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Strona 1 - ULTRA-1

ULTRA-1 ULTRA-2SERVICE & REPAIR MANUALBUNN-O-MATIC CORPORATIONPOST OFFICE BOX 3227SPRINGFIELD, ILLINOIS 62708-3227PHONE: (217) 529-6601 FAX: (2

Strona 2 - 41084 021513

10Auto-fill Cleaning Instructions(With Brixing Pump Installed)Materials required1. Non-sudsing liquid detergent (such as common household automatic di

Strona 3 - SITE PREPARATION

11C. TORSION SPRINGSWEAK TORSION SPRINGSDAMAGED/CORRODED AUGER SHAFTDAMAGED/WORN BUSHINGS/SEALSDIRTY OR DAMAGED TORQUE SENSOR BOARDTOO MUCH KRYTOX GRE

Strona 4 - INTRODUCTION

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

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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

Strona 6 - OPERATING CONTROLS

14TROUBLESHOOTINGA troubleshooting guide is provided to suggest probable causes and remedies for the most likely problems encountered. If the problem

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15TROUBLESHOOTING (cont.) Chills butwon’t freezeDispenser in“DAY” mode?YesNoYesYesYesYesYesNoNoNoNoNo3- Clean113221- Done2- AdjustSet into“DAY” modeDi

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16TROUBLESHOOTING (cont.)No coolingat allYesNoIs ICE/CHILLset to off?Have a certifiedrefrigeration techniciancheck for low refrigerantor blockage.NoSet

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17TROUBLESHOOTING (cont.)Freezes, but notthick enoughAdjust thicknessscreen higherCheck for slightlybent auger shaftpins and/or weaktorsion springs.Ch

Strona 10 - (With Brixing Pump Installed)

18TROUBLESHOOTING (cont.)NoiseAuger jumpingCheck fanLower brix ratioDrum alignmentCheck auger shaft bushingsUsing augerassembly fromCDS 2 or 3?Replace

Strona 11 - PREVENTIVE MAINTENANCE

19TROUBLESHOOTING (cont.) Torque Sensor ErrorYesNoSensor unplugged orbreak in wiringYesNoTORQUE SENSOR ERRORTORQUE SENSORSHORTEDTORQUE SENSOR OPENAre

Strona 12 - INSTRUCTIONS

241084 021513BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTYBunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:1) Airpots, thermal

Strona 13 - 41084 052112

20TROUBLESHOOTING (cont.)Temperature Sensor ErrorTEMPERATURE SENSOR SHORTEDTEMPERATURE SENSOR OPENLeft sideRight sideCheck wiring harness betweentherm

Strona 14 - TROUBLESHOOTING

21TROUBLESHOOTING (cont.)Clean Filter Messages“MONTHLY FILTERCLEAN REQUIRED”Monthly reminderClean filter“FILTER NEEDSCLEANING”“FILTER NEEDS!!!CLEANING!

Strona 15 - 41084 102709

22SERVICEThis section provides procedures for testing and replacing various major components used in this dispenser should service become necessary. R

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23FIG. 2 AUGER MOTOR TERMINALSLocationThe auger motors are located at the upper rear of the dispenser chassis inside the auger motor covers.Test Proce

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24FIG. 4 AUGER MOTOR CAPACITOR TERMINALSSERVICE (CONT.)AUGER MOTOR CAPACITORFIG. 3 AUGER MOTOR CAPACITORSP1341Location:The auger motor capacitor(s) ar

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25SERVICE (cont.)AUGER SHAFT ASSEMBLYAuger Shaft AssyAuger Shaft BushingCooling Drum SealHopper Drum SealFIG. 5 AUGER SHAFT ASSEMBLYLocation: The Aug

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26SERVICE (cont.)AUGER SHAFT ASSEMBLY(cont.)FIG. 7 COOLING DRUM SEALP1760Open face of seal away from toolCooling Drum SealSeal Insertion ToolFIG. 8 MO

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279FIG. 11 CIRCUIT BREAKER (ULTRA-2)SERVICE (cont.)CIRCUIT BREAKERLocation:The circuit breaker is located inside the dispenser on the front right fram

Strona 21

28SERVICE (cont.)COMPRESSOR (AMERICOLD) (ULTRA-2)FIG. 14 COMPRESSOR ASSYFIG. 15 COMPRESSOR ELECTRICAL COMPONENTSTest Procedures: WARNING: The compress

Strona 22 - P3930.30

29SERVICE (cont.)COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.)Compressor Thermal Overload Protector: Refer to FIG. 151. Remove terminal cover retainer (5)

Strona 23 - MOTOR COIL RESISTANCE

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

Strona 24 - ULTRA-1 AUGER MOTOR CAPACITOR

30SERVICE (cont.)COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.)Removal and Replacement:Compressor Assy:NOTE: Before removal of any refrigeration component t

Strona 25

31SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)FIG. 19 COMPRESSOR ASSYFIG. 20 COMPRESSOR ELECTRICAL COMPONENTSTest Procedures: WARNING: The compressor

Strona 26 - ULTRA-2 shown

32SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2) (cont.)Compressor Thermal Overload Protector: Refer to FIG. 201. Remove terminal cover retainer (5) a

Strona 27 - RED to Lamp Relay (ULTRA-1)

33SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2) (cont.)Removal and Replacement:Compressor Assy:NOTE: Before removal of any refrigeration component the

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34SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)Compressor Model: EMBRACO/NT2168GK, 115V 60HZ/100V 50HZCompressor Specification: Commercial Designation

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35SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)Important Safeguards:• Trainedservicepersonnelwiththe knowledge ofservicing andtroubleshootin

Strona 30 - SERVICE (cont.)

36SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)Compressor Windings & Related Component Testing:Note: Measure the resistance (ohms) between termi-n

Strona 31

37SERVICE (cont.)COMPRESSOR (EMBRACO) (ULTRA-2)External Thermal Protector Check for continuity across the thermal protector ter-minals. Before testing

Strona 32

38SERVICE (cont.)COMPRESSOR (APPLIANCES) (ULTRA-1)FIG. 24 COMPRESSOR &COMPONENT LOCATIONSFIG. 25 COMPRESSOR THERMALOVERLOAD PROTECTOR LOCATIONTest

Strona 33

39SERVICE (cont.)COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.)WHI/ORNGRNWHIBRN/WHI (120V) BRN (230V)BLUFIG. 26 RELAY TERMINALSFIG. 27 THERMAL OVERLOAD PRO

Strona 34

4INTRODUCTIONSafety first!To avoid electrical shock, unplug dispenser from power source before servicing inside.WARNING: When powered, the condenser co

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40SERVICE (cont.)COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.)Compressor Assy:NOTE: Before removal of any refrigeration component the refrigerant in the s

Strona 36

41SERVICE (cont.)COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.)Location:The compressor assy is located inside the front of the dispenser chassis.FIG. 29 COMP

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42SERVICE (cont.)COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.)GRNWHIWHI/ORN toOverloadProtectorFIG. 30 RELAY TERMINALSBLK to CompressorRelayBLK to Compresso

Strona 38

43RSERVICE (cont.)RELAY (or CONTACTOR on Early Models)If continuity is present as described, disconnect the dispenser from power source and reconnect

Strona 39

44SERVICE (cont.)CONTROL BOARDFIG. 35 CONTROL BOARD (ULTRA-2)Removal and Replacement:1. Disconnect the main harness from connector J5 (ULTRA-2) or J9

Strona 40

45SERVICE (cont.)COOLING DRUM ALIGNMENTThe “A” shaped Cooling Drum Shipping Supports, removed during Initial Set-Up should be kept and used as a tool

