Vernacare Vortex Technical Manual Download | Manualshive

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Summary of Contents for Vortex

Page 1: ...Issue No 2 ...

Page 2: ...to installation use or repair of this machine 110 volt single phase machine Vernacare MODEL NO Vortex Amps Hz 4 4 60 SERIAL NO PHASE 1 DATE VOLTS 110 Read relevant manual prior to installation use or repair of this machine For Customer Service please contact Customer Care Department Vernacare Limited Folds Road Bolton Lancashire United Kingdom BL1 2TX Telephone 44 0 1204 555988 Fax 44 0 1204 52359...

Page 3: ...ective 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 A Division of Vernagroup Limited Folds Road Bolton Lancashire United Ki...

Page 4: ...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 ava...

Page 5: ...e Page 29 Section 14 Fault Finding Page 30 Appendix A Manual Pump and Outlet pushbuttons Page 39 Appendix B Motor Terminal Wiring Page 40 Appendix C Motor Electrical box plug and socket connections Page 41 Appendix D Orientation of Diodes for drain inlet and drain outlet Page 41 solenoid valve coil terminals Important Information Failure to comply with the instructions recommendations contained wi...

Page 6: ...ne 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...

Page 7: ...cles 40 l min at 5 lbs in 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 32...

Page 8: ...8 Figure 1 Dimensions of the Vernacare Vortex ...

Page 9: ...e 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 13 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 13 Amp to I E C 60269 4 An appropriate I E C Approved 16 Amp isolator shall be...

Page 10: ...tor 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 2 2 2 Drain connection The Ver...

Page 11: ...n Waste must be run separately to soil stack or drain Do not reduce the diameter of the warning pipe at any point A standard warning pipe installation kit is available Contact Vernacare Customer Care Department for details 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 connecte...

Page 12: ...minal 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 dia...

Page 13: ...mber 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 wa...

Page 14: ...er 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: ... start switch is to be held on for approximately 5 seconds until there is an audible sound This clears the display and resets the cycle to its last state prior to the fault The cycle will then continue The 2 minute cycle is controlled by a pre programmed microchip which controls the operation and timing of the water pump the cutter motor and the inlet outlet and deodoriser solenoid valves Shortly ...

Page 16: ...urised 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 di...

Page 17: ...Kit 9207014 1 1 Front Cover 9200531 1 2 Foot Sensor Housing 9200531 1 3 M6 x 20 Panel Screw x2 9750023 2 2 RH Side Panel 9200532 3 3 LH Side Panel 9200533 4 Deodoriser Cap Kit 9207013 4 1 Deodoriser Tank Cap 9200206 4 2 Filler Cap O ring 9200209 5 5 Start Switch Keypad 9200534 6 6 Display Screen 9200819 ...

Page 18: ...chanical Seal x1 9753005 2 Vortex Mechanical Seal Kit 9207006 1 6 Mechanical Seal 9753005 2 2 V Seal 9753000 2 3 M8 x 50 H H S S 9750006 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 Gas...

Page 19: ...phragm and 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 x8 9200326 2 2 Three Lobed Nut x 8 9200327 3 3 Water Inlet Outlet Solenoid Value 9200724 4 4 Non Return Value 9200726 5 5 Diaphragm Chassis 9200328 6 6 Plumbing Elbow 9200729 ...

Page 20: ...20 7 Lid Arm Assembly Figure 5 Lid Arm Assembly ...

Page 21: ...sh x2 9200146 1 11 Press Lok Insert 9200115 1 12 Lid Spray Washer 9200117 1 13 Self Tapping Screw x12 9200120 1 14 Lid Spacer x4 9200122 1 15 Compression Spring 9200121 1 16 M5 Nyloc Nut x4 9750012 1 17 Arm Inlet Pipe 9200161 1 18 D8 Spring Washer 9750033 1 19 D5 Plain Washer x4 9750011 1 20 Lid Arm Label 9200160 1 21 Arm Hinge Shaft x2 9200113 1 22 Damper 9200126 1 23 Arm Spring 9200125 1 24 Hing...

Page 22: ...r Assembly Kit 9207002 1 1 Top Cover 9200158 1 2 Lid Seal 9200159 1 3 Lid Seal Clip 9200152 1 4 Start Switch Keypad 9200534 1 5 Display Screen Not Include in kit 9200819 1 6 Display Membrane 9200535 2 Deodoriser Cap Kit 9207013 2 1 Deodoriser Tank Cap 9200206 2 2 Filler Cap O ring 9200209 3 3 Lever Hook 9200933 ...

Page 23: ...ck Interface Cable Kit 9207018 1 1 Interlock Actuator with cable 2 Interlock Assembly Kit 9207017 2 1 Spring Pin 9200689 2 2 Interlock Pin Pin Shaft 9200687 2 3 Interlock Guide Bush 9200635 2 4 Guide Bush C Clip 9200626 3 Vortex Latch Kit 9207011 3 1 Latch 9200157 3 2 Magnet 9200119 3 3 Locking Block Screw x2 9200120 ...

Page 24: ...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 5 and two nylon washers 4 to prevent leakage an O ring 3 is used to seal the connector to the hopper and is located in a groove on the inner face of the connector KIT REF PART DESCRIPTION KIT NUMBER IT...

