Bunn FMD-5, FMD-4 User Manual

®
BUNN
FMD-4
RINSE
E
RINSE
CUP HERE
RELEASE BUTT
PLACE
CUP HERE
WARNING
!
H O T
L I Q U I D
ON WHEN CUP IS 2/3 FULL
PLACE
CUP HERE
PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEAS
RINSE
RINSE
PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEASE
WARNING
!
H O T
Q U I D
L I
ON WHEN CUP IS 2/3 FULL
RELEASE BUTT
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
35135.0000 03/03 ©2003 Bunn-O-Matic Corporation
www.bunnomatic.com
INTRODUCTION
This equipment dispenses hot beverages or soups on demand from powdered product. 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 (217) 529-6601 or by writing to Post Office Box 3227, Springfield, Illinois 62708-3227; 2) if requested by BUNN, shipping the defective equipment prepaid to an authorized BUNN service location; and 3) receiving prior authorization from BUNN that the defective equipment is under warranty.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of BUNN are not authorized to make modifications to this warranty or to
make additional warranties that are binding on BUNN. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon.
If BUNN determines in its sole discretion that the equipment does not conform to the warranty, BUNN, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the applicable parts and labor warranty periods specified above) to repair the defective components, provided that this repair is done by a BUNN Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for the equipment.
THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AT BUNN’S SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND.
In no event shall BUNN be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.
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.
!
WARNING
H O T
RELEASE BUTTON WHEN CUP IS 2/3 FULL
L I Q U I D
FMD-4 28328.0008
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
CUP HERE
PLACE
CUP HERE
FMD-5 28328.0009
2
35135 012103
USER NOTICES (Cont.)
00831.0000
00656.0000
28368.0000
FMD-4 28964.0004
FMD-5 28964.0003
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35135 012103
INITIAL SET-UP
1. Locate the drip tray assembly inside the dispenser door.
2. Remove the drip tray and the drip tray cover and set them aside.
ELECTRICAL REQUIREMENTS
CAUTION - The dispenser must be disconnected from the power source until specified in
The 120 volt version of this dispenser has an attached cordset and requires 2-wire, grounded service rated 120 volts ac, 15 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-15R.
The 120/208 and the 120/240 versions of this dispenser has an attched cordset. The mating connector must be a NEMA 14-20R.
(
Refer to the dispenser’s dataplate for exact voltage requirement.)
Initial Set-Up.
ELECTRICAL HOOK-UP
CAUTION – Improper electrical installation will damage electronic components.
1. An electrician must provide electrical service as specified.
2. Using a voltmeter, check the voltage and color coding of each conductor at the electrical source.
3. 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 100 psi (138 and 690 kPa). This water source must be capable of producing a minimum flow rate of 4.5 fluid ounces (133.1 ml) 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 water inlet fitting
is 3⁄8" flare.
NOTE - 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 00327-0000). 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).
PLUMBING HOOK-UP
1. Flush the water line and securely attach it to the flare fitting on the bottom of the dispenser.
2. Turn-on the water supply.
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35135 012103
INITIAL FILL & HEAT
CAUTION - The dispenser must be disconnected from the power source throughout the initial set-up, 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 eighty minutes for the water to heat on 120 volt versions or forty minutes for 120/208 volt versions and 120/240 volt versions.
During this waiting period, complete these dispenser set-up steps: a. Place the drip tray in front of the dispenser. Set the drip tray cover in place. b. Place a set of keyholes in the cup locator plate over the screws beneath the hopper access door and push down
gently.
c. Fill the hoppers with the dry product to be dispensed.
LIQUID LEVEL CONTROL
The system automatically maintains the hot water tank’s level by energizing the refill solenoid when the water
level drops below the liquid level probe. If the system has not successfully refilled in 15 minutes, a refill error occurs. When a refill error occurs, the refill solenoid is de-energized and the left rinse L.E.D. will flash about once every 5 seconds. Once the cause of the refill error has been investigated (see the troubleshooting guide in the Operating and Service Manual) and cured, the system can be reset by placing the Rinse/Run switch in the programming (center) position, momentarily.
