SERVICE MANUAL FOR FF 0.4 – 5 E MODELS
Contents
1. 870 820 870 880 1050 1080 1250 1300 326 326 480 480 480 480 480 480 Revised January 2011 IV Operating Procedures 1 1 2 3 4 2 1 2 3 2 Before start up check the following Power connections are safe reliable and complies with local standards and requirements on the rating plate on the machine Water pressure is within the specified range of 0 15 0 5MPa The earth wire is securely connected All fastening bolts have been tightened Start Open water supply valve to fill up the water tank the float valve will automatically close when water reaches the desired level During testing turn on the circuit breaker Turn Manual Off Auto button on the electrical cabinet to Start position enabling the ice maker to enter a 5 minute delay state Start Delay indicator light blinks which is followed by the automatic start of gear box and water pump 1 Check that the ice blade is rotating in the right direction 2 water level in distributor pan is aligned with the red mark and water flow is adequate If operation is normal then switch Stop Start switch to Stop Ice production stage Switch the Start Stop button of ice machine to Start which enables the ice machine to start ice production after a 5 minute delay Start refrigeration system and open suction and liquid line valves When refrigeration system reaches an evaporator temperature of 20c Ice will be produced Stop W2. Revised January 2011 XIII Service Bulletins Coast tip of the week Blocked water filter bypass If you need to bypass the water filter in an emergency you can carry out the following to get you out of trouble until you can replace the cartridge Isolate water to filter Remove filter cartridge Remove small O ring Re install filter cartridge Turn water back on prm a By caring out the above this bypasses the cartridge and allows water to flow to your machine NOTE return and replace the filter cartridge as soon as possible 29 Revised January 2011 Water regulating valve If there is water dripping or flowing into the bin from under the evaporator check the water flow over the evaporator Ball float adjustment under Water flow regulator valve To adjust the water flow so as not to overflow the drain catchment tray adjust this valve slowly to regulate the water flow If the flow is too high the water overflows the drain tray If the flow is insufficient there will be little ice production 30 Revised January 2011 Service 8 Maintenance Scehdule JAN FEB MAR APR MAY JUN oo w L T FE IEEE __ IEEE _ sees IEC _ _ Owwendens Lema LLL LL JUL AUG SEPT OCT NOV DEC oo w E IE Diseases O escher _ wwe IEC _ _ eech can 31 Revised January 2011 1800 688 59
3. Sanitize bin Follow the manufactures directions on the sanitization procedure 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 Carry out correct isolation procedure and test unit for power loss Re connect the compressor overload or solenoid valve coil power Reset the delay timer dip switch no 1 of 8 back to the off position Down Clean the unit condenser and covers where fitted Turn the water back on to the machine Re energize the power and turn the machine on Check operation of unit Check Auto Off Man operation and time clock setting 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 14 Revised January 2011 VIII Trouble shooting Fault Description Possible Causes Machine inactive 1 PC board Power indicator not Main switch is set to OFF position Selector switch needs to be set to on ON position P C board s fuse blown 750mA Replace the fuse and diagnose the cause of fuse fault Malfunction of P C board Replace the P C Board 2 Ice full level indicator on Connection wire loose Check the wiring Malfunction of ice level control assy Clean or replace ice level control assembly 3 Low water level indicator on Low water level or water too soft Please refer to recommendations for lo
