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FBD 56 Series Training

Frozen dispenser
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56X Frozen Dispenser
Training Seminar
24-2285-0001
REV M 02/05/2016
PO Box 18597 • San Antonio, Texas 78218 • 210-637-2800
Tech Support: 866-323-2777 • After Hours: 210-445-2344

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  • Page 1 56X Frozen Dispenser Training Seminar 24-2285-0001 REV M 02/05/2016 PO Box 18597 • San Antonio, Texas 78218 • 210-637-2800 Tech Support: 866-323-2777 • After Hours: 210-445-2344...
  • Page 2 Table of Contents FBD 56X specifications…….5 Initial start up and freeze…….56-58 Typical unit setup …………..7 E-prom replacement………….59 Product flow path …………..8-11 Status light definition…………60 Header assembly…………..12-14 Electrical diagrams…………..61-62 Expansion tank………….….15 Troubleshooting Critical settings………….…..16 boards……………..……….63-66 Beater Motor/Valves………..17-18 Transducers…..……………67 Electrical component ….…..19-20 and solution solenoid..68...
  • Page 3 Goals • The goals of this seminar are: – To give service technicians basic understanding of systems in 56X frozen dispenser. – To equip technicians with basic knowledge to operate 56X frozen dispenser. – To empower technicians with the understanding of the importance of “Preventative Maintenance”...
  • Page 4 56X Frozen Dispenser Specifications High Cap High Cap Certifications ES Certified, NSF, UL, CSA, CE, CB, RoHS, Coca-Cola ATM Refrigerant Charge 42/30 56.5 Compressor [BTU] 15K BTU 19K BTU 15K BTU 19K BTU 19K BTU Refrigeration Valve Electronic PWM Expansion Valves Operating Voltage Range 215 - 245 Current Rating [Amp]...
  • Page 5 56X Setup Requirements FBD FROZEN DISPENSER SETUP FOR FCB 562/563 High Cap Electrical Requirements Supply Voltage [Volt] 215 – 245 LCD readout should be +/- 2 volts of measured voltage at L1 and L2 Current Rating [Amp] Incoming Pressure and Flow Requirements...
  • Page 6 The Four “Ingredients” • The four ingredients to Produce a Frozen Beverage – Water – Syrup – CO – Electricity...
  • Page 7 Typical FBD Unit Setup Syrup Pump 1 per barrel Regulator Water Source Electrical Source Source Syrup BIB...
  • Page 8 Product Delivery System Product Delivery System Water and Syrup Mix Model Solution Module CO2 Module 2 + 1 Extension 2 + 2 Extensions Expansion Tank Active Charge Regulator Syrup Pressure Transducer CO2 Pressure Transducer Water Pressure Transducer Tank Pressure Transducer Dispensing Valve Solenoid Incoming CO2...
  • Page 9 Complete Header Assembly Water Tank Syrup Regulated CO2 Tank Syrup...
  • Page 10 Solution Mixing Module Front View Top View Water Inlet Sample Outlet Sample Valve Solution Outlet Tank Pressure Syrup Inlet Transducer Water Pressure Syrup Transducer Pressure Transducer Water Flow Syrup Flow Adjustment Adjustment Flow Rate Adjustment •Turning Clockwise -Increases flow rate •Turning Counter Clockwise -Decreases flow rate...
  • Page 11 Importance of Water Flow Rate The importance of water flow rate (1.5oz/sec) is: Helps calculate syrup consumption, cups sold and revenue. Prevents drink quality issues based on solution and CO2 ratio CO2 orifice setting is configured to specific water flow rate •...
  • Page 12 CHECK VALVE FAILURE DIAGNOSTICS Usual false diagnostics are: • Control board failure Harness failure Transducer failure • The check valve failure symptoms are: Water pressure and syrup pressure are within +/- 1 psi difference Can’t brix properly Low brix in barrel, and can lead to beater low, frosty compressor, short cycle, and compressor run too long...
  • Page 13 Module Inlet Top View Front View Pressure Transducer Regulated Outlet Extension Module Solenoid Regulated Pressure Settings Pressure Pressure Incoming Regulator Transducer • 70 – 72 psi •Regulated • 60 +/- 2 psi...
  • Page 14 Importance of CO2 Flow Rate • Importance of CO2 flow rate are: High incoming CO2 can cause damage to the water pump – Creates different profiles of frozen product – Prevents drink quality issues based on solution and CO2 ratio –...
