MODEL FBD352 FROZEN BEVERAGE DISPENSER

Transcription

1 FBD Partnership, LP P.O. BOX 8597 SAN ANTONIO, TX 788 USA FAX FBD TECHNICAL SUPPORT TECHNICAL SUPPORT FAX INSTALLATION AND OPERATION MANUAL FOR THE MODEL FBD35 FROZEN BEVERAGE DISPENSER THIS MANUAL APPLIES TO STANDARD PRODUCTION FBD35 FROZEN BEVERAGE DISPENSERS THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This manual must be read and understood BEFORE the installation and operation of the dispenser. FBD35 NOTICE: The information contained in this document is subject to change without notice. FBD MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED 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. 03 FBD Partnership, LP. All Rights Reserved. This manual supersedes and replaces , dated //0, and is designated as Revision 03. Please refer to the FBD web site ( for information relating to FBD Installation, Operation and Service Manuals, Instruction Sheets, Technical Bulletins, Service Bulletins, etc. REV 03: 06/8/03 FBD Part Number:

2 SPECIFICATIONS FOR THE FBD35 DISPENSER DIMENSIONS Width 7.0 inches (43 mm) Depth 7.0 inches (686 mm) Height (Standard Counter top Unit) 34.0 inches (864 mm) Height (Optional Roll Around Unit/Stand) 75.4 inches (98 mm) WEIGHT Shipping 97 pounds (34.7 kg) Empty 0 pounds ( 99.8 kg) Operational 36 pounds (07.0 kg) WATER REQUIREMENTS Minimum flowing pressure 30 psig (07.0 kpag) Maximum static pressure 70 psig (483.0 kpag) CARBON DIOXIDE (CO) REQUIREMENTS Minimum pressure 70 psig (48.6 kpag) Maximum pressure 7 psig (496.4 kpag) SAFETY PRECAUTIONS We at FBD are concerned about your safety. Please carefully read the following precautions before working with FBD35 units. This will familiarize you with proper equipment handling techniques. LIFTING To avoid personal injury or damage, do not attempt to lift the unit without help. The use of a mechanical lift is recommended The empty FBD35 unit weighs approximately 0 pounds (99.8 kg). Use gloves to protect hands from being injured by the edges of cross bracing if lifting by hand. Use proper equipment and lifting techniques when lifting or moving equipment. The unit is top heavy. Maintain unit in a vertical, upright position when lifting and positioning the unit. ELECTRICAL This unit must be properly electrically grounded to avoid possible fatal electrical shock or serious injury to the operator. The power cord is provided with a three prong grounded plug. If a three-hole grounded electrical outlet is not available, use an approved method to ground the unit. Only qualified electricians should perform this task and the work performed should meet all applicable codes. Always disconnect electrical power to the unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components of electrical wiring. CARBON DIOXIDE (CO) CO (carbon dioxide) displaces oxygen. Strict attention must be observed in the prevention of CO gas leaks in the entire CO and soft drink system. If a CO gas leak is suspected, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. To avoid personal injury and/or property damage, always secure CO cylinders in an upright position with a safety chain to prevent cylinders from falling over. Should the valve become accidentally damaged or broken off, a CO cylinder can cause serious personal injury.

3 QUICK REFERENCE SHEET FOR INSTALLING FBD UNITS NOTE: This guide is for quick reference only. It is not intended to replace important detailed information contained in this Installation, Operation and Service Manual. Thoroughly read the entire manual before attempting installation. Checkpoints Verify the line voltage is between 08 VAC and 3 VAC. NOTE: For 30 VAC applications, voltage should be between 5 and 45 VAC. Adjust the CO secondary regulator to between 58 and 6 psig. Verify on the unit s display that the syrup pressures are at about 70 psig static. Verify the water pressure is about 85 psig. Adjust the water fl ow rate to.5 ounces per second. Adjust the Brix to between 3.5 and 5.0. Fill barrels with product. Select Barrel One, press DEFROST and then RUN then select barrel, press DEFROST and then RUN. The freeze down will take approximately 30 minutes, depending on the initial temperature of the product of the barrel. See Sections 5 and 6 of this manual for further details on each of these checkpoints and dispenser installation. NOTE: If the unit has been in storage for longer than 90 days, FBD recommends that the rear seals be replaced. 3

4 OPERATING REQUIREMENTS AIR FLOW WEIGHT (50.8 mm) (50.8 mm) (304.8 mm) (50.8 mm) 35: 36 LB (7 Kg) POWER CO 35: 08-3 VAC 60Hz, 0 A, PH 35: 5-45 VAC 50Hz, 0 A, PH 3/ psig SYRUP H0 3/ psig 3/8 30 psig MIN FLOWING 70 psig MAX STATIC 4