4. b setup of ice full sensor sensitivity Ice full sensor sensitivity may diminish after a certain period of time At this time It can be adjusted by the ice full sensitivity resistor on the PC board Clockwise rotation will increase the number of lights ice full sensor sensitivity will increase accordingly Anti clockwise rotation will decrease sensitivity and decrease the number of lights The LED 1 next to the 8 dip switches is the sensitivity indicator when the LED is lit the bin is empty when the LED is off the bin is full 1 ON Cancel ice full protection 2 ON Cancel evaporation temperature protection J ON Cancel condensing temperature protection 4 ON Cancel low rotating speed protection 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 24 Revised January 2011 Grant Timer with remote switch The Grant unit can be fitted with a remote switch and timer the function of this is twofold As the electrical control board is placed on the unit this can make access to the factory fitted switches difficult The remote switch allows the ON OFF AUTO switch to be placed in an easily accessible location such as when the unit is placed on a large ice bin or transport system i e Follet ITS or DEV The timer is designed to reduce the ice clu
5. 8 4 Water Temperature C Water Temperature 0 FF1 2E FF1 5E 1300 c 1650 c 1200 E 4500 1100 amp 1350 E 1000 1200 gt 900 S 1050 800 S 90 32 28 2 20 16 17 8 4 3 28 2 20 6 170 8 4 Water Temperature C Water Temperature C FFSE a 5500 aap 25 3000 FF3 2E 1 Er 2m EARL IA 2508 Jl eme L A E Yo An Paa e LAA AE EN 205p F m a N od H Se put t 5 Water S ch sao LA el 20 Water temperature ef ut notice FF1 E 1000 900 800 700 Ice output in 24 hrs kg 600 32 28 24 20 1 6 1070 8 4 Water Temperature t FF2 E 2200 2000 1800 1600 14 00 Ice output in 24 hrs kg 1200 32 28 24 20 1 1 8 4 Water Temperature C ut in 24 hrs Ice ou MU TE LA SO 38 32 26 20 15 10 5 Water temperature C Revised January 2011 3 Dimensions see figure 1 Pipe Connection Front View Pipe Connection Top View 2 Suction Line I mi aie A A L A E E ed A D ed vi f ia vi Standard Gear Water Inflow icd Water Water Air Inlet Ice Output Dimension Box Pump Refrigeratio Tube j Weight i over Consum Suction Pipe Type 1000kg mm Motor Motor n Power OD t flow ption Tube OD female 24h LxWxH Power Power D kW O mm imam B m Pipe w W d OD FFO 4E 0 4 1090 700 720 120 10 17 2 2 20 25 170 21 FFO 6E 0 6 1250 750 820 120 10 25 3 3 20 30 160 Y GEN FF1E 1 1050 85
6. X Wiring Diagram E 10A Fuse ID 2A E RMA H6 u21 W21 m fe e zx 2A rw 4 K2 1 BI RD3 Fuse for power supply indicator RD2 Fuse for solenoid valve power RD Fuse for water pump power YA Solenoid valve M2 Water pump M1 Speed reducer KT Delay contactor XJ Protector for phase breaking HI P C board power supply indicator JOSUIS JOA 39 i im E x ECM CP a I l I ECO I I l l I l l l lt gt EN JOSUIS SAI IWM JOSUIS ounjeJoduro Josuopuo JOSUIS JOJOUI XOQ 1290 C Josuos ounjeoduro JIZIIOdRA ge H2 Ice full indicator H3 water shortage indicator H4 Hi condensation temperature start delay indicator et M MUM H5 Low speed high vaporization temperature indicator YA M1 M2 380V 50HZ H6 Breaking phase malfunction indicator lamp 3N H7 Power supply indicator RJ1 Thermal overload protector for speed reducer KM2 AC contactor of water pump KM1 AC contactor of speed reducer 16 K2 P C board switch QF Air switch Notes This machine does not use condenser temperature sensor Revised January 2011 YIJIMS SY Y Ja30p3J 265875 0 JOJ90JU0 JY LWY dung Jaj0 yO 1943040802 jV ZNN Japas naads J0j 10123j0ud PDOJJIAO JDWJIY ify Japu aunjosadway up pDZIJOJDA ybiyy paazs MO LH 03 Cul njep jJPjs 2JnjD2aduis uoijpsuepuo ub 9p JOJCIIPU abpjJous JayDM SH JO4DIIPU N 99 H 91D0xpur Ajddns amod pipog Jd EH 30 02 pil uouysusy ca asoyd uiy0aJg Z
7. plastic water pan at the bottom of evaporator Check water float operation and water level Adjust or replace if required Check water trough for foreign matter and clear if required 10 Check for any water leaks 12 Check water reservoir 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 Jor isolating the power to the liquid line solenoid valve coil on all FFE models 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 Make up correct amount of cleaning solution as per manufacturer s directions and empty solution into the water reservoir 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 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 Once the cleaning time has elapsed turn unit off and drain the water and flush the system 4 times Clean the bin and flush check the drain Drain the water from the water reservoir via rear drain tap Mix up and add sanitizer solution to the system turn unit back on
8. 0 Ph 02 9524 1234 Fax 02 9524 0968 Email sales coastdistributors com au Web www coastdistributors com au COAST DISTRIBUTORS PTY LTD 22
