Bunn -O-MATIC ULTRA-1 Service And Repair Manual
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Bunn -O-MATIC ULTRA-1 Service And Repair Manual

Bunn food warmer user manual
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SERVICE & REPAIR MANUAL
41084.0000B 04/10 ©2009 Bunn-O-Matic Corporation
BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: (217) 529-6601 FAX: (217) 529-6644
ULTRA-1
ULTRA-2

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Summary of Contents for Bunn BUNN-O-MATIC ULTRA-1

  • Page 1 SERVICE & REPAIR MANUAL BUNN-O-MATIC CORPORATION PHONE: (217) 529-6601 FAX: (217) 529-6644 41084.0000B 04/10 ©2009 Bunn-O-Matic Corporation POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227 ULTRA-1 ULTRA-2...

  • Page 2: Springfield, Illinois

    SOLE OPTION AS SPECIFIED HEREIN, TO REPAIR, REPLACEMENT OR REFUND. In no event shall BUNN be liable for any other damage or loss, including, but not limited to, lost profits, lost sales, loss of use of equipment, claims of Buyer’s customers, cost of capital, cost of down time, cost of substitute equipment, facilities or services, or any other special, incidental or consequential damages.

  • Page 3: Table Of Contents

    CONTENTS Warranty ...2 User Notices ...3 Site Preparation ...3 Introduction ...4 Operating Controls ...6 Preventive Maintenance Recommended Cleaning ...8 Auto-fill Cleaning Instructions ...10 Preventive Maintenance Schedule ...11 Troubleshooting ...14 Service Access Panels ...22 Auger Motors ...23 Auger Motor Capacitors ...24 Auger Shaft Assembly ...25 Circuit Breaker ...27 Compressor ...28,31,34,37...

  • Page 4: Introduction

    INTRODUCTION Safety first! To avoid electrical shock, unplug dispenser from power source before servicing inside. WARNING: When powered, the condenser cooling fan will turn on every 30 minutes to aid cooling the entire unit, even when not in the ICE or CHILL modes. KEEP HANDS AWAY FROM FAN! Basic Maintenance In order to maintain proper machine operation, the shaft seals and bushings need to be replaced as a Preventa- tive Maintenance measure.
  • Page 5 TEMP & TORQUE SCREEN Press and hold for five seconds the ULTRA and ICE hidden switches to display the TEMP & TORQUE. The temperature of each cooling drum and the hot gas temperature will toggle back and forth. The auger torque is displayed continuously.

  • Page 6: Operating Controls

    There are three of these switches that will be used for the operation of the dispenser. switch (upper left corner of the control pad) This switch is the ON/OFF toggle switch which powers up the dispenser and the LCD display. When ON the Date and Time toggle back and forth continously except during programming.
  • Page 7 There are five of these switches that will be used for the operation of the dispenser. switch (upper left corner of the control pad) This switch is the ON/OFF toggle switch which powers up the dispenser and the LCD display. When ON the Date and Time toggle back and forth continously except during programming.

  • Page 8: Preventive Maintenance Recommended Cleaning

    RECOMMENDED DAILY CLEANING (ULTRA-2 shown) NOTE – Turn the power OFF to the dispenser before proceeding. 1. Empty all product from the hopper(s). Disconnect the hopper lid lamp cord(s) and remove the lids. 2. Depress the hopper lock plung- er. Lift the hopper up slightly. 5.
  • Page 9 RECOMMENDED DAILY CLEANING (Continued) 1. 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. 4. Thoroughly rinse the hopper(s) and install over the auger(s) and cooling drum(s). Position the faucet seal and re- turn spring in the faucet valve.

  • Page 10: Auto-Fill Cleaning Instructions

    Materials required 1. Non-sudsing liquid detergent (such as common household automatic dishwasher liquid detergent). 2. Household bleach (Sodium chloride solution: 5.25%) or equivalent. 3. Clean five (5) gallon bucket. 4. Measuring Cup 5. An adaptor is needed to hold the Q.C.D. (Quick Connect/Disconnect) fitting on the concentrate suction line open.

