TE 1 Powerknot User Manual.pdf

LFC Family Liquid Food Composter

User’s Manual

Manual Part Number 96-01015

Power Knot LLC 2290A Ringwood Avenue San Jose CA 95131-1718

USA

+1-408-889-8433 http://www.powerknot.com http://www.powerknot.com

Notice The information contained in this document is subject to change without notice.

Power Knot LLC (Power Knot) makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Power Knot shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.

Power Knot assumes no responsibility for the use or reliability of interconnected equipment that is not furnished by Power Knot.

This document contains proprietary information which is protected by copyright © 2010~2016. The contents of this manual and the associated documentation are the property of Power Knot, and all rights are reserved. No part of this document may be photocopied, reproduced, stored in any computer format, translated to another language, or publicly displayed without the prior written consent of Power Knot.

The information contained herein has been prepared by Power Knot solely for use by Power Knot’s employees, agents, and customers. Dissemination or use of the information or concepts contained herein to or by other parties is prohibited without prior written consent from Power Knot.

Power Knot, the Power Knot logo, the Power Knot mark, LFC, LFC Cloud, Powerzyme, and Powerchips are trademarks of Power Knot and may be registered trademarks in certain countries. All other names may be trademarks or registered trademarks of their respective owners.

Multiple patents are pending on certain aspects of the design of the LFC.

Revision History Release Release Date Release Release Date

01 2011-04-15 16 2013-09-29

02 2011-06-25 17 2014-07-04

03 2011-08-10 18 2014-12-22

04 2011-09-12 19 2015-03-05

05 2011-10-05 20 2015-11-30

06 2011-10-06 21 2016-04-12

07 2011-11-16 22d 2016-05-14

08 2011-11-19

09 2011-12-07

10 2011-12-22

11 2012-06-25

12 2012-10-10

13 2012-12-12

14 2013-01-07

15 2013-03-14

LFC Family User’s Manual i

C o n t e n t s

Chapter 1 Introduction

1.1 About the LFC

1.2 Scope of this Manual

1.3 Getting Started

1.4 Documentation Overview

1.5 About Power Knot

Chapter 2 Warnings and Precautions

2.1 Electrical

2.2 Installation, Maintenance, and Service

2.3 Usage

2.4 Disposal

Chapter 3 Selecting a Site for the LFC

3.1 Location

3.2 Power

3.3 Water

Chapter 4 Receiving the LFC

4.1 Precautions

4.2 Initial Inspection

4.3 Shipment Contents

4.4 Returning Items for Repair or Replacement

Chapter 5 Transporting and Unpacking

5.1 Precautions

5.2 Unloading

5.3 Removing the LFC from the Crate

5.4 Packaging for Distribution

5.5 Packaging for Customers

Chapter 6 Installing the LFC

6.1 Introduction

6.2 Positioning the LFC

6.3 Power for the LFC

6.4 Plumbing

ii LFC Family User’s Manual

Contents

Chapter 7 Provisioning the LFC

7.1 Installing the Powerchips

7.2 Preparing for the Powerzyme

7.3 Draining the Excess Water

7.4 Configuring the LFC-IV

7.5 Installing the Powerzyme

Chapter 8 Using the LFC

8.1 Introduction

8.2 What can go in the Machine

8.3 Smells and Odors

8.4 Daily Usage

8.5 Automatic Program

Chapter 9 Using the Control Panel

9.1 Features

9.2 Operating the LFC

Chapter 10 Using the Touch Screen

10.1 Features

10.2 Starting and Stopping the LFC

10.3 Opening the Door and Putting Waste Food into the LFC

10.4 Status

10.5 History

10.6 Configuring the LFC

10.7 Service Items

10.8 Factory Data

Chapter 11 Summary LED and Audible Beeper

11.1 Introduction

11.2 Colors Displayed on the LED

11.3 Audible Alert

Chapter 12 Remote Connectivity: the LFC Cloud

12.1 Features

12.2 Connectivity

12.3 Configuration

12.4 Accessing the Data

12.5 LFC Cloud Interface

12.6 Reports and Alerts

LFC Family User’s Manual iii

Chapter 13 Errors and Diagnostics on the LFC-IV

13.1 Introduction

13.2 Severity of Errors

13.3 Diagnostics Screen

13.4 Excess Weight

13.5 Ignore Sensors

13.6 Touch Screen Under Error Conditions

Chapter 14 Maintenance

14.1 Introduction

14.2 System Verification

14.3 Maximum Power

14.4 Cleaning

14.5 Supplementing the Powerzyme

14.6 Replacing the Powerchips

14.7 Removing a Front or Side Panel

14.8 Mechanical Examination and Verifying the Chain Tension

Chapter 15 Servicing

15.1 Introduction

15.2 Troubleshooting the LFC-III

15.3 Troubleshooting the LFC-IV

15.4 LFC Does not Properly Power On

15.5 Water Blockage

15.6 Replacing the Chain

15.7 Replacement of the Seals

15.8 Gearbox and Motor

15.9 Water Solenoid Valves

15.10 Error 2: Rotating Sensor (LFC-III Only)

Chapter 16 Servicing the LFC-IV

16.1 Introduction

16.2 Faulty Conditions on the Touch Screen

16.3 Updating the Software

16.4 Programming the Factory Data

16.5 Electrical Wiring

16.6 Motor and Main Input Protection Fuses

16.7 Replacing a Load Cell

16.8 Replacing Boards or the Control Plate in the Control Box

Chapter 17 Removing and Recycling

17.1 Introduction

17.2 Moving

iv LFC Family User’s Manual

17.3 End of Life

Appendix A Acronyms

Appendix B Glossary

Appendix C Theory of Operation C.1 Decomposition and Diversion from a Landfill C.2 Accelerating the Decomposition C.3 Characteristics of Decomposition C.4 Slow Digestion

