KESSEL Grease separator `SE` M NS 2, NS 4, NS 7, NS 10, 15 and
Contents
1. 3 Alarm button 4 Pump operation LED START STOP 6 Digital Display Operating instructions 9 Disconnect control unit from power 4 3 Functions Steps of the disposal procedure The control unit is set up for automated or manual operation Manual operation has the priority over automated operation If ik KESSEL manual operation is activated the automated operation is deac tivated internally set automated procedures will not start 0 System info vr Information 2 1 Manual operation 2 4 Service dates 2 5 Activating the Remote Control Note For proper disposal of collected grease the heating fun ction should be run for at least 2 hours before disposal During the last minute of heating the mixing motor should also run If the automated heating times are changed the mixing times should be changed accordingly 4 4 Setting parameters Note When programming the heating mixing times be sure that no times run into the next day For example if hea ting begins at 22 00 it should end at 23 59 Setting the heating times In Menu Section 3 1 1 the day on which heating should occur can be set Also here the starting time of the heating and the duration of the heating can be set 3 Settings 3 1 Parameters 43 1 1 Heating 3 1 1 2 Monday 3 1 1 8 Sunday Setting the mixing function Note When programming the heating mixing times be sure that no times run into the next day For e2. Temperaturfiihler gt Temperaturfuhler 1 s Tali Taia Talia Tene Temperature probe Temperature probe ee O zones 1 KKK gt R 2 zo zz o Temperatursicherung 8 Temperatursicherung S Se 5 Thermal fuse gi Thermal fuse a SNg NT lt 0 4 Q SE Heizwicklun Heizwicklung Heating Ee Jr Tr Ip Gap un qp qp Gp Gp p Heating coil slsl z z sx z sxs 5 40 5Qbei 25 DE ELILIDII Erdung Grounding Pn a ALY dW31 ENIS eNla INIA WEY syndur r BueBuia3 O D o lt lt x vessto of E ul lt S s gt W gE Z pj ES o8s Nn ce G osseo EH O SESO x ITnVj res kg Ss 8 Buje lt 2 E ONNYOLS BunulEAA gt 0 ajo aay Jod gt SE l Me uoy 134 zod e w gt D a I Oo 4 TE Ze O 8832 DER Jac o D D kk m T dega y x CR zs IC CC u Kess a 2 DI Q En En D T ED T m S O m O z Fo inO lt O Z lt O t 6sny efsny DSLT Q Se lt es gt x S Ngse gt x 2 urs ss WSS r aE ro E se oe ap op op ra i E En L s 5 mo Wo o Tso a en SE EERS mea e Sekt w Z3 a z gt _ Z O 5 a LECH ard vesog 5 W O lt rig lt s 1 O o T N ha D O N a ed u es r usss _ z mesos 188 Srl u 5 L ES EOD D2 mn GE zrek we Leva S Nez gt x QER Woes oOo D G ZC ZS e E u gv P H WN GO Huez OTB HSgSo O Fr CSC od e gt 0 dei Hi E g nes Ow o r lt c o CO de EI
3. 4 Installation example Ventilation pipes should be connected directly to outdoor ambient air roof The venti lation pipes should not be connected to one another Grease sepa rator ventilation H ku m S R ls NU WE KESSEL KESSEL SE M NS 2 grease separator 2 Sludge trap Sludge storage barrel Grease storage barrel Sampling chamber KESSEL basement drain The Universal with integrated twin backwater flaps KESSEL Aquailift S Duo lifting station Public sewer A Wastewater from the grease se parator which is collected below the public sewer level should be pumped with a twin pump lifting station The pressure disposal pipe should be plumbed above the local backwater level and J then drained with gravity into the public sewer this prevents any X backwater from disturbing the operation of the lifting station _ Product Accessories I Sourced on site 3 1 Placing separator into operation mode Before allowing wastewater from the kitchen to enter the separator make sure the following is done Interior of separator as well as the inlet and outlet are completely cleaned and free of any debris Completely fill the separator with cold mains drinking water until water flows out of the outlet Check the entire separator and all pipe hose connec tions to assure they are watertight Also assure that the separator was not damaged during shipping or installa
4. for self disposal of waste is its method of disposal While conventional separators must be emptied completely and shut in the case of the SE only the material which has been se parated out needs to be disposed and is drained off via di scharge pipes into exchangeable barrels The grease sepa rator can be emptied any time without having to interrupt the process The separated material is in smaller quantities and is in a fresh state due to the fact that the sludge and grease is emptied multiple times per week Barrels which have been filled are replaced with empty ones Displaced air from the separation system is fed back into the separator meaning that no problematic odours are released during operation disposal If the grease solidifies it can be returned to a liquid state via the separator s heated cover During the heating process self cleaning takes place as the grease liquefies any particles solids settles out of the grease layer and settle to the base of the tank Sediments which settle out in the se parator tank are pumped back to the sludge trap via a circu lation system Recycling Di isposa Grease down while this work is carried out storage tank DIN 4040 The KESSEL grease separators for the self disposal of waste SE are designed in accordance with DIN 4040 The sludge trap and grease separator are housed in different tanks The volume
5. forming in slud ge separation area Very little wastewater volume high grease concentration 19 Connect included rinsing nozzle to the valve and rinse Disposal of sludge more frequently Completely empty sludge trap and clean Install solids filter in kitchen sinks or in main wastewater drain before separator Instruct kitchen to not allow solids into kit chen drainage fixtures Activate the rinsing pump more frequently ik KESSEL 8 Malfunctions and remedial measures Pump ran Possible cause Remedial action O Pump does not pump any Air in pump Run the disposal pump after approx 1 mi fluid nute the pump begins moving fluid again Pump jammed or pump interior area blocked Disconnect control unit from its power source Remove motor s cover and turn motor shaft If the motor is still jammed close valve near pump open the access to the pump s impel ler and clean impeller pump area Note that contents of the sludge disposal pipe will drain out Rotation of pump wrong Caution only allow a licensed professional to handle this repair Disconnect control unit from its power sour ce Change the electrical connection to allow for proper pump rotation Pump s internal thermal Pump is overloaded or very high sludge Caution pump can activate at any time if breaker activates automati content in pumping medium pump cools cally shuts off pumps Permanent odor problems Faut Possible cau
