Bunn Ultra, Ultra 1, Ultra 2 Technical Training Manual
BUNN® TECHNICAL TRAINING
Ultra
Index
Unit 1: Installation
Site Requirements .............................................................................................................. 4
Location of the Serial Number .......................................................................................... 4
Prepping for Install ............................................................................................................. 5
Hopper Assembly ............................................................................................................... 5
Electrical Install .................................................................................................................. 6
PAF Install ...........................................................................................................................6
LAF Install ...........................................................................................................................7
Unit 2: Setup
User Interface ......................................................................................................................13
Setup ....................................................................................................................................14
LAF Setup Menus ......................................................................................................... 14
Set Thickness ............................................................................................................... 14
Set Date & Time ............................................................................................................ 14
Product Preparation ........................................................................................................... 17
PAF Powder Mix Setup .......................................................................................................17
LAF Liquid Concentrate Setup .......................................................................................... 18
Start Up ................................................................................................................................19
Unit 3: Machine Composition
Exterior Overview ............................................................................................................... 21
Product Outlets and Removable Parts ...................................................................... 21
Removing the Enclosure ................................................................................................... 21
Left Side Panel .................................................................................................................... 22
Right Side Panel ................................................................................................................. 23
Top Motor Covers ............................................................................................................... 23
Compressor ........................................................................................................................24
LED Assembly..................................................................................................................... 25
Machine Functions & Operations ..................................................................................... 25
Unit 4: Preventive Maintenance
PM Parts .............................................................................................................................. 29
PM Steps .............................................................................................................................29
Unit 5: Troubleshooting
Service Tools ......................................................................................................................32
Temp & Torque Screen ....................................................................................................... 33
Warning Messages .............................................................................................................34
Error Messages ...................................................................................................................35
Torque Sensor Board ......................................................................................................... 37
Thermistor ........................................................................................................................... 37
Compressor Windings .......................................................................................................38
External Thermal Protector ............................................................................................... 38
PAF Error Messages ........................................................................................................... 40
Ultra 1 Triac Map .................................................................................................................40
Ultra 2 Triac Map .................................................................................................................41
Ultra PAF Triac Map ............................................................................................................42
Rev. A
© 2013 Bunn-O-Matic Corporation. All Rights Reserved
Unit 1 installation
Unit Objectives
Given a realistic scenario depicting a new site install, the learner will be able to install and setup the ULTRA for customer turnover without error.
Given a new machine, all the necessary tools and safety equipment, the learner will be able to install the
ULTRA without error.
The learner will be able to verify that the site requirements have been met for ULTRA or Optional
Accessories.
The learner will be able to locate and document the serial number.
The learner will be able to power up and perform the initial set-up of the ULTRA and Optional Accessory
Systems PAF and LAF.
Installation
Site Requirements
Space
• Counter able to support 180 lbs (PAF Accessory Included).
• Minimum clearance of 6” between the machine side and the wall or another appliances
• Counter area able to accommodate machine’s footprint with six inches of clearance in the rear
for air ow and air lter cleaning.
• Dispenser performs better if not placed near any heating appliance that exhausts heat on and
around dispenser.
• Ultra-1 approx. dimensions (H 32 x W 8 x D 24.5)
• Ultra-2 approx. dimensions (H 32 x W 16 x D 24.5)
Plumbing (PAF Only)
• A shut-off valve should be installed in the line before the machine.
• Cold water with an operating pressure between 20 and 90 psi (138 and 690kpa) from a 1/2 inch
or larger supply line with a shut off valve.
• A strainer assembly should be installed in line prior to the exible water line.
Plumbing (LAF with Water to Product Ratio Brix Pump with Shut Off)
• Cold water with an operating pressure between 20 and 90 psi (138 and 690kpa) from a ½ inch or
larger supply line with a shut off valve.
• Water pressure regulator required and set to 50 psi (345kpa) or SHURo water pressure
reducing valve.
