Bunn ULTRA-2 Coffee Grinder Repair manual

ULTRA-1

ULTRA-2

SERVICE & REPAIR MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

PHONE: (217) 529-6601 FAX: (217) 529-6644

41084.0000D 03/13 ©2009 Bunn-O-Matic Corporation

BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY

Bunn-O-Matic Corp. (“BUNN”) warrants equipment manufactured by it as follows:

1) Airpots, thermal carafes, decanters, GPR servers, iced tea/coffee dispensers, MCP/MCA pod brewers thermal servers and Thermofresh servers (mechanical and digital)- 1 year parts and 1 year labor.

2) All other equipment - 2 years parts and 1 year labor plus added warranties as specified below: a) Electronic circuit and/or control boards - parts and labor for 3 years. b) Compressors on refrigeration equipment - 5 years parts and 1 year labor. c) Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis - parts and labor for 4 years or 40,000 pounds of coffee, whichever comes first.

These warranty periods run from the date of installation BUNN warrants that the equipment manufactured by it will be commercially free of defects in material and workmanship existing at the time of manufacture and appearing within the applicable warranty period. This warranty does not apply to any equipment, component or part that was not manufactured by BUNN or that, in BUNN’s judgment, has been affected by misuse, neglect, alteration, improper installation or operation, improper maintenance or repair, non periodic cleaning and descaling, equipment failures related to poor water quality, damage or casualty. In addition, the warranty does not apply to replacement of items subject to normal use including but not limited to user replaceable parts such as seals and gaskets. This warranty is conditioned on the Buyer 1) giving BUNN prompt notice of any claim to be made under this warranty by telephone at (217) 529-6601 or by writing to Post Office

Box 3227, Springfield, Illinois 62708-3227; 2) if requested by BUNN, shipping the defective equipment prepaid to an authorized BUNN service location; and 3) receiving prior authorization from BUNN that the defective equipment is under warranty.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTY, WRITTEN OR ORAL, EX-

PRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF EITHER MERCHANTABILITY

OR FITNESS FOR A PARTICULAR PURPOSE. The agents, dealers or employees of BUNN are not authorized to make modifications to this warranty or to make additional warranties that are binding on BUNN. Accordingly, statements by such individuals, whether oral or written, do not constitute warranties and should not be relied upon.

If BUNN determines in its sole discretion that the equipment does not conform to the warranty, BUNN, at its exclusive option while the equipment is under warranty, shall either 1) provide at no charge replacement parts and/or labor (during the applicable parts and labor warranty periods specified above) to repair the defective components, provided that this repair is done by a BUNN Authorized Service Representative; or 2) shall replace the equipment or refund the purchase price for the equipment.

THE BUYER’S REMEDY AGAINST BUNN FOR THE BREACH OF ANY OBLIGATION ARISING OUT OF THE SALE OF THIS

EQUIPMENT, WHETHER DERIVED FROM WARRANTY OR OTHERWISE, SHALL BE 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.

392, A Partner You Can Count On, Air Infusion, AutoPOD, AXIOM, BrewLOGIC, BrewMETER, Brew Better Not Bitter, Brew-

WISE, BrewWIZARD, BUNN Espress, BUNN Family Gourmet, BUNN Gourmet, BUNN Pour-O-Matic, BUNN, BUNN with the stylized red line, BUNNlink, Bunn-OMatic, Bunn-O-Matic, BUNNserve, BUNNSERVE with the stylized wrench design,

Cool Froth, DBC, Dr. Brew stylized Dr. design, Dual, Easy Pour, EasyClear, EasyGard, FlavorGard, Gourmet Ice, Gourmet

Juice, High Intensity, iMIX, Infusion Series, Intellisteam, My Café, Phase Brew, PowerLogic, Quality Beverage Equipment

Worldwide, Respect Earth, Respect Earth with the stylized leaf and coffee cherry design, Safety-Fresh, savemycoffee.com,

Scale-Pro, Silver Series, Single, Smart Funnel, Smart Hopper, SmartWAVE, Soft Heat, SplashGard, The Mark of Quality in Beverage Equipment Worldwide, ThermoFresh, Titan, trifecta, Velocity Brew, Air Brew, Beverage Bar Creator, Beverage Profit Calculator, Brew better, not bitter., BUNNSource, Coffee At Its Best, Cyclonic Heating System, Daypart, Digital

Brewer Control, Element, Nothing Brews Like a BUNN, Pouring Profits, Signature Series, Tea At Its Best, The Horizontal

Red Line, Ultra are either trademarks or registered trademarks of Bunn-O-Matic Corporation. The commercial trifecta® brewer housing configuration is a trademark of Bunn-O-Matic Corporation.

2 41084 021513

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

......................................................................................................28,31,34,37

Relay (or Contactor on Early Models) ...............................................................................39

Control Board ....................................................................................................................40

Cooling Drum Alignment ...................................................................................................41

Fan ...............................................................................................................................42,43

Hot Gas Sensor .................................................................................................................44

Lamp Cord Assembly ........................................................................................................45

Lamp Cord Connector .......................................................................................................46

Lamp Holder/Socket Assembly .........................................................................................47

Lamp Relay .......................................................................................................................48

Membrane Switch ........................................................................................................49,50

Solenoids ..........................................................................................................................51

Temperature Sensor Assembly .........................................................................................52

Torque Sensor Circuit Board .............................................................................................53

.....................................................................................................................54

Coolant Schematics ................................................................................................................55

Electrical Schematics ..............................................................................................................57

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.

SITE PREPARATION

The dispenser must have at least four inches of space behind it. This space is needed for airflow, air filter removal, and cleaning. Minimal clearance is required between the dispenser sides and the wall or another appliance. The dispenser performs better if not placed near any heating appliance. Leave some space so the dispenser can be moved for cleaning.

3 41084 102709

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 Preventative Maintenance measure. A reminder message will appear every 6 months. Worn/dirty shaft seals/bushings will have a direct effect on torque sensing and prevent complete freezing in “ICE” mode.

“UPPER” case vs “lower” case

Before beginning the process of troubleshooting, verify simple operating modes, ie; “CHILL” mode will not freeze the product, but “ICE” mode will. You should also observe the letter case size in either mode. UPPER case means the solenoid valve for that side is open, lower case, solenoid is closed.

Valve open

JULY 4, 2002

ICE Ice Valve closed

Fault codes

To aid in troubleshooting, fault codes are now incorporated into the display. See “Troubleshooting”.

4 41084 102709

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. Press and release the ULTRA and ICE hidden switches to return to HOME SCREEN. The

TEMP & TORQUE mode is typically used for service.

DISPLAY

TEMP & TORQUE

30

161

25

-

161°h

30

27

25

-

28°b

NOTICE: While in the TEMP & TORQUE screen, the UPPER/lower case will be replaced by symbols.

The indicates the solenoid valve is open, and the indicates that solenoid is closed.

5 41084 102709

OPERATING CONTROLS

ULTRA-1

There are three of these switches that will be used for the operation of the dispenser.

1

2

3

P3932

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. (upper right corner)

This is used to turn the auger motor to AUGER ON, AUGER OFF or AUGER REFILL ON. (Refill only applicable when installed) (See *NOTE)

3. (lower right corner)

This is used to turn the ice control to OFF, ICE or CHILL.

*NOTE: Refill system includes a “Maximum Fill Time” in the software. If the time to fill the hopper exceeds this limit, the hopper lights will flash and a “Refill Fault” will be displayed on the screen. If this accurs, check the product supply to ensure the BIB is not empty. (Change BIB if empty). Then press the “ULTRA” button for 3 seconds to clear the fault and restart the refill system.

6 41084 102709

OPERATING CONTROLS

ULTRA-2

There are five of these switches that will be used for the operation of the dispenser.

1

P3677

2 3 4 5

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. (bottom left corner)

This is used to turn the left side auger motor to AUGER ON, AUGER OFF or AUGER REFILL ON. (Refill only applicable when installed) (See *NOTE)

3. (bottom left corner)

This is used to turn the left side ice control to OFF, ICE or CHILL.

4. (bottom right corner)

This is used to turn the right side auger motor AUGER ON, AUGER OFF or AUGER REFILL ON. (Refill only applicable when installed) (See *NOTE)

5. (bottom right corner)

This is used to turn the right side ice control to OFF, ICE or CHILL.

7 41084 102709

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 plunger. Lift the hopper up slightly.

3. Pull forward to remove.

4. Pull the auger from the cooling drum.

5. Remove the cooling drum seal from the rear of the drum.

6. Caution: The faucet valve is under spring tension. Spread one side of the handle first, then the other and disconnect from the hopper.

7. Carefully slide the faucet valve up to remove the spring and faucet seal. Extra care should be taken when handling the seal to prevent damage. Do not fold the seal as this will cause damage to the Teflon ® sealing surface.

8. Remove the auger nose bushing from inside the hopper.

9. Care must be taken to ensure this surface does not get scratched during cleaning. Deep scratches could cause leakage around the seal.

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 solution. Use a clean, soft bristle brush as needed for the smaller components and tight areas. Do not immerse

hopper lids. Use a commercial sanitizer that has 100 ppm of available chlorine with a concentration level of at least 3% available chlorine (KAY-5 Sanitizer). Follow the sanitizer’s mixing instructions to ensure 100 ppm of available chlorine.

11. Wash the drums, hopper drip trays, top covers, and outer enclosure using a clean wash cloth that has been dampened in the hot water and sanitizer solution. Pay particular attention to the shaft area and make sure it is thoroughly cleaned and sanitized.

12. Thoroughly rinse all surfaces with a clean wash cloth that has been dampened with hot water. Wipe dry with a clean dry wash cloth before reassembling the dispenser.

NOTE – Although most parts are dishwasher safe, they may be affected by the chemicals in some commercial sanitizing agents. Do not place the hopper nor hopper lids in a dishwasher. Rinse thoroughly before assembly.

8 41084 102709

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.

