GRANULDISK Granule Maxi User manual

Granule Maxi
Service manual
Granule Maxi serial # 920010–
Art.no EN22559–201205
GRANULDISK AB retains the right to make technical changes to the products.
No responsibility is taken for any printing errors.
www.granuldisk.com Tel. [phone]

Contents
CE Declaration of Conformity 5
1 General Description and Safety 7
1.1 To the user 7
1.2 Safety regulations 7
1.3 Disconnecting power 7
1.4 Technical data 9
2 Installation 11
2.1 Installation instructions 11
2.2 Detergent and rinse aid 14
2.3 How to lay the Granule Maxi down on
its side 18
3 Troubleshooting and Alarms 23
3.1 Error codes 25
4 Programming 29
4.1 Preselected values in Service menu 29
4.2 Flashloader 4.2 30
4.3 GDTdirect™ 3.x* 36
4.4 GD Memo™ 40
5 Routines for long time storage 43
6 Warranty 45
7 Maintenance and Service 47
7.1 Service instructions 1 year service 47
7.2 Service instructions 2 year service 51
3

8 Steam heating Granule Maxi®55
8.1 Power/Effective Steam Pressure 55
8.2 Heating time 55
8.3 Steam Consumption 56
8.4 Safety 56
8.5 Connection 56
8.6 Recommended equipment not
included 58
8.7 Diagrams 59
9 Appendix 61
4

CE Declaration of Conformity
The Manufacturer:
GRANULDISK AB
Jägershillgatan 15
SE-213 75 MALMÖ, Sweden
declares that the following machinery:
TheGRANULDISKsystemGranuleMaxi.
The Granule Maxi is a Granule pot washing machine – a pot washing machine for
commercial kitchens that is designed for washing such wares as pots and pans.
Basic conception
a. the equipment, to which the CE Mark has been affixed, complies with the Machinery
Directive, 2006/42/EC.
b. is besides the provisions under a) manufactured according to the following directives:
the EC Low Voltage Directive 2006/95/EC and the EMC Directive 2004/108/EC
c. is manufactured in conformity with the following harmonised standards: EN
60204-1:2006, EN 55014-1, EN 60335-2-58, EN 60439-1, EN 55022, EN ISO
13850:2008, EN ISO 13857:2008, EN 61000-6-3 and EN 61000-6-2
d. is manufactured in accordance with EN 1717 and fitted with a type AB back flow
protection device with airgap in accordance with EN 13077:2008.
Malmö, Sweden 11.02.2012
Signed on behalf of
GRANULDISK AB
GRANULDISK AB
Jägershillgatan 15
213 75 MALMÖ
Phone: [phone]
Fax: [phone]
Peter Schön
President
Rev. 2012-05 5

CE Declaration of Conformity

1 General Description and
Safety
1.1 To the user
Granule Maxi is a Granule pot washing machine – a pot washing machine for commercial
kitchens that is designed for washing pots and pans.
This manual is your guide for the correct installation and use of the Granule Maxi pot washing
machine.
GRANULDISK 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 accepts no responsibility for damage to the equipment or other damage or
injury caused by not following the directions in this manual.
1.2 Safety regulations
The machine uses hot water. Avoid contact with the skin as there is a risk for scalding!
Do not open the doors during a wash cycle! Risk of burn.
The plastic in the Granules is approved for use in conjunction with food.
There is a risk of slipping if Granules are left on the floor.
Formaldehyde, which is dangerous if inhaled, may be formed if the Granules catch fire.
1.3 Disconnecting power
How to disconnect the power safely when performing maintenance.
The machine must be connected to a supply disconnecting device, in accordance with
EN60204–1:2006. This must be in off position. The rinse aid and detergent installation must
also be put out of circuit, unless it is supplied from the GRANULDISK machine.
It must be possible to lock the supply disconnecting device in the off position.
A sign prohibiting all use of the switch must be posted at the separation point. The sign must
be mounted securely so as to remain in place throughout the duration of the work.
Rev. 2012-05 7

1.3 Disconnecting power 1 General Description and Safety
Ensure the machine is dead by undoing the front cover, the lid to the electrical cabinet and
measuring the incoming voltage on Q1. There must not be any voltage between any of the
phases or between any of the phases and protective earth. The measurements must be
performed on both sides of Q1. (Appendix for electrical diagram.)
8Rev. 2012-05

