Grindmaster FDD2500-1-3A-B Service Manual Download

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Grindmaster Model FDD2500

Service Manual

for

Model FDD2500

Warning Labels....................................

Installation ..........................................

Programming ......................................

Start-up & Adjustments ......................

Cleaning ..............................................

Shipping Preparation ........................

Replacing Controller ............................11

Replacing Components ........................11

Product Out Adjustment......................11

Troubleshooting Guide ........................12

Assembly Drawings ..............................14

Wiring Diagrams .................................. 28

Table of Contents

Prior authorization must be obtained from Grindmaster
Corporation for all warranty claims.

0905 Form # AM-342-02

PRINTED IN USA

Part #63361

Grindmaster Corporation

4003 Collins Lane

Louisville, KY 40245 USA

(502) 425-4776

(800) 695-4500 (USA & Canada only)

FAX: (502) 425-4664

www.grindmaster.com

Model FDD2500-1-M-B
Model FDD2500-3-M-B
Model FDD2500-1-3A-B
Model FDD2500-3-3A-B

Summary of Contents for FDD2500-1-3A-B

Page 1: ... Guide 12 Assembly Drawings 14 Wiring Diagrams 28 Table of Contents Prior authorization must be obtained from Grindmaster Corporation for all warranty claims Grindmaster Corporation 2005 0905 Form AM 342 02 PRINTED IN USA Part 63361 Grindmaster Corporation 4003 Collins Lane Louisville KY 40245 USA 502 425 4776 800 695 4500 USA Canada only FAX 502 425 4664 www grindmaster com Model FDD2500 1 M B Mo...

Page 2: ...71582 Located on machine cover and spout mounting bracket Part 63370 For FDD2500 M B models only Located on front splash panel Part 63371 Located next to center spout Part 62981 Located on front splash panel Part 63448 Located on tank drain hose ADVERTENCIA Contenidos pueden causar quemadur as severas si el uso es inadecuado AVERTISSEMENT Contenu peut pr ovoquer des brûlures grâves si il est manip...

Page 3: ... allow for plumbing to a drain 2 Remove front splash panel for access to water hook up see Figure 1 3 Ensure the 3 8 water supply hose has sufficient length to allow the machine to be moved for cleaning or service Supplying hot water to the machine will greatly increase the capacity of the machine The use of copper tubing is required to prevent rupture when using a hot water supply A maximum inlet...

Page 4: ...essary 120 volt power supply for the control circuits Neutral will not be used 6 Remove lid and left side panel see Figure 3 7 Install the front splash panel 8 Install the plastic drain tray into the drain tray rails then place drain grid onto drain tray 9 Flip power supply to machine ON at the branch supply disconnect 10 Flip power switch to the ON position and allow the water tank to fill The ma...

Page 5: ...able password and OFF disable password If ON is selected press to change password a Press to enter new password following steps 3 a b c b Press to confirm new password following steps 3 a b c 5 Press to program Dispense Settings to change Portion Sizes 2E For FDD2500 3A models only a Press for message Select Dispense Button 5A b Press the dispense button for the dispense head you wish to adjust th...

Page 6: ...before going into sleep mode c Press to change sleep mode water tank temperature setting d Press or to increase or decrease the water tank temperature during sleep mode 15 Press to view Manual Dispense mode 9A Models with manual Free Flow Tomlinson handles cannot be changed to portion control 16 Press for Sales Mode 14A This option for future use Free is currently the default setting 17 Press to r...

Page 7: ...eplace hopper lid 6 Lower hinged top 7 Close door THERMOSTAT ADJUSTMENT See machine programming procedure Water tank temperature Tools required None NOTE The thermostat range is approximately 40 F to 205 F 4 C to 96 C The water tank temperature is factory set at 190 F 87 C making the beverage temperature slightly lower than 190 F 87 C HOW TO DISPENSE A DRINK Machine is equipped to dispense into cu...

Page 8: ...ll void the warranty Empty drip pan as needed and wash daily in a dish detergent Wipe down all surfaces of the dispense spouts product storage cabinet splash panel and drip tray areas with a clean soft cloth using a mixture of one ounce Ivory liquid detergent or equivalent to one gallon of fresh water Follow by wiping down all surfaces of the dispense spouts product storage cabinet splash panel an...

Page 9: ...reads should be accessible 6 Remove the auger pinwheel by pulling it forward while stretching out the sides of the hopper 5 Place the washer over the driveshaft bearing threads followed by securing the drivelink onto the driveshaft bearing by turning counterclockwise Secure the auger spring with one hand while attaching the drivelink with the other 7 Remove the drivelink and washer at the rear of ...