2. Align the auger shaft(s) with 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.

3. Install auger nose bushing into inside front of hopper.

4. Thoroughly rinse the hopper(s) and install over the auger(s) and cooling drum(s).

5. Slide into place and push down until the hopper lock plunger(s) snap into place.

6. Set the lids on the hopper(s) and plug in the hopper lid lamp cord(s).

7. Position the faucet seal and return spring in the faucet valve.

8. Slide the faucet valve assembly into place on the hopper.

9. Press down on the valve to compress the spring. Position the faucet handle over the faucet valve one side at a time and snap into place on the hopper.

10. Assemble the drip tray.

9 41084 102709

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. A connector from an empty bag will work.

Sanitizing Procedure

1. Fill bucket with 4 gallons of warm water (120-180 deg. F).

2. Measure 4 ounces (1/2 cup) of the liquid detergent and add to the water.

3. Measure 2 ounces (1/4 cup) of bleach and add to the water, then stir, mixing evenly.

4. Ensure that the refill for the Ultra hopper is turned off.

5. Empty all product from the Ultra hopper

6. Disconnect the concentrate line from the B-I-B and install adaptor on the quick disconnect so the line is open to the sanitizing solution. Place concentrate inlet line into the bucket so that the Q.C.D. will stay at the bottom.

7. Press the auger button to turn on the “Auger Refill On” feature.

8. Allow system to run until the hopper is about 1/4 full then turn off refill.

9. Switch three way sanitize valve to the Sanitize postion.

10. Turn refill system back on and let run until the hopper is almost full then turn off refill.

11. Allow sanitizer to sit in system for 10 minutes.

12. Drain sanitizer from hopper and remove the Q.C.D. from the sanitizer bucket.

13. Empty remaining sanitizer and refill bucket with about 2 gallons of warm (120-180 deg. F) rinse water.

14. Turn sanitize valve back to dispense position.

15. Place Q.C.D. into rinse water and turn on refill system.

16. Run until hopper is about 1/4 full.

17. Turn off refill system and drain hoppers.

18. Refer to the Recommended Daily Cleaning instructions and follow these steps to clean the hopper, lid and other dispense parts.

10 41084 040110

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.

The torque between the auger motor and the frozen product is contolled by the torque sensor board measuring the distance between the pins on the coupler and shaft. When the distance between the pins reaches the maximum allowable distance, the compressor shuts off. The machine thinks the product thickness has reach the maximum and shuts off the compressor. The illustration below shows some of the other possible causes for a false reading from the torque sensor board.

Proper inspection and preventive maintenance (including daily cleaning) will avoid expensive repairs and costly down time.

NORMAL OPERATION

A

B

C

D

E

CHILL MODE

A. MOTOR SHAFT TORQUE SENSOR PIN

B. AUGER SHAFT TORQUE SENSOR PIN

C. TORSION SPRINGS

D. AUGER SHAFT

E. AUGER MOTOR COUPLING

ICE MODE

POSSIBLE CAUSES FOR FALSE READINGS

WEAK TORSION SPRINGS

DAMAGED/CORRODED AUGER SHAFT

DAMAGED/WORN BUSHINGS/SEALS

TOO MUCH KRYTOX GREASE

BENT TORQUE SENSOR PINS MISSING TORQUE SENSOR PINS

DIRTY OR DAMAGED TORQUE SENSOR BOARD

11 41084 102709

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.

The following instructions apply to one hopper only; repeat each step for all hoppers.

Kit Contents

Inventory this kit for completeness before proceeding.

* 34245.0003 PM Kit, ULTRA-2 PAF w/ LEDs

** 34245.0001 PM Kit, ULTRA-2

*** 34245.0002 PM Kit, ULTRA-1

Part Number Qty. Description

* ** ***

26781.0000 2 3 1 Auger Shaft Bushing (Blue)

37593.0000 2 3 1 Cooling Drum Seal

32079.0000 2 3 1 Hopper/Drum Seal

32268.1000 2 3 1 Seal Kit, Faucet (Clear)

29563.0000 - - - Lubricant

28395.0000 1 1 1 Seal Insertion Tool

Auger Motor Cover

Run Capacitor

Auger Motor Assy

Auger Shaft Assy

Hopper/Drum Seal

Cooling Drum

Seal

Cooling Drum

Auger Shaft Bushing

FIG 1

P2528

INSTRUCTIONS

WARNING - Disconnect the dispenser from the power source before the removal of any panel or the replacement of any component.

1. Drain, remove and clean hopper; refer to the Recommended Daily Cleaning instructions for proper cleaning procedures. Discard the hopper/drum seal and faucet seal.

2. Remove the #8 locking screws securing auger motor cover to the cooling drum mount assembly; remove cover and set aside for reassembly.

3. Remove the #8 locking screw on the lower right side (viewed from front) of the auger motor mounting bracket securing the auger motor run capacitor. Set capacitor aside with wires attached.

4. Disconnect the auger motor terminal from the terminal on the main wiring harness.

5. Remove the remaining #8 locking screws securing the cooling drum mounting bracket. Remove motor with mounting bracket.

NOTE: When removing or installing motor and shaft assembies, be sure the motor and shaft pins are turned to a position that will clear the torque sensor circuit board.

12 41084 052112

REQUIRED REGULAR MAINTENANCE (Continued)

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. 40500.1068) and warm sanitize solution, rinse and dry with a towel. Clean the front seal/bushing area of the cooling drum thoroughly with the bristle brush. Refer to Fig. 4 for areas to be cleaned.

9. Refer to FIG 1, and slip new blue bushing into cooling drum.

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

#M2568.1001) to inside diameter of seal. Push seal into bore until it is firmly seated; remove tool.

12. Place a small amount of #29563.0000 “Krytox” lubricant

(provided in kit in a plastic cap) on the end of the motor shaft

(about 1 1 /

2

”) and a thin film in the groove. Install auger shaft assembly onto the motor shaft. See FIG 3. Do not use too much

“Krytox” lubricant. Dirt or grease on pins will cause “optical” misreading by torque sensors.

NOTE: This is the only place “Krytox” lubricant is used.

13. Assemble motor/shaft assembly as shown in FIG 3, then install assembly into cooling drum. Make sure the pins do not hit the sensor board and cooling drum seal is not dislodged as the shaft passes through.

14. Secure motor and capacitor to the cooling drum mounting bracket. Install rear motor cover.

15. Refer to the hopper assembly and installation procedures. Install new hopper/drum seals and faucet seals included in the kit. See

FIG 1 & 5.

16. Remove and clean condenser air filter. See FIG 6.

17. Refer to the Programming Manual, “Menu Function Index”.

Scroll to menu “PM Complete?” and answer “YES” to reset the reminder message “PM Due”.

Open face of seal away from tool

Cooling Drum Seal

Seal Insertion Tool

FIG 2

P1760

Check for weak torsion springs

Pins

Auger Shaft Assy

Lube about 1

Lubricant

1 /

2

” of shaft and in the groove with #29563.0000 “Krytox”

FIG 3

P2529

Hopper/Drum Seal

Inspect & Clean

Cooling Drum

Auger Shaft Bushing

Cooling Drum Seal

FIG 4

Faucet Seal

FIG 5

13

P3695 FIG 6

P3682

41084 052112

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.

• All electronic components have 120 volt ac and/or low voltage dc potential on their terminals. Shorting of terminals or the application of external voltages may result in board failure.

• Intermittent operation of electronic circuit boards is unlikely. Board failure will normally be permanent. If an intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a terminal or crimp.

• Keep away from combustibles.

WARNING – • Exercise extreme caution when servicing electrical equipment.

• Unplug the dispenser when servicing, except when electrical tests are specified.

• Follow recommended service procedures

• Replace all protective shields or safety notices

No

Call licensed electrician for repair

No Power

Correct voltage at outlet?

Yes

Yes

12vac to Control Board at J5-8 & J5-20?

No

No

Yes

Replace Control

Board

Does Membrane

Switch test ok?

No

Replace Membrane

Switch

Replace

Transformer

12vac from secondary of transformer?

Yes

14

Check main wiring harness

41084 102709

TROUBLESHOOTING (cont.)

No

Chills but won’t freeze

Dispenser in

“DAY” mode?

Yes

Set into

“DAY” mode

1

No

Is Thickness screen set low?

Verify augers are turned on

Is display showing

UPPER CASE

“ICE” mode?

No

Yes

Yes

Is Brix level high?

Dispenser in

“ICE” mode?

Yes

Yes No

2

2

Inspect auger drive shafts for weak torsion springs or damaged pins. Check for dirty or worn seals and bushings.

Is Filter dirty?

Yes

3

No

No

Set into

“ICE” mode

1

Have a certified refrigeration technician check for low refrigerant or blockage.

1- Done 2- Adjust 3- Clean

15 41084 102709


Yes

Set into “ICE” or

“CHILL” mode

1

Yes

Plug directly inti outlet

1

No

Call a licensed electrician

No cooling at all

Is ICE/CHILL set to off?

No

No

Is Dispenser on an extension cord?

Is compressor running?

Yes

Is filter dirty?

No

No

Is there correct voltage at outlet?

Check fan

Yes

Follow compressor circuit checks.

Yes

3

Have a certified refrigeration technician check for low refrigerant or blockage.

1- Done 2- Adjust 3- Clean

16 41084 102709


Freezes, but not thick enough

Adjust thickness screen higher

Brix ratio too high

Too much alcohol in product

Ambient temperature too hot

Check for slightly bent auger shaft pins and/or weak torsion springs.

Check for dirty or worn seals and bushings.

Adjust product

Recommended for indoor use only

No

No hood lamps

Is dispenser in

“DAY” mode?

Yes

Set into

“DAY” mode No

Check lamp circuit

Is circuit breaker tripped?

Yes

Verify all 4 bulbs are 912 series & reset breaker

17 41084 102709


Noise

Auger jumping

Lower brix ratio

Drum alignment

Check auger shaft bushings

Check fan

Using auger assembly from

CDS 2 or 3?

Replace with ULTRA p/n 32106.1000

Yes

Check membrane switch

Auger won’t turn

Do they turn during

“AUGER MOTOR TEST” mode?

One direction, but not the other

No

Auger motor/capacitor checks

Replace control board

18 41084 102709


TORQUE SENSOR ERROR

Left side Right side

Are augers turning?

