INSTALLATION AND OPERATING INSTRUCTIONS

Transcription

1 INSTALLATION AND OPERATING INSTRUCTIONS KESSEL Grease Separator G, D and D+S versions Certified under Euro-Norm EN For free standing installation in frost free areas KESSEL Grease separators G, D and D+S versions Product Advantages KESSEL Type D+S Grease Separator with accessories Euro-Norm 1825 certified Certification No. Z Compact / Light Transport Friendly Simple / Quick Assembly Completely Watertight 100 % resistance against aggressive grease acids Recyclable Easy upgrading The installation and service of this unit should be carried out by a licensed professional servicer Company - Telephone No. Edition 01/05-HG ID number (Subject to technical amendment

2 Table of contents 1. Safety precautions Page 3 2. General 2.1 Application Page Separator description Page 4 3. Installation 3.1 Installation Page Assembly Page Installation illustration Page 6 Drawing (Type G) Page Installation illustration Page 7 Drawing (Type D) Page Installation illustration Page 8 Drawing (Type D+S) Page 8 4. Setting up 4.1 Setting up for operation Page Initial instructions Page 8 5. Separator disposal 5.1 Type G disposal Page Type D disposal Page Type D+S disposal Page Maintenance Page Replacement parts and accessories 7.1 Inspection window Page Refill equipment Page Solenoid valve Page Sampling chamber Page Quick release locking clamp Page Lifting stations Page Cover gasket Page Guarantee Page Important contacts / Info Page Separator characteristics Page 16 2

3 1. Safety precautions Dear Customer, Before the KESSEL Euro Separator Version G is installed and placed in operation please carefully read and follow all of the instructions contained in this Installation, Maintenance and User s Manual. Upon 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 instructions listed in the Guarantee section of this user s manual. By installation, use, maintenance and repair of this unit please follow all appropriate DIN / VDE / DVGW safety precautions and accident prevention guidelines. Also please follow any local safety precautions and accident prevention 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 on the separator. During disposal / emptying of a Type G separator, a step ladder should be used to help gain access to the openings on 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 caution 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 personnel No storage of food / groceries / provisions (for hygienic reasons) if the separator is installed underground within a building. The location of the separator should be chosen carefully as to allow sufficient access for maintenance, inspection, repair and disposal of the separator. The wastewater in a grease separator can contain bacteria. After coming in contact with wastewater or the separator itself, it is important to wash, clean and disinfect all skin which has been contaminated. All personnel having anything to do with the separator should have a sound knowledge of the above safety precautions. 3

4 2. General 2.1 Application According to DIN 4040 and EN 1825, the installation of grease separators is required wherever oils and fats from animals and plants are introduced into wastewater systems. Uncollected, oils and fats can cause serious damage to wastewater piping and private / public wastewater treatment plants Separator description The KESSEL Grease Separator G and D versions consist of a grease separator and an integrated sludge trap. The separator is constructed from Polyethylene (PE). Due to the smooth, wax like surface of the material Polyethylene, no additional protective coating is necessary. The separator is designed to be installed on the floor of a frost free room. The version D separator differs from the version G separator in that a disposal pipe is built into the system. The advantage of the version D's built in disposal pipe is that during disposal no covers on the separator need to be opened which helps prevent the release of pungent odours into the surrounding areas. The permanently installed disposal pipe is run to a location with convenient access for the disposal truck (outside wall of the building). This prevents the burdensome and unhygienic task of running the flexible disposal hose from the truck to the separator each time the separator is emptied. The version D's covers need only be opened after disposal is complete to allow the inside of the separator to be cleaned and inspected. Technical data concerning the separator can be found on the identification plate located on the separator or on the last page of this User's Manual. 3. Installation 3.1 Installation The KESSEL grease separator is delivered in ready for operation condition. If the separator consists of more than one container, each container will be packed separately on a pallet. Assembly material and accessories will also be packed on a pallet. In some circumstances the material and accessories will be inside one of the containers. When the shipment arrives, please inspect it immediately for damages which may have been caused during transport / shipping! DIN 1986 and EN 1825 guidelines should be followed while installing the separator. Some of these guidelines include: 1 The separator should be installed on a firm level floor in a frost free room. 2 Vertical drainage pipes should be connected to a calming section before entering the separator. This calming section should be at least 1 meter long and have a downward slope of 2 percent (1:50). The vertical drainage pipe should be connected to the calming section with two 45 degree fittings. 3 In the case that the outlet of the separator is below the backwater lever, a pump / lifting station should be installed after the separator to lift the waste water above the backwater level. 4 Ventilation pipe(s) are to be installed in the wastewater pipe leading to the separator at intervals required by DIN In order that the separator can be properly cleaned, it is recommended that a hot water tap is located near the separator for use in rinsing and cleaning the separator. 3.2 Assembly Assembly for the version G separator 1. Place the separator in its designated area and make sure the separator is perfectly level. 2. Grease the rubber cover seals and fit them in the recessed area on the inside of the covers. Place the covers on the separator and fasten tight using the quick locking clamps. 3. Connect the inlet and outlet of the separator to the wastewater piping. 4

