Bunn FMD-5, FMD-4 User Manual

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BUNN

FMD-4

FMD-5

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

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

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

35135 012103

USER NOTICES (Cont.)

00831.0000

00656.0000

28368.0000

FMD-4 28964.0004

FMD-5 28964.0003

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.

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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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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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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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

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

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

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

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)

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

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

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.

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).

3 4

5 12 13

8 9 10

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

35135 012103

SERVICE (cont.)

AUGER DRIVE COMPONENTS - FMD-4 (cont.)

Auger Drive Motor (Refer to Fig. 2)

1. Remove hopper assy (15), and set aside for reassembly.

2. Remove the four #8-32 screws securing the hopper support plate (11), remove plate and set aside for reassembly.

3. Remove the four #8-32 screws, located inside the dispenser housing on the lower right front of the auger motor mounting panel (19), securing auger motor mounting bracket (16) and auger motor (17) to the rear of the auger motor mounting panel (19).

4. Disconnect the wires from the hopper drive board.

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. Disconnect the wires from the auger motor (17).

8. Remove the four #8-32 screws securing the auger motor (17) to the auger motor mounting bracket (16).

9. Remove auger motor (17) and discard.

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

11. Install dust seal (18) on auger motor shaft and align notch in seal with motor casting.

12. Reconnect the wires to the terminals on the hopper drive board.

13. Refer to Fig. 3 when reconnecting wires.

14. Using four #8-32 locking screws install auger motor, dust seal and mounting bracket to the rear of the auger motor mounting panel (19).

15. Install hopper assy (15).

STATIONS 1 - 4

RED to BRN/WHI from Control Board #1 J3-3 RED to WHI/RED from Control Board #1 J3-2 RED to WHI/ORN from Control Board #1 J3-1 RED to WHI/YEL from Control Board #2 J3-3

BLK to GRN from Control Board J3-4

P1639

FIG. 3 AUGER MOTOR TERMINALS

AUGER DRIVE COMPONENTS - FMD-4 & FMD-5

FIG. 4 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. 5 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 positive (white/or-

ange) wire for the right motor, or the positive

(white/red) wire for the left motor and the negative

(green) wire with a voltmeter. With the rinse/run

switch in the run (lower) position press and hold

the appropriate dispense switch. Connect the dis-

penser to the power supply. After a .6 second

delay the indication must be 4.0 to 24.5 volts dc.

P2635

35135 012103

SERVICE (cont.)

AUGER DRIVE COMPONENTS - FMD-4 & FMD-5 (cont.)

4. Disconnect the dispenser from the power supply.

1 2

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

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 (20) over the tab on hopper support plate (19) and slide hopper assembly out the front of the dispenser.

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

4. Pull off the ejector elbow (13).

5. Remove agitator 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.

14. Install hopper assy (20) in the dispenser by sliding

hopper assy in the guides on the hopper support plate (19) until the slot in the bottom rear the hopper seats against the pin (18) in the hopper support plate.

14 15 16 12 13

FIG. 5 AUGER DRIVE & HOPPER DISASSEMBLY

1. Hopper Lid

2. Mixing Blade

3. Agitator Disk

4. Auger Drive Shaft Bushing

5. Auger Drive Shaft

6. Locknut

7. Auger Drive Bracket

8. Hopper

9. Auger Wire

10. Ejector Elbow

11. Hopper Assy

12. Auger Motor Mounting Panel

13. Hopper Support Plate

14. Auger Motor Bracket

15. Auger Motor

16. Dust Seal

P2634

35135 012103

SERVICE (cont.)

AUGER DRIVE COMPONENTS - FMD-4 & FMD-5 (cont.)

STATIONS 1 - 5

Auger Drive Motor (Refer to Fig. 5)

1. Remove all hopper assemblies (20) and set aside for reassembly.

2. Remove the four #8-32 screws securing the hopper support plate (19), 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 (14), securing auger motor mounting bracket (15) and auger motor (16) to the rear of the auger motor mounting panel (14).

4. Disconnect the wires from the auger motor (16) to be removed.

5. Remove auger motor mounting bracket (15), auger motor (16) and dust seal (17) as an assembly.

6. Remove dust seal (17) from auger motor (16).

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 screws install new auger motor (16) on mounting bracket (15).

10. Install dust seal (17) 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 (14)

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

13. Install hopper support plate (19) and all hopper assemblies (20).

14. Refer to Fig. 6 when reconnecting wires.

RED to BRN/WHI from Control Board #1 J3-3 RED to WHI/RED from Control Board #1 J3-2 RED to WHI/ORN from Control Board #1 J3-1 RED to WHI/YEL from Control Board #2 J3-3 RED to WHI/BLU from Control Board #2 J3-2

BLK to GRN from Control Board J3-4

P1639

FIG. 6 AUGER MOTOR TERMINALS

35135 012103

SERVICE (cont.)

BALLASTS - FMD-4 & FMD-5

FIG. 7 BALLASTS

Location

Removal and Replacement

1. Loosen the three #8-32 screws securing the component bracket to the dispenser housing base.

2. Pull component bracket out the front of the dispenser far enough so the leads on each ballast can be disconnected from the main wiring harness and the door interconnect harness.

3. Remove the two #8-32 screws securing each ballast to the rear of the component bracket.

4. Remove and discard the ballast.

5. Install new ballast on the rear of the component bracket and secure each with two #8-32 screws.

6. Refer to Fig. 8 and reconnect the wires.

7. Place the component bracket into position and tighten the two #8-32 screws securing the component bracket to the dispenser housing base.

BLK to BLK from Main Wiring Harness

P2635

BLK to RED from Main Harness

The front door lamp ballast is located behind the front access panel on the left front side of the component bracket.

Test Procedure

1. Disconnect the dispenser from the power source.

2. Disconnect the two black lead on the ballast from

the main harness.

3. Check for continuity between the two black leads

on the ballast.

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

FIG. 8 BALLAST TERMINALS

P1447

35135 012103

SERVICE (cont.)

CONTROL THERMOSTAT - FMD-4 & FMD-5

P2635

FIG. 9 CONTROL THERMOSTAT

Location

The control thermostat is located at the upper left

rear of the dispenser housing.

