Bunn Coffeemaker U3 User Manual

U3A

OPERATING & 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.

INTRODUCTION

This brewer will brew a three gallon batch of coffee into each reservoir (one at a time). Each reservoir has

its own dispensing faucet(s).The brewer also has a hot water faucet(s) for allied beverage use. It is only for

indoor use on a sturdy counter where ambient temperature is in the range of 10-30°C (50-85°F). Brewer to be

installed at a location where it can be overseen by trained personnel.

USER NOTICES

Carefully read and follow all notices on the brewer and in this manual. They were written for your protection.

All notices on the brewer are to be kept in good condition. Replace any unreadable or damaged labels.

This equipment must be installed to comply

WARNING

with the International Plumbing Code of the

Fill water tank before turning - on -

thermostat or connecting appliance

to power source.

International Code Council and the Food

Code Manual of the Food and Drug Adminis-

tration (FDA). For models installed outside

the U.S.A., comply with the applicable

Plumbing /Sanitation Code.

Use only on a properly protected

circuit capable of the rated load.

Electrically ground the chassis.

Follow national/local electrical codes.

Do not use near combustibles.

#00656.0000

FAILURE TO COMPLY RISKS EQUIPMENT

DAMAGE, FIRE, OR SHOCK HAZARD

READ THE ENTIRE OPERATING MANUAL

BEFORE BUYING OR USING THIS PRODUCT

THIS APPLIANCE IS HEATED WHENEVER

CONNECTED TO A POWER SOURCE

#00831.0000

#37881.0000

WARNING

Very Hot Water

REMOVE FUNNEL

SLOWLY

#03408.0000

Use With Care!

#12593.0000

WARNING

H O T

CAUTION

L I Q U I D

#03409.0000

HOT

ATTENTION: TURN OFF WHEN UNATTENDED

SURFACES

#00878.0000

#12555.0000

#00824.0001

10060 011708

Page 3

ELECTRICAL REQUIREMENTS

CAUTION - The brewer must be disconnected from the power source until speciﬁed in Initial Set-Up.

RED

L2 RED

WHITE

208V OR 240V

380V OR 440V

120V A.C.

BLUE

208V OR 240V

380V OR 440V

208 OR

240V A.C.

208V OR 240V

380V OR 440V

NEUTRAL

L1 BLACK

BLACK

GREEN

P1841

P1843

U3 & U38 requires 3-wire, grounded service rated

120/208or120/240voltsac,U3-30amp,U38-40amp,

single phase, 60 Hz. Proceed as follows:

U333 & U3833 requires 3-wire, grounded service

rated 240 volt ac, 35 amp or 440 volts ac, 30 amp for

U333,three phase, 60 Hz or 380 volts ac, 30 amp for

U3833, three phase, 50 Hz. Proceed as follows:

L1, L2, L3, are the 3 phases

WHITE

(NEUTRAL)

V1 = Phase to phase voltage,

RED

between any 2 phases.

BLACK

BLUE

V2 = Phase to neutral voltage,

any phase to neutral.

BLACK

230V A.C.

RED

GREEN

SYSTEM

VOLTAGE

208

GREEN

208

240

380

120

139

220

P1844

240

380

P1842

440

254

U3833 requires 4-wire, grounded service rated

380 volts ac or 440 volts ac, 30 amp, three phase, 50

Hz. Proceed as follows:

U3Amodelsrequire2-wire,groundedservicerated

230 volts ac, 30 amp, single phase, 50 Hz. Proceed

as follows:

ELECTRICAL INSTALLATION INSTRUCTIONS

NOTE: Electrical source should have a circuit breaker between the brewer and the main supply which breaks all

poles with a contact separation of at least 3 mm.

CAUTION – Improper electrical installation will damage electronic components.

1. An electrician must provide electrical service as speciﬁed.

2. Using a voltmeter, check the voltage and color coding of each conductor at the electrical source.

3. Before electrically connecting the brewer, remove the front cupola cover (some models have the thermostat

knob on the outside of the cover) and rotate the thermostat knob fully counterclockwise to the "OFF" position.

Keep this knob in the "OFF" position until performing the Initial Setup.

4. Electrical service is connected at the upper rear of the single service and scrambler brewers using a junc-

tion box. On double service brewers the rear decorative channel must be removed for access to the terminal

block.

5. Connect the brewer to the power source and verify the voltage at the terminal block before proceeding. Re-

place all panels.

6. If plumbing is to be hooked up later be sure the brewer is disconnected from the power source. If plumbing

has been hooked up, the brewer is ready for Initial Setup.

NOTE: Schematic wiring diagrams are included in this manual.

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Page 4

CE REQUIREMENTS

• This appliance must be installed in locations where it can be overseen by trained personnel.

• For proper operation, this appliance must be installed where the temperature is between 5°C to 35°C.

• Appliance shall not be tilted more than 10° for safe operation.

• An electrician must provide electrical service as speciﬁed in conformance with all local and national codes.

• This appliance must not be cleaned by water jet.

• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental

capabilities, or lack of experience and knowledge, unless they have been given instructions concerning use of

this appliance by a person responsible for its safety.

• Children should be supervised to ensure they do not play with the appliance.

• If the power cord is ever damaged, it must be replaced by the manufacturer or authorized service personnel with

a special cord available from the manufacturer or its authorized service personnel in order to avoid a hazard.

PLUMBING REQUIREMENTS

These brewers must be connected to a cold water system with operating pressure between 20 (138) and 90 psi (620 kPa)

from a 1/2" or larger supply line. A shut-off valve should be installed in the line before the brewer. Install a regulator in the

line when pressure is greater than 90 psi (620 kPa) to reduce it to 50 psi (345 kPa). The water inlet ﬁtting is 3/8" ﬂare.

