Crathco / Grindmaster FDD2500 Service manual
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Grindmaster Model FDD2500
Service Manual
for
Model FDD2500
Table of Contents
Warning Labels....................................
1 2
Installation ..........................................
1 3
Programming ......................................
1 4
Start-up & Adjustments ......................
1 7
Cleaning ..............................................
1 8
Shipping Preparation ........................ 1 10
Replacing Controller ............................11
Replacing Components ........................11
Product Out Adjustment......................11
Troubleshooting Guide ........................12
Assembly Drawings ..............................14
Wiring Diagrams .................................. 28
Prior authorization must be obtained from Grindmaster
Corporation for all warranty claims.
© Grindmaster Corporation, 2005
PRINTED IN USA
Model FDD2500-1-M-B
Model FDD2500-3-M-B
Model FDD2500-1-3A-B
Model FDD2500-3-3A-B
Grindmaster Corporation
4003 Collins Lane
Louisville, KY 40245 USA
(502) 425-4776
(800) 695-4500 (USA & Canada only)
FAX: (502) 425-4664 www.grindmaster.com
0307 Form # AM-342-04
Part #63361
Warning Labels
The following warning labels were on your dispenser when it was shipped from the factory. They should remain on your dispenser in good, readable condition at all times. If one of your labels is missing or damaged, order a replacement label immediately.
Part #71582
Located on machine cover and spout mounting bracket.
Part #63370
For FDD2500- -M-B models only *
Part #63371
Located next to center spout
Part #62981
Located on front splash panel
WARNING
Contents can cause severe burns if handled improperly.
ADVERTENCIA
Contenidos pueden causar quemaduras severas si el uso es inadecuado.
AVERTISSEMENT
Contenu peut provoquer des brûlures grâves si il est manipulé incorrectement.
PN# 62981
Part #63448
Located on tank drain hose
Page 2 Model FDD2500
Installation
WATER INLET CONNECTION
The National Sanitation Foundation requires the following for an NSF approved water hook-up:
1. A quick disconnect water connection or enough coiled tubing so that the machine can be moved for cleaning underneath.
2. An approved backflow prevention device, such as a double check valve to be installed between the machine and water supply. On units plumbed to permanent water line, installation of a water filter/softener system is recommended to prevent lime and scale build up in the machine. On units pumping from remote water container, filtered water is recommended to prevent lime and scale buildup in the machine.
3. Water pipe connections and fixtures directly connected to potable water supply shall be sized, installed and maintained in accordance with Federal, State, and Local codes.
WATER HOOK-UP
1. Install the 4" legs and hand tighten. Install the plastic drain tray onto the drain tray bracket and install drain grid. (Note: The drain tray is provided with a drill-out port to allow for plumbing to a drain.)
2. Remove front splash panel for access to water hook-up. (see Figure 1)
3. Ensure the 3/8" water supply hose has sufficient length to allow the machine to be moved for cleaning or service. Supplying hot water to the machine will greatly increase the capacity of the machine. The use of copper tubing is required to prevent rupture when using a hot water supply. A maximum inlet water temperature of 160°F (71°C) is recommended.
4. Flush the water line to purge any debris from the supply line.
5. Connect a 3/8" water line to the 3/8" male flare connection.
6. Ensure water supply to machine is within 20 to 100psi. Install a pressure regulator if pressure is too high.
7. Turn on water supply and check for leaks.
Figure 1
WARNING: ELECTRIC SHOCK HAZARD
Only qualified service personnel should perform installation of this appliance.
Improper installation could result in serious injury or death.
WARNING: ELECTRIC SHOCK HAZARD
Never use the ground conductor as a neutral conductor. Serious injury or death could occur in the event of a fault condition.
WARNING: ELECTRIC SHOCK HAZARD
Always disconnect power to the machine before servicing or cleaning. Risk of electric shock is present which can cause serious injury or death.
Model FDD2500 Page 3
Installation (cont.)
ELECTRICAL HOOK-UP
Ensure water connection is made to machine before proceeding.
The electrical ratings for your dispenser are located on the serial plate on the outside cabinet and inside door.
For configuration of three heater models to optional wattages, refer to page 31 of service manual.
1. For cord connected models, plug the power cord into an appropriate grounded and dedicated electrical outlet. Go to step 8.
2. For hard-wired models not supplied with an electrical cord, the dispenser should be connected to a dedicated circuit with a fused disconnect switch or a circuit breaker near the dispenser.
3. Strain relief is supplied under the machine chassis for power entry.
(see Figure 2)
• Electrical connections and wiring materials must conform to local codes and/or be in compliance with the National Electric Code
• Use only copper conductors
4. Note: Wiring diagram is on inside of left side panel.
5. Connect the power supply conductors, neutral (optional) and ground wire to the appropriate positions on the terminal block. The ground lug is separate from the terminal block. Note: machine is equipped with a stepdown transformer to provide the necessary 120 volt power supply for the control circuits. Neutral will not be used.
6. Remove lid and left side panel. (see Figure 3)
Figure 2
Move red wire on transformer to:
• “H2” for 208V supply
• “H3” for 240V supply
7. Install the front splash panel.
8. Install the plastic drain tray into the drain tray rails then place drain grid onto drain tray.
9. Flip power supply to machine “ON” at the branch supply disconnect.
10. Flip power switch to the “ON” position and allow the water tank to fill. The machine will make a subtle hissing sound while filling. Allow 3-4 minutes for fill time depending on water pressure.
Figure 3
Attention: This machine employs an interlock switch to disable the dispense and fill circuits when the front door is open. Ensure the front door is closed while installing or operating the machine.
A watchdog circuit also monitors the water level in the tank and will disable the machine if the water level in the tank is not normal within (5) minutes of fill time. The machine will require power to be reset to clear the watchdog timeout.
