ACO Haustechnik. Installation and Operating Manual _01 As per: 03/2010

Transcription

1 ACO Haustechnik Installation and Operating Manual _01 As per: 03/2010 ACO Grease separator plants for free-standing installation and complete disposal according to DIN EN 1825 and DIN Oval shape - Polyethylene (PE-HD) Type Design Approval number ECO-Jet -O Basic design ECO-Jet -OD Extension stage 1 Hydrojet -OS Extension stage 2 Hydrojet -OSE Extension stage 2 with disposal pump Hydrojet -OA Extension stage 3 Hydrojet -OAE Extension stage 3 with disposal pump Z Illustration: Hydrojet-OAE Round shape - Polyethylene (PE-HD) Type Design Approval number ECO-Jet -R Basic design ECO-Jet -RD Extension stage 1 Hydrojet -RS Extension stage 2 Hydrojet -RSE Extension stage 2 with disposal pump Hydrojet -RA Extension stage 3 Hydrojet -RAE Extension stage 3 with disposal pump Z Illustration: Hydrojet-RAE Oval shape - Stainless steel (1.4571) Type Design Approval number Lipurex -O Basic design Lipurex -OD Extension stage 1 Lipurat -OS Extension stage 2 Lipurat -OSE Extension stage 2 with disposal pump Lipurat -OA Extension stage 3 Lipurat -OAE Extension stage 3 with disposal pump Z Illustration: Lipurat-OAE Round shape - Stainless steel (1.4571) Type Design Approval number Lipurex -R Basic design Lipurex -RD Extension stage 1 Lipurat -RS Extension stage 2 Lipurat -RSE Extension stage 2 with disposal pump Lipurat -RA Extension stage 3 Lipurat -RAE Extension stage 3 with disposal pump Z Illustration: Lipurat-RAE

2 Contents Chapter Page 1 Product identifcation / -selection 1.1 Addresses Official approval Grease separators - Range structure Conformity declaration General notes, safety information Product description / Planning notes 2.1 Installation and standard regulations, ambient conditions Design of grease separator plant Grease separator components Functioning of grease separator plant Correct intended use Suggested installation Power supply / -energy consumption (water/current) / group alarm 12 3 Installation 3.1 Transport, delivery and storage Erection, installation and assembly Local connection works (for the plumber / for the fitter) Works for the user and the operating staff 17 4 Operating Manual 4.1 Commissioning Operation Emptying and disposal Disposal process of grease separator - basic design extension stage extension stage 2 23, extension stage 3 25, extension stage 3 and remote control, with or without disposal pump Hints for sampling 28 5 Servicing 5.1 General notes Overview: Regular maintenance works Repair Decommissioning Spare parts and after-sales service Addresses of ACO service partners 31 6 Attachment Characteristic curve and performance data of disposal pump / circuit diagrams of controls

3 ACO Haustechnik _01 1 Product identification 1.2 Addresses Name and address of manufacturer Name and address of electrician ACO Passavant GmbH Im Gewerbepark 11c Stadtlengsfeld After-sales service Tel (0) Service - Tel (0) Fax ++49 (0 ) Service - Fax (0) service@aco-online.de Tel. Fax After-sales service Name and address of supplier Name and address of disposal contractor Tel. Fax After-sales service Tel. Fax After-sales service Name and address of plumber Tel. Fax After-sales service 1.2 Official approval Nominal size / NS Approval number Grease separator - OVAL shape / stainless steel 1 to 10 Z Grease separator - OVAL shape / plastic welded 1 to 10 Z Grease separator - OVAL shape / plastic rotated 1 to 10 Z Grease separator - ROUND shape / stainless steel or plastic 2 to 20 Z I 1.3 Grease separators - Range structure Material stainless steel/v4a Material polyethylene/pe-hd Basic design Extension stage 1 Lipurex -O -OD Lipurex -R -RD Extension stage 2 Extension stage 3 Lipurat -OS -OA Lipurat -RS -RA Lipurat -OSE -OAE Lipurat -RSE -RAE Basic design Extension stage 1 Eco-Jet -O -OD Eco-Jet -R -RD Extension stage 2 Extension stage 3 Hydrojet -OS -OA Hydrojet -RS -RA Hydrojet -OSE -OAE Hydrojet -RSE -RAE 3

4 1.4 EC Conformity declaration Eco-Jet -O and -OD; Hydrojet -OS, -OSE, OA and OAE Grease separators - Full disposal / Oval shape - Polyethylene (PE-HD) / Free-standing installation The manufacturer herewith declares: ACO Passavant GmbH, Ulsterstrasse 3, D Philippsthal that the plant: Eco-Jet -O and -OD / Hydrojet -OS, -OSE, -OA and -OAE conforms to regulation: EG-RL 2006/42/EG Machine parts of the plant are in conformity with further Directives: EG-RL 2006/95/EG Low Voltage Directive The following harmonized standards were applied: DIN EN 1825/ edition The following authorities were employed: DiBt Berlin Addition: DIN / edition For the polyethylene used, fire protection category E as per EN ISO :2002, section 10.3 was proven. Remark: The separators separate fats of vegetable and/or animal origin from wastewater by gravity in drainage systems. Competent documentary agent: Mr Marco Eulenstein Machinery Directive Grease separators: Official test sign Z ACO Haustechnik, Im Gewerbepark 11c, D Stadtlengsfeld Eco-Jet -R and -RD; Hydrojet -RS, -RSE, RA and RAE Grease separators - Full disposal / Round shape - Polyethylene (PE-HD) / Free-standing installation The manufacturer herewith declares: ACO Passavant GmbH, Ulsterstrasse 3, D Philippsthal that the plant: Eco-Jet -R and -RD / Hydrojet -RS, -RSE, -RA and -RAE conforms to regulation: EG-RL 2006/42/EG Machine parts of the plant are in conformity with further Directives: EG-RL 2006/95/EG Low Voltage Directive The following harmonized standards were applied: DIN EN 1825/ edition The following authorities were employed: DiBt Berlin Addition: DIN / edition For the polyethylene used, fire protection category E as per EN ISO :2002, section 10.3 was proven. Remark: The separators separate fats of vegetable and/or animal origin from wastewater by gravity in drainage systems. Competent documentary agent: Mr Marco Eulenstein Machinery Directive Grease separators: Official test sign Z ACO Haustechnik, Im Gewerbepark 11c, D Stadtlengsfeld D Philippsthal, D Philippsthal, Mr Ralf Sand General Manager ACO Passavant GmbH Mr Ralf Sand General Manager ACO Passavant GmbH Lipurex -O and -OD; Lipurat -OS, -OSE, OA and OAE Grease separators - Full disposal / Oval shape - Stainless stell (1.4571) / Free-standing installation The manufacturer herewith declares: ACO Passavant GmbH, Ulsterstrasse 3, D Philippsthal that the plant: Lipurex -O and -OD / Lipurat -OS, -OSE, -OA and -OAE conforms to regulation: EG-RL 2006/42/EG Machine parts of the plant are in conformity with further Directives: EG-RL 2006/95/EG Low Voltage Directive The following harmonized standards were applied: DIN EN 1825/ edition The following authorities were employed: DiBt Berlin Addition: - Remark: DIN / edition The separators separate fats of vegetable and/or animal origin from wastewater by gravity in drainage systems. Competent documentary agent: Mr Marco Eulenstein Machinery Directive Grease separators: Official test sign Z ACO Haustechnik, Im Gewerbepark 11c, D Stadtlengsfeld Lipurex -R and -RD; Lipurat -RS, -RSE, RA and RAE Grease separators - Full disposal / Round shape - Stainless stell (1.4571) / Free-standing installation The manufacturer herewith declares: ACO Passavant GmbH, Ulsterstrasse 3, D Philippsthal that the plant: Lipurex -R and -RD / Lipurat -RS, -RSE, -RA and -RAE conforms to regulation: EG-RL 2006/42/EG Machine parts of the plant are in conformity with further Directives: EG-RL 2006/95/EG Low Voltage Directive The following harmonized standards were applied: DIN EN 1825/ edition The following authorities were employed: DiBt Berlin Addition: - Remark: DIN / edition The separators separate fats of vegetable and/or animal origin from wastewater by gravity in drainage systems. Competent documentary agent: Mr Marco Eulenstein Machinery Directive Grease separators: Official test sign Z ACO Haustechnik, Im Gewerbepark 11c, D Stadtlengsfeld D Philippsthal, D Philippsthal, Mr Ralf Sand General Manager ACO Passavant GmbH Mr Ralf Sand General Manager ACO Passavant GmbH 4

