Garb-el Products Company Promoting Environmental Responsibility Since 1950 Garb-el Free Standing Models Installation, Operation & Maintenance Manual Garb-el Products Company 240 Michigan Street Lockport, NY 14094 Phone: (716) 434-6010 Fax: (716) 434-9148 www.garb-el.com
Table of Contents Introduction Contents of Shipment.3 Location of Garb-el 3 Installation Plumbing 4 Electrical 5 Operation Operating the Garb-el 6,7 Guidelines and Precautions...8 Maintenance General Maintenance Procedures 9 Grinder Mechanism (Hammermill Assembly) 9,10 Mill Screen..11 Worm Screw Auger....11 Troubleshooting Basic Issues. 12 Specific Issues.13 Procedure For Checking Defective Parts 14,15 Parts Breakdown.16 Parts List.17,18 2
Introduction Components of Shipment This pre-wired and pre-plumbed free standing Garb-el disposal unit includes: Nema 4 watertight electrical control enclosure, Nema 4 watertight On/Off push button controls (optional emergency stop button and/or key lock-out), solenoid valve, variable time delay, relay, water saving flow switch, plumbing with pipe fittings to connect to cold water supply, stainless steel sink top and stainless steel adjustable legs with flanged feet. Also included with each machine are an Installation, Operation and Maintenance Manual as well as an electrical schematic. Location of Garb-el The location of the disposal unit will be determined upon the roughing-in for the waste line connection. After the Garb-el has been properly located, make sure that there will be a minimum of about twelve inches (12 ) between the wall on the grinder end and the cleanout cover of the Garb-el and a minimum of seven (7 ) between the centerline of the vertical waste and the tip of the Garb-el disposal spout. Be sure to adjust the level of the disposal unit by means of its adjustable flanged feet. Garb-el recommends raising the two legs at the feed end slightly higher than the legs at the discharge to create a pitch towards the discharge. Further, be sure to bolt/lag the disposer to the floor. Failure to bolt the unit to floor will allow it to move, causing a strain on water and sewer connections. 3
Installation Plumbing Fresh/Cold Water Supply: Connect fresh water line to the union at base of Garb-el as shown in the drawings for your machine. A shutoff valve should be installed in the water line ahead of the union by installing plumber in order to facilitate future servicing of the disposal equipment. IMPORTANT: Local Plumbing Code may require an anti-siphon and/or a backflow preventer in the fresh water (potable) supply. We recommend the use of a backflow preventer with atmospheric vent. There are several such manufactured devices available from your local plumbing supply house. These backflow preventer devices are a single assembly unit and can be easily installed to meet local code and manufacturer s specifications. Sewer: Most potable water distribution codes do not permit the use of anti-siphon vacuum breakers to be used where the water supply pressure is applied to the vacuum breaker continuously. The use of a backflow preventer will meet the requirements of Uniform Plumbing Code when the device is properly installed. The machine discharge is 3 (4 available) male pipe thread. It is recommended that the unit be connected to a 4 lateral, although a 3 lateral will generally suffice. In connecting to a previously unused or little sewer, make sure that the line is clear to the building main. Also, be sure that the plumber makes some provisions for a clean out at the discharge spoutwaste line connection, even if this is not required by your sanitation code. Refer to the enclosed drawings. 4
Installation Electrical Be sure the electrical specifications on the drive motor plate agree with the specifications on the electrical service in the building. On units using 3 Phase 200 or 208 volt for machine operation, the feeder (auger) motor MUST be wired for 115 volts. This means a NEUTRAL must be added to service the machine. Some services may have a wild leg, so be sure the leg you use is 120 volt to ground. This connection is made at the same point of entry into the control box. Garb-el disposal units are pre-wired and only require a field connection from our machine-mounted junction box to a wall fuseable disconnect, and must use time lag fuses (class R). Any other fusing or circuit breaker connection will void all Garb-el warranties!! To make electrical connections, refer to the accompanying wiring diagrams. Please note that there is no external disconnect furnished with the Garb-el s due to variations in municipal codes. For emergency and mechanical servicing purposes, however, a disconnect should be mounted on the wall adjacent