5 NOTES 5

6 TABLE OF CONTENTS SPECIFICATIONS... SAFETY PRECAUTIONS... QUICK REFERENCE SHEET FOR INSTALLING FBD UNITS TABLE OF CONTENTS...6. PREPARING THE LOCATION...7. LOCATION REQUIREMENTS...7. ADDITIONAL REQUIREMENTS...7. RECEIVING AND UNPACKING UNIT...7. RECEIVING...7. UNPACKING INSTALLING THE UNIT FLUSH MOUNTING ROLL AROUND CART CONNECTING TO ELECTRICAL POWER VAC/60 HZ SERVICE VAC/50 HZ SERVICE CONNECTING WATER, CO, AND SYRUP SUPPLIES WATER SUPPLY CO SUPPLY SYRUP SUPPLY STARTING THE UNIT INITIAL POWER-UP CO PURGE BRIXING FILLING THE BARREL... CRITICAL REGULATOR AND FLOW CONTROL SETTINGS OPERATION OF THE DISPENSER OPERATING ELECTRONIC CONTROLS MENUS...4 FBD35 MENU STRUCTURE CLEANING, SANITIZING AND MAINTAINING THE UNIT PREVENTIVE MAINTENANCE GENERAL INFORMATION REQUIRED CLEANING SOLUTION DAILY CLEANING OF THE UNIT SANITIZING THE SYRUP SYSTEMS BASICS OF OPERATION MAKING ADJUSTMENTS TO THE FBD35 UNITS NO DEFROST TIME BLOCK SETTING WAKE/SLEEP TIMES CRITICAL INFORMATION BARRELS 90% FULL ON INITIAL SET UP LINE VOLTAGE DROP LONG TUBING RUNS DRINK TOO HARD AND COLD...0 0,5 DRINK TOO LIQUID CHANGING THE DEFAULT EXPANSION SETTING CHANGING THE THAW-FREEZE VALUES.... TROUBLESHOOTING GUIDE... MECHANICAL... ELECTRICAL...3 ELECTRONIC CONTROLS...4 REFRIGERATION...4 DRINK QUALITY...6 LCD DISPLAY ERROR MESSAGES...7 LCD DISPLAY MESSAGES...9 LCD DISPLAY ERROR MESSAGES...30 WARNING LIGHTS...3. ILLUSTRATIONS, PARTS LISTINGS, AND DIAGRAMS...3. MOUNTING DIAGRAM...3. FLOW DIAGRAM/SCHEMATIC

7 TABLE OF CONTENTS (CONTINUED).3 REFRIGERATION FLOW PATH - FBD ELECTRICAL BOX SCHEMATIC, 5 VAC - FBD ELECTRICAL BOX SCHEMATIC, 30 VAC - FBD PREPARING THE LOCATION. LOCATION REQUIREMENTS A. The operational FBD35 counter top units weigh 36 pounds (07.0 kg) and each unit requires a sturdy, level surface for placement (see Safety Precautions, page ). When selecting a counter location, ensure the counter will support the unit weight plus the weight of any additional equipment placed near it. B. Adequate space above and behind a unit (See Figure.) is required to allow:. Removal of side panels, if service is necessary.. Air circulation around vents on sides, back, and top of unit. C. A well-ventilated room is required with a temperature of 50 F to 90 F (0 C to 3.5 C). Figure. The environment, however, should be stable (FBD35 Unit Displayed) and not subject to abrupt changes in temperature. D. The unit should not be exposed to direct sunlight or chemicals.. ADDITIONAL REQUIREMENTS (TO BE PROVIDED BY THE CUSTOMER) A. CO supply with a pressure of 70-7 psig ( 48.6 to kpag). If a bulk CO supply is used, the pressure should be set at 5 to 0 psig (79.9 to 87.4 kpag) and a secondary regulator installed at the unit to reduce the pressure to 70-7 psig. B. Syrup supply using Bag-in-Box or five (5) gallon syrup tank (figal). C. Water supply with a minimum flowing pressure of 30 psig (06.8 kpag) and a maximum static pressure of 70 psig (48.6 kpag).. RECEIVING AND UNPACKING UNIT. RECEIVING 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.. UNPACKING A. Cut banding from shipping carton and remove carton by lifting up. Remove protective side panels and four corner protectors. B. Contact the dealer if any parts are missing or damaged. C. Remove side panels from unit. D. Inspect unit for concealed damage. If evident, immediately notify delivering carrier and file a claim against same. 3. INSTALLING THE UNIT There are several ways to install the unit. Follow the appropriate directions for the method you are using. Ensure that there is a minimum of twelve () inches (30.48 cm) open space ABOVE and two () inches (5.08 cm) open space on at least one side and BEHIND the unit (see Figure.) for proper ventilation. 7

8 3. FLUSH MOUNTING A. Flush mounting is when the unit is mounted on a counter top. Use the following guidelines to ensure a proper installation.. Be sure the counter will support the weight of the specific FBD unit being installed and the full length of the unit (including the drip tray). If permanently mounting the unit to a counter top, use the information in Section. to mark and drill the four (4) mounting holes in the counter top.. Place unit on the counter using a lift (see Safety Precautions, page ). 3. If permanently mounting the unit to a counter top, install four (4) 3/8-6 UNC bolts (not included) through the underside of the counter and into the frame [through the four (4) mounting holes drilled in the step just above]. 4. When the dispenser is to be permanently mounted to the counter top, seal dispenser base to counter top with a bead of clear silicone caulk or sealant which provides a smooth and easily cleaned bond to the counter. 3. ROLL AROUND CART A. A roll around cart is used when a suitable counter top is not available and allows the unit to be moved for cleaning. These can be purchased from the dealer.. Lock the wheels on the roll around cart.. Place the unit on the cart (see Safety Precautions, page ). 3. Secure the unit to the cart by installing four (4) 3/8-6 UNC bolts (not included) through the cart mounting holes and into the frame of the unit. 4. CONNECTING TO ELECTRICAL POWER 4. 5 VAC/60 Hz SERVICE A. Use the following guidelines to connect electrical power to the machine for 5 VAC/60 Hz service.. The machine requires single phase 5 VAC. If line voltage is below 08 VAC or above 3 VAC, a 0% buck and boost transformer must be used. Operation below 08 VAC or above 3 VAC may damage the unit and cause inconsistent performance. This also voids all warranties.. This unit will not work properly if there is more than a 0V voltage drop in the power supply line between the power source and the machine. A drop of more than 0V indicates undersized wiring or excessively long runs. 3. The unit must be installed on a single branch circuit (on a circuit by itself), installed as follows: a. The 5 VAC/60 Hz FBD35 Units must be protected by 0 Amp service and a 0 Amp fuse (or circuit breaker). It is recommended that a 3 conductor, 0 Amp receptacle (NEMA #5-0R) be used. Using a voltmeter, check voltage to ensure proper wiring and voltage. 4. Do not connect the unit to power at this time VAC/50 Hz SERVICE A. Use the following guidelines to connect electrical power to the machine for 30 VAC/50 Hz service.. The machine requires single phase 30 VAC. If line voltage is below 5 VAC or above 45 VAC, a 0% buck and boost transformer must be used. Operation below 5 VAC or above 45 VAC may damage the unit and cause inconsistent performance. This also voids all warranties.. The 30 VAC/50 Hz unit must be installed on a single branch circuit (on a circuit by itself), installed as follows: a. The Unit must be protected by 0 Amp service and a 0 Amp fuse (or circuit breaker). It is recommended that a 3 conductor, 0 Amp receptacle be used. Using a voltmeter, check voltage across both hot legs (40 VAC) and between ground and each hot leg 8