11. After the water tank has completed the fill cycle, the display will read “Water Heating” signifying that the heating element has been activated. Allow 10-45 minutes for the display to read “Ready” signifying the water tank has reached operating temperature. (Note: Heatup time is dependent on water inlet temperature and input wattage to the machine.)
Page 4 Model FDD2500
Programming Machine from Touchpads
Tools Required: None
MACHINE PROGRAMMING: The machine operating parameters can be changed from the touchpad and LCD display without opening up the machine. (See illustration below).
PROCEED INCREMENT UP
POWER ON/OFF
(STANDBY)
INCREMENT DOWN
To enter Programming Mode:
Press and hold (>) and (+) at the same time for approximately 5 seconds.
Tip: Use the eraser end of two pencils to press the buttons if you are having difficulty entering programming mode.
To Exit programming mode at anytime:
• Wait 20 seconds without pressing a button.
• The display will prompt “Exit?”
• Press (+) or (-) to toggle between YES and NO.
• After selecting YES, you MUST press (>) to SAVE changes, or wait for ready message and machine will exit without saving.
Tip: To verify changes successfully save, re-enter programming mode and check settings.
1) Press (>) to select Language. (1A)
Press (+) to choose English, Spanish, German, or French.
2) Press (>) to set the Time of day on the machine.
Press (+) or (-) to change the time.
3) If password is activated, enter password now.
a) Press (+) to enter first number.
b) Press (>), then (+) to enter second number.
c) Press (>), then (+) to enter third number.
NOTE: The default password is “111”. If the password has been changed and forgotten, press “I/O” and “+” at the same time to proceed.
4) Press (>) to change Password settings. (2B)
Press (+) or (-) to toggle between ON (enable password) and OFF (disable password).
If ON is selected, press (>) to change password.
a) Press (>) to enter new password. (following steps 3 a, b, c) b) Press (>) to confirm new password. (following steps 3 a, b, c)
5) Press (>) to program Dispense Settings. (to change Portion Sizes) (2E) (For FDD2500-**-3A models only) a) Press (+) for message “Select Dispense Button”. (5A) b) Press the dispense button for the dispense head you wish to adjust the settings. LCD will display L, M, or R for left, middle, or right dispense head to acknowledge your selection.
c) Once the dispense head is selected, press (+) or (-) to change the amount of time (portion size) for the beverage being dispensed.
6) Press (>) to change Whipper Settings. (5A1) a) Press the dispense button for the dispense head you wish to adjust the settings. LCD will display L, M, or R for left, middle, or right dispense head to acknowledge your selection.
b) Once the dispense head is selected, press (+) or (-) to toggle between ON (turn whipper ON) and OFF
(turn whipper OFF).
7) Press (>) to return to Dispense Settings. (2E)
Repeat steps 6 & 7 for remaining heads.
8) Press (>) to modify Drink Strength. (7A) a) Press (>) to Select a Dispense Button. (7B) b) Press the dispense button for the dispense head that you want to change the drink strength for.
c) Press (+) or (-) to modify the auger speed which changes the drink strength (0-100% of maximum auger speed in 1% increments).
Note: A faster speed will result in a stronger drink and a slower speed will result in a weaker drink.
Model FDD2500 Page 5
Programming Machine from Touchpads (cont.)
9) Press (>) to modify Auger Delay. a) Press (>) and select dispense button.
b) Press the dispense button for the dispense head that you want to change the auger ON delay time.
c) Press (+) or (-) to modify the time in tenths of a second.
10) Press (>) to modify Auger Off Delay. a) Press the dispense button for the dispense head that you want to change the auger OFF delay time.
b) Press (+) or (-) to modify the time in tenths of a second.
11) Press (>) to change Heater settings. (8A)
Press (+) or (-) to toggle between ON (water tank heater ON) and OFF (water tank heater OFF).
12) Press (>) to modify Water Tank Temperature. (7A)
Press (+) or (-) to increase or decrease water tank temperature.
13) Press (>) to modify Low Temp/No Brew settings. (7B)
Press (+) or (-) to toggle between ON (will not allow drinks to dispense if water temperature is below programmed temperature) and OFF.
a) If turned ON press (>) to modify Minimum Dispensing Temp.
b) Press (+) or (-) to increase or decrease Minimum Dispensing Temp.
14) Press (>) to change Sleep Mode settings. (8A)
Press (+) or (-) to toggle between OFF and ON (forces the water tank temperature to a programmed temperature after a programmed time of inactivity – used for energy savings).
a) If turned ON, press (>) to change Sleep Mode Settings.
b) Press (+) or (-) to increase or decrease the amount of time the unit is inactive before going into sleep mode.
c) Press (>) to change sleep mode water tank temperature setting.
d) Press (+) or (-) to increase or decrease the water tank temperature during sleep mode.
15) Press (>) to view Manual Dispense mode. (9A)
(Models with manual Free-Flow Tomlinson handles cannot be changed to portion control.)
16) Press (>) for Sales Mode. (14A) (This option for future use. “Free” is currently the default setting.)
17) Press (>) to retrieve Sales Data. (15A)
18) Press (>) to view Total Dispense data (number of drinks dispensed per head). (15B)
Press the dispense buttons that you want to retrieve information about.
After viewing each head’s data, proceed to next step.
19) Press (>) to view Total Brews data. (15E)
LCD will display total number of drinks dispensed by the unit.
20) Press (>) for Clear Data options. (16A)
Press (+) or (-) to toggle between YES (resets sales data counter to “0”) and NO.
Important: After selecting YES and then pressing (>) all data will be cleared immediately.
21) Press (>) to view Dispenser Type. (17A)
LCD will display type of dispenser.
22) Press (>) to display Date Code information. (18A)
LCD will display manufacture date.
23) Press (>) to display Software Version on controller. (19A)
Displays current software version stored in controller memory.
