Bunn Coffee Maker FMD-1 Service Manual

FMD Series

Including: FMD-1,2,3,4,5

SERVICE & REPAIR MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

PHONE: (217) 529-6601 FAX: (217) 529-6644

BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY

(Excluding regular maintenance items)

Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:

1) All equipment other than as speciﬁed below: 2 years parts and 1 year labor.

2) Electronic circuit and/or control boards: parts and labor for 3 years.

3) Compressors on refrigeration equipment: 5 years parts and 1 year labor.

4) Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis: parts and labor for 3 years or 30,000 pounds of coffee, whichever comes ﬁrst. These warranty periods run from the date of installation BUNN warrants that the equipment manufactured by it will be commercially free of defects in material and workmanship existing at the time of manufacture and appearing within the applicable warranty period. This warranty does not apply to any equipment, component or part that was not manufactured by BUNN or that, in BUNN’s judgment, has been affected by misuse, neglect, alteration, improper installation or operation, improper maintenance or repair, damage or casualty. This warranty is conditioned on the Buyer 1) giving BUNN prompt notice of any claim to be made under this warranty by telephone at (217) 529-6601 or by writing to Post Ofﬁce Box 3227, Springﬁeld, Illinois 62708-3227; 2) if requested by BUNN, shipping the defective equipment prepaid to an authorized BUNN service location; and 3) receiving prior authorization from BUNN that the defective equipment is under warranty.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of BUNN

are not authorized to make modiﬁcations to this warranty or to make additional warranties that are binding on BUNN. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon. If BUNN determines in its sole discretion that the equipment does not conform to the warranty, BUNN, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the applicable parts and labor warranty periods speciﬁed above) to repair the defective components, provided that this repair is done by a BUNN Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for the equipment.

THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED, AT BUNN’S SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND.

In no event shall BUNN be liable for any other damage or loss, including, but not limited to, lost proﬁts, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.

AutoPOD, AXIOM, BrewLOGIC, BrewMETER, Brew Better Not Bitter, BrewWISE, BrewWIZARD, BUNN Espress, BUNN Family Gourmet, BUNN Gourmet, BUNN Pour-O-Matic, BUNN, BUNN with the stylized red line, BUNNlink, Bunn-OMatic, Bunn-O-Matic, BUNNserve, BUNNSERVE with the stylized wrench design, Cool Froth, DBC, Dr. Brew stylized Dr. design, Dual, Easy Pour, EasyClear, EasyGard, FlavorGard, Gourmet Ice, Gourmet Juice, High Intensity, iMIX, Infusion Series, Intellisteam, My Café, PowerLogic, Quality Beverage Equipment Worldwide, Safety-Fresh, savemycoffee.com, Scale-Pro, Silver Series, Single, Smart Funnel, Smart Hopper, SmartWAVE, Soft Heat, SplashGard, The Mark of Quality in Beverage Equipment Worldwide, ThermoFresh, 392, Beverage Bar Creator, Beverage Proﬁt Calculator, BUNNSource, Coffee At Its Best, Digital Brewer Control, Nothing Brews Like a BUNN, Pouring Proﬁts, Respect Earth, Respect Earth with the stylized leaf and coffee cherry design, Signature Series, Tea At Its Best, The Horizontal Red Line, Titan, Ultra are either trademarks or registered trademarks of Bunn-O-Matic Corporation.

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INTRODUCTION

Safety ﬁrst!

To avoid electrical shock, unplug dispenser from power source before servicing inside.

Basic Maintenance

In order to maintain proper machine operation, a Preventative Maintenance schedule must be performed on a regular basis.

The following procedures pretain to all versions in the FMD family of machines unless otherwise noted.

CONTENTS

Warranty ...................................................................................................................................2

User Notices .............................................................................................................................3

Site Preparation .......................................................................................................................3

Preventive Maintenance

Recommended Cleaning ....................................................................................................4

Preventive Maintenance Schedule .......................................................................................5

Troubleshooting ........................................................................................................................6

Service .................................................................................................................................... 12

Electrical Schematics ..............................................................................................................42

USER NOTICES

All notices on this equipment are written for your protection. All notices are to be kept in good condition.

