Bunn FMD-2 User Manual

FMD-2
FMD-3

(prior to S/N FMD0013000)

! WARNING

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LIQUID

RELEASE BUTTON WHEN CUP IS 2/3 FULL

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OPERATING & SERVICE MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

PHONE: [phone] FAX: [phone]

www.bunnomatic.com

INTRODUCTION

This equipment dispenses hot beverages on demand from powdered product. It has two or three hoppers. The
two and three hopper models may also dispense cold beverages from powdered product from their left dispense
station. It is for indoor use only 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 [phone] 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.

USER NOTICES

Carefully read and follow all notices on the equipment and in this manual. They were written for your protection.
All notices are to be kept in good condition. Replace any unreadable or damaged labels.

PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEASE

FMD-2 28301.0002

PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEASE

FMD-3 28301.0000

2

28364 080202

USER NOTICES (cont.)

00656.0000

00831.0000

MECHANICAL THERMOSTAT

28368.0000

RELEASE BUTTON WHEN CUP IS 2/3 FULL

160°

-

+

TEMPERATURE

ADJUSTMENT

120VAC

190°

HEATER

26527.0002

THERMOSTAT ASSEMBLY

BUNN-O-MATIC CORP

®

ELECTRONIC THERMOSTAT

26536.0002

PLACE

CUP HERE

FMD-2

28328.00003

PLACE

CUP HERE

FMD-3

28328.0000

3

28364 071598

INITIAL SET-UP

1. Locate the drip tray assembly beneath the dispenser nested in the packing material.

2. Remove the drip tray and the drip tray cover and set them aside.

3. Remove the water strainer assembly from the drip tray and set it aside.

4. Remove the four legs from the drip tray, apply non-skid pads to the bottom of the legs and securely install
the legs in the dispenser base.

ELECTRICAL REQUIREMENTS

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

The 120 volt version of this dispenser has an attached cordset. The mating connector must be a NEMA 5-15R.
The 120/208 volt and the 120/240 version of this dispenser has an attached cordset. The mating connector must
be a NEMA 14-20R.
The 240 volt version of this dispenser has an attached cordset without plug.

Initial Set-Up.

ELECTRICAL HOOK-UP

CAUTION - Improper electrical installation will damage electronic components.

1. An electrician must provide electrical service as specified.

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

3. Open the front door of the dispenser and place the heater switch in the “OFF” (upper position).

4. Connect the dispenser to the power source.

5. 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 & Heat.

PLUMBING REQUIREMENTS

This dispenser 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 dispenser.
Install a regulator in the line when pressure is greater than 90 psi (620 kPa) to reduce it to 50 psi(345 kPa). The
water inlet fitting 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. At least 18 inches 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 00326-0000). Bunn-O-Matic does not recommend
the use of a saddle valve to install the dispenser. 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).

4

28364 051100

PLUMBING HOOK-UP

1. Securely attach the short piece of tubing on the water strainer assembly to the inlet fitting on the bottom of
the dispenser.

2. Flush the water line and securely attach it to the flare fitting on the water strainer assembly.

3. Turn-on the water supply.

INITIAL FILL & HEAT

CAUTION - The dispenser must be disconnected from the power source throughout the initial fill & heat, except

when specified in the instructions.

1. Turn-on the water supply and connect the dispenser to the power source.

2. Water will automatically flow into the tank to the proper level and then shut-off. This will take less than five
minutes.

3. When the tank is full of water, open the front door and place the heater switch in the “ON” (lower) position.
A tank full of cold water will take approximately forty minutes for the water to heat on 120 volt versions, and
twenty minutes on 120/240 and 240 volt versions.

During this waiting period, complete these dispenser set-up steps:
a. Place a set of keyholes in the splash panel over the screws beneath the hopper access door and push down

gently.

b. Place the drip tray onto the supports on the splash panel. Hook the tabs on the rear of the drip tray through

the holes in the splash panel. Set the drip tray cover in place.

c. Fill the hopper(s) with the dry product to be dispensed.

DISPENSER USE

1. Simply place a cup on the drip tray beneath the desired dispensing tip.

2. Press the button to froth and dispense the beverage.

3. Release the button when the cup is approximately 2/3 full and allow the mixing chamber to drain.

NOTE - The mixing chamber must drain at the end of each dispense.

COLD BEVERAGE SET-UP (OPTIONAL)

Cold beverages may be dispensed from the left dispense position on the FMD-2 & FMD-3 models. Simply

place the HOT/COLD switch near the left whipper chamber in the “COLD” (upper) position.

CLEANING

Refer to the decal inside the hopper access door for cleaning recommendations and procedures.
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.

ADJUSTMENTS

The hot or cold beverage solenoid(s) is (are) preset to dispense approximately one ounce per second. This

amount can be adjusted:

1. Disconnect the dispenser from the power source.

2. Remove the small left side access panel.

3. Rotate the control at the base of the desired solenoid(s) clockwise to decrease or counterclockwise to
increase the amount of water.

4. For cold beverage adjustment remove the 1-1/2” plug on the lower left side of the dispenser and rotate the
needle valve clockwise to decrease or counterclockwise to increase the amount of cold water.

5

28364 011598

DRAINING THE HOT WATER TANK

CAUTION - The dispenser must be disconnected from the power source throughout these steps.

1. Disconnect the dispenser from the power source.

2. Open front door and place tank heater switch in the “OFF” (upper) position.

3. Shut-off and disconnect the incoming water supply.

4. Remove the top panel.

5. Gently remove one of the grommets from the tank lid.

6. Insert a tube to the bottom of the tank and syphon ALL of the water out.
(Bunn-O-Matic has a syphon assembly #12440.0000 available for this purpose.)

NOTE - The dispenser must be refilled using the INITIAL FILL & HEAT steps before reconnecting to the power
source.

HOPPER DISPENSE RATE OF PRODUCT

1. Hopper dispense rate with 22 tooth gear and auger wire is approximately 4 to 6 grams per second.

2. Hopper dispense rate with 22 tooth gear and auger wire with optional restrictor is approximately 3 to 5
grams per second.

3. Hopper dispense rate with optional 32 tooth gear and auger wire is 6 to 9 grams per second.

TROUBLESHOOTING

A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic
Technical Service Department.

• Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel.

• All electronic components have 120 volt ac or 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

to avoid twists and kinks in the tubing.

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

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

WARNING – • Exercise extreme caution when servicing electrical equipment.

• Unplug the dispenser when servicing, except when electrical tests are specified.

• Follow recommended service procedures

• Replace all protective shields or safety notices

6

28364 011598

TROUBLESHOOTING (cont.)

PROBLEM

Product will not dispense

PROBABLE CAUSE

1. No water

2. No power or incorrect voltage to
the dispenser

3. Dispense switch

REMEDY

Water lines and valves to the dis­penser must be open.

