KESSEL Grease separator PV NS 2, 4, 7, 10

Transcription

1 INSTALLATION AND OPERATING INSTRUCTIONS KESSEL Grease separator PV NS 2, 4, 7, 10 For installati in frost free areas *With fully automated disposal program Versi according to DIN and EN Product Advantages According to DIN (Certificati Nr. Z ) According to EN (Certificati Nr. Z ) Manufactured from Polyethylene Compact cstructi Low maintenance costs due to heavy-duty, easily cleaned polymer cstructi 100 % resistance against aggressive grease acids Recyclable With optial remote ctrol Fig. shows Nr /P1 Installati Inbetriebnahme Einweisung The installati and service of this unit should be carried out by a licensed professial servicer : Name/Sign City Date Editi 01/2013 Stamp Company Id-Number EN Subject to technical amendments

2 1. Safety Instructis Dear Customer, Before the KESSEL Euro Separator Versi PV is installed and placed in operati please carefully read and follow all of the instructis ctained in this Installati, Maintenance and User s Manual. Up delivery of the Euro Separator please thoroughly inspect the separator to make sure that it has not been damaged during shipping. In case damage has occurred to the separator, please follow the instructis listed in the Guarantee secti of this user s manual. By installati, use, maintenance and repair of this unit please follow all appropriate DIN / VDE /DVGW safety precautis and accident preventi guidelines. Also please follow any local safety precautis and accident preventi guidelines established in your area. Please note that the unit is designed to receive kitchen waste water with a maximum temperature of 60 degrees Celsius (140 degrees F). Temperatures higher than 60 degrees Celsius could damage the unit. Do not stand or place excessive weight the separator. During disposal / emptying of a Type PV separator, a step ladder should be used to help gain access to the openings the top of the separator. NO SMOKING! Smoking must not be permitted near the separator during use, maintenance and repair of the unit due to the potential build up of methane / biogas. SLIPPERY WHEN WET! Take cauti when standing / walking near the separator. During disposal, cleaning and maintenance the surrounding area can become extremely slippery due to spilled water / grease / fat. SEPARATOR AREA REGULATIONS: No access of the separator for unauthorized persnel No storage of food / groceries / provisis (for hygienic reass) is allowed in the same area/room as the separator. The locati of the separator should be chosen carefully as to allow sufficient access for maintenance, inspecti, repair and disposal of the separator. The wastewater in a grease separator can ctain bacteria. After coming in ctact with wastewater or the separator itself, it is important to wash, clean and disinfect all skin which has been ctaminated. Change and wash clothes properly that have come in ctact with the ctaminated wastewater. These safety measures are to be made aware to anye who operates, maintains or services this product. 38

3 Table of Ctents 1. General 1.1 Applicati... Page Applicati area... Page Separator descripti... Page Table of article numbers... Page Installati 2.1 General... Page Set-up... Page Electrical Installatis... Page Installati example... Page Dimensied drawings... Page Setting up 3.1 Setting up for operati... Page Initial Instructis... Page What to do... Page Operati / Disposal 4.1 Manually automated disposal... Page First disposal... Page Disposal intervals... Page Disposal procedure fully automated... Page Starting the disposal... Page Re-Programming... Page Disposal steps grease separator 5.1 Grease separator acc. to DIN Page Grease separator acc. to EN Page Kfigurati 6.1 General... Page Setting the Mixing, Filling, Cleaning and Disposal times Page Malfuncti messages... Page Ctrol Unit... Page SicCtrol (Optial) 9.1 Safety instructis... Page General... Page Installati... Page SicCtrol Sensor Installati... Page Installati example... Page Remote Alarm... Page Shortening the sensor cable length... Page Potential free ctact... Page Installati / Cables cnectis... Page Commissiing... Page Inspecti and Maintenance... Page Events display (ly in logbook)... Page Malfunctis display... Page General malfunctis... Page System errors... Page Techical data... Page Replacement parts and accessories... Page Declarati od cformity... Page Accessories / Replacement parts 10.1 Remote Ctrol... Page Sampling chamber... Page Aqualift F lifting stati... Page Maintenance... Page Warranty... Page Declarati of Cformity... Page Separator characteristics... Page Important ctacts/info... Page 70 39

4 1. General 1.1 Applicati Wastewater ctaining oils and greases from animal or plant origin are not allowed to be drained into public wastewater systems and into public waters due to the fact that in a cooled state the oils and greases coat interior drainage pipes causing blockages as well as reducing the drainage capacity of the pipes. In additial, after short periods of time the decomposing greases and oils build up acids which can lead to odour nuisances as well as corroding drainage pipes and building materials. The developing grease layer water surfaces also decreases the ability for required oxygen to enter the water in public watershed areas as well as public wastewater treatment facilities. Also, DIN 1986 Part I required the separati and removal of these damaging wastes. Due to these reass, grease separators are required for installati as well as the separator ctents being properly disposed. The temperature in the grease separator should be as low as possible. A temperature increase of 10 deg Celsius inside the temperature reduces the separator efficiency by 50%. Most natial and local regulatis limit the allowable wastewater temperature which exits a building the German regulatis limits the temperature to 35 deg Celsius. 1.2 Applicati area Grease separators are to be installed in all wastewater drainage pipes which could ctain oils / greases. The separator will remove the fats, oils and sludge from the wastewater. Disposal of a KESSEL PV fully automated grease separator is basically odour free since the disposal, cleaning and refilling of the separator is de without the need to open the separator s covers. The disposal vehicle cnects its disposal pipe to a permanently installed pressure disposal line from the grease separator which should be located in an easy accessible locati (exterior wall of the building for example). The separated oils, greases and sludges are pumped directly into the grease separator. This eliminates the unhygienic process of the truck s disposal hose being brought into the area of the building which ctains the grease separator. 1.3 Separator descripti The KESSEL PV Fully Automated Grease Separator csists of a grease separator with integrated sludge trap. Separators built according to DIN 4040 er a sludge trap which isolated from the grease separati area by a wall. Grease separators manufactured according to EN 1825 do not have the separator sludge trap meaning that all oils, greases and sludge are separated out of the wastewater stream in e area. The separator body is manufactured from polyethylene. The separator is equipped with e pump with a macerator assembly. The separators are equipped with twin odour tight access covers. The polyethylene interior walls of the separator require no extra protective coatings. For important technical informati ccerning this separator please see the shield located the separator itself this informati is also located in this User's Manual. Delivery ctents of a PV grease separator are: - separator body - a refilling system for cold and warm water - a pump for cleaning and disposing of the separator - an actuator valve for ctrolling the cleaning/disposal process - two solenoid valves - a ctrol unit - a maintenance ctract - an inspecti window located the body of the separator. Optial: - SicCtrol grease sensor - Remote ctrol for remote operati of the disposal process 1.4 Table of article numbers accord. DIN 4040 Article number accord. EN 1825 Article number NS (l/sec) Pump left Pump right NS (l/sec) Pump left Pump right / P / P / P / P /P / P /P / P / P / P / P / P / P / P / P / P1 Pump left = operati side in flow directi left Pump right = operati side in flow directi right 40

