JOSAM SUPER FLO GI-2000 Series Instruction Manual

SUPER FLOTM GI-2000
FULLY AUTOMATED GREASE RECOVERY
DEVICE (G.R.D.)
OPERATION, INSTALLATION
AND
MAINTENANCE MANUAL
VERSION 2.4
10/2007
PLEASE READ CAREFULLY
Grease Recovery Device will operate efficiently only when properly installed.
Do not discard this manual. This manual is to be distributed to installer,
operator and maintenance department.
WARNING: Cancer and Reproductive Harm - www.p65warnings.ca.gov

GI-2000 Manual V2.3 Page 2
TABLE OF CONTENTS
1.0 UNPACKING ................................................................................................................................... 3
2.0 INSTALLATION INFORMATION ............................................................................................4-6
3.0 WARNINGS ..................................................................................................................................6
4.0 PLUMBING INSTALLATION .......................................................................................................6-8
5.0 ELECTRICAL INSTALLATION .................................................................................................9-11
6.0 G.R.D TESTING..................................................................................................................... 12-14
7.0 MAINTENANCE ....................................................................................................................15-16
8.0 CONTROLLER OPERATING PROCEDURES
8.1 GENERAL DESCRIPTION OF OPERATION ......................................................................17-23
8.2 AUTOMATIC CLEAN CYCLE - FULL DESCRIPTION.............................................................. 25
8.3 MANUAL CLEAN CYCLE - FULL DESCRIPTION...............................................................26-27
8.4 CALIBRATION MODE .......................................................................................................... 28-34
8.5 CLEAN CYCLE RATE ADJUST MODE ....................................................................................35
8.6 TEST MODE ENTRY AND FUNCTION SELECTION...........................................................36-37
8.7 POWER ON DISPLAYS AND DATA LOGGING RESET .......................................................... 38
8.8 MODEM OPERATION................................................................................................................39
8.9 RECLAIM TANK DISPLAY........................................................................................................ 39
9.0TROUBLESHOOTING GUIDE ..................................................................................................40
10.0 WARRANTY INFORMATION ................................................................................................41

GI-2000 Manual V2.3 Page 3
1.0 UNPACKING
1.1 After unpacking the GI-2000, the unit should be checked for any damage that
may have occurred during shipment. Any damage should be reported to Josam
Company immediately.
The following items should be included with the shipment:
QTY DESCRIPTION
1 GI-2000 G.R.D.Unit
1 GI-2000 Flow Control
1 GI-2000 Manual
1 15’ Controller Cable
1 GI-2000 Controller
1 Reclaim Tank
GI-2000 UNIT
DIAGRAM “A”
Supplemental
Solids Basket
Small Cover
Large Cover
Baffle
Electrical Compartment
Heating Element Access
Outlet
Grease Pump
Dischar
g
e
Sensing Probe
Grease Pum
p
Inlet

GI-2000 Manual V2.3 Page 4
2.0 INSTALLATION INFORMATION
2.1 Unit Sizing
Ensure that you have selected the proper size JOSAM GI-2000 so that it can never exceed
the maximum rating of the grease recovery device to suit your particular requirements. Size
is based on Flow Rate per PDI G-101 and ASME A112 14.4.
SIZING TABLE
Fixture-Equipment
Drain Outlet or
Trap Size
Drainage
Fixture-Unit
Value
Drainage G.P.M.
Equivalent
1-1/4”1 7.5
1-1/2”2 15.0
2” 3 22.5
2-1/2”4 30.0
3” 5 37.5
4” 6 45.0
Model Flow Rate
(GPM) Grease (Lbs.) Inlet Size
60306A 25 50 3”
60307A 35 70 3”
60308A 50 100 4”
60309A 75 150 4”
60310A 100 200 4”
60311A 150 300 4”
60312A 200 400 6”
60313A 250 500 6”
60315A 500 1000 6”

