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OPERATING & SERVICE MANUAL
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
www.bunnomatic.com
INTRODUCTION
This equipment will brew a half-gallon, gallon, or gallon and a half batch of coffee into an awaiting server at
the push of a button and includes a hot water faucet for allied beverage use. The brewer is specifically designed
for use with a BUNN® 1.5GPR server. It is only for indoor use on a sturdy counter or shelf.
WARRANTY
Bunn-O-Matic Corp. (“Bunn”) warrants the equipment manufactured by it to be commercially free from defects
in material and workmanship existing at the time of manufacture and appearing within one year from the date of
installation. In addition:
1.) Bunn warrants electronic circuit and/or control boards to be commercially free from defects in material and
workmanship for two years from the date of installation.
2.) Bunn warrants the compressor on refrigeration equipment to be commercially free from defects in material
and workmanship for two years from the date of installation.
3.) Bunn warrants that the grinding burrs on coffee grinding equipment will grind coffee to meet original factory
screen sieve analysis for three years from date of installation or for 30,000 pounds of coffee, whichever comes first.
This warranty does not apply to any equipment, component or part that was not manufactured by Bunn or that,
in Bunn’s judgement, has been affected by misuse, neglect, alteration, improper installation or operation, improper
maintenance or repair, damage or casualty.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR
ORAL, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of Bunn are
not authorized to make modifications to this warranty or to make additional warranties that are binding on Bunn.
Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not
be relied upon.
The Buyer shall give Bunn prompt notice of any claim to be made under this warranty by telephone at (217)
529-6601 or by writing to Post Office Box 3227, Springfield, Illinois, 62708-3227. If requested by Bunn, the Buyer
shall ship the defective equipment prepaid to an authorized Bunn service location. If Bunn determines, in its sole
discretion, that the equipment does not conform to the warranty, Bunn shall repair the equipment with no charge
for parts during the warranty period and no charge for labor by a Bunn Authorized Service Representative during
the warranty period. If Bunn determines that repair is not feasible, Bunn shall, at its sole option, replace the
equipment or refund the purchase price for the equipment.
THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE
SALE OF THIS EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE LIMITED,
AS SPECIFIED HEREIN, TO REPAIR OR, AT BUNN’S SOLE OPTION, REPLACEMENT OR REFUND.
In no event shall Bunn be liable for any other damage or loss, including, but not limited to, lost profits, lost
sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of
substitute equipment, facilities or services, or any other special, incidental or consequential damages.
Page 2
27038 091900
USER NOTICES
The notices on this brewer should be kept in good condition. Replace unreadable or damaged labels.
00658.0000
00831.0000
00656.0000
12364.0000
ELECTRICAL REQUIREMENTS
CAUTION - The brewer must be disconnected from the power source until specified in Initial Set-Up.
L2 RED
WHITE
WHITE
NEUTRAL
L1 BLACK
NEUTRAL
120V.A.C.
L2 RED
208 or 240V.A.C.
120V.A.C.
120V.A.C.
L1 BLACK
200 OR 240V.A.C.
L1 BLACK
Requires 2-wire, grounded serRequires 3-wire, grounded ser“A" & "B” models require 2-wire,
vice rated 120 volts ac, 20 amp, vice rated 120/208 volts or 120/240 grounded service rated 200 volts ac,
single phase, 60 Hz.
volts ac, 20 amp, single phase, 60 20 amp, single phase, 50 Hz.
Hz.
Page 3
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. Remove the front panel beneath the sprayhead.
Models with electronic control assemblies:
Place the tank heater switch at the top of the control assembly in the “OFF” position.
Models with electro/mechanical thermostats:
Rotate the control thermostat knob fully counterclockwise to the “OFF” position.
4. Feed the cord through the strain relief and connect it to the terminal block.
5. Connect the brewer to the power source and verify the voltage at the terminal block before proceeding. Replace
the front panel.
6. If plumbing is to be hooked up later be sure the brewer is disconnected from the power source. If plumbing
has been hooked up, the brewer is ready for Initial Set-Up.
PLUMBING REQUIREMENTS
This brewer 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 brewer. Install
a regulator in the line when pressure is greater than 90 psi (620 kPa) to reduce it to 50 psi (138 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. A tight coil of copper tubing in the water line will facilitate moving the brewer
to clean the counter top. 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.
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 Sanitation Manual of the Food and Drug Administration (FDA).
PLUMBING HOOK-UP
1. Attach the flare fitting from the short piece of tubing on the strainer/flow control (supplied) to the water inlet
fitting on the bottom of the brewer.
2. Flush the water line and securely attach it to the flare fitting on the strainer/flow control.
3. Turn on the water supply.
Page 4
27038 091900
INITIAL SET-UP
CAUTION – The brewer must be disconnected from the power source throughout the initial set-up, except when
specified in the instructions.
NOTE: ECA Models Only - This brewer is equipped with a temperature sensor that indicates when to brew and,
when selected, locks out the start of a brew cycle until the water has heated to the optimum brewing temperature.
1. Remove the front panel beneath the sprayhead.
Models with electronic control assemblies:
Place the tank heater switch at the top of the control assembly in the “OFF” position.
Models with electro/mechanical thermostats:
Rotate the control thermostat knob fully counterclockwise to the “OFF” position.
2. Connect the brewer to the power source. Water will begin flowing into the tank.
3. When water stops flowing into the tank, remove the front panel and proceed as directed:
Models with electronic control assemblies:
Place the tank heater switch at the top of the control assembly in the “ON” position and replace the front panel.
Models with electro/mechanical thermostats:
Rotate the control thermostat knob fully clockwise to the “ON” position and replace the front panel.
4. Wait approximately twenty-five minutes on 208V,240V Models or fifty minutes on 120V Models for the water
in the tank to heat to the proper temperature.
5. Place an empty server beneath the brew station. Place the Selector switch in the one-gallon position, the On/
OFF switch in the upper position and initiate a brew cycle.
6. Place the On/Off switch in the lower “OFF” position after water has stopped flowing from the funnel, and check
the water volume in the server. It should be 128 ounces.
7. (A) If not, adjust the timer as required. Refer to Adjusting Brew Volumes.
(B) If necessary adjust the needle valve to achieve water volume to be bypassed around the coffee filter in the
funnel.
NOTE: To increase the water bypass turn the needle valve counterclockwise, to decrease the water bypass turn
the needle valve clockwise. An adjustment to the needle valve will require a timer adjustment for volume.
8. Repeat step 7 until the proper water volume is achieved.
9. The brewer is now ready for use in accordance with the coffee brewing instructions.
Page 5
27038 091900
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 and server 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 three clicks are heard. Release the
switch (Failure to release the switch within two seconds after the third click 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 three clicks are heard. Release the switch. (Failure to release the switch within two seconds after
the third click 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 three distinct clicks are heard, and then
release the switch. (Failure to release the switch within two seconds after the third click 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.
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 programming to be done until switch is once again placed in the “SET” position.
Page 6
27038 091900
OPERATING CONTROLS
BREW SELECTOR SWITCH
Placing the switch in the 1⁄2 Gal, 1 Gal, or 11⁄2 Gal position selects the amount of coffee to be brewed in
subsequent brew cycles. Repositioning this switch after a brew cycle has been initiated does not change the brew
batch in progress.
ON/OFF SWITCH
Placing the switch in the unlighted lower position cuts power to the brew station warmer and stops brewing.
Stopping a brew cycle after it has been started will not stop the flow of water from the funnel. Placing the switch
in the lighted upper position supplies power to the brew station warmer and enables the brew circuit.
START SWITCH
Momentarily pressing and releasing this switch starts a brew cycle when the On/Off switch is in the lighted
upper position.
NOTE – The On/Off switch must be in the lighted upper position to initiate and complete a brew cycle.
COFFEE BREWING
1.
2.
3.
4.
5.
6
7.
Select the desired batch size.
Insert a BUNN® filter into the funnel.
Pour the proper amount of fresh coffee into the filter and level the bed of grounds by gently shaking.
Slide the funnel into the funnel rails.
Place an empty server under the funnel.
Place the On/Off switch in the lighted upper position. Momentarily press and release the start switch.
