BUNN
®
HC-2
HC-3
(SERIAL # HC00025000 - UP)
OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
27591.0000 6/00 ©1996 Bunn-O-Matic Corporation
INTRODUCTION
This equipment dispenses hot beverages on demand from powered product. It has two or three hoppers. The
two and three hopper models may also dispense cold beverages from powdered product from their left dispense
station. It is for indoor use only on a sturdy counter or shelf.
WARRANTY
Bunn-O-Matic Corp. (“Bunn”) warrants the equipment manufactured by it to be commercially free from defects
in material and workmanship existing at the time of manufacture and appearing within one year from the date of
installation. In addition:
1.) Bunn warrants electronic circuit and/or control boards to be commercially free from defects in material and
workmanship for two years from the date of installation.
2.) Bunn warrants the compressor on refrigeration equipment to be commercially free from defects in material
and workmanship for two years from the date of installation.
3.) Bunn warrants that the grinding burrs on coffee grinding equipment will grind coffee to meet original factory
screen sieve analysis for three years from date of installation or for 30,000 pounds of coffee, whichever comes first.
This warranty does not apply to any equipment, component or part that was not manufactured by Bunn or that,
in Bunn’s judgement, has been affected by misuse, neglect, alteration, improper installation or operation, improper
maintenance or repair, damage or casualty.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR
ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of Bunn are
not authorized to make modifications to this warranty or to make additional warranties that are binding on Bunn.
Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not
be relied upon.
The Buyer shall give Bunn prompt notice of any claim to be made under this warranty by telephone at (217)
529-6601 or by writing to Post Office Box 3227, Springfield, Illinois, 62708-3227. If requested by Bunn, the Buyer
shall ship the defective equipment prepaid to an authorized Bunn service location. If Bunn determines, in its sole
discretion, that the equipment does not conform to the warranty, Bunn shall repair the equipment with no charge
for parts during the warranty period and no charge for labor by a Bunn Authorized Service Representative during
the warranty period. If Bunn determines that repair is not feasible, Bunn shall, at its sole option, replace the
equipment or refund the purchase price for the equipment.
THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE
OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AS
SPECIFIED HEREIN, TO REPAIR OR, AT BUNN’S SOLE OPTION, REPLACEMENT OR REFUND.
In no event shall Bunn be liable for any other damage or loss, including, but not limited to, lost profits, lost sales,
loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute
equipment, facilities or services, or any other special, incidental or consequential damages.
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27591 061500
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.
26525.0000
00831.0000
00656.0000
12368.0002
11646.0000
27620.0000
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27591 061500
INITIAL SET-UP
1. Locate the drip tray assembly beneath the dispenser nested in the packing material.
2. Remove the drip tray and the drip tray cover and set them aside.
3. Remove the water strainer assembly from the drip tray and set it aside.
4. Remove the four legs from the drip tray, apply non-skid pads to the bottom of the legs and securely install
the legs in the dispenser base.
ELECTRICAL REQUIREMENTS
CAUTION - The dispenser must be disconnected from the power source until specified in
The 120 volt version of this dispenser has an attached cordset. The mating connector must be a NEMA 5-15R.
Initial Set-Up.
WHITE
NEUTRAL
L1BLACK
120V. A.C.
P2185
Requires 2-wire grounded service rated 120 volts ac, 15 amp,
single phase, 60 Hz
L2 RED
WHITE
L1BLACK
120V A.C.
120V A.C.
208 or
240V a.c.
P1841
Requires 3-wire, grounded service
rated 120/208 volts or 120/240 volts
ac, 20 amp, single phase, 60 HZ
L2 WHITE
L1 BLACK
240V A.C.
P2185
“A” models require 2-wire,
grounded service rated 240
volts ac, 20 amp, single
phase, 50 Hz
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. Remove the right side panel of the dispenser.
120 volt versions proceed to step 6.
120/240 volt and 240 volt versions proceed to next step.
5. Install the electrical wiring to the terminal block as illustrated above.
6. Connect the dispenser to the power source and verify the voltage at the terminal block. Reinstall the side
panel.
7. If plumbing is to be hooked-up later be sure the dispenser is disconnected from the power source. If
plumbing has been hooked-up, the dispenser is ready for
Initial Fill & Heat.
PLUMBING REQUIREMENTS
This dispenser must be connected to a COLD WATER system with operating pressure between 20 and 90 psi (138
and 620 kPa) from a 1⁄2" or larger supply line. A shut-off valve should be installed in the line before the dispenser.
Install a regulator in the line when pressure is greater than 90 psi (620 kPa) to reduce it to 50 psi (345 kPa). The
water inlet fitting is 1⁄4" flare.
NOTE - Bunn-O-Matic recommends 1⁄4" copper tubing for installations of less than 25 feet and 3⁄8" for more than
25 feet from the 1⁄2" water supply line. At least 18 inches of an FDA approved flexible beverage tubing, such as
reinforced braided polyethylene or silicone, before the dispenser will facilitate movement to clean the countertop.
It can be purchased direct from Bunn-O-Matic (part number 00326-0000). Bunn-O-Matic does not recommend
the use of a saddle valve to install the dispenser. The size and shape of the hole made in the supply line by this type
of device may restrict water flow.
This equipment must be installed to comply with the Basic Plumbing Code of the Building
Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanitation Manual of the Food and Drug Administration (FDA).
4
27591 061500
PLUMBING HOOK-UP
1. Securely attach the short piece of tubing on the water strainer assembly to the inlet fitting on the bottom of
the dispenser.
2. Flush the water line and securely attach it to the flare fitting on the water strainer assembly.
3. Turn-on the water supply.
INITIAL fill & heat
CAUTION - The dispenser must be disconnected from the power source throughout the initial 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 forty minutes for the water to heat on 120 volt versions, and
twenty minutes on 120/240 and 240 volt versions.
During this waiting period, complete these dispenser set-up steps:
a. Place 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 hopper(s) with the dry product to be dispensed.
DISPENSER USE
1. Simply place a cup on the drip tray beneath the desired dispensing tip.
2. Press the button to froth and dispense the beverage.
3. Release the button when the cup is approximately 2/3 full and allow the mixing chamber to drain.
NOTE - The mixing chamber must drain at the end of each dispense.
COLD BEVERAGE SET-UP (OPTIONAL)
Cold beverages may be dispensed from the left dispense position on the HC-2 & HC-3 models. Simply place
the HOT/COLD switch near the left whipper chamber in the “COLD” (upper) position.
CLEANING
Refer to the decal inside the hopper access door for cleaning recommendations and procedures.
The use of a damp cloth rinsed in any mild, non-abrasive, liquid detergent is recommended for cleaning all
surfaces on Bunn-O-Matic equipment.
ADJUSTMENTS
The hot or cold beverage solenoid(s) is (are) preset to dispense approximately one ounce per second. This
amount can be adjusted:
1. Disconnect the dispenser from the power source.
2. Remove the small right side access panel.
3. Rotate the control at the base of the desired solenoid(s) clockwise to decrease or counterclockwise to
increase the amount of water.
4. For cold beverage adjustment remove the 1-1/2” plug on the lower left side of the dispenser and rotate the
needle valve clockwise to decrease or counterclockwise to increase the amount of cold water.
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27591 031597
DRAINING THE HOT WATER TANK
CAUTION - The dispenser must be disconnected from the power source throughout these steps.
1. Disconnect the dispenser from the power source.
2. Open front door and place tank heater switch in the “OFF” (upper) position.
3. Shut-off and disconnect the incoming water supply.
4. Remove the top panel.
5. Gently remove one of the grommets from the tank lid.
6. Insert a tube to the bottom of the tank and syphon ALL of the water out.
(Bunn-O-Matic has a syphon assembly #12440.0000 available for this purpose.)
