GRANULDISK GD 900 User manual

GD 900
Usermanual
Art.nr 16061/02.2004 EN
Granuldisk AB retains the right to make technical changes to the products.
No responsibility is taken for any printing errors.
1.TECHNICAL DATA............................................. .......................................6
2. INSTRUCTIONS................................................... .......................................8
3. DAILY CLEANING.............................................. .....................................13
4.TROUBLESHOOTING AND ALARMS................................15
Contents
EN

Declaration of Conformity
The Manufacturer:
GRANULDISK AB
Jägershillgatan 15
SE-213 75 MALMÖ, Sweden
declares that the following machinery:
The Granuldisk system GD 900
Basic conception
a)is manufactured in conformity with the Svenska Arbetarskyddsstyrelsens Författningssamling AFS1994:48. This law conforms
with the COUNCIL DIRECTIVE of 22 June 1998 concerning harmonisation of member states` legislation for machinery (the
Machinery Directive 98/37/EG), with particular reference to Annex 1 concerning the essential health and safety requirements
relating to the design and construction of the machinery.
b)is besides the provisions under a) manufactured according to the following directives: the EC Low Voltage Directive 73/23/EEC
and the EMC Directive 89/336/EEC
c) is manufactured in conformity with the following harmonised standards: EN 60204-1, EN 55014, EN 60335-2-58, EN 60439-1,
EN 418, EN 294, EN 50081-1:1992 and EN 50082-2:1995
d)is manufactured in conformity with the following national standards and technical
specifications: ELSÄK-FS 1994:7
Malmö, Sweden 01.08.2000
Signed on behalf of GRANULDISK AB
GRANULDISK AB: Jägershillgatan 15
SE-213 75 MALMÖ, Sweden
............................................... Phone: [phone]
Per Sandberg Fax: [phone]
(Managing Director)

To the user Safety instructions
The GD 900 is a granule potwashing
machine - a potwashing machine for
commercial kitchens that is designed for
washing/cleaning things like pots and pans
This manual is your guide for the correct
installation and use of the GD 900 granule
potwashing machine.
Granuldisk AB recommends that you study
the manual thoroughly to be sure that the
machine is installed and used correctly and
safely.
Ensure that the manual is always available
during the whole life of the machine.
Granuldisk AB accepts no responsibility for
damage to the equipment or other damage
or injury caused by not following the direc-
tions in this manual.
The plastic in the granules is approved for
use in conjunction with food.
The machine uses hot water.Avoid contact
with the skin as there is a risk for scalding.
There is a risk for slipping if granules are left
on the floor.
Formaldehyde,which is dange-rous if
inhaled, may be formed if the granules catch
fi r e .
Regarding the handling of detergent in the
manual, please see the manufacturer’s
instructions.
5

1.Technical data
Weight ................................................720 kg filled machine
Tank volume .....................................195 litres
Granules .............................................20 kg
Wash water temperature ..........65°C
Rinse water temperature...........85°C
Rinse water volume ......................14 litre/wash cycle
Wash programme..........................normal 5 min, 30 s.
Long 8 min, 30 s
Ultrashort 2 min, 30 s
Design ................................................GD 900S with sliding cassette
GD 900K for trolley system with two loose cassettes
Capacity..............................................8 1/1 GN, 200 mm deep
16 1/2 GN, 200 mm deep pans or equivalent pots
Capacity /hr with
normal programme .....................GD 900S 55 GN 1/1 /hr
GD 900K 72 GN 1/1 /hr
Sound level ........................................<70 dB(A)
Tank element* .................................16 kW
Rinse tank element* .....................16 kW
Power* ................................................400 V (standard): 3-phase, earthed
230, 415, 440 and 575V (options): 3-phase, earthed
Fuse** ................................................400 V: 40 A, for steam model 25 A
415 V: 40 A, for steam model 20 A
440 V: 40 A, for steam model 20 A
230 V: 63 A, for steam model 35 A
575 V: 25 A, for steam model 16 A
Frequency ..........................................50/60 Hz
Max. power ........................................22 kW
Pump motor.....................................5.5 kW
Encapsulation class........................IP55
Hot water connection..................3/4” (DN20), 55-65°C, 3-10° dH
NB. Osmosis water and totally softened water must not be used.
Cold water connection................3/4” (DN20), 3-10° dH (condensation unit)
Recommended extraction
capacity ...............................................Machine without condensation unit 700 m3/h
Machine with condensation unit 200 m3/h
Water pressure ...............................3-6 bars with magnetic valve open
Outflow ...............................................Ø 32 mm pipe
Drain ................................................Min. capacity 100 litres/min.
The machine should not be placed directly over the drain.
*Not activated simultaneously.
** See the machine’s sign for more detailed information on this machine.
• Non-return protection in accordance with EN1717 should be fitted between the water supply network and the potwashing
machine.Alternatively, the GD 900 can be supplied with an integrated non-return protection in accordance with DVGW,
SVGW or ETA.
• GD 900 is also available with steam heating.
• The machine is supplied with a 2.5 metre long electric cable for connection to mains box on the wall.The mains box is not
included with the equipment.
6

