Insinger ELIMINATOR 900 is an industrial waste handling system designed to eliminate waste and improve efficiency in various commercial settings. This machine is equipped with advanced features for optimal performance, including:
- Automatic deodorant dispenser to eliminate unpleasant odors
- Chemical defoamer to prevent excessive foaming during the waste handling process
- Visual indicators to monitor the availability of deodorizers and defoamers, ensuring continuous operation
- Compatibility with an optional automatic detergent dispenser for hassle-free cleaning and maintenance
- A durable construction for longevity and reliability in demanding environments
Insinger ELIMINATOR 900 is an industrial waste handling system designed to eliminate waste and improve efficiency in various commercial settings. This machine is equipped with advanced features for optimal performance, including:
- Automatic deodorant dispenser to eliminate unpleasant odors
- Chemical defoamer to prevent excessive foaming during the waste handling process
- Visual indicators to monitor the availability of deodorizers and defoamers, ensuring continuous operation
- Compatibility with an optional automatic detergent dispenser for hassle-free cleaning and maintenance
- A durable construction for longevity and reliability in demanding environments
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
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
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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.
þ
NOTE:
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.
!
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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!
!
þ
NOTE:
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.
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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
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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.
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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.
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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.
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PART 2 GENERAL OVERVIEW
Control Logic Description
The pulper power is applied by pulling out the
ESTOP buttons. Turn the START/STOP switch to
ON. Limit switches and Overloads are checked
and if they are OK, CR1 is energized (pulled in)
passing power to the fill circuit. SOL1 power is ap-
plied until level is met and the time delay T1 has
passed. When level switch is made, CR2 relay en-
ergizes passing power to the run circuit. The op-
erator must press the START pushbutton to pull in
the pump and press extractor motor starters. The
Normally Open (NO) contact on M1 seals the run
circuit and M2 (pulper motor) contactor energizes.
The system should now be running.
If any motor overload is tripped, CR1 drops out,
stopping the entire system by dropping out CR2.
When the Overload is reset, CR1 pulls in allowing
the fill circuit to restart and automatically fill if
needed. The operator must wait until the fill cycle
is completed then press the START push button to
run the motors.
During running, SOL2 is energized, allowing water
to flow to the seal flush and to the pulper refresh at
approximately 1 to 2 gallons per minute. When the
level drops in the extractor for time delay T1, SOL1
is energized for quick fill.
When the selector switch is turned to OFF, timer T2
is energized and as long as M1 was already ener-
gized, (the system is already running), SOL3 is en-
ergized. Thus the extractor spray down cycle be-
gins. For time delay T2 (approximately 5 minutes)
the pulper will continue to run while spraying hot
water on the extractor screen. At the end of the
time delay, the system stops because T2 contacts
change state.
At start-up, the pulper fills to the level determined
by the switch in the extractor. When the pulper first
starts, water is pulled by the recirculation pump into
the feed lines and trough. If water level drops be-
low that set by the switch, the fast feed solenoid
turns on to quickly restore system balance. To
keep the pulping system clean and free of odor a
small amount of fresh water is constantly intro-
duced to the system by the refresh solenoid. This
solenoid also provides the water flush for the mag-
netic seal, which helps seal longevity by eliminating
build-up of pulped material.
Extractor
The Insinger Eliminator, close-coupled pulping
system includes an innovative water extractor that
makes cleaning and maintenance easier. One of
the key design attributes is the bottom mounted
drive for simple screw and screen removal from the
top. Other improved functionality includes adjust-
able discharge locations, full NSF clearance AFF,
and round tank with standard spray system for
easier cleaning.
The slurry input chamber forms the base for the
extractor, with the one inch thick machined plate as
both a gear box support and seal housing. The au-
ger screw is centered in the input chamber and
rides on a bottom bearing. The rolled stainless tank
houses the extractor screen and auger. A latchable
side door creates easy access to the tank internals,
including the spray cleaning system and overflow
drain. At the top of the tank is the compression
chamber, where the “plug” of semi-dry waste enters
the discharge chute and is broken down by the plug
cutter. The discharge chute has an access door
with draw latch and limit switch for controlled ac-
cess to the top of the extractor.
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Mechanical connections
The pulper and extractor are supplied with adjust-
able leveling feet and rubber vibration isolation
pads. The machine should be set on the floor with
the pads under all feet and leveled prior to bolting
to the floor.
PART 2 GENERAL OVERVIEW—INSTALLATION
Chemicals
The pulper is supplied with a pre-wired and mounted
ready to use deodorizer or defoamer dispenser.