NOTE - The dispenser must be refilled using the INITIAL FILL & HEAT steps before reconnecting to the power
source.
HOPPER DISPENSE RATE OF PRODUCT
1. Hopper dispense rate with 22 tooth gear and auger wire is approximately 4 to 6 grams per second.
2. Hopper dispense rate with 22 tooth gear and auger wire with optional restrictor is approximately 3 to 5
grams per second.
3. Hopper dispense rate with optional 32 tooth gear and auger wire is 6 to 9 grams per second.
TROUBLESHOOTING
A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic
Technical Service Department.
• Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel.
• All electronic components have 120 volt ac or 240 volt ac and low voltage dc potential on their terminals.
Shorting of terminals or the application of external voltages may result in board failure.
• Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If an
intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a
terminal or crimp.
• Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are
energized for more than ten minutes without a supply of water.
• The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened. This will help
to avoid twists and kinks in the tubing.
• Make certain that all plumbing connections are sealed and electrical connections tight and isolated.
• This unit is heated at all times. Keep away from combustibles.
WARNING – • Exercise extreme caution when servicing electrical equipment.
• Unplug the dispenser when servicing, except when electrical tests are specified.
• Follow recommended service procedures
• Replace all protective shields or safety notices
6
27591 031597
TROUBLESHOOTING (cont.)
PROBLEM
Product will not dispense
PROBABLE CAUSE
1. No water
2. No power or incorrect voltage to
the dispenser
REMEDY
Water lines and valves to the
dispenser must be open.
(A1) Check the terminal block for
120 volts across the black and
white terminals on two wire 120
volt dispenser.
(A2) Check the terminal block for
120 volts across the red and
white terminal and the black and
white terminal on three wire
120/240 volt dispenser.
(A3) Check the terminal block for
240 volts across the white and
black terminal on two wire 240
volt dispenser.
(B) Check circuit breakers or
fuses.
3. Dispense switch
4. Dispense solenoid valve
(Hot or Cold)
5. Solenoid valve (Inlet)
6. Level control board and probe
7. Overflow protection switch
8. Auger drive
Refer to
Service
- Dispense
Switch for testing procedure.
See page 18
Refer to
Service
- Dispense
solenoid valve for testing procedures. See page 30 or 31
Refer to
Service
- Solenoid Valve
(Inlet) for testing procedures.
See page 32
Refer to
Service
- Level Control
Board and Probe for testing
procedures. See page 26
Refer to
Service
- Overflow
protection switch for testing
procedures. See page 28
Refer to
Service
- Auger Drive.
See page 12
7
27591 031597
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Product will not dispense (cont.)
Water is not hot
9. Water strainer
10. Lime build-up
CAUTION - Tank and tank components should be delimed regularly
depending on local water conditions. Excessive mineral build-up
on stainless steel surfaces can
initiate corrosive reactions resulting in serious leaks.
1. Limit thermostat
CAUTION - Do not eliminate or
bypass limit thermostat. Use only
BOM replacement part
#29329.1000
(A) Direction of flow arrow must
be pointing towards dispenser.
(B) Remove the flow control and
check for obstructions. Clear or
replace.
Inspect the tank assembly for
excessive lime deposits. Delime as
required.
Refer to
Service
- Limit Thermostat for testing procedures. See
page 27
Spitting or excessive steaming
2. Control thermostat (mechanical
or electronic)
3. Tank Heater
4. Tank heater switch
1. Lime build-up
CAUTION - Tank and tank components should be delimed regularly
depending on local water conditions. Excessive mineral build-up
on stainless steel surfaces can
initiate corrosive reactions resulting in serious leaks.
2. Control thermostat (mechanical
or electronic)
Refer to
Service
- Control Thermostat for testing procedures. See
page 16
Refer to
Service
- Tank Heater for
testing procedures. See page 33
Refer to
Service
- Tank Heater
Switch for testing procedures. See
page 34
Inspect tank assembly for excessive lime deposits. Delime as
required.
Refer to
Service
- Control Thermostat for testing procedures. See
page 16
8
27591 061500
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Dripping from dispense tip
Water flows into tank continuously
1. Lime build-up
CAUTION - Tank and tank components should be delimed regularly
depending on local water conditions. Excessive mineral build-up
on stainless steel surfaces can
initiate corrosive reactions resulting in serious leaks.
2. Dispense solenoid valve
(Hot or Cold)
1. Level control board and probe
2. Solenoid valve (Inlet)
Inspect the tank assembly for
excessive lime deposits. Delime as
required.
Remove the dispense solenoid
valve and clear any obstructions.
Rebuild or replace the valve if
necessary. See page 30 or 31
Refer to
Service -
Level Control
Board and Probe for testing
procedures. See page 26
Refer to
Service
- Solenoid Valve
(Inlet) for testing procedures. See
page 32
3. Overflow Protection Switch
Refer to
Service
- Overflow
Protection Switch for testing
procedures. See page 28
9
27591 031597
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Product overflows container
Weak product
1. Dispense switch
2. Dispense solenoid valve
(Hot or Cold)
1. Water temperature
Refer to
Service -
Dispense
Switch for testing procedures. See
page 18
Remove the solenoid valve and
clear any obstructions. Rebuild or
replace the valve if necessary. See
page 30 or 31
Place an empty container beneath
the dispense tip. Initiate a dispense
cycle and check the water temperature immediately below the dispense
tip with a thermometer.
(A) Reading for mechanical thermo-
stat models should be 180°F to 200°F
(see thermostat temperature settings
decal in
USER NOTICES
on page 3.
(B) Reading for electronic thermo-
stat should be185°F to 190°F.
Adjust the control thermostat to increase or decrease the water temperature. Replace if necessary.
2. Whipper motor
3. Frother
4. Dispense solenoid valve
(Hot or Cold)
5. Auger drive
6. Auger spring
7. Auger motor
Refer to
Service
- Whipper Motor for
testing procedure. See page 20
Refer to
Service
- Frother Compo-
nents. See page 20
Refer to
Service
- Dispense Solenoid
Valve for test procedures. See page
30 or 31
Refer to
Service
- Auger Drive Com-
ponents. See page 12
Refer to
Service
- Auger Drive Com-
ponents. See page 12
Refer to
Service
- Auger Drive Com-
ponents. See page 14
10
27591 031597
TROUBLESHOOTING (CONT.)
PROBLEM
Dispenser is making unusual
noises
Excess dust
PROBABLE CAUSE
1. Plumbing Lines
2. Water Supply
3. Tank Heater
1. Fan
2. Hopper Delay Board
REMEDY
Plumbing lines should not be resting on the counter top.
(A) The dispenser must be connected
to a cold water line
(B) Water pressure to the dispenser
must not exceed 90 psi (620 kPa).
Install a regulator if necessary to
lower the working pressure to approximately 50 psi (345 kPa).
Remove and clean lime off the tank
heater. See page 33
Refer to
Service
- Fan for testing
procedures. See page 19
Refer to
Service
- Hopper Delay
Board for testing procedures. See
page 22
Display not lit
3. Transformer (240V 2 Wire
Models Only)
1. Lamp
2. Lamp Holder
3. Starter - Lamp
4. Ballast
Refer to
Service
- Transformer for
testing procedures. See page 35
Refer to
Service
- Lamp, see page
24 for lamp replacement.
Refer to
Service
- Lamp Holder for
testing procedures. See page 24
Refer to
Service
- Starter for
testing procedures. See page 25
Refer to
Service
- Ballast for
testing procedures. See page 15
11
27591 061500
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 covers, reflector, dispenser
top covers, left and right side covers.
for assistance in determining the
AUGER DRIVE COMPONENTS
Refer to the contents listing for component location.