When brewing is completed, simply discard the grounds and filter.
CLEANING
1. 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.
2. Check and clean the sprayhead. The sprayhead holes must always remain open.
NOTE – In hard water areas, this may need to be done daily. It will help prevent liming problems in the brewer and
takes less than a minute.
Page 7
27038 091900
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.
•
•
•
•
•
•
•
WARNING
•
•
•
•
Inspection, testing, and repair of electrical equipment should be performed only by qualified service
personnel.
All electronic components have 120 - 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.
The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened.
This will help 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.
Exercise extreme caution when servicing electrical equipment.
Disconnect power source when servicing, except when electrical tests are specified.
Follow recommended service procedures.
Replace all protective shields or safety notices.
Problem
Probable Cause
Remedy
Equipment will not operate. Brew
cycle will not start.
1. No power or incorrect voltage
(A1) Check the terminal block for
120 volts across the black and white
terminals on 120 volt two wire brewers.
(A2) Check the terminal block for
120 volts across the red and white
terminals and the black and white
terminals on 120/208 or 120/240
volt brewers.
(A3) Check the terminal block for
200 volts on "B Series" brewers or
240 volts on "A Series" brewers
across the red and black terminals.
(B) Check circuit breakers or fuses.
Brew cycle will not start.
1. No water
Check plumbing and shut-off valves
2. Water strainer/flow control (.330 (A) Direction of flow arrow must be
GPM)
pointing towards brewer.
(B) Remove the strainer/flow control and check for obstructions. Clear
or replace.
Page 8
27038 091900
TROUBLESHOOTING (cont.)
Problem
Probable Cause
Remedy
Brew cycle will not start (cont.)
3. ON/OFF switch
Refer to Service - ON/OFF switch for
testing procedures. See page 31
4. Start switch
Refer to Service - Start switch for
testing procedures. See page 34
5. Timer
Refer to Service - Timer for testing
procedures. See page 36 & 38
6. Dispense Valve
Refer to Service - Dispense valve for
testing procedures. See page 22
7. Control Assembly (Electronic)
Refer to Service - Electronic controls for testing procedures. See
pages 23 thru 27
1. No water
Check plumbing and shut-off valves.
2. Water strainer/flow control (.330
GPM)
(A) Direction of flow arrow must be
pointing towards brewer.
Automatic refill will not operate
(B) Remove the strainer/flow control and check for obstructions. Clear
or replace.
3. Limit thermostat (Electro/mechanical and Electronic)
Refer to Service - Limit thermostat
for testing procedures. See page 30
4. Overflow protection switch
Refer to Service - Overflow protection switch for testing procedures.
See page 32
5. (A) Level control board & level
probe. (Electro/mechanical)
Refer to Service - Level control board
for testing procedures. See page 28
(B) Control Assembly (Electronic)
Refer to Service - Electronic controls for testing procedures. See page
23 thru 27
6. Solenoid Valve
Page 9
Refer to Service - Solenoid valve for
testing procedures. See page 33
27038 091900
TROUBLESHOOTING (cont.)
Problem
Probable Cause
Remedy
Water from tank is not hot (cont.)
5. Triac assembly (Electronic)
Refer to Service - Triac assembly for
removal and replacement.See page
27
Server warmer is not hot.
1. ON/OFF switch
Refer to Service - ON/OFF switch for
testing procedures. See page 31
2. Warmer element
Refer to Service - Warmer element
for testing procedures. See page 40
1. (A) Control thermostat (Electro/
mechanical)
Refer to Service - Control thermostat for testing procedures. See page
20
(B) Control assembly (Electronic)
Refer to Service - Control assembly
for testing procedures. See page 23
thru 27
Spitting or unusual steaming from
sprayhead or airvent.
2. Triac assembly (Electronic)
Refer to Service - Triac assembly for
testing procedures. See page 27
3. Lime build-up
Inspect the tank assembly for excessive lime deposits. Delime as required.
CAUTION - Tank and tank components should be delimed regularly
depending on local water conditions.
Excessive mineral build-up on stainless steel surfaces can initiate corrosive reactions resulting in serious
leaks.
Inconsistent beverage level in server.
1. Strainer/flow control (.330 GPM)
(A) Direction of flow arrow must be
pointing towards the brewer.
(B) Remove the strainer/flow control and check for obstructions. Clear
or replace.
2. Improper water pressure
Page 11
Check the operating water pressure
to the brewer. It must be between 20
and 90 psi (138 and 620 kPa).
27038 091900
TROUBLESHOOTING (cont.)
Problem
Probable Cause
Remedy
Inconsistent beverage level in server. 3. Dispense valve
(cont.)
Refer to Service - Dispense valve for
testing procedures. See page 22
Consistently high or low beverage 1. Timer adjustment
level in server.
Adjust the timer as required to
achieve the recommended volume
for each brew cycle.
Dripping from sprayhead.
1. Dispense valve
Refer to Service - Dispense valve
for testing procedures. See page 22
Water overflows filter.
1. Bypass valve (Electro/mechanical)
Refer to Adjustments on page 5 step
#7. For test procedures see page 15.
2. Type of paper filters
BUNN® paper filters should be used
for proper extraction.
3. No sprayhead
Check sprayhead
1. Beverage left in server
The brew cycle should be started
only with an empty server under the
funnel.
2. Timer adjustment
Adjust the timer as required to
achieve the recommended 192 oz
for each 1-1/2 gallon brew cycle.
Refer to Service - Timer for testing
procedures. See page 36 & 38
3. Dispense valve
Refer to Service - Dispense valve for
testing procedures. See page 22
1. Type of paper filters
BUNN® paper filters should be used
for proper extraction.
2. Coffee
A sufficient quantity of fresh drip or
regular grind should be used for
proper extraction.
3. Sprayhead
B.O.M. sprayhead #01082.0002
should be used to properly wet the
bed of ground coffee in the funnel.
Beverage overflows server.
Weak beverage.
Page 12
27038 091900
TROUBLESHOOTING (cont.)
Problem
Probable Cause
Remedy
Weak beverage (cont.)
4. Funnel loading
The BUNN® paper filter should be
centered in the funnel and the bed of
ground coffee leveled by gentle shaking.
5. Water temperature
Empty the server, remove its cover,
and place the server on the warmer.
Place empty funnel over the server
entrance, with ON/OFF switch in the
"ON" position press the start switch
and release it. Check the water temperature immediately below the
sprayhead with a thermometer. The
reading should not be less than
195°F(91°C).
1. Solenoid (Inlet)
The nut on back of the solenoid must
be tight or it will vibrate during operation
2. Plumbing lines
Plumbing lines should not be resting on the counter top.
3. Water supply
(A) The brewer must be connected
to a cold water line.
Brewer is making unusual noises.
(B) Water pressure to the brewer
must not be higher than 90 psi (620
kPa). Install a regulator if necessary
to lower the working pressure to
approximately 50 psi (345 kPa).
4. Tank heater
Remove and clean lime off the tank
heater.
5. Contactor
Check for low voltage.
Page 13
27038 030101
SERVICE
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 electrical equipment should be performed only by qualified
service personnel. The brewer should be unplugged
when servicing, except when electrical tests are required 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 replacement of any component.
All components are accessible by the removal of
the top cover, front inspection panel and warmer base
plate.
The top cover is attached with one #4-40 slotted
head screw.
The front inspection panel is attached with four #632 slotted head screws.
The warmer base is attached with four #6-32
slotted head screws.
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Page 14
SERVICE (cont.)
BYPASS VALVE
Location:
The bypass valve is located inside the right front
of the hood.
Test Procedures:
1. Disconnect the brewer from the power source and
place a server beneath the funnel.
2. Check the water level in the tank to confirm that it
is within 1/2" from the top of the tank.
3. Connect the brewer to the power source.
4. Check the bypass valve for coil action. Place the
ON/OFF switch in the "ON" position, press and
release the BREW switch. Listen carefully in the
vicinity of the bypass valve for a "clicking" sound as
the coil magnet attracts and repels the plunger.