7

2. Instructions
At the start of the day
Check the amount of granules in the granule collectors. When
the granules have been evened out they should reach the 10 kg
marking on each collector. Add more granules as required (fig.
1). Pour the granules into the wash tank. Fill the machine with
water, see Filling the machine p. 11
Preparing utensils
Scrape or rinse off all loose food remnants from utensils before
placing them in the machine (fig.2).
NB! Pots should not be soaked. To avoid foaming, do not prewash
with washing-up liquid. If foaming occurs, the machine will not
clean properly.
Loading utensils
All pots shall be placed in the machine with the insides facing the
spray pipes (fig.3:1).
The GD 975 multi-cassette is supplied as standard with all
machines. There are also a number of optional extras.
Inserting and removing the cassette
GD 900S: The cassette is an integral part of the machine and can
be slid halfway out of the machine (fig.3:1).
GD 900K: Push the trolley up to the loaded cassette. Release the
catch and push the handle up (fig 3:2). Hook on the cassette by
pushing the handle down again. The cassette is then pushed into
the machine using the trolley. Unhook the cassette by releasing
the catch and pushing the handle up (fig 3:3).
The cassette can easily be hung on the hooks on the wall beside
the machine by following the above instructions in reverse
order.
1
2
3
3:1
3:2
8

3:3
4
4:1
4:2
4:3
GD 975 Multicassette (4:1)
For pots, saucepans, bowls, dough hooks etc as well as all
types of 1/1 and 2/1 GN containers. 1/1 and 2/1 GN contain-
ers are stacked directly in the lower part of the cassette
without accessories.
GD 950 Universal holder (4:2)
For ABC pans, pots and saucepans or other equipment that
can be hung on hooks.The GD 950 is fitted in one of the
four existing runners on the cassette.
GD 951 Ladle holder (4:3)
For ladles, whisks and similar utensils.The GD 951 is fitted in
one of the upper runners fitted on the cassette.
9

4:4
4:5
4:6
GD 956 Divider (4:4)
For 1/2, 2/3, 1/3, 1/6 and 1/9 Gastronorm containers.
The GD 952 also makes it possible to load one of the fol-
lowing combinations: (4x1/2 GN containers) or (2x1/3 and
2x2/3 GN containers) or (4x1/6 and 2x2/3 GN containers)
or (6x1/9 and 2x2/3 GN containers).
GD 953 Lid holder (4:5)
Lids, trays and similar equipment with a maximum depth of 20
mm can be washed using this.The GD 953 is best fitted in the
lower cassette runners.
GD 954 Holder for small Gastronorm containers
(4:6)
Holder with runners in three rows for 1/3, 1/6 and 1/9 can-
teens.The GD 954 is placed in one of the four existing runners
on the cassette. Each row in the holder can take the following
combination: 2x1/3 or 4x1/6 or 6x1/9 GN containers.
10
4:7
GD 651 Netbasket (4:7)
Net basket for ladles, whisks, bowls, small saucepans etc.

