Bunn FCD-4 User Manual

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BUNN

FCD-4

INSTALLATION & OPERATING MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

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

www.bunnomatic.com

CONTENTS

Introduction & Warranty .................................................................................... 2

User Notices ...................................................................................................... 3

Initial Set-Up & Electrical Requirements ............................................................ 4

Plumbing Requirements .................................................................................... 5

Operating Controls............................................................................................. 6

Initial Fill ............................................................................................................ 8

Dispenser Use ................................................................................................. 10

Cleaning........................................................................................................... 11

Adjustments & Optional Settings ..................................................................... 13

Function Lists .................................................................................................. 18

Coolant Diagram .............................................................................................. 19

Schematic Wiring Diagram .............................................................................. 20

WARRANTY

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

1.) Bunn warrants electronic circuit and/or control boards to be commercially free from defects in material and

workmanship for two years from the date of installation.

2.) Bunn warrants the compressor on refrigeration equipment to be commercially free from defects in material

and workmanship for two years from the date of installation.

3.) Bunn warrants that the grinding burrs on coffee grinding equipment will grind coffee to meet original factory

screen sieve analysis for three years from date of installation or for 30,000 pounds of coffee, whichever comes first.

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

THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of Bunn are

not authorized to make modifications to this warranty or to make additional warranties that are binding on Bunn. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon.

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

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

In no event shall Bunn be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.

33496 122200

USER NOTICES

Carefully read and follow all notices on the equipment and in this manual. They were written for your protec-

tion. All notices are to be kept in good condition. Replace any unreadable or damaged labels.

! WARNING

DO NOT OVERLOAD CIRCUIT. ALWAYS ELECTRICALLY GROUND THE CHASSIS OR ADAPTOR PLUG. DO NOT DEFORM PLUG OR CORD. FOLLOW NATIONAL AND LOCAL ELECTRICAL CODES. KEEP COMBUSTIBLES AWAY.

FAILURE TO COMPLY RISKS EQUIPMENT

DAMAGE, FIRE OR SHOCK HAZARD.

READ THE ENTIRE OPERATING MANUAL

BEFORE USING THIS PRODUCT

00986.0002

CHARGE

Type R134A, Amount 10 oz

Design Pressures: High 335 Low 88

33461.0000

MAXIMUM RINSE WATER TEMPERATURE: 170˚F (76.6˚C)

Use Bunn-O-Matic tubing, part number 32759.10XX (See Illustrated Parts Catalog for complete part number) for hot water connection.

Hot Water Rinse Connection

Hot Water connection (See Caution)

RINSE WATER CONNECTION

Alternate Connection

(When Hot Water source is not available)

RINSE WATER CONNECTION

27442.0000

MAIN WATER CONNECTION

Cold Water Connection

Cold Water

NOTES:

• Use Bunn-O-Matic tubing, part number 32759.10XX for all connections. (See Illustrated Parts Catalog for complete part number)

• Clamp all hose connections with Bunn-O-Matic part number 21275.0003 (hose clamp)

Connection

3/8" x 3/8" x 3/8" Barb Tee B.O.M. PN 32750.0000 (may be installed internal or external to the dispenser)

33648.0000

33496 030901

INITIAL SET-UP

CAUTION: The dispenser is very heavy! Use care when lifting or moving it. Use at least two people to lift or

move the dispenser. Place the dispenser on a sturdy counter or shelf able to support at least 250 lbs. (113.4 kg). The FCD-4 is designed for indoor use only.

1. Set the dispenser on the counter where it will be used. The FCD-4 requires a minimum of 4 inches (102 mm) of air clearance at the rear and 8 inches (203 mm) of air clearance above the dispenser. Minimal clearance is required between the dispenser sides and the wall or another appliance. For optimum performance, surrounding machines blow on the FCD-4. Leave some space so the dispenser can be moved for cleaning.

2. Assemble the cup stop in the third slot of the drip tray cover as shown in Fig 1.

3. Place the cover/cup stop assembly on the drip tray and install on the dispenser.

do not let warm air from

P2264.50

FIG 1 Installing Cup Stop

ELECTRICAL REQUIREMENTS

CAUTION: The dispenser must be disconnected from the power source until specified in

The dispenser has an attached cord set and requires a 2-wire, grounded, individual branch circuit rated 120 volts ac, 15 amp, single phase, 60Hz. The mating connector must be a NEMA5-15R. (Refer to the dataplate for exact electrical requirements.)

ELECTRICAL HOOK-UP CAUTION: Improper electrical installation will damage electronic components.

1. An electrician must provide electrical service as specified.

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

3. Connect the dispenser to the power source.

4. If plumbing is to be hooked up later, be sure the dispenser is disconnected from the power source. If plumbing has been hooked up, the dispenser is ready for

Initial Fill

Electrical Hook-Up

33496 011101

PLUMBING REQUIREMENTS

This dispenser must be connected to a COLD WATER system with operating pressure between 20 and 100

psi (138 and 690 kPa). This water source must be capable of producing a minimum flow rate of 3 fluid ounces (88.7 milliliters) per second. A shut off valve should be installed in the line before the dispenser. Install a regulator in the line when pressure is greater than 100 psi (690 kPa) to reduce it to 50 psi (345 kPa). The main water inlet is a 3/8” (9.52 mm) barb connection.

Additionally, the dispenser’s rinse connection may be connected to a HOT WATER system.

Caution: MAXIMUM RINSE WATER TEMPERATURE: 170 degrees F (76.6 degrees C)

Use BUNN-O-MATIC tubing, part number 32759.10_ _ (see Illustrated Parts Catalog for complete part

number) for hot water connection.

