Page 1
BUNN
DISCONTINUED VERSION
The information in this manual
®
HC-1
(SERIAL # HC00025000 - UP)
is no longer current.
OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
27591.0001 6/00 ©1996 Bunn-O-Matic Corporation
Page 2
INTRODUCTION
This equipment dispenses hot beverages on demand from powered product. 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 061600
Page 3
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.
26525.0001
00831.0000
00656.0000
12368.0002
11646.0000
27620.0000
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27591 061600
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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
Initial Set-Up.
The 120 volt version of this dispenser has an attached cordset and requires 2-wire, grounded service rated 120
volts ac, 15 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-15R.
The 120/240 volt version of this dispenser requires 3-wire, grounded service rated 120/240 volt ac, 20 amp,
single phase, 60 Hz.
(
Refer to the dispenser’s dataplate for exact voltage requirement.)
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).
120 volt versions proceed to step 6.
120/240 volt versions proceed to next step.
4. Remove the right side panel of the dispenser.
5. Install the electrical wiring to the terminal block as illustrated at right.
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.
L2 RED
WHITE
NEUTRAL
L1 BLACK
120V.A.C.
120V.A.C.
208 or
240V.A.C.
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 brewer 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 brewer. 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).
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27591 061600
Page 5
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 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 with the dry product to be dispensed.
DISPENSER USE
1. Simply place a cup on the drip tray beneath the 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.
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 beverage solenoid is 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 solenoid clockwise to decrease or counterclockwise to increase the
amount of water.
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DRAINING THE HOT WATER TANK
CAUTION - The dispenser must be disconnected from the power source throughout these steps.
1. Disconnect the dispenser from the power source.
2. 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 8 tooth gear and auger wire is approximately 4 to 6 grams per second.
2. Hopper dispense rate with optional 12 tooth gear and auger wire is 6 to 9 grams per second.
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TROUBLESHOOTING
A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic
Technical Service Department.
• Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel.
• All electronic components have 120 volt ac and low voltage dc potential on their terminals. Shorting of
terminals or the application of external voltages may result in board failure.
• Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If an
intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a
terminal or crimp.
• Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are
energized for more than ten minutes without a supply of water.
• The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened. This will help
to avoid twists and kinks in the tubing.
• Make certain that all plumbing connections are sealed and electrical connections tight and isolated.
• This unit is heated at all times. Keep away from combustibles.
WARNING – • Exercise extreme caution when servicing electrical equipment.
• Unplug the dispenser when servicing, except when electrical tests are specified.
• Follow recommended service procedures
• Replace all protective shields or safety notices
PROBLEM
Product will not dispense
PROBABLE CAUSE
1. No water
2. No power or incorrect voltage
tothe dispenser
3. Dispense switch
4. Dispense solenoid valve
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.
(B) Check circuit breakers or fuses.
Refer to
Service
- Dispense Switch
for testing procedure. See page 17
Refer to
Service
- Dispense solenoid
valve for testing procedures. See
page 28
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Page 8
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Product will not dispense (cont.)
5. Solenoid valve (inlet)
6. Level control board and probe
7. Overflow protection switch
8. Auger drive
9. Water strainer
Refer to
Service
- Solenoid Valve
(Inlet) for testing procedures. See
page 29
Refer to
Service
- Level Control Board
and Probe for testing procedures.
See page 24
Refer to
Service
- Overflow protection switch for testing procedures.
See page 26
Refer to
Service
- Auger Drive. See
page 12
(A) Direction of flow arrow must be
pointing towards brewer.
(B) Remove the flow control and
check for obstructions. Clear or replace.
Water is not hot
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
2. Control thermostat (mechanical
or electronic)
3. Tank Heater
Inspect the tank assembly for excessive lime deposits. Delime as required.
Refer to
Service
- Limit Thermostat
for testing procedures. See page 25
Refer to
Service
- Control Thermostat for testing procedures. See page
15
Refer to
Service
- Tank Heater for
testing procedures. See page 30
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TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Water is not hot (Cont.)
Spitting or excessive steaming
Dripping from dispense tip
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)
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.
Refer to
Service
- Tank Heater Switch
for testing procedures. See page 31
Inspect tank assembly for excessive
lime deposits. Delime as required.