Contents
Auger Drive Components...................................... 12
Auger Motor ......................................................... 14
Ballast ...................................................................15
Control Thermostat............................................... 16
Dispense Switch ...................................................18
Fan........................................................................ 19
Frother ................................................................. 20
Hopper Delay Board.............................................. 22
Hot/Cold Switch .................................................... 23
Lamp Holder ......................................................... 24
Lamp .................................................................... 24
Lamp Starter and Socket ...................................... 25
Level Control Board and Level Probe .................... 26
Limit Thermostat .................................................. 27
Overflow Protection Switch .................................. 28
Rinse/Run Switch .................................................29
Solenoid (Cold Drink - Optional) ........................... 30
Solenoid (Dispense) ............................................. 31
Solenoid (Inlet) ..................................................... 32
Tank Heater .......................................................... 33
Tank Heater Switch ............................................... 34
Transformer (240V Models Only) .........................35
Whipper Motor ..................................................... 20
Wiring Diagrams.......................................... 37 & 38
FIG. 1 AUGER DRIVE COMPONENTS
Location
The auger components are located inside
the bottom part of the hopper except for the auger
drive bracket, washer and locknut, which are located
on the outside bottom rear of the hopper. The auger
motors are located on the rear of the front panel.
Refer to Fig. 2 for disassembly and assembly.
Test Procedures - Auger motors
1. Disconnect the dispenser from the power source.
2. Disconnect the wires from the motor to be tested.
3. Check the voltage across the white/violet wire for
the right motor, white/blue wire for the center
motor or the white/red wire for the left motor and
the white/black wire with a voltmeter. Press and
hold the appropriate Dispense switch. Connect the
dispenser to the power supply. The indication
must be :
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power supply.
12
P1199.45
27591 031597
SERVICE
AUGER DRIVE COMPONENTS (cont.)
If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the wiring diagrams and check the dispenser wiring harness.
5. With the wires removed from the motor to be
tested. Check for continuity across the two terminals on the bottom of the auger motor.
If continuity is present as described, reconnect the
wires to the terminals on the bottom of the auger
motor, the auger motor is operating properly.
If continuity is not present as described, replace the
auger motor.
Removal, Cleaning and Replacement
Hopper & Auger
1. Open the dispenser door and raise the top front
cover.
2. Lift the front edge of hopper assy (21) over the
tab on hopper support plate (20) and slide hopper assembly out the front of the dispenser.
3. Remove hopper lid (1) and empty product.
4. Pull off the ejector elbow (14).
5. Remove auger disc assy (2) by pulling agitator
support rod (4) towards agitator disc assy and
lifting agitator disc assy from hopper (10).
6. Remove auger (12) by pulling it out the front of
the hopper (10).
7. Remove auger drive shaft (5) by removing the
retaining clip (6) from auger drive shaft.
8. Slide washer (8) and auger drive shaft bracket
(7) off of the auger drive shaft (5).
9. Slide auger drive shaft (5) from auger drive shaft
bushing (3) and remove from hopper (10).
10. Remove locknut (9) from auger drive shaft bushing (3) and remove auger drive shaft bushing
from hopper (10).
11. Wash components in a mild solution of dish detergent using a bristle brush when needed.
12. Rinse and dry each item thoroughly.
13. Check for damaged or broken components, replace any if necessary and reassemble hopper
assy.
1
2
3
6
5
7
8
9
10
21
15 16 17 18 19 20
FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY
1. Hopper Lid
2. Agitator Disc Assy
3. Auger Drive Bracket
4. Agitator Support Rod
5. Auger Drive Shaft
Bushing
6. Retainer Clip
7. Auger Drive Bracket
8. Washer
9. Locknut
10. Hopper
11. Spring
12. Auger Wire
13. Auger Wire/Restrictor
(Optional)
14. Ejector Elbow
15. Wiring Harness Clamp
16. Auger Motor Bracket
17. Auger Motor
18. Dust Seal
19. Shoulder Screw
20. Hopper Support plate
21. Hopper Assy
13
4
11
13
12
14
P1200.35
27591 111596
SERVICE (cont.)
AUGER DRIVE COMPONENTS (cont.)
14. Install hopper assy (21) in the dispenser by sliding hopper assy in the guides on the hopper support plate (20) until the slot in the bottom rear
the hopper seats against the shoulder screw (19)
in the hopper support plate.
Auger Drive Motor (Refer to Fig. 2)
1. Disconnect the wires from the auger motor (17)
to be removed.
2. Remove hopper assy (21) and set aside for reassembly.
3. Left side auger motor only - Remove the #8-32
screw securing hose routing clamp (15) and auger motor (17) to the auger motor mounting
bracket (16).
4. Remove the four #8-32 locking screws, located
inside on the rear of the front housing, securing
auger motor mounting bracket (16) and auger
motor (17) to the rear of the front panel.
5. Remove auger motor mounting bracket (16),
auger motor (17) and dust seal (18) as an assembly.
6. Remove dust seal (18) from auger motor (17).
7. Remove the three #8-32 screws securing the left
auger motor to the auger motor mounting bracket
or the four #8-32 screws securing the center and
right auger motors to the auger motor mounting
bracket.
8. Remove auger motor and discard.
9. Using three #8-32 screws on the left auger motor or four #8-32 screw on the center or right
auger motor install new auger motor (17) on
mounting bracket (16).
10. Install dust seal (18) on auger motor shaft.
11. Using four #8-32 locking screws install auger
motor, dust seal and mounting bracket to the rear
of the front panel.
12. Left auger motor only - Using one #8-32 screw
attach hose routing clamp (15) to the mounting
bracket.
13. Reconnect the wires to the terminals on the bottom of the auger motor.
14. Install hopper assy (21).
15. Refer to the illustration below when reconnecting wires.
LEFT HC-2 & 3
WHI/BLK to Run/Rinse
Switch
WHI/RED from Hopper
Delay Circuit Board
CENTER HC-3 ONLY
WHI/BLK to Run/Rinse
Switch
WHI/BLU from Hopper
Delay Circuit Board
FIG. 3 AUGER MOTOR TERMINALS
RIGHT HC-2 & 3
WHI/BLK to
Run/Rinse
Switch
WHI/VIO from Hopper
Delay Circuit Board
T1201
14
27591 031597
SERVICE (cont.)
BALLAST
If voltage is not present as described, replace the
ballast.
Removal and Replacement
1. Disconnect the wires from the ballast.
2. Remove the two #8-32 keps nuts securing the
ballast to the dispenser base.
3. Remove and discard ballast.
4. Install new ballast over the two weld studs on
the dispenser base and secure with two #8-32
keps nuts.
5. Refer to the illustration below when reconnecting the wires.
FIG. 4 BALLAST
P1199.40
Location
The front door lamp ballast is located on the
front center of the base behind the front panel.
Test Procedure
1. Disconnect the dispenser from the power source.
2. Disconnect the two terminal plug of the door interconnect harness from the connector of the
ballast.
3. Check the voltage across the white wire and the
blue wire terminal of the ballast with a voltmeter.
Connect the dispenser to power source. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt
models or 120/240 volts models.
c) 240 volts ac for two wire 240 volt models.
WHI to Main
BLK to Terminal Block
Wiring Harness
WHI & BLU to
Door
Interconnect
Harness
120V, 120/208V, & 120/240V Models
WHI to Main
Wiring Harness
RED & BLU to
Door
Interconnect
Harness
BLK to Terminal Block
240V Models
FIG. 5 BALLAST TERMINALS
P1202.45
If voltage is present as described the ballast is operating properly.
15
27591 031597
SERVICE (cont.)