(A1) Check for 120 volts across the
black and white wires on two wire
120 volt dispenser.
(A2) Check for 120 volts across the
red and white wires and the black
and white wires on three wire 120/
240 volt dispenser.
(A3) Check for 240 volts across the
white and black wires on two wire
240 volt dispenser.

(B) Check circuit breakers or fuses.

Refer to

Service

- Dispense Switch

for testing procedure. See page 17

4. Dispense solenoid valve
(Hot or Cold)

5. Solenoid valve (Inlet)

6. Level control board and probe

7. Overflow protection switch

8. Auger drive

Refer to

Service

- Dispense solenoid
valve for testing procedures. See
page 29 or 30

Refer to

Service

- Solenoid Valve
(Inlet) for testing procedures. See
page 31

Refer to

Service

- Level Control Board
and Probe for testing procedures.
See page 24

Refer to

Service

- Overflow protec­tion switch for testing procedures.
See page 27

Refer to

Service

- Auger Drive. See

page 12

7

28364 011598

TROUBLESHOOTING (cont.)
PROBLEM

PROBABLE CAUSE

REMEDY

Product will not dispense (cont.)

Water is not hot

9. Water strainer

10. 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.

1. Limit thermostat
CAUTION - Do not eliminate or by­pass limit thermostat. Use only BOM
replacement part #29329.1000

2. Control thermostat

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

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

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

Refer to

Service

- Limit Thermostat

for testing procedures. See page 26

Refer to

Service

- Control Thermo­stat for testing procedures. See page
16

Spitting or excessive steaming

3. Tank Heater

4. Tank heater switch

1. 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.

2. Control thermostat

Refer to

Service

- Tank Heater for

testing procedures. See page 32

Refer to

Service

- Tank Heater Switch

for testing procedures. See page 33

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

Refer to

Service

- Control Thermo­stat for testing procedures. See
page 16

8

28364 051100

TROUBLESHOOTING (cont.)
PROBLEM

PROBABLE CAUSE

REMEDY

Dripping from dispense tip

Water flows into tank continuously

1. 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.

2. Dispense solenoid valve (Hot or
Cold)

1. Level control board and probe

2. Solenoid valve (Inlet)

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

Remove the dispense solenoid valve
and clear any obstructions. Rebuild
or replace the valve if necessary. See
page 29 or 30

Refer to

Service -

Level Control Board
and Probe for testing procedures.
See page 24

Refer to

Service

- Solenoid Valve
(Inlet) for testing procedures. See
page 31

Product overflows container

3. Overflow Protection Switch

1. Dispense switch

2. Dispense solenoid valve (Hot or
Cold)

Refer to

Service

- Overflow Protec­tion Switch for testing procedures.
See page 27

Refer to

Service -

Dispense Switch

for testing procedures. See page 17

Remove the solenoid valve and clear
any obstructions. Rebuild or replace
the valve if necessary. See page 29
or 30

9

28364 011598

TROUBLESHOOTING (cont.)
PROBLEM

PROBABLE CAUSE

REMEDY

Weak product

1. Water temperature

2. Whipper motor

3. Frother

Place an empty container beneath
the dispense tip. Initiate a dispense
cycle and check the water tempera­ture immediately below the dispense
tip with a thermometer.
(A) Reading for mechanical thermo­stat models should be 180°F to 200°F
(see thermostat temperature settings
decal in

USER NOTICES

on page 3.

(B) Reading for electronic thermo­stat should be185°F to 190°F.
Adjust the control thermostat to in­crease or decrease the water tem­perature. Replace if necessary.

Refer to

Service

- Whipper Motor for

testing procedure. See page 19

Refer to

Service

- Frother Compo-

nents. See page 19

4. Dispense solenoid valve
(Hot or Cold)

5. Auger drive

6. Auger spring

7. Auger motor

8. Rinse/Run switch

Refer to

Service

- Dispense Solenoid
Valve for test procedures. See page
29 or 30

Refer to

Service

- Auger Drive Com-

ponents. See page 12

Refer to

Service

- Auger Drive Com-

ponents. See page 12

Refer to

Service

- Auger Drive Com-

ponents. See page 14

Refer to

Service -

Rinse/Run Switch

for test procedures. See page 28

10

28364 011598

TROUBLESHOOTING (CONT.)

PROBLEM

Dispenser is making unusual
noises

Excess dust

PROBABLE CAUSE

1. Plumbing Lines

2. Water Supply

3. Tank Heater

1. Fan

2. Hopper Delay Board

REMEDY

Plumbing lines should not be rest­ing on the counter top.

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

(B) Water pressure to the dispenser
must not exceed 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 the tank
heater. See page 32

Refer to

Service

- Fan for testing

procedures. See page 18

Refer to

Service

- Hopper Delay Board

for testing procedures. See page 21

Display not lit

1. Lamp

2. Lamp Holder

3. Starter - Lamp

4. Ballast

Refer to

Service

- Lamp, see page 23

for lamp replacement.

Refer to

Service

- Lamp Holder for

testing procedures. See page 23

Refer to

Service

- Starter for testing

procedures. See page 24

Refer to

Service

- Ballast for testing

procedures. See page 15

11

28364 051100

SERVICE

This section provides procedures for testing and
replacing various major components used in this
dispenser should service become necessary. Refer to

Troubleshooting

cause of any problem.
WARNING - Inspection, testing, and repair of electri­cal equipment should be performed only by qualified
service personnel. The dispenser should be un­plugged when servicing, except when electrical tests
are required and the test procedure specifically states
to plug-in the dispenser.

COMPONENT ACCESS
WARNING - Disconnect the dispenser from the power

source before the removal of any panel or the replace­ment of any component.

All components are accessible by opening the
door, removal of the door panels, dispenser top cov­ers, hoppers, hopper support plate, splash
guard,splash panel w/drip tray, lower front access
panel, side and rear access covers.

for assistance in determining the

AUGER DRIVE COMPONENTS

Contents

Auger Drive Components......................................12

Auger Motor .........................................................14

Ballast...................................................................15

Control Thermostat...............................................16

Dispense Switch ...................................................17

Fan........................................................................18

Frother................................................................. 19

Hopper Delay Board..............................................21

Hot/Cold Switch....................................................22

Lamp Holder.........................................................23

Lamp ....................................................................23

Lamp Starter and Socket ......................................24

Level Control Board and Level Probe....................24

Limit Thermostat ..................................................26

Overflow Protection Switch ..................................27

Rinse/Run Switch .................................................28

Solenoid (Cold Drink - Optional)...........................29

Solenoid (Dispense) .............................................30

Solenoid (Inlet).....................................................31

Tank Heater ..........................................................32

Tank Heater Switch...............................................33

Whipper Motor .....................................................19

Wiring Diagrams.......................................... 35 & 36

FIG. 1 AUGER DRIVE COMPONENTS

Location

The auger components are located inside
the bottom part of the hopper except for the auger
drive bracket, washer and locknut, which are located
on the outside bottom rear of the hopper. The auger
motors are located on the rear of the auger motor
mounting panel. Refer to Fig. 2 for disassembly and
assembly.