5 3. Installation Assembly for the version D separator 1. Place the separator in its designated area and make sure the separator is perfectly level 2. Grease the rubber cover seals and fit them in the recessed area on the inside of the covers. 3. Place the covers on the separator and fasten tight using the quick locking clamps. 4. Connect the inlet and outlet of the separator to the wastewater piping. 5. The version D separator is delivered with the direct disposal pipe already fitted to the separator (it can be removed and reinstalled if necessary). This pipe is to be connected to the permanently installed disposal pipe using the flange connection (DN 65, PN 10, DIN 2501, 145mm diameter). Included with the shipment is a coupling which is to be attached to the end of the permanently installed disposal pipe at the location where the disposal truck is to hook up. It is possibly that this permanently installed disposal pipe will need extra reinforcing attachments to prevent vibration noises during disposal. Assembly for the version D+S separator 1. Place the separator in its designated area and make sure the separator is perfectly level. 2. Grease the rubber cover seals and fit them in the recessed area on the inside of the covers. Place the covers on the separator and fasten tight using the quick locking clamps. 3. Connect the inlet and outlet of the separator to the wastewater piping. 4. The outlet disposal pipe is factory mounted to the separator. (If necessary this outlet pipe can be removed by unclipping it and simply removing it from the separator. Outlet pipe should be carefully re-fitting in the greased gasketed seal.) The flange at the end of the disposal pipe should be connected with on-site installed pressure disposal piping (extending to exterior wall of building). Supplied flange is has the following characteristics DN 65, PN 10, DIN 2501, 145mm circular. Also supplied with the separator is a 2 ½ inch interior threaded Storz B coupling which should be attached to the disposal pipe on the exterior of the building (only if available on-site disposal trucks also work with the 2 ½ inch Storz B connection. Due to sound transfer, in certain cases it is advisable to install the disposal pipe with sound reduction measures (ex special sounds reduction hangers). 5. The supplied pump should be secured to the floor with the included screws. To reduce sounds and vibration, the included rubber matt should be place under the pump base. 6. During connection of the water refill connection, DIN 1988, DVGW and local regulations should be followed. The 1 inch refill connection should be connected on site to a cold water drinking supply pipe. Important is that an electronic or hand valve is connected to allow on demand filling of the grease separator. The refill pipe is equipped with an S-Trap which should always be filled with water to avoid odors being released from the grease separator. 7. Electrical Installation Electrical connection should only be made by a qualified, licensed professional. Power cable supplied to the separator should be equipped with a 16 Amp fuse. Connect power to pump. Insure that pump rotates in proper direction. 8. Power Plug with integrated motor protection switch 16 A CEE power plug with settable values (from 4.0 to 6.3 Amp) Amperage must be properly set on power plug (set to 5.6 Amp) Starting and stopping of the Shredder-Mix pump is handled from the control unit (black and red buttons) System equipped with pump rotation control System equipped with thermal shut down (pump temperature continuously monitored) Control unit dimensions (length 270mm width 110mm depth 100mm) Weight approximately 0.2 kg 9. Pump (with macerating system) Type SPF 260 KE Power 2.6 Kw 5.6 Amp Power supply required 400 Volt DS 50 Hz with winding temperature control For pumping grease separator contents for commercial applications Temperature limits of pumping medium - 5 to 35 deg Celsius Temperature limits of surroundings (ambient) 5 to 35 deg Celsius 10. Grease Separator User Manual should be kept in the immediate vicinity of the separator 5

6 3. Installation 3.3 Installation example Illustration shows Version G NG 4 Separator Dimensioned drawing of Version G Separator Waste Water Content Max DN a b h h1 h2 h3 l Sludge Separator Fat Weight flow trap storage (approx)kg 2 (l/s) l 212 l 106 l 50 kg 4 (l/s) l 354 l 177 l 65 kg 7 (l/s) l 567 l 302 l 100 kg 10(l/s) l 794 l 423 l 125 kg 6

7 3. Installation 3.4 Installation example Illustration shows Version D NG 4 Separator Dimensioned drawing of Version D Separator Waste Water Content Max flow DN OD a b b1 h1 h2 h3 l Sludge trap Separator Fat storage 2 (l/s) l 212 l 106 l 4 (l/s) l 354 l 177 l 7 (l/s) l 567 l 302 l 10(l/s l 794 l 423 l 7

