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JOSAM SUPER FLO GI-2000 Series Operation, Installation, And Maintenance Manual

Fully automated grease recovery device
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SUPER FLO
GI-2000
TM
F U L L Y A U T O M A T E D G R E A S E R E C O V E R Y
D E V I C E ( G . R . D . )
O P E R A T I O N , I N S T A L L A T I O N
A N D
M A I N T E N A N C E M A N U A L
VERSION 2.4
10/2007
PLEASE READ CAREFULLY
Grease Recovery Device will operate efficiently only when properly installed.
Do not discard this manual. This manual is to be distributed to installer,
operator and maintenance department.
:
WARNING
Cancer and Reproductive Harm - www.p65warnings.ca.gov

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Summary of Contents for JOSAM SUPER FLO GI-2000 Series

  • Page 1 SUPER FLO GI-2000 F U L L Y A U T O M A T E D G R E A S E R E C O V E R Y D E V I C E ( G . R . D . ) O P E R A T I O N , I N S T A L L A T I O N A N D M A I N T E N A N C E M A N U A L...

  • Page 2: Table Of Contents

    T A B L E O F C O N T E N T S 1.0 UNPACKING ........................... 3 2.0 INSTALLATION INFORMATION .................... 4-6 3.0 WARNINGS ..........................6 4.0 PLUMBING INSTALLATION ....................... 6-8 5.0 ELECTRICAL INSTALLATION ....................9-11 6.0 G.R.D TESTING ........................12-14 7.0 MAINTENANCE ........................

  • Page 3: Unpacking

    1.0 UNPACKING After unpacking the GI-2000, the unit should be checked for any damage that may have occurred during shipment. Any damage should be reported to Josam Company immediately. The following items should be included with the shipment: DESCRIPTION GI-2000 G.R.D.Unit...

  • Page 4: Installation Information

    2.0 INSTALLATION INFORMATION 2.1 Unit Sizing Ensure that you have selected the proper size JOSAM GI-2000 so that it can never exceed the maximum rating of the grease recovery device to suit your particular requirements. Size is based on Flow Rate per PDI G-101 and ASME A112 14.4.
  • Page 5 2.2 FLOW CONTROL SELECTION Josam Company has shipped the proper flow control fitting to suit the GRD that you have ordered. Ensure that the proper flow control fitting is included with your shipment. Changing the flow control fitting is not recommended and will affect the performance and warranty of the GRD.

  • Page 6: Warnings

    As a result, a specially designed Josam flow control fitting with a 3”, 4”, 5” or 6” threaded inlet and outlet connection, depending on size of unit, and a threaded air intake is furnished with every GI 2000 at no extra cost.
  • Page 7 FLOW CONTROL LOCATION The GI 2000 must be correctly installed with the flow control as per model plumbing codes or the local authority having jurisdiction. The GI-2000 must have a flow control device properly vented at the inlet or in close to proximity to the GRD inlet, thus allowing the fixtures to be plumbed and vented as required without having any negative impact on the GRD or flow control device whose purpose is integral to the performance of the GRD.
  • Page 8 DIAGRAM “B” Locate the installation diagram, which most closely suits your requirement. Install the flow control and GI-2000 as shown. Page GI-2000 Manual V2.3...

  • Page 9: Electrical Installation

    220/208 VAC 24000 Watts 2x60 AMP Note: For special order models not listed consult Josam Company for power requirements WARNING! Do not apply power to the unit until the GI-2000 is completely full of water. Install this unit as any GRD would normally be installed with the exception to...
  • Page 10 POWER WIRING The GI-2000 units are provided with power exiting the tank through the wiring conduit port on the side of the tank. The power wires provided are: Red: 120VAC (L1) Black: 120VAC (L2) White: Neutral Green: Ground Typical wiring between the breaker panel and the GI-2000 unit is: Wire Type: (Type MTW) 10 Awg min.
  • Page 11 The GI-2000 controller has an optional integrated reclaim tank alarm system designed to monitor the state of the reclaim tank, alert the user when the reclaim tank is full and prevent overflow of the reclaim tank. The option consists of the following components provided by Josam: Float switch Assembly Float Switch Cable...

  • Page 12: Testing

    6.0 G.R.D.TESTING Leak Check Confirm that the unit is level and unlatch and lift off the large cover on the GI-2000 tank. Run water through the drain installation until the unit is full. The unit is considered full when water runs out of the outlet of the GI-2000. Check the system installation for leaks.
  • Page 13 Pump Check The GI-2000 G.R.D. is equipped a pump to move the grease from the G.R.D into the reclaim tank. The GI-2000 Controller provides the ability to test the pump. To access the test controls inside the Controller, loosen the front panel screws and open the Controller door.
  • Page 14 The GI-2000 Controller provides the ability to check the operation and calibration of the grease level sensor. To access the test controls inside the Controller, loosen the front panel screws and open the Controller door. Follow the procedure in Section 8.6 to check the water level being measured by the grease level sensor.

