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Bunn FMD-1 Service & Repair Manual

Summary of FMD-1

  • Page 1

    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 fmd series including: fmd-1,2,3,4,5.

  • Page 2

    2 42672 030912 bunn-o-matic commercial product warranty (excluding regular maintenance items) bunn-o-matic corp. (“bunn”) warrants equipment manufactured by it as follows: 1) airpots, thermal carafes, decanters, gpr servers, iced tea/coffee dispensers, mcp/mca pod brewers thermal servers and thermof...

  • Page 3

    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 .......................................................................................................................

  • Page 4

    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. Do not clean this equipment with a water jet device. 1 x 24h 37254.0000a 07/04 © 2004 bunn-o-matic corporation notice the cleaning instructions ...

  • Page 5

    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) 25732.0000 ste...

  • Page 6

    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 technical service department. • inspection, testing, and repair of elect...

  • Page 7

    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 - tank and tank compo- nents should be delimed regu...

  • Page 8

    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. Tank heater switch 5. Heater relay 6. Control board 1. Lime build-up caution - tank and tank compo- nents should be delimed regula...

  • Page 9

    9 troubleshooting (cont.) problem water flows into tank continuously (cont.) weak product probable cause 3. Overflow protection switch 4. Digital touch control switch 1. Water temperature 2. Whipper motor 3. Frother 4. Dispense solenoid valve 5. Auger drive 6. Auger spring 7. Auger motor 8. Rinse/ru...

  • Page 10

    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. Tank heater 1. Fan 2. A) hopper drive board - fmd-1 b) control board 1. Lamp...

  • Page 11

    11 notes 42672 122209.

  • Page 12

    12 service this section provides procedures for testing and replacing various major components used in this dispenser should service become necessary. Refer to troubleshooting for assistance in determining the cause of any problem. Warning - inspection, testing, and repair of electrical equipment sh...

  • Page 13

    13 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...

  • Page 14

    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 hopp...

  • Page 15

    15 service (cont.) auger drive components fig. 3 auger drive & hopper disassembly 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. Auger drive shaft 13. Auger wire 14. Ej...

  • Page 16

    16 service (cont.) auger drive components fig. 5 auger drive & hopper disassembly 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. Hopper assy 12. Auger motor mounting pane...

  • Page 17

    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 test procedure: 1. Disconnect the dispenser ...

  • Page 18

    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. 3. Lift the component mounting bracket, and pul...

  • Page 19

    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. Test procedure 1. Disconnect the dispenser from the power source. 2. Disconnect the two black l...

  • Page 20

    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. Test procedure: power supply: 1. Disconnect the dispenser from the power source. 2. With a voltmeter, back pr...

  • Page 21

    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. B) 120 volts ac for three wire ...

  • Page 22

    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 boar...

  • Page 23

    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 pi...

  • Page 24

    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. The indication must again be 120 volts ac for two wire 120 volt models, three wire 120/208 volt models, three wire 120/240 v...

  • Page 25

    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. 2. Remove th...

  • Page 26

    26 control thermostat (fmd-1,-2,-2fd,-3,-4,-5) service (cont.) fig. 14 control thermostat location: the control thermostat (mechanical or electronic) is located inside the dispenser on the upper left side of the housing. Test procedure: mechanical thermostat: 1. Disconnect the dispenser from the pow...

  • Page 27

    27 fig. 15 thermostat terminals p1448 blk from limit thermostat blk from tank heater switch service (cont.) control thermostat (cont.) mechanical thermostat tan to whi/brn in main wiring harness blk to main wiring harness whi to main wiring harness blk to main wiring harness electronic thermostat 42...

  • Page 28

    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. 7. Check for continuity across the term...

  • Page 29

    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. 7. While pressing the appropriate switch, check for continuity across the following pins of the digital touch control ...

  • Page 30

    30 p1685 fig. 19 digital touch control switch to door interconnect harness connector service (cont.) digital 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. 3. Disconnect the wires on t...

  • Page 31

    31 service (cont.) emi filter (230 volt fmd dbc-3) fig. 20 emi filter location: the emi filter is located on the rear of the dispenser base on fmd dbc-3. Test procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the two black wires and two white wires on the emi filter from th...

  • Page 32

    32 vacuum fan (all models) fig. 22 fan location: the fan is located inside the dispenser housing on the right 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. 3. With a voltmeter, che...

  • Page 33

    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...

  • Page 34

    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- tac...

  • Page 35

    35 service (cont.) hopper drive board - fmd-1 only fig. 27 hopper drive board location the hopper drive board is located inside the dispenser mounted on the auger motor mounting bracket. Test procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the white/red wire and the whit...

  • Page 36

    36 service (cont.) hopper drive board - fmd-1 only 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. 27) 1. Remove hopper as...

  • Page 37

    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. Test procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the switch terminals. 3. With th...

  • Page 38

    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. Test procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the ...

