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Bunn ULTRA-1 manual

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Table of contents for the manual

  • Page 1

    UL TRA-1 UL TRA-2 SER VICE & REP AIR MANUAL BUNN-O-MA TIC CORPORA TION POST OFFICE BOX 3227 SPRINGFIELD, ILLINOIS 62708-3227 PHONE: (217) 529-6601 F AX: (217) 529-6644 41084.0000B 04/10 ©2009 Bunn-O-Matic Corporation[...]

  • Page 2

    2 41084 031610 BUNN-O-MA TIC COMMERCIAL PRODUCT WARRANTY Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows: 1) All equipment other than as specified below: 2 years parts and 1 year labor . 2) Electronic circuit and/or control boards: parts and labor for 3 years. 3) Compressors on refrigeration equipment: 5 years part[...]

  • Page 3

    3 USER NOTICES All notices on this equipment are written for your protection. All notices are to be kept in good condition. Replace any unreadable or damaged labels. CONTENTS Warranty ................................................................................................................................... 2 User Notices ...................[...]

  • Page 4

    4 INTRODUCTION Safety first! T o avoid electrical shock, unplug dispenser from power source before servicing inside. WARNING : When powered, the condenser cooling fan will turn on ever y 30 minutes to aid cooling the entire unit, even when not in the ICE or CHILL modes. KEEP HANDS A WA Y FROM F AN! Basic Maintenance In order to maintain proper mac[...]

  • Page 5

    5 TEMP & TORQUE SCREEN Press and hold for five seconds the UL TRA 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 . Press and release the UL TRA and ICE hidden switches to return to HOME SCREEN. The [...]

  • Page 6

    6 OPERA TING CONTROLS UL TRA-1 There are three 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. 2.[...]

  • Page 7

    7 OPERA TING CONTROLS UL TRA-2 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. 2.[...]

  • Page 8

    8 10. 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 wash all components with a clean wash cloth in the hot water and sanitizer solu- tion. Use a clean, soft bristle brush as needed for the smaller components and tight areas. Do not immerse hopper lids. [...]

  • Page 9

    9 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. 2. Al ign the au ger shaf t(s ) wit h the auger(s). Push the auger(s) as far as they will go and rotate so the flat face of the auger shaft is aligned with the flat face of the auger nose. 4. Thoro ughly rins e the hop p[...]

  • Page 10

    10 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. (Qui[...]

  • Page 11

    11 C. TORSION SPRINGS WEAK TORSION SPRINGS DAMAGED/CORRODED AUGER SHAFT DAMAGED/WORN BUSHINGS/SEALS DIRTY OR DAMAGED TORQUE SENSOR BOARD TOO MUCH KRYTOX GREASE CHILL MODE NORMAL OPERATION POSSIBLE CAUSES FOR FALSE READINGS ICE MODE BENT TORQUE SENSOR PINS MISSING TORQUE SENSOR PINS D. AUGER SHAFT A. MOTOR SHAFT TORQUE SENSOR PIN B. AUGER SHAFT TORQ[...]

  • Page 12

    12 REQUIRED REGULAR MAINTENANCE: Semi Annual: Bunn Kit #34245.0002 is required for UL TRA-1 and #34245.0000 & #34245.0001 is required for UL TRA-2, to perform the semi annual Preventive maintenance: Note: Ser vice caused by failure to perform required maintenance is not covered by warranty . The following instructions apply to one hopper only; [...]

  • Page 13

    13 6. 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 and blue bushing from cooling drum and discard them. 8. Inspect inside of the coling drum from the rear for product leakage and clean thoroughly with an extended bristle brush (Bunn part no. 40500.[...]

  • Page 14

    14 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 T echnical Ser vice Department. • Inspection, testing, and repair of electrical equipment shoul[...]

  • Page 15

    15 TROUBLESHOOTING (cont.) Chills but won’t freeze Dispenser in “DA Y” mode? Y es No Y es Y es Y es Y es Y es No No No No No 3- Clean 1 1 3 2 2 1- Done 2- Adjust Set into “DA Y” mode Dispenser in “ICE” mode? Set into “ICE” mode Verify augers are turned on Is display showing UPPER CASE “ICE” mode? Is Brix level high? Is Filter [...]