Page 10: ...tainer to drain 7 5 gallons 28 4L of hot water from the tank into 5 Pinch hose with fingers and remove the hose clamp and plug 2 Disconnect power to machine 6 Allow the tank to drain completely NOTE It may be necessary to pinch the hose and stop the water before container is full Carefully re install plug then empty container Repeat steps 4 6 to completely drain tank 3 Remove the drain tray and fr...

Page 11: ... Slowly move sensor away from the full half of the hopper Indicator light should turn OFF 1 16 from hopper see Figure 7 If needed adjust sensor with micro screwdriver by gently turning adjustment screw see Figure 8 6 Hold sensor bulls eye side flat against the empty half of the hopper see Figure 6 Indicator light should be OFF If indicator light is ON adjust sensor with micro screwdriver until lig...

Page 12: ...nk overflow condition has occurred 3 A water tank heating condition has exceeded the water tank temperature set point due to Welded contacts on heater contactor For 1 3 turn power switch OFF for 5 seconds then ON Call Technical Service for assistance SC3 Low Water Level Machine is filling the water tank Faulty water inlet valve electrical connections Faulty water inlet valve Insufficient water flo...

Page 13: ...h drive motor Check product container for product Check Drink Strength setting see programming guide for setting Drink Strength Water overflows mixing funnel Powder flow rate too fast too much powder to water ratio can prevent adequate mixing resulting in blockage in mixing funnel Outlet is restricted Adjust powder flow rate to prevent blockage in mixing funnel Ensure mixing chamber outlets are fr...

Page 14: ... 61123 FDD Right Hose 1 1 4 ID 24 17 62271 FDD Md Re Tube Silicone 1 2 x 3 4 X 8 75 18 62271 FDD Rt Re Tube Silicone 1 2 x 3 4 X 6 19 62271 FDD Lt Re Tube Silicone 1 2 x 3 4 X 8 75 ITEM NO PART NO DESCRIPTION 20 63098 Logo Grindmaster PIC5 6 21 63446 Decal Kraft Service 22 63358 Pad Top Foam FDD2500 23 63359 Pad Bottom Foam FDD2500 24 63357 Carton FDD2500 25 63357A CARTON BOTTOM FDD2500 26 63360 M...

Page 15: ...racket Hinge Top FDD2500 6 63206 Bracket Hinge Bottom FDD2500 7 63207 Bracket Upper Brace FDD2500 8 63208 Bracket Tank Cradle FDD2500 9 60380 RIVNUT 3 8 16 10 63210 Panel Base Pan FDD2500 11 63119 Rail Drain Tray PIC5 6 12 71256 Leg 4 Plastic 13 62269 Fitting 1 2 Barb SS 14 07920 Connector 3 4 Conduit Metal Romex 15 61303 Screw 8 x 3 8 black trilobe 16 61236 SCRW 10 32X1 2 PH TR SS 17 61186 Washer...

Page 16: ...lay Cover FDD2500 12 62219 Spacer Key Lock 13 100115 Latch Thumb 14 62556 Cam Straight Hook 0 883 15 63289 Sight Gage Assy FDD2500 16 63287 Decal Shuttles FDD2500 17 63292 Decal Upper Door FDD2500 18 63288 Decal Brew Basket FDD2500 19 63298 Screw 1 4 20 x 1 2 SS Ph Hd ITEM NO PART NO DESCRIPTION 20 63384 Screw 1 4 20 x 1 SS Ph Hd 21 61303 Screw 8 x 3 8 black trilobe 22 63296 Harness Display Switch...

Page 17: ... 10 63258 Cover Display Plastic FDD2500 11 63286 Decal Display Cover FDD2500 12 62219 Spacer Key Lock 13 100115 Latch Thumb 14 62556 Cam Straight Hook 0 883 15 63289 Sight Gage Assy FDD2500 16 63287 Decal Shuttles FDD2500 17 63292 Decal Upper Door FDD2500 18 63288 Decal Brew Basket FDD2500 ITEM NO PART NO DESCRIPTION 19 63298 Screw 1 4 20 x 1 2 SS Ph Hd 20 63384 Screw 1 4 20 x 1 SS Ph Hd 21 61303 ...

Page 18: ...6 5 ITEM NO PART NO DESCRIPTION 1 63239 Panel Lid FDD2500 2 63322 Lid Hinged Cover FDD2500 3 61792 flat HINGE PWDR COATED SS 2 LEAF 4 61303 Screw 8 x 3 8 black trilobe 5 61440 CAP 8 SCREW SOFT 6 71582 Decal Warning Disconnect FDD2500 Splash Panel Assembly ...

Page 19: ...0 100068 Strain Relief Heyco SR5M 3 21 100205 Fan 24VDC 60mm 22 63236 Cover Funnel FDD2500 23 63237 Bracket Fan Louver FDD2500 24 62218 Switch Panel Mount Interlock 25 63268 Pan Coffee Catcher FDD2500 26 61440 CAP 8 SCREW SOFT 27 61847 Switch Toggle Spst 28 61847 1 Nut Switch for 61847 29 61242 Label Flush On Off 30 61241 Label Power 31 61466 Switch Toggle 16 Amp Dpst 32 61466 1 Nut Switch for 614...

Page 20: ...Page 20 Model FDD2500 FDD2500 Hopper Assembly ...

Page 21: ... FDD Vent Tubing Silicone 1 2 x 3 4 33 8 70635 TERMINAL 1 4 032 X 45DEG TAB 9 62269 Fitting 1 2 Barb SS 10 63297 NUT 10 24 ESNA SS 11 05826 FDD Short Tubing Silicone 3 8 x 5 8 x 5 12 05826 FDD IValve Tubing Silicone 3 8 x 5 8 x 17 13 61232 Plug 3 8 Barb 14 61152 Tee 7 16 Barbed 15 63448 Decal Tank Drain 5 Gal 16 07327 Clamp Hose 21 32ID Heyco 2322 17 71676 Clamp 671 812 Nylon Hose 18 05826 FDD Dra...

Page 22: ...ter 3 Ph FDD2500 7 1 62271 FDD Vent Tubing Silicone 1 2 x 3 4 33 8 1 70635 TERMINAL 1 4 032 X 45DEG TAB 9 4 62269 Fitting 1 2 Barb SS 10 3 63297 NUT 10 24 ESNA SS 11 1 05826 FDD Short Tubing Silicone 3 8 x 5 8 x 5 12 1 05826 FDD IValve Tubing Silicone 3 8 x 5 8 x 17 13 1 61232 Plug 3 8 Barb 14 1 61152 Tee 7 16 Barbed 15 1 63448 Decal Tank Drain 5 Gal 16 4 07327 Clamp Hose 21 32ID Heyco 2322 17 3 7...

Page 23: ...MET SILICONE WHT 3 61108 PROBE PIC 4 61128 Probe Thermistor 12 5 100160 Probe Safety 6 62305 T STAT HI TEMP LIMIT 7 62239 BRKT T STAT CE MODEL 8 61353 Screw 8 32 X 1 4 PH PN 18 8 SS 9 62265 Element 240V 6 6kW 10 71585 Elbow 1 2mptx5 8barb 90 brass 11 71586 Nut Lock 1 2fpt brass Model FDD2500 Page 23 ...

Page 24: ...O DESCRIPTION 1 63262 Lid Tank FDD2500 2 71147 GROMMET SILICONE WHT 3 61108 PROBE PIC 4 61128 Probe Thermistor 12 5 62305 T STAT HI TEMP LIMIT 6 62239 BRKT T STAT CE MODEL 7 61353 Screw 8 32 X 1 4 PH PN 18 8 SS 8 71585 Elbow 1 2mptx5 8barb 90 brass 9 71586 Nut Lock 1 2fpt brass 10 62403 Element 240V 3 7kW ...

Page 25: ...Control Right FDD2500 2 63345 Valve Inlet 120V Brass 3 100045 TRANSFORMER 100VA CHASSIS MOUNT 4 63400 Controller FDD2500 5 61266 STANDOFF RVRS EDGEMOUNT 6 63346 Fitting 1 2barb x 3 8nptm 7 63347 Fitting 3 8mfl x 3 8nptm 8 71620 Bushing Hole Heyco 1 094 2166 9 61303 Screw 8 x 3 8 black trilobe 10 63293 Harness Right FDD2500 Control Model FDD2500 Page 25 ...

Page 26: ...8 x 3 8 black trilobe 18 60758 WASHER 10 LOCK EXT SS 19 61159 4 Seal Closed Cell Foam 4 20 63449 Decal Step Down Wiring 9 12 6 10 3 11 13 2 1 7 63280 CONTACTOR BRACKET ASSEMBLY FDD2500 3 5 9 4 17 8 8 17 18 17 16 17 14 15 18 19 9 20 ITEM NO PART NO DESCRIPTION 1 63329 Bracket Control Left FDD2500 2 61131 Relay 12 vdc Coil 3 62262 Terminal Block 4 pole 4 61998 Contactor 4 Pole 5 63373 Transformer St...

Page 27: ...triker Pullswitch Item No Part No Description 1 63285 Plate Switch FDD2500 2 62260 Bezel pull switch A1101 020 3 62266 Handle Pull Switch Coffee 62267 Handle Pull Switch Hot Water 62268 Handle Pull Switch Decaf 4 62281 Spring Pull Switch A522120 5 61887 Switch Snap Action Micro 6 61883 Bracket Pull Switch Activation 7 63385 Rod Pull Switch Modified A1101 019 8 62270 Pin Pull Switch A551 015 9 7112...

Page 28: ... 2 1 3 4 4 63211 BLOWER ASSEMBLY FDD2500 ITEM NO PART NO DESCRIPTION 1 61103 Fan Blower 120V 25A 2 63212 Bracket Blower Mt FDD2500 3 63260 Insulation Strip Blower FDD 4 61303 Screw 8 x 3 8 black trilobe FDD2500 Hose Adapter Assembly 63402 Optional ...

Page 29: ...EAM EXHAUST RINSE 120V L2 L3 CONNECT RED TO CONNECT RED TO CONNECT RED TO CONNECT RED TO H2 FOR 208V SUPPLY H2 FOR 208V SUPPLY H2 FOR 208V SUPPLY H2 FOR 208V SUPPLY 120V Blk Blk BLK RED WHT Red Grn Blk PUR WHT B l k FDD2500 WIRING SCHEMATIC PUR ALL VOLTAGE SUPPLIES Left DISPLAY Capacitive Blk Ground Red Middle Right 0 24vdc Blk Yel M Blk M Augers 2 1 4 3 6 5 8 7 10 9 OR Left Sensor Capacitive Righ...

Page 30: ...T2 CONTACTOR L2 L1 TOP VIEW OF WATER TANK H E A T E R 1 FDD Manual Wiring 1 Ph H2 COM H1 CONNECT RED WIRE TO CONNECT RED WIRE TO CONNECT RED WIRE TO CONNECT RED WIRE TO H3 FOR 240V SUPPLY H3 FOR 240V SUPPLY H3 FOR 240V SUPPLY H3 FOR 240V SUPPLY RED BLACK H2 FOR 208V SUPPLY H2 FOR 208V SUPPLY H2 FOR 208V SUPPLY H2 FOR 208V SUPPLY 1 6 6 kW 240 VAC ELEMENT 6 6 kW 28 AMPS 240 VAC 2 WIRE GND 5 0 kW 24 ...

Page 31: ...ON ACHIEVE THE SERIAL PLATE VOLTAGE AND WATTAGE T2 1 1 3 2 T1 1 L3 1 2 2 1 1 3 1 4140 1 1 2 6 7 19 9 5550 2780 1390 1 2 26 8 13 4 23 7 7 5560 1 1850 3700 AMPS WATTS CONNECT NUMBERED HEATER WIRES TO CONTACTOR TERMINALS PER CHART BELOW 2 2 2A FUSE 2 3 2 3 1 3 1 3 1 2 15 5 23 2 26 8 8340 11100 7400 30 9 1 2 10 AWG BLACK HEATER WIRES 3 3 2A FUSE PER THE CHART BELOW TO 1 STEP DOWN TRANSFORMER H1 200V 1...

Page 32: ...Page 32 Model FDD2500 Wiring Schematic within Door for models FDD2500 1 M B FDD2500 3 M B ...

Page 33: ... 4 3 7 6 8 9 S M 2 1 PUR 4 14 BLU W 2 6 10 GRN 12 16 20 5 4 3 7 8 9 15 13 19 17 header 1 24 22 26 W ORG 30 11 header 2 21 1 25 27 29 31 28 header 1 L 6 5 18 2 x 16 backlit LCD display RED 3 4 1 2 WH GRN WHT GRY TO MAIN ORG BLK R W W BLU COM W R BOARD WHT BRN ORG W W R SETTINGS W BLU FDD2500 WIRING DISP 3A FDD2500 3A B 3 PORTION COFFEE DECAF MANUAL HOT WATER SCHEMATIC WITHIN DOOR CENTER SWITCH MANU...

Page 34: ...Page 34 Model FDD2500 ...

Page 35: ...Model FDD2500 Page 35 ...

Page 36: ...ers Crathco Cold and Frozen Beverage Dispensers American Metal Ware Coffee and Tea Systems Tel 502 425 4776 Fax 502 425 4664 1 800 695 4500 P O Box 35020 Louisville KY 40232 USA www grindmaster com email info grindmaster com Grindmaster Corporation 2005 0705 Form AM 342 02 PRINTED IN USA Part 63361 ...

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