Bunn Dual TF BrewWISE DBC Troubleshooting guide

BUNN® TECHNICAL TRAINING
ThermoFresh BrewWISE ® DBC
Index
Unit 1: Installation
Site Requirements............................................................................................................... 4
Location of the Serial Number........................................................................................... 4
Water Supply Install............................................................................................................ 4
Electrical Install................................................................................................................... 5
Initial Start-Up...................................................................................................................... 6
Unit 2: Setup
Setup and Programming..................................................................................................... 8
Programming Lockout.................................................................................................. 8
Level 1 Programming.......................................................................................................... 9
Level 2 Programming.......................................................................................................... 9
Level 3 Programming.......................................................................................................... 10
Calibrating Flow Rate.......................................................................................................... 10
Check and Adjust the Dispense Valve Flow Rate...................................................... 10
Check and Adjust the Bypass Valve Flow Rate......................................................... 11
Programming the Recipes.................................................................................................. 11
Calibrating the Temperature Sensing Probe..................................................................... 12
Unit 3: Machine Composition
Exterior Overview................................................................................................................ 14
Product Outlets and Removable Parts....................................................................... 14
User Interface................................................................................................................ 14
Accessing the Inside of the Brewer................................................................................... 14
Machine Function and Operations..................................................................................... 15
Main Control Board....................................................................................................... 15
Filling System................................................................................................................ 15
Heating System............................................................................................................. 16
Dispensing System....................................................................................................... 17
Coffee Holding System................................................................................................. 17
Unit 4: Preventive Maintenance
Preventive Maintenance...................................................................................................... 19
PM Steps.............................................................................................................................. 19
Unit 5: Troubleshooting
Service Tools....................................................................................................................... 22
Test Outputs.................................................................................................................. 22
Test Switches................................................................................................................ 23
Test Frequency.............................................................................................................. 23
Service Fault Messages...................................................................................................... 23
Operator Fault Messages.................................................................................................... 24
Refill, Heating & Brewing Troublshooting......................................................................... 25
Triac Map.............................................................................................................................. 29
Additional Resources.......................................................................................................... 30
Rev. A
© 2011 Bunn-O-Matic Corporation. All Rights Reserved
Unit 1 Installation
Unit Objectives
Given a realistic scenario depicting a new site install, the learner will be able to install and setup the brewer
for customer turnover without error.
Given a new machine, all the necessary tools and safety equipment, the learner will be able to install the brewer without error.
The learner will be able to verify that the site requirements have been met.
The learner will be able to locate and document the serial number.
The learner will be able to hook up the water supply.
The learner will be able to hook up the electrical supply.
Installation
Site Requirements
Space
• Single TF BrewWISE
- Counter able to support the weight of the machine, approximately 120 pounds (water
tank full)
- Counter area able to support machine placement 35.8”H x 12.5”W x 20.2”D
• Dual TF BrewWISE
- Counter able to support the weight of the machine, approximately 185 pounds (water
tanks full)
- Counter area able to support machine placement 35.8”H x 21.8”W x 21.2”D
Water Treatment
• Sediment filtration to reduce large particles
• Taste and odor filter to remove chlorine
• Scale filtration as needed
• For best results a Bunn Easy Clear® filtration system should be used
Plumbing
• 3/8” flare fitting on the machine
• Dedicated water supply with shut-off
• Connected to the cold water supply
• Water pressure 20-90psi, set to 50psi if regulator is needed
Electrical
• Receptacle within 5 feet of machine
• If a power cord is not attached to the machine the technician will have to supply and install the cord
- Follow National Electric Code set forth by NEC when determining proper breaker, plug and
receptacle.
• 120/208VAC or 120/240VAC
• 3 wire plus ground (Neutral, L1, L2, ground)
• 30 amp dedicated circuit (breaker, plug, and receptacle)
• Receptacle within 5 feet of machine
Location of the Serial Number
The machine’s serial number is located on the data plate which is attached to the bottom of the front panel. The complete serial number will need to be documented on all work orders and warranty tags.
Water Supply Install
Step 1: Check water pressure, install a regulator if above 90psi.
Step 2: Flush water lines.
Step 3: Install shut-off valve.
Step 4: Attach the water line to the 3/8” flare fitting on the bottom of the machine.
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TF BrewWISE® Training Manual
Electrical Install
Refer to the electrical section of the machine’s data plate to select the proper power cord, plug and receptacle for
the brewer. An electrician must provide electrical service as specified in conformance with all local, state, and federal
electrical codes.
Step 1: Remove the front panel (11 flat head screws).
Step 2: Feed the power cord through the strain relief in the bottom of the machine.
Step 3: Attach the wire ends to the terminal block.
Step 4: Attach the ground wire to connector on the frame cross bar.
Step 5: Check that all connections are tight.
Step 6: Tighten the strain relief and replace the front panel.
Step 7: Plug the unit into the power source.
WHI
L2 RED
L2 RED
WHITE
WHITE
NEUTRAL
L1 BLACK
GREEN
NEUTRAL
L1 BLACK
GREEN
L2
BLU
N
RED
L1
BLK
Note: This electrical service
consists of 4 current carrying
conductors (Neutral, L1, L2
and L3) and a separate conductor for earth ground.
