Bunn-O-Matic U3, SRU Service Manual

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U3/SRU

SERVICE MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

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

To ensure you have the latest revision of the Operating Manual, or to view the Illustrated Parts Catalog, Programming Manual, or Service Manual, please visit the Bunn-O-Matic website, at www.bunn.com. This is absolutely FREE, and the quickest way to obtain the latest catalog and manual updates. For Technical Service, contact Bunn-O-Matic Corporation at 1-800-286-6070.

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42770 020510

BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY

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

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

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

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

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

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

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

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

In no event shall BUNN be liable for any other damage or loss, including, but not limited to, lost proﬁ ts, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages. AutoPOD, AXIOM, BrewLOGIC, BrewMETER, Brew Better Not Bitter, BrewWISE, BrewWIZARD, BUNN Espress, BUNN Family Gourmet, BUNN Gourmet, BUNN Pour-O-Matic, BUNN, BUNN with the stylized red line, BUNNlink, Bunn-OMatic, Bunn-O-Matic, BUNNserve, BUNNSERVE with the stylized wrench design, Cool Froth, DBC, Dr. Brew stylized Dr. design, Dual, Easy Pour, EasyClear, EasyGard, FlavorGard, Gourmet Ice, Gourmet Juice, High Intensity, iMIX, Infusion Series, Intellisteam, My Café, PowerLogic, Quality Beverage Equipment Worldwide, Safety-Fresh, savemycoffee.com, Scale-Pro, Silver Series, Single, Smart Funnel, Smart Hopper, SmartWAVE, Soft Heat, SplashGard, The Mark of Quality in Beverage Equipment Worldwide, ThermoFresh, 392, A Partner You Can Count On, Air Brew, Beverage Bar Creator, Beverage Proﬁ t Calculator, Brew better, not bitter., BUNNSource, Coffee At Its Best, Cyclonic Heating System, Digital Brewer Control, Nothing Brews Like a BUNN, Pouring Proﬁ ts, Respect Earth, Respect Earth with the stylized leaf and coffee cherry design, Signature Series, Tea At Its Best, Phase Brew, The Horizontal Red Line, Titan, Ultra are either trademarks or registered trademarks of Bunn-O-Matic Corporation.

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Contents

Circuit Breaker .....................................................14

Contactor ..............................................................15

Control Thermostat ...............................................17

Fuse and Fuse Holder ...........................................18

Limit Thermostat ...................................................19

Liquid Level Board and Level Probe .................... 20

ON/OFF Switch ......................................................22

Pump ....................................................................23

Relay ................................................................... 24

Selector Switch (Half Batch) .................................26

Solenoid ...............................................................27

Start Switch (Brew) ...............................................29

Tank Heater(s) .......................................................30

Thermal Cut-off ................................................... 31

Timer (Early Models).............................................31

Digital Timer (Late Models) ...................................33

Transformer ..........................................................35

Master ON/OFF Switch (Late Models) ...................36

Schematic Wiring Diagrams ..................... 37 thru 42

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PROBLEM

Brew cycle will not start

PROBABLE CAUSE

1. No water

2. No power or incorrect voltage to the brewer

REMEDY

Water lines and valves to the brewer must be open.

(A1) Check the terminal block for 120 volts ac across the red and white terminals and the black and white terminal on three wire 102/208 volt or 120/240 volt models. (A2) Check the terminal block for 208 volts ac, 230 volts ac or 240 volts ac on "A Series" brewers across the red and black terminals on two wire single phase 208 volt, 230 volt and 240 volt models. (A3) Check the terminal block for 208 volts ac, 240 volts ac, 380 volts ac across the black and blue terminals, the blue and red and the black and red terminals on three wire three phase 208 volt, 240 volt and 380 volt models.

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 qualiﬁ ed service person-

nel.

• All electronic components have 120 volt ac and low voltage dc potential on their terminals. Shorting of

terminals or the application of external voltages may result in board failure.

• Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If

an intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a

terminal or crimp.

• Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are

energized for more than ten minutes without a supply of water.

• The use of two wrenches is recommended whenever plumbing ﬁ ttings are tightened or loosened. This will

help to avoid twists and kinks in the tubing.

• Make certain that all plumbing connections are sealed and electrical connections tight and isolated.

• This brewer is heated at all times. Keep away from combustibles.

WARNING – • Exercise extreme caution when servicing electrical equipment.

• Unplug the brewer when servicing, except when electrical tests are speciﬁ ed.

• Follow recommended service procedures

• Replace all protective shields or safety notices

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TROUBLESHOOTING (cont.)

PROBLEM

Brew cycle will not start (cont)

Brew cycle starts with brew lockout

relay engaged.

PROBABLE CAUSE

2. No power or incorrect voltage to the brewer (cont)

3. Water level below pump housing. (Water level in the hot water gauge glass should be approximately half full).

4. ON/OFF Switch

5. Start Switch

6. Relay

7. Timer

8. Pump

9. Solenoid Valve

10. Strainer

1. Relay

REMEDY

(A4) Check the terminal block for 440 volts ac across the black and blue terminals, black and red terminals and the red and blue terminals on four wire three phase 440 volt models. (B) Check circuit breakers or fuses.

Be sure water shut-off valve is open and that the in-line ﬁ lters or strainers are not blocking water ﬂ ow. (Do not confuse water shut-off valve with the manual ﬁ ll and drain valve underneath the brewer).

Refer to Service - ON/OFF Switch for testing. See page 22

Refer to Service - Start Switches for testing procedures. See page 29

Refer to Service - Relay for testing procedures. See page 24

Refer to Service - Timer for testing procedures. See page 31 or 33

Refer to Service - Pump for testing procedures. See page 23

Refer to Service - Solenoid Valve for testing procedures. See page 27

(A) Direction of ﬂ ow arrow must be pointing towards brewer.

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

Refer to Service - Relay for testing procedures. See page 24

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TROUBLESHOOTING (cont.)

PROBLEM

Tank not ﬁ lling

Water running out of the overﬂ o w

PROBABLE CAUSE

1.ON/OFF Switch (This switch must be in the "ON" position for the reﬁ ll circuit to operate.

2. No water

3. Solenoid Valve

4. Probe

5. Liquid Level Board

1.Brewer not level

2. Solenoid Valve

3. Liquid Level Board

4. Probe

5. Manual ﬁ ll and drain valve underneath brewer open.

REMEDY

Refer to Service - ON/OFF Switch for testing procedures. See page 22

Be sure water shut-off is open and that in-line ﬁ lters or strainers are not blocking water ﬂ ow. (Do not confuse water shut-off valve with the manual ﬁ ll and drain valve underneath brewer).

Refer to Service - Solenoid Valve for testing procedures. See page 27

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

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

Brewer must be level and installed on a sturdy structure.

Refer to Service - Solenoid Valve for testing procedures. See page 27

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

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

Be sure valve is closed.

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PROBABLE CAUSE

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

2. Control Thermostat

3. Tank Heater(s)

4. Contactor

1. Circuit Breaker

2. Tank Heater(s)

1. Timer

2. Start Switch

1. Timer

2. Solenoid Valve

3. Lime build-up in swing spout and pump tubing.

1. Filters

2. Hole in bottom of funnel obstructed.

TROUBLESHOOTING (cont.)

