Vernacare Vortex User manual

Issue No: 2

Machine number ..................................
Installation date .....................................
Commissioning date .............................
Machine location .................................
Technical Manual (Version 1.4)
230 volt single phase machine
Vernacare
MODEL NO. Vortex Amps/Hz 3.2 @ 50
SERIAL NO. PHASE 1~
DATE VOLTS 230
Read relevant manual prior to installation, use or repair of this machine
110 volt single phase machine
Vernacare
MODEL NO. Vortex Amps/Hz 4.4 @ 60
SERIAL NO. PHASE 1~
DATE VOLTS 110
Read relevant manual prior to installation, use or repair of this machine
For Customer Service please contact:
Customer Care Department
Vernacare Limited
Folds Road
Bolton
Lancashire
United Kingdom
BL1 2TX
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]

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
A Division of Vernagroup Limited
Folds Road
Bolton
Lancashire
United Kingdom
BL1 2TX
DATED 23/05/2016
AUTHORISING SIGNATURE
C.E.O of Vernacare Limited

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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 further details.
B. Conditions of warranty
1. The Vortex must be installed to the instructions provided in this technical manual.
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,
or available upon request from Vernacare:
Telephone: [phone] Fax: [phone]
E-mail: [e-mail]
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.

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Contents
Section 1 Specifications Page 06
Section 2 Installation / Commissioning Page 09
Section 3 General Description Page 15
Section 4 Outer Casing Page 17
Section 5 Motor Assembly Page 18
Section 6 Drain Valve Assembly Page 19
Section 7 Lid Arm Assembly Page 20
Section 8 Top Cover Assembly Page 22
Section 9 Lid Interlock Assembly Page 23
Section 10 Tub Vent Arrangement Page 24
Section 11 Water Distribution Page 25
Section 12 Electrical Circuit Page 27
Section 13 Periodic Maintenance Page 29
Section 14 Fault Finding Page 30
Appendix A Manual Pump and Outlet pushbuttons Page 39
Appendix B Motor Terminal Wiring Page 40
Appendix C Motor Electrical box plug and socket connections Page 41
Appendix D Orientation of Diodes for drain inlet and drain outlet Page 41
solenoid valve coil terminals
Important Information
Failure to comply with the instructions & recommendations contained within this manual
may impair the safe operation and reliability of the Vernacare Vortex.
Vernagroup Ltd, operate a policy of continuous improvement. Whilst every effort is made
to ensure that the information contained within this manual is correct, we reserve the right
to make technical changes.

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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 macerator 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.
Where supplementary protection is provided by an RCD/RCBO, this should be rated at
100mA.

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Note: The machine should not be switched off at the mains supply in mid-cycle 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 P Trap 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.

8
Figure 1 –Dimensions of the Vernacare Vortex

9
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” macerator should be positioned adjacent to the following:
a) A suitable power supply point.*
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 be provided
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 13 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 13 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.

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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.
An ‘Approved’ double check valve or some other no less effective device providing
backflow prevention protection to at least fluid category three shall be fitted at the
point of connection between the water supply and the Vortex. A servicing valve shall
be installed on the supply to the fitting in a readily accessible location.
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.
Points to watch:
Ensure that the supply line to the unit is at no point less than 15mm - larger if 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.
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.
Points to watch Part 1:
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.

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Points to watch Part 2:
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.
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.
Points to watch:
Ensure that the discharge from the overflow is visible.
Overflow 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.
A standard warning pipe installation kit is available. Contact Vernacare Customer Care
Department for details.
2.3 Electrical
2.3.1 Single-phase electrical system (230v, 1 Ph, 50 HZ) (110v, 1 ph, 60 HZ)
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.

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2.3.2 Back-up generator tests / mains electrical supply surges.
Damage to internal electrical components of the Vortex macerator can occur as a
result of voltage surges / spikes occurring In the electrical supply to 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 temperatures up 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.

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2.7 Display screen icons and warning messages –explanations
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).

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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
3.1 General description
The “Vernacare Vortex” macerator is designed to operate within a 2-minute cycle
using 25 litres +/-10% of water. The machine can dispose of up to four ‘Vernacare”
disposable pulp products, at one time.
The products are placed within the hopper; the lid is closed and secured by the
handle catch. The lid is closed against a moulded silicone section which gives an
effective seal whilst maintaining an abrasion resistant face.
When the lid catch is fully closed, the lid proximity sensor is made via a magnet and
the lid interlock is energised locking the lid. In the event of the solenoid failing, or the
lid-lock being physically disengaged, the interlock switch will stop the cycle.
The cycle is initiated by, momentarily, depressing the start switch, at which point the
machine will give an ‘audible sound’ and the cycle will commence. An auto-start
option is also available. Contact Vernacare for more information.
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 displayed upon the display screen and the cycle stopped. The Vortex will
remain in this condition until the fault is cleared.
When the fault has been rectified, the start switch is to be held on for approximately 5
seconds until there is an ‘audible sound’. This clears the display and resets the cycle to
its last state prior to the fault. The cycle will then continue.
The 2-minute cycle is controlled by a pre-programmed microchip, 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 cools the outer faces of the
mechanical seal and helps prevent ingress of dirt and fibres into the mechanical seal
cavity.
c) The diaphragm drain valve, where water is fed through the non-return and inlet
solenoid valve to the back of the diaphragm drain valve, the water outlet is shut off
by the normally closed outlet solenoid valve, and the developing pressure expands
the diaphragm drain valve to form a seal.
The combined water from a, b and c above builds up inside 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 by the vent valve and non-return valve
arrangement, i.e. the non-return valve prevents the egress of air from within the tub into
the atmosphere.

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With the pump switched off, the diaphragm valve stays sealed as the water behind it is
held by the non-return valve and solenoid valve.
During the period when the pump is running, the cutter motor starts up via the invertor
unit, and breaks up the products by a combined mechanical and hydraulic action into
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 which allows the pressurised water behind 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 requires re-filling.
Vernacare recommend the use of Vernacare macerator 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 interlock pin is withdrawn from the
lid catch and the lid springs to the open position.
Vortex Normal Cycle Sequence

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4 Outer Casing
Figure 2 - 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
9200532
3
3
LH Side Panel
9200533
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

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5 Motor Assembly
Figure 3 - Cutter Motor Assembly
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 (x1)
9200402
1.6
Mechanical Seal (x1)
9753005
2
Vortex Mechanical Seal Kit
9207006
(1.6)
Mechanical Seal
9753005
2.2
V Seal
9753000
2.3
M8 x 50 H.H.S.S
9750006
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
(also in kit 9207004)
9753010
3.8
D8 Spring Washer
9750033
4
4
Cutter Motor Assembly Kit
9207005

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6 Drain Valve Assembly
Figure 4 - Diaphragm Valve and Ancillary components
KIT
REF
PART DESCRIPTION
KIT NUMBER
ITEM NUMBER
1
Diaphragm and 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 x8
9200326
2.2
Three Lobed Nut x 8
9200327
3
3
Water Inlet/Outlet Solenoid Value
9200724
4
4
Non Return Value
9200726
5
5
Diaphragm Chassis
9200328
6
6
Plumbing Elbow
9200729

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7 Lid Arm Assembly
Figure 5 –Lid Arm Assembly