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Insinger Eliminator 900 User manual

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TECHNICAL MANUAL
For
Waste Handling System
Eliminator 900
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
800.344.4802
Fax 215.624.6966
www.insingermachine.com
Installation, Operation, and Maintenance Instructions
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48022
Thank you for purchasing this quality
Insinger product.
On the space provided below please record the
model, serial number and start-up date of this unit:
Model:__________________________________
Serial Number:___________________________
Start-Up Date:____________________________
When referring to this equipment please have this
information available.
Each piece of equipment at Insinger is carefully
tested before shipment for proper operation. If the
need for service should arise please contact your
local Authorized Insinger Service Company.
A Service Network Listing is provided on our web
site, www.insingermachine.com or call Insinger at
800-344-4802 for your local authorized servicer.
For proper activation of the Insinger Limited
Warranty a SureFire™ Start-Up & Check-Out
Service should be completed on your machine.
Refer to the Introduction section in this manual for
an explanation of Insinger SureFire™ Start-Up &
Check-Out Program.
Please read the Insinger Limited Warranty and all
installation and operation instructions carefully
before attempting to install or operate your new
Insinger product.
To register your machine for warranty by phone,
fax or the internet or for answers to question
concerning installation, operation, or service
contact our Technical Services Department:
Toll-Free 800-344-4802
Fax 215-624-6966
E-mail [email protected]m
Web www.insingermachine.com
TECHNICAL SERVICE CONTACTS
TABLE OF CONTENTS
Part 1
Technical Information
• Introduction
• Catalogue Cut-sheet & Installation Drawing
• Warranties
• Disclaimers
1-6
Part 2
General Overview
• General Overview
• Installation Instructions
7-10
Part 3
Operating Instructions
• Operation and Cleaning Instructions 11-12
Part 4
Maintenance
• Procedures
• Troubleshooting
13-17
Part 5
Recommended Spare Parts 18
Part 6
Electrical Schematics
• Machine Wiring Diagrams
• Control Panel Layout and Component Drawing
• Replacement Parts
19-24
Part 7
Replacement Parts
• Assembly Drawings 25-42
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48021
WASTE HANDLING SYSTEM
Eliminator 900
INTRODUCTION
Purpose
The purpose of this technical manual is to provide
installation, operation, cleaning and maintenance
directions.
A section is provided for replacement parts.
Scope
This manual contains all pertinent information to
assist in the proper installation, operation, cleaning,
maintenance, and parts ordering for Eliminator 900
Waste Handling System.
The installation instructions are intended for
qualified equipment installers. The operation and
cleaning instructions are intended for the daily
users of the equipment. The maintenance and
parts sections are intended for qualified service
and/or maintenance technicians. Replacement
parts may be ordered directly from our factory
or from your local Insinger Authorized Service
Agency. You can speak to the Insinger Technical
Services Department, 800/344-4802, or e-mail us
at service@insingermachine.com. When calling
for warranty information or replacement parts
please provide the model and serial number of your
Insinger Equipment. These important numbers
should be noted in this manual on the spaces
provided on the opening page.
Surefire™ Start-up & Check-out Program
Insinger is proud to offer our exclusive Surefire™
Start-up & Check-out Program to our commercial
customers. This service is included in the purchase
price of your new Insinger dishwasher. We will
provide an authorized factory service technician for
the initial start-up of your new Insinger dishwasher
to ensure it is running at optimum levels from the
very first pass. Please call the factory or your local
Insinger Sales Representative to schedule this
service.
PART 1 TECHNICAL INFORMATION
Chemical deodorizers and defoamers
This machine must be operated with an automatic
deodorant dispenser and, if applicable, an chemical
defoamer, including a visual means to verify that
deodorizers and defoamers are delivered or a
visual or audible alarm to signal if deodorizers
and defoamers are not available for delivery to the
respective pulping and extracting systems.
Please see instructions for electrical and plumbing
connections located in this manual and in the
feeder equipment manual.
CAUTION:
Indicates potential equipment damage.
þNOTE:
Indicates helpful operating hints or tips.
Definitions
Throughout this guide you will find the following
terms: WARNING, CAUTION, & NOTE.
WARNING indicates potential physical danger.
CAUTION indicates potential equipment damage.
NOTE indicates helpful operating hints or tips.
You will visually be able to identify each as
shown below:
WARNING:
Indicates potential physical danger.
!
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48022
WASTE HANDLING SYSTEMS
Safety Summary
The following are general safety precautions that
are not related to any specific procedures. These
are recommended precautions that personnel must
understand and apply during many phases of
operation and maintenance.
Power Down
Always disconnect main power feeding the ma-
chine when doing any type of cleaning or mainte-
nance in the pulping chamber or main electrical
control box.
Lock Out/Tag Out refers to the specific practice and
procedures to safeguard employees from the unex-
pected energization or startup of machinery and
equipment, or the release of hazardous energy dur-
ing cleaning, service or maintenance activities.