NOTE - Bunn-O-Matic recommends 3/8" copper tubing for installations from the 1/2" water supply line. A tight coil of

copper tubing in the water line will facilitate moving the brewer to clean the countertop. Bunn-O-Matic does not recom-

mend the use of a saddle valve to install the brewer. The size and shape of the hole made in the supply line by this type

of device may restrict water ﬂow.

ThisequipmentmustbeinstalledtocomplywiththeInternationalPlumbingCodeoftheInternational

Code Council and the Food Code Manual of the Food and Drug Administration (FDA). For models

installed outside the U.S.A., you must comply with the applicable Plumbing/Sanitation Code for

your area.

INITIAL SETUP

CAUTION - The brewer must be disconnected from the power source throughout the initial setup, except when speciﬁed

in the instructions.

IMPORTANT: Brewer must be level and installed on a sturdy structure.

Electrician's and Plumber's Instructions are provided. These instructions should be carefully followed

before proceeding with initial setup.

Be sure all electrical and plumbing connections are tight.

1. Open manual ﬁll valve located on the bottom of the brewer. Water should start ﬁlling the tank. When water is visible

in the hot water gauge glass (center spigot), close valve. Approximate time for ﬁlling manually is 3 minutes.

CAUTION: Never leave brewer unattended while manually ﬁlling tank.

2. Connect the brewer to the power source. Turn "ON/OFF" switch to the "ON" position. Water should ﬁnish ﬁlling tank

automatically.

NOTE: It is recommended that the "ON/OFF" switch be left in the "OFF" position at the end of the operating day or when

unattended for a long period of time.

3. Disconnect the brewer from the power source. Remove front cupola cover for access to thermostat knob and timer.

On some brewers the thermostat knob is located on the front of the cupola cover.

4. Turn the thermostat knob clockwise to an approximate 5 o'clock position. Allow 1-1/2 hours for water to heat. Time

will vary with incoming water temperature.

5. On initial warm-up, some water may ﬂow thru the overﬂow spigot due to expansion of the cold water in the tank.

This will not recur during the use of the brewer and may be avoided on the initial warm-up by drawing off 1/2 gallon

decanters of water each 15 minutes till brewing temperature is reached.

10060 102808

Page 5

INITIAL SETUP (cont.)

6. Brewing cycles may be started whenever water temperature is correct. This condition is indicated by the dial

thermometer on front of the brewer. Whenever the pointer is in the green, brewer is ready for brewing. The

recommended brewing temperature is approximately 200^°F (93°C). Water temperature may be increased by

turning thermostat knob clockwise, decreased by turning knob counterclockwise.

7. When desired temperature is reached, insert funnel support, funnel and funnel cover in position. Be sure

the water swing spout is over the center of the funnel cover, turn "ON/OFF" switch to the "ON" position, push

and release "START" and run a brew cycle of hot water only. At the end of this cycle, brewer will be ready for

checking timer adjustment.

8. The timer has been preset for a 4 minute cycle. This setting will deliver approximately 3 gallons of water per

brewing cycle. To increase or decrease amount of water, adjust the timer as required. See Adjusting Brew

Volumes.

9. Having determined ﬁnal settings of the thermostat and the timer, replace front cupola cover. Brewer is now

ready for brewing coffee.

ADJUSTING BREW VOLUMES

CAUTION - Disconnect the power source from the brewer prior to the removal of any panel for the replacement

or adjustment of any component.

NOTE: Prior to setting or modifying batch sizes, check that the brewer is connected to water supply, the tank is

properly ﬁlled, and a funnel support, funnel and funnel cover are in place.

1. Modifying batch sizes. To modify a batch volume, ﬁrst check that the SET/LOCK switch is in the “SET” posi-

tion on the circuit board.

To increase a batch size. Press and hold the START or BREW 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) and press it again one or more times. Each time the switch is pressed, two seconds are

added to the brew time period. Allow the brew cycle to ﬁnish in order to verify that the desired volume has

been achieved.

To decrease a batch size. Press and release the START or BREW switch once for every two-second interval

to be removed from the total brew time period; then immediately press and hold down the START or BREW

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 ﬁnish in order to

verify that the desired volume has been achieved.

2. Setting batch sizes. To set a batch volume, ﬁrst check that the SET/LOCK switch is in the “SET” position on

the circuit board. Press and hold the START or BREW 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” (lower). 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, batch volumes will decrease due to absorption by the coffee grounds.

NOTE: HALF-BATCH AND FULL BATCH SETTINGS MUST EACH BE SET SEPARATELY.

3. Setting programming disable feature. If it becomes necessary to prevent anyone from changing brew times

once programmed, you can set the SET/LOCK switch to the “LOCK” position. This will prevent any program-

ming to be done until switch is once again placed in the “SET” position.

10060 080900

Page 6

COFFEE BREWING

1. Brewing cycles may be started whenever water temperature is correct. This condition is indicated by the dial

thermometer on front of the brewer. Whenever the pointer is in the green, brewer is ready for brewing.

2. Insert Bunn^®ﬁlter in funnel and add desired amount of coffee.

3. Level the bed of coffee and place funnel into the funnel support. Place funnel cover over the funnel and be

sure the water swing spout is over the center of the funnel cover.

4. Turn "ON/OFF" switch to the "ON" position.

5. Push and release "START" switch to start the brew cycle.

6. Water swing spout should not be moved as long as water is ﬂowing into the funnel cover. When water stops

ﬂowing, it may then be moved for access to brewing funnel.

7. Remove funnel cover. Funnel should not be removed from brewer until drip out of coffee has been com-

pleted.

8. To empty funnel, invert it over a waste container to dispose of ﬁlter and grounds. An additional ﬂange is

provided on the funnel to help make this step easier.

