Instruction/ maintenance manual of the product FMD-5 Bunn
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SER VICE & REP AIR MANU AL BUNN-O-MA TIC CORPORA TION POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227 PHONE: (217) 529-6601 F AX: (217) 529-6644 42672.
2 42672 030912 BUNN-O-MA TIC COMMERCIAL PRODUCT WARRANTY (Excluding regular maintenance items) Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows: 1) Airpots, thermal car.
3 USER NOTICES All notices on this equipment are written for your protection. All notices are to be kept in good condition. Replace any unreadable or damaged labels. CONTENTS Warranty ...................................................................
4 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.
5 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.
6 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 T echnical Service Department.
7 TROUBLESHOOTING (cont.) PROBLEM Product will not dispense (cont.) Water is not hot PROBABLE CAUSE 7. Level Control Board and Probe - FMD-1 8. Control Board 9. Overflow Protection Switch 10. Auger Drive 11. Water Strainer 12. Lime build-up CAUTION - T ank and tank compo- nents should be delimed regularly depending on local water conditions.
8 TROUBLESHOOTING (cont.) PROBLEM Water is not hot (Cont.) Spitting or excessive steaming Dripping from dispense tip Water flows into tank continuously PROBABLE CAUSE 4. T ank Heater Switch 5. Heater Relay 6. Control Board 1. Lime build-up CAUTION - T ank and tank compo- nents should be delimed regularly depending on local water conditions.
9 TROUBLESHOOTING (cont.) PROBLEM Water flows into tank continuously (Cont.) Weak product PROBABLE CAUSE 3. Overflow Protection Switch 4. Digital T ouch Control Switch 1. Water T emperature 2. Whipper Motor 3. Frother 4. Dispense Solenoid Valve 5. Auger Drive 6.
10 TROUBLESHOOTING (CONT .) PROBLEM Product overflows container Dispenser is making unusual noises Excess dust Display not lit PROBABLE CAUSE 1. Dispense Switch 2. Dispense Solenoid Valve 1. Plumbing Lines 2. Water Supply 3. T ank Heater 1. Fan 2. A) Hopper Drive Board - FMD-1 B) Control board 1.
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12 SERVICE This section provides procedures for testing and replacing various major components used in this dispenser should service become necessar y .
13 SERVICE(CONT .) ACCESS P ANELS 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.
14 SERVICE (CONT .) AUGER DRIVE COMPONENTS (all Models) J4 J1 J2 J3 J4 J1 J2 J3 FIG. 2 AUGER DRIVE COMPONENTS Location The auger components are located inside the bottom part of the hopper except for the auger drive bracket, spacer and retaining clip, which are located on the outside rear of the hopper base.
15 SERVICE (CONT .) AUGER DRIVE COMPONENTS FIG. 3 AUGER DRIVE & HOPPER DISASSEMBL Y 1. Hopper Lid 2. Hopper 3. Wiper Shaft 4. Wiper Blade 5. Wiper Drive Gear 6. Auger Drive Bracket 7. Spacer 8. Hopper Base 9. Washer 10. Retainer Clip 11. Hopper Support Plate 12.
16 SERVICE (CONT .) AUGER DRIVE COMPONENTS FIG. 5 AUGER DRIVE & HOPPER DISASSEMBL Y 1. Hopper Lid 2. Mixing Blade 3. Agitator Disk 4. Auger Drive Shaft Bushing 5. Auger Drive Shaft 6. Locknut 7. Auger Drive Bracket 8. Hopper 9. Auger Wire 10. Ejector Elbow 11.
17 SERVICE (CONT .) AUXILLARY CONTROL BOARD (FMD DBC-3 only) FIG. 6 AUXILIARY CONTROL BOARD P4102.40 Location: The auxiliary control board is located behind the lower front access cover , mounted on the rear side of the component bracket. Hot Water Dispense T est Procedure: 1.
18 Removal and Replacement: 1. Loosen the two #8-32 screws securing the compo- nent mounting bracket to the dispenser housing. 2. Slide the component mounting bracket forward until the screw heads align with the large diameters of the keyhole openings.
19 SERVICE (cont.) BALLAST (all Models) J4 J1 J2 J3 J4 J1 J2 J3 Location The front door lamp ballasts are located behind the front access panel and may be on either side of the component bracket assembly . T est Procedure 1. Disconnect the dispenser from the power source.
20 SERVICE (cont.) CONTROL BOARD (FMD-2,-2FD,DBC-2FD,DBC-3) FIG. 10 CONTROL BOARD Location: The Control Board is located behind the lower front access cover mounted on the component bracket. T est Procedure: Power Supply: 1. Disconnect the dispenser from the power source.
