JOSAM EGOLD-1000 User manual

EGOLD-1000
Electronic Grease Level Detector
Installation and Operating Procedures
Josam Company
2501 South Front Street
Philadelphia, PA 19148
215-339-5370
WARNING: Cancer and Reproductive Harm - www.p65warnings.ca.gov

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 2
www.JOSAM.com
REV I 1/23/06
Table of Contents
1.0 GENERAL DESCRIPTION ............................................................................................................3
2.0 EGOLD-1000 INSTALLATION......................................................................................................5
3.0 EGOLD-1000 CONTROLS AND INDICATORS ..........................................................................9
4.0 EGOLD-1000 CALIBRATION......................................................................................................11
5.0 EGOLD-1000 OPERATION...........................................................................................................13
6.0 EGOLD-1000 MAINTENANCE....................................................................................................15
Figures
FIGURE 1-1 ILLUSTRATES THE ELECTRONIC GREASE LEVEL DETECTION SYSTEM .............................................4
FIGURE 2-1 ILLUSTRATES THE TANK PROBE INSTALLATION INSTALLATION.......................................................8
Figure 3-1 illustrates the TANK PROBE INSTALLATION INSTALLATION……………….……………..……10
Appendices
APPENDIX ITANK PROBE ASSEMBLY MOUNTING TEMPLATE........................................................................16
APPENDIX II OPTIONAL EXTERNAL ALARM UNIT..........................................................................................17
APPENDIX III OPTIONAL EXTERNAL MODEM ................................................................................................18

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 3
1.0 General Description
The EGOLD-1000 Electronic Grease Level Detector product consists of the following components:
A wall mounted Control Unit that contains the level measurement micro-controller
electronics, control switches and indicators.
A Tank Probe assembly consists of a tank probe mounted to a bracket. Multiple probe lengths
are available to fit most existing manual interceptor configurations.
A U.L. approved wall mount low voltage power module.
A Cable to interconnect the wall mounted Control Unit and the Tank Probe assembly.
The Control Unit GLS housing, connectors, control switches and indicators are water resistant for
splash or spray conditions. The Tank Probe assembly is a sealed against water penetration.
The EGOLD-1000 Electronic Grease Level Detector product provide the following functions and
features:
Provides a continuous grease level measurement system that can be calibrated to most
existing manual interceptor configurations. Note: The interceptors must be made of metal.
Provides an integral level alarm to alert the user of the need for interceptor cleaning.
Provides a switch closure for a remote level alarm option.
Provides an easy method of alarm level calibration.
Provides an interface for an external Modem option that allows remote monitoring of the
system by telephone.
Figure 1-1 provides an illustration of the EGOLD-1000 System