Replace any unreadable or damaged labels.

SITE PREPARATION

A minimal clearance is required between the dispenser sides and the wall or another appliances. Leave some space so the dispenser can be moved for cleaning.

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CLEANING

1 x 24h

NOTICE

The cleaning instructions noted above are for non-dairy 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.

NOTA:

Las instrucciones de limpieza descritas anteriormente excluyen productos lacteos azucarados. La limpieza de las camaras de mezcla y de los codos de salida de cada tolva deberá realizarse diariamente.

1 x 7d

a. Wash b. Rinse c. Sanitize d. Dry

a. Lave b. Enjuague c. Desinfecte d. Seque

Replace Light Bulbs as required.

1. Para limpiar las camaras de mezcla, coloque el interruptor en la posicón ENJUAGUE/MARCHA (”RINSE/RUN”) y pulse el boton

para espumar y distribuir la bebida (”DISPENSE”).

2. Gire el codo hacia arriba, remueva las tolvas, llene las tolvas con producto y coloque las tolvas nuevamente en la maquina.

3. Vacie la bandeja de goteo y limpiela con un detergente liquido suave no abrasivo.

1. Rinse out Whipper Chambers by placing RINSE/RUN switch in the "RINSE" position and activating DISPENSE switches.

2. Turn elbow up, remove Hoppers, refill with product and replace hoppers into dispenser

3. Empty Drip Tray and wash in a solution of dish detergent.

Cambie los bombillos quemados cuando sea necesario.

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. Do NOT clean this equipment with a water jet device.

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REQUIRED REGULAR MAINTENANCE:

When performing Daily-Weekly Cleaning procedures, inspect o-rings, seals, and bushings for signs of wear or damage and replace immediately.

Check and/or replace every 6 months or as required:

32906.0000 Mixing Chamber Kit (Includes items indented below)

25732.0000 Steam Collector

25733.0000 Mixing Chamber

25734.0000 Whipper Chamber

25736.0000 Dispense Tip

24733.0010 O-ring

25902.0000 Frother

26356.0000 Shaft Seal

28866.0000 Receptacle

25903.0000 Elbow

29128.0000 Whipper Motor Seal Kit (Includes items indented below)

24733.0010 O-ring

28867.0000 Slinger

26356.0000 Shaft Seal

Check and/or replace every 3 months or as required:

26356.1000 Whipper Shaft Seal Kit (Contains 6 Seals)

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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qualiedserviceperson-

nel.

• Allelectroniccomponentshavehighvoltage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ttings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specied.   • Followrecommendedserviceprocedures   • Replaceallprotectiveshieldsorsafetynotices

PROBLEM

Product will not dispense

PROBABLE CAUSE

1. No water

2. No power or incorrect voltage to the dispenser

3. Dispense Switch

4. Digital Touch Control Switch

5. Dispense Solenoid Valve

6. Solenoid Valve (Inlet)

REMEDY

Water lines and valves to the dispenser must be open.

(A) Check for correct voltage to the dispenser.

(B) Check circuit breakers or fuses.

Refer to Service - Dispense Switch for testing procedure. See page 28

Refer to Service - Digital Touch Control Switch for testing procedure. See page 29

Refer to Service - Dispense Solenoid Valve for testing procedures. See page 47

Refer to Service - Solenoid Valve (Inlet) for testing procedures. See page 49

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TROUBLESHOOTING (cont.)

PROBLEM

Product will not dispense (cont.)

PROBABLE CAUSE

7. Level Control Board and Probe FMD-1

REMEDY

Refer to Service - Level Control Board and Probe for testing procedures. See page 41

8. Control Board

9. Overﬂow Protection Switch

10. Auger Drive

11. Water Strainer

12. 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.

