Bunn-O-Matic CDS-2, CDS-3 Operation Manual

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Page 1

CDS-2 CDS-3

DISCONTINUED VERSION

The information in this manual

is no longer current.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

To obtain the Illustrated Parts Catalog, visit the Bunn-O-Matic website, at www.bunn.com. This is absolutely FREE, and the quickest way to obtain the catalog. Contact Bunn-O-Matic Corporation at 1-800-286-6070 to obtain a paper copy of the required Illustrated Parts Catalog mailed via U.S. Postal Service.

www.bunnomatic.com

Page 2

INTRODUCTION

This equipment dispenses granita-type and cold liquid drinks on demand from separate hoppers. Operating

controls are accessible only to key operators.

CONTENTS

Introduction & Warranty .....................................................................................2

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

Site Preparation, Electrical Requirements & Initial Setup ...................................5

Operating Controls ..............................................................................................8

Using the Dispenser & Recommendations ........................................................10

Recommended Cleaning ..................................................................................12

Lubrication ........................................................................................................13

Faucet Handles ..................................................................................................14

Auger Assembly ................................................................................................15

Troubleshooting ................................................................................................16

Service ..............................................................................................................21

Refrigerant Flow Diagrams ................................................................................51

Schematic Wiring Diagrams ..............................................................................54

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 three years from the date of installation.

2.) Bunn warrants the compressor on refrigeration equipment to be commercially free from defects in mate-

rial 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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USER NOTICES

HAZARDOUS

VOLTAGE

DISCONNECT FROM

POWER SOURCE

BEFORE REMOVING!

WARNING

CHARGE

Type R22, Amount 8.4 oz

Design Pressures: High 210 Low 32

CAUTION

Instructional video that accompanies every

machine should be viewed before using

Carefully read and follow all notices on the equipment and in this manual. They were written for your protec-

tion. All notices are to be kept in good condition. Replace any unreadable or damaged labels.

27444.0000

12559.0003

00986.0002

28720.0000

27443.0000

27646 120601

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USER NOTICES (CONT.)

CHARGE

Type R22, Amount 8.4 oz

Design Pressures: High 210 Low 32

AFTER CLEANING &

BEFORE REASSEMBLY

LUBRICATION

1. Apply lubricant* on lip of auger seal where contact is made with cooling drum.

2. Apply lubricant* on outside surface of cooling drum seal or inside bore of hopper.

3. Apply lubricant* over o-rings on faucet spool before inserting into faucet housing. * Refer to product literature for Bunn approved lubricant.

CHARGE

Type R404A, Amount 25 oz

Design Pressures: High 320 Low 44

CHARGE

Type R404A, Amount 9.5 oz (269 gm) Design Pressures: High 215 psi (15 bar) (1.48 MPa) Low 40 psi (3 bar) (0.28 MPa)

CHARGE

Type R404A, Amount 22 oz

Design Pressures: High 380 Low 52

27444.0000 (CDS-2 Only)

29373.00000 (CDSA-2 Only)

27664.0000

28519.0000 (CDS-3 Prior to S/N CDS0019500)

29424.0000 (CDS-3 S/N CDS0019500 - UP)

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SITE PREPARATION

These dispensers are very heavy. Place them on a sturdy counter or shelf capable of supporting at least 180

lbs for the CDS2 and 250 lbs for the CDS3. They are for indoor use only.

The dispenser must have at least four inches of space behind it. This space is needed for airﬂow, air ﬁlter

removal, and cleaning. Minimal clearance is required between the dispenser sides and the wall or another appli-

ance. The dispenser performs better if not placed near any heating appliance. Leave some space so the dispenser

can be moved for cleaning.

ELECTRICAL REQUIREMENTS

CAUTION – Improper electrical installation will damage components. An electrician must provide electrical

service as speciﬁed below.

Model CDS-2, This dispenser has an attached cordset and requires a 2-wire, grounded, individual branch

circuit rated 120 volts ac, 15 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-15R. (Refer

to the dataplate for exact electrical requirements.)

Model CDSA-2, This dispenser has an attached cordset and requires a 2-wire, grounded, individual branch

circuit rated 230 volts ac, 10 amp, single phase, 50 Hz. The mating connector must be a NEMA 5-15R. (Refer

to the dataplate for exact electrical requirements.)

Model CDS-3, This dispenser has an attached cordset and requires a 2-wire, grounded, individual branch

circuit rated 120 volts ac, 20 amp, single phase, 60 Hz. The mating connector must be a NEMA 5-20R. (Refer

to the dataplate for exact electrical requirements.)

Model CDSA-3, This dispenser has an attached cordset and requires a 2-wire, grounded, individual branch

circuit rated 230 volts ac, 15 amp, single phase, 50 Hz. The mating connector must be a NEMA 5-20R. (Refer

to the dataplate for exact electrical requirements.)

NOTE – Bunn-O-Matic does not recommend the use of any extension cord with these dispensers.

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6.0"

MIN.

6.0"

MIN.

6.0"

MIN.

DO NOT REMOVE

INITIAL SETUP

CAUTION – The dispenser is very heavy! Use care when lifting or moving it. Use at least two people to lift or

move the dispenser.

1. Set the dispenser on the counter where it will be used. The CDS-3 dispenser requires a minimum of 6.0”

air clearance on both sides and at the rear of the dispenser. For optimum performance, do not let warm air from surrounding machines blow on the CDS-3 and DO NOT REMOVE VINYL DEFLECTOR.

NOTE – The dispenser should be level or slightly lower in front for proper operation.

Vinyl Deﬂector

2. Remove all shipping material, including the compressor support eye-bolts, the cooling drum supports, the

“Do Not Lift Here” signs from the cooling drums, and the “Rinse Before Using” signs from each hopper.

NOTE – Use BOM M2550.0000 lubricant where speciﬁed.

3. Squeeze some lubricant into

hand.

4. Apply a thin ﬁlm of lubricant to

each cooling drum seal.

5. Install the seal over the ﬂange

at the rear of each cooling drum as shown.

6. Press the seals firmly into

place.

7. Apply a thin ﬁlm of lubricant to

the inside of each auger shaft seal.

8. Install the seals on the auger

shafts. Wipe the cooling drums to remove any lubricant.

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INITIAL SETUP (CONT.)

APPROXIMATELY .25"

9. Align the auger shaft with the

ﬂat ﬁn of the auger. Push the augers as far as they will go and rotate them so the ﬂat ﬁns are pointing up.

12. Plug in the hopper lid lamp

cables.

10. Thoroughly rinse the hoppers

and install them over the cooling drums with augers. Slide them into place and push them

down as far as they will go.

As much as possible, keep lubricant from the inside of the hoppers. The cleaner you keep the food zone, the cleaner the product you’ll serve the customer.

13. (CDS-2 only) Assemble the drip

tray.

11. Set the lids on the hoppers.

Slide front-to-back or lift off for ﬁlling.

14. (CDS-3 only) Loosen the two

front legs by turning counterclockwise to gain approximately .25” clearance. Install the slots of the support bracket over threaded studs of the legs as shown in illustration. Tighten the legs by turning clockwise to secure the bracket in place.

15. (CDS-3 only) Install the drip

tray.

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OPERATING CONTROLS

(CDS-3 Controls Illustrated)

ICE CONTROLS

Controls the consistency of the ice in the hoppers when the DAY/NIGHT switch is in the left “DAY” position and the ICE/OFF/NO-ICE switch is in the left “ICE” position.

Turn this control clockwise to produce a coarser ice or counterclockwise to produce a ﬁner ice. (The dispenser is set to deliver satisfactory ice at a 1:00 setting.)

AUGER SWITCHES ”—” – This is the normal operating posi-

tion. Energizes the auger motor when in

the right position. The dispenser will cool to the ice consistency or liquid temperature presets only with the switch in the right position.

“o” – Removes power from the auger motor when in the left position.

ICE/OFF/NO-ICE SWITCHES ICE – This is the normal operating position. Freezes

and maintains the ice in the selected hopper to the consistency set with the ICE control(s) when in the left “ICE” position.

OFF – Provides no cooling to the selected hopper when in the center “OFF” position.

NO-ICE – Maintains cooling yet allows any ice in the selected hopper to naturally thaw when in the right “NO-ICE” position.

DAY/NIGHT SWITCH DAY – This is the normal operating position.

The hoppers’ display lights will glow and the electronic controls will maintain ice when the switch is in the left “DAY” position, the individual hoppers’ ICE/OFF/NO-ICE switches are in the left “ICE” position, and the individual hoppers’ AUGER switches are in the right “—” position.

POWER OFF/ON SWITCH ON – This is the normal operating position. The dis-

penser is electrically energized when the switch is in the right “ON” position. NOTE – The compressor will start after a 3 minute 20 second delay on the CDS-2

will be kept cold in all hoppers when this switch is in the right “NIGHT” position and the AUGER switches are in the right “—”position.

NIGHT – Use this position at night. The hoppers’ display lights will be out yet the liquid

and a 6 minute 30 second delay on the CDS-3. OFF – All electrical components of the dispenser are

without power when the switch is in the left “OFF” position.

NOTE: When Day/Night Timer is used, the Day/Night Switch in the control drawer must be kept in the “DAY” position.

POWER INDICATOR (Located on the front of the drawer)

Glows to show that the POWER OFF/ON Switch is in the right “ON” position.

STATUS INDICATORS

The electronic controls continuously diagnose the operational status of the dispenser and indicate as listed: FLASHING 50% ON / 50% OFF – Glows while preparing for coolant to ﬂow to the selected hopper. (Flashes for

10-seconds, then glows steady for two minutes.) STEADY GLOW – Glows for two minutes before coolant ﬂows to the selected hopper, then continues to glow while coolant ﬂows. The electronics also sense and indicate error conditions in the dispenser as listed:

ONE FLASH EVERY FOUR SECONDS – Cooling is needed by the selected hopper, but the auger isn’t turning. Try placing the AUGER switch for the selected hopper in the right “—” position.

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OPERATING CONTROLS (Cont.)

TWO FLASHES EVERY FOUR SECONDS – A temperature error is being sensed. Call Bunn-O-Matic for Sup-

port.

THREE QUICK FLASHES – Low auger torque is being sensed. Call Bunn-O-Matic for Support.

FOUR QUICK FLASHES – High auger torque is being sensed. Call Bunn-O-Matic for Support.

DAY/NIGHT TIMER

The quartz driven timer offers 24-hour programming with 96 actuators that operate in 15-minute incre-

ments. All actuators can be individually set to the inside or outside position. The timer is located behind the

right side panel.

SETTING TIME

1. Locate marker on the inner (stationary) dial that points to outer dial. The marker is at approximately the two O’clock position.

2. Turn outer dial clockwise until the marker is pointing to the correct time. The clock hands will turn with the outer dial indicating the same time as the marker. NOTE - the outer dial has AM and PM settings.

SETTING NIGHT TIME MODE

1. Locate the actuators positioned around the outer dial. Inward position indicates day time mode and outer position indicates night time mode.

2. Determine the desired times that night time mode is to begin and end.

3. Position all actuators between begin and end times in the outer position.

EXAMPLE: Night Time Mode is 11:00 PM - 7:00 AM

Place the actuator at 11:00 PM to the outside position. Con-

tinue placing actuators to the outside position counterclock wise around the dial to 7:00 AM. All actuators from 7:00 AM to 11:00 PM must be in the inside position.

