GRANULDISK Granule Maxi Service Manual Download Page 3

Page: 3 / 97

Contents

CE Declaration of Conformity

1 General Description and Safety

1.1 To the user

1.2 Safety regulations

1.3 Disconnecting power

1.4 Technical data

2 Installation

2.1 Installation instructions

2.2 Detergent and rinse aid

2.3 How to lay the Granule Maxi down on

its side

3 Troubleshooting and Alarms

3.1 Error codes

4 Programming

4.1 Preselected values in Service menu

4.2 Flashloader 4.2

4.3 GDTdirect™ 3.x*

4.4 GD Memo™

5 Routines for long time storage

6 Warranty

7 Maintenance and Service

7.1 Service instructions 1 year service

7.2 Service instructions 2 year service

Summary of Contents for Granule Maxi

Page 1: ...e 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 46 40 671 50 60 ...

Page 2: ......

Page 3: ...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...

Page 4: ...eating 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 ...

Page 5: ...e 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...

Page 6: ...CE Declaration of Conformity ...

Page 7: ... 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 T...

Page 8: ...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 8 Rev 2012 05 ...

Page 9: ...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 6...

Page 10: ...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 disconne...

Page 11: ...k 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 Check...

Page 12: ...6 bar a relief valve must be installed 6 Connect the drain pipe on the back right to the drain Ø 32 mm C Figure 2 on page 13 Place the valve in open position shown by symbols on the side panel The drain capacity must be at least 100 litres minute The machine should not be placed directly over a floor drain since it is important for the drain to be accessible for cleaning 7 All electrical connectio...

Page 13: ...2 Installation 2 1 Installation instructions Figure 2 Rev 2012 05 13 ...

Page 14: ...inse 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...

Page 15: ... 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 ...

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

Page 17: ... 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 ...

Page 18: ...ant 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 A pallet truck Two EUR pallets Standard tool kit Profiles from the machin...

Page 19: ... 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 profiles and cut off a part of them according to 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 ...

Page 20: ...e 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 Th...

Page 21: ...2 Installation 2 3 How to lay the Granule Maxi down on its side Figure 14 The machine is now ready to be moved 9 To rise the machine up perform in reversed order Rev 2012 05 21 ...

Page 22: ...2 3 How to lay the Granule Maxi down on its side 2 Installation ...

Page 23: ...will not light up 1 Fuse F5 24 V 2 Cable connection between PCB and display panel 3 Main switch Q1 in electrical connection box No Granules when washing with Granules is selected 1 Granules loaded into the wash tank 2 Granules are chosen on the operators panel 3 Granule valve is opening properly Granules left on the items washed 1 That wash nozzles are not blocked 2 That pots are angled correctly ...

Page 24: ...nning correctly Doors leaking 1 That the machine is in level 2 The door alignment 3 Upper and lower locking mechanism bearings undamaged 4 Centre seal correctly positioned against the cabin seal Foam test 1 Run a wash program with Granules 2 When separation is done and no Granules are circulating stop the program 3 When the machine is stopped open the door immediately and check how much foam there...

Page 25: ...impeller is blocked by Granules or by small utensils Check that the impeller turns freely reset the motor circuit breaker start the machine and check the current of all three phases Check the volume of charged granules 102 Motor circuit breaker for wash pump left tripped The motor is overloaded The impeller is blocked by Granules or by small utensils Check that the impeller turns freely reset the ...

Page 26: ...s Check overheat protector Non 400 V machines only Check the heating element circuit breaker and the contactor in the electrical cabinet Can also be caused by low temperature of incoming water 108 Temperature not reached in rinse tank The rinse water in the rinse tank does not reach its preset temperature during the wash process Check overheat protector Non 400 V machines only Check the heating el...

Page 27: ... sensor in the rinse tank has not been activated within 5 minutes of the solenoid valve opening Check the water supply to the machine as well as the solenoid valve for rinse tank filling Check the condition sensitivity value of level sensors in the rinse tank 116 Low water level problem with foam Foam forming in the machine Avoid using detergent designed for washing up by hand Change the wash wate...

Page 28: ...ed out too fast causing insufficient heating and rinsing of the pots and pans Check all rinse nozzles no missing nozzles leaks Check that nozzles are not too open worn out 140 An initiation error of the tempera ture sensors has occurred Temper ature sensor in the wash tank or rinse tank not function ing The communication between the temperature sensors and the PCB was disturbed during start up The...

Page 29: ...Time control the rinse pump Pot wash Other NO NO NO NO NO na 41 Eco Rinse time 20 20 20 20 20 s 42 Other Rinse time 40 40 40 40 40 s 43 Eco fine Rinse time 20 s 44 Other fine Rinse time 20 s 45 Steam reduction equipment YES YES YES NO NO na 46 Steam reduction time Eco program 0 0 0 0 0 s 47 Steam reduction time Other program 60 60 60 30 30 s 48 Steam reduction time Fine Eco program 0 s 49 Steam re...

Page 30: ...e not reached 15 15 15 15 15 min 61 Alarm Long fill time in the wash tank 20 20 20 20 20 min 62 Alarm Long fill time in the rinse tank 5 5 5 5 5 min 63 Change water after 25 25 25 25 25 cy cles 64 Run test program 65 Load factory settings 66 Value on the level sensors 67 Read operation data 68 Read accumulated values 4 2 Flashloader 4 2 With this PC program it is possible to Upgrade the software a...

Page 31: ...e computer does not have a serial port a USB serial adapter can be used For information on what is suitable to a particular computer contact an IT specialist 2 Connect the cable in the machine s electrical cabinet to the J11 terminal on the PCB 4 2 3 How to use the Flashloader 1 Put the wash machine in stop mode by pressing the STOP button 1 2 Start the program by double clicking on the program fi...

Page 32: ...4 2 Flashloader 4 2 4 Programming Figure 16 Making the connection with the machine 5 Press Run from Flash Figure 17 Computer connected and ready to take control 32 Rev 2012 05 ...

Page 33: ... Flash Loader on page 33 4 2 4 Flashloader for troubleshooting 1 Connect the computer by pressing Autodetect and then select Run from Flash if not done in previous section CAUTION Only tick one function at a time Heaters can be turned on without water Pumps will only run if the doors are closed 2 When the Outports field is white the outputs can be forced remotely Rev 2012 05 33 ...

Page 34: ...when the sensor function is manipulated By hand or using the Out Ports In this mode no information is shown on the machine s display 4 2 5 Uploading NOTE If the main PCB is replaced all data is lost if possible read out the values for Service and Granules before the PCB is exchanged The values are then noted and can be entered using Flashloader after the new PCB is installed 1 Connect the computer...

Page 35: ...ect software version e g for Smart WashProg Smart 4 0 bin for Maxi Gastro Combi Flexi WashProg 4 3 bin Figure 20 Press Browse and select the software to be loaded 5 Make sure that only Wash program file checkbox is ticked If languagefile is to be updated as well tick Language file and choose the correct Language file spk 6 Then press Upload Uploading Rev 2012 05 35 ...

Page 36: ...ead off directly on the display For complete storage of all data an external computer can be connected to the machine and operating data can be stored in separate files The system requirements for external computers connected are Windows 2000 Windows XP or Windows 7 x is current version number and begins with 0 4 3 1 Reading data on the control panel display 1 Press the STOP 2 button and release i...

Page 37: ...in the wash tank during washing 85 indicates the minimum temperature in the rinse tank during the final rinse OK indicates that the rinse water volume is correct in accordance with the factory settings If the settings have been changed NA not applicable is displayed instead If the wash program has been interrupted on account of a handling error or a technical fault no temperature is indicated and ...

Page 38: ... connected Note Duplicates may appear in this mode 4 3 3 Cable connection 1 Connect a serial RS 232 cable straight between the machine serial connector and the computer s serial port Some machines will not be fitted with the cable The cable can in these cases be obtained as a spare part If the computer does not have a serial port an USB serial adapter can be used For information on what is suitabl...

Page 39: ...vals to avoid too long files 6 Data is displayed directly on the computer screen The window is fixed in size and cannot be changed Table headings are in English The columns can be widened by placing the mouse cursor in the table header and extending it From left to right the following information can be collected Date Time Eco Short Normal Program type Granules G washing with Granules or NO Washin...

Page 40: ...appears once the water has been changed or can be reset by pressing Stop 2 releasing it waiting 3 seconds and then pressing button 7 five times OK is shown in the display during 2 seconds after the reset This reminder appears after every 25 wash cycles in preset The number of washes may be varied between 15 and 40 washes 2 Time to change Granules to maintain the wash power in the machine The Washi...

Page 41: ...set Service message appears every 8000 programmes or once a year whichever occurs first 4 Alarm priority If the reminders Change water Change Granules now or Time for service occurs at the same time the messages are prioritised as follows Change wash water will always have first priority Once the water has been changed and the message reset the next message can be shown Second priority Change Gran...

Page 42: ...ng water any value above 500 factory setting is read as level by the software WT Wash tank URT Upper rinse tank LRT Lower rinse tank 3 Read operation data Here the data from the last 97 programs are stored see section 4 3 1 Reading data on the control panel display on page 36 4 Read accumulated values In this menu the number of occurrences of most errors are stored that has occurred during wash cy...

Page 43: ...he door seals and Granule valve gasket with rubber grease 7 Turn off the supply disconnecting device and the inlet water supply 8 Next day drain the detergent solution from the sink where the Granules has been stored overnight 9 Rinse the Granules with plenty of water Shake well to remove as much water as possible 10 Store the clean Granules in the Granule collector 11 Place the Granule collectors...

Page 44: ...5 Routines for long time storage ...

Page 45: ...ntenance has been performed by an authorized Service Partner and reported to the local GRANULDISK representative The GRANULDISK Product s Operator display reminds users when Service is needed Periodic Maintenance and parts needed for this are not covered by the Warranty The warranty does not cover wear to metal and consumables such as light bulbs filters fuses gaskets etc Every month the distribut...

Page 46: ...6 Warranty ...

Page 47: ...with new ones Twist the nozzle with a pair of adjustable pliers until the lug snaps and the nozzle comes off e Make sure that the upper part and the hole in the white plastic bearing of the wash arm is clean Clogged hole could cause problems removing the wash arms during daily cleaning Figure 23 Make sure the hole is not clogged and no granules f Mount o rings on the wash nozzles and mount the was...

Page 48: ...the machine c Undo the frame holding the seal 14 Nuts d Replace the seal and mount the frame again Exploded view of Granule damper mechanism e Undo right cover plate f Undo the brass nut that holds the right damper shaft bearing g Push the bearing into the machine h Undo the bolt M12 that fixes the arm to the shaft 48 Rev 2012 05 ...

Page 49: ...ing and replace the o rings The o ring between machine wall and bearing is mounted dry Lubricate the o ring for the shaft well before mounting l Slide the bearing on the shaft and fit the shaft in the right hand hole for bearing m Slide the nut on the shaft Slide the arm on n Secure the arm with the bolt o Fit the shaft into the left hand bearing p Fit the right hand bearing and tighten the brass ...

Page 50: ...ten for good joint e Remount the seal holders 5 Replace middle seal left door a Undo old seal b Fit seal top bottom and centre Align the phased parts of the centre seal against the cabin seal picture Figure 26 Alignment to cabin seal same alignment up and down c Press in the rest of the seal d Close door and make sure that the seal sits straight in the holder for a tight fit 50 Rev 2012 05 ...

Page 51: ...thdrawing tool do not tap tapping might damage the seat for bearing or welding f Undo the wash arms and the shafts together Undo the locking washer and washer NOTE If the arms where removed previously cover the lower wash arms bearings The shafts will end up in the wash hoses if the lower bearings are not covered g Undo the slide bearings h Undo the wash nozzles and check for foreign objects in th...

Page 52: ...in is secured o Mount shaft on washer arm Mount washer arm together with the shaft p Check that the washer arms are firmly locked with the locking device q Mount the washer and locking washers on the shafts r Mount the rocker arms and remount the screws 3 Dismount and clean the washer arm motor fan cover and remount it 4 Replace the y piece in the rinse system 18056 6005171 a Check rinse hoses for...

Page 53: ...te and drain it Abundance of lime scales could be caused by too hard water If possible soften the water c Undo all rinse nozzles d Fit new rinse nozzles 6 Replace the Granule damper seal and change o rings for Granule damper shaft 18070 60477 10930 Perform point 3 on page 47 7 Replace wash hoses 18270 18271 60415 a Undo hose clamps b Undo wash hoses c Fit new hoses and clamps 8 Replace cabin seal ...

Page 54: ...7 2 Service instructions 2 year service 7 Maintenance and Service ...

Page 55: ...x 5 minutes heating time Diagram 1 p 4 shows how the steam pressure and the original temperature of the rinse water affect the heating time for the final rinse water If the theoretical heating time exceeds approx 5 minutes the wash time is automatically increased until a temperature of 85 C has been reached in the rinse tank In this way a hygienically clean wash result is guaranteed Example If the...

Page 56: ...of time when both the elements are on at the same time is shown in diagram 4 on page 60 This information is used to determine the capacity of the steam and condensation systems 8 4 Safety The steam element is tested at 10 bars for 30 seconds strength calculations according to pipe norms Maximum working pressure for the magnetic valves is 10 bars 8 5 Connection 8 5 1 Steam pressure 0 3 2 0 bars 8 5...

Page 57: ...8 Steam heating Granule Maxi 8 5 Connection Steam connections Rev 2012 05 57 ...

Page 58: ...rt 8 6 Recommended equipment not included Other essential or recommended equipment not included in the steam version of the Granule Maxi 1 Separate closing valve 1 2 2 Condensation carrier e g thermally encapsulated condensation carrier 1 2 3 Non return valve 1 2 58 Rev 2012 05 ...

Page 59: ...8 Steam heating Granule Maxi 8 7 Diagrams 8 7 Diagrams Diagram 1 Diagram 2 Rev 2012 05 59 ...

Page 60: ...8 7 Diagrams 8 Steam heating Granule Maxi Diagram 3 Diagram 4 60 Rev 2012 05 ...

Page 61: ...9 Appendix Service record 1 year service Service record 2 year service Wiring diagrams Rev 2012 05 61 ...

Page 62: ...9 Appendix This page intentionally left blank 62 Rev 2012 05 ...

Page 63: ...closing function 5 Overflow drain sieve Is it undamaged clean and in place 6 Steam reduction unit Check the solenoid valve and nozzles Can be checked with open doors and Flashloader software 7 Spray pipe motor Clean the fan cover on the spray pipe motor 8 Link system bearings and nozzles Wear and leakage in the spray pipe bearings and or O rings Exchange wash nozzles Binding in the pipe or link sy...

Page 64: ...ure that only original Granules are used in the machine PowerGranules 8 kg Order no 19833 20 kg Order no 19834 Fill the machine with water and Granules And make a test run 14 Heater wash tank and rinse tank Check that the current the same to all three leads Measure by the contactor 15 Temperatures Check the temperature sensors Are the probes inserted properly in the wash rinse tank Are the probe s...

Page 65: ... in the wash water 21 Outflow Check the drain time Do granules emerge with the water when the machine is emptied Check the overflow pipe 22 User manual wall chart Are they available 23 Accessories for pots trolleys Check that welds etc are undamaged 24 Trolley Check trolleys function and ware Check trolley wheels ware and function 25 Reset GDMemo Reset Service notification in GDMemo ...

Page 66: ...ieve Is it undamaged clean and in place 6 Steam reduction unit Check the solenoid valve and nozzles Can be checked with open doors and Flashloader software 7 Spray pipe motor Clean the fan cover on the spray pipe motor 8 Link system bearings and nozzles Exchange wash nozzles Exchange the slide bearings Binding in the pipe or link systems Lubricate ball and socket joints and bearings Check the spra...

Page 67: ...rGranules 8 kg Order no 19833 20 kg Order no 19834 Fill the machine with water and Granules And make a test run 15 Heater wash tank and rinse tank Check that the current the same to all three leads Measure by the contactor 16 Temperatures Check the temperature sensors Are the probes inserted properly in the wash rinse tank Are the probe screws tightened Wash temperature 65 C Rinse temperature 85 C...

Page 68: ...ck the drain time Do granules emerge with the water when the machine is emptied Check the overflow pipe 23 User manual wall chart Are they available 24 Accessories for pots trolleys Check that welds etc are undamaged 25 Trolley Check trolleys function and ware Check trolley wheels ware and function 26 Reset GDMemo Reset Service notification in GDMemo ...

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Page 75: ...75 208 575 V CSA ...

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Page 81: ...81 230 400 415 V Steam heated ...

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Summary of Contents for Granule Maxi

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GRANULDISK Granule Maxi, Service Manual, Page: 3 / 97

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