Bunn Ultra-1 Service & Repair Manual
  1. Manuals
  2. Brands
  3. Bunn Manuals
  4. Beverage Dispenser
  5. BUNN-O-MATIC ULTRA-1
  6. Service & repair manual

Bunn Ultra-1 Service & Repair Manual

Frozen beverage dispensers
Hide thumbs Also See for Ultra-1:
Table of Contents

Advertisement

Quick Links

Ultra
®
Frozen Beverage Dispensers
SERVICE & REPAIR MANUAL
Bunn-O-Matic Corporation
Post Office Box 3227, Springfield, Illinois 62708-3227
Phone (217) 529-6601 | Fax (217) 529-6644
www.bunn.com
57654.0000 A 12/20 © 2020 Bunn-O-Matic Corporation

Advertisement

Table of Contents
loading

Related Manuals for Bunn Ultra-1

Summary of Contents for Bunn Ultra-1

  • Page 1 Ultra ® Frozen Beverage Dispensers SERVICE & REPAIR MANUAL Bunn-O-Matic Corporation Post Office Box 3227, Springfield, Illinois 62708-3227 Phone (217) 529-6601 | Fax (217) 529-6644 www.bunn.com 57654.0000 A 12/20 © 2020 Bunn-O-Matic Corporation...

  • Page 2: Warranty

    LIMITED, AT BUNN’S 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 ........................4 SITE PREPARATION ......................4 INTRODUCTION ........................4 TEMP & TORQUE SCREEN ....................5 OPERATING CONTROLS .....................6 USING THE DISPENSER FOR GRANITA-TYPE PRODUCTS ..........7 USING THE DISPENSER FOR COLD LIQUID PRODUCTS ..........7 RECOMMENDED CLEANING ....................8 ASSEMBLY FOLLOWING CLEANING ..................9 AUTO-FILL CLEANING INSTRUCTIONS ................10 PREVENTIVE MAINTENANCE SCHEDULE ..............11 REQUIRED REGULAR MAINTENANCE ...............12,13...

  • Page 4: User Notices

    USER NOTICES Carefully read and follow all notices on the equipment and in this manual. They were written for your protection. All notices are to be kept in good condition. Replace any unreadable or damaged labels. SITE PREPARATION The dispenser is very heavy. Place it on a sturdy counter or shelf capable of supporting at least 180 lbs. It is for indoor use only.

  • Page 5: Temp & Torque Screen

    TEMP & TORQUE SCREEN Press and hold for five seconds the left and right 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

    OPERATING CONTROLS There are five of these switches that will be used for the operation of the dispenser. 1. 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: Using The Dispenser For Granita-Type Products

    6. Wait for the liquid to freeze to the desired consistency. HINT: BUNN recommends that the product in the dispenser be thawed each day, usually overnight. The ice granules get too large and a consistent product is difficult to maintain if left frozen for an extended period of time.

  • Page 8: Recommended Cleaning

    RECOMMENDED CLEANING Frequency of cleaning should be as directed by the product manufacturer. 1. Turn cooling to OFF selection. Empty all product from the hopper(s). Turn auger to OFF selection. Disconnect the hopper lid lamp cord(s) and remove the lids. On models with autofill, disconnect fill hoses and level probe from hopper. 2.

  • Page 9: Assembly Following Cleaning

    ASSEMBLY FOLLOWING CLEANING 1. Install the seal(s) over the flange at 2. Align the auger shaft(s) with the 3. Install auger nose bushing into the rear of the cooling drum(s) and auger(s). Push the auger(s) as far inside front of hopper. press the seal(s) firmly into place as they will go and rotate so the flat as shown.

  • Page 10: Auto-Fill Cleaning Instructions

    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.

  • 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

    REQUIRED REGULAR MAINTENANCE Semi-annual Auger Motor Cover BUNN Kit #34245.0000 & #34245.0001 are required to perform the semi-annual preventive maintenance: Run Capacitor Auger Motor Assy : Service caused by failure to perform required NOTE maintenance is not covered by warranty.
  • Page 13 10. Place seal on insertion tool #28395.0000 as shown in FIG 2. Cooling Drum Seal Make sure open face of seal is toward cooling drum. Seal Insertion Tool 11. Apply a small amount of food grade lubricant (Bunn P1760 #M2568.1001) to inside diameter of seal. Push seal into bore FIG 2 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 personnel.