9 (0 VAC) to ensure proper wiring and voltage. b. If connected to a delta three phase electrical system, use the two low voltage legs (check each leg to ground to ensure the low voltage legs are used). Using the high voltage leg will cause the machine to malfunction. In some locations, the power supply may have only one 30 volt hot leg. If so, ensure the hot leg goes to the L contactor in the electrical box. 3. This unit will not work properly if there is more than a 0V voltage drop in the power supply line between the power source and the machine. A drop of more than 0V indicates undersized wiring or excessively long runs. 4. Remove the plug from the power cord and feed the cord through the strain relief located at the back of the unit. Tighten the strain relief securely. Reinstall the plug on the power cord and check for continuity on the plug across both hot legs and no continuity between each hot leg and ground B. Do not connect the unit to power at this time. 5. CONNECTING WATER, CO, AND SYRUP SUPPLIES (SEE FIGURES 5. THROUGH 5.3) 5. WATER SUPPLY IMPORTANT A WATER PUMP AND WATER REGULATOR ARE INSTALLED IN THE BASE OF THE MACHINE. A WATER FILTER SHOULD BE INSTALLED IN THE WATER LINE BEFORE BEING CONNECTED TO THE MACHINE. FLUSH THE FILTER WITH SEVERAL GALLONS (-5 LITERS) OF WATER PRIOR TO USE TO ENSURE BLACK CARBON FINES ARE NOT FED INTO THE BARRELS. NOTE: Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained in accordance with federal, state and local codes. A. Connect a backflow prevention assembly to the water inlet of the unit (see Figure 5.). A backflow prevention assembly is available from FBD under PN CAUTION: THE BACKFLOW PREVENTION DEVICE (FBD PN ) MUST HAVE A DRAIN LINE CONNECTED TO THE VENT (SEE FIGURE 5.). THIS IS REQUIRED TO DRAIN AWAY WATER IN THE EVENT OF A BACKFLOW SITUATION OR A FAILURE OF THE BACKFLOW DEVICE. FAILURE TO DO SO MAY RESULT IN FLOODING OF THE ESTABLISHMENT. B. Fabricate a 3/8 inch supply line for connecting the unit to a potable water supply (a 3/8 barb by /4 flare nut fitting will be required). C. Install a shutoff valve in the water line as close to the unit as practical and convenient. The use of a water filter is recommended. D. Clear the line by running a minimum of two () gallons (7.57 liters) of water through the line before attaching the line to the unit. E. Connect the line to the bulkhead fitting labeled WATER located at the rear of the unit (see Figure 5.). F. Route the drain line to a drain location. G. Do not turn water on at this time. 5. CO SUPPLY NOTE: The CO supply may come from either an independent tank/regulator or a bulk CO system. If connected to a bulk CO system, install a shutoff valve and a secondary supply regulator [to be set at 70-7 psig ( kpag)] in the line. Ensure that the CO line comes directly from the main branch on the bulk supply and is not branched off down line. Failure to do so may starve the unit of CO flow and cause performance problems. A. Fabricate a 3/8 inch supply line for connecting the unit to a CO supply. 9

10 DRAIN TO UNIT WATER SUPPLY SYRUP RIGHT SYRUP LEFT CO WATER Backflow Prevention - Water Connections Figure 5. Bulkhead Fittings, FBD35 Figure 5. B. Connect the supply line to the CO bulkhead fitting labeled CO located at the rear of the unit (see Figure 5.). A 3/8 barb by /4 flare nut fitting will be required to make connection. C. Splice a barb cross into the CO supply line and run two () lines to the syrup pump CO inlets. Or If a Figal tank will be utilized, splice a barb cross into the CO supply line and run two () lines to tank location and install CO tank couplers to end of lines. D. Do not turn on the CO at this time. 5.3 SYRUP SUPPLY A. 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. B. BIB SUPPLY. Fabricate the appropriate number of 3/8 inch supply lines for connecting the unit to the syrup pumps.. Connect the syrup lines to the bulkhead fittings as follows: a. For the FBD35 Unit - Connect to bulkhead fittings labeled SYRUP LEFT and SYRUP RIGHT located at the rear of the unit (see Figure 5.). 3. Do not turn on the CO at this time. NOTE Installations requiring long runs of tubing [5 feet or more (7.6 meters)] may encounter pressure fluctuation problems. The machine s sensors may indicate that the machine is out of syrup, water, or CO. To avoid pressure fluctuations, consider the following solutions. A. Increase the tubing size to / inch diameter. B. Install booster pumps in the supply lines. Use a vacuum regulating valve with syrup booster pumps. C. Increase primary CO regulator pressure from bulk or tank CO to 05-0 psig (73.9 to 87.4 kpag). A secondary regulator will be necessary for syrup pumps to avoid exceeding manufacturer s recommended operating pressures. Set the secondary regulator to 70-7 psig ( kpag). C. FIVE GALLON (FIGAL) TANK SUPPLY. Fabricate the appropriate number of 3/8 inch supply lines for connecting the unit to the syrup tanks.. Connect the syrup lines to the bulkhead fittings as follows: a. For the FBD35 Unit - Connect to bulkhead fittings labeled SYRUP LEFT and SYRUP RIGHT located at the rear of the unit (see Figure 5.). 3. When using five gallon (figal) syrup tanks, a Syrup Soldout device and tank couplers must be used on each line. Warranties will be void if a Soldout device is not installed. a. The OUT OF devices in the machine will not function properly without the use of a 0