5 2. Installati 2.1 General The separator is to be installed in a dry, frost free room / area a smooth, solid and level surface. This is especially important due to the electric equipment accompanied with the separator. Based the size of the grease separator it can be equipped with the following pumps (custom separators may be equipped with custom pumps). 3 kw Pump mit 400 V, 50 Hz, IP 55 protecti class, Pumping performance: Q = 30 m 3 /h, H = 12 m/h Customized systems Pump specificatis for customized systems will be supplied with the manual for the custom separator. Förderhöhe (m) [m] Design criteria for grease pump 2.2 Set-up / Installati 3,0 kw [Qm 3 /h] Förderstrom Q (m 3 /h) 1. DIN 4040 / EN 1825 and EN regulatis must be followed during installati! 2. The entire system must be installed completely level. 3. The pump (included in the delivery) is to be placed and securedto the floor with the included fastening bolts. In order to dampen pump vibratis be sure to place the included rubber matts under each of the pumps. 4. The pump s outlet should be cnected to the disposal pipe using a rubber coupling with twin steel fastening clamps. Clamps should be tightened to a torque of 10 Nm. 5. The disposal pressure pipe is to be cnected to the included flange the end of the separator's disposal pipe stub (flange cnecti is DN65, PN 10 DIN 2501, holediameter 145mm). The Storz B coupling (with R 2 1/2 inch inside threads) supplied with the system should be installed to the end of the disposal pipe where the disposal truck will cnect its sucti hose. Vibrati dampeners should be used when installing the disposal pipe to prevent vibratis from transferring to the building during disposal. The disposal pipe should be laid with a slight slope back toward the separator. 6. The remote ctrol should be installed near the Storz B coupling, if possible - above the coupling. 7. In order to protect the coupling and the remote ctrol from unauthorized access, it is advised that both of these items be ctained in a lockable protective enclosure (not included with the delivery). Recommended enclosure dimensis (width mm, height mm, depth mm). 8. The two included 1 inch solenoid valves (for the cold water refill and the warm water rinsing) must be installed perfectly level (please see included installati guide). The magnet system should be installed upwards this prevents materials from settling in the system should could lead to a shortened lifespan. The cold and warm water supply pipes should be flushed clean after installati (follow included installati manual) 9. Follow DIN 1988, DVGW as well as local installati codes when cnected the cold water refill and the warm water rinsing pipes. Installati of KESSEL refill funnel (included with shipment): - Cnect warm and cold water supply pipes with each other as a T cnecti. The outlet of the T cnecti should be threaded to the R1 inch inner threads of the KESSEL refill funnel. 10. The cold water supply pipe is the refilling system and the warm water supply pipe is the cleaning / rinsing cnecti 11. The inlet and outlet drainage pipes should be cnected to the grease separator. If SML cast ir drainage piping is used according to DIN then steel inner support rings should be used the inlet and the outlet of the separator (which are available as accessories). If other drainage piping material is being used then standard rubber cnecti couplings (FERNCO type couplings) should be used. 12. According to DIN EN , the grease separator as well as the inlet and outlet drainage pipes must be properly ventilated. The main inlet pipe to a grease separator should be directly ventilated to the roof of the building. An additial ventilati pipe should be installed near the inlet of the grease separator in the case that the main inlet pipe is lger than 10 meters and ers no ventilati for this 10 meters. All secdary drainage pipes 5meters or lger which enter the main inlet pipe should also be separately ventilated. 2.3 Electrical Installatis All electrical cnectis and work should be handled by a professial, licensed electrician. 1. The pump, actuator valve and solenoid valves should be cnected to the ctrol unit following the cnecti instructis located inside the ctrol unit. The cnecti cable 5 x 4mm or 5 x 2, 5 mm square depending line length (according to DIN VDE)) should be cnected site. 41

6 2. Installati 3.0 pump requires a T 16 Amp fuse. 2. The rotatial directi of the pump must be checked (improper rotati will cause operatial noise as well as decrease pump. 3. The remote ctrol (available as an accessory) is supplied with a 15 meter cnecti cable. The cable can be replaced with a lger cable if required (use a protected cable LiYCY 3 x 0.34 mm square) Please take care that: - That the user's manual and all operating instructis ccerning the separator are kept in a safe locati nearby the separator. - That the disposal procedure is cducted exactly as it is described in the user's manual. - Only allow professial licensed disposal companies to handle the disposal of the separator. Right reserved for technical changes. Ctrol unit installati: In order to open the ctrol unit, the power safety switch must be set at the 0 positi. In order to mount the ctrol unit a drilling template, dowels and screws are required. For DIN separators, the ctrol unit can be mounted a PE (polyethylene) plate directly the grease separator itself. For EURO separators the ctrol unit should be mounted a nearby wall. Cables running from the ctrol unit to the separator should be laid in a protective cduit. The ctrol unit should be installed in a dry, frost free and easily accessible locati. Protect the ctrol unit from direct sunlight. The cap screws shall be sealed with 1 Nm. 2.4 Installati example a b Ventialti Grease Separator Ventilati pipe Cnecti for disposal truck Sidewalk Cnecti to public sewer Wastewater which collects below backwater level (ground level) should be pumped into the public sewer with an appropriate wastewater lifting stati a b KESSEL NS 4 E+S PV grease separator Storz-B coupling Sampling chamber Cold and Warm water supply cnecti Closure valve Water supply cnecti cold water supply warm water supply Disposal pipe Electrical cnecti Solenoid valves Sediment trap / collector KESSEL basement drain with backwater flaps (The Universal ) KESSEL lifting stati Ctrol unit 42