24) Press (>) to Retrieve Error Codes. (20A)
Press (+) or (-) to toggle through and review all error codes. The LCD will display the number of times each error code has occurred. Error Codes:
SC1: No Water Pressure
SC2: Reset Power (Error has occurred that requires power to be reset).
SC3: Low Water Level (Inlet valve ON for more than 5 minutes.)
Page 6 Model FDD2500
Programming Machine from Touchpads (cont.)
24) Press (>) to Retrieve Error Codes. (20A) (cont.)
SC4: Thermistor Failure (Temperature is out of range – less than 32°F or greater than 210°F.)
SC6: Check Heating (Tank is too hot.)
SC8: Overcooling
SC9: Overflow (Water level safety probe is tripped.)
SC10: Adjust Temperature (Temperature adjusted from touchpad.)
25) Press (>) for Clear Error Code options. (20B)
Press (+) or (-) to toggle between YES (clears all stored error codes from memory) and NO.
Important: After selecting YES and then pressing (>) all data will be cleared immediately.
26) Press (>) for EXIT option
Press (+) or (-) to toggle between YES and NO.
Important: After selecting YES, you MUST press (>) to SAVE changes, or wait for READY message and machine will exit without saving.
WARNING: Disconnect power before servicing machine.
FILLING PRODUCT HOPPERS (see Figure 4)
1) Open door.
2) Lift hinged top.
3) Remove hopper lid.
4) Carefully pour product into hopper.
5) Replace hopper lid.
6) Lower hinged top.
7) Close door.
THERMOSTAT ADJUSTMENT
(See machine programming procedure: Water tank temperature)
Figure 4
Tools required: None
NOTE: The thermostat range is approximately 40°F to 205°F (4°C to 96°C). The water tank temperature is factory set at 190°F (87°C), making the beverage temperature slightly lower than 190°F (87°C).
HOW TO DISPENSE A DRINK
Machine is equipped to dispense into cups, decanters, 1.3 L servers, 2.2 L airpots or hose connected to 5 gal. containers.
WARNING: Server must rest flat on tray with a 1/4" (6 mm) clearance between cup and spout. Contents can cause severe burns if handled improperly.
For Manual Machines FDD2500-1-M-B and FDD2500-3-M-B:
1) Place a server under the selected drink dispense nozzle.
2) Pull dispense handle until cup is 2/3 full, then release handle.
For Automatic Machines FDD2500-1-3A-B and FDD2500-3-3A-B:
1) Place a server under the selected drink dispense nozzle.
2) Press and release desired dispense button.
NOTE: To stop a dispense, simply press-and-release any button.
DRINK STRENGTH ADJUSTMENT
Auger (%)
Soluble Coffee
(grams/oz)
Freeze Dried
Coffee (grams/oz)
Tools required: None
1) Dispense a drink to determine if drink is too strong or weak.
2) See Drink Strength section within machine programming.
NOTE: Water flow rate cannot be adjusted. Flow rate will be in the range of 2.0-2.4 oz/second. To change drink strength, adjust auger speed from the programming menu.
Estimated grams of coffee per ounce of water for Soluble and Freeze
Dried Coffee at each auger speed setting (see chart on right):
70
75
80
85
50
55
60
65
15
20
25
30
35
40
45
0.54
0.55
0.62
0.70
0.73
0.77
0.84
0.88
0.13
0.17
0.22
0.28
0.32
0.39
0.44
0.40
0.43
0.46
0.50
0.54
0.55
0.63
0.63
0.11
0.15
0.20
0.24
0.29
0.33
0.36
Model FDD2500 Page 7
WARNING: Disconnect power before servicing machine.
PORTION SIZE ADJUSTMENTS (FDD2500-*-3A-B Models Only)
To adjust portion sizes for each button, adjust times within “Dispense Settings” section from the programming menu.
Estimated portion times for given volumes:
Ounces
12
32
44
60
74
84
5 Gallons
Liters
0.35
1.0
1.3
1.8
2.2
2.5
19
26
33
38
Portion Time
(seconds)
5.3
14
9
280
Cleaning
Daily Cleaning
1.
CAUTION: When cleaning the unit, do not use cleansers, liquid bleach, powders or any other substance that contains chlorine. These products promote corrosion of stainless steel and plastic parts. Use of these products will void the warranty.
WARNING : Do not use a water jet to clean machine. Risk of electric shock.
Empty drip pan as needed and wash daily in a dish detergent.
Wipe down all surfaces of the dispense spouts, product storage cabinet, splash panel and drip tray areas with a clean soft cloth using a mixture of one ounce Ivory liquid detergent (or equivalent) to one gallon of fresh water. Follow by wiping down all surfaces of the dispense spouts, product storage cabinet, splash panel and drip tray areas with a clean soft cloth moistened with fresh water and allow to air dry.
2.
Rinse out the funnel by placing the rinse switch (located to the right of the dispensing valves when the door is open) in the ON position. Dispense one to two cupfuls until the water is clear.
Short bursts of dispensing may also help clean the chambers. When complete, return the rinse switch to the OFF position.
Cleaning the Funnel – Disassembly
1.
Open the door and remove the large tube from the funnel cover, then remove the cover.
Weekly Cleaning
Cleaning the Funnel – Reassembly
1.
Place funnel into position, then connect hoses.
2.
Remove the mixing funnel by removing silicone tube at the side, then remove funnel.
2.
Place funnel cover on funnel and connect large tube.
3.
PARTS IN CONTACT WITH FOOD MUST BE WASHED,
RINSED, SANITIZED, AND AIR DRIED.
Page 8 Model FDD2500
Cleaning (cont.)
Cleaning Hoppers – Disassembly
CAUTION: Do not wash hopper without first disassembling.
1.
Open door, disconnect large hose from funnel cover and then lift off funnel cover.
Weekly Cleaning (cont.)
Cleaning Hoppers – Reassembly
IMPORTANT: All components must be completely dry prior to reassembly.
1.
