disperator 500A-HK User manual
FOOD WASTE DISPOSER 500A-HK EXCELLENT SERIES
WITH PROTECTIVE LID FOR INSTALLATION IN
WORKING BENCH OR TABLETOP
Product Descripon Installaon Safety Operaon Service
USER MANUAL
User manual in Original
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Mälarvägen 9, 141 71 Segeltorp Web page: www.disperator.se
User manual in Original
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DISPERATOR AB Tel: 08-724 0160 E-mail: info@disperator.se
Mälarvägen 9, 141 71 Segeltorp Web page: www.disperator.se
User manual in Original
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Mälarvägen 9, 141 71 Segeltorp Web page: www.disperator.se
Statement of Compliance
DNV·GL
Folder: A1003885
Document N14240EG
no:
Regulation 4
Discharge of garbage outside special areas
Regulation 5
Special requiremen r discharge of garbage from jed or oating plaorms
Regulation 6
Discharge garbage within special areas
®
lf any person suffers loss or damage which is proven to have been caused by any negligent act or emission of the Society, then the Society shall pay compensation ta such person for his proven direct loss or damage. However, the
compensation shall not exceed an amount equal to ten times the fee charged for the service in question. The maximum compensation shall never exceed USD 2 million.
In this provision the “Society” shall mean DNV GLAS as well as all its direct and indirect owners, affiliates, subsidiaries, directors, officers, employees, agents and any other person or entity acting on behalf of DNV GLAS.
© DNV
GL
2014. DNV
GL AND THE HORIZON GRAPHIC ARE TRADEMARKS OF
DNV
GLAS.
Form
No.:
40.91a lssue: 2014-07
w.dnvgl.com
Page 1 of 1
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Table of Contents
1. Safety Precauons _______________________________________________________ 7
1.1. Safety Signs __________________________________________________________ 7
1.2. Personnel Qualicaons and Training______________________________________ 8
2. Company Prole _________________________________________________________ 9
3. Product Descripon and Technical Specicaon _______________________________ 10
3.1. Food Waste Disposer 500A-HK EXCELLENT-Series with Protecve Lid for
Installaon in Working Bench or Tabletop __________________________________ 10
3.2. Technical Specicaon _________________________________________________ 12
4. Storage and Displacement _________________________________________________ 13
4.1. Storage of the Machine_________________________________________________ 13
4.2. Displacement of the Machine____________________________________________ 13
5. Included in Delivery ______________________________________________________ 14
5.1. Documentaon _______________________________________________________ 14
5.2. Food Waste Disposer___________________________________________________ 14
6. Installaon Descripon for the Machine _____________________________________ 16
6.1. Assembly of the Machine _______________________________________________ 16
6.1.1. Mounng the Disposer With a HK Mounng _____________________________ 16
6.1.2. Mounng and Support against Floor/Floor plate __________________________ 16
6.1.3. Fixaon of the Machine _____________________________________________ 17
6.2. Connecon of ushing water ____________________________________________ 18
6.2.1. Water pipe DN15___________________________________________________ 18
6.2.2. Line Strainer DN15 and Solenoid Valve DN15_____________________________ 18
6.2.3. Hose with Protecve Steel-Covered Stocking for Flushing Water, minimum
inner-Ø 9 mm _____________________________________________________ 18
6.2.4. Other orders / installaons for which standard EN 1717 does not apply _______ 19
6.3. Connecon of Machine Outlet to Water Trap and Sewer Pipe __________________ 20
6.3.1. Dimensions _______________________________________________________ 20
6.3.2. Depth and Threshold of Water Trap ____________________________________ 20
6.3.3. Curves and Bends __________________________________________________ 20
6.3.4. Level Dierence of Water Trap ________________________________________ 20
6.3.5. Slope of Sewer Pipe_________________________________________________ 20
6.3.6. Vacuum Evacuaon _________________________________________________ 20
6.4. Electrical Connecon___________________________________________________ 21
6.4.1. Supply Voltage_____________________________________________________ 21
6.4.2. Mains Fuses _______________________________________________________ 21
6.4.3. Wall/Bulkhead Mounted Electrical Security Breaker _______________________ 21
6.4.4. Cable Dimension ___________________________________________________ 21