N
L3
L2
L1
G
GREEN
120/208 and 120/240 volt ac
single phase, 60 Hz models
Note: This electrical service consists
of 3 current carrying conductors
(Neutral, L1 and L2) and a separate
conductor for earth ground.
GREEN
120/208 and 120/240 volt ac
3 phase & multi phase,
60 Hz models
SYSTEM
VOLTAGE
208
240
V1
208
240
V2
120
120
L1, L2, L3, are the 3 phases
V1 = Phase to phase voltage, between any 2
phases.
V2 = Phase to neutral voltage, L1 to neutral
must be 120V.
CAUTION: Do not connect L1 to a circuit
operating at more than 150 volts to
ground.
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Units without a Neutral
The field-switchable Duals will have an internal step-down transformer and a 2-pole contactor in addition to a 3rd
heating element. The step-down transformer is a 208/240-120VAC transformer. The transformer is installed for locations that do not have a neutral on site.
200 or
230V
L1 BLACK
L2 RED
GREEN
GREEN
L3 BLU
L3 BLU
L2 RED
L2 RED
L1 BLACK
GREEN
200 and 230 volt ac
single phase, 60 Hz models
L1 BLACK
GREEN
120/208 and 120/240 volt ac
multi phase, 60 Hz models
Note: This electrical service
consists of 2 current carrying
connect an external neuDo NOT connect an external neutral toDo
thisNOT
brewer.
conductors (L1 and L2) and a
tral to this brewer.
separate conductor
for earthservice consists of 3 current carrying conductors (L1, L2 and L3) and a separate conductor for
Note: This electrical
ground. earth ground. For single phase installation,
(blue)
terminalservice
is not used.
Note:L3This
electrical
consists of 3 current carrying conductors (L1, L2 and L3) and a separate
conductor for earth ground.
Initial Start-Up
Step 1: Flip the master On/Off switch to the On position.
PLEASE WAIT
TANK FILLING
When the machine is turned on, it will begin to fill the tank. After the tank fills the machine
will automatically begin the heating cycle. This will take approximately 20 minutes.
Once the water temperature has reached the programmed Brew Lockout temperature it will
display the ready screen. The machine will continue to heat until it reaches its programmed
shut-off temperature.
HEATING
WATER TEMP ###°
READY TO BREW
WATER TEMP 200°
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TF BrewWISE® Training Manual
Unit 2 Setup
Unit Objectives
Given a realistic scenario depicting a new site install, the learner will be able to install and setup the brewer
for customer turnover without error.
Given an installed machine, all the necessary tools and safety equipment, the learner will be able to set the machine up for initial operation.
The learner will be able to power on the machine.
The learner will be able to perform the calibrations.
Setup and Programming
The BrewWISE® software is the latest evolution of BUNN’s digital brewer control (DBC®) system. The software allows precise brewing control and multiple extraction recipes to be stored on the brewer and onboard troubleshooting
capabilities for the technician. The software also allows the brewer to communicate with a DBC® grinder, to reduce
operator errors when selecting products and batch sizes.
Accessing and using the brewer’s programming features is done from the front panel and requires no special tools.
The programming menu is accessed by pressing the hidden switch, located under the trademark symbol, on the right
side of the Bunn logo. The hidden switch on the left side will allow you to scroll backwards.
Left Hidden Switch
Right Hidden Switch
ENABLE
ENABLE
ON / OFF
ON / OFF
BREW
BREW
Digital
Brewer
Control
Right Hidden Switch: This is used to access the programming mode and is also used to scroll forward through the
function list.
Left Hidden Switch: This is used to scroll backwards through the function list.
Digital (lower left under the display): This is used to select options that appear on the display during programming.
Brewer (center under the display): This is used to select options that appear on the display during programming.
Control (lower right under the display): This is used to select options that appear on the display during
programming.
Programming Lockout
While the programming lockout switch is in the On position, the programming menus cannot be accessed. The switch
is located on the control board. Remove the top panel, locate the switch and place it into the Enable position.
Program Lockout
Switch
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TF BrewWISE® Training Manual
Level 1 Programming
Press and hold the right hidden switch until the display screen reads “Brew Lockout?” and release.
BREW LOCKOUT ?
ON
DONE OFF
This function will lockout an operator if a predetermined temperature has not been achieved message will read “Brew temp to low please wait heating”.
Level 2 Programming
Press and hold the right hidden switch until the display screen reads “Units” and release.
UNITS
METRIC DONE ENG
This function allows the operator to choose between English or Metric.
SET NEW RECIPE ?
NO
YES
This screen is for setting water volumes for the Brew (dump) valve and the Bypass valve. Pulse Brewing will also be found in this screen.
REVIEW RECIPES ?
NO
YES
This screen allows the user to preview recipes that are already programmed you can also modify or set the recipes manually in this screen.
ASSIGN RECIPE ?
NO
YES
This function allows for assigning a coffee name other than No-Name to the brew switch. COPY SETTINGS ?
NO
YES
If one NO NAME coffee is set up, this function allows you to copy the settings to the opposite side.
ENABLE ADS ?
NO DONE YES
This screen allows the operator to utilize the screen for advertising; a tag card can be programmed with your message.
