Vernacare Vortex+ Technical Manual

Vortex+ Technical Manual

www.vernacare.com

NOV 2017

Contents

Declaration of Conformity Page 01

Warranty Page 02

Section 1 - Specifications Page 05

Section 2 - Installation & Commissioning Page 08

Section 3 - General Description Page 15

Section 4 - Outer Casing Page 17

Section 5 - Motor Assembly Page 18

Section 6 - Diaphragm Valve Assembly Page 19

Section 7- Lid Arm Assembly Page 20

Section 8 - Top Cover Assembly Page 22

Section 9 - Hopper Vent Arrangement Page 23

Section 10 - Water Distribution Page 24

Section 11 - PCB Page 25

Section 12 - Electrical Enclosure Page 26

Section 13 - Sensor Terminal Page 26

Section 14 - Additional Items & Kits Page 26

Appendix A - Manual Pump and Outlet Buttons Page 28

Appendix B - Motor Terminal Wiring Page 29

Appendix C - Motor Electrical Box Plug & Socket Connectors Page 30

Appendix D - Orientation of Diodes for Solenoid Valve Coil Terminals Page 30

Appendix E - Suggested Periodic maintenance Page 31

Page | 3

Declaration of Conformity

VERNACARE

Declare that this declaration has been issued under the sole

responsibility of the manufacturer. The object of the declaration is in conformity with the relevant Union harmonisation

PRODUCT

Vernacare Vortex / Vortex + Macerator

DIRECTIVE

EC Directive 2014/30/EU

EC Directive 2006/42/EC EC Directive 2014/35/EU EC Directive 2002/95/EC (RoHS) EC Directive 2011/65/EU (RoHS 2) EC Directive 2002/96/EC (WEEE)

STANDARDS

IEC EN61010 - 1: 2001

BS EN61010-1: 2001 BS EN 61000-6-1:2005 BS EN 61000-6-3:2007

Conformity is demonstrated by the affixing of the CE Mark.

LOCATION

Vernacare Limited

Folds Road Bolton Lancashire United Kingdom BL1 2TX

DATED

23/05/2016

AUTHORISING SIGNATURE

C.E.O of Vernacare Limited

Page | 4

Warranty

A. Warranty terms

1. The warranty is for 12 months from the date of commissioning or 18 months from the date of delivery, whichever is the shortest period.

2. The warranty will cover parts and labour.

3. The warranty will not cover customer damage or abuse.

4. Warranty requests should be submitted in writing, quoting the machine number, date of commissioning and the machine fault.

5. The warranty will not affect your statutory rights, or rights given in the company’s Terms and Conditions of Sale.

6. Extended warranties are available. Contact Vernacare for further details.

B. Conditions of warranty

1. The Vortex+ must be installed to the instructions provided in this technical manual.

2. The Vortex+ must be commissioned by a person authorised by Vernacare, failure to do so may invalidate the warranty.

3. Unauthorised modifications may invalidate the warranty if not carried out by a person authorised by Vernacare.

The above warranty details should be read in conjunction with the Company Terms and Conditions of Sale, copies of which are included with your invoice, or available upon request from Vernacare:

Telephone: +44(0)1204 555988 Fax: +44(0)1204 523595 E-mail: [email protected]

C. Service Contracts

To ensure continued reliability and performance, service contracts are available. All warranty and service contract work will be carried out by Vernacare Technical

Services, a division of Vernacare Limited OR in the case of an overseas installation, warranty and service contract work will be carried out by a Vernacare approved technician.

Page | 5

1

Specifications

1.1 Capacities and usage

The “Vernacare Vortex +” macerator will dispose of a maximum of four “Vernacare”

disposable products such as bedpan liners, bottles etc. together with their contents in a single cycle. Please note due to their physical size only two Vernacare wash bowls

may be disposed of per cycle.

Products should be placed in the Vortex + one at a time and should not be stacked inside each other.

Do not stack products inside each other or attempt to dispose of more than four items in a single cycle as this will impair the effective operation of the machine and in severe cases, may cause the motor to stall. It is considered good practice to operate the machine each time a utensil is placed into the machine.

Do not place string, wipes, plastic or metal items inside the machine as these may damage components.

Note: Vernacare “Senset” wipes can be disposed of in the Vortex macerator.