8 3. Installation 3.5 Installation example Illustration shows Version D+S NG 4 Separator Dimensioned drawing of Version D+S Separator Waste Water Content Max flow DN OD a b b1 h1 h2 h3 l Sludge trap Separator Fat storage 2 (l/s) l 212 l 106 l 4 (l/s) l 354 l 177 l 7 (l/s) l 567 l 302 l 10(l/s l 794 l 423 l 8

9 4. Setting up 4.1 Setting up for operation Before the separator is put into operation, 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 installation. the separator is completely filled with clean cold water. Completely filling the separator is complete when water begins to drain from the outlet. 4.2 Initial instructions Placing the separator into full operation is normally handled by a licensed tradesman although upon order can be handled by a KESSEL representative. 1. The following personnel should be on hand when the initial instructions for placing the separator into operation are given: Building facilities manager Building maintenance workers Contracted plumber / tradesman Contracted disposal company 2. Commissioning preparation Separator is completely filled with clean water 3. Commissioning Separator to be checked for watertightness and for proper functionality Contents of this user s manuals to be discussed with those present Transfer of this manual to the appropriate personnel 5. Separator disposal The first disposal / emptying of the separator should be scheduled and occur within 2-3 weeks after being placed into operation. Disposal Intervals: According to DIN V separators should be emptied every 14 days and at a minimum every month. Attention: Proper disposal intervals are extremely important in assuring the separator functions properly. Because of the importance of proper disposal intervals, it is recommended that a disposal contract is signed with the appropriate disposal company. Due to potential odours during the disposal process, it is recommend that disposal is scheduled during off business hours. 9

10 5. Separator disposal 5.1 Separator version G disposal Carefully remove the quick-lock clamps and remove the covers. Place the suction hose of the disposal truck in the bottom of the separator and empty the chamber. When placing the hose in the separator stay clear of the inlet and outlet to assure that the polyethylene work in these areas is not damaged. After the chamber has been emptied, clean and rinse the interior walls of the separator. Again, re-empty contents of chamber. Completely fill separator with clean cold water (until water reaches outlet level). Check and clean the cover seals (replace if necessary) Put covers back on separator and secure with lock clamps. Connect disposal truck s suction hose to exterior building hook-up and suck out contents of separator. Replace protective exterior hook-up cover and completely refill the separator with cold clean water. If necessary: Carefully remove the quick-lock clamps and remove the covers. Clean and rinse the interior walls of the separator. Empty remaining contents of chamber. Completely fill separator with clean cold water (until water reaches outlet level). Check and clean the cover seals (replace if necessary) Put covers back on separator and secure with lock clamps. 5.2 Separator version D disposal Disposal truck connection of vacuum suction hose to disposal pipe coupling on exterior of building. If necessary: Carefully remove the quick-lock clamps and remove the covers. After the chamber has been emptied, clean and rinse the interior walls of the separator. Again, re-empty contents of chamber. Completely fill separator with clean cold water (until water reaches outlet level). Check and clean the cover seals (replace if necessary) Put covers back on separator and secure with lock clamps. 5.3 Disposal steps for D+S grease separator Disposal truck connection of vacuum suction hose to disposal pipe coupling on exterior of building. Disposal truck should turn on suction pump and immediately thereafter the pump on the separator should be started by pressing the black start button on the grease separator s control unit. Shortly before the entire contents of the separator have been disposed, turn on the cold water refilling valve on full flow. Allow full flow of cold water for approximately 5 minutes or until interior of separator appears to be clean (by viewing through the inspection window) then turn off the separator s pump by pressing the red button on the control unit of the separator. Vacuum pump on the disposal vehicle should also now be turned off. Continue filling with cold water until level has reached the outlet height of the separator. Now turn off cold water supply. If access to interior of separator is required: Un-latch quick release cover and remove polymer separator cover(s). Inspect cover seal (in recessed area of separator) clean / replace if necessary. Replace cover(s) and secure with quick release locking flange 10

11 6. Maintenance Before the separator is placed into operation and at regular intervals thereafter, the separator should be checked to make sure that it is water tight. The interior walls of the separator, as well as the exterior walls, should be cleaned and checked for damage every time the separator contents are disposed. The separator should be inspected every 6 months. At this time the separator contents should be disposed and the entire unit should be cleaned. During the cleaning check the sludge trap and grease separation portions of the separator to make sure they are in proper working condition. It is recommended that a written log is kept for the separator. Documentation and information concerning all disposals and any other work done to the separator should be kept in this log for future reference. Please make sure that: 1. This Installation, Service and Maintenance Guide and any other documentation relating to the separator is kept in a safe place accessible to all who work on the unit. 2. Disposal of the contents of the separator follows the exact guidelines stated in this guide. 3. The disposal of the separator is carried out by a qualified, licensed company. 7. Replacement parts and accessories 7.1 Inspection window The Inspection Window allows the rising level of grease / fat to be observed without the need of opening the top covers (which would cause odour releases). The handle can be turned clockwise and counterclockwise and is used to clean the inside of the inspection window so that a clear view of the grease / fat layer can be observed. If the inspection window is not originally ordered with the separator, it can be purchased and installed at a later date (the inspection window along with all necessary screws is included). Type Art. No. Connection left Connection right Refill equipment Before the separator is placed into service and also after every disposal the separator need to be completely filled with cold clean water. This can be accomplished by: the disposal truck a facet or hose to manual filling a permanently installed KESSEL refill attachment The KESSEL refill attachment will be installed onsite to a 1 inch drinking water valve. To stop the release of odours out of the open refill attachment, the P-trap portion of the refill attachment must always contain a sufficient quantity of water. The refill attachment can also be installed at a later date. The KESSEL refill attachment abides by DIN 1988 DVGW standards. Type Art. No. Connection left Connection right

12 7. Replacement parts and accessories 7.3 Solenoid valve The closing of cold and warm water valves connected to the separator can be turned on and off by a remote controlled solenoid valve Type Art. No. For 1 inch pipes For 1.5 inch pipes Sampling chamber DN 100 or DN 150 KESSEL offers various sampling chambers for installation in frost free rooms or for underground installation. Sampling chambers are odour tight and are opened and closed by a quick release locking clamp. This sampling chamber makes it possible to take samples of the grease free wastewater for testing (according to DIN 38409). Each chamber is equipped with a DN 100 and DN 150 inlet and outlet. The required sizes can be obtained by cutting off the respective section. Type Art. No. Horizontal outlet Vertical outlet Quick release locking clamp This is the locking mechanism used to fix the covers to the separators or the sampling chambers. Type Art. No. Locking clamp

13 7. Replacement parts and accessories 7.6. Lifting stations KESSEL offers various lifting stations for installation after the separator so that the effluent can be pumped up to sewer levels. The KESSEL Aqualift F for grey or sewage effluent for frost free areas consists of: Submersible (IP 68) single or double pumps units with single vane impellers (40mm maximum passage) and rotation direction indicator and 5 meter connection cable DN 100 outlet (pressure) with backflow preventer and rubber coupling Control unit for fully automatic pump control, splash-proof (IP65), wall mounted, operated on 400 V direct or 230 V alternating current at 50 Hz. A polyethylene collection chamber Pneumatic level control Clean-out DN 100 inlet ready DN 70 ventilation port DN 32 emergency hand pump port KESSEL Aqualift F Mono (single pump) Output Power Oulet Size Art. No. 1.1 kw 400 V direct (3-Phase) DN kw 230 V AC (1-Phase) DN kw 400 V direct (3-Phase) DN kw 400 V direct (3-Phase) DN kw 230 V AC (1-Phase) DN kw 400 V direct (3-Phase) DN KESSEL Aqualift F Duo (double pump) Output Power Oulet Size Art. No. 1.1 kw 400 V direct (3-Phase) DN kw 400 V direct (3-Phase) DN kw 400 V direct (3-Phase) DN kw 400 V direct (3-Phase) DN Cover gasket This is the gasket used to seal the cover to the separator or the sampling chamber. Type Art. No. Seal (450mm diam)

14 8. Guarantee 1. In the case that a KESSEL product is defective, KESSEL has the option of repairing or replacing the product. If the product remains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair or replace the product, the customer the has the right to cancel the order / contract 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 soon 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 only 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 months. This warranty period begins on the day the product is shipped from KESSEL to its customer. The warranty only applies to newly manufactured products. Additional information can be found in section 377 and 378 of the HGB. 2. Wear and tear on a product will not be considered a defect. Problems with products resulting from improper installation, handling or maintenance will also not be considered a defect

15 9. Important contacts / Info Separator Type Day / Hour Project description / Building services supervisor Address Telephone / Fax Builder Address Telephone / Fax Planner Address Telephone / Fax Contracted plumbing company Address Telephone / Fax Commissioning no. KESSEL System operator / owner Address Telephone / Fax Other remarks The system operator, and those responsible, were present during the commissioning of this system. Place and Date 15

16 10. Separator characteristics Type Production number / production year Weight / kg length x width X height EN Approval Sludge trap volume / l Oil storage volume / l Control stamp Material (Accessories) This unit has been checked for watertightness to be sure that it is fully operational before leaving the factory. Date Name of examiner 16

17 Everything for drainage Backwater valves and cleanouts Polymer and cast iron drains Volatile liquid traps Lifting stations, pumps, warning and control units Rainwater management systems Grease separators Oil/fuel and coalescence separators Inspection chambers Custom projects for industrial applications 17