RINSE TIMERS
The dispenser is shipped from the factory with the rinse timers disabled. To enable the rinse timers, remove
power from the dispenser, remove the lower access panel, and remove the jumper from J1 of the control boards. Replace the lower access panel, and return power to the dispenser. When enabled, the rinse timers automatically keep track of the time since the dispenser was last run through a rinse sequence. If the dispenser detects that a rinse sequence has not been run for 8 hours, the appropriate rinse L.E.D. will flash continually. If, after an additional 4 hours (12 hours total), a rinse sequence has still not been run, the appropriate rinse L.E.D. will light continuously, and the appropriate hopper drives will be disabled until a rinse sequence has been run.
RUNNING A RINSE SEQUENCE
1. Place the rinse/run switch in the rinse position.
2. Sequentially, or simultaneously, at each of the positions dispense for at least 10 seconds.
3. After the rinse L.E.D. has extinguished, the rinse timer is reset.
4. Return the rinse/run switch to the run position.
DISPENSER USE
1. Simply place a cup on the drip tray beneath the dispensing tip.
2. Press the button and dispense the beverage.
3. Release the button when the cup is approximately 2/3 full and allow the whipper chamber to drain.
NOTE - The whipper chamber must drain at the end of each dispense.
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35135 012103
COLD BEVERAGE SET-UP (OPTIONAL)
Cold beverages may be dispensed from the left dispense position. Simply place the HOT/COLD switch near the left whipper chamber in the “COLD” (upper) position.
CLEANING
Refer to the decal on the rear of the dispenser door for cleaning recommendations and proccedures.
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 beverage solenoid is preset to dispense approximately 9/10 ounce per second. This amount can be adjusted:
1. Disconnect the dispenser from the power source.
2. Remove product hopper(s).
3. Remove the hole plug(s) in the auger motor mounting panel.
4. Rotate the control at the base of the solenoid clockwise to decrease or counterclockwise to increase the amount of water.
5. Reinstall plug(s) and hopper(s).
HOPPER MOTOR SPEED PROGRAMING
The hopper dispense rate is preset at the factory. With 22 tooth gear and auger wire the preset dispense rate is approximately 3 to 5 grams per second. With 30 tooth gear and auger wire the preset dispense rate is approximately 5 to 7 grams per second. The hopper dispense rate can be adjusted to produce a wide range of dispense rates as follows:
1. Place the rinse/run switch in the center (program) position.
2. Place the increase/decrease switch in the desired (increase or decrease) position.
3. Press and release the dispense switch for the chamber you wish to adjust. Each time the dispense switch is pressed, the rinse L.E.D. will flash, and the motor speed for that hopper will be increased/decreased by approximately 2 1/2%.
4. Return the rinse/run switch to the run position after hopper motor speed adjustments are complete.
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35135 012103
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. Place the tank heater switch in the “OFF” position.
3. Shut-off and disconnect the incoming water supply.
4. Remove the front, lower access panel.
5. Pull out drain tube to empty into a sink or a container with a minimum of 6-1/2 gallon capacity.
6. Make sure drain clamp is closed. Then, remove drain plug.
7. Direct tube into sink or container and open drain clamp. Continue draining tank until ALL of the water is out. WARNING: Be very careful with the draining water because it can be very hot.
8. Close drain clamp, insert drain plug, place drain tube back into machine, and replace lower access panel. NOTE - The dispenser must be refilled using the source.
INITIAL FILL & HEAT
steps before reconnecting to the power
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35135 012103
TROUBLESHOOTING
A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic Technical Service Department.
Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel.
All electronic components have 120 volt ac and low voltage dc potential on their terminals. Shorting of terminals or the application of external voltages may result in board failure.
Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If an intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a terminal or crimp.
Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are energized for more than ten minutes without a supply of water.
The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened. This will help to avoid twists and kinks in the tubing.
Make certain that all plumbing connections are sealed and electrical connections tight and isolated.
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
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 dispensers. (A2) Check for 120 volts across the red and white wires and the black and white wires, 208 volts across the red and black wires on three wire 120/208 volt dispensers and 240 volts across the red and black wires on three wire 120/240 volt dispens­ers.
(B) Check circuit breakers or fuses.
