KESSEL Grease Separator Euro “G” NS 1, 2 and 4 for underground
Contents
1. IK KESSEL 3 Installation gt Dimensioned Drawing NS 4 860 DAN i FAR IERTI UJJUU 750 750 bis 800 mm Inlet Outlet Sludge trap Grease separation area 6 Upper section with cover load clas B D Chamber connection 4 1 Separator commissioning Beforethe separator is put into service please make sure that The separator is completdy dean indudinginlet and outlet and that theinterior of thechamber isfreeof dirt and debris The deaned separator is completely filled with dean cold water up to theoutlet 4 2 Commissioning partici pants The commissioning of the separator is usually handled by a tradesman although this can be handled by a KESSEL contractor or KESSEL em ployeeif desired 1 The following people should be on hand duringthe commiss oning Building contractor representative Plumber tradesman who will bemaintaining the separator Building maintenance personne Disposal company who will behandlingthe disposal account 2 Commissioning preparation Separator iscompletely filled with dean water 3 Commissioning Separator to be checked for watertightnessand for proper functiona lity Contents of thisuser s manualsto be discussed with those present 4 Transfer of thismanual tothe appropriate personne IK KESSEL 5 Separator contents disposal Thefirst emptying disposal of theseparator contentsshoul2. EN 124 in cast iron incl removal mechanism Drop height 120 mm Installation Inlet fits Art depthT mm Outlet separator Class B Calss D 1180 1630 DN 100 NS 1 2 und 4 9151010 B 9151010 D 1180 1630 DN 150 NS 7 und 10 9151015 B 9151015 D 1180 1630 DN 200 NS 15 20 und 9151020 B 9151020 D custom made Other installation depths available on request 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 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 begins on the day the product is shipped form KESSEL to its customer The warra
3. INSTALLATION AND OPERATING INSTRUCTIONS KESSEL Grease Separator Euro G NS 1 2 and 4 for underground installation KESSEL Grease Separator G Product advantages according to EN 1825 1 E Euro Norm 1825 1 certified E Quick and easy assembly m Compact light m 100 resistance against aggressive grease and soil acids E Transport friendly E Vertically adjustable upper section Illustration shows Euro Norm separator and sampling chamber load class D The installation and service of this unit should be carried out by a licensed professional servicer Company Telephone No stamp i IK KESSEL MAN Subject totechnical amendment 1 Safety Precautions By installation use maintenance and repair of this unit please follow all appropriate DIN VDE DVGW safety precautionsand accident prevention guiddines Also pleasefollowanv local safety pre cautions and aod dent prevention guidelines established in your area Also please observe the follo wing e BGV C22 formerly VBG37 e DIN 4124 Safety precautionsfor excavations trenches e DINEN 1610 Standard proceduresfor theinstallation of drainage pi ping BGR 117 formerly ZH1 77 Standard procedures for workingin confined spaces Do not allow any typeof wastewater into the separator which could hinder the proper separation bet ween oils fudsand water ACCESS NO SMOKING Smoking is strictly prohibited near or around the separator a
4. SEL Euro Grease Separator Version G must be installed below the frost level This can be achieved by the use of the vertically adjustable upper sections The manho le covers for the upper sections are lockable odour tight and available in load classes A 1 5 ton B 12 5 ton and D 40 0 ton and meet EN 124 standards Installation 1 The excavation in which the separator is to be installed must be level and capable of handling the appropriate loads 2 Place the separator in the prepared excavation hole Make sure the separator rests at the appropriate level Fill the separator with water to the outlet level 3 The excavation should now be backfilled with non binding material such as sand gravel or process Backfill only the main body of the separator do not backfill around the upper sections The backfill should be firmly compacted at incremental levels approx 500 mm For load class D 40 0 ton situations the upper section and manhole cover of the underground separator must be poured into a steel reinforced concrete apron for proper load support Addi tional information regarding this load class D support is available from KESSEL 4 Connect the inlet and outlet of the separator to the drai nage piping 5 No vertical pipes should be connected within one meter of the inlet of the separator This one meter section imme diately prior to the inlet of the separator serves as a wa stewater calming section which hinders turbulenc