11 Syrup Soldout device. If the OUT OF devices do not function, the machine will supply only water to the barrel and it will freeze up.. When replacing a figal, ensure that the syrup line to the dispenser is attached to the figal before the CO line is attached to the figal. This will allow the SRV to work properly. 3. To operate the Soldout device, press the restart button after syrup tank is changed. The product out light beside each barrel will then go out and product will refreeze. 4. Do not turn on the CO at this time. 6. STARTING THE UNIT IMPORTANT THE FBD35 SETUP IS SIMILAR BUT NOT EXACTLY THE SAME AS OTHER FBD UNITS. YOU MUST FOLLOW THESE PROCEDURES STEP-BY-STEP TO ENSURE THE PROPER SETUP IS ACCOMPLISHED NOTE Do not adjust the brix with the water flow control setting unless you are not able to obtain the desired brix with adjustments to the syrup flow control. Brix reading is affected by temperature. Samples taken from the barrel should be at the same temperature as from the sample valve. 6. INITIAL POWER-UP A. Plug unit in to the electrical power. The graphics display should illuminate. Check for the display of information on the LCD keypad (this will read COPYRIGHT on bottom line of LCD display). 6. CO PURGE A. Follow these steps to purge air from the barrels:. Turn on CO supply to the unit and adjust the secondary regulators to 60 psig (44 kpag). NOTE This regulator is a non-vent regulator. This means that if you lower the regulator setting, you will need to dispense drinks (with Fill activated) until cylinder begins to refill before the new setting will register on the gauge.. Close the inline water and syrup shutoff valves or adjust the water and syrup flow controls all the way out (counter-clockwise). 3. Scroll down to SYRUP SOL in the Menu and press the SELECT key to fill the barrel with CO. 4. After about five (5) seconds, pull the pressure relief valve on the faceplate until no more air is heard escaping. 5. Repeat previous step two more times. 6. Press Select again to turn off. B. Select the other barrel and repeat the purge process for that barrel. 6.3 BRIXING A. With the unit plugged in, press the STOP ALL button on the display to ensure the unit is in the OFF state. CAUTION CHECK ALL SUPPLY LINES TO ENSURE THAT THEY ARE CONNECTED TO THE CORRECT FITTINGS. IF LINES ARE NOT CONNECTED PROPERLY, COMPONENTS WILL BE DAMAGED. B. Open the water supply valve and check all water line connections for leaks. C. Connect the BIB connectors, or the syrup and CO couplers, to figal tanks. Check all syrup supply connections at the rear of the machine for leaks D. Open the CO tank valve and adjust the incoming regulator to 70-7 psig (48.6 KPag to kpag). Check all CO line connections for leaks.

12 E. Adjust the CO secondary regulators (located inside the machine) to read 58-6 psig (400.0 to 47.0 kpag). F. Close Syrup flow controls by backing the right adjustment screw all the way out, by turning counter-clockwise (see Figure 6.). G. Turn off the CO with the CO shut off valve (see Figure 6.). H. Adjust the water flow control two and one quarter ( /4) turns clockwise. I. Open the sample valve and check the water flow rate and set to provide a flow of 5 ounces in 0 seconds using a graduated container. Do this for every solution module. Turn the water flow control (left adjustment screw) clockwise to increase flow or counter-clock-wise to decrease flow. Repeat process for the remaining barrel. WATER PRESSURE TRANSDUCER FLOW CONTROL ADJUSTMENT (WATER) REGULATED CO PRESSURE GAUGE CO REGULATOR Figure 6. SAMPLE VALVE OUTLET STEM SHUTOFF (TO OPEN SAMPLE VALVE) SYRUP PRESSURE TRANSDUCER FLOW CONTROL ADJUSTMENT (SYRUP) CO SHUTOFF VALVE J. Pre-set Syrup flow by turning Syrup flow controls in two and one fourth ( /4) turns (turning clockwise). K. Place a container under the sample tube and turn the sample valve until a good water and syrup mixture is obtained (see Figure 6.). This sample should be discarded. L. Place a cup under sample tube and open the sample valve until 9 - ounces ( liter) have been dispensed into the cup. M. Measure the brix with a refractometer. Set brix to between 3.5 and 5.0 by adjusting the syrup brix flow controller clockwise to increase brix level or counter-clockwise to decrease brix level. After making any brix adjustments, open the sample valve for a few seconds to flush and then discard. Run 9 - ounce sample to check brix again. N. Repeat steps H through M above for the other barrel. 6.4 FILLING THE BARREL A. Open CO shut off valve. B. Select Barrel, then the FILL button to begin filling the barrel with product. If the barrel does not fill, gently pull the relief ring until filling begins and then release. As the barrel fills, the pressure in the barrel will increase until it rises above the fill point pressure. At this point, the barrel 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 barrel is 90% full (level with relief valve), then press Fill button to turn OFF. Fill one () barrel at a time. C. Repeat Step B for the remaining barrel. D. Select Barrel and then press the FILL button, press the DEFROST button and then the RUN button to begin the freezing process. Select Barrel and repeat the process. The unit will complete a minimum forty-five (45) second defrost cycle on each barrel and then begin the freeze process. E. After an initial freeze down, the product will be frozen and ready to dispense. NOTE On an initial freeze down, products must be given adequate time to absorb CO. Until CO is properly and adequately absorbed, drinks may appear to be wet or heavy. If after allowing time for absorption adjustments are deemed necessary, refer to Section 9 for instructions. F. Re-check CO, Water, and Syrup lines for leaks.