Refer to
Service
- Dispense Switch
for testing procedure. See page 23
4. Dispense Solenoid Valve
8
Refer to
Service
- Dispense Solenoid Valve for testing procedures. See page 35
35135 012103
TROUBLESHOOTING (cont.)
PROBLEM
Product will not dispense (cont.)
PROBABLE CAUSE
5. Solenoid Valve (Inlet)
REMEDY
Refer to
Service
- Solenoid Valve (Inlet) for testing procedures. See page 37
6. Control Board #1 and Probe
7. Auger Drive
8. Water Strainer
9. 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.
10. Transformer
Refer to
Service
- Control Board and Probe for testing procedures. See page 20
Refer to
Service
- Auger Drive. See
page 13 & 15
Remove the strainer and check for obstructions. Clear or replace.
Inspect the tank assembly for exces­sive lime deposits. Delime as re­quired.
Refer to
Service
- Transformer for
testing procedures. See page 41
Water is not hot
1. Limit Thermostat CAUTION - Do not eliminate or by­pass limit thermostat. Use only BOM replacement part #29329.1000
2. Control Thermostat
3. Tank Heater
Refer to
Service
- Limit Thermostat
for testing procedures. See page 31
Refer to
Service
- Control Thermo­stat for testing procedures. See page 19
Refer to
Service
- Tank Heater for
testing procedures. See page 38
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35135 012103
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Water is not hot (Cont.)
Spitting or excessive steaming
4. Tank Heater Switch
5. Relay (120V versions only)
6. Control Board #2 (120V versions only)
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 Switch
for testing procedures. See page 39
Refer to
Service
- Relay for testing
procedures. See page 40
Refer to
Service
- Control Board #2
for testing procedures. See page 22
Inspect the tank assembly for exces­sive lime deposits. Delime as re­quired.
Refer to
Service
- Control Thermo­stat for testing procedures. See page 19
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
1. Control Board #1 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 35
Refer to
Service -
Control Board and Probe for testing procedures. See page 20
Refer to
Service
- Solenoid Valve (Inlet) for testing procedures. See page 37
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35135 012103
TROUBLESHOOTING (cont.) PROBLEM
PROBABLE CAUSE
REMEDY
Product overflows container
Weak product
1. Dispense Switch
2. Dispense Solenoid Valve
1. Water Temperature
2. Whipper Motor
3. Frother
Refer to
Service -
Dispense Switch
for testing procedures. See page 23
Remove the solenoid valve and clear any obstructions. Rebuild or replace the valve if necessary. See page 35
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. Reading should be 180°F to 200°F (see ther­mostat temperature settings decal in
USER NOTICES
Refer to
Service
on page 3.)
- Whipper Motor for
testing procedure. See page 27
Refer to
Service
- Frother Compo-
nents. See page 26
4. Dispense Solenoid Valve
5. Auger Drive
6. Auger Spring
7. Auger Motor
8. Rinse/Run Switch
9. Rinse Timer
10. Relay (120V versions only)
Refer to
Service
- Dispense Solenoid Valve for test procedures. See page 35
Refer to
Service
- Auger Drive Com-
ponents. See page 13 & 15
Refer to
Service
- Auger Drive Com-
ponents. See page 13 & 15
Refer to
Service
- Auger Drive Com-
ponents. See page 13 & 15
Refer to
Service -
Rinse/Run Switch
for test procedures. See page 32
Refer to
Operation
- Rinse Timer.
See Page 5
Refer to
Service
- Relay for testing
procedures. See page 40
11. Control Board #2 (120V versions only)
11
Refer to
Service
- Control Board #2
for testing procedures. See page 22
35135 012103
TROUBLESHOOTING (CONT.)
PROBLEM
Dispenser is making unusual noises
Excess dust
Display not lit
PROBABLE CAUSE
1. Plumbing Lines
2. Water Supply
3. Tank Heater
1. Fan
1. Lamp
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 100 psi (690 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 38
Refer to
Service
- Fan for testing
procedures. See page 25
Refer to
Service
- Lamp, see page 29
for lamp replacement.