PROBLEM

Water not hot

Circuit breaker keeps tripping

Water keeps running from swing

spout

Inconsistent coffee yield

Funnels overﬂ ow

REMEDY

Refer to Service - Limit Thermostat for testing procedures. See page19

Refer to Service - Control Thermostat for testing procedures. See page 17

Refer to Service - Tank Heater for testing procedures. See page 30

Refer to Service - Contactor for testing procedures. See page 15

Refer to Service - Circuit Breaker for testing procedures. See page 14

Refer to Service - Tank Heater for testing procedures. See page 30

Refer to Service - Timer for testing procedures. See page 31 or 33

Refer to Service - Start Switch for testing procedures. See page 29

Refer to Service - Timer for testing procedures. See page 31 or 33

Refer to Service - Solenoid Valve for testing procedures. See page 27

Remove swing spout and insert deliming rod down into pump tubing as far as possible.

Use Bunn

ﬁ lters made for the

U3 brewer.

Remove obstruction.

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TROUBLESHOOTING (cont.)

PROBLEM

Funnels overﬂ ow (cont.)

Coffee reservoir overﬂ ows

Brewer is making unusual noises

PROBABLE CAUSE

REMEDY

3. Pump - Flow Rate

4. Soft Water

1. Coffee reservoir not completely empty before a brew cycle was started.

2. Timer

3. Pump - Flow Rate

1. Solenoid Valve

2. Plumbing lines

3. Water supply

4. Tank Heater(s)

Check pump ﬂ ow rate with a watch. Pump ﬂ ow rate should be approximately 24 ounces in 15 seconds. Be sure pump assembly is free of any obstructions.

When using a water softener, a coarse grind of coffee may be preferred. If required, a bypass system is available as an optional feature.

Be sure coffee reservoir is empty before brew cycle is started.

Refer to Service -Timer for testing procedures. See page 31 or 33

Check pump ﬂ ow rate with a watch. Pump ﬂ ow rate should be approximately 24 ounces in 15 seconds. Be sure pump assembly is free of any obstructions.

The nut on the solenoid must be tight or it will vibrate during operation.

Plumbing lines should not be resting on the counter top.

(A) The brewer must be connected to a cold water line.

(B) Water pressure to the brewer must not exceed 90 psi (620 kPa). Install a regulator if necessary to lower the pressure to approximately 50 psi (345 kPa).

Remove and clean lime off the tank heater. See page 30

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This section provides procedures for testing and

replacing various major components used in this

brewer should service become necessary. Refer to

Troubleshooting for assistance in determining the

cause of any problem.

WARNING - Inspection, testing, and repair of electri-

cal equipment should be performed only by qualiﬁ ed

service personnel. The brewer should be unplugged

when servicing, except when electrical tests are re-

quired and the test procedure speciﬁ cally states to

plug in the brewer.

COMPONENT ACCESS - U3

WARNING - Disconnect the brewer from the power

source before the removal of any panel or the replace-

ment of any component.

All components are accessible by the removal of

the swing spout, front cupola cover, rear cupola cover

and the cupola.

Disconnect the swing spout nut from the swing

spout base ﬁ tting. Remove swing spout.

Remove the four #8-32 screws, two on the front and

rear, securing front and rear cupola covers to the

cupola.

Slip cupola off of the component bracket.

FIG. 9a COMPONENT ACCESS

P1317.30

FIG. 9b COMPONENT ACCESS

P2053.25

COMPONENT ACCESS - SRU

WARNING - Disconnect the brewer from the power

source before the removal of any panel or the replacement of any component.

The control thermostat, limit thermostat, pump, solenoid valve, liquid level probe and tank heater are accessible by removal of the swing spout, front cupola cover, rear cupola cover and the cupola.

Disconnect the swing spout nut from the swing spout base ﬁ tting. Remove swing spout.

Remove the four #8-32 screws, two on each side, securing the side covers to the cupola.

Slip cupola off of the component bracket.

The on/off switch, selector switch, start switch, timer, contactor and liquid level control board are accessible by removal of the front lower panel.

Remove the four #8-32 screws securing the front access panel to the base.

The circuit breaker, fuse and fuse holder are accessible by removal of the rear utility cover.

Remove the six #8-32 screws securing the rear utility cover to the housing.

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CIRCUIT BREAKER (120/208V and 120/240V Three Wire Models and 440V Four Wire Models)

Location: SRU

The circuit breaker is located on the rear of the urn, behind the rear utility cover.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the black wire from the main harness

from the circuit breaker and the white wire on the

P2209.60

FIG. 10a CIRCUIT BREAKER

TL1

TL2

TL3

TL4

TL5

pump assembly. With a voltmeter, check the voltage across the black wire and the white wire. Connect the brewer to the power source. The indication must be:

a) 120 volts ac for three wire 120/208 volt and

120/240 volt models.

b) 208 or 240 volts ac for four wire 440 volt mod-

els.

3. Disconnect the brewer from the power source.

If voltage is present as described, reconnect the white wire to the pump assembly and proceed to #4. If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness.

4. With the black wire removed, remove the other black wire from the circuit breaker.

5. Check for continuity across the terminals on the circuit breaker.

If continuity is present as described the circuit breaker is operating properly. If continuity is not present as described, press the reset button and repeat step 5, if continuity is not present as described, replace the circuit breaker.

Removal and Replacement:

1. Remove wires from the circuit breaker.

2. Remove the nut securing the circuit breaker to the component bracket.

3. Remove circuit breaker and discard.

4. Install new circuit breaker on component bracket and secure with nut.

5. Refer to Fig. 10c and reconnect the wires.

BLK from Main Harness

BLK from ON/ OFF Switch

FIG. 10c CIRCUIT BREAKER TERMINALS

P1723

Location: U3

The circuit breaker is located on the right rear of the component bracket.

P2115.30

FIG. 10b CIRCUIT BREAKER

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FUSE AND FUSE HOLDER (208V, 240V, 230V Two Wire Models and 380V Three Wire Models)

FIG. 11a FUSE AND FUSE HOLDER

P1731.55

Test Procedures:

1. Disconnect the brewer from the power source.

2. Remove the cap and fuse from the 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 the 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.

Fuse Holder:

1. Disconnect the wires from the rear of the fuse

holder.

2. Remove the 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 and secure with nut.

5. Refer to Fig. 11c and reconnect the wires.

BLK from ON/OFF Switch (208V, 240V Two Wire Models and 380V Three Wire Models)

RED from ON/OFF Switch (230V Two Wire Models)

FIG. 11c FUSE HOLDER TERMINALS

P1331

BLK from Main Harness (208V and 240V Two Wire Models) BLK from Transformer (380V Three Wire Models) RED from Main Harness (230V Two Wire Models)

Location: U3

The fuse and fuse holder are located on the right rear of the component bracket.

FIG. 11b FUSE AND FUSE HOLDER

P2122.30

Location: SRU

The fuse and fuse holder are located on the rear of the urn behind the rear utility cover.

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P2209.60

FIG. 12a CONTACTOR

CONTACTOR

Location: SRU The contactor is located inside the front lower access panel, left of center on the component bracket.

Test Procedures:

1. Disconnect the brewer from the power source. 2A. 120/208V, 120/240V, 380V THREE WIRE MODELS,

380V and 440V FOUR WIRE MODELS

Disconnect the black wire from the contactor coil

to the limit thermostat and black wire from the white wire on the main harness.

