BUNN Ultra 2 Slush Machine Technical Training

2© 2001 Bunn-O-Matic Corporation. All rights reserved. Confidential material.
• 120 volt / 15 amp dedicated outlet
• (no extension cord)
• At least 6” clearance for airflow (back and sides).
• Recommended for indoor use. If it must be used outdoors, it
will take longer to freeze. (Keep out of direct sunlight)
Site Requirements

Installation
•Save black plastic drum supports (They will be used as
servicing jigs later) Do not lift by the drums!
•Machine should be level or slightly lower in front
•Remove shipping eye-bolts from compressor
•Install rear gaskets on drums (no grease on ULTRA)
•Install augers (no grease on ULTRA)
•Install hoppers (no grease on ULTRA)
•Fill with product & install hopper lids
•Unit can now be powered up

Cooling Drum Alignment
The "A" shaped Cooling Drum Shipping Supports,
removed during Initial Setup, should be kept and used
as a tool to reset the alignment of the cooling drums
should it ever be required.
Symptoms:
Squeaky Operation, hopper lifts or won't seat properly,
hopper is pushed to one side or the other.
To check alignment
1. Place the "A" shaped support on the auger shaft
with the ledge under the cooling drum.
2. Lift the cooling drum while rotating the support
into a vertical position. The boss on the very
bottom will drop into the hopper drip tray's drain hole.
When in its proper position, the cooling drum will cause a
slight pressure on the hopper drip tray drain hole and the
two legs will be equidistant from the hopper drip tray.
If adjustment is needed, remove the support and gently
force the free end of the evaporator in the direction the
adjustment is needed.
Reinstall the support, check the alignment, and readjust
the cooling drums as required.

Plastic grates molded into
top cover of drip tray
(interchangeable w/CDS-2)
Touch pad
replaces drawer,
switches & dials!
Foam seal acts as a
moisture barrier for
the Control Board
Clamp for ribbon cable
Bottom
unchanged
Front
Tray has a molded
hose connection for
using an optional
3/8” drain hose

1 Turn on main power switch
2 Turn on Auger Switch, Auger will
rotate clockwise. (No display
indication)
3 Turn the Ice/OFF/CHILL switch
to the Ice position
· UPPER CASE indicates
refrigerant solenoid open.
· Lower case indicates refrigerant
solenoid closed.
* After 10 seconds the machine will
open the solenoid valves to allow
equalization of the refrigerant,
there will be one audible click.
Left Right
2 3
1
Home screen toggles
time, date, serial, & asset
numbers continuously
Touch pad
ICE chill
JAN.1, 2002

Home screen
Off Off
JAN.1, 2002
Off Off
10:00:00 AM
Off Off
ULT00001234
Off Off
AN000001234

Hold these 2 hidden switches for 5
seconds. Then you will see the above
display. After releasing buttons, it will
alternately display drum & hot gas
line temps & auger torque
Press both
switches again
to return to
home screen
DISPLAY
TEMP
& TORQUE
Home screen

0
36
Left Right
0
36°h
0
67
Left Right
0
67°b
Top row - indicates auger operating torque (% of revolution)
Bottom row - (b) barrel temp (h) high temp same for both since there’s
only one thermistor on hot gas line.
Note: If powered down, display remains, but back light will turn off
Home screen

Menu Function index
Off Off
10:45:30 AM
Hold this hidden switch for 5 seconds
to enter the menu function index. You
can also use it as a “NEXT” button.

TEST AUGERS ?
Pressing “YES” will allow you to operate either
auger in forward and/or reverse directions
NO YES
Test augers

Membrane Switch
Check continuity of the switches
using pin #7 as common.
#7-#1 (shield) no continuity
#7-#2 (Left Auger)
#7-#3 (I/O)
#7-#4 (not used)
#7-#5 (Left ICE/CHILL/OFF)
#7-#6 (ULTRA)
#7-#8 (GOURMET)
#7-#9 (not used)
#7-#10 (ICE)
#7-#11 (Right Auger)
#7-#12 (Right ICE/CHILL/OFF)

Hoppers
• Lowered to 3 gallons, the overall
hopper/hood profile is 3 inches
shorter than CDS
• Marked in Gallons/Liters
• Teflon coated nylon nose
bushing is keyed into rail to
prevent rotation & slides up/down
to ease hopper installation
Hoppers for Auto-
fills also available
for ULTRA