NOTE: For Day/Night Timer to operate, the Day/Night Switch

in the control drawer must be kept in the “DAY” position.

P1948

Shown in “Night Time” Mode

P1947

Shown in “Day Time” Mode

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USING THE DISPENSER FOR GRANITA-TYPE PRODUCTS

1. Slide the lid for the selected hopper to the front or back to gain access to the hopper.

2. Place the premixed liquid product in the selected hopper.

3. Simply press all switches to the center of the control drawer for granita products. a. Place the POWER OFF/ON switch in the right “ON” position. b. Place the auger switch for the selected hopper in the right “—” position. c. Place the DAY/NIGHT switch in the left “DAY” position. d. Place the ICE/OFF/NO-ICE switch in the left “ICE” position.

4. Wait for the liquid to freeze to the desired consistency.

HINTS – Bunn-O-Matic recommends that the product in the dispenser be thawed each day, usually overnight.

The ice granules get too large and a consistent product is difﬁcult to maintain if left frozen for an extended period of time. Place the DAY/NIGHT switch in the right “NIGHT” position for a few hours each night. Then return it to the left “DAY” position when the product has thawed sufﬁciently. You’ll know it is in the night position because the hopper lid lights are out.

USING THE DISPENSER FOR COLD LIQUID PRODUCTS

1. Slide the lid for the selected hopper to the front or back to gain access to the hopper.

2. Place the premixed liquid product in the selected hopper.

3. Simply place all switches to the center of the control drawer except the ICE/OFF/NO-ICE switch. a. Place the POWER OFF/ON switch in the right “ON” position. b. Place the auger switch for the selected hopper in the right “—” position. c. Place the DAY/NIGHT switch in the left “DAY” position. d. Place the ICE/OFF/NO-ICE switch in the right “NO-ICE” position.

4. Wait for the liquid to cool.

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OTHER RECOMMENDATIONS FOR YOUR DISPENSER

• Whetherliquidconcentrateorgranulatedpowder,allproductmustbethoroughlymixedBEFOREaddingit

to the hoppers.

• Forbestresultswithgranita-typeproducts,useonlyproductswithanapparentbrixof12orhigher.Some

products may work with an apparent brix as low as 9. Your experimentation with other products will be the best guide in this area.

• Keepthepremixedliquidproductrefrigerated.Thisreducescooling/freezingtimeinthedispenser.

• Keepthehopperstopped-offduringpeakservingperiods.Addpremixedliquidproductasitisdispensed.

This reduces the cooling/freezing time and assures you of always having product ready to dispense.

• Keeptheproductlevelinthehoppershigherthantheauger.Airwillbecomeentrappedinthemixtureresult-

ing in a clouded foamy consistency.

• Youmaynditbenecialtoturndowntheicecontrolstokeeptheicegranulesfromgrowingtoolarge.

Refer to the operating controls on page 1-6.

• Someproductsfreezeatalowertemperaturethanothers.Youmaynoticefrostoriceonthehoppers.This

is normal and should not be a concern.

• Humidityintheairmaycausesweatingontheoutsidesurfacesofthehoppers.Thisistobeexpectedand

should not be a concern. The drip trays beneath the hoppers will capture this and cause it to ﬂow to the lower drip tray for disposal.

• Somenoisesaretobeexpectedduringnormaloperationofthedispenser.Bybecomingfamiliarwiththe

noises made during normal operation, you will be better able to listen for problems.

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RECOMMENDED DAILY CLEANING (SUGAR & ALCOHOL PRODUCTS!)

NOTE – Close the control drawer before proceeding.

1. Empty all product from the hoppers.

2. The driptray should be cleaned as needed for proper presentation of the product.

3. MixapacketofKay-5Sanitizerdilutedwithtwo-gallonsofwarm(120°F)waterforeachhopper.

4. Open the lids and add the solution.

5. Allow the solution to work for about ﬁve minutes with the dispenser on the ”NIGHT” position.

6. Drain the sanitizing solution from the hoppers and completely rinse each with clean water.

7. Wash the underside of hopper covers or powder autoﬁll dispensers with hot water and a mild detergent

solution. Rinse all surfaces and apply some commercial sanitizing agent. Do not immerse hopper lids.

NOTE – The hoppers and augers should be removed and disassembled for cleaning at least once a week using

the procedure below.

RECOMMENDED WEEKLY CLEANING (SUGAR & ALCOHOL BASED PRODUCTS!) RECOMMENDED DAILY CLEANING (DAIRY PRODUCTS!)

NOTE – Close the control drawer before proceeding.

1. Empty all product from the hoppers. Disconnect the hopper lid cords and remove the lids.

2. Lift the hopper up slightly, then

use a hard plastic utensil to pry it up. Pull forward to remove.

5. Spread the sides of the dis-

pense handle and pull it off to remove the faucet pieces.

3. Pull the auger from the cool-

ing drum. Remove the auger shaft seal from the front of the cooling drum and the cooling drum seal from the rear of the drum.

6. Push the metal pin out through

the faucet. Unscrew the plastic cap, and push the faucet spool and spring out the bottom.

4. Disassemble the auger for

cleaning by spreading apart the latches and removing each piece.

7. Squeeze the O-rings to free

them from the grooves in the faucet spool.

8. Roll the O-rings off of the faucet

spool.

9. Remove the black plug from the faucet spool for cleaning. Do

not use tools to remove this.

10. Pull down, then out on the

air ﬁlter at the rear of the dispenser.

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RECOMMENDED WEEKLY CLEANING (CONT.)

11. Wash all components with a wash cloth in mild hot water and detergent solution. Do not immerse hopper lids.

12. Wash the drums, hopper drip trays, top covers, and outer enclosure using a clean wash cloth that has been dampened in a mild solution of detergent and hot water.

13. Thoroughly rinse all surfaces with a clean wash cloth that has been dampened with hot water. Wipe dry with a clean dry wash cloth before reassembling the dispenser.

14. Remove the lower drip tray assembly. Wash and thoroughly rinse all pieces before reinstallation.

NOTE – Although most parts are dishwasher safe, they may be affected by some commercial sanitizing agents. Do not place the hopper nor hopper lids in a dishwasher.

LUBRICATION

NOTE – Use BOM M2550.0000 lubricant where speciﬁed.

1. Squeeze some lubricant into

hand.

4. Press the seals firmly into place.

7. Align the auger shafts with the ﬂat ﬁn of the augers. Push the augers as far as they will go and rotate them so the ﬂat ﬁns are pointing up.

2. Apply a thin ﬁlm of lubricant to

each cooling drum seal.

5. Apply a thin ﬁlm of lubricant to

the inside of each auger shaft seal.

8. Thoroughly rinse the hoppers

and install them over the cooling drums with augers. Slide them into place and push them

down as far as they will go.

As much as possible, keep lubricant from the inside of the hoppers. The cleaner you keep the food zone, the cleaner the product you’ll serve the customer.

3. Install the seals over the ﬂange

at the rear of the cooling drums as shown.

6. Install the seals on the auger

shafts. Wipe the cooling drums to remove any excess lubricant.

9. Set the lids on the hoppers.

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LUBRICATION (cont.)

10. Reinstall the black plug into the faucet spool. Do not lubricate the plug.

13. Reinstall the plastic caps,

springs, spools, and metal pins. Spread the dispense handles and reinstall them.

NOTE – When reinstalling the faucet

caps, they MUST be twisted as far as they will go. (Past the point where it clicks.)

11. Apply a thin ﬁlm of lubricant to

each faucet spool O-ring.

14. Plug in the hopper lid lamp

12. Slide the O-rings onto the

spools.

15. Assemble the drip tray.

cables.

NOTE – The faucet spool plugs, faucet O-rings, cooling drum hopper seals,

and auger shaft seals are to be replaced whenever they appear worn or damaged. Bunn-O-Matic recommends their replacement at least every six-months. Refer to page 24 for replacement instructions.

FAUCET HANDLES

Dispensing from the hoppers will occur when the faucet handles are installed with the handles in the upright position. (shown, left hopper)

Dispensing from the hoppers will not occur when the handles are installed upside-down. (shown, right hopper) You may consider this handle position when the product in the hoppers is not yet ready to serve. Just spread the handles or disassemble them as shown, and install them upside down.

DISASSEMBLY

1. Unscrew the balls from the handle assemblies. Turn them in a counterclockwise direction until they are no longer attached to the handles.

2. Remove the metal sleeves from the assemblies.

3. Separate the two halves of the handles and remove them from the faucet bodies.

ASSEMBLY

1. Place the two halves of the handles on the faucet bodies. Check that the faucet dowel pins are in place all the way through the faucet bodies. The dowel pins must be captured by the keyholes in the handle halves.

2. Place the metal sleeves over the threads and install the balls by turning them in a clockwise direction.

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AUGER ASSEMBLY & DISASSEMBLY (EARLY AUGERS ONLY)

The augers may look intimidating at ﬁrst glance. But there are really just a few pieces snapped together. Please familiarize yourself with this procedure. It’ll make cleaning and routine maintenance easier. The augers should be taken apart for cleaning and then reassembled for use.

Short Auger Latch

Auger Sections (3 req’d.)

ASSEMBLY

1. Snap one of the auger sections

to the long auger latch.

2. Snap another auger section

in place.

Long Auger Latch

Auger Nose

4. Snap the auger nose onto the

last section installed.

5. With the long auger latch on

top, place the short auger latch inside the augers and snap it onto the assembly.

3. Snap the third auger

section in place.

DISASSEMBLY

1. Firmly pull the auger section connections apart at each slot in the long auger latch.

2. Firmly pull the connection between the auger section and auger nose apart.

3. Separate the slots in the short auger latch as you remove the auger sections.

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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120voltacand/or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.

• 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

Doesn’t work (Switches do nothing, auger not turning, no hopper lid lights, no fan, no compressor sound.)

Hopper Lid Lights not on

PROBABLE CAUSE

1. No power or incorrect voltage to the dispenser

2. ON/OFF Switch

1. DAY/NIGHT Switch

REMEDY

(A) Check for proper voltage at the wall outlet.

(B) Check circuit breakers or fuses.

(A) The ON/OFF Switch must be in the “ON” position.

(B) Refer to Service - Dispenser ON/ OFF Switch for testing procedures. See page 37.

(A) The DAY/NIGHT Switch must be in the “DAY” position.

(B) Refer to Service - DAY/NIGHT Switch for testing procedures. See page 36.

2. Lamp Cord Assembly

(A) The lamp cord must be plugged into the lamp cord connector.

(B) Refer to Service - Lamp Cord Assembly for testing procedures. See page 42.

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TROUBLESHOOTING (cont.)

PROBLEM

PROBABLE CAUSE

REMEDY

Hopper Display Lights not on

(cont.)

Auger Motor won’t turn

3. Circuit Breaker

4. Lamps

5.Transformer

6. Lamp Holder/Socket Assy

1. Auger ON/OFF Switch(es)

(A) The circuit breaker must not be tripped.

(B) Refer to Service - Circuit Breaker for testing procedures. See page

27.

Remove the lamps and check for continuity across the base and tip. Replace if necessary.

Refer to Service - Transformer for testing procedures. See page 49.

Refer to Service - Lamp Holder/Sock- et Assembly for testing procedures. See page 44.

(A) The auger switch must be in the “ON” position.

