Presentation on theme: "Technical Training Presentation"— Presentation transcript:
1Technical Training Presentation ULTRA-2TechnicalTrainingPresentation
2Site 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)
3InstallationSave 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 frontRemove shipping eye-bolts from compressorInstall 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 lidsUnit can now be powered up
4Cooling 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 alignment1. Place the "A" shaped support on the auger shaftwith the ledge under the cooling drum.2. Lift the cooling drum while rotating the supportinto a vertical position. The boss on the verybottom 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.
5Touch pad replaces drawer, switches & dials! FrontFoam seal acts as a moisture barrier for the Control BoardTouch 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 hoseClamp for ribbon cableBottom unchanged
6Home screen toggles time, date, serial, & asset numbers continuously Touch pad1Turn on main power switchTurn on Auger Switch, Auger will rotate clockwise. (No display indication)Turn the Ice/OFF/CHILL switch to the Ice positionUPPER 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, 2002ICEchillLeftRight23Home screen toggles time, date, serial, & asset numbers continuously
7Home screen JAN.1, 2002 10:00:00 AM Off Off Off Off AN000001234 ULTOffOffOffOff
8Home 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 torquePress both switches again to return to home screen
9Home 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
10Menu 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.
11Test augersTEST AUGERS ?NOYESPressing “YES” will allow you to operate either auger in forward and/or reverse directions
12Membrane SwitchCheck 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)
13Hoppers Hoppers for Auto-fills also available for ULTRA Lowered to 3 gallons, the overall hopper/hood profile is 3 inches shorter than CDSMarked in Gallons/LitersHoppers for Auto-fills also available for ULTRATeflon coated nylon nose bushing is keyed into rail to prevent rotation & slides up/down to ease hopper installation
14Insert locking pin through these holes FaucetInsert locking pin through these holesNew style faucet handle is reversible to be ADA compliantSpread handle to remove, then slide faucet assembly up & out of railsADA – American Disabilities Act
15FaucetNew faucet seal is keyed at bottom for one way installation (coated side toward hopper)keyed
16Use small screwdriver to pry out vents & replace lamps HoodsUse small screwdriver to pry out vents & replace lampsLower hood profileUse a small screwdriver to pry out the new vents912 industry standard bulbs, T-5 wedge base1 amp at 12vacRated at 1100 hoursDo not replace with 921 bulbs, these draw 1.4 amps and will overload the 5 amp circuit breakerOn during “day” mode only
17Cooling 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!
18Cooling Drums/Auger BUNN New coated rear drum seal (32079.0000) New auger ( ) to compensate for discontinued front sealDrum, mounting, motors & shafts unchangedBUNN
20Auger Drive Motor 120vac 39.6RPM @ 60Hz Rotation: clockwise (front view)56.8.48 amp (no load)Locked rotor .9 ampThermal overload ProtectionTorque in-lbs.
21Auger Drive ControlRelays 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 .
22Auger Drive/PMKeep grease & dirt off pins, or it could prevent freezing!Ceramic coatingPM every 6 months
23Auger 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 systemsSealFront of drum
24Auger 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
25Auger Drive/Torque Sensing Torsion springs transmit driving force from motor drive coupler to shaft drive couplerAs 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
26Torque SensingThe 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- CommonPhototransistorLEDIf there’s no reading, check for 5v supply, at pins 2-3Direction of light beam
27Torque SensingInvisible 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.
28Fault codes- Torque Sensor Unplugged LEFT TORQUERIGHT TORQUEFAULTICEICEFAULTSENSOR OPENSENSOR OPENFAULTICEICEFAULT
29Viewed from rear side of machine Torque Sensing1/4” gap (minimum)Viewed from rear side of machineTorque sensor“reads” the gap between pins during shaft rotation.Starts freezing
30Viewed from rear side of machine Torque Sensing1/2” gap (maximum)Viewed from rear side of machineTorque sensor“reads” the gap between pins during shaft rotation.Stops freezing
31Viewed from rear side of machine Torque SensingSatisfied point will vary withthickness settingsViewed from rear side of machineTorque sensor“reads” the gap between pins during shaft rotation.Stops freezing
32Torque Sensing Fault: no rotation detected No freezing Both pins missing, or no motor rotationViewed from rear side of machineTorque sensor“reads” the gap between pins during shaft rotation.Fault: no rotation detected No freezing
33Torque 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 machineTorque sensor“reads” the gap between pins during shaft rotation.Fault: torque lower than possible No freezing
34Viewed from rear side of machine Torque SensingViewed from rear side of machineBent,broken,ormissing pin.gap widerthan 1/2”Torque sensor“reads” the gap between pins during shaft rotation.Fault: torque higher than possible No freezing
40Filter/Condenser/Fan Optional coverFilterOne piece shroud on CDS unitsCondenser3 screws to remove 120vac fan/motor assy.air flowThermistor added to discharge line, detects overheating due to clogged filter, will shut down cooling system
41ACTUAL DISPLAY MESSAGE! Filter Clean ReminderACTUAL DISPLAY MESSAGE!MONTHLY FILTERCLEAN REQUIREDA 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 DAYSHOLD ULTRA SWTCH3 SECS TO CLEAR
42Filter Clean - Urgent FILTER NEEDS CLEANING FILTER NEEDS Hot Gas Sensor detects 220° FCLEANINGFILTER NEEDSHot Gas Sensor detects 250° F (refrigeration shuts down)!!!CLEANING!!!