21 SERVICE (cont.) CONTROL BOARD (CONT .) 11. With a voltmeter check the voltage across the terminals of the inlet solenoid valve. Connect the dispenser to the power source. After a 10 second delay , the indication must be : a) 120 volts ac for two wire 120 volt models.
22 J3 J2 J1 J4 J1 FIG. 11 CONTROL BOARD CONNECTORS P1680 SERVICE (cont.) J3 J2 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.
23 J4 J1 J2 J3 J4 J1 J2 J3 5. Disconnect the dispenser from the power source. 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. Carefully connect a piece of insulated jumper wire to pin 10 (top right) of J2 on control board #1.
24 SERVICE (cont.) CONTROL BOARD (CONT .) 14. Move the probe’ s flat end to the dispenser housing. The indication must be 0. 15. Move the probe’ s flat end away from the housing.
25 J4 J1 J2 J3 J4 J1 J2 J3 J4 J3 FIG. 13 CONTROL BOARD CONNECTORS P2637 J1 J2 J1 J2 J4 J3 CONTROL BOARD #1 CONTROL BOARD #2 SERVICE (cont.) CONTROL BOARD (CONT .) Removal and Replacement: 1. Disconnect the three plugs on the main wiring har - ness from the connectors on the control board.
26 CONTROL THERMOST A T (FMD-1,-2,-2FD,-3,-4,-5) SERVICE (cont.) FIG. 14 CONTROL THERMOST A T Location: The control thermostat (mechanical or electronic) is located inside the dispenser on the upper left side of the housing. T est Procedure: Mechanical Thermostat: 1.
27 FIG. 15 THERMOST A T TERMINALS P1448 BLK from Limit Thermostat BLK from T ank Heater Switch SERVICE (cont.) CONTROL THERMOST A T (cont.) MECHANICAL THERMOST A T T AN to WHI/BRN in Main Wiring Harne.
28 P1449 FIG. 17 DISPENSE SWITCH TERMINALS DISPENSE SWITCHES (FMD-1,-2,-2FD,-3,-4,-5) SERVICE (cont.) If voltage is present as described, proceed to #7. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness.
29 SERVICE (cont.) If voltage is present as described, proceed to step 7. If voltage is not present as described, refer to the wiring diagram and check the dispenser wiring harness.
30 P1685 FIG. 19 DIGIT AL TOUCH CONTROL SWITCH TO DOOR INTERCONNECT HARNESS CONNECTOR SERVICE (cont.) DIGIT AL TOUCH CONTROL SWITCH (cont.) Removal and Replacement: 1. Open the dispenser door . 2. Remove the five #6-32 screws securing the bottom door cover and remove cover .
31 SERVICE (cont.) EMI FIL TER (230 V olt FMD DBC-3) FIG. 20 EMI FIL TER Location: The EMI Filter is located on the rear of the dispenser base on FMD DBC-3. T est Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the two black wires and two white wires on the EMI Filter from the EMI Filter wiring harness.
32 V ACUUM F AN (all Models) FIG. 22 F AN Location: The fan is located inside the dispenser housing on the right rear of the dispenser base plate. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the black and white wires from the fan terminals.
33 P4102.40 SERVICE (cont.) FROTHER AND WHIPPER MOTOR (all Models except -2FD) 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 . The whipper motors are located on the back side of the whipper motor mounting panel.
34 SERVICE (cont.) FROTHER AND WHIPPER MOTOR (cont.) 6. Pull the frother (6) off the motor shaft. Notice the flat side on the shaft and the matching flat inside the frother . It is important that these two flats are lined up when reassembling. 7. Slip the o-ring (5) off the whipper chamber recep- tacle (8).
35 SERVICE (cont.) HOPPER DRIVE BOARD - FMD-1 ONL Y FIG. 27 HOPPER DRIVE BOARD Location The hopper drive board is located inside the dispenser mounted on the auger motor mounting bracket. T est Procedures: 1. Disconnect the dispenser from the power source.
36 SERVICE (cont.) HOPPER DRIVE BOARD - FMD-1 ONL Y J1 Connector for Three Pin Plug from Potentiometer RED from Hopper Motor FIG. 28 HOPPER DRIVE BOARD TERMINALS P1669 BLK from Hopper Motor RED/WHI from Main Harness WHI from Main Harness Removal and Replacement: (Refer to Fig.
37 FIG. 29 HOT/COLD SWITCH P1684.40 HOT/COLD SWITCH (Optional for FMD DBC-3) Location: The hot/cold switch is located on the left side of the whipper motor mounting panel. T est Procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the switch terminals.