13 7. OPERATION OF THE DISPENSER 7. OPERATING ELECTRONIC CONTROLS A. The electronic machine controls are designed to provide a logical sequence of operation. System operating parameters are selected and set from a menu (see Figure 7. for the Menu structure). RUN/OFF DEFROST BARREL BARREL SELECT SCROLL BEATER FILL FBD35 Keypad Figure 7. B. Buttons (see Figure 7.). The first 4 buttons listed are process buttons and are double acting switches. Pressing the button once activates the process. Pressing the button a second time deactivates the process. Take care not to double press the buttons when first activating a process. The RUN/OFF button initiates the freeze process. After pressing this button, the RUN/OFF beater motors will run for five (5) seconds before the compressor starts. Run also maintains the flow of product into the barrels when needed. You should always press the DEFROST button first to baseline the unit. BEATER DEFROST The BEATER button activates the beaters inside the barrels. The beaters can be activated to mix the slurry. NOTE: The beaters start automatically when the RUN or DEFROST buttons are pressed. The DEFROST button allows the user to manually defrost the barrel. Because the unit automatically defrosts during the day, it is not necessary to defrost manually during normal daily operation. FILL SELECT The FILL button starts the fill process for each barrel. Each barrel should be filled to 90% of capacity (level with the pressure relief vent valves) prior to start-up. See Section 6.4 for specifics. The SELECT button is used to manually turn items ON/OFF and allows adjustment to settings. (Buttons display continued on next page) 3

14 SCROLL The SCROLL buttons are used to navigate through the MENU and change setting values. BARREL BARREL Selects which barrel to make or view changes to functions, valves, or settings. STOPS ALL FUNCTIONS FOR ALL BARRELS (FILL, FREEZE, DEFROST, AND BEATER). Exits Wake/Sleep mode menu. C. How to Access and Change Values The following steps allow the parameters of the control system to be monitored and changed.. Only the MENU items in blue, purple and orange (see Figure 7.) can be modified. The other items display information or the status of the unit.. Select the barrel to make changes to by pressing the # or # key. 3. Scroll down to the value that needs to change. 4. Pressing the SELECT button will manually turn on or off the Manual ON/OFF items. 5. To make changes to the displayed setting, press the SELECT button. When a value in the lower half of the display begins to flash, this indicates the value can be changed. NOTE: Common settings or common readouts are values or readings that affect or are common to both barrels. The values can be viewed or changed through either of the barrel menus (see Figure 7.). 7. MENUS A. There are three main types of menus: Readouts, Settings and Manual ON/OFF (see Figure 7.).. Readout menus are for information and trouble shooting and cannot be adjusted. Unit Copyright Version HO Pressure Tank Pressure Beater % Syrup Pressure Return Temp READOUTS Shows unit description Displays copyright screen. Shows current version of the software installed. Displays water pressure at the header. Displays current pressure in each barrel. Represents the Frozen/Thaw status of each barrel. Displays syrup pressure at the header for each barrel. Represents the current temperature of the return refrigerant line to the compressor. 4

15 0-0 (5% per point) ± 50 Points 0-6 (Factory Setting =3) 35X MENU STRUCTURE MAIN MENU Barrel Barrel Unit Unit Copyright Copyright Version Version Time Time DL Saving DL Saving Date Date H0 Pressure H0 Pressure Tank Pressure Tank Pressure Beater % Beater % Syrup Pressure Syrup Pressure Return Temp Return Temp Product out ON/OFF Product out ON/OFF Syrup Sol ON/OFF Syrup Sol ON/OFF Ref Sol ON/OFF Ref Sol ON/OFF Def Sol ON/OFF Def Sol ON/OFF FAN ON/OFF FAN ON/OFF Compressor ON/OFF Compressor ON/OFF FUB Mode ON/OFF FUB Mode ON/OFF Thaw/Freeze 0-0 (5% per point) ± 50 Points Thaw/Freeze Expansion 0-6 (Factory Setting =3) Expansion No Def St. START TIME, ENDS IN 3 HRS No Def St. No Def St. START TIME, ENDS IN 3 HRS No Def St. WAKE/SLEEP WAKE: 6AM - PM SLEEP: 6PM AM WAKE/SLEEP RUN/OFF DEFROST BARREL BARREL SELECT SCROLL BEATER FILL CLEAR GLASS WINDOW READOUTS COMMON READOUTS CANNOT CHANGE Manual ON/OFF CHANGE BY PRESSING SELECT KEY Common Settings CHANGE BY PRESSING SELECT KEY AND PRESSING UP/DOWN KEYS TO Settings CHANGE THE VALUES UP/DOWN ARROWS USED TO NAVIGATE MENU AND CHANGE SETTING VALUES ON/OFF BUTTON INITIATES THE FREEZE PROCESS. THIS ALSO TURNS BARREL OFF THE DEFROST BUTTON MANUALLY DEFROSTS THE BARREL TURNS THE BEATER MOTOR ON/OFF USED TO MANUALLY TURN ON/OFF ITEMS, IT ALSO ALLOWS CHANGES TO SETTINGS FILLS THE BARREL TO A PRE-SET PRESSURE STOPS ALL FUNCTIONS (FILL, FREEZE, DEFROST AND BEATER) FOR ALL BARRELS FBD35X Series, Menu Structure Figure 7. 5