Refer to
Service
- Control Thermostat for testing procedures. See
page 15
Inspect the tank assembly for excessive lime deposits. Delime as required.
Water flows into tank continuously
2. Dispense solenoid valve
1. Level control board and probe
2. Solenoid valve (Inlet)
3. Overflow Protection Switch
Remove the dispense solenoid valve
and clear any obstructions. Rebuild
or replace the valve if necessary. See
page 28
Refer to
Service -
Level Control Board
and Probe for testing procedures.
See page 24
Refer to
Service
- Solenoid Valve
(Inlet) for testing procedures. See
page 29
Refer to
Service
- Overflow Protection Switch for testing procedures.
See page 26
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TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Product overflows container
Weak product
1. Dispense switch
2. Dispense solenoid valve
1. Water temperature
Refer to
Service -
Dispense
Switch for testing procedures. See
page 17
Remove the solenoid valve and
clear any obstructions. Rebuild or
replace the valve if necessary. See
page 28
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
5. Auger drive
6. Auger spring
7. Auger motor
Refer to
Service
- Whipper Motor for
testing procedure. See page 19
Refer to
Service
- Frother Compo-
nents. See page 19
Refer to
Service
- Dispense Solenoid
Valve for test procedures. See page
28
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 12
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TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Dispenser is making unusual
noises
Excess dust
1. Plumbing Lines
2. Water Supply
3. Tank Heater
1. Fan
2. Hopper Delay Board
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 30
Refer to
Service
- Fan for testing
procedures. See page 18
Refer to
Service
- Hopper Delay Board
for testing procedures. See page 21
Display not lit
1. Lamp
2. Lamp Holder
3. Starter - Lamp
4. Ballast
Refer to
Service
- Lamp, see page 23
for lamp replacement.
Refer to
Service
- Lamp Holder for
testing procedures. See page 23
Refer to
Service
- Starter for testing
procedures. See page 23
Refer to
Service
- Ballast for testing
procedures. See page 14
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Page 12
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 ......................................................... 12
Ballast ................................................................... 14
Control Thermostat...............................................15
Dispense Switch ...................................................17
Fan........................................................................18
Frother ................................................................. 19
Hopper Delay Board.............................................. 21
Lamp Holder ......................................................... 22
Lamp .................................................................... 23
Lamp Starter and Socket ...................................... 23
Level Control Board and Level Probe .................... 24
Limit Thermostat .................................................. 25
Overflow Protection Switch .................................. 26
Rinse/Run Switch .................................................27
Solenoid (Dispense) ............................................. 28
Solenoid (Inlet) ..................................................... 29
Tank Heater .......................................................... 30
Tank Heater Switch ............................................... 31
Whipper Motor ..................................................... 19
Wiring Diagram .................................................... 32
FIG. 1 AUGER DRIVE COMPONENTS
P1226
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 rear of the hopper base. The auger motor is
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.
3. Check the voltage across the white/red wire and
the white/black wire with a voltmeter. Press and
hold the 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.
4. Disconnect the dispenser from the power sup-
ply.
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Page 13
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 diagram and check the dispenser wiring harness.
5. With the wires removed from the motor . 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 hopper assy (18) over the pins (17) on
hopper support plate (13) and slide hopper assembly out the front of the dispenser.
3. Remove hopper lid (1) and empty product.
4. Lift hopper (2) off of the hopper base(9).
5. Pull off the ejector elbow (16).
6. Remove retainer pin (11) and washer (10) from
the bottom of the hopper base (9).
7. Remove whipper shaft (3), wiper blade (4) and
wiper drive gear (5) from the hopper base (9).
8. Remove auger wire (15) by pulling it out the front
of the hopper base (9).
9. Remove auger drive shaft (14) by removing the
retaining clip (6) from auger drive shaft.
10. Slide spacer (8) and auger drive shaft bracket (7)
off of the auger drive shaft (14).
11. Remove auger drive shaft (14) from hopper base
(9).
12. Wash components in a mild solution of dish deter-
gent using a bristle brush when needed.
13. Rinse and dry each item thoroughly.
14. Check for damaged or broken components, re-
place any if necessary and reassemble hopper
assembly.
