATERS (TWO)

INTERLOCK

ASSY

ORA

WHI/ORA

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

RIGHT SW.

LEFT SW.

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

120/208 VOLTS AC OR

BLU-12

BLU-12BLK-12 W H

t°

TANK HEATER

PNK GRY GRY GRY

BRN/BLK

RED/BLK

ELECTRONIC

CONTROL

ASSY

WHI/VIO

RIGHT

2 3 4 5

WHI/ORA

WHI/GRN WHI/YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

WHI

WHI/VIO

WHI/RED

LEFT

2 3 4 5

ORA

WHI/BRN

YEL

BREW TIMER

WATER

BYPASS

SOL

120/240 VOLTS AC

3 WIRE

Page 47

WHI/GRN

WHI/RED

OPTIONAL RECOVERY BOOSTER

BLU-12

K1 N.O.

BLU-12

TAN BLU

WHI/BRN

PIN 20

(PROBE)

5 4

BLK

GRN

WHI/VIO

SOL

WHI/BLU

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

WHI/RED

START SW.

100W WARMER

(NOT AVAILABLE ON

WHI/RED

SOL

DUAL-TF)

RECOVERY BOOSTER

WHI/BRN

WHI/RED

RED-12

WHI-12

RED

SOL

OPTIONAL

K2 N.O.

WHI

WHI WHI

WHI

WHI WHI

GRY

27040 041100

Page 48

SCHEMATIC WIRING DIAGRAM DUAL-A & -B BREWER ECA

(W/TWO-GRINDER INTERFACE)

THERMOSTAT

BLK-12

BLK BLK

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH TWO-GRINDER INTERFACE OPTION

TAN

R T

S E L E C T O R

TAN

L T

S E L E C T O R

GRN/YEL

LIMIT

READY

L.E.D.

OVERFLOW

PROTECTION SW

RED RED

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

GRY PNK TAN

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

BLK-12

PNK

4 3 2

PNK

TANK HEATERS (TWO)

PNK

GRY

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

GRINDER

INTERFACE

CONNECTOR

GRINDER

INTERFACE

CONNECTOR

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

INTERLOCK

ASSY

RIGHT SW.

BLU-12

BLU-12BLK-12

t°

TANK HEATER

PNK

GRY GRY GRY

BRN/BLK

RED/BLK

ORA

WHI/ORA

RIGHT BREW TIMER

WATER

BYPASS

SOL

2 3 4 5

ELECTRONIC

CONTROL

ASSY

WHI/VIO

WHI/ORA

WHI/GRN WHI/YEL

WHI/GRN

RED

WHI/VIO

LEFT SW.

WHI/RED

LEFT

2 3 4 5

ORA

WHI/BRN

YEL

BREW TIMER

WATER

BYPASS

SOL

200 OR 240 VOLTS AC

2 WIRE

OPTIONAL RECOVERY BOOSTER

BLU-12 RED-12

K1 N.O.

BLU-12

TAN BLU

WHI/BRN

PIN 20

(PROBE)

5 4

BLK

GRN

2 1

WHI/VIO

SOL

WHI/RED

START SW.

WHI/RED

SOL

WHI/GRN

WHI/BRN

WHI/RED

WHI/BLU

WHI-12

SOL

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/RED

K2 N.O.

RED

GRY

27040 062200

Page 48

Page 49

120/208 VOLTS AC OR

120/240 VOLTS AC

3 WIRE

R T

S E L E C T O R

VIO

PROBE

PIN-20

LIQUID LEVEL

BOARD

BLUBLK

WHI

LIMIT THERMOSTAT

SOL

WHI

OVERFLOW

PROTECTION SW

RED RED

SW. & THERMOSTAT

READY INDICATORS

OPTIONAL

RECOVERY BOOSTER

BLKBLU

K2 N.O. K3 N.O.

RED

SCHEMATIC WIRING DIAGRAM DUAL BREWER

(W/ONE-GRINDER INTERFACE)

BLU

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

TAN

GRY

PNK

WHI/VIO

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH ONE-GRINDER INTERFACE OPTION

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

TAN

GRY

PNK

WHI/VIO

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

L T

S E L E C T O R

WHI

WHI/ORA

WHI/VIO

WHI/GRN

WHI/YEL

WHI

WHI/RED

WHI/GRN

RIGHT BREW TIMER

4 5

SOL

WHI

ORA

WHI/RED

WHI/BRN

YEL

WHI

WHI/RED

WHI/GRN

SOL

WATER

BYPASS

WATER

BYPASS

LEFT BREW TIMER

4 5

LEFT SW.

RIGHT SW.