Test Procedures - Auger motors

1. Disconnect the dispenser from the power source.

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

3. Check the voltage across the white/violet wire for

the right motor, orange wire for the center motor
or the red wire for the left motor and the gray wire
with a voltmeter. With the rinse/run switch in the
run position press and hold the appropriate dis­pense switch. Connect the dispenser to the power
supply. After a .7 second delay the indication must
be :
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.

12

SERVICE

AUGER DRIVE COMPONENTS (CONT.)

4. Disconnect the dispenser from the power supply.

If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the wir­ing diagrams and check the dispenser wiring harness.

5. With the wires removed from the motor to be
tested. Check for continuity across the two ter­minals on the bottom of the auger motor.

If continuity is present as described, reconnect the
wires to the terminals on the bottom of the auger
motor, the auger motor is operating properly.

If continuity is not present as described, replace the
auger motor.

Removal, Cleaning and Replacement
Hopper & Auger

1. Open the dispenser door and raise the top front
cover.

2. Lift the front edge of hopper assy (21) over the
tab on hopper support plate (20) and slide hop­per assembly out the front of the dispenser.

3. Remove hopper lid (1) and empty product.

4. Pull off the ejector elbow (14).

5. Remove auger disc assy (2) by pulling agitator
support rod (4) towards agitator disc assy and
lifting agitator disc assy from hopper (10).

6. Remove auger (12) by pulling it out the front of
the hopper (10).

7. Remove auger drive shaft (5) by removing the
retaining clip (6) from auger drive shaft.

8. Slide washer (8) and auger drive shaft bracket
(7) off of the auger drive shaft (5).

9. Slide auger drive shaft (5) from auger drive shaft
bushing (3) and remove from hopper (10).

10. Remove locknut (9) from auger drive shaft bush­ing (3) and remove auger drive shaft bushing
from hopper (10).

11. Wash components in a mild solution of dish de­tergent using a bristle brush when needed.

12. Rinse and dry each item thoroughly.

13. Check for damaged or broken components, re­place any if necessary and reassemble hopper
assy.

FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY

1. Hopper Lid

2. Agitator Disc Assy

3. Auger Drive Shaft
Bushing

4. Agitator Support Rod

5. Auger Drive Shaft

6. Retainer Clip

7. Auger Drive Bracket

8. Washer

9. Locknut

10. Hopper

11. Spring

13

12. Auger Wire

13. Auger Wire/Restrictor
(Optional)

14. Ejector Elbow

15. Auger Motor Mount­ing Panel

16. Auger Motor Bracket

17. Auger Motor

18. Dust Seal

19. Shoulder Screw

20. Hopper Support plate

21. Hopper Assy

SERVICE (cont.)

AUGER DRIVE COMPONENTS (cont.)

14. Install hopper assy (21) in the dispenser by sliding
hopper assy in the guides on the hopper support
plate (20) until the slot in the bottom rear the
hopper seats against the shoulder screw (19) in
the hopper support plate.

Auger Drive Motor (Refer to Fig. 2)

1. Remove hopper assy (21) and set aside for reas­sembly.

2. Remove the the four #8-32 screws securing the
hopper support plate (20), remove plate and set
aside for reassembly.

3. Remove the four #8-32 locking screws, located
inside the dispenser housing on the front of the
auger motor mounting panel (15), securing auger
motor mounting bracket (16) and auger motor

(17) to the rear of the auger motor mounting panel
(15).

4. Disconnect the wires from the auger motor (17) to
be removed.

5. Remove auger motor mounting bracket (16), au­ger motor (17) and dust seal (18) as an assembly.

6. Remove dust seal (18) from auger motor (17).

7. Remove the four #8-32 screws securing the auger
motor to the auger motor mounting bracket.

8. Remove auger motor and discard.

9. Using four #8-32 screw install new auger motor
(17) on mounting bracket (16).

10. Install dust seal (18) on auger motor shaft.

11. Using four #8-32 locking screws install auger
motor, dust seal and mounting bracket to the rear
of the auger motor mounting panel (15)

12. Reconnect the wires to the terminals on the bot­tom of the auger motor.

13. Install hopper support plate (20) and hopper as­sembly (21).

14. Refer to Fig. 3 when reconnecting wires.

14

BLK to BLU
from Door
Interconnect
Harness

15

SERVICE (cont.)

CONTROL THERMOSTAT

FIG. 6 CONTROL THERMOSTAT

Location

The control thermostat (mechanical or elec­tronic) is located inside the dispenser on the upper
left side of the housing.

Test Procedure
Mechanical Thermostat

1. Disconnect the dispenser from the power source.

2. Disconnect the black wire of the control thermo-

stat from the black lead from the limit thermo­stat.

3. Remove bulb from the tank.

4. Check the voltage across black wire on the con-

trol thermostat and the white or red wire on the
tank heater with the tank heater switch in the “ON”
lower position with a voltmeter. Connect the dis­penser to the power source. The indication must
be:
a) 120 volts ac for two wire 120 volt models.
b) 208 volts ac for three wire 120/208 volt or 240
volts ac for 120/240 volt models.

c) 240 volts ac for two wire 240 volt models.

5. Disconnect the dispenser from the power source.

16

SERVICE (cont.)

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

CONTROL THERMOSTAT (cont.)

10. Carefully bend the capillary tube so that the tube
and bulb inside the tank are in the vertical position
and away from any electrical connections.

BLK from Limit

Thermostat
BLK from Tank
Heater Switch

MECHANICAL THERMOSTAT

NOTE - The capillary tube must be clear of any electri-

cal termination and not kinked.

TAN to WHI/BRN
on Tank Heater Switch

BLK to Main
Wiring Harness

WHI to Main
Wiring Harness

BLK to Limit
Thermastat

ELECTRONIC THERMOSTAT

DISPENSE SWITCH

FIG.8 DISPENSE SWITCH

FIG. 7 THERMOSTAT TERMINALS

P1448

NOTE: The center dispense switch is for FMD-3 Mod­els only.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Open the dispenser door and remove the bottom
door cover.