5. ct outlet pipe with ou tlet seeAbb 7 Insert sealing gasket into recessed hole of top sec tion Lubricate the visble portion of the gasket and then insert upper section with cast iron manhole cover into top section of se parator 6 Connect two chamber tanks with another with the supplied cou pling see Abb 9 IK KESSEL 3 Installation IK KESSEL 3 Installation gt Installation Illustrations Class D KESSEL Grease 15 cm thick concrete load support plate Separator G NS 2 6 8 cm support layer pport ay 4 cm Asphalt Sludge trap pecca OBON J E AI a separation que asa IDE zak ADASA i x X Upper section with jA Bejn E GASS JAN cover load clas B D INLET ee ei Pie E El id OUTLET ENTE Nt Abe Ne AS l g A aa sa 3 ma z NENTI Earth Earth 5 10 cm sand 30 cm gravel process Dimensions in cm 0 32 compacted 0 20 40 60 80 100 Illustration shows NS 2 gt Dimensioned Drawing NS 1 und NS 2 ES peo E E 2 oO co a 2 Inlet Outlet Sludge trap Grease separation area 6 Upper section with cover load clas B D wastewater content NS DN a b hi h2 h3 h4 Sludge trap Grease Storage Weight ca kg 1 100 1055 1020 1020 1120 650 720 1201 405 145 kg 2 100 1355 1300 1136 1236 750 750 200 935 195 kg
6. dtake place within 2 to 3 weeksfrom the day the separator was placed into service Disposal intervals Accordingto DIN V 4040 2 it is advised that Judge and grease separa torsshould be fully emptied deaned and refilled with cold fresh water at fourteen day intervals or at least on a monthly basis In order for a greasesepar ator tofunction asdesigned it isvery important that these parator isemptied at regular inter valsasdescribed above Duetothis it isreocommended that alicensed disposal company iscontracted to empty theseparator at regular intervals and during times when strong odours will not present a problem Disposal procedure e Removemanhole cover e Place disposal trudk ssuction hoseinside separator and renove entire contects of chamber e Rinseand dean interior wallsof chamber Remove coagulated fat oil and debris e Refill chamber with cold dean water e Clean and greaseall accessibleseals Replacesealsif necessary e Replace cover s and secure with cover damps Maintenance of the separator The separator should be tested to make sure that it is completely watertight before it is placed into operation and also during periodic intervals thereafter 1 Surface care the interior walls of the separator should be cleaned and checked for problems at regular inter vals 2 The separator should be thoroughly checked two times per year During these inspections the separator should be completely emptied and thoroughly cl
7. e Fax Builder Address Telephone Fax Planner Address Telephone Fax Contracted plumbing company Address Telephone Fax KESSEL Commissions no System operator owner Address Telephone Fax User Address Telephone Fax Person of delivery Other remarks The system operator and those responsible were present during the commissioning of this system Place and date Signature owner Signature user IK KESSEL Everything for drainage Backwater valves and cleanouts Grease separators Polymer and Ecocast drains Oil fuel and coalescence separators Volatile liquid traps Inspection chambers Lifting stations pumps warning and control units e Custom projects for industrial applications Rainwater management systems ik KESSEL
8. e are available upon request Note The KESSEL Euro Grease Separator Version G is designed for locations where 1 Dispersion of odours during the emptying cleaning or maintenance of the separator will not pose a problem 2 Access of the disposal hose from the disposal truck to the separator will not pose a problem IK KESSEL 3 Installation 3 1 Installation Illustrations Class B 12 5 ton Art 93004 120D 915880D Dimensioned drawing 875 _ gt 5610 Ablauf Installation Depth OD Outer diameter 100 110 1380 1106 1050 540 610 1401 2301 Z 2 100 110 1380 1106 1300 790 860 2001 3701 1201 4 100 110 1380 1106 1550 1040 1110 4001 3701 1601 Additional installation depths available upon request IK KESSEL 3 Installation Assembly The KESSEL separator is shipped fully assembled and ready for ope ration Each chamber isshipped on an individual pallet Accessories may either be packed along s de the separator or possibly be stored insidea separator tank Notice Separators are packaged and shipped ups de down due to the heavy weight of thecast iron manholecover Takecaution when unpacking theseparators Theseseparatorscan beeasilv dissassembledif required In order to re assamblethe separator please follow these steps NS1 Kus NS2 Separator 2 dicasi ter area After gas ket isinstalledlubricatetheupper visual portion of thegasket