NOTE: Hot water may be drawn from the hot water faucet during a brew cycle. However, if a large amount of

hot water is drawn off (over 1 gallon) operator should wait to do so between brewing cycles.

CLEANING

NOTE: Tanks and tank components should be delimed regularly based on local water conditions. Excessive

mineral build-up on stainless steel surfaces can initiate corrosion reactions resulting in serious leaks.

1. Remove both funnels, funnel lids and supports, under hot water, rinse away all coffee oils. Wipe with a clean

damp cloth.

2. Drain both coffee reservoirs by opening coffee faucets. When empty, close faucets.

3. Cycle two or three inches of water into each coffee reservoir and scrub entire reservoir area.

NOTE: The brewer must NOT be rinsed or cleaned by a water jet device.

4. Drain both coffee reservoirs and rinse. Use clean damp cloth to wipe both reservoirs.

5. Install both coffee funnel supports, funnels and funnel lids.

6. Remove the sight gauge cap, insert sight gauge cleaning brush into the sight gauge glass tube and clean.

7. To clean coffee faucets, remove the faucet handle from the faucet and faucet clean out cap. Clean faucet with

a faucet cleaning brush and wipe all parts with a damp cloth. Replace faucet seat cups periodically if badly

stained or to stop faucet dripping. DO NOT CLEAN THE HOT WATER FAUCET.

8 Reassemble the coffee faucets.

9. Wipe the entire outside surface of the machine with a clean damp cloth. Wipe dry.

FILTER HOLDER

1. A ﬁlter holder is supplied with each U3 coffee brewer. Its purpose is to keep the ﬁlters in their originally

formed shape to properly ﬁt the brewer funnel.

2. It is suggested that only one cluster of ﬁlters be placed in the holder at one time for best results.

3. Not using the ﬁlter holder may permit the ﬁlters to gradually widen out towards a ﬂat shape, especially so if

humidity is present. Once a ﬁlter has lost its upright side walls, it may tend to collapse inward when placed

in the brewing funnel. If this happens the hot water spray may cause one side to fall inwards, letting coffee

grounds ﬂow over the edge of ﬁlter and into the brewed coffee. Proper use of the holder should prevent this

problem.

10060 081106

Page 7

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.

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 ﬁttings 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 speciﬁed.

• Follow recommended service procedures

• Replace all protective shields or safety notices

PROBLEM

PROBABLE CAUSE

REMEDY

Brew cycle will not start

1. No water

Water lines and valves to the brewer

must be open.

(A1) Check the terminal block for

120voltsacacrosstheredandwhite

terminals and the black and white

terminal on three wire 102/208 volt

or 120/240 volt models.

2. No power or incorrect voltage to

the brewer

(A2)Checktheterminalblockfor208

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)Checktheterminalblockfor208

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.

10060 031500

Page 8

TROUBLESHOOTING (cont.)

PROBLEM

REMEDY

PROBABLE CAUSE

Brew cycle will not start (cont)

(A4) Check the terminal block for

440 volts ac across the black and

blue terminals, black and red termi-

nals and the red and blue terminals

on four wire three phase 440 volt

models.

2. No power or incorrect voltage to

the brewer (cont)

(B) Check circuit breakers or

fuses.

Be sure water shut-off valve is open

and that the in-line ﬁlters or strain-

ers are not blocking water ﬂow. (Do

not confuse water shut-off valve

with the manual ﬁll and drain valve

underneath the brewer).

3. Water level below pump housing.

(Water level in the hot water gauge

glass should be approximately half

full).

RefertoService-ON/OFFSwitchfor

testing. See page 22

4. ON/OFF Switch

5. Start Switch

6. Relay

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

7. Timer

Refer to Service - Pump for testing

procedures. See page 23

8. Pump

Refer to Service - Solenoid Valve for

testing procedures. See page 27

9. Solenoid Valve

10. Strainer

(A) Direction of ﬂow arrow must be

pointing towards brewer.

(B) Remove the strainer and check

for obstructions. Clear or replace.

Brew cycle starts with brew lockout

relay engaged.

Refer to Service - Relay for testing

procedures. See page 24

1. Relay

10060 080900

Page 9

TROUBLESHOOTING (cont.)

PROBLEM

PROBABLE CAUSE

REMEDY

1.ON/OFF Switch (This switch

must be in the "ON" position for

the reﬁll circuit to operate.

Tank not ﬁlling

Refer to Service - ON/OFF Switch

for testing procedures. See page

2. No water

Be sure water shut-off is open and

that in-line ﬁlters or strainers are

not blocking water ﬂow. (Do not

confuse water shut-off valve with

the manual ﬁll and drain valve

underneath brewer).

3. Solenoid Valve

Refer to Service - Solenoid Valve

for testing procedures. See page

4. Probe

RefertoService-Probefortesting

procedures. See page 20

5. Liquid Level Board

Refer to Service - Liquid Level

Board for testing procedures. See

page 20

1.Brewer not level

2. Solenoid Valve

Water running out of the over-

ﬂow

Brewer must be level and installed

on a sturdy structure.

Refer to Service - Solenoid Valve

for testing procedures. See page

3. Liquid Level Board

4. Probe

Refer to Service -Liquid Level

Board for testing procedures. See

page 20

RefertoService-Probe fortesting

procedures. See page 20

5. Manual ﬁll and drain valve un-

derneath brewer open.

Be sure valve is closed.

10060 080900

Page 10

TROUBLESHOOTING (cont.)

PROBLEM

PROBABLE CAUSE

REMEDY

Water not hot

1. Limit Thermostat

Refer to Service - Limit Thermo-

stat for testing procedures. See

page19

CAUTION - Do not eliminate or

bypass limit thermostat. Use only

Bunn-O-Matic replacement part

#29329.1000

2. Control Thermostat

Refer to Service - Control Ther-

mostat for testing procedures.