Page 25: ...25 11 Water Distribution Figure 9 Water Distribution ...

Page 26: ...on Head 9200212 N A Float Valve Bracket 9200211 N A M4 Plain Washer s s 9200540 2 2 Deodoriser Tank Kit 9207009 N A Tank Level Switch 9200208 N A Deodoriser Tank 9200207 N A Red Male Bullet x2 9200663 3 3 2 P Trap Kit 9207008 N A Hose Clips 60mm 9757035 N A Drain Connector 9757001 N A 2 P Trap 9757002 4 4 Water Pump 9200529 5 5 Anti Syphon Valve 9200875 6 6 Pump Inlet Assembly 9200728 7 7 Deodoris...

Page 27: ...27 12 Electrical Circuit Figure 10 Electrical Circuit ...

Page 28: ... Foot Sensor 9200681 8 Start Switch Keypad 9200534 9 Lid Sensor 9200691 10 Power Supply Unit 110v Outside UK 9200921 11 Auto Start Jumper Plug 9200646 PART DESCRIPTION KIT NUMBER Interlock Interface Cable Kit 9207018 Solenoid Diode Kit 9207019 Water Disinfectant Cable Kit 9207020 PCB Power Cable Kit 9207022 Water Pump Cable Kit 9207023 Sheathed Data Cable to be used with 9200920 9200921 9207029 In...

Page 29: ...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 Ch...

Page 30: ...he lid 33 Fault 6 Water leaking internally 34 Fault 7 Lid seal leaking bubbling 34 Fault 8 Hopper does not empty 35 Fault 9 Product stock has large particle size 35 Fault 10 Machine is not clean after use internally 35 Fault 11 Deodoriser is not working 37 Fault 12 Display screen not working 37 Appendix A Manual Pump and Outlet pushbutton 37 Appendix B Motor Terminal Wiring 38 Appendix C Motor Ele...

Page 31: ...heck the PCB is operating neon indicator on Replace board if required Check the power supply 24v dc output Check that the drain is not blocked Disconnect pressure tube from pressure switch if the fault persists replace the pressure switch Check stop cock valve is open Check float valve operation Check water level sensor connections Check level sensor operation Replace Check level switch sensors fo...

Page 32: ...osed Check display icon shows lid closed no boot symbol Check magnet on handle insert is present and unobscured Machine motor overload tripped Display screen indicates Blocked Blades Display on the invertor Indicates OL Cutter blade jammed Clear reset See section 1 regarding maximum number of products to be disposed of in one cycle Motor jammed see fault 2 Mechanical seal jammed Clear reset Fault ...

Page 33: ...codes press reset button on inverter panel to clear Check motor wiring connections Including plug socket Ensure machine not being overloaded Water pump does NOT function Pump unit has failed Icon is shown but no pump noise Check electrical connections to the pump Repair Check pump motor rotation Replace Check PCB operation Replace Check 5 amp fuse Replace Pump fuse has blown Check pump motor has n...

Page 34: ...on when lid is closed Replace seal Check seal face is free from debris Clean Unable to open the lid Interlock pin not disengaging Interlock solenoid jammed Replace Check interlock pin movement is free Adjust Check foot sensors function replace Check output from PCB to solenoid Replace PCB Hydraulic damper failed Remove hydraulic damper Replace Vent tubing blocked Clear vent pipe work Non return va...

Page 35: ...ge Replace Lid seal leaking Bubbling Lid seal is not sealing Debris on the seal face Clean Check lid arm alignment see fault 4 Hinge bushes worn Replace Check condition of lid seal Replace Check operation of lid handle insert Repair Check seal is seated correctly Replace Leaking pipe work Pressure transducer not operating Back pressure from adjacent items in Sluice room Hopper vent outlet blockage...

Page 36: ... for blockage Clear Product stock has large particle size over 10 mm Lack of water in the hopper For lack of water see fault 3 Damaged cutter blade Inspect cutter blade for damage Replace Motor running slow Check invertor output speed reprogram replace Check hopper has not been overloaded Check outlet valve operation Check diaphragm spring attachment Check diaphragm not spilt or damaged Fault 8 Fa...

Page 37: ... pipe work Check pipes from water pump for blockage Clean Check water pump feed pipe for blockage Clean Check connection of pipe to lid arm for blockage Clean Diaphragm outlet failure Check diaphragm condition Replace Check solenoid water valve is operating Replace Check water solenoid valve filters for blockage Clean Check diaphragm valve spring is not damaged or detached Replace Blocked drain BL...

Page 38: ... valve for blockage clean Deoderisor Tank empty Check fill level and display icon functions Check level switch replace Check non return valve for blockage clean Display screen blank No power to the screen Check connections from pcb and at the display ensure all pins engaged replace Check power is on at the pcb illuminated neon Display blank replace display Fault 11 Fault 12 ...

Page 39: ...tlet 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 wate...

Page 40: ... Macerator Note Readings are for a product load of four bottles CURRENT RANGE 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 41: ...41 Appendix C Diagram for motor electrical box plug and socket connections Appendix D Orientation of Diodes for drain inlet and drain outlet solenoid valve coil terminals ...

Page 42: ...42 The latest version of this manual can be found at www vernacare com ...

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