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.
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.
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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.
OPERATING CONTROLS ULTRA-1 There are three of these switches that will be used for the operation of the dispenser. P3932 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.
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OPERATING CONTROLS ULTRA-2 There are five of these switches that will be used for the operation of the dispenser. P3677 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.
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- 3. Pull forward to remove. 4.
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RECOMMENDED DAILY CLEANING (Continued) 1. Install the seal(s) over the 2. Align the auger shaft(s) with the 3. Install auger nose bushing into flange at the rear of the cooling auger(s). Push the auger(s) as inside front of hopper. drum(s) and press the seal(s) far as they will go and rotate so firmly into place as shown.
Auto-fill Cleaning Instructions (With Brixing Pump Installed) 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.
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.
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REQUIRED REGULAR MAINTENANCE: Semi Annual: Auger Motor Cover Bunn Kit #34245.0002 is required for ULTRA-1 and Run Capacitor #34245.0000 & #34245.0001 is required for ULTRA-2, to perform the semi annual Preventive maintenance: Auger Motor Assy Note: Service caused by failure to perform required maintenance is not covered by warranty.
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10. Place seal on insertion tool #28395.0000 as shown in FIG 2. Make sure open face of seal is toward cooling drum. Cooling Drum Seal 11. Apply a small amount of food grade lubricant (Bunn Seal Insertion Tool #M2568.1001) to inside diameter of seal. Push seal into bore until it is firmly seated;...
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.
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TROUBLESHOOTING (cont.) Chills but won’t freeze Dispenser in “DAY” mode? Set into “DAY” mode Dispenser in “ICE” mode? Verify augers Set into are turned on “ICE” mode Is display showing UPPER CASE “ICE” mode? Is Brix Is Thickness level high? screen set low? Is Filter dirty? Inspect auger drive shafts...
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TROUBLESHOOTING (cont.) No cooling at all Is ICE/CHILL set to off? Set into “ICE” or “CHILL” mode Is compressor running? Is filter Is Dispenser on dirty? an extension cord? Plug directly inti outlet Is there correct Check fan voltage at outlet? Call a licensed Have a certified electrician...
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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.
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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...
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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...
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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...
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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.
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.
SERVICE(CONT.) Removal and Replacement AUGER MOTORS 1. Remove the two #8 locking screws securing the auger ULTRA-2 shown motor cover to the cooling drum mount assembly. 2. Remove the cover and set aside for reassembly. 3. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor run capacitor.
SERVICE (CONT.) AUGER MOTOR CAPACITOR Removal and Replacement ULTRA-2 shown 1. Remove the two #8 locking screws securing the auger motor cover to the cooling drum mount assy. 2. Remove the cover and set aside for reassembly. 3. Disconnect the wires from the auger motor capacitor terminals.
SERVICE (cont.) 7. Pull the auger shaft assembly straight out of cool- ing drum. Inspect the shaft for abnormal wear or AUGER SHAFT ASSEMBLY scoring. 8. From the front of dispenser, remove the seal and Auger Motor Cover blue bushing from cooling drum and discard Run Capacitor them.
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SERVICE (cont.) AUGER SHAFT ASSEMBLY(cont.) 16. Refer to Hopper Installation for hopper assembly and installation procedures. Be sure to use new Open face of seal away hopper/drum seal and faucet seals from tool Cooling Drum Seal Seal Insertion Tool P1760 FIG.
SERVICE (cont.) CIRCUIT BREAKER FIG. 11 CIRCUIT BREAKER (ULTRA-2) FIG. 12 CIRCUIT BREAKER (ULTRA-1) 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. WHI/BLU from Transformer Test Procedures: 1.
SERVICE (cont.) COMPRESSOR (AMERICOLD) (ULTRA-2) Test Procedures: WARNING: The compressor start capacitor must be properly discharged before proceeding. This is most commonly done on low voltage capacitors by shorting across the terminals with a screwdriver. Compressor Start Relay: Refer to FIG. 15 1.
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SERVICE (cont.) COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.) 6. Install retainer (3) on new overload protector (2). Removal and Replacement: 7. Install retainer (3) and overload protector (2) on the Compressor Start Relay: Refer to FIG. 15 compressor terminal bracket. 1. Remove the terminal cover retainer (5) and the terminal 8.
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SERVICE (cont.) COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.) Removal and Replacement: 6. Install new compressor over the four studs in the dis- penser chassis with the fill valve to the left side of the Compressor Assy: dispenser. NOTE: Before removal of any refrigeration component the 7.
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SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) Test Procedures: WARNING: The compressor start capacitor must be properly discharged before proceeding. This is most commonly done on low voltage capacitors by shorting across the terminals with a screwdriver. Compressor Start Relay: Refer to FIG. 20 1.
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SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) (cont.) 6. Install retainer (3) on new overload protector (2). Removal and Replacement: 7. Install retainer (3) and overload protector (2) on the Compressor Start Relay: Refer to FIG. 20 compressor terminal bracket. 1. Disconnect the wires from the compressor start re- 8.
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SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) (cont.) Removal and Replacement: 6. Install new compressor over the four studs in the dis- penser chassis with the fill valve to the left side of the Compressor Assy: dispenser. NOTE: Before removal of any refrigeration component the 7.
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SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) Compressor Model: Electrtic Motor Type: The type of motor being used EMBRACO/NT2168GK, 115V 60HZ/100V 50HZ in the ULTRA-2 HP dispenser is known as CSR motor (Capacitive Start & Run). Compressor Specification: The CSR version uses a start and run capacitor with Commercial Designation: ¾...
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SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) Important Safeguards: • Trained service personnel with the knowledge of servicing and troubleshooting refrigeration systems or related components should be used. • Always be alert of smell and sounds (arching, popping and humming) coming from the compressor. Discon- nect power or unplug immediately and get away.
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Step 1: Disconnect all electrical power to the BUNN ULTRA-2 HP. Step 2: Access compressor terminal pins and discon- nect the wire leads going to the compressor pins.
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SERVICE (cont.) COMPRESSOR (EMBRACO) (ULTRA-2) External Thermal Protector Start Capacitor Start Capacitor: BUNN P/N# 39804.0004 Rating: 243-292 MFD 165V 50/60HZ Disconnect the start capacitor from the system. Re- move the bleed resistor. Use a capacitance meter to measure the capacitance. The capacitance value should be the rated value minus 0% to plus 20%.
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SERVICE (cont.) Test Procedures: COMPRESSOR (APPLIANCES) (ULTRA-1) Compressor Start Relay: Refer to FIG. 25 WARNING: The compressor capacitor must be properly discharged before proceeding. This is most commonly done on low voltage capacitors by shorting across the terminals with a screwdriver. 1.
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SERVICE (cont.) COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.) Removal and Replacement: WHI/ORN 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.
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SERVICE (cont.) COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.) Compressor Assy: 6. Install new compressor over the four studs in the dis- NOTE: Before removal of any refrigeration component the penser chassis with the fill valve to the right side of the refrigerant in the system must be reclaimed by a licensed dispenser.
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SERVICE (cont.) COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.) 6. Disconnect the two black wires from the compressor start relay. 7. Remove relay from the compressor. 8. Check for continuity across the upper left terminal and the right pin socket on the rear of the relay. If continuity is present as described, the compressor start relay is operating properly.
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SERVICE (cont.) COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.) Removal and Replacement: Compressor Assy: NOTE: Before removal of any refrigeration component the Compressor Start Relay: Refer to FIG. 30 refrigerant in the system must be reclaimed by a licensed 1. Remove the terminal cover (4) refrigeration repair person.
SERVICE (cont.) RELAY (or CONTACTOR on Early Models) If continuity is present as described, disconnect the ULTRA-2 shown dispenser from power source and reconnect wires to terminals #6 and #8, the relay is working. If continuity is not present as described, do the same continuity test across terminals #2 and #4.
SERVICE (cont.) CONTROL BOARD TIC board TIC board Control board Control board FIG. 35 CONTROL BOARD (ULTRA-2) FIG. 36 CONTROL BOARD (ULTRA-1) Location: Removal and Replacement: The control board is located behind the front panel, 1. Disconnect the main harness from connector J5 on the front of the chassis.
SERVICE (cont.) COOLING DRUM ALIGNMENT Ledge Drip Tray Drain Hole Boss Legs P1510 FIG. 38 CHECKING ALIGNMENT FIG. 37 COOLING DRUM SHIPPING SUPPORT When in its proper position, the cooling drum will cause The “A” shaped Cooling Drum Shipping Supports, a slight pressure on the hopper drip tray drain hole removed during Initial Set-Up should be kept and used and the two legs will be equidistant from the hopper...
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SERVICE (cont.) FAN - ULTRA-2 FIG. 39 FAN FIG. 40 FAN COMPONENTS Location: 6. Remove speed nut (2) from the motor shaft. The fan is located inside the dispenser chassis just 7. Remove fan (3). in front of the condenser. 8.
SERVICE (cont.) FAN - ULTRA-1 Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Remove the air filter from the back of the dis- penser. 3. Remove the four #8-32 hex screws attaching the fan and shroud assy to the condenser frame. 4.