No

Torque Sensor Error

TORQUE SENSOR

SHORTED

Yes

Go to motor troubleshooting

Are augers shaft pins damaged or missing?

Yes

Replace as necessary

No

Check sensor circuit

TORQUE SENSOR OPEN


Sensor unplugged or break in wiring

19 41084 102709


TEMPERATURE SENSOR SHORTED


Check wiring harness between thermistor and control board

Temperature Sensor Error

TEMPERATURE SENSOR OPEN


Product not covering back end of drum.

Drum temperature falls below 9° F.

Replenish product

Thermistor unplugged or break in wiring

Check thermistor circuit

20 41084 102709


Clean Filter Messages

“MONTHLY FILTER

CLEAN REQUIRED”

Monthly reminder

“FILTER NEEDS

CLEANING”

Hot gas thermistor sensing over 220° F

“FILTER NEEDS

!!!CLEANING!!!”

Freezing is Disabled

Hot gas thermistor sensing over 250° F

Clean filter

Dirty filter; air flow blockage; wrong refrigerant or over charged

Hold ULTRA button for 3 seconds to reset. *

* Early units have to reset to factory defaults in order to reset

21 41084 102709

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. The dispenser should be disconnected from the power source when servicing, except when electrical tests are required and the test procedure specifically states to connect the dispenser to the power source.

COMPONENT ACCESS PANELS

WARNING - Disconnect the dispenser from the power source before the removal of any panel or the replacement of any component.

All components are accessible by removal of the auger motor cover, lower drip tray, front cover and the left and right side covers.

Refer to the contents listing for component location.

22

P3930.30

41084 102709

SERVICE(CONT.)

AUGER MOTORS

ULTRA-2 shown

FIG. 1 AUGER MOTORS P1341

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. Turn “ON” the appropriate auger switch.

3. Nudge the auger to start it turning.

If the auger doesn’t turn, replace the motor.

If auger starts to turn, replace the start capacitor.

WARNING: The compressor start capacitor must be properly discharged before removing. This is most commonly done on low voltage capacitors by shorting across the terminals with a screwdriver.

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. Set capacitor aside with wires attached.


5. Remove the three remaining #8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket.

6. Remove motor with mounting bracket, drip tray, split pin and torsion spring bearing as an assembly.

NOTE: When removing or installing the motor be sure the split pin in the motor shaft is turned to a position that will clear the torque sensor circuit board.

7. Install new motor with mounting bracket, drip tray, split pin and torsion spring bearing using three #8 locking screws onto the cooling drum bracket.

8. Install the auger motor capacitor on the lower right side of the auger mounting bracket, using the remaining #8 locking screw.

9. Connect the auger motor terminal to the terminal on the main wiring harness.

10. Refer to Fig. 2 when reconnecting the wires.

J1-1 Boost Coil

J1-2 Run Coil

J1-3 Common

ULTRA-2 LEFT AUGER MOTOR

J1-1 BRN/WHI to Left Auger Motor Capacitor

J1-2 BRN/BLK to J5-3 of Control Board

J1-3 WHI to Main Harness

ULTRA-2 RIGHT AUGER MOTOR

J1-1 WHI/RED to Right Auger Motor Capacitor

J1-2 RED/BLK to J5-1 of Control Board


ULTRA-1 AUGER MOTOR

J1-1 BRN/WHI to Auger Motor Capacitor

J1-2 BRN/BLK to J10-9 of Control Board


FIG. 2 AUGER MOTOR TERMINALS

J1-3 to:

WHITE

MOTOR COIL RESISTANCE

J1-1 = 58 ohms

BLACK

J1-2 = 58 ohms

RED

23 41084 102709

SERVICE (CONT.)

AUGER MOTOR CAPACITOR

ULTRA-2 shown

Removal and Replacement

1. Remove the two #8 locking screws securing the auger motor cover to the cooling drum mount assy.


3. Disconnect the wires from the auger motor capacitor terminals.

4. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor capacitor.

5. Install a new capacitor on the lower right side of the auger mounting bracket and secure with a #8 locking screw.

6. Reconnect the wires to the capacitor terminals.


FIG. 3 AUGER MOTOR CAPACITORS 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).

Test Procedures

1. Remove the hopper from the same side as the motor to be tested.

2. Turn “ON” the appropriate auger switch.

3. Nudge the auger to start it turning.

If the auger doesn’t turn, replace the motor.

If auger starts to turn, replace the start capacitor.

WARNING: The compressor start capacitor must be properly discharged before removing. This is most commonly done on low voltage capacitors by shorting across the terminals with a screwdriver.

ULTRA-2 LEFT MOTOR CAPACITOR

BRN/WHI to Left Auger Motor J13-2

BRN/BLK to Control Board J13-3

ULTRA-2 RIGHT MOTOR CAPACITOR

WHI/RED to Right Auger Motor J13-13

RED/BLK to Control Board J13-1

ULTRA-1 AUGER MOTOR CAPACITOR

BRN/WHI to Auger Motor J10-8

BRN/BLK to Control Board J10-9

FIG. 4 AUGER MOTOR CAPACITOR TERMINALS

24 41084 102709

SERVICE (cont.)

AUGER SHAFT ASSEMBLY

Auger Motor Cover

Run Capacitor

Auger Motor Assy

Auger Shaft Assy

Ceramic Coating

7. Pull the auger shaft assembly straight out of cooling drum. Inspect the shaft for abnormal wear or scoring.

8. From the front of dispenser, remove the seal and blue bushing from cooling drum and discard them.

9. Clean seal and bushing surfaces of the cooling drum very thoroughly.

10. Refer to Fig 6 and slip new blue bushing into cooling drum.

Hopper Drum Seal

Auger Shaft Bushing

Cooling Drum Seal

Cooling Drum

FIG. 5 AUGER SHAFT ASSEMBLY

P1758

Location:

The Auger Shaft Assembly is located in each of the cooling drums.

Blue bushing

Do NOT get any Lube on this surface

(between Drum and Bushings/Seals)

Removal and Replacement:

1. Drain, remove and clean hopper; refer to the Rec-

ommended Daily Weekly Cleaning Section of this manual, for proper cleaning procedures. Discard the hopper/drum seal and faucet seal.

2. Remove the #8 locking screws securing auger motor cover to the cooling drum mount assembly; remove cover and set aside for reassembly.

3. Remove the #8 locking screw on the lower right side

(viewed from front) of the auger motor mounting bracket securing the auger motor run capacitor. Set capacitor aside with wires attached.


5. Remove the remaining #8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket.

6. Remove motor with mounting bracket, split pin and torsion spring bearing as an assembly.

FIG. 6 AUGER SHAFT BUSHING

P1759

11. Place seal on insertion tool #28395.0000, as shown in Fig. 7. Make sure open face of seal is toward cooling drum.

12. Push seal into bore until it is firmly seated; remove tool.

13. Place a small amount of #29563.0000 “Krytox” lubricant (provided in kit in a plastic cap) on the end of the motor shaft (about 1 1/2”) and a thin film in the groove. Install auger shaft assembly onto the motor shaft. See Fig. 8. Do not use too much

“Krytox” lubricant.

NOTE - This is the only place “Krytox” lubricant is used.

NOTE - When removing or installing motor and shaft assemblies, be sure the split pins are turned to a position that will clear the torque sensor circuit board.

25 41084 102709

SERVICE (cont.)

AUGER SHAFT ASSEMBLY(cont.)

Open face of seal away from tool

16. Refer to Hopper Installation for hopper assembly and installation procedures. Be sure to use new hopper/drum seal and faucet seals

Cooling Drum Seal

Seal Insertion Tool

P1760

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 cooling drum seal is not dislodged as the shaft passes through.

FIG 9

17. Remove and clean condenser air filter, Fig. 10.

18. Refer to the Programming Manual, “Menu Function

Index”. Scroll to menu “PM Complete?” and answer

“YES” to reset the reminder message “PM Due”.

Lube about 1 1/2” of shaft and in the groove with #29563.0000

“Krytox” Lubricant

ULTRA-2 shown

Auger Shaft Assy

P1761

FIG. 8 MOTOR/SHAFT ASSEMBLY

15. Secure motor and capacitor to the cooling drum mounting bracket. Install rear motor cover.

FIG 10

P3682

26 41084 102709

SERVICE (cont.)

CIRCUIT BREAKER

R

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. Remove the wires from the circuit breaker.

3. Check for continuity between the terminals. Continuity must be present between the terminals.

If continuity is present as described the circuit breaker is functioning properly.

If continuity is not present as described, press the reset button and repeat step #3, if continuity is not present as described, replace the circuit breaker.


1. Remove the right side panel on ULTRA-2 models; or remove the Auger Motor cover on ULTRA-1 models.

2. Remove the wires from the circuit breaker.

3. Compress the clips on the back side of the component bracket and gently push the circuit breaker through the opening in the bracket.

4. Push the new circuit breaker into the opening in the bracket until the clips snap into position.

5. Reconnect the wires to the circuit breaker.


9

27

FIG. 12 CIRCUIT BREAKER (ULTRA-1)

WHI/BLU from Transformer

WHI/YEL to Lamp Relay (ULTRA-2)

RED to Lamp Relay (ULTRA-1)

FIG. 13 CIRCUIT BREAKER TERMINALS

41084 102709

9

SERVICE (cont.)

COMPRESSOR (AMERICOLD) (ULTRA-2)

FIG. 14 COMPRESSOR ASSY

Location:

The compressor assy is located inside the front of the dispenser chassis.

1 2 3

120V COMPRESSORS

1 2 3 4 5 6

230V COMPRESSORS

FIG. 15 COMPRESSOR ELECTRICAL COMPONENTS

1. Compressor Start Relay

2. Thermal Overload Protector

3. Overload Protector Retainer

4. Compressor Terminal Cover

5. Terminal Cover Retainer

6. Compressor Run Capacitor

4 5

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


2. Remove compressor terminal cover retainer (5) and compressor terminal cover (4).

3. Connect a voltmeter across the white wire and the white/ orange wire. Connect the dispenser to the power source.

Verify the dispenser is in “ICE” or “CHILL” mode.

The indication must be:

(a) 120 volts ac for two wire 120 volt models or

(b) 230 volts ac for two wire 230 volt models.


