FBD FBD550, Installation, Operation And Service Manual

Page 1: ...D TO THIS MATERIAL INCLUDING BUT NOT LIMIT ED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE FBD shall not be liable for errors contained herein or for incidental consequential damages in connection with the furnishings performance or use of this material This document contains proprietary information which is protected by copyright All rights reserved Copyright ...

Page 2: ...ED CLEANING EQUIPMENT 14 8 3 DAILY CLEANING OF THE UNIT 14 8 4 SANITIZING THE SYRUP SYSTEMS 14 9 BASICS OF OPERATION 15 9 1 MAKING ADJUSTMENTS TO THE FBD550 15 10 CHANGING FACTORY SET LEVEL CONTROL 16 10 1 BEFORE CHANGING LEVEL CONTROL SETTINGS 16 10 2 DRINK TOO HARD AND COLD 17 10 3 DRINK TOO LIQUID 17 10 4 CHANGING THE DEFAULT LEVEL CONTROL SETTING 17 11 CHANGING FACTORY THAW AND FREEZE SETTINGS...

Page 3: ...lified personnel should service internal components of electrical wiring CARBON DIOXIDE CO2 CO2 carbon dioxide displaces oxygen Strict attention must be observed in the prevention of CO2 gas leaks in the entire CO2 and soft drink system If a CO2 gas leak is suspected immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentrations of CO2 gas...

Page 4: ...VING Each unit is tested and thoroughly inspected before shipment At the time of shipment the carrier accepts the unit and any claim for damages must be made with the carrier Upon receiving the unit from the delivering carrier carefully inspect carton for visible indication of damage If damage exists have carrier note same on bill of lading and file a claim with the carrier 2 2 UNPACKING A Cut ban...

Page 5: ...low 215VAC or above 245VAC a 10 buck and boost transformer must be used If a buck and boost transformer is installed ensure that the boosted leg is on L1 of the contactor Operation below 215VAC or above 245VAC may damage the unit and cause inconsistent performance This also voids all warranties B If connected to a delta three phase electrical system use the two low voltage legs check each leg to g...

Page 6: ...CO2 supply line and run two 2 lines to tank location and install CO2 tank couplers to end of lines D Do not turn on the CO2 at this time 5 3 SYRUP SUPPLY The unit may be connected to either a BIB Bag in Box or a five gallon syrup supply figal Use the appropriate connection method below NOTE Installations requiring long runs of tubing 25 feet or more 7 62 meters or more may encounter pressure fluct...

Page 7: ...duct will refreeze D Do not turn on the CO2 at this time 6 STARTING THE UNIT Access Panel Electrical Box Cover 6 1 INITIAL POWER UP A Insure the electrical power is disconnected from the unit B Open the front marquee door by disengaging the latch located behind the right side of the door C Using a Phillips head screwdriver remove the stainless steel access panel located below the keypad see Figure...

Page 8: ...rols all the way out see Figure 6 4 G Using water only check the flow rate through the sample valve and set water flow to provide a flow of 15 ounces in 10 seconds using a graduated container Do this for both left and right side flow controls Turn control adjustment screw clockwise to increase flow or counter clock wise to decrease flow H Pre set Syrup flow by turning in Syrup flow controls 2 1 4 ...

Page 9: ...this point the chamber will stop filling and the LCD will readout Fill Hold It will then be necessary to pull the relief ring to relieve the pressure and allow filling to continue Slowly pull the relief ring until the pumps activate then release Repeat the venting process until the chamber is 90 full level with relief valve then press Fill button to turn OFF Fill one 1 chamber at a time E Repeat s...

Page 10: ...eration and chamber refill systems All of the electronic controls are still active CRITICAL REGULATOR AND FLOW CONTROL SETTINGS SET ALL PRESSURES USING THE LCD READOUTS ON THE UNIT NOT BY THE GAUGES ON THE REGULATORS CO2 PRIMARY REGULATOR The CO2 Primary Regulator MUST BE SET TO 70 72 PSIG 482 6 TO 496 4 KPa CO2 SECONDARY REGULATOR The CO2 Secondary Regulator SHOULD BE SET AT 28 32 PSI Secondary R...