2B. 208V or 240V TWO WIRE MODELS (Prior to

# U300004095), 208V and 240V THREE WIRE MODELS

Disconnect the black wire from the contactor coil

to the limit thermostat and black wire from the red wire on the main harness.

2C. 230V MODELS (S/N U300004095 - UP) Disconnect the red wire from contactor coil to the

limit thermostat and the black wire from the main harness.

3. Connect the brewer to the power source.

4. Check the voltage across the coil wire and the wire from the main harness. The indication must be:

a) 120 volts ac for three wire 120/208, 120/240

volt and 380 volt models.

b) 230 volts ac for two wire 230 volt models. c) 208 or 240 volts ac for two wire 208 or 240 volt

models.

d) 220 or 254 volts ac for four wire 280 or 440

volt models.

5. Disconnect the brewer from the power source.

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

6. Check for continuity between the black leads on the contactor coil or the left and right terminals on the contactor coil on 230V models.

If continuity is present as described, reconnect the wires and proceed to #7. If continuity is not present as described, replace the contactor.

7. On all brewers, with a voltmeter, check the voltage across the upper left terminal and the upper right terminal on the contactor. Connect the brewer to the power source. The indication must be:

a) 120 volts ac for three wire 120/208, 120/240

volt and 380 volt models.

b) 230 volts ac for two wire 230 volt models. c) 208 or 240 volts ac for two wire 208 or 240 volt

models.

d) 220 or 254 volts ac for four wire 280 or 440

volt models.

8. Disconnect the brewer from the power source.

Location: U3 The contactor is located on the left front of the component bracket.

P2208.40

FIG. 12b CONTACTOR

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RED to Left Tank

Heater (T2) RED to Terminal Block(L2)

BLK Thermal Fuse to Left Tank Heater

BLK to left Tank Heater (L1)

BLK to Right Tank Heater (T1) BLK to Terminal Block (L1)

RED to Right Tank Heater (L2)

WHI from Main Harness (120/208V,120/240V,380V Three Wire Models, 380V and 440V Four Wire Models) RED from Main Harness (208V, 240V Two Wire Models and 208, 240V Three Wire Models)

RED to Limit Thermostat

RED Thermal Fuse to Left Tank Heater RED to Terminal Block (L2)

BLK to Terminal Block (L2)

RED Thermal Fuse to Right Tank Heater

BLK Thermal Fuse to Right Tank Heater BLK to Terminal Block (L1)

120/208V, 120/240V, 208V, 240V, 380V 440V MODELS

230V - CE Models

P1725

FIG. 13a CONTACTOR TERMINALS

CONTACTOR (cont.)

If voltage is present as described, proceed to #9. If voltage is not present as described, refer to the Wiring

Diagrams and check the brewer wiring harness.

9. Check for continuity across the terminals on the left side of the contactor by manually closing the contacts. Continuity must not present when the contact is released.

10. Check for continuity across the terminals on the right side of the contactor by manually closing the contacts. Continuity must not be present when the contact is released.

If continuity is present as described, the contactor is

operating properly.

If continuity is not present as described, replace the

contactor.

Removal and Replacement:

1. Disconnect all the wires from the contactor.

2. Remove the two #8-32 screws securing the contactor to the contactor mounting bracket, remove contactor and protective shield. Discard contactor.

3. Install new contactor with shield between mounting bracket and contactor and secure with two #8-32 screws

4. Refer to Fig. 13a and reconnect the wires.

BLK to Limit Thermostat

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CONTROL THERMOSTAT

FIG. 14a CONTROL THERMOSTAT

P2209.60

Model 120/208V & 120 240V - 3 wire w/ ground single phase

230V - 2 wire w/ ground single phase

208V or 240V - 2 wire w/ground single phase

280V or 440V - 4 wire w/ground 3 phase

380V - 3 wire w/ ground 3 phase w/ stepdown

transformer

4. Disconnect the brewer from the power source. If voltage is present as described, proceed to #5. If voltage is not present as described, refer to the Wiring

Diagrams and check the brewer wiring harness.

5. Disconnect the black wires from the control ther-

mostat.

6. Check for continuity across the terminals on the

control thermostat with the control thermostat in the "ON" position (fully clockwise), continuity must not be present when the thermostat is in the "OFF" position (fully counterclockwise).

If continuity is present as described, the control ther-

mostat is operating properly.

If continuity is not present as described, replace the

control thermostat.

Removal and Replacement:

1. Disconnect the wires from the control thermo-

stat.

2. Remove the thermostat capillary bulb by ﬁ rmly

pulling up on the capillary at the component bracket. This will disengage the grommet from the component bracket.

3. Remove the #8-32 screw securing the control

thermostat and mounting bracket to the component bracket. Remove control thermostat and bracket as an assembly.

4. Remove knob from control thermostat.

5. Remove the two #6-32 screws securing the control

thermostat to the thermostat mounting bracket. Remove and discard thermostat.

6. Install new control thermostat on thermostat

Check Voltage Across Black wire on thermostat from main harness to white wire in terminal block.

Red wire on thermostat from main harness to black wire in terminal block.

Black wire on thermostat from main harness to red wire in the terminal block.

Black wire on thermostat from main harness to white wire in terminal block.

Black wire on thermostat from main harness to white wire on step down transformer.

Voltage 120V

230V

208V or 240V

220V or 254V

120V

FIG. 14b CONTROL THERMOSTAT

P2113.40

Location: U3 The control thermostat is mounted on the right front of the component bracket.

Location: SRU The control thermostat is mounted on the left front of the top component bracket.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Locate the thermostat and the voltage check points.

3. Connect the brewer to the power source.

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BLK from Main Harness (All Models Except 230V CE Models RED from Main Harness (230V CE Models)

BLK to Limit Thermostat (All Models Except 230V CE Models RED to Limit Thermostat (230V CE Models)

P1730.80

FIG. 15a CONTROL THERMOSTAT TERMINALS

mounting bracket and secure with two #6-32 screw.

7. Install knob on thermostat.

8. Install thermostat and mounting bracket on the

component bracket and secure with one #8-32

screw.

9. Carefully bend the capillary tube so that the tube

and bulb inside the brewer are in the vertical position.

NOTE: The capillar y tube must be clear of any electrical

termination and not kinked.

10. Refer to Fig. 7 and reconnect the wires.

11. Adjust the control thermostat as required.

Removal and Replacement:

1. Disconnect the wires from the control thermo-

stat.

2. Remove the thermostat capillary bulb by ﬁ rmly

pulling up on the capillary at the component bracket. This will disengage the grommet from the component bracket.

3. Remove the #8-32 screw securing the control

thermostat and mounting bracket to the component bracket. Remove control thermostat and bracket as an assembly.

4. Remove knob from control thermostat.

5. Remove the two #6-32 screws securing the control

thermostat to the thermostat mounting bracket. Remove and discard thermostat.

6. Install new control thermostat on thermostat

mounting bracket and secure with two #6-32 screw.

7. Install knob on thermostat.

8. Install thermostat and mounting bracket on the

component bracket and secure with one #8-32

screw.

9. Carefully bend the capillary tube so that the tube

and bulb inside the brewer are in the vertical position.

NOTE: The capillar y tube must be clear of any electrical

termination and not kinked.

10. Refer to Fig. 15a and reconnect the wires.

11. Adjust the control thermostat as required.

CONTROL THERMOSTAT (cont.)

