Bunn FMD-1 Service & Repair Manual
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Bunn FMD-1 Service & Repair Manual

Bunn FMD-1 Service & Repair Manual

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See also: Operation & Service Manual
FMD Series
Including: FMD-1,2,3,4,5
SERVICE & REPAIR MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
42672.0000B 06/12 ©2009 Bunn-O-Matic Corporation

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  • Page 1 FMD Series Including: FMD-1,2,3,4,5 SERVICE & REPAIR MANUAL BUNN-O-MATIC CORPORATION POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227 PHONE: (217) 529-6601 FAX: (217) 529-6644 42672.0000B 06/12 ©2009 Bunn-O-Matic Corporation...

  • Page 2: Warranty

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

  • Page 3: Table Of Contents

    INTRODUCTION Safety first! To avoid electrical shock, unplug dispenser from power source before servicing inside. Basic Maintenance In order to maintain proper machine operation, a Preventative Maintenance schedule must be performed on a regular basis. The following procedures pretain to all versions in the FMD family of machines unless otherwise noted. CONTENTS Warranty ...........................2 User Notices ..........................3...

  • Page 4: Preventive Maintenance Recommended Cleaning

    CLEANING The use of a damp cloth rinsed in any mild, non-abrasive, liquid detergent is recommended for cleaning all sur- faces on Bunn-O-Matic equipment. Do NOT clean this equipment with a water jet device. 1 x 24h 1. Rinse out Whipper Chambers by placing RINSE/RUN 1.

  • Page 5: Preventive Maintenance Schedule

    REQUIRED REGULAR MAINTENANCE: When performing Daily-Weekly Cleaning procedures, inspect o-rings, seals, and bushings for signs of wear or damage and replace immediately. Check and/or replace every 6 months or as required: 32906.0000 Mixing Chamber Kit (Includes items indented below) 25732.0000 Steam Collector 25733.0000 Mixing Chamber...

  • Page 6: Troubleshooting

    TROUBLESHOOTING A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic Technical Service Department. • Inspection, testing, and repair of electrical equipment should be performed only by qualified service person- nel.
  • Page 7 PROBABLE CAUSE REMEDY Product will not dispense (cont.) 7. Level Control Board and Probe - Refer to Service - Level Control Board FMD-1 and Probe for testing procedures. See page 41 8. Control Board Refer to Service - Control Board and Probe for testing procedures.
  • Page 8 TROUBLESHOOTING (cont.) PROBLEM PROBABLE CAUSE REMEDY Water is not hot (Cont.) 4. Tank Heater Switch Refer to Service - Tank Heater Switch for testing procedures. See page 5. Heater Relay Refer to Service - Heater Relay for testing procedures. See page 51 6.
  • Page 9 TROUBLESHOOTING (cont.) PROBLEM PROBABLE CAUSE REMEDY Water flows into tank continuously 3. Overflow Protection Switch Refer to Service - Overflow Protec- (Cont.) tion Switch. See page 44 4. Digital Touch Control Switch Refer to Service - Digital Touch Con- trol Switch for testing procedures. See page 29 Weak product 1.
  • Page 10 See page 50 Excess dust 1. Fan Refer to Service - Fan for testing procedures. See page 32 2. A) Hopper Drive Board - FMD-1 Refer to Service - Hopper Drive Board for testing procedures. See page 35 B) Control board Refer to Service - Control Board for testing procedures.
  • Page 11 NOTES 42672 122209...

  • Page 12: Service

    Dispense Switches ...........................28 Digital Touch Control Switch ......................29 EMI Filter (FMD DBC-3) ........................31 Fan ..............................32 Frother ............................33 Hopper Drive Board (FMD-1) ......................35 Hot/Cold Switch (FMD DBC-3) ......................37 Increase/Decrease Switch ........................38 Lamp ..............................39 Lamp Holder ............................39 Lamp Starter & Socket ........................40 Level Control Board (FMD-1) ......................41...

  • Page 13: Access Panels

    SERVICE(CONT.) ACCESS PANELS Location: All access panels are similar through the whole FMD family (FMD-5 shown). Before removing panels, make sure power is OFF to the machine and water is disconnected accept where indicated in testing procedures. Retain all screws and other attaching hardware for re-assembly. FMD-5 shown FIG.