Faucet
• New style faucet handle is
reversible to be ADA compliant
•Spread handle to remove, then slide
faucet assembly up & out of rails
Insert locking pin through these holes
ADA – American Disabilities Act

Faucet
New faucet seal is keyed at bottom
for one way installation
(coated side toward hopper)
keyed

Hoods
• Lower hood profile
• Use a small screwdriver to pry out
the new vents
• 912 industry standard bulbs, T-5
wedge base
• 1 amp at 12vac
• Rated at 1100 hours
• Do not replace with 921 bulbs,
these draw 1.4 amps and will
overload the 5 amp circuit breaker
• On during “day” mode only
Use small screwdriver
to pry out vents &
replace lamps

Cooling Drum/Auger
Brix level should be at
least 9-12, if it’s less, the
ice could be too solid to
shave off, and possibly
break the auger. Too high,
and it may not freeze!
Auger shaves ice off
as it forms on drum

New coated rear drum
seal (32079.0000)
New auger (32106.0000)
to compensate for
discontinued front seal
Drum, mounting,
motors & shafts
unchanged
Cooling Drums/Auger

Cooling Drums/Auger Drive
Bushing
Seal

Auger Drive Motor
*120vac
*39.6RPM @ 60Hz
*Rotation: clockwise (front view)
*56.8Ω
*.48 amp (no load)
*Locked rotor .9 amp
*Thermal overload Protection
*Torque 20-50 in-lbs.

Relays on control board will
energize once every hour to
reverse auger motors for 2
minutes. This breaks up
chunks of ice that may be
floating on top. Torque sensing
is ignored during reverse
mode. (ULTRA software will
start a reverse sequence if the
solenoids stay open for an
extended time .
Auger Drive Control

Auger Drive/PM
Ceramic
coating
Keep grease & dirt
off pins, or it
could prevent
freezing!
PM every 6 months

Auger Drive/PM
Front of drum
Failure to PM this
area could lead to
loss of freezing,
due to product
(sugar) build up
on the bushings &
seals over-loading
the torque sensing
systems
Seal
Bushing

Auger Drive/PM
Keeps product
out of spring
Install brown seal
with spring facing
away from product
and towards the
auger motor.

Auger Drive/Torque Sensing
As the ice thickens, the
torsion springs allow a slight
twisting motion, allowing the
two pins to move farther
apart. If user has to keep
setting thickness to a higher
level, it may be an indication
of worn or broken springs
Torsion springs transmit
driving force from motor drive
coupler to shaft drive coupler

The torque sensor is a 5vdc
board consisting of an infra-red
LED & photo-transistor. Output
is 5v when blocked by pins or 0v
unblocked. To test, turn off
Augers, connect meter across
pins 1 & 3, using a strip of
paper, block & unblock the light
beam between the two sensors.
Watch the meter for HIGH-low
switching.
Switching line
+ 5vdc
- Common
Phototransistor
LED
If there’s no reading, check
for 5v supply, at pins 2-3
Torque Sensing
Direction
of light
beam

Invisible Infra red beam
is momentarily blocked
by the Motor pin, then
the Shaft pin.
Torque Sensing
As the Auger drive shaft rotates, the two
pins block the beam of light. The micro-
processor calculates the distance between
the pins and determines the refrigerant
solenoid shut off point, based on where the
thickness adjustment is set.

Fault codes- Torque Sensor Unplugged
LEFT TORQUE RIGHT TORQUE
SENSOR OPENSENSOR OPEN
FAULT ICE ICE FAULT
FAULT ICE ICE FAULT

S H A F T
Viewed from rear
side of machine
1/4” gap (minimum)
Starts freezing
Torque sensor
“reads” the gap
between pins
during shaft
rotation.
Torque Sensing

S H A F T
1/2” gap (maximum)
Stops freezing
Viewed from rear
side of machine
Torque sensor
“reads” the gap
between pins
during shaft
rotation.
Torque Sensing

Satisfied point
will vary with
thickness
settings
S H A F T
Stops freezing
Viewed from rear
side of machine
Torque sensor
“reads” the gap
between pins
during shaft
rotation.
Torque Sensing

Fault: no rotation detected No freezing
Both pins missing,
or no motor rotation
S H A F T
Viewed from rear
side of machine
Torque sensor
“reads” the gap
between pins
during shaft
rotation.
Torque Sensing

Fault: torque lower than possible No freezing
Bent pin, debris, grease,
or anything that would
optically close gap to less
than 1/4”
S H A F T
Viewed from rear
side of machine
Torque sensor
“reads” the gap
between pins
during shaft
rotation.
Torque Sensing

Fault: torque higher than possible No freezing
Bent,
broken,or
missing pin.
gap wider
than 1/2”
S H A F T
Torque Sensing
Viewed from rear
side of machine
Torque sensor
“reads” the gap
between pins
during shaft
rotation.

