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Vernacare VORTEXAIR Technical Manual

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Summary of Contents for Vernacare VORTEXAIR

  • Page 1 Page | 1 Page | 1 Page | 1 E S S E N T I A L T O H E A L T H...

  • 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 ..........................9 3.3.
  • Page 3 5.7. Care & Maintenance ......................24 Assembly Diagrams & Descriptions ....................25 6.1. Electrical Assembly ....................... 25 6.2. Diaphragm/Drain Valve Assembly ..................26 6.3. Safety Switch Assembly ......................27 6.4. Rotary Actuator ........................28 6.5. Lid Assembly ......................... 29 6.6. Pneumatics Assembly ......................

  • 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 Macerator Disposal Unit Product Name: (as per technical file) Vernacare Limited Folds Road Legal Manufacturer: Bolton BL1 2TX Globalnorm GmbH Kurfürstenstr.
  • Page 5 2014/30/EU: Electromagnetic compatibility (EMC) - Part 6-1: EN 61000-6-1:2007 Generic standards; Immunity for residential, commercial and light-industrial environments Electromagnetic compatibility (EMC) - Part 6-3: Generic standards; Emission standard for residential, commercial and light-industrial EN 61000-6-3:2007 EN 61000-6-3/A1:2007 EN 61000-6- environments 3/A1/AC:2012 2011/65/EU: Technical documentation for the assessment of...

  • Page 6: Warranty Information

    To ensure continued reliability and performance, service contracts are available. All UK based services and warranty work will be carried out by a VTS Engineer (Vernacare Technical Services- A division of Vernacare). For international installations, all work will be carried out by a Vernacare approved technician.

  • 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.
  • Page 8 ‘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...

  • Page 9: Dimensions

    3.2. Dimensions Page | 9 FOR MORE INFORMATION CONTACT YOUR ACCOUNT MANAGER ON FREEPHONE 1800 269 534 OR VISIT www.eboshealthcare.com.au...

  • Page 10: 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 Front Cover Side Panels Page | 10...

  • Page 11: 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 12: Installation & Commissioning

    4. Installation & Commissioning 4.1. Quick Install Guide Please note that this guide is focused on sites that are fitting a Vortex Air in replacement of a Vortex or Vortex +. If you are installing a Vortex Air in replacement of a non-Vortex macerator, please move onto the following section: Water Inlet Drain...
  • Page 13 Disconnect the electrical connection (A), drain (B) and water inlet (C). The location of these may differ depending on the existing install. If the machine is bolted to the floor, remove the 2 fixing bolts (X). (You will need to remove the front cover to do this) With all the points now disconnected, the machine is now safe to remove.
  • Page 14 Connecting the Vortex Air is simple a reversal of steps 1 & 2. First bring the Air close to the connections and connect both the water inlet and mains cable. Note that the Air does not come with a plug so one will have to be fitted. The Air also opens wider than previous machines, ensure there is 40mm clearance above the lid.

  • Page 15: 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 16: Water Inlet & Drainage Requirements

    4.3. 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 17: Operation

    5. Operation 5.1. Instructions For Use Approach the macerator and open the automatic lid by placing your foot in the footwell. ▪ Place the single-use disposable pulp products into the macerator, please: ▪ do not exceed the following maximum capacities: ▪...

  • Page 18: Icons & Error Messages

    5.3. Icons & Error Messages Page | 18 FOR MORE INFORMATION CONTACT YOUR ACCOUNT MANAGER ON FREEPHONE 1800 269 534 OR VISIT www.eboshealthcare.com.au...

  • Page 19: Cycle Sequences

    5.4. 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 5.4.1.

  • Page 20: Heavy Duty Mode

    5.4.3. 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 | 20 FOR MORE INFORMATION CONTACT YOUR ACCOUNT MANAGER ON...

  • Page 21: Pcb Diagram

    5.5. PCB Diagram Conn Reference Number Description PCB Board Internal Clock Battery RFID Compatible Terminal Display Ribbon Cable Audible Buzzer PCB Health LED Software Update Fob Connection Point Serial Number Text Area AC Motor Cable PCB Power Supply Cable Air Pump Cable Lid Motor Cable Main Water Cable Drain Valve Cable...

  • Page 22: Engineers Mode' Instructions

    5.6. ‘Engineers Mode’ Instructions To access ‘ENGINEERS MODE’ first switch the machine off. Press and hold the yellow button on top of the electrical cabinet then switch the machine back on again. The engineers mode message should flash on the LCD display if done correctly. = Start switch (Located underneath the display) 5.6.1.

  • Page 23: Setting 'Auto Start' & Adjusting Cycle Modes

    5.6.2. Setting ‘AUTO START’ & Adjusting Cycle Modes AUTO START (ON) /OFF AUTO START AUTO START (OFF) SERVICE RESET (ON) /OFF SERVICE RESET SERVICE RESET ON/(OFF) STANDARD CYCLE CYCLE SELECT PLUS CYCLE SET TIME&DATE ECO CYCLE CYCLE SETTINGS COMMS SETTINGS PRIME PUMPS SERIAL NUMBER SAVE&EXIT...

  • Page 24: Care & Maintenance

    5.7. Care & Maintenance Daily Routine Recommended cleaning procedure for Vortex Air using Azo Detergent Wipes or detergent and water. With the lid open, clean the inside surface of the lid seal and underside of the top cover using ▪ IPA based wipes or detergents with warm water.

  • Page 25: Assembly Diagrams & Descriptions

    6. Assembly Diagrams & Descriptions 6.1. 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

    6.2. 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

    6.3. 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

    6.4. 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

    6.5. 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

    6.6. 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

    6.7. 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

    6.8. 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

    6.9. 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

    6.10. 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

    6.11. AC Motor Wiring Diagram Motor wired in Delta for 220v input from the inverter unit. Ø Ø Ø 6.12. Electrical Enclosure MAINS SUPPLY 1PH 230/110v 24V DC POWER EMC FILTER SUPPLY Lid Position Safety Switch INVERTER Page | 35 FOR MORE INFORMATION CONTACT YOUR ACCOUNT MANAGER ON FREEPHONE 1800 269 534 OR VISIT...

  • Page 36: Fault Finding Guide

    7. Fault Finding Guide F F a a u u l l t t S S y y m m p p t t o o m m s s The machine has been switched off at the 1. The LCD display is M M A A C C H H I I N N E E D D O O E E S S N N O O T T isolator.
  • 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 •...
  • Page 43 Notes FOR MORE INFORMATION CONTACT YOUR ACCOUNT MANAGER ON FREEPHONE 1800 269 534 OR VISIT www.eboshealthcare.com.au...
  • Page 44 EBOS HEALTHCARE: 300 Victoria Street, Wetherill Park, NSW 2164 Free Phone: 1800 269 534 Free Fax: 1800 810 257 Email: customerservice@ebosgroup.com.au Online Ordering: www.eboshealthcare.com.au WAREHOUSE LOCATIONS: New South Wales: 300 Victoria Street, Wetherill Park, NSW 2164 Queensland: Unit 2, 39 Distribution Street Motorway Business Park Larapinta QLD 4110...

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