Grant FF Series User manual

Revised January 2012
FF SERIES OF FLAKE ICE MACHINES COMPLETE UNIT
（ ）
SERVICE MANUAL FOR FF 1 - 3.2 AR MODELS
380v – 415v 3 Phase 50Hz
（）
Refrigerant: R404A

Revised January 2012
Table of Contents
IV. Operating Principles
Maintenance & Trouble Shooting
III. Packing, Transportation and Installation
I. Overview ............................................................................................................................. 4
II. Operation Conditions & Performance Parameters
VI. Electrical Information ..................................................................................................... 17
a) Control Panel ............................................................................................................. 17
b) Electrical Wiring Diagram of the Slice Ice Machine .................................................. 18
c) Timer Control Wiring Diagram .................................................................................. 23
VII. PC Board Explained ..................................................................................................... 24
1. Circuit Board Layout ................................................................................................ 24
a) Ice making machine PC Board layout (back) ...................................................... 24
b) ice making external indicator small board layout .............................................. 24
c) Ice full sensor sensitivity small board layout ..................................................... 25
2. Fault Indicator ........................................................................................................... 25
3. Dip Switch .................................................................................................................. 26
V.
1. Water Circulation System ............................................................................................................. 12
2. Ice level Control System ............................................................................................................. 12
3. The Gearbox ................................................................................................................................. 13
4. P.C. Board Controlling System .......................................................................................................
13
1. Packing, Transporting and Storing ..................................................................................................
9 2. Installation ......................................................................................................................................
9 3. Installation Procedures .................................................................................................................
10 5. Operating Instructions ................................................................................................................
11
1. Equipment Maintenance .............................................................................................................. 14
2. Cleaning Procedures .....................................................................................................................
15 3. Trouble Shooting ..........................................................................................................................
16
1. Conditions for Operation of FF Series Scale Ice Machine ...............................................................
4 2. Diagram for Ice Output of Scale Ice Machine
................................................................................. 5 3. Parameters of Scale Ice Machine
.................................................................................................... 6
4. Working Pressure (Ambient temperature : 25℃) ...........................................................................
7
5. Refrigerant Charge .......................................................................................................................... 7
6. Dimensions ..................................................................................................................................... 8

Revised January 2012
a) 8-bit DIP Switch .................................................................................................. 26
b) 4-bit DIP Switch .................................................................................................. 27
4. Electrical Wiring Diagram .......................................................................................... 28
a) Ice machine PC Board wiring diagram ............................................................... 28
b) Ice Machine external indicator (small board) wiring diagram ........................... 29
c) Ice Making sensor wiring diagram ..................................................................... 29
5.Ice Full Sensor sensitivity and DIP switch settings ..................................................... 30
a)Full sensor sensitivity settings ............................................................................ 30
b) Ice Full sensor sensitivity and adjustment method ........................................... 30
VIII. Timer Switch ....................................................................................................... 31
a)Parts Identification .............................................................................................. 31
b)Operating Instructions ........................................................................................ 31
c)Specifications....................................................................................................... 32
IX. Technical Notes ...................................................................................................... 34
X. Service Bulletins .............................................................................................................. 35

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4
I. Overview
II. Operation Conditions & Performance Parameters
1. Conditions for Operation of FF Scale Ice Machine
Minimum Operating
Conditions
Ambient Temperature 5℃
Water Temperature 5℃
Water Pressure 0.15MPa
Voltage Variation -10%
Maximum Operating
Conditions
46℃
35℃
0.5MPa
+10%
Read this service manual carefully before installation, troubleshooting and operation of this sub-zero ice
machine.
This Service Manual gives an introduction of operation conditions, performance parameters, installation,
troubleshooting and operating procedures of FF series sub-zero ice machines. The ice making system has
a vertical, static evaporator with a rotating auger. The machine is equipped with a solid state PC board,
which controls and monitors the functionality of the ice machine, indicating:
(1) Ice level
(2) Water level
(3) Motor and gearbox operation
(4) Temperature of condenser
(5) Level of refrigerant

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5
2. Diagram for Ice Output of sub Zero Ice Machine

