®
BUNN
SRUA
OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
10067.0003A 07/02 ©2002 Bunn-O-Matic Corporation
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.
#00656.0000
#00831.0000
ATTENTION:TURN OFF WHEN UNATTENDED
#10044.0000
#00878.0000
#03408.0000
#03409.0000
#12593.0000
#12555.0000
#29299.0000
10067.3 070102
Page 3
ELECTRICAL REQUIREMENTS
CAUTION - The brewer must be disconnected from the power source until specified in Initial Set-Up.
L2 RED
230V
A.C.
L1 BLACK
P1842
SRUA Models require 2-wire, grounded service
rated 230 volts ac, 30 amp, single phase, 50 Hz.
Proceed as follows:
ELECTRICAL INSTALLATION INSTRUCTIONS
CAUTION – Improper electrical installation can damage the equipment and injure the installer. The chassis must
be properly grounded. Do not assume a plumbing line will provide an adequate ground.
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. Beforeelectricallyconnectingthebrewer, removetheleftsidepanelfromthehoodandrotatethecontrolthermostat
knob fully clockwise to the "OFF" position. Keep this knob in the "OFF" position until performing the Initial Setup.
Replace the side panel.
4. Remove the lower front panel and connect the proper electrical service to the terminal block.
5. Connectthebrewertothepowersourceandverifythevoltageattheterminalblockbeforeproceeding. Replace
the lower front panel.
6. Disconnect the brewer from the power source. If plumbing has been hooked up, the brewer is ready for the
Initial Setup.
NOTE: A Schematic wiring diagram is included in this manual.
PLUMBING REQUIREMENTS
The brewer must be connected to a cold water system with operating pressure between 20 and 90 psi (138
and 621 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 (621 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. Bunn-
O-Matic does not recommend 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.
10067.3 070102
Page 4
PLUMBING REQUIREMENTS(cont.)
Plumbing Hook-up
1. Make certain the 3/8" female flare fittings on the short tube from the outlet of strainer (supplied) is securely
attached to the male fitting at the bottom rear of the brewer.
2. Flush the water line and securely attach it to the 3/8" male flare fitting on the inlet of the strainer.
3. Turn on the water supply.
4. Inspect the connection for leaks.
This equipment must be installed to comply with the Basic Plumbing Code of the Building
OfficialsandCodeAdministratorsInternational, Inc. (BOCA)andtheFoodServiceSanitation
Manual of the Food and Drug Administration (FDA).
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. Disconnect the brewer from the power source.
2. Remove the left side panel from the hood and rotate the control thermostat knob fully counterclockwise to the
"OFF" position. Replace the side panel.
3. Connect the brewer to the power source and place the lighted ON/OFF switch in the "ON" position. Water will
flow into the tank and should automatically stop after approximately 15 minutes.
NOTE - The lighted ON/OFF switch must be in the "ON" position to automatically refill the tank. The switch should
be in the "OFF" position whenever the brewer is left unattended.
4. Disconnect the brewer from the power source.
5. Remove the left side panel from the hood and rotate the control thermostat knob clockwise to the 5 o'clock
position. Replace the side panel.
6. Connect the brewer to the power source and wait for the water in the tank to heat to the proper temperature.
This will take approximately 1-2 hours, depending on the incoming water temperature. Some water will flow
from the overflow tube during this time due to expansion. Draw off a 1/2 gallon decanter of water every 15
minutes during the initial heat-up to lessen the chance of hot water flow from this expansion.
7. Determinethewatertemperaturebycheckingthewaterwithathermometeratthehotwaterfaucet(redhandle).
The best brewing temperature is between 195˚(91˚C) and 200˚F(93˚C). The temperature may be increased by
turning the thermostat knob clockwise and decreased by turning the knob counterclockwise.
8. Whenthedesiredtemperatureisattained,placethefunnelsupport,funnel,andfunnelcoverontopofthecoffee
reservoir. Center the discharge of the water swing spout over the opening in the top of the funnel cover.
9. Place the lighted ON/OFF switch in the "ON" position and momentarily press and release the start switch. Water
should flow from the swing spout into the funnel assembly.
10. Drain and measure the water from the reservoir when the flow of water from this initial cycle stops. If it is three
gallons, proceed to step 12. If it is more or less than three gallons, proceed to step 11.
11. Adjust the brew timer as required. See Adjusting Brew Volumes. Repeat steps 9 & 10.
12. The brewer is now properly adjusted to brew coffee.
10067.3 070102
Page 5
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”
position 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 until switch is once again placed in the “SET” position.
