© 2001 bunn-o-matic corporation. all rights reserved. confidential material

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 Off10:45:30 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) *56.8*.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


SHAFT

Viewed from rear side of machine

1/4” gap (minimum)

Starts freezing

Torque sensor“reads” the gap between pins during shaft rotation.

Torque Sensing


SHAFT

1/2” gap (maximum)

Stops freezing



Torque Sensing


Satisfied point will vary withthickness settings

SHAFT

Stops freezing



Torque Sensing


Fault: no rotation detected No freezing

Both pins missing, or no motor rotation

SHAFT



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”

SHAFT



Torque Sensing


Fault: torque higher than possible No freezing

Bent, broken,ormissing pin.gap wider than 1/2”

SHAFT

Torque Sensing




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:

2k @ 77°F

5650 @ 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

OverloadPTC

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 DATEJAN.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 SwitchSPST

Supplies L1 to transformer and Control board


Test SwitchTEST 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

frotherreceptacle

nylon slingerrubber seal

Whipper motor 120vac 18,000 rpm (no load)


Probe Circuit

To J1-12

motor cover

CDS hopper

PAF unit

resistor301k 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

© 2001 bunn-o-matic corporation. all rights reserved. confidential material

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