Test Procedure
CONTROL THERMOSTAT
MECHANICAL
P1199.45
Mechanical Thermostat
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 pole on the terminal block 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) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
c) 240 volts ac for two wire 240 volt models.
5. Disconnect the dispenser from the power source.
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.
ELECTRONIC (OPTIONAL)
FIG. 6 CONTROL THERMOSTAT
P1203.45
Location
Mechanical Thermostat
The mechanical thermostat is located on the
upper right side of the rear panel inside the dispenser.
Electronic Thermostat (Optional)
The electronic thermostat is located on the
right front side of the base just behind the front panel.
Electronic Thermostat (Optional)
1. Disconnect the dispenser from the power source.
2. Disconnect the black wire of the control thermo-
stat from the black lead from the limit thermostat.
3. Remove temperature probe from the tank
4. Check the voltage across black wire on the control
thermostat and the white pole on the terminal
block 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) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
5. Disconnect the dispenser from the power source.
If voltage is present as described the control thermostat is operating properly.Reinstall teperature probe
into the tank.
If voltage is not present as described, replace the thermostat.
16
27591 031597
SERVICE (cont.)
CONTROL THERMOSTAT (cont.)
Removal and Replacement.
Mechanical Thermostat
1. Disconnect the wires from the thermostat.
2. 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.
3. Remove the #8-32 screw securing the thermostat to the rear panel.
4. Slide the thermostat off of the guide stud on the
rear panel and discard.
5 Slide new thermostat over the guide stud on rear
panel.
6. Secure the thermostat to the rear panel using a
#8-32 screw.
7. Slide the grommet to the line 4.5” above the bulb
on the new capillary tube.
8. 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.
9. 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.
10. Refer to the illustration below and reconnect the
wires.
NOTE - The capillary tube must be clear of any electrical termination and not kinked.
Electronic Thermostat (Optional)
1. Disconnect the wires from the thermostat.
2. Remove the two #8-32 keps nuts securing the
thermostat to the dispenser base.
3. Remove the temperature probe from the grommet in the tank lid.
4. Remove thermostat and discard.
5. Install new thermostat over the studs on the dispenser base and secure with two #8-32 keps nuts.
6. Push the temperature probe into the grommet in
the tank lid until the top of the tube is flush with
grommet.
7. Refer to the illustration below and reconnect the
wires.
BLK to Limit Thermostat
BLU to Tank
Heater Switch
MECHANICAL
BLK to Limit
Thermostat
FIG. 7 THERMOSTAT TERMINALS
TAN to Tank
Heater
Switch
BLK to Terminal
Block
WHI to Terminal
Block
ELECTRONIC
P1204
17
27591 031597
SERVICE (cont.)
5. Disconnect the dispenser from the power source.
DISPENSE SWITCH
P1196.70
FIG.8 DISPENSE SWITCH
Location:
The dispense switches are located on the lower
outside of the dispenser door.
NOTE: The center dispense switch is for HC-3 Models
only.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Open the dispenser door and remove the bottom
door cover.
3. Disconnect the connector of the dispense switch
to be tested from the connector on the door
interconnect wiring harness.
4. Check for voltage across the black and red/black
wires for the right dispense switch, black and
red/white wires for the center dispense switch or
the black and red wires for the left dispense
switch in the connector of the door interconnect
wiring harness. Connect the dispenser to the
power supply. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
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.
6. Check for continuity across the wires removed
from the dispense switch with the switch in the
“ON” pressed position. Continuity must not be
present when the switch is in the “OFF” released
position.
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 bottom door cover and remove cover.
3. Disconnect the connector on the dispense switch
to be removed from the door interconnect wiring
harness connector.
4. Remove the mounting nut from the dispense
switch and remove switch from the front side of
the door.
5. Install new switch through the front of the door
and secure with mounting nut.
6. Reconnect the connector on the dispense switch
to the connector on door interconnect wiring harness.
7. Reinstall the door bottom cover using six #8-32
screws.
8. Refer to the illustration below when reinstalling
wires.
FIG. 9 DISPENSE SWITCH CONNECTORS
18
P1205.58
27591 031597
SERVICE (cont.)
FAN
Removal and Replacement:
1. Remove hoppers from the dispenser. Refer to Fig.
2 for hopper removal.
2. Remove the four #8-32 screws securing the hopper mounting plate to the front panel and remove
panel.
3. Remove the four screws securing the fan mounting plate to the dispenser front panel.
4. Lift fan mounting plate out of the front panel far
enough so the fan leads can be disconnected from
the main wiring harness.
5. Remove fan mounting plate, fan and exhaust tube
as an assembly.
6. Remove the four #8-32 screws and four #8-32
nuts securing exhaust tube and fan to the bottom
of the fan mounting plate and discard fan.
7. Install new fan and the exhaust tube to the bottom
of the fan mounting plate using four #8-32 screws
and four #8-32 nuts.
NOTE: Be sure arrow on the new fan is pointing down.
FIG. 10 FAN
P1199.45
Location:
The fan is located inside the front panel, mounted
on a plate beneath the hopper mounting plate.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the black and white wires from the
black leads on the fan.
3. Check the voltage across the black and white
wires on the main harness or transformer with a
voltmeter. Connect the dispenser to the power
source. The indication must be:
a) 120 volts ac for two wire 120 volts models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 120 volts ac for two wire 240 volt models.
8. Set fan mounting plate with fan and exhaust tube
inside the front panel far enough to connect the
black leads from the fan to the black and white
leads on the main wiring harness.
9. Install fan mounting plate into position and secure
with four #8-32 screws.
10. Install hopper mounting plate using four #8-32
screws.
11. Install hoppers, refer to Fig. 2.
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.
19
27591 031597
SERVICE (cont.)
FROTHER AND WHIPPER MOTOR
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power source.
If voltage is present as described, replace the motor.
If voltage is not present as described, refer to the wiring diagrams and check the dispenser wiring harness.
1 2
P1203.45
FIG. 11 FROTHER AND WHIPPER MOTOR
Location:
The frothers are located behind the dispenser
door, mounted on the front of the front panel inside
the whipper chamber.
The whipper motors are located on the back
side of the front section of the front panel.
NOTE: The center position is for HC-3 Models only.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the white/violet and white wires on
the right motor, white/blue and white wires on
the center motor or the white/red and white wires
on the left motor from the black leads on the
motors.
3. Press and hold the appropriate dispense switch
and check the voltage across the disconnected
harness wires with a voltmeter. Connect the dispenser to the power source. The reading must
be:
12
11
10 9 8 7 6 5 4 3
FIG. 12 MIXING/WHIPPER CHAMBER
COMPONENTS
1. Steam Collector
2. Mixing Chamber
3. Dispense Tip
4. Whipper Chamber
5. O-Ring
6. Frother
7. #6-32 Screw
8. Receptical w/Seal
9. Teflon Washer
10. O-Ring
11. #8-32 Acorn Nut
12. Motor Assy.
Removal, Cleaning and Replacement (Refer to Fig. 12):
1. Open the dispenser door.
2. Remove the steam collector (1) by pulling it forward and at the same time twisting it clockwise.
3. Pull the mixing chamber (2) out of the whipper
chamber (4).
20
P1206
27591 031597
SERVICE (cont.)
FROTHER AND WHIPPER MOTOR (cont.)
4. Remove dispense tip (3) and twist the whipper
chamber (4) clockwise and pull it off the whipper
chamber receptacle (8).
5. 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.
6. Slip the o-ring (5) off the whipper chamber
receptical (8).
7. Remove the two #6-32 screws (7) securing whipper chamber receptical (8) to the front panel.
8. Slide the receptical w/seal off of the motor shaft.
9. Slide teflon washer (9) and o-ring (10) off of the
motor shaft.