10067.3 070102
Page 6
COFFEE BREWING
1. Brew 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 a 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.(This switch must be in the "ON" position to start and complete a
brewing cycle.)
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 urn until drip out of coffee has been completed.
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: Tankandtankcomponentsshouldbedelimedregularlybasedonlocalwaterconditions. Excessive mineral
build up on stainless steel surfaces can initiate corrosion reactions resulting in serious leaks,
1. Removefunnel,funnellidandsupport.Underhotwater,rinseawayallcoffeeoils.Wipewithacleandampcloth.
2. Drain coffee reservoir by opening coffee faucet. When empty, close faucet.
3. Cycle two or three inches of water into the coffee reservoir, adding a bucket of crushed ice to obtain a more
desirable cleaning temperature, and scrub entire reservoir area.
4. Drain coffee reservoir and rinse. Use clean damp cloth to wipe reservoir.
5. Install coffee funnel support, funnel and funnel lid.
6. Remove the sight gauge cap, insert sight gauge cleaning brush into the sight gauge glass tube and clean.
7. To clean coffee faucet, remove the faucet handle from the faucet and faucet clean out cap. Clean faucet with
afaucetcleaningbrushandwipeallpartswithadampcloth.Replacefaucetseatcupperiodicallyifbadlystained
or to stop faucet dripping. DO NOT CLEAN THE HOT WATER FAUCET.
8 Reassemble the coffee faucet.
9. Wipe the entire outside surface of the machine with a clean damp cloth. Wipe dry.
CAUTION - Surfaces of machine are hot.
FILTER HOLDER
1. AfilterholderissuppliedwitheachSRUcoffeebrewer.Itspurposeistokeepthefiltersintheiroriginallyformed
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.
10067.3 070102
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, andrepairofelectricalequipmentshouldbeperformedonlybyqualifiedservicepersonnel.
All electronic components have 230 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 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
REMEDY
PROBLEM
PROBABLE CAUSE
Water lines and valves to the brewer
must be open.
Brew cycle will not start
1. No water
(A)Checktheterminalblockfor 230
volts ac across the red and black
terminals.
2. No power or incorrect voltage to
the brewer
(B) Check fuse.
Be sure water shut-off valve is open
and that the in-line filters or strain-
ers are not blocking water flow.
3. Water level below pump housing.
(Water level in the hot water gauge
glass should be approximately half
full).
RefertoService-SwingArmSwitch
for testing procedures. See page 25
4. Swing Arm Switch
RefertoService-ON/OFFSwitchfor
testing. See page 20
5. ON/OFF Switch
10067.3 070102
Page 8
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
6. Start Switch
Refer to Service - Start Switch for
testing procedures. See page 24
Brew cycle will not start (cont.)
7. Timer
Refer to Service - Timer for testing
procedures. See page 28 or 29
8. Pump
Refer to Service - Pump for testing
procedures. See page 21
9. Solenoid Valve
10. Strainer
Refer to Service - Solenoid Valve for
testing procedures. See page 23
(A) Direction of flow arrow must be
pointing towards brewer.
(B) Remove the strainer and check
for obstructions. Clear or replace.
1.ON/OFF Switch (This switch must
be in the "ON" position for the refill
circuit to operate.
RefertoService-ON/OFFSwitchfor
testing procedures. See page 20
Tank not filling
2. No water
Be sure water shut-off is open and
thatin-linefiltersorstrainersarenot
blocking water flow.
3. Solenoid Valve
4. Probe
Refer to Service - Solenoid Valve for
testing procedures. See page 23
Refer to Service - Probe for testing
procedures. See page 18
5. Liquid Level Board
RefertoService-LiquidLevel Board
for testing procedures. See page 18
10067.3 070102
Page 9
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
1. Brewer not level
Water running out of the overflow
Brewer must be level and installed
on a sturdy structure.
2. Solenoid Valve
3. Liquid Level Board
4. Probe
Refer to Service - Solenoid Valve
for testing procedures. See page
23
Refer to Service -Liquid Level
Board for testing procedures. See
page 18
Refer to Service - Probe for test-
ing procedures. See page 18
1. Limit Thermostat
Water is not hot
Refer to Service - Limit Thermo-
stat for testing procedures. See
page 17
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-
mostatfortestingprocedures.See
page 15
3. Tank Heater
4. Contactor
Refer to Service - Tank Heater for
testing procedures. See page 26
Refer to Service - Contactor for
testing procedures. See page 14
5. Thermal fuses
Refer to Service - thermal fuses
for testing procedures. See page
27
1. Fuse
Fuse Opening
Refer to Service - Fuse for testing
procedures. See page 16
Refer to Service - Tank Heater for
testing procedures. See page 26
2. Tank Heater
10067.3 070102
Page 10
TROUBLESHOOTING (cont.)