  • Page 11: Preventive Maintenance Schedule

    PREVENTIVE MAINTENANCE A common problem occurs when the proper preventive maintenance procedures are not followed. Failure to perform these procedures may result in damaged equipment and may not be covered by warranty. Please check the following items before assuming a refrigeration fault. When the product does not freeze, there are several possibilities other than a failure in the refrigeration system.
  • Page 12 REQUIRED REGULAR MAINTENANCE: Semi Annual: Bunn Kit #34245.0002 is required for ULTRA-1 and #34245.0000 & #34245.0001 is required for ULTRA-2, to perform the semi annual Preventive maintenance: Note: Service caused by failure to perform required maintenance is not covered by warranty.
  • Page 13 10. Place seal on insertion tool #28395.0000 as shown in FIG 2. Make sure open face of seal is toward cooling drum. 11. Apply a small amount of food grade lubricant (Bunn #M2568.1000) to inside diameter of seal. Push seal into bore until it is firmly seated;...

  • Page 14: Troubleshooting

    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 person- nel.
  • Page 15 TROUBLESHOOTING (cont.) Set into “DAY” mode Verify augers are turned on Is display showing UPPER CASE “ICE” mode? Is Thickness screen set low? Inspect auger drive shafts for weak torsion springs or damaged pins. Check for dirty or worn seals and bushings. Chills but won’t freeze Dispenser in...
  • Page 16 TROUBLESHOOTING (cont.) Set into “ICE” or “CHILL” mode Plug directly inti outlet Call a licensed electrician No cooling at all Is ICE/CHILL set to off? Is compressor running? Is Dispenser on an extension cord? Is there correct voltage at outlet? Follow compressor circuit checks.
  • Page 17 TROUBLESHOOTING (cont.) Freezes, but not thick enough Ambient Too much Adjust thickness Brix ratio temperature alcohol in screen higher too high too hot product Recommended Check for slightly Adjust for indoor bent auger shaft product use only pins and/or weak torsion springs.
  • Page 18 TROUBLESHOOTING (cont.) Noise Auger jumping Using auger Check fan assembly from CDS 2 or 3? Lower brix ratio Replace with ULTRA p/n 32106.1000 Drum alignment Check auger shaft bushings Auger won’t turn Do they turn during “AUGER MOTOR TEST” mode? One direction, Auger motor/capacitor but not the other...
  • Page 19 TROUBLESHOOTING (cont.) Torque Sensor Error TORQUE SENSOR ERROR TORQUE SENSOR OPEN TORQUE SENSOR SHORTED Right side Left side Right side Left side Are augers Sensor unplugged or turning? break in wiring Go to motor troubleshooting Are augers shaft pins Check sensor damaged or missing? circuit Replace as necessary...
  • Page 20 TROUBLESHOOTING (cont.) Temperature Sensor Error TEMPERATURE SENSOR OPEN TEMPERATURE SENSOR SHORTED Left side Left side Right side Right side Product not covering Check wiring harness between back end of drum. thermistor and control board Drum temperature falls below 9° F. Replenish product Thermistor unplugged or break in wiring...
  • Page 21 TROUBLESHOOTING (cont.) Clean Filter Messages “FILTER NEEDS “MONTHLY FILTER “FILTER NEEDS CLEANING” CLEAN REQUIRED” !!!CLEANING!!!” Freezing is Disabled Hot gas thermistor Hot gas thermistor Monthly reminder sensing over 250° F sensing over 220° F Dirty filter; air flow blockage; Clean filter wrong refrigerant or over charged Hold ULTRA button for 3 seconds to reset.

  • Page 22: Service

    SERVICE This section provides procedures for testing and replacing various major components used in this dispenser should service become necessary. Refer to Troubleshooting for assistance in determining the cause of any problem. WARNING - Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel.

  • Page 23: Auger Motors

    SERVICE(CONT.) AUGER MOTORS FIG. 1 AUGER MOTORS Location The auger motors are located at the upper rear of the dispenser chassis inside the auger motor covers. Test Procedures 1. Remove the hopper from the same side as the motor to be tested. 2.

  • Page 24: Auger Motor Capacitors

    SERVICE (CONT.) AUGER MOTOR CAPACITOR FIG. 3 AUGER MOTOR CAPACITORS Location: The auger motor capacitor(s) are located on the lower right side of the auger motor mounting bracket inside the auger motor cover(s). Test Procedures 1. Remove the hopper from the same side as the motor to be tested.

  • Page 25: Auger Shaft Assembly

    SERVICE (cont.) AUGER SHAFT ASSEMBLY Auger Motor Cover Run Capacitor Auger Motor Assy Auger Shaft Assy Hopper Drum Seal Cooling Drum FIG. 5 AUGER SHAFT ASSEMBLY Location: The Auger Shaft Assembly is located in each of the cooling drums. Removal and Replacement: 1.
  • Page 26 SERVICE (cont.) AUGER SHAFT ASSEMBLY(cont.) Open face of seal away from tool Cooling Drum Seal Seal Insertion Tool FIG. 7 COOLING DRUM SEAL 14. Assemble motor/shaft assembly as shown in Fig. 8, then install assembly into cooling drum. Make sure the pins do not hit the sensor board and cool- ing drum seal is not dislodged as the shaft passes through.

  • Page 27: Circuit Breaker

    SERVICE (cont.) CIRCUIT BREAKER FIG. 11 CIRCUIT BREAKER (ULTRA-2) Location: The circuit breaker is located inside the dispenser on the front right frame post on ULTRA-2 models; and under the Auger Motor cover on ULTRA-1 models. Test Procedures: 1. Disconnect the dispenser from the power source. 2.

  • Page 28: Compressor

    SERVICE (cont.) COMPRESSOR (AMERICOLD) (ULTRA-2) FIG. 14 COMPRESSOR ASSY Location: The compressor assy is located inside the front of the dispenser chassis. 120V COMPRESSORS 230V COMPRESSORS FIG. 15 COMPRESSOR ELECTRICAL COMPONENTS 1. Compressor Start Relay 2. Thermal Overload Protector 3. Overload Protector Retainer 4.
  • Page 29 SERVICE (cont.) COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.) Removal and Replacement: Compressor Start Relay: Refer to FIG. 15 1. Remove the terminal cover retainer (5) and the terminal cover (4) 2. Disconnect the wires from the compressor start re- lay. 3. Pull relay (1) off of the compressor pins and discard. 4.
  • Page 30 SERVICE (cont.) COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.) Removal and Replacement: Compressor Assy: NOTE: Before removal of any refrigeration component the refrigerant in the system must be reclaimed by a licensed refrigeration repair person. NOTE: When replacing the compressor it is recommended that the dryer also be replaced.
  • Page 31 SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) FIG. 19 COMPRESSOR ASSY Location: The compressor assy is located inside the front of the dispenser chassis. Model T-2155 Model T-2168 FIG. 20 COMPRESSOR ELECTRICAL COMPONENTS 1. Compressor Start Relay 2. Thermal Overload Protector 3. Overload Protector Retainer 4.
  • Page 32 SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) (cont.) Removal and Replacement: Compressor Start Relay: Refer to FIG. 20 1. Disconnect the wires from the compressor start re- lay. 3. Pull relay (1) off of the compressor pins and discard. 4. Push new relay onto the compressor pins. 5.
  • Page 33 SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) (cont.) Removal and Replacement: Compressor Assy: NOTE: Before removal of any refrigeration component the refrigerant in the system must be reclaimed by a licensed refrigeration repair person. NOTE: When replacing the compressor it is recommended that the dryer also be replaced.
  • Page 34 SERVICE (cont.) COMPRESSOR (APPLIANCES) (ULTRA-1) FIG. 24 COMPRESSOR & COMPONENT LOCATIONS Location: The compressor assy is located inside the front of the dispenser chassis. FIG. 25 COMPRESSOR THERMAL OVERLOAD PROTECTOR LOCATION 1. Compressor Start Relay 2. Compressor Run Capacitor 3. Thermal Overload Protector 4.
  • Page 35 SERVICE (cont.) COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.) Removal and Replacement: Compressor Start Relay: Refer to FIG. 25 1. Remove the terminal cover (4) 2. Disconnect the wires from the compressor start relay. 3. Pull relay (1) off of the compressor pins and discard. 4.
  • Page 36 SERVICE (cont.) COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.) Compressor Assy: NOTE: Before removal of any refrigeration component the refrigerant in the system must be reclaimed by a licensed refrigeration repair person. NOTE: When replacing the compressor it is recommended that the dryer also be replaced. 1.
  • Page 37 SERVICE (cont.) COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.) FIG. 29 COMPRESSOR & COMPONENT LOCATIONS Location: The compressor assy is located inside the front of the dispenser chassis. Test Procedures: Compressor Start Relay: Refer to FIG. 30 WARNING: The compressor capacitor must be properly discharged before proceeding.
  • Page 38 SERVICE (cont.) COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.) Removal and Replacement: Compressor Start Relay: Refer to FIG. 30 1. Remove the terminal cover (4) 2. Disconnect the wires from the compressor start relay. 3. Pull relay (1) off of the compressor pins and discard. 4.

  • Page 39: Relay (Or Contactor On Early Models)

    SERVICE (cont.) RELAY (or CONTACTOR on Early Models) FIG. 32 RELAY Location: The relay (or contactor) is located inside the dis- penser chassis on the lower outside of the component bracket. Test Procedures: 1. Disconnect the dispenser from the power source. 2.

  • Page 40: Control Board

    SERVICE (cont.) CONTROL BOARD Control board FIG. 35 CONTROL BOARD (ULTRA-2) Location: The control board is located behind the front panel, on the front of the chassis. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Remove the left and right side panels. Remove the front panel and unplug ribbon cable from J5 (ULTRA-2) or J9 (ULTRA-1) .

  • Page 41: Cooling Drum Alignment

    SERVICE (cont.) COOLING DRUM ALIGNMENT Ledge FIG. 37 COOLING DRUM SHIPPING SUPPORT The “A” shaped Cooling Drum Shipping Supports, removed during Initial Set-Up should be kept and used as a tool to reset the alignment of the cooling drums should it ever be required. Symptoms: Squeaky Operation, hopper lifts or won’t seat properly, hopper is pushed to one side or the other.
  • Page 42 SERVICE (cont.) FAN - ULTRA-2 FIG. 39 FAN Location: The fan is located inside the dispenser chassis just in front of the condenser. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the gray and white wires from the main harness to the fan leads.

  • Page 43: Fan

    SERVICE (cont.) FAN - ULTRA-1 FIG. 42 FAN Location: The fan assembly is located inside the rear of the dispenser chassis behind the condenser. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Connect a voltmeter across pins 1 and 2 of either fan connector of the main wiring harness.

  • Page 44: Hot Gas Sensor

    SERVICE (cont.) HOT GAS TEMPERATURE SENSOR ULTRA-2 shown FIG. 43 HOT GAS SENSOR Location: The Hot Gas Sensor is located on the Condenser- to-Compressor tube on the left side of the housing. Test Procedures: 1. Remove the left side housing panel. 2.

  • Page 45: Lamp Cord Assembly

    SERVICE (cont.) LAMP CORD ASSY FIG. 45 LAMP CORD ASSY Location: The lamp cord assembly is located in the top center of the auger motor cover. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Unplug the lamp cord assembly from lamp cord connector assembly.

  • Page 46: Lamp Cord Connector

    SERVICE (cont.) LAMP CORD CONNECTOR FIG. 47 LAMP CORD CONNECTOR Location: The lamp cord connectors are located inside the center top of the auger motor covers. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the plug on the dispenser main harness from the connector from the lamp cord connec- tor.

  • Page 47: Lamp Holder/Socket Assembly

    SERVICE (cont.) LAMP HOLDER/SOCKET ASSEMBLY FIG. 49 LAMP HOLDER/SOCKET ASSEMBLY Location: The lamp holder/socket assemblies are located inside the hopper covers. Test Procedures: 1. Disconnect the lamp cord assembly from the lamp cord connector. 2. Remove the lamps from the lamp holder/socket assembly.