Refer to Service - Control Board and Probe for testing procedures. See page 20

Refer to Service - Overﬂow Protection Switch. See page 44

Refer to Service - Auger Drive. See page 14

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

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

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

Water is not hot

13. Transformer

14. Rinse Cycle Not Run

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

2. Control Thermostat

3. Tank Heater

Refer to Service - Transformer for testing procedures. See page 40

Refer to Cleaning for running a Rinse Cycle.

Refer to Service - Limit Thermostat for testing procedures. See page 43

Refer to Service - Control Thermostat for testing procedures. See page 26

Refer to Service - Tank Heater for testing procedures. See page 50

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TROUBLESHOOTING (cont.)

PROBLEM

PROBABLE CAUSE

REMEDY

Water is not hot (Cont.)

Spitting or excessive steaming

4. Tank Heater Switch

5. Heater Relay

6. Control Board

1. Lime build-up CAUTION - Tank and tank components should be delimed regularly depending on local water conditions. Excessive mineral build-up on stainless steel surfaces can initiate corrosive reactions resulting in serious leaks.

2. Control Thermostat

Refer to Service - Tank Heater Switch for testing procedures. See page 52

Refer to Service - Heater Relay for testing procedures. See page 51

Refer to Service - Control Board for testing procedures. See page 20

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

Refer to Service - Control Thermostat for testing procedures. See page 26

Dripping from dispense tip

Water ﬂows into tank continuously

2. Dispense Solenoid Valve

1. Control Board

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 47

Refer to Service - Control Board and Probe for testing procedures. See page 20

Refer to Service - Solenoid Valve (Inlet) for testing procedures. See page 49

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TROUBLESHOOTING (cont.)

PROBLEM

PROBABLE CAUSE

REMEDY

Water ﬂows into tank continuously

(Cont.)

Weak product

3. Overﬂow Protection Switch

4. Digital Touch Control Switch

1. Water Temperature

2. Whipper Motor

3. Frother

4. Dispense Solenoid Valve

Refer to Service - Overﬂow Protection Switch. See page 44

Refer to Service - Digital Touch Control Switch for testing procedures. See page 29

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.(see thermostat temperature settings decal)

Refer to Service - Whipper Motor for testing procedure. See page 34

Refer to Service - Frother Components. See page 33

Refer to Service - Dispense Solenoid for test procedures. See page 47

5. Auger Drive

6. Auger Spring

7. Auger Motor

8. Rinse/Run Switch

9. Rinse Timer

10. Tank Heater Relay

11. Control Board

Refer to Service - Auger Drive Components. See page 14

Refer to Service - Rinse/Run Switch for test procedures. See page 45

Refer to the Installation and Operating Manual

Refer to Service - Relay. See page 51

Refer to Service - Control Board. See page 20

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TROUBLESHOOTING (CONT.)

PROBLEM

Product overﬂows container

Dispenser is making unusual noises

PROBABLE CAUSE

1. Dispense Switch

2. Dispense Solenoid Valve

1. Plumbing Lines

2. Water Supply

REMEDY

Refer to Service - Dispense Switch for testing procedures. See page 28

Remove the solenoid valve and clear any obstructions. Rebuild or replace the valve if necessary. See page 47

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).

Excess dust

Display not lit

3. Tank Heater

1. Fan

2. A) Hopper Drive Board - FMD-1

B) Control board

1. Lamp

2. Lamp Holder

3. Starter - Lamp

Remove and clean lime off the tank heater. See page 50

Refer to Service - Fan for testing procedures. See page 32

Refer to Service - Hopper Drive Board for testing procedures. See page 35

Refer to Service - Control Board for testing procedures. See page 20

Refer to Service - Lamp, see page 39 for lamp replacement.

Refer to Service - Lamp Holder for testing procedures. See page 39

Refer to Service - Starter for testing procedures. See page 40

4. Ballast

Refer to Service - Ballast for testing procedures. See page 19

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NOTES

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SERVICE

This section provides procedures for testing and replacing various major components used in this dispenser should service become necessary. Refer to Troubleshooting for assistance in determining the cause of any problem.