PROBLEM
PROBABLE CAUSE
REMEDY
Water keeps running from swing
spout
1. Timer
RefertoService-Timerfortesting
procedures. See page 28 or 29
2. Start Switch
1. Timer
Refer to Service - Start Switch for
testing procedures. See page 24
Inconsistent coffee yield
RefertoService-Timerfortesting
procedures. See page 28 or 29
2. Solenoid Valve
Refer to Service - Solenoid Valve
for testing procedures. See page
23
3. Lime build-up in swing spout
and pump tubing.
Remove swing spout and insert
delimingroddownintopumptub-
ing as far as possible.
Funnel overflows
1. Filters
Use Bunn filters made for the SRU
brewer.
2. Hole in bottom of funnel ob-
structed.
Remove obstruction.
3. Pump - Flow Rate
Checkpumpflowratewithawatch.
Pumpflowrateshouldbeapproxi-
mately 24 ounces in 15 seconds.
Be sure pump assembly is free of
any obstructions.
4. Soft Water
When using a water softener, a
coarse grind of coffee may be pre-
ferred. If required, a bypass sys-
tem is available as an optional
feature.
10067.3 070102
Page 11
TROUBLESHOOTING (cont.)
PROBABLE CAUSE
PROBLEM
Coffee reservoir overflows
REMEDY
Be sure coffee reservoir is empty
1. Coffee reservoir not completely
empty before a brew cycle was
started.
before brew cycle is started.
Refer to Service -Timer for test-
ing procedures. See page 28 or 29
2. Timer
Checkpumpflowratewithawatch.
Pumpflowrateshouldbeapproxi-
mately 24 ounces in 15 seconds.
Be sure pump assembly is free of
any obstructions.
3. Pump - Flow Rate
Plumbinglinesshouldnotberest-
ing on the counter top.
Brewer is making unusal noises
1. Plumbing lines
2. Water supply
(A)Thebrewermustbeconnected
to a cold water line.
(B) Water pressure to the brewer
must not exceed 90 psi (621 kPa).
Install a regulator if necessary to
lower the pressure to approxi-
mately 50 psi (345 kPa).
Remove and clean lime off the
tank heater. See page 26
3. Tank Heater
10067.3 070102
Page 12
SERVICE
Contents
Contactor ............................................................. 14
Control Thermostat.............................................. 15
Fuse and Fuse Holder .......................................... 16
Limit Thermostat ................................................. 17
Liquid Level Board and Level Probe.................... 18
ON/OFF Switch..................................................... 20
Pump ................................................................... 21
Selector Switch (Half Batch) ................................ 22
Solenoid .............................................................. 23
Start Switch (Brew) ............................................. 24
Swing Arm Switch ............................................... 25
Tank Heater ......................................................... 26
Thermal Fuse ...................................................... 27
Timer ................................................................... 28
Digital Timer ........................................................ 29
Wiring Diagram ................................................... 31
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.
The control thermostat, limit thermostat, pump,
solenoid valve, liquid level probe, swing spout switch
andtankheaterareaccessiblebyremovalof theswing
spout, side cupola covers and the cupola.
Disconnect the swing spout nut from the swing
spout base fitting. Remove swing spout.
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Remove the four #8-32 screws, two on each side,
securing the side covers to the cupola.
Slip cupola off of the component bracket.
The on/off switch, selector switch, start switch,
timer, contactor and liquid level control board are
accessible by removal of the front access panel.
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Remove the four #8-32 screws securing the front
access panel to the base.
P2130.25
FIG. 1 COMPONENT ACCESS
Thefuseandfuseholderareaccessiblebyremoval
of the rear utility cover.
Remove the six #8-32 screws securing the rear
utility cover to the housing.
10067.3 070102
Page 13
SERVICE (cont.)
CONTACTOR
If voltage is present as described, proceed to #9.
If voltage is not present as described, refer to the
wiring diagram and check the brewer wiring harness.
9. Check for continuity across the terminals on the
left side of the contactor by manually closing the
contacts. Continuitymustnotbepresentwhenthe
contact is released.
10. Check for continuity across the terminals on the
right side of the contactor by manually closing the
contacts. Continuitymustnotbepresentwhenthe
contact is released.