Fan not spinning (With adjustment

Board L.E.D.s ON steadily for two

minutes)

Fan spins after compressor shuts

off

2. Auger Motor Capacitor(s)

3. Auger Motor(s)

1. Fan Motor

1. Time Delay

(B) Refer to Service - Auger ON/OFF Switch(es) for testing procedures. See page 26.

Refer to Service - Auger Motor Capacitor(s) for testing procedures. See page 23.

Refer to Service - Auger Motor(s) for testing procedures. See page 22.

Refer to Service - Fan Motor for test- ing procedures. See page 39.

The fan motor will run for approximately two minutes after compressor shuts off.

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TROUBLESHOOTING (cont.) PROBLEM

PROBABLE CAUSE

REMEDY

Compressor not running (With Adjustment Board L.E.D.s ON steadily for two minutes)

1. Power cord

2. Fuse

3. Contactor

4. Electronic Control

5. Compressor Start Relay

6. Thermal Overload Protector

The dispenser must not be connected with an extension cord. Refer to Electrical Requirements.

Refer to Service - Fuse and Fuse Holder for testing procedures. See page 40.

Refer to Service - Contactor for test- ing procedures. See page 34.

Refer to Service - Electronic Control for testing procedures. See page

38.

Refer to Service - Compressor Start Relay for testing procedures. See page 28 (CDS-2) or 31 (CDS-3).

Refer to Service - Compressor Ther- mal Overload Protector for testing procedures. See page 28 (CDS-2) or 31 (CDS-3).

Compressor runs but will not cool (With adjustment Board L.E.D.s ﬂashing once every 4 seconds)

Compressor runs but will not cool (With adjustment Board L.E.D.s ﬂashing twice every 4 seconds)

Compressor runs but will not cool (With adjustment Board L.E.D.s flashing 3, or 4 times every 4 seconds)

7. Compressor Start Capacitor

8. Compressor

1. Auger not turning

1. Temperature Sensor Assembly

1. Torque Sensor Circuit Board

Refer to Service - Compressor Start Capacitor for testing procedures. See page 28 (CDS-2) or 31 (CDS-3).

Refer to Service - Compressor for testing procedures. See page 28 (CDS-2) or 31 (CDS-3).

Refer to Troubleshooting - Auger Mo- tor Won’t Turn on previous page.

Refer to Service - Temperature Sensor Assembly for testing procedures. See page 47.

Refer to Service - Torque Sensor Circuit Board for testing procedures. See page 48.

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Page 19

TROUBLESHOOTING (cont.)

PROBLEM

Compressor runs but will not cool

(With adjustment Board L.E.D.s

flashing 3, or 4 times every 4

seconds) (cont.)

Product Won’t Freeze

PROBABLE CAUSE

2. Air Filter or Condenser

3. Refrigerant

1. DAY/NIGHT Switch

2. Sugar content of product

3. Voltage Divider

REMEDY

The air ﬁlter and condenser MUST be cleaned regularly. Any dust buildup will affect cooling ability.

Have a qualiﬁed service person check the refrigerant charge.

(A) The DAY/NIGHT Switch must be in the “DAY” position.

(B) Refer to Service - DAY/NIGHT Switch for testing procedures. See page 36.

Bunn recommends the use of products with an apparent brix of 12 or higher.

Refer to Service - Voltage Divider for testing procedures. See page 50.

Product freezes but ice granules are

too ﬁne or too large

Dispenser is making unusual noises.

(Some noises are a normal occurance

with this type of device. You need to

become familiar with those that are

normal, to determine when they have

become unusual.)

1. Ice adjustment

2. Sugar content of product

1. Lubrication

2. Cooling Drum(s)

Turn the Ice control for the desired hopper a small amount clockwise to increase the ice granule size or counterclockwise to decrease the ice granule size.

Adjust the sugar content of the product. Increasing the apparent brix results in ﬁner ice granules. Decreasing the apparent brix results in larger ice granules.

Always lubricate the dispenser as directed in this manual before reassembling and using the dispenser.

Use the cooling drum support to determine that the auger shaft is still the proper distance from the hopper drip tray. The cooling drum may be gently lifted to return it to the necessary horizontal position. Refer to Service - Cooling Drum Alignment. See page 35.

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TROUBLESHOOTING (cont.) PROBLEM

Dispenser is making unusual noises. (Some noises are a normal occurance with this type of device. You need to become familiar with those that are normal, to determine when they have become unusual.) (cont.)

Product is leaking into the inside of the drum.

PROBABLE CAUSE

3. Fan Motor

4. Auger Motor(s)

1. Worn Shaft

2. Worn Seals

REMEDY

Remove the air ﬁlter at the rear of the dispenser and listen for fan motor noise. Replace the motor if excessively noisy.

Place the Auger switches in the “ON” position and the ICE/OFF/NO-ICE switches in the “OFF” position. Listen for auger motor noise. Replace the motor if excessively noisy.

Replace Shaft. Refer to Service - Au- ger Shaft Assembly. See page 24.

Replace Cooling Drum Seal. Refer to Service - Auger Shaft Assembly. See page 24.

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Page 21

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 prob- lem.

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 removal of the auger motor cover, lower drip tray, front cover and the left and right side covers.

Refer to the contents listing for component location.

Contents

Auger Motors ....................................................................................................22

Auger Motor Capacitors ....................................................................................23

Auger Shaft Assembly .......................................................................................24

Auger ON/OFF Switches ....................................................................................26

Circuit Breaker ..................................................................................................27

Compressor (CDS-2) ........................................................................................28

(Compressor, Compressor Start Capacitor, Compressor Start Relay, Thermal Overload Protector)

Compressor (CDS-3) ........................................................................................31

(Compressor, Compressor Start Capacitor, Compressor Start Relay, Thermal Overload Protector)

Contactor ..........................................................................................................34

Cooling Drum Alignment ...................................................................................35

Day/Night Switch ..............................................................................................36

Dispenser ON/OFF Switch .................................................................................37

Electronic Control .............................................................................................38

Fan ....................................................................................................................39

Fuse and Fuse Holder ........................................................................................40

ICE/OFF/NO ICE Switch .....................................................................................41

Lamp Cord Assembly ........................................................................................42

Lamp Cord Connector .......................................................................................43

Lamp Holder/Socket Assembly .........................................................................44

L.E.D./Adjustment Board ...................................................................................45

Solenoids ..........................................................................................................46

Temperature Sensor Assembly .........................................................................47

Torque Sensor Circuit Board .............................................................................48

Transformer .....................................................................................................49

Voltage Divider ..................................................................................................50

Coolant Schematics ..........................................................................................51

Electrical Schematics ........................................................................................54

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Page 22

SERVICE(CONT.)

AUGER MOTORS

FIG. 1 AUGER MOTORS

P1341

Location

The auger motors are located at the upper rear of

the dispenser chassis inside the auger motor covers.

4. Disconnect the auger motor terminal from the terminal on the main wiring harness.

5. Remove the three remaining #8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket.

6. Remove motor with mounting bracket, drip tray, split pin and torsion spring bearing as an assembly.

NOTE: When removing or installing the motor be sure the split pin in the motor shaft is turned to a position that will clear the torque sensor circuit board.

7. Install new motor with mounting bracket, drip tray, split pin and torsion spring bearing using three #8 locking screws onto the cooling drum bracket.

8. Install the auger motor capacitor on the lower right side of the auger mounting bracket, using the remaining #8 locking screw.

9. Connect the auger motor terminal to the terminal on the main wiring harness.

10. Refer to Fig. 2 when reconnecting the wires.

Test Procedures

1. Disconnect the dispenser from the power source.

2. Disconnect the wires from the motor to be tested.

3. With a voltmeter, check the voltage across the white/brown wire for the left motor, the white/blue wire for the right motor, or the grey wire for the center motor and the white/black wire. Place the appropriate auger switch in the “-” (“ON”) position. Connect the dispenser to the power supply. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

4. Disconnect the dispenser from the power supply.

If voltage is present as described, replace the motor. If voltage is not present as described, refer to the Wiring

Diagram and check the dispenser wiring harness.

Removal and Replacement

1. Remove the two #8 locking screws securing the auger motor cover to the cooling drum mount assembly.

2. Remove the cover and set aside for reassembly.

3. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor run capacitor. Set capacitor aside with wires attached.

FIG. 2 AUGER MOTOR TERMINALS

P1321

27646 022500

Page 23

SERVICE (CONT.)

AUGER MOTOR CAPACITOR

FIG. 3 AUGER MOTOR CAPACITORS

P1341

Location:

The auger motor capacitors are located on the lower right side of the auger motor mounting bracket inside the auger motor covers.

Removal and Replacement

1. Remove the two #8 locking screws securing the auger motor cover to the cooling drum mount assy.

2. Remove the cover and set aside for reassembly.

3. Disconnect the wires from the auger motor capacitor terminals.

4. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor capacitor.

5. Install a new capacitor on the lower right side of the auger mounting bracket and secure with a #8 locking screw.

6. Reconnect the wires to the capacitor terminals.

7. Refer to Fig. 4 when reconnecting the wires.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the wires from the capacitor to be tested.

3 With a voltmeter, check for voltage across the

white/blue wire on the right capacitor, the white /brown wire on the left capacitor, or the grey wire on the center capacitor and the white/black wire on the auger motor terminal. Place the appropriate auger switch in the “-” (“ON”) position. Connect the dispenser to the power source.The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 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 the dispenser wiring harness.

5. Check for continuity across the auger motor capacitor terminals.

P1324

FIG. 4 AUGER MOTOR CAPACITOR TERMINALS

If continuity is present as described, reconnect the wires to the auger motor capacitor.

If continuity is not present as described, replace the auger motor capacitor.

27646 022500

Page 24

SERVICE (cont.)

AUGER SHAFT ASSEMBLY

Auger Shaft Assy

Auger Shaft Bushing Cooling Drum Seal Auger Shaft Seal

Hopper Drum Seal

P1758

FIG. 5 AUGER SHAFT ASSEMBLY

Location: The Auger Shaft Assembly is located in each of the cooling drums.

Removal and Replacement:

1. Drain, remove and clean hopper; refer to the Rec- ommended Daily Weekly Cleaning Section of this manual, page 12, for proper cleaning procedures. Discard the auger shaft seal, hopper/drum seal and faucet spool o-rings.

2. Remove the #8 locking screws securing auger motor cover to the cooling drum mount assembly; remove cover and set aside for reassembly.

3. Remove the #8 locking screw on the lower right side (viewed from front) of the auger motor mounting bracket securing the auger motor run capacitor. Set capacitor aside with wires attached.

4. Disconnect the auger motor terminal from the terminal on the main wiring harness.

5. Remove the remaining #8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket.

6. Remove motor with mounting bracket, drip tray (if present) split pin and torsion spring bearing as an assembly.

NOTE - When removing or installing motor and shaft assemblies, be sure the split pins are turned to a position that will clear the torque sensor circuit board.

7. Pull the auger shaft assembly straight out of cooling drum. Inspect the shaft for abnormal wear or scoring.

8. From the front of dispenser, remove the seal and blue bushing from cooling drum and discard them.

9. Clean seal and busing surfaces of the cooling drum very thoroughly. All old lubricant must be removed.

10. Refer to Fig 6A and slip new blue bushing into cooling drum. Lightly lube I.D. of bushing

with #M2550.0000 “Lubri-lm” provided in Kit

#28106.0000 (CDS-2) or #28106.0001 (CDS-3). Do not use anything such as a cotton swab that might leave lint or unravel. DON NOT GET ANY LUBE ON THE SEAL COUNTERBORE SURFACE.

