Vernacare Vortex+ User manual

Vortex+ Technical Manual
www.vernacare.com NOV 2017

Vernacare Vortex+ Technical Manual
Contents
Declaration of Conformity Page 01
Warranty Page 02
Section 1 - Specifications Page 05
Section 2 - Installation & Commissioning Page 08
Section 3 - General Description Page 15
Section 4 - Outer Casing Page 17
Section 5 - Motor Assembly Page 18
Section 6 - Diaphragm Valve Assembly Page 19
Section 7- Lid Arm Assembly Page 20
Section 8 - Top Cover Assembly Page 22
Section 9 - Hopper Vent Arrangement Page 23
Section 10 - Water Distribution Page 24
Section 11 - PCB Page 25
Section 12 - Electrical Enclosure Page 26
Section 13 - Sensor Terminal Page 26
Section 14 - Additional Items & Kits Page 26
Appendix A- Manual Pump and Outlet Buttons Page 28
Appendix B - Motor Terminal Wiring Page 29
Appendix C - Motor Electrical Box Plug & Socket Connectors Page 30
Appendix D - Orientation of Diodes for Solenoid Valve Coil Terminals Page 30
Appendix E - Suggested Periodic maintenance Page 31

Page | 3
Declaration of Conformity
VERNACARE Declare that this declaration has been issued under the sole
responsibility of the manufacturer. The object of the declaration is in conformity with the
relevant Union harmonisation
PRODUCT Vernacare Vortex / Vortex + Macerator
DIRECTIVE EC Directive 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
Folds Road
Bolton
Lancashire
United Kingdom
BL1 2TX
DATED 23/05/2016
AUTHORISING SIGNATURE
C.E.O of Vernacare Limited

Page | 4
Warranty
A. Warranty terms
1. The warranty is for 12 months from the date of commissioning or 18 months from the
date of delivery, whichever is the shortest period.
2. The warranty will cover parts and labour.
3. The warranty will not cover customer damage or abuse.
4. Warranty requests should be submitted in writing, quoting the machine number, date
of commissioning and the machine fault.
5. The warranty will not affect your statutory rights, or rights given in the company’s
Terms and Conditions of Sale.
6. Extended warranties are available. Contact Vernacare for furtherdetails.
B. Conditions of warranty
1. The Vortex+ must be installed to the instructions provided in this technicalmanual.
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, oravailable
upon request from Vernacare:
Telephone: [phone] Fax: [phone]
E-mail: se[email protected]m
C. Service Contracts
To ensure continued reliability and performance, service contracts are available.
All warranty and service contract work will be carried out by Vernacare Technical
Services, a division of Vernacare Limited OR in the case of an overseas installation,
warranty and service contract work will be carried out by a Vernacare approved
technician.

Page | 5
1 Specifications
1.1 Capacities and usage
The “Vernacare Vortex +” macerator will dispose of a maximum of four “Vernacare”
disposable products such as bedpan liners, bottles etc. together with their contents in a
single cycle. Please note due to their physical size only two Vernacare wash bowls
may be disposed of per cycle.
Products should be placed in the Vortex + one at a time and should not be stacked inside
each other.
Do not stack products inside each other or attempt to dispose of more than four items
in a single cycle as this will impair the effective operation of the machine and in severe
cases, may cause the motor to stall. It is considered good practice to operate the
machine each time a utensil is placed into the machine.
Do not place string, wipes, plastic or metal items inside the machine 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 still attached to the pallet provided.
1.4 Electrical specification
The machine is supplied with a 3-meter length of 1.5mm flex, which shall be connected
to either:
230 Volt Machine –16 Amp MCB to BS EN60898 Type C or alternatively fused 16 Amp
to BS EN60269-1. 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 16 Amp
to BS EN60269-1. An appropriate I.E.C Approved 16 Amp isolator shall be installed in
both cases.
It is recommended that the disposal unit is supplied by a dedicated circuit.
Where supplementary protection is provided by an RCD/RCBO, this should be rated at
100mA.
Note: The machine should not be switched off at the mains supply in mid-cycle

Page | 6
except in case of emergency, as this will impair the effective operation of the
machine and may cause damage to the components.
1.4.1 Motor
1.1 KW; 3 Phase; 220-240v 50Hz/ 380-420v 50Hz; IP55; D90 frame size. Rating at
peak load 4.57 amps (nominal).
1.4.2 Invertor
AC invertor with either 110v or 230v supply voltage, 230v motor output and utilising
current monitoring.
1.4.3 Pump
0.27 kW; 24vdc; 50 cycles. 40 l/min at 5 lbs/in². 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 PTrap 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/32mm tank connector is supplied, which should be used to connect the
water tank warning pipe to a separate drain line, according to the relevant water
regulations.
A standard warning pipe installation kit is available. Contact Vernacare Customer Care
Department for details.

Page | 7
150mm Clear each side
100mm Clear at rear
Deodoriser
fill cap
NOTE:
Water inlet & warning pipe
connections can be made to
either the left or right hand side
of the machine.
2" Drain
Connector
ALL DIMENSIONS IN mm
2 Mounting
Holes Ø9
Dimensions of the Vernacare Vortex +
Water Inlet
½’’ BSP Male
Warning Pipe
Connection
(drain)
with lid open
!IMPORTANT!

Page | 8
2 Installation / Commissioning
Installation
Note: Installation of this equipment should only be carried out by a suitable
qualified person.
2.1 Siting and fixing
The “Vernacare Vortex +” disposal unit should be positioned adjacent to the following:
a) A suitable power supplypoint.*
b) An adequate water supply line.
c) A suitable drainage connection.
Check the floor area is firm and level. The unit must be bolted down using the holes
provided. Mark out the bolt positions on the floor and fit bolts utilizing the
dimensions given in Figure 1.
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.
Important- To comply with UK WRAS regulations sufficient clearance must beprovided
to allow water to freely discharge from the 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 16 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 16 Amp
to I.E.C 60269-4. An appropriate I.E.C Approved 16 Amp isolator shall be installed in
both cases.
Where supplementary protection is provided by an RCD/RCBO, this should be rated at
100mA.
For all installations, an I.E.E. approved disconnection device must be fitted to the
final installation. This device shall be positioned in close proximity to the Vortex and
within easy reach of the operator & shall also be clearly marked as being the
disconnecting device for the machine.
For installations where the height of the existing drain causes difficulty a plinth is
available which may be utilised in order to raise the height of the Vortex so that
better alignment is achieved.
Please contact Vernacare for further information

Page | 9
2.2 Plumbing
2.2.1 Water supply
The machine should be connected to a suitable cold water supply as follows:-
The connection to the machine water tank is made at the upper rear left or right hand
side corner of the machine. It is a standard connection to a 1/2 inch BSP float-type
cistern valve. This can be made in rigid or flexible piping, according to customer
preference. Flow rate should be 18 litres per minute (4 gallons/minute) minimum, into
the water tank, which holds sufficient water for a complete cycle.
Note: The inlet flow valve is supplied already fitted with a flow restrictor in place. The
restrictor should be left in place on tank fed installations with heads above 50ft or mains
fed installations with pressures above 1.5 bar (25psi). In all other circumstances the flow
restrictor is not required.
2.2.2 Drain connection
The “Vernacare Vortex +” is fitted with a 2 inch/50mm ‘P’ Trap. In order to connect to the
drain, it is necessary to cut a minimal clearance hole in the plastic drain access cover
located at the rear of the machine below the water tank. It is important to ensure that the
drain access cover is fitted so as to prevent access to internal electrical components.
The drain is secured by tightening the compression fitting on the ‘P’ Trap onto the
inserted plastic pipe. The free area below the water tank allows for the fitting of a swept
bend if required.

Page | 10
2.2.3 Overflow - Warning Pipe
The Vortex Is supplied with a 32mm (1 ¼“) tank connector which should be installed
using one of the predrilled holes in either the Left Hand side or Right Hand side of the
water tank. It is Important that any discharge from the warning pipe is visible.
A standard warning pipe installation kit is available. Contact Vernacare Customer Care
Department for details.
Points to Watch
Ensure that the supply line to the unit is at no point less than 15mm or larger is 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.
Ensure that the route taken to soil drain is the shortest, with minimum number of bends. If
necessary, use long radius or ‘swept’ bends - never short or 90’ elbows.
The waste must be run separately to the soil stack or drain.
Ensure that there is a fall of a minimum of 1 in 25 or a sufficient fall to maintain a self-
cleansing velocity.
Provide easy access for Roding.
Ensure a clean run inside the pipework - leave no burrs or reducing shoulders.
With plastic pipework, ensure that there is no reduction in the bore size and that there is
adequate support for horizontal runs to prevent sagging. Remember, ceiling voids can get
very warm.
Avoid running the drain line near or across hot water pipes.
Anti-syphon precautions should be in line with general practice.
Ensure that the discharge from the warning pipe is visible.
Warning pipe arrangement must include an air break prior to a connection to a drain.
Waste must be run separately to soil stack or drain.
Do not reduce the diameter of the warning pipe at any point.

