OL & RL (S/N RL00006929 & up) INSTALLATION & OPERATING GUIDE 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.
BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows: 1) Airpots, thermal carafes, decanters, GPR servers, iced tea/coffee dispensers, MCP/MCA pod brewers thermal servers and Thermofresh servers (mechanical and digital)- 1 year parts and 1 year labor. 2) All other equipment - 2 years parts and 1 year labor plus added warranties as specified below: a) Electronic circuit and/or control boards - parts and labor for 3 years.
CONTENTS INTRODUCTION Introduction.................................................................2 User Notices................................................................3 Electrical Requirements...............................................4 Plumbing Requirements..............................................4 Initial Set-Up................................................................5 Operating Controls.......................................................6 Coffee Brewing.....................
ELECTRICAL REQUIREMENTS CAUTION - Do not connect the brewer to the power source until specified in Initial Set-Up. L2 RED L1 BLACK MODELS OL15 & 20 require 2-wire, grounded service rated 120 volts ac, 15 or 20 amp respectively, single phase, 60 Hz. 200, 230 or 240V A.C. MODELS OLA, RLA, OL35B & RL35B require 2-wire, grounded service rated 240 volts ac or 200 volts ac, 20 amp single phase, 50 Hz.
PLUMBING REQUIREMENTS This brewer must be connected to a cold water system with operating pressure between 20 and 90 psi 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 to reduce it to 50 psi. The water inlet fitting is 1/4” flare. NOTE - Bunn-O-Matic recommends 1/4” copper tubing for installations of less than 25 feet and 3/8” for more than 25 feet from the 1/2” water supply line.
INITIAL SETUP CAUTION - The brewer must be disconnected from the power source throughout the initial setup, except when specified in the instructions. 1. 2. 3. 4. 5. Remove the top panel. Rotate the control thermostat knob fully counterclockwise to the “OFF” position and replace the panel. Insert an empty funnel into the funnel rails. Place a decanter containing a small amount of water on the warmer beneath the funnel.
OPERATING CONTROLS A. On/Off Brew Station Warmer Switch Placing the switch in the upper position supplies power to the brew station warmer and enables brewing. Placing the switch in the lower position cuts power to the brew station warmer and stops brewing. Stopping a brew cycle after it has been started will not stop the flow of water into the funnel until the tank syphons down to its proper level.
COFFEE BREWING Start each brew cycle with an empty, clean, half-gallon decanter. 1. 2. 3. 4. 5. 6. Insert a BUNN® filter into the funnel. Pour the fresh coffee into the filter and level the bed of grounds by gently shaking. Slide the funnel into the funnel rails. Place the On/Off brew station warmer switch in the upper position. Momentarily press the start switch. When brewing is completed, simply discard the grounds and filter. CLEANING 1.
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 personnel. • All electric components have 120 volt ac voltage on their terminals.
TROUBLESHOOTING (cont.) Remedy Problem Probable Cause Brew cycle will not start. (cont.) 4. On/Off Brew Station Warmer Refer to Service - On/Off Brew Station Warmer Switch for testing Switch procedures. See page 15. 5. Start Switch Refer to Service - Start Switch for testing procedures. See page 17. 6. Relay Refer to Service - Relay for testing procedures. See page 21. 7. Solenoid Valve Refer to Service - Solenoid Valve for testing procedures. See page 20. Water flows into fill basin continu- 1.
TROUBLESHOOTING (cont.) Problem Probable Cause Spitting or unusual steaming from 1. Control Thermostat sprayhead. 2. Lime build-up CAUTION Tank and tank components should be delimed regularly depending on local water conditions. Excessive mineral build-up on stainless steel surfaces can initiate corrosive reactions resulting in serious leaks. Remedy Refer to Service - Control Thermostat for testing procedures. See page 13. Inspect the tank assembly for excessive lime deposits. Delime as required.
TROUBLESHOOTING (cont.) Problem Probable Cause Remedy Beverage overflows decanter. 1. Beverage left in decanter The brew cycle should be started only with an empty decanter under the funnel. Weak beverage. 1. Type of paper filters BUNN® paper filters should be used for proper extraction. 2. Coffee A sufficient quantity of fine or drip grind coffee should be used for proper extraction. 3. Sprayhead B.O.M. sprayhead #01082.0000 should be used to properly wet the bed of ground coffee in the funnel.
SERVICE This section provides procedures for testing and replacing various major components used in this brewer should service become necessary. Refer to Troubleshooting for assistance in determining the cause of any problem. Component Access WARNING - Disconnect the brewer from the power source before the removal of any panel or the replacement of any component. The control thermostat, solenoid valve and relay are located under the top cover or top warmer housing, FIG.
SERVICE (cont.) Control Thermostat 5. source. The indication must be as described in step 2. Voltage must not be indicated across these terminals when the thermostat is turned “OFF” (fully counterclockwise). Disconnect the brewer from the power source. If voltage is present as described, the control thermostat is operating properly. If voltage is not present as described, replace the control thermostat. Removal and Replacement: 1. Remove the top cover or top warmer housing from the brewer to gain access.
SERVICE (cont.) Warmer(s) OL: Brew Station & Upper RL: Left Rear, Left Front, Brew Station, Right Rear & Right 5. Front Check for continuity from the wire terminal of the white or red wire to the splice or indicator lamp using the chart below. If continuity is present as described, proceed to #6. If continuity is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness. 6. Check for continuity across the two terminals on the warmer.
SERVICE (cont.) Warmer Switch(es) OL: On/Off Brew Station & Upper RL: On/Off Brew Station If voltage is present as described, proceed to #4. If voltage is not present as described, refer to the Wiring Diagrams and check the brewer wiring harness. 4. 5. Check the voltage across the other switch terminal and the terminal on the indicator lamp with white or red wires with a voltmeter when the switch is in the upper position. Connect the brewer to the power source.
SERVICE (cont.) 4. Warmer Switch(es) RL: Left Rear, Left Front, Right Rear & Right Front Disconnect the brewer from the power source. If voltage is present as described, the switch is operating properly. If voltage is not present as described, replace the switch. Removal and Replacement: 1. Remove the knob from the switch. 2. Loosen the 5/8” nut on the switch shaft and push the switch through the opening. 3. Remove the wires from the switch terminals. 4. Refer to FIG. 11 when reconnecting the wires. 5.
SERVICE (cont.) If continuity is present as described, reconnect the wires, the switch is operating properly. If continuity is not present as described, replace the switch. Start Switch Removal and Replacement: 1. Remove all wires from the switch terminals. 2. Compress the clips inside the housing and gently push the switch through the opening. 3. Push the new switch into the opening and spread the clips to hold the switch captive in the housing. 4. Refer to FIG. 14 when reconnecting the wires.
SERVICE (cont.) Indicator Lamp(s) 4. Disconnect the brewer from the power source. If voltage is present, the indicator lamp is operating properly. If voltage is not present, replace the indicator lamp. Removal and Replacement: 1. Compress the clips inside the housing and gently push the indicator lamp through the opening. 2. Remove the wires from the indicator lamp terminals. 3. Refer to FIG. 17 when reconnecting the wires. 4. Push the new indicator lamp firmly into the opening. P1712 FIG.
SERVICE (cont.) 4. Limit Thermostat Check for continuity across the limit thermostat terminals. If continuity is present as described, the limit thermostat is operating properly. If continuity is not present as described, replace the limit thermostat. Removal and Replacement: 1. Remove both wires from the limit thermostat terminals. 2. Carefully slide the limit thermostat out from under the retaining clip. 3. Carefully slide the new limit thermostat into the retaining clip. 4. Refer to FIG.
4. SERVICE (cont.) Solenoid Valve 5. Check the solenoid valve for coil action. Connect the brewer to the power source, place the On/Off brew station warmer switch in the upper position, press and release the start switch. Listen carefully in the vicinity of the solenoid valve for a “clicking” sound as the coil magnet attracts and after the approximate setting of the level float switch, repels the plunger. Disconnect the brewer from the power source.
SERVICE (cont.) Relay 5. 6. 7. 8. P1478 FIG. 22 RELAY Location: The relay is located under the top cover or top warmer housing, FIG. 22. Test Procedure: 1. Disconnect the plug terminal from the relay to the main wiring harness. Check the voltage across the pins of the black wire (P3) and white wire (P2) on the main harness with a voltmeter when the On/Off brew station warmer switch is in the upper “ON” position. Connect the brewer to the power source.
SERVICE (cont.) Tank Heater FIG. 23 TANK HEATER P1715 Location: The tank heater is located in the bottom of the tank assembly, FIG. 23. Test Procedure: 1. Check the voltage across the black and white or red wires on the tank heater with a voltmeter when the control thermostat is turned “ON” (fully clockwise). Connect the brewer to the power source. The indication must be: a) 120 volts ac for two wire 120 volt models.
SERVICE (cont.) If continuity is present as described, reconnect the wires as shown in FIG. 30, the switches are operating properly. If continuity is not present as described, replace the failed switch. Water Level and Overflow Safety Switch P1478 FIG. 25 WATER LEVEL and OVERFLOW SAFETY SWITCHES Location: The water level and overflow safety switches are located under the top cover or top warmer housing and inside and front of the tank fill basin, FIG. 25. Test Procedure: 1.
SERVICE (cont.) Master ON/OFF Switch 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. 29. 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. If continuity is present as described, reconnect the wires, the switch is operating properly.
SCHEMATIC WIRING DIAGRAM GREEN OL 35 L1 N BLK RED L2 MAIN ON/OFF SWITCH (Late Models only) BLK SW. & THERMOSTAT LIMIT THERMOSTAT BLK BLU BLK TANK HEATER RED WHI WHI "KEEP WARM" HEATER BLK BLK P3 P2 & P3 ARE PINS OF A POLARIZED THREE-PIN CONNECTOR. WHI BLK WHI P2 WHI UPPER WARMER BLK WHI BLK BLK WHI BREW STATION WARMER BREW SW BLK SOL LEVEL SW PNK PNK BLK P3 BLK BLU P1 BLU WHI P2 WHI K1 N.O.
SCHEMATIC WIRING DIAGRAM OLA L1 SW. & THERMOSTAT LIMIT THERMOSTAT BLK L2 GRN/YEL BLK BLU TANK HEATER RED WHI WHI "KEEP WARM" HEATER BLK BLK P3 WHI BLK WHI P2 RED UPPER WARMER BLK BLK RED BLK RED BREW STATION WARMER BREW SW BLK SOL LEVEL SW PNK PNK BLK P3 BLK BLU P1 BLU WHI P2 WHI K1 K1 N.O. SAFETY SW PNK PNK BLK BLK P3 BLK BLU P1 BLU WHI P2 OPTIONAL LOW WATER PRESSURE VALVE WHI VIO SOL BR.
SCHEMATIC WIRING DIAGRAM OL25B GRN/YEL L1 BLK-12 BLK-12 TANK HEATER N WHI-12 T1 L1 K2 N.O WHI-12 L2 T2 K2 N.O HEATER INDICATOR BLK LIMIT THERMOSTAT SW. & THERMOSTAT BLU BLK WHI K2 BLK WHI BLK BLK WHI BREW STATION WARMER LEVEL SW PNK PNK BLK SOL K1 N.O. BLK P3 BLK BLU P1 BLU WHI P2 WHI K1 BREW SW OVERFLOW PROTECTION SW PNK PNK BLK BLK P3 BLK BLU P1 BLU WHI P2 WHI P1, P2, & P3 ARE PINS OF A POLARIZED THREE-PIN CONNECTOR.
SCHEMATIC WIRING DIAGRAM OL35B L2 RED BLK L1 RED MAIN ON/OFF SWITCH (Late Models only) BLK READY INDICATOR BLK BLU LIMIT THERMOSTAT BLK GREEN SW. & THERMOSTAT BLU BLK TANK HEATER P2 & P3 ARE PINS OF A POLARIZED THREE-PIN CONNECTOR. IND SW BLK WHI BLK P3 WHI BLK P2 BLK BLK RED UPPER WARMER IND SW RED RED BLK RED BREW STATION WARMER BREW SW BLK SOL LEVEL SW SAFETY SW PNK PNK PNK PNK K1 BLK P3 BLK BLU P1 BLU WHI P2 WHI N.O.
GRN N L2 WHI BLK L1 RED SCHEMATIC WIRING DIAGRAM RL MAIN ON/OFF SWITCH (Late Models only) LIMIT THERMOSTAT BLK SW. & THERMOSTAT BLK BLU BLK RED TANK HEATER WHI WHI "KEEP WARM" HEATER BLK BLK WHI BLK WHI BREW STATION WARMER BREW SW LEVEL SW PNK PNK BLK SOL K1 BLK P3 BLK BLU P1 BLU WHI P2 WHI SAFETY SW PNK PNK N.O. K1 BLK BLK P3 BLK BLU P1 BLU WHI P2 WHI P1, P2, & P3 ARE PINS OF A POLARIZED THREE-PIN CONNECTOR. OPTIONAL LOW WATER PRESSURE VALVE WHI VIO BR.
SCHEMATIC WIRING DIAGRAM RLA L1 L2 GRN/YEL BLK SW. & THERMOSTAT LIMIT THERMOSTAT BLU BLK TANK HEATER RED "KEEP WARM" HEATER WHI BLK BLK BLK BLK SOL WHI INDICATOR PNK RED RED BREW STATION WARMER LEVEL SW SAFETY SW PNK PNK BLK P3 BLK P1 BLU BLK P3 BLK K1 N.O. BLU BLU P1 BLU WHI P2 WHI P2 WHI K1 PNK BREW SWITCH BLK RED OPTIONAL LOW WATER PRESSURE VALVE WHI VIO BR. RECT BLK P1, P2, & P3 ARE PINS OF A POLARIZED THREE-PIN CONNECTOR.
SCHEMATIC WIRING DIAGRAM RL35B L1 READY INDICATOR BLK BLU SW. & THERMOSTAT LIMIT THERMOSTAT BLK BLU TANK HEATER BLK IND BLK RED RED BREW STATION WARMER BLK BLK L2 GREEN RED BREW SW LEVEL SW PNK PNK BLK K1 N.O. BLK P3 BLK BLU P1 BLU WHI P2 WHI SOL K1 SAFETY SW PNK PNK BLK BLK P3 BLK BLU P1 BLU WHI P2 RED P1, P2, & P3 ARE PINS OF A POLARIZED THREE-PIN CONNECTOR. OPTIONAL LOW WATER PRESSURE VALVE WHI BLK VIO SOL BR.