Upon completed installation of the pulping system,
contact a local chemical supplier for the correct
chemicals for your area.
Note: A proper detergent/deodorant combination is
recommended. This will ensure a clean, odor free
system.
CAUTION:
As with any 3 phase wiring system, an electrician
should check all motors for proper phasing. Pump
should be rotating in the direction indicated by arrow on
housing. Also, pulper and extractor should be rotating
CCW when viewed from above.
INSTALLATION INSTRUCTIONS
Eliminator 900
Waste Handling System
Electrical Connections
The pulper comes pre-wired (single point connection)
to a junction box that is mounted on the machine.
All machine devices are wired to this junction box.
Also, the machine is supplied with a wall mounted
electrical enclosure. The electrical connection for
this single point set-up requires running a conduit
from the J-Box to the enclosure and terminating as
shown on the installation drawing.
þ
NOTE: The main power feed (by customer)
must be made to a circuit breaker or fused
disconnect as required by local codes.
þ
NOTE: A wiring diagram is provided inside
the control panel and should be returned
when finished.
Main Electrical Enclosure
The main electrical enclosure is designed to be
mounted on a wall according to local codes or as
shown on installation drawing.
þ
NOTE: Floor should be minimum 4” thick
concrete for accepting the recommended 3/8
inh diameter anchors. All feet should be
bolted to the floor with vibration pads under
each foot.
þ
NOTE: Do not reduce the size of the lines
as shown on the installation drawing. All
lines are sized to facilitate necessary flows,
pressures, etc.
Connect hot and cold water supply to the supplied
connections as labeled. The connections supplied
are shown on the installation drawing.
Connect from the drain line to the floor sink as
shown on the installation drawing. IT IS
STRONGLY RECOMMENDED THAT CLEAN OUT
PROVISIONS ARE MADE IN THE DRAIN LINE.
Small ‘fines’ are generated in the pulping process
and in some case may slowly clogged drain lines.
þ
NOTE: Provide Clean Out Connections in
the Drain Line.
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Insinger equipment is user-friendly, making it the
easiest equipment on the market to operate and
maintain.
By following these operating procedures your
Insinger equipment will give you years of trouble
free service.
PART 3 OPERATION & CLEANING PROCEDURES
OPERATION INSTRUCTIONS
Directions for Operation of Pulper & Extractor
Close-Coupled system
Start-Up Instructions
1. Turn on the main power switch on the electrical
control panel.
Shutdown Instructions
1. At the end of the waste feed, pulping of card-
board and other non-food waste is recom-
mended to allow the system to remove food
waste.
2. Turn the Selector Switch to OFF(CLEAN).
3. The unit will run for approx. 5 minutes including
automatic spray down of the extractor with HOT
water.
4. The unit will automatically stop after the 5 to 15
minute delay.
5. Open the drain valve to empty all water from
the pulper system.
Waste Feeding Instuctions
1. TYPE OF MATERIAL: In general the Insinger
Eliminator is designed to handle standard food
service waste consisting of a mix of food, paper,
Styrofoam trays, plastic utensils, cardboard,
plastic cups and other disposables. Other mate-
rials should never be fed into the pulper.
2. FEED RATE: It is important to feed pulpable
waste in the trough at a uniform rate. “Slugging”
or forcing large amounts of waste into the pulper
at intermittent intervals will actually result in re-
duced waste capability and should be avoided.
3. DEBRIS and METAL: Occasional non-pulpable
items like silverware, cans and foil will get into
the waste stream. The pulper is designed to
handle small amounts of these items and the
lighter materials will be pulped and sent out the
extractor. However, heavier items will be cap-
tured either by the silver catch in the trough or by
the silver saver in the pulper tank. Both these
catch areas should be cleaned out daily accord-
ing to the cleaning instructions.
2. Close the drain on the pulper. Make sure the
doors are closed and latched.
þ
NOTE: An emergency stop PB’s are
located on the electrical panel and on the
machine operator station. Either of these
buttons shut the entire pulper system down.
Be sure to check that they are in the ON (out)
position prior to trying machine start-up.
3. Make sure feed water valves are open.
4. Pull all ESTOP buttons to the out position (ON)
by rotating CW and gently pulling toward your-
self.
5. Turn the Selector Switch to ON.
6. The pulper will begin to fill. When the fill is
complete press the START PB. The pulping
system will being running. Wait a few minutes
to allow water levels to stabilize and then begin
feeding waste in a uniform fashion.