9. 0 870 180 10 42 5 5 12 7 22 170 A 021 FF1 2E 1 2 1050 850 880 180 10 50 6 6 12 7 22 180 21 FF1 5E 1 5 1050 850 1050 180 10 63 8 5 12 7 28 200 Y GEN FF2E 2 1050 850 1080 180 20 83 11 0 127 28 230 21 FF2 4E 2 4 1050 850 1250 180 20 100 13 5 12 7 28 240 21 FF3 2E 3 1050 850 1300 180 20 125 16 5 12 7 28 280 21 FF5E 5 1850 1150 1250 370 65 208 28 0 28 54 800 1 2 021 4 Specifications Notes 1 Standard operating conditions Ambient temperature 25 air and water temperature 16 2 The evaporator temperature shall be 22 and condenser temperature 45 air cooled or 40 water cooled An EPR valve is recommended with multi compressor evaporator systems 3 Power supply 415V 50HZ 3N 4 Refrigerant R404A 5 Supply water pressure 0 15 0 5MPa Revised January 2011 lll Packing Transportation Storing and Installation 1 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 B 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 2 Installation Electrical conne
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11. Revised January 2011 G2RGR NT SERVICE MANUAL FOR FF 0 4 5 E MODELS Evaporator Only 380v 415v 3 phase 50hz pm SE nf 8 D oo p 7 APT A A Revised January 2011 Table of Contents MS A A A E E E 4 Il Operation Conditions amp Performance Parameters d EREECHEN EE 4 2 Diagram ot ce Output of ICG Machi es aan a A a 4 SE e Ee LEE 6 es PEN CONS ad 7 lll Packing Transportation Storage amp Installation 1 Transportation and Wa Ee e nas 7 ZAS atada aa 7 9 PIpe Connecti n DIG SAI tios 8 IV Operating e Le TEE 9 V Operating Principles Ls Ce len ii d 11 Z AN ater Circulation Stern 11 Sce LOVE COMO MASSE Dy ata 12 hs WAVE Ge Ale e EE 12 SAPO Board Control SY St MA AS 12 VI Safety EEGEN ee gek 13 VII Cleaning Oe DE 14 VIN Trouble ShooOtllig o dcus c o asalta 15 Xe WV irine Dias AM E 16 Winne Diagrami WIT iMac 17 MPC Board EX lain he aii ib 18 T Circuit BO ALC ME EE 18 a Ice making machine PC Board layout back 18 b ice making external indicator small board layout occcooocccnnonnocnnnnnanonononos 18 C Ice full sensor sensitivity small board layout cc ceeeccecesscceeeeseceeseeseceeeeeseees 19 Revised January 2011 SEH Td To e EE rocas 19 IO 20 ale TE ue T E 20 JAS o IA 21 A Electrical Wiring DIM ei 22 a Ice machine PC Board wiring diagram ccccoooccnnccnncnnnonnnonnnonaronnnonaronnnnanonononanoss 22 b Ice Machin
12. ark the specified water level can be achieved through adjusting the valve in water tank or the valve fixed on the top of evaporator with the depth of water in the pan being 26mm for 10 ton and smaller ice machine 38mm for 15 ton and bigger ice machine Gear motor I VAX Gearbox Water pump a um il A e Bee Ice blade i m rss I H gi Gnd Je ames mecs N Lj Le Te Cl a az M E a Soon M n B n re Suction line JH LLL ni ot Evaporator Water tank Liquid line Drip pan ALL A T ianea o B 222575 JT Figure 7 11 Revised January 2011 3 Ice Level Control Between ice machine and ice storage tank there is an optical ice level control sensor When the ice reaches the sensor and blocks the optical beam the red LED at the center of the P C board goes out immediately After the light beam has been blocked for a given time production of ice stops and the yellow LED turns on to indicate ice full state When ice is removed from the sensor the light beam resumes and the red LED on the P C board lights immediately Ice machine restarts in 10 seconds and ice full yellow LED goes out 4 Gear box system This system consists of gearbox motor and gearbox The former drives the latter and the gearbox output shaft propels the rotating ice blade and water distributor pan When gearbox motor runs in the wrong direction or its speed is less than 1300rpm a signal is sent by the sensor to the P C board which stops the operati
13. ation and maintenance of ice machine 1 No repair or maintenance shall be carried out before ice machine has been confirmed not in operation and disconnected from main power supply 2 With ice machine in operation or energized no body part or other object shall be allowed to enter the evaporator barrel 3 After a power loss or outage Take care to check rotation of gearbox 4 During installation commissioning and operation be sure not to allow body to contact discharge pipes 5 All refrigerant pipe work needs to be inspected and fully pressure tested before commissioning 6 All state and local guide lines and standards must be adhered to 13 Revised January 2011 VII Cleaning Procedures Warning No cleaning or maintenance shall be carried out on the machine prior to carrying out correct isolation procedures to isolate the machine N from the power and water supply Coast Distributors recommends the WN e 0 NOU P 13 14 15 16 use of PPE when carrying out a service or maintenance on either the ITS BIN or Grant ice machine Carry out correct isolation procedures and test unit for power loss Isolate the water supply to the machine Remove and replace the water filter cartridge and purge approx 4ltrs of water through filter Carry out visual inspection of the unit Remove the black top plastic cover on the evaporator Check condition of water distributor and tubes Check condition of