  • Page 15 Troubleshooting Solenoids • Manually activate “faulty” solenoid, if doesn’t properly actuate • Disconnect harness from solenoid and measure supply power, range from 22VAC to 28VAC • 0 volt indicates faulty relay board • 22VAC to 28VAC indicates faulty solenoid • Faulty “shorted” solenoid will lead to a burned relay board. When required check and replace relay board.
  • Page 16 Active Charge System Diaphragm Product area before freezing 70psi 30 psi Active Charge Regulator Product area after freezing...
  • Page 17 Importance of Active Charge System • Controls the freeze and thaw of product • Maintains pressure stability of product barrel to prevent P- Max Condition – Below 28 Psig the expansion tank will be filled with product not allowing for expansion to continue, resulting in a P-Max.
  • Page 18 P-MAX DIAGNOSTICS • Active Charge Assembly – Drain Barrel until tank pressure is 0 Psi – Verify active charge regulator is 2 to 4 Psi above the “FULL” pressure using tire gauge, adjust if needed. • Expansion Tank – Verify if there is a torn bladder by determining whether syrup is on CO2 side of expansion tank •...
  • Page 19 P-MAX DIAGNOSTIC FLOW CHART...
  • Page 20 Product Dispensing Valves SDV Valve ADA DDV Valve DDV Valve...
  • Page 21 Scraping & Beating System Scrapping and Beating System Beater Drive Model Coupler Beater bar w/blades Beater Beater Drive Coupling Motor Motor w/Capacitor Motor Mounting Plate Washer Rear Seal Motor Capacitor Beater bar Cold Pack w/blades...
  • Page 22 Importance of Scrapping & Beating System • Importance of Scrapping & Beating System are – To trigger freeze cycle when recognize product in barrel is no long acceptable – To scrape ice off of the barrel wall – To beat and mix product evenly within the barrel to create consistency...
  • Page 23 Failures In The Scraping Beating System • Beater Low triggers a defrost cycle, caused by following: – Low brix, rapid freeze and scrapper blades can’t keep up with the freezing speed – Low refrigerant, over freeze in the back of barrel –...
  • Page 24 Refrigeration System Hot Gas Valve Compressor Filter/Dryer Refrigeration Operation Pressures [Psig] Evaporator Discharge Suction Receivers One Barrel 250 - 275 28-35 Condenser Two Barrels 250 - 275 40-45 Thress Barrels 250 - 275 45-52 Four Barrels 250 - 275 48-55 Access Valve Heat Exchanger Expansion Valve...
  • Page 25 Temperature Sensor Inlet Temperature Sensor Return Temperature Sensor Total Count Return Temperature Sensor Inlet Temperature Sensor...
  • Page 26 Temperature Sensor Orientation and Failures • Temperature Sensor failure will cause following problems Sensor fails and reads 97F at evaporator return will lead to refrigerant flood back, incomplete defrost cycles. Temperature Sensor Sensor fails and reads -40F at evaporator return will starve evaporator Sensor fails and reads -40F at evaporator inlet will lead to refrigerant flood back.
  • Page 27 Temperature Sensor Temperature Sensor Connector Location on Aux Temperature Sensor Connector Location on Main PC Board Board Cold Pack Temperature Connection Configuration JA26 JB26 JC26 Barrel 1 Barrel 2 Barrel 1 Barrel 2 Barrel 3 Barrel 1 Barrel 2 Barrel 3 Barrel 4 Jumper to JA26 Jumper to P26...
  • Page 28 Electrical System Electrical System Model Eeprom Relay Board Main PC Auxiliary Board Clock/Timer Board Contactor LCD Display Lower Board Capacitor Contactor Transformer Transformer Lower Board Compressor Run Cap LCD Display Main PC Board Memory/Timer Chip EEPROM Auxiliary board Relay Board...
  • Page 29 Primary Lower Power board DC Power Supply to Upper Board Control Signals to & from Upper Board Voltage Offset Screw To Upper Board and LED Merchandiser(P10) From Transformer FUSES 12 & 24VAC (P9) To Contactor Coil 24VAC (P8) Beater Motor #1 (2.5 amp fuse) Beater Motor #1 (P7) Beater Motor 2 (2.5 amp fuse) Beater Motor #2 (P6)
  • Page 30 Secondary lower power board DC Power Supply to Auxiliary (AUX) Board Control Signals to & from Auxiliary (AUX) Board Auxiliary (AUX) Board SLOW-BLOW FUSES From Transformer 12 & 24VAC Beater Motor #4 Beater Motor #4 Transformer From Contactor L1 & L2...
  • Page 31 562/563 Electrical Diagram...
  • Page 32 564 Electrical Diagram...