Test Procedure

1. Disconnect the dispenser from the power source.

2. Disconnect the black wire of the control thermostat from the black lead from the limit thermostat.

3. Remove bulb from the tank.

4. Check the voltage across black wire on the control 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 models. c) 240 volts ac for three wire 120/240 volt models.

5. Disconnect the dispenser from the power source.

Removal and Replacement.

1. 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.

2. Loosen the two #6-32 screws securing the thermostat to the front tank mounting bracket.

3. Disconnect the wires from the thermostat.

4. Remove thermostat and remove the screws and spacers from the thermostat.

5. Discard thermostat.

6. Install two spacers and two #6-32 screws on the new thermostat.

7. Position the thermostat on the botttom side of the front tank mounting bracket and tighten the two #6-32 screws.

8. Slide the grommet to the line 4.5" above the bulb on the new capillary tube.

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

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.

11. Refer to Fig. 10 and reconnect the wires.

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

BLK from Limit Thermostat

If voltage is present as described the control thermostat is operating properly. Reinstall bulb into the tank. If voltage is not present as described, replace the thermostat.

BLK from Tank Heater Switch

P1668

FIG. 10 THERMOSTAT TERMINALS

35135 012103

SERVICE (cont.)

CONTROL BOARD

FIG. 11 CONTROL BOARD

P2635

Location:

The Control Boards are located behind the lower

front access cover mounted on the component bracket.

Test Procedure: Liquid Level Control Circuitry(Control Board #1):

1. Disconnect the dispenser from the power source.

2. Disconnect the six pin connector from J3 of the control board.

3. Check the voltage across pins 5 & 6 of the six pin connector on the wiring harness with a voltmeter. Connect the dispenser to the power source. The indication must be 24 volts ac.

4. Disconnect the dispenser from the power source.

5. Reconnect the six pin connector of the wiring harness to J3 of the control board.

6. Disconnect the four pin connector from J4 of control board #1.

7. Check the voltage across pins 1 & 4 of the four pin connector on the wiring harness 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.

8. Disconnect the dispenser from the power source.

If voltage is present as described, proceed to step 9. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness.

9. Reconnect the four pin connector of the wiring harness to J4 of control board #1.

10. Disconnect the ten pin connector from J2 of control board #1.

11. Carefully connect a piece of insulated jumper wire to pin 10 (top right) of J2 on the control board. Keep the other end of this wire away from any metal surfaces of the dispenser.

12. Check the voltage across the terminals of the inlet solenoid valve 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 after a delay of approximately 10 seconds.

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

14. Move the jumper wire away from the 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 after a delay of approximately 5 seconds.

15. Disconnect the dispenser from the power source and remove the jumper wire.

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

If voltage is present as described, proceed to step 16. If the voltage is not present as described, replace control board #1.

35135 012103

SERVICE (cont.)

CONTROL BOARD (CONT.)

16. Reconnect the ten pin connector of the wiring harness to J2 of control board #1.

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

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

19. Check the voltage across the terminals of the inlet solenoid valve 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 after a delay of approximately 10 seconds.

20. Move the probe’s flat end to the dispenser housing. The indication must be 0.

21. Move the probe’s flat end away from the 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 after a delay of approximately 5 seconds.

22. Disconnect the dispenser from the power source.

If the voltage is present as described, re-install the probe. The liquid level control circuitry is operating properly. If the voltage is not present as described, check the pink probe wire and green tank wire for continuity.

Hopper Motor Control Circuitry (Stations 1-3, Control Board #1 & Stations 4-5, Control Board #2):

1. Disconnect the dispenser from the power source.

2. Disconnect the six pin connector from J3 of the appropriate control board.

3. Check the voltage across pins 5 & 6 of the six pin connector on the wiring harness with a voltmeter. Connect the dispenser to the power source. The indication must be 24 volts ac.

4. Disconnect the dispenser from the power source.

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

5. Reconnect the six pin connector of the wiring harness to J3 of the control board.

6. Check that the rinse/run switch is in the run position.

7. Check the voltage across the red (+) terminal and the black (-) terminal of the auger motor with a voltmeter. Connect the dispenser to the power source. Press and hold the appropriate dispense switch. After a delay of about .6 seconds, the indication must be between +4.0 and +24.5 volts dc.

If the voltage is present as described, the hopper motor control circuitry is operating properly. If the voltage is not present as described, replace the control circuit board.

35135 012103

Tank Heater Relay Control Circuitry (Control Board #2)(120V dispensers only):

1. Disconnect the dispenser from the power source.

2. Disconnect the six pin connector from J3 of control board #2.

3. Check the voltage across pins 5 & 6 of the six pin connector on the wwiring harness with a voltmeter. Connect the dispenser to the power source. the indication must be 24 volts ac.

4. disconnect the dispenser from the power source.

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

5. Reconnect the six-pin connector of the wiring harness to J3 of control board #2.

6. Disconnect the four-pin connector from J4 of control board #2.

7. Check the voltage across pins 1 & 4 of the four-pin connector on the wiring harness with a voltmeter. The indication must be 120 volts ac.

8. Disconnect the dispenser from the power source.

If voltage is present as described, proceed to step 9. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness.

9. Reconnect the four-pin connector of the wiring harness to J4 of control board #2.

10. Check the voltage across the coil terminals of the tank heater relay with a voltmeter. Connect the dispenser to the power source. The indication must be 0 volts ac.

If voltage is absent as described, proceed to step 11. If voltage is present, replace the control circuit board #2.

11. Place containers below any three dispenser nozzles.

12. Simultaneously initiate dispenses at each of the selected dispense stations while monitoring the voltage across the coil terminals of the tank heater relay. The indication must be 120V ac.

If voltage is present as described, the control board #2 is functioning correctly. If voltage is not present as described, replace the control circuit board #2.

Removal and Replacement:

1. Disconnect the three plugs on the main wiring harness from the connectors on the control board.

2. Remove the four #6-32 keps nuts securing the control board to the component bracket.

3. Remove control board and discard.

4. Install new control board on the component bracket using four #6-32 keps nuts.

5. Reconnect the three plugs on the main harness to the connectors on the control board.

NOTE: J4 is not connected on Control Board #2 on

120/208 - 240V dispensers.