14. ault indicator Solid C Yellow Water shortage indicator Flashing Red Condensing temperature fault indicator solid light start up delay indicator flashing C Yellow low speed alarm indicator solid light evaporation temperature fault indicator flashing When the power frequency is lower than 45Hz more than five seconds all the indicator lights flash at the same time Revised January 2011 3 Dip Switch 1 8 bit DIP switch Attention Please press reset button before resetting DIP switch Cancel the buzzer off BO000000 Start up delay function on 2 3 4 5 B Open the buzzer on Cancel start up delay function Cancel the test Select 1440RPM model D0900008 parameters factory 1234 8 5 7 Select sub zero ice machines on Open the test IBBCODOR ice full sensor HULA parameters factory i 2 3 4 5 6 7 8 Eight bit DIP switches on the centre of the PC board Figure 3 1 are from left to right Override is when dip switch is in the on position The function of the first bit DIP switch Selects the starting up delay function When the first bit DIP 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 se
15. ctions must comply with local standards and requirements on the rating plate of the machine B Anisolation 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 D The ice machine shall not be placed 1 without suitable ventilation 2 next to heat sources or 3 outdoors E Toensure ice quality a water filter should be installed in icemaker inlet water line Revised January 2011 3 Pipe connection Diagram and Machine dimensions and Ice Outlet Dimensions Pipe connection Front Type FFO 4E FFO 6E FF1E FF1 2E FF1 5E FF2E FF2 4E FF3 2E A 87 95 150 150 150 150 150 150 395 450 750 750 750 750 750 750 Pipe connection Top 658 665 198 198 198 198 198 198 Figure 3 D E 447 216 430 419 490 310 490 310 490 310 490 310 490 310 490 310 1050 1250 1050 1050 1050 1050 1050 1050 Dimension of ice outlet 2 IES tps E 850 750 850 850 850 850 850 850
16. e external indicator small board wiring diagram 22 c Ice Making sensor wiring diagram ccccoocccnnccnncnnncnnncnnnnnnaconnnnnnronnnonanonnnonanonononos 23 5500 ad 7 5000 E c 4500 3 3000 38 32 26 20 15 10 5 Water temperature IO Revised January 2011 l Overview Read this service manual carefully before installation and operation of this ice machine This Service Manual gives an introduction of operating conditions performance parameters installation and troubleshooting procedures of the FFE series ice machine The ice making system has a vertical static evaporator with a rotating auger The machine is equipped with a P C board which controls and monitors the functionality indicating 1 Ice level 2 Water level in water tank 3 Motor and gearbox operation 4 Temperature of Evaporator Il Operation Conditions amp Performance Parameters 1 Conditions for Operation Minimum Operating Maximum Operating Conditions Conditions Ambient Temperature 40 0 15MPa 0 5MPa Deviation from Voltage Rating 2 Ice output in 24 hrs kg Ice output in 24 hrs kg Ice output in 24 hrs kg Revised January 2011 Diagram for Ice Output of Ice Machine FFO 4E FFO 6E 450 E 650 400 600 350 A 550 300 500 250 2 450 200 S 400 3 28 24 20 1 14 8 L 32 28 24 20 6 7
17. elay The switch is set to OFF position at factory No 2 amp No 3 switches are in ON position for sub zero ice production No 6 switch Alarm buzzer factory set in On position 10 Revised January 2011 V Operating Principles 1 Refrigeration System See Figure7 When liquid refrigerant flows through evaporator cylinder the refrigerant lowers the temperature of the evaporator cylinder through heat exchange meanwhile water in contact with the evaporator surface freezes and ice detaches from the surface from the action of the ice blade rotation and falls into ice storage bin 2 Water Circulation System See Figure7 Supply water flows into the water tank via the float valve Water is pumped into the distributor pan and then flows to the evaporator s interior surface The cooling process occurs gradually and part of the water turns into ice The ice is detached from the interior by the rotating blade and falls into the ice storage bin Note 1 Feed water level is monitored by a sensor In case water tank runs out of water or has soft water demineralized P C board stops the operation of the machine and the yellow LED turns on to indicate low water level alarm The machine will reset to normal operation after water level recovers 2 When being tested at the factory the water level in water distributor pan has been set in line with the red mark on the water level indicating bolt If the water level is not in line with the red m
18. hen the Manual Off Auto button is switched off water pump and liquid line solenoid valve stop working immediately and the gear box stops working after a 3 minute delay so as to remove ice left on the interior of the evaporator cylinder Failure due to alarm Unit stopped due to ice full level alarm normal stop When PC board detects full level of ice in storage bin Water pump and solenoid valve are stopped first and then the gear box motor stops after a 3 minute delay and ice full level indicator turns on at the same time Now the system is in stand by mode After the ice is removed from bin full sensor the system will return to normal operating status gear box motor water pump and solenoid valve will be started in sequence Failure due to low water level alarm When PC board detects low water level in the storage tank water pump and solenoid valves stop first and then gear box motor stops after a 1 minute delay and low water level indicator turns on at the same time Now the system is in stand by mode After the water tank is refilled the system automatically returns to normal operating status gear box motor water pump and solenoid valve will be started in sequence 3 Failure due to low speed of gear box motor Fault Light ON When PC board sensor detects suspension reversal or low speed of gear box motor Gear box motor water pump and solenoid valve stop and give alarms simultaneously Fault will need to be diagnosed elimina
19. lect 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 The function of the sixth bit DIP switch Selects the buzzer alarm When the sixth bit DIP switch is in the on position the buzzer will alarm when a fault is triggered in contrast the buzzer is silent when the dip switch is in the off position The function of the seventh bit DIP switch DIP switch is invalid The function of the eighth bit DIP switch Selects the test parameters testing the PC board design parameters at factory the switch has been set off at the factory 20 Revised January 2011 b 4 bit DIP switch Warning Please press reset button before resetting DIP switch Turns on the low rotating speed fault Turns on the evaporating temperature protection protection Cancels the low rotating speed fault Cancels the evaporator temperature protection protection Turns on the condensing temperature Turns on the ice full protection protection Cancels the condensing temperature Cancels the ice full protection protection Four bit DIP switches on the center of the PC board Figure 3 2 are in order from left to right The function off the 4 dip swi
20. mping found with storing scale type ice for long periods The theory is to supply only the ice needed for the demand an example would be Grant one ton FFE on a Follett DEV ice bin Customer requires 400 kg of ice at 7am and 200kg at 4pm Timer will require to be set from 10pm to 7am and 11am to 4pm Grant 1 ton FFE 1000kg 24hrs 41kg 1hr 400kg will require the unit to run for 10hours 200kg will require the unit to run for 5hours Of course this is only an example and every application will vary but the principal is the same it will be up to the technician to consult with the customer and set timer to suit their needs With the timer set up correctly the machine will produce Ice on demand and prevent clumping of ice in the storage bin a Parts Identification Ciruit diagram 3 gr Present time 7 terminal MIC j M Power supply indicator Load terminal j Present time 25 Revised January 2011 b Operating Instructions Before turning power ON Check that your unit conforms to the operating voltage If the unit has not been in operation for a long period the battery may have discharged and may not work immediately Connect the unit and switch power source on wait for approximately ten minutes before setting the timer Full power reserve is built up after approximately 72 hours 1 Setting the timer Set the setting pin between the desired times to the left or right of the dial Set the setting pin t