38 INCREASE/DECREASE SWITCH (FMD-2,-2FD,-3,-4,-5) FIG. 31 INCREASE/DECREASE SWITCH P1666 Location: The increase/decrease switch is located on the lower left front of the whipper motor mounting panel. T est Procedure: 1. Disconnect the dispenser from the power source.
39 SERVICE (cont.) PUSH and HOLD BUTTON UNTIL CUP IS 2/3 FULL, THEN RELEASE LAMP HOLDER (all Models) FIG. 33 LAMP HOLDERS P1454.70 Location: The lamp holders are located on the front of the upper panel behind the display panel. T est Procedure: 1. Disconnect the dispenser from the power source.
40 SERVICE (cont.) LAMP ST ARTER and SOCKET Location: The lamp starter (6) is located inside the door assy (1) on the top of the door lower panel (5). T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the starter leads from the door wiring harness.
41 SERVICE (cont.) J1 LEVEL CONTROL BOARD AND LEVEL PROBE (FMD-1 only) FIG. 34 LEVEL CONTROL BOARD AND PROBE Location: The level control board is located behind the lower access panel mounted on the right side of the compo- nent bracket. The Level probe is located on the left center of the tank lid just in front of the overflow tube.
42 P1671 FIG. 35 LEVEL BOARD TERMINALS TI VIO to Inlet Solenoid Coil T2 BLK to Main Harness T3 WHI to Main Harness T4 PNK to Probe 13. Place the probe so that neither end is in contact with any metal surface of the dispenser . 14. Check the voltage across terminals 1 & 3 with a voltmeter .
43 FIG. 37 LIMIT THERMOST A T TERMINALS P1800 LIMIT THERMOST A T (all Models) FIG. 36 LIMIT THERMOST A T Location: The limit thermostat is located in the center of the tank lid. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect both black wires from the limit thermo - stat.
44 SERVICE (cont.) OVERFLOW PROTECTION SWITCH (FMD-3,DBC-3-4,-5) FIG. 39 OVERFLOW PROTECTION SWITCH LEADS P1212 FIG. 38 OVERFLOW PROTECTION SWITCH Location: The overflow protection switch is located inside the copper overflow cup on the left side of the tank.
45 RINSE /RUN SWITCH (all Models) FIG. 40 RINSE/RUN SWITCH P1684.40 Location: The rinse/run switch is located on the lower right side of the whipper motor mounting panel. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the switch terminals.
46 FIG. 43 COLD WA TER SOLENOID TERMINALS P1215 SOLENOID V AL VE (COLD W A TER - OPTIONAL for FMD-2,-3,-4,-5) FIG. 42 COLD WA TER SOLENOID V AL VE Location: The cold water solenoid valve is located on the left side of the dispenser base just behind the component bracket.
47 FIG. 45 DISPENSE SOLENOID V AL VE TERMINALS P1645 SERVICE (cont.) SOLENOID V AL VES (DISPENSE) (all Models) FIG. 44 DISPENSE SOLENOID V AL VES P1637.40 Location: The dispense solenoids are located on the side of the tank. T est Procedures: 1. Disconnect the dispenser from the power source.
48 P4102 FIG. 46 HOT WA TER DISPENSE SOLENOID V AL VE Location: The hot water solenoid valve is located on the left side of the tank. T est Procedures: 1. Disconnect the dispenser from the power source. 2. With a voltmeter check the voltage across the white and blue wires at the solenoid valve.
49 SERVICE (cont.) SOLENOID V AL VE (INLET) (all Models) FIG. 48 INLET SOLENOID V AL VE Location: The inlet solenoid is located inside on the rear of the dispenser base. T est Procedures: 1 . Disconnect the dispenser from the power source. 2 . Disconnect the two wires from the solenoid valve.
50 SERVICE (cont.) T ANK HEA TER (all Models) FIG. 50 T ANK HEA TER P4102.40 Location: The tank heater is located inside the tank and secured to the tank lid.
51 J4 J1 J2 J3 J4 J1 J2 J3 T ANK HEA TER RELA Y (FMD-4,-5,120V Dispensers only) FIG. 52 T ANK HEA TER RELA Y P4095 Location: The tank heater relay is located behind the lower front access cover , mounted on the left rear side of the component bracket.
52 P1684.40 SERVICE (cont.) T ANK HEA TER SWITCH (all Models) FIG. 54 T ANK HEA TER SWITCH Location: The tank heater switch located is inside the dispenser on the upper right of the whipper motor mounting panel. T est Procedure: 1. Disconnect the dispenser from the power source.
