Bunn POWDER AUTO FILL User Manual

BUNN® POWDER AUTO FILL ™

OPERATING & SERVICE MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

PHONE: [phone] FAX: [phone]

29793.0000B 1/00 ©1999 Bunn-O-Matic Corporation

INTRODUCTION

This equipment supplies a liquid mix to the hoppers on the CDS-2 or 3 dispensers. 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 [phone] 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.

INITIAL SET-UP

1.Locate the hopper elbow with slide gate, whipping chamber with dispense tip, and mixing chamber located in the Powder Auto-Fill hopper.

2.Assemble the hopper elbow with slide gate to the hopper.

3.Assemble the whipping chamber with dispense tip to the whipper receptacle on the Powder Auto-Fill.

4.Assemble the mixing chamber to the whipping chamber and water inlet on the Powder Auto-Fill.

5.Locate the door assembly and door mounting hardware taped to the back of the door assembly.

6.Remove the door mounting hardware from the bag and set it aside

7.Carefully lift the door and locate the lamp cord connector.

8.Connect the door lamp cord connector to the receptacle located on the top of the Powder Auto-Fill.

9.Carefully rotate the support arms on the back of the door so they are roughly perpendicular to the rear of the door.

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10.Slowly feed the door support arms through the slots located on the front of the Powder Auto-Fill.

11.Continue to slowly feed the door support arms through the slots until the magnet strikes on the back of the door engage the magnets on the Powder Auto-Fill.

12.Locate the #8-32 x .375" truss head screws and brass spacers set aside earlier.

13.Place one brass spacer on each screw.

14.Insert one screw/spacer assembly through the door hinge, locating the spacer inside the hinge bushing and threading the screw into the hinge mount on the Powder Auto-Fill cover. Repeat for other side.

15.Install PAF level probe (BOM #29728.1000) by sliding it into the notched area at the top rear of the CDS hopper. The probe should be firmly seated in the notch and touching the contact pin protruding from the front of the CDS cooling drum mount.

NOTE: At this point, it is important that the CDS machine is fully assembled according to the instructions outlined in the CDS Operating and Service Manual.

16.Place the assembled Powder Auto-Fill on top of a hopper of a fully assembled CDS machine, taking care to align the Powder Auto-Fill guide rails over the rollers on the CDS.

17.Connect the Powder Auto-Fill power cord to the outlet located on the CDS auger motor cover.

18.Attach a flexible water line to the .25" flare fitting on the back panel of the Powder Auto-Fill.

NOTE: A water strainer assembly (BUNN-O-MATIC #23820.1000) should be installed in line prior to the flexible water line.

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.

00656.0000 00986.0000

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OPERATING INSTRUCTIONS

1.On the CDS control panel, make the following switch settings:

a)POWER- "ON"

b)DAY/NIGHT- "DAY"

2.Pull the Powder Auto-Fill fully forward on its support rails and open the door.

3.Fill the Powder Auto-Fill product hopper as follows:

a)Pull the slide gate closed on the Powder Auto-Fill product hopper elbow and remove the hopper from the Powder Auto-Fill.

b)Remove the lid from the product hopper and fill the hopper with a powdered granita mix.

c)Install the product hopper into the Powder AutoFill. Insure hopper is fully seated behind retainer plates.

d)Push the slide gate on the hopper ejector elbow to the open position.

4.Place the ON/OFF switch at the Powder Auto-Fill whipper panel to "ON".

5.After allowing 5 seconds for the Powder Auto-Fill to initialize, observe the door lamp. The door lamp should not be lit. If the door lamp is lit, consult the fault list located on the decal placed on the back of the door. Clear the fault before proceeding.

NOTE: If the Powder Auto-Fill is being used for the first time with the selected granita mix, perform an adjustment as described in ADJUSTMENTS.

6.Close the Powder Auto-Fill door and observe the following:

a)The door lamp lights steadily.

b)The Powder Auto-Fill begins dispensing liquid granita product.

7.The Powder Auto-Fill will continue to fill the CDS product hopper until the liquid level in the CDS hopper reaches the product level probe or for 5 minutes, which ever occurs first.

8.If the Powder Auto-Fill fails to fill the CDS hopper in 5 minutes, the following will occur:

a)The Powder Auto-Fill will stop dispensing product.

b)The door lamp will flash 4 times about every 2 seconds.