3. Disconnect the wires from the door interconnect
wiring harness to the dispense switch to be
tested.

4. Check for voltage across the black and red/black
wires for the right dispense switch, black and
red/white wires for the center dispense switch or
the black and red wires for the left dispense

SE

ELEA

N R

IS 2/3 FULL, THE

P

N UNTIL CU

TTO

LD BU

H and HO

L

US

L

P

U

F

/3

ARNING

2

! W

IS

T

P

D

U

O

I

U

C

H

N

Q

I

E

L

H

E

C

A

W

E

L

N

R

P

E

O

H

T

P

T

U

U

C

B

E

S

A

E

L

E

E

C

R

A

E

L

R

P

E

H
P

U

C

E

C

A

E

L

R

P

E

H

P

U

C

switch from the door interconnect wiring har­ness. Connect the dispenser to the power supply.
The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.

P1436

5. Disconnect the dispenser from the power source.

Location:

The dispense switches are located on the lower

outside of the dispenser door.

If voltage is present as described, proceed to #6.
If voltage is not present as described, refer to the wir­ing diagram and check the dispenser wiring harness.

17

28364 071598

FAN

FIG. 10 FAN

P1436

Location:

The fan is located inside the dispenser hous-

ing on the right rear of the dispenser base plate.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the black and white wires from the
fan terminals.

3. Check the voltage across the black and white
wires with a voltmeter. Connect the dispenser to
the power source. The indication must be:
a) 120 volts ac for two wire 120 volts models.

b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.

If voltage is present as described, replace the fan
If voltage is not present as described, refer to wiring
diagram and check the dispenser wiring harness.

Removal and Replacement:

1. Disconnect the vacuum hose from the fan.

2. Remove the two #8-32 locking screws securing

the fan to the dispenser housing base plate.

3. Disconnect the wires from the fan terminals and

discard the fan

4. Refer to Fig.11 and connect the wires to the new

fan.

5. Install new fan through the rear access hole and

secure to the dispenser housing base plate using
two #8-32 locking screws.

18

SERVICE (cont.)

FAN (cont.)

6. Reconnect the vacuum hose to the fan.
BLK from Control Harness

3. Press and hold the appropriate dispense switch
and check the voltage across the disconnected
harness wires with a voltmeter. Connect the dis­penser to the power source. The reading must
be:

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

4. Disconnect the dispenser from the power source.

If voltage is present as described, replace the motor.
If voltage is not present as described, refer to the wir­ing diagrams and check the dispenser wiring harness.

WHI from Control Harness

FIG. 11 FAN TERMINALS

P1507

FROTHER AND WHIPPER MOTOR

P1450.40

FIG. 11 FROTHER AND WHIPPER MOTOR

Location:

The frothers are located behind the dispenser
door, mounted on the whipper motor shaft inside the
whipper chamber.
The whipper motors are located on the back side of
the whipper motor mounting panel.
NOTE: The center position is for FMD-3 Models only.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the white/violet and white wires on

the right motor, orange and white wires on the
center motor or the red and white wires on the
left motor from the black leads on the motors.

12
13
14
11

10 9 8 7 6 5 4 3

FIG. 12 MIXING/WHIPPER CHAMBER

COMPONENTS

1. Steam Collector

2. Mixing Chamber

3. Dispense Tip

4. Whipper Chamber

5. O-Ring

6. Frother

7. #6-32 Screw

8. Receptical w/Seal

9. Teflon Washer

19

15 16 17

1 2

P1440.35

10. O-Ring

11. #8-32 Acorn Nut

12. Motor Assy.

13. Washer

14. Nut

15. Fan

16. Vacuum Hose

17. Baffle

28364 071598

SERVICE (cont.)

FROTHER AND WHIPPER MOTOR (cont.)

Removal, Cleaning and Replacement (Refer to Fig. 12):

1. Open the dispenser door and raise the top front
cover.

2. Lift the front edge of the each hopper assembly
over the tab on the hopper support panel and
slide each hopper assembly out the front of the
dispenser. Set aside for reassembly.

3. Remove the four #8-32 screws securing the hop­per support panel to auger motor mounting panel
and the whipper motor mounting panel. Set aside
for reassembly.

4. Disconnect vacuum hose (16) from fan baffle
(17).

5. Remove the two #4-40 x .25" screws securing
the fan baffle(17) to the whipper motor mouting
panel and remove fan baffle. Set aside for reas­sembly.

6. Remove the steam collector (1) by pulling it for­ward and at the same time twisting it clockwise.

7. Pull the mixing chamber (2) out of the whipper
chamber (4).

8. Remove dispense tip (3) and twist the whipper

chamber (4) clockwise and pull it off the whipper
chamber receptacle (8).

9. Pull the frother (6) off the motor shaft. Notice the

flat side on the shaft and the matching flat inside
the frother. It is important that these two flats are
lined up when reassembling.

10. Slip the o-ring (5) off the whipper chamber

receptical (8).

11. Remove the two #6-32 screws (7) securing whip-

per chamber receptical (8) to the front panel.

12. Slide the receptical w/seal off of the motor shaft.

13. Slide teflon washer (9) and o-ring (10) off of the

motor shaft.

14. Disconnect the black leads on the motor (12) from

the main wiring harness.

15. Remove the two #8-32 acorn nuts (11) securing

the motor (12) to the rear of front panel.

16. Remove motor and discard.

17. Install new motor (12) on rear of front panel and

secure with two #8-32 acorn nuts (11) and con­nect black leads on the motor to the main wiring
harness. Refer to FDig. 13 when reconnecting
wires

18. Slide o-ring (10) onto the motor shaft to approxi-

mately 1/16" of the front panel.

19. Wash remaining components in a mild solution of
dish detergent using a bristle brush.

20. Rinse thoroughly and allow to dry before reinstall­ing in the dispenser.

21. Place teflon washer into back opening of whipper
chamber receptical and align one notch with bump
in the opening.

22. Slide whipper chamber receptacle w/seal on to the
motor shaft and secure to the front panel using two
#6-32 screws (7).

23. Slip o-ring (5) onto the whipper chamber receptical
(8).

24. Push frother (6) onto the motor shaft, making sure
the flat in the frother (6) lines up with the flat on the
motor shaft.

25. Install whipper chamber (4) on the whipper cham­ber receptical (8) by twisting counterclockwise
until the tabs on the whipper chamber (4) lock with
the tabs on the whipper chamber receptical (8). Be
sure dispense port is pointing down.

26. Install dispense tip (3) into the bottom of the
whipper chamber (4). Be sure the cutout part of
the dispense tip is facing the outside of the dis­penser.

27. Using two #4-40 screws secure the fan baffle to
the to the whipper motor mounting panel.

28. Install vacuum hose (16) on fan baffle (17).

29. Install hopper support panel using four #8-32
screws.

30. Slip the mixing chamber (2) onto the mixing
chamber water inlet tube far enough so the mixing
chamber (2) will seat inside the whipper chamber
(4).

31. Install the steam collector (1) onto the mixing
chamber (2) by pushing down and toward the
dispenser while twisting until the flange on the
steam collector lines-up with the slot in the front
panel.

