Bunn JDF-2S, Service & Repair Manual

Page 1: ...e 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 49179 0000E 03 16 2013 Bunn O Matic Corporation ...

Page 2: ...ements 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 op tion 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 specif...

Page 3: ...is required between the dispenser sides and the wall or another appliances For optimum performance do not allow warm air from surrounding machines blow on the JDF dispenser Leave some space so the dispenser can be moved for cleaning INTRODUCTION Safety first To avoid electrical shock unplug dispenser from power source before servicing inside Basic Maintenance In order to maintain proper machine op...

Page 4: ...let 8 Dispense from each station un til finished product flows from the dispense nozzles 7 Replace drip tray and dispense nozzles 6 With a warm soapy cloth wipe down interior of cabinet and splash panel area behind dis pensing nozzles 5 Remove dispense nozzles and drip tray Wash all parts in warm soapy water 4 Open dispenser door and recon nect all product containers 3 Dispense from each station u...

Page 5: ...r or damage and replace immediately Check and or replace every 6 months or as required 39690 0000 Pump Tube Replacement Kit Includes items indented below 28755 1011 Tube Norprene 25 ID x 17 0 lg 32732 0000 Clamp 39 48 32656 0000 Fitting Elbow 25 Barb x 38 Barb 21275 0003 Clamp 57 70 34325 0032 Hose Flex 38 ID x 5 25 lg 49179 110613 ...

Page 6: ...upply 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 unit is heated at all times Keep away from combustibles WARNING Exercise extreme caution when servicing electrical equipment Unplug t...

Page 7: ...en check for dirty con denser filter or adequate ventilation and space around machine Check refrigeration system for leaks and proper charge A Set switch to ON position B Check switch and harness for proper continuity Check all previous items that pretain to refrigeration or cold water recir culation 1 Compressor ON OFF switch 2 Dirty condenser filter or fins 3 Condenser fan not running 4 Compress...

Page 8: ...ter supply Frozen bath Inlet water valve failed Place switch in ON position Check switch and harness for proper continuity Check for ON position A Compressorrelay contactsshort ed replace relay B Recirculating pump replace or check for kinked flex line A Check for 120V or 230V power when dispensing If yes replace valve Ifno checkharnessforproper continuity Thenreplacecircuitboard if needed 49179 1...

Page 9: ...roper counterclockwise rotation of pump rollers If coun terclockwise replace pump tubing If clockwise wire connection to pump is reversed Switch wires on terminals A Check speed setting on circuit board and increase speed turn clockwise B Check for d c power to pump motor If yes replace motor assy If no check harness for proper conti nuity Then replace circuit board if needed Water solenoid Concen...

Page 10: ... coil Dispense nozzle mixer missing or broken Dispense solenoid Some expansion normal May fill drip tray during initial ice block formation Inspect or replace fittings clamps o rings solenoids and quick discon nect fittings NOTE Dispense deck area slopes to drain tube that leads to the drip tray Install water pressure regulator and reduce to 50 psi A Check all internal water connec tions B Check i...

Page 11: ...uctbeforeuse 35 40 Maintain 20 psi or higher and a mini mum flow rate of 1 fl oz sec Over 100 psi install a pressure regu lator and set to 50 psi A Perform 3 second water dispense test Factory setting is 1 0 oz sec Acceptable water flow rate is 0 8 to 1 5 oz sec depending on the mix ratio 4 1 B Adjust water to proper mix ratio Oncewaterisset adjustmotorspeed to achieve brix Check for proper brix r...

Page 12: ...ng the door removal of the door panels dispenser top covers hopper s hopper support plate splash guard splash panel w drip tray lower front access panel and rear ac cess cover Refer to the contents listing for component location INDEX Access Panels 13 Dispense Platform Removal 14 Ballast 15 Cabinet Fan 16 Compressor 17 Compressor Switch 23 Condenser Fan 24 Control Board Main 25 Control Board Porti...

Page 13: ...h the whole JDF family JDF 4S shown Before removing panels make sure power is OFF to the machine and water is disconnected accept where indicated in testing procedures Retain all screws and other attaching hardware for re assembly FIG 1 ACCESS PANELS JDF 4S shown 49179 110613 ...

Page 14: ... shelf to access dispense platform s 3 Remove front thumb screw holding dispense platform s 4 Disconnect 12 pin connector above dispense platform in rear 5 Disconnect 3 8 water line at quick disconnect 6 Remove dispense platform s by pulling forward The JDF 4S uses 2 of the two head dispense platforms FIG 2 DISPENSE PLATFORM REMOVAL JDF 2S shown 49179 110613 ...