9. e which can introduce unwanted oxygen and foam into the sepa rator All connections of vertical pipe outside of the 1 meter calming section should me connected to the main inlet pipe with two 45 degree fittings rather than one ab rupt 90 degree fitting 6 Install and adjust the upper section s of the separator to the desired level and secure with the included clamp ring clamp ring will rest on the chamber itself Final upper section level ad justments can be made by manipulating the elevation adjustment screws located on the clamp ring Watertightness test Before the separator is fully backfilled the upper section and gasket must be tested for watertight ness To perform this test insert inflatable closure balloons into the inlet and out let of the separator and inflate to insure a tight seal Fill the remainder of the separator with fresh water until the water level is toward the top of the upper section where the man hole cover is placed Check to make sure that there are no leaks If there are no leaks the inflatable closure balloons can be removed and the upper section can be backfilled and compacted Note When the outlet of the separator is to be installed below the sewer or wastewater piping level a lifting station based on DIN 1986 and prEN1825 must be installed KES SEL offers a full line of lifting stations designed for this cir cumstance Note Underground separators to be installed below the gro undwater tabl
10. eaned B gt The interior walls of the separator as well as the exte rior walls should be cleaned and checked for dama ge every time the separator contents are disposed B gt It is recommended that a written log is kept for the se parator Documentation and information concerning all disposals and any other work done to the separa tor should be kept in this log for future reference Please make sure that 1 This Installation Service and Maintenance Guide and any other documentation relating to the separator is kept in a safe place accessible to all who work on the unit 2 Disposal of the contents of the separator follows the exact guidelines stated in this guide 3 The disposal of the separator is carried out by a quali fied licensed company 11 IK KESSEL 7 Replacement parts and accessories ix KESSEL KESSEL Sampling Chamber B 400 for connection to separator systems For underground installation free flowing sample availability For installation depths T DN 100 150 inlet outlet required size cut off on site connection to SML pipe according to DIN 19522 Sampling chamber internal diameter 400mm vertically ad justable upper section with Load Class A B or D covers odour tight locked inlet outlet height difference 120mm Manufacturer KESSEL Installat
11. er manufacturer for additional details Table of contents 1 Safety precautions ii Page 2 2 General 2 1 Applicali0i lt celiaca lane Page 4 2 2 Separator description Page 4 3 Installation installation i ia eee Page 5 4 Commissioning 4 1 Separator COMMISSIONINQ eee Page 10 4 2 Commissioning participants n Page 10 5 Separator contents disposal Page 11 6 Maintenance 000000 unAn n EANN EENEENNEAAEANEEANENEEAAEENEEENEENEEEAEEAEEENEENE EENEN EEEE Page 11 7 Replacement parts and accessories iii Page 12 B Guarante lella Page 13 9 Separator characteristics ll Page 14 10 Important contacts inforra tt Page 15 Dear Customer Before the KESSEL Euro Separator Version G is installed and placed in operation please carefully read and follow all of the instructions contained in this Installation Maintenance and User s Manual Upon delivery of the Euro Separator please thoroughly inspect the separator to make sure that it has not been damaged during shipping In case damage has occurred to the separator please follow the instructions listed in the Guarantee section of this user s manual IK KESSEL 2 1 Application According to DIN 4040 and EN 1825 the installation of grea se separators is required wherever oils and fats from animals and plants are introduced into waster water systems Un collec
12. ion Inlet Outlet Art No height T mm DN OD ClassA ClassB ClassD 400 1300 100 150 110 160 915 880A 915880B 915880D 1330 1660 100 110 915813A 915813B 915813D 1330 1660 150 160 915 823A 915823B 915823D Neck portion of chamber can be sawed of on site to reduce installation height do not cut at recessed gasket area Article Number 915402 for deeper installations KESSEL Extension section for sampling chambers for deeper installation Max extension height 600 mm Manufacturer KESSEL KESSEL Extension section for underground KESSEL separator systems polyethylene material includes gasket Extension height Art No 512mm 917 406 1012 mm 917 407 12 7 Replacement parts and accessories von 100 bis 550 DN KESSEL Sampling chamber 9 1000 mm in polyethylene synthetic material for separa tion systems for underground installation Inlet and outlet for synthetic material pipes in PE HD according to DIN 19537 PVC according to DIN V19534 PP or AS Installation depths T mm in monolithic structure water tight resistant to aggresive wastewater with in tegrated access steps with telescopically height ad justable upper section made of polymer sealed odor tight with cover class B D according to