32. Install hopper assembly in the dispenser by sliding
hopper assembly on the hopper support panel
until the slot in the bottom rear of the hopper seats
against the shoulder screw in the hopper support
panel.

20

28364 011598

21

SERVICE (cont.)

HOT/COLD SWITCH (Optional)

FIG. 15 HOT/COLD SWITCH

Location:

The hot/cold switch is located on the left side

of the whipper motor mounting panel.

P1452.40

If voltage is present as described, reconnect the four
pin plugs and proceed to #5.
If voltage is not present as described, refer to the
wiring diagram and check the main wiring harness.

5. Disconnect the wires from the switch termi-

nals.

6. With the switch in the upper “Cold” position check

for continuity between the center terminal and
the bottom terminal. With the switch in the down
“Hot” position check for continuity between the
center terminal and the upper terminal.

If continuity is present as described, the hot/cold
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. Remove the mounting nut on the front of the

whipper motor mounting panel.

3. Remove the hot/cold switch from the rear of the

front panel and discard.

4. Reconnect the wires to the terminals on the rear

of the new switch.

5. Push new hot/cold switch through the hole on

the left side of the whipper motor mounting panel
and secure with mounting nut.

6. Refer to Fig. 16 when reconnecting the wires.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the four pin plug from the hot/cold
switch and the four pin connector on the main
wiring harness.

3. Press the left dispense switch on the door and
check the voltage across the white wire (P4) and
red wire (P2) in the four pin connector on the main
wiring harness with a voltmeter. Connect the dis­penser to the power source. The indication must
be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.

4. Disconnect the dispenser from the power source.

22

TAN to Main Harness

RED to Main Harness

WHI/YEL to Cold
Solenoid

FIG. 16 HOT/COLD SWITCH TERMINALS

P1208

28364 011598

SERVICE (cont.)

LAMP HOLDER

1

3

5

2

6

PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEASE

FIG. 17 LAMP HOLDERS

1. Door Assy

2. Lamp Holders

3. Lamp

4. Upper Panel

5. Lower Panel

6. Starter W/Socket

Location:

The lamp holders are located on the front of

the upper panel behind the display panel.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Remove upper door panel (4) and disconnect the

door wiring harness from the leads on the lamp
holders.

3. Remove lamp from lamp holders.

4. Check for continuity on each lead of the lamp

holders.

If continuity is present as described, lamp holders are
operating properly.
If continuity is not present as described replace the
lamp holder.

4

P1454.70

Removal and Replacement:

1. Open dispenser door (1).

2. Remove the five #6-32 screws securing lower
door panel (5) to the door (1) and remove cover.

3. Disconnect the door wiring harness from the door
interconnect wiring harness.

4. Remove five #6-32 screws securing the upper
door panel (4) to the door.

5. Remove the upper door cover (4), lamp (3), lamp
holders (2) and door wiring harness as an assem­bly.

6. Disconnect the wires from the lamp holder to be
replaced from the door wiring harness.

7. Rotate lamp (3) 90° and remove from lamp hold­ers (2).

8. Remove the #6-32 screw securing the lamp holder
(2) to be removed, remove lamp holder (2) and
discard.

9. Install new lamp holder (2) and secure with a #6­32 screw.

10. Connect the wires on the new lamp holder to the
door wiring harness.

11. Install lamp (3) into lamp holders (2) and turn 90°
until the pins snap in place.

12. Install upper door panel (4), lamp (3), lamp hold­ers (2) and door wiring harness as a assembly
using five #6-32 screws.

13. Reconnect the plug on the door wiring harness to
the connector on the door interconnect wiring
harness.

14. Install the door lower panel (5) using five #6-32
screws.

LAMP REPLACEMENT (Refer to Fig. 17)

1. Remove the outside window and display graphic.

2. Remove the two #4-40 screws securing the inside
window to the door and remove window.

3. Rotate lamp (3) 90° and remove from the lamp
holders (2).

4. Insert new lamp (3) into lamp holders (2) and turn
90° until the pins snap in place.

5. Using two #4-40 screws secure the inside window
to the door.

6. Install outside window and slide display graphic
down between the inside window and the outside
window.

23

28364 011598

SERVICE (cont.)

LAMP STARTER and SOCKET

Location:

The lamp starter (6) is located inside the door

assy (1) on the top of the door lower panel (5).

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the starter leads from the door wiring
harness.

3. Remove lamp starter from starter socket.

4. Check for continuity on each lead of the starter
socket.

If continuity is present as described the starter socket
is operating properly.
If continuity is not present as described replace the the
starter socket.

6. Remove starter (6) from starter socket.

7. Check for continuity across the pins on the bottom
of the starter (6).

9. Connect the sockets leads to the door wiring
harness.

10. Install door lower panel (5) with starter and starter
socket on door assy (1) using five #6-32 screws.

LEVEL CONTROL BOARD AND LEVEL PROBE

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

Note: If continuity tests are both as described and
lamp does not light, replace the starter socket.

Removal and Replacement (Refer to Fig.17):

1. Open dispenser door assy (1)

2. Remove the five #6-32 screws securing the door
lower panel (5) to the door assy (1).

3. Disconnect the leads on the starter socket from the
door wiring harness.

4. Remove lower door panel (5) and starter w/socket
(6) as assembly.

5. Compress the spring tabs on the socket and re­move socket from the door bottom cover (5).

6. Rotate starter 90° and remove from the starter
socket.

7. Insert new starter (6) into socket and turn 90° until
the pins snap in place.

8. Install new socket by compressing spring tabs on
the socket and pushing the socket up through the
hole in the lower door panel (5) and releasing
spring tabs.

FIG. 18 LEVEL CONTROL BOARD AND PROBE

Location:

The level control board is located behind the
lower access panel mounted on the right side of the
component bracket.

The Level probe is located on the left center
of the tank lid just in front of the overflow tube.

Test Procedure:

1. Disconnect the dispenser from the power source.

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

from terminal 4 of the circuit board.

3. Check the voltage across terminals 2 & 3 with a

voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for
two wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models.

4. Disconnect the dispenser from the power source.

24

SERVICE (cont.)

LEVEL CONTROL BOARD AND LEVEL PROBE
(cont.)

If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the
wiring diagram and check the dispenser wiring haness.

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 dispenser.

7. Check the voltage across terminals 1 & 3 with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for two
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models after a delay
of approximately 5 seconds.

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

9. Move the jumper wire away from the dispenser
housing. The indication must again be 120 volts ac
for two wire 120 volt models, three wire 120/208
volt models , three wire 120/240 volt models and
240 volts ac for two wire 240 volt models after a
delay of approximately 5 seconds.

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

16. Move the probe's flat end away from the dispenser
housing. The indication should again be 120 volts
ac for two wire 120 volt models, three wire 120/
208 volt models, three wire 120/240 volt models
and 240 volt ac for two wire 240 volt models after
a delay of approximately 5 seconds.