If continuity is present as described, the contactor is
operating properly.
If continuity is not present as described, replace the
contactor.
P2211.40
Removal and Replacement:
FIG. 2 CONTACTOR
Location:
1. Disconnect all the wires from the contactor.
2. Remove the two #8-32 screws securing the
contactor to the contactor mounting bracket.
3. Install new contactor and secure with two #8-32
screws.
The contactor is located inside the front lower
access panel, left of center on the component bracket.
Test Procedures:
1. Disconnect the brewer from the power source.
2 Disconnect the red wire from contactor coil to the
control thermostat and the black wire from the
contactor coil to the main harness.
3. Connect the brewer to the power source.
4. Check the voltage across the control thermostat
wire and the wire from the the main harness.The
indication must be 230 volts ac.
4. Refer to Fig. 3 and reconnect the wires.
BLK to Terminal
Block (L2)
BLK to Main Har-
ness
5. Disconnect the brewer from the power source.
If voltage is present as described, proceed to #6.
If voltage is not present as described refer to the
Wiring Diagram and check the brewer wiring harness.
RED to Terminal
Block (L1)
BLK Thermal
Fuse to Tank
Heater
6. Check for continuity between the left and right
terminals on the contactor coil.
If continuity is present as described, reconnect the
wires and proceed to #7.
If continuity is not present as described, replace the
contactor.
7. On all brewers check the voltage across the upper
left terminal and the upper right terminal on the
contactor with a voltmeter. Connect the brewer to
the power source. The indication must be 230
volts ac.
RED to Control
Thermostat
RED Thermal Fuse
to Tank Heater
P1725.50
8. Disconnect the brewer from the power source.
FIG.3 CONTACTOR TERMINALS
10067.3 070102
Page 14
SERVICE (cont.)
CONTROL THERMOSTAT
Removal and Replacement:
1. Disconnect the wires from the control thermostat.
2. Remove the thermostat capillary bulb by firmly
pullinguponthecapillaryatthecomponentbracket.
This will disengage the grommet from the compo-
nent bracket.
3. Remove the #8-32 screw securing the control
thermostat and mounting bracket to the compo-
nent bracket. Remove control thermostat and
bracket as an assembly.
4. Remove knob from control thermostat.
5. Remove the two #6-32 screws securing the con-
trolthermostattothethermostatmountingbracket.
Remove and discard thermostat.
6. Install new control thermostat on thermostat
mounting bracket and secure with two #6-32
screws.
P2180
FIG. 4 CONTROL THERMOSTAT
Location:
The control thermostat is mounted on the left
front of the top component bracket.
7. Install knob on thermostat.
Test Procedures:
8. Install thermostat and mounting bracket on the
component bracket and secure with one #8-32
screw.
9. Carefully bend the capillary tube so that the tube
and bulb inside the brewer are in the vertical
position with the grommet located 5 1/2" above
the capillary bulb.
1. Disconnect the brewer from the power source.
2. Locate the thermostat and check for 230 volts ac
between the red wire from the limit thermostat to
the control thermostat and the black wire on the
main terminal block.
3. Disconnect the brewer from the power source.
NOTE:Thecapillarytubemustbeclearofanyelectrical
termination and not kinked.
If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the
wiring diagram and check the brewer wiring harness.
10. Refer to Fig. 5 and reconnect the wires.
11. Adjust the control thermostat as required.
4. Disconnect the red wires from the control thermo-
stat.
5. Check for continuity across the terminals on the
control thermostat with the control thermostat in
the"ON"position(fullyclockwise),continuitymust
not be present when the thermostat is in the "OFF"
position (fully counterclockwise).
RED from Main
Harness
If continuity is present as described, the control ther-
mostat is operating properly.
If continuity is not present as described, replace the
control thermostat.
RED to Limit Thermostat
P1730
FIG. 5 CONTROL THERMOSTAT TERMINALS
10067.3 070102
Page 15
SERVICE (cont.)
FUSE AND FUSE HOLDER
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. Push fuse holder through the hole in the compo-
nent bracket.
4. Install new fuse holder and fuse through the hole
in the component bracket and secure with nut.
5. Refer to Fig. 7 and reconnect the wires.
REDfromON/OFFSwitch
P2176.30
FIG.6 FUSE AND FUSE HOLDER
Location:
The fuse and fuse holder are located on the rear of
the urn behind the rear utility cover.