16 . Settings menus are for making adjustments to machine settings. SETTINGS TIME Sets the time of day. The machine uses a 4 hour format (military time) clock. The clock has a battery backup which maintains correct time even if not connected to electrical power. DL Saving Sets Daylight Saving Time (DST) option. ON for use of DST; OFF for use of Standard time. Date Displays current date. Thaw/Freeze Changes the temperature of the drink for each barrel (see Section 9. for more detail). Expansion Adjusts the expansion in the drink for each barrel (see Section 0.4 through 0.7 for more information). NO DEFST ST Sets the start times for a three (3) hour window with NO DEFROST. The settings affect both barrels and will not defrost either barrel during this NO DEFST ST time block. These settings can be changed from either barrel menu. WAKE / SLEEP Wake sets the time at which the machine will automatically turn on. Sleep sets the time at which the machine will automatically turn off. 3. Manual ON/OFF menus turn items or functions on or off. Manual ON/OFF Product out ON/OFF Turns the sold out light on and off manually for each barrel. Syrup Sol ON/OFF Activates/Deactivates the solenoid for the solution module for each barrel. Ref Sol ON/OFF Activates/Deactivates the refrigeration solenoid for each barrel. Def Sol ON/OFF Activates/Deactivates the defrost solenoid. Compressor ON/OFF Turns the compressor on and off. FUB Mode Allows the use of a FUB product (no CO in the product). Default setting is OFF. Select ON to initiate the mode. User must turn off CO valve at solution module when using FUB mode. 8. CLEANING, SANITIZING AND MAINTAINING THE UNIT 8. PREVENTIVE MAINTENANCE An annual Preventive Maintenance schedule is recommended by FBD and should include the following steps. A. Clean Air Filter The air filter should be cleaned every 90 days, or more frequently as required by the installation environment. A dirty air filter can reduce performance of the machine.. Open merchandiser.. Remove filter by grasping filter edge protruding from the front cover. 3. Wash filter with clean water; shake off excess water. 4. Allow filter to dry. 5. Reinstall filter. 6. Close merchandiser. B. Check Brix refer to Section 6.. C. Replace rear seals (seals are replaced from the front and do not require removal of the beater motor). D. Inspect and replace scraper blades if necessary. E. Sanitize syrup systems refer to Section 8.4. F. Check all fittings and components for leaks. Repair if necessary. G. Verify Time and Date settings. Adjust as necessary. 6

17 8. GENERAL INFORMATION NOTE The following cleaning and sanitizing procedures pertain to the FBD equipment identified by this manual. If other equipment is being cleaned, follow the guidelines established for that equipment. A. FBD equipment (new or reconditioned) is shipped from the factory, cleaned and sanitized in accordance with NSF guidelines. After installation is complete, the operator of the equipment must provide continuous maintenance as required by this manual and/or state and local health department guidelines to ensure proper operation and sanitation requirements are maintained. B. Cleaning and sanitizing should be accomplished only by trained personnel. Sanitary gloves are to be used during cleaning and sanitizing operations. Applicable safety precautions must be observed. Instruction warnings on the product being used must be followed. C. Water lines are not to be disconnected during the cleaning and sanitizing of syrup lines to avoid contamination. D. Do NOT use strong bleaches or detergents. They tend to discolor and corrode various materials. E. Do NOT use metal scrapers, sharp objects, steel wool, scouring pads, abrasives, solvents, etc., on the dispenser. F. Do NOT use hot water above 40 F (60 C). This may damage certain materials. 8.3 REQUIRED CLEANING SOLUTION A. A mild soap solution (for example, Ivory Liquid, Calgon, etc.) mixed with clean, potable water at a temperature of 90 to 0 F (3 to 44 C) should be used to clean the external components of the equipment. Any equivalent mild soap solution may be used as long as it provides a caustic based, non-perfumed, easily rinsed mixture containing at least two () percent sodium hydroxide (NaOH). Rinsing must be thorough and use clean, potable water which is also at a temperature of 90 to 0 F (3 to 44 C). B. Any sanitizing solution may be used as long as it is prepared in accordance with the manufacturer s written recommendations and safety guidelines, and provides 00 parts per million (PPM) available chlorine. Please note that a fresh water rinse cannot follow sanitization of equipment. Purge only with the end use product until there is no after taste in the product. This is an NSF requirement. 8.4 DAILY CLEANING 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 in accordance with Section 8.3.A above. 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. 8.5 SANITIZING THE SYRUP SYSTEMS The FBD35 unit should be sanitized annually during a regularly scheduled Preventive Maintenance Program as recommended by FBD. The following procedure takes about one () hour. A. Press the OFF button, followed by the DEFROST button, for both barrels. B. Turn syrup and water off at the inlet of the unit or at the source. C. After defrost is complete, activate the syrup solenoid on each barrel. D. Place a container under the dispensing valve and empty the barrels. Activate the beaters to facilitate removal of product. E. Turn off the syrup solenoids and beaters after the barrels are empty. F. Prepare five (5) gallons of sanitizing solution in accordance with Section 8.3.B above. The water temperature should be 0 to 5 F (44 to 46 C). Stir the solution until sanitizing agent has completely dissolved. G. Take an empty bag from a syrup BIB and cut the threaded connection off of it to use as a BIB adapter. H. Disconnect all BIB connectors from syrup boxes, then install BIB Adapters 7

18 I. Place a container under the sample valve tube and open the sample valve tube to purge syrup and water from lines. When the Tygon BIB tubing is clear of syrup, lower sanitizing adapters into sanitizing solution. Continue purging lines until any syrup in the line clears. J. Activate the syrup solenoids for each barrel using the SELECT key. K. Fill each barrel approximately /3 full with sanitizing solution/water mixture, then deactivate the syrup solenoids. L. Remove the BIB connectors from the cleaning solution. M. Activate the syrup solenoids to evacuate the solution from the barrels. Once the barrels are evacuated, deactivate the syrup solenoids and purge pressure from cylinders by pulling faceplate relief valve. N. Place the BIB connectors in the cleaning solution and activate the syrup solenoid and allow the barrel to fill / full of sanitizing solution. Deactivate the syrup solenoid and turn on beaters. Let solution agitate for three (3) minutes. O. Remove the BIB connectors from the cleaning solution. P. Activate the syrup solenoids and evacuate the sanitizing solution from barrel. Then turn off beater, deactivate the syrup solenoids and purge pressure from barrel. Q. Remove sanitizing adapters from the BIB lines and reconnect the lines to the syrup supplies. R. Turn on water at source. S. Partially refill the barrels (/3 full) with syrup and water by activating the syrup solenoids. Turn off the solenoids. Run the beaters for a few seconds. T. Drain the product by opening the dispense valve. U. Partially refill the barrel again and test the product for off taste. Repeat the drain/fill process until no off taste exists. V. When there is no more off taste, fill the unit following the procedure outlined in sections 6. through BASICS OF OPERATION NOTE On an initial freeze down, products must be given adequate time to stabilize. Making adjustments too quickly may negatively affect drink quality. 9. MAKING ADJUSTMENTS TO THE FBD35 UNITS A. In order to produce a consistent, quality beverage with the FBD35 Frozen Beverage Dispensers, there are a few critical settings that must be maintained. These settings are preset when you receive the machine from the factory. Due to variations that occur (e.g., in operating environments, syrups, and individual machines, etc.), it may be necessary to make minor adjustments to these settings. These adjustments are made using the keypad located behind the door at the front of the machine, or by adjusting the CO regulator located behind the access panel behind the drip tray. B. The settings that control product quality and production rate are:. Beverage Syrup Content or Brix Level (Set on Syrup Flow Control). Barrel Expansion 3. Regulated CO Injection Pressure 4. Freeze and Thaw Settings C. In Sections 6 and 7 of this manual are instructions on machine installation and initial operation. These instructions should be followed for initial setup of the machine. If the product quality is not as desired after allowing time for stabilization, the above settings should be checked and adjusted as necessary. The following sections discuss the sequence and method to verify these settings. These four (4) settings are explained here to help better your understanding of how the machine operates so you can make adjustments, if necessary.. Adjusting the Brix Level a. Consistent, high quality beverages require adjusting and maintaining the syrup content of the drink or brix level between 3.5 and 5. A brix level lower than 3.0 may cause operational problems. A low brix level (lower than 3.0) will produce a weak tasting drink 8

