KESSEL Grease separator `SE` M NS 2, NS 4, NS 7, NS 10, 15 and
Contents
1. l bh l WILNALOd WET I deih D OME T as a 3 O J Iguondo MOOSL Xew ZHOS DV ADE A00F Queues sed anb aqissod a efeyneyo sjqissod JUBLEA AQ00P Ag Ajuo Yous buneeH E HOITDON IALNUVIIVA A00F 139 YNN Z AVLSZISH ik KESSEL 17 7 Gontrol unit Electrical information 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 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 Protection class IP 54 Fusing CH C16A 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 Watt2. 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 professional 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
3. JOnuo5 SOL UOIIDSULIOS ONNNI 0IANHIH SSNIHISNY m e A G teH gt CH ia Erdung Grounding K o A c o D 5 D be Q e 5 O o lt o o o D Heizhaube Heating mantle g Ha Clos ou Ojos Kiel NI e Den jazz 4 1 Clans Husn H smj D pul CNII NIJ wely gu sindur EUI SE e 1 op op op ap op op op op D E ALY dWaL ENI CA Temperatursicherung Thermal fuse 1000 10 Q bei 25 lt 0 40 Temperaturf hler Temperature probe Heizwicklung Heating coil 40 50 bei 25 Erdung Grounding Temperaturf hler Temperature probe Temperatursicherung Heizwicklung Heating coil Thermal fuse MOSZ xew ZHOS DV ADEE Bd WO 97214 dund ysn IdNNdINds inajdes duet Josues Ouer 431HN0d dal ZH 09 OV A00F MOS xeu Moosi xew jeuondo ZHOS OV ADT ZHOS DV AOC ZHOS OV ADE nauga aeyneyo ap Nes jueyy neasey JEKI apueu DUDEet SUE SI HISIN JANVHZIdH ZLAIN e ele HO Heo s 2 oC e Hal Dec ediz Hablts Geos SE m leedltazio Gol Heg g Hal 957 beat eja 2 Sr nage of e e CeGldSes Feeble Heke 4 a S EERS ed s HHS DIER s E gt stet 5 NYG Z3 AVUI SLE Ld SE euondo reegen ZHOS DVAOEZ VS 0 ACH AA 006L xew ajgisns JORIUOD ep ags esn SIGH UOIX UUOOD ZHOS OV ADEE esn SND23HD2IS DB uO2 UJ NWAS an abeyneyo SNNY3HI9IS 884 PUO Yms Bullgari LMYILINOM L AWLSZIIH 7 e e E a t13I3214
4. 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 separa tor 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 drainage valve as soon as
5. 00 SE1 CNS 93207 00 SE1 CNS 93210 00 SE1 CNS Art Nr 93215 00 SE1 CNS 93220 00 SE1 CNS 93225 00 SE1 CNS 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 to install the grease separator in a tiled room with at le
6. 2 2 Assembly 1 Grease and sludge separator components Set up the grease separator tank 10a and the sludge separa tor 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 AnschlieBen Connect the inlet and the outlet of the grease separator to the on site drainage pipes as well as connecting the main drai nage pipe to a ventilation pipe 2 2 2 Checks 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 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 in a position so that the cover can be completely opened to allow full access into the control unit 2 4 Installation example Ventilation pip
7. LED 6 START STOP Digital Display Operating instructions 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 manual operation is activated the automated operation is de ik KESSEL activated internally set automated procedures will not start 0 System info 4 1 Information 2 1 Manual operation 2 2 Automated operation 2 3 SDS Self Diagnosis System 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 heating 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 ParametersH 3 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
8. Ubereinstimmung der Produkte ist auf dem Typenschild das Zeichen der Richtlinie 93 68 EWG angebracht The 93 68 EWG code mark should be located on the ID plate on the product Le marquage et l indentification du produit figurent sur la plaquette d identification selon les directives 93 68 EWG Lenting den 04 01 2012 df M Rinckens E Thiemt CL A Leiter Innovationsmanagement Dokumentationsverantwortlicher Vorstand Innovation Management Manager Responsible for Documentation Managing Board Responsable du management pour innovation et de la documentation Conseil d administration ik KESSEL 24 dr 2 ond E EN Q jet Q us E D LL K GA aja S Q Q ABUILUEX8 JO QUWIEN qd AOS y Buineaj 1oj q peuonesado Ant s 1 yey ains ag o ss uluBIL eA 10 p yo y u q sey yun SIU z uondiuo5s dq uonduoseq Ausueq QUINJON SUOISUAWIG eAoJddy N3 IDISMISLUSIEINI ON It SJE DO1d ON 19D4O ON IEN uoldii9s G 1el AC KESSEL 25 15 Hand over certificate Separator Type Day Hour Project description Building services supervisor Address Telephone Fax Builder Address Telephone Fax Planner Address Telephone Fax Contracted plumbing company Address UU Telephone Fax KESSEL Commissions no System operator owner Address Telephone Fax User Address Telephone Fax Person of delivery Other remarks The system o
9. degree bends This reduces the risk of the siphon and siphon trap being sucked empty gt the amount of air admitted to the system air movements and build up of bad odours gt 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 requi re 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 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 In 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 the separator pumps and valves to mal function