1
2
3
4
5
6
7
8
14 15 16
9
10
11
12
13
17
18
19 20 21
FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY
1. Hopper Lid
2. Hopper
3. Wiper Shaft
4. Wiper Blade
5. Wiper Drive Gear
6. Retainer Clip
7. Auger Drive Bracket
8. Spacer
9. Hopper Base
10. Washer
11. Retainer Clip
12. Shoulder Screw
13. Hopper Support Plate
14. Auger Drive Shaft
15. Auger Wire
16. Ejector Elbow
17. Hopper Locating Pins
18. Hopper Assembly
19. Auger Motor Bracket
20. Auger Motor
21. Dust Seal
P1227
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Page 14
SERVICE (cont.)
AUGER DRIVE COMPONENTS (cont.)
15. Install hopper assy (18) in the dispenser by sliding hopper assy on the hopper support plate (13)
until the slot in the rear of the hopper base (9)
seats against the shoulder screw (12) and pins
(17) in the hopper support plate (13).
Auger Drive Motor (Refer to Fig. 2)
1. Disconnect the wires from the auger motor (20).
2. Remove hopper assy (18) and set aside for reassembly.
3. Remove the four #8-32 locking screws, located
inside on the rear of the front housing, securing
auger motor mounting bracket (19) and auger
motor (20) to the rear of the front panel.
4. Remove auger motor mounting bracket (19), auger motor (20) and dust seal (21) as an assembly.
5. Remove dust seal (21) from auger motor (20).
6. Remove the four #8-32 screws securing the auger motor (20) to the auger motor mounting
bracket (19).
7. Remove auger motor (20) and discard.
8. Using three #8-32 screws install new auger motor (20) on mounting bracket (19).
9. Install dust seal (21) on auger motor shaft and
align notch in seal with motor casting.
10. Using four #8-32 locking screws install auger
motor, dust seal and mounting bracket to the rear
of the front panel.
11. Reconnect the wires to the terminals on the bottom of the auger motor.
12. Install hopper assy (18).
13. Refer to Fig. 3 when reconnecting wires.
BALLAST
P1226
FIG. 4 BALLAST
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 120/208 volt models or 120/
240 volt models.
WHI/BLK to Run/Rinse
Switch
WHI/RED from Hopper
Delay Circuit Board
FIG. 3 AUGER MOTOR TERMINALS
P1201
If voltage is present as described the ballast is operating properly.
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.
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Page 15
SERVICE (cont.)
BALLAST (cont.)
5. Refer to the illustration below when reconnecting the wires.
BLK to Terminal Block
WHI to Main
Wiring Harness
WHI & BLU to
Door
Interconnect
Harness
FIG. 5 BALLAST TERMINALS
CONTROL THERMOSTAT
P1202
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.
Test Procedure
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.
5. Disconnect the dispenser from the power source.
MECHANICAL
ELECTRONIC (OPTIONAL)
FIG. 6 CONTROL THERMOSTAT
P1226
P1230
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 Thermostat (Optional)
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 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.
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.
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SERVICE (cont.)
CONTROL THERMOSTAT (cont.)
Removal and Replacement.
Mechanical Thermostat
1. Disconnect the wires from the thermostat.
2. Remove the thermostat capillary bulbby 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 #832 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 grom-
met in the tank lid.
4. Remove thermostat and discard.
5. Install new thermostat over the studs on the dis-
penser 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
FIG. 7 THERMOSTAT TERMINALS
BLK to Limit
Thermostat
TAN to Tank
Heater
Switch
BLK to Terminal
Block
WHI to Terminal
Block
ELECTRONIC
P1204
16
27591 111596
Page 17
SERVICE (cont.)
DISPENSE SWITCH
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FIG.8 DISPENSE SWITCH
Location:
The dispense switch is located on the lower
outside center of the dispenser door.
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
from the connector on the door interconnect wiring harness.
4. Check for voltage across the black in the connector of the door interconnect wiring harness
and the white section of the terminal block. Connect the dispenser to the power supply. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
5. Disconnect the dispenser from the power source.
P1195
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
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 reconnecting wires.
P1220
FIG. 9 DISPENSE SWITCH CONNECTORS
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.
17
27591 111596
Page 18
SERVICE (cont.)
FAN
Removal and Replacement:
1. Remove hopper 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
P1226
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 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.