Place driveshaft bearing inside hopper with threads going through hole in the rear of the hopper.
2.
Lift off ring heater and set aside.
3.
Lift open lid and remove coffee spill pan.
2.
Secure the bearing by attaching the palnut to the bearing outside rear hopper opening. Use one hand inside the hopper to push the bearing outward while turning the palnut clockwise.
4.
Remove the hopper from the cabinet.
5.
6.
Remove the hopper cover and empty hopper contents.
Remove the auger pinwheel by pulling it forward while stretching out the sides of the hopper.
PULL
3.
Install the auger spring driveshaft and the auger spring by inserting the flat end of the spring into the hole in the auger spring driveshaft.
4.
Insert assembly into lower front hopper opening, making sure the threaded end of the auger spring driveshaft completely inserts into the plastic driveshaft bearing in the rear of the hopper. The driveshaft bearing threads should be accessible from the outside rear of the hopper.
5.
Place the washer over the driveshaft bearing threads followed by securing the drivelink onto the driveshaft bearing by turning counterclockwise. Secure the auger spring with one hand while attaching the drivelink with the other.
6.
Replace the auger pinwheel making sure the pins are securely positioned inside the locator holes in the hopper.
Auger Spring
Driveshaft
7.
Remove the drivelink and washer at the rear of the hopper by holding the auger spring with one hand at the front of the hopper while turning the drivelink clockwise with the other hand.
8.
Remove the auger spring and auger spring driveshaft by pulling out through the lower front opening of the hopper.
9.
Remove the palnut at the rear of the hopper by turning it counterclockwise then remove the driveshaft bearing from the inside of the hopper.
Driveshaft
Bearing
10.
All parts in contact with food must be washed, rinsed, sanitized, and air dried.
7.
8.
Carefully fill the hopper with product and replace the cover.
Reinstall hopper into the machine, making sure it is properly aligned.
Install ring heater to front spout.
10.
Open lid and install coffee spill pan.
11.
Install funnel cover with large tube attached.
Model FDD2500 Page 9
Prepare for Shipment
Important: Always completely empty water tank and PRODUCT HOPPERS prior to shipping unit. (See Draining the Tank and Cleaning the Hoppers section).
NEVER SHIP UNIT WITH PRODUCT IN HOPPER OR WATER IN TANK –
THIS WILL CAUSE IRREPARABLE DAMAGE.
Draining the Tank
Always empty the tank before shipping.
WARNING: Draining of the tank should be performed by a qualified service technician. The tank contains
7.5 gallons (28.4L) of very hot water. May cause severe burns.
1.
Prepare a heat resistant container to drain 7.5 gallons
(28.4L) of hot water from the tank into.
5.
Pinch hose with fingers and remove the hose clamp and plug.
2.
Disconnect power to machine.
3.
Remove the drain tray and front access panel.
4.
Locate the silicone drain hose.
Put the end of the drain hose into the container. Secure the end of the drain hose (i.e. with tape) into the container.
6.
Allow the tank to drain completely.
NOTE: It may be necessary to pinch the hose and stop the water before container is full. Carefully re-install plug, then empty container. Repeat steps 4-6 to completely drain tank.
7.
Once the tank is empty, securely replace the plug and clamp on the end of the hose. Reposition the drain hose.
8.
Reassemble the front access panel and drain tray.
Page 10 Model FDD2500
WARNING: Disconnect power before servicing machine.
REPLACING CONTROLLER
Tools Required: Phillips Head Screwdriver
1. Remove 4 screws and lift off lid.
2. Lift off right side panel.
3. Carefully disconnect each wiring connector from controller.
NOTE: Pull only on connectors. Do not pull on wires.
4. Carefully spring-back mounting clips and lift controller out of clips.
NOTE: Do not pull or press on sensitive controller components. Handle controller by touching the edges.
NOTE: Reverse procedure to install controller. Make sure connector ramps and pins are properly aligned before installing connectors.
REPLACING COMPONENTS
Tools Required: Phillips Head Screwdriver
1. Remove drain tray.
2. Remove 2 screws then remove front panel.
3. Remove 4 screws then remove lid.
4. Lift off side panels and/or rear panel.
5. Replace components as needed.
ADJUSTMENT TO “ADD PRODUCT” SENSORS
Capacitive Sensors might need to be adjusted if either situation occurs:
• Hoppers are full and display reads “ADD PRODUCT” when attempting a dispense.
• Hoppers are empty and display does NOT read “ADD PRODUCT” when attempting a dispense.
Adjusting Capacitive Sensors:
1. Remove one hopper.
2. Install empty hopper securely in place.
3. With small screwdriver, turn adjustment inside sensor until light turns ON.
(see Figure 5)
4. Slowly turn adjustment until light turns OFF.
5. Display should read “Add Product”.
6. Install full hopper.
7. Display should NOT read “Add Product”.
8. Readjust if needed.
9. Repeat on other head if needed.
Figure 5
Model FDD2500 Page 11
Troubleshooting Guide
NOTE: The LCD display provides diagnostic feedback for determining the cause of fault or abnormal conditions. Error codes listed below are stored in the controller memory and can be retrieved through the programming menu. Additional diagnostic LEDs are located on the controller located behind the right side panel. See wiring schematics for LED locations and descriptions. Disconnect power before servicing machine.
Failure to do so can result in risk of electric shock.
Problem Possible Cause Solution
LCD display not illuminated • Power switch turned “OFF”
• No power supplied to machine
• Ground Fault Circuit Interrupter (GFCI) has tripped
• Machine control transformer circuit breaker has tripped
• Fuse has blown.
• Faulty wiring connections
• Press and release “I/O” button located under the display.
• Turn power switch “ON”.
• Ensure machine is plugged in at wall socket.
• Reset GFCI (if applicable) at power outlet
• Check if green LED is illuminated on control board located behind right panel. If LED is not illuminated, reset the control transformer circuit breaker located next to the control board.
