Bunn FMD-4 Operating & Service Manual
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Bunn FMD-4 Operating & Service Manual

Bunn fmd-4: user guide
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FMD-4
FMD-5
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
35135.0000D 10/07 ©2003 Bunn-O-Matic Corporation

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  • Page 1 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.
  • Page 2 SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND. In no event shall BUNN be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.

  • Page 3: User Notices

    READ THE ENTIRE OPERATING MANUAL BEFORE BUYING OR USING THIS PRODUCT THIS APPLIANCE IS HEATED WHENEVER CONNECTED TO A POWER SOURCE 00831.0000F 3/98 ©1998 BUNN-O-MATIC CORPORATION 00831.0000 This equipment must be installed to comply with the Basic Plumbing Code of the Building Officials and Code Administrators International, Inc.

  • Page 4: Electrical Requirements

    NOTE - At least 18 inches of an FDA approved flexible beverage tubing, such as reinforced braided polyethylene or silicone, before the dispenser will facilitate movement to clean the countertop. Bunn-O-Matic does not recommend the use of a saddle valve to install the dispenser. The size and shape of the hole made in the supply line by this type of device may restrict water flow.

  • Page 5: Initial Fill & Heat

    INITIAL FILL & HEAT CAUTION - The dispenser must be disconnected from the power source throughout the initial set-up, except when specified in the instructions. 1. Turn-on the water supply and connect the dispenser to the power source. 2. Water will automatically flow into the tank to the proper level and then shut-off. This will take less than five minutes.
  • Page 6 Refer to the decal on the rear of the dispenser door for cleaning recommendations and procedures. The use of a damp cloth rinsed in any mild, non-abrasive, liquid detergent is recommended for cleaning all sur- faces on Bunn-O-Matic equipment. ADJUSTMENTS The beverage solenoid is preset to dispense approximately 9/10 ounce per second.

  • Page 7: Draining The Hot Water Tank

    DRAINING THE HOT WATER TANk CAUTION - The dispenser must be disconnected from the power source throughout these steps. 1. Disconnect the dispenser from the power source. 2. Place the tank heater switch in the “OFF” position. 3. Shut-off and disconnect the incoming water supply. 4.

  • Page 8: 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 9 TROUBLESHOOTING (cont.) PROBLEM Product will not dispense (cont.) Water is not hot PROBABLE CAUSE 5. Solenoid Valve (Inlet) 6. Control Board #1 and Probe 7. Auger Drive 8. Water Strainer 9. Lime build-up CAUTION - Tank and tank compo- nents should be delimed regularly depending on local water condi- tions.
  • Page 10 TROUBLESHOOTING (cont.) PROBLEM Water is not hot (Cont.) Spitting or excessive steaming Dripping from dispense tip Water flows into tank continuously PROBABLE CAUSE 4. Tank Heater Switch 5. Relay (120V versions only) 6. Control Board #2 (120V versions only) 1. Lime build-up CAUTION - Tank and tank compo- nents should be delimed regularly depending on local water condi-...
  • Page 11 TROUBLESHOOTING (cont.) PROBLEM Product overflows container Weak product PROBABLE CAUSE 1. Dispense Switch 2. Dispense Solenoid Valve 1. Water Temperature 2. Whipper Motor 3. Frother 4. Dispense Solenoid Valve 5. Auger Drive 6. Auger Spring 7. Auger Motor 8. Rinse/Run Switch 9.
  • Page 12 TROUBLESHOOTING (CONT.) PROBLEM Dispenser is making unusual noises Excess dust Display not lit PROBABLE CAUSE 1. Plumbing Lines 2. Water Supply 3. Tank Heater 1. Fan 1. Lamp 2. Lamp Holder 3. Starter - Lamp 4. Ballast REMEDY Plumbing lines should not be resting on the counter top.

  • Page 13: Table Of Contents

    Refer to the contents listing for component loca- tion. Contents Auger Drive Components (FMD-4) ... 13 Auger Drive Components (FMD-5) ... 15 Ballast ... 18 Control Thermostat ... 19 Control Board ... 20 Dispense Switch ...
  • Page 14 SERVICE AUGER DRIVE COMPONENTS - FMD-4 (CONT.) 5. Check the voltage across the positive (red wire) terminal and the negative (black wire) terminal on the auger motor with a voltmeter. With the rinse/ run switch in the run (lower) position press and hold the dispense switch.

