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.
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.
CONTENTS User Notices...............................................................................................................................3 Operating Instructions................................................................................................................4 Adjustments................................................................................................................................5 Preventive Maintenance Cleaning......................................................
OPERATING INSTRUCTIONS 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 set-up, the 5 minute refill fault may be cleared by simply opening and closing the Powder Auto-Fill door. 10.
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.
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.
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 REQUIRED REGULAR MAINTENANCE: Semi Annual: Bunn Kit #45319.
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.
TROUBLESHOOTING (cont.) PROBLEM PROBABLE CAUSE Product level in ULTRA is lower 1. Powder Auto-Fill not pulled comthan level Probe - ULTRA running; pletely forward. Powder Auto-Fill door lamp flashes two times 2. ULTRA level probe misaligned. REMEDY 1. Check that the Powder Auto-Fill is pulled completely forward until the guide rails roll into the indented position. 2.
TROUBLESHOOTING (cont.) PROBLEM PROBABLE CAUSE Powder Auto-Fill will not dispense 1. No water product REMEDY Water lines and valves to the dispenser must be open and free of obstructions. 2. No power or incorrect voltage to the dispenser. Check that the power cord is connected to the ULTRA dispenser and for voltage from the ULTRA dispenser. 3. Dispense Solenoid Valve Refer to Service- Dispense Solenoid Valve for testing procedures. See page 32 4.
TROUBLESHOOTING (cont.) PROBLEM Product overflows ULTRA hopper Weak product Dispenser is making unusual noises PROBABLE CAUSE REMEDY 1. Control Board and Probe Refer to Service- Control Board and Probe for testing procedures. See page 18 2. Dispense Solenoid Valve Refer to Service- Dispense Solenoid Valve for testing procedures. See page 32 1. Whipper Motor Refer to Service- Whipper Motor for testing procedures. See page 16 2. Frother Refer to Service- Frother for testing procedures.
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 unplugged when servicing, except when electrical tests are required and the test procedure specifically states to plug-in the dispenser.
SERVICE (cont.) AUGER DRIVE COMPONENTS 12. Rinse and dry each item thoroughly. 13. Check for damaged or broken components, replace any if necessary and reassemble hopper assembly. 14. Install hopper assembly in the dispenser by sliding hopper assy on the hopper support plate (12) until the hopper base (9) seats firmly behind the retainer plates (16) on the hopper support plate (12). 1 2 3 4 5 FIG.
SERVICE (cont.) AUGER DRIVE MOTOR Removal and Replacement: 1. Remove hopper assembly and set aside for reassembly. 2. Remove six #8-32 screws securing the rear cover and remove the rear cover. 3. Remove the four #8-32 screws located inside the dispenser housing on the lower right front of the auger motor mounting panel, securing the auger motor mounting bracket and auger motor to the rear of the auger motor mounting panel. 4 Disconnect the wires from the auger drive motor. 5.
SERVICE (cont.) FROTHER AND MIXING/WHIPPER CHAMBER FIG. 6 FROTHER AND MIXING/WHIPPER CHAMBER 10. Slide whipper chamber receptacle with seal (6) and O-ring (4) on to the motor shaft. 11. Rotate the receptacle with seal (6) counterclockwise until it snaps into place on the motor mounting nuts (7). 12. Push frother (5) onto the motor shaft, making sure the flat in the frother (5) lines up with the flat on the motor shaft. 13.
SERVICE (cont.) WHIPPER MOTOR Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Open the dispenser door and remove the hopper assembly out the front of the dispenser. 3. Remove the four #8-32 screws securing the hopper support panel to the auger motor mounting panel and the whipper motor mounting panel. 4. Slowly lift the hopper support panel up and disconnect the red/black and green wires from the hopper switch. 5. Pull the mixing chamber out of the whipper chamber. 6.