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LIMIT THERMOSTAT

FIG. 16c LIMIT THERMOSTAT TERMINALS

FIG. 16a LIMIT THERMOSTAT

P2209.60

Location: SRU

The limit thermostat is located on the center rear of the component bracket behind the tank heater.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the black wires or the red wires from the limit thermostat.

3. With an ohmmeter, check for continuity across the limit thermostat terminals.

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

BLK to Control Thermostat (All Models Except 230V CE Models) RED to Control Thermostat (230V Models)

Removal and Replacement:

1. Remove the wires from the limit thermostat terminals.

2. Carefully slide the limit thermostat out from under the retaining clip and remove the limit thermostat.

3. Carefully slide the new limit thermostat into the retaining clip.

4. Refer to Fig. 16c and reconnect the wires.

BLK to Contactor (All Models Except 230V CE Models) Red to Contactor (230V CE Models)

FIG. 16b LIMIT THERMOSTAT

P1732

Location: U3

The limit thermostat is located on the center front of the component bracket behind the timer mounting bracket.

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P1800

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THERMAL FUSES (230V-CE MODELS ONLY)

FIG. 17a THERMAL FUSES

P1750.65

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the thermal fuse from the tank heater

terminal and the contactor terminal.

3. Check for continuity across the terminals on the

ends of the thermal fuse.

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

Removal and Replacement:

1. Disconnect the thermal fuse from the tank heater

terminal and the contactor and discard.

2. Connect the new thermal fuse to the tank heater

terminal and the contactor terminal.

Location: U3

The thermal fuses are mounted on the tank heater

terminals and the contactor terminals.

FIG. 17b THERMAL FUSES

P2121.40

Location: SRU

The thermal fuses are mounted on the tank heater

terminals.

42770 012610

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O L

T E S

1 L

T L T

Page 18

TANK HEATERS

FIG. 18b TANK HEATER

P2209.60

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the wires from the tank heater.

3. Check for resistance across the tank heater termi-

nals. Refer to chart.

4. Check for continuity from each tank heater terminal to the metal sheath or mounting ﬂ ange.

If resistance/continuity is present as described, heater is working. If resistance/continuity is not present as described, replace the tank heater.

Location: U3

The tank heaters are located on the right center and the left center of the component bracket.

FIG. 18a TANK HEATER

P2113.40

Location: SRU

The tank heater is located on the front center of the upper component bracket.

BLK to Contactor T1 (All Models Except 230V-CE Models)

BLK (Thermal Fuse) to T1 (230V-CE Models)

RED to Contactor T2 (120/208V, 120/240 Three Wire Single Phase, 208V and 240V Two Wire, Single Phase)

RED (Thermal Fuse) to T2 (230V-CE Models)

P1746

FIG. 18c TANK HEATER TERMINALS

42770 012610

Page 19

TANK HEATERS (cont.)

BLK to Contactor T1 (All Models Except 230V-CE Models)

BLK (Thermal Fuse) to Contactor Top Left Terminal) (230V-CE Models)

RED to Contactor T2 (All Models Except 230V-CE Models)

RED (Thermal Fuse) to Contactor Top Right Terminal) (230V-CE Models)

BLK to Contactor L1 (120/208V, 120/240 Three Wire Single Phase, 208V and 240V Two Wire, Single Phase)

BLU to Main Harness (208V, 240V, 380V Three Wire ,Three Phase and 380V,440V Four Wire, Three Phase

BLK (Thermal Fuse to Contactor Lower Left Terminal) (230V-CE Models)

RED to Contactor L2 (120/208V, 120/240 Three Wire Single Phase, 208V and 240V Two Wire, Single Phase)

BLU to Main Harness (208V, 240V, 380V Three Wire ,Three Phase and 380V,440V Four Wire, Three Phase

RED (Thermal Fuse) to Contactor Lower Right Terminal)

FIG. 19a TANK HEATER TERMINALS

P1746

LEFT

RIGHT

Removal and Replacement:

1. Remove the wires or thermal fuses from the tank heater.

2. Remove the four #8-32 screws securing the tank heater to the component bracket.

3. Remove tank heater and gasket.

4. Position new tank heater and gasket on the component bracket and secure with four #8-32 screws.

5. Refer to Fig. 18c/19a and reconnect the wires.

2875W-208V 14.05-16.39 3325W-240V 16.20-19.25 3950W-208V 10.23-11.93 3950W-240V 13.62-15.89 3950W-380V 34.14-39.82 3950W-440V 45.77-53.39 6000W-208V 6.74- 7.85 6000W-240V 8.95-10.45

TERMINAL TO SHEATH - INFINITE (OPEN)

HEATER RESISTANCE

42770 012610

Page 20

LIQUID LEVEL BOARD AND LEVEL PROBE

FIG. 20a LIQUID LEVEL BOARD AND

LEVEL PROBE

P2209.60

Location: SRU

The liquid level board is located behind the lower front access panel, to the right of center on the component bracket. The level probe is located on the right front of the upper component bracket.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the blue wire (T1) and the pink wire (T4).

3. Check the voltage across terminals (T2) and (T3) with the ON/OFF switch in the "ON" position. The indication must be:

a) 120 volts ac for 120/208 volt, 120/240 volt and

380 volt models.

b) 208 volts ac or 240 volts ac for two wire 208

volt or 240 volt models.

d) 230 volts ac for two wire 230 volt models. e) 220 volts ac or 440 volts ac for four wire 280

volt or 440 volt machines.

4. Disconnect the brewer from the power source.

If voltage is present as described, proceed to #5. If voltage is not present as described, refer to Wiring Diagrams and check the brewer wiring harness.

5. Reconnect the blue wire to T1 on the liquid level board.

6. Carefully connect a piece of insulated jumper wire to terminal 4. Keep the other end of this wire away from any metal surface of the brewer.

7. Touching the free end of the jumper to the brewer's frame simulates a "FULL" condition, preventing jumper from touching the brewer's frame simulates "NEED WATER" condition. Connect the brewer to the power source, simulate the conditions in the chart below while measuring the voltage between T1 and T3 0n the liquid level board. Repeat these several times. There is an approximate ﬁ ve second delay for output to stabilize.

NOTE: Marine versions typically use a LLB with an

11 second delay.

Voltage Jumper Not Touching Frame

120V

230V

208V or 240V

Model

120/208V & 120/240V - 3 wire w/ground single phase

230V - 2 wire w/ground single phase

208V or 240V 2 wire w/ground single phase

Voltage Jumper Touching Frame

0 0

Location: U3

The liquid level board is located on the left rear of the component bracket. The level probe is located on the right rear of the component bracket.

FIG. 20b LIQUID LEVEL BOARD AND

LEVEL PROBE

P2208.40

(continued)

42770 012610

Page 21

LIQUID LEVEL BOARD AND LEVEL PROBE (cont.)

T1 BLU to Solenoid Valve

T2 BLK to ON/OFF Switch (All models except 230V-CE models)

T3 WHI to Main Harness (120/208V, 120/240V, four wire 380V and 440V models) T3 WHI to Transformer (380V three wire models) T3 RED to Main Harness (208V, 240V single phase and three phase models) T3 BLK to Main Harness (230V two wire models)

T4 PIN to Level Probe

FIG. 21a LIQUID LEVEL BOARD TERMINALS

P1733

8. Disconnect the brewer from the power source and remove the jumper wire from terminal 4.

If voltage is present as described, liquid level board is operating properly, proceed to #9. If voltage is not present as described, replace the liquid level board.