6. open the valve and check that the pump is operating properly check flow Additional comments If a sampling chamber has been installed clean the interior and remove any debris Carry out maintenance on the lifting station in accordance with the manufacturer s installation instructions Warm water Is recommended when cleaning the lifting station Re commissioning the grease separator 1 Check the whole separator system for leaks 2 Re start the KESSEL SE grease separator plant in ac cordance with Section 5 1 ik KESSEL 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 repla ce the product or it is economically unfeasible to repair or re place the product the customer 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 repla ced 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 KES
7. suolru ulid jeaoiddy NF 4a WIENIN ON It SJE DO ON JODICH ON IEN uoldii9s G1 el KESSEL E 25 Leistungserklarung Declaration of performance d claration de performance i Konformit tserkl rung Declaration of conformity d claration de conformit Hersteller manufacturer fabricant Produkt product produit Bestimmung definition d finition Bezeichnung description description i Ausf hrung version ex cution Werkstoff material mat riau BaugrdRen sizes tailles NS nominal size taille nominale KESSEL Fettabscheider SE Selbstentsorger Grease se separator SE S parateur de graisse SE Maschinenrichtlinie Machinery Directive directive machines Niederspannungsrichtlinie Low Voltage Directive Directive bassetension elektromagnetische Vertr glichkeit Electromagnetic ity compatibilit lectromagn tique Notifizierte Pr fstelle notified testing office KESSEL AG Bahnhofstra e 31 D 85101 Lenting Abahalderantaba zur Aufbereitung von fetthaltigem Abwassers mit separatem Schlammfang Separator for the treatment of greasy wastewater with separated sludge trap S parateur pour le traitement des eaux us es contenant des Schlammfang Volumen ly sludge collector volume UV volume du collecteur de boue Fettspeicher Volumen UV grease storage volume Ou volume de stockage des 2006 42 EG 2006 495 EG 2004 108 E
8. to install the grease separator in a tiled room with at least one floor drain and a hot water supply in order to ease maintenance and cleaning work The height of the room must be sufficient for work to be carried out at the maintenance ports minimum 30 cm from the ceiling The width of the room should allow for a working space of about 1 m on all sides 6 In the case of rooms with restricted access the tanks can be dismantled and reassembled see exploded diagram on Page 14 7 Be sure that the maximum allowable floor loading in the room of installation is not exceeded see weight table 8 The plant must be installed on a level surface in a frost free area 9 In order for the separator to function properly the tempera ture in the room of installation should not be below 15 degre es Celsius 10 The service side is pre assembled at the factory in accor dance with the order This can be altered on site See as sembly instructions Assemble the plant components using the connection elements supplied with the equipment Screw the tanks together using a maximum torque of 7 Nm 11 The inlet and outlet of the separator feed and discharge pipe must be connected on site Do this in accordance with the standards DIN 1986 12 The fall drainage pipes to the inlet of the separator should have at least a 1 meter long horizontal run with a slope of at least 1 50 before entering the separator The transition from th
9. u ik KESSEL 7 Control unit Electrical information F No heating rod Single heating rod Twin heating rods Power supply 230V single phase 50 Hz onnection Connection jacks Power supply disconnection Mains switch on control unit Connection values Max 2430 Watt when connecting Heating dome 230 V single phase 50 Hz 1200 Watt Mixing motor 230 V single phase 50 Hz 180 Watt Rinsing motor 230 V single phase 50 HZ max 750 Watt Protection class IP 54 Fusing CH Ci6A On site RCD FI 30 mA ik KESSEL 230V single phase 50 Hz Connection jacks Mains switch on control unit Max 3630 Watt when connecting Heating dome 230 V single phase 50 Hz 1200 Watt Mixing motor 230 V single phase 50 Hz 180 Watt Rinsing motor 230 V single phase 50 HZ max 750 Watt Heating rod 230 V single phase 50 Hz max 1500 Watt IP 54 C16A FI 30 mA 400V 3 phase 50 Hz Connection jacks Mains switch on control unit Max 5130 Watt when connec ting Heating dome 230 V single phase 50 Hz 1200 Watt Mixing motor 230 V single phase 50 Hz 180 Watt Rinsing motor 230 V single phase 50 HZ max 750 Watt Heating rods 230 V single phase 50 Hz max 1500 Watt e S2 C 16 Amp FI 30 mA 8 Malfunctions and remedial measures Follow the safety instructions before carrying out any work on the separator see Page 2 The following checks and remedies must be carried out by a licensed profession
10. 5 00 SE1 CNS NS 20 200 200 4100 1300 1750 1730 1800 2300 3650 505 93220 00 SE1 CNS NS 25 200 200 4600 1400 1850 1730 1800 2300 4350 535 93225 00 SE1 CNS ik KESSEL 2 Installation 2 1 Installation instructions The grease separation plant is supplied complete in pre as sembled units Under normal circumstances the equipment is set up by a plumber or can if requested be installed by a KESSEL technician for an agreed upon fee When installing the plant the following must be observed 1 The safety instructions on Page 4 must be followed 2 The instructions on the packaging must be taken into ac count No non approved parts of the separator should be used to move or lift the separator during transport or instal lation 3 The grease separation plant must be checked for transport damage immediately on arrival 4 The technical data relating to your plant will be found on the serial plate on one of the tanks and the electrical data will be found on the serial plate attached to the control unit All data are recorded in these instructions as well the plant pass Documents relating to the equipment are included at the back of the instructions 5 Bad odours will be released if the plant or barrels are not handled properly or maintenance work is not carried out in the proper manner For this reason we recommend installing the grease separator in a separate room with suitable venti lation such as a fan It is also advisable