  • Page 15: Auger Drive Components (Fmd-5)

    Control Board #2 J3-3 BLK to GRN from Control Board J3-4 FIG. 3 AUGER MOTOR TERMINALS AUGER DRIVE COMPONENTS - FMD-4 & FMD-5 FIG. 4 AUGER DRIVE COMPONENTS Location The auger components are located inside the bottom part of the hopper except for the auger drive bracket, washer and locknut, which are located on the outside bottom rear of the hopper.
  • Page 16 SERVICE (cont.) AUGER DRIVE COMPONENTS - FMD-4 & FMD-5 (cont.) 4. Disconnect the dispenser from the power sup- ply. If voltage is present as described and the auger does not turn, replace the auger motor. If voltage is not present as described, refer to the wiring diagrams and check the dispenser wiring har- ness.
  • Page 17 SERVICE (cont.) AUGER DRIVE COMPONENTS - FMD-4 & FMD-5 (cont.) Auger Drive Motor (Refer to Fig. 5) 1. Remove all hopper assemblies (20) and set aside for reassembly. 2. Remove the four #8-32 screws securing the hopper support plate (19), remove plate and set aside for reassembly.

  • Page 18: Ballast

    SERVICE (cont.) BALLASTS - FMD-4 & FMD-5 FIG. 7 BALLASTS Location The front door lamp ballast is located behind the front access panel on the left front side of the com- ponent bracket. Test Procedure 1. Disconnect the dispenser from the power source.

  • Page 19: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) CONTROL THERMOSTAT - FMD-4 & FMD-5 FIG. 9 CONTROL THERMOSTAT Location The control thermostat is located at the upper left rear of the dispenser housing. Test Procedure 1. Disconnect the dispenser from the power source. 2. Disconnect the black wire of the control thermostat from the black lead from the limit thermostat.

  • Page 20: Control Board

    SERVICE (cont.) CONTROL BOARD FIG. 11 CONTROL BOARD Location: The Control Boards are located behind the lower front access cover mounted on the component bracket. Test Procedure: Liquid Level Control Circuitry(Control Board #1): 1. Disconnect the dispenser from the power source. 2.
  • Page 21 SERVICE (cont.) CONTROL BOARD (CONT.) 16. Reconnect the ten pin connector of the wiring harness to J2 of control board #1. 17. Gently pull the liquid level probe out of the tank lid and inspect for corrosion. Replace it if necessary. 18.
  • Page 22 Tank Heater Relay Control Circuitry (Control Board #2) (120V dispensers only): 1. Disconnect the dispenser from the power source. 2. Disconnect the six pin connector from J3 of control board #2. 3. Check the voltage across pins 5 & 6 of the six pin connector on the wiring harness with a voltmeter.

  • Page 23: If Voltage Is Not Present As Described, Refer To The Wiring

    SERVICE (cont.) DISPENSE SWITCH(S) - FMD-4 & FMD-5 FIG.13 DISPENSE SWITCHES Location: The dispense switches are located on the lower outside of the dispenser door. Test Procedure: 1. Disconnect the dispenser from the power source. 2. Open the dispenser door and remove the bottom door cover.
  • Page 24 SERVICE (cont.) DISPENSE SWITCHES (cont.) 7. Check for continuity across the terminals (top right to top left; bottom right to bottom left) of the dispense switch with the switch in the “ON” position. Continuity must not present when the switch is in the “OFF” released position. If continuity is present as described, reconnect the connector to the door interconnect wiring harness, the switch is operating properly.

  • Page 25: Fan

    SERVICE (cont.) FIG. 15 FAN Location: The fan is located inside the dispenser housing on the center rear of the dispenser base plate. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the black and white wires from the fan terminals.

  • Page 26: Frother

    SERVICE (cont.) FROTHER AND WHIPPER MOTOR - FMD-4 (shown) & FMD-5 FIG. 17 FROTHER AND WHIPPER MOTOR Location: The frothers are located behind the dispenser door, mounted on the front panel inside the whipper chamber. The whipper motors are located on the back side of the whipper motor mounting panel.

  • Page 27: Whipper Motor

    SERVICE (cont.) FROTHER AND WHIPPER MOTOR - FMD-4 (shown) & FMD-5 (cont.) 4. Disconnect vacuum hose (12) from fan baffle (13). 5. Remove the steam collector (1) by pulling it forward and at the same time twisting it clockwise. 6. Pull the mixing chamber (2) out of the whipper chamber (4).

  • Page 28: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) INCREASE/DECREASE SWITCH FIG. 20 INCREASE/DECREASE SWITCH Location: The increase/decrease switch is located on the lower left front of the whipper motor mounting panel. Test Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the switch terminals. 3.

  • Page 29: Lamp Holder

    SERVICE (cont.) LAMP HOLDERS FIG. 22 LAMP HOLDERS Door Assy Upper Panel Lamp Holders Lower Panel Lamp Starter W/Socket Location: The lamp holders are located on the front of the upper panel behind the display panel. Test Procedure: 1. Disconnect the dispenser from the power source.