9. Reconnect the pink wire to terminal 4.

10. Remove the level probe and inspect for corrosion. Replace if necessary.

12 Place the probe so that neither end is in contact

with any metal surface of the brewer.

13. Connect the brewer to the power source. Repeat steps 6-7, referring to chart.

14. Disconnect the brewer from the power source.

If voltage is present as described, reinstall the level probe, the liquid level board and level probe are operating properly. If voltage is not present as described, check the pink wire on the level probe from liquid level board terminal 4.

Removal and Replacement:

1. Remove all wires from the liquid level board.

2. Remove the #10-32 screw and ﬂ at washer securing the protective shield to the component bracket.

3. Remove the #10-32 screw and internal tooth lock washer securing the liquid level board to the component bracket.

4. Remove liquid level board and discard.

5. Install new liquid level board on component bracket and secure with a #10-32 screw and internal tooth lock washer.

6. Install protective shield and secure with #10-32 screw and ﬂ at washer.

7. Refer to Fig. 21a and reconnect the wires.

Voltage Jumper Not Touching Frame

220V or 254V

120V

Model

280V or 440V 4 wire w/ground 3 phase

380V - 3 wire w/ground 3 phase w/ stepdown transformer

Voltage Jumper Touching Frame

0 0

42770 012610

Page 22

DIGITAL TIMER (Late Models)

FIG. 22a DIGITAL TIMER

P2209.60

Location: SRU The timer is located inside the front of the trunk on the top of the component bracket.

Test Procedure. NOTE: Do not remove or install wires while timer board is installed. Pressure applied to one side may cause damage to the board.

1. Disconnect the brewer from the power source.

2. With a voltmeter, check the voltage across terminals

TL1 and TL2 when the "ON/OFF" switch is in the "ON" position. Connect the brewer to the power source. The indication must be:

a) 120 volts ac for three wire 120/208 volt , 120/240

volt and 380 volt models. b) 208 volts ac for two wire 208 volt models. c) 240 volts ac for two wire 240 volt models. d) 230 volts ac for two wire 230 volt CE models. e) 208 or 240 volts ac for four wire 440 volt mod-

els.

3. Disconnect the brewer from the power source.

If voltage is present as described, proceed to #4. If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness.

4. With a voltmeter, check the voltage across terminals

TL1 and TL4 when the "ON/OFF" switch is in the

"ON" position. Connect the brewer to the power

source. The indication must be 0 volts.

If voltage is as described, proceed to #5. If voltage is not as described, disconnect the brewer from the power source and replace the timer.

5. With a voltmeter, check the voltage across ter-

minals TL1 and TL4 when the "ON/OFF" switch

is in the "ON" position. Connect the brewer to the

power source and press the "START" switch. The

indication must be as follows: a) 120 volts ac for three wire 120/208 volt, 120/240

els.

If voltage is present as described, the brew timer is operating properly. If voltage is not present as described, disconnect the brewer from the power source and replace the timer.

Removal and Replacement:

1. Remove the two #8-32 screws securing circuit

board to the mounting bracket.

2. Remove circuit board and spacers (as required).

3. Remove all wires from the timer.

4. Attach all wires to the replacement timer board

Location: U3 The timer is located on the front center of the component bracket.

FIG. 22b DIGITAL BREW TIMER

P2208.40

LATE MODELS

42770 012610

Page 23

DIGITAL TIMER (Late Models)

BLU/BLK wire from TL5 to P1 WHI/GRN wire from TL4 to (WHI) Pump WHI/BLU wire from TL3 to (BLK) Pump WHI wire from TL2 to P2 BLK wire from TL1 to P3

J2 - Three Pin connector from Half/Full Batch Switch

P2037

FIG. 23a DIGITAL TIMER TERMINALS

prior to installation to the component mounting bracket. Refer to FIG. 23a when reconnecting the wires.

5. Install new circuit board with spacers (as required) to the component mounting bracket.

6. Adjust the timer as described below.

To increase a brew volume, place the ON/OFF switch in the “ON” position, press and hold the START switch until you see three breaks in the water stream from the swing arm. Release the switch and press it again one or more times. (Failure to release the switch within two seconds after the third break in the water stream causes the volume setting to be aborted and previous volume setting will remain in memory.) Each time the switch is pressed, two seconds are added to the brew time period. Allow the brew cycle to ﬁ nish in order to verify that the desired volume has been achieved.

To decrease a brew volume, place the ON/OFF switch in the “ON” position, press and release the START switch once for every two-second interval to be removed from the total brew time period; then immediately press and hold down the START switch until you see three breaks in the water stream from the swing arm. Release the switch. (Failure to release the switch within two seconds after the third break in the water stream causes the volume setting to be aborted and previous volume setting will remain in memory). Allow the brew cycle to ﬁ nish in order to verify that the desired volume has been achieved.

2. Setting brew volumes. To set a brew volume, ﬁ rst check that the SET/LOCK switch is in the “SET” position on the circuit board. Place the ON/OFF switch in the “ON” position, press and hold the START switch until you see three breaks in the water stream from the swing arm and then release the switch. (Failure to release the switch within two seconds after the third break in the water stream causes the volume setting to be aborted and previous volume setting will remain in memory.) View the level of the liquid being dispensed. When the desired level is reached, turn the ON/OFF switch to “OFF”. NOTE: The brewer remembers this volume and will continue to brew batches of this size until the volume setting procedure is repeated. NOTE: When brewing coffee, volume will decrease due to absorption by the coffee grounds. NOTE: Half-Batch and full batch settings must each be set separately.

Timer Setting: NOTE: Prior to setting or modifying volumes, check that the brewer is connected to water supply, the tank is properly ﬁ lled, and funnel is in place. NOTE: All volume settings must be done with the sprayhead installed.

1. Modifying brew volumes. To modify a brew vol-

ume, ﬁ rst check that the SET/LOCK switch is in the “SET” position on the circuit board.

42770 012610

Page 24

TIMER (Early Models)

FIG. 24a TIMER

P1722.55

Location: U3

The timer is located behind the front access panel on the right side of the component bracket.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the polarized, three pin connector from the brewer main harness and rotate the brew timer

dial fully counterclockwise.

3. With a voltmeter, check the voltage across sockets P2 and P3 (white and black wire or red wire) of the female connector on the main wiring harness when the "ON/OFF" switch is in the "ON" (upper) position. Connect the brewer to the power source. The indication must be:

a) 120 volts ac for three wire 120/208 volt, 120/240

volt, 380 volt models and 208 or 240 volts ac for four wire 440 volt models.

b) 208 volts ac for two and three wire 208 volt

models.

c) 240 volts ac for two and three wire 240 volt

models.

d) 230 volts ac for two wire 230 volt CE models.

4. Disconnect the brewer from the power source.

If voltage is present as described, proceed to #5. If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness.

5. With a voltmeter, check the voltage across the sockets P1 and P2 (blue and white wires) of the female connector on the main harness when the "ON/OFF" switch is in the "ON" (upper) position and the start switch pressed. Connect the brewer to the power source. The indication must be:

a) 120 volts ac for three wire 120/208 volt, 120/240

volt, 380 volt models and 208 or 240 volt ac for four wire 440 volt models.

b) 208 volts ac for two and three wire 208 volt

models.

c) 240 volts ac for two and three wire 240 volt

models.

d) 230 volts ac for two wire 230 volt CE models.