1
2
3
4
5
6
7
8
10
9
Controlpanel
1. Start button
2. Stop button
3. Select normal programme
4. Select long programme
5. Washing with granules
6. Washing without granules
7. Close drain valve
8. Empty tank
9. Show rinse water temperature
10. Show wash water temperature
Filling the machine
In order to fill the machine, the drain valve must be closed by
pressing the close button 7 or by selecting a programme. The
machine automatically fills with water when the doors are closed
and a programme selected.
Select washing with granules or without
Washing with granules 5 is selected for all potwashing. Wash-
ing without granules 6 should however be selected for pans
with holes and utensils in which granules can fasten as well as
transparent plastic materials. There is an ultrashort programme
for lightly soiled utensils.
The ultrashort programme is not designed to cope with burnt-
on food.
Select required wash time
Normal 5 min, 30 s. 3
Long 8 min, 30 s. 4
Ultrashort 2 min, 30 s. 1 + 3
Keep button pressed down for normal 3 programme whilst
simultaneously pressing start button 1 .
Lamp 3 will blink as confirmation of selection.
Start
Press the start button 1. The water temperature in the wash
tank should be at least 60 °C to achieve the best results (the
temperature is preset to 65 °C.) Washing at temperatures that
are too low increases the risk of foaming and the pots will not
be properly cleaned. The machine can be preprogrammed so
that it will not start before the temperature in the wash tank has
reached at least 60 °C. Reprogramming may only be carried out
by qualified staff.
For machines equipped with GDT™, automatic HACCP
documentation, this temperature level is factory-set.
Operation
The wash programme begins either with or without granules for
1, 4 or 7 minutes. After washing with granules, there is a final
wash without granules for about a minute followed by a final
rinse with fresh water at 85 °C for 30 seconds. If the final rinse
water is insufficiently hot, the cycle time increases until 85 °C is
reached. If a condensation unit is fitted, the air in the machine
is cooled for 1 minute to reduce the temperature of the pots and
remove steam.
When the elements in the rinse or wash tanks are on and water
is being heated, this is shown by the lamps under the rinse tank
thermometer 9 or the wash tank thermometer 10 being
lit. These elements cannot be activated simultaneously. If the
machine is heated with steam however, both elements can
function at the same time.
NB! The doors cannot be opened before the wash programme is
complete and the running light goes out 1a.
5
7
3
4
1
3
3
1
3
5
6
1
910
11
1a
1a .

Stopping the machine during a programme
If you need to stop the machine before the wash programme is
completed, switch to washing with water for about 30 seconds
6 to rinse off all granules. Then press the stop button 2 . If the
programme without granules has been selected, or if the machine
must be stopped in an emergency, the stop button can be pressed
immediately.
NB! Utensils can have remnants of detergent on them and should be
washed again before they are taken out of the machine and used!
Inspecting pots and pans
It is important, as with all washing up, that staff check the
results. Remove any granules that have fastened in corners, sharp
angles and other inaccessible places, fig 6.
Granules
Granule potwashing machines from Granuldisk AB work best
with our specially designed granules. Their design ensures the
best wash results and the longest working life both for themselves
and the machine. The guarantee only applies if granules from
Granuldisk AB are used. The plastic material in the granules is
approved for use in conjunction with food. We recommend that
granules are replaced several times a year.
Hygiene
The machine is prepared for automatic HACCP documentation.
Specially developed software, GDT™, the Granuldisk
Documentation Tool and a modem are then required.
6
62
12

3. Daily cleaning
Collecting and cleaning the granules
The granule collectors, which come with the machine, are the
easiest way of emptying the machine of granules for cleaning
or changing. They are fitted in the cassette’s lower runners. The
doors are then shut and the ‘long’ programme is started (see p.
11). The granules then gather in the collectors. Each collector
can hold 10 kg of granules and is equipped with a level mark
(ill. 7).
Take out the filled granule collectors and wash (shower) them
thoroughly so that any food remains are washed away.
Alternative method for control of granule level, please see Serv-
icemanual page 15.
NB! Never use too many granules in the machine. This can lead to
blockages in the spray pipes as well as an inferior wash result.
Emptying the tank
Press the stop button (see p.11). Then the emptying button
8 ( see p.11).
The lamp lights briefly while the valve moves into the open
position.
Cleaning
• Lift out the cassettes.
• Examine the nozzles on the spray pipes (fig. 8). The spray
pipes should be taken out if anything has caught in the
nozzles. The spray pipe lock is first turned upwards. Then
press the spray pipe up and pull to the side (fig. 9). The
spray pipe is then pulled gently down and removed from the
machine. The spray pipe is now ready for cleaning (fig 10).
• Lift out the bottom grating (fig.11)
• Lift out the overflow sieve (A, fig.12)
• Remove the filter cap by unscrewing the knob (B, fig.12)
• Wipe the level monitor. (C, fig 12)
• The drip channel should be rinsed clean and dried. It is
important that water can drain away effectively (D, fig.12)
• Rinse the inside of the machine with water only
• Then clean the removed fittings. Be careful to ensure that the
spray pipes are not blocked.
• Wipe the door seals.
• Wipe the outside of the machine with a damp cloth. The
outside of the machine should not be washed with high-
pressure water.
• The top should be wiped off as needed or at least once a
month.
2
8
7
8
9
13
10

Replacing the fittings
Put all fittings back in place.
Ensure that the knob on the filter cap is tightened (B, fig. 12).
Leave the doors slightly open so that the air can circulate in the
machine. The granules should be stored in the granule collectors
standing in the machine.
NB! If the overflow filter (A, fig.12) is not replaced then the granules
will run down the drain.
For a longer shutdown
• Ensure that the wash tank is completely empty after cleaning.
Any water remaining in the bottom should be removed with
a sponge or cloth.
• Leave the doors slightly open so that the air can circulate in
the machine.
• The granules should be stored in the granule collectors
standing in the machine.
• After a longer stoppage, check the operation of the machine
according to the service manual, possibly with the assistance
of a service engineer.
14
11
12
A
B
C
D

4.Troubleshooting and alarms
Check the following if the utensils are not completely clean:
• Are the spray nozzles blocked?
• Were the utensils located correctly?
• Was the right programme selected?
• Is the wash water very dirty?
• Are there sufficient granules?
• Is the detergent dosing correct?
The machine is equipped with various alarm functions:
Spray pipe motor
Should the spray pipe become blocked the machine stops
completely and all the lamps 1 - 10 on the control panel
begin to blink together. If the alarm goes off: Switch the machine
off by pressing the stop button 2 . Open the doors, check what
has caused the alarm and remedy the fault. Then close the doors,
select a new wash programme and start the machine.
NB! If no fault is found, contact the service staff.
Long filling time
If it takes too long to fill the wash tank, the lamp 6 for emptying
the wash tank blinks out of time with the others. Check that the
water supply is switched on. Another cause can be a block in the
drain valve or a false reading for the water level.
NB! If the drain valve is blocked or there is a false level reading,
contact the service staff.
Long time after filling
If the washing with granules lamp blinks out of time with the
others, the most likely problem is foaming in the machine.
NB! Contact the service staff to check that the temperatures in the
wash and rinse tanks are correct. Check that washing-up liquid is
not being used in the machine. Contact your detergent supplier to
check if the detergent dosing is correct.
Wrong temperature in the wash or rinse
tank
If either of the lamps under the symbols for the wash water or
rinse water thermometers blinks out of time with the others
the thermostat is not working. The machine cannot be started
before the thermostat has been replaced.
NB! Contact the service staff for a check.
1
2
8
6
10
9
10
15
1
2
3
4
5
6
7
8
10
9

Notes