11. Lightly lube I.D. of new cooling drum seal with #M2550.0000, provided in kit. Use care not to get any lube on O.D. of seal. Place seal on insertion tool #28395.0000, as shown in Fig. 6B. Make sure open face of seal is toward cooling drum.

12. Push seal into bore until it is ﬁrmly seated; remove tool.

13. Clean the auger shaft assembly, then wipe a small amount of #M2550.0000 “Lubri-ﬁlm” (provided in kit) over the ﬁrst two inches of the front end of the shaft.

14.Place a small amount of #29563.0000 “Krytox”

lubricant (provided in kit in a plastic cap) on the end of the motor shaft (about 1 1/2”) and a thin ﬁlm in the groove. Install auger shaft assembly onto the motor shaft. See Fig. 6C. Do not use too much

“Krytox”lubricant.

NOTE - This is the only place “Krytox” lubricant is

used.

15. Assemble motor/shaft assembly as shown in Fig. 6C, then install assembly into cooling drum. Make sure the pins do not hit the sensor board and cooling drum seal is not dislodged as the shaft passes through.

16. Secure motor and capacitor to the cooling drum mounting bracket. Install rear motor cover.

17. Refer to Initial Setup for hopper assembly and installation procedures. Be sure to use new hopper/drum seal, auger shaft seal and faucet spool o-rings when reassembling.

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Page 25

SERVICE (cont.)

AUGER SHAFT ASSEMBLY(cont.)

Lightly lube the bushing I.D. with M2550.0000 “LubriFilm”

Do NOT get any Lube on this surface

Lube about 1 1/2” of shaft and in the groove with#29563.0000“Krytox” Lubricant

Auger Shaft Assy

Lube about 2.0” of shaft with #M2550.0000 “Lubri-ﬁlm”

FIG. 6A AUGER SHAFT BUSHING

Open face of seal away from tool

Cooling Drum Seal Seal Insertion Tool

P1759

P1761

FIG. 6C MOTOR/SHAFT ASSEMBLY

FIG. 6B COOLING DRUM SEAL

P1760

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SERVICE (cont.)

AUGER ON/OFF SWITCHES

P1343

FIG. 7 AUGER ON/OFF SWITCHES

Location: The auger switches are located inside the dispenser drawer.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the white/green wire from the switch to be tested and white/black wire from contactor located on the outside bottom of the component bracket .

3. With a voltmeter, check the voltage across the white/ green and the white/black wires and the “ON/OFF” switch in the “ON” position. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

4. Disconnect the dispenser from the power source.

If continuity is present as described, the auger switch is operating properly.

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

Removal and Replacement:

1. Pull the dispenser drawer out until the drawer hits the drawer stop. Using a screwdriver gently pry up on the drawer stop and remove the drawer from the dispenser.

2. Remove the four #8-32 locking screws securing the switch panel to the drawer.

3. Lift the switch panel with wires and L.E.D./adjustment board out as an assembly.

4. Turn switch panel over and remove the wires from the auger switch that is to be replaced.

5. Compress the clips on the back of the control panel and gently push switch through the opening.

6. Push the new switch into the opening, with the “o” on the switch to the outside, until the clips snap into position.

7. Reconnect the wires to the switch. Refer to Fig. 8 when reconnecting wires.

8. Position the switch panel inside the drawer and secure with four #8-32 locking screws.

9. Reinstall drawer.

If voltage is present as described, reconnect the white/ black wire to the contactor and proceed to #5. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

5. Remove the white/blue wire from the right auger switch, the white/brown wire from the left auger switch, or the grey wire from the center auger switch.

6. With the auger switch to be tested in the “ON” position check for continuity across the terminals. Continuity must not be present when the switch is in the “OFF” position.

FIG. 8 AUGER SWITCH TERMINALS

P1336

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Page 27

R22

SERVICE (cont.)

CIRCUIT BREAKER

5. Push the new circuit breaker into the opening in the component bracket until the clips snap into position.

6. Reconnect the wires to the circuit breaker.

7. Position the component bracket in chassis and secure with four #8-32 locking screws.

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

RED from Transformer

FIG.9CIRCUITBREAKER

P1342

Location:

The circuit breaker is located inside the dispenser

on the upper left side of the component bracket.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Remove the wires from the circuit breaker.

3. Check for continuity between the terminals. Continuity must be present between the terminals.

If continuity is present as described the circuit breaker is functioning properly.

If continuity is not present as described, press the reset button and repeat step #3, if continuity is not present as described, replace the circuit breaker.

Removal and Replacement:

1. Remove the four #8-32 locking screws securing the component bracket to the chassis.

2. Tip the top of the component bracket forward far enough to allow access to the rear of the circuit breaker.

3. Remove the wires from the circuit breaker.

4. Compress the clips on the back side of the component bracket and gently push the circuit breaker through the opening in the component bracket.

RED from Main Harness

P1330

FIG.10CIRCUITBREAKERTERMINALS

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Page 28

R22

SERVICE (cont.)

COMPRESSOR & COMPONENTS (CDS-2)

FIG. 11 COMPRESSOR ASSY

Location:

The compressor assy is located inside the front

of the dispenser chassis.

1 4

3 2 5 6

120V COMPRESSORS

P1342

Test Procedures: WARNING: The compressor start capacitor must be

properly discharged before proceeding.

Compressor Start Relay: Refer to FIG. 12

1. Disconnect the dispenser from the power source.

2. Remove compressor terminal cover retainer (6) and compressor terminal cover (5).

3. Disconnect the black wire from the thermal overload protector (3) and white/black wire from the compressor start relay (1).

4. With a voltmeter, check voltage across the black wire and the white/black wire and the ON/OFF switch in the “ON” position, DAY/NIGHT switch in the “DAY” position and the ICE/OFF/NO ICE switch in the “ICE” position. Connect the dispenser to the power source. The indication must be 120 volts ac for two wire 120 volt models or 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 #6. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

6. Disconnect the two black wires from the compressor start capacitor.

7. Remove relay from the compressor.

8. Check for continuity across the upper left terminal and the right pin socket on the rear of the relay.

If continuity is present as described, the compressor start relay is operating properly.

4 3 1

5 6 7

230V COMPRESSORS

FIG. 12 COMPRESSOR ELECTRICAL COMPONENTS

1. Compressor Start Relay

2. Overload Protector Retainer

3. Thermal Overload Protector

4. Compressor Start Capacitor

5. Compressor Terminal Cover

6. Compressor Terminal Cover Retainer

7. Compressor Run Capacitor

P1344

If continuity is not present as described, replace relay.

Compressor:

1. With the compressor start relay (1) removed, disconnect the black wire from the compressor.

2. Check for continuity across the terminal on the compressor and the left pin on the compressor.

If continuity is present as described, the electrical part of the compressor is operating properly.

If continuity is not present as described, replace the compressor.

Thermal Overload Protector:

1. Check for continuity across the terminals on the thermal overload protector (3).

If continuity is present as described, the thermal overload protector is operating properly.

If continuity is not present as described, replace the thermal overload protector.

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Page 29

SERVICE (cont.)

COMPRESSOR & COMPONENTS (CDS-2) (cont.)

Compressor Start Capacitor:

1. Check for continuity across the terminals on the compressor start capacitor.

If continuity is present as described, the start capacitor is operating properly.

If continuity is not present as described, replace the capacitor.

NOTE: If all the electrical components are operating properly and the compressor does not operate, there is an internal mechanical problem. Replace the compressor.

11. Position the component bracket in the chassis and secure with four #8-32 locking screws.

12. Reconnect tubes from the condenser and the accumulator to the compressor.

13. Evacuate the system.

NOTE: When replacing the compressor it is recommended that the dryer also be replaced.

14. Recharge 120V system with 8.4 oz. of Type R22 refrigerant. Design Pressures: High 210 - Low 32

Recharge 230V system with 9.5 oz. of Type 404A

refrigerant. Design Pressures: High 215 - Low 40

NOTE: The charging of the system must be done by a licensed refrigeration repair person.

Removal and Replacement:

Compressor Assy: NOTE: Before removal of any refrigeration component

the refrigerant in the system must be reclaimed by a licensed refrigeration repair person.

1. Disconnect the tubes from the condenser and the accumulator.

2. Disconnect the compressor wiring harness from the dispenser main wiring harness.

3. Remove the four .25-20 keps nuts and washers securing the compressor to the chassis. Set nuts and washers aside for reassembly.

4. Remove the four #8-32 locking screws securing the component bracket to the dispenser chassis.

5. Disconnect the wires from the circuit breaker, fuse holder, transformer, electronic control and the contactor.

6. Remove component bracket with circuit breaker, fuse holder, transformer, electronic control and contactor as an assembly. Set component bracket and screws aside for reassembly.

7. From the right side of the dispenser lift the compressor assembly over the four studs in the chassis and remove compressor.

8. Install new compressor over the four studs in the dispenser chassis with the ﬁll valve to the left side of the dispenser.

9. Secure compressor to the dispenser chassis using four .25-20 keps nuts and washers.

10. Reconnect the wires to the components on the component bracket and plug the main wiring harness into the electronic control.

NOTE: When reconnecting wires refer to Fig. 10 for circuit breaker, Fig. 34 for fuse holder, Fig. 51 for transformer and Fig. 22 for contactor.

Compressor Start Capacitor: Refer to FIG. 12 WARNING: The compressor start capacitor must be

properly discharged before proceeding.

1. Remove terminal cover retainer (6) and terminal cover (5). Set aside for reassembly.

2. Disconnect the two leads from the capacitor.

3. Pry the end of the capacitor mounting bracket off of the boss on the capacitor and remove the capacitor.

4. Install new capacitor on the capacitor mounting bracket.

5. Refer to Fig. 13 and reconnect the wires to the capacitor.

6. Reinstall terminal cover (5) and cover retainer (6).

120V DISPENSERS

230V DISPENSERS

FIG. 13 COMPRESSOR START CAPACITOR

TERMINALS

27646 122200

P1340

Page 30

SERVICE (cont.)

COMPRESSOR & COMPONENTS (CDS-2) (cont.)

Compressor Start Relay: Refer to FIG. 12

1. Remove the terminal cover retainer (6) and the terminal cover (5)

WARNING: The compressor start capacitor must be properly discharged before proceeding.

2. Disconnect the wires from the compressor start relay.

3. Pull relay (1) off of the compressor pins and discard.

4. Push new relay onto the compressor pins.

5. Refer to Fig. 14 and reconnect the wires.

6. Reinstall terminal cover (5) and cover retainer (6).

Compressor Thermal Overload Protector (230V): Refer to FIG. 12

1. Remove terminal cover retainer (6) and terminal cover (5).

2. Disconnect the black wire from the thermal overload protector.

3. Pull thermal overload protector off of the compressor pin and discard.

4. Push new thermal overload protector onto the compressor pin.

5. Refer to Fig. 15 and reconnect the wire.

6. Reinstall terminal cover (5) and cover retainer (6).

120V DISPENSERS

230V DISPENSERS

P1338

FIG. 14 COMPRESSOR START RELAY

TERMINALS

Compressor Thermal Overload Protector (120V): Refer to FIG. 12

1. Remove terminal cover retainer (6) and terminal cover (5).

2. Disconnect the wire from thermal overload protector to the compressor and the wire from the compressor wiring harness to the thermal overload protector.