Page 15: ... 4 BALLAST TERMINALS P1219 5 Remove the wire to the ballast from the back of each bracket 6 Todisengagetheballastwirefromthebracket push a 1 16 allen wrench or equivalent tool into the front hole that lines up with the wire in the back Pull the wire out 7 Repeat for each bracket 8 White jumper must remain in place on the back of the light socket 9 Removescrewsfromeachballast Removethegreen ground ...

Page 16: ...is operat ing properly If continuity is not present as described replace the fan Removal and Replacement 1 Disconnect the dispenser from the power source 2 Removethefourscrewsattachingthefanandcover assembly 3 Gently pull the cover forward and disconnect the 2 pin connector from the main wiring harness 4 Removethefanfromthecoverassemblyanddiscard the old fan 5 Install the new fan to the cover asse...

Page 17: ...eck for continuity across the terminal and the pin socket on the rear of the relay If continuity is present as described the compressor start relay is operating properly If continuity is not present as described replace relay Compressor 1 Remove relay and yhermal overload protector 2 Check for continuity across the bottom pin on the compressor and the left top pin on the compressor If continuity i...

Page 18: ...r and the accumulator 2 Disconnect the compressor wiring harness from the dispenser main wiring harness 3 Remove the four 25 20 keps nuts and washers securing the compressor to the chassis Set nuts and washers aside for reassembly 4 Disconnect and remove the transformer 5 From the right side of the dispenser lift the com pressorassemblyoverthefourstudsinthechassis and remove compressor WHI Wire BL...

Page 19: ...es sor start relay 7 Remove relay from the compressor 8 Check for continuity across the upper left terminal and the right pin socket on the rear of the relay If continuity is present as described the compressor start relay is operating properly If continuity is not present as described replace re lay Compressor 1 With the compressor start relay 1 removed dis connect the black wire from the compres...

Page 20: ...r it is recom mended that the dryer also be replaced 1 Disconnect the tubes from the condenser and the accumulator 2 Disconnect the compressor wiring harness from the dispenser main wiring harness 3 Remove the four 25 20 keps nuts and washers securing the compressor to the chassis Set nuts and washers aside for reassembly 4 Disconnect and remove the transformer BLU BLK GRN WHI FIG 13 RELAY TERMINA...

Page 21: ... the compressor 8 Check for continuity across the upper left terminal and the right pin socket on the rear of the relay If continuity is present as described the compressor start relay is operating properly If continuity is not present as described replace re lay Compressor 1 With the compressor start relay 1 removed dis connect the black wire from the compressor 2 Check for continuity across the ...

Page 22: ...cing the compressor it is recom mended that the dryer also be replaced 1 Disconnect the tubes from the condenser and the accumulator 2 Disconnect the compressor wiring harness from the dispenser main wiring harness 3 Remove the four 25 20 keps nuts and washers securing the compressor to the chassis Set nuts and washers aside for reassembly FIG 17 RELAY TERMINALS FIG 18 THERMAL OVERLOAD PROTECTOR T...

Page 23: ...n Continuity must not be present when the switch is in the OFF position If continuity is present as described reconnect the wires to the switch terminals If continuity is not present as described replace the switch Removal and Replacement 1 Disconnect the dispenser from the power source 2 Remove the cover or splash panel to gain access to the switch 3 Gently disconnect the wiring harness from the ...

Page 24: ...not present as described replace the fan Removal and Replacement 1 Disconnect the dispenser from the power source 2 Removethefourscrewsattachingthefanandcover assembly to the refrigeration cabinet 3 Gentlypullthecoverassemblyforwardanddiscon nect the 2 pin connector from the fan to the main harness 4 Remove the fan from the cover assembly and dis card 5 Install the new fan onto the cover assembly ...

Page 25: ...tor on the wiringharness Connectthedispensertothepower source The indication must be 24 volts ac 6 Disconnect the dispenser from the power source Ifvoltageisnotpresentasdescribed refertotheWiring Diagrams and check the dispenser wiring harness back to the transformer See TRANSFORMER Removal and Replacement 1 Removethefour 6 32screwssecuringthecontrol board to the component bracket 2 Disconnectallt...

Page 26: ...ove the five screws securing the door cover to the door frame 2 Carefully pull the cover forward and disconnect all switch harnesses from the connectors on the control board 3 Removethefour 6 20screwssecuringthecontrol board to the light panel 4 Remove the spacers from the control board and discard the old board 5 Install the spacers on to the new control board 6 Install new control board on the l...

