Bunn 34000.0012 Service & Repair Manual Download

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Ultra

Frozen Beverage Dispensers

Bunn-O-Matic Corporation

Post Office Box 3227, Springfield, Illinois 62708-3227

Phone (217) 529-6601 | Fax (217) 529-6644

www.bunn.com

SERVICE & REPAIR MANUAL

Summary of Contents for 34000.0012

Page 1: ...everage Dispensers 57654 0000 A 12 20 2020 Bunn O Matic Corporation Bunn O Matic Corporation Post Office Box 3227 Springfield Illinois 62708 3227 Phone 217 529 6601 Fax 217 529 6644 www bunn com SERVICE REPAIR MANUAL ...

Page 2: ...uld not be relied upon If BUNN determines in its sole discretion that the equipment does not conform to the warranty BUNN at its exclu sive 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 BUN...

Page 3: ... won t turn 18 Torque sensor error 19 Temperature sensor error 20 Clean filter messages 21 SERVICE Access Panels 22 Auger Motors 23 Auger Motor Capacitors 24 Auger Shaft Assembly 25 26 Circuit Breaker 27 Compressor Americold 28 29 30 Embraco 31 32 33 34 35 36 37 Relay or Contactor on Early Models 38 Control Board 39 Cooling Drum Alignment 40 Fan 41 Hot Gas Temperature Sensor 42 Lamp Cord Assembly ...

Page 4: ...ted into the display See Troubleshooting INTRODUCTION I O Valve Open Valve Closed JAN 25 2019 ICE Ice USER NOTICES Carefully read and follow all notices on the equipment and in this manual They were written for your protection All notices are to be kept in good condition Replace any unreadable or damaged labels The dispenser is very heavy Place it on a sturdy counter or shelf capable of supporting...

Page 5: ...oggle back and forth The auger torque is displayed continuously Press and release the left and right hidden switches to return to HOME SCREEN The TEMP TORQUE mode is typically used for service NOTICE While in the TEMP TORQUE screen the UPPER lower case will be replaced by symbols The indicates the solenoid valve is open and the indicates that solenoid is closed I O DISPLAY TEMP TORQUE TEMP TORQUE ...

Page 6: ...rner This is used to turn the left side auger motor to AUGER ON AUGER OFF or AUGER REFILL ON Refill only applicable when installed 3 bottom left corner This is used to turn the left side ice control to OFF ICE or CHILL 4 bottom right corner This is used to turn the right side auger motor AUGER ON AUGER OFF or AUGER REFILL ON Refill only applicable when installed 5 bottom right corner This is used ...

Page 7: ...tton for 3 seconds to clear the fault and restart the refill system 1 Lift the lid slightly for the selected hopper and slide back to gain access to the hopper 2 Place the pre mixed liquid product in the selected hopper 3 Press and release the ON OFF switch to power on the dispenser 4 Press and release the appropriate left or right side ON OFF switch to start the Auger Motor and to turn on AutoFil...

Page 8: ...r safe they may be affected by the chemicals in some commercial sanitizing agents Do not place the hopper nor hopper lids in a dishwasher Rinse thoroughly before assembly 2 Depress the hopper lock plunger Lift the hopper up slightly 5 Remove the cooling drum seal from the rear of the drum 4 Pull the auger from the cooling drum 9 Care must be taken to ensure this surface does not get scratched duri...

Page 9: ...d plug in the hopper lid lamp cord s 10 Assemble the drip tray 8 Slide the faucet valve assembly into place on the hopper 9 Press down on the valve to com press the spring Position the faucet handle over the faucet valve one side at a time and snap into place on the hopper 7 Position the faucet seal and return spring in the faucet valve I O I O I O I O 5 Slide into place and push down until the ho...

Page 10: ...s open to the sanitizing solution Place concentrate inlet line into the bucket so that the Q C D will stay at the bottom 7 Press the auger button to turn on the Auger Refill On feature 8 Allow system to run until the hopper is about 1 4 full then turn off refill 9 Switch three way sanitize valve to the Sanitize postion 10 Turn refill system back on and let run until the hopper is almost full then ...