2.2 FLOW CONTROL SELECTION
Josam Company has shipped the proper flow control fitting to suit the GRD that you have
ordered. Ensure that the proper flow control fitting is included with your shipment.
Changing the flow control fitting is not recommended and will affect the performance and
warranty of the GRD.
Flow Control
Rating (GPM) Orifice Diameter
25 1-1/4”
35 1-1/2”
50 1-3/4”
75 2-1/8”
100 2-7/16”
150 3”
200 3-7/16”
250 3-3/4”
500 5-1/8”
GI-2000 Manual V2.3 Page 5

3.0 WARNINGS
3.1 The GI-2000 uses heating elements in its operation. Therefore, the unit must always
be filled with water. Elements damaged by electricity prior to the unit being filled with
water will void any said warranties.
3.2 To maintain optimum system performance and accuracy it is necessary to remove
solids accumulations in the tank on a regular basis.
4.0 PLUMBING INSTALLATION
4.1 INSTALLER
Installation is to be performed by a licensed and certified plumber.
4.2 LOCATION OF GRD
The Plumbing & Drainage Institute (PDI) recommends that the unit be located within
25’ or as close as possible to the source of grease being served. The unit may be set
on the floor, partially recessed or completely recessed below the floor. If the unit is to
be recessed you must have proper installation of the electrical hook-up, drain line
and LCD control unit.
4.3 CLEARANCE
When installing, ensure that there is 6” minimum clearance per side for latch removal.
Also provide a minimum of 24” on the outlet end in the event that the heating elements
require service. Provide adequate space on the inlet side for installation or flow control
servicing. When installing the GI-2000 in a pit/vault provide a drain or a sump pump to
prevent water damage.
4.4 LEVELING THE UNIT
The GRD must be leveled from front to back and from side to side. The unit must be
leveled prior to calibration.
4.5 IMPORTANCE OF FLOW CONTROL FITTING
Extensive test reports conclude that both satisfactory operation and maximum
efficiency of the GI-2000 is dependant on the proper rate of flow for the GI-2000
connected, which is accomplished by a flow control fitting. As a result, a specially
designed Josam flow control fitting with a 3”, 4”, 5” or 6” threaded inlet and outlet
connection, depending on size of unit, and a threaded air intake is furnished with every
GI 2000 at no extra cost. The flow control must be installed to prevent overloading the
trap and to maintain maximum grease retention efficiency.
GI-2000 Manual V2.3 Page 6

4.6 FLOW CONTROL LOCATION
The GI 2000 must be correctly installed with the flow control as per model plumbing
codes or the local authority having jurisdiction. The GI-2000 must have a flow control
device properly vented at the inlet or in close to proximity to the GRD inlet, thus
allowing the fixtures to be plumbed and vented as required without having any
negative impact on the GRD or flow control device whose purpose is integral to the
performance of the GRD. (See Diagram B)
4.7 FLOW CONTROL INSTALLATION
Install air intake vent from flow control to outside opening and fit elbow, turned down;
or intersect a common vent or vent stack without a trap as permitted by local codes.
Top of air intake from Flow Control is to be at least 6” above flood rim level of the
lowest fixture served. (See Diagram B) It is recommended that the air intake be tied to
the vent stack.
4.8 VENTED WASTE
The GI 2000 must have a vented waste (outlet), sized as required by local code or local
authority having jurisdiction for venting traps to retain water seal and prevent
siphoning. (See Diagram B)
4.9 ADDITIONAL REQUIREMENTS
When local codes require floor drains to flow through a GRD, the flow control
must be accessible and installed prior to the inlet of the unit.
GI-2000 Manual V2.3 Page 7

DIAGRAM “B”
Locate the installation diagram, which most closely suits your
requirement. Install the flow control and GI-2000 as shown.
GI-2000 Manual V2.3 Page 8