10. Disconnect the black leads on the motor (12) from
the main wiring harness.
11. Remove the two #8-32 acorn nuts (11) securing
the motor (12) to the rear of front panel.
12. Remove motor and discard. See NOTE.
13. Install new motor (12) on rear of front panel and
secure with two #8-32 acorn nuts (11) and connect black leads on the motor to the main wiring
harness.
14. Slide o-ring (10) onto the motor shaft to approximately 1/8” of the front panel.
15. Wash remaining components in a mild solution of
dish detergent using a bristle brush.
16. Rinse thoroughly and allow to dry before reinstalling in the dispenser.
17. Place teflon washer into back opening of whipper
chamber receptical and align one notch with bump
in the opening.
18. Slide whipper chamber receptacle w/seal on to the
motor shaft and secure to the front panel using two
#6-32 screws (7).
19. Slip o-ring (5) onto the whipper chamber receptical
(8).
20. Push frother (6) onto the motor shaft, making sure
the flat in the frother (6) lines up with the flat on the
motor shaft.
21. Install whipper chamber (4) on the whipper chamber receptical (8) by twisting counterclockwise
until the tabs on the whipper chamber (4) lock with
the tabs on the whipper chamber receptical (8). Be
sure dispense port is pointing down.
22. Install dispense tip (3) into the bottom of the
whipper chamber (4). Be sure the cutout part of
the dispense tip is facing the outside of the dispenser.
23. 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).
24. 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.
25. Refer to illustration below when reconnecting the
wires.
NOTE: To remove the center motor you also have to
remove the hopper assy., fan and exhaust tube. Refer
to AUGER DRIVE COMPONENTS and FAN.
P1207.50
FIG.13 WHIPPER MOTOR TERMINALS
21
27591 031597
SERVICE (cont.)
HOPPER DELAY BOARD
If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness.
5. Reconnect the white and black wires of the hopper delay board harness to the main harness.
6. Check the voltage across the terminals on the
auger motor with a voltmeter. Press and hold the
appropriate dispense switch. Connect the dispenser to the power source. After a delay of .7
seconds the indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
7. Disconnect the dispenser from the power source.
If voltage is present as described the hopper delay
board is operating properly.
If voltage is not present as described, replace the hopper delay board.
FIG. 13 HOPPER DELAY BOARD
P1199.45
Location
The hopper delay board is located on the left
front side of the dispenser base just behind the front
panel.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the white and black wires of the hopper
delay board harness from the main wiring harness.
3. Check the voltage across the white and black wires
of the main wiring harness with a voltmeter. Connect the dispenser to the power source. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power source.
Removal and Replacement:
1. Disconnect the eight pin plug from the hopper
delay board.
2. Remove the two #8-32 keps nuts securing the
hopper delay board mounting bracket to the dispenser base.
3. Remove hopper delay board mounting bracket
with hopper delay board and shield attached.
4. Remove the two #8-32 screws securing the hopper delay board to the mounting bracket and discard the delay board.
5. Install new delay board on the mounting bracket
with shield between the bracket and the delay
board using two #8-32 screws.
6. Install mounting bracket with hopper delay board
and shield over the studs on the dispenser base,
secure with two #8-32 keps nuts.
7. Reconnect the eight pin connector to the hopper
delay board.
If voltage is present as described, proceed to #5.
22
27591 031597
SERVICE (cont.)
4. Disconnect the dispenser from the power source.
HOT/COLD SWITCH (Optional)
FIG. 14 HOT/COLD SWITCH
Location:
The hot/cold switch is located on the left side
of the front panel.
P1199.45
If voltage is present as described, reconnect the four
pin plugs and proceed to #5.
If voltage is not present as described, refer to the
wiring diagram and check the main wiring harness.
5. Disconnect the wires from the switch terminals.
6. With the switch in the upper “Cold” position check
for continuity between the center terminal and
the bottom terminal. With the switch in the down
“Hot” position check for continuity between the
center terminal and the upper terminal.
If continuity is present as described, the hot/cold
switch is operating properly.
If continuity is not present as described, replace the
switch.
Removal and Replacement:
1. Remove all wires from the switch terminals.
2. Remove the mounting nut on the front of the front
panel.
3. Remove the hot/cold switch from the rear of the
front panel.
4. Push new hot/cold switch through the hole on
the left side of the front panel and secure with
mounting nut.
5. Reconnect the wires to the terminals on rear of
the switch.
6. Refer to the illustration below when reconnecting the wires.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the four pin plug from the hot/cold
switch and the four pin connector on the main
wiring harness.
3. Press the left dispense switch on the door and
check the voltage across the white wire (P4) and
white/red wire (P2) in the four pin connector on the
main wiring harness with a voltmeter. Connect the
dispenser to the power source. The indication
must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
23
WHI/BRN to Main
Harness
WHI/RED to Main
Harness
WHI/YEL to Cold
Solenoid
FIG. 15 HOT/COLD SWITCH TERMINALS
27591 031597
P1208
SERVICE (cont.)
LAMP HOLDER
1
If continuity is present as described, lamp holders are
operating properly.
If continuity is not present as described replace the
lamp holder.
2
3
4
5
6
FIG. 16 LAMP HOLDERS
1. Door Assy
2. Lamp Holders
3. Lamp
4. Upper Cover W/Reflector
5. Lower Cover
2
P1209.75
6. Starter W/Socket
Location:
The lamp holders are located on the front of
the reflector behind the display panel.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the plugs on the door wiring harness
from the connectors on the lamp holders.
3. Remove lamp from lamp holders.
4. Disconnect the two pin plugs of each lamp holder
from the door wiring harness.
5. Check for continuity on each lead of the lamp
holders.
Removal and Replacement:
1. Open dispenser door (1).
2. Remove the six #8-32 screws securing bottom
door cover (5) to the door (1) and remove cover.
3. Disconnect the door wiring harness from the door
interconnect wiring harness.
4. Remove eight #8-32 screws securing the upper
door cover w/reflector (4) to the door.
5. Remove the upper door cover w/reflector (4),
lamp (3), lamp holders (2) and door wiring harness as a assembly.
6. Rotate lamp (3) 90° and remove from lamp hold-
ers (2).
7. Remove the #6-32 securing the lamp holder (2) to
be removed, remove lamp holder (2) and discard.
8. Install new lamp holder (2) and secure with a #632 screw.
9. Install lamp (3) into lamp holders (2) and turn 90°
until the pins snap in place.
10. Install upper door cover w/reflector (4), lamp (3),
lamp holders (2) and door wiring harness as a
assembly using eight #8-32 screws.
11. Reconnect the plug on the door wiring harness to
the connector on the door interconnect wiring
harness.
12. Install the door bottom cover (5) using six #8-32
screws.
LAMP REPLACEMENT (Refer to Fig. 16)
1. Open the dispenser door (1).
2. Remove the upper door cover w/reflector (4),
lamp (3), lamp holders (2) as an assembly.
3. Rotate lamp (3) 90° and remove from the lamp
holders (2).
4. Insert new lamp (3) into lamp holders (2) and turn
90° until the pins snap in place.
5. Reinstall upper door cover w/reflector (4), new
lamp (3) and lamp holders (2) on the door assy (1).
24
27591 031597
SERVICE (cont.)
LAMP STARTER and SOCKET (120V, 120/208V &
120/240V Models Only)
Location:
The lamp starter (6) is located inside the door
assy (1) on the top of the door bottom cover (5).
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the plug on the starter leads from the
connector on the door wiring harness.
3. Remove lamp starter from starter socket.
4. Disconnect the two pin plugs of each of the starter
sockets from the door wiring harness.
5. Check for continuity on each lead of the starter
socket.
