Grant FF Series User manual

Revised January 2012
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    FFSERIESOFFLAKEICEMACHINES COMPLETEUNIT
（）
SERVICEMANUALFORFF0.4AR&FF0.6ARMODELS 
230v1Phase50HZ
（）
Refrigerant:R404A
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Revised January 2012
TableofContents
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IV.OperatingPrinciples
Maintenance&TroubleShooting
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III.Packing,TransportationandInstallation
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VI.ElectricalInformation.....................................................................................................15
a)ControlPanel.............................................................................................................15
b)ElectricalWiringDiagramoftheSliceIceMachine..................................................16
c)T imerControlW iringDiagram.................................................................................. 17
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VII.PCBoardExplained .....................................................................................................18
1.CircuitBoardLayout ................................................................................................18
a)IcemakingmachinePCBoardlayout(back)......................................................18
b)Icemakingexternalindicatorsmallboardlayout..............................................18
c)icefullsensorsensitivitysmallboardlayout......................................................19
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I.Overview.............................................................................................................................4
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II.OperationConditions&PerformanceParameters
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V.
2.WaterCirculationSystem...........................................................................................................10
3.IcelevelControlSystem ...........................................................................................................10
4.TheGearbox...............................................................................................................................11
5.P.C.BoardControllingSystem.....................................................................................................11
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1.Packing,TransportingandStoring................................................................................................7
2.Installation...................................................................................................................................7
3.InstallationProcedures.................................................................................................................8
InstallationSchematicDiagramforSplitUnit...............................................................................8
5.OperatingInstructions ...............................................................................................................9
1.EquipmentMaintenance............................................................................................................12
2.CleaningProcedures...................................................................................................................13
3.TroubleShooting........................................................................................................................14

1.ConditionsforOperationofFFSeriesScaleIceMachine..............................................................
4 2.DiagramforIceOutputofScaleIceMachine...............................................................................
 4
3.ParametersofScaleIceMachine..................................................................................................5
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4.WorkingPressure(Ambienttemperature:25)...........................................................................5
5.RefrigerantCharge.......................................................................................................................5
6.Dimensions,Drawings,Airflow&Clearances..............................................................................6

Revised January 2012
2.FaultIndicator...........................................................................................................19
3.DipSwitch..................................................................................................................20
a)8‐bitDIPSwitch...................................................................................................20 b)4‐
bitDIPSwitch..................................................................................................21
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4.ElectricalWiringDiagram..........................................................................................22
a)IcemachinePCBoardwiringdiagram...............................................................22
b)IceMachineexternalindicator(smallboard)wiringdiagram...........................23
c)IceMakingsensorwiringdiagram.....................................................................23
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5.IceFullSensorsensitivityandDIPswitchsettings.....................................................24
a)Fullsensorsensitivitysettings............................................................................24
b)IceFullsensorsensitivityandadjustmentmethod...........................................24
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VIII.GrantT
imer...........................................................................................................25
a)PartsIndentification............................................................................................25
b)OperatingInstructions........................................................................................26
c)Specifications.......................................................................................................27
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IX.TechnicalNotes...................................................................................................
.....28 
X.ServiceBulletins…................................................................................................
.....29 
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I. Overview
0.4AR 
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Readthisservicemanualcarefullybeforeinstallation,troubleshootingandoperationofthissub‐zeroice
machine.
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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: 
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(1)Icelevel
(2)Waterlevel 
(3)Motorandgearboxoperation
(4)Temperatureofcondenser
(5)Levelofrefrigerant
(6)Temperatureofevaporator
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II.OperationConditions&PerformanceParameters
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1.ConditionsforOperationofFFScaleIceMachine 
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 MinimumOperatingMaximumOperating
Conditions Conditions
AmbientTemperature 
5℃ 46℃
WaterTemperature 
5℃ 35℃
WaterPressure 0.15MPa 0.5MPa
VoltageVariation ‐10% +10%
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2.DiagramforIceOutputofsubZeroIceMachine
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                Watertemperature( )     Watertemperature( )
℃ ℃
Ice output in 24 hrs (kg)
Ice output in 24 hrs (kg)
Ambient Temperature
Ambient Temperature

Revised January 2012
Note:
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3.ParametersofSubZeroIceMachine
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Model FF0.4ARFF0.6AR
Voltage(v) 230V/50HZ/1N230V/50HZ/1N
Current(A) 14.518
CondensingType AircooledAircooled
Compressor(HP) 2 3
Power(W) 31003900
WiringSize(mm2) 3x2.5 3x2.5
WaterUsageL/h 17 25
WaterInlet(outsidethread) ¾” ¾”
Drain(outsidediametermm) 21 21
Weight(kg) 180250
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4.WorkingPressure(Ambienttemperature25℃,R404A)
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Model FF0.4AR FF0.6AR
DischargePressure 1850Kpa 1850Kpa
SuctionPressure 200Kpa 200Kpa
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5.RefrigerantCharge
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Model FF0.4ARFF0.6AR
RefrigerantCharge(g) 2000g 3200g
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Note: 
Thismayvaryifmachineparameterschange
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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.
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Model description: FF×××AR model is a complete unit including refrigeration system ready for
connection to power,wateranddrainage. 