7 2. Installati 2.5 Dimensied drawing Grease separator acc. to DIN 4040 alle Maße in mm Inlet Outlet Sludge trap Grease trap Quick-release covers Inspecti window Two way valve Actuator valve Cleaning jets Cleaning water stream Pump with closure Warm water cnecti (rinsing) and cold water cnecti (refilling with fresh water) Ctrol unit Disposal pipe cnecti NS (l/sec) DN Einbringmaße axb a b b h h h h Separator volumes sludge chamber Separator 220 l 570 l 430 l 1070 l 720 l 1870 l 1052 l 2480 l Weight approx 240 kg 290 kg 400 kg 440 kg Grease separator acc. to EN 1825 OD = Outer Dimensi b1 = wide all in mm NS (l/sec) NS 2 NS 4 NS 7 NS 10 DN/OD 100/ / / /160 a Einbringmaße l x b b h h h Separator volumes sludge chamber Separator 200 l 212 l 400 l 354 l 700 l 567 l 1000 l 794 l Grease storage 106 l 177 l 302 l 423 l 43

8 3. Setting up 3.1 Setting up for operati Prior to placing the separator into operati, please make sure that: the separator is clean and the interior is free from any objects which may have been placed inside during shipping or installati. the separator is completely filled with clean cold water. Completely filling the separator is complete when water begins to drain from the outlet. check to separator tank to make sure that it is fully watertight, that no damage during shipping or installati has occurred and that all pipe cnecti have been properly made and are watertight. 3.2 Initial Instructis Placing the separator into full operati is normally handled by a licensed tradesman although up request can be handled by a KESSEL representative. 1. The following persnel should be hand when the initial instructis for placing the separator into operati are given: Building facilities manager Ctracted plumber / tradesman Also recommended to be in attendance: Building maintenance workers Ctracted disposal company Grease separator operator 2. Preparati of commissiing instructis: All plumbing cnectis must be made Separator must be completely filled with water The disposal truck / company must be -site 3. Instructis: Informati ccerning the proper disposal of the separator Instructi ctrol unit operati Operatial test Instructis how often separator disposal should take place 4. Hand-over of installati and operating manual to owner / building facilities persnel 5. After the commissiing is completed, the separator should be returned to operati, this requires that the separator is completely filled with cold water. 6. Fill out the commissiing documentati report / log 3.3 Handover Certificate 4. Operati 4.1 Operati The ctrol unit er fully automated disposal which can be activated by Start / Stop butt (5) the ctrol unit. The same butt can also be used to stop the process during the automatic disposal. The alarm butt (3) can be used to cfirm / silence an alarm. The current operating status is displayed by the LED 1, alarms / malfunctis are displayed by LED 2, and the pump operati is displayed by LED 4. The digital display (6) can be operated / navigated by used the up and down butts as well as the escape (ESC) and OK butts (butts 7). Please follow the operating instructis (8). The ctrol unit should be completely discnected from power before any work is de the ctrol unit (9)(see safety instructis) ➀ ➁ ➂ ➃ ➄ Operati LED Alarm LED Alarm butt Pump operati LED Start / Stop Display Fully automated operati Navigati butts up, down, escape and ok Operatial manual Discnect ctrol unit from power source before any work is de. The KESSEL PV fully automated grease separator csists of a ctrol unit with fully automated ctrol, operatial panel and digital display as well as an optial remote ctrol (Protecti Class IP 54). The disposal program / software for this separator has already been installed into the ctrol unit at the factory. If the ctrol unit is changed or replaced please keep this in mind and ctact KESSEL if required. The ctrol unit is capable of the following settings: Fully automated: The disposal steps being operating automatically when the Start butt is pressed followed by the pressing of the OK butt ➈ ➇ ➆ ➅ 44

9 4. Operati Manual operati: The disposal steps can also be operated manually under the display heading Maintenance Manual Operati Operatial cditis, disposal steps and malfunctis are displayed the ctrol unit and the remote ctrol. The mixing, rinsing and disposal times can be changed in parameter 3.1 the digital display. 4.2 Grease separator disposal functi / steps Disposal of the grease separator can take place in the automatic or manual modes. Turn the ctrol unit with the main power switch Changing from manual to automatic mode can be de at any time! In the case that during automatic disposal that the ctrol unit is changed to manual mode, the automated disposal will be stopped. The mixing, rinsing and disposal times have been set at the factory. On-site cditis may vary and require these times to be changed which can be de using the ctrol unit. 0 Systeminfo 1 Informatis 2 Maintenance 2.1 Manual operati 3 Settings 2.2 Automatic operati 2.3 SDS 2.4 Maintenance 2.5 Free Switching RemoteCtrol Without SicCtrol-Opti ohne SicCtrol Opti im Ñ Leerlaufì 0. Systeminfo Datum Uhrzeit 11:32:55 Fettabscheider DIN 4040 NS 2 2 Pumpen 2,6kW 3.0 OK With SicCtrol-Opti mit SicCtrol Opti im Ñ Leerlaufì ESC 0. Systeminfo Datum Uhrzeit 11:32:55 Fettabscheider DIN 4040 NS 2 Schicht-Dicke 4 cm Temperatur 22 C 1. Informatien Wartung Einstellungen Men OK ESC 1.1 Informatien Betriebsstunden Logbuch Steuerungstyp Wartungstermin Akt. Messwerte OK ESC Betriebsstunden Gesamtlaufzeit Laufzeit Pumpe Anl ufe Pumpe Netzausfall OK ESC Gesamtlaufzeit 00001,0h 45