1 General Description and Safety 1.4 Technical data
1.4 Technical data
Weight ............................. 666 kg (filled machine), 485 kg (empty machine)
External dimensions ............... 2029 (± 25 mm) x 1452 x 1089 mm (H x W x D)
Tank volume ....................... 165 litres
Granule amount .................... 16 kg
Wash water temperature .......... 65 °C
Rinse water temperature .......... 85 °C
Wash programmes w Granules .... Eco: 2 min, 30 sec
Short:4min,40sec(1minlongerwithsteam
reduction)
Normal: 6 min, 40 sec (1 min longer with steam
reduction)
Wash programmes w/o Granules . Eco: 2 min, 30 sec
Short:3min,40sec(1minlongerwithsteam
reduction)
Normal: 5 min, 40 sec (1 min longer with steam
reduction)
Rinse water volume ................ 7 litres/ECO programme
14 litres/short, normal programme
To achieve 3600 HUE according to NSF/ANSI 3, 14
litres is necessary.
Capacity ............................ 8 x GN1/1 or 16 x GN1/2, or equivalent in other items
Loading volume .................... 450 litres (w 540 x h 1060 x d 680 mm)
Design .............................. Compact System with extractable cassette.
Flow System with 1 trolley and 2 loose cassettes.
Freeflow System with 2 trolleys and 2 loose cassettes.
Voltage** .......................... 400 V (standard); 3-phase, earth
230, 415, 440 and 575 V (option); 3-phase, earth
Fuse** ............................. 400 V: 40 A (steam heated 20 A, cold water option
50 A)
230 V: 63 A (steam heated 25 A)
415, 440 V: 40 A
575 V: 25 A (steam heated 16 A)
Frequency. ........................ 50 Hz (standard) or 60 Hz
Maximum power .................. 21 kW (steam heated 5 kW, cold water option 29 kW)
Wash pump motor ................ 2 x 2.2 kW (2 x 3.0 kW 575 V)
Rinse pump motor ................ 0,37 kW
Wash tank element* .............. 16 kW (cold water option 24 kW)
Rinse tank element* .............. 16 kW (cold water option 24 kW)
Encapsulation class ............... IP55
Sound pressure level .............. < 70 dB(A)
Hot water .......................... ½” (DN15), 55-65 °C, 3-10 °dH
NB! Reverse osmosis water and totally softened water
must not be used.
Water pressure/flow h.w .......... 1-6 bar, 25 l/min
Rev. 2012-05 9

1.4 Technical data 1 General Description and Safety
Cold water ......................... ½” (DN15), 3-10 °dH
Water pressure / flow c.w ........ 1-6 bar, 15 litres per min (steam reduction; 3-6 bar)
Recommended ventilation capacity
...................................... 700 m3/h (without steam reduction)
200 m3/h (with steam reduction). N.B. steam
reduction is factory fitted for Granule Maxi. For
ECO-programmes, the factory setting for Steam
reduction is OFF.
Outflow ............................ Pipe Ø 32 mm
Drain ............................... Required capacity 100 l/min.
The machine should not be placed directly above the
drain.
* Not in use simultaneously
** For specific data regarding delivered machines, please see machine rating plate
NOTE
The Granule Maxi is supplied with a 2 metres long electric cable to be
connected to an approved supply disconnecting device on the wall. The
supply disconnecting device is not included in the delivery.
10 Rev. 2012-05

2 Installation
WARNING
All operations described in this chapter must only be carried out by qualified
staff. All electrical components described in this chapter apply to 400 volt
machines. Recalculated electrical values apply to other voltages (
see section
1.4 Technical data on page 9
).
2.1 Installation instructions
The Granule Maxi is delivered well packaged and placed on a pallet.
1. Remove the packaging so that the machine is left standing on the pallet.
Undo the 8 fixing screws, remove the beams from front and back side.
Lift the machine from the front or back using a pallet truck now you can remove the
beams at the sides.
Fit the feet to the legs and remove the pallet truck.
2. Place the machine in position and adjust the legs, use a spirit level and the arrows on the
doors to get the machine in level. Check front, left and right side.
Figure 1: Check level front, left and right.
The arrows should be in line.
3. Checktoothatallexternalscrewsaswellthescrewsonthedoor’shingesaretightened.
4. For the Granule Maxi, Flow System and Freeflow System: Also make this test using
an empty cassette.
-fill a cassette to it’s maximum 60 kg with items to be washed, then move this into
the machine using a cassette trolley.
Rev. 2012-05 11

2.1 Installation instructions 2 Installation
- Make sure that the cassette moves freely into the machine, adjust the feet if
necessary.
- The machine can be laid down on its side when being moved in.
5. Connectthehotandcoldwater(AandBFigure 2 ,on page 13).
The connections are located at the back of the machine – (Figure 2 )andaremarked
red and blue . Use flexible connection hoses with a minimum internal diameter of 9
mm. Ensure that there is at least 500 mm of extra hose in order to make it possible to
move the machine forward for service. Incoming water must be at a pressure of 1-6 bar
when the solenoid valve is open. If the water pressure is in excess of 6 bar, a relief
valvemustbeinstalled.
6. Connect the drain pipe on the back right to the drain Ø 32 mm (C Figure 2 ,on page 13).
Placethevalveinopenposition(shownbysymbolsonthesidepanel).Thedraincapacity
must be at least 100 litres/minute. The machine should not be placed directly over a floor
drain, since it is important for the draintobeaccessibleforcleaning.
7. All electrical connections in the electrical cabinet must be tightened before the electrical
supply is connected. Connect the electric cable (E Figure 2 ,on page 13) to a supply
disconnecting device on the wall. Check that the power supply complies with the
Technical Data on the rating plate.
8. Fill the machine by starting the filling process. If the machine will not fill, check water
supply and rotation direction of pumps. Rotation according to markings on pumps
(arrows).
12 Rev. 2012-05

2 Installation 2.1 Installation instructions
Figure 2:
Rev. 2012-05 13

2.2 Detergent and rinse aid 2 Installation
2.2 Detergent and rinse aid
NOTE
Only pre drilled hole and connections must be used for sensor, detergent
and rinse aid.
The dosing equipment is only to be connected in the detergent connection
box.
All dosing equipment must be fitted with a main switch.
Donotusedetergentcontainingchlor.
To obtain the best performance of this GRANULDISK pot washer we strongly recommend
installing sensor controlled detergent dosing equipment and appropriate rinse aid equipment.
Figure 3: Detergent and rinse aid junction box
The 230 V AC and the 24 V AC supply as well as the control signals for the detergent and
rinse aid equipment are located in the junction box behind the front cover plate. There are
terminal blocks as listed below in the junction box (Picture:Figure 4 Detergent and rinse aid
junction box).
The dosing of rinse aid is normally done during filling of the rinse tank, depending on rinse
aid this could cause foaming in the rinse tank causing error 112. To avoid this the rinse aid
dosing equipment could use the detergent signal and the equipment set to dose on time, if
possible (fixed volume on positive flank). This means the dosing of rinse aid is done when the
rinse tank is full and the foam is avoided.
14 Rev. 2012-05

2 Installation 2.2 Detergent and rinse aid
Figure 4: Detergent and rinse aid junction box
1. Constant 230 VAC J 1-2
2. Neutral 230 VAC J 1-6
3. Detergent connection 230 VAC J 1-7/D
4. Rinse connection 230 VAC
5. Earth PE
6. Constant 24 VAC 113
7. Neutral 24 VAC J 16-12
8. Detergent connection 24 VAC J 8-9/D
9. Rinse connection 24 VAC J 8-4/R
10. Central metering (full wash tank) J 8-5/TF
11. Operations indication J 6-4
12. Emergency stop J 8-3
13. Emergency stop J 8-8
Rev. 2012-05 15

2.2 Detergent and rinse aid 2 Installation
Figure 5:
The detergent inlet is a tube.
16 Rev. 2012-05

2 Installation 2.2 Detergent and rinse aid
Figure 6: Detergent inlet tube
The machine is equipped with a rinse aid connection (see section D, on page 16). The
tube is connected to the rinse tank.
Figure 7: Detergent and rinse aid connections.
The pre-drilled sensor hole is found on the right hand side. To make it easier to find, a red
plastic plug is fitted in the hole. In case a sensor is not installed replace the plug with a
more durable plug.
Figure 8: Predrilled hole for detergent sensor, red plug.
Rev. 2012-05 17

2.3 How to lay the Granule Maxi down on its side 2 Installation
In case of solid detergent being connected, the hot water connection point (1/8”) for the
dosing equipment is located at the machine’s hot water connection ( A, on page 16).
Figure 9: Connection point warm water for solid detergent.
CAUTION
It is very important that the detergent supplier uses the existing holes so that
no unnecessary holes are made in the machine.
All dosing equipment must be fitted with a main switch.
2.3 How to lay the Granule Maxi down on
its side
To pass low doorways when moving the Granule Maxi it is possible to lay it down on the
right side.
Material needed:
-Apallettruck
- Two EUR pallets
-Standardtoolkit
-Profiles from the machines wooden frame
-Fourstrongmen
1. Remove the plastic packing material and the bottom wooden frame.
18 Rev. 2012-05

2 Installation 2.3 How to lay the Granule Maxi
down on its side
Figure 10: Machine prepared for to be tilted to right side.
2. Open doors and take out all removable parts like the multi-cassette, other accessories,
tank grids and overflow filter.
3. Remove the plastic roof, front cover plate, all three cover panels on the right side and
right support-frame (some models) for these three panels.
4. Take the front and the rear wooden profilesandcutoffapartofthemaccordingto
Figure 2.
Figure 11: Cutting the beams to the correct length
5. Lift the machine up on wooden profiles according to Figure 3. Put short planks under
booth left leg-profiles to incline (lean) the machine.
Rev. 2012-05 19

2.3 How to lay the Granule Maxi down on its side 2 Installation
Figure 12: Plank under left pair of legs. Correct distance, 550 mm
6. Right leg-profiles have to be placed in the centre of wooden beams.
CAUTION
Please mind the correct position, otherwise machine could fall of the beams.
If it falls off the bottom plate could be damaged by the beams.
7. Put two EUR pallets according to the Figure 3. It is important to keep the distance 550
mm, between the pallets and the order to avoid damages on the cabinet and the spray
arm bearings.
8. Tilt the machine with caution until it rests on the pallets. Figure 5 and 6. The machine
can now be moved.
Figure 13: The machine is tilted with caution.
20 Rev. 2012-05