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Model
FF0.4AR
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FF0.6AR
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W(mm)
1090
1250
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6.Drawings,Dimensions,AirflowandClearances 
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D(mm)
700
750
H(mm)
720
820
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Externaldimensionsincl
stainlesssteelcover 
D

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1.
2.
A.
B.
C.
A
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B
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C.
D.
E.
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Packing,TransportationandStoringTheicemachineispackedinplywood.
Beware of collision, vibration, ti lting , inversion, etc. in transportation and storage. Ice machine
should bekeptbelow40C,dry,andwell‐ventilated
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Beforeyoubegin:
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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. 
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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 kPa to 0.5 MPa) and stop cock shall be
supplied within 1 mtr of the ice machine. Suitable drainage point shall be within 1 mtr 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

Revised January 2012
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3.InstallationProcedures 
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(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stopcock.
(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)
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OperatingInstructions
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(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 Manual “Off/Auto” to “manual on” position (turn the
switch in a clockwisedirection) and the machine wi ll be on 5 minutes’ delay (the four thred light
of the secondrow of thecontrolboxwillbeflashing).After5minutes’delay,themachinewillstart. 
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(2)Tostopthemachine
Turn off the Manual “Off/Auto” switch and the machine will stop. Each time you turn on the
“On/Off” switchandstartthemachine,themachinewillbegintorunautomaticallyafter5minutes’delay.
A.The5indicatorlightsinthesecondrowonthefrontpanelofthecontrolboxmonitorthefollowing:
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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.
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B.  Thethirdredlightinthefirstrow(C)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.
C.  Ineventofemergency,pushthe“EmergencyShutdown”buttontostopthemachine.

Revised January 2012
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1. WaterCirculationSystem(Seefigure6)
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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.
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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) 
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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 wi ll break the light  beam of the ice l evel photoelec tr ic
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

Revised January 2012
11
TheP.C.boardcontrolsthewholeoperationofthemachineaccordingtosignalssentbyvarioussensors
. 

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)

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 2 & 3:
should be in "ON" position. DO
NOTTOUCH.Switch6inthe“On”positionprovidesanaudiblefaultalarm;(seefigure8).


F igure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


F igure7
Micro-processor
Fan motor
Compressor
contactor
Gear motor

Revised January 2012
12
Warning:


V.Maintenance&Trouble‐shooting

No cleaning or maintenance shall be carried out on the machine prior,
to
carryingoutcorrectisolationprocedurestoisolatethemachinefromthepow
er and water supply. Coast Distri butors 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.Dai ly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.

Revised January 2012
13
.
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.
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.
   


Revised January 2012
14
3. Trouble Shooting
 
Symptom PossibleCauses Solution
8.T imedelaylightflashing.
2.PCBoardlightisoff
Sti llnoPCBoardLight

IceMachinenotrunning.

1.Powersupplylightisoff

7.T ime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.



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4.WatershortagelightisON.


5.Compressorfailurelighton.
10.Lowrotation/HiEvaplightflashing.
11.Nopowerontimertransformer
(greenLEDoff)
LP/HPtripped.
Powersupplyturnedoff


Blocked water filter cartridge.
Blockedwaterstraineratinlet.
Waterfloatjammedorbroken.
Compressoroverloadtripped.
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 fa ul ty.
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.
BlownRD4fuse
Liquidlinereached55degCorambientlower
than4degC
Uniton5mintimedelay Noactionrequired.


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.

    Dirtycondenser,Toohigh/toolowambient,faultysensor.
Cleancondenser,rectifyambientconditions(ventilation)
Replacefaultysensor.

Revised January 2012
15
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a) GRANTFF0.4AR/FF0.6AR 
VI.ElectricalInformation
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LOCATIO
N A
B
C
D
E
F
G
H
J
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On/Offswitchfitted                      ManualOn/OffswitchonITSsystemis 
locatedonBin.

Revised January 2012
16
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Electrical W
iring Diagram of the Scale Ice Machines
FF0.4AR/FF0.6AR(240v50HzSinglePhase)

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
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

Revised January 2012
17
d)T imerControlW iringDiagram

FF0.4AR/FF0.6AR

Revised January 2012
18
VIIPCBOARDEXPLAINED
1

IcemakingPCboardlayout(back

b)Icemakingexternalindicatorsmallboardlayout
、 ） 



Revised January 2012
19
c)Icefullsensorsensitivitysmallboardlayout
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2.FaultIndicator

* When the power frequency is lower than 45Hz more than five seconds al
thesametime




Revised January 2012
20
3. DipSwitch
a).8‐bitDIPswitch(


Eight‐bit DIP switches on the centre of the PC board (F igure 3‐1) are from left to right. Override
is when dipswitchisintheonposition.

The func tion of the first bit  DIP switch: Selects the star ti ng up delay function. When the first bit
DI P switch  is on, the unit will start up with no delay. (This feature is used during maintenance of
the ice machine). When dip switch is in the off position the unit will have a five minute delay,
which is to ensure the sensor isclearofice.

The function of the second and third bit DIP switch: Select the ice full sensor to suit ice type. To
select sub  zeromachineice‐fullsensor,bothdipswitch`s2and3areintheonposition.
ThefunctionofthefourthbitDIPswitch:DIPswitchinvalid.
ThefunctionofthefifthbitDIPswitch:Selectsthemodelsofthegearmotor.
1440RPMwhenthedipswitchisintheoffposition(thelocationofswitchhasbeensetupatthefactory
, theusershouldnotbetouched)
Attention:PleasepressresetbuttonbeforeresettingDIPswitch.







Startupdelayfunctionon


Cancelstartupdelay
function


Select1440RPMmodel

Select sub zero ice machines
icefullsensor




)

Cancelthetest
parameters(factory)

Openthetest
parameters(factory)

Openthebuzzer(on)

Cancelthebuzzer(off)
1 (ON): Cancel starting up delay.
2,3 (ON):Select sub zero ice machine’s ice-full sensor
4 (OFF): Not Used
5 (OFF): Select 1440RPM model.
6 (ON): Turn on the buzzer.
Warning: Please press reset button before resetting DIP switch