6. Disconnect the brewer from the power source.

7. Reconnect the three pin connector from the main wiring harness to the connector on the timer.

If voltage is present as described, proceed to #8. If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness.

8. Disconnect the black and white wires to the pump.

9. With a voltmeter, check the voltage across the black and white wires when the "ON/OFF" switch is in the "ON" (upper) position and the start switch pressed to the start position and released. Connect

Location: U3

The timer is located on the front center of the component bracket.

FIG. 24b TIMER

P2114.40

42770 012610

Page 25

TIMER (Early Models) (cont.)

the brewer to the power source. The indication must be:

a) 120 volts ac for three wire 120/208 volt, 120/240

volt, 380 volt and 208 or 240 volt ac for four wire 440 volt models.

b) 208 volts ac for two and three wire 208 volt

models.

c) 240 volts ac for two and three wire 240 volt

models.

d) 230 volts ac for two wire 230 volt CE models.

If voltage is present as described, the brew timer is operating properly. Reset the timer dial as required, to obtain the desired brew volume. If voltage is not present as described, replace the timer.

Removal and Replacement:

1. Separate all connectors between the brewer wiring harness and the timer.

2. Disconnect the timer leads from the pump leads.

3. Remove the two #8-32 screws securing the brew timer to the component bracket and remove timer.

4. Install new timer circuit board as described in Digital Timer kit instructions.

To Three Pin Female Connector on Main Harness

BLK to Pump Lead

WHI to Pump Lead

Three Pin Connector from Half/Full Batch Switch

FIG. 25a TIMER TERMINALS

P1751

EARLY MODELS

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Page 26

PUMP ASSEMBLY

FIG. 26a PUMP ASSEMBLY

P2209.60

Location: SRU The pump is located on the center rear of the component bracket.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the black wire from the black lead on the pump and the white wire from the black lead on the pump.

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

a) 120 vac for three wire 120/208V, 120/240V and

380V models).

b) 208 vac for two or three wire 208V models. c) 240 vac for two or three wire 240V models. d) 230 vac for two wire 230V models. e) 208 or 240 vac for four wire 440V models

4. Disconnect the brewer from the power source.

If voltage is present as described, reconnect the wires

to the pump. Install swing spout and position over the reservoir. Place the ON/OFF in the "ON" (upper) position and push the start switch and release. If pump does not run, replace the pump. If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness.

Removal and Replacement (Refer to Fig. 17):

1. Disconnect the wires from the pump assembly.

2. Loosen the #8-32 screw (2) securing the clamp (3) on the ﬁ ll tube (1) and slide the clamp (3) up

the ﬁ ll tube (1).

3. Disengage the tube (1) from the pump base (4).

4. Remove the four #8-32 screws (6) securing the pump assembly to the component bracket (7).

5. Remove pump assembly (4).

6. Remove pump gasket (5) and inspect, replace if necessary.

7. Position gasket (5) on component bracket (7).

8. Install new pump assembly on component bracket (7) and secure with four #8-32 screws (6).

9. Install ﬁ ll tube (1) on pump assembly (4).

10. Slide clamp (3) down into position on the ﬁ ll tube (1) and tighten screw (2).

11. Refer to Fig. 26c and reconnect the wires.

WHI from Brew Timer

BLK from Brew Timer

FIG. 26c PUMP INSTALLATION

P1737

Location: U3 The pump is located on the center rear of the component bracket.

FIG. 26b PUMP ASSEMBLY

P2113.40

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Page 27

42770 012610

THIS PAGE INTENTIONALLY LEFT BLANK

Page 28

RELAY - BREW LOCKOUT OPTION

FIG. 28a RELAY

P1731.55

Location: U3

The relay is located on the front part of the component bracket, mounted on the top of the timer bracket.

Test Procedures: All Models Except 230V - CE Models

1. Disconnect the brewer from the power source.

2. Disconnect the wires from relay terminals A & B. Check for continuity between terminals A & B.

If continuity is present as described, reconnect the wires to terminals A & B and proceed to # 3. If continuity is not present as described replace the relay.

3. Disconnect the wires from relay terminals 2 & 7.

4. Check for continuity across terminals 2 & 7.

If continuity is present as described, reconnect the wires to terminals 2 & 7 and proceed to # 5. If continuity is not present as described, replace the relay.

5. Disconnect the wires from relay terminals 5 & 7.

6. Check for continuity across terminals 5 & 7 by manually closing relay contact. Continuity must not be present when contact is released.

If continuity is present as described, reconnect the wires, the relay is operating properly. If continuity is not present as described, replace the relay.

230V - CE Models

1. Disconnect the brewer from the power source.

2. Disconnect the black wire from relay terminal A and the red wire from relay terminal B. Check the voltage across the black and red wire with a voltmeter. Connect the brewer to the power source. The indication must be 230 volts ac.

If voltage is present as described, proceed to #3. If voltage is not present as described, refer to the Wir- ing Diagrams and check the brewer wiring harness.

3. Disconnect the brewer from the power source.

4. Check for continuity between terminals A & B.

120/208V, 120/240V, 208V, 380V, 440V AND 240V

MODELS PRIOR TO #U300004095

230V MODELS #U300004095 AND UP

FIG. 28b RELAY TERMINALS

P1739.50

RED from Main Harness

BLU from Brew Timer

BLK to Control Thermostat

BLU to Start Switch

BLU from Brew Timer

BLK from Main Harness

RED to Control Thermostat

BLU from Start Switch

42770 012610

Page 29

RELAY - BREW LOCKOUT OPTION (cont.)

If continuity is present as described, reconnect the wires to terminals A & B and proceed to #5. If continuity is not present as described, replace the relay.

5. With the thermostat in the "ON" position and the relay engaged disconnect the brewer from the power source.

6. Disconnect the blue wires from relay terminals 1 and 7. Check for continuity across terminals 1 and

If continuity is present as described, proceed to #7 If continuity is not present as described, replace the relay.

7. Turn the thermostat to the "OFF" position, connect the brewer to the power source and turn the thermostat back to the "ON" position. Continuity should not be present across terminals 1 & 7.

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

Removal and Replacement:

1. Disconnect the wires from the relay.

2. For 120/208V, 120/240V, 208V, 380V, 440V and 240V models prior to #U300004095 remove the #6-32 screw securing the relay to the relay mounting bracket. For 230V models #U300004095 and up, remove the two screws securing the relay to the relay mounting bracket.

3. Remove relay and discard.

4. For 120/208V,120/240V, 208V, 380V, 440V and 240V models prior to #U300004095, install new relay on relay mounting bracket and secure with a #6-32 screw. For 230V models #U300004095 and up, install new relay on relay mounting bracket and secure with two #6-32 screws.

5. Refer to Fig. 28b and reconnect the wires.

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Page 30

SOLENOID

FIG. 30a SOLENOID

P2209.60

Location: SRU

The solenoid is mounted on the upper left rear of the component bracket.

Test Procedures:

1. Disconnect the dispenser from the power source.

2. A) For 120/208 volt and 120/240 volt three wire, single phase models, 380 volt three wire, three phase models and 380 volt, 440 volt four wire, three phase models, disconnect the black wire from the liquid level board #2 and the white wire on the solenoid. With a voltmeter, check the voltage across the black and the white wire. Connect the brewer to the power source. The indication must be:

a) 120 volts ac for 380 volt three wire, three phase

models and 208 0r 240 volts ac for four wire three phase 440 volt models.

b) 208 volts ac for three wire 120/208 volt mod-

els.

c) 240 volts ac for three wire 120/240 volt mod-

els.