1.2 Dimensions

The dimensions of the “Vernacare Vortex +” are shown on page 9 (Figure 1)

1.3 Handling

The weight of the “Vernacare Vortex +” complete with pallet and packaging is 83 kg (machine only 72 kg). The “Vernacare Vortex +” should be moved to the point of

installation by fork, pallet or sack truck whilst still attached to the pallet provided.

1.4 Electrical specification

The machine is supplied with a 3-meter length of 1.5mm flex, which shall be connected to either:

230 Volt Machine – 16 Amp MCB to BS EN60898 Type C or alternatively fused 16 Amp to BS EN60269-1. An appropriate I.E.C Approved 16 Amp isolator shall be installed in both cases.

110 Volt Machine – 16 Amp MCB to BS EN60898 Type C or alternatively fused 16 Amp to BS EN60269-1. An appropriate I.E.C Approved 16 Amp isolator shall be installed in both cases.

It is recommended that the disposal unit is supplied by a dedicated circuit.

Where supplementary protection is provided by an RCD/RCBO, this should be rated at

100mA.

Note: The machine should not be switched off at the mains supply in mid-cycle

Page | 6

except in case of emergency, as this will impair the effective operation of the machine and may cause damage to the components.

1.4.1 Motor

1.1 KW; 3 Phase; 220-240v 50Hz/ 380-420v 50Hz; IP55; D90 frame size. Rating at peak load 4.57 amps (nominal).

1.4.2 Invertor

AC invertor with either 110v or 230v supply voltage, 230v motor output and utilising current monitoring.

1.4.3 Pump

0.27 kW; 24vdc; 50 cycles. 40 l/min at 5 lbs/in². Protected by a 5 amp fuse.

1.5 Water requirements

Inlet supply: Cold water ONLY with flow rate of 18 l/min (4 gals/min) nominal. Nominal overall usage; 25 litres (+/- 10%) per cycle.

1.6 Drainage

A 2 inch/ 50mm P Trap compression fitting to be connected either directly, or via a swept bend, to a standard 2in/50mm drain pipe with a 1 in 25 or suitable fall into a soil drain.

A 1 1/4 inch/32mm tank connector is supplied, which should be used to connect the water tank warning pipe to a separate drain line, according to the relevant water regulations.

A standard warning pipe installation kit is available. Contact Vernacare Customer Care Department for details.

Page | 7

150mm Clear each side

100mm Clear at rear

Deodoriser

fill cap

NOTE:

Water inlet & warning pipe

connections can be made to

either the left or right hand side

of the machine.

2" Drain

Connector

ALL DIMENSIONS IN mm

2 Mounting

Holes Ø9

Dimensions of the Vernacare Vortex +

Water Inlet

½’’ BSP Male

Warning Pipe

Connection

(drain)

with lid open !IMPORTAN

T!

Page | 8

2 Installation / Commissioning

Installation

Note: Installation of this equipment should only be carried out by a suitable qualified person.

2.1 Siting and fixing

The “Vernacare Vortex +” disposal unit should be positioned adjacent to the following: a) A suitable power supply point.*

b) An adequate water supply line. c) A suitable drainage connection.

Check the floor area is firm and level. The unit must be bolted down using the holes provided. Mark out the bolt positions on the floor and fit bolts utilizing the dimensions given in Figure 1.

Ensure that adequate space is maintained at each side of the Macerator to allow for access. Vernacare recommend a gap of 6” - 8” (150 - 200mm) per side and 4”

- 5” (100 - 125mm) away from the wall at the back. Important- To comply with UK WRAS regulations sufficient clearance must be provided

to allow water to freely discharge from the water tank overflow weir. Check that the unit is level in both directions.

230 Volt Machine – 16 Amp MCB to BS EN60898 Type C or alternatively fused 16 Amp to I.E.C 60269-4. An appropriate I.E.C Approved 16 Amp isolator shall be installed in both cases.

110 Volt Machine – 16 Amp MCB to BS EN60898 Type C or alternatively fused 16 Amp to I.E.C 60269-4. An appropriate I.E.C Approved 16 Amp isolator shall be installed in both cases.

Where supplementary protection is provided by an RCD/RCBO, this should be rated at

100mA.