CONTROL BOARD #1

J3 J1

J4 J2

CONTROL BOARD #2

J4 J2

FIG. 12 CONTROL BOARD CONNECTORS

35135 012103

P2637

SERVICE (cont.)

DISPENSE SWITCH(S) - FMD-4 & FMD-5

RINSE

ON UNTIL CUP IS 2/3 FULL, THEN RELEAS

RINSE

PUSH and HOLD BUTT

PLACE

CUP HERE

WARNING

H O T

L I Q U I D

RELEASE BUTTON WHEN CUP IS 2/3 FULL

PLACE

CUP HERE

PLACE

CUP HERE

PLACE CUP HERE

FMD-4

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/white

wires for the dispense switch to be teseted 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.

5. Disconnect the dispenser from the power source.

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.

RINSE

ELEASE

IS 2/3 FULL, THEN R

ON UNTIL CUP

RINSE

PUSH and HOLD BUTT

PLACE

CUP HERE

WARNING

H O T

L I Q U I D

PLACE

CUP HERE

RELEASE BUTTON WHEN CUP IS 2/3 FULL

PLACE

CUP HERE

PLACE

CUP HERE

PLACE CUP HERE

FMD-5

FIG.13 DISPENSE SWITCHES

Location:

The dispense switches are located on the lower

outside of the dispenser door.

6. With a voltmeter, check the voltage across the

remaining two wires of the dispense switch being tested from the door interconnect wiring harness. Connect the dispenser to the power source. The indication must be +5 volts dc.

If voltage is present as described, proceed to #7. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness.

P2636

35135 012103

SERVICE (cont.)

DISPENSE SWITCHES (cont.)

7. Check for continuity across the terminals (top right to top left; bottom right to bottom left) of the dispense switch with the switch in the “ON” position. Continuity must not present when the switch is in the “OFF” released position.

BLK RED/WHI

If continuity is present as described, reconnect the connector to the door interconnect wiring harness, the switch is operating properly. If continuity is not present as described, replace the switch.

Removal and Replacement

1. Open the dispenser door.

2. Remove the six #8-32 screws securing the bot-

tom door cover and remove cover.

3. Disconnect the wires on the dispense switch from

the door interconnect wiring harness.

4. Compress the clips inside the door on the dis-

pense switch and gently push the switch through the opening

5. Push the new switch into the opening and spread

the clips to hold the switch in the door.

6. Reconnect the wires to the dispense switch from

the door interconnect wiring harness.

7. Reinstall the door bottom cover using six #8-32

screws.

8. Refer to Fig. 14 when reconnecting wires.

STATIONS

-1-

BLK/WHI

RED

ORN

GRN/WHI

BLU

WHI/BLK

-2-

RED/BLK

-3-

ORN/BLK

-4-

GRN/BLK

-5-

BLU/BLK

FIG. 14 DISPENSE SWITCH TERMINALS

P1449

35135 012103

SERVICE (cont.)

FAN

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. 16 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.

6. Reconnect the vacuum hose to the fan.

BLK from Main Harness

P2635

FIG. 15 FAN

Location:

The fan is located inside the dispenser housing

on the center 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 on the main harness 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.

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.

WHI from Main Harness

P1507

FIG. 16 FAN TERMINALS

35135 012103

SERVICE (cont.)

FROTHER AND WHIPPER MOTOR - FMD-4 (shown) & FMD-5

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.

P2635

FIG. 17 FROTHER AND WHIPPER MOTOR

Location:

The frothers are located behind the dispenser door, mounted on the front panel inside the whipper chamber.

The whipper motors are located on the back side of the whipper motor mounting panel.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the red and white wires (FMD-1 &

FMD-2 left motor) or orange and white wires

(FMD-2 right motor) of the main harness from the

black leads of the motor.

3. Press and hold the 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.

11 12 13

9 8 6 5

P2628

FIG. 18 MIXING/WHIPPER CHAMBER

COMPONENTS

1. Steam Collector

2. Mixing Chamber

3. Dispense Tip

4. Whipper Chamber

5. O-Ring

6. Frother

8. Nut

9. Slinger

10. Motor Assy.

11. Fan

12. Vacuum Hose

13. Baffle

7. Receptacle w/Seal

Removal, Cleaning & Replacement (Refer to Fig. 18):

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.

35135 012103

SERVICE (cont.)

FROTHER AND WHIPPER MOTOR - FMD-4 (shown) & FMD-5 (cont.)

4. Disconnect vacuum hose (12) from fan baffle (13).

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

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

7. Remove the two #4-40 x .25" screws securing the fan baffle (13) to the whipper motor mounting panel and remove fan baffle. Set aside for reassembly.

8. Remove dispense tip (3) and twist the whipper chamber (4) clockwise and pull it off the whipper chamber receptacle (7).

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 receptacle (7).

11. Slide the receptacle w/seal off of the motor shaft.

12. Slide the slinger (9) off of the motor shaft.

13. Remove the two nuts (8) securing whipper chamber receptacle (7) and whipper motor (10) to the front panel.

NOTE: To remove the receptacle only rotate clockwise

until the receptacle clears the nuts (8) and slide off of the motor shaft.

14. Disconnect the black leads on the motor (10) from the main wiring harness.

15. Remove motor and discard.

16. Install new motor (10) on rear of front panel and secure with two nuts (8) and connect black leads on the motor to the main wiring harness. Refer to Fig. 19 when reconnecting wires

17. Slide slinger (9) onto the motor shaft flush against the front panel.

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

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

20. Slide whipper chamber receptacle w/seal (7) and O-ring (5) on to the motor shaft.

21. Rotate the receptacle w/seal (7) counterclockwise until it snaps into place on the motor mounting nuts (8).

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

23. Install whipper chamber (4) on the whipper chamber receptacle (7) by twisting counterclockwise until the tabs on the whipper chamber (4) lock with the tabs on the whipper chamber receptacle (7). Be sure dispense port is pointing down.

24. Install dispense tip (3) into the bottom of the whipper chamber (4).

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

26. Install vacuum hose (12) on fan baffle (13).

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

28. 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).

29. 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.