6.4.5. Cable Protecon ___________________________________________________ 21
6.4.6. Earth Wire ________________________________________________________ 21
6.4.7. Direcon of Rotaon for the Disposer __________________________________ 21
6.4.8. Protecve Cover Connected to Safety Interlock Switch _____________________ 21
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6.5. Start Up and Final Tesng _______________________________________________ 22
6.5.1. Check before Start Up _______________________________________________ 22
6.5.2. Checks during Start Up ______________________________________________ 22
6.5.3. Final Measures ____________________________________________________ 22
7. Safety Instrucons _______________________________________________________ 23
8. Operang Instrucons ____________________________________________________ 24
8.1. Start and stop ________________________________________________________ 25
8.2. Daily cleaning of the disposer ____________________________________________ 25
8.3. Trouble Shoong ______________________________________________________ 26
8.3.1. Disposer Reduces Speed, Stops or does not Start _________________________ 26
8.3.2. Machine Starts but there is no Flushing Water ___________________________ 26
8.3.3. Machine does not Start and makes no Sound ____________________________ 26
9. Service Instrucons ______________________________________________________ 27
9.1. Authorizaon_________________________________________________________ 27
9.2. Exploded Views and Spare Parts List for the Disposer _________________________ 27
9.3. Overhaul of Protecon Cover with Switch, Assembly and Connecons ___________ 35
9.4. Dismantling of Disposer ________________________________________________ 35
9.5. Assembly of Disposer __________________________________________________ 38
9.6. Overhaul and Maintenance Intervals ______________________________________ 42
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This manual contains instrucons for installaon, operaon and maintenance of the food waste disposer
(below also called the machine). It is therefore essenal for the installer, union representaves and
users of the machine to read the manual thoroughly prior to installaon, commissioning, operaon and
overhaul & maintenance.
This manual must always be at hand where the machine is being used.
It is not only the general safety instrucons in this secon that need to be considered, but also the other
special safety instrucons given in this manual.
1. Safety Precautions
1.1. Safety Signs
The following safety signs are used in this manual and on the machine. Failure to comply with the safety
regulaons contained in this manual as well as on the machine may cause personal injury or damage the
machine.
Read this User Manual before use
Use protecve goggles
Use ear protecon
Warning for electric voltage
General personal danger
Warning for mechanically caused damage (rotang parts)
Warning plates located on or close to the machine must always be observed and kept legible.
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1.2. Personnel Qualications and Training
All personnel managing the below tasks for the machine as described in this manual, must have the
necessary qualicaons to carry out this work. Areas of responsibility, scope of authority and sta
supervision must be carefully dened by the machine owner. If the personnel do not have the necessary
qualicaons for this, they must receive training and instrucons. Such training can be provided by the
manufacturer / supplier. Moreover, it is the responsibility of the machine owner to make sure that all
users read and understand the content of this User Manual.
Moving the Machine
Sta responsible for moving the machine must have knowledge about the handling of the liing gear
and stopping devices and have knowledge of applicable safety regulaons for these. If they lack this
knowledge, they must receive the required training.
Installaon
Personnel responsible for the installaon of the machine must have knowledge equivalent to educaon
in industrial mechanics/technician. The electric connecon must be performed by trained and cered
electrician.
Commissioning and Maintenance
Personnel responsible for commissioning, overhaul and maintenance of the machine must be familiar
with all funcons, and how to operate these funcons. Furthermore, they must know of all safety
precauons in this manual, and which in other respects also are valid where the machine is used.
Operaon
All persons who operate and maintain the machine must be aware of the risks that may occur with its use
and as described in this manual.