For all installations, an I.E.E. approved disconnection device must be fitted to the final installation. This device shall be positioned in close proximity to the Vortex and within easy reach of the operator & shall also be clearly marked as being the disconnecting device for the machine.

For installations where the height of the existing drain causes difficulty a plinth is available which may be utilised in order to raise the height of the Vortex so that better alignment is achieved.

Please contact Vernacare for further information

Page | 9

2.2 Plumbing

2.2.1 Water supply The machine should be connected to a suitable cold water supply as follows:-

The connection to the machine water tank is made at the upper rear left or right hand side corner of the machine. It is a standard connection to a 1/2 inch BSP float-type cistern valve. This can be made in rigid or flexible piping, according to customer preference. Flow rate should be 18 litres per minute (4 gallons/minute) minimum, into the water tank, which holds sufficient water for a complete cycle.

Note: The inlet flow valve is supplied already fitted with a flow restrictor in place. The restrictor should be left in place on tank fed installations with heads above 50ft or mains fed installations with pressures above 1.5 bar (25psi). In all other circumstances the flow restrictor is not required.

2.2.2 Drain connection

The “Vernacare Vortex +” is fitted with a 2 inch/50mm ‘P’ Trap. In order to connect to the

drain, it is necessary to cut a minimal clearance hole in the plastic drain access cover located at the rear of the machine below the water tank. It is important to ensure that the drain access cover is fitted so as to prevent access to internal electrical components.

The drain is secured by tightening the compression fitting on the ‘P’ Trap onto the

inserted plastic pipe. The free area below the water tank allows for the fitting of a swept bend if required.

Page | 10

2.2.3 Overflow - Warning Pipe The Vortex Is supplied with a 32mm (1 ¼“) tank connector which should be installed

using one of the predrilled holes in either the Left Hand side or Right Hand side of the water tank. It is Important that any discharge from the warning pipe is visible.

A standard warning pipe installation kit is available. Contact Vernacare Customer Care Department for details.

Points to Watch

 Ensure that the supply line to the unit is at no point less than 15mm or larger is available

head is low.

 Ensure that the water supply cannot be starved by any other fittings.

 Fit an easily accessible, full way isolating valve close to the unit.

 For installations with dirty water supplies it is recommended that an in-line filter is fitted.

 Ensure that the route taken to soil drain is the shortest, with minimum number of bends. If

necessary, use long radius or ‘swept’ bends - never short or 90’ elbows.

 The waste must be run separately to the soil stack or drain.

 Ensure that there is a fall of a minimum of 1 in 25 or a sufficient fall to maintain a self-

cleansing velocity.

 Provide easy access for Roding.

 Ensure a clean run inside the pipework - leave no burrs or reducing shoulders.

 With plastic pipework, ensure that there is no reduction in the bore size and that there is

adequate support for horizontal runs to prevent sagging. Remember, ceiling voids can get

very warm.

 Avoid running the drain line near or across hot water pipes.

 Anti-syphon precautions should be in line with general practice.

 Ensure that the discharge from the warning pipe is visible.

 Warning pipe arrangement must include an air break prior to a connection to a drain.

 Waste must be run separately to soil stack or drain.

 Do not reduce the diameter of the warning pipe at any point.

Page | 11

2.3 Electrical

2.3.1 Single-phase electrical system (230v, 1 Ph, 50 HZ) (110v, 1 ph, 60 HZ) The machine is supplied with a 3 metre length of 1.5mm flex to BS6500 which

shall be connected to:

• 230 Volt Machine – 16 Amp MCB to BS EN60898 Type C or fused 16 Amp to IEC 60269.

• 110 Volt Machine – 16 Amp MCB to BS EN60898 Type C or fused 16 Amp to IEC 60269.

Notes:

1. All electrical installation to comply with current I.E.E. regulations.

2. Mains supplies to be protected by:

1 Phase 230v ......... 16 Amp approved I.E.C. fuse.

1 Phase 110v…….. 16 Amp approved I.E.C. fuse.

3. For all installations, an I.E.E. approved disconnection device must be fitted to the final installation. This device shall be positioned in close proximity to the Vortex and within easy reach of the operator & shall also be clearly marked as being the disconnecting device for the machine.