30. 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.

BLK to Main Harness WHI

BLK to Main Harness BRN Station #1 BLK to Main Harness RED Station #2 BLK to Main Harness ORN Station #3 BLK to Main Harness YEL Station #4 BLK to Main Harness BLU Station #5

P1221

FIG.19 WHIPPER MOTOR TERMINALS

35135 012103

SERVICE (cont.)

INCREASE/DECREASE SWITCH

P2635

FIG. 20 INCREASE/DECREASE SWITCH

Location:

The increase/decrease switch is located on the

lower left front of the whipper motor mounting panel.

Removal and Replacement:

1. Open the dispenser door.

2. Remove the facenut securing the increase/decrease switch to the whipper motor mounting panel.

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. 21 when connecting the wires to the new switch.

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

RED/BLK from Control Board J2-6 GRN from Control Board J2-9 WHI/VIO from Control Board J2-1

P1208

FIG. 21 INCREASE/DECREASE SWITCH

TERMINALS

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the wires from the switch terminals.

3. Check for continuity between the center terminal and upper terminal with switch in the decrease position (lower). Check for continuity between the center terminal and the lower terminal with the switch in the increase position (upper).

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

35135 012103

SERVICE (cont.)

LAMP HOLDERS

4 6

RINSE

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

P2638

FIG. 22 LAMP HOLDERS

1. Door Assy

2. Lamp Holders

3. Lamp 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. Upper Panel

5. Lower Panel

6. Starter W/Socket

Removal and Replacement:

1. Open dispenser door (1).

2. Remove the six #8-32 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 three #8-32 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 an assembly using three #8-32 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 six #8-32 screws.

LAMP REPLACEMENT (Refer to Fig. 22)

1. Open dispenser door (1).

2. Remove the six #8-32 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 three #8-32 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. Rotate lamp (3) 90° and remove from lamp holders (2).

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

8. Install upper door panel (4), lamp (3), lamp holders (2) and door wiring harness as an assembly using three #8-32 screws.

35135 012103

SERVICE (cont.)

LAMP REPLACEMENT (Refer to Fig.22)(cont.)

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

10. Install the door lower panel (5) using six #8-32 screws.

LAMP STARTER and SOCKET (Refer to Fig. 22)

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 starter socket.

Removal and Replacement (Refer to Fig.22):

1. Open dispenser door assy (1)

2. Remove the four #8-32 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.

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 four #8-32 screws.

5. Remove starter (6) from starter socket.

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

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.

35135 012103

SERVICE (cont.)

LIMIT THERMOSTAT

FIG. 23 LIMIT THERMOSTAT

Location:

The limit thermostat is located in the center of the

tank lid.

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. 24 when reconnecting the wires.

BLK to Tank Heater

BLK to Control Thermostat

P2635

P1800

FIG. 24 LIMIT THERMOSTAT TERMINALS

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.

35135 012103

SERVICE (cont.)

RINSE/RUN SWITCH

FIG. 25 RINSE/RUN SWITCH

Location:

The rinse/run switch is located on the lower center

of the whipper motor mounting panel.

P2635

Removal and Replacement:

1. Open the dispenser door.

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

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. 26 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.

BRN/BLK to Main Harness

GRY to Control Board J2-2

GRN to Control Board J2-9

BLK from Main Harness

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Check for continuity between the center left terminal and left bottom terminal, also between the center right terminal and the right bottom terminal with the switch in the rinse position (upper). Check for continuity across the center left terminal and the top left terminal, also between center right terminal and the top right terminal with the switch in the run position (lower). Continuity must not be present when the switch is in the center position.

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

BRN/BLK to Main Harness

WHI/GRY to Control Board J2-3

FIG. 26 RINSE/RUN SWITCH TERMINALS

P1644

35135 012103

SERVICE (cont.)

HOT/COLD SWITCH (Optional)

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 Diagrams

and check the main wiring harness.

5. Disconnect the wires from the switch terminals.

6. With the switch in the “Cold” (upper) position check for continuity between the center terminal and the bottom terminal. With the switch in the “Hot” (lower) 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.

P2635

FIG. 27 HOT/COLD SWITCH

Location:

The hot/cold switch is located on the left side of

the whipper motor mounting panel.

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, with a voltmeter, check the voltage across the white wire (pin 4) and red wire (pin 2) in the four pin connector on the main wiring harness. Connect the dispenser to the power source. The indication must be: a) 120 volts ac for two wire 120 volt models, and three wire 120/208 volt and 120/240 volt models. b) 240 volts ac for two wire 240 volt models.

4. Disconnect the dispenser from the power source.

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. 28 when reconnecting the wires.

TAN to Main Harness

RED to Main Harness

WHI/YEL to Cold Solenoid

P1208

FIG. 28 HOT/COLD SWITCH TERMINALS

35135 012103

SERVICE (cont.)

SOLENOID VALVE (COLD WATER - OPTIONAL)

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.

P2635

FIG. 29 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 dis-

pense switch on front of the door.

3. With a voltmeter, check the voltage across the

white and white/yellow wires. Connect the dis-

penser to the power source. The indication must

be:

a) 120 volts ac for two wire 120 volt models, three

wire 120/208 volt, and 120/240 volt models.

b) 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

Diagrams

and check dispenser wiring harness.

Wiring

5. Check for continuity across the solenoid valve coil

terminals.

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.

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

3. Turn off the water supply to the dispenser.

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

5. 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.

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

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

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

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

10. Refer to Fig. 30 when reconnecting the wires.

WHI/YEL to Hot/ Cold Switch WHI to Main Wiring Harness

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.

P1215

FIG. 30 COLD WATER SOLENOID TERMINALS

35135 012103

SERVICE (cont.)

SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5

P2635

FIG. 31 DISPENSE SOLENOID VALVE

Location:

The dispense solenoid is located on the upper left

center of the tank.

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 wires to the solenoid (see Fig. 32), proceed to #6

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 "RINSE/ RUN” switch in the "RINSE" upper position press the 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 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.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the two wires from the solenoid valve that is being tested. With the “RINSE/RUN” switch in the "RINSE" upper position press the dispense switch on front of the door.