  • Page 15: Maintenance

    The GI-2000 requires that the grease level sensor be periodically cleaned of grease or debris that may be stuck to the sensor. JOSAM recommends the grease level sensor be cleaned every time the interceptor tank is pumped out. As a minimum, the tank probe should be cleaned every 3 months.
  • Page 16 Page GI-2000 Manual V2.3...

  • Page 17: Controller Operating Procedures

    8.0 CONTROLLER OPERATING PROCEDURES 8.1 GENERAL DESCRIPTION OF OPERATION 8.1.1 CONTROLLER MODES OF OPERATION The GI-2000 G.R.D. controller provides the following modes of operation: Automatic Clean Cycle Mode This operating mode automatically starts the clean cycle that pumps the grease out of the interceptor trap whenever the volume of grease reaches the preset level.
  • Page 18 Table 1 Test Functions Time and Date Entry - Allows maintenance personnel to set the time and date Heater Test - Allows maintenance personnel the ability to turn the power on and off to the heater Pump Test - Allows maintenance personnel the ability to turn the power on and off to the pump Temp Switch Test - Allows maintenance personnel the ability to...
  • Page 19 Internal Controls Table 3 lists the internal controls are available to maintenance personnel when the door to the controller enclosure is open: Table 3 Internal Controls Cal Mode/Up Switch - Initiates the water level sensor calibration mode and increments time and date values in the time and date entry mode.
  • Page 20 Figure 8.1.2-1 Illustration of the external switches and indicators on the front of the controller enclosure JOSAM GI-2000 GREASE RECOVERY SYSTEM OPERATING SOFTWARE VERSION X.X OSAM GI2000 Grease Interceptor Controller Unit POWER CLEAN AUTO MANUAL START/ CYCLE STOP ACTIVE Page...
  • Page 21 Figure 8.1.2-2 Illustrates the internal switches and indicators inside the controller enclosure. JOSAM GI-2000 GREASE RECOVERY SYSTEM OPERATING SOFTWARE VERSION X.X ACTY 2 PUMP ON HTR ON LEVEL HI ACTY 1 TEMP SW CAN/TEST ENTER UP/CAL DOWN/CC RESET BUTTON DIP SWITCH Page GI-2000 Manual V2.3...
  • Page 22 8.1.3 TYPICAL CONTROLLER OPERATION The following sections describe typical GI-2000 controller operation: Typical Controller Power ON When power is first applied to the GI-2000 the unit will beep and go through internal diagnostics (See Section 8.7 for typical display messages after initial power ON or reset).
  • Page 23 Typical Manual Cycle When the controller’s front panel Manual Mode Switch is pressed and the Manual Mode LED is ON, the user is required initiate the cleaning cycle. A clean cycle is typically initiated when the grease level reaches the preset level as indicated by the GREASE LEVEL HI indicator on the controller’s front panel.
  • Page 24 8.2 AUTOMATIC CLEAN CYCLE - FULL DESCRIPTION The following message is displayed when the unit is operating in Automatic mode: AUTOMATIC OPERATING MODE DyCyc:XX WkCyc:XX MoCyc:XX YrCyc:XXX When the controller measures a level of water that indicates the clean cycle should begin the following occurs: a) The Clean Cycle LED turns on and the horn sounds.

  • Page 25: Automatic Clean Cycle - Full Description

    AUTOMATIC CYCLE IN PROGRESS PUMP ON XXXXX Note: This display indicates the pump run time remaining in seconds. AUTOMATIC CLEAN CYCLE COMPLETE d) The unit will not run another clean cycle within for 12 hours unless the clean cycle limit has been disabled (see Section 8.4). The unit display will cycle to the main automatic display mode.

  • Page 26: Manual Clean Cycle - Full Description

    8.3 MANUAL CLEAN CYCLE - FULL DESCRIPTION The following messages are displayed when the unit is operating in Manual mode: MANUAL OPERATING MODE DyCyc:XX WkCyc:XX MoCyc:XX YrCyc:XXX and cycles every few seconds to: MANUAL OPERATING MODE PRESS “START” TO BEGIN CYCLE a) Once the operator presses the Start/Stop button the Clean Cycle LED light turns on and the horn sounds.
  • Page 27 MANUAL CYCLE IN PROGRESS PUMP ON XXXXX Note: This display indicates the pump run time remaining in seconds. MANUAL CLEAN CYCLE COMPLETE d) The unit display will cycle to the main manual mode. Note: Another clean cycle should not be initiated until the water level rises back to the outlet level. e) The unit will display the following message is the user presses Start/Stop button at any point in the clean cycle to interrupt the cycle.