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 4
Figure 1-1
MODEM

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 5
2.0 EGOLD-1000 Installation
2.1 Important Installation Points
Check that you have selected the proper Tank Probe length to suit your particular interceptor tank
requirements. Tank Probe length is based on inside wall height of the interceptor tank. The proper
Tank Probe length should be 2 inches less then the inside wall height
For example: An interceptor tank with an inside wall height of 15 inches will require Tank Probe
assembly part number MA47-13. An interceptor tankwith an inside wall height of 20 inches will
require Tank Probe assembly part number MA47-18.
Note: For inside tank wall heights greater than 22 inches consult JOSAM for the proper Tank
Probe assembly part number.
Prior to mounting the Tank Probe assembly in the interceptor tank, insure that the tank probe
location chosen will not interfere with any baffle elements in the interceptor tank when installed.
Installation will require drilling of the interceptor tank wall. Note: Care should be taken when
operating power tools around the interceptor tank due to the presence of water.
It is important to carefully follow the calibration procedure outlined below, in order to insure
proper grease level detection.
The wall mount power module that powers the Control Unit must be directly plugged into
an outlet. Do not use an extension cord. If electric service is required, a licensed and
certified electrician must install it.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 6
2.2 Control Unit Installation
The Control Unit has integral mounting brackets for wall mounting.
Install the Control Unit as follows:
1) Find a wall location that is within 10 feet of the interceptor and within 5 feet of an 115VAC
wall outlet.
2) Place the Control Unit on the wall and mark the two (2) mounting hole locations. Drill 3/16”
holes to accept the mounting hardware.
3) Use the mounting hardware provided to fasten the Control Unit to the wall.
4) Plug the power module provided into the wall and plug the power module cord into the
Control Unit. Note: The LED indicators should flash ON then OFF when the unit is properly
powered.
See Appendix II for optional remote level alarm installation procedure.
See Appendix III for optional Modem installation procedure.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 7
2.3 Tank Probe Assembly Installation
The Tank Probe Assembly consists of a bracket set and the Tank Probe mounted to it. Figure 2-1
illustrates an installed Tank Probe Assembly.
Install the Tank Probe Assembly as follows:
1) The interceptor should be located within 10 feet of the Control Unit mounting location.
2) Place Bracket A the top of the tank wall in the area where the Tank Probe Assembly is to be
mounted. Mark and drill holes for self tapping 10-24 hardware.
Note:Before drillingthe holesinsure thatthe TankProbeAssemblywillnot interferewithany
mechanical or baffle elements in the tank when installed.
3) Secure the bracket indicated as Bracket A with (2) 10-24 self tapping screws provided into
the holes drilled in the tank wall.
4) Attach the bracket indicated as B to bracket A with the ¼-20 screw and wing nut provided.
Bracket B should be free to slide up and down on bracket A. Attach the probe to the underside of
bracket A with the ¼-20 screw provided. Slide the probe and bracket B assembly until the
bottom of the yellow band on the probe is at the same level as the bottom of the outlet pipe.
Once positioned tighten the wing nut holding bracket B to Bracket A.
Note: Be careful not to bend, scrape or otherwise damage the probe shaft when mounting the
Tank Probe assembly.
5) Attach the connector of the cable provided from the Control Unit to the Tank Probe Assembly.
A path for the cable to exit the tank between the tank cover and side wall must be provided.
Note: The cable must not be sharply bent or crushed as it exits the tank.
6) Note: Care must be taken to prevent the cable running between the interceptor tank and
the Control Unit from becoming a safety hazard for foot traffic or damaged. If run along
the floor, a method such as saw cutting a groove in the floor or covering the cable with a
cable guide will be required.
7) Attach the cable to the Control Unit.
This completes the installation of the EGOLD-1000 Electronic Grease Level Detector system.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 8
Figure 2-1
STATIC WATER LEVEL
OUTLET
BRACKET A
BRACKET B
MOUNTING
SCREWS
YELLOW
BAND

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 9
EGOLD-1000 System
3.0 EGOLD-1000 Controls and Indicators
3.1 Control Unit
The face of Control Unit has two (2) momentary push button controls:
Calibrate Button -This button is pressed to initiate a calibration procedure.
Alarm Reset Button -This button is pressed to turn off the level alarm buzzer.
The face of the Control Unit has the following LED indicators:
Power LED -When ON this LED indicates that the Control Unit has power applied.
Operating LED -When ON this LED indicates that the EGOLD-1000 Electronic Grease Level
Detector system is operating properly in the grease level detection mode.
Calibration LED -When ON this LED indicates that the EGOLD-1000 Electronic Grease Level
Detector system is in the grease level calibration mode.
Level LEDs -A set of 5 vertical LED indicators displays the current level of grease being
detected in the interceptor tank. Each LED indicator represents approximately
one fifth (1/5) of the maximum grease level volume.
-The bottom three (3) Green LEDs indicate the grease volume is below the
level required for grease interceptor tank cleaning. Note: The three (3) Green
LED indicators are also used during the system calibration.
-The Yellow LED indicates the grease volume is approaching the level
required for cleaning the grease interceptor tank.
-TheRed LED indicates the grease volume has reached the level requiring the
grease interceptor tank to be cleaned.
Figure 3-1 illustrates the face of the Control Unit.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 10
2.5mm POWER JACK
CENTER POSITIVE
MOUNT USING #8 HARDWARE
(PROVIDED IN KIT)
Figure 3-1
Control Unit Face

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 11
4.0 EGOLD-1000 Calibration
The calibration of the EGOLD-1000 Electronic Grease Level Detector system sets the grease level at
which the alarm (Horn) sounds indicating that the grease interceptor is due for cleaning.
Typically the alarm level is approximately 1/3 of the distance between the bottom of the outlet pipe
on the interceptor tank and the bottom of the tank.
4.1 Calibration Procedure
Perform the following steps to calibrate a newly installed EGOLD-1000 Electronic Grease Level
Detector system:
1) Start with the Control Unit unpowered (power module removed from the wall socket).
2) Mark a line on the inside interceptor tank wall that is approximately 1/3 of the distance from the
bottom of the outlet pipe to the bottom of the tank
Note: When grease fills the interceptor tank down to this level the alarm will be activated.
3) Fill the interceptor tank with water up to the line marked in Step 2.
4) Secure the tank cover with the Tank Probe Assembly installed onto the interceptor tank.
5) Power up the Control Unit (plug power module into the wall socket) The LED indicators should
flash ON then OFF (the horn will also beep) to indicate Power has been applied.
6) The Control Unit LED indicators should be in the following states:
- Run LED is OFF
- Cal LED is Off
- Red Level LED will be flashing (the horn will also intermittently beep)
- The other Level Indicating LEDS are OFF
7) Press the Cal Set Button on the Control Unit. The CAL LED will start flashing indicating the
Control Unit is in the calibration mode. The Red Level LED will go OFF.
Note: Calibration mode can be cancelled at any time by pressing the Alarm Reset Button.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 12
8) The bottom two (2) Green LEDs should turn ON. Then press the Cal Set Button on the Control
Unit. The two (2) Green LEDs will begin flashing and then turn OFF after several minutes (the
horn will also beep). The CAL LED will continue flashing indicating the Control Unit is still in
the calibration mode.
9) Fill the interceptor tank with water until water flows out of the interceptor tank outlet pipe.
10) Press the Cal Set Button on the Control Unit. The two (2) Green LEDs will begin flashing. After
several minutes the CAL LED and the two (2) Green LEDs will turn OFF (the horn will also
beep). The Run LED will then turn ON indicating that calibration was successfully complete and
the unit is now operating in the grease level detection mode.
Note: The Red Level LED will turn ON and the CAL LED will continue flashing indicating the
system calibration was not successful. Repeat the calibration procedure a second time. Contact
JOSAM for technical support if system calibration is not successful the second time.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 13
5.0 EGOLD-1000 Operation
Once the EGOLD-1000 Electronic Grease Level Detector system is calibrated, operation is fully
automatic and requires no operator interaction.
Normal Operation
The EGOLD-1000 Electronic Grease Level Detector system operates as follows:
The interceptor grease level is continuously monitored.
The Level Indicating LEDs provide an indication of the current level.
-The bottom three (3) Green LEDs indicate the grease volume is below the
level required for grease interceptor tank cleaning.
-The Yellow LED indicates the grease volume is approaching the level
required for cleaning the grease interceptor tank.
-The Red LED indicates the grease volume has reached the level requiring the
grease interceptor tank to be cleaned.
The audible Alarm will sound once the Red LED indicates the grease volume has reached the
level requiring the grease interceptor tank to be cleaned
Note: If installed, the optional Alarm will also sound at this time.
Pressing the Alarm Reset Button on the Control Unit can silence the Alarms.
Note: The audible alarm will again sound after several minutes if the grease volume still at
the level requiring the tank to be cleaned.
Power should be removed from the Control Unit (unplug power module into the wall socket)
when cleaning the grease interceptor tank.
Note: The EGOLD-1000 Electronic Grease Level Detector system will maintain calibration
when unpowered.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 14
Error Indications
The Control Unit will indicate system operating errors as follows:
The Operating LED will be OFF.
The Red Level LED will be flashing.
The audible Alarm will sound intermittently (short beeps once every ten seconds).
System errors include:
Loss of a proper signal from the Tank Probe Assembly
-disconnected or broken cable to Tank Probe Assembly
-electronic failure in the Tank Probe Assembly
System Calibration improper
-Tank Probe Assembly level signal outside the calibration limits