3. Check the voltage across the two 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 and 120/240 volt models.

4. Disconnect the dispenser from the power source.

35135 012103

SERVICE (cont.)

SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5 (cont.)

Removal and Replacement:

1. Remove the four #8-32 screws securing the side access panel to the housing. Remove panel and set aside.

2. Remove the wires from the solenoid valve.

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

4. Using the tank drain tube, drain enough water from the tank so the water level is below the dispense valve mounting hole.

5. Disconnect the water line from the solenoid valve.

6. Remove the #8-32 keps nut securing the solenoid valve bracket to side of the tank. Remove solenoid valve.

7. Install new solenoid valve and o-ring on side of the tank and secure in place with valve mounting bracket and #8-32 keps nut.

8. Push the water line onto the tube on bottom of solenoid valve.

9. Refer to Fig. 32 and reconnect the wires.

10. Reinstall side access panels.

WHIto Main Harness

TAN to Main Harness Station #1 RED to Main Harness Station #2 ORN to Main Harness Station #3 YEL to Main Harness Station #4 BLU to Main Harness Station #5

P1672

FIG. 32 DISPENSE SOLENOID VALVE

TERMINALS

35135 012103

SERVICE (cont.)

SOLENOID VALVE (INLET)

P2635

FIG. 33 INLET SOLENOID VALVE

Location:

The inlet solenoid is located on the lower left side

near the rear panel.

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 and 120/240 volt models.

4. Disconnect the dispenser from the power source,

6. Check the solenoid valve for coil action. Connect the dispenser to the power source. 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.

Removal and Replacement:

1. Remove the white and violet 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. Remove the two #8-32 screws securing the solenoid to the rear of the dispenser housing. Remove solenoid.

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.

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

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

9. Refer to Fig. 34 and reconnect the wires.

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.

WHI from Main Harness

VIO from Main Harness

P2641

FIG. 34 INLET SOLENOID VALVE TERMINALS

35135 012103

SERVICE (cont.)

TANK HEATER

P2635

FIG. 35 TANK HEATER

Location:

The tank heater is located inside the tank and se-

cured 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 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.

3. Disconnect the dispenser from the power source.

Removal and Replacement:

1. Disconnect the dispenser from the power source.

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

3. Disconnect the black wires on the limit thermstat.

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 and the green wire from the tank.

6. 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.

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

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

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

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

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

12. Connect water inlet line to the tank lid.

13. 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.

14. Refer to Fig. 36 when reconnecting the wires to the tank heater.

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.

5. Check for continuity across the tank heater termi-

nals.

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.

WHI or RED to Main Harness

FIG. 36 TANK HEATER TERMINALS

BLK to Limit Thermostat

P1218

35135 012103

SERVICE (cont.)

TANK HEATER SWITCH

Removal and Replacement:

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

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

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

4. Connect the wires to the new switch, refer to Fig.

38.

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

P2635

FIG. 37 TANK HEATER SWITCH

Location:

The tank heater switch located inside the dispenser

on the upper right of the front panel.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the black wires from the main wiring harness.

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.

BLK to Main Harnesss

BLK from Main Harness

P1219

FIG. 38 TANK HEATER SWITCH TERMINALS

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

35135 012103

SERVICE (cont.)

TANK HEATER RELAY (120V Dispensers only)

P2635

FIG. 39 TANK HEATER RELAY

Location:

The tank heater relay is located behind the lower front access cover, mounted on the left rear side of the component bracket.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Place the tank heater switch in the “OFF” (upper)

position.

3. With an ohmmeter, check for continuity between

normally closed (NC-5) and common (COM-3)

terminals of the relay. The indication must be less

than 1 ohm.

6. With an ohmmeter, check for continuity between the normally closed (NC-5) and common (COM-3) terminals of the relay.

7. Place containers below any three dispense nozzles.

8. Connect the dispenser to the power source.

9. Simultaneously initiate dispenses at each of the selected dispense stations while monitorintg continuity across the referenced terminals of the tank heater relay. The indication must be open circuit.

If continuity is absent as described, the relay is functioning correctly. If continuity is present, replace the relay.

Removal and Replacement:

1. Loosen the three #8-32 screws securing the component bracket to the dispenser housing base.

2. Pull component bracket out the front of the dispenser far enough so the tank heater relay can be disconnected from the main wiring harness.

3 Disconnect the tank heater relay from the main

wiring harness.

4. Remove the two #8-32 screws securing the tank heater relay to the rear of the component bracket.

5. Remove and discard the tank heater relay.

6. Install new tank heater relay on the rear of the component bracket and secure with two #8-32 screws.

7. Connect the tank heater relay to the main wiring harness (see Fig. 40).

8. Place the component bracket into position and tighten the three #8-32 screws.

If continuity is present as described, proceed to step 4. If continuity is not present as described, replace the relay.

4. With an ohmmeter, check the resistance across the coil terminals (1 & 2) of the relay. The indication must be approximately 4,000 ohms (4kΩ).

If the resistance measures as described, proceed to step 5. If the resistance does not measure as described, replace the relay.

5. Disconnect the wires from the normally closed (NC-5) and common (COM-3) terminals of the relay.

BRN/BLK from Main Harness

BLK from Main Harness

FIG. 40 TANK HEATER RELAY TERMINALS

BLK from Main Harness

WHI from Main Harness

No Connection

P2639

35135 012103

SERVICE (cont.)

TRANSFORMER

P2635

FIG. 41 TRANSFORMER

Location:

The transformer is located behind the lower front access cover, mounted on the right rear side of the component bracket.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the four wires of the main harness

from the transformer. 3 Check the voltage across black wire and the white

wire on the main harness. Connect the dispenser

to power source. The indication must be:

a. 120 volts ac for two wire 120 volt models.

b. 120 volts for three wire 120/208 volt models and

three wire 120/240 volt models.

4. Disconnect the dispenser from the power source.

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

5. Check the voltage between J3-5 and J3-6 on the six pin connector at either control board. Connect the dispenser to the power source. The indication must be 24 volts ac.

If voltage is present as described the transformer is operating properly. If voltage is not present as described, replace the transformer.