NOTE: An overload condition can reoccur. The overload condition must be diagnosed and corrected.
• Replace fuse. (see figure on right)
• Ensure all wiring connectors are plugged into display board and control board correctly. Check if any wires have pulled loose from terminals.
Fuse
#63395
LCD display shows error code (i.e. SC 1, 2, 3, etc.)
SC1: No Water Pressure
SC2: Reset Power
SC3: Low Water Level
SC4: Thermistor Fail
SC6: Check Heating
This feature is disabled and should not appear.
• A fault condition described below has occurred requiring power to be reset to machine.
1) Water tank fill circuit has exceeded the maximum run time (5 minutes)
2) A water tank overflow condition has occurred
3) A water tank heating condition has exceeded the water tank temperature set point due to:
• Welded contacts on heater contactor
• Machine is filling the water tank
• Faulty water inlet valve electrical connections
• Faulty water inlet valve
• Insufficient water flow rate to machine (typically during dispensing only).
• Thermistor is disconnected
• Thermistor was subjected to sudden temperature change (i.e. filling or draining tank)
• Thermistor resistance valve is out of
“valid” range
Water temperature has increased above set point due to:
• Abnormal increase or decrease in water tank temperature
• Welded contacts on heater contactor.
• For #1-3, turn power switch OFF for 5 seconds, then ON.
• Call Technical Service for assistance.
• Allow machine to fill the water tank
• Ensure electrical leads are properly made to water inlet valve
• Check for power across water inlet valve terminals. If power is not detected, replace water inlet valve.
• Allow water tank to fill. If problem continues, check for restrictions in water line and check for proper water pressure (20-100 psi).
• Check thermistor wiring connections
• Allow water temperature to stabilize, reset power to machine.
• Reset power first, if continues, check thermistor resistance (consult factory for details), replace if necessary
• Inlet water temperature must be below temperature set point of water tank
• Check heater contactor for welded contacts, replace contactor if necessary
SC9: Overflow condition • Water inlet valve weeping (leaking valve seal)
• Water inlet valve stuck open
• Loose water level probe connection
• Replace inlet valve
• Replace inlet valve
• Check connection to water level probe
Add Product • Hopper is empty
• Hopper is disengaged
• Capacitive sensor needs to be adjusted
• Fill hopper
• Make sure hopper is properly in place
• See “Add Product” Adjustment section on page 9.
Page 12 Model FDD2500
Troubleshooting Guide (cont.)
Problem Possible Cause
LCD display shows “Standby” • Machine is in “STANDBY” mode
No water or product is dispensed
• Machine is in “STANDBY” mode
• Door is open
Solution
• Press “I/O” on touchpad to activate machine. (Standby switch acts as a power switch to the control module of the machine; however, the machine is still powered up.)
• Press “I/O” on touchpad to activate machine. (Standby switch acts as a power switch to the control module of the machine; however, the machine is still powered up.)
• A door interlock disables the dispense circuit when the door is open. The door interlock switch is located behind the door near the lower hinge and can be overridden by pulling the switch plunger out. The switch will reset when the door is closed.
No water is dispensed • Blockage in water delivery circuit • Check for kinked water delivery tubing, lime and scale blockage to and from dump valve.
Powder not dispensing • Coffee dispense outlet clogged
• Hopper drive link not engaged with drive motor
• Low or no product
• “Drink Strength” setting too low
• Clean hoppers according to cleaning procedure
• Remove and reinstall hopper to engage with drive motor
• Check product container for product
• Check “Drink Strength” setting (see programming guide for setting Drink Strength)
Water overflows mixing funnel • Powder flow rate too fast – too much powder to water ratio can prevent adequate mixing resulting in blockage in mixing funnel
• Outlet is restricted
• Adjust powder flow rate to prevent blockage in mixing funnel
Drink is too cold or hot
Drink is too weak or strong
Water tanks boils water • Water temperature too high for elevation of installation
• Ensure mixing chamber outlets are free of blockage. Follow rinse and cleaning procedure to prevent buildup of product in mixing system.
• Check temperature set point and adjust as needed. (Refer to
Programming Guide for Thermostat Adjustment section)
• Check drink strength to desired taste. (Refer to Programming
Guide for Drink Strength Adjustment)
• Adjust water temperature down. Refer to Thermostat
Adjustment section.
If you still need help, call our service department (Monday – Friday, 8 am – 8 pm EST) at (800) 695-4500 (USA and Canada only) or (502) 425-4776 or an authorized service center in your area. Please have the model and serial numbers ready so that accurate information may be given. Prior authorization must be obtained from Grindmaster Corporation’s Technical
Services Department for all warranty claims.
Model FDD2500 Page 13
FDD2500 Assembly
Page 14 Model FDD2500
FDD2500 Frame Assembly
Model FDD2500 Page 15
FDD2500 Door Assembly
for models FDD2500-1-M-B
FDD2500-3-M-B
FDD2500-1-3A-B
FDD2500-3-3A-B
Page 16 Model FDD2500
FDD2500 Lid Assembly (part # 63238)
4
2
4
3
1
5
6
ITEM NO.
PART NO.
DESCRIPTION
1 63239 Panel, Lid, FDD2500
4
5
2
3
6
63322
61303
61440
71582
Lid, Hinged Cover FDD2500
61792-flat HINGE, PWDR COATED SS 2 LEAF
Screw, #8 x 3/8 black trilobe
CAP, #8 SCREW SOFT
Decal, Warning Disconnect
FDD2500 Splash Panel Assembly (part # 63241)
Model FDD2500 Page 17
FDD2500 Hopper Shelf Assembly (part # 63225)
Page 18 Model FDD2500
FDD2500 Hopper Assembly (part # 63227)
Model FDD2500 Page 19
FDD2500 Tank Assembly (part # 63213) – 1 Heater, 6.6 KW
20
6
10
8
2
4
5
21
7
3
1
17
9
9
9
18
9
19
11
15
13
16
Page 20
17
17
16
14
16
ITEM NO.