If continuity is present as described the starter socket
is operating properly.
If continuity is not present as described replace the the
starter socket.
hole in the bottom cover (5) and releasing spring
tabs.
8. Insert new starter (6) into socket and turn 90° until
the pins snap in place.
9. Connect the plug on the sockets leads to the
connector on the door wiring harness.
10. Install door bottom cover (5) with starter and
starter socket on door assy (1) using six #8-32
screws.
6. Remove starter (6) from starter socket.
7. 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 test are both as described and lamp
does not light, replace the starter socket.
Removal and Replacement (Refer to Fig.16):
1. Open dispenser door assy (1)
2. Remove the six #8-32 screws securing the door
bottom cover (5) to the door assy (1).
3. Disconnect the plug on the starter socket and the
connector on the door wiring harness.
4. Remove cover (5) with starter w/socket (6) as
assembly.
5. Rotate starter 90° and remove from the starter
socket.
6. Compress the spring tabs on the socket and remove socket from the door bottom cover (5).
7. Install new socket by compressing spring tabs on
the socket and pushing the socket up through the
25
27591 031597
SERVICE (cont.)
wiring diagram and check the dispenser wiring haness.
LEVEL CONTROL BOARD AND LEVEL PROBE
5. Reconnect the violet wire to terminal 1.
6. Carefully connect a piece of insulated jumper wire
to terminal 4. Keep the other end of this wire away
from any metal surface of the dispenser.
7. Check the voltage across terminals 1 & 3 with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for two
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models after a delay
of approximately 5 seconds.
8. Touch the free end of jumper wire to the dispenser
housing. The indication must be 0.
9. Move the jumper wire away from the dispenser
housing. The indication must again be 120 volts ac
for two wire 120 volt models, three wire 120/208
volt models , three wire 120/240 volt models and
240 volts ac for two wire 240 volt models after a
delay of approximately 5 seconds.
10. Disconnect the dispenser from the power source
and remove the jumper wire from terminal 4.
P1203.45
FIG. 17 LEVEL CONTROL BOARD AND PROBE
Location:
The level control board is located on the upper
right rear of the front panel just in front of the tank.
The Level probe is located on the right center of the
tank lid.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Remove the violet wire from terminal 1 & pink wire
from terminal 4 of the circuit board.
3. Check the voltage across terminals 2 & 3 with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for
two wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power source.
If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the
If voltage is present as described, the level control
board is operating properly, proceed to #11.
If voltage is not present as described, replace the level
control board.
11. Reconnect the pink wire to terminal 4.
12. Gently pull the probe out of the tank lid and inspect
for corrosion. Replace it if necessary.
13. Place the probe so that neither end is in contact
with any metal surface of the dispenser.
14. Check the voltage across terminals 1 & 3 with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for two
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models after a delay
of approximately 5 seconds.
15. Move the probe's flat end to the dispenser housing. The indication must be 0.
16. Move the probe's flat end away from the dispenser
housing. The indication should again be 120 volts
ac for two wire 120 volt models, three wire 120/
208 volt models, three wire 120/240 volt models
and 240 volt ac for two wire 240 volt models.
26
27591 031597
SERVICE (cont.)
LEVEL CONTROL BOARD AND LEVEL PROBE (cont.)
If voltage is present as described, reinstall the probe,
the level control board and level probe are operating
properly.
If voltage is not present as described, check the pink
probe wire for continuity.
Removal and Replacement:
1. Remove all wires from the level control board.
2. Remove two #8-32 keps nuts holding level control
board to upper left rear of the front panel.
3. Remove level control board and spacers.
3. Install the new level control board and spacers to
the upper left rear of the front panel using two #832 keps nuts.
4. Refer to the illustration below when reconnecting
the wires.
Location:
The limit thermostat is located in the center of
the tank lid.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect both black wires from the limit thermostat.
3. Check for continuity across the limit thermostat
terminals.
If continuity is present as described, the limit thermostat is operating properly.
If continuity is not present as described, replace the
limit thermostat.
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 the illustration below when reconnecting the wires.
FIG. 18 LEVEL BOARD TERMINALS
LIMIT THERMOSTAT
P1210
BLK to Control
Thermostat
BLK to Tank
Heater
FIG. 20 LIMIT THERMOSTAT TERMINALS
P1800
FIG. 19 LIMIT THERMOSTAT
P1199.45
27
27591 061500
SERVICE (cont.)
OVERFLOW PROTECTION SWITCH
Removal and Replacement:
1. Disconnect the red leads from the overflow protection switch from the black wire from the terminal block and the blue wire from the liquid level
board.
2. Remove the nut beneath the copper overflow cup.
3. Remove the entire switch assembly from the cup.
4. Place the new switch assembly into the cup, wires
first. Make sure that a gasket is in place around the
threaded switch stem.
NOTE - The magnets must be at the top of float and
there must be NO adjusting washers installed for
the overflow protection switch to operate properly.
5. Install the nut beneath the copper overflow cup. Be
sure not to overtighten.
6. Refer to the illustration below when reconnecting
wires.
P1199.45
FIG. 21 OVERFLOW PROTECTION SWITCH
Location:
The overflow protection switch is located inside the copper overflow cup on the upper front of
the tank.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Remove the wire nuts connecting the red wires
from the overflow protection switch to the black
wire from the terminal block and blue wire from the
liquid level board.
3. Check for continuity across the safety overflow
switch red wires only until the plastic float is raised
and check that continuity returns when the plastic
float is again lowered.
If continuity is present as described, reconnect the
red wires to the black wire from the terminal block
and the blue wire from the liquid level board.
If continuity is not present as described, replace the
overflow protection switch.
RED to BLK Wire
from Terminal
Block
RED to BLU Lead
from Liquid Level
Board
FIG. 22 OVERFLOW PROTECTION
SWITCH LEADS
P1212
28
27591 111596
SERVICE (cont.)
RUN/RINSE SWITCH
3. Remove switch with wires attached from the back
side of the front panel.
4. Disconnect the wires from the switch and discard the switch.
5. Referring to the illustration below (Fig. 24) reconnect the wires to the new switch.
6. Install new switch with wires attached through
the hole in the front panel and secure with facenut.
FIG. 23 RUN/RINSE SWITCH
P1199.45
Location:
The run/rinse switch is located on the right
side of the front panel.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Check for continuity between center terminals and
the upper terminals with the switch in the “RUN”
lower position. Continuity must not be present
with the switch in the “RINSE” upper position.
FIG. 24 RUN/RINSE SWITCH TERMINALS
P1213
If continuity is present as described, 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 facenut securing the run/rinse switch
to the dispenser front panel.
29
27591 111596
SERVICE (cont.)
SOLENOID VALVE (COLD WATER - OPTIONAL)
If voltage is not present as described, refer to wiring
diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
white and white/yellow wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect
the brewer 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.
P1214.45
FIG. 25 COLD WATER SOLENOID VALVE
Location:
The cold water solenoid valve is located on
the left side of the dispenser base just behind the hopper delay board.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the white and white/yellow wires
from the solenoid valve. With the “HOT/COLD”
switch in the "COLD" upper position press the left
dispense switch on front of the door.
3. Check the voltage across the white and white/
yellow wires with a voltmeter. Connect the dispenser to the power source. The indication must
be 120 volts ac for two wire 120 volt models,
three wire 120/208, 120/240 volt models and 240
volts ac for two wire 240 volt models.
4. Disconnect the brewer from the power source,
If voltage is present as described, proceed to #5
If the sound is not heard as described, replace the
solenoid valve.
Removal and Replacement:
1. Remove the white and white/yellow wires from
the solenoid valve.