Page 27: ...ROL BOARD CONNECTORS Removal and Replacement 1 Remove the five screws securing the door cover to the door frame 2 Carefully pull the cover forward and disconnect all switch harnesses from the connectors on the control board 3 Removethefour 6 20screwssecuringthecontrol board to the light panel 4 Remove the spacers from the control board and discard the old board 5 Install the spacers on to the new ...

Page 28: ...e the five screws securing the door cover to the door frame 2 Carefully pull the cover forward and disconnect all switch harnesses from the connectors on the control board 3 Removethefour 6 20screwssecuringthecontrol board to the light panel 4 Remove the spacers from the control board and discard the old board 5 Install the spacers on to the new control board 6 Install new control board on the lig...

Page 29: ... and Replacement 1 Removedispenseplatform s foreaseoftakingout recirculating pump 2 Remove left and right side panels 3 Remove silicone condensation hose out of bath tank along side recirculating pump 4 Disconnect pump motor and condenser fan wires 1 4 spade terminals 5 Remove2screwsleftandrightsideofthecondenser mountingbracket Removecondenserfanassembly out the right side of the machine 6 Releas...

Page 30: ...ty must be present when the switch is in the ON position If continuity is not present replace the switch Removal and Replacement 1 Disconnect the dispenser from the power source 2 Loosen the two 8 32 screws securing the com ponent mounting bracket to the dispenser base 3 Disconnect the two black wires from the switch 4 Press the locking tabs of the old switch and remove from the component mounting...

Page 31: ...be and the rotor 3 Inspect the pump tubing for signs of wear and replace every six months or as needed 4 Inspectthepumprotorforsignsofwearandreplace if necessary 5 Install the new pump tube around the rotor and position into the rear housing with the clamp rest ing on the top edge 6 Install the front housing to be flush with the rear housing 7 Position the pump assembly back on the platform andsec...

Page 32: ...ribed replace the motor Ifvoltageisnotpresentasdescribed refertotheWiring Diagrams and check the dispenser wiring harness back to the transformer See TRANSFORMER Removal and Replacement 1 Disconnect the two wires from the dispense mo tor 2 Loosen the four 8 32 screws securing the motor to the platform assembly and remove the motor 3 Inspect the gasket and rubber bushings for signs of wear and repl...

Page 33: ...TRANSFORMER Removal and Replacement 1 Disconnect the two wires from the dispense valve 2 Remove the 6 32 screw and plate securing the water manifold tube to the valve 3 Loosen the two 6 32 screws securing the valve to the platform assembly and remove the valve 4 Install the new valve onto the platform and secure with two 6 32 screws previously removed 5 Inspect the o ring on the manifold tube conn...

Page 34: ...the dispense switch with the switch in the ON position Continuity must not be present when the switch is in the OFF released posi tion If continuity is present as described reconnect the door wiring harness the switch is operating properly If continuity is not present as described replace the switch Removal and Replacement 1 Disconnect the dispenser from the power source 2 Remove the five screws a...

Page 35: ... left of the dispense switch with the switch in the ON position Continuity must not be present when the switch is in the OFF released posi tion If continuity is present as described reconnect the door wiring harness the switch is operating properly If continuity is not present as described replace the switch Removal and Replacement 1 Disconnect the dispenser from the power source 2 Remove the five...

Page 36: ...val and Replacement 1 Disconnect the dispenser from the power source 2 Open the dispenser door 3 Remove the four 8 32 screws securing the lower door panel and remove the panel 4 Disconnect the six pin harness from the switch board 5 Carefully peel the membrane switch from the front of the switch bezel 6 Remove any excess adhesive from the bezel sur face 7 Remove the backing from the new membrane s...

Page 37: ...oval and Replacement 1 Disconnect the dispenser from the power source 2 Open the dispenser door 3 Remove the four 8 32 screws securing the lower door panel and remove the panel 4 Disconnect the three pin harness from the switch board 5 Carefully peel the membrane switch from the front of the switch bezel 6 Remove any excess adhesive from the bezel sur face 7 Remove the backing from the new membran...

Page 38: ...tance between the two black leads on the EMI Filter If resistance is present as described the EMI Filter is operating properly If resistance is not present as described replace the EMI Filter Removal and Replacement 1 Disconnect the wires from the EMI Filter 2 Remove the two 8 32 screws and nuts securing the EMI Filter 3 Remove and discard EMI Filter 4 Install new EMI Filter using two 8 32 screws ...

Page 39: ...llast white to red If voltage is present as described replace ballast If voltage is not present as described refer to the Wiring Diagrams and check the wiring harness back to the transfomer rectifier Removal and Replacement 1 Disconnect the dispenser from the power source 2 Remove the five 10 32 screws securing the door cover to the door and move the cover aside to gain access to the light panel 3...

Page 40: ...hedispenser door Test Procedures No illumination at all First verify that the dispense lockout switch has not been turned off 1 Disconnect power from the dispenser 2 CheckthevoltageacrosstheblackandredleadsofJ2 or J3 at the LED regulator board with a voltmeter Reconnect power to the dispenser The indication must be 24 volts dc 3 Disconnect power from the dispenser If voltage is present as describe...

Page 41: ...e electrical component mounting bracket on the lower front of the dispenser behind the splash panel Test Procedures 1 Disconnect the dispenser from the power source 2 Remove the blue wire and the white wire from the rectifier 3 Check the voltage across the and terminals on the rectifier with a voltmeter Connect the dis penser to the power source The indication must be approximately 24 volts dc 4 D...

Page 42: ...sis Remove and discard relay 3 Install the new relay to the mounting bracket and thenonthechassisusingtwo 8 32lockingscrews 4 Refer to Fig 58 to reconnect the wires Location The relay or contactor is located inside the dis penser chassis on the lower outside of the component bracket Test Procedures 1 Disconnect the dispenser from the power source 2 Withavoltmeter checkthevoltageacrossthewhite wire...

Page 43: ... the relay at the electrical component mounting bracket on the lower front of the dispenser behind the splash panel Test Procedures 1 Disconnect the dispenser from the power source 2 Remove the resistor from the relay 3 Check the resistance across the terminals of the resistor with a ohmmeter The indication must be approximately 36k 5 4 Disconnect the dispenser from the power source If resistance ...

Page 44: ...lenoid If continuity is not present as described replace the solenoid valve 6 Check the solenoid valve for coil action Connect the dispenser to the power source Press the Cold Water dispense switch and listen carefully in the vicinity of the solenoid valve for a clicking sound as the coil magnet attracts 7 Disconnect the dispenser from the power source If the sound is heard as described and water ...

Page 45: ...rce If the sound is heard as described and water will not pass through the solenoid valve there may be a block age in the water line before the solenoid valve or the solenoid valve may require inspection for wear and removal of waterborne particles If the sound is not heard as described replace the solenoid valve Removal and Replacement 1 Remove the two wires from the solenoid valve 2 Turn off the...

Page 46: ...ould be con ducted anytime the main circuit board or the bath thermistor is being replaced Recalibration procedure Step 1 Remove the front splash panel so you can see the LED s on the main circuit board Step 2 Place the Program switch in the On posi tion For early models without the program switch place the dispense on off switch in the off position Step 3 Remove the thermistor from the bath tank ...

Page 47: ...from the tank lid 5 Slide a new grommet on to the new temperature probe 6 Insert the temperature probe through the hole in the tank lid and press the grommet firmly and evenly so that the groove in the grommet fits into the tank lid 7 Reconnect the two pin connector to the dispenser main wiring harness BLKorORNpin1 WHI pin 2 TEMP RESISTANCE VOLTAGE SHORTED 0 Ω 0VDC 32 F 31 2k 34k Ω 3 0VDC 0 0 C 77...

Page 48: ... 1 Remove the left side housing panel 2 Disconnect the plug on the temperature sensor leads from the connector on the dispenser main harness 3 Open the cabinet door and remove the product containers 4 Remove the cabinet fan and fan guard assembly 5 Clip off the connector and pull the temperature sensor from the top left rear of the cabinet and discard 6 Push new temperature sensor wires into the g...

Page 49: ...n The transformer is located on the electrical com ponent mounting bracket on the lower front of the dispenser behind the splash panel Test Procedure 1 Disconnect the dispenser from the power source 2 Check the voltage across black wire and the white wire from the main harness Connect the dispenser to power source The indication must be a 120 volts ac for two wire 120 volt models three wire 120 20...

Page 50: ...ounting bracket on the lower front of the dispenser behind the splash panel Test Procedure 1 Disconnect the dispenser from the power source 2 Disconnectthefourpinplugfromthemainharness from the four pin connector on the transformer 3 Check the voltage across black wire pin 1 and the white wire pin 2 on the plug from the main har ness Connect the dispenser to power source The indication must be a 1...

Page 51: ...sor Relay Q25 2 Station 2 Water Q27 3 Station 1 Water Q28 4 Station 1 Concentrate Q23 5 Station 2 Concentrate Q18 6 Station 3 Concentrate Q17 7 Station 4 Concentrate Q13 8 Station 3 Water Q7 9 Cold Water Valve Q11 10 Inlet Water Valve Q10 11 Station 4 Water Q8 ...

Page 52: ...BLU EMI FILTER 120 VOLTS AC or 220 230 VOLTS AC 2 WIRE SINGLE PHASE J1 1 J1 3 J5 1 J5 5 J4 1 J4 5 J3 1 J3 5 J2 1 J2 5 PUSH BUTTON OPTION Models with Membrane Switches Models with Mechanical Switches Models with Lited Doors STATIC SHIELD DISPENSE STATION 2 STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD DISPENSE STATION 1 DISPENSE STATION 2 DISPENSE STATION 1 STOP PLUS LARGE MEDIUM SMALL DISPENSE STATIC...

Page 53: ...OLTS AC 2 WIRE SINGLE PHASE J1 1 J1 3 J5 1 J5 5 J4 1 J4 5 J3 1 J3 5 J2 1 J2 5 PUSH BUTTON OPTION Models with Membrane Switches Models with Mechanical Switches STATIC SHIELD DISPENSE STATION 2 STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD DISPENSE STATION 1 DISPENSE STATION 2 DISPENSE STATION 1 STOP PLUS LARGE MEDIUM SMALL DISPENSE STATIC SHIELD DISPENSE STATIC SHIELD GRN or YEL RED BLK BLK BLK RED BL...

Page 54: ... RED BLU YEL ORN AUXILLARY CONTROL BOARD J1 1 DISPENSE DISPENSE STATIC SHIELD STATIC SHIELD COLD WATER SWITCH DISPENSE STATION 4 J1 3 J5 1 J5 5 J4 1 J4 5 J3 1 J3 5 J2 1 J2 5 DISPENSE STATIC SHIELD COLD WATER SWITCH STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD PUSH BUTTON OPTION STATIC SHIELD DISPENSE STATION 3 STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD DISPENSE STATION 2 STOP PLUS LARGE MEDIUM SMALL...

Page 55: ...UXILLARY CONTROL BOARD J1 1 DISPENSE DISPENSE STATIC SHIELD STATIC SHIELD COLD WATER SWITCH DISPENSE STATION 4 J1 3 J5 1 J5 5 J4 1 J4 5 J3 1 J3 5 J2 1 J2 5 DISPENSE STATIC SHIELD COLD WATER SWITCH STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD PUSH BUTTON OPTION STATIC SHIELD DISPENSE STATION 3 STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD DISPENSE STATION 2 STOP PLUS LARGE MEDIUM SMALL STATIC SHIELD DIS...

Page 56: ... BLK TRANSFORMER WHI BLK WHI BLU WHI BLU L O A D L I N E WHI WHI BLK K1 120V MODELS N A B A B A B L1 A B 230V MODELS GRN YEL N L1 GND BRN BLU EMI FILTER 120 VOLTS AC or 230 VOLTS AC 2 WIRE SINGLE PHASE J15 1 J15 4 J12 1 J12 3 WHI BLU BLU TRANSFORMER BLU WHI BLU L O A D L I N E COLD WATER VALVE WHI VIO WHI SOL J11 1 J11 5 J6 1 J6 5 BLK RED BLU YEL ORN BLK RED BLU YEL ORN AUXILLARY CONTROL BOARD POW...

Page 57: ... A D L I N E WHI WHI BLK K1 120V MODELS N A B A B A B L1 A B 220 230V MODELS GRN YEL N L1 GND BRN BLU EMI FILTER 120 VOLTS AC or 220 230 VOLTS AC 2 WIRE SINGLE PHASE J15 1 J15 4 J12 1 J12 3 WHI BLU BLU TRANSFORMER BLU WHI BLU L O A D L I N E COLD WATER VALVE WHI VIO WHI SOL J11 1 J11 5 J6 1 J6 5 BLK RED BLU YEL ORN BLK RED BLU YEL ORN AUXILLARY CONTROL BOARD BLK BLK BLK BLK DISPENSE LOCKOUT SWITCH...

Page 58: ... 12 TAN WHI VIO PNK VIO VIO BLU WHI ORN GRY YEL WHI GRN RED RED RED GRN ORN ORN SOL SOL WATER INLET VALVE BRN WHI SOL WHI VIO BLK TRANSFORMER WHI BLK WHI BLK WHI BLK WHI BLU WHI BLU L O A D L I N E WHI WHI BLK K1 120V MODELS N A B A B A B L1 A B 230V MODELS GRN YEL N L1 GND BRN BLU EMI FILTER 120 VOLTS AC or 230 VOLTS AC 2 WIRE SINGLE PHASE J15 1 J15 4 J12 1 J12 3 WHI BLU BLU TRANSFORMER BLU WHI B...