þ
NOTE: An interlock is provided to shut the
machine down if the doors are open, there-
fore the machine will not run if doors are
opened.
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PART 3 OPERATION & CLEANING PROCEDURES
CLEANING PROCEDURES
Daily
The following procedures should be done daily, at
the end of the shift and between meal times where
applicable.
1. While pulper is running in full Auto, turn the
selector switch to OFF. The unit will run
through the automatic spray cycle.
2. When the unit stops open the main drain valve
to allow all water to leave the system.
3. Open the pulper doors and LOCK-OUT electri-
cal power at the electrical panel.
4. Remove any debris left in the pulper.
DAILY OPERATOR CHECKS:
1. During machine operation check for proper wa-
ter level and flow balance. If water level is in-
correct or fluctuating refer to water level set-up
procedure below.
2. Insure that there is no debris or fouling matter
on the level probe. Clean daily.
þ
NOTE: Be careful of sharp metal and
glass left in the pulper when cleaning out
the tank.
5. Spray down the pulper and extractor interiors,
paying particular attention to the extractor
screen and Level Probe and pulper cutting
mechanism.
6. Wipe down the exterior of the equipment.
þ
NOTE: The level probe must be kept clean
of debris and fouling matter in order for the
machine to operate properly.
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PART 4 MAINTENANCE
ANNUAL INSPECTION:
1. Inspect cutting mechanism for wear. The blade
edges should be free of nicks and gouges. If
impeller blades are dull, damaged, or missing,
rotate them if there is a sharp edge available;
otherwise replace blades.
2. Inspect condition of solenoid valve seats and
diaphragms according to valve disassembly di-
rections below.
3. Inspect pump and pump motor including pump
impeller for damage or broken vanes according
to disassembly directions below.
Solenoid Valve Disassembly
1. Disconnect power supply to machine at main
electrical panel and lock-out. Turn off water
supply.
2. Remove cap on top of coil. Remove coil.
3. Remove 4 hex bolts and lift bonnet from valve
body. Note positioning of spring and plunger.
4. Remove main piston.
5. Inspect for dirt, wear or lime build-up. Clean or
replace as required.
6. Reassemble in reverse of disassembly
Pump Disassembly
1. Before disassembling pump ensure there are
no obstructions in the pump intake.
2. The pump discharge has a union connection for
easy disassembly. Loosen the union connec-
tion to separate the pump from the discharge
piping.
3. Remove the pump impeller housing and impel-
ler by removing the 4 hex bolts attaching them
to the pump motor.
4. Inspect impeller for damage or excessive wear.
5. Repair or replace the pump parts as required.
6. Reassemble in reverse of disassembly.
þ
NOTE: LOCK-OUT of electrical power is
required prior to any maintenance proce-
dures. Shut-down the pulper according to
normal operation procedures and LOCK-OUT
electrical power at the electrical panel.
ANNUAL INSPECTION AUGER BRUSH:
1. Unbolt the 8 allen head screws at the top
of the extractor housing.
2. Remove the discharge chamber and
chute.
3. With gloves on, lift the screw and screen
out of the extractor.
4. Clean screw and screen with detergent
and hot water spray down.
5. Inspect both items for wear: The brush
attached to the screw should extend past
the screw approximately 1/8”. The screen
should be consistent thickness with a
consistent small hole pattern and no obvi-
ous wear points. If brush replacement is
required due to wear or damage follow the
directions in procedures section below.
Auger Brush Replacement
1. Unbolt Auger brush clamps.
2. Remove old brush.
3. Install new brush by rotating onto the screw and
aligning under the clamps.
4. Set brush to outside diameter 6 1/8”, which is
1/8” overlap with stainless screw flights outside
diameter.
5. Tighten bolts as you work down the screw.
6. Reassemble in reverse of disassembly.
MAINTENANCE PROCEDURES
þ
NOTE: When blade edges appear overly
worn, damaged, missing or the pulper is un-
able to cut material at proper rate maintenance
is required.
Pulper DOC PULPER 1.0 06
www.insingermachine.com 800-344-480214
PART 4 MAINTENANCE
12. If the level in the extractor appears continually
low, close the gate valve a few turns.
13. If the level in the extractor appears high
(constant fast overflow to drain), open the gate
valve a few turns.
14. Each adjustment should be followed by a wait-
ing period to see if system balances in 1 to 2
minutes.
þ
NOTE: If the level switch appears to be
malfunctioning, stop the system and open the
extractor door. Placing your hand in front of
the level switch well should illuminate the
LED. If you are unable to get a response
from the LED check wiring connections.