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6
Note:
3. Parameters of Sub Zero Ice Machine
FF1AR
FF1AS
FF1.2AR
FF1.2AS
FF1.5AR
FF1.5AS
FF2AR
FF2AS
FF2.5AR
FF2.5AS
FF3.2AR
FF3.2AS
FF3.2WR
(V)
380V/50Hz/3N
(A)
11.5
11.5
15
15
16
16
18.5
18.5
21
21
23
23
23
Air-cooled
unit
Air-cooled
split unit
Air-cooled
unit
Air-cooled
split unit
Air-cooled
unit
Air-cooled
split unit
Air-cooled
unit
Air-cooled
split unit
Air-cooled
unit
Air-cooled
split unit
Air-cooled
unit
Air-cooled
split unit
Water-coole
d unit
6 6
6.5
6.5
8
8
10
10
12
12
12
12
12
(HP) (W)
3400
3400
5100
5100
6700
6700
7500
7500
9800
9800
10500
10500
10500
5×2.5
5×2.5
5×2.5
5×2.5
5×2.5
5×2.5
5×4
5×4
5×4
5×4
5×4
5×4
5×4
(mm2)
42
42
50
50
63
63
85
85
100
100
125
125
125
(l/h)
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
3/4
″
21
21
21
21
21
21
21
21
21
21
21
21
21
315
320
320
325
380
385
470
475
550
560
590
595
570
(kg)
Daily ice output is directly related to the air temperature at the condenser and inlet water temperature. In
order to keep optimum operation performance of FF series sub-zero ice machines maintenance must be
performed on a regular basis as per service manual section V.
Model description: FF×××AR model is a complete unit including refrigeration system ready for connection to
power, water and drainage. The FF×××AS is a split system comprising two components, low side evaporator
with control system and air cooled refrigeration condensing unit. To be installed by qualified refrigeration
technician only. The FF×××WR is a complete system with water cooled condenser, ready to connect to water
supply, power and drainage and condenser water (to be supplied by others).
Model Voltage Current Condensing
Type
Compressor Power Wiring
Size
Water
usage
Inlet
pipe
(outside
thread)
Drain
pipe
(outsid
e
diamet
er)mm
Weight

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Model
Discharge Pressure
Suction Pressure
FF2AR/FF2AS
1800Kpa
200Kpa
5 Refrigerant Charge
Model FF 1 AR FF 1.2 AR
Refrigerant Charge 4800g 5300g
Note:
This may vary if machine parameters change
4. Working Pressure (Ambient temperature 25℃,R404A)
Model FF1AR/FF1AS FF1.2AR/FF1.2AS
Discharge Pressure 1850Kpa 1850Kpa
Suction Pressure 200Kpa 200Kpa
FF2.5AR/FF2.5AS
1800Kpa
200Kpa
FF 1.5 AR
6500g
FF 2 AR
10000g
FF1.5AR/FF1.5AS
1800Kpa
200Kpa
FF3.2AR/FF3.2AS
1650Kpa
200Kpa
FF 2.5
AR
11500g
FF3.2W
R
1550Kpa
200Kpa
FF 3.2
AR
15000g

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6. Dimensions (See figure 1)
Model
FF1AR
FF1AS(Split unit)
FF1.2AR
FF1.2AS(Split unit)
FF1.5AR
FF1.5AS(Split unit)
FF2AR
FF2AS(Split unit)
FF2.5AR
FF2.5AS(Split unit)
FF3.2AR
FF3.2AS(Split unit)
FF3.2WR(Water-cooled unit)
W(mm)
1320
1320
1320
1320
1320
1320
1620
1620
1620
1620
1620
1620
1620
D(mm)
1050
1050
1050
1050
1050
1050
1050
1050
1050
1050
1050
1050
1050
H(mm)
870
870
890
890
1050
1050
1150
1150
1250
1250
1500
1250
1250
------
1100
------
1200
------
1200
------
1250
------
1400
------
1500
------
×475×835
×475×630
×475×630
×475×630
×475×835
×475×935
condenser size for split unit

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E.
1.
B
.
C
.
2.
A.
A.
B.
C.
D.
Packing,Transportation and Storing The ice machine is packed in plywood.
Beware of collision, vibration, tilting, inversion, etc. in transportation and storage. Ice machine should
be kept below 40C, dry, and well-ventilated
Before you begin:
Check your paperwork to determine the model received matches your order.
After uncrating and removing all packing material, inspect equipment for any shipping damage.
Check whether all connections (water system, refrigerant system, etc.), electrical connections (wires,
PC board, etc.) and mechanical system are in good condition.
Installation (See figure 2)
Electrical connections must comply with local standards and requirements on the rating plate of the
machine.
An isolation switch must be installed
Constant water supply (Pressure between 0.15 to 0.5 MPa) and stop cock shall be supplied within 1
metre of the ice machine. Suitable drainage point shall be within 1 metre of ice machine. Two
separate water drainage lines shall be required for draining the ice machine and the ice storage bin.
The ice machine shall not be placed (1) without suitable ventilation; (2) next to heat sources; or (3)
outdoors.
To ensure ice quality a water filter should be installed in icemaker inlet water line.
Packing/ Transportation/ Storing and Installation