13. nty only applies to newly manufactured 2 products Additional information can be found in section 377 and 378 of the HGB 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 usabi lity 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 Wear and tear on a product will not be considered a defect Problems with products resulting from improper installation handling or maintenance will also be considered a defect 10 11 2009 13 IK KESSEL 9 Separator characteristics Bahnhofstr 31 D 85101 Lenting Article Type Art Ser Year EN Approval Ixwxh Sludge trap volume l Grease storage volume I Volume Material Control stamp Weight This unit has been checked for watertightness to be sure that it is fully operational before leaving the factory Date Name of examiner IK KESSEL Important contacts Info Separator Type Day Hour Project description Building services supervisor Address Telephon
14. only seeAbb 2 3 Place sudge trap in the appropriate location in the base section seeAbb 3 4 Place sudgetrap overflowin the direction of the outlet of the se parator seeAbb 4 5 Lower top section of separator onto the base section until Sotson top section insert into dotson basesection seeAbb 5 Makesure that the lubricated seal on the base section is completely inserted into the recessed gasket area of the top section 6 Connect thetop and base section together with the provided dips asillustrated see Abb 6 a b d Placethe outlet pipeinto thesepa rator through theopeningon thetop section until thebasefitsinto the guide dot at the base of the separator Lubricated the gasket and connect outlet pipewith outlet seeAbb 7 Insert sealing gas ket into recessed holeof top section Lubricatethevisibleportion of the gasket and then insert upper section with cast iron manho le cover into top section of separator 1 Place separator base section on floor see Abb 1 i NS4 Separator aiy Tienaa aN giant diat ber section with different diameters Besurethat theproper sized sealing gasket is used with the corresponding sized chamber sec tion seeAbb 2 3 Connect thetop and base section together with the provided dips asillustrated see Abb 6 a b d 4 Placetheoutlet pipeintotheseparator through theopeningon the top section until the base fits into the guide dot at the base of the separator Lubricated the gasket and conne
15. t all times All sources of ignition or sparks are prohibited near or around the separator at all times SLIPPERY WHEN WET Take caution when standing walking near the separator Du ring disposal cleaning and maintenance the surrounding area can become extremely slippery due to spilled oil fuel SEPARATOR AREA REGULATIONS No access of the separator for unauthorized personnel The location of the separator should be chosen carefully as to allow sufficient access for maintenance inspection repair and disposal of the separator The wastewater in the separator can contain skin irritants After coming in contact with wastewater or the separator itself it is important to wash clean and disinfect all skin and clothing which has been contaminated All personnel having anything to do with the separator should have a sound knowled ge of the above safety precautions Helpful Hints 1 Manhole covers on top of fuel separators must not be screwed or locked on 2 Manhole covers on top of fuel separators must not have ventilation ports 3 All drains connected to the separator must not have any type of odour trap 4 All drains connected to the separator should be equipped with sludge traps 5 Wastewater must not be pumped into the separator it must be gravity fed 6 Detergents and cleaners used to clean the separator must not be emulsifiable they should be cleaners which separate quickly with water contact detergent clean
16. ted oils and fats can cause serious damage to waste water piping and private public waste water treatment plants 2 2 Separator description The KESSEL Euro Grease Separator Version G consist of a grease separator with integrated sludge trap The separator is constructed from Polyethylene PE Due to the smooth wax like surface of the material Polyethylene no additional protective coating is necessary The separator is designed to be installed underground at a predetermined depth below the frost level and with the selected load class manhole cover Class A B or D IK KESSEL 3 Installation The KESSEL grease separator is delivered in ready for ope ration condition If the separator consists of more than one container each container will be packed separately on a pal let Assembly material and accessories will also be packed on a pallet In some circumstances the material and acces sories will be inside one of the containers When the ship ment arrives please inspect it immediately for damages which may have been caused during transport shipping The KESSEL Euro Grease Separator Version G should be installed underground as close as possible to the fixtures to which it is connected In circumstances where it is not pos sible to install the separator in near proximity to the fixtures to which it is connected the drainage piping from fixtures to separator should be equipped with heating elements The inlet of the KES
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