3. Remove overload protector retainer (2) and thermal overload protector (3) as an assembly.

4. Remove retainer (2) from overload protector (3) and discard overload protector.

5. Install retainer (2) on new overload protector (3).

6. Install retainer (2) and overload protector (3) on the compressor terminal bracket.

7. Refer to Fig. 15 and reconnect the thermal overload protector wires.

8. Reinstall terminal cover (5) and cover retainer (6).

230V DISPENSERS

FIG. 15 THERMAL OVERLOAD PROTECTOR

TERMINALS

Compressor Run Capacitor (230V Dispensers Only): Refer to FIG. 12

1. Remove terminal cover retainer (6) and terminal cover (5).

2. Disconnect the run capacitor leads.

3. Remove the #6 crimptite screw securing the run capacitor to the rear of the component bracket.

4. Remove run capacitor and discard.

5. Place new run capacitor on the rear of component bracket and secure with #6 crimptite screw.

6. Refer to Fig. 15A and reconnect the wires.

FIG. 15A COMPRESSOR RUN CAPACITOR

TERMINALS

P1339

P1816

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Page 31

SERVICE (cont.)

COMPRESSOR & COMPONENTS (CDS-3)

2 3

FIG. 16 COMPRESSOR &

COMPONENT LOCATIONS

Location:

The compressor assy is located inside the front

of the dispenser chassis.

P1558.30

3. Disconnect the black wire to the thermal overload protector (4), the white and black or red wires to the compressor.

4. With a voltmeter, check voltage across the black wire removed from the thermal overload protector and the white wire with the ON/OFF switch in the “ON” position, DAY/NIGHT switch in the “DAY” position and the ICE/OFF/NO ICE switch in the “ICE” position. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

5. Disconnect the dispenser from the power source.

If voltage is present as described, proceed to #6. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

6. Disconnect the two black wires from the compressor start capacitor.

7. Check for continuity across contacts 1 & 2 of the relay.

If continuity is present as described, the compressor start relay is operating properly.

4 5

6 7

FIG. 17 COMPRESSOR THERMAL

P1819

OVERLOAD PROTECTOR LOCATION

1. Compressor Start Relay

2. Compressor Start Capacitor

3. Compressor Run Capacitor

4. Thermal Overload Protector

5. Overload Protector Retainer

6. Compressor Terminal Cover

7. Compressor Terminal Cover Retainer Test Procedures:

Compressor Start Relay: Refer to FIG. 17 WARNING: The compressor capacitors must be prop-

erly discharged before proceeding.

1. Disconnect the dispenser from the power source.

2. Remove the compressor terminal cover retainer (7) and compressor terminal cover (6).

If continuity is not present as described, replace relay.

Compressor:

1. With the compressor start relay (1) removed, disconnect the black or red wire from the compressor.

2. Check for continuity across the terminal on the compressor and the left pin on the compressor.

If continuity is present as described, the electrical part of the compressor is operating properly.

If continuity is not present as described, replace the compressor.

Thermal Overload Protector:

1. Check for continuity across the terminals on the thermal overload protector.

If continuity is present as described, the thermal overload protector is operating properly.

If continuity is not present as described, replace the thermal overload protector.

Compressor Start Capacitor:

1. Check for continuity across the terminals on the compressor start capacitor.

If continuity is present as described, the start capacitor is operating properly.

If continuity is not present as described, replace the capacitor.

27646 122200

Page 32

SERVICE (cont.)

COMPRESSOR & COMPONENTS (CDS-3) (cont.)

Compressor Run Capacitor:

1. Check for continuity across the terminals on the compressor run capacitor.

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

NOTE: If all the electrical components are operating properly and the compressor does not operate, there is an internal mechanical problem. Replace the compressor. Removal and Replacement: Compressor Assy: NOTE: Before removal of any refrigeration component the refrigerant in the system must be reclaimed by a licensed refrigeration repair person.

1. Disconnect the tubes from the condenser, accumulator also remove access valve and tube..

2. Disconnect the compressor wiring harness from the dispenser main wiring harness.

3. Remove the four .312”-18 screws, keps nuts and washers securing the compressor to the chassis. Set screws, nuts and washers aside for reassembly.

4. Remove the four #8-32 locking screws securing the component bracket to the dispenser chassis.

5. Pull the component bracket, with wires attached, out of the chassis far enough to gain access to the compressor.

6. Disconnect the compressor wiring harness from the compressor.

7. Remove the two #8-32 screws securing the contactor mounting bracket to the dispenser base.

8. Remove the contactor mounting bracket, contactor, contactor cover and the compressor wiring harness as an assembly. Set aside for reassembly.

9. Disconnect the fan leads from the main wiring harness.

10. Remove the three #6 thread cutting screws securing the fan to the condenser shroud. Remove the fan and set aside for reassembly.

11. Slide the compressor out the right side of the dispenser.

12. Remove the four grommets and sleeves from the old compressor and install them on the new compressor.

13. Slide new compressor into position on the dispenser chassis, with the tube connections to the front.

14. Secure compressor to the dispenser chassis using four .312”-18 screws, washers and nuts.

15. Install the fan on the condenser shroud and secure with three #6 thread cutting screws.

16. Reconnect the leads on the fan to the main harness.

17. On dispensers serial number CDS0019500 - up install the contactor bracket, contactor, contactor cover and compressor wiring harness as an assembly. Secure contactor bracket to the chassis using two #8-32 screws.

18. Refer to Fig.17A and reconnect the wires to the compressor.

19. Position the component bracket in the chassis and secure with four #8-32 locking screws.

20. Reconnect tubes from the condenser and the accumulator to the compressor, also reconnect access valve and tube.

21. Evacuate the system.

NOTE: When replacing the compressor it is recommended that the dryer also be replaced.

22. Dispensers prior to serial number CDS0019500 recharge system with 25 oz. of Type R404A refrigerant. Design Pressures: High 320 - Low 44

Dispensers serial number CDS0019500 - up re-

charge system with 22 oz of type R404A refrigerant. Design Pressures: High 380 - Low 52

NOTE: The charging of the system must be done by a licensed refrigeration repair person.

RED from Relay T2 WHI from Relay T4

BLKfrom

Relay T-5

FIG. 17A COMPRESSOR TERMINALS

P1819

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Page 33

SERVICE (cont.)

COMPRESSOR & COMPONENTS (CDS-3) (cont.)

Compressor Start Capacitor: WARNING: The compressor start capacitor must be

properly discharged before proceeding.

1. Disconnect the two leads on the compressor start capacitor.

2. Loosen the capacitor retaining strap and remove the capacitor.

3. Securely install new start capacitor under the retaining strap.

4. Refer to Fig. 18 and reconnect the wires to the start capacitor.

Compressor Run Capacitor: WARNING: The compressor run capacitor must be

properly discharged before proceeding.

1. Disconnect the three leads from the compressor run capacitor.

2. Loosen the capacitor retaining strap and remove the capacitor.

4. Securely install new run capacitor under the retaining strap.

5. Refer to Fig. 18 and reconnect the wires to the relay.

BLKtoCompressor

Relay T6

BLKtoCompressor

Relay T1

BLK

BLKtoCompressor

Relay T2

T4 WHI from Compressor and Main Harness

T4BLKfromRunCapacitor

T5BLKfromCompressor

Thermal Overload Protector and Main Harness

T1BLKfromStartCapacitor T2BLKfromRunCapacitor

T2 Red from Compressor

P1820

FIG. 19 COMPRESSOR RELAY TERMINALS

Compressor Thermal Overload Protector: Refer to FIG. 17

1. Remove terminal cover retainer (7) and terminal cover (6).

2. Remove the wire from thermal overload protector from the compressor wiring harness to the thermal overload protector.

3. Remove overload protector retainer (5) and thermal overload protector (4) as an assembly

4. Remove retainer (5) from overload protector (4) and discard overload protector.

5. Install retainer (5) on new overload protector (2).

6. Install retainer (5) and overload protector (4) on the compressor terminal bracket.

7. Refer to Fig. 20 and reconnect the thermal overload protector wires.

8. Reinstall terminal cover (6) and cover retainer (7).

START

FIG. 18 COMPRESSOR CAPACITOR TERMINALS

Compressor Start Relay WARNING: The compressor start capacitor must be

properly discharged before proceeding.

RUN

P1817

BLKtoCompressorRelayT5

P1821

FIG. 20 THERMAL OVERLOAD PROTECTOR

TERMINALS

1. Disconnect the wires from the compressor relay.

2. Remove the #6-32 screw securing the relay to the rear of the component bracket.

3. Remove and discard relay.

4. Install new relay on the rear of the component bracket and secure with a #6-32 screw.

5. Refer to Fig. 19 and reconnect the wires.

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Page 34

SERVICE (cont.)

R22

CONTACTOR - ELECTRONIC CONTROL

P1342

FIG. 21 CONTACTOR - ELECTRONIC CONTROL

Location:

The contactor is located inside the dispenser chas-

sis on the lower outside of the component bracket.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect white/black wire from contactor terminal #0 (terminal #2, on CDS-3 ﬁrst type contactor) and brown/black from terminal #1.

3. With a voltmeter, check the voltage across the white/black wire and the brown/black wire and the ON/OFF switch in the “ON” position. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 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.

5. Check for continuity across contactor terminals #0 & #1 (#1 & #2, CDS-3 ﬁrst type contactor).

If continuity is present as described reconnect the white/black wire and the brown/black wire to the contactor and proceed to #6. If continuity is not present as described, replace the contactor.

6. Disconnect the black wires from contactor terminals #6 & #8 (#5 & #6, CDS-3 ﬁrst type contactor).

7. With ON/OFF switch in the “ON” position, connect the dispenser to the power source and check for continuity across terminals on contactor.

If continuity is not present as described, on CDS-3 ﬁrst type contactors, replace contactor. If continuity is not present between terminals #6 & #8 as described on all CDS-2 contactors and CDS-3 second type contactors, check for continuity across terminals #2 and #4.

If continuity is present as described, disconnect the dispenser from power source and reconnect black wires to terminals #2 and #4, the contactor will operate properly.

If continuity is not present as described, replace the contactor.

Removal and Replacement:

1. Disconnect the wires from the contactor.

2. Remove the two #8-32 locking screws securing the contactor to the component bracket. Remove and discard contactor.

3. Install the new contactor on the component bracket using two #8-32 locking screws.

4. Refer to Fig. 22 and reconnect the wires.

Terminal #4

Terminal #2

Terminal #6

BLKfromMain

Harness/Power Cord

Terminal #8

BLKfromCompressor

Harness

Terminal #0

WHI/BLKfromMainHarness/

Power Cord/Compressor

Terminal #1

BRN/BLK from Main

Harness/Control Board

ALL CDS-2 CONTACTORS

CDS-3 SECOND TYPE CONTACTORS

Terminal #2

Terminal #1

BRN/BLK from Main

Harness/Control Board

Terminal #5

BLKfromCompressor

Harness

WHI/BLKfromMainHarness/

Power Cord/Compressor

Terminal #6

BLKfromMain

Harness/Power Cord

CDS-3 FIRST TYPE CONTACTORS

FIG. 22 CONTACTOR TERMINALS

P1333

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Page 35

SERVICE (cont.)

