Bunn-O-Matic POWDER AUTO FILL For ULTRA-2 Service Manual
POWDER
AUTO FILL
For 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
41087.0000D 01/10 ©2008 Bunn-O-Matic Corporation
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 (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, 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.
AutoPOD, AXIOM, BrewLOGIC, BrewMETER, Brew Better Not Bitter, BrewWISE, 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, PowerLogic, Quality Beverage Equipment Worldwide, 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, 392, A Partner You Can Count On, Air Brew, Beverage Bar Creator, Beverage Profit
Calculator, Brew better, not bitter., BUNNSource, Coffee At Its Best, Cyclonic Heating System, Digital Brewer Control,
Nothing Brews Like a BUNN, Pouring Profits, Respect Earth, Respect Earth with the stylized leaf and coffee cherry design,
Signature Series, Tea At Its Best, Phase Brew, The Horizontal Red Line, Titan, Ultra are either trademarks or registered
trademarks of Bunn-O-Matic Corporation.
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41087 020510
CONTENTS
User Notices ..............................................................................................................................3
Operating Instructions ...............................................................................................................4
Adjustments ...............................................................................................................................5
Preventive Maintenance
Cleaning ..................................................................................................................................... 6
Fault List ....................................................................................................................................7
Troubleshooting .........................................................................................................................8
Service ....................................................................................................................................12
Auger Drive Components ......................................................................................................... 13
Auger Motor .............................................................................................................................14
Frother and Mixing/Whipper Chamber .....................................................................................15
Whipper Motor .........................................................................................................................16
Control Board and Level Probes ...............................................................................................18
TEST/SERVICE Switch .............................................................................................................21
Main Power ON/OFF Switch .....................................................................................................22
Door Panel Assembly
Lamp Cord Assembly ......................................................................................................... 23
Lamp Cord Connector ........................................................................................................24
Lamp Holder/Socket ..........................................................................................................25
LED Door Lights .................................................................................................................26
Transformer .............................................................................................................................27
Potentiometer ..........................................................................................................................28
Hopper Level Indicator .............................................................................................................29
Hopper Switch .........................................................................................................................30
Door Switch .............................................................................................................................31
Pressure Regulator and Needle Valve ......................................................................................32
Dispense Solenoid ...................................................................................................................33
Wiring Diagrams ...................................................................................................................... 34
USER NOTICES
All notices on the equipment are written for your protection. All notices are to be kept in good condition. Replace
any unreadable or damaged labels.
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41087 092509
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 Auto-
Fill. 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 prod-
uct.
b) The door lamp will flash 4 times about every 2
seconds.
9. After checking the ULTRA and Powder Auto-Fill
set-up, 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.
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41087 040308
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 as-
sembled 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 fol-
lows:
i) Pull the slide gate closed on the Powder Auto-
Fill 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 pow-
dered 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 measur-
ing 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.
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41087 040308
Ejector Elbow
Auger
Auger Drive
Shaft
Auger Drive
Bracket
Spacer
Retaining
Ring
Wiper Blade
Shaft
Wiper Blade
Wiper Drive Gear
Hopper Base
Slide Gate
Mixing Chamber
Whipper Chamber
Frother
Dispense Tip
Whipper Chamber
Receptacle
O-ring
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.
Thorough cleaning of the hopper
(once a week):
1. Open the cabinet door.
2. Remove the hopper/base assembly from the cabinet,
remove the cover and empty the contents.
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 unscrewing the
drive bracket 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 reas-
The cleaning instructions noted above are for nondairy sugar based food products. When dispensing any
NOTICE
sembling.
other food product, the cleaning cycle for the whipping chamber assembly and ejector elbow must be performed
daily.
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41087 061109
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
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41087 040308
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,andrepairofelectricalequipmentshouldbeperformedonlybyqualiedserviceperson-
nel.
• Allelectroniccomponentshave120voltacandlowvoltagedcpotentialon their terminals. Shorting of
terminals or the application of external voltages may result in board failure.
• Intermittentoperationofelectroniccircuitboardsisunlikely.Boardfailurewillnormallybepermanent.If
an intermittent condition is encountered, the cause will likely be a switch contact or a loose connection at a
terminal or crimp.
• Solenoidremovalrequiresinterruptingthewatersupplytothevalve.Damagemayresultifsolenoidsare
energized for more than ten minutes without a supply of water.
• Theuseoftwowrenchesisrecommendedwheneverplumbingttingsaretightenedorloosened.Thiswill
help to avoid twists and kinks in the tubing.
• Makecertainthatallplumbingconnectionsaresealedandelectricalconnectionstightandisolated.
• Keepawayfromcombustibles.
WARNING – • Exerciseextremecautionwhenservicingelectricalequipment.
• Unplugthedispenserwhenservicing,exceptwhenelectricaltestsarespecied.
• Followrecommendedserviceprocedures
• Replaceallprotectiveshieldsorsafetynotices
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 AutoFill.
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.
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41087 040308
TROUBLESHOOTING (cont.)
PROBABLE CAUSE REMEDYPROBLEM
Product level in ULTRA is lower
than level Probe - ULTRA running;
Powder Auto-Fill door lamp flashes
two times
Product level in ULTRA is lower
than level Probe - ULTRA running;
Powder Auto-Fill door lamp flashes
three times
Product level in ULTRA is lower
than level Probe - ULTRA running;
Powder 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
product 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.
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41087 040308
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. See page 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
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41087 040308
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 nois-
es
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
41087 040308
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