Page 11: ...he maximum allowable distance the compressor shuts off The machine thinks the product thickness has reach the maximum and shuts off the compressor The illustration below shows some of the other possible causes for a false reading from the torque sensor board Proper inspection and preventive maintenance including daily cleaning will avoid expensive repairs and costly down time PREVENTIVE MAINTENANC...

Page 12: ...y remove cover and set aside for reassembly 3 Remove the 8 locking screw on the lower right side viewed from front of the auger motor mounting bracket securing the auger motor run capacitor Set capacitor aside with wires attached 4 Disconnect the auger motor terminal from the terminal on the main wiring harness 5 Remove the remaining 8 locking screws securing the cooling drum mounting bracket Remo...

Page 13: ... auger shaft assembly onto the motor shaft See FIG 3 Do not use too much Krytox lubricant Dirt or grease on pins will cause optical misreading by torque sensors NOTE This is the only place Krytox lubricant is used 13 Assemble motor shaft assembly as shown in FIG 3 then install assembly into cooling drum Make sure the pins do not hit the sensor board and cooling drum seal is not dislodged as the sh...

Page 14: ... circuit boards is unlikely Board failure will normally be permanent If an intermittent condition is encountered the cause will likely be a switch contact or a loose connection at a terminal or crimp Keep away from combustibles WARNING Exercise extreme caution when servicing electrical equipment Unplug the dispenser when servicing except when electrical tests are specified Follow recommended servi...

Page 15: ... Set into ICE mode Verify augers are turned on Is display showing UPPER CASE ICE mode Is Brix level high Is Filter dirty Is Thickness screen set low Have a certified refrigeration technician check for low refrigerant or blockage Inspect auger drive shafts for weak torsion springs or damaged pins Check for dirty or worn seals and bushings TROUBLESHOOTING continued ...

Page 16: ... blockage No Set into ICE or CHILL mode 3 Clean 1 3 1 Done 2 Adjust 1 No No No Yes Yes Yes Yes Is compressor running Is Dispenser on an extension cord Is filter dirty Plug directly inti outlet Call a licensed electrician Is there correct voltage at outlet Check fan Follow compressor circuit checks TROUBLESHOOTING continued ...

Page 17: ...irty or worn seals and bushings Brix ratio too high Too much alcohol in product Ambient temperature too hot Adjust product Recommended for indoor use only No hood lamps Is dispenser in DAY mode No Yes No Yes Set into DAY mode Is circuit breaker tripped Check lamp circuit Verify all 4 bulbs are 912 series reset breaker TROUBLESHOOTING continued ...

Page 18: ...aft bushings Using auger assembly from CDS 2 or 3 Replace with ULTRA p n 32106 1000 Auger won t turn Auger motor capacitor checks Check membrane switch Yes No Do they turn during AUGER MOTOR TEST mode One direction but not the other Replace control board TROUBLESHOOTING continued ...

Page 19: ... Yes No TORQUE SENSOR ERROR TORQUE SENSOR SHORTED TORQUE SENSOR OPEN Are augers turning Left side Right side Left side Right side Go to motor troubleshooting Are augers shaft pins damaged or missing Check sensor circuit Replace as necessary TROUBLESHOOTING continued ...

Page 20: ... Left side Right side Check wiring harness between thermistor and control board Left side Right side Product not covering back end of drum Drum temperature falls below 9 F Replenish product Thermistor unplugged or break in wiring Check thermistor circuit TROUBLESHOOTING continued ...

Page 21: ...TER NEEDS CLEANING Hot gas thermistor sensing over 220 F Hot gas thermistor sensing over 250 F Dirty filter air flow blockage wrong refrigerant or over charged Hold ULTRA button for 3 seconds to reset Early units have to reset to factory defaults in order to reset Freezing is Disabled TROUBLESHOOTING continued ...

Page 22: ... should be disconnected from the power source when servicing except when electrical tests are required and the test procedure specifically states to connect the dispenser to the power source COMPONENT ACCESS PANELS WARNING Disconnect the dispenser from the power source before the removal of any panel or the replacement of any component All components are accessible by removal of the auger motor co...