The rinse water operating pressure must be between 20 and 100 psi (138 and 690 kPa). A shut off valve should be installed in the line before the dispenser. Install a regulator in the line when pressure is greater than 100 psi (690 kPa) to reduce it to 50 psi (345 kPa). The rinse water inlet is a 3/8” (9.52 mm) barb connection.

NOTE- At least 18 inches (457 mm) of an FDA approved flexible beverage tubing, such as reinforced braided polyethylene or silicone, before the dispenser will facilitate movement to clean the countertop. It can be purchased direct from BUNN-O-MATIC (part number 32759.10_ _ [see Illustrated Parts Catalog for complete part number.]) BUNN-O-MATIC does not recommend the use of saddle valves to install the dispenser. The size and shape of the hole(s) made in the supply line(s) by saddle valves may restrict water flow.

Note- A water strainer (Bunn-O-Matic part number 23720.1000) should be installed in line, prior to the flexible water line.

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 HOOKUP CAUTION: The dispenser must be disconnected

from the power source throughout the plumbing hookup.

Hot Water

connection

(See Caution)

All plumbing connections are located behind the dispenser’s splash panel. Water lines may

RINSE WATER CONNECTION

enter the dispenser through the access holes in either the bottom panel or the rear panel of the dispenser. To access plumbing connections: remove the drip tray assembly; remove the two screws securing the splash panel to the dispenser; lower the splash panel from the front of the dispenser.

Refer

MAIN WATER CONNECTION

Cold Water Connection

MAIN WATER CONNECTION

to FIG 2 for proper water hookup.

3/8" x 3/8" x 3/8" Barb Tee

Cold Water Connection

B.O.M. PN 32750.0000 (may be installed internal or external to the dispenser)

Hot Water Rinse Connection

FIG 2 Plumbing Connections

Alternate Connection

(When Hot Water source is not available)

P2265.70

33496 011101

FIG 3 Refrigeration Switch

OPERATING CONTROLS

Refrigeration Switch

The refrigeration switch is located on the top of the dispenser near the left rear corner. This switch controls power to the compressor and the condenser fan motor.

P2262.60

Sanitize Switch

The sanitize switch is located behind the drip tray in the lower left corner of the chassis. The drip tray can be removed to provide easy access to the switch. The sanitize switch is used to enter and exit the sanitize mode and to initiate the sanitize automatic cycle. Refer to Weekly Sanitizing in the Cleaning section for detailed instructions on the use of this switch.

FIG 4 Sanitize Switch & Water Valves

A. Sanitize Switch B. Water Bath Valve C. Main Water Valve

Water Bath and Main Water Valves

These valves are manually operated and are located above the drip tray, behind the splash panel. The drip tray and splash panel must be removed to gain access to the

P2263

valves. The upper (small) one is the water bath valve and the lower (large) one is the main water valve. Refer to the Initial Fill section for detailed instructions on the use of these valves.

33496 122200

OPERATING CONTROLS (cont.)

AAA

FIG 5 Press and Hold Models

A. Product Dispense Switch

Pressing and holding switch will initiate product flow from the respective nozzle; releasing the switch will

stop the flow. B. Chilled Water Dispense Switch

Pressing and holding switch will initiate chilled water flow from the nozzle; releasing the switch will stop

the flow. C. Hidden Switch

These switches are used to access, change and exit the dispenser program mode.

EEE

FIG 6 Portion Control Models

B. Chilled Water Dispense Switch

Pressing and holding switch will initiate chilled water flow from the nozzle; releasing the switch will stop

the flow. C. Hidden Switch

These switches are used to access, change and exit the dispenser program mode. D. Product Dispense Switch

Momentarily pressing and releasing one of the switches will initiate a timed dispense. Each station has

three different timed dispenses which are preset at the factory. Refer to DISPENSER USE section for

preset volumes and adjustment procedures. E. Plus/Stop Switch

This switch can be used to “top-off” a beverage. Pressing and holding switch will initiate product flow

from the respective nozzle; releasing the switch will stop the flow. Momentarily pressing this switch during

a timed dispense will stop the flow.

33496 122200

INITIAL FILL

CAUTION: The dispenser must be disconnected from the power source throughout the initial fill except when

specified in the instructions.

1. Remove drip tray assembly and splash panel from the dispenser.

2. Pull the overflow tube from its retaining clip and place the end into an empty 64 fluid ounce (2 liter) container.

3. Ensure that the Main Water Valve and the Water Bath Valve Fig 4, are turned off (handles positioned at 6 o’clock and 12 o’clock, respectively,) and that the Refrigeration Switch Fig 3, is in the OFF (rear) position.

4. Turn on the water supply.

5. While observing the water bath sight gauge (the clear tube located just to the left of the plumbing connections,) begin filling the water bath by rotating the handle of the Water Bath Valve counterclockwise to the 9 o’clock position.

6. When the water level in the sight gauge comes within 1 inch (25.4 mm) of the clear plastic tee, reduce the water flow by rotating the handle of the Water Bath Valve clockwise to the 11 o’clock position.

7. When the water in the water bath sight gauge begins to trickle down into the drip tray, turn the Water Bath Valve off by rotating the handle clockwise to the 12 o’clock position.

8. Connect the dispenser to the power source.

9. After approximately 3 minutes (this allows the recirculating pump and cabinet cooling components an opportunity to fill with water,) top off the water bath tank by rotating the handle of the Water Bath Valve counterclockwise to the 11 o’clock position.

10. Again, when the water in the water bath sight gauge begins to trickle down into the drip tray, turn the Water Bath Valve off by rotating the handle clockwise to the 12 o’clock position.