B) For 208 volt, 240 volt two wire single phase and

208 volt, 240 volt three wire three phase models, disconnect the black wire from the liquid level board #2 and the red wire from the solenoid. With a voltmeter, check the voltage across the black and red wires. Connect the brewer to the power source. The indication must be:

a) 208 volts ac for 208 volt two wire single phase

and 208 volt three wire three phase models.

b) 240 volts ac for 240 volt two wire single phase

and 240 volt three wire three phase models.

C) For 230V - CE two wire single phase models,

disconnect the red wire from the liquid level board #2 and the black wire from the solenoid. With a voltmeter, check the voltage across the red wire and the black wire. Connect the brewer to the power source. The indication must be 230 volts ac.

3. Disconnect the dispenser from the power source.

If voltage is present as described, proceed to #4. If voltage is not present as described, refer to the brewer Wiring Diagrams and check the wiring harness.

4. Disconnect the blue wire and the white wire, the blue wire and the red wire or blue wire and black wire from the solenoid terminals.

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

If continuity is present as described, reconnect the wires to the solenoid. If continuity is not present as described, replace the solenoid valve.

6. Check the solenoid valve for coil action. Connect the dispenser to the power source. Listen carefully in the vicinity of the solenoid valve for a "clicking" sound as the coil magnet attracts.

If the sound is heard as described and water will not pass through the solenoid valve, there may be a blockage in the water line before the solenoid valve or, the

Location: U3

The solenoid is mounted on the upper left rear of the component bracket.

FIG. 30b SOLENOID

P2113.40

42770 012610

Page 31

SOLENOID (cont.)

solenoid valve may require inspection for wear, and removal of waterborne particles. If the sound is not heard as described, replace the solenoid valve.

BLU from Liquid Level Board #1

WHI from Main Harness (120/208V, 120/240V, 380V and 440V Models)

RED from Main Harness (208V and 240V Models)

BLK from Main Harness

BLU from Liquid Level Board #1

EARLY 230V - CE MODELS

FIG. 31a SOLENOID TERMINALS

P1741

BLU from Liquid Level Board #1

WHI from Main Harness (120/208V, 120/240V, 380V and 440V Models)

RED from Main Harness (208V and 240V Models)

EARLY MODELS

LATE MODELS

Removal and Replacement:

1. Remove the wires from the solenoid valve.

2. Turn off the water supply to the dispenser.

3. Disconnect the water inlet line from the connector

on the solenoid valve.

4. Remove the #10-32 screw and the ﬂ at washer

securing the liquid level board, shield and the solenoid to the component bracket.

5. Remove solenoid, connectors, air chamber and

tank inlet tube as an assembly.

6. Remove the tank inlet tube grommet and dis-

card.

7. Install new tank inlet tube grommet.

8. Install new solenoid assembly.

9. Install liquid level board, shield and secure solenoid

assembly and shield to the component bracket with a #10-32 screw and ﬂ at washer..

10. Install water inlet tube to connector on the sole-

noid.

11. Turn on the water supply to the brewer.

12. Refer to Fig. 31a and reconnect the wires.

42770 012610

Page 32

BLK from Terminal Block

TRANSFORMER (380V THREE WIRE MODELS ONLY)

FIG. 32a TRANSFORMER

P1752.55

Location: The transformer is located on the top rear of the timer mounting bracket.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect black wire and the red wire from the terminal block at the transformer.

3. With a voltmeter, check the voltage across the black wire and the red wire. Connect the brewer to the power source. The indication must be 380 volts ac.

4. Disconnect the brewer from the power source.

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

5. Reconnect the black wire and the red to the transformer.

6. Disconnect the black wire and the white wire from the transformer terminals.

7. With a voltmeter, check the voltage across the transformer terminals. Connect the brewer to the power source. The indication must be 120 volts ac.

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. Disconnect all the wires from the transformer.

2. Remove the two #8-32 screws securing the transform to the transformer mounting bracket.

3. Remove the transformer and discard.

4. Position new transformer on transformer mounting bracket and secure with two #8-32 screws.

5. Refer to Fig. 32b and reconnect the wires.

RED from Terminal Block

WHI from Main Harness

BLK from Main Harness

FIG. 32b TRANSFORMER TERMINALS

P1753

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Page 33

MASTER ON/OFF SWITCH (Late Models)

FIG. 33c MASTER ON/OFF SWITCH WIRING

Location: SRU The Master ON/OFF switch is located in the base, at the left rear, FIG. 31.

Test Procedure:

1. Disconnect the brewer from the power source and remove the wires from all terminals of the Master ON/OFF switch.

2. Check for continuity across the two terminals on the switch at L1 BLK and BLK to Main Harness when it is held in the lower position, Fig. 32. Check for continuity across the two terminals on the switch at L2 RED and RED to Main Harness when it is held in the lower position.

Continuity must not be present across these

terminals in the upper position.

If continuity is present as described, reconnect the wires, the switch is operating properly. If continuity is not present as described, replace the switch.

Removal and Replacement:

1. Remove all wires from the switch terminals.

2. Remove the two screws from the outside of the base and gently push the switch through the opening.

3. Locate the new switch into the opening and secure with screws removed in step 2.

4. Refer to FIG. 33c when reconnecting the wires.

Incoming Power Supply L1 - BLK

L2 - RED

Main Wiring harness BLK

RED

P3955

TL1

TL4

TL5

FIG. 33a MASTER ON/OFF SWITCH LOC.

P1752.55

Location: U3 The Master ON/OFF switch is located in the top housing at the rear, FIG. 36.

FIG. 33b MASTER ON/OFF SWITCH

P2053.25

ALL MODELS EXCEPT 230V - CE MODELS

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wire on the power indicator light.

3. Connect the brewer to the power source. With a voltmeter, check the voltage across the removed wires. The indication must be:

a) 120 volts ac for 120/208 volt, 120/240 volt and

380 volt models.

b) 208 volts ac for two or three wire 208 volt

models.

c) 240 volts ac for two wire 240 volt models prior to

#U300004095 and three wire 240 volt models.

d) 230 volts ac for two wire 230 volt models

#U300004095 and up).

e) 208 or 240 volts ac for four wire 440 volt mod-

els.

4. Disconnect the brewer from the power source.

If voltage is present as described, reconnect the wires and proceed to #5 If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness.

5. Disconnect the wires on the ON/OFF switch.

6. a) 120/208V, 120/240V, 208V, 240V, 380V and 440V Models - Check for continuity across the terminals on the rear of the switch with the switch in the "ON" (upper) position. Continuity must not be present when the switch is in the "OFF" (lower) position.

b) 230V - CE Models - Check for continuity across

the center terminal (2) and the lower terminal (1) when the switch is in the "ON" (upper) position. Continuity must not present when the switch is in "OFF" (lower) position.

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

Removal and Replacement:

1. Remove the wires from the switch terminals.

2. Compress the clips on the back side of the switch mounting bracket and gently push the through the opening.

3. Push the new switch into the opening and spread the clips to hold switch in the mounting bracket.

NOTE: ON 230V - CE models terminal (3) must be

on the top.

4. Refer to Fig. 35a and reconnect the wires.

ON/OFF SWITCH

FIG. 34a ON/OFF SWITCH

P2209.60

Location: SRU The ON/OFF switch is located on the left side of the lower front panel.