RED from Main Harness
Test Procedures:
P2112
1. Disconnect the brewer from the power source.
2. Remove the cap and fuse from the fuse holder.
3. Remove fuse from the cap.
FIG. 7 FUSE HOLDER TERMINALS
4. Check for continuity through the fuse.
Ifcontinuityispresentasdescribed, reinstallthefuse,
the fuse is operating properly.
If continuity is not present as described replace the
fuse.
Removal and Replacement:
Fuse:
1. Remove the cap from the fuse holder.
2. Remove fuse from the fuse holder, inspect, if
blown discard.
3. Install new 5 amp fuse in the fuse holder.
4. Reinstall fuse holder cap.
10067.3 070102
Page 16
SERVICE (cont.)
LIMIT THERMOSTAT
RED to Main
Harness
RED to Control
Thermostat
P1984
P2180
FIG. 9 LIMIT THERMOSTAT TERMINALS
FIG. 8 LIMIT THERMOSTAT
Location:
The limit thermostat is located on the center rear
of the component bracket behind the tank heater.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the red wires from the limit thermo-
stat.
3. Check for continuity across the limit thermostat
terminals with an ohmmeter.
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 the wires from the limit thermostat termi-
nals.
2. Carefully slide the limit thermostat out from under
the retaining clip and remove the limit thermostat.
3. Carefully slide the new limit thermostat into the
retaining clip.
4. Refer to Fig. 9 and reconnect the wires.
10067.3 070102
Page 17
SERVICE (cont.)
7. Touchingthefreeendofthejumpertothebrewer's
frame simulates a "FULL" condition, preventing
jumper from touching the brewer's frame simu-
lates"NEEDWATER"condition.Connectthebrewer
tothepowersource,simulateeachconditionwhile
measuring the voltage between T1 and T3 on the
liquid level board. The indication should be 0 volts
with jumper touching the frame and 230 volts ac
nottouchingtheframe.Repeattheseseveraltimes.
Keep in mind there is an approximate five second
delay for output to stabilize.
LIQUID LEVEL BOARD AND LEVEL PROBE
8. Disconnect the brewer from the power source and
remove the jumper wire from T4.
If voltage is present as described, liquid level board is
operating properly, proceed to #9.
Ifvoltageisnotpresentasdescribed,replacetheliquid
level board.
P2116.40
FIG.10 LIQUID LEVEL BOARD AND
LEVEL PROBE
Location:
The liquid level board is located behind the lower
front access panel, to the right of center on the
component bracket. The level probe is located on the
right front of the upper component bracket.
9. Reconnect the pink wire to T4.
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.
13. Connect the brewer to the power source and
simulte the "FULL" and "NEED WATER" conditions
by touching the end of the probe to any metal
surface of the brewer. Measure the voltage be-
tween T1 and T3 on the liquid level board. The
indication should be 0 volts with the probe touch-
ing the frame and 230 volts ac not touching the
frame. Keep in mind there is an approximate delay
of five seconds for output to stabilize.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the blue wire (T1) and the pink wire
(T4).
3. Check for 230 volts ac across terminals (T2) and
(T3) with the ON/OFF switch in the "ON" position.
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.
14. Disconnect the brewer from the power source.
5. Reconnect the blue wire to T1 on the liquid level
board.
6. Carefully connect a piece of insulated jumper wire
to T4. Keep the other end of this wire away from
any metal surface of the brewer.
If voltage is present as described, reinstall the level
probe, the liquid level board and level probe are
operating properly.
If voltage is not present as described, check the pink
wire on the level probe from liquid level board T4.
10067.3 070102
Page 18
SERVICE (cont.)
LIQUID LEVEL BOARD AND LEVEL PROBE (cont.)
Removal and Replacement:
1. Remove all wires from the liquid level board.
2. Remove the #10-32 screw and flat washer secur-
ingtheprotectiveshieldtothecomponentbracket.
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.
6. Install protective shield and secure with #10-32
screw and flat washer.
7. Refer to Fig. 11 and reconnect the wires.
T1 BLU to Solenoid Valve
T2 RED to ON/OFF Switch
T3 BLK to Main Harness
T4 PNK to Level Probe
P1733.50
FIG.11 LIQUID LEVEL BOARD TERMINALS
10067.3 070102
Page 19
SERVICE (cont.)
ON/OFF SWITCH
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. Remove the wires from the switch terminals.
2. Compress the clips on the back side of the switch
and gently push them through the opening.
3. Push the new switch into the opening and spread
the clips to hold switch.
!
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4. Refer to Fig. 13 and reconnect the wires.