5 ACO Haustechnik _ General notes, Safety information Field of application of installation and operating manual This manual applies to the ACO Haustechnik grease separator plants for free-standing installation and full disposal, made of stainless steel and polyethylene PE-HD. These operating instructions contain fundamental information and precautionary notes. Please read the manual thoroughly prior to installation of unit, connection to power supply and commissioning. It is imperative to comply with all other operation instructions referring to components of this grease separator. The mentioned safety notes, the pertinent national accident prevention regulations as well as possible internal working-, operation and safety regulations of the user have to be observed. The safety notes which could lead to danger to people in the case of their non-observance as well as in the case of warning of electric voltage are marked with the general safety marks. All indications on possible standards, test sign, quality marks and registered trademarks are state-of-the-art at the time of being printed. Deviations with the illustrations, dimensional and weight indications are possible. We reserve the right to carry out modifications and improvements without prior notice. Availability of the manual The operating manual must always be available at location where separator plant is installed. Copyright ACO Haustechnik holds the copyright for these operating instructions. These operating instructions are written for the assembly, operating, maintenance and supervisory staff. They contain regulations and technical drawings whose complete or partial reproduction, dissemination or use for competitive purposes or passing on to others is prohibited unless authorised in advance. Safety notes The safety notes which could lead to danger to people in the case of their non-observance as well as in the case of warning of electric voltage are marked with the general safety marks (according to DIN W8/9). General risk symbol Beware of suspended loads Environment-relevant measures Beware of electrical voltage Paragraphs within this operating manual bearing this symbol must be particularly observed in order to keep rules, standards, regulations, notes and correct sequence of works and in order to avoid damaging of the plant, its component parts and its surroundings and in order to guarantee proper function. Staff The staff for operation, maintenance, inspection and assembly must have relevant qualifications for these works. Responsibility, competence and supervision of staff must be precisely ruled by the operator. If the staff members do not have the necessary knowledge, they have to be trained and instructed. Furthermore, the operator has to make sure that contents of the operation manual are fully understood by the staff members. To protect the staff members, the user has to safeguard the following parts from being touched: hot or cold plant elements which could lead to danger moving parts electric components. In the case of leakages (e. g. shaft seal of disposal pump), dangerous delivery media (e. g. explosive, chemically/biologically aggressive, toxic, hot) have to be disposed of in such a manner that there is no risk for persons and the environment. Legal regulations have to be adhered to. Exposure to danger by electric energy has to be expelled (particular attention to state specific regulations and to regulations of local electric power supply companies). Electrical safety Connection must be carried out by a qualified contractor; VDE regulations (0100, 0113) have to be adhered to. The electrical installation of a plant component must comply with the specifications laid down in European standards EN 1012 Part 1 and EN Part 1. If necessary, installation must also comply with the local regulations laid down by the electricity utilities. The local potential adaptations have to be included. Work on the electrical equipment in a separator must only be carried out by a properly qualified electrician or by properly instructed persons working under the instruction or supervision of a properly qualified electrician in accordance with the electrical regulations. Before any work is carried out on the electrical equipment in a separator, it is essential for the following measures to be implemented in the following order: 1. All-pole disconnection (switching off the main plug or pulling out the mains plug) 2. Securing against accidental switching on. 3. Checking that the system is not connected to the circuit. Correct intended use The separator plant is intended exclusively for separation of saponifiable oils and fats of vegetable and animal origin. Further use is not regarded as correct intended use and the manufacturer is not liable for any damage resulting from improper use; the risk is borne by the operator. The correct intended use also includes adherence to assembly, commissioning, operating and servicing conditions set out by the manufacturer. For safety reasons, conversion works at plant are not permitted. The correct intended use also includes: Observe national laws and regulations Adhere to inspection and maintenance information. 5

6 Endangering in the case of non-observance Non-observance of safety notes, regulations and manufacturers information may lead to endangering persons as well as the environment and plant. No damage claims are accepted in the case of non-observance of safety notes. Delayed installation If it is already known or expected during installation that commissioning of plant will be carried out only after a protracted period, following measures should be taken to protect (conserve) the plant: Protect plant from damp and pollution Move function parts from time to time to prevent seizing In case, commissioning is carried out more than 1 year after installation had taken place, plant should be checked by ACO Haustechnik - aftersales service (at a charge). Stopping and re-commissioning Works at the plant may basically only be performed during stillstand periods. The process sequence to stop plant, described in the operation manual, must be adhered to. Directly following completion of works, all safety and protection devices must be re-installed or set into function. Prior to re-commissioning, all points mentioned in section initial commissioning have to be observed. Maintaining the plant in good condition To maintain the plant in good condition, we recommend two inspections annually. Any repairs required can be performed in good time, the service life of the plant is extended. Relevant contracts can be taken out with our after-sales service department. Environmental protection The regulations laid down in Waste Law must be observed when disposing of the substances removed from the separator. Maintenance, inspection and assembly works have to be carried out by authorised and qualified contractors. Arbitrary modification and spare parts manufacture Alterations or modifications of plant are permissible only after prior agreement with manufacturer. Original spare parts and accessories authorised by the manufacturer serve safety purposes. The use of different parts may annul warranty claims for damages arisen thereof. The use of ACO Haustechnik original parts guarantees a safe and reliable operation of the separator plant. 2 Product description / Planning notes 2.1 Installation and standard regulations, ambient conditions Installation Operations generating greasy wastewater must install grease separators in accordance with DIN EN 1825 and DIN Extract from DIN , section 6.2. Backflow level Grease separators whose normal water level is beneath the backflow level (refer to EN 752-1), must be drained by downstream lifting plants. Extract from DIN EN , section 7.3 Ventilation connection Inlet and outlet lines of grease separator plants have to be adequately vented. For this purpose, inlet line has to be taken above the roof as ventilation line. Extract from DIN EN Other horizontal piping sections connected to the grease separator which are longer than 5 m must also be vented through the roof. If the horizontal inlet piping is longer than 10 m and contains no other additional venting pipes, it is necessary to install an additional venting pipe extending beyond the roof in the direct vicinity of the grease separator inflow. Extract from DIN EN For this purpose, the connection port at separator cover (available with all types) can be used instead of an additional connection in inlet line. Container ventilation Grease separator plants must be vented separately through the roof. Extract from DIN Sampling Advantages and disadvantages of sampling pipes compared with integrated sampling methods for grease separators: Sampling pipes (used with free-standing separators) have an open pipe end on the inside of the inlet with a drop of at least 160 mm to the lowest point of the outlet pipe leading to the sewers. This is the only arrangement which allows proper and safe sampling by the authorities using the recommended wide-neck bottles and the necessary amount of inspection control. The other crucial advantages of this design which make inspection easier are the easy access to the discharge pipes feeding into the sewers and the piping coming out of the grease separator, particularly for inspection with video cameras and when cleaning the piping with an HP flush tanker. Only where this drop in height is not realisable for construction reasons or where there is inadequate space to install a sampling pipe, is it acceptable to choose the integrated sampling option, for reasons including costs (height from the lowest point must be at least 30 mm). Extract from DIN , section