SERVICE (cont.) HOT GAS TEMPERATURE SENSOR Removal and Replacement (Refer to Fig. 43) ULTRA-2 shown 1. Remove the left side housing panel. 2. Disconnect the plug on the hot gas sensor leads from the connector on the main harness. 3. Remove the clamp securing the hot gas sensor to Condenser-to-Compressor tube.
SERVICE (cont.) LAMP CORD ASSY 7. Strip the wires from the lamp holder/socket as- ULTRA-2 shown sembly approximately .375”. 8. Using the two wire nuts, supplied, connect the new lamp cord assembly to the lamp holder/socket as- sembly wires. 9. Reinstall the hopper liner to the bottom of the hop- per cover.
SERVICE (cont.) LAMP CORD CONNECTOR If continuity is not present when lamp cord assembly ULTRA-2 shown is connected or continuity is present when lamp cord assembly is not connected, replace the lamp cord connector. Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp cord connector.
SERVICE (cont.) LAMP HOLDER/SOCKET ASSEMBLY Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp ULTRA-2 shown cord connector assembly in the top of the auger motor cover. 2. Remove the hopper cover with the lamp cord as- sembly from the hopper.
SERVICE (CONT.) LED Lamps If voltage is present as described, the LED board is faulty. If voltage is not present as described, retrace the wiring circuit to find the fault. 5. Check for continuity across the terminals on the leads and the LED harness. If continuity is present as described, the lamp is op- erating properly.
SERVICE (cont.) LAMP RELAY Test Procedures: (Contacts) 1. Disconnect the dispenser from the power source. ULTRA-2 shown 2. Disconnect the WHI/VIO and WHI/YEL wires. Con- nect an ohmmeter across the two coil terminals where the wires were just removed. 3. Connect the dispenser from the power source.. 4.
SERVICE (cont.) MEMBRANE SWITCH (ULTRA-2) Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Remove right and left side panels. 3. Remove front panel and disconnect ribbon cable. 4. Peel the old Membrane Swith off the front panel and discard.
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SERVICE (cont.) MEMBRANE SWITCH (ULTRA-1) Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Remove right and left side panels. 3. Remove front panel and disconnect ribbon cable. 4. Peel the old Membrane Swith off the front panel and discard.
SERVICE (cont.) SOLENOIDS NOTE: Before removal of any refrigeration component ULTRA-2 shown the refrigerant in the system must be reclaimed by a licensed refrigeration repair person. Removal and Replacement: 1. Disconnect the wires from both solenoids. 2. Disconnect the refrigerant lines from the solenoids to the cooling drums and the refrigerant line from the filter/drier/splitter assembly.
SERVICE (cont.) Removal and Replacement: TEMPERATURE SENSOR 1. Remove the two #8-32 screws securing the auger ULTRA-2 shown motor cover to cooling drum mount and remove cover. Set aside for reassembly. 2. Disconnect the plug on the temperature sensor leads from the connector on the dispenser main harness.
SERVICE (cont.) TORQUE SENSOR CIRCUIT BOARD Removal and Replacement: ULTRA-2 shown 1. Remove the two #8-32 locking screws securing the auger motor cover to the cooling drum mount. 2. Remove the cover and set aside for reassembly. 3. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor run capacitor.
SERVICE (cont.) TRANSFORMER -L IN FIG. 65 TRANSFORMER - ULTRA-1 FIG. 66 TRANSFORMER - ULTRA-2 Location: Removal and Replacement: The transformer is located inside dispenser onthe lower 1. Disconnect the dispenser from the power source. right side of the chassis. 2.
SERVICE (CONT.) Liquid Autofill System WATER INLET SHUT-OFF VA LVE WATER REGUL AT OR Syrup Pump (WHEN PRESSURE IS ABO VE 80PSI) DOUBLE CHECK VA LVE (WHEN REQUIRED BY LO CAL REGUL AT IONS ) Suppl y B.I.B. OR VENTED TANK Optimal Pressure Setting 40 -80 psi FIG.
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SERVICE (CONT.) Liquid Autofill System Location: Removal and Replacement: Under each hopper motor cover there are two 1. Shut off and disconnect the product and water constant flow (CF) valves, one for water and one for supply lines to the solenoid valves. syrup.
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SERVICE (CONT.) Liquid Autofill System (50 PSI RECOMMENDED) * Should be located no more than 6” from pump. FIG. 70 LIQUID AUTOFILL SYSTEM 41084 081216...
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SERVICE (CONT.) Liquid Autofill System Location: Removal and replacement: Located inside the right access cover are the Syrup 1. Shut off and disconnect the product and water and water solenoid valves for each hopper. Some models supply lines to the machine. will have only syrup valves and lines.
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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 FUNCTION COMPONENT VOLTAGE NUMBER AND GAUGE White/Blue 18 - - - - - - Rectifier - - - - - - Blue 22...
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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 FUNCTION...