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BLK from Main Harness
(3)
RED to Fuse holder
(2)
P2130.25
RED to Start Switch, Brew
Timer & Liquid Level Board
(1)
FIG.12 ON/OFF SWITCH
Location:
P2120.50
FIG. 13 ON/OFF SWITCH TERMINALS
The ON/OFF switch is located on the left side of the
lower front access panel.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Remove the red wire on the ON/OFF switch from
the fuse holder and the black wire from the main
harness.
3. Connect the brewer to the power source. Check
the voltage across the removed wires with a volt-
meter. The indication must be 230 volts ac.
4. Disconnect the brewer from the power source.
If voltage is present as described, reconnect the wires
and proceed to #5
If voltage is not present as described, refer to the
wiring diagram and check the brewer wiring harness.
5. Disconnect all wires on the ON/OFF switch.
6. Check for continuity across the center terminal (2)
andthelowerterminal(1)whentheswitchisinthe
"ON"(upper)position. Continuitymustnotpresent
when the switch is in "OFF" (lower) position.
10067.3 070102
Page 20
SERVICE (cont.)
3. Disengage the fill tube (1) from the pump assem-
bly (4).
4. Remove the four #8-32 screws (6) securing the
pump assembly (4) to the component bracket (7).
5. Remove pump assembly (4).
PUMP ASSEMBLY
6. Remove pump gasket (5) and inspect, replace if
necessary.
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).
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).
11. Refer to Fig. 15 and reconnect the wires.
P2180
FIG.14 PUMP ASSEMBLY
Location:
The pump is located on the right of the upper
component bracket.
RED from Brew Timer
BLK from Swing Arm
Switch
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the black wire from the black lead on
the pump and the red wire from the black lead on
the pump.
3. With a voltmeter, check the voltage across the
black wire and the red wire with the swing arm
switch plunger depressed. Connect the brewer to
the power source. The indication must be 230
volts ac.
1
2
3
4
5
6
7
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. Place the ON/OFF in the "ON" (upper) posi-
tion and push the start switch and release. If pump
does not run, replace the pump.
If voltage is not present as described, refer to the
wiring diagrams and check the brewer wiring harness.
Removal and Replacement (Refer to Fig. 15):
1. Disconnect the wires from the pump assembly.
2. Loosenthe#8-32screw(2)securingtheclamp(3)
on the fill tube (1) and slide the clamp (3) up the fill
tube (1).
P2177
FIG.15 PUMP INSTALLATION
10067.3 070102
Page 21
SERVICE (cont.)
Removal and Replacement:
SELECTOR SWITCH (HALF BATCH OPTION)
1. Remove the wires from the switch terminals.
2. Compress the clips on the back side of the switch
and gently push them through the opening.
3. Push the new switch into the opening and spread
the clips to hold switch.
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FORE
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REPLACEMENT OF
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OWER SOURCE
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!
4. Refer to Fig. 17 and reconnect the wires.
G
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!
OWER SOURCE
OMPONENT!
D
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OF ANY
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DISCONNECT FROM
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BEFORE REMOVAL OF ANY PANEL OR
REPLACEMEN
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:
N
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GRY to Brew Timer
PNK to Brew Timer
P2130.25
FIG. 16 SELECTOR SWITCH (HALF BATCH)
Location:
P2118.60
FIG.17 SELECTOR SWITCH TERMINALS
The selector switch is located to the right of the
front access panel above the start switch.
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" (lower - half)
position. Continuity must not be present when the
switch is in the "OPEN" (upper - full) position.
If continuity is present as described, the switch is
operating properly.
If continuity is not present as described, replace the
switch.
10067.3 070102
Page 22
SERVICE (cont.)
SOLENOID
7. 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
blockage 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:
P2180
FIG. 18 SOLENOID
1. Remove all wires from the solenoid valve.
2. Turn off the water supply to the brewer.
3. Disconnect the water inlet line from the connector
on the solenoid valve.
4. Remove solenoid, connectors, and tank inlet tube
as an assembly.
Location:
The solenoid is mounted on the upper left rear of
the component bracket.
Test Procedures:
5. Remove the tank inlet tube grommet and discard.
6. Install new tank inlet tube grommet.
7. Install new solenoid assembly.
8. Install water inlet tube to connector on the sole-
noid.
9. Turn on the water supply to the brewer.
10. Refer to Fig. 19 and reconnect the wires.
1. Drain 1/2 gallon of water from the faucet in order
to activate the probe.
2. Disconnect the brewer from the power source.
3. Place the ON/OFF switch in the ON position.
4. Disconnect the blue wire from the liquid level
boardT1andtheblackwirefromthemainharness
to the solenoid. With a voltmeter, check the volt-
age across the blue wire and the black wire.