  • Page 14: Auger Drive Components

    2. Disconnect the white/red wire and the white wire hand threads from auger drive shaft (12). from the hopper drive board (FMD-1) or relative 9. Slide spacer (7) and auger drive shaft bracket (6) wires from the control board(all other models).
  • Page 15 SERVICE (CONT.) Auger Drive Motor (Refer to Fig. 2) AUGER DRIVE COMPONENTS 1. Remove hopper assy (15), and set aside for reas- FMD-4 shown sembly. 2. Remove the four #8-32 screws securing the hopper support plate (11), remove plate and set aside for reassembly.
  • Page 16 SERVICE (CONT.) AUGER DRIVE COMPONENTS FMD-5 shown Removal, Cleaning and Replacement Hopper & Auger (all other hoppers) Open the dispenser door and raise the top front cover. Lift the front edge of hopper assy (20) over the tab on hopper support plate (19) and slide hopper assembly out the front of the dispenser.

  • Page 17: Auxillary Control Board (Fmd Dbc-3)

    SERVICE (CONT.) AUXILLARY CONTROL BOARD (FMD DBC-3 only) 4. Back probe check the voltage across pins 2 (black wire) and 5 (white wire) of the six pin J2 connector on the wiring harness with a voltmeter. Connect the dispenser to the power source. The indication must a) 120 volts ac for two wire 120 volt models b) 120 volts ac for three wire 120/208 or 120/240 volt models...
  • Page 18 SERVICE (CONT.) AUXILLARY CONTROL BOARD (CONT.) Removal and Replacement: 4. On the dispenser whipper panel, ensure that the tank 1. Loosen the two #8-32 screws securing the compo- heater switch is in the “ON” (lower) position. nent mounting bracket to the dispenser housing. 5.

  • Page 19: Ballast

    SERVICE (cont.) BALLAST (all Models) FMD-4 shown Removal and Replacement 1. Loosen the three #8-32 screws securing the com- ponent bracket to the dispenser housing base. 2. Pull component bracket out the front of the dis- penser far enough so the leads on each ballast can be disconnected from the main wiring harness and the door interconnect harness.

  • Page 20: Control Board (Main)

    SERVICE (cont.) CONTROL BOARD (FMD-2,-2FD,DBC-2FD,DBC-3) 4. With a voltmeter, back probe check the voltage FMD DBC-3 shown across pins 2 & 4 of the six pin J2 connector on the wiring harness. Connect the dispenser to the power source. The indication must be: a) 120 volts ac for two wire 120 volt models b) 120 volts ac for three wire 120/208 volt models or three wire 120/240 volt models...
  • Page 21 SERVICE (cont.) CONTROL BOARD (CONT.) 11. With a voltmeter check the voltage across the 5. With a voltmeter check the voltage across the red terminals of the inlet solenoid valve. Connect the (+) terminal and the black (-) terminal of the auger dispenser to the power source.
  • Page 22 SERVICE (cont.) CONTROL BOARD (cont.) If the voltage is present as described, the whipper mo- tor and dispense solenoid control circuitry is operating properly. If the voltage is not present as described, replace the control circuit board. Removal and Replacement: 1.
  • Page 23 SERVICE (cont.) CONTROL BOARD (FMD-3,-4,-5) 5. Disconnect the dispenser from the power source. FMD-4 shown If voltage is present as described, proceed to step 6. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness. 6.
  • Page 24 SERVICE (cont.) CONTROL BOARD (CONT.) Tank Heater Relay Control Circuitry (Control Board #2) 14. Move the probe’s flat end to the dispenser housing. (120V dispensers only): The indication must be 0. 1. Disconnect the dispenser from the power source. 15. Move the probe’s flat end away from the housing. 2.
  • Page 25 SERVICE (cont.) CONTROL BOARD (CONT.) Removal and Replacement: CONTROL BOARD #1 J1 J2 1. Disconnect the three plugs on the main wiring har- J1 J2 ness from the connectors on the control board. 2. Remove the four #6-32 keps nuts securing the control board to the component bracket.

  • Page 26: Control Thermostat

    SERVICE (cont.) Electronic Thermostat (Optional): CONTROL THERMOSTAT (FMD-1,-2,-2FD,-3,-4,-5) 1. Disconnect the dispenser from the power source. 2. Disconnect the black wire of the control thermostat FMD-3 shown from the black wire from the limit thermostat. 3. Remove temperature probe from the tank.
  • Page 27 SERVICE (cont.) CONTROL THERMOSTAT (cont.) TAN to WHI/BRN in Main Wiring Harness BLK to Main Wiring Harness WHI to Main Wiring Harness BLK from Limit Thermostat BLK from Tank Heater Switch BLK to Main Wiring Harness MECHANICAL THERMOSTAT ELECTRONIC THERMOSTAT FIG.

  • Page 28: Dispense Switches

    SERVICE (cont.) DISPENSE SWITCHES (FMD-1,-2,-2FD,-3,-4,-5) If voltage is present as described, proceed to #7. FMD-5 shown If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness. 7. Check for continuity across the terminals (top right to top left;...