SERVICE (cont.) WHIPPER MOTOR (cont.) 21. Install dispense tip into the bottom of the whipper chamber. 22. Slip the mixing chamber onto the mixing chamber water inlet tube far enough so the mixing chamber will seat inside the whipper chamber. 23. Install hopper assembly in the dispenser by sliding hopper assembly on the hopper support panel until the slot in the bottom rear of the hopper seats against the pin and retainer plates on the hopper support panel. 13.
SERVICE (cont.) 8. Select the “OFF” position of the main power switch and disconnect the dispenser from the power source. CONTROL BOARD and LEVEL PROBE If voltage is present as described, proceed to #9. If voltage is not present as described refer to the wiring diagram and check the dispenser wiring harness. 9. Reconnect the four pin connector to the control board (J7). 10. Disconnect the twelve pin connector (J1) from the control board. 11.
SERVICE (cont.) If voltage is present as described, proceed to #12. If voltage is not present as described, replace the photo transistor. CONTROL BOARD and LEVEL PROBE (cont.) Test Procedure: Low Product Detect 1. Disconnect the dispenser from the power source. 2. Disconnect the twelve pin connector (J1) from the control board. 3. Check the voltage across pins 2 & 3 of the twelve pin connector on the wiring harness with a voltmeter.
SERVICE (cont.) CONTROL BOARD and LEVEL PROBE (cont.) Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Remove the two plugs (J1 and J7) from the main wiring harness, the potentiometer plug (J3), the photo transistor plug (J6), and the photo LED plug (J2) from the control board. 3. Remove the four #6-32 keps nuts securing the control board to the hopper motor mounting panel. 4. Remove the control board. 5.
SERVICE (cont.) Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Open the dispenser door and remove the hopper assembly out the front of the dispenser. 3. Remove the four #8-32 screws securing the hopper support panel to the auger motor mounting panel and the whipper motor mounting panel. 4. Slowly lift the hopper support panel up and disconnect the red/black and green wires from the hopper switch. 5.
SERVICE (cont.) MAIN POWER ON/OFF SWITCH Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Open the dispenser door and remove the hopper assembly out the front of the dispenser. 3. Remove the four #8-32 screws securing the hopper support panel to the auger motor mounting panel and the whipper motor mounting panel. 4. Slowly lift the hopper support panel up and disconnect the red/black and green wires from the hopper switch. 5.
SERVICE (cont.) LAMP CORD ASSEMBLY Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the dispenser. 2. Open the dispenser door and remove the five screws securing the rear cover to the door. 3. Disconnect the lamp cord assembly from the lamp holder/socket assembly and set the rear panel aside. 4. Cut the terminals off of the lamp cord assembly. 5. Remove lamp cord assembly from the door assembly and discard. 6.
SERVICE (cont.) LAMP CORD CONNECTOR If continuity is present as described, the lamp cord connector is operating properly. If continuity is not present as described, replace the lamp cord connector. P1923 FIG. 19 LAMP CORD CONNECTOR Location: The lamp cord connector is located on top of the dispenser. Test Procedures: 1. Disconnect the dispenser from the power source. 2. Disconnect the lamp cord from the lamp cord connector. 3.
SERVICE (cont.) If continuity is present as described, the lamp is operating properly. If continuity is not present as described, replace the lamp. LAMP HOLDER/SOCKET ASSEMBLY Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the dispenser. 2. Remove the display graphic from the dispenser door. 3. Open the dispenser door. 4. Remove the five #6-32 screws securing the rear door cover to the door. 5.
SERVICE (cont.) OPTIONAL LED DOOR LIGHTS 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. Removal and Replacement: 1. Disconnect the lamp cord assembly from the lamp cord connector assembly in the top of the dispenser. 2. Remove the display graphic from the dispenser door. 3. Open the dispenser door. 4.