7 ACO Haustechnik _01 Disposal The grease separator must be completely emptied and cleaned at least once a month and preferably every two weeks. The grease separator must be subsequently refilled with water (e. g. drinking water, process water) in compliance with the local discharge regulations. Extract from DIN , section 12.2 Servicing The grease separator must be serviced annually by properly qualified personnel following the manufacturer s instructions. Extract from DIN , section 12.3 Properly qualified personnel Properly qualified personnel are defined as staff working for the operator or third parties whose training, knowledge and practical experience ensure that they can properly carry out the necessary evaluations or tests required in the relevant areas... Extract from DIN General inspection Prior to commissioning and then at regular intervals not exceeding five years, the grease separator must be inspected by a properly qualified technician after first being completely emptied and cleaned, to ensure that the grease separator is in proper operating condition and that it is operating in compliance with the regulations. The main aspects covered by the inspection are primarily the rating of the grease separator, the structural condition and tightness of the separator, the condition of the inner walls, components, electrical devices, the layout of the inlet and vent pipes, complete filling out of the operations log, documentation conforming proper disposal of the contents of the separator and the existence of all necessary certificates and documentation. Extract from DIN , section 12.4 Properly qualified technician Properly qualified techninicians are defined as the staff of third party companies, experts or other institutions with certified special technical knowledge on the operation, maintenance and testing of the separators described here, and the necessary technical understanding of the separators required to test the separators. On a case-by-case basis, when involving large companies, these inspections can also be carried out by in-house properly qualified technicians employed by the operator who act independently and whose responsibilities free them from having to obey instructions and who have the necessary qualifications and the necessary technical understanding to professionally carry out the inspection. Extract from DIN tinuous gradient of at least 1:50 because otherwise the wastewater would have to be raised (pumped) upstream of the grease separator. This has the serious disadvantage of intensely mixing the grease and the water which complicates the grease separation process and will inevitably lead to situations where statutory contamination limits are exceeded. If the installation of a pump is unavoidable because of the situation within the building, it is possible to largely prevent intense mixing by installing special liftings plants with displacement pumps. Access routes/bringing-in When installing grease separators for free-standing installation, access to installation premises has to be checked. In order the choose the correct separator which, in case of need, may also be brought in via stairs, angle-like corridors or via light wells, it is essential to know the local conditions. Different shapes and designs enable a user-oriented bringing-in. The dimensions of ACO Haustechnik grease separator plants are designed in such a way that the plants can be transported through existing doors and staircases completely mounted. The segment design separator plants can be transported dismantled and re-mounted at installation site. The individual parts can also be welded in situ by the ACO aftersales service. Inflow piping arrangement If inflow pipes are laid in unheated or openly accessible rooms where there is a risk of frost, these piping sections must be fitted with an auxiliary pipe heating system, e. g. automatic heating strips and insulation. Inflow piping must be carefully selected and laid because this can already have a positive or negative effect on the separation efficiency. Vertical inflow piping must be designed as follows where they join horizontal piping to prevent impermissible turbulence in the greasy wastewater: vertical downpipe, 45 bend, straight piping minimum 250 mm or more, 45 bend, horizontal piping feeding into the grease separator minimum 10 x DN long (example: DN 100 = 1 m, DN 150 = 1.50m). Operations log An operations log must be kept for each grease separator. The operations log records: the results of the checks carried out by the operator, maintenance, inspection and disposal reports. The operations logs must be kept in a safe place by the operator and made available upon request to the responsible authorities. Extract from DIN , section 12.5 Installation room The installation room must be separate, dry and equipped with a properly working ventilation and aeration system. Grease separators must always be installed on level surfaces. The wastewater should flow towards the grease separator along a con- 7

8 Temperatures If wastewater temperatures in the separator exceed 60 C or if the grease separator is installed in areas where danger of fire persists, we recommend the use of stainless steel separators. Sampling pipe Directly at separator outlet and prior to being mixed with other wastewater, an appliance for sampling and inspection has to be installed. Extract from DIN , section 5.5. and 11 Pressureless operation The grease separators are only suitable and approved for unpressurised operation. Odourproof does not mean the same as backflowprotected!!! Care should be taken when selecting the lifting plant to ensure that a twin lifting plant is installed (statutory requirement in industrial and commercial applications) to ensure that if one of the pumps fails, uninterrupted operation can still be guaranteed. It should also be noted that residual grease in the wastewater can also separate out downstream of the grease separator, and that this can give rise to the accumulation of grease in the lifting plant. Regular inspection of the lifting plant is therefore necessary whenever the grease separator is serviced. 2.2 Design of grease separator plant The grease separator plant is intended for free-standing installation in frost-proof rooms. The plant components are made of stainless steel, material grade (V4A) or polyethylene (PE-HD). Depending on type, plants are composed of following components: Basic body Housing (one piece or segments (max. 3 off)) Separator inlet / internal separator inflow Separator outlet / internal separator outflow Maintenance openings Disposal connection Ventilation connection Buoyancy safeguard Transport eyebolts Component parts Inspection window Filling device High-pressure internal cleaning: HP pump and HP Orbital cleaning head Disposal pump Measuring empty Controls (depending on design) Accessories Inspection window, filling device, remote control, heating rod, stop valve, sampling, coarse trap, on-wall and in-wall housing 8

9 ACO Haustechnik _ Grease separator components Revision opening 7 Revision opening 12 Outlet Inlet HP pump Connection possibility Drain plug Legend The components marked in colour... are supplied in basic design or are available as accessory/ retro-fit as from this design group are supplied with extension stage 2 or are available as accessory/retro-fit as from this design group are supplied with extension stage 3 or are available as accessory/retro-fit as from this design group Separator housing Suction line (in separator housing with extension stage 1) Filling device with manual ball valve (with solenoid valve as from extension stage 3) Inspection window Heating rod High-pressure pump High-pressure Orbital cleaning head Measuring empty Gate valve Disposal pump Control Remote control 9

10 2.4 Functioning of grease separator plant Grease separating compartment Sludge collecting compartment Functioning of e.g. Hydrojet NG 4 Description The grease separator plant consists of sludge trap and separator (superposed in housing) and works purely physically as per the gravity principle (difference in density): Heavy wastewater substances sink to the bottom, light substances like animal oils and fats rise to the top in the separator plant. Prior to commissioning, separator must be filled with water until water flows out through the outlet. During disposal, contents are pumped com- pletely into the suction vehicle (as a function of design of separator, either by submerging the suction hose into the separator or by connecting the suction hose to the direct suction). This process can be carried out by suction vehicle pump or disposal pump at separator (depending on design). Before and during emptying process, contents are crushed, mixed and homogenised by the high-pressure water jet of the rotating HP Orbital cleaning head (if available). Then, inside of separator is cleaned once again and wastewater required for cleaning is pumped off. The separator must again be filled with water (up to the overflow). The separator is now ready for operation. 2.5 Correct intended use The grease separator plants only retain free separable fats and oils as well as sludge (sediments). Emulsified and soluble components cannot be retained by the separator plant. These may lead to exceeding the locally determined wastewater limit values. A different use is not correct! The correct intended use also includes: Do not carry out any conversion works at plant Observe all notes given in this manual Observe national laws and regulations Adhere to inspection and maintenance information 10