Appendix D Software and Hardware Versions D.1 Introduction D.2 Hardware Versions D.3 Software Versions

Appendix E Log (History of Activities) E.1 Introduction E.2 On and Off E.3 Door E.4 Weight E.5 Abnormal Conditions E.6 Manual Mode E.7 Configuration E.8 Service

Appendix F Passwords

Appendix G Replacement Parts and Recommended Spares G.1 Introduction G.2 Replacement Parts

Appendix H Service Records H.1 Introduction H.2 Installation H.3 Powerzyme Supplemented H.4 Powerchips Replaced H.5 Scheduled Maintenance

Index

C h a p t e r 1

Introduction

1.1 About the LFC

1.1.1 Basics

The LFC decomposes waste food in real time. It saves you money because you no longer have to have such garbage hauled off site. It is the green alternative because it prevents such waste food from going to a landfill where it will degrade into methane (CH4). Methane is a gas that is 70 times worse for the atmosphere than carbon dioxide (CO2).

You install the LFC in the kitchen or other work area where waste food is produced or accumulated. It is installed similarly to a dishwasher or washing machine. It connects to:

• hot and cold water supplies

• a drain for the exit of grey water

• electricity

Figure 1-1 LFC-100 (LFC-IV): machine to process nominally 100 kg (220 lb) of waste per day

LFC Family User’s Manual

The LFC uses aerobic decomposition to decompose the waste food. This process produces no odors or smells and is safe to be placed next to other equipment or processes in the kitchen.1

You use the LFC on a continuous basis. That is, you put waste food into the machine as it is generated throughout the day. At any time, the drum of the machine may contain new waste food, older waste food in various stages of decomposition, and fully decomposed waste that is about to be flushed out of the machine.

1.1.2 Capacity

Power Knot supplies the LFC in different sizes each having a different capacity. We distinguish the different capacities by a number following the LFC. This number represents the nominal daily capacity of a machine in kg. Images of the various sizes of LFCs are shown as follows:

• LFC-20 (nominal daily capacity of 20 kg, 44 lb): figure 7-1 on page 67

• LFC-50 (nominal daily capacity of 50 kg, 110 lb): figure 2-1 on page 11

• LFC-70 (nominal daily capacity of 70 kg, 150 lb): figure 3-1 on page 17

• LFC-100 (nominal daily capacity of 100 kg, 220 lb): figure 1-1 on page 1;

• LFC-200 (nominal daily capacity of 200 kg, 440 lb): figure 4-1 on page 37

• LFC-300 (nominal daily capacity of 300 kg, 660 lb): figure 6-1 on page 49

The nominal daily capacities are based upon typical waste food that may be generated by a typical restaurant. That is, the waste food comprises some mixture of raw meat, fish, grains, and vegetables and also some cooked meat, fish, grains, and vegetables. 95% of the waste food placed in the LFC is decomposed in 24 hours and the nominal daily capacity assumes this type of composition and variety.

If you have waste food type that is predominantly of one type of food or another, then the capacity may be greater than or less than the nominal daily capacity. For example, boiled rice decomposes very fast and if it is the only waste food that is discarded into the LFC, the capacity of the LFC may be easily twice that of its nominal daily capacity.

Further, the nominal daily capacity assumes the waste food is added periodically over a 12 hour period. It is not possible to accumulate the rated amount of waste food and add it to the machine at one time. The machine will be overloaded and will stop. If the waste food is added periodically for 16 hours each day, the capacity of the LFC will typically be 20% more than if waste food is added during 12 hours each day.2

If your business fluctuates, or is increasing, buy a machine that is bigger than your average use now. This will accommodate the increased waste food without problems; an LFC will work consistently well with a third of its nominal capacity per day. However, if your business is stable, use the size that is right for your business today. If the machine you have is too big for your current requirements, you may need to add additional Powerchips to fill the space.

1. See the Glossary on page 271 for a definition of aerobic decomposition.

2. When the LFC-IV is connected to the LFC Cloud, you can see the length of the working day on the Details tab as de-scribed in section 12.5.6.3 on page 151.

1. Introduction

1.1.3 Major Components

The major components of the LFC-IV are shown in figure 1-2. The LFC-III is similar in construction, but it has a flat panel controller instead of the color touch screen and no load cells.

More detailed pictures of the LFC-IV are:

• touch screen and LED in figure 11-1 on page 133

• inside the drum in figure 14-3 on page 190

• side view in figure 14-9 on page 194

• motor and control box in figure 15-6 on page 205

Referring to figure 1-2, the components are (starting top left and proceeding anti-clockwise):

Audible beeper. This is in the display box and beeps to inform you of any problems or errors.

Door. This is hinged at the back and opens from the front. You put waste food into the LFC through this door.

Door handle. Lift the door handle to open the door.The handle latches the door in the closed position.

Outer case. The outer case is made of stainless steel. There are several panels you can remove to access inside the various components of the LFC.

Electronics control box. This houses the computer and power circuitry that controls the LFC.

Water output. The grey water from the LFC flows to the drain from the left of the machine.

Adjustable feet. These allow you to make the LFC level and to balance the weight evenly on the four feet.

Mounting pads. These dampen noise and vibrations and lift the LFC from the floor.

Load cells. These weigh the LFC and its contents, allowing the LFC to report the amount of waste food ingested.

Figure 1-2 Major components of the LFC-IV outer case electronics control box door handle door audible beeper adjustable feet (4) water output supply water inputs

LED

Ethernet touch screen paddle washout arm shaft drum chain motor gearbox load cell (4) mounting pad (4)

Motor. The motor turns the arms inside the drum of the LFC.