10. 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 cause 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 Article Nr KESSEL offers sampling chambers for indoor free standing installation or for underground installation All sampling cham Lateral outlet 915871 bers are completely odor tight T
11. 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 month This warranty period be gins on the day the product is shipped form KESSEL to its cu stomer The warranty only applies to newly manufactured products Additional information can be found in section 377 of the HGB 23 In addition to the standard warranty KESSEL offers an addi tional 20 year warranty on the polymer bodies of class Il 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 Arequirement 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 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 Note Only the manufacturer may open sealed components or screw connections Otherwise the warranty may become null and void 01 06 2010 ik KESSEL CE ir KESSEL EU KONFO
12. 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 in 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 separator should be fully emptied and cleaned Included in this general 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 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 certification
13. 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 s 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 barrel s immediately to prevent
14. Compensation tank Ventilation pipe Control unit Pump cables Heating dome cables Mixer cables Grease collection barrel Filling hose Ventilation hose Sludge collection barrel Filling hose Ventilation hose Exchange stub s KESSEL 7 Gontrol unit Control unit picture Control unit ID sticker description G J Fettabscheider Grease Separator SE The control unit ID sticker is located on the right narrow side of the control unit ill 1 Control unit ID sticker description IK KESSEL Bahnhofstra e 31 Q Control unit type D 85101 Lentine Control unit article number 6 enting 3 Connection voltage and frequency i Current range FA SE Protection class IP Control unit serial number mim 999 Togo ADAY Control unit replacement part number 363 323 363 403 Danger symbol Protection category U e 400 VAC 50 Hz x sei A e 6 3 10 0 A 1 Disposal information do not dispose of D S control unit in household trash Control unit hardware id Outputs Potential free contact changeover contact center contact closing contact open Contact OI e max 42 VAC 0 5 A oer AAAA Revotd AA Optional Remote e Connection contacts speaker alarm for remote speaker Artikel Nr 20162 alarm ik KESSEL Made in Germany Sachi 363 310 ill 2 r de al lt Q O L09946 Ieuoudol GCOUHPISID D pugurnuoa Jnod JU LUBDIOIDEY
15. 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 Product Advantages m 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 KESSEL Edition 2012 07 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
16. RMITATSERKLARUNG EC declaration of conformity D claration CE de conformit Nach der Maschinenrichtlinie 2006 42 EG der Niederspannungsrichtlinie 2006 95 EG Richtlinie der elektromagnetischen Vertraglichkeit 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 EEC Selon les directives m caniques 2006 42 EG les directives de basse tension 2006 95 EG les directives pour la compatibilit lectromagn tique 2004 108 EG et les directives de construction 89 106 EWG Hiermit erkl ren wir Herewith we declare Par la pr sente nous d clarons KESSEL AG BahnhofstraBe 31 D 85101 Lenting dass das Produkt that the product que le produit KESSEL Fettabscheider SE M und SE CNS zur freien Aufstellung in frostgeschutzten Raumen KESSEL SE M and SE CNS Grease Separator for interior installation S parateur a graisses KESSEL SEI M et SE CNS pour une installation en local a l abri du gel den Bestimmungen der EN 1825 1 2004 entspricht und die Vorraussetzungen f r die CE Kennzeichnung gema Anhang ZA der Norm erfillt meets EN 1825 1 2004 requirements and fulfills the pre requisites for the CE Mark attachment ZA est conforme a la norme EN 1825 1 2004 et pr sente les directives pour marquage CE selon compl ment ZA de la norme Zur Kennzeichnung der
17. an 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 anda function LED 4 The control unit can be ope rated by using the UpA Down 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 O po D 1 Operation LED Navigation buttons Alarm LED Up down ESC OK Alarm button Pump operation
18. 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 bar rels 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 screwed storage transport covers 1 Screwed cover Grease collection barrel
19. ast 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 Inthe 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 de grees 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 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 the fall pipe to the calming stretch must be constructed from two 45
20. ducting 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 separa tor 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 water until water flows out of the outlet This c
21. eparator Warning The sludge trap must be filled to the overflow level The rin sing process must not be started immediately after sludge di scharge 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 until either the barrel