WHI/VIO

SOL

OPTIONAL

RECOVERY BOOSTER

WHI/RED

WHI/BRN

SOL

OPTIONAL

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

WHI/RED

WHI

WHI/VIO

BLK

WHI

GRN

RED-12

BLK-12 BLK-12

N.O.

RED-12

TANK HEATERS (TWO)

N.O.

BLK-12

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

START SW.

GRIND

SELECTOR

GRY

TAN

PNK

GRY

TAN

PNK

GRINDER INTERFACE

CONNECTOR

GRY

TAN

PNK

Page 49

27040 062200

Page 50

SCHEMATIC WIRING DIAGRAM DUAL BREWER ECA

(W/ONE-GRINDER INTERFACE)

THERMOSTAT

BLK-12

BLK BLK

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH ONE-GRINDER INTERFACE OPTION

TAN

R T

S E L E C T O R

TAN

L T

S E L E C T O R

GRN

LIMIT

READY

L.E.D.

OVERFLOW

PROTECTION SW

RED RED

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

GRY PNK TAN

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

BLK-12

TANK HEATERS (TWO)

PNK

GRY

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

PNK

GRINDER INTERFACE

3/4 BATCH BATCH COMMON

CONNECTOR

GRY PNK

TAN

GRIND

SELECTOR

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

PNK

3/4 BATCH BATCH COMMON

INTERLOCK

ASSY

WHI/ORA

4 3

2 1

120/208 VOLTS AC OR

BLU-12

BLU-12BLK-12 W H

t°

TANK HEATER

PNK GRY GRY GRY

BRN/BLK

RED/BLK

ORA

ELECTRONIC

CONTROL

ASSY

WHI/VIO

RIGHT

2 3 4 5

WHI

WHI/ORA

WHI/GRN WHI/YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

RIGHT SW.

WHI/VIO

LEFT SW.

WHI/RED

LEFT

3 4 5

ORA

WHI/BRN

YEL

BREW TIMER

WATER

BYPASS

SOL

120/240 VOLTS AC

3 WIRE

Page 50

WHI/GRN

WHI/RED

OPTIONAL RECOVERY BOOSTER

BLU-12

K1 N.O.

BLU-12

TAN BLU

WHI/BRN

PIN 20

(PROBE)

5 4

BLK

GRN

WHI/VIO

SOL

WHI/BLU

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

WHI/RED

START SW.

100W WARMER

(NOT AVAILABLE ON

WHI/RED

SOL

DUAL-TF)

RECOVERY BOOSTER

WHI/BRN

WHI/RED

RED-12

WHI-12

RED

SOL

OPTIONAL

K2 N.O.

WHI

WHI WHI

WHI

WHI WHI

GRY

27040 062200

Page 51

SCHEMATIC WIRING DIAGRAM DUAL-A & -B BREWER

LIMIT THERMOSTAT

(W/ONE-GRINDER INTERFACE)

BLK-12BLK-12

N.O.

OVERFLOW

PROTECTION SW

BLK

RED RED

BLK

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH ONE-GRINDER INTERFACE OPTION

TAN

R T

S E L E C T O R

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

GRY PNK TAN

GRY

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

PNK

GRINDER INTERFACE

3/4 BATCH BATCH COMMON

CONNECTOR

GRY PNK

TAN

GRIND

SELECTOR

PNK TAN

TAN

L T

S E L E C T O R

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

PNK

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

3/4 BATCH BATCH COMMON

4 3

2 1

BLK-12

TANK HEATERS (TWO)

READY INDICATORS

SW. & THERMOSTAT

BLU

OPTIONAL

RECOVERY BOOSTER

RED

K2 N.O. K3 N.O.

WHI/VIO

RIGHT

3 4 5

WHI/ORA WHI/GRN

WHI/YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

WHI/RED

RIGHT SW.

RED

WHI/VIO

LEFT SW.

WHI/RED

LEFT

3 4 5

ORA

WHI/BRN

YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

WHI/RED

200 OR 240 VOLTS AC

2 WIRE

BLKBLU

START SW.

RED-12

LIQUID LEVEL

BOARD

2 3 4

WHI/VIO

SOL

WHI/RED

SOL

GRN/YEL

N.O.

VIO

BLU

SOL

PIN-20

PROBE

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/RED WHI/BRN

RED-12

RED

RED RED

RED

27040 062200

Page 51

Page 52

SCHEMATIC WIRING DIAGRAM DUAL-A & -B BREWER ECA

(W/ONE-GRINDER INTERFACE)

THERMOSTAT

BLK-12

BLK BLK

OPTIONAL 3-SET SELECTOR SWITCHES SHOWN

WITH ONE-GRINDER INTERFACE OPTION

TAN

R T

S E L E C T O R

S W

TAN

L T

S E L E C T O R

S W

GRN/YEL

LIMIT

READY

L.E.D.