Page | 12

2.3.2 Back-up generator tests / mains electrical supply surges. Damage to internal electrical components of the Vortex macerator can occur as a result

of voltage surges / spikes occurring in the electrical supply to the machine. The likelihood of such damage occurring is increased when frequent testing of back-up electrical supplies are carried out.

To prevent such damage, Vernacare recommends that transient voltage suppressors (in accordance with IEC class 3 surge protection) be installed in the electrical supply to the machine.

2.4 Environment

Indoor use only. Altitudes up to 2000m. Temperatures 5C to 40C. Maximum relative humidity 80% for temperatures up to 31C, decreasing linearly to 50%

relative humidity at 40C. Mains supply voltage fluctuations not to exceed +/- 10% of nominal voltage.

2.5 Commissioning

After installation, to ensure warranty validity the machine should be commissioned by a Vernacare technician OR in the case of an overseas installation, by a Vernacare approved technician. The machine should not be run until after this check has been done.

Important

The machine MUST be bolted down before use. The machine should be run once

- empty - to prime the pipework, diaphragm valve, deodoriser feed etc. Note: For warranty, service or repair please quote the machine serial number which can

be found clearly marked upon the rating plate which is positioned on the RH side, bottom front of the machine.

2.6 Warning labels and icons – explanations

Please refer to the technical manual prior to installation, maintenance or operation of this equipment.

Symbol indicates presence of 230v 50hz/ 415v 3phase 50hz electrical

supply.

Start Cycle – Press this button to start the machine. An auto-start option is also available. Contact Vernacare for more information.

Page | 13

2.7 Display screen icons and warning messages –

explanations

ERROR

DESCRIPTION

RUNNING

The machine has been started and is running through its cycle.

END

The machine has finished the cycle and is ready to open.

BLOCKED BLADES

The motor invertor has defaulted to overload due to a blockage of the

machine cutter blades.

BLOCKED DRAIN

The pressure transducer has sensed an over pressure in the chamber

due to a blockage of the drain outlet.

LOW WATER

There is insufficient water in the water supply tank.

POWER FAIL

There has been an interruption to the mains power supply/cycle.

The motor is running and the cutter blades are rotating.

The water pump is running.

The deodoriser reservoir is empty.

The outlet diaphragm is open.

The outlet diaphragm is closed.

The water tank reservoir level is low.

The water tank reservoir is full.

The lid is open.

The lid is closed.

The drain is blocked.

The foot sensor has been operated.

(For details of the fault finding guide see section 14 page 29).

Page | 14

2.7.1 Cycle Counter

At the end of each cycle the LCD screen will briefly display the TOTAL cycle count for the machine and also the SERVICE count which is the number of cycles since the machine was last serviced.

The TOTAL cycle display counts every machine cycle and is not resettable (unless the machine is reprogramed).

The SERVICE count is reset by the engineer when the machine is serviced. The

service count will also trigger a “Service” message on the LCD display once 20,000

cycles have been completed since the last service visit.

Page | 15

3 General Description

3.1 General description

The “Vernacare Vortex +” disposal unit is designed to operate within a 2-minute cycle using 24 litres +/-10% of water. The machine can dispose of up to four ‘Vernacare” disposable single- use products, at one time.

Disposable single-use products are placed within the hopper. Activation of the foot sensor causes the lid to descend and lock when in the fully closed position. The lid is closed against a moulded silicone section which gives an effective seal whilst maintaining an abrasion resistant face.

Sensors in the lid actuator and lid lock ensure that the lid is fully closed & physically locked. Failure or loss of signal from either sensor will prevent / stop the cycle. Once the lid is fully closed and locked the cycle is initiated automatically, at which point the

machine will give an ‘audible sound’ and the cycle will commence

The display screen will then indicate the machine is ‘Running’ and the icons at the

bottom of the screen will show the status of operation. (See section 2.7) In the event of low water level, blocked blades or power failure, the fault will be clearly

indicated upon the display screen and the cycle stopped. The Vortex+ will remain in this condition until the fault is cleared by following the instructions on the display screen.

The 2-minute cycle is controlled by a microprocessor, which controls the operation and timing of the water pump, the cutter motor and the inlet, outlet and deodoriser solenoid valves.