Fault codes- Sensor Good, Check Pins
LEFT TORQUE RIGHT TORQUE
SENSOR ERRORSENSOR ERROR
FAULT ICE ICE FAULT
FAULT ICE ICE FAULT

TEMPERATURE SENSING
Thermistor monitors the actual
temperature of each cooling
drum. “Night” and “Chill”
modes maintain 35° F, instead
of Torque sensing (Thickness)

TEMPERATURE SENSING
Resistance values:
2kΩ @ 77°F
5650Ω @ 32°F
Voltage readings:
0vdc = short circuit
1.5vdc @ room temp
2.7vdc @ 35°F
5vdc = open circuit

Fault codes- Temperature Sensor Unplugged
LEFT TEMPERATURE RIGHT TEMPERATURE
SENSOR OPENSENSOR OPEN
FAULT ICE ICE FAULT
FAULT ICE ICE FAULT

Refrigeration Schematic

Filter/Condenser/Fan
Filter
Condenser
Optional cover
air
flow
Thermistor added to discharge
line, detects overheating due to
clogged filter, will shut down
cooling system
3 screws to remove
120vac fan/motor
assy.
One piece shroud
on CDS units

Filter Clean Reminder
MONTHLY FILTER
CLEAN REQUIRED
XX DAYS
HOLD ULTRA SWTCH
3 SECS TO CLEAR
A monthly counter will
automatically show this message,
to remind users to clean the
condenser filter. Once it starts
displaying this screen, the third
line shows how many days it’s
overdue! (Thermistor will sense
overheating & shut down
refrigeration if left untouched)
ACTUAL
DISPLAY
MESSAGE!

Filter Clean - Urgent
FILTER NEEDS
CLEANING
Hot Gas Sensor detects 220° F
FILTER NEEDS
!!!CLEANING!!!
Hot Gas Sensor detects 250° F
(refrigeration shuts down)

Refrigeration System
Thermistor (Hot Gas Sensor)
New filter/dryer/splitter
Fewer braze joints!
Larger
accumulator
Some units
now have a
high side port
(R404A)

Unplugged Overheated
HOT GAS HOT GAS
SENSOR SHORTEDSENSOR OPEN
OFF OFF OFF OFF
OFF OFF OFF OFF

Solenoids
120vac, controlled individually by
main board (Parker valves)
Mounted on front left corner post
Must be certified in refrigeration to
remove stem and plunger assemblies
Replace each valve as an assembly
No repair kit

Fan Assembly
Pulls in air to cool condenser
120vac controlled by main board.
.8 amp (same as CDS-2)
Turns on aprox. Same time as
compressor, but may continue
running for a while after
compressor turns off
CAUTION: It will also turn on
every ½ hr. to cool auger motors
3 screws
for
removal

Compressor Relay
L1 from Control Board
Neutral
coil
contacts (N.O.)
L1 from main harness
To compressor circuit
alternate set of contacts (N.O.)

Americold Compressor
Overload
PTC
120vac 7.3 amps 1/4hp 3955 BTU
(locked rotor condition aprox. 41 amps)
Used in early units

Embraco Compressor
Overload
PTC
120vac 7.3 amps 1/4hp 3955 BTU
(locked rotor condition aprox. 41 amps)
Start capacitor
145-175µfd
250vac
Used in later units

Refrigeration system
Thermistor, discharge line
New Parker valves
mounted on frame
(no repair kit)
New filter/dryer/splitter
Fewer braze joints!
Larger
accumulator
New 404A Refrigerant

Start Circuit
Contactor
Start Relay
Line
PTC resistance starts
low, allowing the start
winding to operate.
The PTC gets hotter as
current flows through it.
The resistance increases
to the point where the
start winding is disabled.