• Double check valve with vent required after pressure regulator.
• 3 - Way Sanitizing Valve required within 6 inches of the brix pump
• Use 3/8 inch I.D. FDA approved exible beverage tubing and stainless steel ttings with Oetiker
clamps.
Water Treatment
• Cold water hook-up only.
• Adequate space for water lter and maintenance.
• Water lter or water cartridge purged before machine installation.
• Installation date recorded on water lter decal.
Electrical
• 120VAC
• Dedicated 15AMP Circuit with proper breaker and receptacle
• Receptacle within 5 feet of machine
• Mating connector must be NEMA 5-15R
Location of the Serial Number
The machine’s serial number is located on the data plate, which is located on
the right side panel. The serial number half tag can be found on the inside of the
machine on the main machine frame.
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Ultra Training Manual
Prepping Machine for Install
Step 3: Place the machine in the desired location on the counter. Do not lift the Ultra by the drum(s).
Step 4: Document the complete serial number of the machine.
Step 5: Remove and save the black plastic drum support(s). This will be used as a servicing jig later.
Step 6: Adjust the legs on the machine so that it is level or slightly lower in the front.
Step 7: Remove the shipping eye bolts, located on the bottom of the machine, from the compressor.
Step 1: Verify that all of the site requirements have been met.
Step 2: Unbox the machine and all the parts.
Step 3: Place the machine in the desired location on the counter. Do not lift the Ultra by the drum(s).
Step 4: Document the complete serial number of the machine.
Step 5: Remove and save the black plastic drum support(s). This will be used as a servicing jig later.
Step 6: Adjust the legs on the machine so that it is level or slightly lower in the front.
Step 7: Remove the shipping eye bolts, located on the bottom of the machine, from the compressor.
Hopper Assembly
Step 1: Insert the auger nose
bushing from inside the hopper.
Step 4: Install the hopper over the
auger and cooling drum and slide it into
place.
Step 2: Install the seal(s) over the
ange at the rear of the cooling drum(s)
and press the seal(s) rmly into place
as shown.
Step 5: Push down until the hopper
lock plunger snaps into place.
Step 3: Align the auger shaft(s) with
the auger(s). Push the auger(s) as far
as they will go and rotate so the at face
of the auger shaft is aligned with the at
face of the auger nose.
Step 6: Set the hopper lid on the hopper with lamp cord at the back.
Step 7: Plug in the hopper lid lamp
cord.
Step 10: 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.
Step 8: Position the faucet seal and
the return spring in the faucet valve.
Step 11: Install the drip tray and cover.
Step 9: Slide the faucet valve assem-
bly into place on the hopper.
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Electrical Install
place.
Step 2: Place PAF platform assembly
on top of the motor covers and install
support rod into hole in trim strip.
Step 3: Tighten support rod from top of
platform. Retighten motor cover screws.
Step 6: Press the seals rmly into
place.
Step 8: Install the auger nose bushing
into the front of hopper.
Step 9: Thoroughly rinse the hoppers
and install them over the augers and
cooling drums.
Step 11: Install level probes into slots
at top rear of PAF hoppers.
Step 12: Install PAF unit onto platform
and plug power cord into rear of
platform. Plug platform power cord into
proper outlet.
Step 13: Assemble the drip tray.
Step 3: Tighten support rod from top of
platform. Retighten motor cover screws.
Step 6: Press the seals rmly into
place.
Step 9: Thoroughly rinse the hoppers
and install them over the augers and
cooling drums.
Step 12: Install PAF unit onto platform
and plug power cord into rear of
platform. Plug platform power cord into
proper outlet.
Step 1: Plug machine into 120VAC outlet.
Powder Autoll (PAF) Installation (Optional)
Step 1: Remove the rear plastic
plug from trim strip between the
hopper drip trays and loosen the
auger motor cover screws.
Step 4: Plug RCA cord into Ultra
base unit.