If voltage is present as described, proceed to the following test procedures.

If voltage is not present as described, refer to the Relay and check the relay.

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.

If continuity is not present as described, replace relay.

Compressor:

1. With the compressor start relay (1) removed, disconnect the black wire from the compressor.

2. Check for continuity across the terminal on the compressor and the left pin on the compressor.

If continuity is present as described, the electrical part of the compressor is operating properly.

If continuity is not present as described, replace the compressor.

Thermal Overload Protector:

1. Check for continuity across the terminals on the thermal overload protector (2).

28

If continuity is present as described, the thermal overload protector is operating properly.

If continuity is not present as described, replace the thermal overload protector.

41084 102709

SERVICE (cont.)

COMPRESSOR (AMERICOLD) (ULTRA-2) (cont.)



1. Remove the terminal cover retainer (5) and 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. Push new relay onto the compressor pins.

5. Refer to Fig. 16 and reconnect the wires.

6. Reinstall terminal cover (4) and cover retainer (5).

6. Install retainer (3) on new overload protector (2).

7. Install retainer (3) and overload protector (2) on the compressor terminal bracket.

8. Refer to Fig. 17 and reconnect the thermal overload protector wires.


WHI/ORN from

Main Harness

White from Main Harness

BLK to Compressor

Plug directly to two lower terminals on Compressor

120V DISPENSERS

Black from Run Capacitor



230V DISPENSERS

FIG. 16 COMPRESSOR START RELAY

TERMINALS

P1338

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 protector retainer (3) and thermal overload protector (2) as an assembly.

5. Remove retainer (3) from overload protector (2) and discard overload protector.

FIG. 17 THERMAL OVERLOAD PROTECTOR

TERMINALS

Compressor Run Capacitor (230V Dispensers Only): Refer to FIG. 15


(4).

2. Disconnect the run capacitor leads.

3. Remove the #6 crimptite screw securing the run capacitor to the rear of the component bracket.

4. Remove run capacitor and discard.

5. Place new run capacitor on the rear of component bracket and secure with #6 crimptite screw.


BLK to Start Relay T1


FIG. 18 COMPRESSOR RUN CAPACITOR

TERMINALS

P1816

29 41084 102709

SERVICE (cont.)

COMPRESSOR (AMERICOLD) (ULTRA-2) (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 condenser and the accumulator.

2. Disconnect the compressor wiring harness from the dispenser main wiring harness.

3. Remove the four .25-20 keps nuts and washers securing the compressor to the chassis. Set nuts and washers aside for reassembly.

4. Disconnect and remove the transformer.

5. From the right side of the dispenser lift the compressor assembly over the four studs in the chassis and remove compressor.

6. Install new compressor over the four studs in the dispenser chassis with the fill valve to the left side of the dispenser.

7. Secure compressor to the dispenser chassis using four

.25-20 keps nuts and washers.

8. Reconnect tubes from the condenser and the accumulator to the compressor.

9. Reinstall transformer.

10. Evacuate the system.

11. Recharge 120V system with 10 oz. of Type 404A refrigerant. Design Pressures: High 240 - Low 34

Recharge 230V system with 9.5 oz. of Type 404A refrigerant. Design Pressures: High 215 - Low 40

NOTE: The charging of the system must be done by a licensed refrigeration repair person.

NOTE: Refer to Wiring Diagrams when reconnecting wires to Compressor, Thermal Overload Protector, Start Relay, and Run Capacitor.

30 41084 102709

SERVICE (cont.)

COMPRESSOR (EMBRACO) (ULTRA-2)

FIG. 19 COMPRESSOR ASSY

Location:


Model T-2155

Model T-2168

FIG. 20 COMPRESSOR ELECTRICAL COMPONENTS



3. Overload Protector Retainer


5. Terminal Cover Retainer


2

6

3

1

5

4

6

3

1

5

4

2

31

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.



2. Remove compressor terminal cover retainer (5) and compressor terminal cover (4).














Compressor:









41084 102709

SERVICE (cont.)

COMPRESSOR (EMBRACO) (ULTRA-2) (cont.)








6. Install retainer (3) on new overload protector (2).

7. Install retainer (3) and overload protector (2) on the compressor terminal bracket.




WHI/ORN from

Main Harness


Model T-2155



BLK to Compressor

P1339

FIG. 22 THERMAL OVERLOAD

PROTECTOR TERMINALS

Compressor Run Capacitor: Refer to FIG. 20


2. Remove the nut securing the run capacitor to the capacitor mounting bracket.


4. Place new run capacitor on capacitor mounting bracket and secure nut.




Model T-2168

FIG. 21 COMPRESSOR START RELAY

TERMINALS

P1338





(4).



4. Remove overload protector retainer (3) and thermal overload protector (2) as an assembly.

5. Remove retainer (3) from overload protector (2) and discard overload protector.

FIG. 23 COMPRESSOR RUN CAPACITOR

TERMINALS

P1816

32 41084 102709

SERVICE (cont.)

COMPRESSOR (EMBRACO) (ULTRA-2) (cont.)


Compressor Assy:








6. Install new compressor over the four studs in the dispenser chassis with the fill valve to the left side of the dispenser.






11. Recharge 120V system with 10 oz. of Type 404A refrigerant. Design Pressures: High 430 - Low 80

Recharge 230V system with 9.5 oz. of Type 404A refrigerant. Design Pressures: High 215 - Low 40



33 41084 102709

SERVICE (cont.)


Compressor Model:

EMBRACO/NT2168GK, 115V 60HZ/100V 50HZ

Compressor Specification:

Commercial Designation: ¾ HP

Nominal Voltage:

115VAC 60 HZ 1 PH / 100VAC 50 HZ 1 PH

Electrical Rating: 115VAC 60 HZ: 8 RLA (Rated Load

Amps), 54.5 LRA (Locked Rotor Amps)

Start Winding Resistance: 2.66 OHMS

Run Winding Resistance: 0.43 OHMS

Displacement: 0.885 CU IN

Refrigerant: R-404A

Oil Type: ESTER/IS022

Oil Charge: 15.22 FL. Oz.

Electrtic Motor Type: The type of motor being used in the ULTRA-2 HP dispenser is known as CSR motor

(Capacitive Start & Run).

The CSR version uses a start and run capacitor with an external thermal protector. The start capacitor is in series with the compressor motor start winding. A potential starting relay coil is wired across the start winding which can sense change in voltage. The starting winding voltage will increase along with motor speed. When the voltage has reached a point, the relay contacts will open, de-energizing the start winding capacitor.

Capacitor Ratings:

Start Capacitor: 243-292 MFD 165V 50/60HZ

Run Capacitor: 35 +/-5% MFD 425V 50/60HZ

Refrigerant Charge:

Type: R404A

Amount: 11 oz.

Design Pressure: High 430 & Low 80

CSR Motor Wiring Diagram:

34

SERVICE (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.

• Always ensure main power is disconnected before any removal of a protective cover.

• Compressor oil and refrigerant being vented can create a hazardous condition of chemical burn, frostbite or fire.

• Never reset a breaker or replace a blown fuse without checking the compressor or related components for a short circuit or ground fault condition first.

• Always wear and use the appropriate safety gear when servicing a refrigeration system. Protective gloves, eyewear, shoes, clothes and tools.

• If compressor ground fault condition exists, keep power off, disconnect power leads, mark or tag compressor to indicate ground fault or defective compressor before replacing with a new compressor.

Compressor Wiring Diagram:

35

SERVICE (cont.)


Compressor Windings & Related Component Testing:

Testing Compressor Windings/Insulation with a Megger

A megger is a preferred test over using a typical ohm meter for testing the compressor windings. The megger checks the insulation factor of a winding making sure it is actually insulated and not leaking current

(Ground Fault). An ohm meter usually produce a low voltage for reading resistance verses a megger uses higher direct voltage source to measure insulation resistance to detect a breakdown in the motor winding insulation.

Step 1: Disconnect all electrical power to the BUNN

ULTRA-2 HP.

Step 2: Access compressor terminal pins and disconnect the wire leads going to the compressor pins.

Note: Measure the resistance (ohms) between terminal pins C&S and C&R around ambient temperature of 77° F. Add the resistance between C & S and C & R.

The sum should equal the resistance found between S

& R. A 10% deviation is acceptable.

Step 3: Set the megger to the compressor applicable voltage rating. If the megger you are using only has a few specific voltage ranges, select the next highest voltage above your compressor volt range.

Step 4: Connect one lead of the megger to the copper suction line or housing. Connect the other lead to one of the compressor terminal pins (winding).

Continuity must be present between C & S and C & R.

If there is no continuity on start or run winding, there is an interruption within that winding.

Check the C (common) compressor winding to compressor ground terminal/housing. If continuity is present, one of the compressor windings is shorted to ground.

Step 5: Repeat the procedure for the two remaining terminal pins. If the instrument indicates any resistance less than 2 megohms between any pin and the housing (copper suction line), a ground fault exists.

Replace compressor.

Check Compressor Windings for Ground Fault:

Upon removal of the protective terminal cover, if evidence is shown by any lead or terminal being overheated, it is a good indication that a compressor winding problem may exist. Follow the recommended step below to check the compressor winding insulation. If a ground fault is detected with the compressor, keep the power off, thermal protector and potential relay disconnected. A licensed certified refrigerant technician will need to replace a defective compressor.

36

SERVICE (cont.)


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. The capacitance value should be the rated value minus 0% to plus 20%. If it is outside of this range, then the start capacitor needs to be replaced.

Check for continuity across the thermal protector terminals. Before testing the external thermal protector, ensure the thermal protector had enough time to cool off and reset. If no continuity is present across the terminals, replace the thermal protector.

Note: Use a 20,000 ohm resistor set-up to discharge the capacitor before removing from the machine. By doing this, will avoid possible damage to the capacitior, measuring device and risk of electrical shock.

Once the capacitor is properly discharged, use a capacitance meter to check the capacitance value. The value should be within 5% range of the marked capacitior value.

Potential Start Relay Mounting Position

Run Capacitior

Run Capacitior: BUNN P/N# 44820.0004

Run Capacitor: 35 +/-5% MFD 425V 50/60HZ

Always check the relay for correct mounting position before continuing with the following continuity check.

• Relay terminal 2 and 5: No continuity, broken coil, replace relay.

• Relay terminal 1 and 2: No continuity, contacts are open, replace relay.

37

SERVICE (cont.)

COMPRESSOR (APPLIANCES) (ULTRA-1)

FIG. 24 COMPRESSOR &

COMPONENT LOCATIONS

Location:


3 1

2 4

FIG. 25 COMPRESSOR THERMAL

OVERLOAD PROTECTOR LOCATION





Test Procedures:


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.


2. Remove compressor terminal cover retainer (4).








If voltage is not present as described, refer to the Contactor and check the contactor.






Compressor:









38 41084 102709

SERVICE (cont.)

COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.)



1. Remove the terminal cover (4)





6. Reinstall terminal cover (4).


1. Remove terminal cover (4).



4. Remove overload protector (3) and start relay as an assembly.

5. Remove overload protector (3) and discard overload protector.

6. Install new overload protector (3) on to the relay (1).

7. Install relay (1) and overload protector (2) on the compressor terminal bracket.






3. Remove the #8-32 screw securing the run capacitor to the top of the dispenser chassis.


5. Place new run capacitor on the top of the dispenser chassis and secure with #8-32 screw.


WHI/ORN

GRN

WHI

BRN/WHI (120V)

BRN (230V)

BLU

FIG. 26 RELAY TERMINALS

Plugs into Relay

FIG. 27 THERMAL OVERLOAD PROTECTOR

TERMINALS

BRN/WHI (120V) to Relay

BRN (230V) to Relay

BLU to Relay

FIG. 28 COMPRESSOR CAPACITOR TERMINALS

39 41084 102709

SERVICE (cont.)

COMPRESSOR (APPLIANCES) (ULTRA-1) (cont.)

Compressor Assy:








6. Install new compressor over the four studs in the dispenser chassis with the fill valve to the right side of the dispenser.






11. Recharge 120V and 230V system with 6 oz. of Type

404A refrigerant.

Design Pressures: High 330 - Low 60



40 41084 021710

SERVICE (cont.)

COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.)

FIG. 29 COMPRESSOR &

COMPONENT LOCATIONS

Location:







Compressor:





Test Procedures:


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.


2. Remove compressor terminal cover retainer (4).




(a) 100 volts ac for two wire 100 volt models.




41 41084 102709

SERVICE (cont.)

COMPRESSOR (DANFOSS) (ULTRA-1B) (cont.)



1. Remove the terminal cover (4)






GRN

WHI

WHI/ORN to

Overload

Protector





3. Disconnect the run capacitor from the mounting bracket located at the front of the dispenser chassis.


5. Snap new run capacitor on the mounting bracket located at the front of the dispenser chassis.


BLK to Compressor

Relay

BLK to Compressor

Relay

Compressor Assy:








6. Install new compressor over the four studs in the dispenser chassis with the fill valve to the right side of the dispenser.






11. Recharge the 100V system with 6 oz. of Type 404A refrigerant.

Design Pressures: High 330 - Low 60



FIG. 31 COMPRESSOR CAPACITOR TERMINALS

42 41084 021710

SERVICE (cont.)

RELAY (or CONTACTOR on Early Models)

R

ULTRA-2 shown

FIG. 32 RELAY

Location:

The relay (or contactor) is located inside the dispenser chassis on the lower outside of the component bracket.

Test Procedures:


2. Remove the right side panel.

3. Connect the dispenser to the power source.

4. Turn on power (I/O) switch. Verify UPPER case

“ICE” or “CHILL” mode.

5. With a voltmeter, check the voltage across the white wire and the orange wire.

The indication must be: a) 120 volts ac for 120 volt models.

b) 230 volts ac for 230 volt 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 continuity is present between terminals #2 and #4, reconnecr wires to terminals #2 and #4 instead of #6 and #8.

If continuity is not present as described, replace the relay.


1. Disconnect the wires from the relay.

2. Remove the two #8-32 locking screws securing the relay to the chassis. Remove and discard relay.

3. Install the new relay on the chassis using two #8-32 locking screws.

4. Refer to Fig. 33 and 34 to reconnect the wires.

Early Model ULTRA-2

Terminal #4

Terminal #2

Terminal #0

WHI from Main Harness

Terminal #6

BLK from Main

Harness/Power Cord

Terminal #8

WHI/ORN from

Compressor Harness

Terminal #1

ORN from

Control Board

FIG. 33 CONTACTOR TERMINALS

Late Model ULTRA-2 & ULTRA-1

Terminal #0

WHI from

Main Harness

Terminal #1

ORN from

Main Harness

P1333

If voltage is present as described, proceed to #7.

If voltage is not present as described, refer to the Wir-

ing Diagram and check the dispenser wiring harness.

If harness has continuity, replace Control Board.

7. Disconnect the black wire and the WHI/ORN wires from relay terminals #6 and #8.


9. Turn on power (I/O) switch. Verify UPPER case

“ICE” or “CHILL” and check for continuity across terminals on relay.

43

Terminal #2

Terminal #4

Terminal #8

BLK from

Main Harness

Terminal #6

WHI/ORN from

Main Harness


41084 102709

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:

The control board is located behind the front panel, on the front of the chassis.

Test Procedures:


2. Remove the left and right side panels. Remove the front panel and unplug ribbon cable from J5

(ULTRA-2) or J9 (ULTRA-1) .

3. With a voltmeter, check the supply voltage from

J5-8 (WHI/BLU) to J5-20 (WHI/BLK).



Approximately 12.6 volts ac for all models.


1. Disconnect the main harness from connector J5

(ULTRA-2) or J9 (ULTRA-1) on the control board.

2. Remove the four #8-18 pan head screws securing the control board to the mounting box. Disconnect

TIC (memory) board from connector J1 on the control board.

NOTE: On models with Auto-Fill, remove the auto-fill adapter board.

3. Reconnect TIC board to J1 on the new control board.

4. Secure the control board to mounting box with the four #8-18 pan head screws.

5. Reconnect the main harness to J5 (ULTRA-2) or

J9 (ULTRA-1) on the control board.


If voltage is present as described and the dispenser does not operate, replace Control Board.

If voltage is not present as described, refer to the Wir-

ing Diagram and check the dispenser wiring harness.

44 41084 102709

SERVICE (cont.)

COOLING DRUM ALIGNMENT

Ledge

Boss

Legs

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.

To check alignment

1. Place the “A” shaped support on the auger shaft with the ledge under the cooling drum.

2. Lift the cooling drum while rotating the support into a vertical position. The boss on the very bottom will drop into the hopper drip tray’s drain hole.

Drip Tray

Drain Hole

P1510

FIG. 38 CHECKING ALIGNMENT

When in its proper position, the cooling drum will cause a slight pressure on the hopper drip tray drain hole and the two legs will be equidistant from the hopper drip tray.

If adjustment is needed, remove the support and gently force the free end of the evaporator in the direction the adjustment is needed.

Reinstall the support, check the alignment, and readjust the cooling drums as required.

Never try to remove the cooling drums (4 screws) unless trained refrigeration technician is replacing the evaporator assembly.

45 41084 102709

SERVICE (cont.)

FAN - ULTRA-2

1

2 3 4

5 6

Location:

The fan is located inside the dispenser chassis just in front of the condenser.

Test Procedures:

FIG. 39 FAN


2. Disconnect the gray and white wires from the main harness to the fan leads.

3. With a voltmeter, check the voltage across the gray and the white wires. Connect the dispenser to the power source. In the “ICE” or “CHILL” mode;




If voltage is present as described, replace the fan.

If voltage is not present as described, refer to Wiring

Diagram and check the dispenser wiring harness.

Removal and Replacement (Refer to Fig. 40)

NOTE: Leave the hopper in place. This keeps it in alignment while the condenser shroud is removed.

1. Disconnect the fan leads from the wiring harness.

2. Remove the four #6 crimptite screws securing the condenser shroud and fan assy (1) to the condenser and the two #8-32 locking screws securing the condenser shroud and fan assy (1) to the chassis base.

3. Remove the condenser shroud and fan assy from the right side of the dispenser.

4. Remove the three #6 thread cutting screws securing the fan assy to condenser shroud (7). Set condenser shroud and screws aside for reassembly.

5. Remove the three #8-32 thread forming screws securing motor (5) to condenser fan shroud/mount

(6). Set shroud and screws aside for reassembly.

46

7

FIG. 40 FAN COMPONENTS

6. Remove speed nut (2) from the motor shaft.

7. Remove fan (3).

8. Remove silencer (4).

1. Condenser Shroud and Fan Assy

2. Speed Nut

4. Silencer

6. Shroud/Mount

3. Fan Blade

5. Motor

7. Condenser Shroud

9. Install silencer (4) on new motor assy.

10. Install fan (3) on new motor assy.

11. Install speed nut (2) on new motor assy.

12. Using three #8-32 thread forming screws secure new motor assy to shroud/mount (6).

13. Using three #6-32 thread cutting screws secure new motor and shroud/mount to the condenser shroud

(7).

14. Using two #8-32 locking screws secure condenser shroud and fan assy (1) to the chassis base.

15. Using four #8-32 crimptite screws secure the condenser shroud and fan assy (1) to the condenser.

16. Refer to Fig. 41 and reconnect the leads on the new motor to the dispenser wiring harness.

17. Use cable ties to secure wires away from fan blades.

BLK to Main Harness WHI

BLK to Main Harness GRY

FIG. 41 FAN MOTOR TERMINALS P1326

41084 102709

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:


2. Connect a voltmeter across pins 1 and 2 of either fan connector of the main wiring harness.


4. Turn on Power (I/O) Switch. Verify the dispenser is in the “DAY” mode.

The indication must be: a) 12 volts dc in the “DAY” mode, b) 0 volts dc in the “NIGHT” mode.



2. Remove the air filter from the back of the dispenser.

3. Remove the four #8-32 hex screws attaching the fan and shroud assy to the condenser frame.

4. Disconnect the wiring harness from the fan being replaced.

5. Remove the four screws attaching the fan to the fan shroud and replace the fan.

6. Install the new fan such that the direction of air flow matches that of the remaining fan. (arrow on fan pointing toward condenser)

7. Reconnect the fan to the main wiring harness.

8. Install the fan and shroud assembly to the condenser frame.

9. Replace the air filter and reconnect the dispenser to power.

If voltage is present as described, proceed to step 5.

If voltage is not present as described, refer to the Wiring

Diagrams and check the main wiring harness.

5. Check for continuity with an ohmmeter across the red and black wires of the fan.

If continuity is present as described, the fan is operating properly.

If continuity is not present as described, replace the fan.

6. Repeat test for other fan.

47 41084 102709

SERVICE (cont.)

HOT GAS TEMPERATURE SENSOR

ULTRA-2 shown

FIG. 43 HOT GAS SENSOR

Location:

The Hot Gas Sensor is located on the Condenserto-Compressor tube on the left side of the housing.

Test 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 be: a) Approx. 4.0 vdc @ 37° F b) Approx. 3.4 vdc @ 82° F

Removal and Replacement (Refer to Fig. 43)


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.

4. Securing the new hot gas sensor to Condenserto-Compressor tube using the clampp previously removed.

5. Refer to Fig. 44 and plug the new sensor into the connector on the main harness.

FIG. 44 HOT GAS SENSOR

2

1

ULTRA-1

1- WHI to YEL J10-11

(Control Board) Positive

ULTRA-2

1- WHI to YEL J5-10


2- WHI to WHI/BLK Main Harness/

J10-15 (Control Board) Negative

2- WHI to WHI/BLK Main Harness/

J5-9 (Control Board) Negative

If voltage reading is 0v, the Control Board is not supplying the necessart 5v and should be replaced. If the reading stays at 5vdc, replace the hot gas sensor.

Alternate Test:

2. Disconnect the plug on the hot gas sensor leads from the connector on the main harness.

3. Connect an ohmmeter across the two leads of the hot gas sensor;

The indication must be: a) 678 ohms @ 212° F ± 10% b) 10k ohms @ 77° F ± 10%

If resistance reading is not within the range listed above, replace sensor.

48 41084 102709

SERVICE (cont.)

LAMP CORD ASSY

ULTRA-2 shown

7. Strip the wires from the lamp holder/socket assembly approximately .375”.

8. Using the two wire nuts, supplied, connect the new lamp cord assembly to the lamp holder/socket assembly wires.

9. Reinstall the hopper liner to the bottom of the hopper cover.

10. Reinstall the hopper cover to the hopper.

11. Plug in the new lamp cord assembly to the lamp cord connector assembly on top of the auger motor cover.


FIG. 45 LAMP CORD ASSY

Location:

The lamp cord assembly is located in the top center of the auger motor cover.

Test Procedures:


2. Unplug the lamp cord assembly from lamp cord connector assembly.

3. Check for continuity across the tip of the cord assembly and the housing. Continuity must not be present when both lamps are removed.

If continuity is present as described, the cord assembly is operating properly.

If continuity is not present as described, replace the cord assembly.


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. Remove hopper cover liner from the hopper cover.

4. Cut the closed splice terminals connecting lamp cord assembly to the lamp holder/socket assembly off.

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.

49

FIG. 46 LAMP CORD WIRES

P1332

41084 102709

SERVICE (cont.)

LAMP CORD CONNECTOR

ULTRA-2 shown

Location:

FIG. 47 LAMP CORD CONNECTOR

The lamp cord connectors are located inside the center top of the auger motor covers.

Test Procedures:


2. Disconnect the plug on the dispenser main harness from the connector from the lamp cord connector.

3. Connect the dispenser to the power source. Turnon power (I/O) switch. The indication must be approximately 12.6 volts dc.


If voltage is present as described, proceed to #5.

If voltage is not present as described, refer to the

Wiring Diagram and check the dispenser main wiring harness.

NOTE: Lamp cord assembly (Fig. 47) and lamps, must be tested and determined to be functioning properly before proceeding to step 5.

5. Check for continuity across the black wire pin and red wire pin of the lamp cord connector (Fig. 48).

Continuity must be present when the lamp cord assembly is connected and must not be present when lamp cord assembly is disconnected from 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.


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.

3. Disconnect the lamp cord connector wires from the dispenser main wiring harness.

4. Remove nut and washer securing the lamp cord connector to the auger motor cover and discard nut, washer and lamp cord connector.

5. Remove new nut and washer from new lamp cord connector.

6. Push new lamp cord connector through the hole in the auger motor cover and secure with the new nut and washer.

7. Reconnect the wires on the cord connector to the dispenser main wiring harness.

8. Position auger motor cover on auger motor bracket/ cooling drum bracket and secure with two #8-32 locking screws.

9. Refer to Fig. 48 when reconnecting wires.

BLK to Main Wiring Harness

RED to Main Wiring Harness

FIG.48 LAMP CORD CONNECTOR P1323

50 41084 102709

SERVICE (cont.)

LAMP HOLDER/SOCKET ASSEMBLY

ULTRA-2 shown

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.

3. With a voltmeter, check the voltage across the pin sockets in the plugs in the “DAY” mode. Reconnect the lamp cord to the lamp cord connector. The indication must be approximately 12.6 volts dc.

4. Disconnect the lamp cord from the lamp cord connector.

If voltage is present as described, the lamp holder/ socket assembly is operating properly.

If voltage is not present as described, replace the lamp holder/socket assembly.

5. Check for continuity across the terminals on the lamps.

If continuity is present as described, the lamps are operating properly.

If continuity is not present as described, replace the lamp.





4. Cut off the closed-end splices connecting lamp cord assembly to the lamp holder/socket assembly.

5. Remove the two lamps.

6. Remove the two #2-56 screws and elastic lock nuts securing the lamp holder/socket assembly to the mounting bracket. Remove lamp holder/socket assembly and discard.

7. Install new lamp holder/socket assembly on mounting bracket using two #2-56 screws and elastic lock nuts.

8. Reinstall lamps.

9. Strip the wires from the lamp cord assembly approximately .38”.

10. Using the two wire nuts, supplied, connect the lamp cord assembly to the new lamp holder/socket assembly wires.

11. Reinstall the hopper liner to the bottom of the hopper cover.

12. Reinstall the hopper cover to the hopper.

13. Plug in the lamp cord assembly to the lamp cord connector assembly on left top of the auger motor cover.


FIG. 50 LAMP HOLDER/SOCKET ASSEMBLY

WIRES

P1322

51 41084 102709

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 operating properly.

If continuity is not present as described, replace the lamp.

P4110

FIG. 45 LED HOPPER LIGHTS

Location:

The LED hopper lights are located inside the hopper lid.

Test Procedures:

1. Disconnect power from the dispenser.

2. Disconnect the black and red leads from the LEDs.

3. Check the voltage across the two leads with a voltmeter. Reconnect power to the dispenser. The indication must be approximately 12 volts ac.







5. Remove the two #2-28 screws securing the LED circuit board assembly to the cover liner.

6. Replace the LED circuit board assembly.

52

SERVICE (cont.)

LAMP RELAY

ULTRA-2 shown

R

Test Procedures: (Contacts)


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..


The indication must be: a) continuity in the “DAY” mode, b) open in the “NIGHT” mode.

If continuity is present as described, the Relay is operating properly.

If continuity is not present as described, replace the

Relay.

FIG. 51 LAMP RELAY

Location:

The Lamp Relay is located under the upper deck of the chassis, on the right side.

Test Procedures: (Coil)


2. Connect a voltmeter, across BLU/BLK wire (+) and the VIO wire (-).

3. Connect the dispenser from the power source.


The indication must be: a) 12 volts dc in the “DAY” mode, b) 0 volts dc in the “NIGHT” mode.

If voltage is present as described, the Control Board is operating properly. Replace Relay if it does not energize when voltage is present.



If harness has continuity, replace the Control Board.

Not Used (N/C)

3 1

4 2

FIG. 52 LAMP RELAY

ULTRA-2

1. (-) 12vdc (VIO) from

Control Board J5-7

2. (+) 12vdc (BLU/BLK) to

Control Board J5-19

3. 12vac (WHI/VIO) to

Lamp Connectors

4. 12vac (WHI/YEL) from

Circuit Breaker

ULTRA-1

1. (-) 12vdc (VIO) from

Control Board J10-12

2. (+) 12vdc (BLU/BLK) to

Control Board J10-14

3. 12vac (WHI/RED) to

Lamp Connector

4. 12vac (RED) from

Circuit Breaker

53 41084 102709

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.


2. Remove the right and left side panels.

3. Remove the front panel and disconnect ribbon cable.

4. Check for continuity of the switches using pin #7 as common.

#7 - #1 (shield) no continuity

#7 - #2 (Left Auger)

#7 - #3 (I/O)

#7 - #4 (not used)

#7 - #5 (Left ICE/CHILL/OFF)

#7 - #6 (ULTRA)

#7 - #8 (GOURMET)

#7 - #9 (not used)

#7 - #10 (ICE)

#7 - #11 (Right Auger)

#7 - #12 (Right ICE/CHILL/OFF)

If continuity is not present when the appropriate switch is pressed, the Membrane Switch must be replaced.

If continuity is present, chech the short harness going to J2 on the Control Board.

54



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 mineral spirits and then alcohol.

5. Remove protective paper backing from back side of new Membrane Switch.

6. Guide ribbon cable through narrow slot in panel.

Carefully position new Membrane Switch on panel, while centering display window to opening.

7. Refer to Fig. 54 and connect the ribbon cable to the chort harness from the Control Board.

NOTE: The black wire should correspond to the #1 printed on the clear portion of the cable.

I/O

SHIELD

LEFT RIGHT


1

MEMBRANE

SWITCH

FIG. 55 MEMBRANE SWITCH and RIBBON CABLE

12

1

41084 102709

SERVICE (cont.)

MEMBRANE SWITCH (ULTRA-1)


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.


2. Remove the right and left side panels.

3. Remove the front panel and disconnect ribbon cable.

4. Check for continuity of the switches using pin #2 as common.

#2 - #1 (shield) no continuity

#2 - #3 (I/O)

#2 - #4 (ULTRA)

#2 - #5 (GOURMET)

#2 - #6 (ICE)

#2 - #7 (ICE/CHILL/OFF)

#2 - #8 (Auger Motor)

If continuity is not present when the appropriate switch is pressed, the Membrane Switch must be replaced.

If continuity is present, check the short harness going to J11 on the Control Board.



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 mineral spirits and then alcohol.

5. Remove protective paper backing from back side of new Membrane Switch.

6. Guide ribbon cable through narrow slot in panel.

Carefully position new Membrane Switch on panel, while centering display window to opening.

7. Refer to Fig. 57 and connect the ribbon cable to the

Control Board.

MEMBRANE

SWITCH SHIELD

1


1

8

55

FIG. 58 MEMBRANE SWITCH and RIBBON CABLE

41084 102709

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:


2. Remove the left side panel.

3. Connect a voltmeter across the white wire and the other wire on the solenoid to be tested (output from Control Board must be checked with load connected).


5. Turn on the power (I/O) switch.

6. Verify that the side being tested is in the UPPER case “ICE” or “CHILL” mode.




If voltage is present as described, proceed to #8

If voltage is not present as described, refer to the Wiring Diagram and check the main wiring harness.

8. Disconnect both wires and check for continuity across the solenoid valve coil (Approximately 350 ohms).

If continuity is present as described, reconnect the wires to the solenoid.

If continuity is not present as described, replace the solenoids.

9. Repeat steps 4-6. If the cooling drum fails to buildup a layer of frost, there may be a blockage in the refrigerant line or solenoid. This will require a licensed refrigeration repair person to evacuate the system and make repairs as necessary.

56


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.

3. Remove the #8-32 locking screw securing solenoid bracket to the dispenser chassis.

4. Remove bracket and solenoids from the chassis assembly.

5. Remove the two #6 crimptite screws securing the solenoids to the bracket.

6. Remove solenoid and clean or discard.

7. Install new solenoids on mounting bracket using two #6 crimptite screws.

8. Reinstall mounting bracket and solenoids inside the dispenser chassis, securing with a #8-32locking screw.

9. Reconnect the tubes from the accumulator and the cooling drums.



12. Recharge the system with the appropriate coolant and to the pressures directed on the decals.


1. WHI from Main Harness

2 1

2. Left Coolant Solenoid (ULTRA-2)

BRN from Control Board J13-15

2. Right Coolant Solenoid (ULTRA-2)

RED from Control Board J13-16

2. Coolant Solenoid (ULTRA-1)

BRN from Control Board J10-19

FIG.60 SOLENOID TERMINALS

41084 102709

SERVICE (cont.)

TEMPERATURE SENSOR

ULTRA-2 shown

FIG. 61 TEMPERATURE SENSOR P1341

Location:

The Temperature Sensor(s) are located inside the top rear of the cooling drum under the Auger Motor covers.

Test Procedures:


2. Connect a voltmeter, across the two leads of the temperature sensor (leave plug connected);

The indication must be: a) Approx. 1.4 vdc @ 71° F b) Approx. 2.6 vdc @ 32° F


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.

3. Pull the temperature sensor from the tube at the top rear of the cooling drum and discard.

4. Push new temperature sensor into tube at the top rear of the cooling drum as far as it will go.


6. Position auger motor cover on cooling drum mount and secure with two #8-32 locking screws.

1. Ultra-2 Left Temperature Sensor

WHI to TAN J13-21


1. Ultra-2 Right Temperature Sensor

WHI to PNK J13-22


1. Ultra-1 Temperature Sensor

WHI to TAN J10-3


2. WHI to WHI/BLK Main Harness

(Control Board) Negative

2 1

FIG. 62 TEMPERATURE SENSOR

If voltage reading is 0v, the Control Board is not supplying the necessary 5v and should be replaced. If the reading stays at 5vdc, replace thermistor.

Alternate Test:

2. Disconnect the plug on thermistor leads and check resistance as indicated below.

The indication must be: a) 5650 ohms @ 32° F ± 10% b) 2000 ohms @ 77° F ± 10%

If resistance reading is not within the range listed above, replace thermistor.

57 41084 102709

SERVICE (cont.)

TORQUE SENSOR CIRCUIT BOARD

ULTRA-2 shown

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.

P1341

Test Procedures:

1. Place black meter lead at J1-3 (common) and red lead at J1-1 (signal). Set meter to 10 - 20volts DC scale. Turn on power switch.

DO NOT TURN ON AUGERS!

2. Using a strip of paper, momentarily block the light path between red LED and white phototransistor.

If the meter displays 5vdc when blocked and 0v when unblocked, then the Torque Sensor is good.

If there is no 5vdc reading, verify that both red and white sensors are clean.

3. If there is still no 5vdc reading when blocked, place the red meter lead at J1-2 and verify that there is

4.5vdc supplied to Torque Sensor. If there is no

5vdc supplied, check wiring between control board and Torque Sensor. If wiring is ok, then replace the main control board.

1. Ultra-2 Left Signal (WHI/GRY)

1. Ultra-2 Right Signal (WHI/GRN)

1. Ultra-1 Signal (WHI/GRY)

2. (+) 5vdc (BLU)

3. (-) common (WHI/BLK)

1

J1


1. Remove the two #8-32 locking screws securing the auger motor cover to the cooling drum mount.


3. Remove the #8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor run capacitor. Set capacitor aside with wires attached.

4. Disconnect the auger motor plug from the connector on the main wiring harness.

5. Remove the three remaining #8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket.

6. Remove motor with mounting bracket, split pin/ torsion spring bearings as an assembly and set aside for reassembly.

NOTE: When removing or installing the motor be sure the split pin in the motor shaft is turned to a position that will clear the torque sensor circuit board.

7. Disconnect the plug from the dispenser main wiring harness to the torque sensor circuit board.

8. Remove the #8-32 locking screw and washer securing torque sensor circuit board to the cooling drum mount.

9. Remove torque sensor circuit board and discard.

10. Install new torque sensor circuit board in the slot in the rear of the cooling drum mount and secure with a #8-32 locking screw and washer.


12. Reinstall motor with mounting bracket, drip tray, split pin and torsion spring bearings using three

#8 locking screws onto the cooling drum bracket.

13. Install the auger motor capacitor on the lower right side of the auger mounting bracket using the remaining #8 locking screw.

14. Connect the auger motor terminal to the terminal on the main wiring harness.


16. Position the auger motor cover on the cooling drum mount and secure with two #8-32 locking screws.

L.E.D.

PHOTOTRANSISTOR

FIG. 64 TORQUE SENSOR CIRCUIT

BOARD TERMINALS

58 41084 102709

SERVICE (cont.)

TRANSFORMER

-LINE-

R

FIG. 65 TRANSFORMER - ULTRA-1

Location:

The transformer is located inside dispenser onthe lower right side of the chassis.

Test Procedures:


2. Remove right side panel.


4. Connect a voltmeter from the WHI/BLU wire to the

WHI/BLK wire on the transformer.

The indication must be: a) Aprox. 12.6 volts ac.

If voltage is present as described, the transformer is working properly.



5. Connect a voltmeter from the WHI wire to the BLK wire on the transformer.



If voltage is present as described, replace transformer.



FIG. 66 TRANSFORMER - ULTRA-2



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. Remove transformer and discard.

6. Position new transformer on the chassis base, and secure with two #8-32 nuts.


WHI/BLU to

Main Harness

“LOAD”

WHI to Main Harness

Ultra-1 WHI/GRY to Main Harness

Ultra-2 WHI/BLK to Main Harness

BLK to Main Harness

-LINE

-

“LINE”

FIG. 67 TRANSFORMER TERMINALS

59 41084 102709

COOLANT SCHEMATIC ULTRA-1

FOR COOLANT CHARGE INFORMA

COPPER TUBE .25” O.D. X .030”


60


41084 102709

COOLANT SCHEMATIC ULTRA-2



61


41084 102709

TRIAC MAP for ULTRA-1

ULTRA-1 TRIACS

TH1 & MOV4 controls

TH2 & MOV1 controls

TH3 & MOV2 controls

TH4 & MOV3 controls

Auger @ J10-8 Reverse & J10-9 Forward

Compressor Relay @ J10-20

Cooling Valve

Refill Valve

@ J10-19

@ J10-18

62 41084 102709

TRIAC MAPS for ULTRA-2

LIQUID AUTO-FILL BOARD

ULTRA-2 TRIACS

TH1 & MOV3 controls

TH2 & MOV1 controls

TH3 & MOV4 controls

TH4 & MOV2 controls

TH5 & MOV5 controls

TH6 & MOV6 controls

Left solenoid @ J13-15

Compressor Relay @ J13-17

Fan

Right solenoid

Left Auger

Right Auger

@ J13-14

@ J13-16

@ J13-2 Reverse & J13-3 Forward

@ J13-13 Reverse & J13-1 Forward

LIQUID AUTO-FILL TRIACS

TH1 & MOV1 controls

TH2 & MOV2 controls

Right fill solenoid @ J2-9

Left fill solenoid @ J2-4

63 41084 102709

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

PIN

NUMBER

1

4

5

2

3

10

11

12

13

14

15

6

7

8

9

16

17

18

19

20

WIRE COLOR

AND GAUGE

White/Blue 18

Blue 22

Tan 22

White/Gray 22

White/Black 18

Not used

Not used

Brown/White 18

Brown/Black 18

Black 18

Yellow 22

Violet 18

Gray 22

Blue/Black 18

White/Black 22

Not used

White 18

Not used

Brown 22

Orange 18

FUNCTION

- - - - - -

Output

Input/Signal

Output

- - - - - -

Not used

Not used

Output

Output

Supply

Input/Signal

Output/Switched

Output

Output

Board Ground

Not used

Neutral

Not used

Output

Output

COMPONENT

Rectifier

Torque Sensor

Temp Sensor

Torque Sensor

Rectifier

Not used

Not used

Auger Motor

Auger Motor

PC Board

Hot Gas Temp

Lamp Relay

Condenser Fans

Lamp Relay

Sensors

Not used

PC Board

Not used

Solenoid

Compressor Relay

VOLTAGE

*With sensor disconnected you will read +5VDC, but when connected, voltage will vary according to temperature. To check sensor, see repair section.

- - - - - -

5VDC

*

5VDC

- - - - - -

Not used

Not used

120VAC

120VAC

120VAC

*

12VDC

120VAC

+12VDC

5VDC

Not used

Neutral

Not used

120VAC

120VAC

J11 connector for touch pad/ membrane switch (see touch pad pin out test).

64 41084 102709

MEMBRANE

SWITCH SHIELD

Configuration for CF VALVE Models

WHI WHI

WATER

SOL.

SOL.

PRODUCT

WHI/YEL

120 VOLTS AC or

230 VOLTS AC

2 WIRE

SINGLE PHASE

50/60 HZ

SCHEMATIC WIRING DIAGRAM ULTRA-1

J9-1 1

TRANSFORMER

WHI/VIO

J9-5

J9-10

D

I

S

P

L

A

Y

BLK WHI/YEL

WHI/BLK

-

RECTIFIER

+

1

RED/BLK

J11-1

J9-16 16

5

AMP

CIRCUIT

BREAKER

J11-5

WHI/RED FAN

MOTOR

FAN

MOTOR

J11-8

8

C

LAMP

RELAY

GRY-22

J10-1

R

O

L

C

O

N

T

B

O

A

R

D

J10-5

J10-10

J10-15

J10-20

WHI/BLU

BLU-22

TAN-22

WHI/GRY-22

WHI/BLK

PNK

BRN/WHI

BRN/BLK

BLK

YEL-22

VIO

GRY-22

BLU/BLK

WHI/BLK-22

WHI

RED

BRN-22

ORN

GRN

ORN

LAMP

ASSY

WHI/RED WHI/BLK

C

230V

MODELS

GND L1 N

BRN-22

SOL

EMI

FILTER

A B

WHI

WHI

BLK

WHI

WHI

COMPRESSOR RELAY

BLK

120V

MODELS

L1 N

A B

A B

TORQUE

SENSOR

1

J1-1

WHI-22

BLK-22

1

CLOCK

LEVEL

PROBE t

1

BOWL

TEMP.

RED

SOL.

WHI

PRODUCT t

1

HOT

GAS

M

AUGER

MOTOR

WHI/ORN

COMPRESSOR ASSY

COMPRESSOR

MOTOR

C

OVERLOAD

A P

STARTING

CAPACITOR

RELAY

WHI

65 41084 052112

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

PIN

NUMBER

1

2

3

4

5

6

13

14

15

16

17

18

7

8

9

10

11

12

19

20

21

22

23

24

WIRE COLOR

AND GAUGE

Red/Black 18

Brown/White 18

Brown/Black 18

Black 18

White 18

Not used

FUNCTION

Output

Output

Output

Supply

Neutral

Not used

Violet 18

White/Blue 18

Output/Switched

Supply

White/Black 22 Board Ground

Yellow 22 Input/Signal

Blue 22

White/Black 22

Output

Output

White/Red 18

Gray 18

Brown 20

Red 20

Orange 18

Not used

Blue/Black 18

White/Black 18

Tan 22

Pink 22

White/Gray 22

White/Green 22

Output

Output

Output

Output

Output

Not used

Output

Supply

Input/Signal

Input/Signal

Input/Signal

Input/Signal

COMPONENT

Right Auger Motor

Left Auger Motor

Left Auger Motor

PC Board

PC Board

Not used

Lamp Relay

PC Board

Sensors

Hot Gas Temp

Torque Sensors

Torque Sensors

Right Auger Motor

Condenser Fan

Left Solenoid

Right Solenoid

Compressor Relay

Not used

Lamp Relay

PC Board

Left Temp Sensor

Right Temp

Sensor

Left Torque

Sensor

Right Torque

Sensor

VOLTAGE

0 or 5VDC

0 or 5VDC

*With sensor disconnected you will read +5VDC, but when connected, voltage will vary according to temperature. To check sensor, see repair section.

120VAC

120VAC

120VAC

120VAC

Neutral

Not used

-12VDC

12VAC

-5VDC

*

5VDC

5VDC

120VAC

120VAC

120VAC

120 VAC

120VAC

Not used

+12VDC

12VAC

*

*

66 41084 102709

I/O

I/O I/O

MEMBRANE

SWITCH

12

WHI/RED-22

WHI/BLK-22

PNK-22

TAN-22

WHI-22

GRY-22

VIO-22

BLU-22

GRN-22

YEL-22

ORN-22

BLK-22

1

SHIELD

WHI WHI WHI WHI

SOL.

LEFT

WATER.

BLU

SOL.

LEFT

PRODUCT.

RIGHT

WATER

SOL.

SOL.

RIGHT

PRODUCT

RED

J1-1

LEFT

LEVEL

PROBE

RIGHT

LEVEL

PROBE

TAN

PNK

BLU

WHI

GRN

GRN

RED

J2-1

J2-5

J2-10

J1-14

WHI

Configuration for CF VALVE Models

WHI

SOL.

LEFT

WATER.

SOL.

LEFT

PRODUCT.

WHI/YEL

WHI WHI

RIGHT

WATER

SOL.

SOL.

RIGHT

PRODUCT

WHI/YEL

SCHEMATIC WIRING DIAGRAM ULTRA-2 AF

J5-1 1

LEFT

LAMP

ASSY

RIGHT

LAMP

ASSY

J2-1

J2-5

J5-5

J5-10

A

Y

S

P

D

I

L

J2-10

J2-12

J5-16

R

O

L

C

O

N

T

B

O

A

R

D

J13-1

J12-1

J13-5

16

J13-10

J13-15

J12-14

J13-20

J13-24

J1-1

RED/BLK

BRN/WHI

BRN/BLK

BLK

WHI

VIO

WHI/BLU

WHI/BLK-22

YEL-22

BLU-22

WHI/BLK-22

WHI/RED

GRY

BRN-20

RED-20

ORN

BLU/BLK

WHI/BLK

TAN-22

PNK-22

WHI/GRY-22

WHI/GRN-22

WHI-22

BLK-22

1

CLOCK

LEFT

AUGER

M

BLK RED WHI

BRN/WHI BRN/BLK

RIGHT

AUGER

M

WHI/VIO-22 WHI/BLK-22 WHI/VIO-22 WHI/BLK-22

C

LAMP

RELAY

WHI/YEL

1

LEFT

TORQUE

SENSOR

1

RIGHT

TORQUE

SENSOR

GRN

5

AMP

CIRCUIT

BREAKER

FAN

MOTOR

230V

MODELS

GND L1 N

120V

MODELS

L1 N

EMI

FILTER

A B

A B

A B

LEFT

SOL.

RIGHT

SOL.

TRANSFORMER t

1 t

1

LEFT RIGHT

1 t

HOT

GAS

WHI/BLK

ORN

C

WHI

WHI/ORN

COMPRESSOR RELAY

BLK

COMPRESSOR ASSY

3

6

4

5

2

N

1

WHI

J2-1

J2-5

J2-10

120 VOLTS AC or

230 VOLTS AC

2 WIRE

SINGLE PHASE

50/60 HZ

3

4

6 5

2

N

PTC

ASSY

R

1

230V COMPRESSOR ASSY

67 41084 052112

68 41084 102709

Bunn ULTRA-2 Coffee Grinder Repair manual

SERVICE & REPAIR MANUAL

BUNN-O-MATIC CORPORATION

CONTENTS

USER NOTICES

SITE PREPARATION

INTRODUCTION

-

-

OPERATING CONTROLS

ULTRA-1

1

2

3

OPERATING CONTROLS

ULTRA-2

1

2 3 4 5

RECOMMENDED DAILY CLEANING (ULTRA-2 shown)

RECOMMENDED DAILY CLEANING (Continued)

Auto-fill Cleaning Instructions

(With Brixing Pump Installed)

PREVENTIVE MAINTENANCE

REQUIRED REGULAR MAINTENANCE:

Semi Annual:

INSTRUCTIONS

TROUBLESHOOTING

SERVICE

COOLANT SCHEMATIC ULTRA-1

COOLANT SCHEMATIC ULTRA-2

TRIAC MAP for ULTRA-1

TRIAC MAPS for ULTRA-2

Input and Output Chart (ULTRA-1)

Input and Output Chart (ULTRA-2)

Related manuals

Table of contents

Bunn ULTRA-2 Coffee Grinder Repair manual

SERVICE & REPAIR MANUAL

BUNN-O-MATIC CORPORATION

CONTENTS

USER NOTICES

SITE PREPARATION

INTRODUCTION

-

-

OPERATING CONTROLS

ULTRA-1

1

2

3

OPERATING CONTROLS

ULTRA-2

1

2 3 4 5

RECOMMENDED DAILY CLEANING (ULTRA-2 shown)

RECOMMENDED DAILY CLEANING (Continued)

Auto-fill Cleaning Instructions

(With Brixing Pump Installed)

PREVENTIVE MAINTENANCE

REQUIRED REGULAR MAINTENANCE:

Semi Annual:

INSTRUCTIONS

TROUBLESHOOTING

SERVICE

COOLANT SCHEMATIC ULTRA-1

COOLANT SCHEMATIC ULTRA-2

TRIAC MAP for ULTRA-1

TRIAC MAPS for ULTRA-2

Input and Output Chart (ULTRA-1)

Input and Output Chart (ULTRA-2)

Related manuals

Bunn-O-Matic

ULTRA-1

Bunn

ULTRA-2, Black/Stainless w-Low Level Alert

Bunn

Ultra-2 HP Manual Fill, Coastal - Extended Handle

Bunn

Ultra-2 HP Manual Fill, Coastal, Standard Handle

Lennox

ECM Motor Replacement Kit

Bunn

ULTRA 1

Bunn-O-Matic

ULTRA-2

Bunn

ULTRA 1

Bunn

ULTRA NX, 120V BLK/SST LAF

Bunn

BUNN-O-MATIC ULTRA-1

Bunn

ULTRA NX, 120V BLK/SST LAF

Bunn

ULTRA NX, 120V BLK/SST LAF

Table of contents