Compressor
relay
Lamp relay
(12vdc coil)
Lamp circuit breaker
Main
control
board
Memory/battery
backup board (TIC)
(10 yr. Life)
Transformer (new)
Electrical Components

Electrical Components
Step down transformer
Compressor
relay
Lamp relay
5 amp breaker
Main harness routed along
top of frame, instead of
being tied to condenser

Lamp Circuit
Not used (N/C)
White/Yellow (N/O)
Blue/Black (+)
Violet (-)
White/Violet
(Common)
12vdc coil
Transformer supplies 12vac to
hood lamps & PC board at J5-8
(white/blue) and J5-20 (white/black)

Home Screen
Off Off
JAN.1, 2002
Off Off
10:00:00 AM
Off Off
ULTR0001234
Off Off
AN000001234

Hold these 2 hidden switches for 5
seconds. Then you will see the above
display. After releasing buttons, it will
alternately display drum & hot gas
line temps & auger torque
Press both
switches again
to return to
home screen
DISPLAY
TEMP & TORQUE
Display Temp & Torque

0
36
Left Right
0
36°h
0
67
Left Right
0
67°b
Top row - indicates auger operating torque (% of revolution)
(initial setting x 3. Plus 1 will shut off solenoid)
Bottom row - (b) barrel temp (h) high temp same for both since there’s
only one thermistor on hot gas line.
Note: If powered down, display remains, but back light will turn off
Temp & Torque Screens
SOLENOID ON solenoid off

Entering Program Modes
Off Off
10:45:30 AM
Hold this hidden switch for 5 seconds
to enter the menu function index. You
can also use it as a “NEXT” button.

CLEANING GUIDE ?
Pressing “YES” will walk you through hopper
removal and cleaning, step by step. This is used to
reset the “1-14” day cleaning reminder. Cooling
drums must also warm up to 50° F to reset counter.
NO YES
Cleaning Guide

SET THICKNESS ?
Pressing “YES” lets you adjust thickness of product from
1 (thin) to 16 (thick) with 10 as default
NO YES
Adjusting Product Thickness
Use the
ON/OFF switch
to back up one
screen

TEST AUGERS ?
Pressing “YES” will allow you to operate either auger in
forward and/or reverse directions, starting with left side.
NO YES
Auger Test Modes

SET DATE TIME ?
Pressing “YES” allows you to set year;
month; day; hour; minutes & seconds
NO YES
Set Date & Time

PASSWORD 0
NEXT(-) (+)
If a password had previously been set, you must enter it here
in order to proceed to next screen. Must be 4 digits from 0001
to 9999. (6601) is built in back door password from factory.
Use “+” to scroll up, or “-” to scroll down
Entering a Password

SET NIGHT TIME
(-) (+)DISABLED
“+” will start at 12:01 AM; “-” will start at
11:59 PM; once enabled, it will now give
you access to a second screen to set
“DAY” mode in a similar manner.
Night/Day mode

DEFROST MINUTES
(-) (+)OFF
Acts similar to night mode, but does not
turn off hood lights. Range is 10-60
minutes. Once enabled, a second screen
will prompt for “FREEZE MINUTES” This is
the time increment between “DEFROST”
cycles. The range for this screen is 20-180
minutes.
Night/Day mode

PM COMPLETE ?
Use this screen to reset 6 month PM
reminder message by pressing “YES”
NO YES
Reset PM Counter

6 MONTH PM
ENABLED(-) (+)
Toggles 6 month PM counter on/off.
Press either “+” or
“-” to toggle changes. (No lockout)
Enable PM Counter
SHAFT SEAL
MAINTENANCE DUE
6 month
reminder
display

DAY TO CLEAN OFF
NEXT(-) (+)
“DAYS TO CLEAN” (1-14) sets counter for routine
daily or weekly cleaning. When enabled, you will then have to choose
“message only” or “lockout” If lockout is chosen, it will stay in “CHILL” mode
until reset. You will need to step through the cleaning guide (1 minute
minimum) & drums also have to warm up to 50°F to reset counter.
Set Days to Clean
CLEAN DUE TODAY
ACTUAL
DISPLAY
MESSAGE!