Test Procedures:

1. Disconnect the brewer from the power source.

2. a)120/208V, 120/240V, 208V and 240V Models Remove the black wire on the ON/OFF switch from the fuse holder or circuit breaker and the red wire on the power indicator light.

b) 380V and 440V Models - Remove the black wire

on the ON/OFF switch from the fuse holder or circuit breaker and the white wire from the power indicator light.

c) 230V - CE Models - Remove the red wire on the

ON/OFF switch from the fuse holder and the black

Location: U3 The ON/OFF switch is located on the left side of the switch mounting bracket. The switch mounting bracket is mounted on the front of the component bracket.

FIG. 34b ON/OFF SWITCH

P2053.25

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ON/OFF SWITCH (cont.)

BLK from Main Harness

BLK to Start Switch, Brew Timer & Liquid Level Board L2

120/208V, 120/240V, 208V, 240V, 380V AND 440V

MODELS

BLK from Main Harness

RED to Main Harness

RED to Start Switch, Brew Timer & Liquid Level Board

230V - CE Models

P1735

BLK to On/Off Switch BLK to Liquid Level Board L2

120/208V, 120/240V, 208V and 240V MODELS

BLK from Indicator Light

RED to Fuse

RED to Start Switch, Brew Timer & Liquid Level Board

230V - CE Models

P2120.50

FIG. 35a ON/OFF SWITCH TERMINALS

BLK to On/Off Switch BLK to Start Switch

BLK to Circuit Breaker or Fuse

WHI or RED to Indicator Light

Step #6

SRU

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START SWITCH (BREW) U3

FIG. 36a START SWITCH (BREW)

P1317.30

BLU to Brew Timer or Brew Lockout Relay

BLK from ON/OFF Switch

ALL MODELS EXCEPT 230V - CE MODELS

BLU to Brew Timer or Brew Lockout Relay RED from ON/OFF Switch

230V - CE MODELS

FIG. 36b BREW START SWITCH TERMINALS

P1743

Test Procedures:

1. Disconnect the brewer from the power source.

2. Remove the wires from the start switch terminals.

3. Check for continuity across the switch terminals when the switch is held in the lower position. Continuity must not be present when the switch is in the upper position.

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

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

Removal and Replacement:

1. Remove the wires from the switch terminals.

2. Compress the clips on the back side of the switch mounting bracket and gently push the through the opening.

3. Push the new switch into the opening and spread the clips to hold switch in the mounting bracket.

4. Refer to Fig. 36b and reconnect the wires.

Location: U3

The brew start switch is located on the upper right side of the brewer component housing.

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START SWITCH (BREW) SRU

FIG. 37a START SWITCH (BREW)

P2053.25

Location: SRU

The brew start switch is located on the lower right side of the front access panel at the base of the urn on all models except 230 volt CE. On 230 volt CE models, the start switch is located on the lower right of the front access panel, beneath the selector switch.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Remove the wires from the start switch termi-

nals.

3. Check for continuity across the switch terminals

when the switch is held in the lower position. Continuity must not be present when the switch is in the upper position.

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

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

Removal and Replacement:

1. Remove the wires from the switch terminals.

2. Compress the clips on the back side of the switch

mounting panel and gently push them through the opening.

3. Push the new switch into the opening and spread

the clips to hold switch in the mounting panel.

4. Refer to Fig. 37b and reconnect the wires.

BLU to Brew Timer

BLK from ON/OFF Switch

ALL MODELS EXCEPT 230V - CE MODELS

BLU to Brew Timer

RED from ON/OFF Switch

230V - CE MODELS

FIG. 37b BREW START SWITCH TERMINALS

P2119.65

ALL MODELS EXCEPT 230V - CE MODELS

230V - CE MODELS

P2117.25

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SELECTOR SWITCH (HALF BATCH OPTION) U3

FIG. 38a SELECTOR SWITCH (HALF BATCH)

Location: U3

The selector switch is located in the upper center of the switch mounting panel.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the wires from the switch terminals.

3. Check for continuity across the switch terminals with the switch in the "CLOSED" (left - half) position. Continuity must not present when the switch is in the "OPEN" (right - full) position.

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

GRY to Brew Timer

PNK to Brew Timer

FIG. 38b SELECTOR SWITCH TERMINALS

P1740

Removal and Replacement:

1. Remove the wires from the switch terminals.

2. Compress the clips on the back side of the switch mounting bracket and gently push the through the opening.

3. Push the new switch into the opening and spread the clips to hold switch in the mounting bracket.

4. Refer to Fig. 38b and reconnect the wires.

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P1317.30

Page 39

SELECTOR SWITCH (HALF BATCH OPTION) SRU

FIG. 39a SELECTOR SWITCH (HALF BATCH)

P2053.25

Location: SRU

The selector switch is located in the center of the front access panel at the base of the urn on all models except the 230V CE Models. The selector switch is located to the right of the front panel, above the start switch on the 230V CE Models.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the wires from the switch terminals.

3. Check for continuity across the switch terminals with the switch in the "CLOSED" (bottom - half) position. Continuity must not be present when the switch is in the "OPEN" (top - full) position.

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

ALL MODELS EXCEPT 230V CE MODELS

230V CE MODELS

P2117.25

Removal and Replacement:

1. Remove the wires from the switch terminals.

2. Compress the clips on the back side of the switch mounting panel and gently push them through the opening.

3. Push the new switch into the opening and spread the clips to hold switch in the mounting panel.

4. Refer to Fig. 39b and reconnect the wires.

GRY to Brew Timer

PNK to Brew Timer

ALL MODELS EXCEPT 230V - CE MODELS

230V - CE MODELS

FIG. 39b SELECTOR SWITCH TERMINALS

P2118.60

GRY to Brew Timer

PNK to Brew Timer

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120/208 VOLTS AC 120/240 VOLTS AC

3 WIRE + GND

WHI

BLK

RED

MAIN ON/OFF SWITCH

(Late Models only)

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G 8

/BLK

WHI/GRN

WHI/BLU

T5 T3

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PNK

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WHI

BLK

RED

MAIN ON/OFF SWITCH

(Late Models only)

RED

BLK

120/208 VOLTS AC 120/240 VOLTS AC

3 WIRE + GND

SINGLE PHASE

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BLK-12

SCHEMATIC WIRING DIAGRAM U3833

BLK

P1, P2, & P3 ARE PINS

OF A POLARIZED

THREE-PIN CONNECTOR.

208 VOLTS AC 240 VOLTS AC

3 WIRE 3-PHASE

BLK

BLU-12

N.O.

LIMIT

THERMOSTAT

SW. &

THERMOSTAT

BLK BLK

START

SWITCH

BLU

SOL

PROBE

PNK

BLK

BLU

BLK

WHIBLK

BLU

WHI

BREW

TIMER

PUMP

BLK

FULL/HALF

SWITCH

PNK

GRY

LIQUID

LEVEL

BOARD

RED-12

BLK-12

GRN

N.O.

RED-12

SELECTOR SWITCH

(N/A W/HALF

BATCH OPTION)

ON/OFF

SWITCH

BLK RED

POWER IND.

HALF BATCH OPTION

RED

BLK

TANK HEATER

BLU-12

AMP

FUSE

42770 012610

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42770 012610

Bunn-O-Matic U3, SRU Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual