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Vernacare Compact Plus Technical Manual-

Revision 2-Issued by N.Shields 14.2.2020

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3.3.

Compact Plus Normal Cycle Sequence

Start Button Pressed



Lid Interlock Activated



Air Pump On- Drain Valve Closed and Lid Seal On



Water Pump On



Water Pump Off



Motor On



Drain Valve Vented & Opened



Motor Off



Deodoriser Pump On (for 2 seconds)



Motor On



Water Pump On- (for Cleaning)



Lid Seal Vented

Cycle Completed

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Summary of Contents for COMPACT+

Page 1: ......

Page 2: ...neral Description 9 3 1 General description 9 3 2 Safety related control functions 9 3 3 Compact Plus Normal Cycle Sequence 10 3 4 General Assembly 11 3 5 Dimensions of the Vernacare Compact Plus 12 4 Installation Commissioning 13 4 1 Required Install Clearences and Heights 13 4 2 Using the Wall Bracket Assembly 14 4 3 Siting and fixing 15 4 4 Plumbing 16 4 4 1 Water supply 16 4 4 2 Drain connecti...

Page 3: ...s Spares 30 5 13 Cable Spares 31 5 14 Sensor Switch Spares 31 6 PCB Layout 32 7 Electrical Enclosure 33 8 Sensor Arrangement 34 9 Air Water Distribution 35 10 AC Motor Information 36 10 1 Motor Electrical Box Plug Socket Connections 36 10 2 Motor terminal Wiring Diagram 36 11 Fault Finding 39 BLOCKED DRAIN Error Message Displayed 39 REFILLING WATER please wait Error Message Displayed 39 LOW WATER ...

Page 4: ...ct Plus Technical Manual Revision 2 Issued by N Shields 14 2 2020 Page 4 Hopper Sides Lid Not Clean At End of Cycle 41 Water Leaking From Machine 41 Disposable Products Not Cut At End of Cycle 42 Lid Does Not Move 42 ...

Page 5: ...lity Directive 2011 65 EU 2012 19 EU The Restriction of Hazardous Substances Directive The Waste Electrical Electronic Equipment Directive 2014 35 EU The Low Voltage Directive Conformity is shown by compliance with the applicable requirements of the following documents Reference Date Title EN ISO 12100 2010 Safety of machinery General principles for design ISO 12100 2010 EN 61010 1 2010 Safety req...

Page 6: ...ided in this technical manual II The Compact Plus must be commissioned by a person authorised by Vernacare failure to do so may invalidate the warranty III 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 wi...

Page 7: ... and packaging is 78 kg machine only 70 kg The Vernacare Compact Plus should be moved to the point of installation by fork pallet or sack truck whilst still attached to the pallet provided 2 3 Electrical specification The machine is supplied with a 3 meter length of 1 5mm flex which shall be connected to either 230 Volt Machine 10 Amp MCB to BS EN60898 Type C or alternatively fused 10 Amp to BS EN...

Page 8: ...y voltage 230v motor output and utilising current monitoring 2 6 Pump 0 18 kW 24vdc 50 cycles Protected by a 10 amp fuse 2 7 Water requirements Inlet supply Cold water ONLY with flow rate of 8 l min minimum Nominal overall usage 18 litres 10 per standard cycle BSP connections male 2 8 Drainage A 2 inch 50mm drain pipe to be connected either directly or via a swept bend to a standard 2 in 50mm drai...

Page 9: ... time the lid is closed in manual mode the disposal cycle is started by pressing the start button The disposal cycle lasts around 3 minutes during which time water is added to the hopper and the waste materials are broken down by the cutter motor blades At the end of the cycle the drain valve opens to allow the contents to drain and the inside of the machine is rinsed with clean water and deodoris...

Page 10: ...pact Plus Normal Cycle Sequence Start Button Pressed Lid Interlock Activated Air Pump On Drain Valve Closed and Lid Seal On Water Pump On Water Pump Off Motor On Drain Valve Vented Opened Motor Off Deodoriser Pump On for 2 seconds Motor On Water Pump On for Cleaning Lid Seal Vented Cycle Completed ...