11 ACO Haustechnik _ Suggested installation Regulations on installation site Extract from DIN EN , Grease separator plants should be installed in the vicinity of points of wastewater incidents, but not, however, in unventilated rooms or in traffic or storage areas. In order to avoid odour nuisance, the plant should not be installed near lounges or, in particular, near windows or ventilation openings. Grease separator plants should be arranged in such a way that frost damages are avoided and that all parts which need regular maintenance are easily accessible at any time. We recommend to leave free space of at least 600 mm all around. They must be easily accessible for cleaning vehicles. The disposal connection outside the building must be easily accessible for the suction vehicle. The wastewater must be fed to the separator plant in free slope. In order to avoid grease deposits, the inlet lines of the grease separator plants must have a slope of at least 2 % (1:50). If this is not possible, we recommend the use of our special lifting plants with positive displacement pumps. Here, an additional energy feed is avoided (as e. g. with the use of centrifugal pumps) and the separating effect is not negatively affected. The passage from downpipes to horizontal pipes has to be carried out with two 45 pipe bends and an intermediate piece of at least 250 mm length (or pipe bends with adequate radius). Then, a stabilisation path has to be carried out in flow direction whose length must correspond to at least 10 times the nominal width in mm of the separator inlet pipe. Drain points, e. g. floor drains, have to be fitted with odour seals and buckets, if required, which can be taken out for cleaning purposes. If water level of separator lies below the locally determined backflow level, drainage has to be carried out via a downstream lifting plant. Two pumps have to be fitted to guarantee permanent operation. Legend: 1 Grease separator inlet 2 Coarse trap (option) 3 Grease separator (here: Lipurat-OAE) 4 Sampling pot 5 Wastewater lifting plant 6 Disposal line 7 Connection coupling for suction vehicle 8 Pressure piping of lifting plant 9 Water supply of filling device (with ball valve) 10 Control of lifting plant 11 Cellar drainage pump 12 Ventilation of lifting plant 13 Ventilation of grease separator 14 Ventilation of inlet line 15 Flexible pipe bushing 16 Hot water / cold water connection 11

12 2.7 Power supply/ energy consumption Water supply For the filling device, a drinking water connection R ¾ is required. A pressure reducer (set to 4 bar) is already fitted. Power supply and consumption For types -OS and -RS Unit: High-pressure internal cleaning / performance 3.9 kw For the high-pressure pump and the high-pressure internal cleaning motor, an electric connection 400 V / 50 Hz / prefuse 3 x 16 A is required. Potential-free contact - group alarm All control units are equipped with a potential-free contact for transmission of a group alarm. Contact is realised by a change-over unit. The electric circuits of devices to be connected are galvanically separated. Please take terminal assignment from relevant wiring diagram (refer to attachment or attached to control box). For types -OSE and -RSE Unit: Control type -OSE or -RSE / performance 6.9 kw For the control, a CEE mains socket with connecting value 400 V / 50 Hz / prefuse 3 x 16 A is required. For types -OA and -RA Unit: Control type -OA or -RA / performance 3.9 kw For the control, a CEE mains socket with connecting value 400 V / 50 Hz / prefuse 3 x 16 A is required. For types -OAE and -RAE Unit: Control type -OAE or -RAE / performance 6.9 kw For the control, a CEE mains socket with connecting value 400 V / 50 Hz / prefuse 3 x 16 A is required. 3 Installation 3.1 Transport, delivery and storage Delivery Normally, separator plant is supplied fully mounted, fixed to a wooden pallet and wrapped in a foil. If required because of space restrictions in installation premises of and/or access road to separator plant, stainless steel plant can either be supplied dismantled into single segments or with non-mounted components. Stainless steel separator Polyethylene separator Packaging The type of packaging used partially depends on the means of transport. If not specified directly, the packaging must comply with the packaging regulations (HPE) of the German Wooden Articles, Pallets and Export Packaging Federation, and those specified by the Federation of German Mechanical Engineering Institutes. Storage The separator should be stored in its packaged state in a closed, frostfree room. 12

13 ACO Haustechnik _01 Transport instructions To ensure that the grease separators are not damaged during transport, use a forklift truck, lifting truck or sling ropes. Transport with forklift trucks or lifting trucks When transporting the grease separator with a forklift truck or a lifting truck, make sure that the separator is firmly placed on a suitable transport medium (e.g. wooden pallet). Never lift up the separator on its own without an underlying transporting medium; otherwise there is a significant risk of damaging the separator. Transport with crane hooks When transporting the separator with a crane, it is essential to observe all of the safety regulations for load suspension equipment and lifting equipment. Never stand beneath any suspended loads. Never exceed the authorised maximum lifting weight of the lifting equipment. Connection of ventilation line A connecting socket DN 70 and DN 100 for connection of ventilation line is located at separator cover. Connection is dimensioned as per DIN EN 877. For laying of ventilation line, observe relevant notes (see section 2.1)! If inlet and outlet line are sufficiently aerated, connection of a ventilation line at this socket can be dispensed with. In this case, however, connecting socket must be tightly closed (end cover, pipe connector). All lines have to be stress-free mounted Buoyancy safeguard For buoyancy safeguard of the separator plant, the slots at bottom of plant can be used (design V4A separators). In the case of PE-HD designs, the protruding bottom can be fixed with several mounting plates. When transporting the separator plant by means of a crane, the safety regulations for load suspension equipment and lifting equipment have to be observed. For transporting the separator plant with crane hooks, fix relevant sling ropes to base frame or to supply units. Suspension point of stainless steel separators Suspension point of polyethylene separators 3.2 Erection, installation and assembly Erection To reduce noise and to aerate bottom of separator plant, put it on sound-absorbing supports (included in scope of supply) and align them horizontally. We recommend to keep adequate space (approx. 600mm) for problem-free assembly and operation of the separator plant. 3.3 Local connection works for the plumber (incl. provision of relevant material) Connection of inlet and outlet line Sockets facing each other are mounted to the separator housing for connection of inlet and outlet line. Nominal width corresponds to nominal size. The sockets are marked inlet and outlet. Connection is dimensioned as per DIN EN 877. A pipe connector fitting to this pipe type (for inlet and outlet) is included in scope of supply. For laying of inlet line, observe relevant notes (see section 2.1)! Connection of disposal line These separator types have a connection for the disposal of separator contents. A connecting coupling / internal pipe thread with blank cover Storz 75 (B) system, R 2 3/4 as per DIN is included in scope of supply. If this connection is not easily accessed by the suction vehicle, a disposal line can be laid. The connecting coupling with blank cover can be dismounted from disposal line of separator and be connected to end of in situ disposal line. Rp 2 1/2" R 2 1/2" The line must at least have DN 65 and must be laid with gradient to separator. In order to avoid noise transmission and vibrations, compensators have to be used. Max. length of disposal line to be determined in accordance with performance of suction pump / suction vehicle and disposal pump (characteristic curve see attachment) included in scope of supply. An outside wall connecting box for housing the disposal, ventilation and water connection as well as a remote control is included in our scope of supply. 13

14 Fresh water connection The filling device feeds the high-pressure pumps with water and fills separator plant with water. A fresh water line has to be connected to connection Rp 3/4. Install a ball valve or a gate valve in connecting line to filling device (see suggested installation). In order to support cleaning process of high-pressure pump, warm water (max. 60 ) may also be connected. A required min. throughflow quantity of 30 l/min. must be guaranteed. Connection of high-pressure internal cleaning device These separator types are equipped with a high-pressure internal cleaning device. A drinking water connection R 3/4 has to be connected to the water storage tank of the high-pressure pump. In order to increase cleaning effect, connection can be carried out to warm water line. Operating temperature of high-pressure pump may not exceed 60 C. Connection of control and remote control Connection must be carried out by a qualified contractor; VDE regulations (0100, 0113) have to be adhered to. The control units are supplied with a 5 m long cable with CEE plug, ready for connection. A relevant CEE mains socket has to be mounted in situ. Assembly of segments in case of component supply In exceptional cases and if agreed upon in case of narrow access openings, separator housing (round design) is supplied in segments. These have to be assembled as follows: Sealing Upper part A throughflow capacity of at least 30 l/min. have to be guaranteed. A ball valve or a shut-off device have to be installed in water line feeding high-pressure pump. Tension ring Stainless steel separator Bottom part To ventilate oil container, cut rubber projection of cap. Please use oil type SAE 90. Sealing Upper part HP Orbital cleaning head In exceptional cases, HP Orbital cleaning head (mounted at cover) is loosely applied due to transport height. Assembly has to be carried out as shown on sketch below (seal connection and adjust rod with adjusting ring to height). The electric connecting cable and the pressure hose connection to the high-pressure pump is carried out at the works. Tension screw PE-HD separator min. 8 mm Bottom part Observe correct seating of seal! Adjusting ring Housing cover app. 100 seal in with Teflon or Loctite 14