Shortly after commencement of the cycle, the water pump starts to take water from the reservoir tank and pumps it to the following areas:

a) The lid spray, which provides a curtain of water, which washes over the lid and tub

sides and provides the bulk of the ‘tub fill’ water. b) The mechanical seal flush, which flushes and lubricates the faces of the

mechanical seal to prevent ingress of pulp fibres into the mechanical seal cavity. c) The drain diaphragm valve, where water is fed through the non-return and inlet

solenoid valve to the back of the drain diaphragm valve, water outlet is shut off by the normally closed outlet solenoid valve, thus developing pressure expands the drain diaphragm valve to form a seal.

The combined water from a, b and c above enters the tub whilst the pump runs for a pre-set time period to put 12 litres (+/- 10%) of water into the tub.

When the outlet valve has closed and the volume of water is building up in the tub, the displaced air is vented away through the drain via the vent valve and non-return valve arrangement, i.e. the non-return valve prevents the egress of foul air from within the tub into the atmosphere.

With the pump switched off, the diaphragm valve remains sealed as the water behind It is restrained by the non-return and solenoid valves.

During the period when the pump is running, the cutter motor starts up via the inverter unit, and breaks up the products by a combined mechanical and hydraulic action into

Page | 16

small particles which can be easily flushed down the drain. If the cutter motor is initially stalled by bottles blocking the blades, the invertor will reverse

the blades and attempt to cut through the blockage again. This will be attempted three times before a ‘Blocked Blade’ fault is displayed. At which point the lid is to be opened and the blockage removed.

Approximately three-quarters of the way through the cycle the pump restarts to give a dilution flush of an additional 12 litres (+/- 10%) to the tub and its contents.

At the same time the inlet solenoid valve closes thus preventing additional pumped water from reaching the drain diaphragm, as the inlet solenoid valve is closed and the outlet solenoid valve opens which allows the pressurised water behind the drain diaphragm valve to dissipate. This allows the drain diaphragm to open and the contents of the tub to run to the drain.

During this period, the motor will initiate for a few brief seconds. This will dissipate any pulp particles from the blades and allow them to be washed to the drain.

Also at this point the deodoriser valve is opened and a small quantity of deodoriser is dispensed from the storage reservoir into the chamber removing any odours that may be present. In the event of the deodoriser reservoir being empty, the cycle will continue but the icon on the display will indicate the tank is empty and requires re-filling.

Vernacare recommend the use of Vernacare Vortex+ disposal unit deodoriser (902DL1000, 902DL2000, 902SD1000, 902SD2000).

The water pump then stops, the outlet solenoid valve closes a second later and then the overall cycle program ends. The display will indicate `End`.

The Vortex+ will remain in this condition with the lid locked until the foot sensor is

operated. When the infra red beam is broken by the insertion of the operator’s foot into

the foot well at the bottom front of the machine, the lid lock disengages and the lid actuator opens the lid.

Vortex+ Normal Cycle Sequence

Pump

ON ON OFF ON ON ON ON ON ON

Motor Forward

OFF ON ON ON ON ON OFF ON OFF

Motor Speed 1 (55Hz)

OFF ON ON OFF OFF OFF OFF OFF OFF

Motor Speed 2 (66Hz)

OFF OFF OFF ON ON ON OFF ON OFF

Deodoriser Valve

OFF OFF OFF OFF ON OFF OFF OFF OFF

Inlet Solenoid

ON ON OFF OFF OFF OFF OFF OFF OFF

Outlet Solenoid

OFF OFF OFF ON ON ON ON ON ON

Cy cle

E nd

Step

9 (120

s )

Step

8 (114

s )

Step

7 (105

s )

Step

6 (104

s )

Step

5 (103

s )

Step

4 (9 4

s)

Step

3 (4 6

s)

Step

2 (1 7

s)

Step

1 (

2 s

)

St ar t

Cy cle

Page | 17

SECTION 4: Outer Casing

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Front Cover Kit

9207014

1.1

Front Cover

9200531

1.2

Foot Sensor Housing

9200531

1.3

M6 x 20 Panel Screw (x2)