Page 23: ...ove the cover and set aside for reassembly 3 Remove the 8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor run capacitor Set capacitor aside with wires at tached 4 Disconnect the auger motor terminal from the terminal on the main wiring harness 5 Remove the three remaining 8 locking screws secur ing the auger motor mounting bracket to cooling drum ...

Page 24: ...inals with a screwdriver Removal and Replacement 1 Remove the two 8 locking screws securing the auger motor cover to the cooling drum mount assy 2 Remove the cover and set aside for reassembly 3 Disconnect the wires from the auger motor capacitor terminals 4 Remove the 8 locking screw on the lower right side of the auger motor mounting bracket securing the auger motor capacitor 5 Install a new cap...

Page 25: ... an assembly NOTE When removing or installing motor and shaft assemblies be sure the split pins are turned to a posi tion that will clear the torque sensor circuit board 7 Pull the auger shaft assembly straight out of cooling drum Inspect the shaft for abnormal wear or scoring 8 From the front of dispenser remove the seal and blue bushing from cooling drum and discard them 9 Clean seal and bushing...

Page 26: ... sure the pins do not hit the sensor board and cool ing drum seal is not dislodged as the shaft passes through 15 Secure motor and capacitor to the cooling drum mounting bracket Install rear motor cover 16 Refer to Hopper Installation for hopper assembly and installation procedures Be sure to use new hopper drum seal and faucet seals 17 Remove and clean condenser air filter Fig 10 18 Refer to the ...

Page 27: ...nt as described press the reset button and repeat step 3 if continuity is not present as described replace the circuit breaker Removal and Replacement 1 Remove the right side panel 2 Remove the wires from the circuit breaker 3 Compress the clips on the back side of the component bracket and gently push the circuit breaker through the opening in the bracket 4 Push the new circuit breaker into the o...

Page 28: ... compressor 8 Check for continuity across the upper left terminal and the right pin socket on the rear of the relay If continuity is present as described the compressor start relay is operating properly If continuity is not present as described replace relay Compressor 1 Withthecompressorstartrelay 1 removed disconnect the black wire from the compressor 2 Check for continuity across the terminal o...

Page 29: ...6 and reconnect the wires 6 Reinstall terminal cover 4 and cover retainer 5 Compressor Run Capacitor 230V Dispensers Only Refer to FIG 15 1 Removeterminalcoverretainer 5 andterminalcover 4 2 Disconnect the run capacitor leads 3 Remove the 6 crimptite screw securing the run capacitor to the rear of the component bracket 4 Remove run capacitor and discard 5 Placenewruncapacitorontherearofcomponentbr...

Page 30: ...enser lift the compressor assembly over the four studs in the chassis and remove compressor 6 Install new compressor over the four studs in the dispenser chassis with the fill valve to the left side of the dispenser 7 Secure compressor to the dispenser chassis using four 25 20 keps nuts and washers 8 Reconnect tubes from the condenser and the accumulator to the compressor 9 Reinstall transformer 1...

Page 31: ...lay 6 Disconnect the two black wires from the compressor start relay 7 Remove relay from the compressor 8 Check for continuity across the upper left terminal and the right pin socket on the rear of the relay If continuity is present as described the compressor start relay is operating properly If continuity is not present as described replace relay Compressor 1 Withthecompressorstartrelay 1 remove...

Page 32: ...ssor pins 5 Refer to Fig 21 and reconnect the wires 6 Reinstall terminal cover 4 and cover retainer 5 Compressor Run Capacitor Refer to FIG 20 1 Disconnect the run capacitor leads 2 Removethenutsecuringtheruncapacitortothecapaci tor mounting bracket 3 Remove run capacitor and discard 4 Place new run capacitor on capacitor mounting bracket and secure nut 5 Refer to Fig 23 and reconnect the wires FI...

Page 33: ...ser lift the compressor assembly over the four studs in the chassis and remove compressor 6 Install new compressor over the four studs in the dis penser chassis with the fill valve to the left side of the dispenser 7 Secure compressor to the dispenser chassis using four 25 20 keps nuts and washers 8 Reconnect tubes from the condenser and the accumulator to the compressor 9 Reinstall transformer 10...