Gearbox. The gearbox divides the speed of the motor by 90:1 or 100:1 depending on the model of the LFC.

Chain. The chain takes the power from the output of the gearbox to drive the shaft.

Drum. The drum holds the Powerchips and the waste food.

Arm. There are four to six arms depending on the model. These arms are fixed to the shaft.

Shaft. The shaft is driven by the chain and rotates approximately once every 12 seconds.

Washout water. This water flows into the LFC and flushes residues from under the bottom of the drum.

Supply water. This injects water into the drum to keep the waste food moist.

Paddle. A paddle is on the end of each arm. This is used to mix the contents of the drum.

Ethernet. This allows connection of the LFC to the cloud so you can view the status remotely.

Touch screen. This is housed in the display box and shows the status of the LFC, reports the statistics about usage numerically and graphically, and allows you to configure the system.

LED. This provides a summary indication of the status of the LFC.

1.1.4 EMI Statement

1.1.4.1 USA

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with this User’s Manual, may cause harmful interference to radio communications.

Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his or her own expense.

1.1.4.2 Canada

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

1.2 Scope of this Manual

1.2.1 Audience

This manual is intended for people installing, commissioning, operating, and servicing one of Power Knot’s Liquid Food Composters (LFCs).

Some parts of the manual necessarily use technical terms. We have included a list of acronyms used in the manual in appendix A, starting on page 267 and a glossary of some terms in appendix B, starting on page 271.

1.2.2 Types of LFC Covered by this Manual

The manual provides details about the following machines:

• second generation (abbreviated LFC-II), manufactured before 1 June 2011

• third generation (abbreviated LFC-III), manufactured between 1 June 2011 and 1 March 2014

• fourth generation (abbreviated LFC-IV), manufactured after 1 March 2014

We designate the generation of the machine with Roman numerals after the term LFC.1 Briefly, second generation machines (LFC-II) had a geared motor drive (not a chain) and had a fan at the top right of the back of the machine. Third generation machines (LFC-III) had a chain drive and retained the LED control panel at the front right of the machine. The fourth generation machines (LFC-IV) added load cells to weigh the LFC and its contents and introduced a color touch screen at the top rear of the machine.2

The control panel (with LED lights) on the LFC-II and LFC-III operate identically. The touch screen on LFC-IV operates very differently from the control panel. All other basic operation principles are the same for all machines. Where there are operational differences, these are identified in the text.3

1.2.3 Products covered by this Manual

1.2.3.1 Models

The model numbers for the various LFCs covered by this manual are listed in figure 1-3.

1. Do not confuse these Roman numerals with the Arabic numerals that designate the nominal capacity of a machine in kg.

2. Load cells are sometimes referred to as strain gauges.

3. Because of the similarities between the LFC-II and LFC-III, this manual generally refers to “LFC-III” to mean LFC-II or

LFC-III. Where there are differences, these are noted in the text.

Model Nominal ac voltage AC power phases Model number

LFC-20

120 V

230 V

90-10071

90-10073

LFC-20

(marine)

120 V

230 V

90-10075

90-10077

LFC-50

120 V

230 V

90-10001

90-10003

LFC-70

120 V

230 V

90-10011

90-10013

LFC-100

120 V

230 V

208 V

400 V

90-10021

90-10023

90-10022

90-10024

Figure 1-3 Model numbers for the LFCs covered by this manual

The voltages listed in figure 1-3 are the nominal voltages. See section 3.2.6 on page 25 and section

3.2.7 on page 26 for the voltages that are acceptable to the models.

You can view the model number on the service plate as described in section 4.3.3 on page 38 and in the Machine screen and Factory Data screen of the LFC-IV as described in section 10.4.2 on page 108 and section 10.8 on page 130.1

1.2.3.2 Hardware and Software Versions

This manual covers the following hardware and software versions:

For the LFC-III. Hardware version 3.0; software version 3.0

For the LFC-IV. Hardware versions 3.4, 3.6, and 3.8; screen version 0ECL; software version 1.46

For the LFC-IV, see section 10.4.2 on page 108 for how to identify the hardware, screen, and software versions.

If the software or hardware version of your LFC is lower than those listed above you may not have access to all of the features described in this manual. Review the history of the various software and hardware versions for the LFC-IV that is given in appendix D, starting on page 289.

Contact Power Knot or your authorized reseller if you need access to features you do not have and want to update your software or hardware. Instructions how to update the software are described in section 16.3 on page 224.

1.2.4 What this Manual Includes

This manual provides detailed information and instructions on the complete installation, provisioning, operation, and servicing of the LFC. The programming of the machine is performed through the operator panel or touch screen and that is described in this manual.

This manual provides ordering numbers and descriptions for accessories and replacement service parts that are sold directly by Power Knot.

LFC-200

230 V

208 V

400 V

90-10033

90-10032

90-10034

LFC-300

208 V

400 V

90-10042

90-10044

LFC-500

208 V

400 V

90-10052

90-10054

LFC-1000

208 V

400 V

90-10096

90-10098

1. The part number used to order the LFC may be different from the model number. For example, different ordering num-bers are used to order the LFC with liquid or powder Powerzyme but the LFCs will have the same part number. (For a description of liquid and powder Powerzyme, see section 14.5.2 on page 188.)

Model Nominal ac voltage AC power phases Model number

Figure 1-3 Model numbers for the LFCs covered by this manual (Continued)

1.2.5 What this Manual Does Not Include

This manual does not necessarily describe all the specifications of the LFC. It does, however, describe many technology aspects to allow you to understand how the LFC works.

This manual does not include information on warranty or service. Consult the Power Knot web site for details on these, consult documentation that may have accompanied your LFC, or contact the distributor or reseller who sold you the LFC or Power Knot directly if you purchased the LFC from Power Knot.