Step 7: Align the auger shaft with
the n of the auger. Push the
augers as far as they will go and ro-
tate them so the at n is facing up.
Step 2: Place PAF platform assembly
on top of the motor covers and install
support rod into hole in trim strip.
Step 5: Install each hopper seal over the ange
at the rear of the cooling drums as shown.
Step 8: Install the auger nose bushing
into the front of hopper.
Step 3: Tighten support rod from top of
platform. Retighten motor cover screws.
Step 6: Press the seals rmly into
place.
Step 9: Thoroughly rinse the hoppers
and install them over the augers and
cooling drums.
Step 10: Slide the hopper(s) into
place and push down until the
hopper lock plunger snaps into
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Ultra Training Manual
Step 11: Install level probes into slots
at top rear of PAF hoppers.
Step 12: Install PAF unit onto platform
and plug power cord into rear of
platform. Plug platform power cord into
proper outlet.
Liquid Autoll (LAF) Installation (Optional)
(50 PSI RECOMMENDED)
*
* Should be located no more
than 6” from pump.
The Brix pump should be placed as close to the concentrate supply as possible.•
The Brix pump mounting placement should be the same level or slightly higher than the concentrate BIB.•
Ease of access to the brix pump and sanitize valve for sanitizing procedure.•
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Installing Liquid Autoll Kits (Autoll ready Ultra-2)
ULTRA-2
INSTRUCTIONS FOR INSTALLING
LIQUID AUTOFILL KITS
INTRODUCTION
These instructions are for installing the Liquid Autofill Kits on Autofill ready ULTRA-2 cold drink dispensers.
There are three different kits available:
INSTRUCTIONS (Continued)
37960.0000 ULTRA-2 Liquid Autofill Kit 120V with Separate Water Lines
37960.0001 ULTRA-2 Liquid Autofill Kit 120V without Water Lines
37960.0002 ULTRA-2 Liquid Autofill Kit 230V with Separate Water Lines
INSTRUCTIONS
1. Unplug machine from power source before removing any panels.
2. Drain both hoppers and clean the machine if needed before proceeding.
3. Remove hoppers, drip tray, both side
panels and front panel.
4. Remove both motor covers and locate
.50” round knock out in top right area
of plastic drum mount.
5. With a standard screwdriver and a
hammer, punch out the hole needed
for the level probe. Repeat this step
for both sides.
6. Install level probe assembly into hole
and secure with nut provided.
9. Reinstall the main board into the
machine using the original mounting
screws.
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Ultra Training Manual
7. Remove 4 screws holding in the main
circuit board.
10. Remove hole covers from the base of
the machine as needed to route water
and product tubing through base.
8. Connect Auto Fill board to main board.
Be sure to snap the plastic stand off’s
completely into the main board.
11. Install provided bushings into product/
water holes to protect the tubing.
INSTRUCTIONS (Continued)
11. Install provided bushings into product/
water holes to protect the tubing.
10. Remove hole covers from the base of
the machine as needed to route water
and product tubing through base.
9. Reinstall the main board into the
machine using the original mounting
screws.
INSTRUCTIONS (Continued)
skip to step 24 through 26.
Early Models
INSTRUCTIONS (Continued)
14. Install valve and bracket assembly by
feeding the attached tubing through
the smaller snap bushings in the base
of the machine.
13. Remove top nut off of grounding stud
in the base of the machine, add on the
green grounding wire from the new har-
ness and reinstall the nut onto the stud.
Make sure that all the other grounding
wires remain on the ground stud.
12. Plug wire harness (supplied with kit)
into Auto Fill board connector and route
wires back into the machine.
11. Install provided bushings into product/
water holes to protect the tubing.
10. Remove hole covers from the base of
the machine as needed to route water
and product tubing through base.
9. Reinstall the main board into the
machine using the original mounting
screws.