Strona 41 - COMPONENT LOCATIONS

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

Strona 42 - FIG. 30 RELAY TERMINALS

47SERVICE (cont.)FAN - ULTRA-1FIG. 42 FANLocation:The fan assembly is located inside the rear of the dispenser chassis behind the condenser.Test Proce

Strona 43 - Early Model ULTRA-2

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

Strona 44 - TIC board

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

Strona 45

5TEMP & TORQUE SCREENPress and hold for five seconds the ULTRA and ICE hidden switches to display the TEMP & TORQUE. The temperature of each co

Strona 46 - 2 3 4

50SERVICE (cont.)LAMP CORD CONNECTORIf continuity is not present when lamp cord assembly is connected or continuity is present when lamp cord assembly

Strona 47

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

Strona 48

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

Strona 49

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

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541121MEMBRANESWITCHI/OULTRAGOURMETICESHIELDLEFT RIGHTRemoval and Replacement:1. Disconnect the dispenser from the power source.2. Remove right and

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5581MEMBRANESWITCHULTRAPOWERGOURMETICESHIELD1SERVICE (cont.)MEMBRANE SWITCH (ULTRA-1)Removal and Replacement:1. Disconnect the dispenser from the pow

Strona 52

56FIG.60 SOLENOID TERMINALSSERVICE (cont.)SOLENOIDSFIG. 59 SOLENOIDSLocation: The solenoids are mounted on a bracket that is attached to the front le

Strona 53

57FIG. 62 TEMPERATURE SENSORSERVICE (cont.)TEMPERATURE SENSOR FIG. 61 TEMPERATURE SENSORP1341Location:The Temperature Sensor(s) are located inside the

Strona 54

58FIG. 64 TORQUE SENSOR CIRCUIT BOARD TERMINALSSERVICE (cont.)TORQUE SENSOR CIRCUIT BOARDFIG. 63 TORQUE SENSOR CIRCUIT BOARDP1341Location:The torque s

Strona 55 - MEMBRANE

59SERVICE (cont.)TRANSFORMERFIG. 67 TRANSFORMER TERMINALSFIG. 65 TRANSFORMER - ULTRA-1Location:The transformer is located inside dispenser onthe lower

Strona 56

641084 102709OPERATING CONTROLSULTRA-1 There are three of these switches that will be used for the operation of the dispenser. 1. switch (upper lef

Strona 57

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

Strona 58

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

Strona 59

62TRIAC MAP for ULTRA-1ULTRA-1 TRIACS TH1 & MOV4 controls Auger @ J10-8 Reverse & J10-9 ForwardTH2 & MOV1 controls Compressor

Strona 60 - COOLANT SCHEMATIC ULTRA-1

63TRIAC MAPS for ULTRA-2ULTRA-2 TRIACS TH1 & MOV3 controls Left solenoid @ J13-15TH2 & MOV1 controls Compressor Relay @ J13-17TH

Strona 61 - COOLANT SCHEMATIC ULTRA-2

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).

Strona 62 - TRIAC MAP for ULTRA-1

65J10-1J10-5J10-10J9-1J9-5J9-10J9-16116J11-1J11-5J11-8J10-15J10-20CONTROLBOARDDISPLAYBLU-22TAN-22WHI/GRY-22WHI/BLKWHI/BLUBRN/WHIBRN/BLKBLKBLU/BLKWHIWH

Strona 63 - TRIAC MAPS for ULTRA-2

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).

Strona 64

67J13-1J1-1J13-5J13-10J5-1J5-5J5-10J5-16116J2-1J2-5J2-10J2-12J13-15J13-20J13-24CONTROLBOARDDISPLAYRED/BLKWHI/RED-22BLK-22ORN-22YEL-22GRN-22GRNGRNBLU-2

Strona 65

6841084 102709

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741084 102709OPERATING CONTROLSULTRA-2 There are five of these switches that will be used for the operation of the dispenser. 1. switch (upper left

Strona 67

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

Strona 68

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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