  • Page 29: Digital Touch Control Switch

    SERVICE (cont.) DIGITAL TOUCH CONTROL SWITCH (FMD DBC-2,DBC-3) If voltage is present as described, proceed to step 7. FMD DBC-3 shown If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness. 7. While pressing the appropriate switch, check for continuity across the following pins of the digital touch control switch assembly’s multi-pin connec- tor:...
  • Page 30 SERVICE (cont.) DIGITAL TOUCH CONTROL SWITCH (cont.) Removal and Replacement: 1. Open the dispenser door. TO DOOR INTERCONNECT Align arrows on 2. Remove the five #6-32 screws securing the bottom HARNESS CONNECTOR connectors door cover and remove cover. 3. Disconnect the wires on the dispense switch to be removed from the door interconnect wiring har- ness.

  • Page 31: Emi Filter (Fmd Dbc-3)

    SERVICE (cont.) EMI FILTER (230 Volt FMD DBC-3) Removal and Replacement: 1. Disconnect the wires from the EMI Filter. 2. Remove the two #8-32 screws and nuts securing the EMI Filter. 3. Remove and discard EMI Filter. 4. Install new EMI Filter using two #8-32 screws and nuts to secure EMI Filter to its former location.

  • Page 32: Fan

    SERVICE (cont.) VACUUM FAN (all Models) FMD DBC-3 shown Removal and Replacement: 1. Disconnect the vacuum hose from the fan. 2. Remove the two #8-32 locking screws securing the fan to the dispenser housing base plate. 3. Disconnect the wires from the fan terminals and discard the fan 4.

  • Page 33: Frother

    SERVICE (cont.) FROTHER AND WHIPPER MOTOR (all Models except -2FD) FMD DBC-3 shown 11 12 13 P4102.40 FIG. 24 FROTHER AND WHIPPER MOTOR Location: The frothers are located behind the dispenser door, mounted on the whipper motor shaft inside the whipper chamber.

  • Page 34: Whipper Motor

    SERVICE (cont.) FROTHER AND WHIPPER MOTOR (cont.) 20. Install whipper chamber (4) on the whipper chamber 6. Pull the frother (6) off the motor shaft. Notice the receptacle (8) by twisting counterclockwise until flat side on the shaft and the matching flat inside the tabs on the whipper chamber (4) lock with the the frother.

  • Page 35: Hopper Drive Board (Fmd-1)

    SERVICE (cont.) HOPPER DRIVE BOARD - FMD-1 ONLY If voltage is present as described, proceed to #5. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness. 5. Check the voltage across the positive (red wire) terminal and the negative (black wire) terminal on the auger motor with a voltmeter.
  • Page 36 SERVICE (cont.) HOPPER DRIVE BOARD - FMD-1 ONLY Removal and Replacement: (Refer to Fig. 27) RED from Hopper 1. Remove hopper assy (17), and set aside for reas- Motor sembly. 2. Remove the four #8-32 screws securing the hopper J1 Connector for...

  • Page 37: Hot/Cold Switch (Fmd Dbc-3)

    SERVICE (cont.) HOT/COLD SWITCH (Optional for FMD DBC-3) Removal and Replacement: 1. Remove all wires from the switch terminals. 2. Remove the mounting nut on the front of the whip- per motor mounting panel. 3. Remove the hot/cold switch from the rear of the front panel and discard.

  • Page 38: Increase/Decrease Switch

    SERVICE (cont.) INCREASE/DECREASE SWITCH (FMD-2,-2FD,-3,-4,-5) Removal and Replacement: FMD-3 shown 1. Open the dispenser door. 2. Remove the facenut securing the increase/decrease switch to the whipper motor mounting panel. 3. Remove switch with wires attached from the back side of the whipper motor mounting panel. 4.

  • Page 39: Lamp

    SERVICE (cont.) LAMP HOLDER (all Models) Removal and Replacement: (Refer to Fig. 33) FMD DBC-3 shown 1. Open dispenser door (1). 2. Remove the five #6-32 screws securing lower door panel (5) to the door (1) and remove cover. 3. Disconnect the door wiring harness from the door interconnect wiring harness.

  • Page 40: Lamp Starter & Socket

    SERVICE (cont.) Removal and Replacement (Refer to Fig. 33): LAMP STARTER and SOCKET 1. Open dispenser door assy (1) Location: 2. Remove the five #6-32 screws securing the door The lamp starter (6) is located inside the door assy (1) lower panel (5) to the door assy (1).