21. o the right of the dial ON position If the setting pin is set to the ON position continuously it will continue only for the number of setting pins x 15 minutes Set the setting pin to the right until a click is heard Set the setting pin to the left of the dial OFF position ua UT LETT TT hi st LIC f way ma E GN ma Y y E I Set the setting pin as shown on the above the time chart is as follows 2 Adjust the present time Turn the dial until the index is on the current time 3 Set the manual switch Use this switch to select either ON or OFF in manual or ON OFF in the operation program Auto output is turned ON and OFF according to the set program Manual ON output is turned ON irrespective of the program Use this mode for test operation Manual OFF output is turned OFF irrespective of the program After completing test operation set the manual switch to AUTO 26 Revised January 2011 C Specifications ae Capacity mde RA 2T Revised January 2011 XII Technical Notes 1 All PC boards after November 2009 will be the bypass model which will allow all sensors to be bypassed for diagnostic purposes All Grant ice machines up to 10 ton use the same PC board All grant ice machines 10 ton and over use a PLC All the old style PC boards have no bypass on any faults except by bridging using the correct ohm resister Bin full sensor can be bypas
22. on of ice machine The cause of fault must be identified and the fault eliminated before ice machine will restart Press the Reset button on the P C board once or turn the Start Stop button to reset the unit 5 P C Board Control System See Figure 8 THE P C Board controls the entire process of ice machine operation based on the signals transmitted by different sensors Water level Water level judgment Detection electrode circuit 1 Ice level sensor Ice level judgment Circuit 2 Motor operation Motor rotation Sensor signal circuit 3 Evaporation temperature Evaporation temperature Sensor t circuit 4 High temperature protection circuit 5 Low temperature Protection circuit Compressor controlling Compressor circuit 9 Contactor Gear motor controlling De Gear motor circuit 10 Fan controlling Ean EE circuit 11 Ice level sensor Condensation temperature Sensor Not used on FFE state indication Figure 8 12 Revised January 2011 VI Safety Precautions N Warning Main power supply must be cut before conducting any operation for cleaning and maintenance Especially when the ice machine is in the bin full and no water states In this case DO NOT do any maintenance or repair of the ice machine especially the inner part of the machine Ice machine may automatically start at any time Special care for the following safety precautions shall be taken into account during commissioning normal oper
23. sed by bridging terminals 2 and 3 All sensors can be bypassed with the correct resister Low temp sensor can be bypassed with a 10 ohm resister High condenser temp sensor can be bypassed with a 91 ohm resister LD CON On Ui A U N Gear motor speed sensor cannot be bypassed 10 The square blue potentiometer on the PC board is to set adjust the sensitivity of the bin full sensor A correct setting is 5 lights on the small circuit card on the front of the board If the sensitivity is set to high the sensor can burn out 11 Speed sensor operates at 1440rpm with a 7 differential 12 Speed of the gearbox is governed by the hertz and should be checked on every installation 13 Hertz under 45 will cause low rotation fault 14 Phase fail control requires a voltage of not less than 380 or greater than 450 volts but can be set at 10 lower to get out of trouble but is not recommended 15 Scraper must always be set at 0 3mm off evaporator shell use a set of feeler gauges 16 Incorrect ice thickness will trip speed sensor and cause shuddering 17 If gearbox scrapper shuddering occur water flow is too great and should be reduced and or TX valve may need adjusting 18 TX feed can be checked by ice formation on evaporator i e ice forming lines in evaporator increase TX feed 19 The core dryer fitted to the suction line has no core fitted the dryer is there for quality control at the factory and is removed after testing 28