Page 11: ...ecrease or lower values numbers The FWD button steps the operator forward within the current level This button also allows the operator to increase or raise values The SELECT button allows the operator to enter changes in the unit programming and it also allows the operator to move into different levels in the menu 2 The LCD display screen in the center of the control panel allows the operator acc...

Page 12: ...r BACK button until the desired mode is displayed When the desired mode is displayed press SELECT to enter the mode 2 To make changes to the displayed mode press the SELECT button When a value in the lower half of the display begins to flash this indicates that the value can be changed 3 To change the value press the FWD button to increase the value or the BACK button to decrease the value Any on ...

Page 13: ...ll Full Base PSI Rfill Base PSI PressConFac Current Full Current Rfill Right Side Thaw Freeze One Side Min One Side Thaw One Side Max Two Side Min Two Side Thaw Two Side Max Full Freeze Delta T Min Delta T Max One Side Min One Side Thaw One Side Max Two Side Min Two Side Thaw Two Side Max Full Freeze Delta T Min Delta T Max Base Refrigeration Left Side Duty Cycle Right Side Duty Cycle H2O Reset 50...

Page 14: ... Right Side defrost times by 60 minutes 6 WAKE SLEEP TIME Sets the machine wake and sleep times 00 00 To manually wake up and operate the unit press DEFROST then RUN 7 FAULT CODE This feature stores the last 10 error codes and helps HISTORY the service agent to readily diagnose a problem The readout is formatted as shown in the two examples below 0 Out of syrup first error is an out of syrup error...

Page 15: ...4 F to 28 F before adjusting Defrost Max Time Max Def Time 420 Number of minutes Defrost Cycle will run unless Return Temperature reaches 50 F first Common Settings Voltage Offset 0 Use this offset to match the Line Voltage readout in Common Readouts to the actual incoming voltage measured with a voltmeter at L1 and L2 of the contactor This must be completed prior to starting machine for operation...

Page 16: ... the current incoming CO2 pressure Regulated CO2 This represents the current internally REGULATED CO2 as set by the secondary CO2 regulator Line Voltage This represents the current incoming line voltage 8 CLEANING AND SANITIZING THE UNIT 8 1 GENERAL INFORMATION NOTE The following cleaning and sanitizing procedures pertain to the FBD equipment identified by this manual If other equipment is being c...

Page 17: ...ING OF THE UNIT CAUTION DO NOT USE ABRASIVE TYPE CLEANERS A On a daily basis or more often if necessary wash all exterior surfaces of unit with a mild soap solution Rinse with clean water Wipe dry with a clean soft cloth B Remove and wash drip tray in mild soap solution Rinse with clean water Reinstall drip tray on unit 8 4 SANITIZING THE SYRUP SYSTEMS The unit should be sanitized every 90 days Fo...

Page 18: ... individual machines etc it may be necessary to make minor adjustments to these critical settings Adjustments are easily made using the keypad located behind the door at the front of the machine or by adjusting the CO2 regulator located behind the access panel below the keypad B The settings that control product quality and production rate are 1 Beverage Syrup Content or Brix Level Set on Syrup Fl...

Page 19: ...OMPRESSOR SHORT CYCLE CAN OCCUR THAT WILL CAUSE THE COMPRESSOR TO OVERHEAT IF A LOWER SETTING IS USED THE DISPENSER OPERATION MUST BE MONITORED TO INSURE THE COMPRESSOR DOES NOT SHORT CYCLE c The Thaw and Freeze settings may be raised or lowered to change the temperature of the product A default setting of 3 is set at the factory To decrease the temperature decrease the numerical setting to 2 or 1...