  • Page 33 Navigation System •The keypad is used to operate machine and navigate through operation menus. Key functions are listed below FILL: Activates and deactivate solution and CO2 solenoid to fill barrel BEATER: Activates and deactivate the beater motor BEFROST: Activates and deactivate DEFROST cycle RUN: Activates machine to self sustaning running cycle OFF:...
  • Page 34 Example •To Set Time •Scroll left or right on 1 level of menu until it displays TIME •Press select button • Value to be changed will blink •Press FORWARD or BACK to change setting on blinking value •Press CANCEL if you don’t want to make changes, •Press SELECT to finalize value, and blinking will stop...
  • Page 35 Menu Structure Software Dependant Basic Level Menu Daylight Defrost Wake/Sleep Fault Code Service Software Beeper Alt Lang* Copyright Version Time Date Version Savings Times Times History Menu Enb* Blackout Auto Defrost Sides Defrost* Defrost* Only on units with auto defrost Service Tech Interface Level Menu Machine Manual...
  • Page 36 Basic Level Menu Daylight Defrost Wake/Sleep Fault Code Service Software Beeper Alt Lang* Copyright Version Time Date Version Savings Times Times History Menu Enb* COPYRIGHT Software Released Year VERSION Model, Date Software was Last Updated, Frequency TIME Military Time: 15:00 as 3PM DATE YY-MM-DD DAYLIGHT SAVINGS...
  • Page 37 Service Interface Level Menu Machine Manual Machine Load All Readouts Bevtrak* Settings On/Off Totals Defaults Side Common MACHINE SETTINGS SIDE (1-4) Expansion Setting Range 0 - 6, Defaulted at 3 Thaw/Freeze Setting Range 0 -20, Defaulted at 10 FUB Mode Allows Customer to Formulate Non-Carbonated Product, Defaulted at OFF COMMON SER #...
  • Page 38 Service Interface Level Menu Machine Manual Machine Load All Readouts Bevtrak* Settings On/Off Totals Defaults Side Common READOUTS SIDE (1-4) BEATER % Ranges 0-1000, Indication of Frozen Production in Barrel TANK PRESS Indication of Pressure in Barrel SYRUP PRESS Indication of Syrup Pressure RETURN TEMP Indication of Refrigerant Temperature Flowing Out of Barrel INLET TEMP...
  • Page 39 Service Interface Level Menu Machine Manual Machine Load All Readouts Bevtrak* Settings On/Off Totals Defaults Side Common MANUAL ON/OFF SIDE (1-4) CO2 SOL Activate and Deactivate Solenoid SOLUTION SOL Activate and Deactivate Solenoid BEATER MOTOR Activate and Deactivate Beater Motor DEFROST SOL Activate and Deactivate Solenoid REFRIG SOL...
  • Page 40 Service Interface Level Menu Machine Manual Machine Load All Readouts Bevtrak* Settings On/Off Totals Defaults Side Common Set Totals MACHINE TOTALS SIDE (1-4) DEFROST CYL Total Defrost Cycles SOLD OUT HRS Total Out of Product Hours BEATER HRS Total Motor was In Operation Hours RUN ON HRS Total Compressor On Hours ERROR HRS...
  • Page 41 Service Interface Level Menu Machine Manual Machine Load All Readouts Bevtrak* Settings On/Off Totals Defaults Are You Sure? LOAD ALL DEFAULTS Restore Settings to Factory Settings Are You Sure Yes to Reset, No to Cancel Reset...
  • Page 42 Expansion Adjustment Expansion setting is used to increase or decrease Refill and Full pressure. Table below demonstrates the effects of change in Refill and Full pressure •Higher Barrel pressure represents higher expansion •Lower Barrel pressure represents lower expansion EXPANSION SETTINGS VALUE REFILL FULL...
  • Page 43 Thaw/Freeze Adjustment Thaw/Freeze setting is used to increase or decrease Freeze and Thaw. Table below demonstrates the effects of change in Freeze and Thaw beater % •High beater % represents liquidly frozen product •Low beater % represents firmer frozen product THAW/FREEZE SETTINGS VALUE FREEZE BEATER %...
  • Page 44 Voltage Offset Adjustment Machine Readouts Method 1 “Voltage Offset” Settings •Measure L1 and L2 voltage at contactor when machine is off, Side Common Side Common •Volt Offset = Measured Voltage – Line Volt O Pressure •Example Ser # Pressure Volt Offset Regulated CO Blink Out of Line volt...
  • Page 45 Troubleshooting UPB • All LED lights on Upper Board should be SOLID GREEN under normal operation. • Dim or Off LED lights: • Check each test point and verify tolerances are within 5 % of +15 ,-15, and 5 DC voltage. •...