Removal and Replacement:

1. Loosen the three #8-32 screws securing the component bracket to the dispenser housing base.

2. Pull component bracket out the front of the dispenser far enough so the transformer can be disconnected from the main wiring harness.

3 Disconnect the transformer from the main wiring

harness.

4. Remove the two #8-32 screws securing the transformer to the rear of the component bracket.

5. Remove and discard the transformer.

6. Install new transformer on the rear of the component bracket and secure with two #8-32 screws.

7. Connect the transformer to the main wiring harness (see Fig. 42).

8. Place the component bracket into position and tighten the three #8-32 screws.

LINE

WHI from Main Harness

BLK from Main Harness

WHI/GRN from Main Harness

WHI/BLK from Main Harness

P2640

FIG. 42 TRANSFORMER TERMINALS

35135 012103

TANK HEATER

SWITCH

BLK-16

BLK

WHI

J4-1

VIO

WHI

WHI/VIO

J4-4

N T R O L

WHI/ORN

J3-1

WHI/RED

BRN/WHI

R C

GRN

WHI/GRN

J3-5

WHI/BLK

WHI/VIO

J2-1

GRY

WHI/GRY

WHI/RED

TAN

J2-5

RED/BLK

WHI/BLK WHI/ORN

GRN

PNK

J2-10

J1-1

J1-4

GRN

PROBE

BLK BLK BLK

BLK

BLK-16 BLK-16 BLK-16 BLK-16

OVERFLOW PROTECTION SWITCH

RED RED

GRN

I N C

WHI/VIO

WHI/GRY

GRY

BRN/BLK

SCHEMATIC WIRING DIAGRAM FMD-4

LAMP #1 BALLAST

WHI/VIO

INCREASE/

DECREASE

SWITCH

RED/BLK

RINSE/PROGRAM/

RUN SWITCH

RINSE

PGM

RUN

RINSE

PGM

RUN

CONTROL

THERMOSTAT

RED

GRN

BLK

RED

BRN/WHI

BRN

LIMIT

THERMOSTAT

BLK BLK

LAMP #2 BALLAST

WHI/BLK

120V : 24V AC

LOAD

TRANSFORMER

WHI/GRN

HOPPER #1

RED

BLK

STATION #1

WHIPPER

BLK BLK BLK BLK BLK BLK BLK BLK

STATION #1

DISPENSE

VALVE

TAN WHI WHI ORN WHI

SOL

TANK HEATER

FAN

BLK WHI

BLK BLK

BLK

LINE

WHI

WHI/RED

GRN

WHI

RED

WHI

RED

HOPPER #2

STATION #2

WHIPPER

STATION #2

DISPENSE

VALVE

SOL

VIO

BLK

REFILL VALVE

SOL

WHI/ORN

GRN

WHI

HOPPER #3

STATION #3

WHIPPER

STATION #3

DISPENSE

VALVE

SOL

WHI

J4-1

BRN/BLK

WHI

GRN

WHI

WHI/YEL

YEL

HOPPER #4

RED

STATION #4

WHIPPER

STATION #4

DISPENSE

VALVE

YEL WHI

SOL

BLK

WHI/YEL

WHI/GRN WHI/BLK

WHI/VIO

WHI/GRY

BLU/BLK RED/BLK WHI/YEL

WHI/ORN

WHI/BLK

WHI/RED

GRN

BLK

WHI

BLK

J4-4

N T R O L

C I

J3-1

R C U

GRN

J3-5

B O

J2-1

GRY

A R

GRN

J2-5

# 2

GRN

J2-10

J1-1

J1-4

GRN

WHI-16

RED

ORN

PNK

GRY

"RINSE" #1-3 L.E.D.

PNK

GRY

"RINSE" #4 & 5 L.E.D.

WHI/RED

YEL

BRN

RED

ORN

WHI/YEL

WHI/BLK

TAN

GRN

BLU/BLK

RED/WHI

BLU/WHI

RED/GRN ORN/RED

1234

BLK

BLK/WHI WHI/BLK

WHI/RED

GRN

WHI/ORN

WHI/RED

RED

ORN

WHI/RED

BLK/WHI

GRN/WHI

RED

RED/BLK

WHI/RED

BLK BLK BLK

BRN/BLK

RED

BLK

ORN

ORN/BLK

WHI WHI

BLK/RED

WHI/RED

RED

BLU/RED

GRN

1614

WHI/BLK

ORN/BLK

GRN/BLK

RED/BLK

GRN/WHI

GRN/BLK

WHI

BRN BRN TAN WHI

BLK/RED

BLU

WHI

COLD DRINK OPTION (LEFT ONLY)

HOT/COLD SWITCH

RED RED TAN WHI

WHI

RED

BLK

BLU/RED

BLU

RED

BLK

WHI

STARTER

COLD

HOT

WHI/YEL

SOL

WHI

BLU

WHI

BLU

RED

BLK

WHI

STARTER

JUMPER PLUG MUST BE

RED

USED WHEN COLD

RED

DRINK FEATURE NOT

RED

INSTALLED

120 VOLTS AC - 2 WIRE

SINGLE PHASE, 60HZ

35135 012103

SCHEMATIC WIRING DIAGRAM FMD-4

GRN

J4-1

C O

J4-4

T R O

J3-1

I R C U

J3-5

B O

J2-1 A R D

J2-5

# 1

J2-10

J1-1

J1-4

PNK

GRY

"RINSE" #1-3 L.E.D.

PNK

GRY

"RINSE" #4 & 5 L.E.D.