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 hopper, 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.
18
27591 111596
Page 19
SERVICE (cont.)
FROTHER AND WHIPPER MOTOR
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
FIG. 11 FROTHER AND WHIPPER MOTOR
P1226
Location:
The frother is located behind the dispenser
door, mounted on the front of the front panel inside
the whipper chamber.
The whipper motor is located on the back side
of the front section of the front panel.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the white/red and white wires of the
main harness from the black leads on the motor.
3. Press and hold the dispense switch and check
the voltage across the disconnected harness
wires with a voltmeter. Connect the dispenser to
the power source. The reading must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
4. Disconnect the dispenser from the power source.
12
11
10 9 8 7 6 5 4 3
FIG. 12 MIXING/WHIPPER CHAMBER
P1228
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).
19
27591 111596
Page 20
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.
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.
BLK to Main Harness WHI/RED
BLK to Main Harness WHI
P1221
FIG.13 WHIPPER MOTOR TERMINALS
20
27591 111596
Page 21
SERVICE (cont.)
HOPPER DELAY BOARD
P1226
FIG. 14 HOPPER DELAY BOARD
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 hop-
per 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.
4. Disconnect the dispenser from the power source.
ing 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
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.
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.
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.
If voltage is not present as described, refer to the wir-
21
27591 111596
Page 22
SERVICE (cont.)
LAMP HOLDER
If voltage is present as described, proceed to # 4.
If voltage is not present as described, refer to the
wiring diagram and check the dispenser wiring harnesses.
1
2
3
4
5
2
6
FIG. 15 LAMP HOLDERS
P1229
1. Door Assy
2. Lamp Holders
3. Lamp
4. Upper Cover W/Reflector
5. Lower Cover
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 plug on the door wiring harness
from the connector on the door interconnect wiring harness.
3. Check the voltage across the green/white and
green/black wires on the door interconnect 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.If voltage is present as described,
replace the lamp holder.
4. Remove lamp from lamp holders.
5. Disconnect the two pin plugs of each lamp holder
from the door wiring harness.
6. Check for continuity on each lead of the lamp
holders.
If continuity is present as described, lamp holders are
operating properly.
If continuity is not present as described replace the
lamp holder.
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.
22
27591 111596
Page 23
SERVICE (cont.)
LAMP REPLACEMENT (Refer to Fig. 15)
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).
LAMP STARTER and SOCKET
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. Check for continuity on each lead of the starter
socket.
Removal and Replacement (Refer to Fig.15):
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
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.
If continuity is present as described the starter socket
is operating properly.
If continuity is not present as described replace the the
starter socket.
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.
23
27591 111596
Page 24
SERVICE (cont.)
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 and three wire 120/240 volt models after
a delay of approximately 5 second.
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 and three wire 120/240 volt models
after a delay of approximately 5 second.
10. Disconnect the dispenser from the power source
and remove the jumper wire from terminal 4.
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.
P1226
FIG. 16 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 and three wire 120/240 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 the dispenser wiring harness.
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 and three wire 120/240 volt models after
a delay of approximately 5 second.
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 and three wire 120/240 volt
models.
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.
24
27591 111596
Page 25
SERVICE (cont.)
LEVEL CONTROL BOARD AND LEVEL PROBE (cont.)
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.
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. 17 LEVEL BOARD TERMINALS
LIMIT THERMOSTAT
FIG. 18 LIMIT THERMOSTAT
P1210
P1226
BLK to Control
Thermostat
BLK to Tank
Heater
FIG. 19 LIMIT THERMOSTAT TERMINALS
P1800
Location:
The limit thermostat is located in the center of
the tank lid.
25
27591 061600
Page 26
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.
FIG. 20 OVERFLOW PROTECTION SWITCH
P1226
Location:
The over flow 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
FIG. 21 OVERFLOW PROTECTION
SWITCH LEADS
RED to BLU Lead from
Liquid Level Board
P1212
26
27591 111596
Page 27
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. 23) 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. 22 RUN/RINSE SWITCH
P1226
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. 23 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.
27
27591 061600
Page 28
SERVICE (cont.)
SOLENOID VALVE (DISPENSE)
If continuity is present as described, reconnect the
white and white/red 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 dispense switch and listen carefully in the
vicinity of the solenoid valve for a "clicking" sound
as the coil magnet attracts.