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3.Installation Procedures
(1) Place the ice machine on appropriate ice storage bin and fix. See figure 2.
(2) Ensure machine is level
(3) Connect water supply with a hose.
(4) Connect the drains with sufficient fall.
(5) Open the water supply stop cock.
(6) Connect power to approved outlet.
(7) Use a qualified service technician for installation.
(8) See figure 3 for installation of split unit.(See figure 3)
Figure 2

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Operating Instructions
(1) To start up
After the machine has been installed as per instructions, plug in and switch on. The indicator light A (the
green light) will come on. Turn the “On/Off” switch on the control box to “On” position (turn the switch in
a clockwise direction) and the machine will be on 5 minutes’ delay (the fourth red light of the second row
of the control box will be flashing). After 5 minutes’ delay, the machine will start.
(2) To stop the machine
Turn off the Manual “Off/Auto” switch on the control box and the machine will stop Each time you turn on
the Manual “Off/Auto” switch and start the machine, the machine will begin to run automatically after 5
minutes’ delay.
A. The 5 indicators lights in the second row on the front panel of the control box monitor the following:
Note:
1. Reasons for high condenser temperature: faulty fan motor; blocked condenser; high ambient
temperature; damaged condenser, faulty temperature sensor or P.C board.
2. Reasons for high evaporator temperature: check refrigeration system, faulty evaporator temperature
sensor or P.C board.
C. The third red light in the first row (H3) on the front panel of the control box will be on if the discharge
pressure of the compressor is higher than the specified value (factory set) or if the suction pressure is
lower than the specified value (factory set). Please identify causes and rectify before resetting the
machine manually.
D. In event of emergency, push the “Emergency Shutdown” button to stop the machine.

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1. Water Circulation System (See figure 6)
Water enters the machine through the float valve and into the water reservoir. Water is then pumped to
the water distributor by a water pump and then flows on to the inner surface of the evaporator. It is
cooled down gradually and forms ice. The ice blades scrape the ice from the inner surface of the
evaporator and it drops into the ice storage bin through the ice shute. Some of the remaining water will
flow back to the water reservoir.
Note:
a. Water supply is monitored by a sensor. If there is no water in the water reservoir or the water is too soft
(not containing mineral substances), the P.C. board will stop the machine, and the yellow light will
indicate a lack of water.
b. The water level has been factory set. Do NOT adjust it. If the water level requires adjusting, this can be
achieved by adjusting the valve in the water reservoir. (The correct level is 26mm from the bottom of
the water distributor)
2. Ice Level Control System
There is a light-operated ice level controller between the machine and the ice storage bin. When the
storage bin is full of ice, the ice will break the light beam of the ice level photoelectric sensor and then the
red LED in the center of P.C. board will be turned off. The yellow light indicating “ice full” will be turned on
after the light beam has been broken for a continuous period of time and stops the machine. The light
beam will be reset and the red light in the center of the P.C. board will be turned on if the ice is removed.
IV. Operating Principles

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3. The Gearbox
This system includes a gear motor and gear box. The gear motor drives the gearbox. The output shaft of
the gearbox drives the auger and water distributor at a speed of 2 rpm. In case of wrong rotation
direction or low speed of the gear motor, the sensor will send a signal to the P.C. board, which will stop
the machine. Causes of the trouble should be identified and fault should be rectified before the machine
is re-started. Press the Reset key or put the On/Off switch at the "OFF" position first and then to "ON"
position, the machine will begin to work again normally.
4. P.C. Board Control System ( please refer to figure 7 )
The P.C. board controls the whole operation of the machine according to signals sent by various sensors.
Notice:
There are 8 switches on the P.C. board. Switch 1: if it is in "ON" position there will be no 5 minutes'
delay after start-up; if it is in "OFF" position there will be a 5 minute delay after start-up. The switch
should be set at "OFF" position for normal operation. Switch 3: should be in "OFF" position. DO NOT
TOUCH. Switch 6 in the “On” position provides an audible fault alarm; (see figure 8).
Figure 8
Water level Water level Power display
sensor circuit 1
Bin Full
Ice level sensor Ice level
circuit 2 Water level
High Condenser temperature
Motor rotation Motor rotation
sensor signal circuit 3 Low rotation speed and
high evaporator temperature
Evaporator temperature High Evaporator temperature
sensor circuit 4
High-temperature protection Compressor
circuit 5 circuit 9
Condenser temperature Low-temperature protection Gear motor
sensor circuit 6 circuit 10
Fan cycle Fan cycle
circuit 7 circuit 11
Figure 7
Micro-processor
Fan motor
Gear motor
Compressor
contactor