to the Garb-el by the installing electrician. Grounding: Located inside the junction box is a green screw for the installing electrician to connect a ground wire when bringing service into the unit. After the electrical connections have been completed, the installing electrician should check the rotation of the pulverizer or grinder mechanism. If not rotating in accordance with the decals on the pulley side of the grinder housing or the diagram on control box cover, the electrician should change the wiring connections in the junction box so that the grinder rotation is reversed. Be sure that the electrical connections do not interfere with removal of any panels of the cabinet. Note: Each Garb-el has the correct wiring diagram affixed to the inside of the electrical control box. 5
Operation Normal Operation Be sure water and power is ON for the Garb-el unit Push the GREEN ON Button 1. Auger should start 2. Water should start (Minimum 4 G.P.M.) 3. Grinder should start NOTE: All 3 should start immediately Push RED OFF Button 1. Auger should stop immediately 2. Water and grinder should shutdown after timer has been given allotted time to do so. What the electrical components do? Magnetic Starter (The Contactor and the Overload) The Contactor: The contactor feeds power to the overload and shuts the unit down if there is a problem with the controls, including if the overload kicksout. There is an auxiliary contact that will shut the feeder motor off if the grinder shuts down unexpectedly. The Overload: The overload protects the grinder motor. If the motor draws too much amperage for a period of time, the overload portion, of the starter, will kick out. This will stop the grinder and the auger motors from running. The water will continue to run until the timer has timed out. When sufficient time has elapsed for the overload to cool, you must push the reset button on the control box to resume operation. If unit kicks out frequently, the cause must be found or you may burn out the grinder motor, see page 8 on motors for explanation. The side contact, which is connected to the feeder motor circuit, must not be bypassed. This ensures that if the grinder motor kicks out the auger motor will also stop running to avoid jamming the unit between the auger and the hammermill. There is an amperage range dial on the overload, which should be set to the grinder motor amperage. There is also a dial for MANUAL and AUTOMATIC (AUT) Reset. IT MUST NEVER BE SET TO AUT, FOR SAFETY REASONS. Relay (Part # 0003-5-2): Located in Control Box. It is used to initiate the Time Delay when ON Button is pushed. It is also used as a holding contact to keep unit running until the OFF Button is pushed. After this, the unit will run until the time delay times out. 6
Operation What the electrical components do? Time Delay (Part # 1744): Located in the Control Box. The timer keeps the unit, except for the auger, running for a set time for the clean out of the Garb-el unit. It is actuated by the power relay, and feeds power to the solenoid valve. The timer has a built-in dial for adjusting time to shut unit down after OFF Button is pushed. It can be set from 5 seconds to 10 minutes. It is factory set at approximately 1 minute, which usually gives enough time for the Garb-el to clean itself out. Solenoid Valve (Part # 1355): Located on the incoming water line near Garb-el unit. The Solenoid is turned ON and OFF by the timer. **NOTE: The base of the Solenoid must be installed for proper direction of flow of water. See arrow on bottom of the brass base. 6. Flow Switch (Part # 1092): Once the Solenoid allows the flow of water, the flow switch is actuated when the water volume is sufficient, usually about 4 GPM. The flow interlock will then feed power to the coil on the magnetic starter (through the overload). If the water pressure is sufficient, the unit will start. If the water volume drops, the grinder and auger will stop. Once the volume of water increases sufficiently again, you must push the START button to re-start Garb-el unit. **NOTE: The flow interlock must be installed for proper flow direction. See arrow on top of plastic bushing in flow switch. Emergency Stop Button (Optional): The safety switch is an option added to the Garb-el unit that is used to instantly stop the unit in case of a problem. Once the problem has been corrected; push the START button to resume operation. The EMERGENCY STOP is not be used to operate the unit, but only as an emergency device. 7
Operation Garb-el disposers are designed to handle food waste, not including large quantities of cornhusks. Also, avoid feeding the machine: wood, rags, metal, glass, cellophane and plastics. Garb-el disposers are designed for ease of operation. Inasmuch as this machine can be started or stopped under load, it is recommended to start the unit and feed it material as it is being processed. This will make the unit work easier and thus help prolong the life of the unit. The disposal unit is started and stopped by means of the push button on the front cabinet panel of the unit. When started, the feeder mechanism and pulverizer start simultaneously. When stopped, the feeder mechanism will stop instantly, but the water and pulverizer mechanism will continue to run for the period of time the time delay has been set to provide extra flushing of the machine and waste line. Do not cram or pack food waste into the hopper of the Garb-el. You will find that your Garb-el will take care of the trim waste easily and quickly if the machine is fed with normal care. Do not allow trim waste to pile up; feed the waste into the Garb-el as it accumulates. Grinder Overload: The grinder or pulverizer of the Garb-el can be overloaded by feeding too much hard to grind material. This will cause the overload control of the magnetic starter to kick out causing the Garb-el to stop. W A R N I N G If the Garb-el stops due to overload, pull wall disconnect switch so that no electrical power reaches the unit. Open the trap cover and clear hammermill area so it can be easily rotated by hand. Check waste material being fed into pulverizer and remove material causing trouble. If the Garb-el will not start after following this procedure, check wall disconnect for burned fuse(s). If difficulty persists, call your maintenance department. Feeder Motor: The feeder motor will not operate unless the grinder motor is operating. The feeder motor can be stopped independently of the grinder motor by pushing the STOP button. The feeder mechanism will stop instantaneously and the water and grinder will stop after the time delay period expires. Feeder Breakdown: A feeder breakdown can be caused by foreign material lodging between the feed hopper and worm screw feeder, causing the feeder motor fuse (located inside control box) to blow. Cleaning Instructions: After each days use, run the Garb-el for several minutes until both the feed hopper and the grinding chamber are clear of waste material; this procedure will flush out the Garb-el and the sewer line. 8
Maintenance General Maintenance Procedures WARNING: Always disconnect the power supply to the machine when working on the Garb-el. Access to the grinder mechanism is through the trap cover located above the discharge spout of the Garb-el. In the event that foreign material enters the mill or there is a jam in the mill causing an overload, open the trap cover for clean-out purposes. Lubrication: None is required with the exception of those grinder shaft bearings having grease fittings, which may need to be greased once every two or three months or when necessary. V Belts: After the Garb-el has been operated a short time, the V belts should be examined. The V belts often stretch so that the upper and lower strands will touch (or almost) when squeezed together. The slack in the V belts can be taken up by adjusting the grinder motor. Grinder Mechanism (Hammermill Assembly) 1. Grinder shaft bearing, grinder shaft seals and rubber flingers: If the Garb-el becomes excessively noisy, the grinder shaft bearings may be at fault. Remove the grinder housing top so that the hammermill assembly can be thoroughly examined, if it first cannot be checked by opening the trap cover door. 2. Replacement of grinder shaft bearings only: a. If there is bearing failure only no damage to the grinder shaft seals remove the bearings by means of a wheel puller and/or heat (if necessary). Make sure that set screws are first unscrewed by means of an allen wrench. b. Replace the grinder shaft bearings with new bearings supplied by Garb-el Products Company, which have special machined bearings housings. Because of the difficulty in determining which bearing (if not both) has failed, we recommend that both bearings be replaced in every instance. 9
Maintenance 3. Replacement of grinder shaft bearings, grinder seals, and rubber flingers. a. If an examination of the grinder mechanism reveals that bearing failure has resulted in seal damage with subsequent scoring of the grinder shaft and yet the balance of the mechanism is still okay and the blades have a useful life, our grinder shaft kit (Part # 1566) should be used to repair the mechanism. b. Remove the hammermill assembly from the grinder housing. c. Replace the worn parts of the assembly with the parts included in the grinder shaft kit in accordance with the instructional drawing (Drawing # 122-A-1) that accompanies the kit. d. Replace the screen in the grinder housing base unless it is in excellent condition. A new screen with sharp, square edges increases the pulverizing efficiency of the Garb-el. e. Secure the hammermill assembly on the grinder housing base. Make sure that the grinder shaft bearing set screws are turned down firmly into the shaft after the bearings have been bolted to the bearing supports. f. Secure the grinder pulley to the grinder shaft after the grinder and main motor pulleys have been properly aligned. g. Replace the V belts and grinder-housing top. 4. Replacing hammermill assembly if impact edges are worn beyond further usage, a new hammermill assembly (Part # 1605) will be required. a. Remove old hammermill assembly from grinder housing. b. Remove the old screen and insert new screen (Part# 1019) in the grinder housing unless the old screen is in excellent condition. c. Secure the new hammermill assembly on the grinder housing base. Bolt mill top in place to grinder housing base and be sure hammermill rotates freely. Make sure that the grinder shaft bearing set screws are turned down firmly into the shaft after the bearings have been bolted to the bearing supports. Gasket material should be used to reline the mill base before securing mill top in order to eliminate leaking of water. d. Secure the grinder pulley to the grinder shaft after the grinder and main motor pulleys have been properly aligned. e. Replace V belts and grinder housing top. 10
Maintenance Mill Screen: A new mill screen (Part # 1019) with sharp edges increases the pulverizing efficiency of the Garb-el. Whenever the mill screen shows excessive wear or has been damaged by abuse of the equipment, remove the top of the grinder housing, lift out the old or damaged mill screen, and insert the new one. Worm Screw Auger: After disconnecting the power supply to the Garb-el, remove the feeder chain from the feeder sprocket and unbolt the feeder bearings from the frame of the Garb-el. These steps will allow the stub shaft to back off when the worm screw is rotated in a counter clockwise direction on AR models and clockwise on AL models. After the two pieces are disengaged, the worm screw can be removed through the hopper opening. Be sure to check the thrust plate with feeder shaft seal (Part # 1576) whenever the worm screw auger is replaced. It is altogether possible that the thrust plate with feeder shaft seal should be replaced at the same time in order to insure a continued watertight condition at the feeder end of the Garb-el. 11
Troubleshooting Basic Disposal Problems: 12 Check: 1. Disposal won t start - Is main power turned on at the disconnect and/or main circuit breaker? - Is power Lock-Out device in control box in the ON position? - Is the water turned on in the in-coming water line? - Are the fuses good in main disconnect? - Are the circuit breakers tripped? - Try reset button on disposal unit. 2. Disposal shuts down while in use - Not enough water volume (disposal is designed to shut down when water volume is below 4 GPM) 3. Machine keeps running when water shuts off - Starter overload (check reset button) - Check main fuses and circuit breakers - Did someone hit the safety switch? - Defective flow switch 4. Machine is backing up - Blades on the hammermill are worn (machine can t grind properly). - Hammermill blades are full of rubber bands and plastic. - Mill screen holes are worn, elongated or broken. - Check for proper rotation of hammermill. - Check for blockage in sewer lines. NOTE: When replacing a hammermill, it is advisable to also change the mill screen. THE UNIT MUST HAVE A MILL SCREEN IN GRINDER HOUSING TO AVOID PLUGGING UP SEWER LINE.
Troubleshooting Specific Machine Problems: Check: 1. Hammermill is noisy - Grinder shaft bearings are defective or worn - Broken or bent blade(s) 2. Hammermill is leaking around shaft - Seal(s) defective - Remove belts to make sure noise is not main motor - Hammermill is out of balance, or is worn 3. Machine and water will not shut off after timer has had sufficient time to shut down unit - Defective time delay - Defective solenoid valve - Defective push button - Defective power relay 4. Auger (worm screw) won t turn - Feeder motor fuse blown - Defective feeder motor - Defective capacitor (a bad capacitor can also cause a good feeder motor to run in the wrong direction) 5. Auger (worm screw) drags - Worn feeder bearings 6. Water leaks where auger shaft enters hopper - Faulty seal and/or thrust plate 13
Troubleshooting Procedures For Checking Defective Parts 1. Solenoid Valve To check if a solenoid is working properly, while disposal is running, pull the solenoid coil off of the base (unscrew top screw and lift coil (blacktop section). Water should discontinue flowing. If water continues to run, the base is bad. There are no exposed wires to come in contact with in following this procedure. If water continues to run, the solenoid base is defective. If unit will not start, to check solenoid, remove solenoid wire from terminal #1 on time delay. Jump this wire to L1 on starter. Turn power on. If water does not flow, the solenoid is defective. **NOTE: The base of the Solenoid must be installed for proper direction of flow of water. See arrow on bottom of the brass base. 2. Flow Switch If the water shuts off but the disposal continues to run, the Flow Switch may be defective. Should be done by qualified or trained personnel such as an electrician. **NOTE: The flow switch must be installed for proper flow direction. See arrow on valve beneath where plastic bushing is threaded on. 3. Push Button With power to unit off, check continuity across terminals on each contact block. 4. Relay When push button is working properly, you should see the contact arm moving while pushing the ON and OFF buttons. If the arm is moving, and unit will not run, you can try jumping from bottom of relay to the top. If no change, relay is probably good. 5. Electronic Time Delay If disposal and water have not shut off after allotted time of timer, after OFF button has been depressed, you may have a defective time delay. With the machine off, there should be a voltage reading between wires #1 and 2. When the machine is on position and during the timing period for the unit to shut off, there should be a voltage reading between wire terminals #1 and 3. Anything contrary to this means a bad time delay. Should be done by qualified or trained personnel such as an electrician. 14
Trouble shooting Procedures For Checking Defective Parts 6. Motors If a feeder motor fuse blows or starter continually kicks out, it could mean the motor is pulling more Amps than it should. Take a reading of the motor and compare it to the motor nameplate. If the reading is higher than what is on the nameplate, the motor is defective. Should be done by qualified or trained personnel such as an electrician. **NOTE: When checking for power, you must check across terminals or 2 wires. The wiring uses coils. Many times you will get false readings if you go to ground. IMPORTANT It is advisable that only qualified personnel attempt to repair a GARB-EL unit. If you do not have a Service Department, call Garb-el Products Company, with Model and Serial Numbers, at (716) 434-6010 for a Service Agency in your area. When you must order parts, it is very helpful to have the model and serial numbers of the Garb-el unit you are servicing. 15
Parts Breakdown 16
Parts List 1 Stainless Steel Top 1127 Specify Model (AR or AL) 2 Cabinet Assembly Complete 1830 3 Curtain Assembly 1887 Complete 4 Front Curtain 1873 5 Removable Stub Shaft 1711 or 1714 6 All Metal Worm Screw 1712 or 1715 7 Worm Screw with Hytrel Flighting 1721 or 1722 8 Hytrel Flighting only with Hardware 1717 9 Thrust Plate with Seal and Hardware 1576 10 Feeder Sprocket (Upper Chain Sprocket) 1493 11 Shear Bolt with Locking Nut 1245 12 Feeder Chain 1490 13 Feeder Chain with Connecting Link 1491 14 Feeder Chain Half Link 1492 15 Feeder Motor Sprocket (3 & 5 HP) 0011 16 Feeder Motor Sprocket (7.5 HP) 0012 17 Feeder Bearing 1339 18 Feeder Motor with Capacitor 1834 19 START/STOP Push Button (Emergency Stop Optional) 20 Feeder Motor Fuse 1835-F 21 Trap Cover with Gasket 1016 22 Gasket For Trap Cover 1330 23 Eye Bolts with Washer & Nut 1033 24 Mill Screen 1018 or 1019 25 Grinder Motor Pulley (3 & 5 HP) 1322 Grinder Motor Pulley (7.5 HP) 1322 & 1322-1 26 Grinder Pulley (6") 1321 27 Grinder Motor Belts 1325 28 Grinder Shaft Bearings (1 3/16") 1555 29 Rubber Flingers 1319 30 Grinder Shaft Seals with Outer Seal Ring 1317 31 Grinder Shaft Kit 1566 32 Hammermill Assembly 1605 33 Grinder Motor 3 HP 3 PH 208-240-480 Volt 1660 34 Grinder Motor 5 HP 3 PH 208-240-480 Volt 1662 35 Grinder Motor 7.5 HP 3 PH 208-240-480 Volt 1664 36 Grinder Motor 5 HP 1 PH 208-240 Volt 1666 37 Variable Time Delay 1744 38 Relay (Socket Mount) Socket 0003-5-2 0005 39 Relay Socket 0005-2 40 Solenoid Valve 1355 41 Flow Switch 1092 17
Parts List (continued) 42 Disconnect Switch 1900 Contactor 42 5 HP 200 Volt 30-1445-A 43 5 HP 240 Volt 30-1445-B 44 5 HP 480 Volt 30-1445-C- 45 7.5 HP 200 Volt 30-1445-D 46 7.5 HP 240 Volt 30-1445-E 47 7.5 HP 480 Volt 30-1445-F Overload 48 5 HP 200 Volt 30-1445-A 49 5 HP 240 Volt 30-1445-B 50 5 HP 480 Volt 30-1445-C- 51 7.5 HP 200 Volt 30-1445-D 52 7.5 HP 240 Volt 30-1445-E 53 7.5 HP 480 Volt 30-1445-F 54 Feeder Bearing Kit 1676 Must Specify Model 18