22. ergy 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 and floating sludge accumulate on the surface and can be re Dimensioned drawing and information table 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 fitted with odour proof covers made from Duroplast 2K The fittings and units are resistant against corrosive aggressive 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 st
23. es should be connected directly to outdoor ambient air roof The venti lation pipes should not be connected to one another Grease sepa rator ventilation sx KESSEL j w er s sol KESSEL SE MNS 2 grease separator Sludge trap Sludge storage barrel Grease storage barrel Sampling chamber 6 KESSEL basement drain The Universal with integrated twin backwater flaps KESSEL Aqualift S Duo lifting station Public sewer 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 K then drained with gravity into the public sewer this prevents any x backwater from disturbing the operation of the lifting station g z _ Product _ Accessories P 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 tion Check all pipes for watertightness by con
24. from a kitchen 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 bacte
25. ge 9 4 Operation 4 1 Control unit settings i Page 10 4 2 OLE eain oneei piane esaa aa Page 10 4 3 Functions Steps of the disposal procedure Page 10 4 4 Setting parameters Page 10 5 Disposal Disposal steps a ees Page 1 1 6 Explosion diagram eee tt ii Page 14 7 Control unit 8 Q Q r L C C C C CC C CICICa ela Page 16 8 Malfunctions and remedial measures a tL ie Page 19 9 Accessories and replacement parts ee Page 21 10 Maintenance and servicing checks ll O h uuog r Page 22 11 Maintenance instructions for SE separators n Page 22 KZ ie CIE Page 23 13 Declaration of Conformity Nn Page 24 14 Manufacturer Separator data and information a Page 25 15 Hand over certificate J J 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 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 informatio
26. he 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 cordance with DIN 38409 Before taking a sample the interi or of the sampling chamber should be cleaned and rinsed DIN 1986 Part 1 requires the installation of sampling cham bers please contact your local authorities for information if a sampling chamber is required for your installation Aqualift F Lifting Station Pump i KESSEL offers various lifting stations which can be installed power Power connection before or after the grease separator Please note that a twin 400VDS 8 phase pump lifting station should be installed after a grease separa A A priest AN We ESE tor 2 2 kW 400 V DS 3 phase DN 100 28631 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
27. ir KESSEL
28. n contained in this Installation Operation and Maintenance Manual KESSELAG sz KESSEL 1 1 Application Oils and greases in wastewater are not allowed to be drai ned 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 grea se disposed of appropriately Inlet 1 2 System Description Separator function The special feature of the Type SE grease separator for self disposal of waste is its method of disposal While conventional separators must be emptied completely and shut down while this work is carried out storage terial which has been separated out needs to be disposed and is drained off via discharge pipes into exchangeable bar rels The grease separator can be emptied any time without having to inter
29. next day For example if heating begins at 22 00 it should end at 23 59 3 Settings 3 1 Parameters 3 1 2 Mixing Setting the rinsing function 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 1 Parameters 3 1 3 Rinsing 10 5 Disposal Disposal Steps The aim of re utilising grease requires frequent waste dis posal from the grease separator in order to keep the bio chemical decomposition process to a minimum The di scharge of separated material must therefore be carried out not only according 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 accordance with the Standard The collection barrel holds approx 60 litres Failure free and proper operation of the plant is 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 sludge trap into the grease s
30. nnection 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 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 1 Inthe 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 re placed the newly repaired
31. orage barrel Grease storage barrel Ventilation Cleaning access Control unit Grease mixing motor lever Rinsing pump OO 000900008d0 Waste Contents EC EE h h h Siudge trap_ Grease wap Weight ampi 1850 2000 1020 1400 1450 1570 650 410 570 200 kg 1200 kg 1850 2200 1300 1700 1450 1570 730 410 1060 260 kg 1750 kg see illustration ik KESSEL 2 Installation h3 h1 F Illustration shows NS 2 and NS 15 1 Inlet Outlet Sludge trap 4 Grease separation area 5 Cover with quick release clamp 6 Heating dome Sludge storage barrel NS NS 2 NS 4 NS 7 NS 10 NS NS 15 NS 20 NS 25 iki KESSEL DN 100 100 150 150 DN 200 200 200 110 110 160 160 200 200 200 Dimensions I x b 1760 930 1830 930 2230 1300 2230 1300 Dimensions I x b 3600 1200 4100 1300 4600 1400 b1 1330 1300 1700 1700 b1 1650 1750 1850 h1 1230 1630 1630 1730 h1 1730 1730 1730 I Ken U Grease storage barrel 9 Ventilation Cleaning access Op Control unit 2 Grease mixing motor lever 3 Rinsing pump h2 1300 1700 1700 1800 h2 1800 1800 1800 h3 1700 2100 2200 2300 h3 2300 2300 2300 Separator in Liter 600 950 1450 1600 Separator in Liter 2950 3650 4350 Weight in kg 97 128 186 192 Weight in kg 485 505 535 Art Nr 93202 00 SE1 CNS 93204