11. Place the Refrigeration Switch ON (forward.)

12. It will take approximately 4 hours at 70 degrees F (21 degrees C) ambient to create the ice bank required for full dispenser performance. During this time, some further trickling from the water bath is expected due to expansion caused by ice bank formation. While the refrigeration system is creating the ice bank, the dispenser may be readied for use as described in

13. The dispenser will safely store concentrate once the “COOLING” indicator completely extinguishes (not lit steadily or flashing.)

14. After the refrigeration compressor switches off, turn Main Water Valve on by rotating the handle counterclockwise to the 3 o’clock position. Secure the overflow tube into its retaining clip and replace the splash panel and drip tray assembly.

Loading, Priming

and

Adjustment.

LOADING Frozen Concentrates

1. Thaw the frozen concentrate in a refrigerated 35-40 degrees F (1.6-4.4 degrees C) environment for 36 to 48 hours before use.

2. Thoroughly mix the thawed concentrate by vigorously shaking the product container.

3. Open the dispenser door.

4. Prior to placing the product container in the dispenser, make sure that the o-ring on the container adapter is lubricated. This will ease removal of the container when it becomes necessary.

5. Place the product container in the desired position and press it firmly into the bottle adapter opening.

6. Open the vent hole in the product container.

Note: Concentrate in the container must be completely thawed and be within the temperature range of 35-40 degrees F (1.6-4.4 degrees C.) Product outside of this temperature range, especially below, will produce an “out of brix” drink.

33496 011101

INITIAL FILL (cont)

Ambient Concentrates (Optional)

1. Install an Ambient Concentrate Conversion Kit (BUNN-O-MATIC part number 33699.0000) per the instructions

provided in the kit.

2. Attach the concentrate product hose to the appropriate concentrate line located behind the dispenser’s splash

panel.

3. Attach the other end of the product hose to the product container through an appropriate fitting.

PRIMING

1. Open the dispenser door

2. Load concentrate per instructions in section titled

3. Close the dispenser door.

Note: The dispenser will not operate with the door open.

4. Place a large container under the appropriate dispense nozzle.

5. Dispensers with Press and Hold Feature:

Press and hold the “Product Dispense Switch” Fig 5, until concentrate dispenses from the dispense nozzle.

Dispensers with Portion Control Feature:

Press and hold the “+/STOP Switch” Fig 6, until concentrate dispenses from the dispense nozzle.

Note: This may take several seconds, depending on the installation and programmed pump speed.

33496 011101

DISPENSER USE

Press and Hold Models (Refer to Fig 5)

1. Place a cup on the drip tray beneath the desired dispensing nozzle.

2. Press and hold the “Product Dispense” or “Chilled Water” switch until the beverage/water reaches the desired level, then release.

Portion Control Models (Refer to Fig 6)

1. Place a cup on the drip tray beneath the desired dispensing nozzle.

2. Momentarily press the appropriate cup size switch to dispense the beverage. The dispenser is factory preset to produce the approximate beverage sizes as follows:

Small (4.0 seconds): approximately 7 fl.oz. (207 ml) Medium (6.9 seconds): approximately 12 fl.oz. (355 ml) Large (9.1 seconds): approximately 16 fl.oz. (473 ml)

The dispense times can be individually programmed by following the procedures described in

MENT - Cup Size Programming

ADJUST-

To stop a timed dispense, momentarily press the “+/Stop Switch”.

3. To “top-off” a beverage, press and hold the “+/Stop Switch” until the beverage reaches the desired level, then release.

4. To dispense chilled water, press and hold the “Chilled Water Switch” until the water reaches the desired level, then release.

33496 011101

CLEANING & PREVENTIVE MAINTENANCE

General Cleaning and Sanitizing Procedures

Note: The Bunn Juice Dispenser incorporates a rinse reminder feature which lights the rinse led on the front panel

when it is time to rinse. See dip switch function list to activate this feature.

Daily: Rinse Procedure

Tools required: 32 oz. (946 ml) minimum empty container

1. Open the refrigerated compartment’s door to access the “DISPENSE/RINSE” Knobs Fig 7.

2. Select the stations that will be rinsed and then rotate the appropriate Knob(s) to the rinse position. It is recommended that ALL dispense heads be rinsed daily. Note: If a station is in service lockout, leave its knob in the Dispense position.

3. Close the refrigerated compartment’s door.

4. Place the empty container under the dispense nozzle to catch the rinse water.

(CAUTION: THE BUNN JUICE DISPENSER CAN BE PLUMBED FOR A HOT WATER RINSE. RINSE WATER CAUGHT

IN THIS STEP SHOULD BE HANDLED WITH EXTREME CARE.)

5. Press and release the appropriate “Product Dispense Switch” Fig 5. This will initiate a timed rinse cycle. Portion control users can press any of the 3 “Product Dispense Switches” Fig 6, to initiate a timed rinse cycle.

6. Repeat for each dispense head.

7. Open the refrigerated compartment’s door and return each knob to the dispense position.

8. Actuate the station’s Dispense Switch until concentrate appears from the dispense nozzle.

FIG 7 Dispense/Rinse Switch

Daily: Parts Washing

1. Remove and wash the dispense nozzle(s), mixing element(s), drip tray, drip tray cover, and cup stop in a mild detergent solution. Rinse thoroughly.

2. Wipe splash panel, areas around dispense nozzle(s), and drip trough in refrigerated compartment with a clean, damp cloth.

Weekly: Sanitizing

Tools required: Nozzle tubing (BUNN-O-MATIC part number 03289.1002) recommended when sanitizing multiple dispense heads simultaneously, 1 empty 5 gallon (18.9 L) bucket, 1 packet of Kay 5 sanitizer, and clean, empty concentrate containers.

Note: The Bunn juice dispenser features a semiautomatic sanitizing program. When sanitizing multiple heads simultaneously, attach Bunn sanitize tubing (BUNN-O-MATIC part number 03289.1002) on the end of each dispense nozzle and run tubing to the 5 gallon (18.9 L) bucket.

1. Remove any juice concentrate from the dispenser and store in a separate refrigerated compartment.

2. Perform the rinse procedures as previously described. (Note: If the dispenser is plumbed for hot water rinse, proceed to step 9.)

3. Fill clean empty concentrate container(s) with approximately 32 oz. (946 ml) of the hot tap water (approximately 140°F (60°C). Load the containers of hot water into the dispenser (just like concentrate). Verify the rinse knobs are in the “DISPENSE” position.

4. Remove the drip tray and verify that the nozzle tubes are positioned within the empty bucket.

5. Press and hold the “Sanitize Switch” Fig 4, located on the front left portion of the base, for 5 seconds. The “SANITIZE” indicator on the front panel will begin to flash and the beeper will sound twice indicating that you have entered the sanitize mode.

6. Select the dispense stations by pressing the “Dispense Switch” for that station. Use the “+/Stop Switch” for

33496 030701

CLEANING (cont)

portion contol dispensers. The “REFILL” indicator will light and the beeper will sound for the dispense head selected.

7. Once the dispense heads have been selected, press and hold the “Sanitize Switch” for 5 seconds again to initiate the automatic cycle. (When the cycle is initiated the “SANITIZE” indicator lights steadily and the “REFILL” indicator for each station being sanitized will flash.)

Note: The sanitize routine takes 8 minutes. During the sanitize routine the following steps will occur in sequence:

A) The pumps at the selected dispense heads will run for 1 minute, or until the bottles filled

with hot water empty, whichever occurs first. B) The dispenser will sit idle for 5 minutes. C) The pumps at the selected dispense heads will run for 2 minutes or until the bottles filled

with hot water empty, whichever occurs first. D) The beeper will sound once every 3 seconds to indicate completion of the sanitize

routine.

Note: To terminate a sanitize program mid-cycle, momentarily press and release the “Sanitize Switch” and proceed to step 17. The sanitize program should be restarted from step 1 to ensure proper sanitization.

8. Once the cycle is completed, disconnect the sanitizing hose(s) from the nozzle(s) and empty the bucket.

9. Remove each dispense nozzle and mixing element and run under hot tap water to remove excess pulp.

10. Prepare 2.5 gal. (9.46 L) of sanitizing solution by dissolving 1 packet of Kay 5 sanitizer into 2.5 gal. (9.46 L) of 120°F (48.9°C) water to ensure 100 ppm of available chlorine.

11. Place nozzle(s) and mixing element(s) in a separate 1 quart container of sanitizing solution and mix thoroughly. Allow the part to soak for 2 minutes.

12. Clean the dispense nozzle receptacle(s) (dispense valves) with the sanitizing solution and a soft bristle brush.

13. Clean the concentrate bottle’s inlet adapter(s) using the sanitizing solution and a soft bristle brush.

14. Replace the mixing element(s) and nozzle(s), reattach the sanitizing hose(s) to the nozzle(s), and insert the hoses into the catch bucket.

15. Fill approximately 64 ounces (1.89 L) of clean sanitizing solution into clean, empty concentrate container(s). Do not use the sanitizing solution used in step 11. Load the containers into the dispenser.

16. Repeat steps 5 through 8.

Note: The sanitize routine takes 8 minutes. During the sanitize routine the following steps will occur in sequence:

A) The pumps at the selected dispense heads will run for 1 minute, or until the bottles filled

with sanitizing solution empty, whichever occurs first. B) The dispenser will sit idle for 5 minutes. C) The pumps at the selected dispense heads will run for 2 minutes or until the bottles filled

with sanitizing solution empty, whichever occurs first. D) The beeper will sound once every 3 seconds to indicate completion of the sanitize

routine.

17. Replace the sanitizing solution with concentrate and reattach the drip tray.

18. Activate a rinse cycle at each station as described in DAILY RINSE PROCEDURE.

19. At each station, actuate the Dispense Switch until juice appears. Then pour one 12 ounce (354.9 ml) glass of juice and discard.

20. Wipe internal and external surfaces with a clean, damp cloth.

33496 030901

CLEANING (cont)

Monthly: Clean Condenser Air Filter

1. Remove the condenser air filter located on the rear of the dispenser.

2. Using a water spray, clean the air filter.

Annually: Replace Pump Tubing

1. Open dispenser door.

2. Remove all product containers and place them in a refrigerated (35-40 degrees F [1.6-4.4 degrees C])

environment. Disconnect all connections to ambient products from the bottle adapter.

3. Close the dispenser door and dispense product at each station until the product runs clear.

4. Remove the drip tray assembly and splash panel from the dispenser.

5. Replace the drip tray assembly.

6. Turn the Main Water valve to the 6 o’clock position.

7. Open the dispenser door and remove the product shelf.

8. Remove the DISPENSE/RINSE knobs Fig 7, all dispense nozzles, the 2 screws securing the cover to the

dispense platform, and the cover.

9. Disconnect the dispense platform’s water lines from the supply lines inside the refrigerated cabinet and

disconnect the wiring connections from the cabinet receptacles.

10. Remove the 2 thumb-screws securing the dispense platform to the cabinet .

11. Slowly pull the dispense platform forward to allow access to the rear wiring harness connector.

12. Disconnect the rear wiring harness connector from its receptacle.

13. Pull the dispense platform completely out of the cabinet and place it on a flat work surface.

14. Close the dispenser door.

15. Remove the screw securing the tubing retainer plate to the pump body and set it and the tubing retainer plate

aside.

16. Gently pull the socket head screw from its notch in the pump body, releasing the spring tension on the pump

band.

17. Gently pull the pump tube from around the pump’s rotor.

18. Inspect the pump band for signs of wear. Replace if necessary.

19. Release the clamps securing the old pump tubing to the plastic elbows.

20. Pull the plastic elbows from the old pump tubing, and discard the old pump tubing.

21. Insert the plastic elbows into the new pump tubing and secure it with the clamps.

22. Apply lubricant (BUNN-O-MATIC part number M2548.0000) to the new pump tubing’s rotor side.

23. Gently wrap the new pump tubing around the pump’s rotor, making sure that the elbows and clamps end up

on the top-side of the pump body and don’t protrude through the exit slots.

24. Replace the socket-head screw into its notch in the pump body.

25. Replace the tubing retainer plate and its retaining screw.

26. Repeat steps 15 through 24 for the remaining pumps.

27. Replace the dispense platform into the refrigerated cabinet, making sure to reconnect all electrical and water

connections.

28. Turn the Main Water Valve to the 3 o’clock position. Check for leaks.

29. Replace the thumb-screws, cover, cover screws, DISPENSE/RINSE knobs and dispense nozzles.

30. Turn all DISPENSE/RINSE knobs to the RINSE positions. Close the door and run a rinse at each station. Check

for leaks.

31. Replace product shelf and product containers. Reconnect any connections to ambient product containers.

32. Prime the pumps as described in “PRIMING” in the Initial Fill Section.

33496 030901

ADJUSTMENT & OPTIONAL SETTINGS

SETTING THE MIX RATIO/BRIX Ratio Cup Method

1. Adjust the water flow as described in

2. Remove the dispense nozzle from the appropriate dispense position.

3. Assemble, lubricate, and install the Flow Separator Assembly (BUNN-O-MATIC part number 32629.0000) into the dispense nozzle receptacle (dispense valve,) making sure to point the arrow on the separator body away from the dispenser.

4. Place an empty container under the Flow Separator Assembly.

5. Dispensers with Press and Hold Feature:

Press and hold the “Product Dispense Switch” Fig 5, until water and concentrate begin flowing freely from the Flow Separator Assembly nozzles. Dispensers with Portion Control Feature:

Press and hold the “+/Stop Switch” Fig 6, until water and concentrate begin flowing freely from the Flow Separator Assembly nozzles.

6. Place the empty brixing cup (BUNN-O-MATIC part number 33095.0000) under the Flow Separator Assembly nozzles, small (concentrate) chamber to the left and large (water) chamber to the right.

7. Dispensers with Press and Hold Feature:

Press and hold the “Product Dispense Switch” until concentrate reaches the 1 oz. (black line) mark.

Dispensers with Portion Control Feature:

Press and hold the “+/Stop Switch” until concentrate reaches the 1 oz. (black line) mark.

8. Read the level in the water chamber. This reading directly determines the mix ratio (i.e. If the water level reads

4.0 oz., then the mix ratio is 4 [water] + 1 [concentrate].)

9. Adjust the pump speed (down to increase the ratio, up to decrease the ratio) to achieve the correct mix ratio as described in

Pump Speed Programming.

10. Remove the Flow Separator Assembly and replace the dispense nozzle assembly into the dispense nozzle receptacle (dispense valve.)

Water Flow Testing and Adjustment.

Temperature Compensated Refractometer Method

1. Adjust the water flow as described in

Water Flow Testing and Adjustment.

2. Place an empty container under the appropriate dispense nozzle.

3. Dispensers with Press and Hold Feature:

Press and hold the “Product Dispense Switch” Fig 5, until water and concentrate begin flowing freely from the dispense nozzle. Dispensers with Portion Control Feature:

Press and hold the “+/Stop Switch” Fig 6, until water and concentrate begin flowing freely from the dispense nozzle.

4. Discard the product caught previously and place the empty container back under the dispense nozzle.

5. Dispensers with Press and Hold Feature: Press and hold the “Product Dispense Switch” until the cup is filled.

Dispensers with Portion Control Feature:

Press and hold the “+/Stop Switch” until the cup is filled.

6. Stir the contents of the cup, and use the refractometer (according to the manufacturer’s instructions) to check

the brix %.

7. Adjust the pump speed (down to decrease the brix %; up to increase the brix %) to achieve the correct brix

% as described in

Pump Speed Programming.

33496 011101

ADJUSTMENT & OPTIONAL SETTINGS (cont)

Water Flow Testing and Adjustment

1. Enter the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches” Fig 5 or Fig 6. Note that the beeper sounds twice and that the “PROGRAM” indicator begins flashing.

2. Place a graduated measuring cup or the large chamber of the empty brixing cup (BUNN-O-MATIC part number 33095.0000) under the appropriate dispense nozzle.

3. Press and hold the desired “Product Dispense Switch” Fig 5 (“+/Stop Switch” Fig 6, for portion control dispensers) for 5 seconds. Note that

FIG 8 Adjusting Water Flow

P2253.70

the beeper sounds once per second (6 times, total) during this period.