  • Page 16

    16 TROUBLESHOOTING (cont.) No cooling at all Y es No Is ICE/CHILL set to off? Have a certified refrigeration technician check for low refrigerant or blockage. No Set into “ICE” or “CHILL” mode 3- Clean 1 3 1- Done 2- Adjust 1 No No No Y es Y es Y es Y es Is compressor running? Is Dispenser on an extension cord? Is filter dirty? Plug direc[...]

  • Page 17

    17 TROUBLESHOOTING (cont.) Freezes, but not thick enough Adjust thickness screen higher Check for slightly bent auger shaft pins and/or weak torsion springs. Check for dirty or worn seals and bushings. Brix ratio too high T oo much alcohol in product Ambient temperature too hot Adjust product Recommended for indoor use only No hood lamps Is dispens[...]

  • Page 18

    18 TROUBLESHOOTING (cont.) Noise Auger jumping Check fan Lower brix ratio Drum alignment Check auger shaft bushings Using auger assembly from CDS 2 or 3? Replace with UL TRA p/n 32106.1000 Auger won’t turn Auger motor/capacitor checks Check membrane switch Y es No Do they turn during “AUGER MOTOR TEST” mode? One direction, but not the other R[...]

  • Page 19

    19 TROUBLESHOOTING (cont.) T orque Sensor Error Y es No Sensor unplugged or break in wiring Y es No TORQUE SENSOR ERROR TORQUE SENSOR SHORTED TORQUE SENSOR OPEN Are augers turning? Left side Right side Left side Right side Go to motor troubleshooting Are augers shaft pins damaged or missing? Check sensor circuit Replace as necessary 41084 102709[...]

  • Page 20

    20 TROUBLESHOOTING (cont.) T emperature Sensor Error TEMPERA TURE SENSOR SHORTED TEMPERA TURE SENSOR OPEN Left side Right side Check wiring harness between thermistor and control board Left side Right side Product not covering back end of drum. Drum temperature falls below 9° F . Replenish product Thermistor unplugged or break in wiring Check ther[...]

  • Page 21

    21 TROUBLESHOOTING (cont.) Clean Filter Messages “MONTHL Y FIL TER CLEAN REQUIRED” Monthly reminder Clean filter “FIL TER NEEDS CLEANING” “FIL TER NEEDS !!!CLEANING!!!” Hot gas thermistor sensing over 220° F Hot gas thermistor sensing over 250° F Dirty filter; air flow blockage; wrong refrigerant or over charged Hold UL TRA button [...]

  • Page 22

    22 SERVICE This section provides procedures for testing and replacing various major components used in this dispenser should ser vice become necessar y . Refer to T roubleshooting for assistance in determining the cause of any problem. WARNING - Inspection, testing, and repair of electrical equipment should be per formed only by qualified ser vice[...]

  • Page 23

    23 FIG. 2 AUGER MOTOR TERMINALS Location The auger motors are located at the upper rear of the dispenser chassis inside the auger motor covers. T est Procedures 1. Remove the hopper from the same side as the motor to be tested. 2. T urn “ON” the appropriate auger switch. 3. Nudge the auger to start it turning. If the auger doesn’t turn, repla[...]

  • Page 24

    24 FIG. 4 AUGER MOTOR CAP ACITOR TERMINALS SERVICE (CONT .) AUGER MOTOR CAP ACITOR FIG. 3 AUGER MOTOR CAP ACITORS P1341 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). T est Procedures 1. Remove the hopper from the same side as the motor to be tested. 2.[...]

  • Page 25

    25 SERVICE (cont.) AUGER SHAFT ASSEMBL Y Auger Shaft Assy Auger Shaft Bushing Cooling Drum Seal Hopper Drum Seal FIG. 5 AUGER SHAFT ASSEMBL Y Location: The Auger Shaft Assembly is located in each of the cooling drums. Removal and Replacement: 1. Drain, remove and clean hopper; refer to the Rec- ommended Daily Weekly Cleaning Section of this manual,[...]