5.0 ELECTRICAL INSTALLATION
5.1 INSTALLER
The electric service and connections to the GRD must be installed by a licensed
certified electrician.
5.2 POWER HOOKUP
The following table lists the electrical power requirements for the various models of
GI-2000 units. Note: A 4-Wire GFI Circuit Breaker is required.
MODEL VOLTAGE HEATING WATTS GFI BREAKER
60306A 220/208 VAC 4000 Watts 25 AMP
60307A 220/208 VAC 7000 Watts 40 AMP
60308A 220/208 VAC 7000 Watts 40 AMP
60309A 220/208 VAC 7000 Watts 40 AMP
60310A 220/208 VAC 9000 Watts 50 AMP
60311A 220/208 VAC 12000 Watts 60 AMP
60312A 220/208 VAC 12000 Watts 60 AMP
60313A 220/208 VAC 12000 Watts 60 AMP
60315A 220/208 VAC 24000 Watts 2x60 AMP
GI-2000 Manual V2.3 Page 9
Note: For special order models not listed consult Josam Company for power
requirements
WARNING! Do not apply power to the unit until the GI-2000 is completely full of
water. Install this unit as any GRD would normally be installed with the exception to
provide a 220/208VAC, single phase, Ground Fault Circuit Interrupter (do not apply
power to the unit at this point), 4 wire connection hard wired to the GI-2000 via a
conduit per code. The electrical installation must conform to NEMA-4 standards. The
main power wire cannot be run through a wall and must be wired to the main breaker
panel so that it can be viewed from the GI-2000 area.

5.3 POWER WIRING
The GI-2000 units are provided with power exiting the tank through the wiring conduit
port on the side of the tank. The power wires provided are:
Red: 120VAC (L1)
Black: 120VAC (L2)
White: Neutral
Green: Ground
Typical wiring between the breaker panel and the GI-2000 unit is:
Wire Type: (Type MTW) 10 Awg min.
Conduit Description: 1” Liquid-Tight Flexible Nonmetallic Conduit
Note: Larger GI-2000 models with special configurations are supplied with
additional wiring information.
WARNING! System power should be secured to the GI-2000 in a method that
conforms to NEMA-4 standards. Wire nuts are used to connect the power wires
behind the power conduit port.
5.4 INITIAL POWER TEST
After confirming that the unit is level, fill the GI-2000 with water before applying
power to the unit. Apply power to the unit and verify with a current probe that L1 and
L2 are below 1 amp. Once confirmed, remove power from the unit.
5.5 CONTROLLER CABLE
Connect the cable from the controller to the round connector near the top of the GRD
on the GI-2000 unit (See Diagram A). Should additional length be required use
Beldon type 8469 (9 Conductor Cable). DO NOT exceed 200’. The cable extension
connections should be done using watertight junction boxes.
5.6 RECLAIM TANK
The GI-2000 is shipped with a ¾” NPT brass outlet fitting. The fitting if removed is
a ¾” M.I.P. fitting. Maximum head is 15’ (maintain ¾” connection). Appropriate
material should be used to accommodate possible temperatures of 140°F, as well
as vibrations, when pumping. When applications warrant a distance between the
GI-2000 and the reclaim tank, the piping must be sloped toward the reclaim tank.
Heat tracing may also be required. Venting is required.
GI-2000 Manual V2.3 Page 10

5.7 RECLAIM TANK ALARM
The GI-2000 controller has an optional integrated reclaim tank alarm system designed to
monitor the state of the reclaim tank, alert the user when the reclaim tank is full and
prevent overflow of the reclaim tank. The option consists of the following components
provided by Josam:
-Float switch Assembly
-Float Switch Cable
The GI-2000 controller will prevent further grease pump out and alert the user as follows:
-Prior to starting a clean cycle the GI-2000 controller will check the status of the
reclaim tank switch.
-If a full reclaim tank is detected the clean cycle will be prevented from starting.
-If a full reclaim tank is detected during a grease pump, the pump will be
immediately stopped.
-The horn will sound (distinct dual beep verses the standard clean cycle single
beep) to indicate a full reclaim tank situation.
-The LCD display will also indicate a full reclaim tank situation exists.
The GI-2000 controller alarm will continue to sound periodically and the display the
reclaim tank full alert until the reclaim tank is no longer full.
Note: See Section 8.9 for details on the GI-2000 controller reclaim tank display.
Installation of the GI-2000 reclaim alarm system consists of:
-Mounting the float switch assembly to the cover of the reclaim tank.
-Attaching one end of the cable provided to the GI-2000 controller via the
mating connector.
-Running the cable from the GI2000 controller to a junction box located at the
reclaim tank.
-Running wires from the float switch assembly to the junction box using a water
tight conduit
Proper operation of the GI-2000 reclaim system can be verified as follows:
-Manually lift the float on the float switch assembly
-The GI-2000 controller alarm should immediately sound and the display switch
to the reclaim tank alarm message.
-Release of the float will stop the GI-2000 alarm and the display will return to
the normal.
GI-2000 Manual V2.3 Page 11

6.0 G.R.D.TESTING
6.1 Leak Check
Confirm that the unit is level and unlatch and lift off the large cover on the GI-2000
tank.
Run water through the drain installation until the unit is full. The unit is considered full
when water runs out of the outlet of the GI-2000. Check the system installation for
leaks.
6.1 Power On Check
Apply power to the GI-2000. The controller will beep and start the initialization
sequence. Note: Refer to Section 8.7 for details of the GI-2000 Controller’s power ON
display sequence. At the end of the initialization sequence the Controller display will
indicate the unit is operating in either the Manual or Automatic mode. If the Controller
display indicates it is operating in the Automatic Mode press the Manual Mode button
until the display indicates the unit is in Manual mode. The Controller initialization
sequence takes approximately 15-20 seconds. If after that time period the Controller is
not displaying other than a Mode see the Controller Operating Section 8.0 and
Troubleshooting Guide Section 9.0 for details on addressing possible problems with
the GI-2000.
6.2 Heater Check
The GI-2000 G.R.D. is equipped with heaters to thin the grease prior to
pumping out the grease into the reclaim tank.
The GI-2000 Controller provides the ability to test the heater. To access the
test controls inside the Controller, loosen the front panel screws and open
the Controller door.
Follow the procedure in Section 8.6 to turn the heaters ON. The heater LED
indicator should turn ON and a contactor relay on an interface board located
in the GI-2000 should close powering the heaters. Observe the heaters for
several minutes to see that the water around the heater elements is
beginning to heat evidenced by heat waves and bubbles forming around the
heater elements.
Follow the procedure in Section 8.6 to turn the heaters OFF. The heater LED
indicator should turn OFF and heating activity around the heater elements
should begin to cease. Note: The heaters will also automatically shut off after
three minutes.
WARNING! Do not run the heater dry! Running the heater dry may cause damage to
the heaters and the unit.
GI-2000 Manual V2.3 Page 12

6.3 Pump Check
The GI-2000 G.R.D. is equipped a pump to move the grease from the G.R.D
into the reclaim tank.
The GI-2000 Controller provides the ability to test the pump. To access the
test controls inside the Controller, loosen the front panel screws and open
the Controller door.
Follow the procedure in Section 8.6 to turn the pump ON. The pump LED
indicator should turn ON and a solid state relay on an interface board located
in the GI-2000 should close powering the pump. Observe that the pump is
running and water is being pumped into the reclaim tank.
Follow the procedure in Section 8.6 to turn the pump OFF. The pump LED
indicator should turn OFF and the pump should stop running. Note: The
pump will also automatically shut off after 60 seconds.
WARNING! Do not run the pump dry! Running the pump dry may cause damage to
the pump.
6.4 Temperature Sensor Check
The GI-2000 G.R.D. is equipped a temperature sensor to detect when the
water has been sufficiently heated by the heaters during a clean cycle to
start pumping the grease from the G.R.D into the reclaim tank.
The GI-2000 Controller provides the ability to check the temperature sensor.
To access the test controls inside the Controller, loosen the front panel
screws and open the Controller door.
Follow the procedure in Section 8.6 to check the state of the temperature
sensor. For a tank filled with cold water the temperature sensor should be in
the OFF state. For a tank filled with hot water (>100OC) the temperature
sensor should be in the ON state.
6.5 Grease Level Sensor Check
The GI-2000 G.R.D. is equipped a grease level sensor to detect when the
amount of grease in the tank requires a clean cycle to pump the grease from
the G.R.D into the reclaim tank. The grease level sensor is designed to
detect a 4” range of water below the bottom of the outlet pipe.
GI-2000 Manual V2.3 Page 13

The GI-2000 Controller provides the ability to check the operation and
calibration of the grease level sensor. To access the test controls inside the
Controller, loosen the front panel screws and open the Controller door.
Follow the procedure in Section 8.6 to check the water level being measured
by the grease level sensor. For a tank filled with water (containing little or no
grease) up to the bottom of the outlet pipe, the water level test should
indicate 4.0” inches of water. For a water level 1.0” inch below the bottom of
the outlet pipe, the water level test should indicated 3.0” inches of water. For
a water level 4.0” inches below the bottom of the outlet pipe, the water level
test should indicated 0.0” inches of water.
If the indicated water levels are not correct, the GI-2000 may need
recalibration. See Section 8.4 for instructions on how to recalibrate the
system.
6.7 COMPLETION OF TESTING
To exit test mode press Test/Cancel button twice.
Carefully close the control front panel and reinstall the locking screws.
Turn the Auto/Manual switch on the front panel to AUTO.
Install the top cover of the grease trap section.
GI-2000 Manual V2.3 Page 14

7.0 MAINTENANCE
WARNING! Remove power from the GI-2000 GRD system prior to performing
maintenance operations.
7.1 Solids Removal
To maintain optimum system performance and accuracy it is important to remove all
solids that have accumulated in the solids interceptor. Do not allow any solids to
build up in the GI-2000.
7.2 Sensor Maintenance
The GI-2000 requires that the grease level sensor be periodically cleaned of grease
or debris that may be stuck to the sensor.
JOSAM recommends the grease level sensor be cleaned every time the interceptor
tank is pumped out. As a minimum, the tank probe should be cleaned every 3
months.
Grease level sensor 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.
Warning: Do not use an abrasive material (i.e. scouring pad, steel wool, etc.) to clean
the tank probe as this may damage the grease level sensor protective covering. Do
not bend the grease level sensor during cleaning.
7.3 Periodic Calibration
Recalibration of the system is not typically required after the grease level sensor has
been cleaned. JOSAM recommends that system calibration be performed once a year
after the interceptor tank is pumped out.
7.4 Controller Maintenance
The controller requires no scheduled maintenance.
7.5 Maintenance Log
It is recommended that owner maintain a daily maintenance log to insure GI-2000
maximum performance. See sample Maintenance Log on next page.
GI-2000 Manual V2.3 Page 15

Comments
Temp LED ON
Time
9:00AM
Initial
CT
Reclaim Tank Status
Half Full
Cleaned Solids
Y
Water Level
4.0
Cycles Completed
0-1-2-3
Mode
Auto
Power Y
Date
Ex. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
JOSAM GI-2000 MAINTENANCE LOG MONTH:________________________ CONTACT:______________________ PHONE: [phone]
PART NUMBER:_________________ SERIAL NUMBER:_______________
GI-2000 Manual V2.3 Page 16