OVERFLOW

PROTECTION SW

RED RED

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

GRY PNK TAN

GRY

FRACTIONAL

BATCHES

(CONNECT

AS REQUIRED)

FULL BATCH

(NO CONNECTION)

WHI/VIO

BLK-12

TANK HEATERS (TWO)

PNK

GRY

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

PNK

GRINDER INTERFACE

3/4 BATCH BATCH COMMON

CONNECTOR

GRY PNK

TAN

GRIND

SELECTOR

1/4 BATCH 1/3 BATCH 1/2 BATCH 2/3 BATCH

PNK

3/4 BATCH BATCH COMMON

INTERLOCK

ASSY

RIGHT SW.

4 3

2 1

LEFT SW.

BLU-12

BLU-12BLK-12

t°

TANK HEATER

PNK GRY

GRY GRY

BRN/BLK

RED/BLK

ORA

WHI/ORA

RIGHT BREW TIMER

WATER

BYPASS

SOL

3 4 5

ELECTRONIC

CONTROL

ASSY

WHI/VIO

WHI/ORA

WHI/GRN WHI/YEL

WHI/GRN

RED

WHI/VIO

WHI/RED

LEFT

3 4 5

ORA

WHI/BRN

YEL

WHI/GRN

BREW TIMER

WATER

BYPASS

SOL

WHI/RED

200 OR 240 VOLTS AC

2 WIRE

OPTIONAL RECOVERY BOOSTER

BLU-12 RED-12

K1 N.O.

BLU-12

TAN BLU

WHI/BRN

PIN 20

(PROBE)

5 4

BLK

GRN

2 1

WHI/BLU

WHI/VIO

SOL

WHI/RED

START SW.

WHI/RED

SOL

WHI/BRN

WHI-12

SOL

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/VIO

WHI/GRN

100W WARMER

(NOT AVAILABLE ON

DUAL-TF)

OPTIONAL

RECOVERY BOOSTER

WHI/RED

K2 N.O.

RED

GRY

27040 062200

Page 52

Page 53

SCHEMATIC WIRING DIAGRAM

DUAL BREWER W/DIGITAL BREWER CONTROL

J1-1

I T

B R

C O N

T R O

J1-24

R C

J3-1

B O A R D

J3-40

WHI/RED WHI/RED

WHI WHI WHI WHI

BLK

WHI/GRN WHI/GRN

WHI TAN BLU

TAN BLU

BLK

WHI/BLU

BLK

WHI/VIO

BLK

YEL

BLK

RED

BLK

PNK TAN

ORA GRY

WHI WHI RED

BLU RED

PNK YEL

VIO

GRY

GRN

PNK

RED

PNK

WHI RED

REFILL

SOL SOL SOL

RED

N.C.

OVERFLOW

PROTECTION SWITCH

LT START SW

RED

BLK

RED RED

PNK

WHI

& DISPLAY

CONNECTOR

INTERFACE

2 1

RT BREW

SOL

LT BREW

WHI

RED

BLK BLK

WHI

GRY

PNK

CONTROL

OPTIONAL

RT BYPASS

WHI

SOL

OPTIONAL

LT BYPASS

OPTIONAL

DAY/NIGHT

SWITCH

RT START SW

TEMP.

SENSOR

READY

DRY PLUG

DETECTION

LIQUID LEVEL SENSOR

PNK

Page 53

WHI

RT LIMIT T'STAT

BLK

WHI

LT LIMIT T'STAT

BLK

RT ON/OFF SW

WHI

GRY

TAN

PNK

WHI/VIO

WHI/RED

VIO

YEL

ORA

WHI/VIO

WHI/GRN

BLK

WHI/VIO

WHI

BLK

WHI/RED

RT TANK HEATER

LT ON/OFF SW

WHI/GRN

LT TANK HEATER

GRY

C H

120V.A.C.

208 0R 240V.A.C.

120V.A.C.

GRN

BLU

GRY PNK TAN

RT WARMER

TRIAC

LT WARMER

TRIAC

GRINDER

INTERFACE

CONNECTOR

WHI/RED

BLU

TAN

WHI/GRN

BLU

BLU WHI/VIO

TAN

PNK TAN

120/208 OR

120/240 VOLTS AC

3 WIRE

SINGLE PHASE

WHI/VIO

27040 032201

Bunn Dual, Dual DUAL010000 Operating & Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual