Bunn dispenser User Manual

®

POWDER

BUNN

AUTO FILL

For ULTRA-2

™

OPERATING & SERVICE MANUAL

BUNN-O-MATIC CORPORATION

POST OFFICE BOX 3227

SPRINGFIELD, ILLINOIS 62708-3227

PHONE: [phone] FAX: [phone]

29793.0001B 08/02 ©2002 Bunn-O-Matic Corporation

www.bunnomatic.com

INTRODUCTION

This equipment supplies a liquid mix to the hoppers on the ULTRA-2 dispenser. It is for indoor use only on a
sturdy counter or shelf.

BUNN-O-MATIC COMMERCIAL PRODUCT WARRANTY

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

1) All equipment other than as specified below: 2 years parts and 1 year labor.

2) Electronic circuit and/or control boards: parts and labor for 3 years.

3) Compressors on refrigeration equipment: 5 years parts and 1 year labor.

4) Grinding burrs on coffee grinding equipment to grind coffee to meet original factory screen sieve analysis: parts
and labor for 3 years or 30,000 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, damage or casualty. This warranty is conditioned on the
Buyer 1) giving BUNN prompt notice of any claim to be made under this warranty by telephone at [phone]
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,
EXPRESS 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.

2

29793.1 080102

INITIAL SET-UP

1. Loosen auger motor cover screws.

2. Remove rear plastic plug from trim strip between hopper drip trays.

3. Install support rod into hole in trim strip.

4. Place PAF platform assembly on top of motor covers.

5. Tighten support rod from top of platform.

6. Retighten motor cover screws.

7. Plug RCA cord into ULTRA base unit.

8. Install hopper seal and press firmly into place on the flange of the cooling drum.

9. Align the auger shaft with the flat fin of the auger. Push the augers as far as they will go and rotate them so
the flat fin is facing up.

10. Place level probes in notch in rim of hoppers and install hoppers.

10. Install PAF units onto hoppers and platform.

11. Plug PAF power cord into rear of platform.

12. Plug PAF platform power cord into proper electrical outlet.

13. Attach a flexible water line to the .25" flare fitting on the back panel of the Powder Auto-Fill.

NOTE: A water strainer assembly (BUNN-O-MATIC #23820.1000) should be installed in line prior to the flexible

water line.

USER NOTICES

Carefully read and follow all notices on the equipment and in this manual. They were written for your protection.
All notices are to be kept in good condition. Replace any unreadable or damaged labels.

00656.0000

00986.0000

Push back until fully latched

before removing or manually

filling chilled product hopper.

34561.0000

3

29793.1 080102

OPERATING INSTRUCTIONS

1. On the Ultra touch pad, make the following settings:
a) POWER- "ON"
b) DAY/NIGHT- "DAY"

2. Pull the Powder Auto-Fill fully forward on its sup­port rails and open the door.

3. Fill the Powder Auto-Fill product hopper as follows:
a) Pull the slide gate closed on the Powder Auto-Fill
product hopper elbow and remove the hopper from
the Powder Auto-Fill.
b) Remove the lid from the product hopper and fill
the hopper with a powdered granita mix.
c) Install the product hopper into the Powder Auto­Fill. Insure hopper is fully seated behind retainer
plates.
d) Push the slide gate on the hopper ejector elbow
to the open position.

4. Place the ON/OFF switch at the Powder Auto-Fill
whipper panel to "ON".

5. After allowing 5 seconds for the Powder Auto-Fill to
initialize, observe the door lamp. The door lamp
should not be lit. If the door lamp is lit, consult the
fault list located on the decal placed on the back of
the door. Clear the fault before proceeding.

NOTE: If the Powder Auto-Fill is being used for the first
time with the selected granita mix, perform an adjust­ment as described in ADJUSTMENTS.

6. Close the Powder Auto-Fill door and observe the
following:
a) The door lamp lights steadily.
b) The Powder Auto-Fill begins dispensing liquid
granita product.

7. The Powder Auto-Fill will continue to fill the ULTRA
product hopper until the liquid level in the ULTRA
hopper reaches the product level probe or for 5
minutes, which ever occurs first.

8. If the Powder Auto-Fill fails to fill the ULTRA hopper
in 5 minutes, the following will occur:
a) The Powder Auto-Fill will stop dispensing prod­uct.
b) The door lamp will flash 4 times about every 2
seconds.

9. After checking the ULTRA and Powder Auto-Fill set­up, the 5 minute refill fault may be cleared by simply
opening and closing the Powder Auto-Fill door.

10. Once the product level in the ULTRA covers the
auger, make the following switch settings at the
ULTRA control panel:
a) AUGER - "1".
b) ICE/OFF/CHILL - "ICE" or "CHILL" as appropriate
for the granita product.

11. From this point onward, the Powder Auto-Fill will
continue to automatically refill the ULTRA hopper,
maintaining the ULTRA product at an approximate
2 gallon level.

12. When the Powder Auto-Fill powder level falls low,
the door lamp will cycle ON and OFF, but will
continue to dispense product for a preset period.
When this period expires, the Powder Auto-Fill will
continue to cycle the door lamp ON and OFF and will
stop dispensing product.

13. To clear the low product fault, simply refill the
powder as follows:
a) Open the Powder Auto-Fill door.
b) Close the hopper slide gate.
c) Remove the product hopper.
d) Refill the product hopper with powdered granita
mix.
e) Replace the hopper.
f) Push the slide gate on the hopper ejector elbow
to the OPEN position.
g) Close the Powder Auto-Fill door.

4

29793.1 021202

ADJUSTMENTS

When using the Powder Auto-Fill with a new powdered granita mix, follow the procedure outlined below to

adjust the Powder Auto-Fill to produce the correct recipe.

1. Determine the mix ratio of powdered granita mix.
Convert the recipe so that it is expressed in terms
of weight units [grams (g), dry ounces (oz), or
pounds (lbs)] of powdered granita mix to fluid
ounces (fl.oz.) of water [1 gallon (gal) = 128 fl.oz.;
1 liter (l) = 33.8 fl.oz.].

2. The delivery rate of the water ingredient is factory
preset to 1 fl.oz. per second. Therefore, it is only
necessary to adjust the delivery rate of the pow­dered granita mix. Adjustment is accomplished as
follows:
a) Place the Powder Auto-Fill on top of a fully
assembled ULTRA taking care to align the Powder
Auto-Fill guide rails over the rollers on the platform
guide rails.
b) Connect the Powder Auto-Fill power cord to the
outlet located on the ULTRA auger motor cover.
c) Attach a flexible water line to the .25" flare fitting
on the back panel of the Powder Auto-Fill.

NOTE: A water strainer assembly (BUNN-O-MATIC
#23820.1000) should be installed in line prior to the
flexible water line.

d) On the ULTRA touch pad, make the following
settings:

i) POWER- "ON"

ii) DAY/NIGHT- "DAY"
e) Pull the Powder Auto-Fill fully forward on its
support rails
f) Fill the Powder Auto-Fill product hopper as fol­lows:

i) Pull the slide gate closed on the Powder Auto­Fill product hopper elbow and remove the product
hopper from the Powder Auto-Fill.

ii) Remove the lid from the product hopper and
fill the hopper with a powdered granita mix.

iii) Install the product hopper into the Powder
Auto-Fill.
g) Place the ON/OFF switch at the Powder Auto-Fill
whipper panel to "ON".
h) After allowing 5 seconds for the Powder Auto-Fill
to initialize, observe the door lamp on the whipper
panel. The door lamp should not be lit. If the door
lamp is lit, consult the fault list and clear the fault
before proceeding.

i) Remove the hole plug on the whipper panel.
Using a screwdriver, set potentiometer to approxi­mately mid range.
j) Remove the mixing chamber from the Powder
Auto-Fill and place a small container, such as a cup,
under the product hopper ejector elbow.
k) Push the slide gate on the product hopper ejector
elbow to the OPEN position.
l) Momentarily set the TEST/SERVICE switch on the
whipper panel to the TEST position.
m) The hopper motor will run and dispense pow­dered granita mix for 10 seconds.
n) After the Powder Auto-Fill has finished the 10
second throw test, weigh the dispensed product.
o) Determine the dispense rate of the powdered
product (weight units per second) by dividing the
measured weight by 10.
p) Compare the measured dispense rate with the
mix ratio in step 1.
q) Adjust the MIN/MAX control clockwise to in­crease the dispense rate or counterclockwise to
decrease the dispense rate of the powdered granita
mix.
r) Repeat steps l through q as necessary until
proper mix ratio is achieved.
s) Replace the mixing chamber removed in step j.
Replace hole plug.

3. Once the mix ratio has been adjusted, the Powder
Auto-Fill can be run with the door open to allow the
user to catch dispensed product for brix testing as
follows:
a) Hold a container under the dispense tip of the
Powder Auto-Fill.
b) Hold the TEST/SERVICE switch on the whipper
panel to the SERVICE position.
c) When the container is filled to the desired level,
release the TEST/SERVICE switch.
d) Measure the brix using the appropriate measur­ing device.
e) Remove the hole plug. Using a screwdriver,
adjust the potentiometer clockwise to increase the
brix or counterclockwise to decrease the brix of the
product. Replace the hole plug.

5

29793.1 021202

CLEANING

RECOMMENDED DAILY CLEANING AND MAINTENANCE TIPS

This should be done in conjunction with the recommended weekly cleaning of your ULTRA-2 machine.

Removing and cleaning the whipper chamber

(once a day):

1. Open the cabinet door.

2. Pull the mixing chamber out of the whipper cham­ber.

3. Twist the whipper chamber clockwise and pull it off
the whipper chamber receptacle.

4. Pull the frother off the motor shaft. Notice the flat
keyway on the shaft and the matching keyway
inside the frother. It is important that these two
keyways are lined up when reassembling.

5. Twist the whipper chamber receptacle clockwise
and pull it off the motor shaft.

6. Slip the O-ring off the whipper chamber receptacle.

7. Wash components in a mild solution of dish deter­gent using a bristle brush.

8. Rinse thoroughly and allow to dry before reinstall­ing in the machine.

Whipper Chamber
Receptacle

O-ring

Frother

Mixing Chamber

Dispense Tip

Whipper Chamber

Thorough cleaning of the hopper

Wiper Blade
Shaft

Wiper Blade
Wiper Drive Gear

(once a week):

1. Open the cabinet door.

2. Remove the hopper/base assembly from the cabi­net, remove the cover and empty the contents.

Retaining
Clip

3. Pull the ejector elbow off the hopper base; remove
the slide gate from the ejector elbow.

4. Remove the wiper blade and drive gear by removing
the retaining ring from the wiper blade shaft.

5. Remove the auger by pulling it out of the front
hopper base.

6. Remove the auger drive shaft by removing the
retaining clip from the auger drive shaft.

7. Wash components in a mild solution of dish deter­gent using a bristle brush when needed.

8. Rinse and dry each item thoroughly before reas­sembling.

Auger Drive
Bracket

Retaining
Ring

Hopper Base

Auger Drive
Shaft

Auger

Ejector Elbow

Slide Gate

NOTICE

The cleaning instructions noted above are for nondairy sugar based food products. When dispensing any other

food product, the cleaning cycle for the whipping chamber assembly and ejector elbow must be performed daily.

6

29793.1 021202

FAULT LIST

Door Lamp Fault

ON Normal operation - Powder Auto-Fill ready to

dispense

Flashes ON/OFF at 50% duty cycle Low product level in Powder Auto-Fill hopper

Two flashes about every 2 seconds ULTRA/Powder Auto-Fill probe circuit open

Three flashes about every 2 seconds Powder Auto-Fill hopper not in place

Four flashes about every 2 seconds ULTRA refill exceeded 5 minutes

OFF Door not closed

7

29793.1 021202

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 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.

• Solenoid removal requires interrupting the water supply to the valve. Damage may result if solenoids are

energized for more than ten minutes without a supply of water.

• The use of two wrenches is recommended whenever plumbing fittings are tightened or loosened. This will help

to avoid twists and kinks in the tubing.

• Make certain that all plumbing connections are sealed and electrical connections tight and isolated.

• 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

PROBLEM

ULTRA and Powder Auto-Fill do not
run - Main power on ULTRA is OFF

Product level in ULTRA is lower than
level Probe - ULTRA running; Pow­der Auto-Fill door lamp is OFF

Product level in ULTRA is lower than
level Probe - ULTRA running; Pow­der Auto-Fill door lamp flashes ON
and OFF

PROBABLE CAUSE

1. ULTRA power cord disconnected
or main power switch in ON posi­tion.

1. The ULTRA DAY/NIGHT setting is
in the NIGHT mode.

2. Powder Auto-Fill power cord dis­connected.

3. Powder Auto-Fill main power
switch in OFF position.

5. Powder Auto-Fill door is open.

1. Low product in Powder Auto-Fill.

REMEDY

Check that the power cord is con­nected to proper electrical source
and that the ULTRA main power
switch is in the ON position.

1. The ULTRA DAY/NIGHT setting
should be in the DAY mode.

2. Check that the Powder Auto-Fill is
plugged into the top of the ULTRA
auger motor cover.

3. Select the ON position of the main
power switch.

5. The Powder Auto-Fill door should
be closed securely.

Remove hopper and fill with pow­dered mix.

8

29793.1 021202

TROUBLESHOOTING (cont.)