GI-2000 Manual V2.3 Page 17
8.0 CONTROLLER OPERATING PROCEDURES
8.1 GENERAL DESCRIPTION OF OPERATION
8.1.1 CONTROLLER MODES OF OPERATION
The GI-2000 G.R.D. controller provides the following modes of operation:
Automatic Clean Cycle Mode
This operating mode automatically starts the clean cycle that pumps the grease out of
the interceptor trap whenever the volume of grease reaches the preset level.
Manual Clean Cycle Mode
Allows the operator to manually start the clean cycle independent of the volume of
grease in the interceptor trap. Note: In manual mode operation the Grease Level HI LED
indicator will light when the volume of grease reaches the preset level.
Calibration Mode
The calibration mode allows maintenance personnel to calibrate the water level
measurement sensor located in the interceptor trap. Calibration consists of filling the trap
with water to two (2) predetermined levels that the controller later uses to calculate the
water level in the interceptor trap during actual operation. The calibration mode also
allows the user to configure system operating parameters.
Clean Cycle Rate Adjust Mode
The clean cycle rate adjustment allows the grease volume threshold at which the clean
cycle automatically starts to be adjusted without re-calibration of the system. The normal
rate is based on the calibration of the system at installation and setup. Adjustments are
made in software to the water level at which the clean cycle starts relative to the results
from the initial calibration. The clean cycle rate will increase when the water level value
at which the clean cycle starts is raised and the clean cycle rate will decrease when the
water level value is decreased. This mode allows maintenance personnel to quickly and
easily adjust clean cycle rate to better match the requirements of a specific installation.
Test Mode
The test mode allows maintenance personnel to exercise various system functions to
facilitate trouble shooting and repair. Table 1 provides a summary of the available test
functions:

Table 1
Test Functions
Time and Date Entry - Allows maintenance personnel to set the time
and date
Heater Test - Allows maintenance personnel the ability to
turn the power on and off to the heater
Pump Test - Allows maintenance personnel the ability to
turn the power on and off to the pump
Temp Switch Test - Allows maintenance personnel the ability to
check the status of the temperature switch.
Water Level Test - Allows maintenance personnel the ability to
display the water level the controller is
currently calculating.
Display & LED Test- Exercises the LCD display and LED indicators
for proper operation.
8.1.2 CONTROLS, DISPAYS AND INDICATORS
The following controls, displays and indicators are available on the GI-2000 Controller:
External Controls
The external controls on the controller enclosure available to the operator are
summarized in Table 2:
Table 2
External Controls
Auto/Manual Mode Switches - Allows the operator to select between
automatic clean cycle operation and manual
clean cycle operation.
Manual Mode Start/Stop Switch - Allows the operator to start the manual clean
cycle operation.
GI-2000 Manual V2.3 Page 18

Internal Controls
Table 3 lists the internal controls are available to maintenance personnel when the door
to the controller enclosure is open: Table 3
Internal Controls
Cal Mode/Up Switch - Initiates the water level sensor calibration
mode and increments time and date values in
the time and date entry mode.
CC Rate Switch - Initiates the clean cycle rate adjustment
mode.
Test Mode Switch - Initiates the test mode operation.
Enter Switch - Mode selection and data entry control switch
Display and Indicators
Table 4 lists the displays and indicators are provided on the GI-2000 controller:
Table 4
Display Indicators
Power On Pilot Light - External pilot light on the controller enclosure
door indicating the unit is powered up.
Clean Cycle Pilot Light - External pilot light on the controller enclosure
door indicating that the clean cycle is in
operation.
Manual Mode LED External pilot light on the controller enclosure
door indicating the unit is manual mode
operation.
Automatic Mode LED External pilot light on the controller enclosure
door indicating the unit is automatic mode
operation.
LCD Display - Four (4) line X 20 character LCD display
provides information and instructions to
operators and maintenance personnel. LCD
display visible through the controller enclosure
door.
LED Indicators - The following LED indicators are visible
through the controller enclosure door:
Heaters On
Pump On
Grease Level High
Temperature Switch On
Activity 1 - Modem Activity (See Section x.x)
Activity 2 - Sign of life flashing once per
second to indicate proper firmware is
operating properly
GI-2000 Manual V2.3 Page 19

Controller Unit
GI2000 Grease Interceptor
CLEAN
CYCLE
ACTIVE
POWER AUTO STOP MANUAL START/
JOSAM
JOSAM GI-2000 GREASE
RECOVERY SYSTEM
OPERATING SOFTWARE
VERSION X.X
Figure 8.1.2-1
Illustration of the external switches and indicators
on the front of the controller enclosure
GI-2000 Manual V2.3 Page 20