  • Page 46 Test Points UPB TP1. +5 VDC for Relay Board coils, comes from Lower Power Board TP2. +5 VDC for logic power supply, comes from Lower Power Board TP10 TP3. +15VDC analog voltage for temp. & pressure sensor readouts TP5. -15 VDC analog voltage for temp. & pressure sensor readings TP6.
  • Page 47 UPS E-Prom Replacement Record machine settings such as • “Voltage Offset” , Defrost Times and Wake/Sleep Times Disconnect power to machine Notch Up Remove old E-PROM with chip puller Install new E-PROM with notch up. Reconnect power to machine. Wait 1 minute for software to load Scroll to Load All Defaults to reset Re-enter recorded values from step 1 back to the machine settings Press “Off”, “Defrost”, then “Run”...
  • Page 48 Troubleshooting LPB Ground L2 L1 Lower power board • All Test Lights on LPB should be SOLID GREEN. (under normal operation) • If any LED lights are DIMMED or ABSENT on LPB, disconnect P13 and P14 from LPB to gain access to the test points •Use Ground TP-4(GND) to check voltage at test points TP-1 (+15VDC),TP-2 (+5VDC) and TP-3 (-15VDC) •If voltage not present, test voltage at TP8 for 24VAC and TP18 for 12VAC...
  • Page 49 Troubleshooting Condenser fan • During defrost, fan does not normally operate, but there are some units that have the option to turn it on during defrost. • The fan will only turn on manually, if the compressor is turned • Disconnect wire harness from P12 on LPB and inspect connection for separated pins or broken wire harness.
  • Page 50 Initial Start-Up and Freeze 1. Validate the setups matches 56X Setup Requirements 2. Perform visual inspections for leaks 3. Load All Defaults 4. Fill barrel with CO until tank pressure reaches to 10 psig, then purge barrel until tank pressure is at 0 psig. Repeat this process for 3 times to empty out the air. 5.
  • Page 51 Status Lights Annunciator Pad Sold Out Light...
  • Page 52 LCD Messages DISPLAY MEANING HOT PRODUCT SHUTDOWN Comp on with both temp sensors are @ 90F or below -20° for 3min and 20sec Cmp ran too long-OFF Comp on for longer than 90 mins DEFPRO/RUNPRO Product out condition for more than 15 min. Stop BTR LongPrd out RunPmx Tank pressure at 55psig for more than 15 min...
  • Page 53 LCD Messages MEANING DISPLAY Defrost mode from machine OFF mode. DefBtr Defrost is in Waiting mode DefWt Machine is in defrost mode Defrst Defrost suspended due to freezing of other barrels DefSpd Out of product condition during defrosting DefPrO Tank pressure in above FULL pressure in filling mode FILL H Freeze mode from machine OFF mode.
  • Page 54 Preventive Maintenance Manually activate CO Solenoids to assist emptying barrels. Deactivate all CO Solenoids and depressurize barrels. Perform visual inspections for leaks Replace rear seals per PM recommendation, and repair DDV valve as needed. Sanitize unit following recommended procedures. Clean air filter. Follow “Initial Start-Up and Freeze”...
  • Page 55 Remote Condenser...
  • Page 56 NOTE: Blow out the copper line set with nitrogen to remove any foreign debris before completing the connections to the condenser and FBD dispenser. c.Complete piping to remote condensers on roof. Secure with same unistrut and cushioned clamps. d.Connect signal wire and 230V power supply to corresponding connections in disconnect box. See wiring diagram for hookup details (see Figure 2).
  • Page 57 Remote Condenser Layout...
  • Page 58 Remote Trap Layout...
  • Page 59 Remote Refrigerant Charge Matrix FBD remote condenser Heatcraft remote condenser...
  • Page 60 Product Warranty...
  • Page 61 • The warranty does not apply to destruction or damage caused by alterations, using parts other than FBD authorized replacement parts, risks of transportation, damage by fire, flood or acts of God.
  • Page 62 Product Warranty FBD WARRANTY POLICY PARTS REQUIRED FOR RETURN UNDER WARRANTY Upper Header Compressor Failed spare parts which • Relay PCB Solution Modules Pressure Transducer Cold Pack carry a 90-day part warranty Temperature Sensor CO2 Modules MUST BE RETURNED. Beater Motors Refrigeration Hot Gas Bypass Valves •...
  • Page 63 Product Warranty ALL RETURNED PARTS MUST HAVE AN RGA# AND A COMPLETED WARRANTY CLAIM FORM...
  • Page 64 Thank you.

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