4. At the end of the 5 second period, the selected position will dispense water (no concentrate) for only 3 seconds.

5. Measure the water dispensed.

6. Adjust the water flow rate Fig 8, (clockwise to increase flow rate; counterclockwise to decrease flow rate) to the corresponding product mix ratio as follows:

Mix Ratio Adjust water flow rate to: Product Brix %

(water + concentrate)

2+1 3.75 fluid ounces (111 ml) Prune Juice 16.0%

per 3-second test Other *

Orange Juice 11.8%

4+1 Pineapple Juice 12.8%

Cranberry Fruit Cocktail 14.0%

4.5 fluid ounces (133 ml) Grapefruit Juice 10.6% per 3-second test Lemonade

5+1 Apple Juice 12.0%

Fruit Punch Grape Juice 13.0%

3+1 through 7+1 Other *

Above 7+1 6.0 fluid ounces (177 ml) Other *

per 3-second test

Note: Information for specific products listed in this table is to be used for reference only. Consult the product label for exact mix ratio and/or brix %. See product label for target brix %.

7. Repeat steps 3 through 6 as necessary until the correct water flow rate is achieved.

8. Repeat steps 3 through 7 for the remaining dispense positions.

9. Exit the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the beeper sounds twice and the “PROGRAM” indicator extinguishes.

Pump Speed Programming

1. Enter the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator begins flashing.

2. To increase the pump speed, press and hold the right-hand “Hidden Switch” (filled circle) and then momentarily press the “Product Dispense Switch” Fig 5 (“+/STOP Switch” Fig 6, for portion control dispensers). Each time the “Product Dispense Switch “(+/STOP Switch”) is pressed, the motor speed is increased by one step (5 revolutions per minute [RPM].) Note that each step is confirmed by a single flash of the appropriate “REFILL” indicator and a single tone from the beeper.

3. To decrease the pump speed, press and hold the left-hand “Hidden Switch” (half-filled circle) and then momentarily press the “Product Dispense Switch (“+/STOP Switch” for portion control dispensers). Each time the “Product Dispense” (“+/STOP”) Switch is pressed, the motor speed is decreased by one step (5 RPM.) Note

33496 011101

ADJUSTMENT & OPTIONAL SETTINGS (cont)

that each step is confirmed by a single flash of the appropriate “REFILL” indicator and a single tone from the beeper.

4. Repeat as necessary at the remaining dispense stations.

5. Exit the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator extinguishes.

Chilled Water Flow Testing and Adjustment

1. Enter the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator begins flashing.

2. Place a graduated measuring cup or the large chamber of the empty brixing cup (BUNN-O-MATIC part number

33095.0000) under the appropriate dispense nozzle.

3. Press and hold the “Chilled Water Switch” Fig 5 or Fig 6, for 5 seconds. Note that the beeper sounds once per second (6 times, total) during this period.

4. At the end of the 5 second period, the chilled water will dispense for 3 seconds.

5. Measure the water dispensed. (Approx. 4.5 fl. oz. [133 ml])

6. If adjustment is required, remove all concentrate bottles from dispenser and disconnect any optional ambient concentrate hoses. Remove product shelf from dispenser.

7. Adjust the Chilled Water Flow Valve Fig 9, clockwise to decrease flow rate; counterclockwise to increase flow rate.

8. Repeat steps 3 through 6 as necessary until the desired water flow rate is achieved.

9. Exit the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator extinguishes.

FIG 9 Chilled Water Flow Valve

P2263

Cup Size Programming (Portion Control Dispensers Only)

1. Enter the “Cup Size Programming” mode by simultaneously pressing the “LARGE” and “SMALL” cup size switches at any dispense station. Note that the beeper sounds twice and that the “PROGRAM” indicator lights steadily.

2. Press and hold the desired cup size switch at the appropriate dispense position until the correct cup volume is achieved. Top up as necessary by momentarily pressing the same cup size switch. Note that if DIP switch #2 on the control board is set to the “on” position, concentrate must be present in order to dispense or program cup sizes.

3. Repeat as necessary for the remaining cup sizes and dispense stations.

4. Exit the “Pump Speed Programming” mode by pressing any of the “+/STOP Switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator extinguishes.

Dispenser Lockout

Dispense and Rinse functions of the dispenser can be electronically locked-out to prevent unauthorized use of the dispenser, while keeping the refrigeration system running.

1. Enter the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator begins flashing.

2. Enter a “Lockout” password as follows: a) Press and hold either “Hidden Switch”.

33496 011101

ADJUSTMENT & OPTIONAL SETTINGS (cont)

b) In a 5 second period, press and release the “Chilled Water Switch” the number of times that you want the password set to (maximum of 10.) For example: If you want the password set to 3, press and release the “Chilled Water Switch” 3 times in the 5 second period. c) Release the “Hidden Switch”. d) At the end of the 5 second period, the password will be confirmed by the “REFILL” indicators flashing the password.

3. Exit the “Pump Speed Programming” mode by simultaneously pressing both “Hidden Switches”. Note that the

beeper sounds twice and that the “PROGRAM” indicator extinguishes.

4. To lockout the dispenser, proceed as follows:

a) Press and hold either “Hidden Switch”. b) In a 5 second period, press and release the “Chilled Water Switch” the “password” number of times. For example: If the password is set to 3, press and release the “Chilled Water Switch” 3 times in the 5 second period. c) Release the “Hidden Switch”. d) At the end of the 5 second period, the dispenser will extinguish the merchandising lamp, and all dispense functions will be disabled.

5. To enable the dispenser, proceed as follows:

a) Press and hold either “Hidden Switch”. b) In a 5 second period, press and release the “Chilled Water Switch” the “password” number of times. For example: If the password is set to 3, press and release the “Chilled Water Switch” 3 times in the 5 second period. c) Release the “Hidden Switch”. d) At the end of the 5 second period, the dispenser will light the merchandising lamp, and dispense functions will be enabled.