Page 20: ... If the drink is cold but is still a liquid adjust the level control to a lower level setting Use the recommended settings that follow to properly adjust the level control B It will be necessary to drain off several drinks to allow the chamber to fill and rebalance It is then necessary to defrost the chamber and allow the product to refreeze If the drink is still too liquid repeat the process taki...

Page 21: ...sing the DEF buttons located on the control panel The machine may correct any problems with drink quality after going through a defrost cycle 1 After the defrost and refreeze cycle the compressor may cycle on and off several times to ensure that the product is uniformly frozen Wait several minutes and dispense several drinks before judging the quality of the product 2 The product should freeze to ...

Page 22: ...d the machine will start defrosting then freezing 12 2 CHAMBERS 90 FULL ON INITIAL SET UP Before beginning a RUN FREEZE cycle the chambers should be filled approximately 90 full up to relief valve If the chambers are above the 90 level with Fill Off open the dispensing valve and allow a small amount of liquid to drain out If the chambers are not 90 full press OFF then FILL and then slowly pull the...

Page 23: ...input Replace Relay Board if necessary H Lower Board problem H Test Lower Board for 5 15 and 15 outputs at J 5 plug see Figure 14 3 Replace Lower Board if necessary I 192 VA Transformer problem I Test transformer for 220VAC input Also check for 24VAC and 12VAC output see Figure 14 3 Replace transformer if necessary 13 2 Chamber fills even A Solution solenoid plunger A In Manual On Off energize whe...

Page 24: ...y 13 4 Product does not flow A Faulty CO2 check valve A Inspect CO2 check valve Clean or freely or does not flow replace at all from dispensing B CO2 solenoid valve won t B In Manual On Off energize valve open solenoid and check for 24VAC at coil Clean or replace solenoid if necessary C Solution solenoid valve C In Manual On Off energize won t open solenoid and check for 24VAC at coil Clean or rep...

Page 25: ...ners C Tighten loose fasteners ELECTRICAL 13 9 Solenoids not activating A Solenoid plunger not lifting A In Manual On Off energize solenoid on and off checking for plunger movement and 24VAC at coil Clean or replace solenoid if necessary B Relay Board failure B Test solenoid relay on Relay Board for 24VAC output and 5VDC input Replace if necessary C Connectors not plugged in C Assure connections a...

Page 26: ...lace if necessary 13 16 Fan motor not running A Unit in Defrost cycle A Check fan after completion of defrost cycle B Failed compressor or fan B Test compressor or fan relays on relay on relay board Relay Board for 24VAC output and 5VDC input Replace Relay Board if necessary C Lower motor control board C Replace lower board failure D Contactor not engaging D Check for 24 volt at coil and 220 volt ...

Page 27: ... SECONDS If contactor does not energize quickly check voltage across contactor coil terminals for 24VAC If voltage is present replace contactor F Relay board not sending F Test relay board for 24VAC output power to contactor coil and 5VDC input on contactor relay Replace relay board if necessary G Lower Board problem G Test lower board for 5 15 and 15 outputs at J 5 plug see Figure 14 3 H 192 VA T...

Page 28: ...t is under warranty Put gages on system and check pressures Single side suction should be 32 35psi dual side 42 45psi Single and dual side discharge should be 275 300 psi Check for and repair leaks recharge system with 48 5 oz of R404 A CAUTION DO NOT PRESSURIZE LOW SIDE EVAPORATOR AND COMPRESSOR SUCTION ABOVE 150 PSI FOR ANY REASON COMPONENTS WILL FAIL AND WARRANTIES WILL BE VOID 13 23 High head ...

Page 29: ...ace Relay Board if necessary J THAW FREEZE settings J Lower the THAW FREEZE are set too high settings using the instructions in Section 11 2 this manual K CO2 orifice is blocked K Remove blockage 13 26 Drink quality is too A Chamber not filled properly A Defrost and assure chamber is light 90 full B Incorrect Brix or water syrup B Check water and syrup flows and flow rates adjust if necessary Then...