SERVICE (cont.) TRANSFORMER 5. Check the voltage between J1-2 and J1-3 on the twelve pin connector at the control board. Connect the dispenser to the power source. The indication must be 24 volts ac. If voltage is present as described, the transformer is operating properly. If voltage is not present as described, replace the transformer. Removal and Replacement: 1. Remove the hopper from the dispenser. 2. Remove the four #8-32 screws securing the hopper support panel to the dispenser. 3.
SERVICE (cont.) POTENTIOMETER If the resistance measures as described, proceed to #7. If resistance does not measure as described, replace the potentiometer assembly. 7. Adjust the potentiometer fully counterclockwise. 8. Check resistance between pins 1 & 2 of the potentiometer connector with an ohmmeter. The indication must be between 800 and 1200 ohms. Check the resistance between pins 2 & 3 of the potentiometer connector with an ohmmeter. The indication must be less than 20 ohms.
SERVICE (cont.) HOPPER LEVEL INDICATOR 7. Remove the six #8-32 round head screws securing the front of the housing to the side panels. 8. Remove the six #8-32 truss head screws securing the back of the housing to the side panels. 9. Carefully lift and spread the housing to remove it from the rest of the dispenser. 10. Disconnect the photo transistor (J6) or LED (J2) plug from the control board. 11. Cut the cable tie securing the cable assembly to the cable tie mount. 12.
SERVICE (cont.) 7. Disconnect the wires from the hopper switch. 8. Check continuity between the N.O. and COM. terminals of the hopper switch using an ohmmeter. Continuity must be present when the actuator is engaged. Continuity must not be present when actuator is released. HOPPER SWITCH If continuity is present as described, refer to wiring diagram and check the dispenser wiring harness. If continuity is not present as described, replace the hopper switch. P1933 FIG.
SERVICE (cont.) Removal and Replacement: 1. Disconnect the dispenser from the power source. 2. Remove the hopper assembly from the dispenser. 3. Remove the dispenser from the CDS machine and place it on a flat work surface. 4. Disconnect the door lamp cord from the lamp connector. 5. Remove the two #8-32 screws securing the door hinge to the dispenser housing. 6. Carefully pull the door forward until the door support arms come completely out of the dispenser housing and set aside. 7.
SERVICE (cont.) PRESSURE REGULATOR and NEEDLE VALVE 3. Disconnect the .25” copper tube from the outlet of the pressure regulator. 4. Loosen the nut securing the bulkhead fitting to the dispenser. 5. Remove the bulkhead fitting from the inlet to the pressure regulator. 6. Remove the pressure regulator assembly. 7. Attach the regulator to the bulkhead fitting making sure that the copper bushing is seated properly in the regulator and tighten securely. 8.
SERVICE (cont.) DISPENSE SOLENOID VALVE 7. Disconnect the dispenser from the power source. If the sound is heard as described and water will not pass through the solenoid valve, there may be a blockage in the water line before the solenoid valve or, the solenoid valve may require inspection for wear and the removal of waterborne particles. If the sound is not heard as described, replace the solenoid valve. Removal and Replacement: 1. Disconnect the dispenser from the power source and the water supply. 2.
SCHEMATIC WIRING DIAGRAM PAF/PAFA L1 Models With Optional Water Bypass MAIN POWER SWITCH BLK BLK BRN WHI/GRN PNK GRN or GRN/YEL BLU WHI/BLK GRN L2 MAIN POWER SWITCH (Not Used With Optional Water Bypass) WHI BLK WHIPPER MOTOR 120V : 24V AC or 230V : 24V AC TRANSFORMER WHI/RED DISPENSE SOLENOID HOPPER MOTOR BLK M WHI/BRN M RED 4 SOL 1 J1 RED 1 WHI/GRN WHI/BLK 2 GRY BLK-22 BLK BLK RED-22 VIO 5 1 WHI/ORN BLK BLK GRN GRN ORN TEST/SERVICE RED/BLK SWITCH 10 WHI/ORN BLU/BLK SERVICE GRN PNK B