15 ACO Haustechnik _01 Retro-fit of filling device Undo screws of pipe connector, take off end cover, put connecting pipe of filling device in pipe connector and re-tighten screws. Retro-fit of heating rod Heating rod has to be assembled as shown in figures Step 1-6. Step 1 Step 2 Pneumatic box End cover Filling device min Rack Pipe connector Lower liquid level in separator to min. level. Mount pneumatic box on rack. Free pipe end Step 3 Lower edge of cover Step 4 Measuring pipe In the case of PE-HD separators, cut off free pipe end of the odour seal prior to assembly of filling device. Socket peak X Outlet X Retro-fit of inspection window with wiper Undo nuts and disks, take off blind flange, push Plexiglas flange and counterflange over the stud bolts and re-fix with disks and nuts. Determine dimension X. Step 5 Pneumatic box / rack Shorten measuring pipe (1235 mm long) to dimension X. Step 6 Socket Rp2 (11/2) e. g. LOCTITE Container wall Sealing Stud bolt Blind flange Disk Nut Counterflange Plexiglas flange with wiper Check proper condition of sealing (exchange, if required) and tighten nuts evenly across. Blind cover Sealing Meas. pipe Remove blind cover, mount measuring pipe and unit pneumatic box / rack. Heating rod IP 64 Reducer The electrical connection must be carried out by a specialised contractor in accordance with pertinent VDE regulations. Plug Pull out plug, seal reducer (if required) and heating rod at thread and insert in socket. 15

16 3.4 Local connection works for the fitter (incl. provision of relevant material) Connection must be carried out by a qualified contractor; VDE regulations (0100, 0113) have to be adhered to. Pneumatic box The hose between mini compressor and measuring pipe has to be fixed by means of the hose clamps. Hose clamps Hose Pneumatic box Control of heating rod Installation of a CEE mains socket for high-pressure pump Type -S The high-pressure pump is supplied with a 5 m long cable with CEE mains plug / 16 A ready for connection. A relevant CEE mains socket has to be fitted locally. Connecting value: 400 V / 50 Hz Fuse: 3 x 16A, slow-blowing Installation of a CEE mains socket for the control Typs -SE / -A /-AE The controls (protection type IP 54) are supplied with a 5 m long cable with CEE mains plug / 16 A ready for connection. A relevant CEE mains socket has to be fitted locally. Connecting value: 400 V / 50 Hz Fuse: 3 x 16A, slow-blowing Measuring pipe Combination heating rod control and grease separator control Type -SE / -A / -AE Here, the CEE mains plug of the connecting cable of the grease separator control has to be cut off and the cable has to be connected to the heating rod control. Heating rod control Installation of remote control Type -A /-AE The remote control (protection type IP 54) has to be fitted at a floodproof location, preferably near the disposal connection. Laying of the in situ connecting cable Type -A /-AE A connecting cable must be laid between the plant control and the remote control: up to 50 m distance Cable 7 x 1 mm2 / without protective conductor from 50 to 200 m distance Cable 7 x 1.5 mm2 / without protective conductor Installation of a CEE mains socket for heating rod control Type -basic / -D / -S Control The control (190x280x140 mm/wxhxd, protection type IP 55) of the heating rod is to be fitted at a flood-proof location. As connecting cables to the electrical consumers, following types have to be laid in situ: a) Pressure switch pneumatic box 3 x 1 mm2 / Ölflex b) Mini compressor / pneumatic box 3 x 1 mm2 / Ölflex c) Heating rod 4 x 1.5 mm2 / HO7 d) Connecting cable grease separator control (existing) Grease separator control Laying of the in situ connecting cable Type -SE /-A /-AE All controls have a potential-free contact for transmission of a collective fault signal. The contact is realised via a change-over contact. The electric circuits of the devices to be connected are galvanically disconnected. Please take the terminal connections from the relevant wiring diagram (attached to the control box). Please take the terminal connections of the connecting cables in the control and the pneumatic box from the relevant wiring diagram (attached to the control box). 16

17 ACO Haustechnik _ Works for the user and the operating staff Ventilate oil container of high-pressure pump and check oil level Type -S / -SE / -A / -AE In order to ventilate the oil container, the rubber projecting end of the cap must be cut off. Please use oil type SAE 90. Cap 17

18 4 Operating manual 4.1 Commissioning Prerequisites All connecting and assembly works must be finished. All electric works must be finished. Separator plant has to be thoroughly cleaned. General inspection of separator plant as per DIN was carried out by a properly qualified technician and possible objections were remedied. If existing, gate valves in inlet and outlet lines have to be opened. The separator plant was filled with water up to still-water level (pipe bottom of outlet socket). Test run In the case of separator plants with emptying and rinsing device, a test run has to be carried out. Operational readiness Type -A / -AE Following the test run, leave the trigger switch solenoid valve/filling of the automatic controls at Auto. The solenoid valve is thus automatically opened once a day for 3 seconds and the odour seal of the filling device is filled with water (no odour nuisance). Info: Each time the mains plug is plugged in, the solenoid valve is opened for 3 minutes for test purposes. Filling of separator plant, water storage The separator plant must be filled with water until water flows over into separator outlet pipe or into downstream sampling pipe. Filling process, in detail: 1. in the case of separator series -O, -R, -OD, -RD Filling via inlet line of separator plant or via a maintenance opening (if a filling device is supplied as accessory, please refer to section 2.) 2. in the case of separator series -OS, -RS, -OSE, -RSE, Filling by opening ball valve of filling device 3. in the case of separator series -OA, -RA, -OAE, -RAE Filling by operating control unit accordingly. Hand-over The plant has to be handed over to the operator in operational condition, the operating mode must be explained and the installation and operating manual, the building application documents as well as the official approval have to be handed on. It is recommended to issue an acceptance record and a hand-over certificate. Tightness test Separator plant as well as all pipe connections have to be tested for tightness. The maintenance openings / covers have to be shut. Plant is ready for operation. Presence during commissioning Following persons should be present during commissioning: plumber electrician operating staff / operator disposal company 18

19 ACO Haustechnik _ Operation The plant must be operated (operation, maintenance and servicing) by expert and trained staff members. They must be familiar with the installation and operating manual and the instructions and pertinent regulations on operational safety and accident prevention contained therein. An operations log has to be kept. Documentation Plant documentation, consisting of: Operating log, building application documents, permission, approval, acceptance protocol, installation and operating manual, official approval/test sign must be kept at plant location. Operation Only such cleaning agents, rinsing agents, detergents, disinfectants and additives may be fed into the wastewater which do not contain or release chlorine, which are separator-friendly and do not generate any stabile emulsions. The following is recommended for further reduction of total wastewater load: Consequent dry removing any leftovers from dishes and pre-rinsing of dishes without cleaning agents prior to placing them into the dishwasher. In cooperation with the cleaning agents supplier, the dosage of the cleaner for the dishwasher is to be reduced, if acceptable for hygienic reasons. Check Plant operability should be checked regularly, at least once a week, by a properly qualified person. This check includes following measures: Visual check of separator plant and its connections, visual check of fittings (e. g. pumps) and electrical components, determination of sludge volume in sludge trap (max. half of sludge trap volume), determination of grease layer thickness in the separator (max. 160 mm or reaching the max. grease storage volume as per type plate indication), possible removing of coarse floating substances on water surface, operating the high-pressure internal cleaning (if any). If defects are ascertained during check, these have to be remedied without delay. The checks carried out and the possible defects and their remedy have to be documented in the operating log. Maintenance Grease separator plants have to be emptied once a year as per the manufacturer s specifications and to be serviced by qualified personnel in cleaned condition (refer to DIN ). Despite the measures taken during emptying and disposal, maintenance comprises the following works: Check of internal wall areas of separator plant, particularly check of metal materials for corrosion in the three-phase area (water and grease layer, air film); Functional check of electrical appliances and installations, if any, Cleaning and functional check of suction device and possible check of free outlet of filling device as per DIN EN ; Cleaning of odourproof cover and check of sealing for overall condition and sealing capability. The ascertainments and works carried out incl. their rating have to be documented in a maintenance report and to be entered in the operations log. If defects are ascertained during maintenance, these have to be remedied without delay. In order to maintain the value and operability of the plant as well as the prerequisite for warranty rights, we recommend 1-2 services annually. ACO Haustechnik after-sales service offer relevant maintenance contracts as a service. Additional maintenance works As and when required, the works have to be carried out by properly qualified personnel, in detail: Cleaning of coarse trap. If a coarse trap is fitted in the inlet line of the grease separator, the trap sieve should be cleaned daily. Separator with filling device. In order to avoid drying out of the filling device odour seal, the ball valve in the inlet line should be opened once a week. In the case of automatic control designs (toggle switch must be set at Auto ), the solenoid valve in the inlet line is opened automatically once a day for 3 seconds and the odour seal is thus filled with water. The additional works have to be entered in the operations log. Control Grease separator plants must be controlled in intervals of max. 5 years by a properly qualified technician: Dimensioning of the separator plant; structural condition and tightness of separator plant (tightness test as per DIN , section 13); Condition of internal wall areas, components and electrical appliances (if any); Arrangement of vent line of separator plant as vent line above roof as per DIN EN , section 7.4; Completeness and plausibility of records in the operating log; proof of proper disposal of separator contents taken out; Availability and completeness of required approvals and documents (permissions, drainage plans, operating and maintenance manuals etc.) If defects are ascertained during check, these have to be remedied without delay. The checks carried out and possible corrective works have to be entered into the operations log. Note ACO Haustechnik after-sales service offer a relevant general inspection (initial commissioning, too) by a properly qualified technician as a service. 19

20 Supervision As a rule, the discharging of wastewater from grease separator plants into the public wastewater treatment plant is supervised in line with the municipal indirect discharging control. The respective discharging conditions have to be observed. The supervision dates and relevant discharging values have to be entered into the operations log. Information on sampling The following should be observed without fail: Sampling must be done from wastewater flowing out of plant. As a general rule, the fault deriving from false sampling is more severe than the analysis fault. For this reason, sampling should be carried out exclusively by persons with an adequate qualification. Operating log The following should be contained in the operations log: Building application data with information on separator plant type, user, operation, contact person, installation location, discharging conditions, installation date, general inspection prior to commissioning, commissioning date,... Operating data, supervision and internal control with mentioning of water consumption, ascertainment of sludge and grease layer thicknesses, ph value and temperature measurements, disposal dates,... Maintenance contracts, repair works,... Test and inspection results or reports,... Note Operations logs are available from ACO Haustechnik after-sales service department. 4.3 Emptying and disposal Separator plants with emptying and rinsing device have to be emptied in accordance with the manufacturer s specifications. Works carried out have to be entered into the operations log. Heating (in the case of separators with heating rod accessory) upon requirement 4-6 hours prior to emptying Grad Switch on: Turn main switch to position 2. Automatic switch-off: after 10 hours without disposal process in the case of grease separators without control of operating schedule During disposal process after reaching the lower edge measuring pipe of heating rod level Manual switchoff: Turn main switch to position Thermostate presetting 65 A heating temperature of 60 may not be exceeded in plastic separators. General notes There is an obligation to utilize the separated fatty substances. The user has to make sure that disposal and evacuation are carried out by approved contractors only. Note For emptying of separator plant and disposal of contents, DIN EN 1825 in connection with DIN as well as the pertinent Waste Law have to be observed. Depending on unit-specific wastewater composition, the disposal intervals have to be scheduled as per requirement, if possible, however, every 2 weeks, and at least once a month, by properly qualified personnel. Timing of required disposal works is determined during operation by means of grease and sludge layer thicknesses measured. Besides the control works, disposal works comprise: complete emptying, cleaning, replenishment with water*, cleaning of drain channel or sampling device. * The separator plant has to be filled with water up to operating water level. Rainwater, operating water or processed wastewater from separating plant can be used if use complies with local discharging conditions. If for replenishment wastewater from the disposal vehicle is used, the adherance to municipal wastewater limit values must be documented. The disposal contractor must hand out to the user relevant documents. 20

21 ACO Haustechnik _ Disposal process of grease separator, basic design Eco-Jet-O/-R/-G/Lipurex-O/-R Recommendation: Disposal: Once a month (standard rule) When making an appointment with the disposal contractor, indicate wastewater quantity to be disposed of. Guidance value: total contents plus 15 % for rinsing water. Emptying After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). 2. Remove cover of maintenance opening and suck off entire contents of the separator into the suction vehicle by means of the suction hose. Cleaning 1. Clean inside of separator thoroughly. 2. Suck off wastewater. Filling 1. Suction hose has to be drawn in by suction vehicle. 2. Filling of the separator (at least 2/3 of the entire volume): a) via maintenance opening b) via inlet line c) via filling device if any (b) (a) (c) 3. Open gate valve if any. Wastewater can again flow in. 4. Enter disposal in the operating log. Separator ready for operation! 21

22 4.5 Disposal process of grease separator (with direct suction), extension stage 1 Eco-Jet-OD/-RD/-GD/Lipurex-OD/-RD Recommendation: Disposal: Once a month (standard rule) When making an appointment with the disposal contractor, indicate wastewater quantity to be disposed of. Guidance value: total contents plus 15 % for rinsing water. Emptying After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). 2. Connect suction hose to direct suction connection and suck off entire contents of the separator into the suction vehicle by means of the suction hose. Cleaning 1. Clean inside of separator thoroughly. 2. Suck off wastewater. Filling 1. Suction hose has to be drawn in by suction vehicle. 2. Filling of the separator (at least 2/3 of the entire volume): a) via maintenance opening b) via inlet line c) via filling device if any (b) (a) (c) 3. Open gate valve if any. Wastewater can again flow in. 4. Enter disposal in the operating log. Separator ready for operation! 22

23 ACO Haustechnik _ Disposal process of grease separator extension stage 2 (with direct suction, high-pressure cleaning, manual control), Hydrojet-OS/-RS/Lipurat-OS/-RS Recommendation: Disposal: Once a month (standard rule) When making an appointment with the disposal contractor, indicate wastewater quantity to be disposed of. Guidance value: total contents plus 15 % for rinsing water. Cleaning and emptying After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). 2. Connect suction hose to direct suction connection. 3. Open ball valve of filling device. Switch on high-pressure pump manually and suck off entire contents of the separator into the suction vehicle by means of the suction hose. 4. Following cleaning, switch off high-pressure pump. Switch off suction pump of suction vehicle. Caution! Maintenance openings must be shut. Risk of injury! A Filling 1. Suction hose has to be drawn in by suction vehicle. 2. Filling of the separator via filling device (at least 2/3 of the entire volume). After filling, shut ball valve of filling device. 3. Open gate valve, if any. Wastewater can again flow in. 4. Enter disposal in the operating log. Separator ready for operation! 23

24 4.7 Disposal process of grease separator - extension stage 2 (with direct suction, high-pressure internal cleaning, manual control and disposal pump), Hydrojet-OSE/-RSE/Lipurat-OSE/-RSE Recommendation: Disposal: Once a month (standard rule) When making an appointment with the disposal contractor, indicate wastewater quantity to be disposed of. Guidance value: total contents plus 15 % for rinsing water. Cleaning and emptying After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). 2. Connect suction hose to disposal connnection. C G 3. Key switch in 1 position (A). Switch on disposal pump for approx. 30 seconds in order to lower water level (B). 4. Open ball valve of filling device (C). 5. Switch on high-pressure pump (D). 6. Switch on disposal pump (E). 7. In the case of measuring empty, the disposal pump switches off following termination of after-running time (residual disposal). A B D 8. Switch off high-pressure pump (F). 9. Disposal completed. E F Filling 1. Suction hose has to be drawn in by suction vehicle. 2. Filling of the separator (at least 2/3 of the entire volume): a) via inlet line and/or b) via filling device. (a) (b) 3. Open gate valve if any. Wastewater can again flow in. 4. Shut ball valve of filling device (G). 5. Key switch in 0 position (H). 6. Enter disposal in the operations log. H Separator ready for operation! 24