9.After checking the CDS and Powder Auto-Fill setup, the 5 minute refill fault may be cleared by simply opening and closing the Powder Auto-Fill door.

10.Once the product level in the CDS covers the auger, make the following switch settings at the CDS control panel:

a)AUGER - "1".

b)ICE/OFF/NO ICE - "ICE" or "NO ICE" as appropriate for the granita product.

11.From this point onward, the Powder Auto-Fill will continue to automatically refill the CDS hopper, maintaining the CDS product at an approximate 2 gallon level.

12.When the Powder Auto-Fill powder level falls low, the door lamp will cycle ON and OFF, but will continue to dispense product for a preset period. When this period expires, the Powder Auto-Fill will continue to cycle the door lamp ON and OFF and will stop dispensing product.

13.To clear the low product fault, simply refill the powder as follows:

a)Open the Powder Auto-Fill door.

b)Close the hopper slide gate.

c)Remove the product hopper.

d)Refill the product hopper with powdered granita mix.

e)Replace the hopper.

f)Push the slide gate on the hopper ejector elbow to the OPEN position.

g)Close the Powder Auto-Fill door.

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ADJUSTMENTS

When using the Powder Auto-Fill with a new powdered granita mix, follow the procedure outlined below to adjust the Powder Auto-Fill to produce the correct recipe.

1.Determine the mix ratio of powdered granita mix. Convert the recipe so that it is expressed in terms of weight units [grams (g), dry ounces (oz), or pounds (lbs)] of powdered granita mix to fluid ounces (fl.oz.) of water [1 gallon (gal) = 128 fl.oz.; 1 liter (l) = 33.8 fl.oz.].

2.The delivery rate of the water ingredient is factory preset to 1 fl.oz. per second. Therefore, it is only necessary to adjust the delivery rate of the powdered granita mix. Adjustment is accomplished as follows:

a) Place the Powder Auto-Fill on top of a fully assembled CDS taking care to align the Powder Auto-Fill guide rails over the rollers on the CDS guide rails.

b) Connect the Powder Auto-Fill power cord to the outlet located on the CDS auger motor cover.

c) Attach a flexible water line to the .25" flare fitting on the back panel of the Powder Auto-Fill.

NOTE: A water strainer assembly (BUNN-O-MATIC #23820.1000) should be installed in line prior to the flexible water line.

d)On the CDS control panel, make the following switch settings:

i)POWER- "ON"

ii)DAY/NIGHT- "DAY"

e)Pull the Powder Auto-Fill fully forward on its support rails

f)Fill the Powder Auto-Fill product hopper as follows:

i)Pull the slide gate closed on the Powder AutoFill product hopper elbow and remove the product hopper from the Powder Auto-Fill.

ii)Remove the lid from the product hopper and fill the hopper with a powdered granita mix.

iii)Install the product hopper into the Powder Auto-Fill.

g)Place the ON/OFF switch at the Powder Auto-Fill whipper panel to "ON".

h)After allowing 5 seconds for the Powder Auto-Fill to initialize, observe the door lamp on the whipper panel. The door lamp should not be lit. If the door lamp is lit, consult the fault list and clear the fault before proceeding.

i)Remove the hole plug on the whipper panel. Using a screwdriver, set potentiometer to approximately mid range.

j)Remove the mixing chamber from the Powder Auto-Fill and place a small container, such as a cup, under the product hopper ejector elbow.

k)Push the slide gate on the product hopper ejector elbow to the OPEN position.

l)Momentarily set the TEST/SERVICE switch on the whipper panel to the TEST position.

m)The hopper motor will run and dispense powdered granita mix for 10 seconds.

n)After the Powder Auto-Fill has finished the 10 second throw test, weigh the dispensed product.

o)Determine the dispense rate of the powdered product (weight units per second) by dividing the measured weight by 10.

p)Compare the measured dispense rate with the mix ratio in step 1.

q)Adjust the MIN/MAX control clockwise to increase the dispense rate or counterclockwise to decrease the dispense rate of the powdered granita mix.

r)Repeat steps l through q as necessary until proper mix ratio is achieved.

s)Replace the mixing chamber removed in step j. Replace hole plug.