  • Page 26

    26 SERVICE (cont.) AUGER SHAFT ASSEMBL Y(cont.) FIG. 7 COOLING DRUM SEAL P1760 Open face of seal away from tool Cooling Drum Seal Seal Insertion T ool FIG. 8 MOTOR/SHAFT ASSEMBL Y P1761 Lube about 1 1/2” of shaft and in the groo ve with #2956 3.00 00 “Krytox” Lubricant Auger Shaft Assy 14. Assemble motor/shaft assembly as shown in Fig. 8, the[...]

  • Page 27

    27 9 FIG. 11 CIRCUIT BREAKER (UL TRA-2) SERVICE (cont.) CIRCUIT BREAKER Location: The circuit breaker is located inside the dispenser on the front right frame post on UL TRA-2 models; and under the Auger Motor cover on UL TRA-1 models. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Remove the wires from the circuit breaker [...]

  • Page 28

    28 SERVICE (cont.) COMPRESSOR (AMERICOLD) (UL TRA-2) FIG. 14 COMPRESSOR ASSY FIG. 15 COMPRESSOR ELECTRICAL COMPONENTS T est 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 Rel[...]

  • Page 29

    29 SERVICE (cont.) COMPRESSOR (AMERICOLD) (UL TRA-2) (cont.) Compressor Thermal Overload Protector: Refer to FIG. 15 1. Remove terminal cover retainer (5) and terminal cover (4). 2. Disconnect the WHI/ORN wire of the harness from the thermal overload protector . 3. Disconnect the BLK wire from the Compressor’ s upper terminal. 4. Remove overload [...]

  • Page 30

    30 SERVICE (cont.) COMPRESSOR (AMERICOLD) (UL TRA-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. 1. Disconnect the[...]

  • Page 31

    31 SERVICE (cont.) COMPRESSOR (EMBRACO) (UL TRA-2) FIG. 19 COMPRESSOR ASSY FIG. 20 COMPRESSOR ELECTRICAL COMPONENTS T est 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[...]

  • Page 32

    32 SERVICE (cont.) COMPRESSOR (EMBRACO) (UL TRA-2) (cont.) Compressor Thermal Overload Protector: Refer to FIG. 20 1. Remove terminal cover retainer (5) and terminal cover (4). 2. Disconnect the WHI/ORN wire of the harness from the thermal overload protector . 3. Disconnect the BLK wire from the Compressor’ s upper terminal. 4. Remove overload pr[...]

  • Page 33

    33 SERVICE (cont.) COMPRESSOR (EMBRACO) (UL TRA-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. 1. Disconnect the t[...]

  • Page 34

    34 SERVICE (cont.) COMPRESSOR (APPLIANCES) (UL TRA-1) FIG. 24 COMPRESSOR & COMPONENT LOCA TIONS FIG. 25 COMPRESSOR THERMAL OVERLOAD PROTECTOR LOCA TION T est Procedures: 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 b[...]

  • Page 35

    35 SERVICE (cont.) COMPRESSOR (APPLIANCES) (UL TRA-1) (cont.) WHI/ORN GRN WHI BRN/WHI (120V) BRN (230V) BLU FIG. 26 RELA Y TERMINALS FIG. 27 THERMAL OVERLOAD PROTECTOR TERMINALS Plugs into Relay BRN/WHI (120V) to Relay BRN (230V) to Relay BLU to Relay FIG. 28 COMPRESSOR CAP ACITOR TERMINALS Removal and Replacement: Compressor Start Relay: Refer to [...]

  • Page 36

    36 SERVICE (cont.) COMPRESSOR (APPLIANCES) (UL TRA-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. Disconnect the tubes from the condense[...]

  • Page 37

    37 SERVICE (cont.) COMPRESSOR (DANFOSS) (UL TRA-1B) (cont.) Location: The compressor assy is located inside the front of the dispenser chassis. FIG. 29 COMPRESSOR & COMPONENT LOCA TIONS T est Procedures: Compressor Start Relay: Refer to FIG. 30 WARNING: The compressor capacitor must be properly discharged before proceeding. This is most commonl[...]

  • Page 38

    38 SERVICE (cont.) COMPRESSOR (DANFOSS) (UL TRA-1B) (cont.) GRN WHI WHI/ORN to Overload Protector FIG. 30 RELA Y TERMINALS BLK to Compressor Relay BLK to Compressor Relay FIG. 31 COMPRESSOR CAP ACITOR TERMINALS Removal and Replacement: Compressor Start Relay: Refer to FIG. 30 1. Remove the terminal cover (4) 2. Disconnect the wires from the compres[...]

  • Page 39

    39 R SERVICE (cont.) RELA Y (or CONT ACTOR 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. If continu- ity is present between terminal[...]

  • Page 40

    40 SERVICE (cont.) CONTROL BOARD FIG. 35 CONTROL BOARD (UL TRA-2) Removal and Replacement: 1. Disconnect the main harness from connector J5 (UL TRA-2) or J9 (UL TRA-1) on the control board. 2. Remove the four #8-18 pan head screws securing the control board to the mounting box. Disconnect TIC (memor y) board from connector J1 on the control board. [...]

  • Page 41

    41 SERVICE (cont.) COOLING DRUM ALIGNMENT 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 . T o chec[...]

  • Page 42

    42 1 2 3 4 5 6 7 SERVICE (cont.) F AN - UL TRA-2 FIG. 39 F AN Location: The fan is located inside the dispenser chassis just in front of the condenser . T est Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the gray and white wires from the main harness to the fan leads. 3. With a voltmeter , check the voltage across th[...]

  • Page 43

    43 SERVICE (cont.) F AN - UL TRA-1 FIG. 42 F AN Location: The fan assembly is located inside the rear of the dispenser chassis behind the condenser . T est 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. 3. Connect the dispenser to the powe[...]

  • Page 44

    44 SERVICE (cont.) HOT GAS TEMPERA TURE SENSOR 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. T est Procedures: 1. Remove the left side housing panel. 2. Connect a voltmeter , across the two leads of the hot gas sensor (leave plug connected); The indication must [...]

  • Page 45

    45 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 . T est Procedures: 1. Disconnect the dispenser from the power source. 2. Unplug the lamp cord assembly from lamp cord connector assembly . 3. Check for continuity across the tip of the cord as- sembly and [...]

  • Page 46

    46 SERVICE (cont.) LAMP CORD CONNECTOR If continuity is not present when lamp cord assembly 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 . 2. Remove the two #8-32 locking screws securing the[...]

  • Page 47

    47 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 as- sembly from the hopper . 3. Remove hopper cover liner from the hopper cover . 4. Cut off the closed-end splices connec ting lamp cord assembly to the lamp hold[...]

  • Page 48

    48 T est Procedures: (Contacts) 1. Disconnect the dispenser from the power source. 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. T urn on Power (I/O) Switch. Verify the dispenser is in the “DA Y” mode. The in[...]

  • Page 49

    49 1 12 1 MEMBRANE SWITCH I/O ULTRA GOURMET ICE SHIELD LEFT RIGHT 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. Clean any remaining adhesive from front panel with mine[...]

  • Page 50

    50 8 1 MEMBRANE SWITCH UL TRA POWER GOURMET ICE SHIELD 1 SERVICE (cont.) MEMBRANE SWITCH (UL TRA-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. Clean any remaining a[...]

  • Page 51

    51 FIG.60 SOLENOID TERMINALS SERVICE (cont.) SOLENOIDS FIG. 59 SOLENOIDS Location: The solenoids are mounted on a bracket that is attached to the front left corner of the chassis. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Remove the left side panel. 3. Connect a voltmeter across the white wire and the other wire on the[...]

  • Page 52

    52 FIG. 62 TEMPERA TURE SENSOR SERVICE (cont.) TEMPERA TURE SENSOR FIG. 61 TEMPERA TURE SENSOR P1341 Location: The T emperature Sensor(s) are located inside the top rear of the cooling drum under the Auger Motor covers. T est Procedures: 1. Remove the left side housing panel. 2. Connect a voltmeter , across the two leads of the temperature sensor ([...]

