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Summary of Contents for Vernacare VORTEX AIR
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Page 2: Table Of Contents
Table of Contents EU Declaration of Conformity ......................4 Warranty Information ........................6 2.1. Warranty Terms ........................6 2.2. Conditions of Warranty ......................6 2.3. Service Contracts ........................6 Machine Specifications ........................7 3.1. General Overview ........................7 3.2. Dimensions ..........................10 3.3. - Page 3 5.3. Safety Switch Assembly ......................27 5.4. Rotary Actuator ........................28 5.5. Lid Assembly ......................... 29 5.6. Pneumatics Assembly ......................30 5.7. AC Motor Assembly....................... 31 5.8. Interlock Assembly ........................ 32 5.9. Water Tank ..........................33 5.10. Sensor Schematic ......................34 5.11.
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Page 4: Eu Declaration Of Conformity
1. EU Declaration of Conformity The undersigned declares that the products described in this document conform to the European Directives listed. General Product Name: Macerator Disposal Unit Vernacare Limited Folds Road Legal Manufacturer: Bolton BL1 2TX Globalnorm GmbH Kurfürstenstr. 112... - Page 5 Product Code Product Description 2040ZA001 Vortex Plus 2050ZA001 Compact 2060ZA001 Compact Plus 2070ZA001 Vortex Air (230V) 2071ZA001 Vortex Air (110V) Appendix III (Technical File Authorisation): Person authorised to compile the technical file: Name: Globalnorm GmbH Address: Kurfuerstenstr. 112 10787 Berlin GERMANY info@globalnorm.de...
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Page 6: Warranty Information
2.2. Conditions of Warranty The Vortex Air must be installed as per instructions provided within this manual. The Vortex Air 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 authorised by Vernacare and conducted by appropriately trained person(s). -
Page 7: Machine Specifications
3.1. General Overview The Vernacare Vortex Air disposal unit is designed to operate within a 2-minute cycle using 23 litres +/-10% of water (standard cycle mode). The machine can dispose of up to 6 ‘Vernacare” disposable single- use products in a single cycle. To comply with Australian Watermark standards, the total ‘pulp weight’... - Page 8 One of the 2 events below will occur at this stage depending on the activation of ‘Auto-Start’ mode: ▪ Auto-Start Enabled- The Vortex Air will commence the cycle sequence. ▪ Auto-Start Disabled- The machine will remain in standby mode. To commence the cycle sequence the blue start button on the display membrane must be pressed.
- Page 9 When dealing with an error code or any other machine fault it is important you follow the processes as per the ‘Vortex Air Fault Finding Guide’. Failure to follow the correct rectifications may further damage your machine and in some cases even invalidate a warranty claim. If you do not have access to the guide, please contact your Vernacare representative and if in doubt forward enquiries to: https://www.vernacare.com/technical-support...
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Page 10: Dimensions
3.2. Dimensions Page | 10... -
Page 11: General Assembly
3.3. General Assembly The exploded images of the Vortex Air assembly below should be used for familiarisation with key components and assemblies. Top Cover Lid Top Lid Bottom Water Tank Deodoriser Tank Inverter Power Supply Unit (motor control) Hopper Display Membrane... -
Page 12: Electrical Specifications
3.4. Electrical Specifications 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 16 Amp to BS EN60269-1. -
Page 13: Ac Motor
3.4.1. AC Motor 0.75 KW; 3 Phase; 220-240v 50Hz/ 380-420v 50Hz; IP55; D71 frame size. Rating at peak load 2.6 amps (nominal). 3.4.2. Inverter AC inverter with either 110v or 230v supply voltage, 230v motor output and utilising current monitoring. 3.4.3. -
Page 14: Sitting & Fixing
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. -
Page 15: Water Inlet & Drainage Requirements
3.6. Water Inlet & Drainage Requirements The machine should be connected to a suitable cold water supply as follows:- The connection to the machine water tank is made at the rear of the machine on the top left hand side corner of the machine. It is a standard connection to a ¾” BSP male fitting. Flow rate should be 18 litres per minute minimum. -
Page 16: Environmental Considerations
‘nest’ inside one another within the macerator. DON’T put non-maceratable wipes, dressings, plastic containers, incontinence pads, metal objects, cotton wool, sanitary or paper towels, plastic gloves, aprons, syringes or any other non-maceratable items into the Vortex Air. Page | 16... -
Page 17: Icons & Error Messages
4.3. Icons & Error Messages Page | 17... -
Page 18: Cycle Sequences
4.4. Cycle Sequences A: Start Button/Auto Start, B: Lid Lock, C: Air Pump, D: Lid Seal Solenoid Valve, E: Drain Solenoid Valve, F: Water Pump, G: Motor Forward 55Hz, H: Motor Reverse 55Hz, I: Motor Forward 66Hz, J: Deodoriser Pump, K: Cycle Complete 4.4.1. -
Page 19: Heavy Duty Mode
4.4.3. Heavy Duty Mode A: Start Button/Auto Start, B: Lid Lock, C: Air Pump, D: Lid Seal Solenoid Valve, E: Drain Solenoid Valve, F: Water Pump, G: Motor Forward 55Hz, H: Motor Reverse 55Hz, I: Motor Forward 60Hz, J: Deodoriser Pump, K: Cycle Complete Time (Seconds) Page | 19... -
Page 20: Pcb Diagram
Water Pump Cable IFM Cable (Splitter Box) A ‘Engineer Mode’ Push Button Cable (Compact Range Only) Start Button Cable Floor LED Cable (Compact Range Only) Lid Seal Valve Cable Conn 19 Engineering Mode Board Ribbon Cable (Vortex Air Only) Page | 20... -
Page 21: Engineers Mode' Instructions
4.6. ‘Engineers Mode’ Instructions To access ‘ENGINEERS MODE’. Press and hold the blue button on the engineering membrane panel (below) for 5 seconds. The engineers mode message should flash on the LCD display if done correctly. Up – press to move up within menu items list Down –... - Page 22 Serial Number Use up / down buttons to Old:000000 change value. Press enter to set. New: NB- Must enter 6 digits Set Language English French Spanish Use up / down buttons to select required language option. Press enter to set. Portuguese Dutch Japanese...
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Page 23: Explanation Of Engineering Mode Features
4.6.1 Explanation of Engineering Mode Features 1.Auto Start – when selected ON machine will commence cycle automatically when the lid is opened & closed for loading. 2.Service Reset – Reset service count to zero following service. 3.Standard cycle – 120 second cycle using 23 liters of water. Suitable for normal load conditions. Motor reverse at start of cycle is via current detection. -
Page 24: Care & Maintenance
Wipe over the control panels with a damp (not wet) cloth and dry. NB. Drying each surface after cleaning is vitally important to help prevent microbial growth. ▪ Finally start the Vortex Air to run one cycle without any disposable single-use products to flush the hopper through and clean the inside of the macerator. Page | 24... -
Page 25: Assembly Diagrams & Descriptions
5. Assembly Diagrams & Descriptions 5.1. Electrical Assembly How it Works This is often referred to as the ‘PSU’ unit. The electrical assembly consists of both the power supply and inverter unit. The power supply distributes incoming mains power to the PCB board and machine components. -
Page 26: Diaphragm/Drain Valve Assembly
5.2. Diaphragm/Drain Valve Assembly How it Works The diaphragm assembly is also known as the drain valve. When a cycle is commenced, the rubber diaphragm will inflate via air distributed from the pneumatics assembly. Once inflated, all of the macerator’s contents will be help until the end of the cycle. Once completed the valve is quickly deflated sending the processed waste directly to the drain through the P-Trap. -
Page 27: Safety Switch Assembly
5.3. Safety Switch Assembly How it Works Found on the right hand side of the top-cover assembly, the safety switch has been introduced as a secondary mechanism to prevent the motor running with an open lid. This uses a mechanical microswitch linked to the inverter unit. -
Page 28: Rotary Actuator
5.4. Rotary Actuator How it Works The rotary lid actuator is found on the left hand side of the top-cover. It is a single unit designed to open/close the lid following a signal to the software from the foot sensor. Within the unit there is a clutch to protect the motor mechanism. -
Page 29: Lid Assembly
5.5. Lid Assembly How it Works The lid assembly houses many key components including the inflatable seal. At the beginning of each cycle the compressor inflates the seal which applies pressure between the lid and top cover to ensure a full aerosol free seal during operation. The water is also added through the lid via the idle shaft on the right-hand side of the top cover. -
Page 30: Pneumatics Assembly
5.6. Pneumatics Assembly How it Works The pneumatics assembly is responsible for distribution of Air throughout the macerators systems. This in turn controls both the drain and lid seal. Each of these contain their own independent pressure sensors so in the event of failure the display will highlight the correct error. Inflatable Lid Seal 3/2 Way Valve Air Compressor Diaphragm 3/2 Way Valve... -
Page 31: Ac Motor Assembly
5.7. AC Motor Assembly How it Works The AC motor (which is controlled by the inverter) directly drives the cutter blades. The gaskets and seals ensure the assembly is watertight as it goes through the central hopper chamber. The blades are angled slightly to produce a ‘Vortex’ in the slurry, this agitation of the water is key to effective maceration. -
Page 32: Interlock Assembly
5.8. Interlock Assembly How it Works The interlock solenoid locks the lid in place when closed. The pin moves linearly into the adjacent recess on the top cover moulding, this physically prevents the lid from opening whilst engaged. Interlock Bracket Microswitch Interlock Solenoid Interlock Pin... -
Page 33: Water Tank
5.9. Water Tank How it Works The water tank holds all necessary water for the macerator to complete a cycle. There is a WRAS compliant type A-B Air Gap preventing water in the tank getting back towards the inlet. The head of water in the tank goes through the water inlet manifold towards the water pump which distributes it when necessary. -
Page 34: Sensor Schematic
5.10. Sensor Schematic LID SAFETY PRESSURE TRANSDUCER Drain Pressure Switch Limit Safety Switch P-SWITCH (LID SEAL) P-SWITCH (DIAPHRAGM) BLANK IFM Pressure Switch IFM Pressure Switch HOPPER FULL FOOT SENSOR IFM Sensor IFM Ultrasonic Sensor LOW DEODORISER LOW WATER IFM Sensor with mount IFM Sensor with mount LID CLOSED LID OPEN... -
Page 35: Ac Motor Wiring Diagram
5.11. AC Motor Wiring Diagram Motor wired in Delta for 220v input from the inverter unit. Ø Ø Ø 5.12. Electrical Enclosure MAINS SUPPLY 1PH 230/110v 24V DC POWER EMC FILTER SUPPLY Lid Position Safety Switch INVERTER Page | 35... -
Page 36: Fault Finding Guide
6. Fault Finding Guide Fault Symptoms The machine has been switched off at the 1. The LCD display is MACHINE DOES NOT isolator. blank and the green SEEM TO HAVE The power supply is faulty. LED on the PCB is POWER OFF. - Page 37 Fault Symptoms There is an issue with the water supply. CYCLE WILL NOT 1. Display screen The inlet pump is not operating correctly. START DUE TO states Refiling The water tank sensor is faulty. ERROR Water/Low Water. If the water tank is full, check the •...
- Page 38 Symptoms The inverter overload safety feature has 1. Display screen indicated something is preventing effective MOTOR IS NOT states Blocked maceration by the motor. WORKING Blades See page 2 for CYCLE WILL NOT START • Lid safety sensor not working correctly. 2.
- Page 39 Fault Symptoms The pump is not receiving any power. WATER PUMP The fuse has blown. 1. The pump is not The whole pump unit has failed. working at all. FUNCTIONAL Check the cable providing power to the • pump. Check the fuse has not blown, replace as •...
- Page 40 Fault Symptoms The interlock has failed to disengage. The lid motor is at fault. LID WILL NOT 1.The lid will not The power supply has been interrupted. OPEN/CLOSE open. The foot sensor is not working effectively. The lid seal has not deflated/vented air. Place your foot under the sensor.
- Page 41 Fault Symptoms A clip requires tightening. 1. There is a leak A pipe has become loose or is damaged. WATER LEAK coming from the The diaphragm or water pump are leaking. internal pipework. Remove the front panel and shine a •...
- Page 42 Fault Symptoms Deodoriser reservoir is empty. DEODORISER The deo pump has failed. 1. No deodoriser is DOSING NOT The pipework is compromised. being dispensed. WORKING Check the tank is full. • Assess the pipework both to and from • the pump. Check for blockages. Check that the pump is working, replace •...
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How to replace inflatable seal on Vernacare Vortex Air