Water Level Set-up
1. Turn on system power and water connection.
Make sure drain is closed.
2. Pull-out all EStop PB’s and close pulper and
extractor doors.
3. Turn Selector switch to On (fill), the pulper will
start filling with water.
4. When the level reaches the level switch the liq-
uid level timer is engaged. You will notice the
level switch red LED is illuminated at this point.
5. After the time delay from the control timer pic-
tured below, the fill is stopped.
6. Level can be increased and decreased by turn-
ing the slotted adjustment screw as shown.
7. Set the gate valve just down stream of the
pump by turning to approximately ½ open.
8. Turn on the pulper by pressing the green Start
PB. You should notice that the pump begins
running and pulling water into the feed trough.
Also, when the pulper begins running, the re-
fresh water should be constantly flowing into
the pulper tank.
9. If the level drops below the level switch in the
extractor the fast fill solenoid will turn-on to fill
the pulper quickly.
10. After about 1 – 2 minutes the system should
balance. With a small amount of overflow to the
drain approximately equal to the 1 – 2 gal per
min of refresh.
11. The proper level in the pulper is just below the
bottom of the trough. The proper level in the
extractor is at the level switch which is notice-
able by the protruding white housing on the in-
side of the extractor tank.
Pulper DOC PULPER 1.0 06
www.insingermachine.com 800-344-480215
PART 4 MAINTENANCE
Pulper Seal Replacement
Remove the fasteners holding the sizing ring. Use
2 fasteners as jack screws in the threaded holes
180 degrees apart on the sizing ring face. Once
freed, remove the ring. Remove the Cutting Disk,
by wedging a piece of wood between the cutting
disk and tank bottom to prevent spinning. Loosen
and remove top bolt and 4 radial bolts from center
cap. Remove center cap. Pull cutting disk straight
up. Be careful to not lose the square key. Once
removed, the cutting disk should contain the upper
seal. Slide this off and discard. Clean shaft of
debris. Carefully pick out lower magnetic seal from
bore and discard.
Magnetic seals should remain in packaging until
ready for installation in unit. When inserting the
seal in place, make sure no dust or foreign matter
are attached to the seal. Make sure the seal cavity
is clean of debris. Make sure there are no sharp
objects on any contact parts.
When the seal is removed from packaging, the ro-
tor portion of the seal (seal case) must be sepa-
rated from the magnet. Pull seal case straight
away from magnet. Discard paper separator.
MAKE SURE THAT YOU DO NOT INSERT THE
LOWER SEAL UPSIDE DOWN! Each half of the
seal should face each other as they did in the origi-
nal packaging. The highly polish surface of the bot-
tom seal faces the magnet surface of the upper
seal.
Caution: To prevent damage to mating faces, do
not slide seal case across magnet. Avoid placing
magnet in area where small metal chips might be
attracted by the magnet.
Remove o-rings and completely lubricate with a
thing film of lubricant and reinstall into grooves.
Apply a thin film of lubricant to the o-ring sealing
surfaces in the bore and on the shaft
Press lower seal into bore gently with the polished
magnet face position upward. Do not use any tools
to do so. Verify that no debris is on the seal face.
Gently slide the upper seal on the cutting disk shaft
so that it is no more than 3/4” from the shaft bot-
tom. Make sure the seal is correctly oriented with
the magnetic surface facing outward away from the
disk.
Gently slide the cutting disk onto the motor shaft,
aligning keyway to key, and lower slowly in one
motion. Once the cutting disk has been lowered,
DO NOT PULL UP ON THE DISK. If any upward
motion is imparted on the cutting disk, the magnetic
seals will separate, and will not seal! The installa-
tion process must be started over by removing the
cutting disk completely and sliding the upper seal
down to within 3/4” from the shaft bottom.
Pulper DOC PULPER 1.0 06
www.insingermachine.com 800-344-480216
PART 4 MAINTENANCE
Extractor Seal Replacement
Remove the extractor outlet assembly, the auger
assembly and the extractor screen from the extrac-
tor. Remove all debris and fouling material from
the drive shaft and bore.
Pick out old seal being careful not to damage or
scratch the shaft or the seal holder bore. Clean
any debris remaining on the shaft and in the bore.
Apply a thin film of o-ring lubricant on the sealing
surface of the seal. Place the seal onto the drive
shaft being careful not to damage the seal.
Excessive force should not be required. Gently
press the seal down onto the shaft and into the
bore.
Using a 2” PVC or other plastic pipe with a straight
cut, smooth & debureed face with no sharp edges,
gently tap the seal into the bore.
Reassemble the extractor in reverse order.
Pulper DOC PULPER 1.0 06
www.insingermachine.com 800-344-480217
PART 4 MAINTENANCE
OPERATING & MAINTENANCE ISSUES
Overfeeding Pulper
Feeding material too fast into the pulper will cause
machine vibration and low recirculation water flow.
Temporarily cease feeding material to the pulper
and allow it to process the current material in the
pulping chamber. Often, the pulping motor will
overload and shut down. In this case, manual
cleaning of the pulper chamber is required. Shut-
down and lock out main power to the unit, drain
pulping chamber and remove debris. If the pulper
motor does not overload, allow it to process mate-
rial until the vibration stops and the recirculation
flow rate returns to normal.
Level Probe
The level probe is critical to operation of the pulper.
If debris or fouling material is present on the level
probe, the probe will read a false high signal and
think that there is enough water in the unit when in
fact it is empty. The level probe, locate at the bot-
tom of the extractor, will show a red LED light
which indicates that it sees water. When this is lit
with no water in the extractor, it is an indication of
debris on the probe. The motors will start, but no
recirculation water will flow. Typically the motors
will overload and shutdown requiring resetting in
the main control box. Make sure operators of the
unit clean the probe daily.
Foaming
If a high rate of paper and cardboard are run
through the pulper, excessive foam may be gener-
ated. These materials have glue and adhesive that
cause foaming in both the pulper and extractor
chambers. Large quantities of foam will interfere
with the pulping and recirculation water flows.
Either use a defoamer or add paper and cardboard
at a lower rate to the pulping infeed.
Non Pulpable Items
While the pulper was designed to handle a large
variety of material, certain items will jam the cutting
blades and possible cause damage to the unit.
Iron, glass, silverware, stones, metal, bolts, un-
cooked beef and pork bones, ceramic, cloth, and
wood SHOULD NOT be fed into the pulper.
Drain
A clear and flowing drain is essential to proper op-
eration of the unit. A clogged drain will cause water
to overflow out the extractor door.
HIGHLY WET PULP DISCHARGE.
If the screen is clogged, the pulp will not properly
dewater. Check to see if the screen holes are
clean and clear. If the auger brush is worn, it will
not keep clear the inside surface of the extractor
screen. Proper brush fit so that it scrubs the inside
surface of the screen is required for dewatering
pulp and scouring the inside screen surface of foul-
ing material. These brushes require periodic re-
placement. It is difficult to determine when the
brush requires replacement as it is affected by run
time, feed material and feed flow volume. Mainte-
nance should periodically check the extractor and
auger for proper operation.
Worn Cutters
The rotating and stationary cutting blades are re-
placement items. If the pulp is not longer cutting
properly and the piping system is clogging due to
large pieces, an inspection of the cutting blades is
required. Worn blades must be replaced.
Corrosion
Although made of 304 stainless steel, the pulper
will be attacked by waste that is acidic or alkaline.
If your waster is corrosive in this manner, a buffer-
ing agent is required to neutralize the water before
it reaches the pulper.
Pulper DOC PULPER 1.0 06
www.insingermachine.com 800-344-480218
PART 5 RECOMMENDED SPARE PARTS
RECOMMENDED PULPER SPARE PARTS LIST
Part Number Quantity Description
Mechanical Parts
1543-161 5 Stationary Cutter Blades
1543-153 2 Impeller Cutter Blades
1548-258 1 Auger Brush
1543-259 2 Auger Brush Clamp Assembly
Call Insinger 5 Extractor spray nozzles
Electrical Parts
DE5-80 1 Level Switch
DE7-38 1 Timer
DE7-35 1 Timer, Level
DE5-37 1 Magnetic Switch
D2930RK 1 Solenoid Valve Repair Kit
DE9-176 1 Fuse, transformer secondary
DE9-171 2 Fuse, transformer primary
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Insinger ELIMINATOR 900 is an industrial waste handling system designed to eliminate waste and improve efficiency in various commercial settings. This machine is equipped with advanced features for optimal performance, including:
- Automatic deodorant dispenser to eliminate unpleasant odors
- Chemical defoamer to prevent excessive foaming during the waste handling process
- Visual indicators to monitor the availability of deodorizers and defoamers, ensuring continuous operation
- Compatibility with an optional automatic detergent dispenser for hassle-free cleaning and maintenance
- A durable construction for longevity and reliability in demanding environments
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