  • Page 53

    53 FIG. 64 TORQUE SENSOR CIRCUIT BOARD TERMINALS SERVICE (cont.) TORQUE SENSOR CIRCUIT BOARD FIG. 63 TORQUE SENSOR CIRCUIT BOARD P1341 Location: The torque sensor circuit board is located on the rear of the cooling drum mount just left of center . T est Procedures: 1. Place black meter lead at J1-3 (common) and red lead at J1-1 (signal). Set meter [...]

  • Page 54

    54 SERVICE (cont.) TRANSFORMER FIG. 67 TRANSFORMER TERMINALS FIG. 65 TRANSFORMER - UL TRA-1 Location: The transformer is located inside dispenser onthe lower right side of the chassis. T est Procedures: 1. Disconnect the dispenser from the power source. 2. Remove right side panel. 3. Connect the dispenser to the power source. 4. Connect a voltmeter[...]

  • Page 55

    55 COOLANT SCHEMA TIC UL TRA-1 COPPER TUBE .25” O.D. X .030” COPPER TUBE .25” O.D. X .030” SUCTION ACCUMULA TOR COPPER TUBE .312” O.D. X .032” CONDENSER EV APORA TOR FIL TER DRYER COMPRESSOR SERVICE VA LV E FOR COOLANT CHARGE INFORMA TION SEE DECAL ON SIDE P ANEL SERVICE VA LV E FOR COOLANT CHARGE INFORMA TION SEE DECAL ON SIDE P ANEL T[...]

  • Page 56

    56 COOLANT SCHEMA TIC UL TRA-2 COPPER TUBE .25” O.D. X .030” COPPER TUBE .25” O.D. X .030” SUCTION ACCUMULA TOR COPPER TUBE .312” O.D. X .032” CONDENSER LEFT EV APORA TOR RIGHT EV APORA TOR FIL TER DRYER COMPRESSOR SERVICE VA LV E FOR COOLANT CHARGE INFORMA TION SEE DECAL ON SIDE P ANEL TO CONTROL BOARD TO CONTROL BOARD THERMISTOR TEMPE[...]

  • Page 57

    57 TRIAC MAP for UL TRA-1 UL TRA-1 TRIACS TH1 & MOV4 controls Auger @ J10-8 Reverse & J10-9 For ward TH2 & MOV1 controls Compressor Relay @ J10-20 TH3 & MOV2 controls Cooling V alve @ J10-19 TH4 & MOV3 controls Refill V alve @ J10-18 41084 102709[...]

  • Page 58

    58 TRIAC MAPS for UL TRA-2 UL TRA-2 TRIACS TH1 & MOV3 controls Left solenoid @ J13-15 TH2 & MOV1 controls Compressor Relay @ J13-17 TH3 & MOV4 controls Fan @ J13-14 TH4 & MOV2 controls Right solenoid @ J13-16 TH5 & MOV5 controls Left Auger @ J13-2 Reverse & J13-3 Forward TH6 & MOV6 controls Right Auger @ J13-13 Reverse &[...]

  • Page 59

    59 Input and Output Chart (ULTRA-1) J9 connector for liquid crystal display. J11 connector for touch pad/ membrane switch (see touch pad pin out test). J10 connector for Main harness PI N NUMBE R WIRE COLOR AND GAUGE FUNCTION COMPONENT VOLTAGE 1 Rectifier 2 Output Output Output Output Torque Sensor 3 Temp Sensor 4 Torque Sensor 5 Rectifier 6 Not us[...]

  • Page 60

    60 41084 102709[...]

  • Page 61

    61 Input and Output Chart (ULTRA-2) J5 connector for liquid cr ys tal displa y. J2 connector for touch pad/ membrane switch (see touch pad pin out test). J12 connector for models with Autofill option. J13 connector for Main harness PIN NUMBER WIRE COLOR AND GAUGE FUNCTION COMPONENT VOLTAGE 1 Red/Black 18 Output Right Auger Motor 120VAC 2 Brown/Whit[...]

  • Page 62

    62 41084 102709[...]

  • Page 63

    63 41084 102709[...]