Connect the brewer to the power source. After an
approximate 5 second delay, the indication must
be 230 volts ac.
BLU from Liquid
Level Board T1
5. Disconnect the brewer from the power source.
If voltage is present as described, proceed to #6.
If voltage is not present as described, refer to the
brewer wiring diagram and check the wiring harness.
BLK from Main
Harness
GRN from Main
Harness
FIG. 19 SOLENOID TERMINALS
6. Check for continuity across the solenoid valve coil
terminals.
P1741.30
If continuity is present as described, reconnect the
wires to the solenoid.
If continuity is not present as described, replace the
solenoid valve.
10067.3 070102
Page 23
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
and gently push them through the opening.
3. Push the new switch into the opening and spread
the clips to hold switch.
4. Refer to Fig. 21 and reconnect the wires.
!
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BLU to Brew Timer
P2130.25
RED from ON/OFF
Switch
FIG. 20 START SWITCH (BREW)
Location:
P2119.65
The brew start switch is located on the lower right
of the front access panel, beneath the selector switch.
FIG.21 BREW START SWITCH TERMINALS
Test Procedures:
1. Disconnect the brewer from the power source.
2. Remove the wires from the start switch terminals.
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.
If continuity is present as described, reconnect the
wires the switch is operating properly.
If continuity is not present as described, replace the
switch.
10067.3 070102
Page 24
SERVICE (cont.)
Removal and Replacement:
NOTE: Measurethedistancefromthetopoftheswitch
plunger to the hood cover. The same distance is
needed when the new switch is installed.
1. Remove nut securing switch to hood cover and
remove switch.
SWING ARM SWITCH
2. Install new switch. Refer to Fig. 23 and reconnect
the wires.
3. Install all panels.
4. Test action of swing arm and switch for activation.
5. Adjust switch assembly up or down as needed for
proper operation.
NOTE: Do not remove cam assembly from swing
spout.
P2139.40
FIG. 22 SWING ARM SWITCH
Location:
The swing arm switch is attached to the cupola
cover.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Remove the cupola cover end caps, swing spout
and cupola cover.
BLK from Pump
3. Disconnect the two black wires connected to the
switch.
BLK from Timer
P2140.70
4. Check for continuity across the terminals on the
switch.
5. Continuity should be present when switch plunger
is depressed.
FIG. 23 SWING ARM SWITCH TERMINALS
If continuity is present as described, the switch is
operating properly.
If continuity is not present as described, replace the
switch.
10067.3 070102
Page 25
SERVICE (cont.)
TANK HEATER
Removal and Replacement:
1. Remove the 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. Position new tank heater and gasket on the com-
ponentbracketandsecurewithfour#8-32screws.
5. Refer to Fig. 25 and reconnect the wires.
RED (Thermal Fuse) to
Contactor Lower Right
Terminal)
P2180
FIG. 24 TANK HEATER
Location:
Thetankheaterislocatedonthefrontcenterofthe
upper component bracket.
BLK (Thermal Fuse) to
Contactor Lower Left
Terminal)
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, tank heater is
operating properly.
If continuity is not present as described, replace the
tank heater.
P1746
FIG. 25 TANK HEATER TERMINALS
10067.3 070102
Page 26
SERVICE (cont.)
THERMAL FUSES
P2121.40
FIG. 26 THERMAL FUSES
Location:
The thermal fuses are mounted between the tank
heater terminals and the contactor terminals.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the thermal fuse from the tank heater
terminal and the contactor lead.
3. Check for continuity across the terminals on the
ends of each thermal fuse.
If continuity is present as described, the thermal fuse
is operating properly.
If continuity is not present as described, replace the
thermal fuse.
Removal and Replacement:
1. Disconnect the thermal fuse from the tank heater
terminal and the contactor lead and discard.
2. Connect the new thermal fuse to the tank heater
terminal and the contactor lead.
10067.3 070102
Page 27
SERVICE (cont.)
TIMER
If voltage is present as described, proceed to #8.
If voltage is not present as described, refer to the
wiring diagram and check the brewer wiring harness.
8. Disconnect the black and white wires to the swing
arm switch and pump leads.
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 230 volts ac.
If voltage is present as described, the brew timer is
operating properly. Reset the timer dial as required, to
obtain the desired brew volume.
3
4
2
1
.5
MINUTES
BUNN-O-MATIC
P/N 2235-120 VAC
If voltage is not present as described, replace the
timer.