53 SERVICE (cont.) FIG. 57 TRANSFORMER TERMINALS P1647 TRANSFORMER (all Models) FIG. 56 TRANSFORMER P1646 Location: The transformer is located behind the lower front access cover , mounted on the right rear side of the component bracket. T est Procedure: 1.
54 Q1 MOV1 MOV2 MOV4 MOV3 Q2 Q5 Q7 Q1 Q1 Bunn Part Number 28826.0006 Bunn Part Number 38739.0000 Bunn Part Number 38739.0001 MOV1 MOV1 TRIAC MAPS for FMD Q1 & MOV1 controls Refill V alve @ J4 Q1 .
55 SOL DISPENSE M WHIPPER M HOPPER RUN/RINSE SWITCH WHI RED WHI RED RED RED RED RED BLK-16 120 VOL TS A C - 2 WIRE 120/208-240 VOL TS AC - 3 WIRE SINGLE PHASE 29096.
56 SOL DISPENSE M WHIPPER M HOPPER RUN/RINSE SWITCH WHI RED WHI RED RED RED RED RED BLK-16 230 VOL TS AC CE 2 WIRE + GN D SINGLE PHASE 50/60 HZ 29096.0006B 04/05 © 2005 BUNN-O-MA TIC CORPORA TION SCH.
57 GRN GRN GRN WHI WHI WHI WHI WHI WHI SOL LEFT DISPENSE M LEFT WHIPPER M LEFT HOPPER M RIGHT HOPPER M RIGHT WHIPPER SOL RIGHT DISPENSE BLK BLK WHI WHI WHI WHI WHI WHI RED RED BLU BLU RED RED RED RED .
58 GRN GRN GRN WHI WHI WHI WHI WHI WHI SOL LEFT DISPENSE M LEFT WHIPPER M LEFT HOPPER M RIGHT HOPPER M RIGHT WHIPPER SOL RIGHT DISPENSE BLK BLK WHI WHI WHI WHI WHI WHI RED RED BLU BLU RED RED RED RED .
59 SCHEMA TIC WIRING DIAGRAM FMD DBC-2 FREEZE DRIED W/HOT WA TER HOT WA TER WHI WHI WHI WHI/VIO RED ORN RIGHT DISPENSE LEFT DISPENSE SOL SOL SOL HOT WA TER L G L G M D M D S M S M STOP LEFT CENTER SWI.
60 GRN GRN GRN WHI WHI WHI WHI SOL SOL LEFT DISPENSE HOT WATR M LEFT HOPPER M RIGHT HOPPER SOL RIGHT DISPENSE BLK BLK WHI WHI WHI WHI RED RED BLK-16 120 VOLTS AC - 2 WIRE 120/208-240 VOLTS AC - 3 WIRE SINGLE PHASE, 60 HZ 29096.
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65 RED (3-WIRE MODELS) BLK (3-WIRE MODELS) BLK (2-WIRE MODELS) WHI (2-WIRE MODELS) GREEN L1 L2 BLK N MAIN ON/OFF SWITCH (Late 3-wire Models only) RED WHI SCHEMA TIC WIRING DIAGRAM FMD DBC-3 (WITH HOT WA TER DISPENSE) 120 VO LT S AC 2 WIRE + GND or 120/208-240 VO LT S AC - 3 WIRE + GND SINGLE PHASE, 60 Hz 29218.
66 L2 L1 29218.0004A 09/01 © 2001 BUNN-O-MA TIC CORPORATION 230 VOL TS AC - 2 WIRE SINGLE PHASE 50/60 HZ BLU/RED WHI/RED BLK/WHI ORN/BLK RED/BLK BLU/BLK BLU/WHI ORN WHI/BLK BLK RED RED/WHI GRN/BLK OR.
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71 GRN GRY WHI/GRY BRN/BLK BRN/BLK BLK I N C D E C INCREASE/ DECREASE SWITCH RINSE/PROGRAM/ RUN SWITCH RUN RUN PGM PGM RINSE RINSE WHI/VIO RED/BLK GRN GRN GRN GRN GRY PNK WHI/ORN WHI/ORN WHI/RED WHI/R.
An important point after buying a device Bunn FMD-5 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Bunn FMD-5 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Bunn FMD-5 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Bunn FMD-5 you will learn all the available features of the product, as well as information on its operation. The information that you get Bunn FMD-5 will certainly help you make a decision on the purchase.
If you already are a holder of Bunn FMD-5, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Bunn FMD-5.
However, one of the most important roles played by the user manual is to help in solving problems with Bunn FMD-5. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Bunn FMD-5 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
