Bunn ULTRA Installation guide

BUNN®TECHNICAL TRAINING
Ultra

Index
Unit 1: Installation
Site Requirements .............................................................................................................. 4
Location of the Serial Number .......................................................................................... 4
Prepping Machine for Install ............................................................................................. 4
Hopper Assembly ............................................................................................................... 5
Electrical Install ..................................................................................................................5
 PowderAutoll(PAF)Installation(Optional) ................................................................... 6
 LiquidAutoll(LAF)Installation(Optional) ..................................................................... 7
Unit 2: Setup
User Interface...................................................................................................................... 13
  SwitchOperation(OperatingControls) ..................................................................... 13
  SwitchOperation(ProgrammingControls)............................................................... 13
Setup.................................................................................................................................... 14
Setup Machine.............................................................................................................. 14
Product Preparation..................................................................................................... 17
  PAF-PowderMixSet-Up(BrixRatio) ......................................................................... 17
  LAF–LiquidConcentrateSet-Up(BrixRatio) .......................................................... 18
  ULTRA1and2StartUpwithLAF............................................................................... 19
Unit3:MachineComposition
 ExteriorOverview ...............................................................................................................21
 RemovingtheEnclosure ................................................................................................... 21
 MachineFunctionandOperations.................................................................................... 24
  TICBoard(TimeInaCan) ........................................................................................... 24
  MainControlBoard...................................................................................................... 24
Mechanical System ...................................................................................................... 24
Refrigeration System ................................................................................................... 24
Temperature Sensing System..................................................................................... 25
Torque Sensing .............................................................................................................. 25
Unit4:PreventiveMaintenance
Tools Required....................................................................................................................27
PM Parts ..............................................................................................................................27
 PriortoservicingtheULTRA............................................................................................. 27
 PreventiveMaintenanceInstructions ............................................................................... 27
Unit 5: Troubleshooting
Test Menus .......................................................................................................................... 30
Test Augers ......................................................................................................................... 30
 RellThreshold(UltrawithLAFKitInstalled) ................................................................. 30
Temp and Torque Screen...................................................................................................31
Warning Messages ............................................................................................................. 31
Error Messages................................................................................................................... 33
 ProductDoesNotFreezeorFormIceCrystals ............................................................... 34
 TorqueSensorBoard ......................................................................................................... 35
Thermistor........................................................................................................................... 35
 UltraPAFErrorMessages ................................................................................................. 36
Triac Maps ........................................................................................................................... 36
© 2010 Bunn-O-Matic Corporation. All Rights Reserved
Rev. A

Unit Objectives
Un i t 1 in s t a l l a t i o n
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.

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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 ½ 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SHURo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 ma-
chine on the main machine frame.
Prepping Machine for Install
Step 1: Verify that all of the site requirements have been met.
Step 2: Unbox the machine and all the parts.

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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
Electrical Install
Step 1: Plug machine into 120VAC outlet.
Step 1: Insert the auger nose
bushing from inside the hopper.
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 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 4: Install the hopper over the
auger and cooling drum and slide it into
place.
Step 5: Push down until the hopper
lock plunger snaps into place. Step 6: Set the hopper lid on the hop-
per with lamp cord at the back.
Step 7: Plug in the hopper lid lamp
cord.
Step 8: Position the faucet seal and
the return spring in the faucet valve. Step 9: Slide the faucet valve assem-
bly into place on the hopper.
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 11: Install the drip tray and cover.

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PowderAutoll(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 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 4: Plug RCA cord into Ultra
base unit.
Step 5: Install each hopper seal over the ange
at the rear of the cooling drums as shown.
Step 6: Press the seals rmly into
place.
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 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 10: Slide the hopper(s) into
place and push down until the
hopper lock plunger snaps into
place.
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.

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LiquidAutoll(LAF)Installation(Optional)
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.•
* Should be located no more
than 6” from pump.
(50 PSI RECOMMENDED)
*

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BUNN-O-MATIC CORPORATION
POST OFFICE BOX 3227
SPRINGFIELD, ILLINOIS 62708-3227
PHONE: [phone] FAX: [phone]
37570.0000D 07/09 ©2005 Bunn-O-Matic Corporation
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:
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.
8. Connect Auto Fill board to main board.
Be sure to snap the plastic stand off’s
completely into the main board.
7. Remove 4 screws holding in the main
circuit board.
6. Install level probe assembly into hole
and secure with nut provided.
5. With a standard screwdriver and a
hammer, punch out the hole needed
for the level probe. Repeat this step
for both sides.
4. Remove both motor covers and locate
.50” round knock out in top right area
of plastic drum mount.
3. Remove hoppers, drip tray, both side
panels and front panel.
(Continued)

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2
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 o of grounding stud
in the base of the machine, add on the
greengroundingwirefromthenewhar-
nessand reinstallthenutontothestud.
Make sure that all the other grounding
wires remain on the ground stud.
12. Plug wire harness (supplied with kit)
intoAutoFillboardconnectorandroute
wires back into the machine.
11. Installprovidedbushingsintoproduct/
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.
17. Positionthevalveandbracketassembly
betweentherightfrontcorner postand
the right side fan shroud and secure
with screws provided.
16. Route Pink and Tan wires up to level
probesandattachusingnutsprovided.
Pink is the right probe and Tan is the
left probe.
15. Connect the wires to the ll valves both
waterandproductasneededaccording
to the wiring schematic provided. Red
and White wires to the right valve(s),
Blueandwhitewirestotheleftvalve(s).
PleasenotethatLeftandRightarefrom
the front of the machine, Users left and
right.
37570 072706

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3
INSTRUCTIONS (Continued)
20. Removeoneorbothplugsfromthehop-
per depending on whether a separate
water line is being installed. Install the
quickdisconnectttingintotheholeon
thehopperandsecurewithnutprovided
with tting.
19. Assemble a .25” quick disconnect t-
ting, 1.25” neoprene tube and barbed
elbow as shown with the .50” barb
pointing down.
18. Reinstallfrontpanel,leftpanelandboth
motor covers.
37570 072706
22. Route the tubes from the solenoids up
to the quick disconnect ttings 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 discon-
necttting. Positionthe clampover the
barb area of the tting and crimp into
place.
NOTE: Make certain the tubes are routed
to the correct hoppers to prevent product
from being mixed or hoppers overowing.
21. Install hoppers onto machine and
slide probes onto hoppers into slots
provided.
24. Installcustomersuppliedpumpsystem.
Turn on pump system and water sup-
ply. Check all tubing connections for
leaks.
23. Connect the tubes to the hoppers.
25. Install snap clamps on to hoses just
above the bushings to prevent hoses
from being pulled loose from the so-
lenoid valves.
(continued)