2. Turn-off the water supply to the dispenser.
3. Disconnect the water lines to and from the solenoid valve.
4. Remove the two #8-32 keps nuts and washers
securing the solenoid mounting bracket to the
base. Remove solenoid bracket and solenoid
valve as an assembly.
5. Remove the two #10-32 screws and lockwashers
securing the solenoid valve to the solenoid
bracket.
6. Using two #10-32 screws and lockwashers install new solenoid valve on solenoid mounting
bracket.
7. Using two #8-32 keps nuts and washers install
solenoid valve and bracket to the base of the dispenser.
8. Securely fasten the water lines to and from the
solenoid valve.
9. Refer to Fig. 26 when reconnecting the wires.
30
27591 031597
SERVICE (cont.)
SOLENOID VALVE (COLD WATER - OPTIONAL) (cont.)
WHI/YEL to Hot/Cold
Switch
WHI to Terminal Block
P1215
FIG. 26 COLD WATER SOLENOID TERMINALS
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the white and white/violet, white/blue
or white/ brown wires from the solenoid valve.
With the “RUN/RINSE” switch in the "RINSE"
upper position press the appropriate dispense
switch on front of the door.
3. Check the voltage across the white and white/
violet, white/blue or white/brown wires with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for
two wire 120 volt models, three wire 120/208,
120/240 volt models and 240 volts ac for two
wire 240 volt models.
4. Disconnect the dispenser from the power source,
SOLENOID VALVES (DISPENSE)
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to wiring
diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
white and white/violet, white/blue or white/brown
wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect
the dispenser to the power source. With "RUN/
RINSE" switch in the "RINSE" upper position press
the appropriate dispense switch and listen carefully in the vicinity of the solenoid valve for a "clicking" sound as the coil magnet attracts.
7. Disconnect the dispenser from the power source.
FIG. 27 DISPENSE SOLENOID VALVES
Location:
The dispense solenoids are located on the
upper right side of the tank.
P1203.45
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.
Removal and Replacement:
1. Remove the white and white/violet, white/blue or
white/ brown wires from the solenoid valve.
2. Turn-off the water supply to the dispenser.
31
27591 031597
SERVICE (cont.)
SOLENOID VALVES (DISPENSE) (cont.)
3. Drain enough water from the tank so the water
level is below the dispense valve mounting hole.
NOTE: Bunn-O-Matic has a syphon assembly,
#12440.0000. available for this purpose.
4. Disconnect the water line from the solenoid valve.
5. Remove the #10-32 screw securing the solenoid
valve to side of the tank. Remove solenoid valve.
6. Using the #10-32 screw install new solenoid valve
on side of the tank
7. Push the water line onto the tube on bottom of
solenoid valve.
8. Refer to Fig. 26 when reconnecting the wires.
SOLENOID VALVE (INLET)
FIG. 26 DISPENSE SOLENOID VALVE
TERMINALS
P1216
FIG. 27 INLET SOLENOID VALVE
P1203.45
Location:
The inlet solenoid is located on the lower right
side of 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, 120/240 volt models and 240 volts ac
for two wire 240 volt models.
4. Disconnect the dispenser from the power source,
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to the
wiring diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
white and violet wires to the solenoid.
32
27591 031597
SERVICE (cont.)
SOLENOID VALVE (INLET) (cont.)
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect
the dispenser to the power source. Listen 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.
If the sound is not heard as described, replace the
solenoid valve.
TANK HEATER
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 #10-32 screws and nuts securing the solenoid to the rear panel. Remove solenoid.
5. Using two #10-32 screws and nuts install new
solenoid valve on rear panel.
6. Securely fasten the water lines to and from the
solenoid valve.
7. Refer to Fig. 28 when reconnecting the wires.
FIG. 29 TANK HEATER
P1199.40
Location:
The tank heater is located inside the tank and
secured to the tank lid.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Check the voltage across the black and white wires
120 volt models or black and red wires for 120/208
volt models or 120/240 volt models with a voltmeter. Connect the dispenser to the power source.
The indication must be:
a) 120 volts ac for two wire 120 volt models;
b) 208 volts ac for three wire 120/208 volt models.
c) 240 volts ac for three wire 120/240 volt models
and two wire 240 volt models.
3. Disconnect the dispenser from the power source.
WHI from Terminal
Block
VIO from Liquid
Level Board
FIG. 28 INLET SOLENOID VALVE TERMINALS
P1217
If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the
dispenser wiring diagram and check the wiring harness.
4. Disconnect the black wire and the white or red
wire from the tank heater terminals.
33
27591 031597
SERVICE (cont.)
TANK HEATER (cont.)
5. Check for continuity across the tank heater terminals.
If continuity is present as described, reconnect the
wires, the tank heater is operating properly.
If continuity is not present as described, replace the
tank heater.
NOTE - If the tank heater remains unable to heat,
remove and inspect heater for cracks in the sheath.
Removal and Replacement:
1. Shut-off water supply to the dispenser.
2. Disconnect the water supply tube on the tank lid.
3. Disconnect the black wires on the limit thermostat.
4. Disconnect the black wire and the white or red wire
from the tank heater terminals.
5. Disconnect the pink wire from the liquid level
probe.
6. 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 a 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. Refer to the limit
thermostat and the liquid level board and probe
sections in this manual when reconnecting wires.
14. Refer to Fig. 30 when reconnecting the wires to the
tank heater.
WHI or RED to
Terminal Block
FIG. 30 TANK HEATER TERMINALS
TANK HEATER SWITCH
FIG. 31 TANK HEATER SWITCH
Location:
BLK to Limit
Thermostat
P1218
P1199.35
The tank heater switch located inside the dis-
penser on the upper right of the front panel.
34
27591 031597
SERVICE (cont.)
TANK HEATER SWITCH (cont.)
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the black wire and the blue/black wire
on electro/mechanical thermostats or the tan wires
on electronic thermostats.
3. With the switch in the “ON” lower position check
for continuity between the center and the upper
terminal. With the switch in the “OFF” upper position no continuity should be present between
center and upper terminals.
If continuity is present as described, the heater “ON/
OFF” switch is operating properly.
If continuity is not present as described, replace the
switch.
Removal and Replacement:
1. 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.
32.
5. Push new switch through hole in the front panel
and secure with face nut.
BLUBLK from Electro/
mechanical Thermostat
or TAN from Electronic
Thermostat
BLK from Terminal
Block (Electro/mechanical)
TAN from Electronic
Thermostat
TRANSFORMER (240V TWO WIRE MODELS ONLY)
1
2
3
FIG. 33 TRANSFORMER
P1289
Location:
The transformer is located behind the front
cover just to the right of the ballest on the dispenser
base.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the two pin connector of the trans-
former from the fan.
3. Connect voltmeter, set to read at least 120 volts ac
across the black and white leads of the transformer connector.
4. Connect the dispenser to the power source. The
voltage indication should be approximately 120
volts ac.
5. Disconnect the dispenser from the power source.
If voltage is present as described the transformer is
operating properly.
If voltage is not present as described, replace the
transformer.
FIG. 32 TANK HEATER SWITCH TERMINALS
P1219
35
27591 031597
SERVICE (cont.)
TRANSFORMER (240V TWO WIRE
MODELSONLY)(cont.)
Removal and Replacement:
1. Disconnect the wires from the transformer.
2. Remove the two #8-32 keps nuts securing the
transformer to the dispenser base.
3. Remove and discard the transformer.
4. Install new transformer over the two weld studs on
the dispenser base and secure with two #8-32
keps nuts.
5. Refer to Fig. 34 when renonnecting the wires.
RED & BLK to
Main Harness
1
2
BLK & WHI to
3
Fan
FIG.34 TRANSFORMER TERMINALS
P1288
36
27591 031597
SCHEMATIC WIRING DIAGRAM HC-2, & HC-3
L1
ELECTROMECHANICAL THERMOSTAT CONFIGURATION
HEATER SW.
