Bunn AutoPOD Installation guide

BUNN®TECHNICAL TRAINING
AutoPOD™

Index
Unit 1: Installation
Site Requirements .............................................................................................................. 4
Location of the Serial Number .......................................................................................... 4
Water Supply Install ........................................................................................................... 4
AutoPOD™....................................................................................................................4
AutoPOD™ with pump.................................................................................................5
Electrical Install ..................................................................................................................5
Initial Start-Up ..................................................................................................................... 5
Unit 2: Setup
User Interface...................................................................................................................... 7
Switch/Display Board and Decal Button Layout.......................................................7
Operation ......................................................................................................................7
Programming Lockout Switch........................................................................................... 7
Programming Menus.......................................................................................................... 8
Calibrating Flow Rate.........................................................................................................9
Brew Tank ..................................................................................................................... 9
Hot Water Tank ............................................................................................................. 10
Coffee Brewing ...................................................................................................................11
Unit 3: Machine Composition
Exterior Overview ............................................................................................................... 13
Accessing the Inside of the Brewer.................................................................................. 13
Machine Function and Operations.................................................................................... 14
Main Control Board......................................................................................................14
Dispensing System......................................................................................................14
Hot Water Tank....................................................................................................... 14
Brew Tank...............................................................................................................15
Heating System ............................................................................................................ 16
Ejector Assembly ......................................................................................................... 16
Unit 4: Preventive Maintenance
Preventive Maintenance..................................................................................................... 19
PM Steps .............................................................................................................................19
Unit 5: Troubleshooting
Service Tools ......................................................................................................................22
Test Outputs .................................................................................................................23
Index Motor...................................................................................................................23
Water Inlet..................................................................................................................... 23
Warning Messages ............................................................................................................. 24
Error Messages................................................................................................................... 24
Tank Draining...................................................................................................................... 25
Hot Water Tank Removal.................................................................................................... 26
Brew Tank Removal............................................................................................................ 26
Level 3 Programming ......................................................................................................... 27
Triac Map ............................................................................................................................. 28
© 2009 Bunn-O-Matic Corporation. All Rights Reserved
Rev. B

Unit Objectives
Unit 1 installation
Given a realistic scenario depicting a new site install, the learner will be able to install and setup the brewer for
customer turnover without error.
Given a new machine, all the necessary tools and safety equipment, the learner will be able to install
the brewer without error.
The learner will be able to verify that the site requirements have been met.
The learner will be able to locate and document the serial number.
The learner will be able to hook up the water supply to the AutoPOD™ and AutoPOD™ with Pump.
The learner will be able to power up and perform the initial set-up of the brewer.

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Installation
Site Requirements
Space
• AutoPOD™ is only for indoor use on a sturdy counter or shelf
• AutoPOD™ dimensions is 15.8”H x 9.7” W x 15.2” D (40.1cm H x 24.6cm W x 38.6cm D)
• Weight 30 lbs
Water Treatment
• Sedimentltrationtoreducelargeparticles
• Tasteandodorltertoremovechlorine
• Scaleltrationasneeded
• For best results a BUNN®Easy Clear®ltrationsystemshouldbeused
Plumbing
• Elbowadapterttingprovidedtoconvertto¼”malearetting
• Dedicate water supply with shut-off
• Connected to the cold water supply
• Water pressure 20-90psi, set to 50psi if regulator is needed
• Ifabackowpreventerisrequiredbycode,ashockarrestorshouldbeinstalledclosetothema
chinebetweenthebackowpreventerandthemachine
Electrical
• 120VAC, 2 wire plus ground
• Dedicated 15Amp circuit breaker
• Receptacle within 5 feet of machine
Location of the Serial Number
The machine’s serial number is located on the data plate which is located on the lower front panel behind the waste
bin and drip tray. The serial number half tag can be found on the inside of the machine attached to the left side wall.
Removing top lid will give you access to the serial number only tag.
Water Supply Install
Step 1:Checkwaterpressure,installpressureregulatorbeforewaterlterifabove90psiandsetto50psi.
Step 2:Installwaterlterandpurgebeforeinstallation.
Step 3:Securelyattachtheadaptorelbowassemblytothe¼”watersupplylinefromthelter.IfusingAutoPOD™
with pump it will have an elbow adapter
with a pressure regulator assembly. The
machine pressure regulator is factory set
at 10 psi; do not adjust. The purpose is to
accommodate locations with low incoming
oructuatingwaterpressure.
Step 4: Securely attach adapter elbow as-
sembly to the .75-11.5 NH (Hose Thread)
ttingattherearofthebrewerandturnon
the water supply.