5. Disconnect the brewer from the power source.
If the sound is heard as described, there may be a
blockage in the bypass valve or the water line to the
sprayhead. Remove the bypass valve and inspect for
wear, and remove waterborne particles.
If the sound is not heard as described, proceed to #6.
Page 15
SERVICE (cont.)
BREW SELECTOR SWITCH
13. Disconnect the tan wire from the selector switch
and tan wire from interface socket.
14. Check for continuity across the tan wires.
15. Reconnect the tan wires.
16. With the selector switch set at 1 and 1-1/2 gallon,
disconnect the white/violet from the bypass valve.
17. Check for continuity across the white/violet wire
and terminal on bypass valve.
18. Reconnect the white/violet wire to the terminal on
the bypass valve.
19. Disconnect the white/red wire from the dispense
valve.
20. Check for continuity across white/red wire and
terminal on dispense valve.
21. Reconnect white/red wire to the terminal on the
dispense valve.
22978.0000
Location:
The brew selector switch is located in the front of
the hood on the right side.
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Test Procedure:
1. Disconnect the brewer from the power supply.
2. Separate the connector on the selector switch
harness from the brew timer circuit board.
3. Carefully slide the plastic cover off of the connector from the switch harness.
4. Check for continuity across the pink and tan wires
on the connector when the switch is in the 1/2
gallon position. Continuity must not be present in
any other switch position.
5. Check for continuity across the pink wire and gray
wire when the switch is in the 1 gallon position.
Continuity must not be present in any other switch
position.
6. Reattach the connector to the brew timer circuit
board.
7. Disconnect the gray wire from the selector switch
and the gray wire from the interface socket.
8. Check for continuity across the gray wires.
9. Reconnect the gray wires from the selector switch
and the interface socket.
10. Disconnect the pink wire from the selector switch
and the pink lead from the interface socket.
11. Check for continuity across the pink wires .
12. Reconnect the pink wires.
If continuity is present as described the switch is
operating properly.
If continuity is not present as described replace switch
assembly.
Removal and Replacement:
1. Disconnect the connector on the selector switch
harness from the brewer timer circuit board.
2. Disconnect wires from the selector switch, interface socket, dispense valve and bypass valve.
3. Loosen the set screw on the switch knob.
4. Remove the 9/16" nut and washer holding the
switch to the hood.
5. Remove the switch.
6. Install the new switch. The positioning tab must be
in the hole in the hood for proper switch and knob
alignment.
7. Install the knob so that the arrow lines up in the 11/2 gallon position when the switch is turned to the
full right position.
8. Reattach the connector to the brew timer circuit
board.
9. Refer to Fig. 4 the next page when reconnecting
the wires.
Page 16
SERVICE (cont.)
BREW SELECTOR SWITCH (cont.)
WHI/VIO to By-Pass Valve
To Timer
TAN
WHI/RED to Dispense Valve
GRY
GRY to GRY Lead on
Interface Socket
PNK to PNK Lead on
Interface Socket
PNK
TAN to TAN Lead on
Interface Socket
P827
FIG. 4 BREW SELECTOR SWITCH TERMINALS
Page 17
27038 091900
SERVICE (cont.)
CONTACTOR ASSEMBLY (W/MECHANICAL THERMOSTAT ONLY)
a.) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
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 Diagrams and check the brewer wiring harness.
6. Check for continuity between the two black wires
of the contactor coil.
If continuity is present as described, reconnect one
black wire to the white wire or red wire from the
terminal block and the other black wire to the black
wire from the control thermostat. Reinstall capillary
tube into tank to line 7" above the bulb and proceed to
#7.
If continuity is not present as described, replace the
contactor.
P814
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Location:
The contactor assembly is located inside the
hood just behind the dispense valve.
Test Procedures:
Mechanical Thermostat
1. Disconnect the brewer from the power source.
2. Disconnect the white wire of the two pole 120V
terminal block, white wire of the three pole 120/
208V or 120/240V or the red wire of the two pole
200V or 240V terminal block and the black wire of
the contactor coil. Disconnect the black wire of the
control thermostat from the remaining black wire
of the contactor coil.
3. Gently remove the capillary bulb and grommet
from the tank.
4. With a voltmeter, check the voltage across the
white wire from the terminal block on 120,120/
208, 120/240 volt units or the red wire from 200,
240 volt units and the black wire from the control
thermostat when the thermostat is turned clockwise to the "FULL ON" position. Connect the brewer
to the power source. The indication must be:
7. Locate the white wire or red wire on L1 terminal
and black wire on the L2 terminal on the contactor.
8. With a voltmeter, carefully check the voltage across
the white or red and black wires. The indication
must be:
a.) 120 volts ac for two wire 120 volt models, 208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 20/240 volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
9. Disconnect the brewer from the power source.
If voltage is present as described, proceed to #10.
If voltage is not present as described, refer to the
Wiring Diagrams and check the brewer wiring harness.
10. Check for continuity across the terminals on the
left side of the contactor by manualy closing the
contacts. Continuity must not be present when the
contact is released.
Page 18
SERVICE (cont.)
CONTACTOR ASSEMBLY (W/ MECHANICAL THERMOSTAT ONLY) (cont.)
11. Check for continuity across the terminals on the
right side of the contactor by manually closing the
contacts. Continuity must not be present when the
contact is released.
If continuity is present as described, the contactor is
operating properly.
If continuity is not present as described, replace the
contactor.
WHI L1 to Terminal Block
(White Insert)
RED L1 to Terminal Block
(Red Insert)
BLK T2 to Tank Heater
BLK L2 to Limit Thermostat
RED T1 to Tank Heater
BLK to WHI Lead from the Two
Pole 120V Terminal Block
BLK to WHI Lead from the Three
Pole 120/208V or 120/240V
Terminal Block
BLK to RED Lead from the Two
Pole 200V or 240V Terminal
Block
BLK to BLK Lead from
Thermostat
P828
FIG. 6 CONTACTOR ASSEMBLY TERMINALS
Removal and Replacement:
1. Remove all wires from the contactor.
2. Remove the two #10-32 slotted head screw securing contactor to the inside of the hood.
3. Securely install the new contactor inside the hood.
4. Refer to Fig. 6 when reconnecting the wires.
Page 19
27038 030901
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22978.0000
Location:
The control thermostat is located inside the lower
left front of the brewer on the component bracket.
1. Disconnect the brewer from the power source.
2. Locate the blue wires on the control thermostat.
3. With a voltmeter, check the voltage across the blue
wires on the control thermostat and the white
insert on the two or three pole 120V, 120/208V,
120/240V terminal block and the red insert on two
pole 240V terminal blocks. Connect the brewer to
the power source. The indication must be:
a.) 120 volts ac for two wire 120 volt models, 208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 120/240 volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
4. Disconnect the brewer from the power source.
If voltage is present as described, reconnect the wire
and proceed to #5.
If voltage is not present as described, refer to the
Wiring Diagrams and check the brewer wiring harness.
Page 20
SERVICE (cont.)
CONTROL THERMOSTAT (cont.)
NOTE - The capillary tube must be clear of any electrical termination and not kinked.
7. Using a #8-32 slotted head screw fasten the control thermostat to the component bracket.
8. Refer to Fig. 8 when reconnecting the wires.
9. Adjust the control thermostat as required.
BLU to Ready Light
BLK to RED Lead from Liquid Level
Switch
BLK to BLK Lead on Contactor Coil
BLK to Ready Light
P842
FIG. 8 CONTROL THERMOSTAT TERMINALS
Page 21
27038 030901
DISPENSE VALVE
22978.0000
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TL2
TL3
TL4
TL5
Location:
Dispense valve is located inside the hood directly
above the sprayhead.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the wires from the dispense valve and
check the voltage across the white/violet wire and
white/green wire. Connect brewer to the power
source. Place the "ON/OFF" Switch in the "ON"
position and press and release the Start Switch.
The indication must be:
a.) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
3. Disconnect brewer from the power source.
If voltage is present as described, proceed to #4.
If voltage is not present as described, refer to the
Wiring Diagrams and check the brewer wiring harness.
Page 22
P829
SERVICE (cont.)
ELECTRONIC CONTROL ASSEMBLY
22978.0000
PROBLEM:
LIQUID LEVEL CONTROL SYSTEM DOES NOT REFILL
REMOVE POWER
OVERFLOW CUP FULL
(4)
YES
DRAIN CUP (4)
RETRY
NO
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DISCONNECT LEVEL PROBE
(7)
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VOLTAGE PRESENT AT
SOLENOID VALVE
(12)
YES
DOES WATER FLOW
NO
NO
1.
2.
3.
4.
5.
6.
7.
Electronic Control 8. Temperature Sensor
9. Dispense Valve
Terminal Block
10. Bypass Valve
Timer
Liquid Level Switch 11. Ready Light
12. Solenoid Valve
& Overflow Cup
13. LED
Tank Heater
14. Temperature Adjustment
Limit Thermostat
Liquid Level Probe 15. Triac Assy
Location:
The electronic control assembly (1) is located
inside the lower left front on the component bracket of
the brewer. Access will also be needed to the temperature sensor (8), liquid level probe (7) located on the
tank lid and to the triac assembly (15) located beneath
the tank.
General:
This system controls the liquid level and water
temperature of the brewer. These two functions act
independently of each other and should be tested
separately.
BREW START - LOCK
The water must be heated to the preset temperature indicated by the glowing ready light before a brew
cycle can be initiated.
REPLACE
CONTROL
ASSEMBLY (1)
YES
REPLACE PROBE
(7)
REPLACE
SOLENOID VALVE
(12)
Liquid Level Control Test Procedure:
1. Disconnect brewer from the power source.
2. With a voltmeter, check the voltage across terminals 3 & 4 of the electronic control assembly (1).
Connect brewer to power source.The indication
must be:
a.)120 volts ac for two wire 120 volt models,208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 120/240 volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
3. Disconnect brewer from the power source.
If voltage was present as described, proceed to #4.
If voltage was not present as described, refer to the
wiring diagrams and check the brewer wiring harness.
4. Remove the pink wire from terminal 5 of the
electronic control assembly (1).
5. With a voltmeter, check the voltage across terminals 1 & 4 of the electronic control assembly (1).
Connect brewer to the power source. The indication must be:
Page 23
SERVICE (cont.)
ELECTRONIC CONTROL ASSEMBLY (cont.)
a.) 120 volts ac for two wire 120 volt models,
three wire 120/208 volt models and three wire
120/240 volt models after a delay of approximately
1 second.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models after a delay of approximately 1 second.
If voltage was present as described, reinstall the
probe, the sensing function of the system is operating
properly.
If voltage was not present as described, check the pink
probe wire and the green ground wire for continuity
and/or replace the probe.
PROBLEM:
LIQUID LEVEL CONTROL OVERFLOWS
6. Disconnect the brewer from the power source.
If voltage was present as described, the liquid level
control system is operating properly, proceed to #7.
If voltage was not present as described, replace the
electronic control assembly (1) and temperature sensor (8) in the tank lid.
NOTE - Each electronic control assembly is calibrated
to a temperature sensor. Both components MUST be
replaced as a set.
DRAIN CUP
(4)
7. Reconnect the pink wire to terminal 5 of the
electronic control assembly (1).
8. Remove the liquid level probe (7) from the tank lid,
and inspect it for mineral deposits. Replace it if
necessary. Keep the exposed ends of the probe
away from any metal surface of the dispenser.
9. With a voltmeter, check the voltage across terminals 1 & 4 of the electronic control assembly (1).
Connect the brewer to the power source. The
indication must be:
a.)120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models after a delay of approximately 1 second.
b.)200 to 240 volts ac for two wire 208 or 240 volt
models after a delay of approximately 1 second.
10. Touch the screw head end of the probe to the
brewer housing. The indication must be 0.
11. Move the probe away from the brewer housing.
The indication must again be:
a.)120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models after a delay of approximately 1 second.
b.)200 to 240 volts ac for two wire 200 or 240 volt
models after a delay of approximately 1 second.
12. Disconnect the brewer from the power source.
YES
Page 24
RETRY
OVERFLOW
?
DRAIN CUP (4)
DISCONNECT PROBE
WIRE FROM PROBE (7)
SHORT PROBE WIRE
TO CHASSIS
RETRY
OVERFLOW
?
NO
REPLACE PROBE (7)
YES
DRAIN CUP (4)
DISCONNECT WIRE
FROM
SOLENOID VALVE (12)
RETRY
OVERFLOW
?
YES
REPLACE SOLENOID
VALVE (12)
NO
REPLACE
CONTROL
ASSEMBLY (1)
P831
27038 091900
SERVICE (cont.)
ELECTRONIC CONTROLS (cont.)
Temperature Control Test Procedure
PROBLEM
WATER NOT HOT ENOUGH
LED ON CONSTANTLY
1. Disconnect the brewer from the power source.
2. With a voltmeter, check the voltage across terminals 3 & 4 of the electronic control circuit board.
Connect the brewer to the power source. The
indication must be:
a.) 120 volts ac for two wire 120 volt models, 208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 120/240 volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
3. Disconnect the brewer from the power source.
TURN TEMPERATURE
ADJUSTING SCREW (14)
CLOCKWISE CONTINUOUSLY
NO
YES
MEASURE VOLTAGE
LED ON
?
AT TANK HEATER (5)
YES
ADJUST FOR CORRECT
WATER TEMPERARURE
NO
REPLACE CONTROL
ASSEMBLY (1)
YES
VOLTAGE PRESENT
REPLACE TANK
HEATER (5)
NO
LIMIT THERMOSTAT (6)
OK
?
NO
REPLACE LIMIT
THERMOSTAT (6)
If voltage was present as described, proceed to #4.
If voltage was not present as described, refer to the
Wiring Diagrams and check the brewer wiring harness.
REPLACE TRIAC (15)
4. Connect the brewer to the power source and place
the tank heater switch in the “ON” position.
5. Observe the red LED indicator on the electronic
control circuit board (13).
6. Disconnect the brewer from the power source.
YES
REPLACE CONTROL
ASSEMBLY (1)
MEASURE VOLTAGE
AT TANK HEATER (5)
VOLTAGE PRESENT
CHECK FOR SPLIT
TANK HEATER (5)
NO
REINSTALL ORIGINAL
CONTROL ASSEMBLY (1)
YES
RECHECK WATER
TEMPERATURE
P844
PROBLEM:
WATER BOILS
DRAIN CUP (4)
RETRY
LED (11)(13) ON
WHILE BOILING
YES
7. With a voltmeter, check the voltage across the tank
heater (5) terminals. Connect the brewer to the
power source. The indication must be:
a.) 120 volts ac for two wire 120 volt models, 208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 120/240 volt models
while the red indicator on the circuit board is on or
blinking.
b.)200 to 240 volts ac for two wire 200 or 240 volt
models while the red indicator on the circuit board
is on or blinking.
8. Disconnect the brewer from the power source.
REPLACE CONTROL
ASSEMBLY (1)
NO
DISCONNECT BLUE WIRE
FROM CONTROL BOARD PIN #7
RETRY
STILL BOILING
?
NO
If the indicator was on or blinking, the temperature
sensor is operating properly, proceed to #7.
If the indicator was off, check the sensor connection
on the electronic control circuit board and/or replace
the temperature sensor (8) and the electronic control
assembly (1).
NOTE - each temperature sensor is calibrated to an
electronic control assembly. Both components MUST
be replaced as a set.
CHECK FOR SPLIT
TANK HEATER (5)
REPLACE TRIAC (15)
NO
REPLACE CONTROL
ASSEMBLY (1)
P845
Page 25
27038 091900
SERVICE (cont.)
ELECTRONIC CONTROL ASSEMBLY (cont.)
If voltage was present as described, the temperature
control of the system is operating properly.
If voltage was not present as described, contact BunnO-Matic to order an electronic control assembly (1),
temperature sensor (8), and triac assembly (15) for
evaluation and proceed to #9.
9. Replace the electronic control assembly (1) and
temperature sensor (8).
NOTE - each electronic control assembly is calibrated
to a temperature sensor. Both components MUST be
replaced as a set.
10. With a voltmeter, check the voltage across the tank
heater terminals (5). Connect the brewer to the
power source. The indication must be:
a.) 120 volts ac for two wire 120 volt models, 208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 120/240 volt models
while the red indicator on the circuit board is on or
blinking.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models while the red indicator on the circuit board
is on or blinking.
11. Disconnect the brewer from the power source.
If voltage was present as described, return the new
triac assembly (15) to Bunn-O-Matic for credit. The
temperature control of the system is operating properly.
If voltage was not present as described, reinstall your
existing electronic control assembly (1) and temperature sensor (8), and proceed to #12.
b.)200 to 240 volts ac for two wire 200 or 240 volt
models while the red indicator on the circuit is on
or blinking.
14. Disconnect the brewer from the power source.
If voltage was present as described, the temperature
control of the system is operating properly. Return the
new electronic control assembly (1) and temperature
sensor (8) to Bunn-O-Matic for credit.
Electronic Controls Removal and Replacement
NOTE - each electronic control assembly is calibrated
to a temperature sensor. Both components MUST be
replaced as a set.
1. Remove all wires from the electronic control assembly terminals.
2. Remove the two 8-32 screws holding the electronic control assembly to the component bracket.
3. Disconnect the temperature sensor and ready indicator wires from the left side of the electronic
control assembly board.
4. Remove the temperature sensor from the grommet in the tank lid.
5. Install the new temperature sensor into the grommet on the tank lid. Route the wires to the location
of the new electronic control assembly.
6. Attach the temperature sensor and ready indicator
wires to the electronic control assembly.
7. Fasten the new electronic control assembly to its
bracket.
8. Reconnect the wires.
9. Refer to Fig. 12 when reconnecting the wires.
10. Review the initial set-up procedures and adjust the
control as required for the desired temperature.
12. Replace the triac assembly (15).
13. With a voltmeter, check the voltage across the tank
heater terminals (5). Connect the brewer to the
power source. The indication must be:
a.) 120 volts ac for two wire 120 volt models, 208
volts ac for three wire 120/208 volt models and
240 volts ac three wire 120/240 volt models while
the red indicator on the circuit board is on or
blinking.
Page 26
27038 030901
SERVICE (cont.)
ELECTRONIC CONTROL ASSEMBLY (cont.)
7. Remove the two #8-32 keps nuts securing tank to
tank mounting bracket.
8. Remove the twelve #8-32 slotted head screws
securing the bottom cover.
9. Remove the bottom cover with the four feet, the
tank mounting brackets, triac/heat sink as an
assembly.
10. Remove triac/heat sink from tank mounting bracket
and discard.
11. Install new triac/heat sink assembly on tank mounting bracket.
12. Route the wires up around the rear of the brewer.
13. Reinstall the bottom cover, four feet, tank mounting brackets and triac/heat sink to the bottom of
the tank using two #8-32 keps nuts.
14. Secure bottom cover to brewer base with twelve
#8-32 slotted head screws.
15. Stand the brewer upright.
16. Reconnect the wires of the new triac assembly.
Refer to Fig. 13 when reconnecting wires.
DO
!
N
Un OT
til W Tu
ate rn O
H
Au ot W r Co n Th
tom a
me e T
a te
s F an
C tica r Sy
kH
r
Ac offee lly W stem om
co
Op eate
rda Bre hen U s –
en r S
we nit Wa
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w
Fa
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ilu With s – F Is Co r Ta d Fa itch
re
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To The Inl The nectek Wil cet!
W d lF
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In nk er!
Vo
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Wa tions
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nty
!
HA
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AG
DIS
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CO
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EC
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P924
Triac Assembly Removal and Replacement
NOTE - Each triac installation requires the use of an
approved silicone heat sink compound. Bunn-O-Matic
recommends the use of Dow Corning 340 compound
or equivalent. It can be purchased direct from Bunn-OMatic (part number M2522.1000).
1. Place the tank heater switch on the electronic
control assembly in the “OFF” position.
2. Completely drain the tank.
3. Place a stryofoam or wood block between the
center of the tank and the rear of the brewer.
4. Disconnect triac wires, white/violet from terminal
block, blue from tank heater, blue from electronic
control and tan from tank heater switch.
5. Carefully set the brewer on its back.
6. Remove the 2" dia hole plug from the bottom
cover.
Page 27
P923
SERVICE (cont.)
LEVEL CONTROL BOARD AND LEVEL PROBE
(Electro/mechanical only)
22978.0000
3
4
2
5
1
S
TE IC
NU AT C
MI -O-M 0 VA
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BU 20
26
P/N
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TL3
TL4
TL5
Location:
The level control board is located inside the front
in center of the brewer on the component bracket. The
level probe is located inside the hood on the center rear
of the tank lid.
Test Procedure:
1. Disconnect the brewer from the power source.
2. Remove the violet wire from terminal 1 & pink wire
from terminal 4 of the circuit board.
3. With a voltmeter, check the voltage across terminals 2 & 3. Connect the brewer to the power
source. The indication must be:
a.) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
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 Diagrams and check the brewer wiring harness.
Page 28
SERVICE (cont.)
LEVEL CONTROL BOARD AND LEVEL PROBE (Electro/
mechanical only)(cont.)
15. Move the probe's flat end to the brewer housing.
The indication must be 0.
16. Move the probe's flat end away from the brewer
housing. The indication should again be
a.) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models after a delay of approximately 1 second.
17. Disconnect the brewer from the power source.
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.
T4 PNK TO PROBE
T3 WHI to Terminal Block (White Insert
on 120V Two Wire, 120/28V or 120/240V
Three Wire Brewers)
T3 RED to Terminal Block (Red Insert on
200V or 240V Brewers)
T2 BLU from Thermostat
T1 VIO to Solenoid Coil
FIG. 15 LIQUID LEVEL CONTROL
BOARD TERMINALS
P832
Removal and Replacement:
1. Remove all wires from the level control board.
2. Remove two #8-32 slotted head screws and
lockwashers holding level control board to component bracket.
3. Install the new level control board to the component bracket. Make certain that the lockwashers
are between the level control board and the component bracket.
4. Refer to Fig. 15 when reconnecting the wires.
Page 29
27038 030901
SERVICE (cont.)
1⁄2
l
ga
l
1 ga
1 1⁄2
3
l
ga
RE
4
2
LE
SE
AD
Y
R
CTO
5
1
.5
ON
S
UTE TIC
MIN -MA VAC
0
12
M
AR
/W
ER
RT
STA
-O
NN
BU 2026
P/N
TW
HO
!
ER
AT
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IO
UT
CA
P833
Location:
The limit thermostat is located inside the hood on
the tank lid just to the left of the tank heater.
Test Procedure:
1. Disconnect the brewer from the power supply.
2. Disconnect both black wires from the limit thermostat.
3. With an ohmmeter, check for continuity across the
limit thermostat terminals.
If continuity is present as described, reconnect the
black wires to the limit thermostat , the limit thermostat is operating properly.
If continuity is not present as described, press the
reset button on the limit thermostat and repeat step
#3.
After repeating step #3, if no continuity is shown,
replace the limit thermostat.
Page 30
SERVICE (cont.)
ON/OFF SWITCH (Warmer)
6. Check for continuity across the center and lower
left terminal with switch in the "ON" position.
Continuity must not be present when switch is in
the "OFF" position.
1⁄2
ga
1 ga
l
l
1 1⁄2
ga
If continuity is present as described, reconnect the
black wire to the center terminal and the white/violet
wire on the switch to the lower left terminal.
If continuity is not present as described, replace the
switch.
l
3
4
RE
2
LE
CT
AD
Y
OR
SE
5
1
ON
S
.5
UTE IC
MIN -MATVAC
-O 0
NN 12
BU 2026
P/N
/W
AR
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T
ST
AR
AT
HO
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TW
N
FIG. 18 ON/OFF SWITCH
P820
Location:
The ON/OFF switch is located on the front of the
hood in the center to the right of the start switch.
Test Procedure:
1. Disconnect the brewer from the power source.
2. Viewing the switch from the back remove the
white wire from the upper right terminal and the
black wire from the center terminal.
3. With a voltmeter, check the voltage across the
white wire and the black wire. Connect the brewer
to the power source. The indication must be:
a.) 120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
4. Disconnect the brewer from the power source.
Removal and Installation:
1. Remove the wires from the switch terminals.
2. Compress the clips inside the hood and gently
push the switch through the opening.
3. Push the new switch into the opening and spread
the clips to hold switch in the hood.
4. Refer to Fig. 19 when reconnecting the wires.
BLk to Terminal
Block (Black Insert)
WHI/VIO to Timer TL1
(Electro/Mechanical)
or WHI/RED (Electronic)
WHI to Terminal
Block (White Insert
on 120/V,120/208V
or 120/240V Models)
RED to Red Terminal
Block (Red Insert on
200V-240V Models)
FIG. 19 ON/OFF SWITCH TERMINALS
P843
If voltage is present as described, reconnect the white
wire, and proceed to #5.
If voltage is not present as described, refer to the
Wiring Diagrams and check the brewer wiring harness.
5. With the black wire removed, remove the white/
violet wire on the switch from the lower left terminal.
Page 31
27038 030901
SERVICE (cont.)
Removal and Replacement:
1. Disconnect the red leads from the overflow protection switch from the black wire from the terminal block and the blue wire from the thermostat or
violet wire from electronic control assembly.
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 properly.
5. Install the nut beneath the copper overflow cup. Be
sure not to overtighten.
6. Refer to Fig. 21 when reconnecting wires.
C
A
U
T
IO
N
:
W
A
R
M
E
R
S
A
N
D
S
U
R
F
A
C
E
S
A
R
E
H
O
T
OVERFLOW PROTECTION SWITCH
P821
Location:
The overflow protection switch is located inside
the hood on the tank inside the copper overflow cup.
To test the overflow protection switch, access will
also be needed to the level control board or electronic
control assembly and terminal block.
Test Procedure:
1. Disconnect the brewer from the power source.
2. Remove the wire nuts connecting the red wires
from the overflow protection switch to the black
wire from the terminal block and the blue wire from
the thermostat or the violet wire from the electronic control assembly.
3. Check for continuity across the safety overflow
switch red wires only until the plastic float is raised
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 thermostat or violet wire from
electronic control assembly.
If continuity is not present as described, replace the
safety overflow switch.
Page 32
P834
SERVICE (cont.)
C
A
U
T
IO
N
:
W
A
R
M
E
R
S
A
N
D
S
U
R
F
A
C
E
S
A
R
E
H
O
T
SOLENOID VALVE (Inlet)
Page 33
SERVICE (cont.)
START SWITCH
3
4
2
5
1
S
.5
UTE IC
MIN -MATVAC
-O 0
NN 12
BU 2026
P/N
Location:
The momentary start switch is located in front of
hood just to the left of the ON/OFF switch.
Test Procedure:
1. Disconnect the brewer from the power source and
remove the wires from both terminals of the switch.
2. Check for continuity across the two terminals on
the switch when it is held in the lower position.
Continuity must not be present across these terminals in the upper position.
If continuity is present as described, reconnect the
wires, the switch is operating properly.
If continuity is not present as described, replace the
switch.
Page 34
SERVICE (cont.)
TANK HEATER
Location:
The tank heater is located inside the hood on the
right rear of the tank lid.
Test Procedure:
Electro/Mechanical Models.
1. Disconnect the brewer from the power supply.
2 Check the voltage across the black and the red wire
on 120V, 208 or 240V models on the tank heaters.
With a voltmeter, and with the control thermostat
turned to the "ON" position (fully clockwise), connect the brewer to the power supply and check the
voltage across the wires. The indication should be:
a.) 120 volts ac for two wire 120 volt models,208
volts ac for three wire 120/208 volt models and
240 volts ac for three wire 120/240 volt models.
b.) 200 to 240 volts ac for two wire 200 or 240 volt
models.
3. Disconnect the brewer from the power supply.
P837
Page 35
SERVICE (cont.)
lock must be bypassed. To bypass brew-lock disconnect white/yellow and orange wires from interlock of
ECA and connect harness leads together.
TIMER (First Type)
5. Check for continuity across the white/orange and
white/yellow wires on electro/mechanical brewers
or the white/yellow and yellow wires on electronic
brewers when the start switch is pressed.
If continuity is present as described, reconnect the
wires to terminals TL3, TL4 and TL5 of the timer board
and interlock wires if necessary, proceed to #6.
3
4
2
5
1
.5
ES
IC
UT
MIN -MATVAC
0
12
-O
NN
BU 2026
P/N
R
M
E
R
S
A
N
D
S
U
R
F
A
C
E
S
A
R
E
H
O
T
P825
C
A
U
T
IO
N
:
W
A
Location:
The timer is located inside the left front of the
brewer on the upper part of the component bracket.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Disconnect the wires from the timer terminals
TL3, TL4 and TL5 and rotate the dial(s) fully
counterclockwise.
3. With a voltmeter, check the voltage across terminals TL1 and TL2 when the "ON/OFF" switch is in
the "ON" position. Connect the brewer to the power
source. The indication must be:
a.)120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.)200 to 240 volts ac for two wire 200 or 240 volt
models.
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 Diagrams and check the brewer wiring harness.
NOTE: ECA MODELS ONLY - Brewer must be at
operating temperature to perform step #5 or brew-
6. With a voltmeter, check the voltage across terminals TL1 and TL4 when the "ON/OFF" switch is in
the "ON" position. Connect the brewer to the power
source and press the start switch. The indication
must be:
a.)120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models for approximately 1 minute for 1-1/2
gallon batch.
b.)200 to 240 volts ac for two wire 200 or 240 volt
models for approximately 1 minute for 1-1/2 gallon batch.
7. Select a 1 gallon batch and repeat #6. The voltage
indication should remain for approximately 40
seconds.
8. Select a 1/2 gallon batch and repeat #6. The
indication should remain approximately 20 seconds.
Removal and Replacement:
1. Remove all wires from the timer.
2. Remove the four #6-32 slotted head screws holding circuit board and dial plate on to the component mounting bracket.
3. Remove circuit board, nylon spacers and dial
plate.
4. Install new timer circuit board as described in
Digital Timer section on the following pages.
5. Refer to Fig. 31 when reconnecting wires.
6. Install the timer setting decal provided with the
replacement timer kit, on the inside of the front
access panel.
7. Adjust timer as required. Refer to Digital Timer
section on the following pages.
Page 36
SERVICE (cont.)
TIMER (First Type)(cont.)
5
IC
ATTIC
-M A
-O -M
3
NNN-O 4
BBUUN
5
3
2
11.5.5
.
ES
UT ATIC C
MIN-O-M 0 VA
2
NN 1
BU 6202
P/N
2
2.2.55
1
1
.5.5
4
6
7
8
2
6
1
ESS
UTTE
IN U
M
MIN
ESS
UTTE
IN U
3
ACC
M
MIN
0 VVA
1220
0 1
ESS
0000
UUTTE
66-0
IN
-00
8
IN
M
4
8
M
22444
PP/N
/N
WHI/VIO TL1 to ON/OFF Switch
WHI/VIO TL1 to Warmer Element
WHI TL2 To Terminal Block and Warmer Element
(120V Two Pole, 120/208V or 120/240V Three Pole
Terminal Block)
RED TL2 to Terminal Block and Warmer Element
(200V or 240V Two Pole Terminal Block)
WHI/ORA TL3 to Start Switch (Top)
WHI/VIO TL1 to ON/OFF Switch
WHI/VIO TL1 to Warmer Element
WHI TL2 To Terminal Block and Warmer Element
(120V Two Pole, 120/208V or 120/240V Three Pole
Terminal Block)
RED TL2 to Terminal Block and Warmer Element
(200V or 240V Two Pole Terminal Block)
WHI/ORA TL3 to Start Switch (Top)
WHI/GRN TL4 to Dispense Valve (Upper Front)
WHI/YEL TL5 to Start Switch (Bottom)
WHI/GRN TL4 to Dispense Valve (Upper Front)
WHI/YEL TL5 to Start Switch (Bottom)
ELECTRO/MECHANICAL
.