COOLING DRUM ALIGNMENT

Ledge

Boss

FIG. 23 COOLING DRUM SHIPPING SUPPORT

Legs

FIG.24CHECKINGALIGNMENT

P1510

The “A” shaped Cooling Drum Shipping Supports, removed during Initial Set-Up should be kept and used as a tool to reset the alignment of the cooling drums should it ever be required.

Symptoms: Squeaky Operation, hopper lifts or won’t seat properly, hopper is pushed to one side or the other.

To check alignment

1. Place the “A” shaped support on the auger shaft

with the ledge under the cooling drum.

2. Lift the cooling drum while rotating the support into

a vertical position. The boss on the very bottom

will drop into the hopper drip tray’s drain hole.

When in its proper position, the cooling drum will cause a slight pressure on the hopper drip tray drain hole and the two legs will be equidistant from the hopper drip tray.

If adjustment is needed, remove the support and gently force the free end of the evaporator in the direction the adjustment is needed.

Reinstall the support, check the alignment, and readjust the cooling drums as required.

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SERVICE (cont.)

DAY/NIGHT SWITCH

FIG. 25 DAY/NIGHT SWITCH

P1343

Location:

The DAY/NIGHT switch is located inside the dis-

penser drawer on the right front of the control panel.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the white/green wire from the switch and the white/black wire from contactor located on the outside bottom of the component bracket .

3. With a voltmeter, check the voltage across the white/green and the white/black and the ”ON/OFF“ switch in the “ON” position. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

4. Disconnect the dispenser from the power source.

5. Remove the white/red wire from the transformer.

6. With the DAY/NIGHT switch in the “DAY” position check for continuity across the terminals. Continuity must not be present when the switch is in the “NIGHT” position.

If continuity is present as described, the day/night switch is operating properly.

If continuity is not present as described, replace the day/night switch.

Removal and Replacement:

1. Pull the dispenser drawer out until the drawer hits the drawer stop. Using a screwdriver gently pry up on the drawer stop and remove the drawer from the dispenser.

2. Remove the four #8-32 locking screws securing the switch panel to the drawer.

3. Lift switch panel with wires and L.E.D. board as an assembly.

4. Turn switch panel over and remove the wires from the DAY/NIGHT switch.

5. Compress the clips on the back of the control panel and gently push switch through the opening.

6. Push the new switch into the opening, with the “o” on the switch to the outside, until the clips snap into position.

7. Reconnect the wires to the switch. Refer to Fig. 26 when reconnecting wires.

8. Position the switch panel inside the drawer and secure with four #8-32 locking screws.

9. Reinstall drawer.

FIG. 26 DAY/NIGHT SWITCH TERMINALS

P1335

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Page 37

SERVICE (cont.)

DISPENSER ON/OFF SWITCH

FIG. 27 ON/OFF SWITCH - DISPENSER

P1343

Location:

The dispenser ON/OFF switch is located inside the dispenser drawer on the left front of the control panel.

Removal and Replacement:

1. Pull the dispenser drawer out far enough to expose the four #8 -32 locking screws securing the switch panel to the drawer.

2. Remove the four #8-32 locking screws.

3. Lift switch panel with wires and L.E.D./adjustment board as an assembly.

4. Turn switch panel over and remove the wires from the dispenser ON/OFF switch.

5. Compress the clips on the back of the control panel and gently push switch through the opening.

6. Push the new switch into the opening, with the “o” on the switch to the outside, until the clips snap into position.

7. Reconnect the wires to the switch. Refer to Fig. 28 when reconnecting wires.

8. Position the switch panel inside the drawer and secure with four #8-32 locking screws.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the black wire from the switch and white/black from contactor located on the outside bottom of the component bracket .

3. With a voltmeter, check the voltage across the black and the white/black. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models. If voltage is present as described, reconnect the white/ black wire to the contactor and proceed to #5. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

5. Disconnect the white/green wire from the ON/OFF switch.

6. With the ON/OFF switch in the “-” (“ON”) down position check for continuity across the switch terminals. Continuity must not be present when the switch is “o” (“OFF”) down position.

FIG. 28 DISPENSER ON/OFF SWITCH

TERMINALS

P1337

If continuity is present as described, the ON/OFF switch is operating properly.

If continuity is not present as described, replace the ON/OFF switch.

27646 122200

Page 38

R22

SERVICE (cont.)

ELECTRONIC CONTROL

Removal and Replacement:

1. Disconnect the plug from the main harness from the connector on the electronic control.

2. Remove the two #8-32 locking screws securing electronic control to the component bracket. Remove and discard the electronic control.

3. Install new electronic control using two #8-32 locking screws.

4. Reconnect the plug from main harness to the connector on the electronic control.

FIG. 29 ELECTRONIC CONTROL

P1342

Location:

The electronic control is located on the outside of the component bracket inside the chassis on the right side.

Test Procedure:

1. Disconnect the dispenser from the power source.

2. Disconnect the plug from the main harness from

the connector on the electronic control.

3. With a voltmeter, check the voltage across the socket

#23 and socket #24 in the plug from the main har-

ness and “ON/OFF” switch in the “ON” position.

Connect the dispenser to the power source. The

indication must be: a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

4. Disconnect the dispenser from the power source. If voltage is present as described, replace the electronic control. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

27646 122200

Page 39

SERVICE (cont.)

FAN

FIG. 30 FAN

P1342

Location:

The fan is located inside the dispenser chassis just

in front of the condenser.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the yellow and white/black wires from the main harness to the fan leads.

3. With a voltmeter, check the voltage across the yellow and the white/black wires and the “ON/OFF” switch in the “ON” position. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

4. Disconnect the dispenser from the power source.

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.

Removal and Replacement (Refer to Fig. 31) NOTE: Leave the hopper in place. This keeps it in align-

ment while the condenser shroud is removed.

1. Disconnect the fan leads from the wiring harness.

2. Remove the four #6 crimptite screws securing the condenser shroud and fan assy (1) to the condenser and the two #8-32 locking screws securing the condenser shroud and fan assy (1) to the chassis base.

3. Remove the condenser shroud and fan assy from the right side of the dispenser.

4. Remove the three #6 thread cutting screws securing the fan assy to condenser shroud (7). Set condenser shroud and screws aside for reassembly.

5. Remove the three #8-32 thread forming screws securing motor (5) to condenser fan shroud/mount (6). Set shroud and screws aside for reassembly.

2 3 4

5 6

FIG. 31 FAN COMPONENTS

6. Remove speed nut (2) from the motor shaft.

7. Remove fan (3).

8. Remove silencer (4).

1. Condenser Shroud and Fan Assy

2. Speed Nut 3. Fan Blade

4. Silencer 5. Motor

6. Shroud/Mount 7. Condenser Shroud

9. Install silencer (4) on new motor assy.

10. Install fan (3) on new motor assy.

11. Install speed nut (2) on new motor assy.

12. Using three #8-32 thread forming screws secure new motor assy to shroud/mount (6).

13. Using three #6-32 thread cutting screw new motor and shroud/mount to the condenser shroud (7).

14. Using two #8-32 locking screws secure condenser shroud and fan assy (1) to the chassis base.

15. Using four #8-32 crimptite screws secure the condenser shroud and fan assy (1) to the condenser.

16. Refer to Fig. 32 and reconnect the leads on the new motor to the dispenser wiring harness.

17. Use cable ties to secure wires away from fan blades.

BLK to Main Harness WHI/BLK BLK to Main Harness YEL

FIG. 32 FAN MOTOR TERMINALS

27646 122200

P1345

P1326

Page 40

SERVICE (cont.)

R22

FUSE AND FUSE HOLDER

FIG. 33 FUSE HOLDER

P1342

Location:

The fuse holder is located inside the dispenser on the upper left side of the component bracket just below the circuit breaker.

Fuse Holder:

1. Disconnect the wires from the rear of the fuse holder.

2. Remove nut securing the fuse holder to the component bracket.

3. Push fuse holder through the hole in the component bracket.

4. Install new fuse holder and fuse through the hole in the component bracket.

5. Secure the fuse holder to the component bracket.

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

WHI/GRN from Main Harness/ON/OFF Switch

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Remove cap and fuse from fuse holder.

3. Remove fuse from the cap.

4. Check for continuity through the fuse. If continuity is present as described, reinstall the fuse,

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

fuse.

Removal and Replacement:

Fuse:

1. Remove the cap from the fuse holder.

2. Remove fuse from the fuse holder, inspect, if blown discard.

3. Install new 5 amp fuse in the fuse holder

4. Reinstall fuse holder cap.

WHI/GRN from Main Harness/Control Board

FIG. 34 FUSE HOLDER TERMINALS

P1331

27646 022500

Page 41

SERVICE (cont.)

ICE/OFF/NO ICE SWITCHES

FIG. 35 ICE/OFF/NO ICE SWITCHES

P1343

Location:

The ICE/OFF/NO-ICE switches are located inside

the dispenser drawer.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the black wire from the switch to be

tested and white/black from contactor located on the outside bottom of the component bracket .

3. With a voltmeter, check the voltage across the black

wire and the white/black wire and all other switches in the down position (“ON”) to the center of the control panel. Connect the dispenser to the power source. The indication must be 5 volts dc.

4. Disconnect the dispenser from the power source. If voltage is present as described, reconnect the white/ black wire to the contactor and proceed to #5. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

5. Remove the white/yellow wire and the white/violet

wire from the right ICE/OFF/NO-ICE switch, the white/orange wire and the red/black from the left ICE/OFF/NO-ICE switch, or the brown/black wire and blue wire from the center ICE/OFF/NO-ICE switch.

6. With the switch to be tested pressed down on the right side, check for continuity between the center terminal and the left terminal. With the switch pressed down to the left, check for continuity between the center terminal and the right terminal. Continuity must not be present when neither side of the switch is pressed down.

If continuity is present as described, the ICE/OFF/NOICE switch is operating properly.

If continuity is not present as described, replace the ICE/OFF/NO-ICE switch.

Removal and Replacement:

1. Pull the dispenser drawer out until the drawer hits the drawer stop. Using a screwdriver gently pry up on the drawer stop and remove the drawer from the dispenser.

2. Remove the four #8-32 locking screws securing the switch panel to the drawer.

3. Lift switch panel with wires and L.E.D./adjustment board as an assembly.

4. Turn switch panel over and remove the wires from the ICE/OFF/NO-ICE switch that is to be replaced.

5. Compress the clips on the back of the control panel and gently push switch through the opening.

6. Push the new switch into the opening until the clips snap into position.

7. Reconnect the wires to the switch. Refer to Fig. 36 when reconnecting wires.

8. Position the switch panel inside the drawer and secure with four #8-32 locking screws.

P1334

FIG. 36 ICE/OFF/NO ICE SWITCH TERMINALS

27646 122200

Page 42

SERVICE (cont.)

LAMP CORD ASSY

FIG. 37 LAMP CORD ASSY

P1343

Location:

The lamp cord assembly is located in the left top

of the auger motor cover.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Unplug the lamp cord assembly from lamp cord connector assembly.

3. Check for continuity across the tip of the cord assembly and the housing. Continuity must not be present when both lamps are removed.