6. If the password is forgotten, it can be reset to “0” (dispenser lockout disabled) as follows:

Note: The following procedure also clears the programming and service lockout password.

a) Disconnect the dispenser from its power source. b) Place the “Refrigeration Switch” Fig 3, in the OFF (reward) position. c) While pressing and holding the “Chilled Water Switch”, connect the dispenser to its power source. d) Continue to hold the “Chilled Water Switch” until the dispenser beeps three times, then release. e) The passwords are now returned to “0” (no programming or service lockout password/dispenser lockout disabled.) f) After 3 minutes, place the “Refrigeration Switch” in the ON (forward) position.

Service Lockout

Should a dispense station become inoperative and require service, the station’s dispense and rinse functions can be independently locked out, while keeping the remaining stations running.

1. To place a single dispense station in “Service Lockout,” open the dispenser door, press and hold either “Hidden

Switch” and the desired dispense station “Product Dispense” (“+/Stop”) switch for 10 seconds.

2. At the end of the 10 second period, the beeper will sound a double tone and the dispense position will be

disabled. Place the DISPENSE/RINSE Knob to “DISPINSE” and close the dispenser door.

3. To remove a dispense station from “Service Lockout,” open the dispenser door, press and hold either “Hidden

Switch” and the desired dispense station “Product Dispense” (“+/Stop”) switch for 10 seconds.

4. At the end of the 10 second period, the beeper will sound a double tone and the dispense position will be

enabled. Close the dispenser door.

33496 011101

ADJUSTMENT & OPTIONAL SETTINGS (cont)

Password Protection

The programming modes and service lockout function may be password protected to prevent accidental or unauthorized access to these features. The dispenser is shipped from the factory with a password of “0” (no password.)

1. Enter the “Pump Speed Programming” mode by simultaneously pressing both “Hidden switches”. Note that the beeper sounds twice and that the “PROGRAM” indicator begins flashing.

2. Program a password as follows: a) Press and hold either “Hidden Switch”. b) In a 5 second period, press and release the “Sanitize Switch” the number of times that you want the password set to (maximum of 10.) For example: If you want the password set to 3, press and release the “Sanitize Switch” 3 times in the 5 second period.

Note: To reset password to “0” (no password) press and hold the “Sanitize Switch”, without either “Hidden Switch” pressed, for the 5 second period. When the password resets to “0”, the beeper will sound and the “Water” indicators will illuminate for approximately 2 seconds.

c) Release the “Hidden Switch”. d) At the end of the 5 second period, the password will be confirmed by the “WATER” indicators flashing the password. e) From this point forward, the password must be entered before access is allowed to programming modes or the service lockout function.

3. To enter the password, proceed as follows: a) Press and hold either “Hidden Switch”. b) In a 5 second period, press and release the “Sanitize Switch” the password number of times. For example: If the password is set to 3, press and release the “Sanitize Switch” 3 times in the 5 second period. c) Release the “Hidden Switch”. d) Wait for the password to be confirmed by the flashing of the “Water” indicators. e) Enter the desired program mode or select service lockout as normal within the next 5 seconds.

Note: If the program mode/service lockout is not selected within 5 seconds, it will be necessary to re-enter the password.

4. If the password is forgotten, it can be reset to “0” (no password) as follows:

Note: The following procedure also clears the dispenser lockout password.

f) Disconnect the dispenser from its power source. g) Place the “Refrigeration Switch” in the OFF (rearward) position. h) While pressing and holding the “Chilled Water Switch”, connect the dispenser to its power source. i) Continue to hold the “Chilled Water Switch” until the dispenser beeps three times, then release. j) The passwords are now returned to “0” (no programming or service lockout password/dispenser lockout disabled.) k) After 3 minutes, place the “Refrigeration Switch” in the ON (forward) position).

33496 011101

Dispense Fault List

“REFILL” indicator Beeper Fault

2 flashes 2 beeps Dispense station locked out. 3 flashes 3 beeps DISPENSE/RINSE sensing fault. 4 flashes 4 beeps DISPENSE/RINSE knob mis-positioned. 5 flashes 5 beeps Pump motor stalled/speed sensor inoperative.

All “REFILL” 3 beeps Dispenser locked out.

indicators flash

3 times

Cooling Fault List

Fault Code “COOLING” DBC display Fault Fault

indicator (optional) Priority

8 8 flashes every fault 8 Bath water level low. 1

5 seconds (Also lights all “WATER” indicators)

7 7 flashes every fault 7 Bath temperature probe short circuit. 2

5 seconds

6 6 flashes every fault 6 Bath temperature probe open circuit. 3

5 seconds

5 5 flashes every fault 5 Cabinet temperature probe short circuit. 4

5 seconds

4 4 flashes every fault 4 Cabinet temperature probe open circuit. 5

5 seconds

3 3 flashes every fault 3 Cooling system failure 6

5 seconds (disables all dispense functions)

0 On steady Bath/cabinet Bath and cabinet temperatures excessive. 7

temperatures

2 2 flashes every Bath/cabinet Bath temperature excessive. 8

5 seconds temperatures

1 1 flash every Bath/cabinet Cabinet temperature excessive. 9

5 seconds temperatures

Dip Switch Function List

Dip Switch Controls Off On

1 “REFILL” indicator when “concentrate out” is detected. Inactive Active 2 Lockout dispense components when “concentrate out” is detected. Inactive Active (Note) 3 Number of positions that can dispense/rinse simultaneously. 3 2 4 Rinse timer Off On 5 Audio feedback during dispenses. On Off 6 Future use. None None

Note: When dip switch 2 is in the “on” position, the “REFILL” indicator is active, regardless of dip switch 1 position.

