Operating & Service Manual: Bunn-O-Matic Corporation

U3
U3A
OPERATING & SERVICE MANUAL

BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
To ensure you have the latest revision of the Operating Manual, or to view the Illustrated Parts
Catalog, Programming Manual, or Service Manual, please visit the Bunn-O-Matic website, at
www.bunn.com. This is absolutely FREE, and the quickest way to obtain the latest catalog and
manual updates. For Technical Service, contact Bunn-O-Matic Corporation at 1-800-286-6070.
10060.0000K 10/08 1984 Bunn-O-Matic Corporation
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BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY
Bunn-O-Matic Corp. (BUNN) warrants equipment manufactured by it as follows:

1) All equipment other than as specified below: 2 years parts and 1 year labor.
2) Electronic circuit and/or control boards: parts and labor for 3 years.
3) Compressors on refrigeration equipment: 5 years parts and 1 year labor.
4) Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis:
parts and labor for 3 years or 30,000 pounds of coffee, whichever comes first.
These warranty periods run from the date of installation BUNN warrants that the equipment manufactured by
it will be commercially free of defects in material and workmanship existing at the time of manufacture and
appearing within the applicable warranty period. This warranty does not apply to any equipment, component or
part that was not manufactured by BUNN or that, in BUNNs judgment, has been affected by misuse, neglect,
alteration, improper installation or operation, improper maintenance or repair, damage or casualty. This warranty is
conditioned on the Buyer 1) giving 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; 2) if requested by
BUNN, shipping the defective equipment prepaid to an authorized BUNN service location; and 3) receiving prior
authorization from BUNN that the defective equipment is under warranty.
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.
If BUNN determines in its sole discretion that the equipment does not conform to the warranty, BUNN, at its
exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts
and/or labor (during the applicable parts and labor warranty periods specified above) to repair the defective
components, provided that this repair is done by a BUNN Authorized Service Representative; or 2) shall replace
the equipment or refund the purchase price for the equipment.
THE BUYERS 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, AT BUNNS
SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, 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 Buyers customers, cost of capital, cost of down time, cost of substitute
equipment, facilities or services, or any other special, incidental or consequential damages.
BrewWISE, BrewLOGIC, BrewWIZARD, BUNN Gourmet Ice, BUNN Pour-O-Matic, BUNN, Bunn-OMatic, Bunn-O-Matic,
BUNNlink, BUNNserve, BUNN Espress, DBC, Dr. Brew, Dual, EasyClear, EasyGard, Easy Pour, FlavorGard, Gourmet Ice,
Gourmet Juice, High Intensity, IMIX, Infusion Series, Quality Beverage Equipment Worldwide, The Mark of Quality in Bev-
erage Equipment Worldwide, My Caf, PowerLogic, Safety-Fresh, Scale-Pro, Single, Smart Funnel, Smart Hopper, Smart-
WAVE, Soft Heat, SplashGard, System III, ThermoFresh, 392, AutoPOD, AXIOM, Beverage Profit Calculator, Beverage
Bar Creator, BrewMETER, BUNNSERVE, BUNNsource, Coffee At Its Best, Cool Froth, Digital Brewer Control, Intellisteam,
Nothing Brews Like a BUNN, Pouring Profits, Pulse Wave, Signature Series, Silver Series, Smart Heat, Tea At Its Best, The
Horizontal Red Line, Titan, Ultra, are either trademarks or registered trademarks of Bunn-O-Matic Corporation.
Page 2 10060 100908

INTRODUCTION
This brewer will brew a three gallon batch of coffee into each reservoir (one at a time). Each reservoir has
its own dispensing faucet(s).The brewer also has a hot water faucet(s) for allied beverage use. It is only for
indoor use on a sturdy counter where ambient temperature is in the range of 10-30C (50-85F). Brewer to be
installed at a location where it can be overseen by trained personnel.
USER NOTICES
Carefully read and follow all notices on the brewer and in this manual. They were written for your protection.
All notices on the brewer are to be kept in good condition. Replace any unreadable or damaged labels.
WARNING This equipment must be installed to comply

with the International Plumbing Code of the
Fill water tank before turning - on - International Code Council and the Food
thermostat or connecting appliance Code Manual of the Food and Drug Adminis-
to power source. tration (FDA). For models installed outside
Use only on a properly protected the U.S.A., comply with the applicable
circuit capable of the rated load. Plumbing /Sanitation Code.
Electrically ground the chassis.
Follow national/local electrical codes. #00656.0000
Do not use near combustibles.
FAILURE TO COMPLY RISKS EQUIPMENT
DAMAGE, FIRE, OR SHOCK HAZARD
READ THE ENTIRE OPERATING MANUAL

BEFORE BUYING OR USING THIS PRODUCT
THIS APPLIANCE IS HEATED WHENEVER

CONNECTED TO A POWER SOURCE
00831.0000F 3/98 1998 BUNN-O-MATIC CORPORATION
#00831.0000
#37881.0000
WARNING WARNING
REMOVE FUNNEL
Very Hot Water SLOWLY
Use With Care! #03408.0000
#12593.0000 WARNING
CAUTION H O T
LIQUID
HOT
SURFACES
#03409.0000
ATTENTION: TURN OFF WHEN UNATTENDED

#00878.0000
#12555.0000
#00824.0001
Page 3 10060 011708

ELECTRICAL REQUIREMENTS
CAUTION - The brewer must be disconnected from the power source until specified in Initial Set-Up.
RED
L2 RED L2
208V OR 240V
120V A.C. BLUE 380V OR 440V
WHITE 208V OR 240V
208 OR L3 380V OR 440V
240V A.C.
208V OR 240V
NEUTRAL
120V A.C. BLACK 380V OR 440V
L1 BLACK L1
GREEN GREEN
P1841 P1843
U3 & U38 requires 3-wire, grounded service rated U333 & U3833 requires 3-wire, grounded service
120/208 or 120/240 volts ac, U3-30 amp,U38-40 amp, rated 240 volt ac, 35 amp or 440 volts ac, 30 amp for
single phase, 60 Hz. Proceed as follows: U333,three phase, 60 Hz or 380 volts ac, 30 amp for
U3833, three phase, 50 Hz. Proceed as follows:
L1, L2, L3, are the 3 phases
WHITE
(NEUTRAL) N
V1 = Phase to phase voltage,
RED
L2 between any 2 phases.
BLACK
L1 BLUE
L3 V2 = Phase to neutral voltage,
RED 230V A.C. BLACK
L1
any phase to neutral.
L2
GREEN GREEN
SYSTEM
VOLTAGE V1 V2
GREEN GREEN 208 208 120
P1844
240 240 139
380 380 220
P1842 440 440 254
U3A models require 2-wire, grounded service rated U3833 requires 4-wire, grounded service rated
230 volts ac, 30 amp, single phase, 50 Hz. Proceed 380 volts ac or 440 volts ac, 30 amp, three phase, 50
as follows: Hz. Proceed as follows:
ELECTRICAL INSTALLATION INSTRUCTIONS
NOTE: Electrical source should have a circuit breaker between the brewer and the main supply which breaks all
poles with a contact separation of at least 3 mm.
CAUTIONImproper 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. Before electrically connecting the brewer, remove the front cupola cover (some models have the thermostat
knob on the outside of the cover) and rotate the thermostat knob fully counterclockwise to the "OFF" position.
Keep this knob in the "OFF" position until performing the Initial Setup.
4. Electrical service is connected at the upper rear of the single service and scrambler brewers using a junc-
tion box. On double service brewers the rear decorative channel must be removed for access to the terminal
block.
5. Connect the brewer to the power source and verify the voltage at the terminal block before proceeding. Re-
place all panels.
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 Setup.
NOTE: Schematic wiring diagrams are included in this manual.
Page 4 10060 011708