WARNING - Inspection, testing, and repair of electrical equipment should be performed only by qualiﬁed service personnel. The dispenser should be disconnected from the power source when servicing, except when electrical tests are required and the test procedure speciﬁcally states to connect the dispenser to the power source.

COMPONENT ACCESS WARNING - Disconnect the dispenser from the power source before the removal of any panel or the replacement

of any component.

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

Refer to the contents listing for component location.

INDEX

Access Panels .................................................................................................................................. 13

Auger Drive Components ................................................................................................................. 14

Auxillary Control Board (FMD DBC-3) ..............................................................................................17

Ballast ..............................................................................................................................................19

Control Board (Main) ..................................................................................................................20,23

Control Thermostat .......................................................................................................................... 26

Dispense Switches ...........................................................................................................................28

Digital Touch Control Switch ............................................................................................................29

EMI Filter (FMD DBC-3) ...................................................................................................................31

Fan ................................................................................................................................................... 32

Frother ............................................................................................................................................33

Hopper Drive Board (FMD-1) ...........................................................................................................35

Hot/Cold Switch (FMD DBC-3) .........................................................................................................37

Increase/Decrease Switch ................................................................................................................ 38

Lamp ................................................................................................................................................39

Lamp Holder ....................................................................................................................................39

Lamp Starter & Socket .....................................................................................................................40

Level Control Board (FMD-1) ...........................................................................................................41

Limit Thermostat ..............................................................................................................................43

Overﬂow Protection Switch ..............................................................................................................44

Rinse/Run Switch ............................................................................................................................45

Solenoid (Cold Drink) .......................................................................................................................46

Solenoid (Dispense) .........................................................................................................................47

Solenoid (Hot Water) .......................................................................................................................48

Solenoid (Inlet) ................................................................................................................................49

Tank Heater ......................................................................................................................................50

Tank Heater Relay (FMD-4,5) ...........................................................................................................51

Tank Heater Switch ..........................................................................................................................52

Transformer .....................................................................................................................................53

Whipper Motor .................................................................................................................................34

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SERVICE(CONT.)

PLACE

CUP HERE

ACCESS PANELS

Location:

All access panels are similar through the whole FMD family (FMD-5 shown). Before removing panels, make

sure power is OFF to the machine and water is disconnected accept where indicated in testing procedures. Retain

all screws and other attaching hardware for re-assembly.

FMD-5 shown

FIG. 1 ACCESS PANELS

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SERVICE (CONT.)

AUGER DRIVE COMPONENTS (all Models)

FMD-4 shown

P4095

FIG. 2 AUGER DRIVE COMPONENTS

Location The auger components are located inside the bottom part of the hopper except for the auger drive bracket, spacer and retaining clip, which are located on the outside rear of the hopper base. The auger motor is located on the lower right rear of the motor mounting panel. Refer to Fig. 3 for disassembly and assembly.

Test Procedures - Auger Motor

1. Disconnect the dispenser from the power source.

2. Disconnect the white/red wire and the white wire

from the hopper drive board (FMD-1) or relative

wires from the control board(all other models).

3. Check the voltage across the white/red wire and

the white wire with a voltmeter. With the rinse/

run switch in the run (lower) position, connect the

dispenser to the power supply. The indication must

be: a) 120 volts ac for two wire 120 volt models. b)120 volts ac for three wire120/208 volt or

120/240 volt models. c) 230 volts ac for two wire 230 volt models.

4. Disconnect the dispenser from the power supply.

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

5. Check the voltage across the positive (red wire) terminal and the negative (black wire) terminal on the auger motor with a voltmeter. With the rinse/ run switch in the run (lower) position press and hold the dispense switch. Connect the dispenser to the power supply. After a .6 second delay the indication must be 4.0 to 24.5 volts dc.

If voltage is present as described, the auger motor drive is operating properly. If auger does not turn, replace the auger motor. If voltage is not present as described, check the auger hopper drive board.