  • Page 48: Lamp Relay

    SERVICE (cont.) LAMP RELAY ULTRA-2 shown FIG. 51 LAMP RELAY Location: The Lamp Relay is located under the upper deck of the chassis, on the right side. Test Procedures: (Coil) 1. Disconnect the dispenser from the power source. 2. Connect a voltmeter, across BLU/BLK wire (+) and the VIO wire (-).

  • Page 49: Membrane Switch

    SERVICE (cont.) MEMBRANE SWITCH (ULTRA-2) FIG. 53 MEMBRANE SWITCH Location: The membrane switch is located on the front panel. Test Procedures: NOTE: Before continuing, check that the ribbon cable is properly connected to the control board and not a pin off in either direction. 1.
  • Page 50 SERVICE (cont.) MEMBRANE SWITCH (ULTRA-1) FIG. 56 MEMBRANE SWITCH Location: The membrane switch is located on the front panel. Test Procedures: NOTE: Before continuing, check that the ribbon cable is properly connected to the control board and not a pin off in either direction. 1.

  • Page 51: Solenoids

    SERVICE (cont.) SOLENOIDS ULTRA-2 shown FIG. 59 SOLENOIDS Location: The solenoids are mounted on a bracket that is attached to the front left corner of the chassis. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Remove the left side panel. 3.

  • Page 52: Temperature Sensor Assembly

    SERVICE (cont.) TEMPERATURE SENSOR FIG. 61 TEMPERATURE SENSOR Location: The Temperature Sensor(s) are located inside the top rear of the cooling drum under the Auger Motor covers. Test Procedures: 1. Remove the left side housing panel. 2. Connect a voltmeter, across the two leads of the temperature sensor (leave plug connected);...

  • Page 53: Torque Sensor Circuit Board

    SERVICE (cont.) TORQUE SENSOR CIRCUIT BOARD FIG. 63 TORQUE SENSOR CIRCUIT BOARD Location: The torque sensor circuit board is located on the rear of the cooling drum mount just left of center. Test Procedures: 1. Place black meter lead at J1-3 (common) and red lead at J1-1 (signal).

  • Page 54: Transformer

    SERVICE (cont.) TRANSFORMER FIG. 65 TRANSFORMER - ULTRA-1 Location: The transformer is located inside dispenser onthe lower right side of the chassis. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Remove right side panel. 3. Connect the dispenser to the power source. 4.

  • Page 55: Coolant Schematics

    COOLANT SCHEMATIC ULTRA-1 41084 102709...
  • Page 56 COOLANT SCHEMATIC ULTRA-2 41084 102709...

  • Page 57: Electrical Schematics

    ULTRA-1 TRIACS TH1 & MOV4 controls Auger TH2 & MOV1 controls Compressor Relay TH3 & MOV2 controls Cooling Valve TH4 & MOV3 controls Refill Valve TRIAC MAP for ULTRA-1 @ J10-8 Reverse & J10-9 Forward @ J10-20 @ J10-19 @ J10-18 41084 102709...
  • Page 58 ULTRA-2 TRIACS TH1 & MOV3 controls Left solenoid TH2 & MOV1 controls Compressor Relay TH3 & MOV4 controls TH4 & MOV2 controls Right solenoid TH5 & MOV5 controls Left Auger TH6 & MOV6 controls Right Auger LIQUID AUTO-FILL TRIACS TH1 & MOV1 controls Right fill solenoid TH2 &...
  • Page 59 Input and Output Chart (ULTRA-1) J1 connector - black is TIC board ground and white is data wire. J9 connector for liquid crystal display. J10 connector for Main harness WIRE COLOR NUMBER AND GAUGE White/Blue 18 Blue 22 Tan 22 White/Gray 22 White/Black 18 Not used...
  • Page 60 41084 102709...
  • Page 61 Input and Output Chart (ULTRA-2) J1 connector - black is TIC board ground and white is data wire. J2 connector for touch pad/ membrane switch (see touch pad pin out test). J5 connector for liquid crystal display. J12 connector for models with Autofill option. J13 connector for Main harness WIRE COLOR NUMBER...
  • Page 62 41084 102709...
  • Page 63 41084 102709...

This manual is also suitable for:

Ultra-2Ultra-1

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