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 15
6.0 EGOLD-1000 Maintenance
The EGOLD-1000 Electronic Grease Level Detector system maintenance requirements are as
follows:
The Control Unit should be unpowered (power module removed from the wall socket) during
maintenance operations.
The Control Unit requires no periodic maintenance.
Note: The Control Unit is water resistant. Therefore the Control unit face may be cleaned
with
a damp cloth as required.
The Tank Probe Assembly requires that the tank probe protruding into the tank be cleaned of
grease or debris that may be stuck to the tank probe periodically. JOSAM recommends the
tank probe be cleaned every time the grease is emptied from the interceptor tank. As a
minimum, the tank probe should be cleaned every 6 months.
Tank probe cleaning can be accomplished by wiping the probe with a soft cloth or sponge. A
degreaser (i.e. dish washing soap, etc.) may also be used. The housing of the Tank Probe
Assembly is water resistant and may be cleaned with a damp cloth as required.
Note: Do not use an abrasive material (i.e. scouring pad, steel wool, etc.) to clean the
tank probe as this may damage the tank probe protective covering. Do not bend the
tank probe during cleaning.
Recalibration of the system is not typically required after the Tank Probe Assembly has been
cleaned. JOSAM recommends that system calibration be performed once a year.
NOTE:
TO MAINTAIN SYSTEM PERFORMANCE AND ACCURACY IT IS NECESSARY TO
REMOVE SOLIDS ACCUMULATION IN THE TANK ON A REGULAR BASIS.
SOLIDS BUILD UP OF GREATER THAN 4 INCHES IN THE TANK WILL ADVERSELY
AFFECT THE PERFORMANCE OF THE SYSTEM.

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 16
Appendix I
Tank Probe Assembly Mounting Template
TBD

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 17
Appendix II
Optional Alarm Unit
TBD

EG0LD-1000 Electronic Grease Level Detector
Installation and Operating Procedures
__________________________________________________________________________________________
Page 18
Appendix III
Optional Modem Unit
Optional Modem Unit Installation
The following items are provided with EGOLD1000 installation kit when the Optional Modem Unit
is provided:
An external Modem Unit including installation and operating procedures.
A U.L. approved wall mount low voltage power module.
A cable to interconnect the Modem Unit to the wall mounted Control Unit.
A telephone cable to connect the Modem unit to the telephone line.
Install the Modem Unit as follows:
1) Find a location that is within 15 feet of the Control Unit, within 5 feet of an 115VAC wall
outlet and within 5 feet of a telephone jack to place the Modem Unit provided.
2) Plug the jack connector of the modem cable provided into the Control unit and the “D”
connector of the modem cable into the rear of the Modem Unit.
3) Plug the telephone cable into the “line” connector on the rear of the Modem Unit and the
telephone jack.
4) Plug the power module provided into the wall and plug the power module cord into the
Modem Unit.
5) Turn the Modem Unit ON as indicated in the operating procedures provided.
6) Cycle the power to the Control Unit. The “RX” and “TX” indicators on the Modem Unit
should flicker. Note: This indicates the Control unit is communicating to the Modem Unit.
7) Contact JOSAM when the installation is complete. JOSAM will perform a test of the remote
grease level monitoring function.