43Refrigeration System New filter/dryer/splitter Fewer braze joints! Larger accumulatorSome units now have a high side port (R404A)Thermistor (Hot Gas Sensor)
44Unplugged Overheated HOT GAS HOT GAS OFF OFF OFF OFF SENSOR OPEN SENSOR SHORTEDOFFOFFOFFOFF
45Solenoids No repair kit 120vac, controlled individually by main board (Parker valves)Mounted on front left corner postMust be certified in refrigeration to remove stem and plunger assembliesReplace each valve as an assemblyNo repair kit
46Fan 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 ascompressor, but may continuerunning for a while aftercompressor turns offCAUTION: It will also turn onevery ½ hr. to cool auger motors3 screws for removal
47Compressor Relay alternate set of contacts (N.O.) Neutral coil L1 from Control BoardTo compressor circuitcontacts (N.O.)L1 from main harness
49Embraco Compressor Overload PTC Start capacitor 145-175µfd 250vac Used in later units120vac 7.3 amps 1/4hp 3955 BTU (locked rotor condition aprox. 41 amps)
50New filter/dryer/splitter Fewer braze joints! Refrigeration systemNew 404A RefrigerantNew filter/dryer/splitterFewer braze joints!New Parker valves mounted on frame (no repair kit)Larger accumulatorThermistor, discharge line
51Start 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
53Electrical Components Compressor relayLamp relay5 amp breakerMain harness routed along top of frame, instead of being tied to condenserStep down transformer
54White/Violet (Common) Lamp CircuitNot used (N/C)White/Yellow (N/O)Blue/Black (+)12vdc coilViolet (-)White/Violet (Common)Transformer supplies 12vac to hood lamps & PC board at J5-8 (white/blue) and J5-20 (white/black)
55Home Screen JAN.1, 2002 10:00:00 AM Off Off Off Off AN000001234 ULTROffOffOffOff
56Display 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 torquePress both switches again to return to home screen
57Temp & 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 offSOLENOID ONsolenoid off
58Entering Program Modes OffOffHold this hidden switch for 5 seconds to enter the menu function index. You can also use it as a “NEXT” button.
59Cleaning 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.
60Adjusting Product Thickness SET THICKNESS ?Use the ON/OFF switch to back up one screenNOYESPressing “YES” lets you adjust thickness of product from (thin) to 16 (thick) with 10 as default
61Auger 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.
62Set Date & Time SET DATE TIME ? NO YES Pressing “YES” allows you to set year; month; day; hour; minutes & seconds
63Entering 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
64Night/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.
65Night/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.
66Use this screen to reset 6 month PM reminder message by pressing “YES” Reset PM CounterPM COMPLETE ?NOYESUse this screen to reset 6 month PM reminder message by pressing “YES”
676 month reminder display Enable PM Counter6 month reminder display6 MONTH PM(-)ENABLED(+)Toggles 6 month PM counter on/off Press either “+” or “-” to toggle changes. (No lockout)SHAFT SEALMAINTENANCE DUE
68ACTUAL DISPLAY MESSAGE! Set Days to CleanDAY 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.
69Enable Thickness Adjustment YES THICK ADJUST(-)NEXT(+)Toggling this to “NO” with either (-) or (+) disables adjustments in screen 2
70Touchpad 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
71Enter 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 “+”
72Set Password SET PASS WR 0 (-) NEXT (+) This is where you program in password from Press “+” to go up or “-” to go down.
73Restore Factory Defaults RESTORE DEFAULT?NOYESIf 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
74View 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.
75Displays currently installed software version View Software VersionULTRAVERSION # 00.44Displays currently installed software version
76Kit plugs into light socket PAF InstallationRail stopsKit plugs into light socketRectifierreceptaclesRelaySupport rod
98Brixing Set brix ratio according to product recommendations To adjust, use hopper throw test & determine ratioIf adjustment is necessary, use a small flat blade screwdriver to pry off cap, then use it to turn the adjusting potentiometerClockwise for more powder, Counterclockwise for less
99MixingWater inlet creates a powerful vortexMixing chamber
100Whipper Whipper motor 120vac 18,000 rpm (no load) nylon slinger rubber sealreceptaclefrotherO-ringwhipper chamberdispensetip
101Probe Circuit PAF unit To J1-12 probe motor cover resistor Resistor prevents Fault # 2 when CDS hopper is lowPAF unitTo J1-12When this connection is broken, Fault code # 2 is displayedprobemotor coverresistor301k 1% tol.CDS hopperShould the PAF fail to fill the CDS hopper in 5 minutes, Fault # 4 displays