PROBE

WHI VIO WHI

WHI/VIO

WHI/ORN WHI/RED BRN/WHI

GRN

WHI/GRN WHI/BLK

WHI/VIO GRY WHI/GRY WHI/RED TAN RED/BLK WHI/BLK WHI/ORN

GRN

PNK

GRN

RED/WHI BLU/WHI

RED/GRN ORN/RED

TANK HEATER

SWITCH

BLK-16

BLK

BLK BLK BLK

BLK

TAN

GRN

BLU/BLK

BLK-16 BLK-16 BLK-16

OVERFLOW PROTECTION SWITCH

RED RED

N C

WHI/VIO

WHI/GRY

BRN/BLK

WHI/YEL

WHI/BLK

GRN

WHI/ORN

WHI/RED

RED

ORN

WHI/RED

BLK/WHI

GRN/WHI

CONTROL

THERMOSTAT

LAMP #1

RED

BALLAST

WHI/VIO

GRN

INCREASE/

DECREASE

SWITCH

RED/BLK

RINSE/PROGRAM/

RUN SWITCH

RINSE

GRN

PGM

GRY

RUN

RINSE

BLK

PGM

RUN

YEL

BRN

RED

ORN

BRN/BLK

1614

BLK

WHI/BLK

ORN/BLK

GRN/BLK

RED/BLK

RED

WHI WHI

BLK/RED

RED

BLU/RED

LIMIT

THERMOSTAT

RED

BLK BLK

LAMP #2 BALLAST

WHI/BLK

120V : 24V AC

LOAD

TRANSFORMER

WHI/GRN

HOPPER #1

BRN/WHI

RED

BLK

STATION #1

WHIPPER

BLK BLK BLK BLK BLK BLK BLK BLK

STATION #1

DISPENSE

BRN

VALVE

TAN WHI WHI ORN WHI

SOL

GRN

TANK HEATER

FAN

BLK WHI

BLK

LINE

WHI

WHI/RED

GRN

WHI

RED

WHI

RED

HOPPER #2

STATION #2

WHIPPER

STATION #2

DISPENSE

VALVE

SOL

WHI

VIO

BLK

COLD DRINK OPTION (LEFT ONLY)

BRN BRN TAN WHI

WHI

BLK/RED

REFILL VALVE

SOL

WHI/ORN

GRN

WHI

RED RED

TAN

WHI

RED-16

RED

STATION #3

ORN

HOT/COLD SWITCH

BLU/RED

HOPPER #3

WHIPPER

DISPENSE

VALVE

SOL

COLD

HOT

WHI

BLK

WHI/YEL

GRN

WHI

SOL

WHI/YEL

YEL

HOPPER #4

RED

STATION #4

WHIPPER

STATION #4

DISPENSE

VALVE

YEL WHI

SOL

RED RED RED

WHI/YEL

WHI/GRN WHI/BLK

WHI/VIO

WHI/GRY

BLU/BLK RED/BLK WHI/YEL

WHI/ORN

WHI/BLK

WHI/RED

GRN

BLK

WHI

WHIWHI

JUMPER PLUG MUST BE

USED WHEN COLD

DRINK FEATURE NOT

INSTALLED

J4-1

C O

J4-4

N T R O L

J3-1

R C U

GRN

J3-5

B O

J2-1

GRY

A R

GRN

J2-5

# 2

GRN

J2-10

J1-1

J1-4

1234

WHI/RED

BLK/WHI WHI/BLK

BLK

RED

WHI/RED

BLK BLK BLK

RED/BLK

WHI/RED

ORN

ORN/BLK

WHI/RED

GRN/WHI GRN/BLK

BLU

RED

BLK

WHI

BLU

RED

BLK

WHI

STARTER

BLU

RED

BLK

WHI

120/208-240 VOLTS AC - 3 WIRE

STARTER

SINGLE PHASE, 60HZ

35135 012103

TANK HEATER

SWITCH

BLK-16

BLK

WHI

J4-1

VIO

WHI

WHI/VIO

J4-4

N T R O L

WHI/ORN

J3-1

WHI/RED

BRN/WHI

R C

GRN

WHI/GRN

J3-5

WHI/BLK

WHI/VIO

J2-1

GRY

WHI/GRY

WHI/RED

TAN

J2-5

RED/BLK

WHI/BLK WHI/ORN

GRN

PNK

J2-10

J1-1

J1-4

GRN

PROBE

BLK BLK BLK

BLK

BLK-16 BLK-16 BLK-16 BLK-16

OVERFLOW PROTECTION SWITCH

RED RED

GRN

I N C

WHI/VIO

WHI/GRY

GRY

BRN/BLK

SCHEMATIC WIRING DIAGRAM FMD-5

LAMP #1 BALLAST

WHI/VIO

INCREASE/

DECREASE

SWITCH

RED/BLK

RINSE/PROGRAM/

RUN SWITCH

RINSE

PGM

RUN

RINSE

PGM

RUN

CONTROL

THERMOSTAT

RED

GRN

BLK

RED

BRN/WHI

BRN

LIMIT

THERMOSTAT

BLK BLK

LAMP #2 BALLAST

WHI/BLK

120V : 24V AC

LOAD

TRANSFORMER

WHI/GRN

HOPPER #1

RED

BLK

STATION #1

WHIPPER

BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK

STATION #1

DISPENSE

VALVE

TAN WHI WHI ORN WHI

SOL

TANK HEATER

FAN

BLK WHI

BLK BLK

BLK

LINE

WHI

WHI/RED

GRN

WHI

RED

WHI

RED

HOPPER #2

STATION #2

WHIPPER

STATION #2 DISPENSE

VALVE

SOL

VIO

BLK

REFILL VALVE

SOL

WHI/ORN

GRN

WHI

HOPPER #3

STATION #3

WHIPPER

STATION #3

DISPENSE

VALVE

SOL

WHI

J4-1

BRN/BLK

WHI/BLU

WHI

BLK

GRN

WHI

HOPPER #4

RED

WHI/YEL

STATION #4

WHIPPER

STATION #4

DISPENSE

VALVE

YEL

YEL WHI BLU

SOL

YEL

WHI/YEL

WHI/GRN WHI/BLK

WHI/VIO

WHI/GRY WHI/BLU

BLU/BLK RED/BLK WHI/YEL

WHI/ORN

WHI/BLK

WHI/RED

WHI/BLU

BLK

GRN

BLU

WHI

BLU

WHI

WHI BLK

GRN

GRY

RED

J2-10

HOPPER #5

STATION #5

WHIPPER

STATION #5

DISPENSE

VALVE

SOL

C O

J4-4

N T R O L

C I

J3-1

R C U I

J3-5

B O

J2-1

A R D

J2-5

# 2

J1-1

J1-4

BLK

GRN

WHI

GRN

WHI-16

RED

ORN

PNK

GRY

"RINSE" #1-3 L.E.D.