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AutoPOD™ with Pump Model
Pressureregulatorwithttingssecuretothe.75-11.5NH(HoseThread)ttingattherearofthebrewerandturnon
the water supply
Electrical Install
Step 1: Plug-in the attached cordset from the brewer into a conventional 120VAC outlet.
Step 2: The brewer LCD (Liquid Crystal Display) will light up and the brewer is ready for the initial setup.
Initial Start-Up
Step 1: Place a large empty cup under the brew chamber.
Step 2: Connect the brewer to the power source.
Step 3:WaterwillowintotheHotWatertankandstopwhenthetankislledtoitscapacity.
Step 4: Open, then close door with switch.
Step 5:PresstheLargeBrewSwitch.WaterwillowintotheBrewtank.Someexcesswaterwillowintothecup.
Step 6: Wait approximately ten minutes for the water in the tank to heat to the proper temperature. Display will show
HEATING until tank reaches it’s operating temperature. Some water will drip from the brew chamber during this time;
this is due to expansion and should not occur there after.
Step 7:Watervolumesandowsettingshavebeenpresetatthefactory.Increaseordecreasethesettingsas
needed.
Step 8: The brewer is now ready for use in accordance with the instructions for coffee brewing.
START-UP MODE
BREW TO FILL TANK
TO LOAD POD
PRESS OPEN
DOOR OPENING
PLEASE WAIT PRESS CLOSE
PLEASE WAIT
DOOR CLOSING
SELECT BREW BREWING
COMPLETE
HEATING

Unit Objectives
Unit 2 setup
Given a realistic scenario depicting a new site install, the learner will be able to install and setup the brewer
for customer turnover without error.
Given an installed machine, all the necessary tools and safety equipment, the learner will be able to
set the machine up for initial operation.
The learner will be able to operate the switch controls.
The learner will be able to enter programming.
  Thelearnerwillbeabletoperformtheowcalibrationofthebrewtankandhotwatertank.
The learner will be able to perform a brew process.

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Setup and Programming
User Interface
The switch decal adheres to the front housing over the electronic switch and LCD (Liquid Crystal Display) board. The
mechanical switches are mounted directly onto the electronic board with a button mounted on the stem for product
actuation. The switch decal is nothing more than a overlay with description of the buttons. The user interface allows
the user to program the brewer for product recipes and begin the brew process with the selection of large or small
cup. The AutoPOD™ brewer also gives the user the option of a Hot Water dispense.
Switch Operation “Programming”
Switch Operation “Operating Controls”
Programming Lockout Switch
The programming lockout switch is located on the main control
board. This switch can be set to prevent access to the program-
ming settings of the brewer. Once all the correct brew settings are
programmed, the operator can set the switch to the “On” position to
prohibit anyone from changing the settings. With the switch in the
“On” position, the programming menus can still be accessed to view
the current settings. However, no changes will be saved.
To access the lockout switch:
Step 1: Disconnect brewer from power source before removing any
panel.
Step 2: Remove the rear panel by removing six standard screws.
Hot Water
“Yes” or (+)
Hidden Switch
Step forward through
screens
Small Brew (B)
Step backwards
through screens
Large Brew (A)
“Done”
Open/Close
“No” or (-)
Hot Water
Push and hold to
dispense hot water
only (Max 10 oz.)
Small Brew (B)
Preset but can be
adjusted
Large Brew (A)
Preset but can be
adjusted
Open/Close
Used to open and
close the pod
holder door