7. Disconnect the dispenser from the power source.
If the sound is heard as described and water will not
pass through the solenoid valve, there may be a blockage in the water outlet before the solenoid valve or,
the solenoid valve may require inspection for wear,
and removal of waterborne particles.
If the sound is not heard as described, replace the
solenoid valve.
P1230
FIG. 24 DISPENSE SOLENOID VALVE
Location:
The dispense solenoid is located on the upper
right center of the tank.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the white and white/red wires from
the solenoid valve. With the “RUN/RINSE” switch
in the "RINSE" upper position press the dispense
switch on front of the door.
3. Check the voltage across the white and white/red
wires with a voltmeter. Connect the dispenser to
the power source. The indication must be 120
volts ac for two wire 120 volt models, three wire
120/208 and 120/240 volt models.
4. Disconnect the dispenser from the power source.
Removal and Replacement:
1. Remove the white and white/red wire from the
solenoid valve.
2. Turn-off the water supply to the dispenser.
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 illustration below when reconnecting the
wires.
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.
28
WHI/RED to Auger Motor
WHI to Terminal Block
FIG. 25 DISPENSE SOLENOID VALVE
TERMINALS
P1231
27591 111596
Page 29
SERVICE (cont.)
SOLENOID VALVE (INLET)
P1230
FIG. 26 INLET SOLENOID VALVE
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
and 120/240 volt models.
4. Disconnect the dispenser from the power source,
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.
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 the illustration below when reconnecting the wires.
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to the
wiring diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve coil
terminals.
If continuity is present as described, reconnect the
white and violet wires to the solenoid.
WHI from Terminal Block
VIO from Liquid Level Board
FIG. 27 INLET SOLENOID VALVE TERMINALS
29
P1217
27591 111596
Page 30
SERVICE (cont.)
TANK HEATER
FIG. 28 TANK HEATER
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.
3. Disconnect the dispenser from the power source.
P1226
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. Disconnect the dispenser from the power source.
2. Disconnect the water supply tube on the tank lid.
3. Disconnect the black wires on the limit 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 an assembly.
9. Remove the two hex nuts securing the tank heater
to the tank lid. Remove tank heater with gaskets
and discard.
10. Install new tank heater with gaskets on the tank lid
and secure with two hex nuts.
11. Install tank lid with limit thermostat, liquid level
probe and tank heater on the tank and secure with
ten #8-32 hex nuts.
12. Connect water inlet line to the tank lid.
13. Reconnect the black wires to limit thermostat, the
pink wire to the liquid level probe. Refer to the limit
thermostat and the liquid level board and probe
sections in this manual when reconnecting wires.
14. Refer to Fig. 29 when reconnecting the wires to the
tank heater.
If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the
dispenser wiring diagram and check the wiring harness.
4. Disconnect the black wire and the white or red
wire from the tank heater terminals.
30
27591 111596
Page 31
SERVICE (cont.)
TANK HEATER (cont.)
Location:
The tank heater switch located inside the dis-
penser on the upper right of the front panel.
WHI or RED to
Terminal Block
FIG. 29 TANK HEATER TERMINALS
TANK HEATER SWITCH
BLK to Limit
Thermostat
P1218
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 tank 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.
31.
5. Push new switch through hole in the front panel
and secure with face nut.
FIG. 30 TANK HEATER SWITCH
P1226
BLU/BLK from Electro/
Mechanical Thermostat or
TAN from Electronic
Thermostat
BLK from Terminal Block
(Electro/Mechanical) or
TAN from Electronic
Thermostat
FIG. 31 TANK HEATER SWITCH TERMINALS
31
P1219
27591 111596
Page 32
SCHEMATIC WIRING DIAGRAM
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/WHI
RED/BLK
1
BLK
RED/BLK
4
1
BLK
RED/WHI
4
1
BLK
RED
4
RED
BLK
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
RED
RED
BLU
BLU
1
USED WHEN COLD
DRINK FEATURE NOT
INSTALLED
BLK
BLK
RED
WHI/BLK
WHI/BLK
WHI/BLK
WHI/BLK
1
STARTER
1
WHI
BLK
BLK
WHI
WHI
32
27591 111596
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