  • Page 41: Level Control Board (Fmd-1)

    SERVICE (cont.) LEVEL CONTROL BOARD AND LEVEL PROBE (FMD-1 only) 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 haness.

  • Page 42: Electrical Schematics

    SERVICE (cont.) LEVEL CONTROL BOARD AND LEVEL PROBE (cont.) 13. Place the probe so that neither end is in contact Removal and Replacement: with any metal surface of the dispenser. 1. Remove all wires from the level control board. 14. Check the voltage across terminals 1 & 3 with a 2.

  • Page 43: Limit Thermostat

    SERVICE (cont.) LIMIT THERMOSTAT (all Models) If continuity is present as described, the limit thermostat FMD DBC-3 shown is operating properly. If continuity is not present as described, replace the limit thermostat. Removal and Replacement: 1. Remove all wires from the limit thermostat termi- nals.

  • Page 44: Overflow Protection Switch

    SERVICE (cont.) OVERFLOW PROTECTION SWITCH (FMD-3,DBC-3-4,-5) FMD DBC-3 shown Removal and Replacement: 1. Disconnect the red leads from the overflow protec- tion switch from the black wire and the blue wire from the main harness. 2. Remove the nut beneath the copper overflow cup.

  • Page 45: Rinse/Run Switch

    SERVICE (cont.) RINSE /RUN SWITCH (all Models) Removal and Replacement: FMD DBC-3 shown 1. Open the dispenser door. 2. Remove the facenut securing the run/rinse switch to the whipper motor mounting panel. 3. Remove switch with wires attached from the back side of the whipper motor mounting panel.

  • Page 46: Solenoid (Cold Drink)

    SERVICE (cont.) 7. Check the solenoid valve for coil action. Connect the dispenser to the power source. With “HOT/COLD” SOLENOID VALVE (COLD WATER - OPTIONAL for switch in the “COLD” (upper) position press the left FMD-2,-3,-4,-5) dispense switch and listen carefully in the vicinity FMD DBC-3 shown of the solenoid valve for a “clicking”...

  • Page 47: Solenoid (Dispense)

    SERVICE (cont.) 6. Check the solenoid valve for coil action. Connect the dispenser to the power source. With “RUN/RINSE” SOLENOID VALVES (DISPENSE) (all Models) switch in the “RINSE” (upper) position press the appropriate dispense switch and listen carefully in FMD DBC-3 shown the vicinity of the solenoid valve for a “clicking”...

  • Page 48: Solenoid (Hot Water)

    SERVICE (cont.) HOT WATER DISPENSE SOLENOID VALVE (FMD-2FD,DBC-2FD,-3,DBC-3) 6. Check the solenoid valve for coil action. Connect FMD DBC-3 shown the dispenser to the power source. Listen carefully in the vicinity of the solenoid valve for a “clicking” sound as the coil magnet attracts. 7.

  • Page 49: Solenoid (Inlet)

    SERVICE (cont.) If the sound is heard as described and water will not SOLENOID VALVE (INLET) (all Models) pass through the solenoid valve, there may be a block- FMD DBC-3 shown age in the water line before the solenoid valve or, the solenoid valve may require inspection for wear, and removal of waterborne particles.

  • Page 50: Tank Heater

    SERVICE (cont.) 4. Disconnect the black wire and the white or red wire from the tank heater terminals. TANK HEATER (all Models) 5. Disconnect the pink wire from the liquid level probe. 6. Disconnect the green wire from the tank. FMD DBC-3 shown 7.

  • Page 51: Tank Heater Relay (Fmd-4,5)

    SERVICE (cont.) TANK HEATER RELAY (FMD-4,-5,120V Dispensers only) 6. With an ohmmeter, check for continuity between the normally closed (NC-5) and common (COM-3) terminals of the relay. 7. Place containers below any three dispense noz- zles. 8. Connect the dispenser to the power source. 9.

  • Page 52: Tank Heater Switch

    SERVICE (cont.) TANK HEATER SWITCH (all Models) Removal and Replacement: FMD DBC-3 shown 1. Refer to the hopper section in this manual and remove the hopper assemblies and the hopper support plate. 2. Remove the switch mounting nut on the front of the front panel.