See page 17

3. Tank Heater(s)

4. Contactor

Refer to Service - Tank Heater for

testing procedures. See page 30

Refer to Service - Contactor for

testing procedures. See page 15

Circuit breaker keeps tripping

1. Circuit Breaker

Refer to Service - Circuit Breaker

for testing procedures. See page

2. Tank Heater(s)

1. Timer

Refer to Service - Tank Heater for

testing procedures. See page 30

Water keeps running from swing

spout

RefertoService-Timerfortesting

procedures. See page 31 or 33

2. Start Switch

1. Timer

Refer to Service - Start Switch for

testing procedures. See page 29

Inconsistent coffee yield

RefertoService-Timerfortesting

procedures. See page 31 or 33

2. Solenoid Valve

Refer to Service - Solenoid Valve

for testing procedures. See page

3. Lime build-up in swing spout

and pump tubing.

Remove swing spout and insert

deliming rod down into pump

tubing as far as possible.

Use Bunn^®ﬁlters made for the

U3 brewer.

Funnels overﬂow

1. Filters

2. Hole in bottom of funnel ob-

structed.

Remove obstruction.

10060 080900

Page 11

TROUBLESHOOTING (cont.)

PROBLEM

PROBABLE CAUSE

REMEDY

Checkpumpﬂowratewithawatch.

Pumpﬂowrateshouldbeapproxi-

mately 24 ounces in 15 seconds.

Be sure pump assembly is free of

any obstructions.

3. Pump - Flow Rate

Funnels overﬂow (cont.)

4. Soft Water

When using a water softener, a

coarse grind of coffee may be

preferred. If required, a bypass

system is available as an optional

feature.

Coffee reservoir overﬂows

Be sure coffee reservoir is empty

before brew cycle is started.

1. Coffee reservoir not completely

empty befor a brew cycle was

started.

RefertoService-Timer for testing

procedures. See page 31 or 33

2. Timer

Checkpumpﬂowratewithawatch.

Pumpﬂowrateshouldbeapproxi-

mately 24 ounces in 15 seconds.

Be sure pump assembly is free of

any obstructions.

3. Pump - Flow Rate

Brewer is making unusal noises

The nut on the solenoid must

be tight or it will vibrate during

operation.

1. Solenoid Valve

Plumbinglinesshouldnotberest-

ing on the counter top.

2. Plumbing lines

3. Water supply

(A)Thebrewermustbeconnected

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 approxi-

mately 50 psi (345 kPa).

Removeandcleanlimeoffthetank

heater. See page 30

4. Tank Heater(s)

10060 080900

Page 12

SERVICE

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

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

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 qualiﬁed

service personnel. The brewer should be unplugged

when servicing, except when electrical tests are re-

quired and the test procedure speciﬁcally states to

plug in the brewer.

COMPONENT ACCESS

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 ﬁtting. 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.

P1317.30

FIG. 1 COMPONENT ACCESS

10060 011708

Page 13

SERVICE (cont.)

CIRCUIT BREAKER (120/208V and 120/240V Three

Wire Models and 440V Four Wire Models)

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.

Ifcontinuityisnotpresentasdescribed,pressthereset

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.

P2209.60

FIG. 2 CIRCUIT BREAKER

5. Refer to Fig. 3 and reconnect the wires.

Location:

The circuit breaker is located on the right rear of

the component bracket.

BLK from Main

Harness

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

pumpassembly.Withavoltmeter,checkthevoltage

across the black wire and the white wire. Connect

the brewer to the power source. The indication

must be:

BLK from ON/

OFF Switch

P1723

FIG. 3 CIRCUIT BREAKER TERMINALS

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 volt-

age is not present as described, refer to the Wiring

Diagrams and check the brewer wiring harness.

10060 080900

Page 14

SERVICE (cont.)

CONTACTOR

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.

IfvoltageisnotpresentasdescribedrefertotheWiring

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.

P2209.60

FIG. 4 CONTACTOR

Location:

The contactor is located on the left front of the

component bracket

If continuity is present as described, reconnect the

wires and proceed to #7.

If continuity is not present as described, replace the

contactor.

Test Procedures:

1. Disconnect the brewer from the power source.

2A. 120/208V,120/240V,380VTHREEWIREMODELS,

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.

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.

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

# U300004095), 208V and 240V THREE WIRE

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.

Disconnect the black wire from the contactor coil

to the limit thermostat and black wire from the red

wire on the main harness.

8. Disconnect the brewer from the power source.

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 the main harness.The indication must

be:

If voltage is present as described, proceed to #9.

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

10060 080900

Page 15

SERVICE (cont.)

CONTACTOR (cont.)

Removal and Replacement:

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.

1. Disconnect all the wires from the contactor.

2. Remove the two #8-32 screws securing the con-

tactor to the contactor mounting bracket, remove

contactor and protective shield. Discard contac-

tor.

3. Installnewcontactorwithshieldbetweenmounting

bracket and contactor and secure with two #8-32

screws

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.

4. Refer to Fig. 5 and reconnect the wires.

If continuity is present as described, the contactor is

operating properly.

If continuity is not present as described, replace the

contactor.

BLK to Right Tank

Heater (T1)

BLK to Terminal

Block (L1)

RED to Left Tank

BLK Thermal Fuse

to Right Tank Heater

BLK to Terminal

Block (L1)

RED Thermal Fuse

to Left Tank Heater

Heater (T2)

RED to Terminal

Block(L2)

BLK to Terminal

Block (L2)

BLK to left

Tank Heater

(L1)

RED to Terminal

Block (L2)

BLK Thermal

Fuse to Left

Tank Heater

RED to Right

Tank Heater

(L2)

WHI from Main Harness

RED to Limit

Thermostat

(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)

BLK to Limit

Thermostat

RED Thermal Fuse

to Right Tank

Heater

230V - CE Models

120/208V, 120/240V, 208V,

240V, 380V 440V MODELS

P1725

FIG.5 CONTACTOR TERMINALS

10060 080900

Page 16

SERVICE (cont.)

CONTROL THERMOSTAT

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 ﬁrmly

pulling up on the capillary at the component

bracket. This will disengage the grommet from

the component bracket.

P2209.60

FIG. 6 CONTROL THERMOSTAT

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

thermostatandmountingbrackettothecomponent

bracket. Remove control thermostat and bracket

as an assembly.

Location:

The control thermostat is mounted on the right

front of the component bracket.

4. Remove knob from control thermostat.

5. Removethetwo#6-32screwssecuringthecontrol

thermostat to the thermostat mounting bracket.

Remove and discard thermostat.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Locate the thermostat and the voltage check

points.

6. Install new control thermostat on thermostat

mounting bracket and secure with two #6-32

screw.

3. Connect the brewer to the power source.

Model

120/208V & 120

240V - 3 wire w/

ground single phase

Check Voltage Across

Voltage

Black wire on thermostat 120V

frommainharnesstowhite

wire in terminal block.

7. Install knob on thermostat.

8. Install thermostat and mounting bracket on the

component bracket and secure with one #8-32

screw.

Red wire on thermostat 230V

frommainharnesstoblack

wire in terminal block.

230V - 2 wire w/

ground single

phase

9. Carefully bend the capillary tube so that the tube

and bulb inside the brewer are in the vertical posi-

tion.

NOTE:Thecapillarytubemustbeclearofanyelectrical

termination and not kinked.

Black wire on thermostat 208V or

from main harness to red 240V

wire in the terminal block.

208V or 240V - 2

wire w/ground

single phase

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

11. Adjust the control thermostat as required.

Black wire on thermostat 220V or

frommainharnesstowhite 254V

wire in terminal block.

280V or 440V - 4

wire w/ground 3

phase

BLK from Main Har-

ness (All Models Ex-

cept 230V CE Models

RED from Main

Harness (230V CE

Models)

Black wire on thermostat 120V

frommainharnesstowhite

wire on step down trans-

former.

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.

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

BLK to Limit Thermostat

(All Models Except 230V CE

Models

RED to Limit Thermostat

(230V CE Models)

P1730.80

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(fullyclockwise),continuitymust

FIG. 7 CONTROL THERMOSTAT TERMINALS

10060 080900

Page 17

SERVICE (cont.)

Removal and Replacement:

Fuse:

1. Remove the cap from the fuse holder.

2. Removefusefromthefuseholder,inspect,ifblown

discard.

FUSE AND FUSE HOLDER (208V, 240V, 230V Two

Wire Models and 380V Three Wire Models)

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. Pushfuseholderthroughtheholeinthecomponent

bracket.

4. Install new fuse holder and fuse through the hole

in the component bracket and secure with nut.

5. Refer to Fig. 9 and reconnect the wires.

P1731.55

BLK from ON/OFF Switch

(208V, 240V Two Wire

Models and 380V Three

Wire Models)

FIG.8 FUSE AND FUSE HILDER

Location:

The fuse and fuse holder are located on the right

rear of the component bracket.

RED from ON/OFF Switch

(230V Two Wire Models)

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.

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)

4. Check for continuity through the fuse.

Ifcontinuityispresentasdescribed, reinstallthefuse,

the fuse is operating properly.

If continuity is not present as described replace the

fuse.

P1331

FIG. 9 FUSE HOLDER TERMINALS

10060 031599

Page 18

SERVICE (cont.)

LIMIT THERMOSTAT

Removal and Replacement:

1. Remove the wires from the limit thermostat ter-

minals.

2. Carefully slide the limit thermostat out from under

the retaining clip and remove the limit thermo-

stat.

3. Carefully slide the new limit thermostat into the

retaining clip.

4. Refer to Fig. 11 and reconnect the wires.

P2209.60

FIG. 10 LIMIT THERMOSTAT

Location:

The limit thermostat is located on the center front

of the component bracket behind the timer mounting

bracket.

BLK to Contactor

(All Models Except

230V CE Models)

Red to Contactor

BLK to Control

Thermostat(All

Models Except

230V CE Models)

RED to Control

Thermostat

(230V Models)

Test Procedures:

(230V CE Models)

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.

P1800

FIG. 11 LIMIT THERMOSTAT TERMINALS

Ifcontinuityispresentasdescribed,thelimitthermostat

is operating properly.

If continuity is not present as described, replace the

limit thermostat.

10060 080900

Page 19

SERVICE (cont.)

LIQUID LEVEL BOARD AND LEVEL PROBE

7. Touchingthefreeendofthejumpertothebrewer's

frame simulates a "FULL" condition, preventing

jumperfromtouchingthebrewer'sframesimulates

"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 ﬁve second

delay for output to stabilize.

Voltage -

Jumper

Touching

Frame

Voltage -

Jumper

Not Touching

Frame

Model

P2209.60

FIG.12 LIQUID LEVEL BOARD AND

LEVEL PROBE

120V

230V

120/208V &

120/240V - 3

wire w/ground

single phase

Location:

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.

230V - 2 wire

w/ground

single phase

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:

208V or

240V

208V or 240V -

2 wire wground

single phase

220V or

254V

280V or 440V -

4 wire w/ground

3 phase

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.

120V

380V - 3 wire

w/ground 3

phase w/

stepdown trans-

former

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.

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.

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.

10060 080900

Page 20

SERVICE (cont.)

14. Disconnect the brewer from the power source.

LIQUID LEVEL BOARD AND LEVEL PROBE (cont.)

9. Reconnect the pink wire to terminal 4.

10. Remove the two #8-32 screws securing the level

probe to the component bracket.

11. Gentlypulltheprobeoutofthecomponentbracket

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.

If voltage is present as described, reinstall the level

probe, the liquid level board and level probe are op-

erating properly.

If voltage is not present as described, check the

pink wire on the level probe from liquid level board

terminal 4.

13. Connect the brewer to the power source. Check

the voltage across terminals 1 and 3, refer to

chart below. There is an approximate delay of ﬁve

seconds for output to stabilize.

Removal and Replacement:

1. Remove all wires from the liquid level board.

2. Removethe#10-32screwandﬂatwashersecuring

the protective shield to the component bracket.

3. Remove the #10-32 screw and internal tooth

lockwasher securing the liquid level board to the

component bracket.

4. Remove liquid level board and discard.

5. Installnewliquidlevelboardoncomponentbracket

and secure with a #10-32 screw and internal tooth

lockwasher.

Voltage -

Jumper

Touching

Frame

Voltage -

Jumper

Not Touching

Frame

Model

120V

230V

120/208V &

120/240V - 3

wire w/ground

single phase

6. Install protective shield and secure with #10-32

screw and ﬂat washer.

7. Refer to Fig. 13 and reconnect the wires.

230V - 2 wire

w/ground

T1 BLU to Solenoid Valve

single phase

T2 BLK to ON/OFF Switch (All models

except 230V-CE models)

208V or

240V

208V or 240V -

2 wire wground

single phase

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)

220V or

254V

280V or 440V -

4 wire w/ground

3 phase

120V

380V - 3 wire

w/ground 3

phase w/

stepdown trans-

former

T4 PIN to Level Probe

P1733

FIG.13 LIQUID LEVEL BOARD TERMINALS

10060 080900

Page 21

SERVICE (cont.)

ON/OFF SWITCH

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.

P2209.60

FIG.14 ON/OFF SWITCH

Location:

The ON/OFF switch is located on the left side of the

switchmountingbracket.Theswitchmountingbracket

is mounted on the front of the component bracket.

If continuity is present as described, the switch is

operating properly.

If continuity is not present as described, replace the

switch.

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.

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.

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.

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.

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

ON/OFF switch from the fuse holder and the black

wire on the power indicator light.

4. Refer to Fig. 15 and reconnect the wires.

BLK from Main Harness

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.

BLK to Start Switch, Brew

Timer & Liuqid Level Board

c)240voltsacfortwowire240voltmodelspriorto

#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.

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

MODELS

BLK from Main Harness

RED to Main Harness

4. Disconnect the brewer from the power source.

RED to Start Switch, Brew

Timer & Liquid Level Board

If voltage is present as described, reconnect the wires

and proceed to #5

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

230V - CE Models

P1735

FIG. 15 ON/OFF SWITCH TERMINALS

10060 080900

Page 22

SERVICE (cont.)

PUMP ASSEMBLY

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 ﬁll tube (1) and slide the clamp (3) up

the ﬁll tube (1).

3. Disengagetheﬁlltube(1)fromthepumpassembly

(4).

4. Remove the four #8-32 screws (6) securing the

pump assembly (4) to the component bracket

(7).

5. Remove pump assembly (4).

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

necessary.

P2209.60

FIG.16 PUMP ASSEMBLY

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

8. Install new pump assembly (4) on component

bracket (7) and secure with four #8-32 screws

(6).

Location:

The pump is located on the center rear of the

component bracket.

9. Install ﬁll tube (1) on pump assembly (4).

10. Slide clamp (3) down into position on the ﬁll tube

(1) and tighten screw (2).

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.

11. Refer to Fig. 17 and reconnect the wires.

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)120voltsacforthreewire120/208volt,120/240

volt and 380 volt models).

WHI from Brew Timer

BLK from Brew Timer

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

models.

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

models.

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

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

to the pump. Install swing spout and position over the

reservoir.PlacetheON/OFFinthe"ON"(upper)position

and push the start switch and release. If pump does

not run, replace the pump.

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

P1737

FIG.17 PUMP INSTALLATION

10060 080900

Page 23

SERVICE (cont.)

RELAY (BREWERS W/BREW LOCKOUT)

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.Connectthebrewertothepowersource.

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 across relay terminals "A" &

"B"

P1731.55

FIG.18 RELAY

Location:

The relay is located on the front part of the com-

ponent bracket, mounted on the top of the timer

bracket.

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.

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".

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, reconnect the

wires to terminals "A" & "B" and proceed to #3.

If continuity is not present as described replace the

relay.

If continuity is present as described, proceed to #7

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.

7. Turn the thermostat to the "OFF" position, con-

nect 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 present as described, reconnect the

wires to terminals 2 & 7 and proceed to # 5.

If continuity is not present as described, replace the

relay.

If continuity is not present as described, the relay is

operating properly.

If continuity is 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.

10060 080900

Page 24

SERVICE (cont.)

RELAY (BREWERS W/BREW LOCKOUT)

BLU from

Start Switch

BLU from

Brew Timer

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

#6-32screwsecuringtherelaytotherelaymount-

ing bracket. For 230V models #U300004095 and

up, remove the two screws securing the relay to

the relay mounting bracket.

BLK to Control

Thermostat

RED from

Main Harness

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

MODELS PRIOR TO #U300004095

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

andup,installnewrelayonrelaymountingbracket

and secure with two #6-32 screws.

BLU to Start

Switch

BLU from

Brew Timer

5. Refer to Fig. 19 and reconnect the wires.

RED to Control

Thermostat

BLK from

Main Harness

230V MODELS #U300004095 AND UP

P1739

FIG.19 RELAY TERMINALS

10060 080900

Page 25

SERVICE (cont.)

SELECTOR SWITCH (HALF BATCH OPTION)

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. 21 and reconnect the wires.

P1317.30

FIG. 20 SELECTOR SWITCH (HALF BATCH)

Location:

GRY to Brew Timer

PNK to Brew Timer

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) posi-

tion. Continuity must not present when the switch

is in the "OPEN" (right - full) position.

P1740

FIG. 21 SELECTOR SWITCH TERMINALS

If continuity is present as described, the switch is

operating properly.

If continuity is not present as described, replace the

switch.

10060 080900

Page 26

SERVICE (cont.)

SOLENOID

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,checkthevoltageacrosstheredwireand

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.

Ifvoltageisnotpresentasdescribed,refertothebrewer

Wiring Diagrams and check the wiring harness.

P2209.60

FIG. 22 SOLENOID

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.

Location:

The solenoid is mounted on the upper left rear of

the component bracket.

Test Procedures:

1. Disconnect the dispenser from the power

source.

If continuity is present as described, reconnect the

wires to the solenoid.

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

onthesolenoid.Withavoltmeter,checkthevoltage

across the black and the white wire. Connect the

brewer to the power source. The indication must

be:

If continuity is not present as described, replace the

solenoid valve.

6. Check the solenoid valve for coil action. Connect

thedispensertothepowersource. Listencarefully

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 block-

age in the water line before the solenoid valve or, the

solenoid valve may require inspection for wear, and

removal of waterborne particles.

If the sound is not heard as described, replace the

solenoid valve.

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

avoltmeter, checkthe voltageacrosstheblackand

redwires.Connectthebrewertothepowersource.

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.

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 ﬂat 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.

10060 080900

Page 27

SERVICE (cont.)

SOLENOID

WHI from Main Harness

(120/208V,120/240V,380V

and 440V Models)

BLU from Liquid Level

Board #1

6. Remove the tank inlet tube grommet and dis-

card.

RED from Main Harness

(208V and 240V Models)

7. Install new tank inlet tube grommet.

8. Install new solenoid assembly.

9. Installliquidlevelboard,shieldandsecuresolenoid

assembly and shield to the component bracket

with a #10-32 screw and ﬂat washer..

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

noid.

EARLY MODELS

11. Turn on the water supply to the brewer.

12. Refer to Fig. 23 and reconnect the wires.

BLU from Liquid

Level Board #1

BLK from Main Har-

ness

EARLY 230V - CE MODELS

LATE MODELS

WHI from Main Harness

(120/208V,120/240V,380V

and 440V Models)

BLU from Liquid Level

Board #1

RED from Main Harness

(208V and 240V Models)

P1741

FIG. 23 SOLENOID TERMINALS

10060 081106

Page 28

SERVICE (cont.)

START SWITCH (BREW)

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. 25 and reconnect the wires.

BLU to Brew Timer or

Brew Lockout Relay

P1317.30

FIG. 24 START SWITCH (BREW)

Location:

The brew start switch is located on the upper right

side of the brewer component housing.

BLK from ON/OFF Switch

Test Procedures:

ALL MODELS EXCEPT 230V - CE MODELS

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.

BLU to Brew Timer or

Brew Lockout Relay

RED from ON/OFF

Switch

230V - CE MODELS

P1743

If continuity is present as described, reconnect the

wires the switch is operating properly.

FIG.25 BREW START SWITCH TERMINALS

If continuity is not present as described, replace the

switch.

10060 031599

Page 29

SERVICE (cont.)

TANK HEATERS

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnect the wires from the tank heater.

3. Check for continuity across the tank heater termi-

nals.

If continuity is present as described, proceed to #4.

If continuity is not present as described, replace the

tank heater.

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. Positionnewtankheaterandgasketonthecompo-

nent bracket and secure with four #8-32 screws.

5. Refer to Fig. 27 and reconnect the wires.

P2209.60

FIG. 26 TANK HEATER

Location:

The tank heaters are located on the right center

and the left center of the component bracket.

RED to Contactor T2 (All

Models Except 230V-CE

Models)

BLK to Contactor T1 (All

Models Except 230V-CE

Models)

RED (Thermal Fuse) to Con-

tactor Top Right Terminal)

(230V-CE Models)

BLK (Thermal Fuse) to

ContactorTopLeftTermi-

nal) (230V-CE Models)

BLK to Contactor L1

(120/208V,120/240Three

Wire Single Phase, 208V

and 240V Two Wire,

Single Phase)

RED to Contactor L2

(120/208V, 120/240 Three

Wire Single Phase, 208V

and240VTwoWire,Single

Phase)

BLU to Main Harness

(208V, 240V, 380V Three

Wire ,Three Phase and

380V,440V Four Wire,

Three 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-CEMod-

els)

RED (Thermal Fuse) to

Contactor Lower Right

Terminal)

RIGHT

LEFT

P1746

FIG. 27 TANK HEATER TERMINALS

10060 031599

Page 30

SERVICE (cont.)

TIMER (Early Models)

THERMAL FUSES (230V-CE MODELS ONLY)

OLD STYLE

FIG. 29 TIMER

P1722.55

P1750.65

FIG. 28 THERMAL FUSES

Location:

The timer is located on the front center of the

component bracket.

The thermal fuses are mounted on the tank heater

terminals and the contactor terminals.

Test Procedures:

1. Disconnect the brewer from the power source.

2. Disconnectthepolarized,threepinconnectorfrom

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:

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.

a)120voltsacforthreewire120/208volt,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.

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.

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.

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

10060 080900

Page 31

SERVICE (cont.)

Removal and Replacement:

1. Separateallconnectorsbetweenthebrewerwiring

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. InstallnewtimercircuitboardasdescribedinLate

Model Timer section on the following pages.