11. G DIN EN 1825 1 Anhang ZA Janisme de contr le notifi Lenting den 1 04 2015 E Thiemt Vorstand Technik KESSEL AG Managing Board Conseil d administration 009 014 No 797 Technische Universitat M nchen R Priller Dokumentenverantwortlicher KESSEL AG Responsible for Documentation Responsable de la documentation sx KESSEL 26 Dichiarazione di prestazione Verklaring van de prestaties Deklaracja w a ciwo ci ydeevnedeklaration Dichiarazione di conformit Verklaring van conformiteit Deklaracja zgodno ci overensstemmelseserkl ring Produttore Fabrikant producent producent Prodotto Product Produkt produkt Impianto separatore di grassi Vetafscheider Separator ttuszczu fedtudskiller Norma Definitie Definicja definition Denominazione Beschrijving Opis beskrivelse Esecuzione Uitvoering Wykonanie udf relse Seperatore per il trattamento delle acque di scarico contenenti grassi con sedimentatore seperato Afscheider voor de behandeling van vethoudend afvalwater met gescheiden slibvanger Separator do oczyszczania ciek w zawieraj cych t uszcz ze oddzielny osadnikiem Separator til behandling af fedt holdigt spildevand med separate slamfang 1 Materiale Materiaal Tworzywo materiale 1 Dimensioni costruttive Afmetingen Rozmiary st rrelser 1 Dimensioni nominali Nominale grootte Rozmiar nominalny nominel st rrelse 13 Volume sedimentatore Slibvangvolume O
12. INSTALLATION OPERATING AND MAINTENANCE INSTRUTIONS KESSEL Grease separator SE M NS 2 NS 4 NS 7 NS 10 15 and 20 with manual waste disposal device KESSEL Grease Separator SE M NS 2 4 7 10 15 and 20 according to DIN 4040 and DIN EN 1825 1 E Product Advantages Compact Light weight for easy shipping and handling Frequent disposal of freshly collected grease and sludge into connected storage tanks even during separator operation Separate disposal collec tion of grease and sludge Smooth wax like surface prevents the building up to coagulated oils and grease The installation and service of this unit should be carried out by a licensed professional servicer Name Signature Company Stamp K ur KESSEL Ea Subject to technical amendment 1 Safety Instructions Follow all local and national accident prevention regulations An electrical heating cable is located inside the heating cover It is FORBIDDEN to damage the heating cover by drilling sawing grinding it or sub jecting it to any other process which takes away metal or by driving screws into it Disconnect the separator from its power source before carrying out maintenance work During operation maintenance or repair of the system all DIN VDE DVGW norms and guidelines as well as any other appropriate local and national sa fety regulations must be followed The system is only designed to handle wastewater from a kitc
13. SEL products are warranted for a period of 24 month This warranty period begins on the day the product is shipped form KESSEL to its customer The warranty only applies to newly manufactured products Additional information can be found in section 377 of the HGB ik KESSEL In addition to the standard warranty KESSEL offers an addi tional 20 year warranty on the polymer bodies of class II fuel separators grease separators inspection chambers wa stewater treatment systems and rainwater storage tanks This additional warranty applies to the watertightness usability and structural soundness of the product A requirement of this additional warranty is that the product is properly installed and operated in accordance with the valid installation and user s manual as well as the corresponding norms regulations 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 Note Only the manufacturer may open sealed components or screw connections Otherwise the warranty may become null and void 01 06 2010 24 dr 2 wend 2 Xa Q per Q us E D lt p Q Fu G che D Q Q JOUIWEXS JO SWeN Aug y HuiAes 1oj q euolesedo Ant SI u yey aime q o ss uluBILI eA JO p yo y u q sey yun SIU qd z uonduosaq uonduoseq ss uy iy J P uln oA
14. al servicer If necessary please contact the company that commissioned the separator Grease separator mt Possible cause Remedial action No or hardly any grease discharged No heating or heating time too short Large quantity of grease stored Room temperature under to 15 C Gradual build up of solid grease layer Build up of layer of floating sludge layer Foreign material blocking the grease di scharge valve Foreign material solids blocking the grease discharge valve Switch heating on again Run heating mode longer If possible raise the temperature of the room Even if grease is fluid in a cold state still use heating function Discharge floating sludge during each dispo Sal Pressure reduction in the heating dome Dismantle hose and valve and clean Clear the discharge hoses remove if neces sary Install solids filter in kitchen sinks or in main wastewater drain before separator Instruct kitchen to not allow solids into kitchen drainage fixtures Clean grease disposal valve Air in the heating dome Ventilate according to the instructions and Not ventilated during commissioning heat if necessary Too little fluid in the sludge trap tank Ensure that the sludge trap tank is filled to its upper edge with water Faut Possible cause Remedial action Sludge separator Little or no sludge drains from separator Sludge disposal blocked Solids blocking disposal valve Grease layer