ES
UT ATIC C
MIN-O-M 0 VA
2
NN 1
BU 6202
P/N
Page 37
SERVICE (cont.)
DIGITAL TIMER (SecondType)
3
4
2
5
1
.5
F
A
C
E
S
A
R
E
H
O
T
P/
ES
IC
UT
MIN -MATVAC
-O 0
NN 12
BU 20N 26
C
A
U
T
IO
N
:
W
A
R
M
E
R
S
A
N
D
S
U
R
Location:
The timer is located inside the left front of the
brewer on the upper part of the component bracket.
Test Procedure.
NOTE: Do not remove or install wires while timer board
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 terminals TL1 and TL2 when the "ON/OFF" switch is in
the "ON" position. Connect the brewer to the power
source. The indication must be:
a) 120 volts ac for two wire 120 volt models and
three wire 120/240 volt models.
b) 200 to 240 volts ac on two wire 200 volt or 240
volt models.
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 Diagrams and check the brewer wiring harness.
Page 38
SERVICE (cont.)
TIMERS (Late Models)(cont.)
Timer Setting:
NOTE: Check that the brewer is connected to water
supply, the tank is properly filled, and a funnel and
server are in place, prior to setting or modifying
volumes.
NOTE: All volume settings must be done with the
sprayhead installed.
1. Modifying brew volumes. To modify a brew volume, first check that the SET/LOCK switch is in the
"SET" position on the circuit board.
To increase a brew volume, place the ON/OFF
switch in the "ON" position, press and hold the
START switch until three clicks are heard. Release
the switch (Failure to release the switch within two
seconds after the third click 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 brew volume, place the ON/OFF
switch in the "ON" position, press and release the
START switch once for every two-second interval
to be removed from the total brew time period;
then immediately press and hold down the START
switch until three clicks are heard. Release the
switch. (Failure to release the switch within two
seconds after the third click 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 three distinct clicks are heard
and then release the switch. (Failure to release the
switch within two seconds after the third click
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
TIMER WIRING
WHI/YEL wire to TL5
WHI/GRN wire to TL4
WHI/ORA wire to TL3
WHI wire to TL2 (120V Two Pole, 120/208V or
120/240V Three Pole Terminal Block)
RED wire to TL2 (200V or 240V
Two Pole Terminal Block)
WHI/VOI wire to TL1
P2037
FIG. 31 DIGITAL TIMER TERMINALS
switch to "OFF". NOTE: Several ounces of water will
continue to syphon from the tank after turning the
switch "OFF". 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, volumes will decrease due to absorption by the coffee grounds.
3. Setting programming disable feature. If it becomes necessary to prevent anyone from changing brew time once programmed, you can set the
SET/LOCK switch to the "LOCK" position. This will
prevent any further programming.
Page 39
27038 030901
SERVICE (cont.)
If voltage is not present as described, refer to the
Wiring Diagrams and check brewer wiring harness.
WARMER ELEMENT
5. Disconnect wires from the warmer element.
6. Check the continuity across the two terminals on
the warmer element.
If continuity is present as described, reconnect the
white or red and white/red wires or the white or red and
white/violet wires on the warmer element.
If continuity is not present as described, replace the
warmer element.
3
4
2
5
1
S
TE IC
NU
MI -MATVAC
-O 0
NN 12
BU 20N 26
.5
P/
Location:
The warmer element is located in the base of the
brewer under the warmer plate.
Removal and Replacement:
1. Remove the three #4-40 slotted head screws securing the warmer assembly to the brewer base.
2. Lift the warmer assembly from the brewer base.
3. Disconnect the two wires from the warmer element terminals.
4. Remove the two #8-32 nuts securing the warmer
element to the warmer plate.
5. Securely install new warmer element.
6. Reconnect the two wires to warmer element terminals.
7. Securely install warmer assembly in brewer base.
8. Refer to Fig. 33 when reconnecting wires.
Test Procedures:
1. Disconnect the brewer from the power source.
2. Use the white wire or red wire to the terminal block
and the white/violet wire to the warmer element.
3. With a voltmeter, on 120V, 120/208V or 120/240V
models, check the voltage across the white wire
and the white/violet wire with the "ON/OFF" switch
in the "ON" position. With a voltmeter, on 200V or
240V models check the voltage across the red wire
and the white/violet wire with the "ON/OFF" switch
in the "ON" position. The indication must be:
a.)120 volts ac for two wire 120 volt models, three
wire 120/208 volt models and three wire 120/240
volt models.
b.)200 to 240 volts ac for two wire 200 or 240 volt
models.
4. Disconnect the brewer from the power source.
If voltage is present as described, proceed to #5.
Page 40
SCHEMATIC WIRING DIAGRAM
SINGLE BREWER
L1
L2 N
GRN
LIMIT THERMOSTAT
BLK-12
BLK-12
BLK
BLK-12
TANK HEATER
RED-12 (208 OR 240V)
RED-12 (208 OR 240V)
WHI-12 (120V)
K1
N.O.
READY INDICATOR
OVERFLOW
PROTECTION SW
RED
RED
SW. & THERMOSTAT
TANK HEATER
CONTACTOR
BLK
BLU
WHI-12 (120V)
K1
N.O.
WHI
K1
REFILL
VIO
BLU
LIQUID 1
LEVEL 2
BOARD 3 PNK-20
4
BLK
OPTIONAL 3-SET SELECTOR SWITCH SHOWN
WITH GRINDER INTERFACE OPTION
TAN
GRY
S
E
L
E
C
T
O
R
S
W
FRACTIONAL BATCHES
(CONNECT
AS REQUIRED)
FULL BATCH
(NO CONNECTION)
1/4 BATCH
1/3 BATCH
1/2 BATCH
2/3 BATCH
PNK
3/4 BATCH
BATCH COMMON
1
BREW 2
TIMER 3
4
5
WHI/VIO
WHI
WHI/ORA
WHI/GRN
WHI/YEL
WATER
BYPASS
WHI/VIO
SOL
WHI
WHI
PROBE
100W WARMER
(NOT AVAILABLE ON
SINGLE-TF)
WHI
WHI/VIO
WHI
SOL
START
SWITCH
DISPENSE
WHI/GRN
SOL
WHI/RED
WHI/RED
GRY
PNK
TAN
4
GRINDER
3
INTERFACE
2
CONNECTOR
1
ON/OFF
SWITCH
WHI
AUXILIARY OUTLET
WHI/VIO
WHI
BLK
GRN
200WATT MAXIMUM
120 VOLTS AC 2 WIRE
120/208 VOLTS AC OR
120/240 VOLTS AC 3 WIRE
SINGLE PHASE
26885.0001B 9/98 © 1996 BUNN-O-MATIC CORPORATION
Page 41
27038 091900
SCHEMATIC WIRING DIAGRAM SINGLE BREWER ECA
L1
N
GRN
LIMIT
THERMOSTAT
BLK-12
TANK HEATER
BLK-12
W
H
I
GRY
INTERLOCK
ASSY
RED
PNK
GRY
GRY
GRY
BLU
7 WHI/BRN
6
5
4
ELECTRONIC 3
CONTROL ASSY 2
1
ORA
WHI/YEL
OVERFLOW
PROTECTION SW
BLK
BLK
TAN
TANK HEATER
SW
PNK
READY
L.E.D.
WHI/VIO-12 (208 OR 240V)
WHI /VIO-12(120V)
BLU-12
W
t° H
I
RED
PNK 20
(PROBE)
RED (208 OR 240V)
WHI (120V)
GRN
WHI/BLU
TAN
GRY
FRACTIONAL BATCHES
(CONNECT
AS REQUIRED)
FULL BATCH
(NO CONNECTION)
S
W
SOL
WHI
VIO
WHI/YEL
OPTIONAL 3-SET SELECTOR SWITCH SHOWN
WITH GRINDER INTERFACE OPTION
S
E
L
E
C
T
O
R
L2
1/4 BATCH
1/3 BATCH
1/2 BATCH
2/3 BATCH
PNK
1
BREW 2
TIMER
3
4
5
3/4 BATCH
BATCH COMMON
WHI/VIO
WHI/ORA
WHI/GRN
WHI/YEL
SOL
WHI
WHI
SOL
START SW.