1
2
5
6
3
4
PART NO.
63214
63355 Tank
63355 Baffle
63220
63222
63294
DESCRIPTION
Tank Weldment FDD2500
Gasket Tank 38"
Gasket Baffle 20"
Tank Lid Asy FDD2500
Insulation Tank FDD2500
Harness Htr 1-Ph FDD2500
12 7
8
9
62271 FDD Vent Tubing Silicone 1/2 x 3/4, 33"
70635 TERMINAL, 1/4-032 X 45DEG TAB
62269 Fitting, 1/2" Barb SS
10 63297 NUT, 10-24 ESNA SS
63213 - TANK ASSEMBLY,
Tubing Silicone 3/8 x 5/8 x 5"
12
13
14
05826 FDD IValve Tubing Silicone 3/8 x 5/8 x 17"
61232 Plug,3/8 Barb
61152 Tee, 7/16" Barbed
19
20
21
15
16
17
18
63448
07327
Decal,Tank Drain 5+ Gal
Clamp,Hose,21/32ID,Heyco#2322
71676 Clamp,.671-.812,Nylon Hose
05826 FDD Drain Tubing Silicone 3/8 x 5/8 x 25"
62282
61353
60262,18
Gasket, Bulkhead
Screw,8-32 X 1/4" PH PN 18-8 SS
TAPE, ALUM HI-TEMP 18.25"
Model FDD2500
FDD2500 Tank Assembly – 3 Heater, 11.1kW
10 20
10
8
6
4
17
7
9
9
9
19
9
17
16
18
16
15
13
2
5
21
3
17
1
11
16
14
12
16
19
20
21
15
16
17
18
11
12
13
14
7
8
9
10
ITEM NO. QTY.
1 1
2 1
5
6
3
4
1
1
1
1
1
1
1
1
4
3
1
1
4
6
1
3
1
1
4
PART NO.
63214
63355 Tank
63355 Baffle
63261
63222
63295
DESCRIPTION
Tank Weldment FDD2500
Gasket Tank 38"
Gasket Baffle 20"
Tank Lid Asy FDD2500
Insulation Tank FDD2500
Harness Heater 3-Ph FDD2500
62271 FDD Vent Tubing Silicone 1/2 x 3/4, 33"
70635 TERMINAL, 1/4-032 X 45DEG TAB
62269
63297
Fitting, 1/2" Barb SS
NUT, 10-24 ESNA SS
05826 FDD Short Tubing Silicone 3/8 x 5/8 x 5"
05826 FDD IValve Tubing Silicone 3/8 x 5/8 x 17"
61232
61152
Plug,3/8 Barb
Tee, 7/16" Barbed
63448
07327
Decal,Tank Drain 5+ Gal
Clamp,Hose,21/32ID,Heyco#2322
71676 Clamp,.671-.812,Nylon Hose
05826 FDD Drain Tubing Silicone 3/8 x 5/8 x 25"
62282
61353
60262,18
Gasket, Bulkhead
Screw,8-32 X 1/4" PH PN 18-8 SS
TAPE, ALUM HI-TEMP 18.25"
63263 - TANK ASSEMBLY FDD2500-3, 15kW
Model FDD2500 Page 21
FDD2500 Tank Lid Assembly (part # 63220)– 1 Heater
Page 22
4
8
8
6
1
2
3
5
2
2
10
11
7
9
11
ITEM NO. PART NO. DESCRIPTION
1
2
63221
71147
Lid Tank FDD2500
GROMMET, SILICONE WHT
5
6
3
4
61108
61128
100160
62305
PROBE, PIC
Probe,Thermistor,12"
Probe,Safety
T-STAT, HI TEMP LIMIT
7
8
9
10
11
62239
61353
62265
71585
71586
BRKT, T-STAT CE MODEL
Screw,8-32 X 1/4" PH PN 18-8 SS
Element 240V 6.6kW
Elbow,1/2mptx5/8barb 90 brass
Nut,Lock,1/2fpt brass
Model FDD2500
FDD2500 Tank Lid Assembly (part # 63261)– 3 Heater
4
7
7
5
6
1
2
2
3
8
9
10 10
10
9
ITEM NO. PART NO. DESCRIPTION
1 63262 Lid Tank FDD2500
4
5
2
3
71147
61108
61128
62305
GROMMET, SILICONE WHT
PROBE, PIC
Probe,Thermistor,12"
T-STAT, HI TEMP LIMIT
8
9
6
7
10
62239 BRKT, T-STAT CE MODEL
61353 Screw,8-32 X 1/4" PH PN 18-8 SS
71585 Elbow,1/2mptx5/8barb 90 brass
71586 Nut,Lock,1/2fpt brass
62403 Element,240V, 3.7kW
Model FDD2500 Page 23
FDD2500 Control Bracket Assembly (part # 63323)
Page 24 Model FDD2500
FDD2500 Contactor Bracket Assembly (part # 63249) – 1 Heater
13
14
15
16
17
18
19
20
8
9
10
11
12
ITEM NO. PART NO. DESCRIPTION
1
2
63329
61131
Bracket Control Left FDD2500
Relay,12 vdc Coil
3
4
5
6
7
62262
62261
63373
63349
62457
Terminal Block 4-pole
Contactor DPST 30A 120V
Transformer StepD 200VA 200/230/460-120
Harness Left Side FDD2500
Harness Htr LCD, FDD 1-ph
62332 Fuseholder, 30A 600V pnl mt
63395 Fuse 2 Amp Time Delay
63396
07921
60394
60746
70426
61303
60758
63449
Decal, 2 Amp Fuse
Lug Ground
Bushing,Snap-7/8"OD x 3/4"
10073 Label, Ground Symbol
62286 Screw 6-32x1.25 PH PN SS (A601018)
10-24 x 5/16" SCREW, PH PN 18-8 SS