Page 30: ...nual into cup B Incorrect Brix or water syrup B Check water and syrup flows and flow rates adjust if necessary Then check brix see Section 6 2 C CO2 level in drink too high C 1 To affect BOTH chambers lower Reg CO2 within 28 32 psi range 2 To affect ONE chamber raise the level control settings using the instructions in Section 10 2 of this manual LCD DISPLAY ERROR MESSAGES 13 29 PMAX A Chamber pre...

Page 31: ...otor to lower control board 2 Change lower control board if necessary 13 34 Syrup Out A Unit receiving no syrup A Check to see that syrup container is not empty and is hooked up B Restriction in lines B Assure all lines are free of crimps or restrictions C Regulator pressures unit C Check Syrups pressure readouts and syrup pumps too low for 70 72psi Adjust regulators if necessary D Syrup Pump fail...

Page 32: ...off B Restriction in lines B Assure all lines are free of crimps or restrictions C Regulator pressures to unit C Check pressure readout CO2 for and syrup pumps too low 70 72psi Adjust regulators if necessary D CO2 can t keep up with D Reroute CO2 lines to maximize unit demand supply pressure or supply unit dedicated CO2 source Bulk regulator must be 105 psi minimum CO2 line must be tied to main br...

Page 33: ... and is waiting to refreeze or when one side is defrosting and the other side is in Run Thaw Mode Run Cmp Wt This is displayed prior to starting a freeze down this is a time delay before the Refrigeration Solenoid opens Run Frz Wt This is displayed after the freeze down has finished Run Freeze This is displayed when a side is freezing down Run Thaw W This is displayed after the Thaw percent has be...

Page 34: ...getting hot A bad return temperature sensor SHUT DOWN may also be at fault Stop BTR Long The beater shuts off after 3 hours of a PMAX error It will restart automatically when PMAX the error is cleared Stop BTR The beater shuts off after 3 hours of a sold out condition It will restart automatically when LongPrd Out the sold out has been cleared 31 WARNING LIGHTS FBD550 FROZEN BEVERAGE DISPENSER PRO...

Page 35: ... MOUNTING DIAGRAM This Figure illustrates the locations of threaded mounting holes in the base of the FBD550 machine 32 14 7 8 1 1 16 10 1 4 32 3 17 20 MACHINE MUST BE SUPPORTED TO THIS POINT EDGE OF MACHINE EDGE OF MACHINE USE 1 2 DRILL BIT 4 HOLES ...

Page 36: ...LVE CO CO2 2 REG P P S S PRODUCT DISPENSER PRODUCT DISPENSER PRODUCT DISPENSER PRODUCT DISPENSER L L E E G G N N D D H2O IN SYRUP IN H2O IN SYRUP IN P A CO2 IN P P P BRIX ADJUSTER CO2 REG BRIX ADJUSTER P S P P S S S CO2 INJECT CHAMBER EXPANSION CHAMBER EXPANSION CHAMBER L SIDE FREEZE CO2 INJECT 0 25 0 039 0 25 0 039 A CO2 REG PRESET RELIEVING CHAMBER R SIDE FREEZE ...

Page 37: ...T RED YEL BLK ORG RV390 RV390 ORG 2 5 AMP SLO GRN GRN BRN BROTHER MOTOR 4uF TRANSFORMER T1 24 VAC OUTPUT TB 1 4 3 2 RV390 1 3 2 1 4 5 6 7 9 8 240 VAC INPUT BROTHER MOTOR 4uF RED BLU BLK GRN YEL BLK YEL YEL RED RED RED BLK BLK BLK BLK RED RED RED RED WHT BRN RED BLU BLK GRN YEL BLK YEL 2 5 AMP SLO RED GRN RED WHT RED GRN GRN GRN GRN GRN GRN GRN BLK L2 L1 GND POWER INPUT 215 245 VAC 60 50 HZ 14 16 R...