Graymills BIOMATIC BIO822-A Troubleshooting guide

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 1
Graymills
Model BIO822-A BIOMATIC®Heated
Bioremediation Parts Cleaner
Operations and Maintenance Instructions
Be sure anyone operating this unit reads and understands all warnings and instructions. Keep this
manual available for reference/training.
SAFETY WARNINGS
You will find various types of safety information on the following pages and on the labels attached to Graymills equipment. The following
Safety Statements explain their meaning:
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid personal injury or
death.
DANGER indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if
not avoided, could result in minor or moderate injury.
CAUTION, without the safety alert symbol, is used to address practices not related to
personal injury.
READ BEFORE OPERATING
•Use only Super BioteneTM cleaning fluids. Do NOT
use solvents, gasoline, etc., as they will create an
extremely hazardous situation.
•Do NOT contaminate cleaning fluid with any
flammable or combustible material such as gasoline,
alcohol, mineral spirits, etc. Drain parts to be cleaned
of any flammable material or combustible material
before cleaning. Even small quantities can create a
dangerous fire hazard.
•Never work with equipment you feel may be unsafe.
Contact your supervisor immediately if you feel a
piece of equipment is in unsafe condition.
•Cleaning solutions may be irritating to skin and eyes.
Always wear gloves, apron and safety glasses when
using. If splashed in eyes, flush thoroughly with
water and follow directions on cleaning solution
MSDS. See “USE OF INDUSTRIAL CLEANING
SOLUTIONS” on page 2.
•Install machine in a well ventilated area.

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 2
•The unit has been factory set to maintain an optimum
temperature for the microbes. Do NOT attempt to
change thermostat setting.
•This is a heated system. Always use caution when
first putting hand under liquid stream to prevent injury
from heated solution. If the liquid feels uncomfortably
hot, discontinue use, unplug machine and call
Graymills Customer Service.
•Failure to keep proper liquid level will result in
burning out the pump and heater coil, creating a
potential fire hazard. To help prevent this, this unit is
equipped with a low liquid level device which will shut
off the pump and heater. If solution stops circulating
and the red “RESET” light becomes illuminated,
immediately turn off and unplug unit. For instructions
on filling the reservoir, please see “INSTALLATION
AND OPERATION” steps 6 through 9.
•After extended use, the gas-spring used to assist in
opening and closing the lid may lose its ability to keep
the lid open. At the first sign of this, replace the gas-
spring immediately.
•Automatic Safety Cover. Since certain soils may be
combustible, e.g., oils, greases, this unit is equipped
with a fusible safety link cover mechanism designed
to support the open cover at a slightly forward angle.
In the event of a fire, the fusible link will melt at 165ºF
permitting the cover to slam shut, limiting oxygen
supply to the fire.
•Do not leave the unit unattended with parts in the tank
which would prevent the cover from closing
completely in the event of a fire. Keep cover closed
when unit is not in use. If the fusible link breaks, do
not operate the unit until a replacement link is
installed.
•DO NOT leave the unit disconnected without power for
extended periods of time (overnight or weekends).
This will cause the microbes to go dormant. This will
adversely affect the bioremediation process. If
microbes do not reactivate after operating
temperature has been reached, a new BIO-POUCH
should be added.
•If unit is to be unused, but not unplugged or turned
off, for extended periods (overnight and weekends), it
may be necessary to top-off tank to the 30-gallon mark
with pre-blended Super BioteneTM cleaning solution to
prevent the machine from shutting down due to low
liquid levels.
POWER SUPPLY, WIRING AND
GROUNDING
•Failure to permanently ground the unit and controls
before connecting to electrical power can cause
shock, burns or death.
•Install ground and wiring according to local and
national electrical code requirements.
•Install a fused disconnect switch on all power legs
near the unit
•Disconnect and lockout electrical supply before
installing or servicing unit.
•Unit must be properly grounded to prevent electric
shock hazard. Connect only to three-prong outlet.
Should cord become cracked, frayed or damaged in
any way, it should be repaired/replaced immediately
by a qualified electrician. Never use an extension
cord. (See Spare Parts List)
•The full-load amperage draw for this machine is 12
amps.
USE OF INDUSTRIAL CLEANING
SOLUTIONS
•Always wear the recommended safety apparel and
glasses.
•Adequate ventilation should be provided when
operating this unit.
•When making an initial batch of cleaning solution or
when adding compound, follow cleaning solution’s
directions exactly.
•Industrial cleaning solutions may be irritating to some
individuals. Be certain to consult the MSDS for the
cleaning solution you are using before filling or using
parts washer.
•If splashed in the eyes, follow cleaning solution MSDS
instructions.
•If cleaning solution is splashed on clothing, remove
promptly and thoroughly wash any body areas which
have been in contact with solution. DO NOT permit
saturated clothing to remain in contact with skin.
Consult cleaning solution’s MSDS instructions.
•Clean up fluid spills immediately. Super BioteneTM can
create a slippery surface. Also, the microbes
metabolize organic materials and could damage floor
coverings or painted surfaces.
•Graymills strongly recommends that federal, state and
local authorities be consulted before proceeding with
discarding and handling of used materials. Graymills
Corporation accepts no responsibility for user’s
failure to comply with regulations.
•For best results, Graymills’ recommends using only
Super BioteneTM 550 (concentrate) or Super BioteneTM
660 (pre-blended).

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 3
MACHINE INSTALLATION AND OPERATION
1. Place unit on a smooth, level surface in a well ventilated area.
2. Read all warnings posted on machine.
3. Inspect electrical control box, cord and plug for wear or damage.
Do not use machine or add fluid if any wear or damage is noticed until impaired components are repaired or replaced.
4. Install filter cartridge:
a. Unscrew filter cartridge bowl.
b. Remove clear plastic packaging from new filter cartridge and remove
BIO-POUCH from hollow center of cartridge.
c. Install new filter cartridge in the cartridge bowl.
d. Re-attach filter cartridge bowl to filter body.
Be sure electrical cord is unplugged and cleaning solution and heater coil is cool before adding cleaning solution or
performing any maintenance.
5. Close drain valve before filling tank.
6. Add 30-gallons of Super BioteneTM solution to the tank. Maximum fluid level is equal to the tops of
the slots in the baffle screen (Right). Fluid level must be maintained above pump and heater coil.
7. Place stainless steel shelf on mounting ridges inside tank. Flow-Thru brush rests on shelf.
8. Add one (1) BIO-POUCH of microbes to tank, found inside filter cartridge.
9. Plug power cord into properly grounded 115V, 15 amp circuit. Full load amp-draw of unit is 12
amps.
10. Toggle POWER switch located on the underside of the electrical box to the ON position. The red
“RESET” light will illuminate.
11. Press TEST button on GFCI on rear of control (right) to ensure switch is operating properly. Press
RESET button on GFCI to prepare unit for operation.
12. Air pump will begin operation immediately upon power being applied to the machine and the red
“RESET” light will illuminate.
13. Toggle RESET switch located under the electrical box to begin operation. If the unit has an
adequate level of cleaning solution in the tank, the green “READY” light will illuminate and the
red “RESET” light will extinguish.
14. The amber “HEAT” light indicates power to the heater.
15. If cleaning solution is not at the appropriate temperature and heat is required you should hear
the thermostat engage with a “CLICK” and the amber “HEAT” light will illuminate. Should this
not happen, press the red thermostat reset button above the lights and switch on the front of
the control box (right). Should this problem persist: unplug machine and call factory.
16. When the unit reaches its predetermined temperature, the “HEAT” light will extinguish,
indicating the cleaning solution is at the proper temperature to obtain maximum cleaning
efficiency. For maximum cleaning efficiency, allow heater to warm solution for 2 to 4 hours
before use.
17. To operate the fluid pump, toggle PUMP switch on front of electrical box to the “ON” position.
18. For fluid via the flexible hose turn the directional valve counterclockwise to the left.
19. For fluid via the flow-thru brush turn the directional valve clockwise to the right.
When not in use return flow-thru brush to brush clip holder to holder to avoid obstructing lid closure.
20. Failure to keep proper liquid level will result in burning out the pump and heater coil, creating a potential fire hazard. To
prevent this, this unit is equipped with a low liquid level device which will shut off the pump and heater. If solution stops circulating
and the red “RESET” light becomes illuminated, immediately turn off and unplug unit.
21. When finished, turn pump off and close lid to minimize liquid loss due to evaporation. Do NOT unplug
the machine for extended periods of time. The internal air pump and heater is necessary for effective bioremediation. This will
cause the microbes to go dormant and will adversely affect the bioremediation process. If microbes do not reactivate after
operating temperature has been reached, a new BIO-POUCH should be added.
Max-Fill Slots
Operator Interface

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 4
ADDING FLUID TO UNIT
Follow instructions and exercise appropriate safety precautions before adding fluid.
1. Turn machine off and unplug.
2. Open lid and remove stainless steel shelf.
3. Add properly diluted cleaning solution to top of max-fill slots (right).
4. Reinstall shelf, restore power and resume normal operation.
RECOMMENDED MAINTENANCE
Be sure electrical cord is unplugged and cleaning solution and heater coil is cool before performing any maintenance.
1. Check fluid level in unit daily.
2. Due to evaporation and drag-out, fluid should be topped off with Super BioteneTM cleaning solution as needed.
3. A new BIO-POUCH should be added to cleaning solution in tank reservoir every 30-40 days.
4. Inspect heater coil on a monthly basis. To inspect, remove baffle screen. Remove any deposits or buildup with a soft wire brush.
Deposits and buildup can cause premature failure of the heating coil.
5. Check operation of liquid level control. Make sure that float switch moves freely up and down.
6. Filter cartridge will require periodic replacement depending on the volume and types of soils involved. A significant reduction in the
flow through the flexible hose signals the need to replace the cartridge (see RECOMMENDED ANNUAL MAINTENANCE). Order
replacement cartridges, part number BIOFL1, from either your Graymills distributor or the factory.
7. After extended use, the gas spring used to assist in opening and closing the lid may lose its ability to keep the lid open. At the first
sign of this, replace the gas spring immediately. Order part number 765-09631.
Save this manual for future training. Do not allow operation without reading and understanding these instructions.
RECOMMENDED ANNUAL MAINTENANCE
Graymills recommends that the entire system be inspected and cleaned annually. To perform this maintenance:
Be sure electrical cord is unplugged and cleaning solution and heater coil is cool before performing any maintenance.
1. Clean filter cartridge assembly:
a. Unscrew filter cartridge bowl.
b. Pour liquid from filter bowl into tank.
c. Remove filter cartridge and dispose of in proper manner.
d. Remove clear plastic packaging from filter cartridge and remove BIO-POUCH from hollow center of cartridge.
e. Install new filter cartridge in the cartridge bowl.
f. Re-attach filter cartridge bowl to filter body.
2. Remove stainless steel shelf from tank and remove baffle screen.
3. Visually inspect pump, pump inlet filter, heater float switch, and tubing for damage or wear.
4. Replace all parts as necessary. Make sure all “tie-offs” for pump, heater and float switch are still in place insuring proper separation
and alignment of these components.
5. Clean excess accumulation off heater coil with a soft wire brush.
6. Inspect surface of cleaning solution and skim to remove any oil, bio-mass or debris.
7. Use tank drain to move cleaning solution into acceptable container for future reuse.
8. Rinse inside of tank with clean water.
9. Refill reservoir tank with saved solution from step 7.
10. Replace baffle screen.
11. If necessary, top-off cleaning solution with enough fresh Super BioteneTM cleaning solution to bring reservoir up to 30-gallon mark.
12. Add a BIO-POUCH to cleaning solution
13. Place stainless steel shelf on mounting ridges inside tank.
Save this manual for future training. Do not allow operation without reading and understanding these instructions.
Max-Fill Slots

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 5
TROUBLESHOOTING
Problem
Probable Cause
Suggested Remedy
No Machine Function
Machine unplugged Plug machine into appropriate wall socket
GFCI tripped Press RESET button on GFCI
No power at outlet Consult plant electrician
Heat Not Working
Thermostat tripped Press red thermostat reset button
Heater malfunction Contact Graymills for more information 1-888-472-9645
Heater coil dirty Clean heater coil (see Recommended Maintenance)
Red “RESET” Light ON
Machine needs to be reset Toggle RESET switch
Low solution level Add cleaning solution
Float sensor or control relay
malfunction
Contact Graymills for more information 1-888-472-9645
Little or No Fluid Flow
Valve shut off Turn valve fully to the left or right to open valve
Clogged filter Replace filter cartridge (Part #BIOFL1)
Cracked or broken hose Inspect and replace hose (See parts list)
Bioremediation No
Longer as Effective Expired microbes Add BIO-POUCH to tank solution
If your problem is not listed above or problems persist, please contact Graymills for further assistance. 1-888-472-9645

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 6
BIO822-A DRAWING AND PARTS LIST
REF DESCRIPTION PART NO.
1
Fuse Link Assembly
451-23482
2
Gas Spring
765-09631
3
Tank Lid
727-92064-BLACK
4
Tank
727-92064T
5
Flexible Hose Assembly
728-90951
6
Stainless Steel Shelf
645-35922-81
7
Tank Base
727-92064
8
Drain Valve
738-09669
9
Directional Valve
738-90795
10
Flex Hose Adapter
728-90796
11
Flow-Thru Brush Ass’y
749-09925
12
Electric Box
727-92064B
13
Electric Box Gasket
744-35793
14
Electric Box Cover
727-92064C
15
Thermostat Kit
C-38718
15A
Spring
765-03264-81
15B
S.S. Cable Tie
769-07704
16
Toggle Switch
770-09192
16A
Toggle Switch Boot
770-08481
17
Pushbutton Switch
770-07011
18
8' Power Cord
777-04152
19A
Indicator Light -Amber
772-92078
19B
Indicator Light -Green
772-92079
19C
Indicator Light -Red
772-92080
20
Float Switch Assembly
770-09644
21
Heater
771-35248
22
Hinge
764-34711-81
23
10" Filter Housing
742-90186
24
Filter Cartridge, 30 Micron
742-09335-1
25
O-Ring
744-90187
26
3/4 Dia Neoprene Tube, 16"
Long
729-90327
27
Pump
390-09663
28
Baffle Screen
647-39748-81
29*
Relay
782-92066
30*
Relay Socket
782-92126
31*
Terminal Block
780-91292
32*
Jumper 3 Pole
780-91289
33*
Jumper 4 Pole
780-91290
34*
End Anchors 35mm
780-91111
35*
Air Pump
390-92151
36*
Tube Bulkhead Compression
Fitting
735-91249
37*
¼” Air Tubing
729-90678
38*
Complete Electrical Control
Ass’y
457-40437
* - These items are not shown on the diagram

795-92239
01/10/11
Graymills Corporation – 3705 N. Lincoln Ave. / Chicago, IL 60613 – Phone: [phone] Fax: [phone] – www.graymills.com – 7
ELECTRICAL SCHEMATIC
WARRANTY INFORMATION
Graymills Corporation warrants that the equipment manufactured and delivered, when properly installed and maintained, shall be
free from defects in workmanship and will function as quoted in the published specification. Graymills does not warrant process
performance, nor assume any liability for equipment selection, adaptation, or installation.
Warranty does not apply to damages or defects caused by shipping, operator carelessness, misuse, improper application or installation,
abnormal use, use of add-on-parts or equipment which damages or impairs the proper function of the unit, and modifications made to
the unit. Warranty does not apply to expendable parts needing replacement periodically due to normal wear and tear.
A new Warranty period shall not be established for repaired or replaced materials or products. Such items shall remain under Warranty
for only the remainder of the Warranty period of the original material or product.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, WHETHER ORAL, WRITTEN, EXPRESSED,
IMPLIED OR STATUTORY. GRAYMILLS CORPORATION MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESS OR
IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED
THE AFORESTATED OBLIGATION ARE HEREBY DISCLAIMED BY GRAYMILLS CORPORATION AND EXCLUDED FROM THIS
SALE. Graymills warranty obligations and Buyer remedies (except to title), are solely and exclusively stated herein. In no case will
Graymills be liable for consequential damages, loss of production, or any other loss incurred due to interruption of service.
Graymills' obligation under this Warranty shall be limited to:
1. Repairing or replacing (at Graymills sole discretion) any non-conforming or defective component within one year from
the date of shipment from Graymills.
2. Repairing or replacing (at Graymills sole discretion), components supplied by, but not manufactured by Graymills, to
the extent of the warranty given by the original manufacturer.
Buyer must give Graymills prompt notice of any defect or failure.
If you believe you have a Warranty claim, contact Graymills at [phone]. Any return material must have an RMA number on
the outside of the package and shipping prepaid or shipment will be refused. Graymills will promptly examine the material and
determine if it is defective and within the Warranty period.