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14
V. Maintenance & Trouble-shooting
Warning: No cleaning or maintenance shall be carried out on the machine prior, to
carrying out correct isolation procedures to isolate the machine from the power
and water supply. Coast Distributors recommends the use of PPE when carrying
out a service or maintenance on either the ITS, BIN, or Grant ice machine.
1. Equipment Maintenance
A. Daily procedures
For continued ice quality, check the following.
 Nothing is allowed to be stored in the ice storage bin.
 Always keep the bin door closed and the ice paddle clean.
 Check for ice clumping, if clumping is present clear the ice or melt the ice with warm water.
To protect the machine from any damage, please pay attention to the items stated below:
 Don’t turn off the water supply when machine is operating.
 Open/close the storage bin door gently and never kick or jerk the door.
 Never stack anything on the top of ice storage bin or ice machine and maintain minimum clearances
for correct air circulation.
B. Regular cleaning & maintenance (monthly)
Users should adopt a regular cleaning and maintenance program in accordance with the surrounding
environmental conditions.
In order to ensure proper performance and sanitary condition, the following regular maintenance should be
carried out, (at an interval of about one month).
 Clean the inside walls of the ice storage bin with detergent and warm water.
 Sanitize the bin surfaces, internally then flush with warm water.
 Clean the external surfaces of the bin and ice machine with a soft cloth and stainless steel cleaner.
Cleaning the Condenser
 Condenser coil should be checked and cleaned if required at monthly intervals.
C. Regular cleaning & maintenance (6 monthly)
Qualified service personal only should carry out the following maintenance and checks.
Carry out correct isolation procedures prior to doing any of the following.
 Visually check for signs of oil leaks around the speed reducer gear box.
 Check and clean if necessary the condenser coil.
 Remove the speed reducer and check for play in the top bearing.
 Remove the 2 plastic top covers on the evaporator and check the following.
 Check the water distribution tray and distribution tubes for foreign materials and restrictions
clean if required.
 Remove the water distribution tray and check the ice blade top and bottom bearings for play,
replace if required.
 Check bottom bearing for movement and or play, replace if required.
 Check bottom water catchment tray for signs of damage or cracks, replace if required.
 Check bottom evaporator water trough for foreign material, clean if required.
 Reassemble and check all bolts for tightness.
 Check water strainer in inlet to the water reservoir for dirt or foreign materials.

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2. Cleaning Procedures
1. Carry out correct isolation procedures and test unit for power loss.
2. Isolate the water supply to the machine.
3. Remove and replace the water filter cartridge and purge approx 4ltrs of water through filter.
4. Carry out visual inspection of the unit.
5. Remove the black top plastic cover on the evaporator.
6. Check condition of water distributor and tubes.
7. Check condition of plastic water pan at the bottom of evaporator.
8. Check water float operation and water level. Adjust or replace if required.
9. Check water trough for foreign matter and clear if required.
10. Check water reservoir.
11. Check for any water leaks.
12. Isolate the refrigeration circuit, so as no refrigeration of the evaporator occurs this can be done by either
separating the compressor overload from the contactor ( all AR models )or isolating the power to the
liquid line solenoid valve coil on (all FFE models)
13. Drain the water from the water reservoir via the drain tap on rear of tank and measure water quantity.
This is to ascertain how much cleaning solution is required.
14. Make up correct amount of cleaning solution as per manufacturer’s directions and empty solution into the
water reservoir.
15. Re-energize the power to the machine and set dip switch 1of 8 (time delay override) to the up position
and turn the machine on.
16. Run the machine for the correct indicated time as per chemical manufactures directions (usually 20 min).
During this time the machine will fault on high evaporator temp alarm (10 min delay) and will require a
reset to start the alarm delay over again.
17. Once the cleaning time has elapsed, turn unit off and drain the water and flush the system 4 times.
18. Clean the bin and flush / check the drain.
19. Drain the water from the water reservoir via rear drain tap.
20. Mix up and add sanitizer solution to the system, turn unit back on.
21. Sanitize bin.
22. Follow the manufactures directions on the sanitization procedure.
23. After 10 min reset and wait another 10 min. Once this time has elapsed, turn the unit off and drain the
water and flush the system 4 times.
24. Carry out correct isolation procedure and test unit for power loss.
25. Re-connect the compressor overload or solenoid valve coil power.
26. Reset the delay timer dip switch (no 1 of 8) back to the off position “Down”.
27. Clean the unit, condenser and covers where fitted.
28. Turn the water back on to the machine.
29. Re-energize the power and turn the machine on.
30. Check operation of unit.
31. Check Auto/Off/Man operation and time clock setting.
32. Check bin legs, door and trolleys where applicable.
The above procedure takes approx 1.5 to 2 hrs depending on, if is on a slope front bin or a Follett ITS.