Removal, Cleaning and Replacement Hopper & Auger (FMD-1,4)

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

2. Lift the hopper assy (15) over the pins on hopper support plate (11) and slide hopper assembly out the front of the dispenser.

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

4. Pull off the ejector elbow (14).

5. Remove retainer clip (10) and washer (9) from the bottom of the hopper base (8).

6. Remove whipper shaft (3), wiper blade (4) and wiper drive gear (5) from the hopper base (8).

7. Remove auger wire (13) by pulling it out the front of the hopper base (8).

8. Remove auger drive bracket (6) by unscrewing left hand threads from auger drive shaft (12).

9. Slide spacer (7) and auger drive shaft bracket (6) off of the auger drive shaft (12).

10. Remove auger drive shaft (12) from hopper base (8).

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

12. Rinse and dry each item thoroughly.

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

14. Install hopper assy (15) in the dispenser by sliding hopper assy on the hopper support plate (11) until the slot in the rear of the hopper base (8) seats against the pins in the hopper support plate (11).

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SERVICE (CONT.)

AUGER DRIVE COMPONENTS

FMD-4 shown

3 4

5 12 13

8 9 10

16 17 18 19 11

FIG. 3 AUGER DRIVE & HOPPER DISASSEMBLY

P2633

Auger Drive Motor (Refer to Fig. 2)

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

sembly.

2. Remove the four #8-32 screws securing the hopper

support plate (11), remove plate and set aside for reassembly.

3. Remove the four #8-32 screws, located inside the

dispenser housing on the lower right front of the auger motor mounting panel (19), securing auger motor mounting bracket (16) and auger motor (17) to the rear of the auger motor mounting panel (19).

4. Disconnect the wires from the hopper drive

board.

5. Remove auger motor mounting bracket (16), auger

motor (17) and dust seal (18) as an assembly.

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

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

8. Remove the four #8-32 screws securing the auger

motor (17) to the auger motor mounting bracket (16).

9. Remove auger motor (17) and discard.

10. Using four #8-32 screws install new auger motor

(17) on mounting bracket (16).

11. Install dust seal (18) on auger motor shaft and align

notch in seal with motor casting.

12. Reconnect the wires to the terminals on the hopper

drive board.

13. Refer to schematic wiring diagrams when recon-

necting the wires.

14. Using four #8-32 locking screws install auger mo-

tor, dust seal and mounting bracket to the rear of the auger motor mounting panel (19).

15. Install hopper assy (15).

1. Hopper Lid

2. Hopper

3. Wiper Shaft

4. Wiper Blade

5. Wiper Drive Gear

6. Auger Drive Bracket

7. Spacer

8. Hopper Base

9. Washer

10. Retainer Clip

11. Hopper Support Plate

12. Auger Drive Shaft

13. Auger Wire

14. Ejector Elbow

15. Hopper Assembly

16. Auger Motor Bracket

17. Auger Motor

18. Dust Seal

19. Auger Motor Mounting panel

RED to Control Board

BLK to GRN from Control Board

FIG. 4 AUGER MOTOR TERMINALS

P1639

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SERVICE (CONT.)

AUGER DRIVE COMPONENTS

Removal, Cleaning and Replacement Hopper & Auger (all other hoppers)

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

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

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

4. Pull off the ejector elbow (13).

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

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

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

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

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

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

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

12. Rinse and dry each item thoroughly.

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

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

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

1 2

3 8

14 15 16 12 13

FMD-5 shown

9 10

P2634

FIG. 5 AUGER DRIVE & HOPPER DISASSEMBLY

1. Hopper Lid

2. Mixing Blade

3. Agitator Disk

4. Auger Drive Shaft Bushing

5. Auger Drive Shaft

6. Locknut

7. Auger Drive Bracket

8. Hopper

9. Auger Wire

10. Ejector Elbow

11. Hopper Assy

12. Auger Motor Mounting Panel

13. Hopper Support Plate

14. Auger Motor Bracket

15. Auger Motor

16. Dust Seal

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SERVICE (CONT.)