WATER
BYPASS
WHI/VIO
WHI/VIO
100W WARMER
(NOT AVAILABLE ON
SINGLE-TF)
WHI/GRN
WHI/RED
GRY
PNK
TAN
4
3
2
1
ON/OFF
SW
GRINDER
INTERFACE
CONNECTOR
WHI
AUXILIARY OUTLET
WHI
WHI/VIO
GREEN
200 WATT MAXIMUM
120 VOLTS AC 2 WIRE
120/208 VOLTS AC OR
120/240 VOLTS AC
3 WIRE
26885.0000B 11/96 © 1996 BUNN-O-MATIC CORPORATION
Page 42
27038 091900
SCHEMATIC WIRING DIAGRAM SINGLE-A & -B BREWER
L1
L2
GRN/YEL
LIMIT THERMOSTAT
BLK-12
BLK-12
K1
N.O.
OVERFLOW
PROTECTION SW
RED
RED
BLK
TANK HEATER
BLK-12
RED-12
RED-12
K1
N.O.
READY INDICATOR
TANK HEATER
CONTACTOR
SW. & THERMOSTAT
BLK
BLU
RED
K1
REFILL
VIO
LIQUID 1
BLU
2
LEVEL
BOARD 3 PNK-20
4
BLK
OPTIONAL 3-SET SELECTOR SWITCH SHOWN
WITH GRINDER INTERFACE OPTION
TAN
S
E
L
E
C
T
O
R
S
W
GRY
FRACTIONAL BATCHES
(CONNECT
AS REQUIRED)
FULL BATCH
(NO CONNECTION)
1/4 BATCH
1/3 BATCH
1/2 BATCH
2/3 BATCH
PNK
3/4 BATCH
BATCH COMMON
1
BREW 2
TIMER 3
4
5
SOL
RED
PROBE
RED
WHI/ORA
WHI/GRN
WHI/YEL
WATER
BYPASS
WHI/VIO
RED
100W WARMER
(NOT AVAILABLE ON
SINGLE-TF)
RED
WHI/VIO
WHI/VIO
SOL
SOL
START
SWITCH
DISPENSE
WHI/GRN
WHI/RED
GRY
PNK
TAN
4
GRINDER
3
INTERFACE
2
CONNECTOR
1
200 OR 240 VOLTS AC
2 WIRE
ON/OFF
SWITCH
RED
WHI/VIO
26885.0003A 3/96 © 1996 BUNN-O-MATIC CORPORATION
Page 43
27038 091900
SCHEMATIC WIRING DIAGRAM SINGLE-A & -B BREWER ECA
L1
L2
GRN/YEL
LIMIT
THERMOSTAT
BLK-12
TANK HEATER
BLK-12
W
H
I
GRY
INTERLOCK
ASSY
RED
PNK
GRY
GRY
GRY
ORA
WHI/YEL
OVERFLOW
PROTECTION SW
BLK
BLK
TAN
TANK HEATER
SW
PNK
READY
L.E.D.
WHI/VIO-12
BLU-12
W
t° H
I
BLU
7 WHI/BRN
6
5
4
ELECTRONIC 3
CONTROL ASSY 2
1
RED
PNK 20
(PROBE)
RED
GRN
WHI/BLU
TAN
GRY
FRACTIONAL BATCHES
(CONNECT
AS REQUIRED)
FULL BATCH
(NO CONNECTION)
S
W
RED
VIO
WHI/YEL
OPTIONAL 3-SET SELECTOR SWITCH SHOWN
WITH GRINDER INTERFACE OPTION
S
E
L
E
C
T
O
R
SOL
1/4 BATCH
1/3 BATCH
1/2 BATCH
2/3 BATCH
PNK
3/4 BATCH
BATCH COMMON
1
BREW 2
TIMER
3
4
5
WHI/VIO
WHI/ORA
WHI/GRN
WHI/YEL
SOL
RED
RED
SOL
START SW.
WATER
BYPASS
WHI/VIO
WHI/VIO
100W WARMER
(NOT AVAILABLE ON
SINGLE-TF)
WHI/GRN
WHI/RED
GRY
PNK
TAN
4
3
2
1
200 OR 240 VOLTS AC
2 WIRE
ON/OFF
SW
GRINDER
INTERFACE
CONNECTOR
RED
WHI/VIO
26885.0002B 11/96 © 1996 BUNN-O-MATIC CORPORATION
Page 44
27038 091900
SINGLE BREWER W/DIGITAL BREWER CONTROL
SCHEMATIC WIRING DIAGRAM
D
I
G
I
T
A
L
B
R
E
W
E
R
C
O
N
T
R
O
L
C
I
R
C
U
I
T
B
O
A
R
D
J1-1
5
WHI/RED
WHI/RED
WHI
WHI
WHI
WHI
WHI
ON/OFF SW
BLK
WHI/RED
WHI/RED LOWER WARMER
TRIAC
REFILL
10
P1 BLU
SOL
BLK
15
P2
BLK
TAN
BLU
GRN
WHI/VIO
BLU
TAN
LIMIT
THERMOSTAT
TANK HEATER
BLK
WHI
120V.A.C.
208 0R 240V.A.C.
120V.A.C.
WHI
BLK
BREW
WHI/BLU
WHI
SOL
BLK
GRN
BLK
WHI
SOL
WHI/VIO
5
15
WHI/RED
BLK
YEL
BLK
RED
BLK
RED
N.C.
RED
P2
PNK
TAN
WHI
WHI
BLU
4
GRY 3 GRINDER
PNK 2 INTERFACE
CONNECTOR
TAN 1
OPTIONAL
DAY/NIGHT
SWITCH
P3
P1
GRY
20
WHI/VIO
START SW
OVERFLOW PROTECTION SWITCH
10
OPTIONAL
BYPASS
(200 WATT MAXIMUM)
J1-24
J3-1
BLK
AUXILIARY OUTLET
20
P1
P2
GRY
TAN
PNK
B
A
T
C
H
S
E
L
E
C
T
S
W
I
T
C
H
P4
WHI
TEMP
SENSOR
WHI
RED
25
PNK
P2
PNK
GRY
30
GRY
GRN
35
J3-40
DRY PLUG
DETECTION
P1
PNK
RED
PNK
WHI
RED
PNK
LIQUID LEVEL SENSOR
RED
BLK
RED
RED
PNK
WHI
6
5 CONTROL
4 & DISPLAY
3 CONNECTOR
2 INTERFACE
1
120/208 OR
120/240 VOLTS AC
3 WIRE
SINGLE PHASE
10851.0000E 9/00 © 1994 BUNN-O-MATIC CORPORATION
Page 45
27038 030901
D
I
G
I
T
A
L
J1-1
SINGLE BREWER W/DIGITAL BREWER CONTROL
SCHEMATIC WIRING DIAGRAM
WHI/RED
WHI/RED
RED
RED
RED
RED
RED
ON/OFF
SW
BLK
B
R
E
W
E
R
WHI/RED
BREW
SOL
BLK
WHI/RED
LOWER WARMER
TRIAC
REFILL
P1 BLU
SOL
WHI/VIO
C
O
N
T
R
O
L
TAN
BLU
BLK
LIMIT
THERMOSTAT
GRN
BLU
P2 TAN
TANK HEATER
BLK
RED
BLK
C
I
R J1-24
C
U J3-1
I
T
B
O
A
R
D
WHI/BLU
BLK
BLK
YEL
BLK
4
GRY 3 GRINDER
PNK 2 INTERFACE
CONNECTOR
TAN 1
RED
BLK
P2
PNK
TAN
P3
P1
GRY
WHI
WHI
BLU
P1
GRY
TAN
PNK
S
E
L
E
C
T
S
W
I
T
C
H
P4
P2
RED
PNK
GRY
GRN
PNK
J3-40
200 – 240 V.A.C.
RED
PNK
BRN
RED
RED
BLK
RED
RED
PNK
BRN
200 – 240 VOLTS AC
2 WIRE
SINGLE PHASE
10853.0000B 5/98 © 1994 BUNN-O-MATIC CORPORATION
Page 46
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