TERM, 1/4F INS QD 18-22 GA
Screw, #8 x 3/8 black trilobe
WASHER, #10 LOCK EXT SS
61159-4 Seal, Closed Cell Foam 4"
Decal, Step-Down Wiring
2
17
12
18
1
17
4
17
16
7
17
18
17 18
5
63249 - CONTACTOR BRACKET ASSEMBLY FDD2500-1
19
10
6
9 9 9
17
8
8
1
18
13
3
9
11 14
20
15
FDD2500 Contactor Bracket Assembly (part # 63280) – 3 Heater
6
12
13
14
15
16
10
11
8
9
ITEM NO. PART NO. DESCRIPTION
1
2
3
63329
61131
62262
Bracket Control Left FDD2500
Relay,12 vdc Coil
Terminal Block 4-pole
6
7
4
5
61998
63373
63349
63350
Contactor 4-Pole
Transformer StepD 200VA 200/230/460-120
Harness Left Side FDD2500
Harness Term to Contact 3-Ph FDD
17
18
19
20
62332
63395
63396
07921
60394
10073
62286
60746
70426
61303
60758
Fuseholder, 30A 600V pnl mt
Fuse 2 Amp Time Delay
Decal, 2 Amp Fuse
Lug Ground
Bushing,Snap-7/8"OD x 3/4"
Label, Ground Symbol
Screw 6-32x1.25 PH PN SS (A601018)
10-24 x 5/16" SCREW, PH PN 18-8 SS
TERM, 1/4F INS QD 18-22 GA
Screw, #8 x 3/8 black trilobe
WASHER, #10 LOCK EXT SS
61159-4 Seal, Closed Cell Foam 4"
63449 Decal, Step-Down Wiring
17
2
12
10
4
16
7
17
17
18
5
63280 - CONTACTOR BRACKET ASSEMBLY FDD2500-3
9 9
19
9
3
17
8
1
8
11
18
13
15
14
20
Model FDD2500 Page 25
FDD2500 Switch Assembly
Item No.
Part No.
1 63285
2 62260
62266
3
4
5
6
7
8
9
10
11
5
6
7
3
4
1
2
Description
Plate, Switch FDD2500
Bezel, pull switch (A1101-020)
Handle, Pull Switch - Coffee
62267 Handle, Pull Switch - Hot Water
63285 Handle, Pull Switch - Decaf
62260 Spring, Pull Switch A522120
62266 Switch, Snap Action Micro
62281 Bracket, Pull Switch Activation
61887 Rod, Pull Switch Modified A1101-019
61883 Pin, Pull Switch A551-015
63385 Screw 4-40 x 5/8 PH HD SS
71128 Nut, 4-40 SS Hex
71261 Nut, 8-32 SS ESNA
12 63447 Plate Striker
1
8
9
10
11
12
Coffee Switch Assy (part # 63282)
Water Switch Assy (part # 63283)
Decaf Switch Assy (part # 63284)
62270 Pin, Pull Switch A551-015
71127 Screw 6-32 x 9/16" SS
71128 Nut 6-32 Hex SS
71261 NUT, 8-32 ESNA SS
63447 Striker Pullswitch
10
5
10
4
7
3 2
12
6
11
9
9
8
FDD2500
Sight Gauge Assembly (part # 63289)
FDD2500
Touchpad Assembly (part # 63435)
2
1
Page 26
ITEM NO. PART NO. DESCRIPTION
1
2
63437
63436
Plate, Switch FDD 3-Portion
Touchpad 3-Port FDD2500
Model FDD2500
FDD2500 Blower Assembly (part # 63211)
2
ITEM NO. PART NO. DESCRIPTION
1
2
61103
63212
Fan, Blower 120V .25A
Bracket Blower Mt FDD2500
3
4
63260
61303
Insulation Strip Blower FDD
Screw, #8 x 3/8 black trilobe
1
4
3
63211 - BLOWER ASSEMBLY FDD2500
4
FDD2500 Hose Adapter Assembly (part # 63402)
(Optional)
Model FDD2500 Page 27
FDD2500 Wiring Schematic
for all models
N L1
RED
BLK
2A FUSE
RED
2A FUSE
BLK
H1
COM
L1
L2 L3
TERMINAL
BLOCK
120V
FDD2500 WIRING SCHEMATIC
ALL VOLTAGE SUPPLIES
SEE OTHER SHEETS FOR HEATER CONFIGS
L1
L2
L3 CONTACTOR
L2
H2
H3
H4
H2 FOR 208V SUPPLY
H3 FOR 240V SUPPLY
STEP-DOWN
TRANSFORMER
120V t°
HI-TEMP LIMIT
THERMOSTAT
POWER SUPPLY
PUR/WHT
FAN
120V
FAN
120V
STEAM EXHAUST
TRANSFORMER
120
WHT
MASTER
POWER
COM
BLK/WHT
HEATER RELAY
C
NC
NO
12VDC
Capacitive
Sensor
Right
BN +
BLK SIG
WHT SIG
BLU -
Capacitive
Sensor
Left
BN +
BLK SIG
WHT SIG
BLU -
DOOR
SWITCH
B lk
B lk
TOUCHPAD
Adj/Rinse
LEVEL
WATER TANK
GROUND
OVERFLOW
FDD2500-1 only
SEE SWITCH
WIRING SCHEMATIC
DISPLAY
THERMISTOR
1
2 3
4 5 6 7 8 9 10 11 12 13
14 15 16
AUGER
MOTORS
Blk
M
Red
Blk
M
Yel
RINSE
Blk
Right 0-24vdc
Middle
Augers:
Left
Ground
CONTROLLER
+24VDC
GND
Red
Blk
CABINET
FAN
120V INLET VALVE
120V LEFT DISP VALVE