19 and tends to freeze product around the beater shaft. A high brix level (higher than 5.0) causes freeze down times to be longer and produces a more liquid drink. See Section 6.3 for set up information.. Expansion a. The FBD35 Frozen Beverage Dispenser utilizes a proprietary liquid level control system (patented) to hold a constant liquid level. A constant liquid level assures a quality frozen product. b. If a more wet product is desired, the numerical setting (0-6) should be increased. If a drier and colder product is desired, the numerical setting should be decreased. c. The default value set at the factory is 3. This setting should produce an excellent quality product. (See Section 0 for instructions on changing settings.) 3. Regulated CO Injection Pressure The CO injection pressure is set by adjusting the secondary regulator, located behind the access panel below the keypad in the front of the machine. The CO regulator should be set at 58-6 psig (400.0 to 47.6 kpag). 4. Thaw and Freeze Settings a. The Thaw and Freeze settings signal the refrigeration system when to start freezing and when to stop freezing. The liquid in the barrel freezes until it reaches the desired frozen consistency; then the refrigeration system shuts off and the barrel begins to thaw. The liquid continues to thaw until it reaches a consistency specified by the Thaw value. The Thaw value is the point at which the refrigeration system turns back on and refreezes the product. This assures the product is maintained in a good acceptable quality frozen drink range. b. Prior to changing any Thaw or Freeze settings, make sure the brix and water flow rate are correct and the liquid level control settings are properly set. Also assure the barrels stay filled to the proper levels with the proper amount of CO. The optimum frozen drink temperature is 4 to 8 F (-4.4 to -. C) and should be checked prior to making any adjustments. (See Section 0 for instructions on changing settings.) c. The Thaw and Freeze settings may be raised or lowered to change the temperature of the product. A default setting of 0 is set at the factory. To decrease the temperature, decrease the numerical setting; to increase the temperature, increase the numerical setting. 9. NO DEFROST TIME BLOCK A. The unit has two () No Defrost time blocks that will prevent the unit from defrosting during a specified three (3) hour time block. These No Defrost time blocks will affect both barrels and can be programmed under either of the barrel menus. B. The No Def St and No Def St represent the start time setting for each No Defrost time block. C. To program the No Defrost time blocks, use the following steps:. Scroll down until the desired defrost menu is displayed and press the SELECT button. Press the up or down buttons until the desired start time is shown (this is a 4 hour time format). Example: No Def St. = 3 No defrost from 3 to 6 AM No Def St. = 3 No defrost from to 4 PM 3. Press the select button to save the setting. 9

20 9.3 SETTING WAKE/SLEEP TIMES WAKE/SLEEP Set Procedure A. Use the UP and DOWN arrows to scroll to WAKE/SLEEP. B. Press the SELECT Key and then press the SELECT Key again to get into WAKE. C. The numbers on WAKE will flash and at this point, use the UP and DOWN keys to change the hour (time is in the 4 hour format). D. Press the Select Key again to make the minutes flash. Use the UP and DOWN keys to adjust the minutes. E. Press the Select Key again when done. F. Use the scroll UP and DOWN keys to move to the SLEEP time. G. Press the Select Key again, and the repeat steps C to E (above) for the SLEEP times. H. Press the STOP ALL button to exit the WAKE/SLEEP Menu. NOTE: The unit will Defrost before going to sleep and when it wakes up. 0. CRITICAL INFORMATION The following information is critical to proper machine operation. Prior to troubleshooting problems with the unit, review the following information. 0. BARRELS 90% FULL ON INITIAL SET UP Before beginning a RUN-FREEZE cycle, the barrels should be filled approximately 90% full (up to relief valve). If the barrels are above the 90% level, with Fill Off, open the dispensing valve and allow a small amount of liquid to drain out. If the barrels are not 90% full, press OFF, then FILL, and then slowly pull the vent ring on the faceplate to vent gas, and allow liquid to fill. The screen will display Filling. While venting, do NOT let the pressure drop more than three to four (3-4) psi. 0. LINE VOLTAGE DROP The FBD35 units require a separate electrical circuit. For specific power requirements see Sections 4. and 4.. The unit will not function properly if the line voltage drops more than 0 volts between the power source and the machine. 0.3 LONG TUBING RUNS A. Long runs of supply tubing can cause problems if the pressure drop (between the CO tank or syrup source and the unit) is too high. Runs longer than 5 feet (7.6 m) will require special attention. The machine s sensors may indicate that the machine is out of syrup, water, or CO. Consider the following solutions:. Increase the tubing size from 3/8 inch diameter to / inch diameter.. Install booster pumps in the supply lines. Use a vacuum regulating valve with syrup booster pumps. 3. Increase primary CO regulator pressure from bulk or tank CO to 05-0 psig (73.9 to 87.4 kpag). An additional regulator will be necessary for pumps (syrup, water) to avoid exceeding manufacturer s recommended operating pressures. 0.4 DRINK TOO HARD AND COLD A. If the drink is too hard and cold or the barrel is not full, adjust the Expansion to a higher level setting. See Section 0.6 for the proper adjustments. B. It will be necessary to dispense several drinks to allow the barrel to fill and rebalance. After dispensing several drinks defrost the barrel and refreeze. If the drink is still too hard, repeat the process taking the Expansion setting to the next higher value. 0.5 DRINK TOO WET A. If the drink is cold, but is still too wet, adjust the Expansion to a lower level setting. See Section 0.7 for the proper adjustments. B. It will be necessary to dispense several drinks to allow the barrel to fill and rebalance. After 0