5. Refer to Fig. 33 to reconnect the wires.

6. Install the Timer Setting Decal, provided with the

timer replacement kit, on the back of the front

access panel.

TIMER (Early Models)(cont.)

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)120voltsacforthreewire120/208volt,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.

7. Adjust the timer as required. Refer to Late Model

Timer section on the following pages.

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.

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

Three Pin Connector from

Half/Full Batch Switch

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

pressedtothestartpositionandreleased.Connect

the brewer to the power source. The indication

must be:

To Three Pin Female

Connector on Main

Harness

a)120voltsacforthreewire120/208volt,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.

BLK to Pump

Lead

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

models.

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

WHI to Pump Lead

OLD STYLE

P1751

FIG. 31 TIMER TERMINALS

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.

10060 080900

Page 32

SERVICE (cont.)

6. Withavoltmeter,checkthevoltageacrossterminals

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.

DIGITAL TIMER (Late Models)

If voltage is as described, proceed to #7.

If voltage is not as described, disconnect the brewer

from the power source and replace the timer.

7. 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)120voltsacforthreewire120/208volt,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.

P2209.60

FIG. 32 DIGITAL TIMER

Location:

The timer is located on the front center of the

component bracket.

Test Procedure.

If voltage is present as described, the brew timer is

operating properly. Reset the timer as required, to

obtain the desired brew volume.

If voltage is not present as described, disconnect the

brewer from the power source and replace the timer.

NOTE:Donotremoveorinstallwireswhiletimerboard

is installed. Pressure applied to one side may cause

damage to the board.

1. Disconnect the brewer from the power source.

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

board to the mounting bracket.

Removal and Replacement:

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

4. Withavoltmeter,checkthevoltageacrossterminals

TL1 and TL2 when the "ON/OFF" switch is in the

"ON" position. Connect the brewer to the power

source. The indication must be:

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

prior to installation to the component mounting

bracket. Refer to FIG. 33 when reconnecting the

wires.

5. Installnewcircuitboardwithspacers(asrequired)

to the component mounting bracket.

a)120voltsacforthreewire120/208volt,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.

6. Adjust the timer as described below.

Timer Setting:

5. Disconnect the brewer from the power source.

NOTE: Prior to setting or modifying volumes, check

that the brewer is connected to water supply, the

tank is properly ﬁlled, and a funnel and server are in

place.

If voltage is present as described, proceed to #6.

Ifvoltageisnotpresentasdescribed,refertotheWiring

Diagrams and check the brewer wiring harness.

10060 080900

Page 33

SERVICE (cont.)

DIGITAL TIMER (Late Models)

NOTE: The brewer remembers this volume and will

continue to brew batches of this size until the volume

setting procedure is repeated.

NOTE: All volume settings must be done with the

sprayhead installed.

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.

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

ume, ﬁrst check that the SET/LOCK switch is in the

“SET” position on the circuit board.

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 ﬁnish

in order to verify that the desired volume has been

achieved.

3. Setting programming disable feature. If it be-

comes necessary to prevent anyone from changing

brew time once programmed, you can set the SET/

LOCK switch to the “LOCK” position. This will prevent

any further programming until switch is once again

put into the “SET” position.

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 ﬁnish in order to verify that

the desired volume has been achieved.

2. Setting brew volumes. To set a brew volume,

ﬁrst 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.)

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

View the level of the liquid being dispensed. When

the desired level is reached, turn the ON/OFF switch

to “OFF”.

P2037

FIG. 33 DIGITAL TIMER TERMINALS

10060 080900

Page 34

SERVICE (cont.)

TRANSFORMER (380V THREE WIRE MODELS ONLY)

If voltage is present as described, the transformer is

operating properly

If voiltage 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 trans-

form to the transformer mounting bracket.

3. Remove the transformer and discard.

4. Positionnewtransformerontransformermounting

bracket and secure with two #8-32 screws.

5. Refer to Fig. 35 and reconnect the wires.

P1752.55

FIG. 34 TRANSFORMER

RED from

Terminal Block

WHI from Main

Harness

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.

BLK from

Terminal Block

Main Harness

5. Reconnect the black wire and the red to the trans-

former.

6. Disconnect the black wire and the white wire from

the transformer terminals.

P1753

FIG. 35 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.

10060 031599

Page 35

SERVICE (cont.)

MASTER ON/OFF SWITCH (Late Models)

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 se-

cure with screws removed in step 2.

4. Refer to FIG. 37 when reconnecting the wires.

Incoming Power Supply

L1 - BLK

P1752.55

L2 - RED

FIG. 36 MASTER ON/OFF SWITCH LOC.

Location:

Main Wiring harness

BLK

The Master ON/OFF switch is located in the top hous-

ing at the rear, FIG. 36.

RED

Test Procedure:

1. Disconnect the brewer from the power source

and remove the wires from all terminals of the

Master ON/OFF switch.

P3955

FIG. 37 MASTER ON/OFF SWITCH WIRING

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.

10060 011708

Page 36

MAIN ON/OFF SWITCH

(Late Models only)

BLK

RED

120/208 VOLTS AC

120/240 VOLTS AC

3 WIRE + GND

SINGLE PHASE

1990 BUNN-O-MATIC CORPORATION

10060 011708

Page 37

10060 080900

Page 38

SCHEMATIC WIRING DIAGRAM U3A & U38A

(BREWERS PRIOR TO U300004095)

10060 080900

Page 39

SCHEMATIC WIRING DIAGRAM U3A - CE

(BREWERS S/N U300004095 - UP)

10060 080900

Page 40

SCHEMATIC WIRING DIAGRAM U3833

10060 080900

Page 41

SCHEMATIC WIRING DIGRAM U3833

10060 080900

Page 42

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