3.Once the mix ratio has been adjusted, the Powder Auto-Fill can be run with the door open to allow the user to catch dispensed product for brix testing as follows:

a)Hold a container under the dispense tip of the Powder Auto-Fill.

b)Hold the TEST/SERVICE switch on the whipper panel to the SERVICE position.

c)When the container is filled to the desired level, release the TEST/SERVICE switch.

d)Measure the brix using the appropriate measuring device.

e)Remove the hole plug. Using a screwdriver, adjust the potentiometer clockwise to increase the brix or counterclockwise to decrease the brix of the product. Replace the hole plug.

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CLEANING

RECOMMENDED DAILY CLEANING AND MAINTENANCE TIPS

This should be done in conjunction with the recommended weekly cleaning of your CDS-2 or CDS-3 machine.

Removing and cleaning the whipper chamber

(once a day):

1.Open the cabinet door.

2.Pull the mixing chamber out of the whipper chamber.

3.Twist the whipper chamber clockwise and pull it off the whipper chamber receptacle.

4.Pull the frother off the motor shaft. Notice the flat keyway on the shaft and the matching keyway inside the frother. It is important that these two keyways are lined up when reassembling.

5.Twist the whipper chamber receptacle clockwise and pull it off the motor shaft.

6.Slip the O-ring off the whipper chamber receptacle.

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

8.Rinse thoroughly and allow to dry before reinstalling in the machine.

Mixing Chamber

Whipper Chamber

Receptacle

O-ring

Frother

Dispense Tip

Whipper Chamber

Wiper Blade

Shaft

Wiper Blade

Wiper Drive Gear

Retaining

Clip

Hopper Base

Auger Drive

Shaft

Auger Drive

Bracket

Retaining

Ring

Auger

Ejector Elbow

Slide Gate

Thorough cleaning of the hopper

(once a week):

1.Open the cabinet door.

2.Remove the hopper/base assembly from the cabinet, remove the cover and empty the contents.

3.Pull the ejector elbow off the hopper base; remove the slide gate from the ejector elbow.

4.Remove the wiper blade and drive gear by removing the retaining ring from the wiper blade shaft.

5.Remove the auger by pulling it out of the front hopper base.

6.Remove the auger drive shaft by removing the retaining clip from the auger drive shaft.

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

8.Rinse and dry each item thoroughly before reassembling.

NOTICE

The cleaning instructions noted above are for nondairy sugar based food products. When dispensing any other food product, the cleaning cycle for the whipping chamber assembly and ejector elbow must be performed daily.

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	FAULT LIST
Door Lamp	Fault
ON	Normal operation - Powder Auto-Fill ready to
	dispense
Flashes ON/OFF at 50% duty cycle	Low product level in Powder Auto-Fill hopper
Two flashes about every 2 seconds	CDS/Powder Auto-Fill probe circuit open
Three flashes about every 2 seconds	Powder Auto-Fill hopper not in place
Four flashes about every 2 seconds	CDS refill exceeded 5 minutes
OFF	Door not closed

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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.

•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

PROBABLE CAUSE

REMEDY

CDS and Powder Auto-Fill do not run - Main power indicator on CDS drawer front OFF

Product level in CDS is lower than level Probe - CDS running; Powder Auto-Fill door lamp is OFF

Product level in CDS is lower than level Probe - CDS running; Powder Auto-Fill door lamp flashes ON and OFF

1. CDS power cord disconnected or main power switch in 0 position.

1.The CDS DAY/NIGHT switch in the NIGHT position.

2.The CDS DAY/NIGHT timer in the NIGHT position.

3.Powder Auto-Fill power cord disconnected.

4.Powder Auto-Fill main power switch in OFF position.

5.Powder Auto-Fill door is open.

1. Low product in Powder Auto-Fill.

Check that the power cord is connected to proper electrical source and that the CDS main power switch is in the 1 position.

1.The CDS DAY/NIGHT switch should be in the DAY position.

2.Reprogram the CDS DAY/NIGHT timer.

3.Check that the Powder Auto-Fill is plugged into the back of the CDS auger motor cover.

4.Select the ON position of the main power switch.

5.The Powder Auto-Fill door should be closed securely.

Remove hopper and fill with powdered mix.

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TROUBLESHOOTING (cont.)

PROBLEM

Product level in CDS is lower than level Probe - CDS running; Powder Auto-Fill door lamp flashes two times

PROBABLE CAUSE

1.Powder Auto-Fill not pulled completely forward.