24. tch s are to bypass any of the 4 sensors so the machine can continue to function until the fault is rectified When a bypass is activated the fault light for that sensor will continue to be activated until the fault is rectified and the unit is reset 21 Revised January 2011 4 Electrical wiring diagram a Ice machine PC board wiring diagram Condensing temperature sensor white Evaporating temperature sensor red Rotate speed sensor red Lem Buzzer interface Compressor Speed reducer Condenser fan Ice making PC board layout front figure 4 1 22 Revised January 2011 b Ice machine external indicator small board wiring diagram Rotating speed fault indicator evaporator Condenser fault indicator delay indicator Fault Indicator Water shortage fault indicator Ice full fault indicator Power Indicator 0000909090900 c Ice making sensor wiring diagram Evaporator Condenser Temperature Temperature sensor sensor Ice Full sensor Water shortage sensor Motor sensor 4 00 B SNC se BE Plug Colour Red Red Yellow Yellow Wiring New Sensor Old Sensor OB TR BBGEB rree rir no d oaau 5 Ice full sensor sensitivity and DIP switch settings w wcye ee f no nk a Ice full sensor sensitivity settings 3 we Flake ice machine XB70 XB550 model 5 indicator Sub Zero machine PBO 4F A PB5OF A model 5 indicator 23 Revised January 2011
25. ted and PC fault reset for system to return to service Revised January 2011 4 High evaporator temperature alarm Fault Light FLASHING After 10 minutes of operation PC board begins temperature detection program when evaporator temperature exceeds a set point the microprocessor implements a Hi temp fault program water pump and solenoid valve stop immediately and gear box stops after a 6 minute delay and gives alarm signal simultaneously The fault will need to be diagnosed rectified and fault reset for system to return to service Other notes This machine does not indicate condenser temp A Electric box Panel Diagram 5 GER GRANT Z 2 2 94 z Low rotation speed Time delay Water Full ice P C ON hi evaporation temp or hi cone shortage N i M Nr j Start Stop Phase Failure Power supply Manual Off Auto switch install on ITS S Figure 5 B Manual Off Auto Switch Starts or Stops the machine Restarts the machine after a fault has been rectified o C DIP Switch P C board is equipped with 8 DIP switches which do not need to be adjusted in normal operation all switches are set to OFF position except No 2 No 3 and No 6 switch to ON position as shown in Figure 6 below ON DIP Figure 6 No 1 Switch When the switch is set to ON position the machine will be started without a 5 minute delay when it is set to OFF position the machine will be started with a 5 minute d
26. w water level alarm 4 Evaporator temp indicator Evaporator temp sensor damaged Replace flashing Low gas charge Check leak test and repair High ambient temp 5b Low rotation speed indicator Gear box motor s rotation reversed Check motor wiring and capacitor on phase rotation Gear box motor s spinning speed is too low Check motor bearing evaporator cylinder bearings TX adjustment Voltage is too low Check supply power and wiring Compressor runs intermittently Non condensables Eliminate the fault Loose compressor contact terminals Check and tighten all wiring Expansion valve partially blocked or Adjust TX valve not adjusted properly Low ice production Moisture in the system Reclaim gas evacuate and charge Low water level in distributor pan Adjust it to the specified water level Low refrigerant charge Check for leaks and charge Ice machine in operation but no No water in water cylinder for ice Check water pump flow valve and ice is being produced production pipe work Gear box not rotating Check repair or replace it Water level is too high in water tank Adjust Water leak Water level is too high in distributor Adjust pan Motor s bearings worn out Check or replace it Noisy gearbox Gear box low in lubrication oil Check gear box and add lube oil Gear box s bearing and gears worn Check and replace the worn parts Low water level Feed water pipe blocked Dismantle and clean the pipe 15 91 Revised January 2011
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