SET TEMP 200O
(-)
DONE
(+)
Sets the temperature of the brew tank.. Range of 185°F to 205°F
SET READY 195O
(-)
DONE
(+)
This function sets the minimum temperature to start a brew cycle (BREW LOCKOUT).
Range of 179°F min. to 203°F max. (or within minimum 2° of tank target temp).
XXX REFILL
155
(-)
DONE
(+)
Set the sensitivity of the refill circuit. Range of 20 (Open circuit) to 230 (Short circuit). Can be adjusted for different water conditions. Increase number for very soft water.
Default is 155
L SPRAY Oz/M: 39.2
(-)
DONE
(+)
R SPRAY Oz/M: 39.2
(-)
DONE
(+)
Enter new number for each sprayhead, after doing CALIBRATE FLOW and measuring output.
Enter new number for each sprayhead, after doing CALIBRATE FLOW and measuring output.
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L BYPASS
Oz/M: 24.1
(-)
DONE
(+)
Enter new number for each bypass valve, after doing CALIBRATE FLOW and measuring output.
R BYPASS
Oz/M: 24.1
(-)
DONE
(+)
Enter new number for each bypass valve, after doing CALIBRATE FLOW and measuring output.
FLOW
CALIBRATE
?
NO
Technician can measure actual flow rate through all 4 valves with 60 second flow test.
YES
BREW
COUNTERS ?
NO
YES
Allows the operator to track the number of brew cycles completed left, right, Combined (resettable) & Combined (no reset).
FUNNEL
DETECT ?
NO
DONE YES
YES allows the operator to prevent the start of a brew cycle, must have a Smart funnel. NO does not need Smart funnel to brew.
FUNNEL
LOCKOUT ?
NO DONE YES
YES prevents the operator from removing the brew funnel during a brew cycle.
SERVICE
TOOLS ?
NO
YES
Allows technician 4 test modes, operate all load components, test touch pad switches, and test frequency of funnel sensing coils.
FACTORY
DEFAULTS
NO
YES
Allows operator to erase anything previously set and returns to factory settings. You will lose calibrations, recipes, adjusted brew volumes, etc.
Level 3 Programming
Press and hold the right hidden switch for 10 seconds.
Insert a digital thermometer probe into the water tank and wait for the temperature reading to stabilize.
200o
CAL
200o
(-)
DONE
(+)
Check and Adjust the Dispense Valve Flow Rate
Step 1: Scroll to Calibrate Flow select Yes.
CALIBRATE FLOW ?
NO
YES
Step 2: Select Yes at the next screen to dispense from the brew valves.
SPRAY HEAD CAL ?
NO
YES
Step 3: Ensure the sprayhead and funnel are in place and put a container, measuring pitcher or server, underneath
the funnel, select Yes.
CONTAINER
QUIT
RDY ?
YES
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TF BrewWISE® Training Manual
Step 4: To activate the flow rate check, press the Brew button of the side of the machine you wish to check.
Step 5: The valve will open for 60 seconds. Once all of the water has dripped out, input the volume into the brewer.
LEFT
OZ
QUIT
36.0
YES
Check and Adjust the Bypass Valve Flow Rate
Step 1: Scroll to Calibrate Flow select Yes.
CALIBRATE FLOW ?
NO
YES
Step 2: Select No at the next screen to dispense from the brew valves.
SPRAY HEAD CAL ?
NO
YES
Step 3: Select Yes at the next screen.
BYPASS
NO
CAL ?
YES
Step 4: Ensure the sprayhead and funnel are in place and put a container, measuring pitcher or server, underneath
the funnel, select Yes.
CONTAINER
QUIT
RDY ?
YES
Step 5: To activate the flow rate check, press the Brew button of the side of the machine you wish to check.
Step 6: The valve will open for 60 seconds. Once all of the water has dripped out, input the volume into the brewer.
LEFT
QUIT
OZ
24.2
YES
The process needs to be repeated for both sides of the brewer if applicable.
Programming the Recipes with a Recipe Card
Every brewer will have a recipe programmed into the main
control board. Most often, if a technician is asked to modify a
brewer’s recipe it will be done using a recipe card. The recipe
card allows new programming data to be uploaded to the
brewer wirelessly.
The recipe card will contain all of the coffee parameters for the
customers coffee flavor profile including: Coffee Name, Brew
Volumes, Bypass Percentages, Cycle Times, Initial On Times,
and Drip-Out Times.
To upload the recipe onto the brewer, remove the funnels and
place the card under the left hand funnel sensing coil. The machine will recognize the recipe card and prompt to upload the
recipe on the display.
TAG CONTAINS
RECIPE FOR
“COFFEE NAME”
SHOW
QUIT
SAVE
TAG CONTAINS RECIPE
Instructions for transfer to brewer.
• Remove both funnels.
• Hold tag under left sense coil.
• Display will show “TAG CONTAINS
RECIPE”
• Follow instructions on screens.
NAME:_________________
T oday’s S pec ial
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Calibrating the Temperature Sensing Probe
Note: Calibrating the temperature sensing probe (thermistor) should be done when replacing the CBA or thermistor.
Allow the tank to heat the water to the ready temperature. No tests should be taken while the tank is heating as the
tank temperature must be stable before any readings are recorded.
Step 1: Remove the top panel of the machine.
Step 2: Gain access to the water in the tank, the thermistor grommet can be removed (keep the thermistor in contact with the water.)
Step 3: Place the probe of a digital thermometer into the water and measure the temperature.
Step 4: Verify and record the temperature of the water.
Step 5: Access level 2 programming by pressing and holding the right hidden switch for 10 200o CAL
200o
seconds. The display screen should read “200° Cal 200°”.
(-)
DONE
(+)
Step 6: Use the Digital (-) and Control (+) switches to enter the temperature that you recorded from the digital thermometer reading.
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TF BrewWISE® Training Manual
Unit 3 Machine Composition
Unit Objectives
Given a realistic scenario in which the learner has access to the machine’s internal components the learner
will understand the composition and functions of the brewer.
Given a realistic scenario requiring the learner to access the internal components of the machine the learner will be able to remove the front panel and top cover.
The learner will disconnect the electrical and water supply.
The learner will remove the front panel and top cover.
Given an operating machine the learner will be able to give a general explanation of how the unit operates.
The learner will be able to identify the functions of the main control board and identify the
components that correspond to each triac.
The learner will be able to identify the components and functions of the filling system.
The learner will be able to identify the components and functions of the heating system.
The learner will be able to identify the components and functions of the dispensing system.
The learner will be able to identify the components and functions of the coffee holding system.
1
Machine Composition
2
4
Exterior Overview
5
Product Outlets and Removable Parts
•
•
•
•
•
•
•
User interface (1)
Display (mounted to the control board) (2)
Hot water outlet (3)
Funnel sensing coil (4)
Funnel (5)
Server (6)
Data plate (7)
7
6
3
User Interface
The user interface is a membrane switch adhered to the front of the brewer. The membrane is connected to the control board by a ribbon cable. The user interface allows the user to select product size and begin a brew cycle.
The machine’s display is mounted to the control board. The display is visible on the front of the machine and provides
information to the user and to the technician.
Batch Selector Switches
ENABLE
ENABLE
ON / OFF
ON / OFF
BREW
BREW
On/Off Switch
Brew Start Switch
Funnel Sensing Coils
Accessing the Inside of the Brewer
The majority of service work done to the BrewWISE® brewer will require the service technician to access the inside
of the unit. The brewer has three removable panels to facilitate access- the front panel, the top panel, and the server
base panel. Depending on the repair the technician may have to remove one or all of these panels.
In order to work safely the power should be disconnected prior to removal of any body panel. Once the panels are
removed the power can be reconnected in order to troubleshoot the machine.
The top panel is secured with 4 small flat head screws. To the remove the panel, remove the four screws, lift the front
of the panel up and slide the rear backwards to unhook the panel from the brewer’s body.
To remove the front panel, first remove the funnels and servers from the machine. The front panel is secured to the
brewer with 11 standard screws. Remove the screws and pull the panel straight off of the unit.
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TF BrewWISE® Training Manual
Machine Function and Operations
Main Control Board
Main Control Board
The main control board is the brain of the brewer. In the Digital
Brewer Control (DBC®) system, the control board is the single component that contains all of the programming software, it interprets
all the data it receives from the level and temperature sensors and
activates components to fulfill those demands. The main control
board responds to the users input through the membrane switch and
activates and controls the brew cycle. The control board can receive
data from Smart Funnels® through the sensing coils on the front of
the machine.
The control board is interchangeable between the single and dual
brewers. There is jumper located on the board to select either single
or dual with dual being default.
In a digital brewer the control board takes the place of the
liquid level control board, the timer board, and the mechancal thermostat. All of these components are combined into a single
unit.
i-
Filling System
The fill system maintains the level of water in the brewer’s tank. Anytime water is drawn off of the tank during a brew
cycle, the fill circuit activates to refill the tank.
The fill system consists of:
• 120VAC solenoid inlet valve
• Fill probe
• Overflow cup
Water enters the brewer through the water supply line and enters the
chassis through copper tubing. The water flows through the inlet solenoid.
The inlet solenoid contains a strainer that restricts large particles from
passing through. Once water passes through the inlet solenoid, water
begins filling the tank.
The 120VAC inlet solenoid is activated by the control board anytime the
brewer calls for water. The valve opens and allows water to flow, under
line pressure, to the top of the tank where the silicon tube connects to an
stainless steel fill tube. The fill tube runs to the bottom of the tank where
the incoming water enters the tank.
The control board monitors the level of water in the tank through a low
voltage level probe mounted to the top of the tank. The control board
grounds a 2.5VAC signal to the tank through the water. If it loses this
signal, the control board will activate the inlet valve.
The brewer features an overflow safety system for the fill circuit. There is
a tube mounted on the top of the tank that will drain water if the tank fills
to the top and continues to fill. The water will drain into the overflow cup;
there is a float switch in the cup. When this switch floats to its top position this signals the control board to deactivate the fill circuit and heating
circuit.
Liquid Level Probe
Float Switch
Overflow
Cup
Fill Tube
Check Valve
(Optional)
Inlet Solenoid
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Heating System
The heating system consists of:
• Water tank
• Heating elements
• Triacs
• Contactor (3 phase only)
• High-limit thermostats
• Temperature sensor
Tank Heater Triac
The heating circuit maintains the water in the tank at a preset temperature. This ensures that the water is always
ready for brewing. Water for brewing is contained in a stainless steel tank. A Dual BrewWISE tank contains 2 heating
elements (3 heating elements if equipped for 3 phase) that are powered by the line voltage into the machine. A single
BrewWISE tank will contain 1 heating element. Each heating element is controlled by the control board through triacs. Each heating element circuit has a limit thermostat that will interrupt the circuit if the water in the tank overheats.
BrewWISE units without a neutral will have an internal step-down transformer and a 2-pole contactor. The step-down
transformer is a 204/240-120VAC transformer.
For 3-phase operation, the 2-pole contactor is used in the heating circuit in addition to a triac for controlling the elements. The contactor will control 2 heating elements while the triac will control the 3rd. During heating all 3 elements
will be energized. Once the temperature is within 2°F of target, the CPU will open the contactor and the remaining
element, controlled by the triac, will heat and maintain the water precisely at the programmed target temperature.
If a BrewWISE unit has the capability for 3 phase operation, but is installed to operate in single phase, the center
heating element and L3 position of the terminal block will not be used.
The control board monitors the water in the tank by a temperature sensor that is in contact with the water.
This temperature sensor is a digital thermistor; the control board reads the temperature as value of resistance. The temperature sensor allows the control board to trigger the two heating element triacs when the
temperature drops below its programmed value and shut down the trigger voltage when the water temperature reaches the programmed holding value.
Tank Heater
3rd Heating Element for
3 Phase goes here.
Limit Thermostat
Heater Triac
Single Tank
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TF BrewWISE® Training Manual
Dual Tank
Bypass Valve
Dispensing System
The dispensing system consists of:
• Brew valve
• Bypass valve
• Sprayhead
• Funnel
• Funnel lock solenoids
Dispense Valve
The dispensing system is what makes the brewer
a coffee brewer. It dispenses the water onto the
ground coffee to create the product.
The BrewWISE® brewer is a gravity dump brewing
system. During the brew cycle the brew and bypass
valves open allowing water to flow from the tank and
out the product outlets. The control board opens and
closes these valves according to its programming
based on the specific recipe called for. The sprayhead, attached to the dispense solenoid, controls
the outlet flow rate of the water. The number and
size of the holes determines the flow rate.
Sprayhead
Funnel Lock
The brewer has a funnel lock feature; during the brew cycle and the programmed drip out time the funnel lock solenoid will be engaged to prevent the funnel from being removed. It is important to note that the control board supplies
120 DC voltage to the funnel lock solenoid to prevent it from vibrating.
Funnel Lock Solenoid
Coffee Holding System
ThermoFresh­® servers are vacuum insulated servers that can keep coffee hot and fresh for hours.
The TF server has a removable stand for flexibility and a space saving profile. The built-in drip tray
can also be removed for cleaning purposes as well as the sight gauge and faucet assembly. The
large cup clearance allows for dispensing into cups, decanters and thermal carafes. Like thermal
servers, the TF server must be pre-heated with hot water before it can properly maintain the beverage temperature.
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Unit 4 Preventive Maintenance
Unit Objectives
Given a realistic scenario depicting a machine requiring a preventive maintenance, the learner will be able to
identify which elements of a component need to be serviced without error.
Given a machine, all the necessary tools and safety equipment, the learner will be able to identify the components that need to be serviced for the PM.
Preventive Maintenance
In order to maintain proper operation and long service life BUNN recommends performing the preventive maintenance every 6 months. Individual customers will vary with some customers choosing not to receive preventive maintenance.
Tools Required:
• 2 Flat blade screwdrivers (#1 - #2)
• Phillips screwdriver
• 2 adjustable wrenches
• Channel lock pliers
• Needle nose pliers
• Deliming tool BUNN PN: 38227.0000
Prior to servicing the brewer:
• Disconnect the electrical supply
• Shut off the water supply
• Drain the water tank
• Remove the front panel
• Remove the top panel
PM Steps
If customer has a BUNN water filtration system installed before the brewer, replace the filter or filter cartridge and
purge before installing to the brewer.
Step 1: Rebuild the inlet solenoid
□□ Shut off the water supply.
□□ Remove both wires from the refill valve.
□□ Disconnect both water lines at the valve.
□□ Remove the two 1/4”-20 screws securing the valve
to the component mounting bracket.
Step 3: Remove and clean the fill tube
□□ Using an adjustable wrench remove the tube fitting from the fill tube on top of the tank
□□ Gently pull the fill tube out of the top of the tank
□□ Wipe any mineral deposits from the exterior of the tube
□□ Clean any mineral deposits from the bottom of the tube
□□ Clean any obstructions from the interior of the tube
□□ Reinstallation is the opposite of removal
Step 4: Rebuild the by-pass solenoids
□□ Remove the hose clamps that secure the tubing to the valve
□□ Remove the two nuts that hold the solenoid bracket to the machine
□□ Gently remove the tubing from the valve body
□□ Using a flat blade screwdriver, remove the four screws and separate the valve assembly
□□ Replace plunger, spring, and rubber seat using the rebuild kit.