2.CDS level probe misaligned.

REMEDY

1.Check that the Powder Auto-Fill is pulled completely forward until the guide rails roll into the indented position.

2.Position the CDS level probe so that it is located in the notch of the CDS hopper and touching the contact protruding from the front of the CDS cooling drum mount.

Product level in CDS is lower than level Probe - CDS running; Powder Auto-Fill door lamp flashes three times

Product level in CDS is lower than level Probe - CDS running; Powder Auto-Fill door lamp flashes four times

The CDS product tastes "watery" or "sugary"

Powder Auto-Fill dispenses dry product only - dry powder build-up in mixing and whipper chambers

1.Powder Auto-Fill hopper not installed.

2.Powder Auto-Fill hopper not installed properly.

1. Refill time exceeded five minutes.

1.Install the Powder Auto-Fill hopper.

2.Reposition the Powder Auto-Fill hopper.

Check that the SERVICE switch is released or reset by opening and closing the Powder Auto-Fill door.

1. Improper adjustment of product mix ratio.

1.Powder Auto-Fill not connected to water source.

2.Water source turned off.

3.Water line obstructed.

Adjust the product mix ratio per instructions in Powder Auto-Fill Adjustment. See page 5.

1.Connect the Powder Auto-Fill to a

20to 90 psi (138 to 620 kPa)water source.

2.Turn water source on.

3.Remove obstruction.

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TROUBLESHOOTING (cont.)
PROBLEM	PROBABLE CAUSE		REMEDY
Powder Auto-Fill will not dispense	1. No water		Water lines and valves to the dis-
product			penser must be open and free of
			obstructions.
	2.	No power or incorrect voltage to	Check that the power cord is con-
	the dispenser.		nected to the CDS dispenser and for
			voltage from the CDS dispenser.
	3.	Dispense Solenoid Valve	Refer to ServiceDispense Solenoid
			Valve for testing procedures. See
			page 32
	4.	Control Board and Probe	Refer to ServiceControl Board and
			Probe for testing procedures. See
			page 18
	5.	Auger Drive	Refer to ServiceAuger Drive for
			testing procedures. See page 13
	6.	Transformer	Refer to ServiceTransformer for
			testing procedures. See page 26
	7.	Water Strainer (Optional)	A) Direction of flow arrow must be
			pointing towards dispenser.
			B) Remove the strainer and check
			for obstructions. Clear or replace.
Dripping from dispense tip	1. Dispense Solenoid Valve		Remove dispense valve and clear
			any obstructions. Rebuild or replace
			the valve if necessary. Seepage 32
Water flows continuously	1. Control Board and Probe		Refer to ServiceControl Board and
			Probe for testing procedures. See
			page 18
	2.	Dispense Solenoid Valve	Refer to ServiceDispense Solenoid
			Valve for testing procedures. See
			page 32

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TROUBLESHOOTING (cont.)
PROBLEM	PROBABLE CAUSE		REMEDY
Product overflows CDS hopper	1. Control Board and Probe		Refer to ServiceControl Board and
			Probe for testing procedures. See
			page 18
	2.	Dispense Solenoid Valve	Refer to ServiceDispense Solenoid
			Valve for testing procedures. See
			page 32
Weak product	1. Whipper Motor		Refer to ServiceWhipper Motor for
			testing procedures. See page 16
	2.	Frother	Refer to ServiceFrother for testing
			procedures. See page 15
	3.	Dispense Solenoid Valve	Refer to ServiceDispense Solenoid
			Valve for testing procedures. See
			page 32
	4.	Auger Drive	Refer to ServiceAuger Drive for
			testing procedures. See page 13
	5.	Auger Spring	Refer to ServiceAuger Spring for
			testing procedures. See page 13
	6.	Auger Motor	Refer to ServiceAuger Motor for
			testing procedures. See page 14
	7. Improper adjustment of product		Set the product mix ratio per Adjust-
	mix ratio		ments. See page 5
Dispenser is making unusual noises	1. Plumbing lines		Plumbing lines should not be rest-
			ing on the counter top.
	2.	Water supply	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 ap-
			proximately 50 psi (345 kPa).
Display not lit	1. Lamp		Refer to ServiceLamp for testing
			procedures. See page 25
	2.	Lamp Holder	Refer to ServiceLamp Holder for
			testing procedures. See page 25

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