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3. Trouble Shooting
Symptom Possible Causes Solution
8. Time delay light flashing.
2.PC Board light is off
Still no PC Board Light
Ice Machine not running.
1.Power supply light is off
4. Water shortage light is ON.
5. Compressor failure light on.
7. Time delay / hi cond light on.
6. Low or High pressure light on.
9. Low rotation / Hi Evap light on.
3. Bin Full light is on but the bin is
empty.
11. No power on timer transformer
(green LED off)
10. Low rotation / Hi Evap light flashing.
Unit on 5 min time delay
LP/HP tripped.
Blown RD4 fuse
Power supply turned off
Compressor overload tripped.
Blocked water filter cartridge.
Blocked water strainer at inlet.
Water float jammed or broken.
Emergency button pressed.
On/Off or Man/off/Auto switch off.
Machine off on timer.
Bin full sensor requires sensitivity adjusting
Check bin full led in middle of PC Board is on
Reamer motor RPM dropped by more than
7%. Hertz lower than 45Hz.
Speed reducer reversed direction
Ice cutting blade incorrect spacing.
Worn bearings.
Speed reducer faulty.
Speed reducer low on oil.
Speed reducer motor faulty.
Suction line out of evaporator failed to reach
-1degC after 10 min from start up or reached
-30degC for a period of 5min.
Faulty sensor.
Liquid line reached 55 deg C or ambient lower
than 4 deg C
No action required.
Dirty condenser, Too high/ too low ambient, faulty sensor.
Clean condenser, rectify ambient conditions (ventilation)
Replace faulty sensor.
Check Hz.
Check motor capacitor, replace if required.
Check ice blade spacing 0.3mm adjust if required. Replace worn
bearings.
Replace speed reducer motor / box
Replace speed reducer motor / box
Replace speed reducer motor / box.
Check gas charge, TX Valve, liquid line solenoid valve,
Refrigeration not working, rectify refrigeration problem.
Check water flow over evaporator,
Replace faulty sensor
Check transformer, timer relay and timer, replace faulty parts as
required.
Check power lead is plugged in and turned on. Check circuit
breaker.
Rotate switch clockwise to reset.
Turn switch to Auto
Turn switch to Manual, if PC Board light comes on then timer
requires adjusting or setting.
If PC Board power light still stays off check F1 fuse on PC Board.
Adjust bin full sensitivity via adjustment pot, (5 LED bars on- 5
off)
If the LED is on, machine should be on time delay, (time delay
light flashing)
If not on time delay replace PC Board.
Replace water filter cartridge / bypass cartridge to test
operation. Clean strainer.
Repair or replace water float.
Check compressor, supply voltage, compressor electrics.
Replace faulty components as required.
LP tripped, check gas charge, TX Valve, Liquid line solenoid valve.
Replace faulty components as required.
HP tripped, check condenser coil, air flow, condenser fan motor,
clean coil or replace fan motor if required.
Repair gas leak and regas system with correct gas charge.

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a) GRANT Control Panel
V I . Electrical Information
J
LOCATIO
N A
B
C
D
E
F
G
H
FUNCTION
Green power light indicates power to machine when lit
Red compressor failure indicates compressor overload tripped when lit
Red light indicates high or low pressure trip when lit
Emergency stop – Push to stop machine, twist clockwise to reset
Green P.C. light indicates power to P.C. Board when lit
Orange light indicates bin is full when lit
Orange light ON indicates no water to machine
Red light on indicates high condensing temperature
Red light flashing indicates unit on 5 minute time delay before starting
Red light on indicates low rotation speed fault
Red light flashing indicates high evaporator fault, suction line failed to reach 1 degree C for 10 min
Or reached -30 degrees C for 5 min.
Control Panel on B400 Bin with Manual Off/Auto switch fitted Manual On/Off switch on ITS system is
located on Bin.

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b) Electrical Wiring Diagrams of the Scale Ice Machines
FF(1-1.5) AR & FF(1-2.5) AS

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19
FF (2-2.5) AR

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20
FF 3.2 AR