Keep Away From Live Circuits
Operating personnel must at all times observe all
safety regulations. Do not replace components or
make adjustments inside the equipment with the
high voltage supply turned on. Under certain con-
ditions, dangerous potentials may exist when the
power control is in the off position. To avoid casu-
alties, always remove power, red tag machine and
ground a circuit before touching it.
PART 1 TECHNICAL INFORMATION
WARNING:
Power Down before Cleaning or Serving!
!
þNOTE:
Use LockOut/Tagout (LOTO) to prevent
injuries during cleaning or maintenance..
Do Not Service or Adjust Alone
Under no circumstances should any person reach
into or enter the enclosure for the purpose of ser-
vicing or adjusting the equipment except in the
presence of someone who is capable of rendering
aid.
Resuscitation
Personnel working with or near high voltages
should be familiar with modern methods of resusci-
tation. Such information may be obtained from the
Bureau of Medicine and Surgery.
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48023
INSINGER MACHINE COMPANY LIMITED WARRANTY
Insinger Machine Company, Inc. (Insinger) hereby
warrants to the original retail purchaser of this
Insinger Machine Company, Inc. product, that if it
is assembled and operated in accordance with the
printed instructions accompanying it, then for a
period of either 15 months from the date of
shipment from Insinger or 1 year (12 months) from
the date of installation, that said Insinger product
shall be free from defects in material and workman-
ship. Whichever one of the two aforestated limited
warranty time periods is the longest shall be the
applicable limited warranty coverage time period.
Insinger may require reasonable proof of your date
of purchase; therefore, you should retain your copy
of invoice or shipping document.
This limited warranty shall be limited to the repair
or replacement of parts which prove defective under
normal use and service and which on examination
shall indicate, to Insinger’s satisfaction, they are
defective. Any part that is claimed to be defective
and covered by this limited warranty must be
returned to Insinger, this may be done through an
Authorized Service Agency. Furnish serial number
of machine with shipment and send to:
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
If Insinger’s inspection confirms the defect and the
claim, Insinger will repair or replace such part
without charge and return it to you freight or post-
age prepaid.
This limited warranty does not cover any failure or
accident, abuse, misuse, alteration, misapplication,
improper installation, fire, flood, acts of God or
improper maintenance or service, or failure to per-
form normal and routine maintenance as set out in
the instruction booklet (operating instructions) or
for improper operation or failure to follow normal
operating instructions (as set out in the instruction
booklet). Insinger is not responsible nor liable for
any conditions of erosion or corrosion caused by
corrosive detergents, acids, lye or other chemicals
used in the washing and or cleaning process.
Service must be done by either Insinger Appointed
Service Agencies or agencies receiving prior
authorization from Insinger.
All warranty work must be done during normal
working hours, unless purchaser receives prior
authorization from Insinger.
There are no other express warrants except as set
forth herein and any applicable implied warranties
of merchantability and fitness are limited in
duration to the period of coverage of this express
written limited warranty. This limited warranty
supersedes all other express warranties, implied
warranties of merchant-ability and fitness or
limited warranties as of this date, January 1, 1998.
Some states do not allow limitation on how long
an implied warranty lasts so this limitation may
not apply to you.
Insinger is not liable for any special, indirect or
consequential damages. Some states do not allow
the exclusion or limitation of incidental or conse-
quential damages, so this limitation nor exclusion
may not apply to you.
Insinger does not authorize any person or company
to assume for it any other obligation or liability in
connection with the sale, installation, use, removal,
return or replacement of its equipment: and no such
representations are binding on Insinger.
PART 1 TECHNICAL INFORMATION
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48024
PART 1 TECHNICAL INFORMATION
INSINGER MACHINE COMPANY LIMITED WARRANTY
COMMERCIAL MARINE USE
Insinger Machine Company, Inc. (Insinger) hereby
warrants to the original retail purchaser of this
Insinger Machine Company, Inc. product, that if it
is assembled and operated in accordance with the
printed instructions accompanying it (installation
manual), then for a period of 15 months from the
date of installation on board the vessel, that said
Insinger product shall be free from defects in
material and workmanship.
Insinger may require reasonable proof of your date
of equipment install, therefore, you should retain
your copy of invoice or shipping document.
This limited warranty shall be limited to the
replacement of parts which prove defective under
normal use and service and which on examination
shall indicate, to Insinger's satisfaction, they are
defective. Any part that is claimed to be defective
and covered by this limited warranty must be
returned to Insinger. Furnish serial number of
machine with shipment and send to:
Insinger Machine Company, Inc.
6245 State Road
Philadelphia, PA 19135-2996
If Insinger's inspection confirms the defect and the
claim, Insinger will repair or replace such part
without charge and return it to you freight or post-
age prepaid. If part damages are not covered,
Insinger will contact the customer and advise.
If a factory trained authorized technician is
required to repair or replace defective parts or ma-
terial during the 18 month warranty period, the
cruise line will be responsible for the payment of
travel expense and a minimum of four hours labor.
Labor will be billed to the customer at a reduced
rate of $40.00 per hour. If sailing with a vessel is
required, then an eight hour per day minimum will
apply.
This limited warranty does not cover accident,
abuse, misuse, alteration, misapplication, improper
installation, fire, flood, or improper maintenance or
service, or failure to perform normal and routine
maintenance as set out in the instruction booklet
(operating instructions) or for improper operation
or failure to follow normal operating instructions
(as set out in the instruction booklet).
Insinger is not responsible nor liable for any condi-
tions of erosion or corrosion caused by corrosive
detergents, acids, lye or other chemicals used in the
washing, caring and or cleaning process.
Warranty service must be done by either Insinger
Appointed Service Agencies or agencies, customers
galley engineers receiving prior authorization from
Insinger.
There are no other express warrants except as set
forth herein and any applicable implied warranties
of merchantability and fitness are limited in dura-
tion to the period of coverage of this express written
limited warranty. This limited warranty supersedes
all other express warranties, implied warranties of
merchantability and fitness or limited warranties as
the above date.
Insinger does not authorize any person or company
locally or overseas to assume for it any other
obligation or liability in connection with the sale,
installation, use, removal, return or replacement
of its equipment; and no such representations are
binding on Insinger.
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48025
PART 1 TECHNICAL INFORMATION
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48026
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48027
Waste Handling System
Eliminator 900
The Insinger pulping system includes a pulper and
extractor with several new innovations. The system
prepares food service waste for disposal in a re-
duced volume and easier to handle form. This
change is created by using the pulper which is cus-
tom designed to reduce paper, plastic, food, and
foil to small pieces.
PART 2 GENERAL OVERVIEW
Operators feed the waste to the continuous flowing
water trough which conveys the waste to the
pulper. Rapid rotation of the cutting blades creates
a strong vortex which pulls the waste into the cut-
ter. The combined force of the cutting blades and
the recirculation pump pulls the water/waste slurry
through the stainless perforated ring that surrounds
the rotating impeller.
Pulper DOC PULPER 1.0 06 www.insingermachine.com 800-344-48028
PART 2 GENERAL OVERVIEW
Just above the pulper discharge and drain assem-
bly is the recirculation pump, which moves the ex-
tracted water back to the feed trough reuse. Note
that this feature greatly reduces water usage. At
the discharge of the recirculation pump, there is an
adjustable gate valve. This valve is set at installa-
tion to balance level between pulper and extractor
and should only be adjusted by qualified mainte-
nance technicians.
Cutting Mechanism
The Insinger pulper is designed with a first class
cutting mechanism for improved waste processing
and reduced maintenance. The hardened stainless
steel cutting blocks can be rotated to get twice the
life before replacement. Also, both the stationary
cutting blocks and those attached to the impeller
are replaceable with a single allen wrench – without
removing the impeller.
The drive motor is vertically mounted to the under-
side of the slurry chamber and is held in place with
four stainless screws. The stainless motor shaft
protrudes through the impeller and is bolted directly
to a retainer plate. Between the impeller and the
machined tank bottom is a removable magnetic
seal that prevents the slurry liquid from leaking out
of the tank. On the bottom side of the impeller are
the pumping vanes which are bolted in place for
easy replacement. Surrounding the impeller is a
perforated stainless security ring which ensures
only small particles can pass through to the extrac-
tor in the slurry.
Piping
Water level is controlled by an engineered system
of solenoid valves, flow controls, and a level switch.
The heart of the water system on the pulper is the
recirculation pump, which re-uses water removed
from the slurry in the extractor and returns it to the
feed trough. A gate valve located downstream of
the pump allows flow adjustment to create balance
between the level in the pulper and extractor.
This slurry is passed to the extractor where the ro-
tating screw conveys the solid waste vertically. The
screw is surrounded by a perforated stainless
screen which allows the water to be separated and
recirculated to the pulper. Solid waste is forced
upwards by the screw and forms a semi-dry pulp at
the entrance to the compression area. Water is
then further extracted in this compression zone. As
the pulp enters the discharge area it is called a
plug. As the plug enters the top of the extractor, it
is broken down by a cutter attached to the rotating
screw. This action allows the semi-dry pulp to be
easily discharged into a waste receptacle.
Pulper
The Insinger Eliminator is the latest in pulping tech-
nology with many innovations for improved opera-
tion, maintenance and cleaning. Some of these
include: NSF clearance above the floor, full vibra-
tion isolation system, true one-piece tank, inte-
grated tubular support frame, adjustable feed
trough and lid orientations, reduced overall height
and cutting mechanism upgrades.
The pulper tank housing includes the trough flange,
lid and water feed connection. At the base of the
tank is the slurry chamber and precision cutting
mechanism. Mounted to the bottom of this cham-
ber is the single drive motor. This one-piece
stainless tank serves as the main structure with a
latchable top lid.
The entire structure is designed with full shrouding
of the electrical and piping, including the drive mo-
tor. This polished stainless housing is supported
on the integrated tubular framing and tied to the
one-piece tank for stability. Just downstream of the
pulper discharge the two removable side covers are
mounted to the frame. They support the piping in-
cluding the customer water and electrical connec-
tions.