  • Page 30: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) LAMP REPLACEMENT (Refer to Fig.22)(cont.) 9. Reconnect the plug on the door wiring harness to the connector on the door interconnect wiring harness. 10. Install the door lower panel (5) using six #8-32 screws. LAMP STARTER and SOCkET (Refer to Fig. 22) Location: The lamp starter (6) is located inside the door assy (1) on the top of the door lower panel (5).

  • Page 31: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) LIMIT THERMOSTAT FIG. 23 LIMIT THERMOSTAT Location: The limit thermostat is located in the center of the tank lid. Test Procedures: Disconnect the dispenser from the power source. Disconnect both black wires from the limit ther- mostat. Check for continuity across the limit thermostat terminals.

  • Page 32: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) RINSE/RUN SWITCH FIG. 25 RINSE/RUN SWITCH Location: The rinse/run switch is located on the lower center of the whipper motor mounting panel. Test Procedures: Disconnect the dispenser from the power source. Check for continuity between the center left terminal and left bottom terminal, also between the center right terminal and the right bottom terminal with the switch in the rinse position (up-...

  • Page 33: Hot/Cold Switch-Optional

    SERVICE (cont.) HOT/COLD SWITCH (Optional) FIG. 27 HOT/COLD SWITCH Location: The hot/cold switch is located on the left side of the whipper motor mounting panel. Test Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the four pin plug from the hot/cold switch and the four pin connector on the main wiring harness.

  • Page 34: Solenoid (Cold Water - Optional)

    SERVICE (cont.) SOLENOID VALVE (COLD WATER - OPTIONAL) FIG. 29 COLD WATER SOLENOID VALVE Location: The cold water solenoid valve is located on the left side of the dispenser base just behind the component bracket. Test Procedures: 1. Disconnect the dispenser from the power source.

  • Page 35: Solenoid (Dispense)

    SERVICE (cont.) SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5 FIG. 31 DISPENSE SOLENOID VALVE Location: The dispense solenoid is located on the upper left center of the tank. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the two wires from the solenoid valve that is being tested.
  • Page 36 SERVICE (cont.) SOLENOID VALVE (DISPENSE) - FMD-4 & FMD-5 (cont.) Removal and Replacement: 1. Remove the four #8-32 screws securing the side access panel to the housing. Remove panel and set aside. 2. Remove the wires from the solenoid valve.

  • Page 37: Solenoid (Inlet)

    SERVICE (cont.) SOLENOID VALVE (INLET) FIG. 33 INLET SOLENOID VALVE Location: The inlet solenoid is located on the lower left side near the rear panel. Test Procedures: 1. Disconnect the dispenser source. 2. Disconnect the white and violet wires from the solenoid valve.

  • Page 38: Tank Heater

    SERVICE (cont.) TANk HEATER FIG. 35 TANK HEATER Location: The tank heater is located inside the tank and secured to the tank lid. Test Procedure: 1. Disconnect the dispenser from the power source. 2. Check the voltage across the black and white wires 120 volt models or black and red wires for 120/208 volt models or 120/240 volt models with a voltme- ter.

  • Page 39: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) TANk HEATER SWITCH FIG. 37 TANK HEATER SWITCH Location: The tank heater switch located inside the dispenser on the upper right of the front panel. Test Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the black wires from the main wiring harness.

  • Page 40: Tank Heater Relay

    SERVICE (cont.) TANk HEATER RELAY (120V Dispensers only) FIG. 39 TANK HEATER RELAY Location: The tank heater relay is located behind the lower front access cover, mounted on the left rear side of the component bracket. Test Procedure: 1. Disconnect the dispenser from the power source. 2.

  • Page 41: 1. Disconnect The Dispenser From The Power

    SERVICE (cont.) TRANSFORMER FIG. 41 TRANSFORMER Location: The transformer is located behind the lower front access cover, mounted on the right rear side of the component bracket. Test Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the four wires of the main harness from the transformer.

  • Page 42: Wiring Diagram

    35135 111103...
  • Page 43 35135 111103...
  • Page 44 35135 012103...
  • Page 45 35135 012103...
  • Page 46 HOT/COLD SWITCH WHI/YEL COLD JUMPER PLUG MUST BE USED WHEN COLD DRINK FEATURE NOT INSTALLED 230 VOLTS AC 2 WIRE + GND SINGLE PHASE, 50/60HZ 34820.0002B 04/05 ©2005 BUNN-O-MATIC CORPORATION J4-1 J4-4 J3-1 J3-5 J2-1 J2-5 J2-10 J1-1 J1-4 HOPPER #5...

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