  • Page 39

    39 service (cont.) pu sh and ho ld butt on un til cu p is 2/3 ful l, t hen rel ease 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. Test procedure: 1. Disconnect the dispenser from the power sourc...

  • Page 40

    40 service (cont.) lamp starter and socket location: the lamp starter (6) is located inside the door assy (1) on the top of the door lower panel (5). Test procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the starter leads from the door wiring harness. 3. Remove lamp start...

  • Page 41

    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 ...

  • Page 42

    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. Connect the...

  • Page 43

    43 fig. 37 limit thermostat terminals p1800 limit thermostat (all models) fig. 36 limit thermostat location: the limit thermostat is located in the center of the tank lid. Test procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect both black wires from the limit thermo- stat. ...

  • Page 44

    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. Test procedures: 1. Disconnect the dispe...

  • Page 45

    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. Test procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the wires from the switch terminals. 3. Models ...

  • Page 46

    46 fig. 43 cold water solenoid terminals p1215 solenoid valve (cold water - optional for fmd-2,-3,-4,-5) fig. 42 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 d...

  • Page 47

    47 fig. 45 dispense solenoid valve terminals p1645 service (cont.) solenoid valves (dispense) (all models) fig. 44 dispense solenoid valves p1637.40 location: the dispense solenoids are located on the side of the tank. Test procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect...

  • Page 48

    48 p4102 fig. 46 hot water dispense solenoid valve location: the hot water solenoid valve is located on the left side of the tank. Test 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. Connect ...

  • Page 49

    49 service (cont.) solenoid valve (inlet) (all models) fig. 48 inlet solenoid valve location: the inlet solenoid is located inside on the rear of the dispenser base. Test procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the two wires from the solenoid valve. 3. Check for ...

  • Page 50

    50 service (cont.) tank heater (all models) fig. 50 tank heater p4102.40 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. With a voltmeter check the voltage across the black and white wires 120 vol...

  • Page 51

    51 j4 j1 j2 j3 j4 j1 j2 j3 tank heater relay (fmd-4,-5,120v dispensers only) fig. 52 tank heater relay p4095 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 po...

  • Page 52

    52 p1684.40 service (cont.) tank heater switch (all models) fig. 54 tank heater switch location: the tank heater switch located is inside the dispenser on the upper right of the whipper motor mounting panel. Test procedure: 1. Disconnect the dispenser from the power source. 2. Disconnect the black o...

  • Page 53

    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. Test procedure: 1. Disconnect the dispenser from the power sour...

  • Page 54

    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 valve @ j4 q1 & mov1 controls left whipper motor @ j2-6 q2 & mov3 controls center whipper motor @ j2-3 q5 & mov4 control...

  • Page 55

    55 sol dispense m whipper m hopper run/rinse switch whi red whi red red red red red blk-16 120 volts a c - 2 wire 120/208-240 volts ac - 3wire single phase 29096.0000c 8/98 © 1998 bunn-o-matic corporation schematic wiring diagram fmd-1 grn grn grn grn l1 n l2 limit thermostat blk-16 tank heater red-...

  • Page 56

    56 sol dispense m whipper m hopper run/rinse switch whi red whi red red red red red blk-16 230 volts ac ce 2 wire + gnd single phase 50/60 hz 29096.0006b 04/05 © 2005 bunn-o-matic corporation schematic wiring diagram fmd-1a grn grn grn grn l1 l2 limit thermostat blk-16 sol tank inlet blk blk blk pro...

  • Page 57

    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 jumper plug must be used when cold drink feature not installed red sol cold drink option (left only)...

  • Page 58

    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 re d red red jumper plug must be used when cold drink feature not installed red sol cold drink option (left only...

  • Page 59

    59 schematic wiring diagram fmd dbc-2 freeze dried w/hot water hot water whi whi whi whi/vio red orn right dispense left dispense sol sol sol hot water l g l g m d m d s m s m stop left center switch unit assy whi whi blk blk blk blk red red blu blu blu whi bl u whi bl u 1 1 starter bl kb lk bl k fl...

  • Page 60

    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 29096.0004a 01/03 © 2003 bunn-o-matic corporation schematic wiring diagram fmd-...

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  • Page 65

    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 schematic wiring diagram fmd dbc-3 (with hot water dispense) 120 volts ac 2 wire + gnd or 120/208-240 volts ac - 3 wire + gnd single phase, 60 hz ...

  • Page 66

    66 l2 l1 29218.0004a 09/01 © 2001 bunn-o-matic corporation 230 volts 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 orn re d ru n rins e gr y whi/bl u whi/or n whi/re d grn whi/brn brn/bl k red/bl k whi/vio-22 whi/vi o bl...

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  • Page 71

    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/vi o red/bl k gr n grn grn grn gry pnk whi/orn whi/orn whi/red whi/red whi/gry whi/vio gry whi/gry whi/vio whi/vio whi vio whi whi/blk whi/grn whi/blk whi/blk whi/re...