Page 34: ...penser is known as CSR motor Capacitive Start Run The CSR version uses a start and run capacitor with an external thermal protector The start capacitor is in series with the compressor motor start winding A potential starting relay coil is wired across the start winding which can sense change in voltage The start ing winding voltage will increase along with motor speed When the voltage has reached...

Page 35: ...il and refrigerant being vented can create a hazardous condition of chemical burn frostbite or fire Never reset a breaker or replace a blown fuse without checking the compressor or related components for a short circuit or ground fault condition first Always wear and use the appropriate safety gear when servicing a refrigeration system Protective gloves eyewear shoes clothes and tools If compresso...

Page 36: ...Compressor Windings Insulation with a Megger A megger is a preferred test over using a typical ohm meter for testing the compressor windings The meg ger checks the insulation factor of a winding making sure it is actually insulated and not leaking current Ground Fault An ohm meter usually produce a low voltage for reading resistance verses a megger uses higher direct voltage source to measure insu...

Page 37: ... Capacitor BUNN P N 39804 0004 Rating 243 292 MFD 165V 50 60HZ Disconnect the start capacitor from the system Remove the bleed resistor Use a capacitance meter to measure the capacitance The capacitance value should be the rated value minus 0 to plus 20 If it is outside of this range then the start capacitor needs to be replaced Run Capacitior Run Capacitior BUNN P N 44820 0004 Run Capacitor 35 5 ...

Page 38: ...nel 3 Connect the dispenser to the power source 4 Turn on power I O switch Verify UPPER case ICE or CHILL mode 5 Withavoltmeter checkthevoltageacrossthewhite wire and the orange wire The indication must be a 120 volts ac for 120 volt models b 230 volts ac for 230 volt models 6 Disconnect the dispenser from the power source If voltage is present as described proceed to 7 If voltage is not present a...

Page 39: ... Location The control board is located behind the front panel on the front of the chassis Test Procedures 1 Disconnect the dispenser from the power source 2 Remove the left and right side panels Remove the front panel and unplug ribbon cable from J5 3 With a voltmeter check the supply voltage from J5 8 WHI BLU to J5 20 WHI BLK 4 Connect the dispenser to the power source The indication must be Appr...

Page 40: ... very bottom will drop into the hopper drip tray s drain hole Boss 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 ...

Page 41: ...ndenser shroud and fan assy from the right side of the dispenser 4 Removethethree 6threadcuttingscrewssecuring thefanassytocondensershroud 7 Setcondenser shroud and screws aside for reassembly 5 Remove the three 8 32 thread forming screws securingmotor 5 tocondenserfanshroud mount 6 Set shroud and screws aside for reassembly 6 Remove speed nut 2 from the motor shaft 7 Remove fan 3 FIG 40 FAN COMPO...

Page 42: ...nnector on the main harness 3 Connect an ohmmeter across the two leads of the hot gas sensor The indication must be a 678 ohms 212 F 10 b 10k ohms 77 F 10 If resistance reading is not within the range listed above replace sensor Removal and Replacement Refer to Fig 42 1 Remove the left side housing panel 2 Disconnect the plug on the hot gas sensor leads from the connector on the main harness 3 Rem...

Page 43: ...ver 2 Remove the hopper cover with the lamp cord assembly from the hopper 3 Remove hopper cover liner from the hopper cover 4 Cut the closed splice terminals connecting lamp cord assembly to the lamp holder socket assembly off 5 Remove lamp cord assembly from hopper cover and discard 6 Push new lamp cord wires through the holes on the left outside top of the hopper cover 7 Strip the wires from the...

Page 44: ...d connectors are located inside the center top of the auger motor covers Test Procedures 1 Disconnect the dispenser from the power source 2 Disconnect the plug on the dispenser main harness from the connector from the lamp cord connector 3 Connect the dispenser to the power source Turnon power I O switch Theindicationmustbeapproxi mately 12 6 volts dc 4 Disconnect the dispenser from the power sour...

Page 45: ...Plug in the lamp cord assembly to the lamp cord connector assembly on left top of the auger motor cover 14 Refer to Fig 49 when reconnecting the wires FIG 49 LAMP HOLDER SOCKET ASSEMBLY WIRES P1322 LAMP HOLDER SOCKET ASSEMBLY FIG 48 LAMP HOLDER SOCKET ASSEMBLY Location The lamp holder socket assemblies are located inside the hopper covers Test Procedures 1 Disconnect the lamp cord assembly from th...