  • Page 53: Transformer

    SERVICE (cont.) TRANSFORMER (all Models) 5. Check the voltage between J1-1 and J1-2 on the FMD DBC-3 shown eight pin connector at the control board. Connect the dispenser to the power source. The indication must be 24 volts ac. If voltage is present as described the transformer is operating properly.
  • Page 54 TRIAC MAPS for FMD MOV1 MOV4 MOV2 MOV3 Bunn Part Number 28826.0006 Q1 & MOV1 controls Left Whipper Motor @ J2-6 Q2 & MOV3 controls Center Whipper Motor @ J2-3 Q5 & MOV4 controls Right Whipper Motor @ J2-1 Q7 & MOV2...
  • Page 55 WHI/RED PROBE 1 2 3 HOPPER DRIVE HOPPER DISPENSE WHIPPER FLUORESCENT DISPENSE SWITCH LAMP BALLAST CHASSIS DOOR 120 VOLTS A C - 2 WIRE STARTER 120/208-240 VOLTS AC - 3WIRE SINGLE PHASE 29096.0000C 8/98 © 1998 BUNN-O-MATIC CORPORATION 42672 122209...
  • Page 56 RUN/RINSE SWITCH WHI/RED PROBE 1 2 3 HOPPER DRIVE HOPPER DISPENSE WHIPPER FLUORESCENT DISPENSE SWITCH LAMP BALLAST CHASSIS DOOR 230 VOLTS AC CE STARTER 2 WIRE + GND SINGLE PHASE 50/60 HZ 29096.0006B 04/05 © 2005 BUNN-O-MATIC CORPORATION 42672 122209...
  • Page 57 DRINK FEATURE NOT INSTALLED CHASSIS 120 VOLTS AC - 2 WIRE 120/208-240 VOLTS AC - 3 WIRE SINGLE PHASE, 60 HZ GRN/BLK DOOR 29096.0001C 10/98 © 1998 BUNN-O-MATIC CORPORATION WHI/BLK "RINSE" L.E.D. STARTER BLK/WHI BLU/WHI RED/WHI LEFT DISPENSE SWITCH RIGHT DISPENSE SWITCH...
  • Page 58 USED WHEN COLD DRINK FEATURE NOT INSTALLED CHASSIS 230 VOLTS AC 2 WIRE + GND SINGLE PHASE, 50 HZ GRN/BLK DOOR 29096.0005B 04/05 © 2005 BUNN-O-MATIC CORPORATION WHI/BLK "RINSE" L.E.D. STARTER BLK/WHI BLU/WHI RED/WHI LEFT DISPENSE SWITCH RIGHT DISPENSE SWITCH...
  • Page 59 SCHEMATIC WIRING DIAGRAM FMD DBC-2 FREEZE DRIED W/HOT WATER HOT WATER WHI/VIO RIGHT HOPPER RIGHT DISPENSE LEFT HOPPER LEFT DISPENSE GRN/BLK RED/WHI CHASSIS FLUORESCENT LAMP SWITCH UNIT ASSY BALLAST DOOR STARTER LEFT CENTER STOP WATER 29096.0003B 05/02 © 2002 BUNN-O-MATIC CORPORATION 42672 122209...
  • Page 60 120/208-240 VOLTS AC - 3 WIRE RED/WHI ORN/BLK SINGLE PHASE, 60 HZ HOT WATER DISPENSE SWITCH 29096.0004A 01/03 © 2003 BUNN-O-MATIC CORPORATION LEFT DISPENSE SWITCH RIGHT DISPENSE SWITCH White Strip-Tac Plus Black Ink Finished Size: 6.25" x 7.20" ≈62% Reduction...
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  • Page 65 (Late 3-wire Models only) BLK (3-WIRE MODELS) RED (3-WIRE MODELS) WHI (2-WIRE MODELS) 120 VOLTS AC 2 WIRE + GND or 120/208-240 VOLTS AC - 3 WIRE + GND SINGLE PHASE, 60 Hz 29218.0002D 03/07 © 1999 BUNN-O-MATIC CORPORATION 42672 122209...
  • Page 66 SWITCH UNIT ASSY GRN/BLK CHASSIS RED/WHI WHI/BLK DOOR BLU/WHI BLU/BLK RED/BLK ORN/BLK BLK/WHI WHI/RED BLU/RED STARTER LEFT CENTER RIGHT READY 230 VOLTS AC - 2 WIRE SINGLE PHASE STOP WATER 50/60 HZ 29218.0004A 09/01 © 2001 BUNN-O-MATIC CORPORATION 42672 122209...
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  • Page 71 BLU/WHI "RINSE" #1-3 L.E.D. RED/GRN ORN/RED "RINSE" #4 & 5 L.E.D. 230 VOLTS AC 2 WIRE + GND WHI/RED BLK/WHI WHI/RED WHI/RED WHI/RED GRN/WHI WHI/RED SINGLE PHASE, 50/60HZ WHI/BLK ORN/BLK BLU/BLK RED/BLK GRN/BLK 34820.0002B 04/05 ©2005 BUNN-O-MATIC CORPORATION 42672 122209...

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