32. perator and those responsible were present during the commissioning of this system Place and date Signature owner Signature user s KESSEL x 26 15 Hand over certificate Handover certificate copy for the company carrying out the installation The initial operation and instruction was carried out in the presence of the person authorised to perform the acceptance and the system operator The system operator person authorised to perform the acceptance was informed about the obligation to ser vice the product according to the enclosed operating instructions Initial operation and instruction were not carried out The client person responsible for initial operation was handed the following components and or product components Initial operation and instruction is being carried out by company address contact phone The exact coordination of the dates for initial operation instruction is being carried out by the system operator and per son responsible for initial operation Place date Signature of person Signature of system operator Signature of the company authorised to perform acceptance carrying out the installation work sz KESSEL 27 1 Backwater protection 1 Septic Systems Lifting Stations and pumps L Inspection Chambers 1 Drains and shower channels LJ Rainwater Management 2 Separators Systems Grease Separators Oil Fuel Coalescence Separators Starch Separators Sediment Separators
33. ria All body parts 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 amp 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 sx KESSEL Table of contents Safety instructions aaa ecsssttetseeeeeeeeeeecccececccececccecceeeeecseeceaeeeeseeeseseeseseeseeeeeeeeeeeeeseeseeeeaeeeseass Page 2 Ti CC CC CN Page 4 2 Installation 2 1 Installation instructions Page 7 2 2 Assembly Page 8 2 3 Control unit MOUNTING a 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 d Hand over protocol Page 9 3 4 fl Bree uuu RO Page 9 3 5 Vue E Pa
34. rupt 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 grea se layer and settle to the base of the tank Sediments which settle out in the separator tank are pumped back to the slud ge trap via a circulation system Recycling Il gt Disposal gt storage tank in the case of the SE only the ma nk s KESSEL 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 vo lumes 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 se parator plants operate without requiring an energy supply du ring grease separation Reduced drinking water consumption and lower en
35. s and documents for the separator are available drainage plan authorizati ons user s manual The results of the general inspection should be documented Any irregularities defects or problems with the separator should also be documented and repaired immediately 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 ex pected Preparation 1 It must be ensured that no waste water runs into the grea se separator during maintenance work inform the ope rator 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 ik KESSEL 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 de posits and clean them 4 Check the feed to the sludge trap for obs
36. 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 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 CEE Possible cause Remedial action i C 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 H 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
37. tructions and deposits and clean if necessary 5 Check the outlet of the rinsing line and clean if necessary Maintenance work on the grease separator tank 1 Pump the water from the grease separator tank to the sludge trap using the rinsing pump until the sludge trap is completely full 2 WARNING Isolate the control box from the power supp ly 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 Re move the heating cover 3 Have the residual water pumped out by for example an effluent disposal company 22 11 Maintenance instructions for SE separators 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 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 surfa ce 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 co
38. with operatio nal cover with transparent hose and ventilation connection 2 Ventilation connec tion port 3 Drainage inlet 4 Center of cover for inlet and ventilation 5 Threaded cover for twist tigh tening 13 Sludge collection bar rel with operational cover with transpa rent hose and ventila tion connection 2 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 sz KESSEL Or ay css ona Of gf I wf S VK g SI N N Y S lt OU 14 IK KESSEL 15 ill shows NS 2 OO OOOO OOO OOG G 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
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