PROBABLE CAUSE REMEDYPROBLEM

Product level in ULTRA is lower than

level Probe - ULTRA running; Pow-

der Auto-Fill door lamp flashes two

times

Product level in ULTRA is lower than

level Probe - ULTRA running; Pow-

der Auto-Fill door lamp flashes three

times

Product level in ULTRA is lower than

level Probe - ULTRA running; Pow-

der Auto-Fill door lamp flashes four

times

1. Powder Auto-Fill not pulled com­pletely forward.

2. ULTRA level probe misaligned.

1. Powder Auto-Fill hopper not in­stalled properly.

1. Refill time exceeded five minutes.

1. Check that the Powder Auto-Fill is
pulled completely forward until the
guide rails roll into the indented po­sition.

2. Position the ULTRA level probe so
that it is located in the notch of the
ULTRA hopper and touching the con­tact protruding from the front of the
PAF platform.

1. Properly position the Powder
Auto-Fill hopper.

.

Check that the SERVICE switch is
released or reset by opening and
closing the Powder Auto-Fill door.

The ULTRA product tastes "watery"

or "sugary"

Powder Auto-Fill dispenses dry prod-

uct only - dry powder build-up in

mixing and whipper chambers

1. Improper adjustment of product
mix ratio.

1. Powder Auto-Fill not connected to
water source.

2. Water source turned off.

3. Water line obstructed.

Adjust the product mix ratio per in­structions in Powder Auto-Fill Ad­justment. See page 5.

1. Connect the Powder Auto-Fill to a
20 to 90 psi (138 to 620 kPa)water
source.

2. Turn water source on.

3. Remove obstruction.

9

29793.1 021202

TROUBLESHOOTING (cont.)

PROBABLE CAUSE REMEDYPROBLEM

Powder Auto-Fill will not dispense
product

1. No water

2. No power or incorrect voltage to
the dispenser.

3. Dispense Solenoid Valve

4. Control Board and Probe

5. Auger Drive

6. Transformer

Water lines and valves to the dis­penser must be open and free of
obstructions.

Check that the power cord is con­nected to the ULTRA dispenser and
for voltage from the ULTRA dis­penser.

Refer to Service- Dispense Solenoid
Valve for testing procedures. See
page 32

Refer to Service- Control Board and
Probe for testing procedures. See
page 18

Refer to Service- Auger Drive for
testing procedures. See page 13

Refer to Service- Transformer for
testing procedures. See page 26

Dripping from dispense tip

Water flows continuously

7. Water Strainer (Optional)

1. Dispense Solenoid Valve

1. Control Board and Probe

2. Dispense Solenoid Valve

A) Direction of flow arrow must be
pointing towards dispenser.

B) Remove the strainer and check
for obstructions. Clear or replace.

Remove dispense valve and clear
any obstructions. Rebuild or replace
the valve if necessary. Seepage 32

Refer to Service- Control Board and
Probe for testing procedures. See
page 18

Refer to Service- Dispense Solenoid
Valve for testing procedures. See
page 32

10

29793.1 021202

TROUBLESHOOTING (cont.)

PROBABLE CAUSE REMEDYPROBLEM

Product overflows ULTRA hopper

Weak product

1. Control Board and Probe

2. Dispense Solenoid Valve

1. Whipper Motor

2. Frother

3. Dispense Solenoid Valve

4. Auger Drive

Refer to Service- Control Board and
Probe for testing procedures. See
page 18

Refer to Service- Dispense Solenoid
Valve for testing procedures. See
page 32

Refer to Service- Whipper Motor for
testing procedures. See page 16

Refer to Service- Frother for testing
procedures. See page 15

Refer to Service- Dispense Solenoid
Valve for testing procedures. See
page 32

Refer to Service- Auger Drive for
testing procedures. See page 13

Dispenser is making unusual noises

5. Auger Spring

6. Auger Motor

7. Improper adjustment of product
mix ratio

1. Plumbing lines

2. Water supply

Refer to Service- Auger Spring for
testing procedures. See page 13

Refer to Service- Auger Motor for
testing procedures. See page 14

Set the product mix ratio per Adjust­ments. See page 5

Plumbing lines should not be rest­ing on the counter top.

A) The dispenser must be connected
to a cold water line.

B) Water pressure to the dispenser
must not exceed 90 psi (620 kPa).
Install a regulator if necessary to
lower the working pressure to ap­proximately 50 psi (345 kPa).

Display not lit

1. Lamp

2. Lamp Holder

11

Refer to Service- Lamp for testing
procedures. See page 25

Refer to Service- Lamp Holder for
testing procedures. See page 25

29793.1 021202