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Programming Menus
Brew Lockout
Prevents brewing if the water temperature is less than the “SET READY” temperature.
Brew Type (A/B) (Tea/Coffee)
Tea setting provides half the “purge” pressure as coffee at the end of brew cycle.
Brew Oz (A/B) (1-16 oz.)
Adjust brew volume.
Brew Meter (A/B) (1-5)
    Simpliedpulsebrewadjustment.1=Preinfusion,2-5=Pulsebrew.2beingtheshortest
pulse brew cycle and 5 being the longest.
Enter Service #
Program service phone number to be displayed anytime there is a fault message.
Enter Password
User must enter a 3 digit password to access remainder of adjustments. If no number
has been pre-programmed (000), then access is allowed.
Set Password (001-999)
Program any 3 digit number as a password.
Set Language
Chose between English and Spanish.
Units
Chose between English (Oz, ºF) or Metric (Ml, ºC).
Set Temp
Adjust tank temperature 185º F to 200º F (85º C to 96º C).
Set Ready
Sets the minimum temperature allowable to start a brew cycle. If BREW LOCKOUT is en
abled. Range: (2º F to 20º F) or (2º C to 10º C) below the set temperature.
Hot H2O Lockout
Prevents a hot water dispense if water is not up to the H2O Ready temperature, if
enabled.
Hot H2O Temp
Adjust tank temperature 185º F to 200º F (85º C to 96º C).
H2O Ready
Sets the minimum temperature allowable to start a hot water dispense.
BREW TYPE A
TEA COFFEEDONE
BREW OZ A: 8.0
(-) (+)DONE
BREW METER A: 3
- +
ENTER SERVICE #?
NO YES
ENTER PASSWORD
0 00
SET PASSWORD
0 00
SET LANGUAGE ?
NO YES
UNITS
METRIC ENGDONE
SET TEMP: 200
O
(-) (+)DONE
SET READY: 195
O
(-) (+)DONE
HOT H2O LOCKOUT ?
NO YESDONE
HOT H2O TEMP: 200
O
(-) (+)DONE
H2O READY: 195
O
(-) (+)DONE
BREW LOCKOUT ?
NO YESDONE

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ENTER ASSET # ?
NO YES
Enter Asset #
Allows you to enter in an optional 4 digit number. This can be useful for tracking the us
age of an individual machine within a group.
Set Pulse Brew (A/B)
Individually adjust on/off times. This will override BREW METER.
Air Time (A/B)
Time the brew tank is purged at the end of each brew cycle.
DRIP TIME (A/B)
Time between brew cycle and pod ejection.
Brews To Empty
Sets number of used pods need in bin to display “Empty Bin” message.
Enable Energy Saver
Choose to have the tank heaters turn off, or reduce the tank temp to 140º F, (60º C) once
the Set Idle Time has expired.
Air Pump Power (1-4)
Adjust air pressure for end of brew cycle purge. Due to pod variations, reduce as needed
if splattering occurs. Range is 1 to 4 with 1 being the weakest and 4 being the strongest.
Brew Count
Retains the total number of brew cycles completed, not resettable.
Brew Count
Retains the total number of brew cycles completed, resettable.
Calibrate Flow
    Allowsyoutoentertheactualowrateofthesprayheadbydispensingforoneminute.
The volume is then entered in ounces per minute.
Calibrate Maximum H2O Time
    Allowsyoutoentertheouncescollectedinowtestandcalibratesthetimeittakesto
deliver a 10 ounce H2O dispense.
Number of Ejects
Option of setting how many times is attempted to eject product before the next brew
cycle.
Seal Replaced
A preventive maintenance menu that is used to reset the factory setting of number of
brews back to 4500 brews for next PM countdown.
Service Tools
Allows testing of load components and switches. It should be only used by trained tech
nicians.
Factory Defaults
Resets all brew settings, calibrations back to factory presets.
SetPulseBrew A/B
NO YES
DONE
AIR TIME A/B: 15.0
(-) (+)
DONE
BREWS TO EMPTY
(-) (+)
25
EnablEnergySavr
NO YES
DONE
AIR PUMP POWER 4
(-) (+)
DONE
BREW COUNT ##
NO YES
BREW COUNT ##
RESET NEXT
CALIBRATE FLOW ?
NO YES
CalibrateMaximum
NO YES
H2O Time?
NUMBER OF EJECTS
SINGLE DOUBLE
SEAL REPLACED ?
NO YES
SERVICE TOOLS ?
NO YES
FACTORY DEFAULTS
NO YES
DRIP TIME A/B: 15
(-) (+)
DONE

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10
Calibrating Brew Flow Rate
Afterinitialstart-up,theowrateforthebrewtankmustbecalibrated.
Step 1: Enter the program mode and scroll to the CALIBRATE FLOW menu and select YES.
Step 2: Menu screens will scroll displaying a message, !!!CAUTION!!! CONTAINER MUST HOLD 10 OUNCES.
Press large or small button to begin calibrating process.
Step 3:ThemachinewilldisplayFLOWCOUNTSanda“defaultowcountnumber657”andwillstartdeliveringhot
wateroutthebrewoutlet.Theowcountnumberwillcountdowntozeroandthewaterwillstop.Themachinewill
display a message PLEASE WAIT until the next menu in step 4 is displayed.
Step 4: Enter the amount of ounces captured in your graduated measuring container into the menu screen utilizing
the -/+ buttons and press the center button under DONE.
Step 5:Theouncesenteredinstep4arebeingcalibratedtotheowcountnumberpreciselytotheamountofwater
whichwasdeliveredduringthecalibrateowtest.Theowcountnumberwillchangeandwillbesetasthenewcali-
brationowratenumberintothecontrolboardassembly.
Note:ReloadingFACTORYDEFAULTSwillerasethecalibratedownumberandgobacktothefactorydefault
number.
Calibrating Maximum H2O Time (Hot Water)
After initial start-up, the maximum H2O time must be calibrated for the H2O tank.
Step 1: Enter the program mode and scroll to the, CALIBRATE MAXIMUM H2O TIME ?, menu and select YES.
Step 2: Menu screens will scroll displaying a message !!!CAUTION!!!, “CONTAINER MUST HOLD 10 OUNCES and
PRESS HOT WATER TO START.
Step 3: Depress the Hot Water button one time and the brewer will start a timed hot water dispense. During this short
time the display will scroll the, CAUTION HOT WATER, message and stop displaying the message when the dis-
penseisnished.Thescreenwillnowsay,ENTEROZ10.0.EnterthecapturedouncesanddepressDONEbutton.
!!!CAUTION!!! CONTAINER MUST
HOLD 10 OUNCES
PRESS
BREW TO START
FLOW COUNTS FLOW COUNTS
0
657
PLEASE WAIT
ENTER OZ : 10.0
(-) (+)DONE
FLOW COUNTS/10 OZ.
643
CalibrateMaximum
NO YES
H2O Time?
!!!CAUTION!!! CONTAINER MUST
HOLD 10 OUNCES
PRESS HOT
WATER TO START
ENTER OZ : 10.0
(-) (+)DONE
CALIBRATE FLOW ?
NO YES

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Step 4: After entering the ounces collected, the machine changed the default time to the actual calibrated dispense
time to deliver 10 ounces of water. The display will revert back to the original menu, CALIBRATE MAXIMUM H2O
TIME?, to repeat test if needed.
Coffee Brewing Process
Step 1: Home screen will display a total of three messages.
Step 2: Place cup under brew chamber onto booster tray or drip tray. The booster tray will allow up to 5 inch cup
clearance or bottom drip tray up to 8 inch cup clearance.
Step 3:PresstheOpen/Closeswitchtoopenthepoddoorandpressacoffeepodrmlydownintothepodholder.
Menu screens will prompt you through the process. The pod holder will accommodate a variety of pods and different
sizes from 50 to 61mm diameter.
Step 4: Press the Open/Door switch to close the pod door. Menu screens will prompt you through closing the door
and selecting brew size.
Step 5: After selecting brew, the menu screens will scroll brewing messages during the brew process and inform you
when brewing is complete. The system will automatically dispense the pod into the pod bin, reset back to standby
position and be ready for next brew command.
AutoPod Brewer Place Cup
To Begin
Press Open
To Load PodReady To Brew
PLEASE WAIT
DOOR OPENING
PRESS POD
IN DRAWER
PLEASE WAIT
DOOR CLOSING
SELECT BREW
PLEASE WAIT
PRE-INFUSION
BREWING BREWING
COMPLETEPLEASE WAIT
ENJOY
YOUR BEVERAGE

Unit Objectives
Unit 3 Machine coMposition
Given a realistic scenario in which the learner has access to the machine’s internal components the learner
will understand the composition and functions of the brewer.
Given a realistic scenario requiring the learner to access the internal components of the machine the
learner will be able to remove the front panel and top cover.
The learner will disconnect the electrical and water supply.
The learner will remove the front panel and top cover.
Given an operating machine the learner will be able to give a general explanation of how the unit
operates.
The learner will be able to identify the functions of the main control board and identify the
components that correspond to each triac.
The learner will be able to identify the components and functions of the hot water tank dispensing
system.
The learner will be able to identify the components and functions of the brew tank dispensing
system.
The learner will be able to identify the components and functions of the heating system.
The learner will be able to identify the components and functions of the ejector assembly.

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Machine Composition
Exterior Overview
Product Outlets and Removable Parts
• Pod Door
• Drip Tray and Grate
• Booster Tray and Grate
• Pod Bin
• Top Cover
• Rear Panel
• Main Housing
• Switch Decal
Accessing the Inside of the Brewer
The majority of service work done to the AutoPOD™ brewer will require the service technician to access the inside of
the unit. The brewer has three removable panels to facilitate access- the main housing, top cover and rear panel.
Depending on the repair the technician may have to remove one or all of these panels.
In order to work safely the power should be disconnected prior to removal of any body panel. Once the panels are
removed the power can be reconnected in order to troubleshoot the machine.
Remove Panels
Step 1: Disconnect unit from power.
Step 2: Use a standard screwdriver and remove the two screws from the top cover of the unit. Lift the top cover up
and away from the unit.
Step 3: Move the rear of the unit and remove the six standard screws securing the back panel. Pull the panel back
and away from the unit.
Step 4: Return to the front of the unit and pull the pod bin out and set aside.
Step 5: Locate the three standard screws found on the bottom edge of the unit below the user interface.
Step 6: Turn the unit so that the right side is facing you. Tilt the unit upward to access the underside and remove the
right side standard screw.
Step 7: Turn the unit so that the left side is facing you. Tilt the unit upward to access the underside and remove the
left side standard screw.
Step 8: Turn the unit so that the front is facing you and then slide the main housing out away from the unit frame.

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Machine Function and Operations
Main Control Board
The main control is the brain of the brewer. The control board
is the single component that contains all of the programming
software, it interprets all the data it receives from the level and
temperaturesensorsandactivatescomponentstofulllthose
demands. The main control board responds to the users input
through the switch/display board and activates and controls the
brew and pod eject process and hot water dispense.
J1 ReedSwitchandH2ORellProbe
J2 Brew Tank Thermistor
J3 Heater Relay Coil and Air Vent Coil
J4 Index Sensor and Pressure Switch
J5 xxxxx
J6 Switch/Display Board
J7 Flow Meter
J8 Index Motor & Air Pump Brew Tank
J9 BR- Brew Inlet Valve Coil
HW – Hot Water Valve Coil
BST Pmp – Brew pump
J11 Hot Water Tank Thermistor
J12 Air Pump Hot Water Tank (H2O)
CBA Bracket Removal
The CBA bracket is mounted to the frame by 3 standard screws.
2 screws located bottom underside and 1 screw located above
the white harness clamp behind the wires. You will need to dis-
connecttheowmeter3-pinconnectorfromtheCBAtofacilitate
removal of CBA with bracket. After removing the CBA bracket
assembly, you will have access to reed switch, brew air pump,
pressureswitchandowmeter.
Dispensing System
The AutoPOD™ has two different dispense systems, one for hot
water dispense and the other for a dispense during brewing.
Hot Water Dispense
The hot water dispense system consists of:
• 20 ounce hot water tank with element
• Inletvalve(.175owcontrol)
• Air pump
• Vent valve
• Stainless outlet tube
• Rellprobe
Thehotwatertankismaintainedbyarellcircuit.Thehotwaterbuttononthefrontisusedasamomentarybutton
for hot water delivery. The maximum amount of ounces delivered in a single dispense is 10 ounces. The delivery of
the hot water is a different process than gravity style or line pressure style faucets. The new process is by pressuriz-
ingthehotwatertankbytheuseofanairpumpandventvalve,forcinghotwateroutwithinacalibratedowtime.
SW1
PRGM
LOCK
SET
ON
J3 J1
J11
J4
J7
J12
J8
J2
J6
4 3
2 1
J5
1
2
3
4
5
1
2
3
1 2 3 4 6 5 4 3 2 1 2 1
2 1
1
2
1
3
2
4
BR
SOL
HW
SOL
BST
PMP

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Waterenterstheinletvalveandisregulatedbya.175owcontrolandentersthebottomofthehotwatertank.The
tankwillllwithwatertorellprobelevelandwillheattotheadjustedtemperature,whichcanbesetinprogramming.
When a user press and holds the momentary hot water button, the air pump will turn on for calibrated period of time
to pressurize the tank while the vent valve closes to deliver a 10 ounce portion of hot water.
Brew Tank Dispense
The brew tank dispense system consists of:
• Inletvalve(.175owcontrol)
• Optional booster pump (set at 10psi)
• Flow meter
• Pressure switch
• Air pump
• Brew tank
• Sprayhead assembly
Thebrewtankisinitiallylleduponstartupandmonitoredbyowcountsfromtheowmeter.Oncethetankhas
metitsowcountnumberthemachinewillbeginheatingthebrewtank.Atthispoint,theincomingbrewwaterwill
displace the 200º F water in the brew tank which will maintain a level of water in the tank when commanded by the
portion buttons. The large and small buttons are adjustable by volume and recipe (coffee or tea) in the programming
menus.Thevolumeorportiondispensesizeiscalculatedfromowdefaultmetercounts.Thisiswhyitsimportant
tocalibratethebrewowuponplacementofthemachinetotheactualamountofbrewwaterdeliveredduringthe
calibrateowtest.TheBUNN®defaultdispensevalueis10ouncesduringthiscalibrationtest.Oncetheactualow
amountisenteredinprogramming,themachinewillautomaticallyadjusttheowcountnumbertoachievea10
ounce dispense.
Duringadispensewaterenterstheinletvalveandisregulatedby.175owcontrolandentersaboosterpump,
(NotallAutoPOD™unitshaveaboosterpump;productnumberspecic),whichiscapableof50psi.Thepumpis
intendedforlowwaterpressureapplications.Withsomeheavier/nergrindpodsthatrequiremorepressuretobrew,
if the pressure gets below 25-30psi they will brew slower. The pump will boost the incoming water pressure to a high
enough level to brew normally. These pumps can create 50+psi, but the pod will determine the actual brewing pres-
sure.
After the booster pump, water en-
terstheinletoftheowmeterand
pushes the paddle wheel and exits
outtheowmeterandconnectsto
thefourwayplumbingttingand
continuesontothebottomttingof
the brew tank. A pressure switch
connects directly opposite of the
waterinletonthe4waytting.The
pressure switch is calibrated to ap-
proximately 40psi. The purpose is
to monitor the pressure during the
coffee brewing process. If pres-
sure should exceed the 40psi in the
brew head assembly, the machine
will abort the brew and display an
error code. After every brew cycle,
the machine will go through a
sequence of running the air pump
longer to empty the sprayhead tube
of any brew water and stop. The
machine will now be ready for the
next brew.

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Heating System
Each heating element is part of the tank and is rated between
1300-1450 watts at 120VAC. The element wires are soldered onto
the heating element terminal and when replacing the element you
will need to replace the entire tank assembly. The heating element
wires will already be attached to the replacement assembly. The
tank element wires will disconnect from the relay contact and termi-
nal on the CBA.
The heating circuit has a relay mounted above the main control
board and is used primarily to switch between the tank assem-
blies for the heating process. The brew tank is the priority tank for
achievingtemperaturerstandthentheCBAwillactivatetherelay
and switch the connection to the hot water tank to achieve its set
temperature. The relay prevents the two tanks from heating at
the same time.
Additionally, the power lead going to the heater relay contact
from the CBA is being switched between the two tanks and can
be pulsed at times and be full on when needed. The purpose of
the triac (heating) on the CBA is to maintain temperature of the
brew tank without the use of blanket warmers and to eliminate
the arc on the relay contacts when the circuit is switched be-
tween the two tanks.
The CBA monitors the two tank thermistors resistance/voltage
and will pulse or turn on the output to the heater relay contact.
Meanwhile, the CBA may activate the heater relay to switch the
circuit to heat the water in the hot water tank (H2O).
Ejector Assembly
Ejector assembly consists of:
• Housing
• Brew head assembly
• Pod holder assembly with linkage
• Pod screen assembly
• Index motor with position disc
• Index sensor
The Ejector assembly is a critical component used to align
the pod holder in different placement positions. The place-
ment positions are: load, brew, eject and set back posi-
tions. The index motor rotates the position disc and pod
holder forward and backward at different intervals. The position disc has slots cut in the metal and rotates between
the index sensor. The index sensor monitors the slots and stops the index motor at the correct placement position for
thepodholderduringtheentirebrewprocessfromstarttonish.
Pod Holder Position during Brew Cycle
Step 1: Depress the open/close button and pod holder rotates outward
to coffee pod load position.
Step 2: Depress the open/close button and the pod holder rotates back
in and stops in the brew position (under sprayhead assembly).
Step 3: After brewing is complete, the pod holder rotates further back
and down to coffee pod eject position. The coffee pod eject has an
option of making a single or double attempt of ejecting the pod in the
programming menu.

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Step 4: After ejecting the coffee pod, the pod holder rotates forward by a set time built in the software (approx. 5 sec-
onds) and stops at the set back position from the sprayhead assembly and is ready for the next brew command.
Ejector Assembly Removal
The Ejector assembly will be replaced as an entire service replacement part if the index motor will not work and
needs to be replaced. The assembly has too many critical adjustments (timing) when replacing the index motor for
correct operation of the brew and pod eject process. The following steps will not take longer than 30 minutes to
change out an Ejector assembly.
Step 1: Disconnect power to the brewer.
Step 2: Remove top cover (2 screws) and rear cover (6 screws).
Step 3: Disconnect the black 4 pin wire connector on the Switch/Display board.
Step 4: Disconnect the 2 pin wire connector going to the index motor.
Step 5: Disconnect the 3 pin wire connector at the index motor sensor.
Step 6:Removethesnapclamp(SNP6)andbraidedhosefromthesprayheadassemblyttinglabeled“W”.
Step 7: Remove the silicone air vent hose from the rear hole of the Ejector assembly.
Step 8: Remove the silicone hot water supply hose routed up by the Switch/Display board which enters the access
holeonthesideoftheEjectorpanel.Pullhosefromtting.
Step 9: Remove the main wrapper housing by 3 screws located underside of the Display or Pod door, 2 screws on
the underside center base bottom.
Step 10: Grab the left and right side of the housing at the rear and spread apart and pull away from main trunk
frame.
Step 11: The Ejector assembly is now ready to be removed. The Ejector is attached to the main trunk frame by 1
standard screw located on each outer side of the tanks. You will need to grab the upper sprayhead assembly while
removing the screws keeping the Ejector from falling free.

Unit Objectives
Unit 4 preventive Maintenance
Given a realistic scenario depicting a machine requiring a preventive maintenance, the learner will be able to
identify which elements of a component need to be serviced without error.
Given a machine, all the necessary tools and safety equipment, the learner will be able to identify the
components that need to be serviced for the PM.

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Preventive Maintenance
In order to maintain proper operation and long service life BUNN®recommends performing the preventive mainte-
nance every 6 months. Individual customers will vary with some customers choosing not to receive preventive main-
tenance. Some of the PM items may require more frequent maintenance depending on the site conditions.
Tools Required:
• 2 standard screwdrivers (1 small tip & 1 medium tip)
• Needle nose pliers
• Pliers
• 2, 8 inch crescent wrench
• Graduated measuring cup
• Tube Brush (.25 0D), BUNN P/N: 26367.0000
PM Parts:
• Sprayhead Seal, BUNN PN: 42310.0000
• Waterlterorcartridge
• Rellprobegrommet,BUNNPN:33201.0000
• Pod Screen Assembly BUNN PN: 40806.1000
Prior to servicing the brewer:
• Depress open/close door switch to open door before disconnecting from power.
• Disconnect the water and electrical supply.
• Assess placement of brewer to perform PM process.
• Allow brewer tanks time to cool down.
• Remove top cover and rear panel.
PM Steps
If customer has a BUNN®waterltrationsysteminstalledbeforethebrewer,replacethelterorltercartridgeand
purge before installing to the brewer.
Note: PM Steps 1 and 2 will require the machine to be plugged in to access the “Test Outputs” screen in program-
ming.
Step 1: Cleaning sprayhead and replacing seal
□Press and hold the hidden programming button (under “BUNN”) until display reads “Brew Lockout”
□Press and release the “Small” brew button until display reads “Service Tools”. Select “Yes”
□Display should read “Test Outputs?” Select “Yes”. Display should now read “Index B Motor”. Press and hold
“Load” (Hot Water) button until pod holder pushes the door open.
□Unscrew sprayhead counterclockwise
□Remove sprayhead and seal
□Check and clean sprayhead. The sprayhead holes must always
remain open. Clean all the holes in the plastic sprayhead to remove
any mineral deposits or coffee oil build up
□Install new sprayhead seal (BUNN P/N: 42310.0000) onto clean
sprayhead
□Re-install sprayhead with gasket. Make sure seal is installed with the ridge facing up
□Remove and clean pod screen assembly of coffee oil build up. Replace pod screen if missing (BUNN P/N:
40806.1000)
Step 2: Clean the stream guide bowl
□Use a screwdriver or similar object to hold door open.
□Press and hold “Dump” (Open/Close) button until pod holder moves back
and just clears the stream guide bowl.
□Disconnect brewer from power supply.
□Remove drip tray and pod bin by pulling straight towards you
□Remove stream guide bowl cap by prying up on seam

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□Insert 26367.0000 cleaning brush from the underside into the coffee outlet hole (rear) and work back and forth
□Use clean wash cloth and wipe out the lower stream guide bowl and the cap removed earlier
□Reinstall bowl cap by aligning the tab and notch and snapping back into position
Step 3: Clean drip tray and pod bin removed earlier
□Separate the parts and wash with mild nonabrasive liquid detergent
□Reassemble components and install when PM is complete
Step4:Removeinletvalveconnectorttingandcleaninletvalvestrainer
□ Usingyourhandandunscrewthevalveadapterttingandsetaside
□Using the needle nose pliers gently grab the strainer tab and pull the strainer out of
the valve
□Clean and rinse strainer of any sediment or mineral build-up
□Reinstallation is the opposite of removal
Step5:Removeandcleanrellprobe
□ Removerellprobewiththepinkwireattachedbygentlypryingupwardwithastan
 dardbladescrewdriverorbytheuseofpliersandpulltightlyttedprobeoutofgrom
met
□ Cleantherellprobeofanymineralbuildup.Useofadelimingsolutionisrecom
mended
□ Installcleanrellprobewithpinkwirebackintogrommet.Warning–Donotpush
 grommetintotank!Wettherellprobeandgentlyrotatebackandforthwhilepushing
the probe downward until it stops
Step 6: Remove and clean thermistor in each tank
□Disconnect the thermistor 2 pin connector from the CBA labeled “Hot Water”
□Disconnect the thermistor 2 pin connector from the CBA labeled “Brew Tank”
□Remove bottom snap clamp from each of the braided tube with the thermistor and remove braided tube with the
thermistor from each tank
□Clean both thermistors of any mineral build up. Use of a deliming solution is recommended. Do Not Immerse the
Wires!
□Reinstall clean thermistors
□Re-connect the thermistor 2 pin connectors back onto the CBA in their appropriate labeled connectors
Step7:CalibratetheowfortheBrewtank
□Install top cover and rear cover
□ Reinstallwaterandconnectortting
□Reinstall power
□Reinstall pod bin & drip tray
□Access programming and go to CALIBRATE FLOW ? menu
□Depress YES button
□Place graduated measuring cup (minimum 10 ounces) under coffee outlet
□Follow the instruction on the display
□ Afterdispensenishes,readnumberofouncesandenterthatamountintobrewerusingthe+/-switches,then
press DONE to set the volume into memory