YES THICK ADJUST
NEXT(-) (+)
Toggling this to “NO” with either (-) or
(+) disables adjustments in screen 2
Enable Thickness Adjustment

SWITCHES
ON(-) (+)
“LOCKOUT” will prevent touchpad switches
from working after 2 minutes of inactivity. To
access touchpad, hold any button for 5 seconds
Touchpad Sleep Mode

ENTER ASSET #
AN00000000
An asset # is for any company that wishes to
assign their own inventory number to each
machine. Press “ULTRA” for “-” or “ICE” for “+”
Enter Asset Number

SET PASS WR 0
NEXT(-) (+)
This is where you program in password from
0001-9999. Press “+” to go up or “-” to go down.
Set Password

RESTORE DEFAULT?
If you press “YES”, it will prompt “ARE YOU
SURE?” After pressing “YES” again, you will see
scrolling numbers, setting everything back to
factory defaults, except for S/N; A/N & install date
NO YES
Restore Factory Defaults

INSTALL DATE
JAN.1, 2002
This date will be burned in automatically when
unit has been PLUGGED IN for 100 hours
consecutively. NOTE: without install date
burned in, the PM & Cleaning counters will not
start. This screen will not be used for warranty.
View Install Date

ULTRA
VERSION # 00.44
Displays currently installed
software version
View Software Version

PAF Installation
Rail stops
receptacles
Relay
Rectifier
Kit plugs into
light socket
Support rod

PAF Installation

PAF Wiring
Rail kit
Light circuit turns on
PAF during day mode,
off during night mode

Powder Auto Fill
TECHNICAL
TRAINING
PRESENTATION

Installation
Use 1/4” f/m flare fitting
and 1/4” flex tubing 20-90 psi
Power cord plugs
into back of CDS
or ULTRA platform

Control Board
Controls all functions
of P.A.F.

Transformer
Supplies 24vac to
operate control board.
Amber colored disk
soldered to transformer
is a P.T.C. style fuse.

Power Switch
SPST
Supplies L1 to transformer
and Control board

Test Switch
TEST position will
initiate 10 second
hopper throw test
Service position will allow
dispensing with door open
SPDT center off

Door
Arms prop door in
upright position &
ride in side rails
Same 12v lamp as
CDS, illuminates
display & flashes 4
possible fault codes

Fault Code List

Door Switch
Actuated by right door arm assembly
Disables door lamp & dispensing

Regulator
Preset to 15 psi (103 kPa) (kilopascal)
no adjustment necessary

Needle Valve
Preset to 1oz. (29.5ml) /second
No adjustment necessary

Inlet Solenoid
01085.0002 same one
as in brewers

Water Outlet
Water outlet goes to
the mixing chamber

Hopper
Auger drive bracket
Slide gate
Elbow
Auger drive shaft
Wiper blade drive gear
Wiper blade
Auger
To fill hopper, close slide
gate, lift front of hopper
above guides, & pull
hopper out

Hopper Switch
green to J1-8 COM.
Red/blk to J1-10 N.O.
Fault code # 3 if not
actuated by hopper

Level Sensor
Photo transistor
(receiver)
J6-1(+) J6-3(-)
5v=hopper full
0v=hopper empty
L.E.D. (sender)
J2-1(+) J2-2(-)
1.5v (infrared)
Fault code # 1
“product level low”

Auger Drive
* R.P.M 15 to 90
* 24 vdc variable speed
* 4.5 vdc-24 vdc (when on)
* 0.35 vdc (when off).

Motor Speed
Clockwise=faster
Counterclockwise=slower

Brixing
∗ Set brix ratio according to product recommendations
∗ To adjust, use hopper throw test & determine ratio
∗ If adjustment is necessary, use a small flat blade screwdriver
to pry off cap, then use it to turn the adjusting potentiometer
∗ Clockwise for more powder, Counterclockwise for less

Mixing
Water inlet creates
a powerful vortex Mixing
chamber

Whipper
dispense
tip
whipper
chamber
O-ring
frother
receptacle
nylon slinger
rubber seal
Whipper motor
120vac
18,000 rpm (no load)

Probe Circuit
To J1-12
motor cover
CDS
hopper
PAF
unit
resistor
301kΩ
1% tol.
When this connection
is broken, Fault code #
2 is displayed
probe
Should the PAF fail to fill the CDS
hopper in 5 minutes, Fault # 4 displays
Resistor prevents Fault # 2
when CDS hopper is low

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