15. arts hands fingers etc which come in contact with the separator should be properly washed and disin fected after the work is completed Clothing coming in contact with the separator or wastewater should also be changed and washed accordingly When leaving the plant always check the following The discharge valves to the grease and sludge barrels must be closed The rinsing line valve must be open The cover to the sludge trap must be tightly closed The storage barrel lids must be screwed on tight Safety procedures instructions concerning the separator must be familiar to all persons operating the separator WER KESSEL EIER dd Safety instructions luuuuurr11111111 11 EEEEEE EEE EEEE EE EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE Page 2 J 7 CVCE Page 4 2 Installation 2 1 Installation instructions Page 7 2 2 Assembly Page 8 2 3 Control unit mounting Page 8 2 4 Installation example Page 8 3 Commissioning 3 1 Placing separator into operating mode Page 9 3 2 Instructions and hand over Page 9 Se Hand over protocol a Page 9 3 4 Fill uuu sa
16. ater until water flows out of the outlet This can be done by running a faucet from a sink which is connected to the grease separa tor 3 5 Ventilation The hood dome of the separator must be ventilated closed WE KESSEL 4 Operation 4 1 Control unit settings 4 1 1 General The following functions are controlled by the control unit Rinsing Euro Norm grease separators do not have the rin sing function Heating Mixing These functions are automatically started and ended accor ding to the programmed settings The system s components can also be operated manually by using the control unit See Menu 2 1 4 1 2 Programming the functions The time of day date and disposal program has been factory set 4 2 Operation The control unit has a Start and Stop button 5 for ma nually controlling the disposal and a button for acknowled ging any alarms 3 The current operating status of the se parator is displayed by an LED 1 an alarm malfunction LED 2 and a function LED 4 The control unit can be ope rated by using the UpA Down Y ESC and OK buttons 7 Please follow the operating manual 8 Before conducting any work on the control unit be sure to disconnect it from its power source 9 see safety instructions Fettabscheider Grease Separator SE So OC EI Operation LED 7 Navigation buttons 2 Alarm LED Up down ESC OK
17. bj to osadu slamfang TT Volume deposito di grasso Volume vetopslag Obj to magazynowania t uszczu tluszczu fedtopbevaring 15 Norme considerate In acht genomen voorschriften uwzgl dniane przepisy anvendt bestemmelse 16 Direttiva macchine Machinerichtlijn Dyrektywa maszynowa maskindirektivet Y Direttiva bassa tensione Laagspanningsrichtlijn Dyrektywa niskiego napiecia lavsp ndingsdirektivet 18 Compatibilit elettromagnetica Elektromagnetische compatibiliteit Zgodno elektromagnetyczna elektromagnetisk kompatibilitet 13 Conformit a normal Conformiteit volgens Zgodno wedtug overensstemmelse med 20 Requisito Eis Wymogi krav 2 Risultato BI Wynik resultat 22 Reazione al fuoco Reactie op brand Reakcja na ogie brandklasse S Impermeapbilit ai liquidi Vioeistofdichtheid Szczelno cieczy vesketzthed 24 Superata Geslaagd przekazywane best et 2 Efficacia Effectiviteit SkutecznoS effektivitet 26 Capacit di carico Draagvermogen No no kapacitet 2 Durevolezza Duurzaamheid Trwatos holdbarhed Stazione di collaudo notificata Genotificeerde instantie Akredytowana jednostka certyfikacyjna bemyndiget organ Director of Technology Directeur techniek Dyrektor Techniczny direkt r for Teknologi S Responsabile della documentazione Verantwoordelijk voor documenten odpowiedzialny za dokumenty ansvarlig for dokumenter 31 Separatore di grassi SE vetafscheider SE S
18. dome cables Mixer cables Grease collection barrel Filling hose Ventilation hose Sludge collection barrel Filling hose Ventilation hose Exchange stub sz KESSEL 7 Control unit Control unit picture Control unit ID sticker description H The control unit ID sticker is located on the right narrow side of the control unit ill 1 Control unit ID sticker description Ir KESSEL Control unit type Bahnhofstra e 31 Control unit article number D 85101 Lenting Connection voltage and frequency Current range ls asli FA SE Protection class IP Control unit serial number 363 323 363 403 Control unit replacement part number Danger symbol Protection category We 400 VAC 50 Hz CE symbol ge le 6 3 100 A St OD Disposal information do not dispose of l IP 54 control unit in household trash 2 Control unit hardware id Outputs 0 Potential free contact changeover contact center contact closing contact open Contact D e max 42 VAC 0 5 A SerNr XAXA Re v5td X X _ Optional Remote e Connection contacts G speaker alarm for remote speaker Artikel Nr 20162 alarm ik KESSEL Made in Germany Sachi 363 310 ill 2 7 Control unit Heizhaube Heating mantle AnschluBbelegung an Pos 11 Wiring at Pos 11 Raccordement pour commande a distance optional 916601 Erdung Grounding Ce ANSCHLUSS FERNBEDIENUNG connection remote contro
19. e collection barrel with operatio nal cover with transparent hose and ventilation connection 2 Ventilation connec tion port Drainage inlet Center of cover for inlet and ventilation Threaded cover for twist tigh tening 13 Sludge collection bar rel with operational cover with transpa rent hose and ventila tion connection Ventilation connection port 3 Drainage inlet 4 Center of cover for inlet and ventilation Operational covers are custom desi gned so that when completely full still have enough room to allow the entire contents of the transparent draina ge hose to fit into the collection barrel when the cover is removed which prevents spilling or overflowing of the contents of the transparent hose during collection barrel exchange ik KESSEL Mu Tee amu ITT M IK KESSEL 14 15 ill shows NS 2 OO OOO OOOO OOO OOG 6000 O 2999 Lower frame Pump rinsing system Rinsing system valve Base section of sludge trap Tank seal gasket Upper section of sludge trap Cover seal Sludge trap cover Quick release clasp Rinsing line hose Rinsing line stub Exchange stub Sludge discharge valve Sludge discharge cover Lower section of grease separator Tank seal gasket Heating dome Grease discharge valve Mixer Grease discharge cover Cover seal gasket Compensation tank Ventilation pipe Control unit Pump cables Heating
20. e fall pipe to the calming stretch must be constructed from two 45 degree bends This reduces gt the risk of the siphon and siphon trap being sucked empty ch the amount of air admitted to the system air movements and build up of bad odours ch the formation of foam in the separator If the separator plant is installed below the local backwater level a wastewater lifting station must be installed in accor dance with DIN 1986 providing local regulations do not require otherwise Lifting units must also be provided with their own ventilation pipe Important on site requirements for proper function and odour free grease separator operation gt Grease separator plants and their feed and discharge pipes must be provided with sufficient ventilation in accordance with DIN EN 1825 2 Consequently as a ventilation pipe the feed must be taken above the roof All pipes connected to the plant that are more than 5 m long must be ventilated se parately If the main wastewater pipe to the separator is lon ger than 10 m and not separately ventilated then this pipe must also be ventilated n order to avoid the build up of bad odours the feed and di scharge pipe connections must be firmly connected and all seals must be fitted carefully All drainage fixtures connected to the grease separator should be equipped with odor traps and sludge traps Large items such as utensils ketchup mustard wrappers and bones etc will cause
21. e trap into the grease separator Warning The sludge trap must be filled to the overflow level The rin sing process must not be started immediately after sludge discharge otherwise the grease separation area will be pum ped out Too frequent or too slow sludge transfer can cause the grea se separator area to be pumped out Automatic rinsing Automatic rinsing is triggered via a time switch For this rea son leave the valve on the rinsing line 1c open during nor mal operation of the grease separator In order to check that the pump is operating properly rinsing should be carried out briefly by hand once per month during waste disposal Whether the pump is delivering or not can be established by the noise of liquid running into the sludge trap Manual rinsing gt gt The valve on the rinsing line 1c page 14 must be open standard position gt gt Start the pump in the manual mode Control Unit Menu Section 2 1 Step 2 Grease disposal Disposal should take place at the end of the programmed heating times Heating times can be customer set see time settings in Sec tion 4 4 in order to better match the operation to on site re quirements At the end of the set heating time set at 2 hours at the fac tory slowly open the grease discharge valve 6a page 14 Observe the flow of grease through the transparent filling hose 10b page 14 Drain the grease and any floating sludge into the grease sto rage barrel
22. eparator t uszczu SE fedt separator SE ik KESSEL 27 Leading in Drainage et Private homes without public sewage connection lt T 088008 er eit Public buildings gagong 2 e g hospital Public buildings e g leisure facility 1121317415 T Commercial buildings e g hotel ete HOPE Commercial buildings e e g industrial manu m facturing facilities 7 Commercial buildings __ e g gas petrol station J 0800 Private homes multifamily apartments flats Backwater valves 2 Wastewater Lifting system Lifting stations CEEE 5 Separator Septic Systems iki KESSEL
23. factory Nevertheless please check immediately whether the system has been delivered to you complete and undamaged In case of any transport da mage please contact the shipping company Before the KESSEL SE separator is installed and placed into operation it is mandatory and in your own interest to completely read through and follow all the information contained in this Installation Operation and Maintenance Manual KESSEL AG ik KESSEL 1 1 Application Oils and greases in wastewater are not allowed to be drained into public wastewater pipes sewers and also not into to lakes rivers Oil and greases in wastewater pipes can collect on the interior walls causing a reduction in the cross sectional area of the pipe and eventually pipe blockage In addition over time the collected grease begins to decompo se and turn acidic which can lead to odour nuisances as well as the corrosion degradation of the drainage pipes and sy stem Without grease separators the oils greases will collect on the surface of ponds lakes as well as wastewater treatment collection ponds causing reduction of oxygen access to these waters DIN 1986 Part 1 requires that harmful sub stances are retained For this reason grease separators in accordance with DIN 4040 must be provided and the grease disposed of appropriately Inlet P a 1 2 System Description Separator function The special feature of the Type SE grease separator
24. fitted with odour proof covers made from Duroplast 2K The fittings and units are resistant against corrosive aggres sive wastewaters and are designed for use in damp areas Illustration shows an NS 2 separator Inlet Outlet Sludge trap Grease separation area Cover with quick release clamp Heating dome Sludge storage barrel Grease storage barrel Ventilation Cleaning access Control unit Grease mixing motor lever Rinsing pump OOOOOCOQOOSOHO p ws JI n 1 B h h WM Sudgetap Grease trap Wes Weight ful_ 1460 1460 see illustration ik KESSEL 2 Installation Illustration shows NS 2 and NS 15 G Inlet Grease storage barrel 2 Outlet 9 Ventilation 3 Sludge trap Cleaning access 4 Grease separation area Op Control unit 5 Cover with quick release clamp 2 Grease mixing motor lever Heating dome 3 Rinsing pump Sludge storage barrel Dimensions Separator Weight NS DN I x b bi h1 h2 h3 in Liter in kg Art Nr NS 2 100 110 1760 9307 1330 Fr 1230 F1500 F 1700 600 97 93202 00 SE1 CNS NS 4 100 110 1830 930 1330 1630 1700 2100 950 128 93204 00 SE1 CNS NS 7 150 160 2230 1300 1700 1630 1700 2200 14501 186 93207 00 SE1 CNS NS 10 150 160 22300 19007 1700 0517390 11300 12300 16001 192 93210 00 SE1 CNS Dimensions Separatorin Weight NS DN I x b b1 hi h2 h3 Liter in kg Art Nr NS 15 200 200 3600 1200 1650 1730 1800 2300 2950 485 9321
25. hen with a maximum temperature of 60 deg Celsius Higher temperatures can result in damage to the system The motor protection relay on the rinsing motor and the internal temperature control ler of the mixing motor automatically reactivate after turning off once the motor has cooled The grease water mixture in the plant may become very hot Please use appropria te care during all work on the system CAUTION risk of slipping During disposal cleaning or maintenance grease or water may spill on the floor of the operating area causing a very slippery surface No part of the plant should be stepped on The plant is not to be climbed on as a means of reaching other installations Use separate ladders etc for this purpose Because of the possible formation of bio gasses SMOKING IS PROHIBITED while Gi the separator is open or the collection barrels are being exchanged Only operate the heater in the heating cover filled with water or grease when venti lated A pocket of air in the upper portion of the heating dome could cause the heating dome to overheat due to the air pocket not allowing the heating cables to cool pro perly No access for UNAUTHORISED PERSONS No storing of foods for reasons of hygiene The operating area must be selected so that there is sufficient access around and above the separator plant for disposal cleaning and maintenance work Wastewater inside the separator can contain bacteria All body p
26. mediately to prevent any blockage from building up in the hoses Store all full barrels in a cool and frost free area Collection barrels which are full should be taken off site as soon as possible If stored too long and depending on the temperature of the storage room the contents of the barrels can begin to decompose causing gas build up which can result in gases odours escaping from the barrels In the case that a disposal company handles the removal of the barrels make sure that any replacement barrels sup plied to you by the disposal company are the same size as the original barrels and have an original KESSEL cover Tips on reducing odour build up 1 When exchanging barrels to it cleanly and quickly 2 Make sure that the barrels covers are properly secured 3 Any spilled wastewater should be quickly cleaned up 4 Any filled or partially filled storage barrels depending on room temperature should be removed from site at a ma ximum within 4 weeks It is recommended that the barrels are stored in a very cool frost free area The decomposition process in the collection barrels results in gas build up inside the barrels which can cause them to bulge and release bad smelling odours By continuous odour problems please see Section Malfunctions and Remedial Measures 12 5 Disposal Exchanging barrels Collection barrel with twist scr ewed storage transport covers 1 Screwed cover Greas
27. n the log book All mechanical and electrical parts such as the pump valves closure valves control unit etc should be inspected every 6 months according the manufacturer s instructions 10 2 General Inspection Before commissioning and then in regular intervals thereafter but at a minimum every 5 years the separator must be fully inspected by a licensed professional to assure all systems are in proper working order Prior to this inspection the sepa rator should be fully emptied and cleaned Included in this ge neral inspection is the following Required size of the grease separator should be checked to assure that the installed separator meets the requirements Condition and watertightness of the separator should be checked ik KESSEL Interior walls of all components and any electrical systems should be checked Assure that a proper ventilation pipe is connected near the separator s inlet this ventilation pipe should be connected to ambient air to the roof Review the separator s log book to make sure all log book entries seem plausible and accurate Check to assure that all grease and sludge taken from the separator has been properly handled disposed Assure that all required certifications and documents for the separator are available drainage plan autho rizations user s manual The results of the general inspection should be documented Any irregularities defects or problems with the sepa
28. nage valve as soon as the amount of draining sludge decreases noticeably or if the sludge barrel is full S Note Make sure to check the following when the disposal process has ended All valves are in the basic setting closed except for the rinsing valve 1c page 14 which should remain in the open position The heating B is off The pump P is off ik KESSEL Step 4 Collection barrel exchange Note close valves and follow all safety instructions Prepare an empty collection barrel and remove its cover Di sconnect the drainage pipe and ventilation pipe from the collection barrel and unclip the quick release clamp Slowly remove the cover from the full tank any remaining fluid in the drainage will have enough room in the collection tank and place onto the empty barrel and connect Place the closed cover onto the full collection barrel and se cure properly Mark the barrel to identify the contents Grea se or Sludge We recommend changing the barrels at a later to date to allow them to cool and settle preferably when the next disposal takes place During this time the grease can settle to the top of the collection barrel and any water can settle to the bottom This will aide in the reduction of odours when exchanging barrels Note In the case that the collection barrels are so full that sludge or grease backs up into the transparent hoses then it is im portant to change the barrels im
29. p using the rinsing pump until the sludge trap is completely full 2 WARNING Isolate the control box from the power supply before starting work The electrical heating cover can now be removed In order to do this release the electrical plug connection s the transparent hose and the heating cover fasteners Remove the heating cover 3 Have the residual water pumped out by for example an effluent disposal company 4 Wash down the inside of the grease separator tank and the heating cover with warm clarified water and clean them carefully removing any deposits that may be there 5 Flush through the transparent hoses with warm water and clean them 6 Clean the pipe connections between the sludge trap and the grease separator tank rinse and clean the discharge 23 valves rinse pump and special covers for the disposal barrels and check for obstructions 7 Check the heating cover seal for any possible damage and exchange if necessary Clean and grease the surface of the seals and reinstall the heating cover 8 Reassemble the plant Maintenance work on the rinsing pump 1 Shut off the rinsing system valve release the electrical plug connection and place a flat container underneath to catch the water from the rinsing line 2 Slacken the screwed fasteners in the feet of the motor and remove the impeller pump 3 Clean the impeller and free the pump from any blockages that may be there 4 Reassemble the pump
30. rator should also be documented and repaired immediately 22 11 Maintenance instructions for SE separators Maintenance instructions for KESSEL SE grease sepa rators The person carrying out maintenance must be familiar with the operation of the plant A spare gasket for the heating cover of the corresponding OE plant should be taken to the site so that this can be changed if necessary When opening the grease separator bad odours must be expected Preparation 1 It must be ensured that no waste water runs into the grease separator during maintenance work inform the operator 2 Dispose of grease and sludge in accordance with the operating instructions abide by the heating times Maintenance work on the sludge trap 1 Open the cover to the sludge trap and remove all the water from inside e g by having it pumped out by an effluent disposal company 2 Check the sludge discharge valve for obstructions clean the inner discharge area and remove any possible block ages caused by larger objects 3 Wash down the inner walls of the sludge trap with warm clarified water free them from any contamination and deposits and clean them 4 Check the feed to the sludge trap for obstructions and deposits and clean if necessary 5 Check the outlet of the rinsing line and clean if neces sary Maintenance work on the grease separator tank 1 Pump the water from the grease separator tank to the sludge tra
31. rdance with DIN 38409 Before taking a sample the interior of the sampling chamber should be cleaned and rinsed DIN 1986 Part 1 requires the installation of sampling chambers please contact your local authorities for information if a sam pling chamber is required for your installation Aqualift F Lifting Station Pump l KESSEL offers various lifting stations which can be installed power Power connection before or after the grease separator Please note that a twin 400 DS amp phase pump lifting station should be installed after a grease separa co S C DN ieee 2 2 kW 400 V DS 3 phase DN100 28631 tor Description Art Number 60 liter storage barrel 10a 11a Storage barrel cover 2e Gasket for barrel cover 2d Chamber gasket for separator tank NS 4 860 113 See explosion diagram on page 14 Article Best Nr General separator inspection from KESSEL Customer Service 917 411 Grease separator log book 917 409 ik KESSEL 21 10 Maintenance and servicing checks Follow all safety instructions 10 1 Maintenance The grease separator should be inspected every 6 months by a professional Along with the disposal of the separator the following work should also be completed The interior walls of the grease and sludge tanks should be inspected The electrical systems and parts of the grease separator should be checked All work completed on the separator should be entered i
32. ree secon E E EE E Page 9 3 5 VentiaUON uu uuu eiia a a Page 9 4 Operation 4 1 Control unit settings Page 10 4 2 Operation soeren ei n i E Page 10 4 3 Functions Steps of the disposal procedure Page 10 4 4 Setting parameters Page 10 5 Disposal Disposal steps Page 11 6 Explosion diagram p o cQ V QO hhQ h g A h RR R Q L N RQ P R r n rrrrsssrrrsssssiissssa Page 14 7 Control unit nec ete ttteeeeeccceececceceeeeeccaaaaaeeeessuusceceeeeeeeeesssssaaeaeeseeeeeeeeeeeeness Page 16 8 Malfunctions and remedial measures r r Page 19 9 Accessories and replacement parts gt a nsn ssnnnssnrrnsnnrrsssrrssssa Page 21 10 Maintenance and servicing checks 7 7 7f LR n 3nF rr Page 22 11 Maintenance instructions for SE separators r rsssssssssaa Page 23 12 Cd CT dE Page 24 13 Manufacturer Separator data and information I Page 25 15 Declaration of performance gt r Page 26 Dear customer We are pleased that you have chosen a KESSEL product The entire system was subjected to a stringent quality control before leaving the
33. s size of calming zones and shape of the installed units to some extent exceed the specifications laid down in the norm standard No external energy requirements means that SE grease separator plants operate without requiring an energy supply during grease separation Reduced drinking water consumption and lower energy costs and wastewater fees resulting from improved water quality and possible re utilisation of fresh grease are the eco nomical and ecological objectives In accordance with the efflu ent disposal regulations the operator can put a higher priority on re utilisation than disposal No bad odours In the grease separator the light substances such as fats oils Dimensioned drawing and information table and floating sludge accumulate on the surface and can be re moved via the grease discharge pipe The heavier material sett les out to the base of the sludge trap and is later drained into the collection and transport barrels Disposal of the material in closed barrels is achieved with almost no smell When changing the barrels there may be a temporary release of odours Materials Series SE KESSEL grease separator plants consist of a se parate sludge trap and grease separator The tanks their inte grated units and pipe work are all made from PE HD The smooth wax like surface of polyethylene hinders the build up of deposits and solids and is therefore easy to clean The plants are
34. se Remedial action Odor problems Drainage pipes Check to ensure all drainage pipes and gaskets are properly connected and in proper operating condition Ventilation pipe missing or ventilation pipe Install ventilation pipe or increase size of size too small existing ventilation pipe Storage barrels and connections Check barrels barrel covers and pipe connections to barrels Hoses Check all hoses and hose connections Full storage barrels not removed in timely Remove full storage barrels from room soo fashion contents begin to decompose ner Lifting station Lifting station which may be connected to outlet of grease separator not properly ven tilated Room where separator is installed has clo Install ventilation fresh air supply to room sed walls and no or improper ventilation where separator is located s KESSEL 20 9 Accessories and replacement parts Accessories can normally be installed to the system at a later date Please contact KESSEL directly Replacement parts Sampling chamber KESSEL offers sampling chambers for indoor free standing Model tote installation or for underground installation All sampling cham Lateral outlet 915 871 bers are completely odor tight The sampling chamber allows Vertical outlet 915 870 wastewater samples to be taken from the separator s effluent stream without allowing odors to escape The wastewater samples can be used to analyze samples for example in ac co
35. the separator pumps and valves to malfunction 2 2 Assembly 2Grease and sludge separator components Set up the grease separator tank 10a and the sludge separator tank 11a Connect the drainage hoses 10b and 11b to the sludge dis posal port 4a and to the grease disposal port 6a Connect the ventilation hoses 10c and 11c to the connection port on the sludge and grease storage barrel covers ik KESSEL 2 Installation 2 2 1 Connect Connect the inlet and the outlet of the grease separator to the on site drainage pipes as well as connecting the main drainage pipe to a ventilation pipe 2 2 2 Checks All pipe hose and storage barrel connections must be checked to assure that they are watertight The manual disposal valves must be placed in the base position meaning Sludge and grease disposal valves in the closed posi tion 4a 6a Rinsing valve between grease and sludge separation areas in the open position 2 3 Control unit mounting The main power switch must be placed in the 0 position in order to open the control unit Use the included mounting template in order to drill four holes in the wall the included dowels and screws should be used for mounting the control unit to the wall The control unit should be mounted in a frost free area and not in direct sunlight It should also be placed in a position so that the cover can be completely opened to allow full access into the control unit 2
36. tion Check all pipes for watertightness by conducting a Visual inspection Pressure test 3 2 Instructions and hand over The commissioning and initial grease separator training is normally handled by a KESSEL customer service represen tative 1 The following persons should be present during the grea se separator commissioning Plumber Representative of the building owner Also recommended to be present Person who will be responsible for the operation of the separator Grease separator disposal company 2 Preparation for the hand over and initial training All sanitary connections must be complete Completely filling the separator with cold mains drinking water The disposal company must be arranged to be present during the first disposal 3 Instructions Information concerning the disposal Practical training of the separator operation Function check of the separator Instructions on how often the grease separator should be disposed 4 Hand over of the installation and operational manual 5 After the initial training has been completed the separator should be returned to normal operational mode mea ning the separator must be filled with clean cold mains drinking water 3 3 Hand over protocol see attachment 3 4 Filling All valves should be in the operational position meaning closed only the sludge transfer valve 1c should remain open Fill the entire separator with clean cold w
37. until either the barrel F is full which can be de tected when no more grease is capable of flowing into the barrel or until grease is no longer visible in the transparent hose 10b page 14 Now close the grease disposal valve 6a page 14 11 ik KESSEL 5 Disposal In the case that no grease flows out into the collection barrel the heating duration must be extended until the hardened grease turns liquid Depending on the room temperature and the amount of grease this heating could me more than two hours On the control unit display the heating mode is dis played The internal temperature sensor regulates the hea ting until the programmed heating time has elapsed The start and stop of the heating dome occurs automatically In the case that no grease drains into the grease collection barrel a The amount of water in the separator is not sufficient to create enough pressure to push out the grease In this case a drainage fixture connected to the grease separator kitchen sink for example should be run to allow more water into the separator b If there is still hardened grease in the separator The dis posal intervals should be shortened draining of grease and sludge should take place more frequently Step 3 Sludge disposal Slowly open the valve 4a page 14 of the sludge trap C Observe the sludge draining through the transparent hose 11b page 14 into the sludge collection barrel Close the sludge drai
38. xample if heating begins at 22 00 it should end at 23 59 Setting the rinsing function 3 Settings 3 1 Parameters 43 1 2 Mixing In Menu 3 1 3 on the control unit the day of the week that rinsing should take place can be set Here you can also set the time of day that the rinsing should begin and also the duration of the rin sing 3 Settings 3 1 Parameters 3 1 3 Rinsing 3 1 3 8 Sunday 10 5 Disposal Disposal Steps The aim of re utilising grease requires frequent waste dispo sal from the grease separator in order to keep the biochemi cal decomposition process to a minimum The discharge of separated material must therefore be carried out not only ac cording to quantity but also according to time at least twice per week The volume of the grease separator in the case of NS 2 is 80 litres and in the case of NS 4 it is 160 litres in ac cordance with the Standard The collection barrel holds ap prox 60 litres A Failure free and proper operation of the plant is IN only guaranteed if the waste from the plant is dis posed of in time gt gt For the flow chart of the separation operation see Sec tion 2 gt A brief set of instructions in which the most important functions are explained are attached to the control unit Step 1 Rinsing During the rinsing process the sediments are transferred from the grease separator into the sludge trap and grease films and floating sludges are conveyed from the sludg
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