10 5. Disposal The first disposal should take place approximately 2-3 weeks afer the separator has been placed into operati. Disposal intervals According to DIN EN the separator should be disposed / emptied every 14 days but at a minimum every mth. The grease layer thickness can be mitored by the new SicCtrol automated grease layer measurement system or by the use of the included inspecti window. Attenti: Timely disposing of the grease separator ctents is required to assure proper grease separator operati. Due to this, the disposal should be handled by a licensed disposal company placed under ctract to empty the separator a regular basis. During disposal, no wastewater should enter the separator. Disposal of the grease separator in fully automatic mode Requirement all grease separator covers must be securely closed 1. Cnect the disposal truck to the end of the separator s disposal pipe 2. To begin disposal, press the Start butt and then the OK butt the ctrol unit. On the ctrol unit s digital display, the individual disposal steps are displayed 3. If a remote ctrol is installed, the disposal can also be started with the remote ctrol however, prior to doing this the ctrol unit must be un-locked by the main ctrol unit by going to the Maintenance Remote ctrol activati setting (2.5.1). The automatic disposal can also be activated here by pressing the OK butt. 4. Begin the automated disposal by pressing the START/STOP butt the ctrol unit or the remote ctrol 5. The automatic disposal program begins operati. The current step of the disposal process is displayed the digital display of the ctrol unit and the remote ctrol. 6. In the case that the disposal truck needs to be changed during the automated disposal process, press the START/STOP butt - remove disposal hose from first truck - cnect disposal hose of new truck - press the START/STOP butt the ctrol unit to ctinue the disposal process 7. When step 13 (final refill) is displayed the ctrol unit or the remote ctrol, the disposal truck can discnect the disposal hose and leave. Step 13 is the final refill step and the grease separator will automatically fill itself and turn when full the presence of the disposal truck is no lger required. The grease separator can also be operated from the remote ctrol. Go to Menu 2 (Maintenance). Here the activati of the remote ctrol can be made. - Here you have the opti of activating the remote ctrol for a specific period of time. - The remote ctrol can also be permanently activated Disposal of the grease separator in manual mode Requirement all grease separator covers must be securely closed 1. Cnect the disposal truck to the end of the separator s disposal pipe 2. To being the manual disposal process go to Menu 2.1 Maintenance Manual Operati and cfirm the desired disposal step by pressing the OK butt. ON the display the chosen disposal step can be followed. 3. If a remote ctrol is installed, the disposal can also be started with the remote ctrol however, prior to doing this the ctrol unit must be un-locked by the main ctrol unit by going to the Maintenance Remote ctrol activati setting (2.5.1). The automatic disposal can also be activated here by pressing the OK butt. 4. Begin the automated disposal by pressing the START/STOP butt the ctrol unit or the remote ctrol 5. The disposal step begins operati. The current step of the disposal process is displayed the digital display of the ctrol unit and the remote ctrol. 6. In the case that the disposal truck needs to be changed during the automated disposal process, press the START/STOP butt - remove disposal hose from first truck - cnect disposal hose of new truck - press the START/STOP butt the ctrol unit to ctinue the disposal process 7. When step 13 (final refill) is displayed the ctrol unit or the remote ctrol, the disposal truck can discnect the disposal hose and leave. Step 13 is the final refill step and the grease separator will automatically fill itself and turn when full the presence of the disposal truck is no lger required. 46

11 5. Disposal steps grease separator acc. to. DIN For separators with Fully Automated disposal Separators NS 2, NS 4, NS 7 and NS 10 acc. to DIN 4040 Pump run times in secds Disposal Step Functi Valve positi Pump Warm water Cold water NS 2 NS 4 NS 7 NS 10 valve valve 1 Dispose Dispose Mixing Mixing Hints reduce filling level degree 30 cm Dispose Filling Mixing Dispose Filling Rinsing Dispose Filling Rinsing Dispose Filling Dispose Mixing Mixing Dispose Rinsing Rinsing Dispose Rinsing Rinsing Dispose Dispose Until the pump runs dry ca. 25 cm filling level Until the pump runs dry ca. 25 cm filling level Until the pump runs dry ca. 25 cm filling level Until the pump runs dry to overfow the system It is possible that -site cditis such as pumping height, temperature and / or water pressure will require that individual disposal step times need to be changed. Outlet from a DN 25 water supply pipe at 4 Bar pressure is approx 23 cubic meters per hour

12 5. Disposal for grease separator acc. to. EN For separators with Fully Automated disposal Separators NS 2, NS 4, NS 7 and NS 10 acc. to EN 1825 Disposal Step Functi Valve positi Pump run times in secds NS 2 NS 4 NS 7 NS 10 Pump Warm water valve Cold water valve 1 Teil-Dispose Dispose Hints reduce filling level degree 30 cm 2 Mixing Rinsing Dispose Filling Mixing Dispose Filling Rinsing Dispose Filling Rinsing Dispose Filling Dispose Rinsing Rinsing Dispose Rinsing Rinsing Dispose Rinsing Rinsing Dispose Dispose Until the pump runs dry ca. 25 cm filling level Until the pump runs dry ca. 25 cm filling level Until the pump runs dry ca. 25 cm filling level Until the pump runs dry to overfow the system It is possible that -site cditis such as pumping height, temperature and / or water pressure will require that individual disposal step times need to be changed. Outlet from a DN 25 water supply pipe at 4 Bar pressure is approx 23 cubic meters per hour

13 6. Kfigurati 6.1 General Please follow all safety instructis! Cfiguring and making setting the ctrol unit should ly be handled by a qualified servicer. Ctrol unit settings can be made in the Settings mode of the ctrol unit here the Norm (3.5) or the Nominal Size (3.6) can be changed. 3 Settings 3.5. Norm DIN DIN Underground installati Euro-Norm Euro-Norm Underground installati 3.6 Nominal Size NS NS Setting the Mixing, Filling, Cleaning and Disposal times Changes to the mixing, filling, cleaning and disposal times can be made in the Parameter secti (3.1) in the ctrol unit 3 Settings 3.1. Parameter Access Code Partial Disposal Value in secds Filling Value in secds In this setting the length of the disposal steps can be changed for example: Partial disposal, Mixing, Disposal, Filling and Cleaning With SicCtrol Accessory also the following can be changed: Alarm layer thickness, Pre-alarm layer thickness, Temperature alarm, Measuring start, Measuring intervals, Level check 49