Page 11: ...y to see full detail on subassemblies and part numbers please view the Subassemblies and Spares section 5 1 2 3 4 5 6 7 8 9 10 11 12 13 REF DESCRIPTION 1 Back Panel 2 Water Tank 3 Power Supply 4 Printed Circuit Board 5 Mitsubishi Inverter 6 AC Motor 7 Lid 8 Deodoriser Tank 9 Frame 10 Hopper Chamber 11 Water Pump 12 Front Cover Panel 13 Pneumatic Assembly ...

Page 12: ...Vernacare Compact Plus Technical Manual Revision 2 Issued by N Shields 14 2 2020 Page 12 3 5 Dimensions of the Vernacare Compact Plus ...

Page 13: ...either side of the Compact This allows tool access during adding removing of the front panel Servicing and maintenance procedures may also be carried out without having to move the machine 150mm 150mm 50mm 350mm SIDE REAR MACHINE CLEARENCE LID CLEARENCE MACHINE HEIGHT A minimum of 350mm clearance is required above the Compact lid Items fitted to the wall directly above the machine may restrict the...

Page 14: ...embly Fit the mounting bracket to the back of the machine as shown The hex head screw which secures the retaining bracket to the wall bracket only needs to be loosely fitted at this stage 150mm 1 2 3 4 Mark the top of the bracket onto the fixing wall The hex head screw can now be removed and set aside Secure the wall bracket to the fixing wall in the previously marked position This must be done so...

Page 15: ...t prior to fixing The machine MUST be bolted down using these holes Ensure the the ground is firm and level 230 Volt Machine 10 Amp MCB to BS EN60898 Type C or alternatively fused 10 Amp to I E C 60269 1 An appropriate I E C Approved 10 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 1 An appropriate I E C ...

Page 16: ...ternal one is not required Points to Watch Ensure that the supply line to the unit is at no point less than 15mm larger if 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 t...

Page 17: ...tallation This device shall be positioned in close proximity to the Compact Plus and within easy reach of the operator shall also be clearly marked as being the disconnecting device for the machine 4 5 2 Back up generator tests mains electrical supply surges Damage to internal electrical components of the Compact Plus macerator can occur as a result of voltage surges spikes occurring in the electr...

Page 18: ... machine 4 8 Warning labels and icons explanations Please refer to the technical manual prior to installation maintenance or operation of this equipment Symbol indicates presence of 230 110 V 50 60 Hz Start Cycle Press this button to start the machine An auto start option is also available Contact Vernacare for more information 4 9 Cycle Counter At the end of each cycle the LCD screen will briefly...

Page 19: ...Vernacare Compact Plus Technical Manual Revision 2 Issued by N Shields 14 2 2020 Page 19 4 10 Display screen icons and warning messages explanations ...

Page 20: ... Compact Plus Motor AM63 0 25KW B14 9210121 2 Motor Mounting Flange 9210024 3 M8 x 35 Button Hd Screw x6 9210077 4 V Seal 9753000 5 M4 x 45 Hex Hd Screw x1 9210094 M4 Nordlock Washer x1 9210060 6 M6 x 12 Button Hd Screw x2 9210073 M6 Nordlock Washer x2 9210071 7 Barbed Seal Flush Fitting 9750100 8 Motor Star Gasket 9752027 9 Mechanical Seal 9210092 10 Cutter Adapter Coupling 9210026 11 Cutter Blad...

Page 21: ...are Compact Plus Technical Manual Revision 2 Issued by N Shields 14 2 2020 Page 21 5 2 Diaphragm Assembly 1 2 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 9210306 1 Diaphragm Spring 9210055 2 Diaphragm 9210091 ...

Page 22: ... Moulding 9210003 4 Idel Shaft 9210053 5 Idle Shaft Bearing 9210054 6 M6 x 35 Hex Hd Screw x2 9210079 7 M3 x 6 Grub Screw x2 9210108 8 Spray Nozzle 9210017 9 Spray Washer Housing 9210016 10 M6 x 20 Cap Hd Screws x2 9210076 11 Spray Washer 9210028 12 M8 x 12 Button Hd Screw 9210080 13 M8 Spring Washer 9750033 14 Idle Shaft Hinge Block 9210023 15 Limit Switch 9210175 16 M3 x 25 Cap Head Screw x2 921...

Page 23: ...al Manual Revision 2 Issued by N Shields 14 2 2020 Page 23 5 4 Lid Motor Assembly 1 2 3 KIT REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 9210304 1 EMS Lid Motor 9210134 2 M6 x 35 Hex Hd Screws x2 9210079 3 M6 Plain Washers x2 9750024 ...

Page 24: ...2 Issued by N Shields 14 2 2020 Page 24 5 5 Interlock Assembly 1 2 3 4 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 9210305 1 Interlock Solenoid Assembly 9210135 2 M5 Plain Washer x2 9750011 3 M5 x 8 Pan Posi Hd Screw x2 9210105 4 Interlock Pin 9210021 ...

Page 25: ...N KIT NUMBER ITEM NUMBER 9210302 1 Inflatable Lid Seal 9210099 2 Rubber Motor Panel Cover 3 Lid Motor Cover Panel with captive screw 9210047 4 Clamp Ring 9210001 5 M4 x 20 Cap Hd Screw x8 9210063 6 Hose Cover Panel with captive screw 9210046 7 Rubber Hose Panel Cover 8 Top Cover 9210000 9 Display Assembly see 5 7 for full detail 9210307 10 Seal 9210097 ...

Page 26: ... 2020 Page 26 5 7 LCD Display Assembly 1 2 3 4 5 6 7 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 9210307 1 M3 Nut x2 9750062 2 Display Strap 9210184 3 M3 Plain Washer x2 9210056 4 Start Switch Membrane 9210031 5 Ribbon Cable N A 6 LCD Display N A 7 M3 x 16 CSK Screw x2 9210058 ...

Page 27: ...nual Revision 2 Issued by N Shields 14 2 2020 Page 27 5 8 Overflow Assembly 1 2 3 4 5 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 1 2 P Trap 2 15mm Copper Branch 3 Overflow Funnel 9210007 4 Rubber Overflow Manifold 5 Copper Overflow Tube ...

Page 28: ...y 1 8 7 2 3 4 5 6 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 9210300 1 Munster Simms valve 9757030 2 Vent Gasket 9210093 3 O Ring 16 6 ID x 2 4 DIA Nitrile 9752018 4 Vent Cowl 9200325 5 M4 x 10 Pan Hd Screw x2 9210062 6 M4 Plain Washer x2 9200540 7 Vent Connector 9200334 8 Compact Plus Hopper Tube 9210034 ...

Page 29: ...ous N A 11 22 OD 16 ID PVC Tube various N A 12 9 OD 5 5 ID PVC Tube various N A 13 11 OD 7 5 ID PVC Tube various N A 14 16 OD 12 ID Silicone Tube various N A 15 18 OD 12 ID Silicone Tube various N A 16 6 OD 4 ID PVC Tube various N A 17 ABA Mini Hose Clips Size 11 9210095 18 ABA Mini Hose Clips Size 14 9210096 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER 9210309 1 x1 BSP M x 6 Swivel Elbow 9210157 2...

Page 30: ...ting for the motor flange 9750100 3 V Seal cutter motor adapter 9753000 4 Compact Plus Front Panel 9210008 5 Cutter Blade 9210033 5 Start Switch Membrane 9210031 7 Threaded Plug deodoriser cap 9210052 8 Mechanical Seal 9210092 9 Inflatable D Seal 9210099 10 Water Pump 9210132 11 Floor LED 9210139 12 Deodoriser Pump 9210133 13 40mm P Trap 9210144 14 3 2 Valve 9210181 15 Compressor Pump 9210131 16 P...

Page 31: ...N A 1 Mains Cable N A 2 M12 F to M8 M Jumper Cable 9210128 3 M8 F to M8 M Jumper Cable 9210129 REF PART DESCRIPTION KIT NUMBER ITEM NUMBER N A 1 Magnetic Sensor Lid Safety Sensor 9200834 2 Pressure Switch Lid Seal Drain Valve 9210137 3 Capactitive Sensor 9210127 4 Magnetic Sensor Lid Open Close 9210136 5 Pressure Transducer Drain Switch 9210212 6 Ultrasonic Foot Sensor 9210130 ...

Page 32: ...al 4 Display Ribbon Cable 5 Audible Buzzer 6 PCB Health Check LED 7 Software Update Fob Connection Point 8 Serial Number Text Area 300 AC Motor Cable 302 PCB Power Supply Cable 305 Air Pump Cable 306 Lid Motor Cable 307 Main Water Cable 308 Drain Valve Cable 309 Deodoriser Pump Cable 311 Lid Interlock cable 312 Water Pump Cable 313 IFM Cable 314 ENGINEER MODE Push Button Cable 318 Start Button Tog...

Page 33: ...nical Manual Revision 2 Issued by N Shields 14 2 2020 Page 33 7 Electrical Enclosure EMC FILTER 24V DC POWER SUPPLY PCB D700 INVERTER M L N E 24v 0v 0v 24v Lid Position Safety Switch MAINS SUPPLY 1PH 230 110v RL SD W V U L3 L2 L1 ...

Page 34: ... SAFETY 1 UGR IFM Ultrasonic Sensor PV7004 IFM Pressure Switch PV7004 IFM Pressure Switch Drain Pressure Switch 9210212 MK5122 IFM Magnetic Sensor MK5122 IFM Magnetic Sensor S870W1D1T Limit Safety Switch IFM SPLITTER BOX 10 x M8 EBC0136 EVC256 M12 F to M8 M Jumper Cable EVC256 M12 F to M8 M Jumper Cable EVC256 M12 F to M8 M Jumper Cable BLANK EVC271 M8 F to M8 M Jumper Cable EVC271 M8 F to M8 M Ju...

Page 35: ...Vernacare Compact Plus Technical Manual Revision 2 Issued by N Shields 14 2 2020 9 Air Water Distribution ...

Page 36: ...20 Page 36 10 AC Motor Information 10 1 Motor Electrical Box Plug Socket Connections Power Supply 110 230V AC socket plug Motor socket plug 1 2 3 1 2 3 10 2 Motor terminal Wiring Diagram Motor wired in Delta for 220 volt input from the invertor unit Ø Ø Ø W2 U2 V2 U1 V1 W1 1 2 3 ...

Page 37: ... on the LCD display if done correctly Toggle switch Located on top of the electrical cabinet Start switch Located underneath the display 11 1 Priming the Pumps Opening the Drain Valve Note that when priming either pumps the start button must be held SET TIME DATE DRAIN VALVE BACK CYCLE SETTINGS COMMS SETTINGS PRIME PUMPS SERIAL NUMBER SAVE EXIT DIAPHRAGM OPENED DEO PUMP PUMP PRIMED WATER PUMP PUMP...

Page 38: ...are happy with your changes scroll to SAVE EXIT then press start to bring you out of engineers mode Note that the alternate cycle modes are as follows Standard Cycle Normal operation 4 products cycle Heavy Duty Cycle Used only for busy wards when the machine is running continuously 4 products cycle Eco Mode Used for light duty machines 1 product only cycle Please take care to select the appropriat...

Page 39: ...s has been detected which could indicate a blockage Press start button to clear error and resume the cycle If the problem persists call maintenance Abort cycle press and hold start button open lid and check hopper drains freely use engineering functions to open drain and rinse if required Check vent pipe is clear Check pressure switch operates correctly REFILLING WATER please wait Error Message Di...

Page 40: ...LID CANNOT OPEN Error Message Displayed Something is obstructing the lid Check nothing is on top of the lid press start button to clear the error If the problem persists call maintenance Check lid open and lid closed sensors for correct operation Check magnetic clutch for slipping Check lid motor is working LID CANNOT CLOSE Error Message Displayed Something is obstructing the lid Check nothing is ...

Page 41: ... lid closed sensors for correct operation Hopper Base Not Clean At End of Cycle Overloading the machine Running a cycle with the machine empty will remove any residue N A Hopper Sides Lid Not Clean At End of Cycle The lid spray is not working correctly Call maintenance Remove and clean the lid spray Water Leaking From Machine N A Call maintenance Water leaking from the lid Check vent pipe for bloc...

Page 42: ...ing correctly Check if motor turns Check that safety switch is operating correctly Check for error codes on inverter Lid Does Not Move Foot sensor not working Lid interlock stuck or not working Lid motor not working Magnetic clutch worn not working Drive shaft broken or damaged Call maintenance Check foot sensor operation recalibrate if required The lid can be manually opened by removing the front...

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