7. Strip the wires from the lamp holder/socket assembly approximately .375”.

8. Using the two wire nuts, supplied, connect the new lamp cord assembly to the lamp holder/socket assembly wires.

9. Reinstall the hopper liner to the bottom of the hopper cover.

10. Reinstall the hopper cover to the hopper.

11. Plug in the new lamp cord assembly to the lamp cord connector assembly on left top of the auger motor cover.

12. Refer to Fig. 38 when reconnecting the wires.

P1332

FIG. 38 LAMP CORD WIRES

If continuity is present as described, the cord assembly is operating properly.

If continuity is not present as described, replace the cord assembly.

Removal and Replacement:

1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the auger motor cover.

2. Remove the hopper cover with the lamp cord assembly from the hopper.

3. Remove hopper cover liner from the hopper cover.

4. Cut the closed splice terminals connecting lamp cord assembly to the lamp holder/socket assembly off.

5. Remove lamp cord assembly from hopper cover and discard.

6. Push new lamp cord wires through the holes on the left outside top of the hopper cover.

27646 122200

Page 43

SERVICE (cont.)

LAMP CORD CONNECTOR

FIG. 39 LAMP CORD CONNECTOR

P1343

Location:

The lamp cord connectors are located inside the

upper left side of the auger covers.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the plug on the dispenser main harness

from the connector from the lamp cord connector.

3. With a voltmeter, check the voltage across the two

pin holes on the main harness plug and DAY/NIGHT switch “-” in the down position and the ON/OFF switch in the “ON” position. Connect the dispenser to the power source. The indication must be approximately 12.6 volts dc.

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 main wiring harness.

If continuity is not present when lamp cord assembly is connected or continuity is present when lamp cord assembly is not connected, replace the lamp cord connector.

Removal and Replacement:

1. Disconnect the lamp cord assembly from the lamp cord connector.

2. Remove the two #8-32 locking screws securing the auger motor cover the auger motor bracket/cooling drum bracket. Move cover back far enough to gain access to the lamp cord connector.

3. Disconnect the lamp cord connector wires from the dispenser main wiring harness.

4. Remove nut and washer securing the lamp cord connector to the auger motor cover and discard nut, washer and lamp cord connector.

5. Remove new nut and washer from new lamp cord connector.

6. Push new lamp cord connector through the hole in the auger motor cover and secure with the new nut and washer.

7. Reconnect the wires on the cord connector to the dispenser main wiring harness.

8. Position auger motor cover on auger motor bracket/ cooling drum bracket and secure with two #8-32 locking screws.

9. Refer to Fig. 40 when reconnecting wires.

NOTE: Lamp cord assembly (Fig. 37) and lamps, must be tested and determined to be functioning properly before proceeding to step 5.

5. Check for continuity across the black wire pin and red wire pin of the lamp cord connector (Fig. 40). Continuity must be present when the lamp cord assembly is connected and must not be present when lamp cord assembly is disconnected from lamp cord connector.

BLKtoMainWiringHarness

RED to Main Wiring Harness

FIG.40 LAMP CORD CONNECTOR

P1323

27646 122200

Page 44

SERVICE (cont.)

LAMP HOLDER/SOCKET ASSEMBLY

P1343

FIG.41LAMPHOLDER/SOCKETASSEMBLY

Location:

The lamp holder/socket assemblies are located

inside the hopper covers.

Test Procedures:

1. Disconnect the lamp cord assembly from the lamp cord connector.

2. Remove the lamps from the lamp holder/socket assembly.

3. With a voltmeter, check the voltage across the pin sockets in the plugs with the DAY/NIGHT switch in the “-” down position and ON/OFF switch in the “ON” position. Reconnect the lamp cord to the lamp cord connector. The indication must be approximately

12.6 volts dc.

4. Disconnect the lamp cord from the lamp cord connector.

If voltage is present as described, the lamp holder/ socket assembly is operating properly. If voltage is not present as described, replace the lamp holder/socket assembly.

5. Check for continuity across the terminals on the lamps.

Removal and Replacement:

1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the auger motor cover.

2. Remove the hopper cover with the lamp cord assembly from the hopper.

3. Remove hopper cover liner from the hopper cover.

4. Cut off the closed-end splices connecting lamp cord assembly to the lamp holder/socket assembly.

5. Remove the two lamps.

6. Remove the two #2-56 screws and elastic lock nuts securing the lamp holder/socket assembly to the mounting bracket. Remove lamp holder/socket assembly and discard.

7. Install new lamp holder/socket assembly on mounting bracket using two #2-56 screws and elastic lock nuts.

8. Reinstall lamps.

9. Strip the wires from the lamp cord assembly approximately .375”.

10. Using the two wire nuts, supplied, connect the lamp cord assembly to the new lamp holder/socket assembly wires.

11. Reinstall the hopper liner to the bottom of the hopper cover.

12. Reinstall the hopper cover to the hopper.

13. Plug in the lamp cord assembly to the lamp cord connector assembly on left top of the auger motor cover.

14. Refer to Fig. 42 when reconnecting the wires.

If continuity is present as described, the lamps are operating properly.

If continuity is not present as described, replace the lamp.

P1322

FIG.42LAMPHOLDER/SOCKETASSEMBLY

WIRES

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Page 45

SERVICE (cont.)

L.E.D./ADJUSTMENT BOARD

FIG. 43 L.E.D./ ADJUSTMENT BOARD

P1343

Location:

The L.E.D./adjustment board is located in the dispenser drawer attached to the bottom of the control panel.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the connector at the rear of the L.E.D./

adjustment board from the dispenser main wiring

harness.

3. With a voltmeter, check the voltage between pin hole

#1 (black wire) and pin hole #8 (pink wire) with

the ON/OFF switch in the “ON” position. Connect

the dispenser to the power source. The indication

must be 5 volts dc.

4. Disconnect the dispenser from the power source. If voltage is present as described, replace the L.E.D./ adjustment board. If voltage is not present as described, refer to the Wiring Diagram and check the dispenser wiring harness.

3. Lift switch panel with wires and L.E.D. /adjustment

board as an assembly and turn over.

4. Disconnect the connector on the dispenser wiring harness from the pin connector on the rear of the L.E.D./adjustment board.

5. Remove the #4 keps nut from the right rear stud on the control panel and remove the green ground wire.

6. Remove the remaining ﬁve #4 keps nuts from the studs on the control panel.

7. Remove the #6 stainless steel washer and the #6 nylon washer from the front stud on the control panel.

8. Remove board and discard.

9. Position a new board on the studs and spacers.

10. Install the #6 nylon washer and the #6 stainless steel washer on the front stud of the control panel. Be sure the nylon washer is installed ﬁrst.

11. Secure the new board to the control panel using ﬁve #4 keps nuts.

12. Connect the green lead from the dispenser main harness to the right rear stud of the control panel and secure with a #4 keps nut.

13. Reconnect the connector from the dispenser main wiring harness to the pin connector at the rear of new L.E.D./adjustment board.

14. Turn board and panel over and position in the dispenser drawer and secure with four #8-32 locking screws.

Removal and Replacement:

1. Pull the dispenser drawer out far enough to expose the four #8 -32 locking screws securing the switch panel to the drawer.

2. Remove the four #8-32 locking screws.

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Page 46

R22

SERVICE (cont.)

7. Disconnect the dispenser from the power source.

SOLENOIDS

FIG. 44 SOLENOIDS

P1342

Location:

The solenoids are mounted on a bracket that is

attached on top of the chassis on the left side.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the white/black wire from the solenoid to be tested and the orange wire from the left solenoid, the violet wire from the right solenoid or the white/violet wire from the center solenoid.

3. With a voltmeter, check the voltage across the white/black wire and the other wire with the ON/OFF switch in the “ON” position and the appropriate ICE/OFF/NO-ICE switch in the “ICE” or “NO-ICE” position. Connect the dispenser to the power source. The indication must be:

a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 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 main wiring harness.

5. Check for continuity across the solenoid valve coil terminals.

If the sound is heard as described and the refrigerant will not pass through the solenoid valve, there may be a blockage in the refrigerant line before the solenoid valve, or the solenoid valve may require inspection for wear, and removal of particles.

If the sound is not heard as described, replace the solenoids.

Removal and Replacement: NOTE: Before removal of any refrigeration component

the refrigerant in the system must be reclaimed by a licensed refrigeration repair person.

1. Disconnect the wires from both solenoids.

2. Disconnect the refrigerant lines from the solenoids to the cooling drums and the refrigerant line from the accumulator.

3. Remove the #6 hex crimptite securing solenoid bracket to the dispenser chassis.

4. Remove bracket and solenoids from the chassis assembly.

5. Remove the four #8-32 locking screws securing the solenoids to the bracket.

6. Remove solenoid and repair or discard.

7. Install new solenoid on mounting bracket using four #8-32 locking screws.

8. Reinstall mounting bracket and solenoids inside the dispenser chassis, securing with a #6 hex crimptite screw.

9. Reconnect the tubes from the accumulator and the cooling drums.

10. Refer to Fig. 45 and reconnect the wires.

11. Evacuate the system.

12. Recharge the system with the appropriate coolant and to the pressures directed on the decals

NOTE: The charging of the system must be done by a licensed refrigeration repair person.

If continuity is present as described, reconnect the wires to the solenoid.

If continuity is not present as described, replace the solenoids.

6. Check the solenoid valve for coil action. Connect the dispenser to the power source. With the auger motor switch in the “ON” position and the ON/ OFF/ICE switch in the “ICE” or “NO-ICE” position press the ON/OFF switch to the “ON” position. After approximately two minutes listen carefully in the vicinity of the solenoid valve for a “clicking” sound as the coil magnet attracts.

FIG.45 SOLENOID TERMINALS

P1327

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Page 47

SERVICE (cont.)

TEMPERATURE SENSOR

P1341

FIG. 46 TEMPERATURE SENSOR

Location:

The temperature sensors are located inside the top rear of the cooling drum under the auger motor covers.

Test Procedures:

1. Position the DAY/NIGHT switch in the “NIGHT”

position, check the L.E.D. on the control panel for

ﬂashes.

2. The L.E.D. for the temperature sensor is located

between the appropriate auger switch and the ice

switch.

3. If the temperature in the cooling drum is less

than20°F(-6˚C)ormorethan120°F(73˚C)for

10 seconds the L.E.D. will ﬂash twice every four

seconds.

4. If ﬂashing is present as described, replace the

temperature sensor.

Removal and Replacement:

1. Remove the two #8-32 securing the auger motor cover to cooling drum mount and remove the cover. Set aside for reassembly.

2. Disconnect the plug on the temperature sensor leads from the connector on the dispenser main wiring harness.

3. Pull the temperature sensor from the tube at the top rear of the cooling drum and discard.

4. Push new temperature sensor into the tube at the top rear of the cooling drum as far as it will go.

5. Refer to Fig. 47 and reconnect the wires.

6. Position auger motor cover on cooling drum mount and secure with two #8-32 locking screws.

P1325

FIG. 47 TEMPERATURE SENSOR

NOTE: Auger motor cover must be in place to give a correct reading.

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Page 48

SERVICE (cont.)

TORQUE SENSOR CIRCUIT BOARD

P1341

FIG. 48 TORQUE SENSOR CIRCUIT BOARD

Location:

The torque sensor circuit board is located on the

rear of the cooling drum mount just left of center.