2. Lamp Holder
3. Starter - Lamp
4. Ballast
Refer to
Service
- Lamp Holder for
testing procedures. See page 29
Refer to
Service
- Starter for testing
procedures. See page 30
Refer to
Service
- Ballast for testing
procedures. See page 18
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35135 012103
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, hopper(s), hopper support plate, splash guard, splash panel w/drip tray, lower front access panel and rear access cover.
Refer to the contents listing for component loca­tion.
Auger Drive Components (FMD-4) ....................... 13
Auger Drive Components (FMD-5) ....................... 15
Ballast ...................................................................18
Control Thermostat............................................... 19
Control Board ....................................................... 20
Dispense Switch ...................................................23
Fan........................................................................ 25
Frother ..................................................................26
Increase/Decrease Switch..................................... 28
Lamp Holder .........................................................29
Lamp .................................................................... 29
Lamp Starter and Socket ......................................30
Limit Thermostat .................................................. 31
Rinse/Run Switch .................................................32
Hot/Cold Switch-Optional ..................................... 33
Solenoid (Cold Water - Optional) .......................... 34
Solenoid (Dispense) ............................................. 35
Solenoid (Inlet) ..................................................... 37
Tank Heater ........................................................... 38
Tank Heater Switch ............................................... 39
Tank Heater Relay ................................................. 40
Transformer ..........................................................41
Whipper Motor ..................................................... 27
Wiring Diagram .............................................. 42-45
for assistance in determining the
Contents
AUGER DRIVE COMPONENTS FMD-4
J1
J2
J4
J3
J1
J2
J4
J3
FIG. 1 AUGER DRIVE COMPONENTS
Location
The auger components are located inside the bottom part of the hopper except for the auger drive bracket, spacer and retaining clip, which are located on the outside rear of the hopper base. The auger motor is located on the lower right rear of the motor mounting panel. Refer to Fig. 2 for disassembly and assembly.
Test Procedures - Auger Motor
1. Disconnect the dispenser from the power source.
2. Disconnect the white/red wire and the white wire
from the hopper speed control board.
3. Check the voltage across the white/red wire and
the white wire with a voltmeter. With the rinse/ run switch in the run (lower) position, 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.
4. Disconnect the dispenser from the power sup-
ply.
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 harness.
13
P2635
35135 012103
SERVICE
AUGER DRIVE COMPONENTS - FMD-4 (CONT.)
5. Check the voltage across the positive (red wire) terminal and the negative (black wire) terminal on the auger motor with a voltmeter. With the rinse/ run switch in the run (lower) position press and hold the dispense switch. Connect the dispenser to the power supply. After a .6 second delay the indication must be 4.0 to 24.5 volts dc.
If voltage is present as described, the auger motor drive is operating properly. If auger does not turn, replace the auger motor. If voltage is not present as described, replace the auger hopper drive board.
Removal, Cleaning and Replacement Hopper & Auger
1. Open the dispenser door and raise the top front cover.
2. Lift the hopper assy (15) over the pins on hopper support plate (11) 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 retainer clip (10) and washer (9) from the bottom of the hopper base (8).
6. Remove whipper shaft (3), wiper blade (4) and wiper drive gear (5) from the hopper base (8).
7. Remove auger wire (13) by pulling it out the front of the hopper base (8).
8. Remove auger drive bracket (6) by unscrewing left hand threads from auger drive shaft (12).
9. Slide spacer (7) and auger drive shaft bracket (6) off of the auger drive shaft (12).
10. Remove auger drive shaft (12) from hopper base (8).
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 assembly.
14. Install hopper assy (15) in the dispenser by sliding hopper assy on the hopper support plate (11) until the slot in the rear of the hopper base (8) seats against the pins in the hopper support plate (11).
1
2
3 4
6
5 12 13
7
14
8 9 10
15
16 17 18 19 11
FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY
1. Hopper Lid
2. Hopper
3. Wiper Shaft
4. Wiper Blade
5. Wiper Drive Gear
6. Auger Drive Bracket
7. Spacer
8. Hopper Base
9. Washer
10. Retainer Clip
11. Hopper Support Plate
12. Auger Drive Shaft
13. Auger Wire
14. Ejector Elbow
15. Hopper Assembly
16. Auger Motor Bracket
17. Auger Motor
18. Dust Seal
19. Auger Motor Mounting panel
P2633
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35135 012103
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