The manual does not provide pricing, names of sales representatives, or names of distribution channels.

1.3 Getting Started

1.3.1 Installation

Prepare the site for the LFC as described in chapter 3, starting on page 17. Install the LFC by following the instructions in chapter 6, starting on page 49. Prepare the LFC as described in chapter 7, starting on page 67.

Warning The LFC is designed to be installed by qualified personnel only. Installation by unqualified individuals may result in injury and damage to the LFC, surrounding equipment, or operating personnel. Study the warnings chapter 2, starting on page 11.

This list is a brief summary of the installation procedure and the time to install an LFC:

Getting the LFC out of the crate. The LFC comes in a wooden crate which is screwed together. Use a power screwdriver to dismantle the crate. Use a forklift to get the LFC out of the crate or construct a ramp to roll it out. This process will take 15 minutes to an hour.

Moving the LFC into place. The LFC moves easily on its wheels and should take just a few minutes to roll it into place if there are no obstacles. Moving the LFC long distances or down stairs can take anywhere from an hour to several hours. Larger LFCs (LFC-200 to LFC-500) require two people. The LFC-1000 requires four people to move it. For the LFC-IV you then need to lift it up to install the feet and rubber pads. Allow an extra ten minutes for that.

Electrical wiring. If power is close to the LFC, no wiring is required: you just plug in the LFC. If you need to run ac power, this could take anywhere from a couple of hours to six hours depending on the length of the cable run. The time is not greatly affected by whether the LFC uses three-phase or single phase, provided there is three phase power at the electrical distribution panel.

Water. It's unlikely that water supplies are already in place, so there is usually some plumbing.

This can take anywhere from a couple of hours to six hours depending how far you need to extend current water supplies and whether you need to take water through a wall or not.

Drainage. If there is a drain close by, running the outlet pipe can take anywhere from half an hour to three hours, depending if you are using copper or PVC piping, the length of the pipe run, and how much support you need to add to the pipe.

Connection to the internet (optional, only for LFC-IV). If you don't have an Ethernet cable nearby, it could take anywhere from minutes to several hours to install it. Alternatively, you can use Wi-Fi or GSM. If you have knowledge of your network and experience in data communications, connecting the Ethernet cable and configuring the Wi-Fi client or GSM modem will take a few minutes.

Balancing the load cells and calibrating the LFC (only for LFC-IV). If you have a pallet jack or a j-bar and an assistant, you can balance the load cells in five minutes. If you use a car jack and do it yourself, this could take 20 minutes. The subsequent calibration is done by the LFC in a few minutes.

System verification. You can run through the system verification in ten minutes.

Installing the microorganisms. This takes a few minutes, but they are usually activated overnight.

1.3.2 Ongoing Maintenance

Review chapter 14, starting on page 183 to understand how to maintain your LFC in good working order. You need to periodically add more Powerzyme (microorganisms and enzymes) and also periodically replace the Powerchips (housing for the microorganisms).

1.4 Documentation Overview

1.4.1 Organization

This user’s manual describes:

• how to move the LFC

• how to unpack it

• how to install the LFC

• how to start it up for the first time

• how to use the machine

• what periodic maintenance you need to do

• how to service the machine, and the estimated times for each service item

• what to do when you are convinced there is a problem

• description of the technology to help you to understand more about the operation of the LFC

1.4.2 Special Paragraph Styles

The following are the notices that are used to attract special attention to certain items. They set text off from the main body of the manual. These notices also appear in other languages where required by certain regulatory bodies:

Important This notice contains special information that should not be ignored.

Caution This notice calls attention to a condition or procedure which, if not observed, could result in damage to the LFC or the creation of mess where used. You may also void the warranty on the LFC.

Warning This notice indicates that if a specific procedure or practice is not correctly followed, permanent damage to the LFC and personal injury may result. You may also void the warranty on the LFC.

Danger This notice warns you of imminent hazard to yourself and others if proper procedures are not followed. If you ignore this, it may result in death or serious injury.

1.4.3 Colophon

This document was produced on personal computers using Adobe’s FrameMaker for Windows.

Starting with the first manual in March 2011, all text has been written by Power Knot LLC in Silicon Valley, California USA and is protected by copyright as indicated in the title page.

The headings are set in Swiss 721, Bitstream’s version of the Helvetica™ typeface; the copy is set in Zapf Calligraphic, Bitstream’s version of the Palatino™ typeface; notices are set in Swiss 721 or News Gothic, Bitstream’s version of the typeface by Kingsley-ATF Type Corporation. Labels for screen names and selectable items on a screen are in Myriad Pro, Adobe’s enhancement of the Frutiger typeface by the Mergenthaler Linotype Company. The drawings are produced using Adobe Photoshop and Adobe Illustrator.

1.4.4 Feedback

Power Knot appreciates any constructive feedback on all our documentation. If you have comments or can error reports on any of our documentation, please submit your feedback to:

Technical Publications Department Power Knot LLC 2290 Ringwood Avenue San Jose CA 95131-1718

USA

techpubs@powerknot.com mailto:techpubs@powerknot.com

1.5 About Power Knot

Power Knot designs and manufactures products that help you to reduce your carbon footprint.

You can find detailed information about us and our products on our web site at:

http://www.powerknot.com/.

If you need support, please contact the company from where you purchased the LFC. If you purchased the LFC directly from Power Knot or if your local sales company is unable to assist you, please contact us at:

LFC Product Support Power Knot LLC 2290 Ringwood Avenue San Jose CA 95131-1718

USA

+1-408-889-8433 support@powerknot.com http://www.powerknot.com/ mailto:support@powerknot.com

C h a p t e r 2

Warnings and Precautions

Important Read this section carefully. Failure to do so may result in equipment failure, injury, or death. Observe the following general precautions for using and working with your LFC.

Important This manual is an integral part of the machine. You must keep it in its entirety in an accessible place for the whole working life of the machine.

2.1 Electrical

Danger Do not work on the system or connect or disconnect cables during periods of lightning activity.

Figure 2-1 LFC-50 (LFC-IV, early model): machine to process 50 kg (110 lb) of waste per day

Danger Before working on a chassis or working near power supplies, unplug the power cord.

Danger Position the power cord carefully; route it so that it cannot be stepped on or tripped over. Be sure that nothing rests on the power cord and that the power cord does not sit where it can get wet.

Danger Never defeat the earth (ground) conductor or operate the equipment in the absence of a suitably installed earth conductor. Contact the appropriate electrical inspection authority or an electrician if you are uncertain whether a suitable earth is available.

Danger The power cord provides the safety ground for the LFC. Keep this cord properly connected at all times, unless working on the machine, even if the equipment is not powered by the ac mains.

Danger If the power cable or plug is damaged, unplug the LFC from the electrical outlet and replace the part or contact your authorized Power Knot service company.

Warning The power plug is the primary means to disconnect the machine from the ac power. The power plug and its socket must be accessible at all times.

Warning Zur sicheren Trennung des Gerätes vom Netz ist der Netzstecker zu ziehen.

Vergewissern Sie sich, daß die Steckdose leicht zugänglich ist.

Warning Le cordon d’alimentation est utilisé comme interrupteur général. La prise de courant doit être située ou installée à proximité du matériel et être facile d’accés.

Warning El enchufe es el medio principal para desconectar la máquina de la corriente alterna. El cable de alimentación y su clavija debe estar accesible en todo momento.

Warning For continued protection against the risk of fire, replace fuses only with the same type and rating of fuse as was installed by Power Knot. A list of fuses is given in figure G-9 on page 306.

2. Warnings and Precautions

Warning Use the correct external power source. Operate the product only from the type of power source indicated on the electrical ratings label. If you are not sure of the type of power source required, consult your Power Knot representative or local power company.

Warning Do not use voltage converters with the LFC.

Caution This product requires short-circuit (over current) protection to be provided as part of the building installation. Ensure that a circuit breaker (or other equivalent means) no larger than specified in section 3.2 on page 24 is used in the building’s ac branch circuit for the conductors that carry ac current.

Important Installation of the LFC must comply with local and national wiring regulations and electrical codes.

2.2 Installation, Maintenance, and Service

Danger Observe and follow service markings. Do not service the LFC except as explained in the documentation. Opening or removing covers that are marked with the triangular symbol with a lightning bolt may expose you to electrical shock.

Components inside these compartments should be serviced only by an authorized service technician.

Warning The LFC is not intended for household use.

Warning This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash your hands after servicing any of the internal parts of the LFC.

Warning Only trained and qualified personnel should be allowed to install, replace, or service this equipment.

Warning Do not operate the LFC in an environment where it is exposed to rain or similar adverse weather.

Warning Always turn the main power off and let the motor and all moving parts cool down and come to a complete standstill prior to attempting any removal of covers, maintenance, adjustment, or cleaning of the inside of the machine.

Caution Do not obstruct electrical switches or push buttons

Caution Do not block the vents that allow the LFC to cool. On some models there is one vent on the rear of the machine and vents below the chassis.

Important During periodic maintenance, check all safety switches to ensure that they are working properly

2.3 Usage

Danger Do not allow children or persons with reduced physical, sensory, or mental capabilities to operate this machine.

Danger Do not allow persons with lack of experience and knowledge to operate this machine unless they are given adequate supervision and instruction.

Danger Before starting the operation of the machine, make sure that all personnel are clear of all moving parts of the machine.

Warning Risk of injury from moving parts.

Warning Do not use the LFC to dispose of hard materials such as glass and metal.

Warning Switch off or unplug the LFC before attempting to free the shaft if it has jammed.

Warning Do not attempt to alter or “jump start” the machine in any way.

Caution Do not remove or alter any guards or safety labels.

2. Warnings and Precautions

Caution Keep the area of operation clean and dry to ensure the safety of those working in the area.

Important Familiarize yourself with the location and operation of all start and stop buttons and safety switches of the machine

Important If the LFC does not operate correctly when you follow the operating instructions, unplug the LFC from the electrical outlet and contact your authorized Power Knot service company.

Important Do not use solvents to clean the machine. Clean daily with a damp sponge or towel (using fresh water only).

2.4 Disposal

Warning The components used for plumbing internal to the LFC may not be suitable for potable water. Do not reuse any of these components in any application for washing or drinking water.

Important Ultimate disposal of this product should be handled according to all national laws and regulations.

C h a p t e r 3

Selecting a Site for the LFC

3.1 Location

3.1.1 Position

The LFC is designed to be permanently installed within a room such as a kitchen or under a weather-proof cover outdoors. You must carefully install the LFC to ensure its proper operation.

Important The LFC is not designed to be subject to the elements of rain, snow, high humidity, and dust. If you install the machine outdoors, ensure that you provide adequate coverage so it is well protected.

A picture showing the basic elements for an installation is shown in figure 3-2. Specific details about each item are in the following sections.

Position the LFC where you can easily access it and see the controls. The LFC-III has an LED control panel and the LFC-IV has a color LCD touch screen. Neither of these is easily visible in direct sunshine or very bright light. Although users of the LFC do not need to access the control panel (on the LFC-III) or touch screen (on LFC-IV) regularly, you should position the LFC so that you can easily access it. On the LFC-200 and larger LFCs, most people need to stand to the right of the LFC to access the touch screen.

Figure 3-1 Key elements for installing an LFC

3.1.2 Temperature

Install the LFC where the ambient temperature remains between 4°C ~ 35°C (39°F ~ 95°F).