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 for continuity.

Removal and Replacement:

1. Remove all wires from the level control board.

2. Remove two #8-32 keps nuts holding level control
board to right side of the component bracket.

3. Remove level control board and spacers.

3. Install the new level control board and spacers to
the right side of the component bracket using two
#8-32 keps nuts.

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

T1 VIO to Inlet
Solenoid Coil
T2 BLU to Overflow
Protection Switch

T3 WHI to Main
Harness

T4 PNK to Probe

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 dispenser.

14. Check the voltage across terminals 1 & 3 with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for two
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models after a delay
of approximately 5 seconds.

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

25

GRN to Tank

FIG. 19 LEVEL BOARD TERMINALS

P1455

28364 011598

SERVICE (cont.)

LIMIT THERMOSTAT

Removal and Replacement:

1. Remove all wires from the limit thermostat ter­minals.

2. Carefully slide the limit thermostat out from un­der the retaining clip and remove the limit ther­mostat.

3. Carefully slide the new limit thermostat into the
retaining clip.

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

P1800

FIG. 21 LIMIT THERMOSTAT TERMINALS

FIG. 20 LIMIT THERMOSTAT

P1445

Location:

The limit thermostat is located in the center of

the tank lid.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect both black wires from the limit ther­mostat.

3. Check for continuity across the limit thermostat
terminals.

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

26

SERVICE (cont.)

OVERFLOW PROTECTION SWITCH

Removal and Replacement:

1. Disconnect the red leads from the overflow pro­tection switch from the black wire from the main
harness and the blue wire from the liquid level
board.

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 a 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.

FIG. 22 OVERFLOW PROTECTION SWITCH

P1199

Location:

The overflow protection switch is located in­side the copper overflow cup on the left side of the
tank.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Remove the wire nuts connecting the red wires

from the overflow protection switch to the black
wire from the main harness and blue wire from the
liquid level board.

3. Check for continuity across the safety overflow

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 black wire from the main harness
and the blue wire from the liquid level board.
If continuity is not present as described, replace the
overflow protection switch.

27

SERVICE (cont.)

RINSE /RUN SWITCH

3. Remove switch with wires attached from the back
side of the whipper motor mounting panel.

4. Disconnect the wires from the switch and dis­card the switch.

5. Refer to Fig. 25 when connecting the wires to
the new switch.

6. Install new switch with wires attached through
the hole in the whipper motor mounting panel
and secure with facenut.

BLK to Main
Wiring Harness

BLK from
Hopper Delay
Board #4

FIG. 24 RINSE/RUN SWITCH

P1452.40

Location:

The rinse/run switch is located on the right

side of the whipper motor mounting panel.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Check for continuity between center terminal and
the upper terminal with the switch in the “RUN”
lower position. Continuity must not be present
with the switch in the “RINSE” upper position.

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

P1456

FIG. 25 RINSE/RUN SWITCH TERMINALS

Removal and Replacement:

1. Open the dispenser door.

2. Remove the facenut securing the run/rinse switch
to the whipper motor mounting panel.

28

28364 011598

SERVICE (cont.)

SOLENOID VALVE (COLD WATER - OPTIONAL)

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

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

If continuity is present as described, reconnect the
white and white/yellow wires to the solenoid.

If continuity is not present as described, replace the
solenoid valve.

6. Check the solenoid valve for coil action. Connect
the dispenser to the power source. With "HOT/
COLD" switch in the "COLD" upper position press
the left dispense switch and listen carefully in the
vicinity of the solenoid valve for a "clicking" sound
as the coil magnet attracts.

7. Disconnect the dispenser from the power source.

If the sound is heard as described and water will not
pass through the solenoid valve, there may be a block­age in the water line before the solenoid valve or, the
solenoid valve may require inspection for wear, and
removal of waterborne particles.

P1445.40

FIG. 26 COLD WATER SOLENOID VALVE

Location:

The cold water solenoid valve is located on
the left side of the dispenser base just behind the com­ponent bracket.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the white and white/yellow wires

from the solenoid valve. With the “HOT/COLD”
switch in the "COLD" upper position press the left
dispense switch on front of the door.

3. Check the voltage across the white and white/

yellow wires with a voltmeter. Connect the dis­penser to the power source. The indication must
be 120 volts ac for two wire 120 volt models,
three wire 120/208, 120/240 volt models and 240
volts ac for two wire 240 volt models.

4. Disconnect the dispenser from the power source.

If voltage is present as described, proceed to #5

If the sound is not heard as described, replace the
solenoid valve.

Removal and Replacement:

1. Loosen the two screws securing the component
bracket to the dispenser base. Lift the compo­nent bracket off of the base and move to the right.

1. Remove the white and white/yellow wires from
the solenoid valve.

2. Turn-off the water supply to the dispenser.

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

4. Loosen the two #8-32 screws and washers se­curing the solenoid mounting bracket to the base.
Remove solenoid bracket and solenoid valve as
an assembly.

5. Remove the two #10-32 screws and lockwashers
securing the solenoid valve to the solenoid
bracket.

6. Using two #10-32 screws and lockwashers in­stall new solenoid valve on solenoid mounting
bracket.

7. Install the solenoid valve and bracket on the dis­penser base and tighten the two #8-32 screws.

29

SERVICE (cont.)

SOLENOID VALVE (COLD WATER - OPTIONAL) (cont.)

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

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

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the white and white/violet, orange or
tan wires from the solenoid valve. With the “RUN/
RINSE” switch in the "RINSE" upper position
press the appropriate dispense switch on front of
the door.

3. Check the voltage across the white and white/
violet, orange or tan wires with a voltmeter.
Connect the dispenser to the power source. The
indication must be 120 volts ac for two wire 120
volt models, three wire 120/208, 120/240 volt
models and 240 volts ac for two wire 240 volt
models.

4. Disconnect the dispenser from the power source,

FIG. 27 COLD WATER SOLENOID TERMINALS

SOLENOID VALVES (DISPENSE)

P1215

If voltage is present as described, proceed to #5
If voltage is not present as described, refer to wiring
diagram and check dispenser wiring harness.

5. Check for continuity across the solenoid valve

coil terminals.

If continuity is present as described, reconnect the
white and white/violet, orange or tan wires to the so­lenoid.

If continuity is not present as described, replace the
solenoid valve.

6. Check the solenoid valve for coil action. Connect

the dispenser to the power source. With "RUN/
RINSE" switch in the "RINSE" upper position press
the appropriate dispense switch and listen care­fully in the vicinity of the solenoid valve for a "click­ing" sound as the coil magnet attracts.

7. Disconnect the dispenser from the power source.

FIG. 28 DISPENSE SOLENOID VALVES

Location:

The dispense solenoids are located on the

upper left side of the tank.

P1445.40

If the sound is heard as described and water will not
pass through the solenoid valve, there may be a block­age in the tank water outlet before the solenoid valve
or, the solenoid valve may require inspection for wear,
and removal of waterborne particles.

If the sound is not heard as described, replace the
solenoid valve.

Removal and Replacement:

1. Remove the white and white/violet,orange or tan

wires from the solenoid valve.

2. Turn-off the water supply to the dispenser.

30

SERVICE (cont.)

SOLENOID VALVES (DISPENSE) (cont.)

3. Drain enough water from the tank (approximately

1.0 gallon) so the water level is below the dispense

valve mounting hole.
NOTE: Bunn-O-Matic has a syphon assembly,
#12440.0000. available for this purpose.

4. Disconnect the water line from the solenoid valve.

5. Remove the #10-32 screw securing the solenoid

valve to side of the tank. Remove solenoid valve.

6. Using the #10-32 screw install new solenoid valve

on side of the tank

7. Push the water line onto the tube on bottom of

solenoid valve.

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

FMD-2 & 3

TAN to Jumper Plug
or to Cold Switch
WHI to Main
Harness

ORN to Auger Motor

WHI to Main Harness

WHI/VIO to Auger Motor
WHI to Main Harness

FIG. 29 DISPENSE SOLENOID VALVE

TERMINALS

FMD-3 ONLY

FMD-2 & 3

P1453.90

SOLENOID VALVE (INLET)

P1445.40

FIG. 30 INLET SOLENOID VALVE

Location:

The inlet solenoid is located inside on the left

rear of the dispenser housing.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the white and violet wires from the
solenoid valve.

3. Check the voltage across the white and violet
wires with a voltmeter. Connect the dispenser to
the power source. The indication must be 120
volts ac for two wire 120 volt models, three wire
120/208, 120/240 volt models and 240 volts ac
for two wire 240 volt models.

4. Disconnect the dispenser from the power source,

If voltage is present as described, proceed to #5
If voltage is not present as described, refer to the
wiring diagram and check dispenser wiring harness.

5. Check for continuity across the solenoid valve

coil terminals.

If continuity is present as described, reconnect the
white and violet wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.

6. Check the solenoid valve for coil action. Connect

the dispenser to the power source. Listen care-

31

28364 011598

SERVICE (cont.)

SOLENOID VALVE (INLET) (cont.)

fully in the vicinity of the solenoid valve for a
"clicking" sound as the coil magnet attracts.

7. Disconnect the dispenser from the power source.

If the sound is heard as described and water will not
pass through the solenoid valve, there may be a block-
age in the water line before the solenoid valve or, the
solenoid valve may require inspection for wear, and
removal of waterborne particles.
If the sound is not heard as described, replace the
solenoid valve.

Removal and Replacement:

1. Remove the white and violet wires from the so-
lenoid valve.

2. Turn-off the water supply to the dispenser.

3. Disconnect the water lines to and from the sole-
noid valve.

4. Loosen the two #8-32 screws securing the sole-
noid to the rear dispenser housing. Remove so-
lenoid.

5. Remove the two #8-32 U-Type fasteners from the
solenoid bracket.

6. Install the two #8-32 U-Type fasteners and the
two #8-32 screws on the new solenoid.

5. Install new solenoid valve on rear of dispenser
housing and tighten the two screws.

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

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

TANK HEATER

FIG. 32 TANK HEATER

P1445.40

Location:

The tank heater is located inside the tank and

secured to the tank lid.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Check the voltage across the black and white wires
120 volt or 240 volt models or black and red wires
for 120/208 volt models or 120/240 volt models
with a voltmeter. Connect the dispenser to the
power source. The indication must be:
a) 120 volts ac for two wire 120 volt models;
b) 208 volts ac for three wire 120/208 volt models.
c) 240 volts ac for three wire 120/240 volt models
and two wire 240 volt models.

3. Disconnect the dispenser from the power source.

FIG. 31 INLET SOLENOID VALVE TERMINALS

P1217

If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the
dispenser wiring diagram and check the wiring har­ness.

4. Disconnect the black wire and the white or red
wire from the tank heater terminals.

32

SERVICE (cont.)

TANK HEATER (cont.)

5. Check for continuity across the tank heater termi­nals.

If continuity is present as described, reconnect the
wires, 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 heater for cracks in the sheath.

Removal and Replacement:

1. Shut-off water supply to the dispenser.

2. Disconnect the water supply tube on the tank lid.

3. Disconnect the black wires on the limit thermo­stat.

4. Disconnect the black wire and the white or red wire
from the tank heater terminals.

5. Disconnect the pink wire from the liquid level
probe.

6. Disconnect the green wire from the tank.

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

8. Remove the ten #8-32 nuts securing the tank lid to
the tank.

9. Remove tank lid with limit thermostat, liquid level
probe and tank heater as an assembly.

10. Remove the two hex nuts securing the tank heater
to the tank lid. Remove tank heater with gaskets
and discard.

11. Install new tank heater with gaskets on the tank lid
and secure with two hex nuts.

12. Install tank lid with limit thermostat, liquid level
probe and tank heater on the tank and secure with
ten #8-32 hex nuts.

13. Connect water inlet line to the tank lid.

14. Reconnect the black wires to limit thermostat, the
pink wire to the liquid level probe and the green
wire to the tank. Refer to the limit thermostat and
the liquid level board and probe sections in this
manual when reconnecting wires.

15. Refer to Fig. 33 when reconnecting the wires to the
tank heater.

WHI or RED to
Main Wiring

BLK to Limit
Thermostat

Harness

FIG. 33 TANK HEATER TERMINALS

P1218

TANK HEATER SWITCH

FIG. 34 TANK HEATER SWITCH

P1452.40

Location:

The tank heater switch located inside the dis­penser on the upper right of the whipper motor mount­ing panel.

33

28364 011598

SERVICE (cont.)

TANK HEATER SWITCH (cont.)

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the black wire from the power supply
and the black wire from the control thermostat.

3. With the switch in the “ON” lower position check
for continuity between the center and the upper
terminal. With the switch in the “OFF” upper posi­tion no continuity should be present between
center and upper terminals.

If continuity is present as described, the heater “ON/
OFF” switch is operating properly.
If continuity is not present as described, replace the
switch.

Removal and Replacement:

1. Refer to the hopper section in this manual and
remove the hopper assemblies and the hopper
support plate.

2. Remove the switch mounting nut on the front of
the front panel.

3. Remove switch with wires attached from the rear
of the front panel.

4. Remove the wires from the switch terminals and
discard switch.

5. Connect the wires to the new switch, refer to fig.

35.