□□ Clean any mineral build-up from the valve
□□ Reassembly is the opposite of disassembly
Step 5: Rebuild the dispense solenoids
□□ Disconnect the wire leads to the solenoid
□□ Unscrew the sprayhead from the bottom of the valve
□□ Remove the securing nut from the bottom of the valve
□□ Remove the clip from the tube on the valve fitting
□□ Remove the tube from the barbed fitting on the rear of the valve
□□ Remove the valve from the brewer
□□ Remove the four Phillips head screws and disassemble the valve
□□ Replace plunger, spring, and rubber seat using the rebuild kit. BUNN P/N: 11517.0008
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Bunn-O-Matic Corporation
□□ Clean any mineral build-up from the valve
□□ Reassembly is the opposite of disassembly
Step 6: Clean the tank fittings that supply water to the solenoid valves (Note depending on the age of the brewer this
will be either a single “T” connector or individual connectors for the dispense and bypass tubes.)
□□ Remove the clip from the end of tubes
□□ Gently remove the tubing from the tank fittings
□□ Use a screwdriver to remove and mineral build-up from the fittings
□□ Reattach the tubing and clips
Step 7: Remove and clean the temperature sensor
□□ Gently pull the temperature sensor from the grommet in the top of the tank
□□ Wipe any mineral build-up from the sensor
□□ Reinstallation is the opposite of removal
Step 8: Remove and clean the fill probe
□□ Gently pull the fill probe out of the grommet
□□ Wipe any mineral deposits off of the probe
Step 9: Remove and clean the sprayheads
□□ Using the pointed end of the deliming tool, remove any mineral build-up from the sprayhead outlet holes
Step 10: Replace the seat cups in all the TF server faucets
□□ Ensure the server is completely empty
□□ Unscrew the faucet bonnet from the assembly
□□ Remove the old faucet seat cup
□□ Install the new seat cup.
□□ Reassembly is the opposite of disassembly
Step 11: Replace the seat cup in the hot water faucet
□□ Unscrew the faucet bonnet from the assembly
□□ Remove the old faucet seat cup
□□ Install the new seat cup.
□□ Reassembly is the opposite of disassembly
Step 12: Check funnels, handle and tip are tight
□□ Ensure the screw securing the handle to the funnel is tight
□□ Ensure the funnel tip, the bottom outlet, is tight
□□ Check funnels for proper operation
S MA R T
F U N NE L
Step 14: Examine water supply for any leaks, reconnect water supply
Step 13: Examine power cord for any damage, reconnect power supply
Step 15: Check the funnel lock solenoids for proper operation (Note the brewer must be on to perform this step)
□□ Manually activate each funnel lock in the Systems Tools menu
Step 16: Calibrate flow rates (Note the brewer must be on to perform this step)
□□ Follow the procedures in section 2 of this manual
Step 17: Check the TF servers for proper operation.
□□ Check for Leaks and proper venting through the lid assembly.
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TF BrewWISE® Training Manual
Unit 5 Troubleshooting
Unit Objectives
Given a realistic scenario depicting a broken machine, the learner will be able to effectively troubleshoot,
diagnose, and repair the problem returning the machine to normal operation.
Given a machine displaying an error message, all the necessary tools and safety equipment, the learner will be able to access the software and diagnose the problem.
The learner will be able to access the programming menu.
The learner will be able to navigate to the Service Tools menu.
The learner will be able use the Service Tools menu to test inputs or outputs.
Given a list of error messages and issues, the learner will be to identify the probable cause of the message or issue.
Given a brewer with a defective component, the learner will be able to test the component to
determine the cause of the defect.
Troubleshooting and Repair
Service Tools
The BrewWISE® brewer features on-board troubleshooting. Since all of the machine’s components are controlled or
activated by the control board, you can activate and test components individually from the user interface. This allows
you to listen to solenoid valves opening, observing the flow of water or test to see if a component is receiving voltage
using a meter.
The Service Tools option is located in Level 1 of the programming. Enter Level 1 programming by pressing and holding the right hidden switch for 3 seconds. Use the right hidden switch to scroll to the “Service Tools” screen.
Press the Control button to select “Yes”. This will enter the “Service Tools” feature.
SERVICE TOOLS ?
NO
YES
In the “Service Tools” selection their are 3 screens available, by selecting “Yes”, you will enter that test function, by
selecting “No” you will move to the next test.
TEST OUTPUTS?
NO
YES
Test Outputs supplies voltage to load components in the brewer.
TEST SWITCHES?
NO
YES
Tests the inputs from the membrane switch.
TEST FREQUENCY?
Indicates the transmit frequency of the funnel sensing coils.
NO
YES
Test Outputs
LEFT BREW VALVE
ON
NEXT
OFF
RIGHT BREW VALVE
ON
NEXT
OFF
REFILL VALVE
ON
NEXT
OFF
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TF BrewWISE® Training Manual
LEFT BYPASS
ON
NEXT
OFF
RIGHT BYPASS
ON
NEXT
OFF
TANK HEATERS
ON
NEXT
OFF
LEFT FUNNEL LOCK
ON
NEXT
OFF
RIGHT FUNNEL LOCK
ON
NEXT
OFF
HEATER CONTACTOR
ON
NEXT
OFF
Test Switches
TEST SWITCHES?
NO
NOTHING PRESSED
YES
Press any of the input buttons on the membrane switch, the display will show which button is being pressed.
ENABLE
ENABLE
ON / OFF
ON / OFF
BREW
BREW
Test Frequency
TEST FREQUENCY?
NO
YES
SERVER124.7
REMOVED
Khz .5
5. 124.7 Khz
IN PLACE
The funnel sensing circuit is tuned to 125 kHz. If the circuit is not tuned correctly, then the funnel information will not
be transferred to the brewer. Therefore, the microprocessor is constantly fine tuning to get as close as possible to
125 kHz. It has eight possible tuning steps numbered 0 - 7. When you look at the “TEST FREQUENCY” screen you
see something like (124.7 KHZ .5) The 124.7 is the frequency, and the 5 is the tuning step. The decimal point next to
the 5 indicates the funnel is being detected; if the funnel is removed the decimal point should turn off.
Service Fault Messages
The brewer features several error messages for problems occurring within the machine. These error messages be
show up on the display.
This indicates that the tank overflow is full. The unit may be overfilling or boiling.
This message will appear if the control board does not see the programmed water
temperature within 60 minutes.
This message will appear if the control board does not see the tank fill within 30 minutes.
If the control board lose contact with the temperature sensor or senses shorted
connection it will display this message.
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Operator Fault Messages
The following fault messages will appear on the display if the operator needs to take corrective action.
The brewer does not sense a funnel in place. The brewer will only display this message
if Yes has been selected in the Funnel Detect programming menu. Otherwise the unit will brew.
Wait for the brewer to heat up to proper temperature. The brewer will only display this message if the Brew Lockout feature is set to NO.
The brewer did not see the funnel removed since the previous brew cycle.
The brew switch was turned off during the brew cycle.
Component Testing and 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: 1-800-286-6345
•
•
•
•
•
•
•
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
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TF BrewWISE® Training Manual
Problem
Equipment will not operate.
Probable CauseRemedy
1. No power or incorrect voltMeasure the voltage at the terminal
age.
block and confirm that it matches the
voltage specified on the brewer data
plate within +/- 10%.
Brew cycle will not start.
1. No water
Check plumbing and shut-off valves
“
“
2. ON/OFF switch
Test the ON/OFF switch. Refer to the
Test Switches in SERVICE TOOLS
section.
“
“
3. Brew switch
Test the BREW switch. Refer to the
Test Switches in SERVICE TOOLS
section
“
“
4. Brew Valve
Test the Brew valve. Refer to Test Outputs in SERVICE TOOLS section.
“
“
5. Electronic Control Board
Substitute a control board known to
be in good working order.
Automatic refill will not
operate or display shows
“FILL TIME TOO LONG”.
1. No water
Check plumbing and shut-off valves
“
“
2. Water strainer/flow control
(.750 GPM)
(A) Direction of flow arrow must be
pointing towards direction of water
flow.
(B) Remove the strainer/flow control
and check for obstructions. Clear or
replace.
“
“
3. Refill Probe or Sensitivity
Setting
Check the sensitivity setting. Refer to
Refill Threshold section in this manual.
“
“
4. Refill Valve
Test the Refill valve. Refer to Testing
Individual Components.
“
“
5. Overflow Protection Switch
When this condition occurs, the
brewer will display OVERFLOW CUP
FULL. EMPTY CUP. The reason for
overfilling could be a defective refill
valve, an incorrect sensitivity setting,
(see above) or boiling
“
“
6. Electronic Control Board
Substitute a control board known to
be in good working order
Water flows into tank
continuously with power
removed from brewer.
1. Refill valve
Foreign material lodged in valve,
holding it in open state
Water flows into tank
continuously with power
applied to brewer
1. Refill Probe or Sensitivity
Setting
Check the sensitivity setting. Refer to
Refill Threshold section in this manual.
“
2. Electronic Control Board
Substitute a control board known to
be in good working order.
1. Limit Thermostat
Remove power from the brewer.
Press reset button on limit thermostat.
Then check for continuity
through it.
“
Water will not heat or display shows HEATING TIME
TOO LONG
CAUTION - Do not eliminate
or bypass limit thermostat.
Use only replacement part
#23717.0003
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Problem
Water will not heat or
display shows HEATING TIME TOO LONG,
(Cont.)
Probable CauseRemedy
2. Tank Heaters
Remove power from the brewer. Check for
continuity through the tank heaters.
“
“
3. Triac
Remove power from the brewer. Connect
a voltmeter across one of the tank heaters. Reapply power to the brewer. If the full
supply voltage is measured when the tank
heater is turned on, and zero voltage is
measured with the triac off, then the triac is
good. If half the supply voltage is measured, the triac is defective. If very low, or
zero voltage is measured, there could be a
defective triac or a defective control board.
“
“
4. Electronic Control Board
Perform the above procedure for testing
triacs. If the voltage measured is very low
or zero, then substitute a control board
known to be in good working order.
Spitting or unusual
steaming from sprayhead
or air vents. (Water too
hot)
1. Triac
Remove power from the brewer. Connect
a voltmeter across one of the tank heaters. Reapply power to the brewer. If the full
supply voltage is measured when the tank
heater is turned on, and zero voltage is
measured with the triac off, then the triac is
good. If half the supply voltage is measured, the triac is defective. If very low, or
zero voltage is measured, there could be a
defective triac or a defective control board.
“
2. Lime Buildup
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 buildup on
stainless steel surfaces can
initiate corrosive reactions
resulting in serious leaks
“
“
3. Electronic control board
Perform the previous procedure
for testing triacs. If the voltage
measured is very low or zero, then
substitute a control board known to
be in good working order
Inconsistent beverage
level in server.
1. Strainer/flow control (.750
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
Check operating water pressure to
the brewer. It must be between 20
and 90 psi.
“
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TF BrewWISE® Training Manual
Problem
Inconsistent beverage
level in server. (Cont.)
Probable CauseRemedy
3. Brew Valve
Test the Brew Valve. Turn the valve
on for 30 seconds and collect the
water dispensed from the sprayhead.
Repeat the test several times to confirm a consistent volume of dispensed
water. If not consistent, check the
valve, tubing and sprayhead for lime
buildup.
“
“
4. Bypass Valve
If bypass is being used on the
inconsistent brewing recipe, test
the Bypass Valve. Turn the valve on
for 30 seconds and collect the water
collected from the bypass opening.
Repeat the test several times to confirm a consistent volume of dispensed
water. If not consistent, check the
valve, tubing and bypass opening for
lime buildup.
“
“
5. Lime buildup
Inspect for lime buildup that could
block the tank, tank fittings, tubing,
valves and sprayhead.
Consistently high or low
beverage level in server.
1. Brew Volume adjustment
Adjust the brew volume as required
to achieve the recommended volume
for each brew cycle.
Dripping from sprayhead.
1. Brew Valve
Repair or replace leaky valve.
Water overflows filter.
1. Type of paper filters
BUNN paper filters should be used
for proper extraction.
“
2. No sprayhead
Check sprayhead
Beverage overflows
server.
1. Beverage left in server from
previous brew
The brew cycle should be started
only with an empty server under
the funnel.
“
2. Brew Volume adjustment
Adjust the brew volume as required
to achieve the recommended volume
for each brew cycle.
1. Type of paper filters
BUNN paper filters should be used
for proper extraction.
“
“
Weak beverage.
“
“
2. Coffee
A sufficient quantity of fresh drip
or regular grind should be used for
proper extraction.
“
“
3. Sprayhead
The correct B.O.M. sprayhead should
be used to properly wet the bed of
ground coffee in the funnel.
“
“
4. Funnel Loading
The BUNN paper filter should be
centered in the funnel and the bed
of ground coffee leveled by gentle
shaking.
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Problem
Weak beverage. (Cont.)
“
“
Probable CauseRemedy
5. Water temperature
Empty the server, remove its cover,
and place the server beneath the
sprayhead. 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).
6. Incorrect Recipe
Consider adjusting bypass percentage, preinfusion, or pulse brew.
Contact Bunn-O-Matic for suggestions.
Brewer is making unusual
noises
1. Plumbing lines
Plumbing lines should not be resting on the counter top.
“
“
2. Water Supply
(A) The brewer must be connected
to a cold water line.
(B) Water pressure to the brewer
must not be higher than 90 psi.
Install a regulator if necessary
to lower the working pressure to
approximately 50 psi.
“
“
4. Tank Heaters.
Remove and clean lime off tank
heaters.
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TF BrewWISE® Training Manual
Triac Map
1
2
3
4
5
6
7
8
9
10
1. Left Funnel Lock
2. Right Funnel Lock
3. Left Transformer
4. Left Dispense Valve
5. Right Dispense Valve
6. Left Bypass Valve
7. Right Bypass Valve
8. Right Transformer
9. Spare
10. Refill Solenoid
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Additional Resources
Visit the BUNN Online Learning Center for technical information on BUNN equipment.
Unit Objectives
•
•
•
•
•
Go to URL: http://training.bunnserve.com/
Go to the menu bar and place your cursor over Courses, then choose “Commercial”.
Browse the list of available courses.
From the course introduction, use the menu on the left to find instruction sheets, manuals, key learnings, checklists and updates on equipment.
BUNN also has a wide range of instructional videos posted on the Online learning center and iTunes. You may subscribe to these videos via email, RSS, or as a podcast. After subscribing, you will be notified when a new video is posted.
QR Code Reader
For quick and direct access to technical resources on the BUNN Online Learning Center, you can download a QRReader application for your SmartPhone .
•
•
•
•
Download QRReader Application for your SmartPhone.
Open the QRReader application on your SmartPhone.
Aim your SmartPhone Camera as if you are taking a picture of the QR code image. (image on the right)
The QRReader Application will direct you to the BOLC, where you will have access to many resources relating to BUNN beverage equipment.
Technical Service & Support Contact Information
•
TF BrewWISE Course
Technical Service Department can be reached at: 1-800-286-6345
(Operators are available from 6:30 am to 5:30 pm CT. Monday - Friday)
Calls received after hours or weekends will go through our Telemessaging Service. You will then be connected to the first available service representative.
Email: tech.service@bunn.com
©Bunn-O-Matic Corporation, 2011. All rights reserved.
Bunn-O-Matic Corporation - 1400 Stevenson Drive -
Springfield, IL 62703 - Ph: (800) 637-8606 - Fax (217) 529-2177