Warning If you install the LFC in an environment where the temperature is outside the specified range this may result in bodily injury and damage to the LFC or surrounding equipment. You will also void your warranty.

If you position the LFC in the sunshine, the temperature of the LFC may exceed its operating temperature even though the general ambient air temperature may be within specification. In general, you should not allow direct sunshine to fall on the LFC.

If the ambient temperature falls below zero, water in the LFC or the pipes leading to or from the LFC may freeze. When that water thaws, it may rupture the pipes. If the LFC is kept below zero for a prolonged period, the water in the drum may freeze and rupture the drum when it thaws.

If the LFC has been placed in an environment where the temperature is below 0°C (32°F) then when the ambient temperature warms, you must pay attention to the pipes.

On the LFC-IV, the ambient temperature of the control system is constantly monitored and reported by the Diagnostics screen as described in section 10.4.4 on page 110.

3.1.3 Ventilation

During normal operation, the LFC generates heat. This mostly comes from the process of digesting the waste food (that is, the process is exothermic), but heat is also generated by the motor and the LFC’s electronics. Further, a small amount of carbon dioxide is generated by the digestion process. Therefore, it is important that you install the LFC where it will receive good ventilation.1

The LFC requires space on all sides and the base for ventilation. On models manufactured before 1 January 2011, a fan sucks air in from the base of the machines and blows warm air out of the machine at the rear. Later models do not have the fan. For these older models, position the LFC so that it is 50 mm (2”) from a wall at the back of the machine.

Figure 3-2 Basic site selection for the installation of an LFC

1. See appendix C, starting on page 273 for more information about the process inside the LFC.

Outlet pipe slopes downward Grade level drain

AC power input

Water supplies

Firm level ground

LFC

3. Selecting a Site for the LFC

In most cases, if you install the LFC in a kitchen or similar location and follow the guidelines in section 3.1.7 below, there will be sufficient ventilation for the LFC. However, if the ambient temperature reaches the maximum indicated in section 3.1.2, you should install fans to move air around the LFC to keep it within its operating parameters. If you install the LFC in a restricted space, follow the guidelines in section 3.1.8.

3.1.4 Altitude

The LFC is rated for normal operation up to 1000 m (3300 ft). Above that height, the air is thin and you must pay attention to keeping the LFC cool. The thin air itself does not cause any harm to the LFC, but it cools the motor and electronics less so you must ensure there is adequate flow of air over the LFC to maintain the temperature of these components within their operating range. You should install fans as shown in figure 3-6 to keep the air flowing. The higher that you operate the LFC, the greater is the need for the flow of air.

Contact Power Knot or your authorized sales representative if you intend to operate the LFC above 3000 m (10,000 ft).

3.1.5 Access

Leave at least 500 mm (18”) either side of the LFC for plumbing connections and for access to the panels. Allow at least 700 mm (24”) of open area at the front of the LFC to allow an operator to put the waste food into the machine.

3.1.6 Flat Surface

The LFC must sit on a reasonably flat surface:

• The LFC-III has four combination castors, one in each corner. These can be adjusted so that height differences of 10 mm (0.4 in) between the corners can be accommodated.

• The LFC-IV has four feet (on the load cells) and four wheels, one set in each corner. The feet can be adjusted so that height differences of 15 mm (0.6 in) between the corners can be accommodated.

If the height differences are greater than this, amend the floor prior to installing the machine.

The floor must be firm. The LFC is heavy and will sink if the ground is infirm. The loads on the floor are shown in figure 3-3.1

Standard concrete can typically tolerate a pressure of 10 MPa to 40 MPa (1500 psi to 6000 psi), so the loading presented by the LFC should not be a problem in most cases. However, you should check the loading requirements in figure 3-3 prior to moving the LFC in place to verify that your structure can tolerate the load.

3.1.7 Space Requirements

The spaces required for each model of LFC are summarized in figure 3-4. Dimensions are given in figure 3-5. The figures also show recommended positions and clearances. Check with your local authorities to identify if different distances are required by local codes or regulations.

1. The weight per foot and the pressure per foot assume that the weight is unevenly distributed to the feet.

3.1.8 Fitting the LFC into a Small Space

You can install the LFC into a space that is smaller than recommended in section 3.1.7 above.

However, in such cases, you must pay careful attention to ventilation, cooling, and accessibility.

Important If you intend to install the LFC into a small space, and the dimensions of the LFC are critical, contact Power Knot or your authorized distributor before proceeding.

The dimensions in figure 3-5 on page 22 are subject to change and older models may be different sizes from those listed.

The LFC generates heat as it operates. This is mostly derived from the digestion process with a lesser amount being derived from the power dissipated by the motor and electronics. It is therefore important that there is good ventilation around the LFC to keep it cool. Without such ventilation, the LFC may overheat, resulting in the machine shutting down or failing.

We recommend that you inspect the LFC regularly as described in chapter 14, starting on page

183. If you install the LFC into a small space, you will need to remove it from that space to be able to perform any periodic maintenance. For such an installation, you must complete it in such a way that the LFC can be moved so that it can be inspected periodically.

Figure 3-6 shows a possible means to install the LFC in a small space. The water pipes on the right use right angle connections to minimize the space. These pipes can be disconnected when the LFC needs to be brought out of the space for inspection.

The drain on the left is brought forward. In this way it can be inspected regularly and can be adjusted or disconnected when it is necessary to bring the LFC out of the space for access.

The electrical socket (and perhaps a circuit breaker as well) is connected to the right of the machine on the side wall and not on the rear wall. This is so that the ac power can be disconnected to service the machine.

