1. Technical Training Presentation
ULTRA-2
Technical
Training
Presentation

2. Site Requirements 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)

3. 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

4. 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.

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

6. Home screen toggles time, date, serial, & asset numbers continuously
Touch pad 1
Turn on main power switch
Turn on Auger Switch, Auger will rotate clockwise. (No display indication)
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.
JAN.1, 2002
ICE
chill
Left
Right 2 3
Home screen toggles time, date, serial, & asset numbers continuously

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

8. Home screen DISPLAY TEMP & TORQUE
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

9. Home screen 0 36 0 36°h 0 67 0 67°b Left Right Left Right
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

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

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

12. 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)

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

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

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

16. Use small screwdriver to pry out vents & replace lamps
Hoods
Use small screwdriver to pry out vents & replace lamps
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

17. Cooling Drum/Auger Auger shaves ice off as it forms on drum
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!

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

19. Cooling Drums/Auger Drive
Bushing
Seal

20. 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 in-lbs.

21. Auger Drive Control
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 .

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

23. Auger Drive/PM Bushing
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
Front of drum

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

25. Auger Drive/Torque Sensing
Torsion springs transmit driving force from motor drive coupler to shaft drive coupler
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

26. Torque Sensing
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
Direction of light beam

27. Torque Sensing
Invisible Infra red beam is momentarily blocked by the Motor pin, then the Shaft pin.
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.

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

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

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

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

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

33. 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”
Viewed from rear side of machine
Torque sensor
“reads” the gap between pins during shaft rotation.
Fault: torque lower than possible No freezing

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

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

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

37. TEMPERATURE SENSING Voltage readings: 0vdc = short circuit
room temp
35°F
5vdc = open circuit
Resistance values:
77°F
32°F

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

39. Refrigeration Schematic

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

41. ACTUAL DISPLAY MESSAGE!
Filter Clean Reminder
ACTUAL DISPLAY MESSAGE!
MONTHLY FILTER
CLEAN REQUIRED
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)
XX DAYS
HOLD ULTRA SWTCH
3 SECS TO CLEAR

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

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

44. Unplugged Overheated HOT GAS HOT GAS OFF OFF OFF OFF SENSOR OPEN
SENSOR SHORTED
OFF
OFF
OFF
OFF

45. Solenoids No repair kit
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

46. Fan Assembly 3 screws for removal 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

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

48. 120vac 7.3 amps 1/4hp 3955 BTU (locked rotor condition aprox. 41 amps)
Americold Compressor
Overload
PTC
Used in early units
120vac 7.3 amps 1/4hp 3955 BTU (locked rotor condition aprox. 41 amps)

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

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

51. Start Circuit Line Contactor Start Relay
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.
Start Relay

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

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

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

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

56. Display Temp & Torque DISPLAY TEMP & TORQUE
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

57. Temp & Torque Screens 0 36 0 36°h 0 67 0 67°b Left Right Left Right
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
SOLENOID ON
solenoid off

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

59. Cleaning Guide CLEANING GUIDE ? NO YES
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.

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

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

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

63. Entering a Password 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 (6601) is built in back door password from factory. Use “+” to scroll up, or “-” to scroll down

64. Night/Day mode 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.

65. Night/Day mode DEFROST MINUTES (-) OFF (+)
Acts similar to night mode, but does not turn off hood lights. Range is 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 minutes.

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

67. 6 month reminder display
Enable PM Counter
6 month reminder display
6 MONTH PM
(-)
ENABLED
(+)
Toggles 6 month PM counter on/off Press either “+” or “-” to toggle changes. (No lockout)
SHAFT SEAL
MAINTENANCE DUE

68. ACTUAL DISPLAY MESSAGE!
Set Days to Clean
DAY TO CLEAN OFF
(-)
NEXT
(+)
ACTUAL DISPLAY MESSAGE!
CLEAN DUE TODAY
“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.

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

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

71. Enter Asset Number 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 “+”

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

73. Restore Factory Defaults
RESTORE DEFAULT? NO
YES
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

74. View Install Date 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.

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

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

77. PAF Installation

78. PAF Installation

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

80. Powder Auto Fill
TECHNICAL
TRAINING
PRESENTATION

81. 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

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

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

84. Power Switch
SPST
Supplies L1 to transformer and Control board

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

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

87. Fault Code List

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

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

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

91. Inlet Solenoid
same one as in brewers

92. Water Outlet
Water outlet goes to the mixing chamber

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

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

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

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

97. Motor Speed
Clockwise=faster
Counterclockwise=slower

98. 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

99. Mixing
Water inlet creates a powerful vortex
Mixing chamber

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

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