Page 46: ...ghts are located inside the hopper lid Test Procedures 1 Disconnect power from the dispenser 2 Disconnect the black and red leads from the LEDs 3 Check the voltage across the two leads with a voltmeter Reconnect power to the dispenser The indication must be approximately 12 volts ac 4 Disconnect power from the dispenser If voltage is present as described the LED board is faulty If voltage is not p...

Page 47: ... the chassis on the right side Test Procedures Coil 1 Disconnect the dispenser from the power source 2 Connect a voltmeter across BLU BLK wire and the VIO wire 3 Connect the dispenser from the power source 4 Turn on Power I O Switch Verify the dispenser is in the DAY mode The indication must be a 12 volts dc in the DAY mode b 0 volts dc in the NIGHT mode If voltage is present as described the Cont...

Page 48: ...MBRANE SWITCH FIG 53 MEMBRANE SWITCH Location The membrane switch is located on the front panel Test Procedures NOTE Before continuing check that the ribbon cable is properly connected to the control board and not a pin off in either direction 1 Disconnect the dispenser from the power source 2 Remove the right and left side panels 3 Removethefrontpanelanddisconnectribboncable 4 Check for continuit...

Page 49: ...ay be a blockage in the refrigerant line or solenoid This will require a licensed refrigeration repair person to evacuate the system and make repairs as necessary NOTE Before removal of any refrigeration component the refrigerant in the system must be reclaimed by a licensed refrigeration repair person Removal and Replacement 1 Disconnect the wires from both solenoids 2 Disconnect the refrigerant ...

Page 50: ...ms 32 F 10 b 2000 ohms 77 F 10 If resistance reading is not within the range listed above replace thermistor Removal and Replacement 1 Remove the two 8 32 screws securing the auger motor cover to cooling drum mount and remove cover Set aside for reassembly 2 Disconnect the plug on the temperature sensor leads from the connector on the dispenser main harness 3 Pull the temperature sensor from the t...

Page 51: ...attached 4 Disconnecttheaugermotorplugfromtheconnector on the main wiring harness 5 Remove the three remaining 8 locking screws securing the auger motor mounting bracket to cooling drum mounting bracket 6 Remove motor with mounting bracket split pin torsion spring bearings as an assembly and set aside for reassembly NOTE When removing or installing the motor be sure the split pin in the motor shaf...

Page 52: ...on the transformer The indication must be a 120 volts ac for 120 volt models b 230 volts ac for 230 volt models If voltage is present as described replace transformer Ifvoltageisnotpresentasdescribed refertotheWiring Diagrams and check the main wiring harness Removal and Replacement 1 Disconnect the dispenser from the power source 2 Remove right side panel 3 Disconnect the four wires from transfor...

Page 53: ...LATIONS B I B OR VENTED TANK CONCENTRATE WATER CO2 SUPPLY WATER REGULATOR WHEN PRESSURE IS ABOVE 80PSI WATER INLET SHUT OFF VALVE CO2 SYRUP PUMP Optimal Pressure Setting 40 80 psi Liquid Autofill System FIG 68 LIQUID AUTOFILL SYSTEM SERVICE continued ...

Page 54: ...int is 65 psi Check for voltage at the Water valve solenoid between theWHTandWHT YELwires Thereadingshouldbe120 vac for 120V machines or 230 vac for 230V machines Check for voltage at the Syrup valve solenoid between theWHTandWHT YELwires Thereadingshouldbe120 vac for 120V machines or 230 vac for 230V machines If voltage is not present as indicated replace solenoid valve s Removal and Replacement ...

Page 55: ... VENTED TANK DOUBLE CHECK VALVE WATER REGULATOR SHURFLO P N 183 0XX 50 PSI RECOMMENDED 3 WAY SANITIZING VALVE SHURFLO P N 94 056 00 Should be located no more than 6 from pump CITY WATER INLET SHUT OFF VALVE WATER OUTLET WATER Liquid Autofill System FIG 70 LIQUID AUTOFILL SYSTEM SERVICE continued ...