BLU-16
TAN
BLU/BLK-16
THERMOSTAT
HEATER SW.
ELECTRONIC
THERMOSTAT
ASSEMBLY
BLKBLK
WHI
TAN
WHI/VIO
WHI/BLU
BLK
WHI/RED
WHI/GRN
WHI/GRN
WHI
BLU
BLK-16
ELECTRONIC THERMOSTAT CONFIGURATION
BLK-16
One Configuration MUST be used!
BLK
BLK-16 BLK-16
BLK-16
BLK-16
BLK-16 BLK-16
1
HOPPER
2
DELAY
3
4
5
6
7
8
LIMIT
THERMOSTAT
LIMIT
THERMOSTAT
BLK
BLK
FLOURESCENT
LAMP
BALLAST
TANK HEATER
TANK HEATER
OVERFLOW SWITCH
RED
BLKBLK
WHI
RED
1
BLK
GRN
RED-16 (3-WIRE MODELS)
WHI-16 (2-WIRE MODELS)
RED-16 (3-WIRE MODELS)
WHI-16 (2-WIRE MODELS)
VIO
1
LIQUID
LEVEL
BOARD
BLU
2
3
PNK-20
4
WHI
WHI WHI
TANK INLET
SOL
PROBE
L2 N
WHI
WHI
WHI
WHI
WHI/RED
HC1 Components
HC2 & HC3 Components
WHI/VIO
WHI/BLU
WHI/BRN
WHI/RED
WHI/RED
WHI
WHI/VIO
WHI/BLU
WHI/BRN
4
1
(CENTER COMPONENTS ELIMINATED ON HC-2)
1
41
DISPENSE
SWITCH
ASSY.
BLK
RED
(RIGHT, MODELS HC-2 & HC-3)
1
(CENTER, MODEL HC-3 ONLY)
4
120 VOLTS AC - 2 WIRE OR
120/208-240 VOLTS AC - 3 WIRE
SINGLE PHASE, 60 HZ
27593.0004B 2/97 © 1996 BUNN-O-MATIC CORPORATION
(LEFT, MODELS HC-2 & HC-3)
DISPENSE
SOL
WHI
RIGHT DISPENSE
SOL
CENTER DISPENSE
SOL
LEFT DISPENSE
SOL
COLD DRINK OPTION (LEFT ONLY)
WHI
WHI/BRN
WHI/RED
WHI/RED
HOT/COLD SWITCH
DISPENSE SWITCH
DISPENSE SWITCH
DISPENSE SWITCH
(ALSO HC-1 SWITCH)
WHI
WHI
WHI
WHI
WHIPPER
RIGHT WHIPPER
CENTER WHIPPER
LEFT WHIPPER
SOL
WHI/YEL
GRN/WHI
GRN/BLK
RED
BLK
RED/WHI
RED/BLK
1
BLK
RED/BLK
4
1
BLK
RED/WHI
4
1
BLK
RED
4
HOPPER
M
M
RUN/RINSE SWITCH
WHI
WHI/BLKWHI WHI WHI/REDWHI/RED
WHI/GRN
WHI
M
WHI
WHI
WHI/BLUWHI/BLUWHI/BLU
WHI/REDWHI/RED
M
M
WHI/GRN
M
CENTER HOPPER
M
LEFT HOPPER
M
RUN/RINSE SWITCH
RIGHT HOPPER
WHI/VIOWHI/VIOWHI/VIO WHI
WHI/GRN
JUMPER PLUG MUST BE
RED
USED WHEN COLD
RED
DRINK FEATURE NOT
RED
BLU
BLU
1
BLK
BLK
INSTALLED
RED
WHI/BLK
WHI/BLK
WHI/BLK
WHI/BLK
1
STARTER
1
WHI
BLK
BLK
WHI
WHI
37
27591 031597
SCHEMATIC WIRING DIAGRAM HCA-2, & HCA-3
GRN
L1 L2
ELECTROMECHANICAL THERMOSTAT CONFIGURATION
HEATER SW.
BLU-16
BLU/BLK-16
THERMOSTAT
BLK-16
LIMIT
THERMOSTAT
BLK-16 BLK-16
TANK HEATER
WHI -16
BLK-16
ELECTRONIC THERMOSTAT CONFIGURATION
BLK-16
One Configuration MUST be used!
BLK
TAN
HEATER SW.
ELECTRONIC
THERMOSTAT
ASSEMBLY
BLKBLK
WHI
TAN
WHI/VIO
WHI/BLU
BLK
WHI/RED
WHI/GRN
WHI/GRN
WHI
RED
RED
BLU
BLU
BLK-16
1
HOPPER
2
DELAY
3
4
5
6
7
8
FLOURESCENT
LAMP
BALLAST
WHI
WHI/RED
HC1 Components
HC2 & HC3 Components
WHI/VIO
WHI/BLU
WHI/BRN
WHI/RED
WHI/RED
WHI/VIO
CENTER DISPENSE
WHI/BLU
WHI/BRN
COLD DRINK OPTION (LEFT ONLY)
WHI
4
1
(CENTER COMPONENTS ELIMINATED ON HC-2)
LIMIT
THERMOSTAT
BLK-16 BLK-16
BLK
WHI
WHI
DISPENSE
SOL
WHI
RIGHT DISPENSE
SOL
WHI
SOL
LEFT DISPENSE
WHI
WHI/BRN
WHI/RED
WHI/RED
WHI
SOL
HOT/COLD SWITCH
BLK
BLK
WHI
WHI
WHI
CENTER WHIPPER
SOL
WHI/YEL
TANK HEATER
OVERFLOW SWITCH
1
BLK
RED
WHIPPER
M
RIGHT WHIPPER
M
M
LEFT WHIPPER
M
RED
WHI
WHI
WHI
LIQUID
LEVEL
BOARD
XFRMR
WHI/GRN
WHI/VIOWHI/VIOWHI/VIO WHI
WHI/BLUWHI/BLUWHI/BLU
WHI/REDWHI/RED
WHI/GRN
WHI/GRN
RED
RED
RED
RED
TANK INLET
VIO
1
BLU
2
3
PNK-20
4
RUN/RINSE SWITCH
PROBE
BLK BLK
WHI
1
HOPPER
M
RIGHT HOPPER
M
CENTER HOPPER
M
LEFT HOPPER
M
RUN/RINSE SWITCH
JUMPER PLUG MUST BE
USED WHEN COLD
DRINK FEATURE NOT
INSTALLED
WHI -16
SOL
WHI/BLKWHI WHI WHI/REDWHI/RED
WHI/BLK
WHI/BLK
WHI/BLK
WHI/BLK
WHI
WHI
WHI
WHI
WHI
WHI
41
41
BLU/BLK
ORA/BLK
DISPENSE
SWITCH
ASSY.
BLK
RED
1
4
(RIGHT, MODELS HC-2 & HC-3)
(CENTER, MODEL HC-3 ONLY)
RED/WHI
RED/BLK
DISPENSE SWITCH
DISPENSE SWITCH
240 VOLTS A C
2 WIRE
SINGLE PHASE,
50 HZ
27593.0004B 2/97 © 1996 BUNN-O-MATIC CORPORATION
DISPENSE SWITCH
(LEFT, MODELS HC-2 & HC-3)
(ALSO HC-1 SWITCH)
BLU
ORA
RED
BLK
1
BLK
RED/BLK
4
1
BLK
RED/WHI
4
1
BLK
RED
4
38
BLU
4
BLU
RED
RED
1
WHI
BLK
1
1
BLK
WHI
27591 031597
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