12. Plug wire harness (supplied with kit)
into Auto Fill board connector and route
wires back into the machine.
15. Connect the wires to the fill valves both
water and product as needed according
to the wiring schematic provided. Red
and White wires to the right valve(s),
Blue and white wires to the left valve(s).
Please note that Left and Right are from
the front of the machine, Users left and
right.
13. Remove top nut off of grounding stud
in the base of the machine, add on the
green grounding wire from the new harness and reinstall the nut onto the stud.
Make sure that all the other grounding
wires remain on the ground stud.
16. Route Pink and Tan wires up to level
probes and attach using nuts provided.
Pink is the right probe and Tan is the
left probe.
14. Install valve and bracket assembly by
feeding the attached tubing through
the smaller snap bushings in the base
of the machine.
17. Position the valve and bracket assembly
between the right front corner post and
the right side fan shroud and secure
with screws provided.
Early Models
18. Reinstall front panel, left panel and both
motor covers.
Early models with quick disconnect fittings,
follow steps 19 through 23.
Late models with new hopper slide fitting
19. Assemble a .25” quick disconnect fitting, 1.25” neoprene tube and barbed
elbow as shown with the .50” barb
pointing down.
20. Remove one or both plugs from the hop per depending on whether a separate
water line is being installed. Install the
quick disconnect fitting into the hole on
the hopper and secure with nut provided
with fitting.
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INSTRUCTIONS (Continued)
20. Remove one or both plugs from the hop -
per depending on whether a separate
water line is being installed. Install the
quick disconnect fitting into the hole on
the hopper and secure with nut provided
with fitting.
19. Assemble a .25” quick disconnect fit-
ting, 1.25” neoprene tube and barbed
elbow as shown with the .50” barb
pointing down.
18. Reinstall front panel, left panel and both
motor covers.
Early models with quick disconnect fittings,
follow steps 19 through 23.
Late models with new hopper slide fitting
skip to step 24 through 26.
Early Models
INSTRUCTIONS (Continued)
21. Install hoppers onto machine and
slide probes onto hoppers into slots
provided.
Late Models
22. Route the tubes from the solenoids up
to the quick disconnect fittings on the
hoppers. The tubes are supplied with
extra length to allow for trimming if
desired. Slip a clamp over the end of
the tube and install a .25” male disconnect fitting. Position the clamp over the
barb area of the fitting and crimp into
place.
NOTE: Make certain the tubes are routed
to the correct hoppers to prevent product
from being mixed or hoppers overflowing.
23. Connect the tubes to the hoppers.
24. Install hoppers onto machine and
slide probes onto hoppers into slots
provided.
27. Install customer supplied pump system.
Turn on pump system and water supply.
Check all tubing connections for leaks.
25. Route the tubes from the solenoids
together and connect to hopper fitting.
28. Install snap clamps on to hoses just
above the bushings to prevent hoses
from being pulled loose from the solenoid valves.
26. Slide hopper fitting into place in the
slot on the hopper.
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Ultra Training Manual
29. Apply power to machine and turn water on for Brix Pump operation. Refer to the Programming section of this manual in the Refill
INSTRUCTIONS (Continued)
27. Install customer supplied pump system.
Turn on pump system and water supply.
Check all tubing connections for leaks.
28. Install snap clamps on to hoses just
above the bushings to prevent hoses
from being pulled loose from the so-
lenoid valves.
Threshold section to check refill for proper operation.
30. At the threshold screen, with no product in the hopper, confirm the number on the left (top) of the screen is around 250. The
number on the right of the screen is factory set to 155. The factory set point should not need any adjustment.
31. After confirming that both hoppers are reading about 250 for the threshold, proceed to the next screen to test the refill circuit.
32. At the test refill screen, select yes.
33. The Activate Valve screen will allow you to test the pumping and refill circuit. Press and hold the ULTRA button to activate the left
refill system. Confirm that the left side is filling when the ULTRA button is pressed. Release the ULTRA button to stop the filling
process. Repeat this process for the right side by pressing the ICE button to test. Check for leaks at the hoses while pumping
system is running.