Critically, you should install fans above the LFC. Figure 3-6 shows one fan each side of the LFC and one behind the LFC. These fans ensure there is a good flow of air around the LFC so that it does not overheat. These fans may be left on all the time or can be controlled with a sensor that will come on when the air temperature measured at a fan is greater than 27°C (80°F). Turning the fans on at this temperature will ensure that the LFC is not subjected to any ambient temperature greater than its specified operating range (as described in section 3.1.2 on page 18). While it may be possible to use a different arrangement of fans from that shown in figure 3-6 you must ensure that there is sufficient ventilation for the LFC to operate.

Model Fully loaded weight Weight per foot Pressure per foot

LFC-20 115 kg 250 lb 38 kg 85 lb 130 kPa 15 psi

LFC-50 300 kg 650 lb 100 kg 220 lb 350 kPa 50 psi

LFC-70 380 kg 830 lb 130 kg 280 lb 440 kPa 65 psi

LFC-100 470 kg 1030 lb 160 kg 350 lb 550 kPa 80 psi

LFC-200 670 kg 1470 lb 230 kg 500 lb 780 kPa 115 psi

LFC-300 910 kg 2020 lb 310 kg 680 lb 1070 kPa 155 psi

LFC-500 1350 kg 3000 lb 450 kg 1000 lb 1580 kPa 230 psi

LFC-1000 2450 kg 5400 lb 830 kg 1800 lb 2860 kPa 420 psi

Figure 3-3 Maximum loading on the floor

Figure 3-4 Dimensions of LFC and recommended space requirements

B

C

C: Position of circuit breaker, switch panel, or power socket

D

F

H

L

M

N

O

P

S

S W

X

Y

Side view with detail of drain exit

A

B D

Q R E

G G

E

Top view with detail of drain pipe

Drain is at floor level (grade level) and pipe slopes down to drain Only one drain is required on left side or right side of LFC Pipes normally run along wall for neatness, but can be direct

Ref Dimension

LFC-

LFC-

LFC-

LFC-

LFC-

LFC-

LFC-

LFC-

A Clearance of bottom of machine to floor 75 mm, 3”

B Back of machine to wall 2 cm, 1” (minimum)

D Depth of machine 54 cm

21”

68 cm

27”

72 cm

28”

75 cm

29”

81 cm

32”

105 cm

41”

120 cm

47”

141 cm

56”

E Total length of exit pipe (pipe should have no more than 3 90° bends)

300 cm, 120” (maximum)

F Clearance at front of machine (to add waste) 60 cm, 24” (minimum)

G Diameter of grade level drain 75 mm, 3” (minimum)

H Height of machine 75 cm

29”

101 cm

40”

108 cm

43”

111 cm

44”

127 cm

50”

149 cm

58”

162 cm

64”

174 cm

69”

L Height of ceiling above machine (to add waste) 230 cm, 90” (minimum)

M Height of bottom of circuit breaker above floor

100 cm, 39” (minimum)

N Height of top of circuit breaker above floor 200 cm, 78” (maximum)

O Top of circuit breaker to ceiling 75 cm, 30” (minimum)

P Side of circuit breaker to any obstruction 45 cm, 18” (minimum)

Q Center of drain exit pipe from rear of machine

24 cm

9½”

28 cm

11”

29 cm

11½”

33 cm

13”

34 cm

13½”

45 cm

18”

52 cm

21”

54 cm

22”

R Diameter of drain exit pipe 1½” 1½” 1½” 1½” 2” 2½” 3” 3”

S Clearance at each side of machine (for servicing) 50 cm, 20” (minimum)

W Width of machine 56 cm

22”

87 cm

34”

95 cm

37”

115 cm

45”

148 cm

58”

154 cm

61”

190 cm

75”

260 cm

102”

X Overall width of floor area

146 cm

58”

187 cm

74”

195 cm

77”

215 cm

85”

248 cm

98”

254 cm

100”

290 cm

114”

360 cm

142”

Y Overall depth of floor area

116 cm

40”

128 cm

50”

132 cm

52”

135 cm

53”

141 cm

56”

165 cm

65”

180 cm

71”

201 cm

79”

Figure 3-5 Dimensions of LFC and recommended space requirements

Figure 3-6 Installing the LFC in a small space

Top View

Water Hoses

Power

Front View

3.2 Power

The LFC uses ac power as its power source. Provide power for the machine as described in the following sections.

Danger Read each of the warnings and precautions in section 2.1 on page 11 before proceeding.

Warning The power for the LFC must be installed by a properly qualified and licensed electrician.

3.2.1 Power Cord

The ac power cord enters the LFC at the following locations (as viewed from the front of the machine):

• for the LFC-II, at the side of the machine, in the lower right

• for the LFC-III, at the back of the machine, in the lower right

• for the LFC-IV, at the side of the machine, in the upper right

The length of the power cord is approximately 1.6 m (63”). Power Knot supplies a plug only for those LFCs sold in USA. For other regions or territories, your distributor may have installed an appropriate plug or you may need to source an appropriate plug and connect it to the power cord.

Install the power socket where the power cord can be connected without the need for an extension cord.

Important The socket that provides power for the LFC must be installed near the LFC and easily accessible so that the plug of the LFC can be removed during servicing.

3.2.2 Protective Earth Ground

It is essential that you provide a reliable, solid protective earth ground to the LFC.

The resistance between the equipment frame and the protective earth ground (per UL 60950, paragraph 2.6.3.3) should be less than 0.1 Ω. An adequate earth ground is normally implemented with a copper rod (about 15 mm or 0.6" diameter) driven at least 4 m (12 ft) into moist soil. Improve conductivity by adding salt or magnesium sulphate to the soil surrounding the rod to a depth of 200 mm (0.6 ft); periodic replenishing may be required.

3.2.3 Safety Disconnect

There is no power switch on the LFC. The ability to stop and start the LFC and the door switch are signals interpreted by the hardware and software of the control system. You must therefore install the LFC with an external switch or circuit breaker for disconnecting the ac supply source.

In compliance with EN61010-1 for permanently connected equipment this switch should meet the following guidelines:

• It shall be included in the building installation.

• It shall be in close proximity to the equipment and within easy reach of the operator.

• It shall be marked as the disconnecting device for the LFC.

• It shall disconnect all live circuits.

• It shall not disconnect the protective earth (ground).

3.2.4 Reliability of Power Source

The LFC is inoperable when ac power fails. If you have waste food in the machine when ac power fails, the waste food will continue to decompose normally for some time. However, without air being introduced by the arm rotating and without water to maintain the moisture content, the decomposition may turn to be anaerobic resulting in smells and acids.

When you install the LFC, we suggest you place a note at or near the circuit breaker that delivers the power to the LFC that this power should be always be kept on. You should check that if much power to the kitchen is turned off at night or at weekends that the power to the LFC is not disrupted.

Under most conditions, the LFC resumes operation when power is restored. If power has been disrupted for over 24 hours, take care when power is restored because the contents of the drum may be sticky leading to excessive load on the motor.

3.2.5 Balanced Phases

For LFCs that use three phase power, you should verify that the phases are balanced. That is, the three voltages between phase to phase are within 5% of each other and for machines that require neutral that the three voltages between phase to neutral are also within 5% of each other.

Preferably, you should measure these voltages when you apply a dummy load to the ac power outlet.

If the voltages are imbalanced, the currents to the motor will be imbalanced and this will lead to a shorter life of the motor. Power Knot will not warrant the motor under these conditions.

On the LFC-IV, any phase imbalance will be reported on the Diagnostics screen (see section 13.3 on page 163) and recorded in the history log (see section 10.5.3 on page 113).

3.2.6 Power Requirements for LFCs sold in North America

3.2.6.1 LFC-20, LFC-50, LFC-70, and LFC-100

• 120 V single phase, 60 Hz

• 2 wires plus protective earth ground, total is three wires

• NEMA 5-15 socket (power cord is terminated in NEMA 5-15 plug)

• Typical current: 3 A to 10 A

• Startup current (peak inrush current): 15 A

• Circuit breaker: 15 A

• Socket to be mounted to the right of the machine, at least 3 foot above grade

Warning Never connect the LFC to a circuit which is protected by a circuit breaker of greater than 15 A.

3.2.6.2 LFC-200, LFC-300, and LFC-500

• 208 V 3-phase, 60 Hz1

• 3 wires plus protective earth ground (no neutral required), total is four wires

• NEMA L15-20 socket (power cord is terminated in NEMA L15-20 plug)

• Typical current: 2 A to 10 A

• Startup current (peak inrush current): 15 A

• Circuit breaker: 15 A

• Socket to be mounted to the right of the machine, at least 3 foot above grade

Warning Never connect the LFC to a circuit which is protected by a circuit breaker of greater than 15 A.

3.2.6.3 LFC-200 single phase

• 230 V single phase, 60 Hz

• 2 wires plus protective earth ground, total is three wires

• NEMA L6-20 socket (power cord is terminated in NEMA L6-20 plug)

• Typical current: 2 A to 5 A

• Startup current (peak inrush current): 8 A

• Circuit breaker: 10 A or 15 A

• Socket to be mounted to the right of the machine, at least 1 m above grade

Warning Never connect the LFC to a circuit which is protected by a circuit breaker of greater than 15 A.

3.2.7 Power Requirements for LFCs sold outside North America

3.2.7.1 LFC-20, LFC-50, LFC-70, and LFC-100

• 220~250 V (nominally 230 V) single phase, 50 or 60 Hz

• 2 wires plus protective earth ground, total is three wires

1. 208 V is the voltage from phase to phase; the phase to neutral voltage is 120 V.

• Plug is installed on the end of the power cord by Power Knot’s authorized distributor

• Typical current: 2 A to 5 A

• Startup current (peak inrush current): 10 A

• Circuit breaker: 10 A or 15 A

• Socket to be mounted to the right of the machine, at least 1 m above grade

Warning Never connect the LFC to a circuit which is protected by a circuit breaker of greater than 16 A.

3.2.7.2 LFC-200, LFC-300, LFC-500, and LFC-10001

• 380~430 V (nominally 400 V) 3-phase, 50 or 60 Hz2

• 4 wires plus protective earth ground (neutral is mandatory), total is five wires

• Plug is installed on the end of the power cord by Power Knot’s authorized distributor

• Typical current: 1 A to 5 A

• Startup current (peak inrush current): 8 A

• Circuit breaker: 10 A or 15 A

• Socket to be mounted to the right of the machine, at least 1 m above grade

Warning Never connect the LFC to a circuit which is protected by a circuit breaker of greater than 16 A.

3.2.7.3 LFC-200 single phase

• 220~250 V (nominally 230 V) single phase, 50 or 60 Hz

• 2 wires plus protective earth ground, total is three wires

• Plug is installed on the end of the power cord by Power Knot’s authorized distributor

• Typical current: 2 A to 5 A

• Startup current (peak inrush current): 8 A

• Circuit breaker: 10 A or 15 A

• Socket to be mounted to the right of the machine, at least 1 m above grade

Warning Never connect the LFC to a circuit which is protected by a circuit breaker of greater than 16 A.

1. As of the time of publication of this manual, the LFC-1000 is not qualified for sale in the USA.

2. 380~430 V (nominally 400 V) is the voltage from phase to phase; the phase to neutral voltage is 220~250 V (nominally

230 V).

3.3 Water

3.3.1 Input

3.3.1.1 Identification

You need to supply fresh water to the LFC. There are two water connection inputs to the…