Page 56: ...ng should be 100 vac for 100V machines 120 vac for 120V machines or 230 vac for 230V machines If voltage is not present as indicated replace solenoid valve s Check for voltage at the Water valve solenoid between theWHTandREDwiresfortherightvalve s orbetween the WHT and BLU wires for the left valve s The read ing should be 100 vac for 100V machines 120 vac for 120V machines or 230 vac for 230V mach...

Page 57: ...R CONDENSER THERMISTOR TEMPERATURE SENSOR THERMISTOR TEMPERATURE SENSOR COPPER TUBE 25 O D X 030 COPPER TUBE 25 O D X 030 COPPER TUBE 312 O D X 032 SUCTION ACCUMULATOR FILTER DRYER CAP TUBE SOLENOID VALVE ELECTRONICALLY CONTROLLED SERVICE VALVE FOR COOLANT CHARGE INFORMATION SEE DECAL ON SIDE PANEL ...

Page 58: ...V4 controls Fan J13 14 TH4 MOV2 controls Right solenoid J13 16 TH5 MOV5 controls Left Auger J13 2 Reverse J13 3 Forward TH6 MOV6 controls Right Auger J13 13 Reverse J13 1 Forward LIQUID AUTO FILL TRIACS TH1 MOV1 controls Right fill solenoid J2 9 TH2 MOV2 controls Left fill solenoid J2 4 LIQUID AUTO FILL BOARD ...

Page 59: ...5 White 18 Neutral PC Board Neutral 6 Not Used Not Used Not Used Not Used 7 Violet 18 Output Switched Lamp Relay 12VDC 8 White Blue 18 Supply PC Board 12VAC 9 White Black 22 Board Ground Sensors 5VDC 10 Yellow 22 Input Signal Hot Gas Temp 11 Blue 22 Output Torque Sensors 5VDC 12 White Black 22 Output Torque Sensors 5VDC 13 White Red 18 Output Right Auger Motor 120VAC 14 Gray 18 Output Condenser Fa...

Page 60: ...Y RIGHT LAMP ASSY BLK RED WHI BLK BLK RED RED BRN WHI BRN BLK WHI RED WHI VIO 22 WHI BLK 22 WHI VIO 22 WHI BLK 22 BRN WHI WHI RED RED BLK BRN BLK RED BLK WHI WHI WHI 1 4 1 1 1 4 LEFT TORQUE SENSOR RIGHT TORQUE SENSOR LEFT 1 1 1 1 1 t RIGHT t HOT GAS t GRN BLK WHI FAN MOTOR C C BLK RED LEFT SOL RIGHT SOL Configuration for CF VALVE Models TRANSFORMER CIRCUIT BREAKER LAMP RELAY COMPRESSOR RELAY 5 AMP...

Page 61: ...2007 BUNN O MATIC CORPORATION M M LEFT AUGER RIGHT AUGER LEFT LAMP ASSY RIGHT LAMP ASSY BLK RED WHI BLK BLK RED RED BRN WHI BRN BLK WHI RED WHI VIO 22 WHI BLK 22 WHI VIO 22 WHI BLK 22 BRN WHI WHI RED RED BLK BRN BLK RED BLK WHI WHI WHI 1 4 1 1 1 4 LEFT TORQUE SENSOR RIGHT TORQUE SENSOR LEFT 1 1 1 1 1 t RIGHT t HOT GAS t N L GRN BLK WHI BLK WHI FAN MOTOR C C BLK RED LEFT SOL RIGHT SOL COMPRESSOR AS...

Page 62: ...BLK BLK BLU BRB GRN or GRN YEL WHT BLU BLK BLU BLK RED BLK BRN BLK BLK L1 N A B L1 L2 RELAY RECTIFIER RCA PLUG CHASSIS GND CHASSIS GND PROBE DETECTOR LEFT RIGHT GRN GRN 301k C SCHEMATIC WIRING DIAGRAM PAFP 120 VOLTS OR 220 240 VOLTS AC 2 WIRE SINGLE PHASE 50 60 HZ ...

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