5. Push new switch through hole in the front panel
and secure with face nut.

7. Refer to the hopper section in this manual and
install the hopper support plate and the hopper
assemblies.

BLK to Control Thermostat
(Mechanical Thermostat)
WHI/BRN to Control Thermostat
(Electronic Thermostat)

BLK from Power Supply
(Mechanical Thermostat)
WHI/BRN to Control Thermostat
(Electronic Thermostat)

FIG. 35 TANK HEATER SWITCH TERMINALS

P1219

34

28364 071598

SCHEMATIC WIRING DIAGRAM FMD-1, FMD-2, & FMD-3

L1

ELECTROMECHANICAL THERMOSTAT CONFIGURATION

HEATER SW.

BLK-16

BLK-16

THERMOSTAT

BLK-16

LIMIT

THERMOSTAT

GRN

BLK-16

TANK HEATER

NL2

RED-16 (3-WIRE MODELS)
WHI-16 (2-WIRE MODELS)

ELECTRONIC THERMOSTAT CONFIGURATION

HEATER SW

WHI/BRN

TAN

BLK-16

One Configuration MUST be used!

ELECTRONIC

THERMOSTAT

BLK

RUN/RINSE SWITCH

BLK

BLK

FMD-1 Components

ASSY.

WHI/VIO

WHI/VIO

ORA

WHI/BRN

TAN

ORA
GRY

BLK

RED
GRY
GRY
WHI

BLK-16

WHI

1
2
3
4
5
6
7
8

BLU

WHI/RED

WHI/VIO

ORA

TAN

HOPPER

DELAY

DISPENSE

RIGHT DISPENSE

CENTER DISPENSE

LEFT DISPENSE

BLK-16

WHI

BLK

BLK

FLUORESCENT

BLK

WHI

SOL

WHI

SOL

SOL

SOL

LAMP

BALLAST

WHI WHI REDWHI/RED

WHI

WHI

BLK-16

OVERFLOW SWITCH

RED

BLK

WHI

WHI

RED

BLK

WHIPPER

RIGHT WHIPPER

CENTER WHIPPER

LEFT WHIPPER

RED

M

M

M

M

TANK HEATER

GRN

LIQUID
LEVEL

BOARD

FAN

WHI

WHI

WHI

ORAORAORA

RED

WHI

RED-16 (3-WIRE MODELS)
WHI-16 (2-WIRE MODELS)

PROBE

VIO

1

BLU

2

3

PNK

4

HOPPER

M

RIGHT HOPPER

WHI/VIOWHI/VIOWHI/VIO WHI

M

CENTER HOPPER

M

LEFT HOPPER

M

TANK INLET

SOL

WHI WHI

GRY

GRY

GRY

GRY

WHI

WHI

WHI

WHI

WHI

WHI

FMD-2 & FMD-3 Components

CHASSIS

(CENTER COMPONENTS ELIMINATED ON FMD-2)

141

GRN

120 VOLTS A C - 2 WIRE OR

120/208-240 VOLTS AC - 3WIRE

SINGLE PHASE, 60 HZ

28341.0000G 7/98 © 1997 BUNN-O-MATIC CORPORATION

COLD DRINK OPTION (LEFT ONLY)

4

WHI

TAN
RED
RED

WHI
TAN
RED
RED

1

DISPENSE SWITCH

(RIGHT, MODELS FMD-2 & FMD-3)

DISPENSE SWITCH

(CENTER, MODEL FMD-3 ONLY)

DISPENSE SWITCH

(LEFT, MODELS FMD-2 & FMD-3)

(ALSO FMD-1 SWITCH)

HOT/COLD SWITCH

35

SOL

WHI/YEL

WHI
BLU

RED/WHI
RED/BLK

BLK

RED
BLK

RED/BLK

BLK

RED/WHI

BLK

RED

DOOR

JUMPER PLUG MUST BE

RED

USED WHEN COLD

RED

DRINK FEATURE NOT

RED

BLU
BLU

1

RED

RED

INSTALLED

BLK
BLK

STARTER

BLK

BLK

WHI

WHI

28364 071598

SCHEMATIC WIRING DIAGRAM FMDA-1, FMDA-2, & FMDA-3

L1

HEATER SW.

BLK-16

BLK

BLK

FMD-1 Components

BLK-16

THERMOSTAT

RUN/RINSE SWITCH

BLK

WHI/VIO

WHI/VIO

ORA

ORA
GRY

BLK
RED

GRY

GRY
WHI

BLK-16

1

HOPPER

2
3
4
5
6
7
8

BLU

WHI/RED

WHI/VIO

ORA

TAN

DELAY

WHI

DISPENSE

SOL

WHI

RIGHT DISPENSE

SOL

CENTER DISPENSE

SOL

LEFT DISPENSE

SOL

LIMIT

THERMOSTAT

BLK

BLK

FLUORESCENT

LAMP

BALLAST

BLK

WHI WHI REDWHI/RED

WHI

WHI

GRN

TANK HEATER

BLK-16

OVERFLOW SWITCH

RED

BLK

WHI

WHI

RED

BLK

WHIPPER

RIGHT WHIPPER

CENTER WHIPPER

LEFT WHIPPER

RED

L2

TANK INLET

SOL

WHI - 16

WHI

WHI

WHI

GRN

LIQUID
LEVEL

BOARD

FAN

3
4

1
2

PROBE

VIO

BLU

PNK

WHI

WHI WHI

HOPPER

M

WHI/VIOWHI/VIOWHI/VIO WHI

WHI

M

WHI

WHI

ORAORAORA

RED

M

M

M

RIGHT HOPPER

M

CENTER HOPPER

M

LEFT HOPPER

M

WHI

GRY

WHI

GRY

GRY

GRY

FMD-2 & FMD-3 Components

CHASSIS

(CENTER COMPONENTS ELIMINATED ON FMD-2)

141

GRN

240 VOLTS A C - 2 WIRE

SINGLE PHASE, 50 HZ

28341.0001E 6/98 © 1997 BUNN-O-MATIC CORPORATION

COLD DRINK OPTION (LEFT ONLY)

WHI
TAN

RED
RED

WHI

4

TAN
RED
RED

1

DISPENSE SWITCH

(RIGHT, MODELS FMD-2 & FMD-3)

DISPENSE SWITCH

(CENTER, MODEL FMD-3 ONLY)

DISPENSE SWITCH

(LEFT, MODELS FMD-2 & FMD-3)

(ALSO FMD-1 SWITCH)

HOT/COLD SWITCH

36

SOL

WHI/YEL

WHI
BLU

RED

BLK
RED/WHI
RED/BLK

BLK

RED/BLK

RED/WHI

BLK

BLK

RED

DOOR

JUMPER PLUG MUST BE

RED
RED
RED

BLU
BLU

1

USED WHEN COLD

DRINK FEATURE NOT

INSTALLED

RED

BLK

STARTER

BLK

RED

WHI
BLK

BLK
WHI

28364 011598