9750023

2

RH Side Panel

9200610

3

LH Side Panel

9200611

4

Deodoriser Cap Kit

9207013

4.1

Deodoriser Tank Cap

9200206

4.2

Filler Cap ‘O’ Ring

9200209

5

Start Switch Keypad

9200534

6

Display Screen

9200819

4.1

4.2

1.1

1.3

1.2

Page | 18

SECTION 5: Cutter & Motor

1.1

1.4

1.3

1.21.53.43.1

3.8

3.6

3.5

3.3

3.7

3.2

2.2

1.6

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Vortex Motor Kit

9207004

1.1

Electric Motor 230V/400V 3Ph 50Hz

9200424

1.2

Motor Gasket

9752027

1.3

Barbed Fitting

9750100

1.4

Vortex Motor Cable

9200693

1.5

Cutter Motor Adaptor

9200402

1.6

Mechanical Seal

9753005

2

Vortex Mechanical Seal Kit

9207006

(1.6)

Mechanical Seal

9753005

2.2

V-Seal 9753000

3

Vortex Blade Kit

9207015

3.1

Top Cutter Blade

9200418

3.2

Bottom Cutter Blade

9200417

3.3

Cutting Blade Locking Plate (Tab Washer)

9753011

3.4

M8 x 20 Hex HD Screw x2

9750077

3.5

M8 x 50 Hex HD Screw x1

9750006

3.6

M8 x 35 Button HD Screw x2

9750075

3.7

Fibre Gasket

9753010

3.8

D8 Spring Washer x2

9750033

4

Cutter Motor Assembly Kit

9207005

Page | 19

SECTION 6: Diaphragm Valve

1.1

5

3

4

3

6

1.3

1.2

2.2

2.1

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Diaphragm & Spring Kit

9207012

1.1

Diaphragm

9200304

1.2

Diaphragm Spring

9200333

1.3

Retaining Pin

9750085

2

Diaphragm Fastening Kit

9207016

2.1

Grub Screw x 8

9200326

2.2

Three Lobed Nut x 8

9200327

3

Water Inlet/Outlet Solenoid Valves

9200724

4

Non Return Valve

9200726

5

Diaphragm Chassis

9200328

6

Plumbing Elbow

9207043

Page | 20

SECTION 7: Lid Arm Assembly

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

1.16

1.17

1.18

1.19

1.20

1.22

1.23

1.24

Page | 21

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Lid Arm Assembly Kit

9207034

1.1

Lid Arm Bottom

9200843

1.2

Lid Arm Top

9200842

1.3

Lid 9200103

1.4

Extension Bracket

9200932

1.5

Arm Seal

9200853

1.6

Lid to Arm Seal

9200109

1.7

Hinge Bush (x2)

9200146

1.8

Press Lok Insert

9200115

1.9

Lid Spray Washer

9200117

1.10

Self-Tapping Screw (x2)

9200120

1.11

Lid Spacer Short (x2)

9200122

1.12

Lid Spacer Long (x2)

9200856

1.13

M5 Nyloc Nut (x4)

9750012

1.14

Arm Inlet Pipe

9200162

1.15

D8 Spring Washer

9750033

1.16

D5 Plain Washer (x4)

9750011

1.17

Lid Arm Label

9200860

1.18

Arm Hinge Shaft (x2)

9200113

1.19

Hinge Block (x2)

9200114

1.20

M10 Aero Nut (x2)

9200865

1.21

M10 Plain Washer (x4)

9200866

1.22

Torx Head Self-Tapping Screws (12)

9200924

1.23

Linear Actuator

9200854

1.24

Neodymium Magnet

9200837

Page | 22

SECTION 8: Top Cover

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Top Cover Assembly Kit

9207035

1.1

Top Cover

9200841

1.2

Lid Seal 9200159

1.3

Lid Seal Clip

9200152

1.4

Start Switch Keypad

9200534

1.5

Display Screen

9200819

1.6

Display Membrane

9200535

2

Deodoriser Cap Kit

9707013

2.1

Deodoriser Tank Cap

9200206

2.2

Filler Cap ‘O’ Ring

9200209

3

Sriker Bolt Kit

9200847

Page | 23

SECTION 9: Hopper Vent Arrangement

1.1

2

1.2

1.3

1.4

1.5

1.6

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Vent Connector Kit

9207007

1.1

Non Return Valve

9757030

1.2

Vent Connector

9200334

1.3

‘O’ Ring 9752018

1.4

Vent Deflector

9200325

1.5

M4 x 8 Lg Slotted Pan Head Screw (x2)

9750064

1.6

M4 Nylon Washer x2

9752022

2

16mm PVC Tubing 1.5m

9200721

Detail of Vent Connection

Situated at the front top right hand side of the hopper is a vent connector (2) which allows the foul air which is displaced whilst water is filling the hopper, to be vented into the drain.

The vent connector is fitted with a non - return valve (push fit into connector with the arrow on its body pointing into the connector). This valve prevents air from being expelled to atmosphere during water filling but allows air to be drawn into the hopper during the drain cycle when a vacuum would otherwise be created.

The connector is secured to the hopper via two M4 screws and two nylon washers, to prevent leakage an O-ring is used to seal the connector to the hopper and is located in a groove on the inner face of the connector

Page | 24

SECTION 10: Water Distribution

KIT

REF

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

1

Water Tank Assembly Kit

9207010

N/A

End Caps (x2)

9757047

N/A

Blank Plug

9757034

N/A

Hydroflo Side Entry Float Valve

9200204

N/A

Water Tank

9200846

N/A

No.6 x ½ Pozi Screw Button Head

9200212

N/A

Float Valve Bracket

9200211

N/A

M4 Plain Washers

9200540

2

Deodoriser Tank Kit

9207009 N/A

Deodoriser Tank

9200207

3

2’’ P trap Kit

9207008

N/A

Hose Clips 60mm

9757035

N/A

Drain Connector

9757001

N/A

2’’ P Trap

9757002

4

Water Pump

9200529

5

Anti-Syphon Valve

9200875

6

Pump Inlet Assembly

9200728

7

Deodoriser Solenoid Valve

9200725

8

Water Inlet/outlet Solenoid

9200724

9

Capacitive Sensors

9200828

Page | 25

SECTION 11: PCB

Vortex + V2

Outlet

Pump

2 3 4 5 6 7 8

1

9 10 11 12 13 14 15

16

18

19

17

20

REF

1 2 3

4

5 6 7 8

9 10 11 12 13 14 15

16

17 18 19 20

DESCRIPTION

24v PCB Power Supply Cable Connection

Actuator Board Cable Connection

Lid-Lock Cable Connection

Solenoid Valve(s) Cable Connection

Data Cable Connection Start Button Cable Connection IFM Sensor Cable Connection

Pressure Transducer Cable Connection

Auto-Start Jumper Plug Connection

Software Fob Cable Connection

Service (Cycle Count Reset) Cable Connection

Audible Buzzer

Pulsing LED PCB Indicator

E-Paper Display Ribbon Cable Connection

Pressure Switch Potentiometer

Manual Pump Button

Manual Outlet button

5A Fuse

5V Voltage Regulator & Heat Sink

Serial Number Marking Area

Page | 26

SECTION 12: Electrical Enclosure

Mains

Supply

(210-240V

OR 110V)

PCB 24V Supply

PCB Signal

24V Water Pump

3-

Phase Moto

220V (Delta)

24V PCB Signal Wires

Lid Sensor Safety Switch

SECTION 13: Sensor Terminal

Detail of Sensor Terminal

The terminal is located on the underside of the motor support plate. It acts as a hub to connect 4 sensors to the PCB via M12 jumper plugs. There are 6 connection points on the terminal, 2 of which are not used and are blanked off. The correct orientation of the jumper cables is as below.

2 1

4 3

Electrical Enclosure

24V

RELAY

5A

EMC FILTER

POWER

SUPPLY

MOTOR

Page | 27

SECTION 14: Additional Items & Kits

PART DESCRIPTION

KIT NUMBER

ITEM NUMBER

Vortex + PCB

9200838

Water Pump

9200529

Power Supply Unit 230V (UK)

9200940

E-Paper Display Screen

9200819

Start Switch Keypad

9200534

Electronic Rotary Latch

9200869

Power Supply Unit 110V (Outside UK)

9200941

Vortex + Actuator Controller

9200855

Solenoid Diode kit

9207019

Water & Disinfectant Cable Kit

9207020

PCB Power Cable Kit

9207022 Water Pump Diode Cable Kit

9207023

Installation Kit

9207025

Vortex + Program Fob

9200750

E-Paper Display Kit ( includes display, PCB &

pressure switch )

9207033

Page | 28

Appendix A

Engineer’s manual pump and outlet pushbuttons

Sited on the face of the PCB within the main electrical panel are two manual push buttons. The first button is the drain outlet valve manual opening. The second button is the pump manual run. The button locations are shown to the right of the Vortex PCB Image below.