CE REQUIREMENTS
This appliance must be installed in locations where it can be overseen by trained personnel.
For proper operation, this appliance must be installed where the temperature is between 5C to 35C.
Appliance shall not be tilted more than 10 for safe operation.
An electrician must provide electrical service as specified in conformance with all local and national codes.
This appliance must not be cleaned by water jet.
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given instructions concerning use of
this appliance by a person responsible for its safety.
Children should be supervised to ensure they do not play with the appliance.
If the power cord is ever damaged, it must be replaced by the manufacturer or authorized service personnel with
a special cord available from the manufacturer or its authorized service personnel in order to avoid a hazard.
PLUMBING REQUIREMENTS
These brewers must be connected to a cold water system with operating pressure between 20 (138) and 90 psi (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 (345 kPa). The water inlet fitting is 3/8" flare.
NOTE - Bunn-O-Matic recommends 3/8" copper tubing for installations from the 1/2" water supply line. A tight coil of
copper tubing in the water line will facilitate moving the brewer to clean the countertop. Bunn-O-Matic does not recom-
mend 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 International Plumbing Code of the International
Code Council and the Food Code Manual of the Food and Drug Administration (FDA). For models
installed outside the U.S.A., you must comply with the applicable Plumbing/Sanitation Code for
your area.
INITIAL SETUP
CAUTION - The brewer must be disconnected from the power source throughout the initial setup, except when specified
in the instructions.
IMPORTANT: Brewer must be level and installed on a sturdy structure.
Electrician's and Plumber's Instructions are provided. These instructions should be carefully followed
before proceeding with initial setup.
Be sure all electrical and plumbing connections are tight.
1. Open manual fill valve located on the bottom of the brewer. Water should start filling the tank. When water is visible
in the hot water gauge glass (center spigot), close valve. Approximate time for filling manually is 3 minutes.
CAUTION: Never leave brewer unattended while manually filling tank.
2. Connect the brewer to the power source. Turn "ON/OFF" switch to the "ON" position. Water should finish filling tank
automatically.
NOTE: It is recommended that the "ON/OFF" switch be left in the "OFF" position at the end of the operating day or when
unattended for a long period of time.
3. Disconnect the brewer from the power source. Remove front cupola cover for access to thermostat knob and timer.
On some brewers the thermostat knob is located on the front of the cupola cover.
4. Turn the thermostat knob clockwise to an approximate 5 o'clock position. Allow 1-1/2 hours for water to heat. Time
will vary with incoming water temperature.
5. On initial warm-up, some water may flow thru the overflow spigot due to expansion of the cold water in the tank.
This will not recur during the use of the brewer and may be avoided on the initial warm-up by drawing off 1/2 gallon
decanters of water each 15 minutes till brewing temperature is reached.
Page 5 10060 102808

INITIAL SETUP (cont.)
6. Brewing cycles may be started whenever water temperature is correct. This condition is indicated by the dial
thermometer on front of the brewer. Whenever the pointer is in the green, brewer is ready for brewing. The
recommended brewing temperature is approximately 200 F (93C). Water temperature may be increased by
turning thermostat knob clockwise, decreased by turning knob counterclockwise.
7. When desired temperature is reached, insert funnel support, funnel and funnel cover in position. Be sure
the water swing spout is over the center of the funnel cover, turn "ON/OFF" switch to the "ON" position, push
and release "START" and run a brew cycle of hot water only. At the end of this cycle, brewer will be ready for
checking timer adjustment.
8. The timer has been preset for a 4 minute cycle. This setting will deliver approximately 3 gallons of water per
brewing cycle. To increase or decrease amount of water, adjust the timer as required. See Adjusting Brew
Volumes.
9. Having determined final settings of the thermostat and the timer, replace front cupola cover. Brewer is now
ready for brewing coffee.
ADJUSTING BREW VOLUMES
CAUTION - Disconnect the power source from the brewer prior to the removal of any panel for the replacement
or adjustment of any component.
NOTE: Prior to setting or modifying batch sizes, check that the brewer is connected to water supply, the tank is
properly filled, and a funnel support, funnel and funnel cover are in place.
1. Modifying batch sizes. To modify a batch volume, first check that the SET/LOCK switch is in the SET posi-
tion on the circuit board.
To increase a batch size. Press and hold the START or BREW switch until you see three breaks in the water
stream from the swing arm. Release the switch (Failure to release the switch within two seconds after the
third break in the water stream causes the volume setting to be aborted and previous volume setting will
remain in memory) and press it again one or more times. Each time the switch is pressed, two seconds are
added to the brew time period. Allow the brew cycle to finish in order to verify that the desired volume has
been achieved.
To decrease a batch size. Press and release the START or BREW switch once for every two-second interval
to be removed from the total brew time period; then immediately press and hold down the START or BREW
switch until you see three breaks in the water stream from the swing arm. Release the switch. (Failure to
release the switch within two seconds after the third break in the water stream causes the volume setting to
be aborted and previous volume setting will remain in memory). Allow the brew cycle to finish in order to
verify that the desired volume has been achieved.
2. Setting batch sizes. To set a batch volume, first check that the SET/LOCK switch is in the SET position on
the circuit board. Press and hold the START or BREW switch until you see three breaks in the water stream
from the swing arm, and then release the switch. (Failure to release the switch within two seconds after the
third break in the water stream causes the volume setting to be aborted and previous volume setting will
remain in memory). View the level of the liquid being dispensed. When the desired level is reached, turn the
ON/OFF switch to OFF (lower). The brewer remembers this volume and will continue to brew batches of
this size until the volume setting procedure is repeated.
NOTE: When brewing coffee, batch volumes will decrease due to absorption by the coffee grounds.
NOTE: HALF-BATCH AND FULL BATCH SETTINGS MUST EACH BE SET SEPARATELY.
3. Setting programming disable feature. If it becomes necessary to prevent anyone from changing brew times
once programmed, you can set the SET/LOCK switch to the LOCK position. This will prevent any program-
ming to be done until switch is once again placed in the SET position.
Page 6 10060 080900

COFFEE BREWING
1. Brewing cycles may be started whenever water temperature is correct. This condition is indicated by the dial
thermometer on front of the brewer. Whenever the pointer is in the green, brewer is ready for brewing.
2. Insert Bunn filter in funnel and add desired amount of coffee.
3. Level the bed of coffee and place funnel into the funnel support. Place funnel cover over the funnel and be
sure the water swing spout is over the center of the funnel cover.
4. Turn "ON/OFF" switch to the "ON" position.
5. Push and release "START" switch to start the brew cycle.
6. Water swing spout should not be moved as long as water is flowing into the funnel cover. When water stops
flowing, it may then be moved for access to brewing funnel.
7. Remove funnel cover. Funnel should not be removed from brewer until drip out of coffee has been com-
pleted.
8. To empty funnel, invert it over a waste container to dispose of filter and grounds. An additional flange is
provided on the funnel to help make this step easier.
NOTE: Hot water may be drawn from the hot water faucet during a brew cycle. However, if a large amount of
hot water is drawn off (over 1 gallon) operator should wait to do so between brewing cycles.
CLEANING
NOTE: Tanks and tank components should be delimed regularly based on local water conditions. Excessive
mineral build-up on stainless steel surfaces can initiate corrosion reactions resulting in serious leaks.
1. Remove both funnels, funnel lids and supports, under hot water, rinse away all coffee oils. Wipe with a clean
damp cloth.
2. Drain both coffee reservoirs by opening coffee faucets. When empty, close faucets.
3. Cycle two or three inches of water into each coffee reservoir and scrub entire reservoir area.
NOTE: The brewer must NOT be rinsed or cleaned by a water jet device.
4. Drain both coffee reservoirs and rinse. Use clean damp cloth to wipe both reservoirs.
5. Install both coffee funnel supports, funnels and funnel lids.
6. Remove the sight gauge cap, insert sight gauge cleaning brush into the sight gauge glass tube and clean.
7. To clean coffee faucets, remove the faucet handle from the faucet and faucet clean out cap. Clean faucet with
a faucet cleaning brush and wipe all parts with a damp cloth. Replace faucet seat cups periodically if badly
stained or to stop faucet dripping. DO NOT CLEAN THE HOT WATER FAUCET.
8 Reassemble the coffee faucets.
9. Wipe the entire outside surface of the machine with a clean damp cloth. Wipe dry.
FILTER HOLDER
1. A filter holder is supplied with each U3 coffee brewer. Its purpose is to keep the filters in their originally
formed shape to properly fit the brewer funnel.
2. It is suggested that only one cluster of filters be placed in the holder at one time for best results.
3. Not using the filter holder may permit the filters to gradually widen out towards a flat shape, especially so if
humidity is present. Once a filter has lost its upright side walls, it may tend to collapse inward when placed
in the brewing funnel. If this happens the hot water spray may cause one side to fall inwards, letting coffee
grounds flow over the edge of filter and into the brewed coffee. Proper use of the holder should prevent this
problem.
Page 7 10060 081106

TROUBLESHOOTING
A troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems
encountered. If the problem remains after exhausting the troubleshooting steps, contact the Bunn-O-Matic
Technical Service Department.
Inspection, testing, and repair of electrical equipment should be performed only by qualified service person-
nel.
All electronic components have 120 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 to avoid twists and kinks in the tubing.
Make certain that all plumbing connections are sealed and electrical connections tight and isolated.
This brewer is heated at all times. Keep away from combustibles.
WARNING Exercise extreme caution when servicing electrical equipment.