33496 030901

CONDENSER

SUCTION

ACCUMULATOR

COMPRESSOR

EVAPORATOR

PROCESS TUBE

FILTER

DRYER

COOLANT SCHEMATIC DIAGRAM

33496 011101

SCHEMATIC WIRING DIAGRAM

BLU/BLK

COMPRESSOR ASSEMBLY

LIMIT

THERMOSTAT

BLU/BLK

BLK

PUMP

WHI/YEL

GRY

RED

1111

SPEED

SENSOR #3

SENSOR #4

GRN

GRY

WHI/BLK

BLK

t°

CABINET

THERMISTOR

#1 REFILL SENSOR

#1 RINSE &

DISPENSE LIMIT

RINSE

DISPENSE

1111

VIO

GRY

WHI/VIO

#1 DISPENSE

WHI/VIO

SOL

ICE WATER DISPENSE

TAN RED/BLK

SOL

120 VOLTS AC

2 WIRE

SINGLE PHASE

PUMP

WHI/ORN

WHI/BLU

GRY

RED

SPEED

SENSOR #1

SENSOR #2

GRN/YEL

WHI

BLK

P R O B E

t°

WATER BATH THERMISTOR

#2 REFILL

#3 REFILL

SENSOR

#3 RINSE &

#2 RINSE &

DISPENSE LIMIT

RINSE

DISPENSE

GRY

ORN

WHI/ORN

#2 DISPENSE

WHI/ORN

RED/BLK

SOL

GRY

RED

SPEED

WHI/BLU

KCOMP.

PUMP

WHI/VIO

RED

VIO

RED

BLK

BEEPER

WHI/RED

PNK

WHI

GRY

WHI

PNK

WHI/RED

GRN

#4 REFILL

SENSOR

#4 RINSE &

DISPENSE LIMIT

RINSE

DISPENSE

BLU

GRY

WHI/YEL

WHI/BLU

RED/BLK

ICE BANK

CONTROL

CONDENSOR

FAN

WHI

MOTOR

GRN

VIO

WHI/VIO

ORN

WHI/ORN

BLU

WHI/BLU

YEL WHI/YEL WHI/YEL WHI/BLU WHI/ORN WHI/VIO

RED

GRY

SANITIZE SWITCH

GRY

DOOR

SWITCH

GRY PNK

RED BLK

FAN

RECIR. PUMP

WHI

BLU

YEL

GRY

WHI/VIO

VIO

ORN

112 VIO ORN

GRY

BLU YEL

YEL

#3 DISPENSE

SOL

RED/BLK

WHI/VIO

WHI/YEL

VIO

BLUBRN

WHI/ORN

114

VIO WHI/VIO ORN WHI/ORN BLU WHI/BLU YEL WHI/YEL WHI/YEL WHI/BLU WHI/ORN WHI/VIO RED

GRY

WHI/YEL

WHI/BLU

WHI/YEL

WHI/BLU

#4 DISPENSE

ON/OFF

BRN/BLK BLKBLU/BLK

GRY

VIO

ORN

BLU

YEL

WHI/VIO

VIO

ORN

BLU

YEL

WHI/VIO

RED/BLK

SOL

WHI/ORN

WHI/BLU

WHI/ORN

WHI/YEL

GRN

WHI

BLK

FLUORESCENT

BLU

LAMP

WHI

BLU

BALLAST

WHI

BLK

GRY

RED/BLK

BRN/BLK

TAN

J6-1

WHI/YEL WHI/BLU WHI/ORN

J6-6

VIO

RED/BLK

GRY GRY GRY

WHI/VIO

RED

WHI/RED

WHI/YEL

WHI/ORN

WHI/YEL WHI/ORN

GRY RED PNK

WHI/BLU

WHT/VIO

VIO

WHI/BLU WHI/VIO

TAN

RED/BLK

101

TAN

RED/BLK

J6-12

J1-10

J1-18

101

WHI/VIO

J3-1 J3-2

J1-1

J1-5

WHI WHI/GRY

WHI

ORN

WHI/ORN

BLU

WHI/BLU

YEL

J5-1

J5-5

J4-5

J4-1

GRY

GRN

WHI/BLK

WHI

BLK

WHI

RINSE

SOL

WHI/YEL

WHI

RED/BLK SHIELD

ORN/BLK WHI/BLK

GRN/BLK

BLU/BLK

RED/WHI GRN/WHI BLU/WHI

BLK/WHI

GRNGRN BLK BLK RED RED

TRANSFORMER

BLU

WHI/BLU

WHI/GRY

BRN/BLK

WHI/RED

WHI

VIO

J5-10

C O N T R O L

B O A R D

PNK

BLU

GRN ORN WHI RED

BLK

J5-15

J9-1

J9-6

J8-1

J8-8

J7-1

J7-5

J7-10

J4-14

J4-10

J7-16

VIO

BLU

YEL

ORN

116

SW#1SW#2SW#3SW

WATER #1

REFILL #1

J5-19

REFILL #2

VIO ORN BLU YEL

RED/BLK GRN/WHI BLU/WHI BLK/WHI

ORN WHI RED RED/WHI BLK BLU/BLK GRN/BLK BLU ORN/BLK WHI/BLK GRN

WATER #2

LEFT LAMP

ASSY.

GRY

RED/BLK

REFILL #3

–

RECT

WHI/BLK

LAMP ASSY.

GRN

ORN/BLK

WATER #3

RIGHT

BLU

GRN/BLK

BLU/BLK

REFILL #4

BLK

RED/WHI

WATER #4

RED

WHI

ORN

BLK/WHI

BLU/WHI

GRN/WHI

SWITCH UNIT ASSY

PROGRAM

RED/BLK

COOLING

WHI

RINSE

NL1

SANITIZE

SW#5SW#6SW

33496 011101

Bunn FCD-4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual