ULTRA-1 ULTRA-2SERVICE & REPAIR MANUALBUNN-O-MATIC CORPORATIONPOST OFFICE BOX 3227SPRINGFIELD, ILLINOIS 62708-3227PHONE: (217) 529-6601 FAX: (2
10Auto-fill Cleaning Instructions(With Brixing Pump Installed)Materials required1. Non-sudsing liquid detergent (such as common household automatic di
11C. TORSION SPRINGSWEAK TORSION SPRINGSDAMAGED/CORRODED AUGER SHAFTDAMAGED/WORN BUSHINGS/SEALSDIRTY OR DAMAGED TORQUE SENSOR BOARDTOO MUCH KRYTOX GRE
12REQUIRED REGULAR MAINTENANCE:Semi Annual: Bunn Kit #34245.0002 is required for ULTRA-1 and #34245.0000 & #34245.0001 is required for ULTRA-2, t
136. Pull the auger shaft assembly straight out of cooling drum. Inspect the shaft for abnormal wear.7. From the front of dispenser, remove the seal
14TROUBLESHOOTINGA troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems encountered. If the problem
15TROUBLESHOOTING (cont.) Chills butwon’t freezeDispenser in“DAY” mode?YesNoYesYesYesYesYesNoNoNoNoNo3- Clean113221- Done2- AdjustSet into“DAY” modeDi
16TROUBLESHOOTING (cont.)No coolingat allYesNoIs ICE/CHILLset to off?Have a certifiedrefrigeration techniciancheck for low refrigerantor blockage.NoSet
17TROUBLESHOOTING (cont.)Freezes, but notthick enoughAdjust thicknessscreen higherCheck for slightlybent auger shaftpins and/or weaktorsion springs.Ch
18TROUBLESHOOTING (cont.)NoiseAuger jumpingCheck fanLower brix ratioDrum alignmentCheck auger shaft bushingsUsing augerassembly fromCDS 2 or 3?Replace
19TROUBLESHOOTING (cont.) Torque Sensor ErrorYesNoSensor unplugged orbreak in wiringYesNoTORQUE SENSOR ERRORTORQUE SENSORSHORTEDTORQUE SENSOR OPENAre
241084 021513BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTYBunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:1) Airpots, thermal
20TROUBLESHOOTING (cont.)Temperature Sensor ErrorTEMPERATURE SENSOR SHORTEDTEMPERATURE SENSOR OPENLeft sideRight sideCheck wiring harness betweentherm
21TROUBLESHOOTING (cont.)Clean Filter Messages“MONTHLY FILTERCLEAN REQUIRED”Monthly reminderClean filter“FILTER NEEDSCLEANING”“FILTER NEEDS!!!CLEANING!
22SERVICEThis section provides procedures for testing and replacing various major components used in this dispenser should service become necessary. R
23FIG. 2 AUGER MOTOR TERMINALSLocationThe auger motors are located at the upper rear of the dispenser chassis inside the auger motor covers.Test Proce
24FIG. 4 AUGER MOTOR CAPACITOR TERMINALSSERVICE (CONT.)AUGER MOTOR CAPACITORFIG. 3 AUGER MOTOR CAPACITORSP1341Location:The auger motor capacitor(s) ar
25SERVICE (cont.)AUGER SHAFT ASSEMBLYAuger Shaft AssyAuger Shaft BushingCooling Drum SealHopper Drum SealFIG. 5 AUGER SHAFT ASSEMBLYLocation: The Aug
26SERVICE (cont.)AUGER SHAFT ASSEMBLY(cont.)FIG. 7 COOLING DRUM SEALP1760Open face of seal away from toolCooling Drum SealSeal Insertion ToolFIG. 8 MO
279FIG. 11 CIRCUIT BREAKER (ULTRA-2)SERVICE (cont.)CIRCUIT BREAKERLocation:The circuit breaker is located inside the dispenser on the front right fram
28SERVICE (cont.)COMPRESSOR (AMERICOLD) (ULTRA-2)FIG. 14 COMPRESSOR ASSYFIG. 15 COMPRESSOR ELECTRICAL COMPONENTSTest Procedures: WARNING: The compress
29SERVICE (cont.)COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.)Compressor Thermal Overload Protector: Refer to FIG. 151. Remove terminal cover retainer (5)
3USER NOTICESAll notices on this equipment are written for your protection. All notices are to be kept in good condition. Replace any unreadable or da
30SERVICE (cont.)COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.)Removal and Replacement:Compressor Assy:NOTE: Before removal of any refrigeration component t
31SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)FIG. 19 COMPRESSOR ASSYFIG. 20 COMPRESSOR ELECTRICAL COMPONENTSTest Procedures: WARNING: The compressor
32SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2) (cont.)Compressor Thermal Overload Protector: Refer to FIG. 201. Remove terminal cover retainer (5) a
33SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2) (cont.)Removal and Replacement:Compressor Assy:NOTE: Before removal of any refrigeration component the
34SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)Compressor Model: EMBRACO/NT2168GK, 115V 60HZ/100V 50HZCompressor Specification: Commercial Designation
35SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)Important Safeguards:• Trainedservicepersonnelwiththe knowledge ofservicing andtroubleshootin
36SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)Compressor Windings & Related Component Testing:Note: Measure the resistance (ohms) between termi-n
37SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)External Thermal Protector Check for continuity across the thermal protector ter-minals. Before testing
38SERVICE (cont.)COMPRESSOR (APPLIANCES) (ULTRA-1)FIG. 24 COMPRESSOR &COMPONENT LOCATIONSFIG. 25 COMPRESSOR THERMALOVERLOAD PROTECTOR LOCATIONTest
39SERVICE (cont.)COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.)WHI/ORNGRNWHIBRN/WHI (120V) BRN (230V)BLUFIG. 26 RELAY TERMINALSFIG. 27 THERMAL OVERLOAD PRO
4INTRODUCTIONSafety first!To avoid electrical shock, unplug dispenser from power source before servicing inside.WARNING: When powered, the condenser co
40SERVICE (cont.)COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.)Compressor Assy:NOTE: Before removal of any refrigeration component the refrigerant in the s
41SERVICE (cont.)COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.)Location:The compressor assy is located inside the front of the dispenser chassis.FIG. 29 COMP
42SERVICE (cont.)COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.)GRNWHIWHI/ORN toOverloadProtectorFIG. 30 RELAY TERMINALSBLK to CompressorRelayBLK to Compresso
43RSERVICE (cont.)RELAY (or CONTACTOR on Early Models)If continuity is present as described, disconnect the dispenser from power source and reconnect
44SERVICE (cont.)CONTROL BOARDFIG. 35 CONTROL BOARD (ULTRA-2)Removal and Replacement:1. Disconnect the main harness from connector J5 (ULTRA-2) or J9
45SERVICE (cont.)COOLING DRUM ALIGNMENTThe “A” shaped Cooling Drum Shipping Supports, removed during Initial Set-Up should be kept and used as a tool
4612 3 45 67SERVICE (cont.)FAN - ULTRA-2FIG. 39 FANLocation:The fan is located inside the dispenser chassis just in front of the condenser.Test
47SERVICE (cont.)FAN - ULTRA-1FIG. 42 FANLocation:The fan assembly is located inside the rear of the dispenser chassis behind the condenser.Test Proce
48SERVICE (cont.)HOT GAS TEMPERATURE SENSORFIG. 43 HOT GAS SENSORLocation:The Hot Gas Sensor is located on the Condenser-to-Compressor tube on the lef
49SERVICE (cont.)LAMP CORD ASSYFIG. 45 LAMP CORD ASSYLocation:The lamp cord assembly is located in the top center of the auger motor cover.Test Proced
5TEMP & TORQUE SCREENPress and hold for five seconds the ULTRA and ICE hidden switches to display the TEMP & TORQUE. The temperature of each co
50SERVICE (cont.)LAMP CORD CONNECTORIf continuity is not present when lamp cord assembly is connected or continuity is present when lamp cord assembly
51Removal and Replacement:1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the auger motor cover.2. Remove t
52SERVICE (CONT.)LED LampsIf voltage is present as described, the LED board is faulty.If voltage is not present as described, retrace the wiring circu
53Test Procedures: (Contacts)1. Disconnect the dispenser from the power source.2. Disconnect the WHI/VIO and WHI/YEL wires. Con-nect an ohmmeter acr
541121MEMBRANESWITCHI/OULTRAGOURMETICESHIELDLEFT RIGHTRemoval and Replacement:1. Disconnect the dispenser from the power source.2. Remove right and
5581MEMBRANESWITCHULTRAPOWERGOURMETICESHIELD1SERVICE (cont.)MEMBRANE SWITCH (ULTRA-1)Removal and Replacement:1. Disconnect the dispenser from the pow
56FIG.60 SOLENOID TERMINALSSERVICE (cont.)SOLENOIDSFIG. 59 SOLENOIDSLocation: The solenoids are mounted on a bracket that is attached to the front le
57FIG. 62 TEMPERATURE SENSORSERVICE (cont.)TEMPERATURE SENSOR FIG. 61 TEMPERATURE SENSORP1341Location:The Temperature Sensor(s) are located inside the
58FIG. 64 TORQUE SENSOR CIRCUIT BOARD TERMINALSSERVICE (cont.)TORQUE SENSOR CIRCUIT BOARDFIG. 63 TORQUE SENSOR CIRCUIT BOARDP1341Location:The torque s
59SERVICE (cont.)TRANSFORMERFIG. 67 TRANSFORMER TERMINALSFIG. 65 TRANSFORMER - ULTRA-1Location:The transformer is located inside dispenser onthe lower
641084 102709OPERATING CONTROLSULTRA-1 There are three of these switches that will be used for the operation of the dispenser. 1. switch (upper lef
60COOLANT SCHEMATIC ULTRA-1COPPER TUBE.25” O.D. X .030”COPPER TUBE.25” O.D. X .030”SUCTIONACCUMULATORCOPPER TUBE.312” O.D. X .032”CONDENSEREVAPORATORF
61COOLANT SCHEMATIC ULTRA-2COPPER TUBE.25” O.D. X .030”COPPER TUBE.25” O.D. X .030”SUCTIONACCUMULATORCOPPER TUBE.312” O.D. X .032”CONDENSERLEFT EVAPOR
62TRIAC MAP for ULTRA-1ULTRA-1 TRIACS TH1 & MOV4 controls Auger @ J10-8 Reverse & J10-9 ForwardTH2 & MOV1 controls Compressor
63TRIAC MAPS for ULTRA-2ULTRA-2 TRIACS TH1 & MOV3 controls Left solenoid @ J13-15TH2 & MOV1 controls Compressor Relay @ J13-17TH
64Input and Output Chart (ULTRA-1) J9 connector for liquid crystal display.J11 connector for touch pad/ membrane switch (see touch pad pin out test).
65J10-1J10-5J10-10J9-1J9-5J9-10J9-16116J11-1J11-5J11-8J10-15J10-20CONTROLBOARDDISPLAYBLU-22TAN-22WHI/GRY-22WHI/BLKWHI/BLUBRN/WHIBRN/BLKBLKBLU/BLKWHIWH
66Input and Output Chart (ULTRA-2) J5 connector for liquid crystal display. J2 connector for touch pad/ membrane switch (see touch pad pin out test).
67J13-1J1-1J13-5J13-10J5-1J5-5J5-10J5-16116J2-1J2-5J2-10J2-12J13-15J13-20J13-24CONTROLBOARDDISPLAYRED/BLKWHI/RED-22BLK-22ORN-22YEL-22GRN-22GRNGRNBLU-2
6841084 102709
741084 102709OPERATING CONTROLSULTRA-2 There are five of these switches that will be used for the operation of the dispenser. 1. switch (upper left
810. Place all parts in a clean sink with mild hot water (120°F) and sanitizer solution. Allow all parts to soak for at least 5 minutes. Carefully wa
91. Install the seal(s) over the flange at the rear of the cooling drum(s) and press the seal(s) firmly into place as shown.2. Align the auger shaft(s
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