AUXILLARY CONTROL BOARD (FMD DBC-3 only)

P4102.40

FIG. 6 AUXILIARY CONTROL BOARD

Location: The auxiliary control board is located behind the lower front access cover, mounted on the rear side of the component bracket.

4. Back probe check the voltage across pins 2 (black wire) and 5 (white wire) of the six pin J2 connector on the 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 or 120/240

volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

5. Disconnect the dispenser from the power source.

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

6. Check the voltage across the terminals of the hot water dispense solenoid with a voltmeter. Connect the dispenser to the power source. Press the hot water dispense switch. The indication must be:

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

volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

7. Disconnect the dispenser from the power source.

If voltage is present as described the hot water dispense circuitry is operating properly. If voltage is not present as described, replace the auxiliary control board.

Hot Water Dispense Test Procedure:

1. Disconnect the dispenser from the power source.

2. With a voltmeter, and using the component mounting bracket as a reference (-), back probe check for voltage at pin 1 (red wire) of J1. Connect the dispenser to the power source. The indication must be approximately 37 volts dc.

3. Disconnect the dispenser from the power source.

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

Ready Light Circuit Test Procedure:

1. Disconnect the dispenser from the power source.

3. Disconnect the dispenser from the power source.

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

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SERVICE (CONT.)

AUXILLARY CONTROL BOARD (CONT.)

4. On the dispenser whipper panel, ensure that the tank heater switch is in the “ON” (lower) position.

5. Disconnect the black wire coming from the control thermostat from the limit thermostat.

6. Remove the control thermostat bulb from the tank.

7. With a voltmeter, and using pin 5 as a reference, back probe check for voltage, in turn, at pin 3 and pin 6 of the six pin J2 connector of the wiring harness. 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 or 120/240

volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

8. Disconnect the dispenser from the power source.

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

9. Re-install the control thermostat bulb.

10. Noting the starting position of the control thermostat knob, adjust the control thermostat knob counterclockwise until a click is heard.

11. With a voltmeter, check for voltage between pins 3 and 6 of the six pin J2 connector of the wiring harness. 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 or 240 volts

ac for three wire 120/240 volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

12. Disconnect the dispenser from the power source. Return the control thermostat knob to the starting position.

Removal and Replacement:

1. Loosen the two #8-32 screws securing the component mounting bracket to the dispenser housing.

2. Slide the component mounting bracket forward until the screw heads align with the large diameters of the keyhole openings.

3. Lift the component mounting bracket, and pull it through the lower access panel opening.

4. Disconnect the two plugs on the main wiring harness from the connectors on the auxiliary control board.

5. Remove the two #6-32 keps nuts securing the

auxiliary control board to the component mounting

bracket.

6. Remove the auxiliary control board.

7. Remove the two snap-in stand-offs from the auxiliary control board and install them in the new auxiliary control board. Discard the old auxiliary control board.

8. Install the new auxiliary control board using the two #6-32 keps nuts.

9. Reconnect the two plugs on the main wiring harness to the connectors on the auxiliary control board.

10. Replace the component mounting bracket and tighten the two #8-32 screws.

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

FIG. 7 AUXILIARY CONTROL

BOARD TERMINALS

P1996.80

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SERVICE (cont.)

BALLAST (all Models)

FMD-4 shown

Removal and Replacement

1. Loosen the three #8-32 screws securing the com-

ponent bracket to the dispenser housing base.

2. Pull component bracket out the front of the dis-

penser far enough so the leads on each ballast can be disconnected from the main wiring harness and the door interconnect harness.

3. Remove the two #8-32 screws securing each ballast

to the rear of the component bracket.

4. Remove and discard the ballast.

5. Install new ballast on the rear of the component

bracket and secure each with two #8-32 screws.

6. Refer to schematic wiring diagrams when recon-

necting the wires.