Unplug the brewer when servicing, except when electrical tests are specified.
Follow recommended service procedures
Replace all protective shields or safety notices
PROBLEM PROBABLE CAUSE REMEDY
Brew cycle will not start 1. No water Water lines and valves to the brewer
must be open.
2. No power or incorrect voltage to (A1) Check the terminal block for

the brewer 120 volts ac across the red and white
terminals and the black and white
terminal on three wire 102/208 volt
or 120/240 volt models.
(A2) Check the terminal block for 208
volts ac, 230 volts ac or 240 volts
ac on "A Series" brewers across the
red and black terminals on two wire
single phase 208 volt, 230 volt and
240 volt models.
(A3) Check the terminal block for 208
volts ac, 240 volts ac, 380 volts ac
across the black and blue terminals,
the blue and red and the black and
red terminals on three wire three
phase 208 volt, 240 volt and 380
volt models.
Page 8 10060 031500

TROUBLESHOOTING (cont.)
Brew cycle will not start (cont) 2. No power or incorrect voltage to (A4) Check the terminal block for
the brewer (cont) 440 volts ac across the black and
blue terminals, black and red termi-
nals and the red and blue terminals
on four wire three phase 440 volt
models.
(B) Check circuit breakers or
fuses.
3. Water level below pump housing. Be sure water shut-off valve is open
(Water level in the hot water gauge and that the in-line filters or strain-
glass should be approximately half ers are not blocking water flow. (Do
full). not confuse water shut-off valve
with the manual fill and drain valve
underneath the brewer).
4. ON/OFF Switch Refer to Service - ON/OFF Switch for

testing. See page 22
5. Start Switch Refer to Service - Start Switches for

testing procedures. See page 29
6. Relay Refer to Service - Relay for testing

procedures. See page 24
7. Timer Refer to Service - Timer for testing

procedures. See page 31 or 33
8. Pump Refer to Service - Pump for testing

9. Solenoid Valve Refer to Service - Solenoid Valve for

10. Strainer (A) Direction of flow arrow must be

pointing towards brewer.
(B) Remove the strainer and check

for obstructions. Clear or replace.
Brew cycle starts with brew lockout 1. Relay Refer to Service - Relay for testing
relay engaged. procedures. See page 24
Page 9 10060 080900

Tank not filling 1.ON/OFF Switch (This switch Refer to Service - ON/OFF Switch
must be in the "ON" position for for testing procedures. See page
the refill circuit to operate. 22
2. No water Be sure water shut-off is open and

that in-line filters or strainers are
not blocking water flow. (Do not
confuse water shut-off valve with
the manual fill and drain valve
underneath brewer).
3. Solenoid Valve Refer to Service - Solenoid Valve

for testing procedures. See page
27
4. Probe Refer to Service - Probe for testing

5. Liquid Level Board Refer to Service - Liquid Level

Board for testing procedures. See
page 20
Water running out of the over- 1.Brewer not level Brewer must be level and installed
flow on a sturdy structure.

27
3. Liquid Level Board Refer to Service -Liquid Level

Board for testing procedures. See
page 20
4. Probe Refer to Service - Probe for testing

5. Manual fill and drain valve un- Be sure valve is closed.

derneath brewer open.
Page 10 10060 080900

Water not hot 1. Limit Thermostat Refer to Service - Limit Thermo-

CAUTION - Do not eliminate or stat for testing procedures. See
bypass limit thermostat. Use only page19
Bunn-O-Matic replacement part
#29329.1000
2. Control Thermostat Refer to Service - Control Ther-

mostat for testing procedures.
See page 17
3. Tank Heater(s) Refer to Service - Tank Heater for

4. Contactor Refer to Service - Contactor for

Circuit breaker keeps tripping 1. Circuit Breaker Refer to Service - Circuit Breaker
14
2. Tank Heater(s) Refer to Service - Tank Heater for

Water keeps running from swing 1. Timer Refer to Service - Timer for testing
spout procedures. See page 31 or 33
2. Start Switch Refer to Service - Start Switch for

Inconsistent coffee yield 1. Timer Refer to Service - Timer for testing


27
3. Lime build-up in swing spout Remove swing spout and insert

and pump tubing. deliming rod down into pump
tubing as far as possible.
Funnels overflow 1. Filters Use Bunn filters made for the

U3 brewer.
2. Hole in bottom of funnel ob- Remove obstruction.

structed.
Page 11 10060 080900

Funnels overflow (cont.) 3. Pump - Flow Rate Check pump flow rate with a watch.
Pump flow rate should be approxi-
mately 24 ounces in 15 seconds.
Be sure pump assembly is free of
any obstructions.
4. Soft Water
When using a water softener, a
coarse grind of coffee may be
preferred. If required, a bypass
system is available as an optional
feature.
Coffee reservoir overflows
1. Coffee reservoir not completely Be sure coffee reservoir is empty
empty befor a brew cycle was before brew cycle is started.
started.
2. Timer Refer to Service -Timer for testing

3. Pump - Flow Rate Check pump flow rate with a watch.

Pump flow rate should be approxi-
mately 24 ounces in 15 seconds.
Be sure pump assembly is free of
any obstructions.
Brewer is making unusal noises
1. Solenoid Valve The nut on the solenoid must
be tight or it will vibrate during
operation.
2. Plumbing lines Plumbing lines should not be rest-

ing on the counter top.
3. Water supply (A) The brewer must be connected

to a cold water line.
(B) Water pressure to the brewer

must not exceed 90 psi (620 kPa).
Install a regulator if necessary to
lower the pressure to approxi-
mately 50 psi (345 kPa).
4. Tank Heater(s) Remove and clean lime off the tank

heater. See page 30
Page 12 10060 080900

SERVICE Contents
This section provides procedures for testing and Circuit Breaker ......................................................14
replacing various major components used in this Contactor...............................................................15
brewer should service become necessary. Refer to Control Thermostat................................................17
Troubleshootingfor assistance in determining the Fuse and Fuse Holder . ..........................................18
cause of any problem. Limit Thermostat....................................................19
Liquid Level Board and Level Probe . ................... 20
WARNING-Inspection, testing, and repair of electri- ON/OFF Switch.......................................................22
cal equipment should be performed only by qualified Pump.....................................................................23
service personnel. The brewer should be unplugged Relay . .................................................................. 24
when servicing, except when electrical tests are re- Selector Switch (Half Batch)..................................26
quired and the test procedure specifically states to Solenoid . ..............................................................27
plug in the brewer. Start Switch (Brew)................................................29
Tank Heater(s)........................................................30
COMPONENT ACCESS Thermal Cut-off . .................................................. 31
WARNING - Disconnect the brewer from the power Timer (Early Models).............................................31
source before the removal of any panel or the replace- Digital Timer (Late Models)....................................33
ment of any component. Transformer...........................................................35
Master ON/OFF Switch (Late Models)....................36
All components are accessible by the removal of Wiring Diagrams....................................... 37 thru 42
the swing spout, front cupola cover, rear cupola cover
and the cupola.
Disconnect the swing spout nut from the swing

spout base fitting. Remove swing spout.
Remove the four #8-32 screws, two on the front and

rear, securing front and rear cupola covers to the
cupola.
Slip cupola off of the component bracket.
P1317.30
FIG. 1 COMPONENT ACCESS
Page 13 10060 011708

SERVICE (cont.)
CIRCUIT BREAKER (120/208V and 120/240V Three
4. With the black wire removed, remove the other
Wire Models and 440V Four Wire Models)
black wire from the circuit breaker.
5. Check for continuity across the terminals on the
circuit breaker.
If continuity is present as described the circuit breaker

is operating properly.
If continuity is not present as described, press the reset
button and repeat step 5, if continuity is not present
as described, replace the circuit breaker.

Removal and Replacement:
1. Remove wires from the circuit breaker.
2. Remove the nut securing the circuit breaker to the
component bracket.
3. Remove circuit breaker and discard.
4. Install new circuit breaker on component bracket
P2209.60
and secure with nut.
FIG. 2 CIRCUIT BREAKER
5. Refer to Fig. 3 and reconnect the wires.
Location:
The circuit breaker is located on the right rear of
the component bracket.
BLK from Main

Test Procedures:
Harness
1. Disconnect the brewer from the power source.
2. Disconnect the black wire from the main harness
BLK from ON/
from the circuit breaker and the white wire on the
OFF Switch
pump assembly. With a voltmeter, check the voltage
across the black wire and the white wire. Connect FIG. 3 CIRCUIT BREAKER TERMINALS P1723
the brewer to the power source. The indication

must be:
a) 120 volts ac for three wire 120/208 volt and
120/240 volt models.
b) 208 or 240 volts ac for four wire 440 volt mod-
els.
If voltage is present as described, reconnect the white

wire to the pump assembly and proceed to #4. If volt-
age is not present as described, refer to the Wiring
Diagrams and check the brewer wiring harness.
Page 14 10060 080900

SERVICE (cont.)
CONTACTOR
a) 120 volts ac for three wire 120/208, 120/240
volt and 380 volt models.
b) 230 volts ac for two wire 230 volt models.
c) 208 or 240 volts ac for two wire 208 or 240 volt
models.
d) 220 or 254 volts ac for four wire 280 or 440
volt models.
If voltage is present as described, proceed to #6.