  • Page 15: Chills But Won't Freeze

    TROUBLESHOOTING (continued) 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...

  • Page 16: No Cooling At All

    TROUBLESHOOTING (continued) 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...

  • Page 17: Freezes, But Not Thick Enough

    TROUBLESHOOTING (continued) Freezes, but not thick enough Ambient Adjust thickness Brix ratio Too much temperature screen higher too high alcohol in too hot product Check for slightly Recommended Adjust bent auger shaft for indoor product pins and/or weak use only torsion springs.

  • Page 18: Noise

    TROUBLESHOOTING (continued) 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: Torque Sensor Error

    TROUBLESHOOTING (continued) Torque Sensor Error TORQUE SENSOR TORQUE SENSOR ERROR TORQUE SENSOR OPEN 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: Temperature Sensor Error

    TROUBLESHOOTING (continued) Temperature Sensor Error TEMPERATURE SENSOR SHORTED TEMPERATURE SENSOR OPEN 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: Clean Filter Messages

    TROUBLESHOOTING (continued) Clean Filter Messages “MONTHLY FILTER “FILTER NEEDS “FILTER NEEDS CLEAN REQUIRED” CLEANING” !!!CLEANING!!!” Freezing is Disabled Hot gas thermistor Hot gas thermistor Monthly reminder sensing over 220° F sensing over 250° 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. - Inspection, testing, and repair of electrical equipment should be performed only by qualified service WARNING personnel.

  • Page 23: Auger Motors

    SERVICE (continued) AUGER MOTORS Removal and Replacement 1. Remove the two #8 locking screws securing the auger 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.

  • Page 24: Auger Motor Capacitors

    SERVICE (continued) AUGER MOTOR CAPACITOR Removal and Replacement 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.

  • Page 25: Auger Shaft Assembly

    SERVICE (continued) AUGER SHAFT ASSEMBLY 7. Pull the auger shaft assembly straight out of Auger Motor Cover cooling drum. Inspect the shaft for abnormal Run Capacitor wear or scoring. Auger Motor Assy 8. From the front of dispenser, remove the seal and Auger Shaft Assy blue bushing from cooling drum and discard them.
  • Page 26 SERVICE (continued) 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.

  • Page 27: Circuit Breaker

    SERVICE (continued) CIRCUIT BREAKER WHI/BLU from Transformer WHI/YEL to Lamp Relay FIG. 12 CIRCUIT BREAKER TERMINALS FIG. 11 CIRCUIT BREAKER Location: The circuit breaker is located inside the dispenser on the front right frame post. Test Procedures: 1. Disconnect the dispenser from the power source. 2.

  • Page 28: Compressor Americold

    SERVICE (continued) COMPRESSOR (AMERICOLD) 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.
  • Page 29 SERVICE (continued) COMPRESSOR (AMERICOLD) (cont.) Removal and Replacement: 6. Install retainer (3) on new overload protector (2). 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 cover (4) 8.
  • Page 30 SERVICE (continued) COMPRESSOR (AMERICOLD) (cont.) Removal and Replacement: 6. Install new compressor over the four studs in the dispenser chassis with the fill valve to the left side of Compressor Assy: the dispenser. NOTE: Before removal of any refrigeration component the 7.
  • Page 31 SERVICE (continued) COMPRESSOR (EMBRACO) 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.
  • Page 32 SERVICE (continued) COMPRESSOR (EMBRACO) (cont.) Removal and Replacement: 6. Install retainer (3) on new overload protector (2). Compressor Start Relay: Refer to FIG. 20 7. Install retainer (3) and overload protector (2) on the 1. Disconnect the wires from the compressor start relay. compressor terminal bracket.
  • Page 33 SERVICE (continued) COMPRESSOR (EMBRACO) (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.
  • Page 34 SERVICE (continued) COMPRESSOR (EMBRACO) (cont.) 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: Commercial Designation: ¾ HP The CSR version uses a start and run capacitor with an external thermal protector.
  • Page 35 SERVICE (continued) COMPRESSOR (EMBRACO) (cont.) 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. Disconnect power or unplug immediately and get away.
  • Page 36 Step 1: Disconnect all electrical power to the BUNN C - Common ULTRA-2 HP. S - Start...
  • Page 37 SERVICE (continued) COMPRESSOR (EMBRACO) 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. • Remove the bleed resistor. • Use a capacitance meter to measure the capacitance.

  • Page 38: Embraco

    SERVICE (continued) RELAY (or CONTACTOR on Early Models) If continuity is present as described, disconnect the 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.

  • Page 39: Control Board

    SERVICE (continued) CONTROL BOARD Removal and Replacement: 1. Disconnect the main harness from connector J5 on the control board. 2. Remove the four #8-18 pan head screws TIC Board securing the control board to the mounting box. Disconnect TIC (memory) board from connector J1 on the control board.

  • Page 40: Cooling Drum Alignment

    SERVICE (continued) COOLING DRUM ALIGNMENT Ledge Boss Drain Hole Legs Drip Tray P1510 FIG. 37 COOLING DRUM SHIPPING SUPPORT FIG. 38 CHECKING ALIGNMENT The “A” shaped Cooling Drum Shipping Supports, When in its proper position, the cooling drum will cause removed during Initial Setup should be kept and used a slight pressure on the hopper drip tray drain hole as a tool to reset the alignment of the cooling drums...

  • Page 41: Fan

    SERVICE (continued) FIG. 39 FAN FIG. 40 FAN COMPONENTS Location: The fan is located inside the dispenser chassis just in 8. Remove silencer (4). front of the condenser. 1. Condenser Shroud and Fan Assy 2. Speed Nut 3. Fan Blade Test Procedures: 4.

  • Page 42: Hot Gas Temperature Sensor

    SERVICE (continued) HOT GAS TEMPERATURE SENSOR Removal and Replacement (Refer to Fig. 42) 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.

  • Page 43: Lamp Cord Assembly

    SERVICE (continued) LAMP CORD ASSEMBLY 5. Remove lamp cord assembly from hopper cover and discard. 6. Push new lamp cord wires through the holes on the left outside top of the hopper cover. 7. Strip the wires from the lamp holder/socket assembly approximately .375”.

  • Page 44: Lamp Cord Connector

    SERVICE (continued) LAMP CORD CONNECTOR Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp cord connector. 2. Remove the two #8-32 locking screws securing the auger motor cover the auger motor bracket/cooling drum bracket. Move cover back far enough to gain access to the lamp cord connector.

  • Page 45: Lamp Holder/Socket Assembly

    SERVICE (continued) LAMP HOLDER/SOCKET ASSEMBLY Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the auger motor cover. 2. Remove the hopper cover with the lamp cord assembly from the hopper. 3.

  • Page 46: Led Lamps

    SERVICE (continued) LED Lamps Removal and Replacement: 1. Disconnect power from the dispenser. 2. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the auger motor cover. 3. Remove the hopper cover with the lamp cord assembly from the hopper.

  • Page 47: Lamp Relay

    SERVICE (continued) LAMP RELAY Test Procedures: (Contacts) 1. Disconnect the dispenser from the power source. 2. Disconnect the WHI/VIO and WHI/YEL wires. Connect an ohmmeter across the two coil terminals where the wires were just removed. 3. Connect the dispenser from the power source. 4.

  • Page 48: Membrane Switch

    SERVICE (continued) MEMBRANE SWITCH 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.

  • Page 49: Solenoids

    SERVICE (continued) SOLENOIDS NOTE: Before removal of any refrigeration component 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.

  • Page 50: Temperature Sensor

    SERVICE (continued) TEMPERATURE SENSOR Removal and Replacement: 1. Remove the two #8-32 screws securing the auger 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.

  • Page 51: Torque Sensor Circuit Board

    SERVICE (continued) TORQUE SENSOR CIRCUIT BOARD Removal and Replacement: 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.

  • Page 52: Transformer

    SERVICE (continued) TRANSFORMER Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Remove right side panel. 3. Disconnect the four wires from transformer. 4. Disconnect the wiring harness from the plug on the transformer. 5. Remove the two #8-32 nuts securing the transformer to the chassis base.
  • Page 53 SERVICE (continued) Liquid Autofill System WATER INLET SHUT-OFF VALVE WATER REGULATOR (WHEN PRESSURE IS ABOVE 80PSI) DOUBLE CHECK VALVE (WHEN REQUIRED BY LOCAL REGULATIONS) SYRUP PUMP SUPPLY B.I.B. OR VENTED TANK WATER CONCENTRATE Optimal Pressure Setting 40 - 80 psi FIG.
  • Page 54 SERVICE (continued) Liquid Autofill System Location: Removal and Replacement: Under each hopper motor cover there are two constant 1. Shut off and disconnect the product and water flow (CF) valves, one for water and one for syrup. supply lines to the solenoid valves. Located on top of the cover is a needle valve for adjust- 2.
  • Page 55 SERVICE (continued) Liquid Autofill System CITY WATER INLET SHUT-OFF VALVE WATER REGULATOR SHURFLO P/N: 183-0XX (50 PSI RECOMMENDED) DOUBLE CHECK VALVE 3-WAY SANITIZING VALVE (SHURFLO P/N: 94-056-00) *Should be located no more than 6” from pump. CONCENTRATE CONCENTRATE OUTLET WATER B.I.B.
  • Page 56 SERVICE (continued) Liquid Autofill System Location: Removal and replacement: Located inside the right access cover are the Syrup and 1. Shut off and disconnect the product and water water solenoid valves for each hopper. Some models supply lines to the machine. will have only syrup valves and lines.

  • Page 57: Coolant Schematics

    COOLANT SCHEMATIC...

  • Page 58: Triac Maps

    TRIAC MAPS LIQUID AUTO-FILL BOARD TRIACS TH1 & MOV3 controls Left solenoid @ J13-15 TH2 & MOV1 controls Compressor Relay @ J13-17 TH3 & MOV4 controls @ J13-14 TH4 & MOV2 controls Right solenoid @ J13-16 TH5 & MOV5 controls Left Auger @ J13-2 Reverse &...

  • Page 59: Input And Output Chart

    INPUT AND OUTPUT CHART 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 PIN NUMBER...
  • Page 60 COMPRESSOR ASSY WATER PRODUCT WATER. PRODUCT. WHI/YEL WHI/YEL LEFT RIGHT TORQUE TORQUE SENSOR SENSOR LEFT RIGHT GRN/YEL J2-1 120 VOLTS AC START 230 VOLTS AC J2-5 2 WIRE WHI/ORN SINGLE PHASE 60/50 HZ 32082.0002 E 05/12 © 2005 BUNN-O-MATIC CORPORATION J2-10...
  • Page 61 LEFT RIGHT LEVEL LEVEL PROBE PROBE START RELAY J2-10 LEFT RIGHT J1-14 J12-14 TORQUE TORQUE LEFT RIGHT SENSOR SENSOR 100 VOLTS AC 2 WIRE CAPACITOR LIMIT SINGLE PHASE THERM. 60 HZ 32082.0004 A 03/07 © 2007 BUNN-O-MATIC CORPORATION COMPRESSOR ASSY...
  • Page 62 SCHEMATIC WIRING DIAGRAM PAFP PROBE DETECTOR LEFT RIGHT RCA PLUG FILTER RECTIFIER CHASSIS CHASSIS BRN/BLK RED/BLK BLU/BLK RELAY BLU/BLK 120 VOLTS 220-240 VOLTS AC 2 WIRE SINGLE PHASE 50/60 HZ...

This manual is also suitable for:

Ultra-234000.053434000.057134000.001334000.052234000.0575 ... Show all

Table of Contents