21 dispensing several drinks defrost the barrel and refreeze. If the drink is still too liquid, repeat the process taking the Expansion to the next lower setting. C. Drink temperature should be between 4 F and 8 F (-4.4 C to -. C). 0.6 CHANGING THE DEFAULT EXPANSION SETTING NOTE Check regulated CO pressures in the unit to make sure they are adjusted properly before adjusting expansion controls! A. The Expansion setting is preset at the factory at a value of 3. B. If the drink is not frozen enough, or if the drink is too hard and too cold and dispenses slowly, after the machine has been running for 0 to 5 minutes, it may be necessary to adjust the Expansion settings. C. To change the machine s Expansion settings, scroll down on the Menu to Expansion.. Use the UP and DOWN keys to scroll to the Expansion.. Use the SELECT key to make the number blink. 3. Use the arrow key to change to the desired Expansion. 4. Use the select key to set the value. NOTE Expansion and Thaw-Freeze values are set for each barrel individually. 0.7 CHANGING THE THAW-FREEZE VALUES A. Use the UP and DOWN keys to scroll to the FREEZE/THAW Menu. B. Press SELECT key to make the FREEZE/THAW value flash. C. Use the UP and DOWN keys to adjust the FREEZE/THAW value to the desired value. D. Press the SELECT key to save the value.. TROUBLESHOOTING GUIDE The following information is a listing of the most common problems that could keep the FBD35X Series Dispenser from operating properly. Contact the factory for details, when necessary. MECHANICAL TROUBLE CAUSE REMEDY. Barrel will not fill. A. Fill off. A. Press Fill button. Filling or Fill Hold will appear on LCD display. NOTE: B. Pressure in barrel above B. Gently pull faceplate relief valve HO readout will be about 5-0 psi higher on the readouts. Keep incoming CO regulated at 70-7 psig. RFill (refill) point. ring to relieve pressure in barrel. C. Defrosting or Sleeping. C. Press Defrost, then Run Wait for unit to freeze and red light to go out. D. Out of CO, Syrup or Water. D. Check LCD messages for Out of. condition. E. Tank Pressure readout not E. Observe Tank Pressure reading. moving between 8 and Check transducer and replace if 40 psig or doesn t lower when necessary. barrel pressure is reduced. F. 00 VA Transformer problem. F. Test transformer for 5 VAC input or 30 VAC input depending on the unit that you have. Also check for 4 VAC output (see Figure.3 for 5 VAC units and see Figure.4 for 30 VAC units). Replace transformer if necessary.

22 TROUBLE CAUSE REMEDY. Barrel fills even A. Syrup solenoid plunger A. Energize syrup solenoid and check when turned off sticking. for 4 VAC at coil. Clean or replace solenoid, if necessary. B. Syrup solenoid left ON B. Turn solenoid off..3 Out of Product A. Unit receiving no water, syrup A. Assure water is on and CO supply displayed (Out of and/or CO. is not empty or turned off. Also Water, Syrup or CO). 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 pressure readouts (HO NOTE: HO readout will be about 5-0 psi higher on the readouts. Keep incoming CO regulated at 70-7 psig. and syrup pumps) too low. and Syrups) for proper settings. Adjust regulators, if necessary. D. Syrup or Water Pump failure. D. Check all pumps and replace, if necessary. E. CO or water can t keep up E. Reroute water or CO lines to with unit demand. maximize supply pressure. Install Water Booster if necessary. F. Excessive pressure drops F. Observe Syrup Press readouts in syrup lines. as barrel fills to verify. Increase line diameter or relocate syrup source closer to unit. Syrup pressures may only be raised (by increasing pump CO pressure) if separate regulators are installed for unit and syrup pumps. Never exceed pump manufacturer s recommended maximum CO inlet pressure (see Section 0.3). G. Transducer problem (HO G. Check pressure readouts (HO or Syrup). and Syrup) for proper settings. If not within psi, adjust regulator and/or check transducer. Replace transducer, if necessary..4 Product does not flow A. Faulty CO check valve. A. Inspect CO check valve. Clean or freely or does not flow replace. at all from dispensing B. Syrup solenoid valve B. Energize syrup solenoid and check valve. won t open. for 4 VAC at coil. Clean or replace solenoid, if necessary. C. Ice particles in dispensing C. Run defrost cycle. If necessary, valve. open and close dispensing valve several times or run warm water over valve. D. Product in cylinder is frozen D.. Check water/syrup flow too hard or solid. rates and brix. Adjust, if necessary (see Section 6.3).. Defrost barrel. Assure barrel is filled to 90% of capacity, then press Run. E. CO Shutoff is closed. E. Open CO Shutoff and adjust secondary CO regulators inside of machine to 60 psig..5 Product leaking from A. Beater drive rear seal is worn A. Replace with new seal. rear of cold pack. or damaged. B. Beater drive coupling is worn. B. Replace coupling. C. Seal is not positioned C. From inside barrel, reseat seal, correctly. making sure it is flush with back of barrel.