In the event of the machine being in failure mode during the cycle, often the tub will be still full of water and or product due to the drain outlet being closed. Operating the manual outlet pushbutton will open the drain outlet diaphragm and allow the contents to empty into the main drain. Additionally the water pump can be run manually to help with the drainage.

If the water tank is full during a cycle when in fault condition, the tank can be drained to allow work to be carried out on the water system. Firstly the water tank has to be isolated from the water supply to stop the water tank from re filling. The manual `pump` pushbutton can then be pressed, this will pump out any water from the tank and out in to the main drain.

Maintenance can then be carried out on the pipe system with only a minimum of water left. Both push buttons are identified in the PCB section (12).

Do not run the pump dry, as this will result in damage to the pump seals.

Page | 29

Appendix B

Diagram for Motor Terminal Wiring

Motor wired in Delta for 220 volt input from the invertor unit.

W2 U2

V2

U1 V1

W1

Ø Ø Ø

Voltage amps check for Vortex Macerator.

Note: Readings are for a product load of four bottles.

VOLTAGE

PHASE

NOM RUNNING LOAD

MAX LOAD

MAX PEAK

110 1 2.5 to 4.8 amp

6.1 to 12.7 amp

44 amp

200 1 2.9 to 3.5 amp

6.3 to 8.8 amp

39 amp

220 1 2.8 to 3.2 amp

5.3 to 9.1 amp

41 amp

230 1 2.4 to 3.1 amp

5.2 to 8.1 amp

44 amp

250 1 2.8 to 3.7 amp

5.3 to 7.9 amp

44 amp

Page | 30

Appendix C

Diagram for motor electrical box plug and socket connections

Power Supply 230V

AC socket/plug

Power Supply 110V

AC socket/plug

Appendix D

Motor socket/plug

Orientation of Diodes for drain inlet and drain outlet solenoid valve coil terminals

Diode

OUTLET VALVE

INLET VALVE

Diode

Page | 31

Appendix E

A Suggested periodic planned maintenance

1 Remove all panels (clean as required, see cleaning instructions below). 2 Clean the lid seal & check for wear or damage. 3 Check that the lid arm lock operates effectively via the foot operation. 4 Check the blade for damage and free rotation. 5 Check the condition and correct positioning of the V- seal on cutter adapter (ensure lip

is in constant contact with hopper bottom). Vortex+ must be electrically isolated whilst carrying out this operation.

6 Operate the machine - when pump stops (after approx. 30 sec) isolate the machine from

power, open lid and check for correct water level in hopper (observe for approx. 5-10

seconds). Correct water level is level with the top of the hopper base +/- 12 mm. 7 Check the condition of the diaphragm valve, its seating and operation. 8 Check the non-return valve’s operation, clean if required. i.e. if the water level is low

within the hopper. 9 Check the solenoid valve’s operation, clean if required. i.e. if the water level is low in

the hopper. 10 Check all plumbing, pipe work and connections for leaks. 11 Check that the solenoid valve filters are clean. 12 Check for water at the seal flush pipe during the cycle and that the pipe is not blocked. 13 Check the operation of the tub vent assembly and small non-return valve. 14 Check the drain and overflow connections for leaks. 15 Check the operation of the water inlet float valve. 16 Check the operation of the deodoriser level switch. 17 Check the operation of the water-level switch (clean if required). 18 Remove and clean the external in-line filter (if fitted). 19 Check the drain pressure sensing unit operates correctly. 20 Check that the foot sensors are working correctly and operating the lid. 21 Check the connections to all electrical components. 22 Replace all panels. 23 Check the deodoriser tank level. Fill if necessary with Vernacare disposal unit

deodoriser part number 203MD005 24 Run a full load test cycle.

B Cleaning Instructions

Wipe down external surfaces using Tuffie 5 wipes, Tuffie detergent wipes or detergent

and water as required. Internal components can be kept clean by running a daily

cleansing cycle (without product).