Service and Repair
Responsible personnel for service and repair of the machine must have knowledge equivalent to
educaon in industrial and design mechanics, and also know and understand the technical data of the
machine described in this manual. Assisng personnel for these jobs must be trained and performed
repair work must be checked by the machine owner.
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2. Company Prole
Disperator’s business idea is to provide innovave and adapve equipment for kitchens on land as well
as galleys at sea, and for the food processing industry, which enables ecient collecon of communited
food leovers for anaerobic digeson or composng in subsequent stages, which is of benet to society.
With over 70 years of experience in the development and producon of such equipment, our devoon
to this has resulted in the unique operaonal reliability required for the extreme condions prevailing in
the marine industry. Furthermore, our innovaveness has provided commercial kitchens on land with an
alternave approach to handle food waste separaon at source, complying with modern demands and
being economically aordable.
Our product assortment is unique! Disperator can as the only manufacturer of such equipment oer
all types of installaon possibilies needed in a kitchen. Our basic range of ve dierent series of
water-based food waste disposers, consisng of three to six dierent sizes in each serie, which may be
combined with as many as 13 dierent mounng assemblies. Furthermore, the advantage of the basic
model’s design is that the waste disposers may easily be integrated into other kitchen manufacturer’s
mounng assembly or furniture. Thereby, each workplace in a kithen or galley can be designed to its
specic requirements regarding funcon, ergonomics and economy. To all this there is also the dierent
series of water-saving processor technology for collecon and storage of grinded food waste in a tank, as
well as disposers that grinds food waste without any ushing water at all.
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3. Product Description and Technical Specication
3.1. Food Waste Disposer 500A-HK EXCELLENT-Series with Protective Lid for
Installation in Working Bench or Tabletop
The immediate and ecient removal of the heaviest part of kitchen waste - the food scraps - is a
necessity in any commercial kitchen. When using a Disperator waste grinder, the food waste can easily
collect and reduce the total amount of waste hygienically and without heavy liing or manual transfer
to a waste storage - in volume, but especially in the handling of the total weight in dierent transport
phases!
Disperator food waste disposers are used in kitchens and marine galleys around the world, providing an
ecient and immediate removal of food waste whenever the need arises and thereby improving hygiene
in the working environment, eliminang bad odors and bacteria formaon and minimizing manual
handling.
Regardless of the selected disposer model, the disposal procedure is the same. Food waste is fed down
into the machine and with water ground into small parcles for further transport in the sewer to a sealed
and odorless special tank where the slurry and grease are separated from much of the liquid which
ows out into the municipal sewer. Alternavely, all the sludge with liquid runs o in the municipal sewer
to a water treatment plant. The tank is emped by a vacuum truck approximately every four weeks or
according to the driving schedule that applies in your municipality. Depending upon preference, the tank
may be placed outdoors buried in the ground, as well as placed indoors. In water treatment plants as well
as in anaerobic digeson facilies the slurry is converted into a valuable renewable energy resource (i.e.
biogas), and oen the digested residue which is le aer biogas producon can also be used as ferlizer
on farmland. Biogas is today one of our society’s most environmentally clean and desired energy forms,
as fuel for vehicles as well as to produce heat and electricity.
Disperator’s broad assortment of dierent technical soluons for source separaon of food waste can be
adapted to your specic kitchen and your specic working environment, regardless of size or layout, and
regardless of the specic municipal’s food waste handling rules in your community!
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Our product range is designed with the user’s needs in focus and meets today’s requirements for
handling of food waste. The high-quality grinding unit of specially alloyed steel together with the unique
and well-proven sealing design between the grinding unit and motor provides the user with many years
of operaonal reliability and low maintenance cost. The disposer’s life span is extended further by the
outer housing of stainless steel EN 1.4301 (AISI 304) and protecon class IP55 for electrical components
as standard.
The wide range of disposer sizes, and where each size ts all models of assemblies, makes it easy to
customize each installaon of disposer to t all workplaces in kitchens onshore as well as at sea. The
Excellent 500-Series disposers may be installed under sinks and washing lines, into tabletops and working
benches or as freestanding separate units. Installaon into an exisng kitchen furniture manufactured by
another supplier is also possible. For CE-marking an approved assembly with protecon above disposer
inlet is needed from Disperator or other manufacturer.
Standard delivery includes a complete start/stop unit with contactor and motor overload protector, and
a complete solenoid valve with line strainer, which for some of the assembly models need to be installed
and connected on site in the kitchen. Cold water will automacally ow when the disposer starts, ushing
the food waste into the grinding chamber, and then into the sewer system or a storage tank.
Food waste disposers within the Disperator Excellent-Series have the Declaraon of Compliance issued by
DNV, verifying compliance with applicable secons of IMO MARPOL consolidated edion 2017 ANNEX V
for disposal of ground food waste into the open sea
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3.2. Technical Specication
e
a
b
c
d
f
170
190
g
393
418
6x60°
¡¡
¡¡
¢
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4. Storage and Displacement
4.1. Storage of the Machine
If the machine will be stocked before installaon and use the following applies:
• The machine should be stored in a dry and clean room where the relave humidity may not
exceed 60%.
• Recommended storage temperature of -20 °C to + 60 °C.
4.2. Displacement of the Machine
The machine should not be lied or moved by hand. During installaon, we recommend using a
pallet jack or forkli, and during service a liing trolley for component parts in a machine (like a
disposer placed inside a cabinet).
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5. Included in Delivery
5.1. Documentation
• This User Manual
• Safety Instrucon (laminated),
• Operang Instrucon (laminated),
• Electric documentaon (connecon & wiring diagram and component layout diagram)
5.2. Food Waste Disposer
Disposer with motor size and voltage
according to the delivery note, including
rubber gasket to be placed between disposer
and cone
HK-discharge cone including:
• Rubber seal to mount between
disposer and cone. Mounted on
disposer on delivery,
• water ushing nozzle, 2pcs,
• solenoid valve G½” (BSPP)
internal thread, with coil and
control voltage according to the
delivery note,
• line strainer G½” (BSPP) internal
thread, with R½” (BSPT) external
thread pre-mounted on cone,
• safety interlock switch connected
to protecve lid
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Start/stop control unit including contactor
with motor overload protector and control
voltage according to the delivery note
Adjustable legs, 3 pcs. for disposer models
having motor power of 1.8 kW or more
Jam release wrench, 1pc. for release of
disposer grinding unit, if a non-grindable
object by mistake happens to fall therein
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6. Installation Description for the Machine
6.1. Assembly of the Machine
6.1.1. Mounting the Disposer With a HK Mounting
In order to weld a strong joint and to be able to grind to an even and ne surface between the
discharge cone and the working bench/tabletop, the cone is welded with its upper ange against
the underside of the working top. The opening in the worktop must be at least 398 ± 2 mm in
diameter. The disposer is then screwed into the lower aachment ring of the cone.
6.1.2. Mounting and Support against Floor/Floor plate
Mounng of models 510 and 515, delivered without legs as standard
The weight of disposer models 510 and 515 allows them, in most cases, to be hung vercally
under the mounng assembly (e.g. under a sink). The standard delivery of these models
therefore does not include legs. However, if they are to be placed standing on the oor/oor
plate (e.g. beside a peeling machine/dishwasher) these models must be ed with legs. If legs
have been ordered it is specied on the delivery note.
To minimize the risk of injuries, two persons shall always be present when the disposer is
installed. Below describe three dierent approaches, depending on the availability of tools at the
installaon site.
Place the disposer ghtly against the ange of the mounng assembly, by using one of below
menoned hoist methods. Make sure that the disposer top rubber seal is correctly posioned.
Tighten the six screws with nuts evenly. The rubber seal should be compressed approximately
1 mm.
Hoist alternave 1
Trolley, see picture below.
Hoist alternave 2
Use a rm and well-balanced jack with a support disk to hoist the disposer into posion under
the mounng ange.
Hoist alternave 3
If no hoisng tools are available, place the disposer on a solid object of the proper height (for
example a wooden crate), and push it in under the mounng ange. To get the proper height of
this object measure the space between the oor and the mounng ange and then subtract the
height of the disposer and the rubber seal (which is 3 mm thick).
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Mounng of models 520, 530, 550 and 575, delivered with legs as standard
The weights of models 520, 530, 550 and 575 require legs for support. At installaon site the
seperatly delivered 3 legs must be xed to the 3 clamps in the disposer boom plate.
Proceed as follows when mounng the legs:
• Measure the height (X mm) between the ange of the mounng assembly and the oor/oor
plate.
• Measure the height (Y mm) of the disposer without legs including the 3 mm rubber seal.
• Lay down the disposer carefully on its side. Slide the three legs into respecve clamp. Each leg
should protrude X – Y - 4 mm.
• Tighten the clamps. Make sure that the legs are xated, and that their posion have not
changed during the ghtening of the screw.
• Place the disposer so that it stands on its legs. Move the disposer carefully into posion under
the ange of the mounng assembly.
• Using the six screws with nuts xate the disposer onto the ange with the 3 mm rubber seal
in between. Tighten the screws alternately and evenly unl the rubber seal is compressed
approximately 1 mm.
• Use a jack or a lever to push up the disposer towards the ange of the mounng assembly.
• While this upward pressure is maintained, unghten each leg and pull it downwards. Make
sure that all legs are rmly pressed against the oor. Tighten the clamps using a torque of 17
Nm. As this is a crical maer, a torque wrench should be used. If no torque wrench is available
use a leaver of approxematly 30 cm and a force of 6 kg.
6.1.3. Fixation of the Machine
The bench/table or cabinet in which the machine is assembled must be xed to the wall/
bulkhead or oor/oor plate. When starng or stopping quickly (e.g. if cutlery mistakenly jams
the grinding unit) the torque of the motor will cause the machine to turn. This may move the
water trap and sewer pipe from its posion causing water leakage.
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6.2. Connection of ushing water
For the machines ordered for connecon to ushing water according to the requirements of standard
EN 1717 (in the UK also WRAS), or to be installed in countries where this standard must be complied
with, the machine’s dra ushing water is delivered according to these requirements to prevent
contaminaon by sucon in drinking water pipes.
This standard EN 1717 denes ve liquid categories that are or could come into contact with drinking
water. Category 5 is the category with the highest protecve requirements and which applies in all
kitchens where food is handled, regardless of whether food waste management equipment is there
or not. If stated when ordering, all Disperator’s machine models can be delivered in accordance with
the requirements for category 5, ie. the category with the highest protecon against contaminaon
of drinking water pipes.
Connecon of ushing water to the delivered machine may only be carried out by a qualied VA
installer and in accordance with current local VA regulaons. DISPERATOR takes no responsibility for,
according to standard EN 1717, a machine that is incorrectly connected to the drinking water line.
The machine’s automac rinsing water control is to be connected to cold rinsing water (hot water is
not needed).
6.2.1. Water pipe DN15
To provide the correct amount of ushing water to the machine, the incoming water pipe (incl.
accessories and protecon devices against sucon, cut-o valves, etc.) must have the same
dimension as the connecon to the machine assembly, ie. DN15. No throling may exist up to
the ushing water connecon on the machine.
6.2.2. Line Strainer DN15 and Solenoid Valve DN15
The delivered line strainer, DN15 must be mounted in the ow direcon before the solenoid
valve, DN15 in the incoming cold water pipe to the machine. Also make sure that the line
strainer and solenoid valve are mounted in the correct ow direcon (see the arrow on these
components), and that the nut on the line strainer (which is to be opened when cleaning the
line strainer) is directed downwards. Line strainer and solenoid valve have G½” (BSPP), internal
thread.
For funnel mounng that is welded into other manufacturers’ table tops / workbenches, and for
freestanding cabinet and table mounng, these components are pre-assembled from the factory
on the assembly for connecon to cold water supply. Connecon to these assemblies is R½”
(BSPT), external thread.
6.2.3. Hose with Protective Steel-Covered Stocking for Flushing Water, minimum
inner-Ø 9 mm
Between the incoming water pipe mounted on the wall/bulkhead, and the connecon for
ushing water on the machine assembly, a hose with protecve steel-covered stocking (with
minimum inner-Ø 9 mm) must be ed. This hose absorbs the compressive push in the pipe
when the ushing water is turned on and absorbs any small vibraons which may occur during
the grinding process of the disposer. This hose is not included in standard delivery but is available
as an opon from Disperator.
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6.2.4. Other orders / installations for which standard EN 1717 does not apply
In cases where standard EN 1717 does not apply (eg countries outside the EU or marine
installaons) it is sll recommended that a vacuum valve (non-return valve), G½” (BSPP), be
installed on top of the lyre-shaped incoming water pipe according to the gure below. The
vacuum valve protects the water pipe against re-sucon in the event of overow. Vacuum valve is
not included in standard delivery but can be ordered as an opon from Disperator.
T h e p i c t u r e a b o v e s h o w s a n e x a m p l e o f t h e l o c a o n o f a v a c u u m v a l v e a b o v e
a standard installaon of a cabinet.
Hose with steel
covered stocking
Incoming water pipe to ushing
nozzle with solenoid valve and
line strainer
Vacuum valve
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6.3. Connection of Machine Outlet to Water Trap and Sewer Pipe
Connecon of water trap and sewer pipe to the delivered disposer must be done by an authorized
installer of sewer supply and in accordance to valid local regulaons. The water trap is not included in
standard delivery but is available as an opon from Disperator.
6.3.1. Dimensions
The water trap and the sewer pipe must have the same dimensions as the outlet ange of the
disposer (i.e. DN50 for models 510, 515 and 520, and DN65 for models 530, 550 and 575), in
order to allow free wastewater ow from the disposer. No throling in the water trap and sewer
pipe may exsist.
6.3.2. Depth and Threshold of Water Trap
The depth of the water trap (measurement “d” in gure below) must be as small as possible in
order to obtain the best possible ow with the largest amounts of food waste. The water trap
must also be deep enough, so that the water threshold “d1” is approximately 100 mm for models
510, 515 and 520 and approximately 160 mm for models 530, 550 and 575.
6.3.3. Curves and Bends
The water trap, and all bends in the sewer pipe, must be drawn without sharp bends or curves,
according to local standards. The distance “k” in the gure below must be 100-120 mm for
models 510, 515 and 520 and 130-150 mm for models 530, 550 and 575.
6.3.4. Level Dierence of Water Trap
The level dierence (measurement “n” in gure below) must be at least equal to the inner
sewer pipe diameter, which is dependent on the wall thickness of the water trap (however
approximately 50 mm for disposer models 510, 515 and 520 and approximately 65 mm for
models 530, 550 and 575).
6.3.5. Slope of Sewer Pipe
The inclinaon of the sewer pipe (measurement “f” in gure below) should normally be 2:100
(minimum 1,5:100, maximum 3:100). Horizontal sewer pipes must always be avoided. Also
greater inclinaon than menoned above must be avoided, as the water then ows faster and
away from the waste.
6.3.6. Vacuum Evacuation
For installaons where the disposer is evacuated by means of a vacuum, a water trap must not be con-
nected to the outlet of the disposer. Instead, the disposer is connected directly to the collecon tank of
the vacuum system. It is important that the sewer pipe, between the disposer and the collecon tank,
has a venlaon pipe that is always open (as shown in the gure below). A venlaon pipe must be ed
even if the collecng tank has automac airing.
Venlaon pipe which
must always be open
Vacuum exhaust valveCollecon tank
Table of contents
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