120V MIDDLE DISP VALVE
120V RIGHT DISP VALVE
FDD2500 Wiring All
MJB, 6/29/05
Page 28 Model FDD2500
1 Heater, 1 Phase, 60 Hz, 240/208 VAC Configuration
for models FDD2500-1-M-B
FDD2500-1-3A-B
(1) 6.6 kW 240 VAC ELEMENT
6.6 kW (28 AMPS) @ 240 VAC (2 WIRE + GND)
5.0 kW (24 AMPS @ 208 VAC (2 WIRE + GND)
6.6 kW (28 AMPS) @ 120/240 VAC (3 WIRE + GND)
5.0 kW (24 AMPS @ 120/208 VAC (3 WIRE + GND)
HE
AT
ER
#1
TOP VIEW OF WATER TANK
T1 T2
CONTACTOR
L1 L2
CONNECT RED WIRE TO:
"H2" FOR 208V SUPPLY
RED
2A FUSE
BLACK
2A FUSE
H4
460V
H3
230V
H2
200V
H1
COM
STEP-DOWN
TRANSFORMER
120 VAC
TO CONTROL CIRCUIT
FDD Manual Wiring 1-Ph
N L1 L2 L3
N L1 L2 L3
TERMINAL
BLOCK
Model FDD2500 Page 29
Three Heater Option Configuration Hookup Diagram
for models FDD2500-3-M-B
FDD2500-3-3A-B
FDD2500-3
3-HEATER WIRING HOOK-UP
HE
ATE
R #3
3
NOTE: MACHINE IS EQUIPPED WITH
(3) 3.7kW 240 VAC ELEMENTS WHICH
CAN BE CONFIGURED TO ACHIEVE
VARIOUS WATTAGE OUTPUTS PER
THE CHART BELOW DEPENDING ON
POWER SOURCE AVAILABLE.
CONNECT RED WIRE TO:
"H2" FOR 208V SUPPLY
"H3" FOR 240V SUPPLY
HE
ATE
R #2
3
2
HE
ATE
R #1
2
1
1
TOP VIEW OF WATER TANK
1 1 2 2 3 3
#10 AWG BLACK HEATER WIRES
ARE CONNECTED TO CONTACTOR
CONNECTIONS "T1,T2,T3,T4"
PER THE CHART BELOW TO
ACHIEVE THE SERIAL PLATE
VOLTAGE AND WATTAGE
CONFIGURATION
T1 T2 T3 T4
CONTACTOR
L1 L2 L3 L4
2A FUSE
RED
2A FUSE
BLACK
N L1 L2 L3
N L1 L2 L3
TERMINAL
BLOCK
H4
460V
H3
230V
H2
200V
H1
COM
STEP-DOWN
TRANSFORMER
120 VAC
TO CONTROL CIRCUIT
# OF ELEMENTS
UTILIZED
SINGLE PHASE
0.5
1
1.5
2
VOLTAGE
208
208
208
208
WATTS
1390
2780
4140
5560
0.5
1
240
240
240
1850
3700
5550 1.5
2 240 7400
THREE PHASE (DELTA CONFIGURATION)
3
3
208
240
8340
11100
Page 30
AMPS
6.7
13.4
19.9
26.8
7.7
15.5
23
30.9
23.2
26.8
CONNECT NUMBERED HEATER WIRES TO
CONTACTOR TERMINALS PER CHART BELOW
T1 T2 T3 T4
1
1
1,2
1,2
2
1
1,3
1,2
1,2
2,2
2,3
3,3
3,3
3,3
-
-
1
1
1,2
1,2
2
1
1,3
1,2
1,2
2,2
2,3
3,3
3,3
3,3
-
-
1,2
1,2
1,3
1,3
2,3
2,3
-
-
FDD2500 Wiring 3-Ph
Model FDD2500
Wiring Schematic within Door
for models FDD2500-1-M-B
FDD2500-3-M-B
Model FDD2500 Page 31
Wiring Schematic within Door
for models FDD2500-1-3A-B
FDD2500-3-3A-B
F D D 2 5 0 0 * 3 A B
3 -
S
P O R T I O N S
C H E M A T I C
P E
W I
R
T H
H E
I N
A D
D O O R
4 3 2 1
G R N
W H
B L K
R E D
2 x 1 6 b a c k il t L C D d i s p l a y
1 3 5
2 4 6
7
8
9 1 1 1 3 1 5 1 7 1 9 2 1 2 3 2 5 2 7 2 9 3 1
1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 h e a d e r h e a d e r 1
2
T O
B
M
O A
A I N
R D
Page 32
1 2 3 4 5 6
1 2 3 4 5 6
S
L E F T
M L
T O U C H P A D
S M
C E N T E R T O U C H P A D
L
N / O
C A P U N U S E D W I R E S
C O M
C E
M A
N T E R
N U A L
S W
F R
I T
E E
C H
F L O W
2 3 4 6 7 8 9
" > "
I / O
" + " " "
S E
T O
T T
U
I N G S
C H P A D
1 2 3 4 5 6
S
R I G H T
M L
T O U C H P A D
F D D 2 5 0 0 W I R I N G D I S P 3 A
Model FDD2500
Model FDD2500 Page 33
Page 34 Model FDD2500
Model FDD2500 Page 35
Grindmaster® Coffee Grinders and Brewers • PrecisionBrew™ Brewing Systems • Espressimo® Espresso Machines
Crathco® Hot Beverage Dispensers • Crathco® Cold and Frozen Beverage Dispensers • AMW Coffee and Tea Systems
Tel (502) 425-4776 • Fax (502) 425-4664 • 1-800-695-4500 (USA & Canada only)
P.O. Box 35020 • Louisville, KY 40232 • USA www.grindmaster.com • email: [email protected]
© Grindmaster Corporation, 2005
PRINTED IN USA
0307 Form # AM-342-04
Part #63361
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