14 7. Malfuncti messages 7.1 Log book entries This table shows the possible malfuncti messages, all errors and results will be stored in the ctrol unit s log book. Result LED Potential free display ctact Fault / Warning First initializati No No Install unit No No Factory settings No No Acute alarm cfirm No No Parameters changed No No Exp. Parameters changed No No Manual operati No No Automated operati No No Read logbook No No Cfirm malfunctis No No Change number of pumps No No Change norm No No Change nominal size No No Save USB No No Send SMS No No Disposal disctinued No No Message Relay switching 1 Yes Warning Relay switching 2 (optial) Yes Warning Relay switching 3 (optial) Yes Warning Malfuncti LED Potential free display ctact Fault Warning Phase malfuncti Yes Error Rotating field malfuncti Yes Error Communicati malfuncti Yes Error Motor protecti 1 Yes Error Motor protecti 2 (optial) Yes Error Motor protecti 2 (optial) Yes Error Over current P 1 Yes Error Over current P 2 (optial) Yes Error Over current P 3 (optial) Yes Error Under current P 1 Yes Error Under current P 2 (optial) Yes Error Under current P 3 (optial) Yes Error Temperature error P 1 Yes Error Temperature error P 2 (optial) Yes Error Temperature error P 3 (optial) Yes Error Relay malfuncti P 1 Yes Error Relay malfuncti P 2 (optial) Yes Error Relay malfuncti P 3 (optial) Yes Error Max. run time exceeded P 1 Yes Error Max. run time exceeded P 2 Yes Error (optial) Max. run time exceeded P 3 Yes Error (optial) Actuator valve error 1 Yes Error Actuator valve error 2 (optial) Yes Error 50

15 7. Malfuncti messages Malfuncti Cause Soluti Pumps do not start Motor protecti switch has activated Motor is blocked Motor does not run smoothly 1 or 2 phases do not have power Ctrol unit shuts due to power surges Remove pump, and remove any debris / blockage in impeller or pump housing area Ctact KESSEL Customer Service for repair Check power supply and fuses ctact power company Pump suddenly starts Rotating field incorrect Pump damaged due to foreign object Foreign object in pump rotating area Switch 2 phases from the incoming cable Check pump for damage and repair / replace if necessary Remove foreign object, check pump for damage and repair / replace if necessary Bad odour Pungent odour Pumping performance too low Grease separator body is not air tight Pump leak Pump(s) running too hot / overloaded Rotating field incorrect Check ventilati, inlet, outlet, pump outlet and separator covers to make sure they are air tight. Add 2 liters of water to re-fill inlet in case P-trap has dried out. Check pump for damage and repair / replace if necessary (via Customer Service) Check pump and impeller for easy rotati, check system for switching problems (especially motor protecti switch) Swap power cables (ctrol unit alarm) Pump rotating in wrg directi Check pump power supply cables for proper cnecti Ctrol unit not functiing (no displays or lights) Power outage - Check to make sure power supply to ctrol unit is intact - Check fuses - Check power supply cable for damage - Check micro-fuses in ctrol unit (ly replace with fuses with identical operating characteristics) 51

16 7. Malfuncti messages Malfuncti Cause Soluti Temperature malfuncti Motor winding temperature Allow pump to cool, alarm must be switch has activated cfirmed ctrol unit. If motor winding temperature ctinues to cause malfunctis replace pump Over current The maximum allowable pump Remove blockage in power has been exceeded impeller (follow safety instructis (impeller blocked) Let pump run shortly in opposite directi ( Maintenance Manual operati Opposite rotati Under current The minimum allowable pump power Check power supply cable and repair has been reached (power supply cable / replace if necessary (replace pump to pump has been cut or damaged) if necessary) Let pump run shortly in opposite directi ( Maintenance Manual operati Opposite rotati ) Motor protecti switch Motor protecti switch has been Check that current supply is correct. has activated improperly set. Current to pump to Remove pump blockage (follow safety high due to defective or blocked pump. instructis). Replace pump if damaged or defective Excessive current due to phase failure. Check power supply for phase loss. Phase error Phase L1, L2 or L3 missing Check ctrol unit, power cable and fuses Check current protecti switch Activati limit System protecti has activated - Can be cfirmed ctrol unit due to more than activatis - System protecti allows another 1000 activati before alarm activates again - Replace system protecti (ctact KESSEL Customer Service - Activati alarm will ctinue to activate after every 1000 pump activatis Actuator valve malfuncti End positi of actuator valve is Check actuator valve for proper rotati not being reached / movement remove any obstructis Rotating field malfuncti Incorrect rotating field at power Swap two phases of power supply cnecti Relay malfuncti Surge protecti does not switch Discnect ctrol unit from power supply. Replace surge protector ctact KESSEL customer service 52

17 8.1 Ctrol unit and descripti of operati panel 8. Ctrol Unit The type plate is the right outside of the ctrol unit. Fig. 1 Ctrol unit descripti: Ctrol unit identificati code Ctrol unit article number Voltage and frequency Amperage Protecti class Ctrol unit serial number Ctrol unit replacement number Danger symbol Electrical protecti class CE symbol Disposal symbol (do not dispose in normal trash) Hardware status code 8.2 Outputs Potential free ctact Change-over ctact, center ctact Closing ctact, Opening ctact max. 42 VAC / 0,5 Amp Optial: remote alarm Cnecti opti (Article Number 20162) for a remotely installed audible alarm Fig. 2 53

18 12. Ctrol unit 54

19 9. SicCtrol (Optial) 9.1 Safety instructis Dear Customer, Before installing and placing the SicCtrol into operati, please read and follow all instructis in the user s and operatial manual! First check that the system has arrived undamaged. In case damage has occurred during shipping, please follow the instructis in the Guarantee secti of this manual (Secti 12). 1. Safety instructis: All local and internatial safety regulatis as well as all related DIN and VDE regulatis should be followed when installing, operating, maintaining or servicing this system! Before placing the system into operati, a qualified professial should insure that all safety measures are in place. Fault current and ground must meet the local power supply regulatis. The SicCtrol should not be installed in areas that are explosi hazards. The system operated electrical current. Not following all local and internatial safety measures could result in significant damage to the system, injury to the operator or somee nearby as well the possibility of a fatal accident. The power supply to the SicCtrol should be discnect before any work is begun. It is important to insure that the power supply cable to the SicCtrol is in perfect operating cditi. If the cable is damage or defective DO NOT cnect the cable to a power source. If the system is in operati and it is determined that the cable is damaged or defective, immediately discnect the SicCtrol from its power source. VDE 0100 regulatis must be followed. The ctrol unit should not be installed in any area / room that are explosi hazards. In order to insure that the system operates appropriately, it should be regularly inspected and maintained. We recommend that a service ctract with a licensed professial is signed. 9.2 General Dear Customer, KESSEL thanks you for choosing this product. Before leaving the factory this system has ge through very strict quality ctrol inspectis. Please check that the system is complete and that no damaged occurred during shipping. In case damage has occurred during shipping, please follow the instructis in the Guarantee secti of this manual (Secti 12). This Installati and Operating manual ctains valuable informati and instructis for the proper installati, operati, maintenance and repair of this product. Prior to doing any work with this system, this entire manual should be thoroughly read and followed. 9.3 Installati Installati of sensor and sensor support ➊ ➋ ➌ ➍ sensor bracket PT screw Torx 40x12 PT screw Torx K 50x20 Pipe clamp PE d25 Drilling template/ screw cover Outlet structure partiti Place the drilling template the outside of the outlet structure and drill 2 x Ø 4 mm holes SicCtrol sensor (top two holes!). Red arrow marking Place the drilling template the inside of the outlet structure and fix in place from the outside (see ). Put the sensor and the pipe clamps together to the sensor bracket. Screw the sensor bracket to the outlet structure using a torque of 1 Nm and clip the sensor in place. 55

20 9. SicCtrol (Optial) 9.4 SicCtrol Sensor Installati Above Freie Aufstellung ground Artikel NS EURO "G" Abstand Distance Oberkannte between top unterer of lower "Finger" sensor zu finger to base of Auslauf separa- Unterkannte (Wasserlinie) tor outlet (waterline) Holes to use drilling template Alarm Alarmniveau level = = max max. grease layer Fettschichtdicke thickness in cm in cm Bohrlöcher in Bohrschable obere beiden Bohrlöcher cm obere beiden Bohrlöcher cm obere beiden Bohrlöcher cm obere beiden Bohrlöcher cm obere beiden Bohrlöcher EURO "D" / D cm obere beiden Bohrlöcher / D cm obere beiden Bohrlöcher / D cm obere beiden Bohrlöcher / D cm obere beiden Bohrlöcher EURO "DS" und.00 / DS cm obere beiden Bohrlöcher und.00 / DS cm obere beiden Bohrlöcher und.00/ DS cm obere beiden Bohrlöcher und.00 / DS cm obere beiden Bohrlöcher EURO E+S "M" und.00 / M cm obere beiden Bohrlöcher und.00 / M cm obere beiden Bohrlöcher und.00 / M cm obere beiden Bohrlöcher und.00 / M cm obere beiden Bohrlöcher EURO E+S "PV" und.00 / P cm obere beiden Bohrlöcher und.00 / P cm obere beiden Bohrlöcher und.00 / P cm obere beiden Bohrlöcher und.00 / P cm obere beiden Bohrlöcher DIN 4040 "G" rund cm obere beiden Bohrlöcher cm obere beiden Bohrlöcher DIN 4040 "D" rund /D cm obere beiden Bohrlöcher /D cm obere beiden Bohrlöcher Underground installati Euro G / 80 / 120 B und D 1 50 cm obere beiden Bohrlöcher / 80 / 120 B und D 2 50 cm obere beiden Bohrlöcher / 80 / 120 B und D 4 50 cm obere beiden Bohrlöcher / 120 B und D 7 48 cm untere beiden Bohrlöcher / 120 B und D cm untere beiden Bohrlöcher / 120 B und D cm untere beiden Bohrlöcher / 120 B und D cm untere beiden Bohrlöcher DIN 4040 "G" / 00 / 80 / 120 B und D 2 58 cm untere beiden Bohrlöcher / 00 / 80 / 120 B und D 4 58 cm untere beiden Bohrlöcher Recommend empfohlenes Prealarm Voralarmniveau in cm (2/3 in of cm max level layer (= 2/3 thickness) des max. Speichervolumens) Maximum sludge layer thickness in cm (50% of total sludge trap volume) Note: For more articles please ctact the KESSEL customer service. After installati completely fill the separator with water, check height and correct if necessary! Completely filled separator must perform the "manual mode" (2.1.15) SicCtrol "0 cm" show. Should be no mechanical correcti possible change in "Parameters -> level adjustment"(3.1.20) to perform. The parameters are password protected - please ctact the KESSEL customer service at +49 (0) 8456/

21 9. SicCtrol (Optial) 9.5 Installati example Grease Separator < NS 15 Ctainer wall < = 10 mm Cable screw cnecti* Drilling ø 19 mm Grease Separator > NS 15 Sensor cable Ctainer wall > = 10 mm Cable screw cnecti* Illustrati shows a Euro Norm NS 2 above ground grease separator * to avoid odor nuisances draw cable screw cnecti close. Thread PG 11 Make sure ScCtrol cable is not in tensi should be loose. Also make sure cable is clear (not below or above) any of the SicCtrol sensors. The sensor should be installed at a 60 degree angle to make sure than the separator s internal support rod is not near the SicCtrol sensors. 57

22 9. SicCtrol (Optial) The included stickers are to notify the disposal company of which separator access hole should be opened and used for disposal of the grease separator. Do not used the access hole which ctains the SicCtrol to empty the grease separator the disposal truck s hose could damage or dislodge the SicCtrol. For above ground grease separators, the sticker should be placed the exterior of the separator near the access cover that should not be used. Note: inform the disposal company when a SicCtrol sensor is installed in a grease separator. 9.6 Remote Alarm The remote alarm (Article Number 20162) should be used when an audible alarm is desired in a different area than where the grease separator s ctrol unit is installed. 9.7 Shortening the sensor cable length The SicCtrol cable can be shortened if necessary. Please note that the cable cnecti jacks are for use with cables with a maximum crossectial area of 1.5 square mm do not use cables with a large area. 9.8 Potential free ctact The potential free ctact can be used to transfer a warning signal to a BMS (Building Management System). (Max cnecti of 42 V / 0.5 Amp). 58

23 9. SicCtrol (Optial) 9.9 Installati / Cables cnectis The cables should be cnected to the ctrol unit as shown in the installati manual. Please use the included M16 cable screws IMPORTANT: After all cables have been cnected, they should be secured with tie-wraps. The sic ctrol cable should be laid separately from the power cable in order to avoid electrical interference. 59