34. Once the testing is complete, exit the programming menu and reinstall the right side panel.
35. The auto fill feature can be turned on by pressing the auger button for each side until the display reads “AUGER REFILL ON”.
NOTE: Some models also include a “Delay Refill” option. This feature is used to dose in small amounts of new product while delaying
between doses. This can help the already frozen product from becoming deluted and not ready to serve. These delay and fill times are
to be determined and set based on each application as desired by the end user.
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Bunn-O-Matic Corporation
Unit 2 setup
Unit Objectives
Given a realistic scenario depicting a new site install, the learner will be able to install and setup the ULTRA for
customer turnover without error.
Given an installed machine, all the necessary tools and safety equipment, the learner will be able to set the
machine up for initial operation.
The learner will be able to operate the switch controls.
The learner will be able to enter and navigate programming.
The learner will be able to understand and perform the task of setting priority menus.
The learner will be able to perform product preparation and adjustments of the optional accessories
(PAF & laF).
User Interface
Using the menu-driven display on the front of the dispenser, the operator has the ability to operate, alter or modify
various parameters such as beverage consistency and set day/night “ON/OFF” times. The operator is also prompted
to check a variety of periodic service functions or even a step-by-step cleaning routine.
Operating Controls
This switch is the ON/OFF toggle switch which powers up the dispenser and the LCD display. This switch
is also used as back up switch in menu mode.
Ultra 1
Ultra 2
Press and release the appropriate (ON/OFF) switch to start the Auger Motor and to turn on AutoFill when
applicable.
Press and release the (OFF/ICE/CHILL) switch and select CHILL to begin the cooling process for the
selected hopper.
Programming Controls
To access the programming mode, and to scroll through the different function screens, hidden programming switches
are used. Press and hold for ve seconds the “Gourmet” button to enter into the programming menus.
“ULTRA” (left under display)
When prompted by a selection from the menu to answer yes or no, the “ULTRA” switch is used to answer
“NO” or (-) minus.
“GOURMET” (center under display)
Press and hold this switch 5 seconds to access the Menu Function Index. This switch is also used as “NEXT”
to scroll through the functions.
“ICE” (right under display)
When prompted by a selection from the menu to answer yes or no, the “ICE” switch is used to answer “YES”
or (+) plus.
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Setup
Setup Machine
The following machine parameters should be set upon placement of machine for product turn over.
□ Set Thickness (Product consistency)
□ Set Date Time
□ Set Language
□ Set Night Time
□ 6 Month PM (Recommended)
□ Day To Clean (Recommended)
LAF Set Up Menus
□ Delayed Rell
□ Enable Rell ? (Ultra-1 Only)
Set Thickness
Setting the thickness changes the ice consistency, or torque of each auger. The factory default is 8 with a range of 1
to 16.
Step 1: Press and hold the Gourmet switch until the display screen reads “Cleaning Guide?”.
Step 2: press and release the Gourmet switch until the “Set Thickness?” option is shown in the display screen.
Step 3: Select Yes (Ice) to access the Set Thickness option.
Step 4: Use Min (-) and Max (+) to adjust the thickness levels. Press the Gourmet switch to accept the desired set-
ting for the left side.
Step 5: Use the same controls to adjust the thickness level for the right side. Press the Gourmet switch to accept the
desired setting.
Step 6: Press Next (Gourmet) until you exit programming and return to the Home Screen.
Set Date Time
Allows the operator to set the DATE (YY MM DD) and TIME (HR MIN SEC) for display on the Home Screen.
Step 1: Press and hold the Gourmet switch until the display screen reads “Cleaning Guide?”.
Step 2: Press and release the Gourmet switch until the “Date/Time” setting option appears in the display screen.
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Ultra Training Manual
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