  • Page 28: Calibration Mode

    8.4 CALIBRATION MODE The calibration mode is intended to allow the user to calibrate the grease level sensor and configure system operating parameters. The following table lists the calibration mode functions: Function Description 8.4.2 Set Time/Date Sets the controller’s real time clock and date 8.4.3 Sensor Calibration Calibrates the grease level sensor 8.4.4 Set Auto Clean Days...
  • Page 29 The third press of Cal Mode button enters auto clean day setting mode with the following display. See section 8.4.4. PRESS UP/DWN KEYS FOR DESIRED CAL PRESS ENTER TO SET AUTO CLEAN DAYS The fourth press of Cal Mode button enters the sensor calibration offset mode with the following display.
  • Page 30 Pressing the Enter button displays: USE UP AND DWN KEYS TO SET MIN, PRESS ENTER WHEN SET. MIN: XX Pressing the Enter button displays: USE UP AND DWN KEYS TO SET MONTH, PRESS ENTER WHEN SET. MONTH: XX Pressing the Enter button displays: USE UP AND DWN KEYS TO SET DAY, PRESS ENTER WHEN SET.
  • Page 31 8.4.3 SENSOR CALIBRATION The grease level sensor calibration is based upon sensing the water level in the tank. Therefore, the tank should not have had any grease introduced in the last hour and as much of the grease as possible must be removed before performing the calibration sequence.
  • Page 32 At this point fill the tank to the second calibration mark. Typically the water level is at the bottom of the outlet pipe. Next, press the Enter button the display will cycle to: READING LEVEL TWO CALIBRATION –WAIT- This reading will take longer than level one and may take up to several minutes. After the level calibration is read, the screen cycles to: LEVEL 2 CAL.
  • Page 33 8.4.5 SET CALIBRATION OFFSET This function allows the user to adjust offsets in the calibration level when the tank is full of water. Normally the test water level reading with the tank full of water is 4.0 inches. If the test water level is not 4.0 inches use this function to adjust the test water level reading to 4.0 inches.
  • Page 34 8.4.7 LONG TERM AVERAGING This function enables or disables averaging of the grease level sensor readings over 7 days. Long term averaging of the measured grease level is intended to prevent short term changes in measured grease level from causing false clean cycle initiations. CAL MODE–USE UP/DWN KEYS TO ENABLE OR DISBALE LT AVERAGE...

  • Page 35: Clean Cycle Rate Adjust Mode

    8.5 CLEAN CYCLE RATE ADJUST MODE The clean cycle rate adjust is provided to easily modify the pumping cycle frequency. This allows the user to quickly adjust the system to operate automatically more or less often. To enter the clean rate cycle adjust mode press the CC Rate button. (Note: If no button activity occurs for ~ 15 minutes the Rate Adjust Mode will time out and the unit returns to either automatic or manual operation.) The first press of CC Rate button causes the following message to appear:...
  • Page 36 8.6.1 TEST MODE ENTRY Press of the Test button and the following message will appear: PRESS UP OR DOWN KEYS UNTIL DESIRED TEST APPEARS Press the Up or Down button to cycle among the available tests. Note: During the test mode, hitting the Cancel button twice will exit to normal operation. If there is no activity at the controller for 15 minutes, the unit will return to Manual or Automatic operation.
  • Page 37 Press the Up or Down button until the following display appears: TEMP.SWITCH TEST: SWITCH STATUS: OFF The status of the temperature switch is displayed (OFF = switch open; ON = switch closed). 8.6.5 WATER LEVEL CHECK Press the Up or Down button until the following display appears: WATER LEVEL TEST: LEVEL: XX.XINCHES The water level is referenced from the first cal mark typically 4”...

  • Page 38: Power On Displays And Data Logging Reset

    Upon power ON or reset of the GI-2000 controller will display the following messages: CURRENT TIME/DATE XX:XX AM XX/XX/XX The display cycles after a few seconds to: JOSAM GI-2000 GREASE RECOVERY SYSTEM OPERATING SOFTWARE VERSION X.X The display cycles after a few seconds to::...

  • Page 39: Modem Operation

    The GI-2000 controller can be remotely accessed via a modem for the purpose of remote configuration setup and grease level data monitoring. This requires an external modem and cable that is supplied by Josam. To activate the modem capability DIP Switch Position 1 must be set. (See Figure 8.1.2-2 for the Dip Switch location).

  • Page 40: Troubleshooting Guide

    9.0 TROUBLESHOOTING GUIDE PROBLEM CAUSE SOLUTION Mis-wired Verify with a digital voltmeter that current between L1 & L2 is below 1 Amp. Wire per section 5.3. Circuit Breaker continuously trips upon power up. Check that a 3-Wire GFI Circuit Breaker has been Wrong style GFI Circuit Breaker installed.

  • Page 41: Warranty Information

    10.0 WARRANTY INFORMATION Josam Company warrants the GI 2000 to be free of defects in workmanship and material for a period of one (1) year following the date of installation, evidenced by the owner’s completion and return of the Josam GI 2000 Installation and Operation form. We shall not be responsible for any labor charges or any loss, injury or damages whatsoever, including incidental or consequential damages.

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