Test Procedures:

1. With the ON/OFF switch and Auger switch in the “ON” position and the ICE/OFF/NO-ICE switch in the “ICE” position check the L.E.D. on the control panel.

2. The L.E.D. for the torque sensor is located between the appropriate auger switch and the ice switch.

3. If the L.E.D. ﬂashes one time every four seconds the auger is not turning. If the L.E.D. ﬂashes three times every four seconds the torque is less than possible. If the L.E.D. ﬂashes four times every four seconds the torque is greater than possible.

4. If the L.E.D. ﬂashes three times every four seconds, four times every four seconds or one time every four seconds with the auger turning, replace the torque sensor circuit board.

6. Remove motor with mounting bracket, drip tray, split pin and torsion spring bearings as an assembly and set aside for reassembly.

NOTE: When removing or installing the motor be sure the split pin in the motor shaft is turned to a position that will clear the torque sensor circuit board.

7. Disconnect the plug from the dispenser main wiring harness to the torque sensor circuit board.

8. Remove the #8-32 locking screw and washer securing torque sensor circuit board to the cooling drum mount.

9. Remove torque sensor circuit board and discard.

10. Install new torque sensor circuit board in the slot in the rear of the cooling drum mount and secure with a #8-32 locking screw and washer.

11. Refer to Fig. 49 and reconnect the wires.

12. Reinstall motor with mounting bracket, drip tray, split pin and torsion spring bearings using three #8 locking screws onto the cooling drum bracket.

13. Install the auger motor capacitor on the lower right side of the auger mounting bracket using the remaining #8 locking screw.

14. Connect the auger motor terminal to the terminal on the main wiring harness.

15. Refer to Fig. 49 when reconnecting the wires.

16. Position the auger motor cover on the cooling drum mount and secure with two #8-32 locking screws.

Removal and Replacement:

1. Remove the two #8-32 locking screws securing the auger motor cover to the cooling drum mount.

2. Remove the cover and set aside for reassembly.

3. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor run capacitor. Set capacitor aside with wires attached.

4. Disconnect the auger motor plug from the connector on the main wiring harness.

5. Remove the three remaining #8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket.

FIG. 49 TORQUE SENSOR CIRCUIT

BOARD TERMINALS

P1328

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Page 49

SERVICE (cont.)

R22

TRANSFORMER

FIG. 50 TRANSFORMER

P1342

Location:

The transformer is located inside the chassis on the

upper rear side of the component bracket.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the plug from the transformer to the

connector from the dispenser main wiring harness.

3. With a voltmeter, check the voltage across the

white/red wire and the white/black wire in the dispenser main wiring harness connector. Connect the dispenser to the power source. The indication

must be: a) 120 volts ac for 120 volt models. b) 230 volts ac for 230 volt models.

5. Reconnect the plug from the transformer to the con-

nector from the dispenser main wiring harness.

6. Connect the dispenser to the power source.

7. Disconnect the lamp cord from the lamp cord con-

nector.

8. With a voltmeter, check the voltage across the inside of lamp cord socket and the outside with the DAY/NIGHT switch in the “-” down position. The indication must be approximately 12.6 volts dc.

9. Disconnect the dispenser from the power source.

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

Removal and Replacement:

1. Remove the four #8-32 locking screws securing the component bracket to the chassis.

2. Pull component bracket from the chassis far enough to gain access to the transformer.

3. Disconnect the connector from the dispenser main wiring harness from the plug on the transformer.

4. Remove the four #8-32 locking screws securing the transformer to the component bracket.

5. Remove transformer and discard,

6. Position new transformer on the component bracket and secure with four #8-32 locking screws.

7. Reconnect the plug on the transformer to the connector on the dispenser wiring harness.

8. Refer to Fig. 51 and reconnect the wires.

9. Position component bracket in the chassis and secure with four #8-32 locking screws.

FIG. 51 TRANSFORMER TERMINALS

P1329

27646 122200

Page 50

SERVICE (CONT.)

VOLTAGE DIVIDER (PAF Models only)

Location:

The voltage divider is located in the wiring harness, inside the chassis near the upper rear side of the component bracket.

Test proceedures:

1. Disconnect the dispenser from the power source.

2. Disconnect the four-pin plug of the main harness

from the four-pin plug on the voltage divider.

3. With a voltmeter, check voltage across the white/

red wire (pin 1) and the white/black wire (pin 2) at

the plug on the main wiring harness. Connect the

dispenser to the power source; set the main power

switch to “ON” position; set the DAY/NIGHT switch

to “DAY” position. The indication must be: a) 120 volts ac for 120 volt 2 wire models. b) 230 volts ac for 230 volt 2 wire models.

4. Disconnect the dispenser from the power source.

5. With a voltmeter, check voltage between J4 pin 3 and J4 pin 23 of the control board. Connect the dispenser to the power source; set the main power switch to “ON” position; set the DAY/NIGHT switch to “DAY” position. The indication must be 12 volts ac.

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

P2268

FIG. 52 VOLTAGE DIVIDER

If voltage is present as described, reconnect the plug and connector and proceed to step 5. If voltage is not present as described, refer to the Wiring Diagrams and check the main wiring harness.

27646 122200

Page 51

COOLANT SCHEMATIC DIAGRAM CDS-2

27646 022500

Page 52

COOLANT SCHEMATIC DIAGRAM CDS-3

LEFT EVAPORATOR CENTER EVAPORATOR

CONDENSER

SUCTION

ACCUMULATOR

COMPRESSOR

RIGHT EVAPORATOR

SPLITTER

FILTER DRYER

AEV

AEV AEV

HOT GAS

BY-PASS VALV E

SOLENOID

(Prior to S/N CDS 0019500)

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LEFT EVAPORATOR CENTER EVAPORATOR

CONDENSER

SUCTION

ACCUMULATOR

COMPRESSOR

RIGHT EVAPORATOR

SPLITTER

FILTER DRYER

TEV

SIGHT

GLASS

COOLANT SCHEMATIC DIAGRAM CDS-3

(S/N CDS 0019500 - Up)

27646 022500

Page 54

27646 0225005527646 022500

Page 55

Page 56

WHI/RED

RIGHT

AUGER

BLK RED

WHI

LEFT

AUGER

BLK RED

WHI

WHI/BLK

BLK

WHI/BLK

RED WHI/BLK

RED-22 BLK-22

SOL

LEFT

ORA-22

WHI/GRN

SCHEMATICWIRINGDIAGRAM FOR CDS-2 PAF

WHI/GRN WHI/GRN

ON/OFF SW.

GRN

120 VOLTS AC

2 WIRE

SINGLE PHASE

60 HZ

J4-1

J4-24

C O N T R O L

B O A R D

J4-5

J4-10

J4-15

J4-20

YEL-22

VIO-22 RED-22 BLK-22

GRY-22 BLU-22 RED-22 GRN-22 ORA-22 BLK-22 PNK-22 RED/BLK WHI/ORA

WHI/GRN-22

WHI/VIO WHI/YEL

WHI/VIO-22

YEL

BRN/BLK

VIO

ORA WHI/BLK WHI/GRN

RED

WHI/GRN

DAY/NIGHT SW.

WHI/GRN

AMP

WHI/BLK WHI/BLK

BLK-22 RED-22

VIO-22

YEL-22

GRN-22 PNK-22

A D J U S T M E N T

B O A R D

WHI/GRN

SOL

RIGHT

BLK

t°

BLK

LEFT

RIGHT

BLK

t°

BLK

WHI/BLK

WHI/GRN-22

WHI/VIO-22

BLK-22

WHI/BLK

ICE/OFF/NO-ICE

SWITCHES

WHI/BLK

FAN

PNK-22

LEFT TORQUE SENSOR

BLU-22

BLK-22

PNK-22

RIGHT TORQUE SENSOR

GRY-22

BLK-22

BLK-22 BLK-22

RIGHTLEFT

PNK-22

BLKBLK

K1-6K1-8

LIMIT

THERMOSTAT

K2COMP.

K2-3

K2-5

K2-1

K2-2

WHI/RED

WHI/BLKWHI/BLK

Voltage

Divider

COMPRESSOR ASSEMBLY

WHI/RED

RIGHT SPRING

CONTACT

LEFT SPRING

CONTACT

GRNGRN GRNGRN

WHI/RED

GRN

WHI/RED

WHI/BLK

WHI/RED

WHI/BRN or VIO

WHI/RED

WHI/BLU

LT. AUGER SW.

RT. AUGER SW.

BLK

5 4 3 2 1

DAY/NIGHT

TIMER

WHI/BLK

WHI/RED

WHI/BLU

WHI/BRN

BLK

WHI/BLK

27646 022500

Page 57

WHI/BRN or VIO

WHI/REDWHI/RED

WHI/BLU

LT. AUGER SW.

RT. AUGER SW.

WHI/BRN

RIGHT

AUGER

BLK RED

WHI

BLK

WHI/BLK

LEFT

AUGER

BLK RED

WHI

WHI/BLK

BLK

WHI/BLK

RED WHI/BLK

RED-22 BLK-22

SOL

LEFT

ORA-22

WHI/GRN

SCHEMATICWIRINGDIAGRAM FOR CDSA-2 PAF

WHI/GRN WHI/GRN

ON/OFF SW.

230 VOLTS AC

2 WIRE

SINGLE PHASE

50 HZ

J4-1

J4-24

C O N T R O L

B O A R D

J4-5

J4-10

J4-15

J4-20

YEL-22

VIO-22 RED-22 BLK-22

GRY-22 BLU-22 RED-22 GRN-22 ORA-22 BLK-22 PNK-22

RED/BLK WHI/ORA

WHI/GRN-22

WHI/VIO WHI/YEL

WHI/VIO-22

YEL

BRN/BLK

VIO

ORA WHI/BLK WHI/GRN

RED

WHI/GRN

DAY/NIGHT SW.

WHI/GRN

AMP

WHI/BLK WHI/BLK

BLK-22 RED-22

VIO-22

YEL-22

GRN-22 PNK-22

A D J U S T M E N T

B O A R D

WHI/GRN

SOL

RIGHT

BLK

t°

BLK

LEFT

RIGHT

BLK

t°

BLK

WHI/BLK

WHI/GRN-22

WHI/VIO-22

BLK-22

WHI/BLK

ICE/OFF/NO-ICE

SWITCHES

WHI/BLK

FAN

PNK-22

LEFT TORQUE SENSOR

BLU-22

BLK-22

PNK-22

RIGHT TORQUE SENSOR

GRY-22

BLK-22

BLK-22 BLK-22

RIGHTLEFT

PNK-22

BLKBLK

K1-6K1-8

LIMIT

THERMOSTAT

WHI/RED

BLK

WHI/BLKWHI/BLK

5 4 3 2 1

DAY/NIGHT

TIMER

Voltage Divider

COMPRESSOR ASSEMBLY

WHI/RED

WHI/BLK

WHI/RED

RIGHT SPRING

CONTACT

LEFT SPRING

CONTACT

GRNGRNGRNGRN

WHI/RED

GRN

WHI/RED

WHI/BLK

WHI/RED

BLU

WHI

GRN/YEL

BRN

BLK

EMI

FILTER

27646 022801

Page 58

27646 0225005927646 022500

Page 59

Page 60

27646 022500

Bunn-O-Matic CDS-2, CDS-3 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual