®
BUNN
HC-2
HC-3
(SERIAL # HC00025000 - UP)
OPERATING & SERVICE MANUAL
BUNN-O-MATICCORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
27591.0000 6/00 ©1996 Bunn-O-Matic Corporation
USER NOTICES
Carefully read and follow all notices on the equipment and in this manual. They were written for your protection.
All notices are to be kept in good condition. Replace any unreadable or damaged labels.
26525.0000
00656.0000
00831.0000
12368.0002
11646.0000
27620.0000
27591 061500
3
INITIAL SET-UP
1. Locate the drip tray assembly beneath the dispenser nested in the packing material.
2. Remove the drip tray and the drip tray cover and set them aside.
3. Remove the water strainer assembly from the drip tray and set it aside.
4. Remove the four legs from the drip tray, apply non-skid pads to the bottom of the legs and securely install
the legs in the dispenser base.
ELECTRICAL REQUIREMENTS
CAUTION - The dispenser must be disconnected from the power source until specified in Initial Set-Up.
The 120 volt version of this dispenser has an attached cordset. The mating connector must be a NEMA 5-15R.
L2 RED
WHITE
L2 WHITE
120V A.C.
WHITE
208 or
NEUTRAL
L1BLACK
120V. A.C.
240V a.c.
240V A.C.
L1 BLACK
120V A.C.
L1BLACK
P2185
P2185
P1841
“A” models require 2-wire,
grounded service rated 240
volts ac, 20 amp, single
phase, 50 Hz
Requires 2-wire grounded ser-
vice rated 120 volts ac, 15 amp,
single phase, 60 Hz
Requires 3-wire, grounded service
rated 120/208 volts or 120/240 volts
ac, 20 amp, single phase, 60 HZ
ELECTRICAL HOOK-UP
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. Open the front door of the dispenser and place the heater switch in the “OFF” (upper position).
4. Remove the right side panel of the dispenser.
120 volt versions proceed to step 6.
120/240 volt and 240 volt versions proceed to next step.
5. Install the electrical wiring to the terminal block as illustrated above.
6. Connect the dispenser to the power source and verify the voltage at the terminal block. Reinstall the side
panel.
7. If plumbing is to be hooked-up later be sure the dispenser is disconnected from the power source. If
plumbing has been hooked-up, the dispenser is ready for Initial Fill & Heat.
PLUMBING REQUIREMENTS
This dispenser must be connected to a COLD WATER system with operating pressure between 20 and 90 psi (138
and 620 kPa) from a 1⁄2" or larger supply line. A shut-off valve should be installed in the line before the dispenser.
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 1⁄4" flare.
NOTE - Bunn-O-Matic recommends 1⁄4" copper tubing for installations of less than 25 feet and 3⁄8" for more than
25 feet from the 1⁄2" water supply line. At least 18 inches of an FDA approved flexible beverage tubing, such as
reinforced braided polyethylene or silicone, before the dispenser will facilitate movement to clean the countertop.
It can be purchased direct from Bunn-O-Matic (part number 00326-0000). Bunn-O-Matic does not recommend
the use of a saddle valve to install the dispenser. The size and shape of the hole made in the supply line by this type
of device may restrict water flow.
This equipment must be installed to comply with the Basic Plumbing Code of the Building
Officials and Code Administrators International, Inc. (BOCA) and the Food Service Sanita-
tion Manual of the Food and Drug Administration (FDA).
27591 061500
4
PLUMBING HOOK-UP
1. Securely attach the short piece of tubing on the water strainer assembly to the inlet fitting on the bottom of
the dispenser.
2. Flush the water line and securely attach it to the flare fitting on the water strainer assembly.
3. Turn-on the water supply.
INITIAL fill & heat
CAUTION - The dispenser must be disconnected from the power source throughout the initial set-up, except
when specified in the instructions.
1. Turn-on the water supply and connect the dispenser to the power source.
2. Water will automatically flow into the tank to the proper level and then shut-off. This will take less than five
minutes.
3. When the tank is full of water, open the front door and place the heater switch in the “ON” (lower) position.
A tank full of cold water will take approximately forty minutes for the water to heat on 120 volt versions, and
twenty minutes on 120/240 and 240 volt versions.
During this waiting period, complete these dispenser set-up steps:
a. Place the drip tray in front of the dispenser. Set the drip tray cover in place.
b. Place a set of keyholes in the cup locator plate over the screws beneath the hopper access door and push
down gently.
c. Fill the hopper(s) with the dry product to be dispensed.
DISPENSER USE
1. Simply place a cup on the drip tray beneath the desired dispensing tip.
2. Press the button to froth and dispense the beverage.
3. Release the button when the cup is approximately 2/3 full and allow the mixing chamber to drain.
NOTE - The mixing chamber must drain at the end of each dispense.
COLD BEVERAGE SET-UP (OPTIONAL)
Cold beverages may be dispensed from the left dispense position on the HC-2 & HC-3 models. Simply place
the HOT/COLD switch near the left whipper chamber in the “COLD” (upper) position.
CLEANING
Refer to the decal inside the hopper access door for cleaning recommendations and procedures.
The use of a damp cloth rinsed in any mild, non-abrasive, liquid detergent is recommended for cleaning all
surfaces on Bunn-O-Matic equipment.
ADJUSTMENTS
The hot or cold beverage solenoid(s) is (are) preset to dispense approximately one ounce per second. This
amount can be adjusted:
1. Disconnect the dispenser from the power source.
2. Remove the small right side access panel.
3. Rotate the control at the base of the desired solenoid(s) clockwise to decrease or counterclockwise to
increase the amount of water.
4. For cold beverage adjustment remove the 1-1/2” plug on the lower left side of the dispenser and rotate the
needle valve clockwise to decrease or counterclockwise to increase the amount of cold water.
27591 031597
5
DRAINING THE HOT WATER TANK
CAUTION - The dispenser must be disconnected from the power source throughout these steps.
1. Disconnect the dispenser from the power source.
2. Open front door and place tank heater switch in the “OFF” (upper) position.
3. Shut-off and disconnect the incoming water supply.
4. Remove the top panel.
5. Gently remove one of the grommets from the tank lid.
6. Insert a tube to the bottom of the tank and syphon ALL of the water out.
(Bunn-O-Matic has a syphon assembly #12440.0000 available for this purpose.)
NOTE - The dispenser must be refilled using the INITIAL FILL & HEAT steps before reconnecting to the power
source.
HOPPER DISPENSE RATE OF PRODUCT
1. Hopper dispense rate with 22 tooth gear and auger wire is approximately 4 to 6 grams per second.
2. Hopper dispense rate with 22 tooth gear and auger wire with optional restrictor is approximately 3 to 5
grams per second.
3. Hopper dispense rate with optional 32 tooth gear and auger wire is 6 to 9 grams per second.
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, andrepairofelectricalequipmentshouldbeperformedonlybyqualifiedservicepersonnel.
All electronic components have 120 volt ac or 240 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.
Theuseoftwowrenchesisrecommendedwheneverplumbingfittingsaretightenedorloosened. Thiswillhelp
to avoid twists and kinks in the tubing.
•
•
Make certain that all plumbing connections are sealed and electrical connections tight and isolated.
This unit is heated at all times. Keep away from combustibles.
WARNING – • Exercise extreme caution when servicing electrical equipment.
• Unplug the dispenser when servicing, except when electrical tests are specified.
• Follow recommended service procedures
• Replace all protective shields or safety notices
27591 031597
6
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
1. No water
Water lines and valves to the
dispenser must be open.
Product will not dispense
2. No power or incorrect voltage to (A1) Check the terminal block for
the dispenser
120 volts across the black and
white terminals on two wire 120
volt dispenser.
(A2) Check the terminal block for
120 volts across the red and
white terminal and the black and
white terminal on three wire
120/240 volt dispenser.
(A3) Check the terminal block for
240 volts across the white and
black terminal on two wire 240
volt dispenser.
(B) Check circuit breakers or
fuses.
3. Dispense switch
Refer to Service - Dispense
Switch for testing procedure.
See page 18
4. Dispense solenoid valve
(Hot or Cold)
Refer to Service - Dispense
solenoid valve for testing proce-
dures. See page 30 or 31
5. Solenoid valve (Inlet)
6. Level control board and probe
7. Overflow protection switch
8. Auger drive
Refer to Service - Solenoid Valve
(Inlet) for testing procedures.
See page 32
Refer to Service - Level Control
Board and Probe for testing
procedures. See page 26
Refer to Service - Overflow
protection switch for testing
procedures. See page 28
Refer to Service - Auger Drive.
See page 12
27591 031597
7
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
9. Water strainer
(A) Direction of flow arrow must
be pointing towards dispenser.
Product will not dispense (cont.)
(B) Remove the flow control and
check for obstructions. Clear or
replace.
10. Lime build-up
Inspect the tank assembly for
CAUTION - Tank and tank compo- excessive lime deposits. Delime as
nents should be delimed regularly
depending on local water condi-
tions. Excessive mineral build-up
on stainless steel surfaces can
initiate corrosive reactions result-
ing in serious leaks.
required.
1. Limit thermostat
Refer to Service - Limit Thermo-
stat for testing procedures. See
page 27
Water is not hot
CAUTION - Do not eliminate or
bypass limit thermostat. Use only
BOM replacement part
#29329.1000
2. Control thermostat (mechanical Refer to Service - Control Thermo-
or electronic)
stat for testing procedures. See
page 16
3. Tank Heater
Refer to Service - Tank Heater for
testing procedures. See page 33
4. Tank heater switch
Refer to Service - Tank Heater
Switch for testing procedures. See
page 34
1. Lime build-up
Inspect tank assembly for exces-
Spitting or excessive steaming
CAUTION - Tank and tank compo- sive lime deposits. Delime as
nents should be delimed regularly
depending on local water condi-
tions. Excessive mineral build-up
on stainless steel surfaces can
initiate corrosive reactions result-
ing in serious leaks.
required.
2. Control thermostat (mechanical Refer to Service - Control Thermo-
or electronic)
stat for testing procedures. See
page 16
27591 061500
8
TROUBLESHOOTING (cont.)
PROBLEM
REMEDY
PROBABLE CAUSE
Inspect the tank assembly for
excessive lime deposits. Delime as
required.
Dripping from dispense tip
1. Lime build-up
CAUTION - Tank and tank compo-
nents should be delimed regularly
depending on local water condi-
tions. Excessive mineral build-up
on stainless steel surfaces can
initiate corrosive reactions result-
ing in serious leaks.
Remove the dispense solenoid
valve and clear any obstructions.
Rebuild or replace the valve if
necessary. See page 30 or 31
2. Dispense solenoid valve
(Hot or Cold)
Refer to Service - Level Control
Board and Probe for testing
procedures. See page 26
Water flows into tank continuously 1. Level control board and probe
2. Solenoid valve (Inlet)
Refer to Service - Solenoid Valve
(Inlet) for testing procedures. See
page 32
Refer to Service - Overflow
Protection Switch for testing
procedures. See page 28
3. Overflow Protection Switch
27591 031597
9
TROUBLESHOOTING (cont.)
PROBLEM
REMEDY
PROBABLE CAUSE
Product overflows container
Refer to Service - Dispense
Switch for testing procedures. See
page 18
1. Dispense switch
Remove the solenoid valve and
clear any obstructions. Rebuild or
replace the valve if necessary. See
page 30 or 31
2. Dispense solenoid valve
(Hot or Cold)
Weak product
Place an empty container beneath
the dispense tip. Initiate a dispense
cycle and check the water tempera-
tureimmediatelybelowthedispense
tip with a thermometer.
1. Water temperature
(A) Reading for mechanical thermo-
statmodelsshouldbe180°Fto200°F
(seethermostattemperaturesettings
decal in USER NOTICES on page 3.
(B) Reading for electronic thermo-
stat should be185°F to 190°F.
Adjust the control thermostat to in-
crease or decrease the water tem-
perature. Replace if necessary.
Referto Service-WhipperMotorfor
testing procedure. See page 20
2. Whipper motor
3. Frother
Refer to Service - Frother Compo-
nents. See page 20
RefertoService-DispenseSolenoid
Valve for test procedures. See page
30 or 31
4. Dispense solenoid valve
(Hot or Cold)
Refer to Service - Auger Drive Com-
ponents. See page 12
5. Auger drive
6. Auger spring
7. Auger motor
Refer to Service - Auger Drive Com-
ponents. See page 12
Refer to Service - Auger Drive Com-
ponents. See page 14
27591 031597
10
TROUBLESHOOTING (CONT.)
PROBLEM
PROBABLE CAUSE
REMEDY
Dispenser is making unusual
noises
1. Plumbing Lines
Plumbing lines should not be rest-
ing on the counter top.
2. Water Supply
(A)Thedispensermustbeconnected
to a cold water line
(B) Water pressure to the dispenser
must not exceed 90 psi (620 kPa).
Install a regulator if necessary to
lower the working pressure to ap-
proximately 50 psi (345 kPa).
3. Tank Heater
1. Fan
Remove and clean lime off the tank
heater. See page 33
Excess dust
Refer to Service - Fan for testing
procedures. See page 19
2. Hopper Delay Board
Refer to Service - Hopper Delay
Board for testing procedures. See
page 22
3. Transformer (240V 2 Wire
Models Only)
Refer to Service - Transformer for
testing procedures. See page 35
Display not lit
1. Lamp
Refer to Service - Lamp, see page
24 for lamp replacement.
2. Lamp Holder
3. Starter - Lamp
4. Ballast
Refer to Service - Lamp Holder for
testing procedures. See page 24
Refer to Service - Starter for
testing procedures. See page 25
Refer to Service - Ballast for
testing procedures. See page 15
27591 061500
11
AUGER DRIVE COMPONENTS
SERVICE
Thissectionprovidesproceduresfortestingand
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 electri-
cal equipment should be performed only by qualified
service personnel. The dispenser should be un-
plugged when servicing, except when electrical tests
are required and the test procedure specifically states
to plug-in the dispenser.
COMPONENT ACCESS
WARNING-Disconnectthedispenser fromthepower
source before the removal of any panel or the replace-
ment of any component.
All components are accessible by opening the
door, removal of the door covers, reflector, dispenser
top covers, left and right side covers.
Refer to the contents listing for component loca-
tion.
Contents
P1199.45
FIG. 1 AUGER DRIVE COMPONENTS
Location
The auger components are located inside
Auger Drive Components......................................12
Auger Motor .........................................................14
Ballast...................................................................15
Control Thermostat...............................................16
Dispense Switch ...................................................18
Fan........................................................................19
Frother ................................................................. 20
Hopper Delay Board..............................................22
Hot/Cold Switch....................................................23
Lamp Holder .........................................................24
Lamp ....................................................................24
Lamp Starter and Socket ......................................25
Level Control Board and Level Probe....................26
Limit Thermostat ..................................................27
Overflow Protection Switch ..................................28
Rinse/Run Switch .................................................29
Solenoid (Cold Drink - Optional)...........................30
Solenoid (Dispense) .............................................31
Solenoid (Inlet) .....................................................32
Tank Heater ..........................................................33
Tank Heater Switch...............................................34
Transformer (240V Models Only) .........................35
Whipper Motor .....................................................20
Wiring Diagrams.......................................... 37 & 38
the bottom part of the hopper except for the auger
drive bracket, washer and locknut, which are located
on the outside bottom rear of the hopper. The auger
motors are located on the rear of the front panel.
Refer to Fig. 2 for disassembly and assembly.
Test Procedures - Auger motors
1. Disconnect the dispenser from the power source.
2. Disconnect the wires from the motor to be tested.
3. Check the voltage across the white/violet wire for
the right motor, white/blue wire for the center
motor or the white/red wire for the left motor and
the white/black wire with a voltmeter. Press and
holdtheappropriateDispenseswitch. Connectthe
dispenser to the power supply. The indication
must be :
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power supply.
27591 031597
12
SERVICE
AUGER DRIVE COMPONENTS (cont.)
4
1
2
3
5
If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the wir-
ing diagrams and check the dispenser wiring harness.
6
11
13
5. With the wires removed from the motor to be
tested. Check for continuity across the two ter-
minals on the bottom of the auger motor.
If continuity is present as described, reconnect the
wires to the terminals on the bottom of the auger
motor, the auger motor is operating properly.
7
8
9
10
12
If continuity is not present as described, replace the
auger motor.
14
Removal, Cleaning and Replacement
21
Hopper & Auger
1. Open the dispenser door and raise the top front
cover.
2. Lift the front edge of hopper assy (21) over the
tab on hopper support plate (20) and slide hop-
per assembly out the front of the dispenser.
3. Remove hopper lid (1) and empty product.
4. Pull off the ejector elbow (14).
5. Remove auger disc assy (2) by pulling agitator
support rod (4) towards agitator disc assy and
lifting agitator disc assy from hopper (10).
6. Remove auger (12) by pulling it out the front of
the hopper (10).
15 16 17 18 19 20
7. Remove auger drive shaft (5) by removing the
retaining clip (6) from auger drive shaft.
8. Slide washer (8) and auger drive shaft bracket
(7) off of the auger drive shaft (5).
9. Slide auger drive shaft (5) from auger drive shaft
bushing (3) and remove from hopper (10).
10. Remove locknut (9) from auger drive shaft bush-
ing (3) and remove auger drive shaft bushing
from hopper (10).
11. Wash components in a mild solution of dish de-
tergent using a bristle brush when needed.
12. Rinse and dry each item thoroughly.
13. Check for damaged or broken components, re-
place any if necessary and reassemble hopper
assy.
P1200.35
FIG. 2 AUGER DRIVE & HOPPER DISASSEMBLY
10. Hopper
11. Spring
12. Auger Wire
1. Hopper Lid
2. Agitator Disc Assy
3. Auger Drive Bracket
4. Agitator Support Rod
5. Auger Drive Shaft
Bushing
6. Retainer Clip
7. Auger Drive Bracket
8. Washer
13. Auger Wire/Restrictor
(Optional)
14. Ejector Elbow
15. Wiring Harness Clamp
16. Auger Motor Bracket
17. Auger Motor
18. Dust Seal
19. Shoulder Screw
20. Hopper Support plate
21. Hopper Assy
27591 111596
9. Locknut
13
5. Remove auger motor mounting bracket (16),
auger motor (17) and dust seal (18) as an as-
sembly.
SERVICE (cont.)
AUGER DRIVE COMPONENTS (cont.)
6. Remove dust seal (18) from auger motor (17).
7. Remove the three #8-32 screws securing the left
auger motor to the auger motor mounting bracket
or the four #8-32 screws securing the center and
right auger motors to the auger motor mounting
bracket.
14. Install hopper assy (21) in the dispenser by slid-
ing hopper assy in the guides on the hopper sup-
port plate (20) until the slot in the bottom rear
the hopper seats against the shoulder screw (19)
in the hopper support plate.
8. Remove auger motor and discard.
9. Using three #8-32 screws on the left auger mo-
tor or four #8-32 screw on the center or right
auger motor install new auger motor (17) on
mounting bracket (16).
10. Install dust seal (18) on auger motor shaft.
11. Using four #8-32 locking screws install auger
motor, dust seal and mounting bracket to the rear
of the front panel.
12. Left auger motor only - Using one #8-32 screw
attach hose routing clamp (15) to the mounting
bracket.
13. Reconnect the wires to the terminals on the bot-
tom of the auger motor.
Auger Drive Motor (Refer to Fig. 2)
1. Disconnect the wires from the auger motor (17)
to be removed.
2. Remove hopper assy (21) and set aside for reas-
sembly.
3. Left side auger motor only - Remove the #8-32
screw securing hose routing clamp (15) and au-
ger motor (17) to the auger motor mounting
bracket (16).
4. Remove the four #8-32 locking screws, located
inside on the rear of the front housing, securing
auger motor mounting bracket (16) and auger
motor (17) to the rear of the front panel.
14. Install hopper assy (21).
15. Refer to the illustration below when reconnect-
ing wires.
CENTER HC-3 ONLY
RIGHT HC-2 & 3
LEFT HC-2 & 3
WHI/BLK to Run/Rinse
Switch
WHI/BLK to Run/Rinse
Switch
WHI/BLU from Hopper
Delay Circuit Board
WHI/BLK to
Run/Rinse
Switch
WHI/RED from Hopper
Delay Circuit Board
WHI/VIO from Hopper
Delay Circuit Board
T1201
FIG. 3 AUGER MOTOR TERMINALS
27591 031597
14
If voltage is not present as described, replace the
ballast.
SERVICE (cont.)
BALLAST
Removal and Replacement
1. Disconnect the wires from the ballast.
2. Remove the two #8-32 keps nuts securing the
ballast to the dispenser base.
3. Remove and discard ballast.
4. Install new ballast over the two weld studs on
the dispenser base and secure with two #8-32
keps nuts.
5. Refer to the illustration below when reconnect-
ing the wires.
BLK to Terminal Block
WHI to Main
Wiring Harness
WHI & BLU to
Door
Interconnect
Harness
120V, 120/208V, & 120/240V Models
P1199.40
WHI to Main
FIG. 4 BALLAST
Wiring Harness
Location
RED & BLU to
Door
Interconnect
Harness
The front door lamp ballast is located on the
front center of the base behind the front panel.
Test Procedure
1. Disconnect the dispenser from the power source.
2. Disconnect the two terminal plug of the door in-
terconnect harness from the connector of the
ballast.
BLK to Terminal Block
240V Models
3. Check the voltage across the white wire and the
blue wire terminal of the ballast with a voltmeter.
Connect the dispenser to power source. The in-
dication must be:
P1202.45
FIG. 5 BALLAST TERMINALS
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt
models or 120/240 volts models.
c) 240 volts ac for two wire 240 volt models.
If voltage is present as described the ballast is oper-
ating properly.
27591 031597
15
SERVICE (cont.)
Test Procedure
Mechanical Thermostat
CONTROL THERMOSTAT
1. Disconnect the dispenser from the power source.
2. Disconnect the black wire of the control thermo-
stat from the black lead from the limit thermo-
stat.
3. Remove bulb from the tank.
4. Check the voltage across black wire on the con-
trol thermostat and the white pole on the termi-
nal block with the tank heater switch in the “ON”
lower position with a voltmeter. Connect the dis-
penser to the power source. The indication must
be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or
120/240 volt models.
MECHANICAL
c) 240 volts ac for two wire 240 volt models.
5. Disconnect the dispenser from the power source.
P1199.45
If voltage is present as described the control thermo-
stat is operating properly. Reinstall bulb into the tank.
If voltage is not present as described, replace the ther-
mostat.
Electronic Thermostat (Optional)
1. Disconnect the dispenser from the power source.
2. Disconnect the black wire of the control thermo-
stat from the black lead from the limit thermostat.
3. Remove temperature probe from the tank
4. Check the voltage across black wire on the control
thermostat and the white pole on the terminal
block with the tank heater switch in the “ON” lower
position with a voltmeter. Connect the dispenser
to the power source. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
ELECTRONIC (OPTIONAL)
P1203.45
FIG. 6 CONTROL THERMOSTAT
c) 240 volts ac for two wire 240 volt models.
5. Disconnect the dispenser from the power source.
Location
Mechanical Thermostat
If voltage is present as described the control thermo-
stat is operating properly.Reinstall teperature probe
into the tank.
The mechanical thermostat is located on the
upper right side of the rear panel inside the dispenser.
If voltage is not present as described, replace the ther-
mostat.
Electronic Thermostat (Optional)
The electronic thermostat is located on the
right front side of the base just behind the front panel.
27591 031597
16
9. Carefully bend the capillary tube so that the tube
and bulb inside the tank are in the vertical posi-
tion and away from any electrical connections.
10. Refer to the illustration below and reconnect the
wires.
NOTE - The capillary tube must be clear of any electri-
cal termination and not kinked.
SERVICE (cont.)
CONTROL THERMOSTAT (cont.)
Removal and Replacement.
Mechanical Thermostat
1. Disconnect the wires from the thermostat.
2. Remove the thermostat capillary bulb by firmly
pulling-up on the capillary at the tank lid. This
will disengage the grommet from the tank lid.
3. Remove the #8-32 screw securing the thermo-
stat to the rear panel.
Electronic Thermostat (Optional)
1. Disconnect the wires from the thermostat.
2. Remove the two #8-32 keps nuts securing the
thermostat to the dispenser base.
3. Remove the temperature probe from the grom-
met in the tank lid.
4. Remove thermostat and discard.
5. Install new thermostat over the studs on the dis-
penser base and secure with two #8-32 keps nuts.
6. Push the temperature probe into the grommet in
the tank lid until the top of the tube is flush with
grommet.
4. Slide the thermostat off of the guide stud on the
rear panel and discard.
5
Slide new thermostat over the guide stud on rear
panel.
6. Secure the thermostat to the rear panel using a
#8-32 screw.
7. Slide the grommet to the line 4.5” above the bulb
on the new capillary tube.
8. Insert the capillary bulb through the hole in the
tank lid and press the grommet firmly and evenly
so that the groove in the grommet fits into the
tank lid.
7. Refer to the illustration below and reconnect the
wires.
BLK to Limit Thermostat
BLK to Limit
Thermostat
BLU to Tank
Heater Switch
TAN to Tank
Heater
Switch
BLK to Terminal
Block
WHI to Terminal
Block
MECHANICAL
ELECTRONIC
P1204
FIG. 7 THERMOSTAT TERMINALS
27591 031597
17
5. Disconnect the dispenser from the power source.
SERVICE (cont.)
DISPENSE SWITCH
If voltage is present as described, proceed to #6.
If voltage is not present as described, refer to the wir-
ing diagram and check the dispenser wiring harness.
6. Check for continuity across the wires removed
from the dispense switch with the switch in the
“ON” pressed position. Continuity must not be
present when the switch is in the “OFF” released
position.
If continuity is present as described, reconnect the
connector to the door interconnect wiring harness, the
switch is operating properly.
If continuity is not present as described, replace the
switch.
Removal and Replacement
1. Open the dispenser door.
2. Remove the six #8-32 screws securing the bot-
tom door cover and remove cover.
3. Disconnect the connector on the dispense switch
to be removed from the door interconnect wiring
harness connector.
P1196.70
FIG.8 DISPENSE SWITCH
4. Remove the mounting nut from the dispense
switch and remove switch from the front side of
the door.
5. Install new switch through the front of the door
and secure with mounting nut.
6. Reconnect the connector on the dispense switch
to the connector on door interconnect wiring har-
ness.
Location:
The dispense switches are located on the lower
outside of the dispenser door.
NOTE: The center dispense switch is for HC-3 Models
only.
Test Procedure:
1. Disconnectthedispenserfromthepowersource.
2. Open the dispenser door and remove the bottom
door cover.
3. Disconnect the connector of the dispense switch
to be tested from the connector on the door
interconnect wiring harness.
7. Reinstall the door bottom cover using six #8-32
screws.
8. Refer to the illustration below when reinstalling
wires.
4. Check for voltage across the black and red/black
wires for the right dispense switch, black and
red/white wires for the center dispense switch or
the black and red wires for the left dispense
switch in the connector of the door interconnect
wiring harness. Connect the dispenser to the
power supply. The indication must be:
a) 120 volts ac for two wire 120 volt models.
b)120voltsacforthreewire120/208voltor120/
240 volt models.
P1205.58
c) 240 volts ac for two wire 240 volt models.
FIG. 9 DISPENSE SWITCH CONNECTORS
27591 031597
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SERVICE (cont.)
Removal and Replacement:
1. Remove hoppers from the dispenser. Refer to Fig.
2 for hopper removal.
FAN
2. Remove the four #8-32 screws securing the hop-
per mounting plate to the front panel and remove
panel.
3. Remove the four screws securing the fan mount-
ing plate to the dispenser front panel.
4. Lift fan mounting plate out of the front panel far
enough so the fan leads can be disconnected from
the main wiring harness.
5. Remove fan mounting plate, fan and exhaust tube
as an assembly.
6. Remove the four #8-32 screws and four #8-32
nuts securing exhaust tube and fan to the bottom
of the fan mounting plate and discard fan.
7. Install new fan and the exhaust tube to the bottom
of the fan mounting plate using four #8-32 screws
and four #8-32 nuts.
NOTE: Be sure arrow on the new fan is pointing down.
8. Set fan mounting plate with fan and exhaust tube
inside the front panel far enough to connect the
black leads from the fan to the black and white
leads on the main wiring harness.
9. Install fan mounting plate into position and secure
with four #8-32 screws.
10. Install hopper mounting plate using four #8-32
screws.
P1199.45
FIG. 10 FAN
Location:
The fan is located inside the front panel, mounted
on a plate beneath the hopper mounting plate.
11. Install hoppers, refer to Fig. 2.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the black and white wires from the
black leads on the fan.
3. Check the voltage across the black and white
wires on the main harness or transformer with a
voltmeter. Connect the dispenser to the power
source. The indication must be:
a) 120 volts ac for two wire 120 volts models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 120 volts ac for two wire 240 volt models.
If voltage is present as described, replace the fan
If voltage is not present as described, refer to wiring
diagram and check the dispenser wiring harness.
27591 031597
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a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
SERVICE (cont.)
FROTHER AND WHIPPER MOTOR
c) 240 volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power source.
If voltage is present as described, replace the motor.
If voltage is not present as described, refer to the wir-
ing diagrams and check the dispenser wiring harness.
1 2
12
11
P1203.45
FIG. 11 FROTHER AND WHIPPER MOTOR
Location:
The frothers are located behind the dispenser
door, mounted on the front of the front panel inside
the whipper chamber.
10 9
8
7 6 5 4 3
P1206
FIG. 12 MIXING/WHIPPER CHAMBER
COMPONENTS
The whipper motors are located on the back
side of the front section of the front panel.
NOTE: The center position is for HC-3 Models only.
1. Steam Collector
7. #6-32 Screw
2. Mixing Chamber
3. Dispense Tip
4. Whipper Chamber
5. O-Ring
8. Receptical w/Seal
9. Teflon Washer
10. O-Ring
11. #8-32 Acorn Nut
12. Motor Assy.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the white/violet and white wires on
the right motor, white/blue and white wires on
the center motor or the white/red and white wires
on the left motor from the black leads on the
motors.
3. Press and hold the appropriate dispense switch
and check the voltage across the disconnected
harness wires with a voltmeter. Connect the dis-
penser to the power source. The reading must
be:
6. Frother
Removal, Cleaning and Replacement (Refer to Fig. 12):
1. Open the dispenser door.
2. Remove the steam collector (1) by pulling it for-
ward and at the same time twisting it clockwise.
3. Pull the mixing chamber (2) out of the whipper
chamber (4).
27591 031597
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whipper chamber (4). Be sure the cutout part of
the dispense tip is facing the outside of the dis-
penser.
SERVICE (cont.)
FROTHER AND WHIPPER MOTOR (cont.)
4. Remove dispense tip (3) and twist the whipper
chamber (4) clockwise and pull it off the whipper
chamber receptacle (8).
5. 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.
23. Slip the mixing chamber (2) onto the mixing
chamber water inlet tube far enough so the mixing
chamber (2) will seat inside the whipper chamber
(4).
24. Install the steam collector (1) onto the mixing
chamber (2) by pushing down and toward the
dispenser while twisting until the flange on the
steam collector lines-up with the slot in the front
panel.
6. Slip the o-ring (5) off the whipper chamber
receptical (8).
7. Remove the two #6-32 screws (7) securing whip-
per chamber receptical (8) to the front panel.
8. Slide the receptical w/seal off of the motor shaft.
9. Slide teflon washer (9) and o-ring (10) off of the
motor shaft.
10. Disconnect the black leads on the motor (12) from
the main wiring harness.
25. Refer to illustration below when reconnecting the
wires.
NOTE: To remove the center motor you also have to
remove the hopper assy., fan and exhaust tube. Refer
to AUGER DRIVE COMPONENTS and FAN.
11. Remove the two #8-32 acorn nuts (11) securing
the motor (12) to the rear of front panel.
12. Remove motor and discard. See NOTE.
13. Install new motor (12) on rear of front panel and
secure with two #8-32 acorn nuts (11) and con-
nect black leads on the motor to the main wiring
harness.
14. Slide o-ring (10) onto the motor shaft to approxi-
mately 1/8” of the front panel.
15. Wash remaining components in a mild solution of
dish detergent using a bristle brush.
16. Rinse thoroughly and allow to dry before reinstall-
ing in the dispenser.
17. Place teflon washer into back opening of whipper
chamberrecepticalandalignonenotchwithbump
in the opening.
18. Slide whipper chamber receptacle w/seal on to the
motorshaftandsecuretothefrontpanelusingtwo
#6-32 screws (7).
FIG.13 WHIPPER MOTOR TERMINALS P1207.50
19. Slipo-ring(5)ontothewhipperchamberreceptical
(8).
20. Pushfrother(6)ontothemotorshaft, makingsure
theflatinthefrother(6)linesupwiththeflatonthe
motor shaft.
21. Install whipper chamber (4) on the whipper cham-
ber receptical (8) by twisting counterclockwise
untilthetabsonthewhipperchamber(4)lockwith
the tabs on the whipper chamber receptical (8). Be
sure dispense port is pointing down.
22. Install dispense tip (3) into the bottom of the
27591 031597
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SERVICE (cont.)
HOPPER DELAY BOARD
If voltage is not present as described, refer to the wir-
ing diagram and check the dispenser wiring harness.
5. Reconnect the white and black wires of the hop-
per delay board harness to the main harness.
6. Check the voltage across the terminals on the
auger motor with a voltmeter. Press and hold the
appropriate dispense switch. Connect the dis-
penser to the power source. After a delay of .7
seconds the indication must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
7. Disconnect the dispenser from the power source.
If voltage is present as described the hopper delay
board is operating properly.
If voltage is not present as described, replace the hop-
per delay board.
Removal and Replacement:
1. Disconnect the eight pin plug from the hopper
delay board.
2. Remove the two #8-32 keps nuts securing the
hopper delay board mounting bracket to the dis-
penser base.
P1199.45
3. Remove hopper delay board mounting bracket
with hopper delay board and shield attached.
4. Remove the two #8-32 screws securing the hop-
per delay board to the mounting bracket and dis-
card the delay board.
5. Install new delay board on the mounting bracket
with shield between the bracket and the delay
board using two #8-32 screws.
6. Install mounting bracket with hopper delay board
and shield over the studs on the dispenser base,
secure with two #8-32 keps nuts.
7. Reconnect the eight pin connector to the hopper
delay board.
FIG. 13 HOPPER DELAY BOARD
Location
The hopper delay board is located on the left
front side of the dispenser base just behind the front
panel.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnectthewhiteandblackwiresofthehopper
delay board harness from the main wiring har-
ness.
3. Checkthevoltageacrossthewhiteandblackwires
of the main wiring harness with a voltmeter. Con-
nect the dispenser to the power source. The indi-
cation must be:
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power source.
If voltage is present as described, proceed to #5.
27591 031597
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4. Disconnect the dispenser from the power source.
SERVICE (cont.)
HOT/COLD SWITCH (Optional)
If voltage is present as described, reconnect the four
pin plugs and proceed to #5.
If voltage is not present as described, refer to the
wiring diagram and check the main wiring harness.
5. Disconnect the wires from the switch termi-
nals.
6. With the switch in the upper “Cold” position check
for continuity between the center terminal and
the bottom terminal. With the switch in the down
“Hot” position check for continuity between the
center terminal and the upper terminal.
If continuity is present as described, the hot/cold
switch is operating properly.
If continuity is not present as described, replace the
switch.
Removal and Replacement:
1. Remove all wires from the switch terminals.
2. Remove the mounting nut on the front of the front
panel.
3. Remove the hot/cold switch from the rear of the
front panel.
4. Push new hot/cold switch through the hole on
the left side of the front panel and secure with
mounting nut.
5. Reconnect the wires to the terminals on rear of
the switch.
6. Refer to the illustration below when reconnect-
ing the wires.
P1199.45
FIG. 14 HOT/COLD SWITCH
Location:
The hot/cold switch is located on the left side
of the front panel.
Test Procedure:
WHI/BRN to Main
Harness
WHI/RED to Main
Harness
WHI/YEL to Cold
Solenoid
1. Disconnect the dispenser from the power source.
2. Disconnect the four pin plug from the hot/cold
switch and the four pin connector on the main
wiring harness.
3. Press the left dispense switch on the door and
check the voltage across the white wire (P4) and
white/redwire(P2)inthefourpinconnectoronthe
main wiring harness with a voltmeter. Connect the
dispenser to the power source. The indication
must be:
P1208
FIG. 15 HOT/COLD SWITCH TERMINALS
a) 120 volts ac for two wire 120 volt models.
b) 120 volts ac for three wire 120/208 volt or 120/
240 volt models.
c) 240 volts ac for two wire 240 volt models.
27591 031597
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If continuity is present as described, lamp holders are
operating properly.
If continuity is not present as described replace the
lamp holder.
SERVICE (cont.)
LAMP HOLDER
1
2
3
Removal and Replacement:
1. Open dispenser door (1).
2. Remove the six #8-32 screws securing bottom
door cover (5) to the door (1) and remove cover.
3. Disconnect the door wiring harness from the door
interconnect wiring harness.
4. Remove eight #8-32 screws securing the upper
door cover w/reflector (4) to the door.
5. Remove the upper door cover w/reflector (4),
lamp (3), lamp holders (2) and door wiring har-
ness as a assembly.
4
5
2
6. Rotate lamp (3) 90° and remove from lamp hold-
ers (2).
7. Remove the #6-32 securing the lamp holder (2) to
be removed, remove lamp holder (2) and discard.
8. Install new lamp holder (2) and secure with a #6-
32 screw.
6
9. Install lamp (3) into lamp holders (2) and turn 90°
until the pins snap in place.
10. Install upper door cover w/reflector (4), lamp (3),
lamp holders (2) and door wiring harness as a
assembly using eight #8-32 screws.
11. Reconnect the plug on the door wiring harness to
the connector on the door interconnect wiring
harness.
P1209.75
FIG. 16 LAMP HOLDERS
1. Door Assy
2. Lamp Holders
3. Lamp
4. Upper Cover W/Reflec-
tor
5. Lower Cover
6. Starter W/Socket
12. Install the door bottom cover (5) using six #8-32
screws.
LAMP REPLACEMENT (Refer to Fig. 16)
Location:
1. Open the dispenser door (1).
The lamp holders are located on the front of
the reflector behind the display panel.
2. Remove the upper door cover w/reflector (4),
lamp (3), lamp holders (2) as an assembly.
3. Rotate lamp (3) 90° and remove from the lamp
holders (2).
4. Insert new lamp (3) into lamp holders (2) and turn
90° until the pins snap in place.
5. Reinstall upper door cover w/reflector (4), new
lamp(3)andlampholders(2)onthedoorassy(1).
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the plugs on the door wiring harness
from the connectors on the lamp holders.
3. Remove lamp from lamp holders.
4. Disconnect the two pin plugs of each lamp holder
from the door wiring harness.
5. Check for continuity on each lead of the lamp
holders.
27591 031597
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hole in the bottom cover (5) and releasing spring
tabs.
SERVICE (cont.)
LAMP STARTER and SOCKET (120V, 120/208V &
120/240V Models Only)
8. Insertnewstarter(6)intosocketandturn90° until
the pins snap in place.
9. Connect the plug on the sockets leads to the
connector on the door wiring harness.
10. Install door bottom cover (5) with starter and
starter socket on door assy (1) using six #8-32
screws.
Location:
The lamp starter (6) is located inside the door
assy (1) on the top of the door bottom cover (5).
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect the plug on the starter leads from the
connector on the door wiring harness.
3. Remove lamp starter from starter socket.
4. Disconnect the two pin plugs of each of the starter
sockets from the door wiring harness.
5. Check for continuity on each lead of the starter
socket.
If continuity is present as described the starter socket
is operating properly.
Ifcontinuityisnotpresentasdescribedreplacethethe
starter socket.
6. Remove starter (6) from starter socket.
7. Checkforcontinuityacrossthepinsonthebottom
of the starter (6).
If continuity is present as described , replace the
starter.
If continuity is not present as described, starter is
operating properly.
Note:Ifcontinuitytestareboth asdescribedandlamp
does not light, replace the starter socket.
Removal and Replacement (Refer to Fig.16):
1. Open dispenser door assy (1)
2. Remove the six #8-32 screws securing the door
bottom cover (5) to the door assy (1).
3. Disconnect the plug on the starter socket and the
connector on the door wiring harness.
4. Remove cover (5) with starter w/socket (6) as
assembly.
5. Rotate starter 90° and remove from the starter
socket.
6. Compress the spring tabs on the socket and re-
move socket from the door bottom cover (5).
7. Install new socket by compressing spring tabs on
the socket and pushing the socket up through the
27591 031597
25
wiringdiagramandcheckthedispenserwiringhaness.
SERVICE (cont.)
LEVEL CONTROL BOARD AND LEVEL PROBE
5. Reconnect the violet wire to terminal 1.
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 dispenser.
7. Check the voltage across terminals 1 & 3 with a
voltmeter. Connect the dispenser to the power
source.Theindicationmustbe120voltsacfortwo
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models after a delay
of approximately 5 seconds.
8. Touch the free end of jumper wire to the dispenser
housing. The indication must be 0.
9. Move the jumper wire away from the dispenser
housing. Theindicationmustagainbe120voltsac
for two wire 120 volt models, three wire 120/208
volt models , three wire 120/240 volt models and
240 volts ac for two wire 240 volt models after a
delay of approximately 5 seconds.
10. Disconnect the dispenser from the power source
and remove the jumper wire from terminal 4.
If voltage is present as described, the level control
board is operating properly, proceed to #11.
If voltage is not present as described, replace the level
control board.
P1203.45
FIG. 17 LEVEL CONTROL BOARD AND PROBE
11. Reconnect the pink wire to terminal 4.
12. Gently pull the probe out of the tank lid and inspect
for corrosion. Replace it if necessary.
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 dispenser to the power
source.Theindicationmustbe120voltsacfortwo
wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models after a delay
of approximately 5 seconds.
15. Move the probe's flat end to the dispenser hous-
ing. The indication must be 0.
16. Movetheprobe'sflat endawayfromthedispenser
housing. The indication should again be 120 volts
ac for two wire 120 volt models, three wire 120/
208 volt models, three wire 120/240 volt models
and 240 volt ac for two wire 240 volt models.
Location:
The level control board is located on the upper
right rear of the front panel just in front of the tank.
TheLevelprobeislocatedontherightcenterofthe
tank lid.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Removethevioletwirefromterminal1&pinkwire
from terminal 4 of the circuit board.
3. Check the voltage across terminals 2 & 3 with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for
two wire 120 volt models, three wire 120/208 volt
models, three wire 120/240 volt models and 240
volts ac for two wire 240 volt models.
4. Disconnect the dispenser from the power source.
If voltage is present as described, proceed to #5.
If voltage is not present as described, refer to the
27591 031597
26
Location:
The limit thermostat is located in the center of
the tank lid.
SERVICE (cont.)
LEVEL CONTROL BOARD AND LEVEL PROBE (cont.)
If voltage is present as described, reinstall the probe,
the level control board and level probe are operating
properly.
If voltage is not present as described, check the pink
probe wire for continuity.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Disconnect both black wires from the limit ther-
mostat.
3. Check for continuity across the limit thermostat
terminals.
Removal and Replacement:
1. Remove all wires from the level control board.
2. Removetwo#8-32 kepsnutsholdinglevelcontrol
board to upper left rear of the front panel.
3. Remove level control board and spacers.
3. Install the new level control board and spacers to
the upper left rear of the front panel using two #8-
32 keps nuts.
If continuity is present as described, the limit thermo-
stat is operating properly.
If continuity is not present as described, replace the
limit thermostat.
Removal and Replacement:
1. Remove all wires from the limit thermostat ter-
minals.
4. Refer to the illustration below when reconnecting
the wires.
2. Carefully slide the limit thermostat out from un-
der the retaining clip and remove the limit ther-
mostat.
3. Carefully slide the new limit thermostat into the
retaining clip.
4. Refer to the illustration below when reconnect-
ing the wires.
BLK to Tank
Heater
BLK to Control
Thermostat
P1210
FIG. 18 LEVEL BOARD TERMINALS
LIMIT THERMOSTAT
FIG. 20 LIMIT THERMOSTAT TERMINALS P1800
P1199.45
FIG. 19 LIMIT THERMOSTAT
27591 061500
27
Removal and Replacement:
SERVICE (cont.)
1. Disconnect the red leads from the overflow pro-
tection switch from the black wire from the termi-
nal block and the blue wire from the liquid level
board.
OVERFLOW PROTECTION SWITCH
2. Remove the nut beneath the copper overflow cup.
3. Remove the entire switch assembly from the cup.
4. Place the new switch assembly into the cup, wires
first. Make sure that a gasket is in place around the
threaded switch stem.
NOTE - The magnets must be at the top of float and
there must be NO adjusting washers installed for
the overflow protection switch to operate prop-
erly.
5. Installthenutbeneaththecopperoverflowcup. Be
sure not to overtighten.
6. Refer to the illustration below when reconnecting
wires.
P1199.45
RED to BLK Wire
RED to BLU Lead
from Terminal
from Liquid Level
Block
FIG. 21 OVERFLOW PROTECTION SWITCH
Location:
Board
P1212
The overflow protection switch is located in-
side the copper overflow cup on the upper front of
the tank.
FIG. 22 OVERFLOW PROTECTION
SWITCH LEADS
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Remove the wire nuts connecting the red wires
from the overflow protection switch to the black
wirefromtheterminalblockandbluewirefromthe
liquid level board.
3. Check for continuity across the safety overflow
switchredwiresonlyuntiltheplasticfloatisraised
and check that continuity returns when the plastic
float is again lowered.
If continuity is present as described, reconnect the
red wires to the black wire from the terminal block
and the blue wire from the liquid level board.
If continuity is not present as described, replace the
overflow protection switch.
27591 111596
28
3. Remove switch with wires attached from the back
side of the front panel.
4. Disconnect the wires from the switch and dis-
card the switch.
SERVICE (cont.)
RUN/RINSE SWITCH
5. Referring to the illustration below (Fig. 24) re-
connect the wires to the new switch.
6. Install new switch with wires attached through
the hole in the front panel and secure with facenut.
P1213
FIG. 24 RUN/RINSE SWITCH TERMINALS
P1199.45
FIG. 23 RUN/RINSE SWITCH
Location:
The run/rinse switch is located on the right
side of the front panel.
Test Procedures:
1. Disconnect the dispenser from the power source.
2. Check for continuity between center terminals and
the upper terminals with the switch in the “RUN”
lower position. Continuity must not be present
with the switch in the “RINSE” upper position.
If continuity is present as described, the switch is
operating properly.
If continuity is not present as described, replace the
switch.
Removal and Replacement:
1. Open the dispenser door.
2. Remove the facenut securing the run/rinse switch
to the dispenser front panel.
27591 111596
29
If voltage is not present as described, refer to wiring
diagram and check dispenser wiring harness.
SERVICE (cont.)
SOLENOID VALVE (COLD WATER - OPTIONAL)
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
white and white/yellow wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect
the brewer to the power source. With "HOT/COLD"
switch in the "COLD" upper position press the left
dispense switch and listen carefully in the vicin-
ity of the solenoid valve for a "clicking" sound as
the coil magnet attracts.
7. Disconnect the dispenser from the power source.
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.
FIG. 25 COLD WATER SOLENOID VALVEP1214.45
Location:
Removal and Replacement:
1. Remove the white and white/yellow wires from
the solenoid valve.
2. Turn-off the water supply to the dispenser.
3. Disconnect the water lines to and from the sole-
noid valve.
The cold water solenoid valve is located on
the left side of the dispenser base just behind the hop-
per delay board.
4. Remove the two #8-32 keps nuts and washers
securing the solenoid mounting bracket to the
base. Remove solenoid bracket and solenoid
valve as an assembly.
5. Remove the two #10-32 screws and lockwashers
securing the solenoid valve to the solenoid
bracket.
6. Using two #10-32 screws and lockwashers in-
stall new solenoid valve on solenoid mounting
bracket.
7. Using two #8-32 keps nuts and washers install
solenoid valve and bracket to the base of the dis-
penser.
Test Procedures:
1. Disconnectthedispenserfromthepowersource.
2. Disconnect the white and white/yellow wires
from the solenoid valve. With the “HOT/COLD”
switchinthe"COLD"upperpositionpressthe left
dispense switch on front of the door.
3. Check the voltage across the white and white/
yellow wires with a voltmeter. Connect the dis-
penser to the power source. The indication must
be 120 volts ac for two wire 120 volt models,
threewire120/208,120/240voltmodelsand240
volts ac for two wire 240 volt models.
4. Disconnect the brewer from the power source,
8. Securely fasten the water lines to and from the
solenoid valve.
If voltage is present as described, proceed to #5
9. Refer to Fig. 26 when reconnecting the wires.
27591 031597
30
Test Procedures:
SERVICE (cont.)
1. Disconnectthedispenserfromthepowersource.
2. Disconnectthewhiteandwhite/violet, white/blue
or white/ brown wires from the solenoid valve.
With the “RUN/RINSE” switch in the "RINSE"
upper position press the appropriate dispense
switch on front of the door.
SOLENOID VALVE (COLD WATER - OPTIONAL) (cont.)
WHI/YEL to Hot/Cold
Switch
WHI to Terminal Block
3. Check the voltage across the white and white/
violet, white/blue or white/brown wires with a
voltmeter. Connect the dispenser to the power
source. The indication must be 120 volts ac for
two wire 120 volt models, three wire 120/208,
120/240 volt models and 240 volts ac for two
wire 240 volt models.
P1215
FIG. 26 COLD WATER SOLENOID TERMINALS
4. Disconnectthedispenserfromthepowersource,
SOLENOID VALVES (DISPENSE)
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to wiring
diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
white and white/violet, white/blue or white/brown
wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect
the dispenser to the power source. With "RUN/
RINSE" switch in the "RINSE" upper position press
the appropriate dispense switch and listen care-
fully in the vicinity of the solenoid valve for a "click-
ing" sound as the coil magnet attracts.
7. Disconnect the dispenser from the power source.
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 outlet before the solenoid valve or,
the solenoid valve may require inspection for wear,
and removal of waterborne particles.
P1203.45
FIG. 27 DISPENSE SOLENOID VALVES
If the sound is not heard as described, replace the
solenoid valve.
Location:
The dispense solenoids are located on the
upper right side of the tank.
Removal and Replacement:
1. Remove the white and white/violet, white/blue or
white/ brown wires from the solenoid valve.
2. Turn-off the water supply to the dispenser.
27591 031597
31
SOLENOID VALVE (INLET)
SERVICE (cont.)
SOLENOID VALVES (DISPENSE) (cont.)
3. Drain enough water from the tank so the water
level is below the dispense valve mounting hole.
NOTE: Bunn-O-Matic has a syphon assembly,
#12440.0000. available for this purpose.
4. Disconnect the water line from the solenoid valve.
5. Remove the #10-32 screw securing the solenoid
valve to side of the tank. Remove solenoid valve.
6. Usingthe #10-32screwinstallnewsolenoidvalve
on side of the tank
7. Push the water line onto the tube on bottom of
solenoid valve.
8. Refer to Fig. 26 when reconnecting the wires.
P1203.45
FIG. 27 INLET SOLENOID VALVE
Location:
The inlet solenoid is located on the lower right
side of the rear panel.
Test Procedures:
1. Disconnectthedispenser fromthepowersource.
2. Disconnect the white and violet wires from the
solenoid valve.
3. Check the voltage across the white and violet
wires with a voltmeter. Connect the dispenser to
the power source. The indication must be 120
volts ac for two wire 120 volt models, three wire
120/208, 120/240 volt models and 240 volts ac
for two wire 240 volt models.
P1216
FIG. 26 DISPENSE SOLENOID VALVE
TERMINALS
4. Disconnectthedispenserfromthepowersource,
If voltage is present as described, proceed to #5
If voltage is not present as described, refer to the
wiring diagram and check dispenser wiring harness.
5. Check for continuity across the solenoid valve
coil terminals.
If continuity is present as described, reconnect the
white and violet wires to the solenoid.
27591 031597
32
TANK HEATER
SERVICE (cont.)
SOLENOID VALVE (INLET) (cont.)
If continuity is not present as described, replace the
solenoid valve.
6. Check the solenoid valve for coil action. Connect
the dispenser to the power source. Listen care-
fully in the vicinity of the solenoid valve for a
"clicking" sound as the coil magnet attracts.
7. Disconnect the dispenser from the power source.
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.
Removal and Replacement:
1. Remove the white and violet wires from the so-
lenoid valve.
2. Turn-off the water supply to the dispenser.
3. Disconnect the water lines to and from the sole-
noid valve.
P1199.40
FIG. 29 TANK HEATER
Location:
4. Remove the two #10-32 screws and nuts secur-
ing the solenoid to the rear panel. Remove sole-
noid.
The tank heater is located inside the tank and
secured to the tank lid.
5. Using two #10-32 screws and nuts install new
solenoid valve on rear panel.
6. Securely fasten the water lines to and from the
solenoid valve.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Checkthevoltageacrosstheblackandwhitewires
120voltmodelsorblackandredwiresfor120/208
volt modelsor120/240voltmodelswithavoltme-
ter. Connect the dispenser to the power source.
The indication must be:
7. Refer to Fig. 28 when reconnecting the wires.
a) 120 volts ac for two wire 120 volt models;
b) 208 volts ac for three wire 120/208 volt models.
c) 240 volts ac for three wire 120/240 volt models
and two wire 240 volt models.
3. Disconnect the dispenser from the power source.
WHI from Terminal
Block
If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the
dispenser wiring diagram and check the wiring har-
ness.
VIO from Liquid
Level Board
P1217
FIG. 28 INLET SOLENOID VALVE TERMINALS
4. Disconnect the black wire and the white or red
wire from the tank heater terminals.
27591 031597
33
SERVICE (cont.)
TANK HEATER (cont.)
WHI or RED to
Terminal Block
BLK to Limit
Thermostat
5. Check for continuity across the tank heater termi-
nals.
If continuity is present as described, reconnect the
wires, the tank heater is operating properly.
If continuity is not present as described, replace the
tank heater.
NOTE - If the tank heater remains unable to heat,
remove and inspect heater for cracks in the sheath.
Removal and Replacement:
1. Shut-off water supply to the dispenser.
2. Disconnect the water supply tube on the tank lid.
3. Disconnect the black wires on the limit thermo-
stat.
4. Disconnecttheblackwireandthewhiteorredwire
from the tank heater terminals.
5. Disconnect the pink wire from the liquid level
probe.
6. Remove the thermostat capillary bulb by firmly
pulling-up on the capillary at the tank lid. This will
disengage the grommet from the tank lid.
7. Remove the ten #8-32 nuts securing the tank lid to
the tank.
P1218
FIG. 30 TANK HEATER TERMINALS
TANK HEATER SWITCH
8. Remove tank lid with limit thermostat, liquid level
probe and tank heater as a assembly.
9. Remove the two hex nuts securing the tank heater
to the tank lid. Remove tank heater with gaskets
and discard.
10. Install new tank heater with gaskets on the tank lid
and secure with two hex nuts.
11. Install tank lid with limit thermostat, liquid level
probe and tank heater on the tank and secure with
ten #8-32 hex nuts.
12. Connect water inlet line to the tank lid.
13. Reconnect the black wires to limit thermostat, the
pinkwiretotheliquidlevelprobe. Refertothelimit
thermostat and the liquid level board and probe
sections in this manual when reconnecting wires.
14. RefertoFig. 30whenreconnectingthewirestothe
tank heater.
P1199.35
FIG. 31 TANK HEATER SWITCH
Location:
The tank heater switch located inside the dis-
penser on the upper right of the front panel.
27591 031597
34
TRANSFORMER (240V TWO WIRE MODELS ONLY)
SERVICE (cont.)
TANK HEATER SWITCH (cont.)
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the black wire and the blue/black wire
onelectro/mechanicalthermostatsorthetanwires
on electronic thermostats.
3. With the switch in the “ON” lower position check
for continuity between the center and the upper
terminal. With the switch in the “OFF” upper posi-
tion no continuity should be present between
center and upper terminals.
1
2
3
If continuity is present as described, the heater “ON/
OFF” switch is operating properly.
If continuity is not present as described, replace the
switch.
P1289
FIG. 33 TRANSFORMER
Location:
The transformer is located behind the front
cover just to the right of the ballest on the dispenser
base.
Removal and Replacement:
1. Remove the switch mounting nut on the front of
the front panel.
2. Remove switch with wires attached from the rear
of the front panel.
3. Remove the wires from the switch terminals and
discard switch.
4. Connect the wires to the new switch, refer to fig.
32.
5. Push new switch through hole in the front panel
and secure with face nut.
Test Procedure:
1. Disconnect the dispenser from the power source.
2. Disconnect the two pin connector of the trans-
former from the fan.
3. Connect voltmeter, set to read at least 120 volts ac
across the black and white leads of the trans-
former connector.
4. Connect the dispenser to the power source. The
voltage indication should be approximately 120
volts ac.