PNK

GRY

"RINSE" #4 & 5 L.E.D.

WHI/RED

BLU

YEL

BRN

RED

ORN

WHI/YEL

WHI/BLK

GRN

TAN

GRN

BLU/BLK

RED/WHI BLU/WHI

RED/GRN ORN/RED

12345

BLK/WHI WHI/BLK

BLK

WHI/BLU

WHI/ORN

WHI/RED

GRN

BLU

RED

ORN

WHI/RED

BLK/WHI

GRN/WHI

RED

WHI/RED

BLK BLK BLK

RED/BLK

WHI/RED

BRN/BLK

RED

BLK

BLU/BLK

ORN

ORN/BLK

WHI WHI

BLK/RED

WHI/RED

RED

BLU/RED

GRN

1614

WHI/BLK

ORN/BLK

GRN/BLK

RED/BLK

GRN/WHI GRN/BLK

WHI/RED

BLU

BLK

BLU/BLK

WHI

BRN BRN TAN WHI

BLK/RED

BLU

WHI

COLD DRINK OPTION (LEFT ONLY)

HOT/COLD SWITCH

RED RED TAN WHI

WHI

RED

BLK

COLD

HOT

BLU/RED

BLU

RED

BLK

WHI

STARTER

WHI/YEL

SOL

WHI

BLU

WHI

BLU

RED

BLK

WHI

STARTER

JUMPER PLUG MUST BE

RED

USED WHEN COLD

RED

DRINK FEATURE NOT

RED

INSTALLED

120 VOLTS AC - 2 WIRE

SINGLE PHASE, 60HZ

35135 012103

SCHEMATIC WIRING DIAGRAM FMD-5

GRN

J4-1

C O

J4-4

N T R O L

J3-1 I R C U

J3-5

I T

B O

J2-1 A R D

J2-5 #

J2-10

J1-1

J1-4

PNK

GRY

"RINSE" #1-3 L.E.D.

PNK

GRY

"RINSE" #4 & 5 L.E.D.

GRN

PROBE

RED/WHI BLU/WHI

RED/GRN ORN/RED

WHI VIO

WHI

WHI/VIO

WHI/ORN WHI/RED BRN/WHI GRN WHI/GRN WHI/BLK

WHI/VIO GRY WHI/GRY WHI/RED TAN RED/BLK WHI/BLK WHI/ORN GRN PNK

TANK HEATER

SWITCH

BLK-16

BLK

BLK BLK BLK

BLK

TAN

GRN

BLU/BLK

BLK-16 BLK-16 BLK-16

OVERFLOW PROTECTION SWITCH

RED RED

I N C

WHI/VIO

WHI/GRY

BRN/BLK

WHI/YEL

WHI/BLK

GRN

WHI/BLU

WHI/ORN

WHI/RED

BLU

RED

ORN

WHI/RED

BLK/WHI

GRN/WHI

CONTROL

THERMOSTAT

LAMP #1

RED

BALLAST

WHI/VIO

GRN

INCREASE/

DECREASE

SWITCH

RED/BLK

RINSE/PROGRAM/

RUN SWITCH

RINSE

GRN

PGM

GRY

RUN

RINSE

BLK

PGM

RUN

BLU

YEL

BRN

RED

ORN

BRN/BLK

ORN/BLK

GRN/BLK

BLK

BLU/BLK

RED

WHI WHI

BLK/RED

1614

WHI/BLK

RED/BLK

RED

BLU/RED

LIMIT

THERMOSTAT

RED

BLK BLK

LAMP #2 BALLAST

WHI/BLK

120V : 24V AC

LOAD

WHI/GRN

BRN/WHI

RED

BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK

BRN

TAN WH I WHI ORN WHI

GRN

TRANSFORMER

HOPPER #1

STATION #1

WHIPPER

STATION #1

DISPENSE

VALVE

SOL

LINE

BLK

TANK HEATER

FAN

BLK WHI

BLK

HOPPER #2

STATION #2

WHIPPER

STATION #2

DISPENSE

VALVE

SOL

WHI

BRN BRN

TAN WHI

BLK/RED

REFILL VALVE

VIO

BLK

COLD DRINK OPTION (LEFT ONLY)

WHI

BLK

WHI

WHI/RED

RED

GRN

WHI

RED

WHI

RED

SOL

WHI/ORN

GRN

WHI

RED RED TAN WHI

RED-16

RED

ORN

HOT/COLD SWITCH

HOPPER #3

STATION #3

WHIPPER

STATION #3

DISPENSE

VALVE

SOL

COLD

HOT

WHI

BLU/RED

WHI

BLK

WHI/YEL

WHI

WHI/YEL

GRN

YEL

WHI

YEL

WHI

SOL

HOPPER #4

RED

BLK

STATION #4

WHIPPER

STATION #4

DISPENSE

VALVE

YEL WHI BLU

SOL

JUMPER PLUG MUST BE

RED

USED WHEN COLD

RED

DRINK FEATURE NOT

RED

WHI/BLU

GRN

WHI

INSTALLED

BLU

WHI/BLU

WHI/YEL

WHI/GRN WHI/BLK

WHI/VIO

WHI/GRY WHI/BLU

BLU/BLK RED/BLK WHI/YEL

WHI/ORN

WHI/BLK

WHI/RED

GRN

GRY

RED

J2-10

HOPPER #5

STATION #5

WHIPPER

STATION #5

DISPENSE

VALVE

SOL

J4-1

C O

J4-4

N T R O L

C I

J3-1

R C U I

J3-5

B O

J2-1

A R D

J2-5

# 2

J1-1

J1-4

BLK

GRN

WHI

12345

WHI/RED

BLK/WHI WHI/BLK

BLK

RED

WHI/RED

BLK BLK BLK

RED/BLK

WHI/RED

ORN

ORN/BLK

WHI/RED

GRN/WHI GRN/BLK

WHI/RED

BLK

BLU BLU/BLK

BLU

RED

BLK

WHI

BLU

RED

BLK

WHI

STARTER

BLU

RED

BLK

WHI

120/208-240 VOLTS AC - 3 WIRE

STARTER

SINGLE PHASE, 60HZ

35135 012103

Bunn FMD-5, FMD-4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual