Grease Guardian D1 User manual

INSTALLATION, OPERATIONS
AND MAINTENANCE MANUAL
Automatic Grease
Removal Unit
Models D1, D2, D3, D4, D5
MANUFACTURED BY FM ENVIRONMENTAL
www.greaseguardian.com
GGPLC / REV 1
GG - MAN2011 I
HEAD OFFICE
FM Environmental Ltd
Greenbank Industrial Estate
Newry, BT34 2QX, N, Ireland
Telephone: +44 [0] 28 302 66616
From ROI Call: 048 302 66616
Fax: +44 [0] 28 302 63233
Email: [email protected]
www.fmenvironmental.com
www.greaseguardian.com
MALTA OFFICE
FM Environmental [Malta] Ltd
Water Technology House
A15B Industrial Estate Marsa, Malta
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Scan for electronic version

FM Environmental Ltd
Greenbank Industrial Estate
Newry, BT34 2QX, N, Ireland
Telephone: +44 [0] 28 302 66616
From ROI Call: 048 302 66616
Fax: +44 [0] 28 302 63233
Email: [email protected]
www.fmenvironmental.com
www.greaseguardian.com

Contents
Product Overview ....................................... 2
How it Works............................................. 3
Dimension & Specication............................. 4
Installation............................................... 5
Time Control Setting ................................... 7
User Maintenance ...................................... 14
Tri-Monthly Servicing .................................. 15
Troubleshooting ........................................ 16
Warranty ................................................ 18
Appendices:................................................
1. Application Specic Controller Setting .......... 20
2. Cycle Overview...................................... 21
3. Writing Diagrams.................................... 22

2 3
How it Works
HOW IT WORKS
1 Grease , solids and wastewater from the kitchen enters the Grease Guardian.
2 Solid food waste is caught in a removable strainer.
3 The grease passes into the middle chamber through slots in the bafe wall
where it remains trapped. With the assistance of a heater the grease separates
from the wastewater and rises to the surface.
4 The liqueed grease adheres to the rotating skimming wheels.
5 The grease passes down a scraper blade into a collection container where it
can be removed and disposed hygienically.
6 The treated water exits under a bafe wall and through the outlet to drain.
7 Kitchen waste water drain
The FM Environmental Grease Guardian series automatic grease removal unit (GRU)
is a totally engineered system for separating free oating grease and oils from
drain water ows. The separated grease and oils are trapped within the stainless
steel tank and are automatically recovered by the system. Only the “cleaned”
water is allowed to pass through the system into the drain lines. Each unit also
separates solid food waste into a removable basket. The Grease Guardian can
be used in a wide variety of applications from restaurants and food processing
operations to many types of industrial operations. Appliances that can be directly
connected include utensils sinks, pre-rinse sinks, combination ovens, and wok
cookers.
Use of the Grease Guardian assures that costly sewer surcharges and nes are
minimised or eliminated through efcient separation and removal of the grease
and oil. In addition, rapidly escalating pumping and disposal costs, which are
associated with conventional grease traps or interceptors are also reduced or
eliminated. The recovered grease and oils are virtually water free so they can be
collected by a local rendering Company or recycler.
The Grease Guardian D1-D5 series
PRODUCT OVERVIEW

4 5
Installation
INSTALLATION PART I: UNDERSINK EXAMPLE
1 13 AMP socket, 230 VAC with dedicated RCD 30mA. To be positioned within 2
metres of Grease Guardian unit
2 Pipework between xture and Grease Guardian to be minimally 1:100
gravity fall
3 Connect Grease Guardian inlet and outlet to piping using 2 x rubber clamp
couplers as supplied
4 P trap to remain in place at sink. 40mm clearance to be observed between
unit cover and P trap
5 Sample valve (where applicable) on outlet pipe, 45 degree spout position
6 Piping after Grease Guardian:
• 50mm (2 inch) diametre minimal
• 1: 100 gravity fall to waste
• no more than 3 metres distance
• contain less than 3 x 90 degree bends
Daily access required,
do not obstruct
When under-appliance installation is not possible the Grease Guardian can be positioned
next to the appliance, observing electrical and piping requirements above
Appliances that can be
directly connected
include utensils sinks,
pre-rinse sinks,
combination ovens,
wok cookers.
Product Dimensions & Specication
PRODUCT DIMENSIONS & SPECIFICATION
MODEL (mm)
A B C D E F G H
D1 640 500 150 150 330 520 310 60
D2 720 620 225 210 410 520 310 60
D3 840 705 310 260 450 520 310 90
D4 922 710 295 230 450 520 310 115
D5 1422 920 405 335 560 592 310 115
Casing Material 16 Gauge;
304 stainless steel;
bright nish
Motor 25 Watt, 230v, 50 Hz
1.3 µF capacitor
Heater 600 Watt, 230v,
Thermal cut-out inc.
Heater 1000 Watt, 230v,
Thermal cut-out inc.
Heater 2000 Watt, 230v,
Thermal cut-out inc.
Controller Programmable
Logic Controller:
Backlit display
Inputs 230 VAC
Outputs 230 VAC
Battery back up
(all units)
(all units)
(all units)
D1, D2
D3, D4
D5
MODEL
D1 D2 D3 D4 D5
Hydraulic
Flow l/second 0.75 1.25 1.75 2.25 3.5
Strainer Capacity, litres 3 4 8 10 14
Grease Collector
Capacity, litres 3.5 4.5 4.5 4.5 11
Skimming Rate, l/hr
Basic model 2 2 4 4 12
Max Skimming Rate, l/hr
Upgraded (3 skimmers) 6 6 12 12 12
PART I: UNDERSINK EXAMPLE

6 7
Initial Note: if no user adjustments are made a
factory setting from 8am-12pm starts the unit on
a LOW cycle daily. This is adequate for smaller
applications including out of town delis, or small
restaurants of less than 50 people.
Otherwise refer to Appendix 1 at back of this manual
for recommended settings for your application.
After machine switch-on, the home screen appears
displaying the controller software version (in this case
E for Europe and version date ddmmyy). The current
time of day, and factory set cycle mode ARE also
displayed.
To change a cycle rst choose from one or more of
the 4 hour programs 08:00-12:00, 12:00-16:00, 16:00-
20:00, and 20:00–00:00, accessed by pressing the OK
and A buttons together. Then advance through the
time slots available by re-pressing A.
Any time-slot can be set to ON/OFF by pressing the B
button. On completion press ESC to return to the
home Screen.
Finally in the home screen press and hold either the +
or - keys for 1 second to ne tune the cycle duration.
The display will indicate the adjustment made from
3 options
- LOW Cycle Mode
- MEDIUM Cycle Mode
- HIGH Cycle Mode
Grease Guardian Controller
TIME CONTROL SETTING
Cycle Programming
See Appendix 1 for suggested setting for your application
1 Ensure unit is positioned on a level surface only and is plumbed in securely.
2 Ensure electrical outlet is waterproof and is tted with or supported by a
dedicated Residual Current Device or ground fault circuit breaker rated 30mA
Points 3 and 4 below should normally be carried out by your market
representative as part of unit commissioning:
3 Prior to mains switch-on ensure the unit is lled with water to the correct
settlement level which occurs when the inowing water stabilises at the base of
the skimming wheel.
4 Set the controller time of day and appropriate cycle programme in accordance
with timer setting instructions detailed in this manual. Observe all
maintenance requirements detailed in this manual
HEALTH, SAFETY AND EFFICIENCY
• Never turn unit on before lling
with water as instructed above.
• Disconnect unit from mains
before accessing any electrical
components
• Unit will lose efciency if not
Maintained.
• The unit is designed to trap and
remove free oating grease oils
and fats only
• The internal solids strainer
provided protects the unit from
coarse solid food waste build
up. To help ensure the highest
efciency and reduce ner solid
food-waste please install primary
strainers in sinks and ensure food
waste is scraped to bin before
washing utensils
• Do not use Hazardous detergents
to clean unit
• Do not install unit externally
unless IP65 weather proof cover
is used
• Do not connect a macerator or
similar device upstream from the
Grease Guardian
• Ensure unit is level and installed
at on the ground or frame where
specied
• Remove blockages and grease
build up from drains before
installing the Grease Guardian
PART 2: PRE START UP CHECKS
INSTALLATION

89
Test Mode
A test of electrical components can be conducted.
Press - and + together to access this screen from the
Home display. Next press any of the Test mode keys
to activate the
corresponding output:
Press A key to activate Heater.
Press B key to activate motor/skimmer.
Press - key to activate Output 3
Press + key to activate Output 4
Return to main menu by pressing ESC
Lid Off Alert
If the main tank cover is removed from the unit at
any time both the heater and motor will be stopped
automatically for safety reasons. The display will
ash a LID OFF alert until the lid is replaced. Power
is restored to the heater and motor after the lid is
replaced
Daily Maintenance Reminder
Once every 24 hours this reminder message
will ash on the controller display. The lid should
be removed and solids basket checked and emptied.
The grease container, internal wiper blade and grease
channel should also be checked at this time. On
replacement of lid the maintenance reminder is re-
set for another 24 hours.
Scheduled Service Reminder
The Grease Guardian unit requires periodic service
inspection and pump out by qualied personnel.
To assist, the controller is pre-set to display a service
due reminder as shown on the due date. Please
contact your Service Provider when this display
appears. The reminder will normally ash at least
once every 90 days in line with service and pump out
requirements for this product
TIME CONTROL SETTING
The time control displays the following information at
various stages of a cycle.
During a cycle both the heating element and the
motor are activated to heat up and skim fats oils
and greases. The main display ashes the message IN
CYCLE. The full cycle sequence is shown in Appendix
2 for each user option chosen.
CONTROLLER ADDITIONAL FEATURES
Heater Off Mode
When wastewater entering the unit is sufciently
hot or if light oils are being intercepted the heater
element may not be required. With this in mind
there is an option to run cycles with the heating
element deactivated. This feature will also provide
savings on energy bills.
To disengage heating element:- from the Home
Screen hold in button “B” for 10 or more seconds.
The display appears as shown. In this mode the
system runs any cycle with only the motor running at
its normal pre-set operation.
See bottom of Appendix 2 for overview of timer
sequence, for “HEATR OFF MODE”.
To re-engage the heater simply hold in the B button
again for 10 seconds until The “HEATR OFF MODE” is
cleared.
TIME CONTROL SETTING

10 11
7 day ON/OFF Control
From the main display access the above display by
pressing OK and ESC together. Choose “Parameter”
using - or + keys then press OK
The display to the left will show. Next using only the
“-” key move the cursor to the “D:MTWTFSS” block
(days of week). To access particular day value press
OK. Then press “-” to cancel any day. Pressing OK
conrms cancellation and moves the cursor to the
next day. On reaching nal Day value, S, press OK to
conrm all.
Example: Controller set to OFF at weekends; the
display is congured as shown left. Press ESC to exit
to home display
TIME CONTROL SETTING
Time of day Set
From the main display access the above display
by pressing OK and ESC together. Choose
“Miscellaneous” using - or + keys then press OK
In the follow on display use the + and - keys to
move the ashing bar to select “CLOCK”. Press OK to
conrm.
Next, use the + and - keys to select “DATE/HOUR
SETUP”, and press OK
Use the + and - keys to move the ashing bar to
select current hour and minutes blocks. Enter and
change these digits by pressing OK, then use + and
- keys to increase/decrease values. Press OK to
conrm current value. Press ESC to save and return
to home display.
TIME CONTROL SETTING
CONTROLLER ADDITIONAL SETTINGS:
TIME RESET AND 7 DAY SETTING

12 13
To Change:
In the “serviced (last)” display select the day, month
or year by pressing either + or - keys to move the
ashing bar through these elds. To lock onto a
specic eld, press OK. The bar icon is dimmed out.
Next use + and – keys to increase or decrease the date
value. When the value is set press OK to store, and
then move to the next eld and repeat. Finally press
ESC to return to the main display.
Service Reminder. Interval Setting
This feature sets the interval for the ashing service
reminder display.
To Check:
From the main display press OK and the “B” button
together.. Then Press “B” twice again to reach the
Service menu. The current interval in month will
appear. Press ESC to return to the main display after
checking.
To Change:
In the “service interval” display select the month by
pressing OK. The bar icon is dimmed out. Next use
+ and – keys to increase or decrease the month value.
When the value is set press OK to store. Finally press
ESC to return to the main display.
TIME CONTROL SETTING
“Commissioned on” date Logger
A basic reference display is used to log the
commissioned date for the unit. The display can be
checked or changed at any time by accessing the
menu as shown.
To Check:
From the main display press OK and the “B” button
together. The Day, Month and Year values will
appear. Press ESC to return to the main display after
checking.
To Change:
In this display select the day, month or year by
pressing either + or - keys to move the ashing bar
through these elds. To lock onto a specic eld,
press OK. The bar icon is dimmed out. Next use +
and – keys to increase or decrease the date value.
When the value is set press OK to store, and then
move to the next eld and repeat. Finally press ESC
to return to the main display.
“Last Service” date Logger
A basic reference display is used to log the last
service date for the unit. The display can be checked
or changed at any time by accessing the menu as
shown.
To Check:
From the main display press OK and the “B” button
together.. Then Press B again to reach the Service
menu. The Last service day, month and year will
appear. Press ESC to return to the main display after
checking.
ENGINEER SETTINGS: COMMISSIONING AND SERVICE
TIME CONTROL SETTING

14 15
Tri-Monthly Maintenance
External Service Partner
ATTENTION!
In addition to the daily and weekly housekeeping, all Grease Guardian units must
receive one service inspection every 3 months to be completed by an approved
FM Environmental service provider only. Failure to implement this service could
result in impairment of unit performance or system failure.
The service will consist minimally of the following steps:
TRI-MONTHLY MAINTENANCE
Unit pump out:
To remove both settled and suspended
solids. A thorough inspection and
cleaning of the heating element will
also be carried out each time
Inspection of all wear and tear parts
Including Wiper rubber, ow restrictor
rubber and lid seal gasket.
Replacement of parts if necessary
Electrical checks
Including controller, heater and motor
checks. Optimisation of components
will be made if necessary.
General Houskeeping
Daily
Remove lid and empty strainer basket
into bin. Replace basket and secure lid.
Empty collection container into barrel.
This can then be taken away by a local
rendering company for recycling.
Open lid and remove, clean and replace
detachable wiper blades.
Fill sinks with clean water and empty
to ush through unit. This keeps
freshwater in tank. Always ensure
water level is reaching wheels.
Weekly
USER MAINTENANCE
Use a brush to clear grease deposits
from the internal channel and external
pipe bend above the grease container.