BLUBLK from Electro/
mechanical Thermostat
or TAN from Electronic
Thermostat
5. Disconnect the dispenser from the power source.
If voltage is present as described the transformer is
operating properly.
If voltage is not present as described, replace the
transformer.
BLK from Terminal
Block (Electro/mechani-
cal)
TAN from Electronic
Thermostat
FIG. 32 TANK HEATER SWITCH TERMINALSP1219
27591 031597
35
SERVICE (cont.)
TRANSFORMER (240V TWO WIRE
MODELSONLY)(cont.)
Removal and Replacement:
1. Disconnect the wires from the transformer.
2. Remove the two #8-32 keps nuts securing the
transformer to the dispenser base.
3. Remove and discard the transformer.
4. Installnewtransformeroverthetwoweldstudson
the dispenser base and secure with two #8-32
keps nuts.
5. Refer to Fig. 34 when renonnecting the wires.
RED & BLK to
Main Harness
1
2
3
BLK & WHI to
Fan
P1288
FIG.34 TRANSFORMER TERMINALS
27591 031597
36
SCHEMATIC WIRING DIAGRAM HC-2, & HC-3
GRN
L2 N
L1
ELECTROMECHANICAL THERMOSTAT CONFIGURATION
HEATER SW.
BLU/BLK-16
BLK-16
LIMIT
RED-16 (3-WIRE MODELS)
WHI-16 (2-WIRE MODELS)
THERMOSTAT
THERMOSTAT
TANK HEATER
TANK HEATER
BLU-16
BLK-16
BLK-16
BLK-16
BLK-16
BLK-16
ELECTRONIC THERMOSTAT CONFIGURATION
HEATER SW.
TAN
TAN
LIMIT
THERMOSTAT
RED-16 (3-WIRE MODELS)
WHI-16 (2-WIRE MODELS)
BLK-16
BLK-16
ELECTRONIC
THERMOSTAT
ASSEMBLY
WHI
OVERFLOW SWITCH
TANK INLET
SOL
BLK
BLK
BLK
RED
RED
VIO
WHI
WHI
WHI/VIO
WHI/BLU
1
1
2
3
4
HOPPER
DELAY
LIQUID
LEVEL
BOARD
BLU
2
3
4
5
6
7
8
PNK-20
BLK
BLK
WHI
BLK
WHI/RED
WHI/GRN
WHI/GRN
WHI
PROBE
FLOURESCENT
LAMP
BALLAST
1
BLK
BLK BLK
WHI
WHI
WHI
BLU
WHI
WHI
WHI
WHI
DISPENSE
WHIPPER
M
HOPPER
WHI/RED
WHI
WHI/RED
WHI
WHI/RED
WHI/BLK
M
SOL
RUN/RINSE SWITCH
WHI/GRN
WHI
WHI
WHI
RIGHT DISPENSE
RIGHT WHIPPER
RIGHT HOPPER
WHI/VIO
WHI/VIO
CENTER DISPENSE
WHI/BLU WHI
WHI/BLU
LEFT DISPENSE
WHI
WHI/VIO
WHI
WHI/VIO
WHI/BLK
M
SOL
M
WHI/VIO
WHI/BLU
CENTER WHIPPER
CENTER HOPPER
WHI/BLU
WHI
WHI/BLU
WHI/BLK
SOL
M
M
LEFT WHIPPER
LEFT HOPPER
WHI/BRN
WHI
WHI/RED
WHI
WHI/RED
WHI/BLK
SOL
M
M
RUN/RINSE SWITCH
WHI/GRN
WHI/BLK
COLD DRINK OPTION (LEFT ONLY)
WHI
WHI/GRN
WHI
4
1
SOL
WHI/BRN
WHI/RED
WHI/RED
WHI/BRN
WHI/RED
WHI/RED
JUMPER PLUG MUST BE
USED WHEN COLD
DRINK FEATURE NOT
INSTALLED
RED
RED
RED
WHI/YEL
HOT/COLD SWITCH
1
1
4
GRN/WHI
GRN/BLK
1
WHI
BLK
BLU
BLU
1
BLK
BLK
RED
BLK
STARTER
RED/WHI
RED/BLK
1
RED
BLK
WHI
1
DISPENSE
SWITCH
ASSY.
DISPENSE SWITCH
(RIGHT, MODELS HC-2 & HC-3)
BLK
1
RED/BLK
4
1
BLK
RED
4
DISPENSE SWITCH
(CENTER, MODEL HC-3 ONLY)
BLK
RED/WHI
4
1
120 VOLTS AC - 2 WIRE OR
120/208-240 VOLTS AC - 3 WIRE
SINGLE PHASE, 60 HZ
DISPENSE SWITCH
(LEFT, MODELS HC-2 & HC-3)
(ALSO HC-1 SWITCH)
BLK
RED
4
27591 031597
37
SCHEMATIC WIRING DIAGRAM HCA-2, & HCA-3
GRN
L1
L2
ELECTROMECHANICAL THERMOSTAT CONFIGURATION
HEATER SW.
BLU/BLK-16
BLK-16
LIMIT
THERMOSTAT
THERMOSTAT
TANK HEATER
BLU-16
BLK-16
BLK-16
BLK-16
BLK-16
WHI -16
ELECTRONIC THERMOSTAT CONFIGURATION
HEATER SW.
TAN
TAN
LIMIT
THERMOSTAT
TANK HEATER
RED
BLK-16
BLK-16
BLK-16
BLK
WHI -16
WHI
ELECTRONIC
THERMOSTAT
ASSEMBLY
OVERFLOW SWITCH
BLK
RED
TANK INLET
WHI/VIO
WHI/BLU
1
HOPPER
VIO
WHI
WHI
2
3
4
5
6
7
8
SOL
DELAY
1
2
3
4
LIQUID
LEVEL
BOARD
BLU
BLK
BLK
WHI
BLK
WHI/RED
WHI/GRN
WHI/GRN
WHI
PNK-20
PROBE
BLK
1
RED
RED
BLU
BLU
BLK
WHI
BLK
WHI
BLK
RED
XFRMR BLK
WHI
FLOURESCENT
LAMP
BALLAST
1
WHI
WHI
WHI
WHI
WHI
WHI/RED
DISPENSE
SOL
WHIPPER
HOPPER
WHI/BLK
M
WHI/RED
WHI
WHI
WHI/RED
M
RUN/RINSE SWITCH
WHI/GRN
WHI
WHI
WHI/VIO
WHI
RIGHT DISPENSE
RIGHT WHIPPER
RIGHT HOPPER
WHI/VIO
WHI/VIO
WHI
WHI
WHI/VIO
WHI/BLK
M
SOL
M
WHI/VIO
WHI/BLU
CENTER DISPENSE
WHI/BLU WHI
WHI/BLU
LEFT DISPENSE
WHI/BRN WHI
CENTER WHIPPER
CENTER HOPPER
WHI/BLU
WHI
WHI/BLU
WHI/BLK
SOL
M
M
LEFT WHIPPER
LEFT HOPPER
WHI/RED
WHI
WHI/RED
WHI/BLK
SOL
M
M
RUN/RINSE SWITCH
WHI/GRN
WHI/BLK
COLD DRINK OPTION (LEFT ONLY)
WHI
WHI/GRN
WHI
4
1
SOL
WHI/BRN
WHI/RED
WHI/RED
WHI/BRN
WHI/RED
WHI/RED
JUMPER PLUG MUST BE
USED WHEN COLD
DRINK FEATURE NOT
INSTALLED
RED
RED
RED
WHI/YEL
HOT/COLD SWITCH
1
4
1
4
4
1
BLU
BLU
RED
RED
WHI
BLK
BLU/BLK
BLU
1
1
ORA/BLK
ORA
RED
BLK
RED/WHI
RED/BLK
DISPENSE
SWITCH
ASSY.
BLK
WHI
1
DISPENSE SWITCH
(RIGHT, MODELS HC-2 & HC-3)
1
4
BLK
RED/BLK
BLK
RED
4
1
DISPENSE SWITCH
(CENTER, MODEL HC-3 ONLY)
BLK
RED/WHI
4
240 VOLTS A C
2 WIRE
SINGLE PHASE,
50 HZ
1
DISPENSE SWITCH
(LEFT, MODELS HC-2 & HC-3)
(ALSO HC-1 SWITCH)
BLK
RED
4
27593.0004B 2/97
©
1996 BUNN-O-MATC CORPORATION
27591 031597
38
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