EARLY MODELS
FIG. 27 TIMER
P2114.40
Removal and Replacement:
Location:
1. Disconnect the male connector on the timer from
the female connector on the main wiring harness.
2. Disconnect the timer leads from the swing arm
switch lead and pump lead.
The timer is located behind the front access panel
on the right side of the component bracket.
3. DisconnectthethreepinconnectorfromtheHALF/
FULLbatchselectorswitchtothethreepinplugon
the brew timer.
4. Remove the two #8-32 screws securing the brew
timer to the component bracket and remove timer.
5. Position new timer on the component bracket and
secure with two #8-32 screws.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnectthepolarized,threepinconnectorfrom
thebrewermainharnessandrotatethebrewtimer
dial fully counterclockwise.
3. With a voltmeter check the voltage across sockets
P2 and P3 (black and 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 230 volts ac.
6. Refer to Fig. 30 and reconnect the wires.
Three Pin Connector from
Half/Full Batch Switch
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 the
wiring diagram and check the brewer wiring harness.
To Three Pin Female
Connector on Main
Harness
5. With a voltmeter check the voltage across the
sockets P1 and P2 (blue and black wires) of the
female connector on the main harness when the
"ON/OFF"switchisinthe"ON"(upper)positionand
thestartswitchpressed.Connectthebrewertothe
powersource.Theindicationmustbe230voltsac.
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.
BLK to Swing Arm
Switch Lead
WHI to RED Pump
Lead
P1751
EARLY MODELS
FIG. 28 TIMER TERMINALS
10067.3 070102
Page 28
SERVICE (cont.)
DIGITAL BREW 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 termi-
nals TL1 and TL4 when the "ON/OFF" switch is in
the"ON"position. Connectthebrewertothepower
source and press the "START" switch. The indica-
tion must be 230 volts ac.
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.
LATE MODELS
P2211.40
Removal and Replacement:
1. Remove the two #8-32 screws securing circuit
board to the mounting bracket.
FIG. 29 DIGITAL BREW TIMER
Location:
2. Remove circuit board and spacers (as required).
3. Remove all wires from the timer.
The timer is located inside the front of the trunk on
the top of the component bracket.
4. Attach all wires to the replacement timer board
prior to installation to the component mounting
bracket. Refer to FIG. 30 when reconnecting the
wires.
5. Install new circuit board with spacers (as re-
quired) to the component mounting bracket.
6. Adjust the timer as described below.
Test Procedure.
NOTE:Donotremoveorinstallwireswhiletimerboard
is installed. Pressure applied to one side may cause
damage to the board.
1. Disconnect the brewer from the power source and
remove the front access panel.
2. Remove the two #8-32 screws securing circuit
board to the mounting bracket.
3. Remove circuit board and spacers (as required).
4. With a voltmeter, check the voltage across termi-
nals TL1 and TL2 when the "ON/OFF" switch is in
the"ON"position. Connectthebrewertothepower
source. The indication must be 230 volts ac.
Timer Setting:
NOTE: Prior to setting or modifying volumes, 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.
NOTE: All volume settings must be done with the
swing spout shield installed.
5. Disconnect the brewer from the power source.
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.
If voltage is present as described, proceed to #6.
If voltage is not present as described, refer to the
Wiring Diagrams and check the brewer wiring har-
ness.
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
6. With a voltmeter, check the voltage across termi-
nals TL1 and TL4 when the "ON/OFF" switch is in
the"ON"position. Connectthebrewertothepower
source. The indication must be 0 volts.
10067.3 070102
Page 29
SERVICE (cont.)
DIGITAL BREW TIMER (Late Models)
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 pre-
vent 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 im-
mediately 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.)
View the level of the liquid being dispensed. When
the desired level is reached, turn the ON/OFF switch
to “OFF”.
NOTE: The brewer remembers this volume and will
continue to brew batches of this size until the volume
setting procedure is repeated.
BLU/BLK wire from TL5 to P1
WHI/GRN wire from TL4 to (WHI) Pump
WHI/BLU wire from TL3 to (BLK) Swing Arm Switch
WHI wire from TL2 to P2
BLK wire from TL1 to P3
J2 - Three Pin connector from Half/Full Batch
Switch
P2037
NOTE: When brewing coffee, volume will decrease due
to absorption by the coffee grounds.
FIG. 30 DIGITAL TIMER TERMINALS
NOTE: Half-Batch and full batch settings must each
be set separately.
10067.3 070102
Page 30
PNK
10067.3 070102
Page 31
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