Page | 11
2.3 Electrical
2.3.1 Single-phase electrical system (230v, 1 Ph, 50 HZ) (110v, 1 ph, 60HZ)
The machine is supplied with a 3 metre length of 1.5mm flex to BS6500 which
shall be connected to:
•230 Volt Machine –16 Amp MCB to BS EN60898 Type C or fused 16 Amp to
IEC 60269.
•110 Volt Machine –16 Amp MCB to BS EN60898 Type C or fused 16 Amp to
IEC 60269.
Notes:
1. All electrical installation to comply with current I.E.E.regulations.
2. Mains supplies to be protected by:
1 Phase 230v ......... 16 Amp approved I.E.C. fuse.
1 Phase 110v…….. 16 Amp approved I.E.C. fuse.
3. For all installations, an I.E.E. approved disconnection device must be fitted to the
final installation. This device shall be positioned in close proximity to the Vortex and
within easy reach of the operator & shall also be clearly marked as being the
disconnecting device for the machine.

Page | 12
2.3.2 Back-up generator tests / mains electrical supplysurges.
Damage to internal electrical components of the Vortex macerator can occur as a result
of voltage surges/ spikes occurring in the electrical supplyto the machine. The likelihood
of such damage occurring is increased when frequent testing of back-up electrical
supplies are carried out.
To prevent such damage, Vernacare recommends that transient voltage suppressors(in
accordance with IEC class 3 surge protection) be installed in the electrical supply to the
machine.
2.4 Environment
Indoor use only. Altitudes up to 2000m. Temperatures 5C to 40C.
Maximum relative humidity 80% for temperaturesup to 31C, decreasing linearly to 50%
relative humidity at 40C.
Mains supply voltage fluctuations not to exceed +/- 10% of nominal 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, diaphragm valve, deodoriser feed etc.
Note: For warranty, service or repair please quote the machine serial number which can
be found clearly marked upon the rating plate which is positioned on the RH side, bottom
front of the machine.
2.6 Warning labels and icons –explanations
Please refer to the technical manual prior to installation, maintenance
or operation of this equipment.
Symbol indicates presence of 230v 50hz/ 415v 3phase 50hz electrical
supply.
Start Cycle –Press this button to start the machine. An auto-start option is also
available. Contact Vernacare for more information.

Page | 13
2.7 Display screen icons and warning messages –
explanations
ERROR
DESCRIPTION
RUNNING
The machine has been started and is running through its cycle.
END
The machine has finished the cycle and is ready to open.
BLOCKED BLADES
The motor invertor has defaulted to overload due to a blockage of the
machine cutter blades.
BLOCKED DRAIN
The pressure transducer has sensed an over pressure in the chamber
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 water tank reservoir is full.
The lid is open.
The lid is closed.
The drain is blocked.
The foot sensor has been operated.
(For details of the fault finding guide see section 14 page 29).

Page | 14
2.7.1 Cycle Counter
At the end of each cycle the LCD screen will briefly display the TOTAL cycle count for
the machine and also the SERVICE count which is the number 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.

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3 General Description
3.1General description
The “Vernacare Vortex +” disposal unit is designed to operate within a 2-minute cycle
using 24 litres +/-10% of water. The machine can dispose of up to four ‘Vernacare”
disposable single- use products, at one time.
Disposable single-use products are placed within the hopper. Activation of the foot
sensor causes the lid to descend and lock when in the fully closed position. The lid is
closed against a moulded silicone section which gives an effective seal whilst
maintaining an abrasion resistant face.
Sensors in the lid actuator and lid lock ensure that the lid is fully closed & physically
locked. Failure or loss of signal from either sensor will prevent / stop the cycle. Once the
lid is fully closed and locked the cycle is initiated automatically, at which point the
machine will give an ‘audible sound’ and the cycle will commence
The display screen will then indicate the machine is ‘Running’ and the icons at the
bottom of the screen will show the status of operation. (See section 2.7)
In the event of low water level, blocked blades or power failure, the fault will be clearly
indicated upon the display screen and the cycle stopped. The Vortex+ will remain in this
condition until the fault is cleared by following the instructions on the display screen.
The 2-minute cycle is controlled by a microprocessor, which controls the operation and
timing of the water pump, the cutter motor and the inlet, outlet and deodoriser solenoid
valves.
Shortly after commencement of the cycle, the water pump starts to take water
from the reservoir tank and pumps it to the following areas:
a) The lid spray, which provides a curtain of water, which washes over the lid and tub
sides and provides the bulk of the ‘tub fill’ water.
b) The mechanical seal flush, which flushes and lubricates the faces of the
mechanical seal to prevent ingress of pulp fibres into the mechanical sealcavity.
c) The drain diaphragm valve, where water is fed through the non-return and inlet
solenoid valve to the back of the drain diaphragm valve, water outlet is shut off by the
normally closed outlet solenoid valve, thus developing pressure expands the drain
diaphragm valve to form a seal.
The combined water from a, b and c above enters the tub whilst the pump runs for a
pre-set time period to put 12 litres (+/- 10%) of water into the tub.
When the outlet valve has closed and the volume of water is building up in the tub, the
displaced air is vented away through the drain via the vent valve and non-return valve
arrangement, i.e. the non-return valve prevents the egress of foul air from within the tub
into the atmosphere.
With the pump switched off, the diaphragm valve remains sealed as the water behind
It is restrained by the non-return and solenoid valves.
During the period whenthe pump is running, the cutter motor starts up via the inverter unit,
and breaks up the products by a combined mechanical and hydraulic action into

Page | 16
small particles which can be easily flushed down the drain.
If the cutter motor is initially stalled by bottles blocking the blades, the invertor will reverse
the blades and attempt to cut through the blockage again. This will be attempted three
times before a ‘Blocked Blade’ fault is displayed. At which point the lid is to be opened
and the blockage removed.
Approximately three-quarters of the way through the cycle the pump restarts to give a
dilution flush of an additional 12 litres (+/- 10%) to the tub and its contents.
At the same time the inlet solenoid valve closes thus preventing additional pumped water
from reaching the drain diaphragm, as the inlet solenoid valve is closed and the outlet
solenoid valve opens whichallows the pressurisedwaterbehind 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
dispensed from the storage reservoir into the chamber removing any odours that may be
present. In the event of the deodoriser reservoir being empty, the cycle will continue but
the icon on the display will indicate the tank is empty and requiresre-filling.
Vernacare recommend the use of Vernacare Vortex+ disposal unit deodoriser
(902DL1000, 902DL2000, 902SD1000, 902SD2000).
The water pump then stops, the outlet solenoid valve closes a second later and then the
overall cycle program ends. The display will indicate `End`.
The Vortex+ will remain in this condition with the lid locked until the foot sensor is
operated. When the infra red beam is broken by the insertion of the operator’s foot into
the foot well at the bottom front of the machine, the lid lock disengages and the lid
actuator opens the lid.
Vortex+ Normal Cycle Sequence
Pump
ON ON OFF ON ON ON ON ON ON
Motor Forward
OFF ON ON ON ON ON OFF ON OFF
Motor Speed 1 (55Hz)
OFF ON ON OFF OFF OFF OFF OFF OFF
Motor Speed 2 (66Hz)
OFF OFF OFF ON ON ON OFF ON OFF
Deodoriser Valve
OFF OFF OFF OFF ON OFF OFF OFF OFF
Inlet Solenoid
ON ON OFF OFF OFF OFF OFF OFF OFF
Outlet Solenoid
OFF OFF OFF ON ON ON ON ON ON
Cycle
End
Step
9
(120s)
Step
8
(114s)
Step
7
(105s)
Step
6
(104s)
Step
5
(103s)
Step
4
(94s)
Step
3
(46s)
Step
2
(17s)
Step
1
(2s)
Start
Cycle

Page | 17
SECTION 4: Outer Casing
KIT
REF
PART DESCRIPTION
KIT NUMBER
ITEM NUMBER
1
Front Cover 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
9200610
3
3
LH Side Panel
9200611
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
4.1
4.2
1.1
1.3
1.2

Page | 18
SECTION 5: Cutter & Motor
1.1
1.4
1.3
1.21.53.43.1
3.8
3.6
3.5
3.3
3.7
3.2 2.2 1.6
KIT
REF
PART DESCRIPTION
KIT NUMBER
ITEM NUMBER
1
Vortex Motor Kit
9207004
1.1
Electric Motor 230V/400V 3Ph 50Hz
9200424
1.2
Motor Gasket
9752027
1.3
Barbed Fitting
9750100
1.4
Vortex Motor Cable
9200693
1.5
Cutter Motor Adaptor
9200402
1.6
Mechanical Seal
9753005
2
Vortex Mechanical Seal Kit
9207006
(1.6)
Mechanical Seal
9753005
2.2
V-Seal
9753000
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 Gasket
9753010
3.8
D8 Spring Washer x2
9750033
4
Cutter Motor Assembly Kit
9207005

Page | 19
SECTION 6: Diaphragm Valve
1.1
5
3
4
3
6
1.3
1.2
2.2
2.1
KIT
REF
PART DESCRIPTION
KIT NUMBER
ITEM NUMBER
1
Diaphragm & 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 x 8
9200326
2.2
Three Lobed Nut x 8
9200327
3
3
Water Inlet/Outlet Solenoid Valves
9200724
4
4
Non Return Valve
9200726
5
5
Diaphragm Chassis
9200328
6
6
Plumbing Elbow
9207043

Page | 20
SECTION 7: Lid Arm Assembly
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.20
1.22
1.23
1.24