25 ACO Haustechnik _ Disposal process of grease separator - extension stage 3 (with direct suction, high-pressure internal cleaning and automatic control), Hydrojet-OA/-RA/Lipurat-OA/-RA Recommendation: Disposal: Once a month (standard rule) When making an appointment with the disposal contractor, indicate wastewater quantity to be disposed of. Guidance value: total contents plus 15 % for rinsing water. Disposal process After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). A E F 2. Connect suction hose to disposal connection (A). C G 3. The switch at high-pressure pump must be switched on (B). Both toggle switches must be in Auto (C) position. B 4. Key switch in 1 (D) position. Disposal programme runs automatically and separator is cleaned. 5. When LED Suction vehicle ON lights up, switch on suction vehicle pump (E). Disposal programme continues automatically, separator is emptied, cleaned and residual water is sucked off. 6. When LED Suction vehicle OFF lights up, switch off suction vehicle pump (F). 7. The suction hose has to be drawn in by the suction vehicle (G). 8. Filling of separator is carried out automatically (for preset time, refer to switchbox). C 9. Open gate valve, if any. Wastewater is again capable of flowing in. D 10. Key switch in 0 position (H). 11. Enter disposal in operations log. The toggle switch at the control for solenoid valve/filling must remain in the "Auto" position to ensure an automatic, daily replenishment of the odour seal. E F H Separator ready for operation! 25

26 4.9 Disposal process of grease separator - extension stage 3 (with direct suction, high-pressure internal cleaning, automatic control and disposal pump), Hydrojet-OAE/-RAE/Lipurat-OAE/-RAE Recommendation: Disposal: Once a month (standard rule) When making an appointment with the disposal contractor, indicate wastewater quantity to be disposed of. Guidance value: total contents plus 15 % for rinsing water. Cleaning and emptying After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). E A 2. Connect suction hose to disposal connnection (A). C 3. The switches at the high-pressure pump must be switched on (B). Both toggle switches must be in Auto (C) position. B 4. Key/programme switch in 1 (D) position. Disposal programme runs automatically. B 5. The disposal pump pumps separator contents to the suction vehicle for 30 seconds and thus lowers water level. 6. Water is fed which supports cleaning effect. The high-pressure jet of the high-pressure Orbital cleaning head destroys the grease layer and homogenises contents The suction pump pumps contents to the suction vehicle until separator is completely emptied. D 8. Water is fed which supports cleaning effect. The high-pressure jet of the high-pressure Orbital cleaning head cleans the interior. The disposal pump pumps cleaning water to the suction vehicle until the separator is com-pletely empty. 9. The separator is filled automatically (for preset time, please refer to switchbox) Cleaning and disposal are finished. The suction hose can be drawn in by the suction vehicle (E). 11. Open gate valve, if any. Wastewater is again capable of flowing in. 12. Key switch in 0 (F) position Enter disposal in operations log. The toggle switch at the control for solenoid valve/filling must remain in the "Auto" position to ensure an automatic, daily replenishment of the odour seal. 12 F Separator ready for operation! 26

27 ACO Haustechnik _ Disposal process of grease separator - extension stage 3 with remote control (with direct suction, highpressure internal cleaning, automatic control and remote control, with or without disposal pump) without disposal pump (-OA/-RA) After the disposal contractor has arrived: A E F with disposal pump (-OAE/-RAE) After the disposal contractor has arrived: 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). C G 1. Stop wastewater inflow by interrupting kitchen operation. Shut gate valve (if any). 2. Connect suction hose to disposal connection (A). B 2. Connect suction hose to disposal connnection (A). 3. The switch at the high-pressure pump must be switched on (B). Both toggle switches are in Auto (C) position. 4. Key switch in 1 (D) position. Disposal programme runs automatically and separator is cleaned. B 3. The switch at the high-pressure pump must be switched on (B). Both toggle switches are in Auto (C) position. 4. Key/programme switch in 1 (D) position. Disposal programme runs automatically. 5. When LED Suction vehicle ON lights up, switch on suction vehicle pump (E). Disposal programme continues automatically, separator is emptied, cleaned and residual water is sucked off. 6. When LED Suction vehicle OFF lights up, switch off suction vehicle pump (F). 7. The suction hose has to be drawn in by the suction vehicle (G). E D D 5. The disposal pump pumps separator contents to the suction vehicle for 30 seconds and thus lowers water level. 6. Water is fed which supports cleaning effect. The high-pressure jet of the high-pressure Orbital cleaning head destroys the grease layer and homogenises contents. 7. The suction pump pumps contents to the suction vehicle until separator is completely emptied. 8. Filling of separator is carried out automatically (for preset time, please refer to switchbox). 9. Open gate valve, if any. Wastewater is again capable of flowing in. 8. Water is fed which supports cleaning effect. The high-pressure jet of the high-pressure Orbital cleaning head cleans the interior. The disposal pump pumps cleaning water to the suction vehicle until the separator is com-pletely empty. 10. Key switch in 0 position (H). 11. Enter disposal in operations log. The toggle switch at the control for solenoid valve/filling must remain in the "Auto" position to ensure an automatic, daily replenishment of the odour seal. F 9. The separator is filled automatically (for preset time, please refer to switchbox). 10. Cleaning and disposal are finished. The suction hose can be drawn in by the suction vehicle (E). 11. Open gate valve, if any. Wastewater is again capable of flowing in. H F 12. Key switch in 0 (F) position. 13. Enter disposal in operations log. The toggle switch at the control for solenoid valve/filling must remain in the "Auto" position to ensure an automatic, daily replenishment of the odour seal. 27

28 4.11 Faults; Cause and their remedy Faults apply to relevant designs. Connection must be carried out by a qualified contractor; VDE regulations (0100, 0113) have to be adhered to. Fault Cause Remedy 1. Odour nuisance during normal operation No water in odour seal No power supply at control type -A or -AE Open ball valve of manual filling device and replenish odour seal with water Check power supply at control type -A or -AE Emergency-Off switch pressed Toggle switch solenoid valve in Off position Unlock Emergency-Off switch Turn toggle switch of solenoid valve to Auto position 2. High-pressure (HP) pump does not run Switch at high-pressure (HP) pump not switched on Breaking current triggered off because of too high charging rate of HP pump HP detector triggered off because of drop in pressure in pressure hose of HP pump (> 15sec) Emergency-Off switch pressed Toggle switch HP pump in Off position CEE mains plug or control without voltage Switch on switch at high-pressure (HP) pump Acknowledge fault at control with Reset button. If fault prevails, have fault remedied by ACO Passavant or an authorised after-sales service Open ball valve in inlet line of filling device Clean filter in inlet line of HP pump Check function of solenoid valve Unlock Emergency-Off switch Turn toggle switch of HP pump to Auto position Check power supply at CEE mains socket or control 3. HP pump does not build up pressure Filter in inlet line of HP pump blocked Clean filter in inlet line of HP pump 4. HP Orbital cleaning head does not turn Switch at HP Orbital cleaning head not switched on Switch on switch at HP Orbital cleaning head 5. Water not escaping HP Orbital cleaning head Filter in inlet line of HP pump blocked Jets of HP Orbital cleaning head blocked Clean filter in inlet line of HP pump Clean jets of HP Orbital cleaning head 6. No function at control No voltage supply at control Emergency-Off switch pressed Programme "hung up" Check power supply at control Unlock Emergency-Off switch Pull out CEE plug of control for a short time (some seconds) 7. Automatic programme does not start up Emergency-Off switch pressed Programme "hung up" Unlock Emergency-Off switch Pull out CEE plug of control for a short time (some seconds) 8. Disposal pump does not run Breaking current triggered off because of too high charging rate of disposal pump Temperature detector has triggered off Emergency-Off switch pressed Toggle switch disposal pump in Off position CEE mains socket or control without voltage Acknowledge fault at control with Reset button. If fault prevails, have fault remedied by ACO Passavant or an authorised after-sales service Acknowledge fault at control with Reset button. If fault prevails, have fault remedied by ACO Passavant or an authorised after-sales service Unlock Emergency-Off switch Turn toggle switch of disposal pump to Auto position Check power supply at CEE mains socket or control 9. Disposal pump does not deliver Pump runs at false sense of rotation Suction opening in separator blocked Have sense of rotation changed by electrician Clean suction opening in separator 10. Disposal pump does not switch off Measuring pipe in separator blocked Measuring empty hose blocked or flexed Clean measuring pipe Clean measuring empty hose and check for free passage Check mini compressor and / or pressure switch 28

29 ACO Haustechnik _01 5 Servicing 5.1 General notes The accident prevention regulations and the regulations for handling of waste substances must be observed. If separator must be entered in exceptional cases, it has to be emptied completely and be ventilated thoroughly. Work on the electrical equipment (accessories) of the separator must only be carried out by a properly qualified electrician or by properly instructed personnel acting under the guidance and supervision of a properly qualified electrician in accordance with the Electrical Regulations. Before carrying out any maintenance work on the separator, first switch off the power supply to the electrical equipment and secure it to prevent it from being switched on accidentally. Re-tighten firmly all connections which were loosened during maintenance and servicing works. The substances as well as exchange components accrued during operation of separator plant have to be disposed of in accordance with environmental protection regulations. Enquiry for quotation of a maintenance contract Grease separator Please let me have your non-binding quotation for regular maintenance of the above-mentioned plant. Fax no.: ++49 (0) / Name, first name Street, house number Post code, city Date of installation Type as per type plate Telephone/Telefax number Nominal size In order to keep value and functioning of plant as well as prerequisite for warranty rights, we recommend to carry out 1-2 services annually. We recommend to have the maintenance and servicing works which are to be carried out regularly performed directly by the manufacturer, ACO Haustechnik. You thus not only have a permanent operational reliability, but in addition you benefit from revisions and upgradings carried out in line with our product development. To request a quotation for a maintenance contract, please copy the adjoining coupon, fill it out completely and fax it to fax number ++49 (0) / , service@aco-online.de. In the case of queries, please contact our after-sales service under tel. no.: ++49 (0) /

30 5.2 Overview: Regular maintenance works Interval To be carried out by Maintenance works Chapter Every 1-2 days the operator Visual check of separator plant Once to twice a week the operator Replenishing of odour seal of filling device with water (if available, does not apply to automatic plants) 4.2 Every 2 weeks a properly qualified disposal Disposal of complete separator contents at the latest once a month contractor As per requirement the operator, properly qualified Functional check by means of functions personnel or ACO Haustechnik manual operation at plant control Every 6 months properly qualified personnel Check of cpl. separator plant for condition and ACO Haustechnik Service function following emptying and cleaning 4.2 Every 5 years a properly qualified technician General inspection of separator plant 4.2 As per requirement the operator, properly qualified Cleaning of filter sieve in suction socket 4.2 personnel or ACO Haustechnik of HP pump (if any) Remove sieve located in water supply line to water storage tank of high-pressure internal cleaning device (if any) and clean Check hose of measuring empty (if any) for free passage Check membrane pump / pneumatic box of measuring empty (if any) Check all flange, pipe and hose connections for tightness Check inspection window (if any) a) Cleaning of filter sieve at suction socket of HP pump (if any). c) Cleaning of connecting hose pneumatic box / measuring pipe of measuring empty (if any). Check hose of measuring empty for free passage and blow through. d) Cleaning of measuring empty pipe (if any). Check and, if required, clean measuring pipe (= air bubble pipe), particularly the pipe mouth in the container, for pollution and cross-section reduction. Remove sieve and clean. b) Cleaning of filter sieve in inlet of water storage tank (if any). e) HP pump and Orbital cleaning head (if any) These should be checked for their performance in the course of a maintenance / inspection (or when required). f) Disposal pump (if any) This pump should be checked for its performance in the course of a maintenance / inspection (or when required). g) Inspection window (if any) In the case of leakage, external threaded bushing can be re-tightened. If this is not sufficient, replace unit. Remove sieve and clean. 30

31 ACO Haustechnik _01 h) Check of the pneumatic box of measuring empty (if any). The mini compressor and the pressure switch are fixed separately in a box on the pilot tube. This measure increases operating reliability and serviceability. If the compressor fails to deliver any air for measuring empty, this may lead to faulty switchings at disposal pump! Check mini compressor and pressure switch for performance and replace, if required. Switchpoints of pressure switches are pre-set at our works, but may be adjusted (please contact ACO Service). 5.3 Repair For repair works, please contact the ACO service partners or the ACO Haustechnik after-sales service, tel (0) or the internet Order information ACO Haustechnik expressly point out that servicing and spare parts as well as fittings not corresponding to the original are neither tested nor released. Fitting andor use of such products may possibly affect design-relevant properties of grease separator plant and thus active and/or passive safety. For damages arising from the use of non-original parts and accessories, ACO Haustechnik do not accept any liability or warranty claims. When ordering spare parts or in the case of queries, please mention (take data from type plate): Further information on spare parts packages in the internet Separator plant type Year of manufacture Article number Serial number Quantity In order to avoid fitting of maintenance and spare parts of minor quality, only original parts from the plant manufacturer should be used. 5.4 Decommissioning Dismantling Dispose of grease separator contents. Clean plant thoroughly, shut water inflow, avoid further water inflow, disconnect control, pull out or release fuses, empty disposal line, dismantle electrical feed line etc. 5.6 Addresses of ACO service partners The ACO Haustechnik service partners can be taken from the internet under Disposal The separator plant consists of recyclable materials. They must be disposed of in accordance with local regulations. Temporary shutdown Protect plant against moisture. Operate fittings (e. g. valve, HP pump, HP Orbital cleaning head, disposal pump) at times in order to avoid seizing. At any rate, plant must be filled with clear water. Protect control against moisture. Depending on duration and surroundings, disassemble fittings and control and store in a dry place. 5.5 Spare parts and after-sales service Servicing and wear and tear parts When contacting the ACO Haustechnik after-sales service, please indicate type, serial number and year of manufacture of separator plant. Further information on spare parts packages can be taken from the internet under 31

32 Attachment Characteristic curve and performance data of disposal pump type V 30 Performance data: PM = 3.0 kw / n = 2850 r.p.m. Q = 20 m3/h at 1 bar medium delivery head Circuit diagram of control OSE/RSE Datasheet terminal connection diagram Grease Separator Control Typ: RSE/OSE (09/07) 24V Emergency-stop control unit Start pressure switch 24V = ~ F1 F2 Rotary field display PE N U V W N PE L1 T1 T2 PE U V W PE L1 L2 L3 N L1 N Membrane pump Potential-free signaling contact (composite error) pressure switch HD-unit M 3 ~ M1 High pressure pump 1 400V, max. 3kW Motor sprax nozzle 230V, max. 3,15A (fused F 3,15A T) M T 3 ~ M2 Disposal pump 400V, max. 3kW plug-in service connection 16A CEE Length approx. 5m Information: If there is no thermal-fuse the contacts T1 and T2 have to be connected. Erstellt Geprüft Freigabe Sach-Nr. von: DN von: MR von: CS am: am: am: Weitergabe sowie Vervielfältigung dieser Unterlage, Verwertung und Mitteilung Ihres Inhaltes nicht gestattet, sowie nicht ausdrücklich zugestanden. Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall der Patenterteilung oder Gebrauchsmuster- Eintragung vorbehalten B 32