24 9. SicCtrol (Optial) Cable extensis watertight (IP 68) The SicCtrol is supplied with 10 meter cables. If required this can be extended site to a max total length of 30 meters. With a total length of over 30 meters, a reliable operati of the SicCtrol can no lger be guaranteed as inductive disturbances effect the sensor. Fig.1 fig.2 Fig. 1: cnect bare cables with compressi cnectors Fig. 2: Enclose cnecti in appropriate watertight encloser and seal both sides 2 Note: Follow all VDE 0100 regulatis when extending the cable. The ctrol unit must not be installed in areas which are at risk of explosi. If the cable is to be laid with other cables the SicCtrol cable should be wrapped with a shielded jacket to prevent interference Commissiing In order to activate the SicCtrol, KESSEL Customer service must be ctacted 9.11 Inspecti and Maintenance The sensor must be cleaned a regular basis. During every disposal of the grease separator, the SicCtrol probe should be cleaned with warm or hot water. If a pressure washer is used spray at a distance of at least 30cm. The sensor does not need to be removed to be cleaned. If the SicCtrol is installed in a KESSEL PV fully automated separator, cleaning of the probe does not need to be de during every disposal. With a PV separator, the Sic- Ctrol should be cleaned during every service / maintenance of the separator. Fig.3 Fig.4 Fig. 3: Fill enclosure with plastic resin Fig. 4: View of completed cnecti Individual parts available up request 60

25 9. SicCtrol (Optial) Please follow all safety instructis in Secti Events display (ly in logbook) Event Cause Remediati measures Type of system changed Type of system was changed Maintenance Maintenance dates have been entered Manual operati Manual operati has been set Cfirm audible alarm Audible alarm has been cfirmed Malfuncti cfirmed Malfuncti has been cfirmed Factory settings Re-set to factory settings 9.13 Malfunctis display Malfuncti display Malfuncti type Cause Remediati measures Pre-Alarm layer thickness Blinking (Alarm) Grease layer level has also Check grease layer been reached thickness and ctact (see Secti 3.3) disposal company if required No calm phase detected Blinking (Alarm) Measurement taking place Check measurement times during kitchen operati in Parameter secti of wastewater entering grease ctrol unit and re-set if separator results in inaccurate required measurements. Grease layer alarm Audible alarm and Maximum grease layer Dispose grease blinking alarm thickness reached separator ctents (also see secti 3.3) Temperature alarm Audible alarm and Wastewater temperature Reduce wastewater blinking alarm entering grease separator temperature entering too high grease separator Communicati error Audible alarm and Error in modem recepti Step 1 check recepti blinking alarm Step 2 if not recepti is available then use of modem is not possible. If recepti is available then replace modem 61

26 9. SicCtrol (Optial) 9.14 General malfunctis First attempt to resolve the problem. If the problem can not be solved place the main switch to the 0 setting and then press the alarm butt for a minimum of 5 secds. This will cfirm the malfuncti and enter the data into the logbook (this will not however solve the problem). Malfuncti Error Cause Remedial measures Deviati between grease Inaccurate Improper installati Check type of separator and layer seen in inspecti SicCtrol of SicCtrol sensor assure SicCtrol setting is window (if available) and measurement correct SicCtrol grease Improper initializati Newly calibrate layer reading of SicCtrol the sensor Dirt or debris SicCtrol sensor Sensors are not in proper positi and are not able to sense accurately Type of grease separator or size/model improperly set Check positi and installati of SicCtrol probe Set type of grease Clean sensor probes 9.15 System errors Malfuncti Cause Remedial measures Odour nuisance Cable entrance point into grease separator Check cduit entrance is not air tight for tightness repair if necessary Water in grease Cable entrance point into grease separator Check cduit entrance separator area is not water tight for tightness repair if necessary 9.16 Techical data Inputs Sensor input Sensor input SicCtrol 62

27 9. SicCtrol (Optial) 9.17 Replacement parts and accessories ➀ ➁ DN/OD 50 innen aussen Order Number 11. Ultrasic sensor Cduit entrance system

28 9. SicCtrol (Optial) 64

29 10. Accessories / Replacement parts Adding accessories to a system is in general not a problem. We would kindly ask you to ctact the KESSEL Customer Service Department for informati ccerning this Remote Ctrol (Article Number ) The remote ctrol can be directly cnected to the main ctrol unit. The remote ctrols allows complete grease separator operati (during disposal) from a remote locati (normally the same locati where the disposal truck cnects its disposal hose to the grease separator disposal pipe). The remote ctrols cable length is 10 meters which can be extended to a maximum length of 100 meters Sampling chamber DN 100/150 KESSEL ers a wide range of sampling chambers for above ground and underground installati. The sampling chambers are odour tight. The sampling chamber allows an accurate sample of the treated wastewater to be taken without the release of annoying odours. The samples can be used for testing purposes for example DIN Prior to taking a sample, the interior of the sampling chamber should be cleaned. There are no uniform regulatis requiring the installati of a sampling chamber but it is required by DIN 1986 Part I. Please follow local guidelines and regulatis in your area. Type Art. Nr. Drainage horiztally Drainage vertically Aqualift F lifting stati KESSEL ers a wide range of lifting stati with different for use prior or after a grease separator. Please note that ly twin pump lifting statis are recommended for use with grease separators in order to assure ctinuous operati. Nominal activity Electrical Cnecti NS Art. Nr. 1,1 kw 400 V DS (3-phase) DN ,2 kw 400 V DS (3-phase) DN

30 10. Accessories / Replacement parts 10.5 Replacement parts / Accessories for maintenance and general inspecti Article Order Nr. For KESSEL DIN 4040 grease separators Separator access cover 630 mm diameter Gasket for access cover 630 mm diameter Quick release clamp for access cover 630 mm diameter For KESSEL EN 1825 grease separators Separator access cover 420 mm diameter Gasket for access cover 420 mm diameter Quick release clamp for access cover 420 mm diameter For all KESSEL grease separators 3.0 kw disposal pump with macerating system (for NS 2-10 separators) Ctrol unit PV General grease separator inspecti (from KESSEL Customer Service) Operatial log book for grease separator Watertightness test

31 11. Maintenance / General Inspecti Please follow all safety instructis! 11.1 Maintenance The grease separator should be inspected ce per year. Alg with the inspecti, the following point should also be cducted: - Inspecti of the interior walls of the grease separator - Inspecti of all electrical parts and cnecti (if separator model has electrical equipment) - Any work de the separator should be entered into the separator s logbook - Cditi of electrical parts (if separator has electrical equipment) - Check for proper grease separator ventilati - Check log book for completeness and accuracy - Cfirmati that separator has been properly and timely disposed - Check for availability and completeness of all paperwork and certificatis The inspecti report should list any defects or problems with the separator which should immediately be repaired or brought into the operating cditi. The mechanical or electromechanical compents such as pumps, valves, sight glass, shut- devices, etc. are to be maintained General Inspecti Before placing the separator into service and every 5 years thereafter, the separator should undergo a general inspecti. The inspecti should take place after the separator has been emptied and cleaned. The following points should be checked during this inspecti: Calculati of separator system - General cditi and watertightness of grease separator - Cditis of internal walls of grease separator 12. Warranty 1. In the case that a KESSEL product is defective, KESSEL has the opti of repairing or replacing the product. If the product remains defective after the secd attempt to repair or replace the product or it is ecomically unfeasible to repair or replace the product, the customer has the right to cancel the order / ctract or reduce payment accordingly. KESSEL must be notified immediately in writing of defects in a product. In the case that the defect is not visible or difficult to detect, KESSEL must be notified immediately in writing of the defect as so as it is discovered. If the product is repaired or replaced, the newly repaired or replaced product shall receive a new warranty identical to that which the original (defective) product was granted. The term defective product refers ly to the product or part needing repair or replacement and not necessarily to the entire product or unit. KESSEL products are warranted for a period of 24 mth. This warranty period begins the day the product is shipped form KESSEL to its customer. The warranty ly applies to newly manufactured products. Additial informati can be found in secti 377 of the HGB. In additi to the standard warranty, KESSEL ers an additial 20 year warranty the polymer bodies of class I / II fuel separators, grease separators, inspecti chambers, wastewater treatment systems and rainwater storage tanks. This additial warranty applies to the watertightness, usability and structural soundness of the product. A requirement of this additial warranty is that the product is properly installed and operated in accordance with the valid installati and user's manual as well as the correspding norms / regulatis. 2. Wear and tear a product will not be csidered a defect. Problems with products resulting from improper installati, handling or maintenance will also not be csidered a defect. Note: Only the manufacturer may open sealed compents or screw cnectis. Otherwise, the warranty may become null and void

32 EU-KONFORMITÄTSERKLÄRUNG EC declarati of cformity/ Déclarati CE de cformité Nach der Maschinenrichtlinie 2006/42/EG, der Niederspannungsrichtlinie 2006/95/EG, Richtlinie der elektromagnetischen Verträglichkeit 2004/108/EG und Bauproduktrichtlinie 89/106/EWG / According to the Machine Guidelines 2006/42/EG, the Low Voltage Guidelines 2006/95/EG, Electromagnetism Guidelines 2004/108/EG and in accordance with Directive 89/106/EWG / Sel les directives mécaniques 2006/42/EG, les directives de basse tensi 2006/95/EG, les directives pour la compatibilité électromagnétique 2004/108/EG et les directives de cstructi 89/106/EWG Hiermit erklären wir, / Herewith we declare, / Par la présente, nous déclars, dass das Produkt/ that the product/ que le produit KESSEL AG Bahnhofstraße 31 D Lenting KESSEL- Fettabscheider Euro E+S PV Zur freien Aufstellung in frostgeschützten Räumen KESSEL Euro E+S PV Grease Separator for interior installati Séparateur à graisses KESSEL Euro E+S PV Pour une installati en local à l abri du gel den Bestimmungen der EN :2004 entspricht und die Vorraussetzungen für die CE- Kennzeichnung gemäß Anhang ZA der Norm erfüllt./ meets EN :2004 requirements and fulfills the pre-requisites for the CE Mark attachment ZA./ est cforme à la norme EN :2004 et présente les directives pour marquage CE sel complément ZA de la norme. Zur Kennzeichnung der Übereinstimmung der Produkte ist auf dem Typenschild das Zeichen der Richtlinie 93/68/EWG angebracht./ The 93/68/EEC code mark should be located the ID plate the product./ Le marquage et l indentificati du produit figurent sur la plaquette d identificati sel les directives 93/68 EWG. Lenting, den M. Rinckens E. Thiemt Leiter Innovatismanagement / Dokumentatisverantwortlicher Vorstand Innovati Management Manager / Respsible for Documentati Managing Board Respsable du management pour innovati et de la documentati Cseil d administrati Prüfstelle/ Accredited Laboratory/ Bureau de vérificati: LGA QualiTest GmbH, TÜV Rheinland Group, Dreikrenstraße 31, D Würzburg 68

33 14. Separator characteristics Mat.-Descripti Mat.-No./Order-No./Prod. Date Ref.No./Material/Weight EN/Approval Dimensis Volume Layer thickness Descripti 1 Descripti 2 This unit has been checked for watertightness to be sure that it is fully operatial before leaving the factory. Date Name of examiner 69 16

34 15. Important ctacts / Info Separator Type: Day / Hour Project descripti /Building services supervisor Address Telephe / Fax Builder Address Telephe / Fax Planner Address Telephe / Fax Ctracted plumbing company Address Telephe / Fax KESSEL-Commissis no.: System operator /owner Address Telephe / Fax User Address Telephe / Fax Pers of delivery Other remarks The system operator, and those respsible, were present during the commissiing of this system. Place and date Signature owner Signature user 70

35 15. Important ctacts / Info Handover certificate (copy for the company carrying out the installati) The initial operati and instructi was carried out in the presence of the pers authorised to perform the acceptance and the system operator. The system operator/pers authorised to perform the acceptance was informed about the obligati to service the product according to the enclosed operating instructis. Initial operati and instructi were not carried out. The client/ pers respsible for initial operati was handed the following compents and/or product compents Initial operati and instructi is being carried out by (company, address, ctact, phe) The exact coordinati of the dates for initial operati/instructi is being carried out by the system operator and pers respsible for initial operati. Place, date Signature of pers Signature of system operator Signature of the company authorised to perform acceptance carrying out the installati work 71

36 Leading in Drainage 6 4 Private homes without public sewage cnecti Public buildings (e.g. hospital) Public buildings (e.g. leisure facility) Commercial buildings (e.g. hotel) 4 5 Commercial buildings (e.g. industrial / manufacturing facilities) Rückstauverschlüsse Hebeanlagen Abläufe / Duschrinnen Kleinkläranlagen Commercial buildings (e.g. gas/petrol stati) Abscheider -Fettabscheider -Öl-/Benzin-/ Koaleszenzabscheider -Stärkeabscheider -Sinkstabscheider 1 Backwater valves 2 Wastewater Lifting system 3 Lifting statis 4 Drains and Channels 5 Separators 6 Septic Systems Private homes/multifamily apartments/flats