7. Place the component bracket into position and

tighten the two #8-32 screws securing the component bracket to the dispenser housing base.

P4095

FIG. 8 BALLASTS

Location The front door lamp ballasts are located behind

the front access panel and may be on either side of the component bracket assembly.

Test Procedure

1. Disconnect the dispenser from the power source.

2. Disconnect the two black leads on the ballast from the main harness.

3. Check for continuity between the two black leads on the ballast.

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

BLK to BLK from Main Wiring Harness

BLK to RED from Main Harness

P1447

FIG. 9 BALLAST TERMINALS

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SERVICE (cont.)

CONTROL BOARD (FMD-2,-2FD,DBC-2FD,DBC-3)

FMD DBC-3 shown

FIG. 10 CONTROL BOARD Location: The Control Board is located behind the lower front access cover mounted on the component bracket.

Test Procedure: Power Supply:

1. Disconnect the dispenser from the power source.

2. With a voltmeter, back probe check the voltage

across pins 1 & 2 of the eight pin J1 connector on the wiring harness. Connect the dispenser to the power source. The indication must be 24 volts ac.

3. Disconnect the dispenser from the power source.

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

P4102.40

4. With a voltmeter, back probe check the voltage across pins 2 & 4 of the six pin J2 connector on the wiring harness. 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 models

or three wire 120/240 volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

5. Disconnect the dispenser from the power source.

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

Liquid Level Control Circuitry

6. Carefully connect a piece of insulated jumper wire to pin 3 (third from left on top row) of J1 on the control board. Keep the other end of this wire away from any metal surfaces of the dispenser.

7. With a voltmeter check the voltage across the terminals of the inlet solenoid valve. Connect the dispenser to the power source. After a 10 second delay, the indication must be :

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

volt models.

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

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

If voltage is present as described, proceed to step 9. If the voltage is not present as described, replace the control circuit board. NOTE: Verify the ground wire is connected to the board mounting stud before replacing the control board.

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

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

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SERVICE (cont.)

CONTROL BOARD (CONT.)

11. With a voltmeter check the voltage across the terminals of the inlet solenoid valve. Connect the dispenser to the power source. After a 10 second delay, the indication must be :

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

volt models.

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

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

13. Move the probe’s ﬂat end away from the housing. After a 5 second delay, the indication must, again, be:

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

volt models.

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

14. Disconnect the dispenser from the power source.

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

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

Whipper Motor and Dispense Solenoid Circuitry:

1. Disconnect the dispenser from the power source.

2. With a voltmeter, back probe check the voltage across pins 1 & 2 of the eight pin J1 connector on the wiring harness. Connect the dispenser to the power source. The indication must be 24 volts ac.

3. Disconnect the dispenser from the power source.

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

Hopper Motor Control Circuitry:

1. Disconnect the dispenser from the power source.

2. With the voltmeter, back probe check the voltage across pins 1 & 2 of the eight pin J1 connector on the wiring harness. Connect the dispenser to the power source. The indication must be 24 volts ac from the transformer.

3. Disconnect the dispenser from the power source.

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

4. Check that the “Rinse/Run” switch is in the “Run” position.

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

4. Check that the RINSE/RUN switch is in the “Rinse” position.

5. With a voltmeter, back probe check the voltage across pins 2 & 4 of the six pin J2 connector on the wiring harness. 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 or 120/240

volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

6. Disconnect the dispenser from the power source.

7. With a voltmeter check the voltage across the terminals of the appropriate dispense solenoid. Connect the dispenser to the power source. Press the appropriate dispense switch. The indication must be :

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

volt models

c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt models.

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SERVICE (cont.)

CONTROL BOARD (cont.)

If the voltage is present as described, the whipper motor and dispense solenoid control circuitry is operating properly. If the voltage is not present as described, replace the control circuit board.

Removal and Replacement:

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

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

3. Remove control board and discard.

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

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

FIG. 11 CONTROL BOARD CONNECTORS

P1680

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