If voltage is not present as described refer to the Wiring
6. Check for continuity between the black leads on

P2209.60 the contactor coil or the left and right terminals
FIG. 4 CONTACTOR
on the contactor coil on 230V models.
Location:
The contactor is located on the left front of the If continuity is present as described, reconnect the
component bracket wires and proceed to #7.
If continuity is not present as described, replace the
Test Procedures: contactor.
2A. 120/208V, 120/240V, 380V THREE WIRE MODELS, 7. On all brewers, with a voltmeter, check the voltage
380V and 440V FOUR WIRE MODELS across the upper left terminal and the upper right
Disconnect the black wire from the contactor coil terminal on the contactor. Connect the brewer to
to the limit thermostat and black wire from the the power source. The indication must be:
white wire on the main harness. a) 120 volts ac for three wire 120/208, 120/240
2B. 208V or 240V TWO WIRE MODELS (Prior to b) 230 volts ac for two wire 230 volt models.
# U300004095), 208V and 240V THREE WIRE c) 208 or 240 volts ac for two wire 208 or 240 volt
MODELS models.
Disconnect the black wire from the contactor coil d) 220 or 254 volts ac for four wire 280 or 440
to the limit thermostat and black wire from the red volt models.
wire on the main harness.
2C. 230V MODELS (S/N U300004095 - UP)
Disconnect the red wire from contactor coil to the If voltage is present as described, proceed to #9.
limit thermostat and the black wire from the main If voltage is not present as described, refer to the Wiring
harness. Diagrams and check the brewer wiring harness.
3. Connect the brewer to the power source.
4. Check the voltage across the coil wire and the wire
from the the main harness.The indication must
be:
Page 15 10060 080900

SERVICE (cont.)
CONTACTOR (cont.)
9. Check for continuity across the terminals on the Removal and Replacement:
left side of the contactor by manually closing the 1. Disconnect all the wires from the contactor.
contacts. Continuity must not present when the 2. Remove the two #8-32 screws securing the con-
contact is released. tactor to the contactor mounting bracket, remove
10. Check for continuity across the terminals on the contactor and protective shield. Discard contac-
right side of the contactor by manually closing the tor.
contacts.Continuity must not be present when the 3. Install new contactor with shield between mounting
contact is released. bracket and contactor and secure with two #8-32
screws
If continuity is present as described, the contactor is 4. Refer to Fig. 5 and reconnect the wires.
operating properly.
contactor.
BLK to Right Tank
Heater (T1) RED to Left Tank BLK Thermal Fuse
BLK to Terminal Heater (T2) to Right Tank Heater
Block (L1) RED to Terminal
Block(L2)
BLK to Terminal
Block (L1)
BLK to Terminal RED Thermal Fuse
Block (L2) to Left Tank Heater
BLK to left RED to Terminal
Tank Heater Block (L2)
BLK Thermal
(L1)
Fuse to Left
Tank Heater
RED to Right
Tank Heater
(L2)
WHI from Main Harness

(120/208V,120/240V,380V RED to Limit
BLK to Limit RED Thermal Fuse Thermostat
Three Wire Models, 380V and
Thermostat to Right Tank
440V Four Wire Models)
Heater
RED from Main Harness
(208V, 240V Two Wire Models
and 208, 240V Three Wire
Models) 230V - CE Models
120/208V, 120/240V, 208V,
240V, 380V 440V MODELS
P1725
FIG.5 CONTACTOR TERMINALS
Page 16 10060 080900

SERVICE (cont.) not be present when the thermostat is in the "OFF"
CONTROL THERMOSTAT position (fully counterclockwise).
If continuity is present as described, the control ther-
mostat is operating properly.
control thermostat.

1. Disconnect the wires from the control thermo-
stat.
2. Remove the thermostat capillary bulb by firmly
pulling up on the capillary at the component
bracket. This will disengage the grommet from
P2209.60
FIG. 6 CONTROL THERMOSTAT the component bracket.
Location: 3. Remove the #8-32 screw securing the control
The control thermostat is mounted on the right thermostat and mounting bracket to the component
front of the component bracket. bracket. Remove control thermostat and bracket
as an assembly.
Test Procedures: 4. Remove knob from control thermostat.
1. Disconnect the brewer from the power source. 5. Remove the two #6-32 screws securing the control
2. Locate the thermostat and the voltage check thermostat to the thermostat mounting bracket.
points. Remove and discard thermostat.
3. Connect the brewer to the power source. 6. Install new control thermostat on thermostat
Model Check Voltage Across Voltage mounting bracket and secure with two #6-32
120/208V & 120 Black wire on thermostat 120V screw.
240V - 3 wire w/ from main harness to white 7. Install knob on thermostat.
ground single phase wire in terminal block. 8. Install thermostat and mounting bracket on the
component bracket and secure with one #8-32
230V - 2 wire w/ Red wire on thermostat 230V
screw.
ground single from main harness to black
wire in terminal block. 9. Carefully bend the capillary tube so that the tube
phase
and bulb inside the brewer are in the vertical posi-
208V or 240V - 2 Black wire on thermostat 208V or tion.
wire w/ground from main harness to red 240V NOTE: The capillary tube must be clear of any electrical
single phase wire in the terminal block. termination and not kinked.
280V or 440V - 4 Black wire on thermostat 220V or 11. Adjust the control thermostat as required.
wire w/ground 3 from main harness to white 254V
phase wire in terminal block.
BLK from Main Har-
380V - 3 wire w/ Black wire on thermostat 120V ness (All Models Ex-
ground 3 phase from main harness to white cept 230V CE Models
w/ stepdown wire on step down trans- RED from Main
transformer former. Harness (230V CE
Models)
If voltage is not present as described, refer to the Wiring BLK to Limit Thermostat
Diagrams and check the brewer wiring harness. (All Models Except 230V CE
Models
5. Disconnect the black wires from the control ther- RED to Limit Thermostat
mostat. (230V CE Models)
P1730.80
control thermostat with the control thermostat in FIG. 7 CONTROL THERMOSTAT TERMINALS
the "ON" position (fully clockwise), continuity must
Page 17 10060 080900

SERVICE (cont.)
FUSE AND FUSE HOLDER (208V, 240V, 230V Two
Fuse:
Wire Models and 380V Three Wire Models)
1. Remove the cap from the fuse holder.
2. Remove fuse from the fuse holder, inspect, if blown
discard.
3. Install new 5 amp fuse in the fuse holder.
4. Reinstall fuse holder cap.
Fuse Holder:
1. Disconnect the wires from the rear of the fuse
holder.
2. Remove the nut securing the fuse holder to the
component bracket.
3. Push fuse holder through the hole in the component
bracket.
4. Install new fuse holder and fuse through the hole
in the component bracket and secure with nut.
P1731.55 BLK from ON/OFF Switch

FIG.8 FUSE AND FUSE HILDER (208V, 240V Two Wire
Location: Models and 380V Three
Wire Models)
The fuse and fuse holder are located on the right RED from ON/OFF Switch
rear of the component bracket. (230V Two Wire Models)
Test Procedures:
BLK from Main Harness
2. Remove the cap and fuse from the fuse holder. (208V and 240V Two Wire
3. Remove fuse from the cap. Models)
4. Check for continuity through the fuse. BLK from Transformer
(380V Three Wire Models)
If continuity is present as described, reinstall the fuse, RED from Main Harness
(230V Two Wire Models)
the fuse is operating properly.
If continuity is not present as described replace the
fuse. P1331
FIG. 9 FUSE HOLDER TERMINALS
Page 18 10060 031599

SERVICE (cont.)
LIMIT THERMOSTAT
1. Remove the wires from the limit thermostat ter-
minals.
2. Carefully slide the limit thermostat out from under
the retaining clip and remove the limit thermo-
stat.
3. Carefully slide the new limit thermostat into the
retaining clip.
P2209.60
FIG. 10 LIMIT THERMOSTAT
Location:
The limit thermostat is located on the center front
of the component bracket behind the timer mounting BLK to Contactor
(All Models Except BLK to Control
bracket. Thermostat(All
230V CE Models)
Red to Contactor Models Except
Test Procedures: (230V CE Models) 230V CE Models)
RED to Control
Thermostat
2. Disconnect the black wires or the red wires from (230V Models)
the limit thermostat.
3. With an ohmmeter, check for continuity across P1800
the limit thermostat terminals. FIG. 11 LIMIT THERMOSTAT TERMINALS
If continuity is present as described, the limit thermostat

is operating properly.
limit thermostat.
Page 19 10060 080900

SERVICE (cont.)
LIQUID LEVEL BOARD AND LEVEL PROBE 7. Touching the free end of the jumper to the brewer's
frame simulates a "FULL" condition, preventing
jumper from touching the brewer's frame simulates
"NEED WATER" condition. Connect the brewer to
the power source, simulate the conditions in the
chart below while measuring the voltage between
T1 and T3 0n the liquid level board. Repeat these
several times. There is an approximate five second
delay for output to stabilize.
Model Voltage - Voltage -

Jumper Jumper
Not Touching Touching
P2209.60 Frame Frame
FIG.12 LIQUID LEVEL BOARD AND
LEVEL PROBE 120V 0
120/208V &
Location: 120/240V - 3
wire w/ground
The liquid level board is located on the left rear of
single phase
the component bracket. The level probe is located on
the right rear of the component bracket. 0
230V - 2 wire 230V
w/ground
Test Procedures: single phase
2. Disconnect the blue wire (T1) and the pink wire 208V or 240V - 208V or 0
(T4). 2 wire wground 240V 0
3. Check the voltage across terminals (T2) and (T3) single phase
with the ON/OFF switch in the "ON" position. The
indication must be: 280V or 440V - 220V or 0
a) 120 volts ac for 120/208 volt, 120/240 volt and 4 wire w/ground 254V 0
380 volt models. 3 phase
b) 208 volts ac or 240 volts ac for two wire 208
volt or 240 volt models. 380V - 3 wire 120V 0
d) 230 volts ac for two wire 230 volt models. w/ground 3
e) 220 volts ac or 440 volts ac for four wire 280 phase w/
volt or 440 volt machines. stepdown trans-
4. Disconnect the brewer from the power source. former
If voltage is not present as described, refer to Wiring
Diagrams and check the brewer wiring harness. 8. Disconnect the brewer from the power source and
remove the jumper wire from terminal 4.
5. Reconnect the blue wire to T1 on the liquid level If voltage is present as described, liquid level board
board. is operating properly, proceed to #9.
6. Carefully connect a piece of insulated jumper wire If voltage is not present as described, replace the
to terminal 4. Keep the other end of this wire away liquid level board.
from any metal surface of the brewer.
Page 20 10060 080900

SERVICE (cont.)
LIQUID LEVEL BOARD AND LEVEL PROBE (cont.) 14. Disconnect the brewer from the power source.
9. Reconnect the pink wire to terminal 4. If voltage is present as described, reinstall the level
10. Remove the two #8-32 screws securing the level probe, the liquid level board and level probe are op-
probe to the component bracket. erating properly.
11. Gently pull the probe out of the component bracket If voltage is not present as described, check the
and inspect for corrosion. Replace if necessary. pink wire on the level probe from liquid level board
12 Place the probe so that neither end is in contact terminal 4.
with any metal surface of the brewer.
13. Connect the brewer to the power source. Check Removal and Replacement:
the voltage across terminals 1 and 3, refer to 1. Remove all wires from the liquid level board.
chart below. There is an approximate delay of five 2. Remove the #10-32 screw and flat washer securing
seconds for output to stabilize. the protective shield to the component bracket.
3. Remove the #10-32 screw and internal tooth
Model Voltage - Voltage -
lockwasher securing the liquid level board to the
Jumper Jumper
component bracket.
Not Touching Touching
4. Remove liquid level board and discard.
Frame Frame
5. Install new liquid level board on component bracket
and secure with a #10-32 screw and internal tooth
120/208V & 120V 0
lockwasher.
120/240V - 3 6. Install protective shield and secure with #10-32
wire w/ground screw and flat washer.
single phase 7. Refer to Fig. 13 and reconnect the wires.
230V - 2 wire 230V 0
w/ground T1 BLU to Solenoid Valve
single phase T2 BLK to ON/OFF Switch (All models
except 230V-CE models)
208V or 240V - 208V or 0
T3 WHI to Main Harness
2 wire wground 240V 0 (120/208V, 120/240V,
single phase four wire 380V and 440V
models)
220V or 0 T3 WHI to Transformer
280V or 440V -
(380V three wire models)
4 wire w/ground 254V 0
T3 RED to Main Harness
3 phase (208V, 240V single phase
and three phase models)
380V - 3 wire 120V 0 T3 BLK to Main Harness
(230V two wire models)
w/ground 3
phase w/
stepdown trans-
former
T4 PIN to Level Probe
P1733
FIG.13 LIQUID LEVEL BOARD TERMINALS
Page 21 10060 080900

SERVICE (cont.) 5. Disconnect the wires on the ON/OFF switch.
ON/OFF SWITCH 6. a) 120/208V, 120/240V, 208V, 240V, 380V and
440V Models - Check for continuity across the
terminals on the rear of the switch with the switch
in the "ON" (upper) position. Continuity must not
be present when the switch is in the "OFF" (lower)
position.
b) 230V - CE Models - Check for continuity across
the center terminal (2) and the lower terminal (1)
when the switch is in the "ON" (upper) position.
P2209.60
Continuity must not present when the switch is in
FIG.14 ON/OFF SWITCH "OFF" (lower) position.
Location:
The ON/OFF switch is located on the left side of the If continuity is present as described, the switch is
switch mounting bracket. The switch mounting bracket operating properly.
is mounted on the front of the component bracket. If continuity is not present as described, replace the
switch.
Test Procedures:
1. Disconnect the brewer from the power source. Removal and Replacement:
2. a)120/208V, 120/240V, 208V and 240V Models 1. Remove the wires from the switch terminals.
Remove the black wire on the ON/OFF switch from 2. Compress the clips on the back side of the switch
the fuse holder or circuit breaker and the red wire mounting bracket and gently push the through the
on the power indicator light. opening.
b) 380V and 440V Models - Remove the black wire 3. Push the new switch into the opening and spread
on the ON/OFF switch from the fuse holder or the clips to hold switch in the mounting bracket.
circuit breaker and the white wire from the power NOTE: ON 230V - CE models terminal (3) must be
indicator light. on the top.
c) 230V - CE Models - Remove the red wire on the 4. Refer to Fig. 15 and reconnect the wires.
ON/OFF switch from the fuse holder and the black
wire on the power indicator light. BLK from Main Harness
3. Connect the brewer to the power source. With a
voltmeter, check the voltage across the removed
wires. The indication must be:
a) 120 volts ac for 120/208 volt, 120/240 volt and
380 volt models. BLK to Start Switch, Brew
b) 208 volts ac for two or three wire 208 volt Timer & Liuqid Level Board
models. L2
c) 240 volts ac for two wire 240 volt models prior to
#U300004095 and three wire 240 volt models. 120/208V, 120/240V, 208V, 240V, 380V AND 440V
d) 230 volts ac for two wire 230 volt models MODELS
#U300004095 and up).
e) 208 or 240 volts ac for four wire 440 volt mod- BLK from Main Harness
els. RED to Main Harness
RED to Start Switch, Brew
If voltage is present as described, reconnect the wires Timer & Liquid Level Board
and proceed to #5 230V - CE Models
If voltage is not present as described, refer to the Wiring FIG. 15 ON/OFF SWITCH TERMINALS P1735
Page 22 10060 080900

SERVICE (cont.)
PUMP ASSEMBLY
Removal and Replacement (Refer to Fig. 17):
1. Disconnect the wires from the pump assembly.
2. Loosen the #8-32 screw (2) securing the clamp
(3) on the fill tube (1) and slide the clamp (3) up
the fill tube (1).
3. Disengage the fill tube (1) from the pump assembly
(4).
4. Remove the four #8-32 screws (6) securing the
pump assembly (4) to the component bracket
(7).
5. Remove pump assembly (4).
P2209.60 6. Remove pump gasket (5) and inspect, replace if
FIG.16 PUMP ASSEMBLY
necessary.
Location: 7. Position gasket (5) on component bracket (7).
The pump is located on the center rear of the 8. Install new pump assembly (4) on component
component bracket. bracket (7) and secure with four #8-32 screws
(6).
Test Procedures: 9. Install fill tube (1) on pump assembly (4).
1. Disconnect the brewer from the power source. 10. Slide clamp (3) down into position on the fill tube
2. Disconnect the black wire from the black lead on (1) and tighten screw (2).
the pump and the white wire from the black lead 11. Refer to Fig. 17 and reconnect the wires.
on the pump.
3. With a voltmeter, check the voltage across the WHI from Brew Timer
black wire and the white wire. Connect the brewer BLK from Brew Timer
to the power source. The indication must be: 1
a) 120 volts ac for three wire 120/208 volt, 120/240
volt and 380 volt models).
b) 208 volts ac for two or three wire 208 volt 2
models.
c) 240 volts ac for two or three wire 240 volt 3 6
models.
d) 230 volts ac for two wire 230 volt models. 4
e) 208 or 240 volts ac for four wire 440 volt mod-
els 5
7
If voltage is present as described, reconnect the wires
to the pump. Install swing spout and position over the
reservoir. Place the ON/OFF in the "ON" (upper) position
and push the start switch and release. If pump does
not run, replace the pump.
If voltage is not present as described, refer to the Wiring
FIG.17 PUMP INSTALLATION P1737
Page 23 10060 080900

SERVICE (cont.)
RELAY (BREWERS W/BREW LOCKOUT) If continuity is present as described, reconnect the
wires, the relay is operating properly.
relay.
230V - CE Models
2. Disconnect the black wire from relay terminal "A"
and the red wire from relay terminal "B". Check
the voltage across the black and red wire with a
voltmeter. Connect the brewer to the power source.
The indication must be 230 volts ac.

If voltage is not present as described, refer to the Wir-
ing Diagrams and check the brewer wiring harness.
P1731.55
FIG.18 RELAY 4. Check for continuity across relay terminals "A" &
Location: "B"
The relay is located on the front part of the com-
ponent bracket, mounted on the top of the timer If continuity is present as described, reconnect the
bracket. wires to terminals "A" & "B" and proceed to #5.
relay.
Test Procedures:
All Models Except 230V - CE Models
5. With the thermostat in the "ON" position and the
relay engaged disconnect the brewer from the
2. Disconnect the wires from relay terminals "A" &
power source.
"B". Check for continuity between terminals "A" &
6. Disconnect the blue wires from relay terminals 1
"B".
and 7. Check for continuity across terminals 1 and
7.
If continuity is present as described, reconnect the
wires to terminals "A" & "B" and proceed to #3.
If continuity is present as described, proceed to #7
If continuity is not present as described replace the
relay.
relay.
3. Disconnect the wires from relay terminals 2 & 7.
7. Turn the thermostat to the "OFF" position, con-
4. Check for continuity across terminals 2 & 7.
nect the brewer to the power source and turn the
thermostat back to the "ON" position. Continuity
should not be present across terminals 1 & 7.
wires to terminals 2 & 7 and proceed to # 5.
If continuity is not present as described, the relay is
relay.
operating properly.
If continuity is present as described, replace the
5. Disconnect the wires from relay terminals 5 & 7.
relay.
6. Check for continuity across terminals 5 & 7 by
manually closing relay contact. Continuity must
not be present when contact is released.
Page 24 10060 080900

SERVICE (cont.)
RELAY (BREWERS W/BREW LOCKOUT)
BLU from
Start Switch BLU from
3 Brew Timer
1. Disconnect the wires from the relay. 2 6
2. For 120/208V, 120/240V, 208V, 380V, 440V and 1 5 9
4
240V models prior to #U300004095 remove the 7
8
B
#6-32 screw securing the relay to the relay mount- BLK to Control
A
ing bracket. For 230V models #U300004095 and RED from Thermostat
up, remove the two screws securing the relay to Main Harness
the relay mounting bracket. 120/208V, 120/240V, 208V, 380V, 440V AND 240V
3. Remove relay and discard. MODELS PRIOR TO #U300004095
4. For 120/208V,120/240V, 208V, 380V, 440V and
240V models prior to #U300004095, install new
BLU to Start
relay on relay mounting bracket and secure with
Switch
a #6-32 screw. For 230V models #U300004095
and up, install new relay on relay mounting bracket BLU from
and secure with two #6-32 screws. 3 Brew Timer
2 6
5. Refer to Fig. 19 and reconnect the wires. 1 5 9
4 8
7
B
RED to Control
Thermostat
BLK from A
Main Harness
230V MODELS #U300004095 AND UP
FIG.19 RELAY TERMINALS P1739
Page 25 10060 080900

SERVICE (cont.)
SELECTOR SWITCH (HALF BATCH OPTION) Removal and Replacement:
1. Remove the wires from the switch terminals.
2. Compress the clips on the back side of the switch
mounting bracket and gently push the through the
opening.
3. Push the new switch into the opening and spread
the clips to hold switch in the mounting bracket.
P1317.30
FIG. 20 SELECTOR SWITCH (HALF BATCH)
Location: GRY to Brew Timer
The selector switch is located in the upper center PNK to Brew Timer
of the switch mounting panel.
Test Procedures:
2. Disconnect the wires from the switch terminals.
3. Check for continuity across the switch terminals
with the switch in the "CLOSED" (left - half) posi- P1740
tion. Continuity must not present when the switch FIG. 21 SELECTOR SWITCH TERMINALS
is in the "OPEN" (right - full) position.
If continuity is present as described, the switch is

operating properly.
switch.
Page 26 10060 080900

SERVICE (cont.)
SOLENOID
C) For 230V - CE two wire single phase models,
disconnect the red wire from the liquid level board
#2 and the black wire from the solenoid. With a
voltmeter, check the voltage across the red wire and
the black wire. Connect the brewer to the power
source. The indication must be 230 volts ac.
3. Disconnect the dispenser from the power
source.

If voltage is not present as described, refer to the brewer
Wiring Diagrams and check the wiring harness.
P2209.60
FIG. 22 SOLENOID 4. Disconnect the blue wire and the white wire, the
Location: blue wire and the red wire or blue wire and black
The solenoid is mounted on the upper left rear of wire from the solenoid terminals.
the component bracket. 5. Check for continuity across the solenoid valve coil
terminals.
Test Procedures:
1. Disconnect the dispenser from the power If continuity is present as described, reconnect the
source. wires to the solenoid.
2. A) For 120/208 volt and 120/240 volt three wire, If continuity is not present as described, replace the
single phase models, 380 volt three wire, three solenoid valve.
phase models and 380 volt, 440 volt four wire,
three phase models, disconnect the black wire 6. Check the solenoid valve for coil action. Connect
from the liquid level board #2 and the white wire the dispenser to the power source. Listen carefully
on the solenoid. With a voltmeter, check the voltage in the vicinity of the solenoid valve for a "clicking"
across the black and the white wire. Connect the sound as the coil magnet attracts.
brewer to the power source. The indication must
be: If the sound is heard as described and water will not
a) 120 volts ac for 380 volt three wire, three phase pass through the solenoid valve, there may be a block-
models and 208 0r 240 volts ac for four wire three age in the water line before the solenoid valve or, the
phase 440 volt models. solenoid valve may require inspection for wear, and
b) 208 volts ac for three wire 120/208 volt mod- removal of waterborne particles.
els. If the sound is not heard as described, replace the
c) 240 volts ac for three wire 120/240 volt mod- solenoid valve.
els.
B) For 208 volt, 240 volt two wire single phase and Removal and Replacement:
208 volt, 240 volt three wire three phase models, 1. Remove the wires from the solenoid valve.
disconnect the black wire from the liquid level 2. Turn off the water supply to the dispenser.
board #2 and the red wire from the solenoid. With 3. Disconnect the water inlet line from the connector
a voltmeter, check the voltage across the black and on the solenoid valve.
red wires. Connect the brewer to the power source. 4. Remove the #10-32 screw and the flat washer
The indication must be: securing the liquid level board, shield and the
a) 208 volts ac for 208 volt two wire single phase solenoid to the component bracket.
and 208 volt three wire three phase models. 5. Remove solenoid, connectors, air chamber and
b) 240 volts ac for 240 volt two wire single phase tank inlet tube as an assembly.
and 240 volt three wire three phase models.
Page 27 10060 080900

SERVICE (cont.)
SOLENOID BLU from Liquid Level WHI from Main Harness
Board #1 (120/208V, 120/240V, 380V
6. Remove the tank inlet tube grommet and dis- and 440V Models)
card. RED from Main Harness
7. Install new tank inlet tube grommet. (208V and 240V Models)
8. Install new solenoid assembly.
9. Install liquid level board, shield and secure solenoid
assembly and shield to the component bracket
with a #10-32 screw and flat washer..
10. Install water inlet tube to connector on the sole-
noid. EARLY MODELS
11. Turn on the water supply to the brewer.
12. Refer to Fig. 23 and reconnect the wires. BLU from Liquid
Level Board #1
BLK from Main Har-

ness
EARLY 230V - CE MODELS
LATE MODELS
BLU from Liquid Level WHI from Main Harness
Board #1 (120/208V, 120/240V, 380V
and 440V Models)
RED from Main Harness
(208V and 240V Models)
P1741
FIG. 23 SOLENOID TERMINALS
Page 28 10060 081106

SERVICE (cont.)
START SWITCH (BREW)

1. Remove the wires from the switch terminals.
2. Compress the clips on the back side of the switch
mounting bracket and gently push the through the
opening.
3. Push the new switch into the opening and spread
the clips to hold switch in the mounting bracket.
BLU to Brew Timer or

FIG. 24 START SWITCH (BREW)
P1317.30
Brew Lockout Relay
Location:
The brew start switch is located on the upper right
side of the brewer component housing. BLK from ON/OFF Switch
Test Procedures:
ALL MODELS EXCEPT 230V - CE MODELS
2. Remove the wires from the start switch termi-
nals. BLU to Brew Timer or
3. Check for continuity across the switch terminals Brew Lockout Relay
when the switch is held in the lower position. RED from ON/OFF
Continuity must not be present when the switch Switch
is in the upper position.
230V - CE MODELS
P1743
If continuity is present as described, reconnect the FIG.25 BREW START SWITCH TERMINALS
wires the switch is operating properly.
switch.
Page 29 10060 031599

SERVICE (cont.)
TANK HEATERS Test Procedures:
2. Disconnect the wires from the tank heater.
3. Check for continuity across the tank heater termi-
nals.
If continuity is present as described, proceed to #4.

tank heater.

1. Remove the wires or thermal fuses from the tank
heater.
2. Remove the four #8-32 screws securing the tank
heater to the component bracket.
3. Remove tank heater and gasket.
4. Position new tank heater and gasket on the compo-
P2209.60 nent bracket and secure with four #8-32 screws.
FIG. 26 TANK HEATER 5. Refer to Fig. 27 and reconnect the wires.
Location:
The tank heaters are located on the right center
and the left center of the component bracket.
RED to Contactor T2 (All

Models Except 230V-CE
Models) BLK to Contactor T1 (All
RED (Thermal Fuse) to Con- Models Except 230V-CE
tactor Top Right Terminal) Models)
(230V-CE Models) BLK (Thermal Fuse) to
Contactor Top Left Termi-
nal) (230V-CE Models)
BLK to Contactor L1
(120/208V, 120/240 Three
Wire Single Phase, 208V
RED to Contactor L2
and 240V Two Wire,
(120/208V, 120/240 Three
Single Phase)
Wire Single Phase, 208V
BLU to Main Harness and 240V Two Wire, Single
(208V, 240V, 380V Three Phase)
Wire ,Three Phase and
BLU to Main Harness
380V,440V Four Wire,
(208V, 240V, 380V Three
Three Phase
Wire ,Three Phase and
BLK (Thermal Fuse to 380V,440V Four Wire,
Contactor Lower Left Three Phase
Terminal) (230V-CE Mod-
RED (Thermal Fuse) to
els)
Contactor Lower Right
Terminal)
LEFT RIGHT
P1746
FIG. 27 TANK HEATER TERMINALS
Page 30 10060 031599

SERVICE (cont.) TIMER (Early Models)
THERMAL FUSES (230V-CE MODELS ONLY)
J2
J1
TL1
TL2
TL3
OLD STYLE
TL4
TL5
P1722.55
FIG. 29 TIMER
P1750.65
FIG. 28 THERMAL FUSES Location:
Location: The timer is located on the front center of the
The thermal fuses are mounted on the tank heater component bracket.
terminals and the contactor terminals.
Test Procedures:
Test Procedures:
2. Disconnect the polarized, three pin connector from
2. Disconnect the thermal fuse from the tank heater
the brewer main harness and rotate the brew timer
terminal and the contactor terminal.
dial fully counterclockwise.
3. With a voltmeter, check the voltage across sockets
ends of the thermal fuse.
P2 and P3 (white and black wire or red wire) of
the female connector on the main wiring harness
If continuity is present as described, the thermal is
when the "ON/OFF" switch is in the "ON" (upper)
operating properly.
position. Connect the brewer to the power source.
The indication must be:
thermal fuse.
volt, 380 volt models and 208 or 240 volts ac for
four wire 440 volt models.
1. Disconnect the thermal fuse from the tank heater
b) 208 volts ac for two and three wire 208 volt
terminal and the contactor and discard.
models.
2. Connect the new thermal fuse to the tank heater
c) 240 volts ac for two and three wire 240 volt
terminal and the contactor terminal.
models.
d) 230 volts ac for two wire 230 volt CE models.

If voltage is not present as described, refer to the Wiring
Page 31 10060 080900

SERVICE (cont.)
TIMER (Early Models)(cont.) 1. Separate all connectors between the brewer wiring
5. With a voltmeter, check the voltage across the harness and the timer.
sockets P1 and P2 (blue and white wires) of the 2. Disconnect the timer leads from the pump
female connector on the main harness when the leads.
"ON/OFF" switch is in the "ON" (upper) position 3. Remove the two #8-32 screws securing the brew
and the start switch pressed. Connect the brewer timer to the component bracket and remove
to the power source. The indication must be: timer.
a) 120 volts ac for three wire 120/208 volt, 120/240 4. Install new timer circuit board as described in Late
volt, 380 volt models and 208 or 240 volt ac for Model Timer section on the following pages.
four wire 440 volt models. 5. Refer to Fig. 33 to reconnect the wires.
b) 208 volts ac for two and three wire 208 volt 6. Install the Timer Setting Decal, provided with the
models. timer replacement kit, on the back of the front
c) 240 volts ac for two and three wire 240 volt access panel.
models. 7. Adjust the timer as required. Refer to Late Model
d) 230 volts ac for two wire 230 volt CE models. Timer section on the following pages.
7. Reconnect the three pin connector from the main
wiring harness to the connector on the timer.
If voltage is present as described, proceed to #8. Three Pin Connector from

If voltage is not present as described, refer to the Wiring Half/Full Batch Switch
8. Disconnect the black and white wires to the

pump.
9. With a voltmeter, check the voltage across the
black and white wires when the "ON/OFF" switch
is in the "ON" (upper) position and the start switch
pressed to the start position and released. Connect
the brewer to the power source. The indication
To Three Pin Female
must be:
Connector on Main
Harness
volt, 380 volt and 208 or 240 volt ac for four wire
440 volt models.
b) 208 volts ac for two and three wire 208 volt BLK to Pump
models. Lead
c) 240 volts ac for two and three wire 240 volt
models. WHI to Pump Lead
d) 230 volts ac for two wire 230 volt CE models. OLD STYLE
P1751
FIG. 31 TIMER TERMINALS
If voltage is present as described, the brew timer is
operating properly. Reset the timer dial as required,
to obtain the desired brew volume.
If voltage is not present as described, replace the
timer.
Page 32 10060 080900

SERVICE (cont.)
DIGITAL TIMER (Late Models) 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. The indication must be 0 volts.
If voltage is as described, proceed to #7.

If voltage is not as described, disconnect the brewer
from the power source and replace the timer.
7. With a voltmeter, check the voltage across ter-

minals 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 as follows:
b) 208 volts ac for two wire 208 volt models.
P2209.60
FIG. 32 DIGITAL TIMER c) 240 volts ac for two wire 240 volt models.
Location: d) 230 volts ac for two wire 230 volt CE models.
The timer is located on the front center of the e) 208 or 240 volts ac for four wire 440 volt mod-
component bracket. els.
Test Procedure. If voltage is present as described, the brew timer is

NOTE: Do not remove or install wires while timer board operating properly. Reset the timer as required, to
is installed. Pressure applied to one side may cause obtain the desired brew volume.
damage to the board. If voltage is not present as described, disconnect the
1. Disconnect the brewer from the power source. brewer from the power source and replace the timer.
2. Remove the two #8-32 screws securing circuit
board to the mounting bracket. Removal and Replacement:
3. Remove circuit board and spacers (as required). 1. Remove the two #8-32 screws securing circuit
4. With a voltmeter, check the voltage across terminals board to the mounting bracket.
TL1 and TL2 when the "ON/OFF" switch is in the 2. Remove circuit board and spacers (as required).
"ON" position. Connect the brewer to the power 3. Remove all wires from the timer.
source. The indication must be: 4. Attach all wires to the replacement timer board
a) 120 volts ac for three wire 120/208 volt , 120/240 prior to installation to the component mounting
volt and 380 volt models. bracket. Refer to FIG. 33 when reconnecting the
b) 208 volts ac for two wire 208 volt models. wires.
c) 240 volts ac for two wire 240 volt models. 5. Install new circuit board with spacers (as required)
d) 230 volts ac for two wire 230 volt CE models. to the component mounting bracket.
e) 208 or 240 volts ac for four wire 440 volt mod- 6. Adjust the timer as described below.
els.
Timer Setting:
5. Disconnect the brewer from the power source. NOTE: Prior to setting or modifying volumes, check
that the brewer is connected to water supply, the
If voltage is present as described, proceed to #6. tank is properly filled, and a funnel and server are in
If voltage is not present as described, refer to the Wiring place.
Page 33 10060 080900

SERVICE (cont.)
DIGITAL TIMER (Late Models)
NOTE: The brewer remembers this volume and will
NOTE: All volume settings must be done with the continue to brew batches of this size until the volume
sprayhead installed. setting procedure is repeated.
NOTE: When brewing coffee, volume will decrease
1. Modifying brew volumes. To modify a brew vol- due to absorption by the coffee grounds.
ume, first check that the SET/LOCK switch is in the NOTE: Half-Batch and full batch settings must each
SET position on the circuit board. be set separately.
To increase a brew volume, place the ON/OFF 3. Setting programming disable feature. If it be-
switch in the ON position, press and hold the START comes necessary to prevent anyone from changing
switch until you see three breaks in the water stream brew time once programmed, you can set the SET/
from the swing arm. Release the switch and press it LOCK switch to the LOCK position. This will prevent
again one or more times. (Failure to release the switch any further programming until switch is once again
within two seconds after the third break in the water put into the SET position.
stream causes the volume setting to be aborted and
previous volume setting will remain in memory.) Each
time the switch is pressed, two seconds are added to
the brew time period. Allow the brew cycle to finish
in order to verify that the desired volume has been
achieved.
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 you see three breaks in the water stream from the
swing arm. Release the switch. (Failure to release the
switch within two seconds after the third break in the
water stream causes the volume setting to be aborted
and previous volume setting will remain in memory).
Allow the brew cycle to finish in order to verify that
the desired volume has been achieved.
2. Setting brew volumes. To set a brew volume,

first check that the SET/LOCK switch is in the SET
position on the circuit board. Place the ON/OFF switch
in the ON position, press and hold the START switch
until you see three breaks in the water stream from BLU/BLK wire from TL5 to P1
the swing arm and then release the switch. (Failure to WHI/GRN wire from TL4 to (WHI) Pump
release the switch within two seconds after the third WHI/BLU wire from TL3 to (BLK) Pump
WHI wire from TL2 to P2
break in the water stream causes the volume setting BLK wire from TL1 to P3
to be aborted and previous volume setting will remain
in memory.) J2 - Three Pin connector from Half/Full Batch
View the level of the liquid being dispensed. When Switch
P2037
the desired level is reached, turn the ON/OFF switch FIG. 33 DIGITAL TIMER TERMINALS
to OFF.
Page 34 10060 080900

SERVICE (cont.)
TRANSFORMER (380V THREE WIRE MODELS ONLY)
If voltage is present as described, the transformer is
operating properly
If voiltage is not present as described, replace the
transformer.
1. Disconnect all the wires from the transformer.
2. Remove the two #8-32 screws securing the trans-
form to the transformer mounting bracket.
3. Remove the transformer and discard.
4. Position new transformer on transformer mounting
bracket and secure with two #8-32 screws.
P1752.55
FIG. 34 TRANSFORMER RED from

Location: WHI from Main
Terminal Block Harness
The transformer is located on the top rear of the
timer mounting bracket.
Test Procedures:
2. Disconnect black wire and the red wire from the
terminal block at the transformer.
black wire and the red wire. Connect the brewer
to the power source. The indication must be 380
volts ac.

If voltage is not present as described, refer to wiring
diagram and check the brewer wiring harness. BLK from BLK from
Terminal Block Main Harness
5. Reconnect the black wire and the red to the trans-
former. FIG. 35 TRANSFORMER TERMINALS
P1753
6. Disconnect the black wire and the white wire from

the transformer terminals.
transformer terminals. Connect the brewer to the
power source. The indication must be 120 volts
ac.
Page 35 10060 031599

SERVICE (cont.)
MASTER ON/OFF SWITCH (Late Models)

1. Remove all wires from the switch terminals.
2. Remove the two screws from the outside of the
base and gently push the switch through the
opening.
3. Locate the new switch into the opening and se-
cure with screws removed in step 2.
4. Refer to FIG. 37 when reconnecting the wires.
Incoming Power Supply

L1 - BLK
P1752.55
L2 - RED
FIG. 36 MASTER ON/OFF SWITCH LOC.
Location: Main Wiring harness

The Master ON/OFF switch is located in the top hous- BLK
ing at the rear, FIG. 36.
RED
Test Procedure:
1. Disconnect the brewer from the power source
and remove the wires from all terminals of the P3955
Master ON/OFF switch. FIG. 37 MASTER ON/OFF SWITCH WIRING

2. Check for continuity across the two terminals on
the switch at L1 BLK and BLK to Main Harness
when it is held in the lower position, Fig. 32.
Check for continuity across the two terminals on
the switch at L2 RED and RED to Main Harness
when it is held in the lower position.
Continuity must not be present across these
terminals in the upper position.

wires, the switch is operating properly.
switch.
Page 36 10060 011708

L1 L2 N
WHI
RED
BLK
MAIN ON/OFF SWITCH
(Late Models only)
BLK
RED
120/208 VOLTS AC
120/240 VOLTS AC
3 WIRE + GND
SINGLE PHASE
10492.0000E 03/07 1990 BUNN-O-MATIC CORPORATION
Page 37 10060 011708

Page 38 10060 080900

SCHEMATIC WIRING DIAGRAM U3A & U38A
(BREWERS PRIOR TO U300004095)
Page 39 10060 080900

SCHEMATIC WIRING DIAGRAM U3A - CE
(BREWERS S/N U300004095 - UP)
Page 40 10060 080900

SCHEMATIC WIRING DIAGRAM U3833
Page 41 10060 080900

SCHEMATIC WIRING DIGRAM U3833
Page 42 10060 080900

Operating & Service Manual: Bunn-O-Matic Corporation

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U3

OPERATING & SERVICE MANUAL

10060.0000K 10/08 1984 Bunn-O-Matic Corporation

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Bunn-O-Matic Corp. (BUNN) warrants equipment manufactured by it as follows:

Page 2 10060 100908

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WARNING This equipment must be installed to comply

READ THE ENTIRE OPERATING MANUAL

THIS APPLIANCE IS HEATED WHENEVER

ATTENTION: TURN OFF WHEN UNATTENDED

Page 3 10060 011708

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Page 5 10060 102808

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ADJUSTING BREW VOLUMES

Page 6 10060 080900

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Page 7 10060 081106

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WARNING Exercise extreme caution when servicing electrical equipment.

PROBLEM PROBABLE CAUSE REMEDY

2. No power or incorrect voltage to (A1) Check the terminal block for

Page 8 10060 031500

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4. ON/OFF Switch Refer to Service - ON/OFF Switch for

5. Start Switch Refer to Service - Start Switches for

6. Relay Refer to Service - Relay for testing

7. Timer Refer to Service - Timer for testing

8. Pump Refer to Service - Pump for testing

9. Solenoid Valve Refer to Service - Solenoid Valve for

10. Strainer (A) Direction of flow arrow must be

(B) Remove the strainer and check

Page 9 10060 080900

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2. No water Be sure water shut-off is open and

3. Solenoid Valve Refer to Service - Solenoid Valve

4. Probe Refer to Service - Probe for testing

5. Liquid Level Board Refer to Service - Liquid Level

2. Solenoid Valve Refer to Service - Solenoid Valve

3. Liquid Level Board Refer to Service -Liquid Level

4. Probe Refer to Service - Probe for testing

5. Manual fill and drain valve un- Be sure valve is closed.

Page 10 10060 080900

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Water not hot 1. Limit Thermostat Refer to Service - Limit Thermo-

2. Control Thermostat Refer to Service - Control Ther-

3. Tank Heater(s) Refer to Service - Tank Heater for

4. Contactor Refer to Service - Contactor for

2. Tank Heater(s) Refer to Service - Tank Heater for

2. Start Switch Refer to Service - Start Switch for

Inconsistent coffee yield 1. Timer Refer to Service - Timer for testing

2. Solenoid Valve Refer to Service - Solenoid Valve

3. Lime build-up in swing spout Remove swing spout and insert

Funnels overflow 1. Filters Use Bunn filters made for the

2. Hole in bottom of funnel ob- Remove obstruction.

Page 11 10060 080900

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