KESSEL SE CN / SE CNS – Self Disposal Grease Separators Size

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KESSEL SE CN / SE CNS – Self Disposal Grease Separators Size | Manualzz
INSTALLATION AND USER’S MANUAL
KESSEL SE CN / SE CNS – Self Disposal
Grease Separators
Size NS 2, 4, 7, 10, 15, 20 and 25
KESSEL SE CN – Self Disposal Grease Separators.
Size NS 2, 4, 7, 10, 15, 20 and 25
Product Advantages
Low weight offers easy
handling and installation
Separate disposal
of grease and sludge
Fully corrosion
resistant PE
Art.Nr. 99210.00/-41
Edition 03/2012
ID-number 010-076-CN
1. Safety Information
All personnel for the installation, assembly, operation, maintenance and repair of this system must have the proper training and qualifications.
Proper installation and operation of this system is required. Technical limits of this system
may not be exceeded.
Observe all local / national norms and safety regulations during the installation, assembly,
operation, maintenance and repair of this system.
DANGERS
WARNING !
NOTICE !
•
•
•
•
•
Gases and fumes may pose a suffocation, infection and explosion hazard
Hazards from falls / slips
Drowning
Infections from germs and contaminated wastewater
Physical and mental strain due to working in dark, tight areas.
Not following this operational manual or local / national safety regulations could result to
damage of the system, physical injury or even death
This system is made up of individual components. During the installation, maintenance,
inspection or repair of any of these individual components, the entire system should be
shut down before any work is undertaken.
This system operates on electrical power and also contains moving parts as well as an electrical heating system. Improperly operating or handling this system could result in damage to the system and / or injury or death to the operation.
When the system is initially connected to a power source the sludge pump or the heating
elements may immediately begin to operate. Keep away from the separator during the electrical connection.
Make sure that the separator is completely installed and all necessary connections are
made before the system is connected to power.
2
Table of Contents
1. Safety Information
..................................................................................page
2
Electrical data ...........................................................page
Dimensioned drawings SE CN .................................page
Dimensioned drawings SE CNS...............................page
4
5
8
wiring diagramm .......................................................page
Control unit ..............................................................page
Outputs ....................................................................page
Control unit settings .................................................page
General ....................................................................page
Programming the funktions ......................................page
Operation .................................................................page
Functions/steps of the disposal procedure ..............page
Setting parameters ..................................................page
11
12
12
13
13
13
13
13
13
2.1
2.2
3. Technical data
3.1
3.2
Application ................................................................page
System description ...................................................page
4. Installation and Assembly
4.1
4.2
Installation information..............................................page 10
Assembly ..................................................................page 10
2. General
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.5
5.6
5.7
5. Electrical connections
6. Commissioning
4
4
..................................................................................page 14
..................................................................................page 15
7. Disposal
..................................................................................page 17
8. Malfunction
..................................................................................page 18
9. Maintenance
10. Guarantee
..................................................................................page 21
11. Important contacts/Info
..................................................................................page 22
..................................................................................page 23
12. Separator characteries
3
2. General
2.1 Application
2.2 System description
This grease separator is designed to separator grease and
sludge from the wastewater stream of a private or public kitchen.
➀ Inlet DN 150/DA160 mm
➁ Outlet DN 150/DA160 mm
➂ Connection for heating rod (heating road is optional)
➃ Sludge transfer pump
➄Sludge and Grease tank
➅ Control unit
➆ Access
➇ Grease disposal pipe
➈ Sludge disposal pipe
➉ Grease mixing lever
Internal ventilation
Grease disposal valve
Sludge disposal valve
Heating dome
The outlet of this grease separator can be connected to private or public sewers.
The separation of grease and sludge from the wastewater
stream is handled by gravity alone.
SE NS 7
3. Technical Data
3.1. Electrical data
Current:
230 V 50 Hz
Total power requirement: 1700 Watt
(Heating dome – 1200 Watt (230 V – 50 Hz)
(Sludge rinsing pump – 500 Watt (230 V – 50 Hz)
Protection class:
Fuse requirements:
4
IP 54
10 amp
3. Technical Data SE CN NS 2-7
3.2 Dimensioned drawings
SE NS 4
SE NS 2
➀Inlet DN 150/DA160 mm
➁ Outlet DN 150/
DA160 mm
➂ Connection for heating
rod (heating road is
optional)
➃ Sludge transfer pump
➄ Sludge and Grease tank
➅ Unit control
➆ Access
➇ Grease disposal pipe
➈ Sludge disposal pipe
➉ Grease mixing lever
11 Internal ventilation
12 Grease disposal valve
13 Sludge disposal valve
14 Heating dome
SE NS 7
5
3. Technical Data SE CN NS 10-15
SE NS 10
SE
NS 15
6
3. Technical Data SE CN NS 20-25
SE NS 20
SE NS 25
7
3. Technical Data SE CNS NS 2-10
h1
h2
h3
SE CNS
NS 2-10
b1
b
l
Nominal size
DN
NS 2
NS 4
NS 7
NS 10
100
100
150
150
Ø
110
110
160
160
Access opening
l x b
1760
1830
2230
2230
930
930
1300
1300
b1
1330
1330
1700
1700
1230
1630
1630
1730
h1
h2
1300
1700
1700
1800
h3
total volume
in liter
weight
in kg
Art. #
1700
2100
2200
2300
600 l
950 l
1450 l
1600 l
97
128
186
192
93202.00/SE1-CNS
93204.00/SE1-CNS
93207.00/SE1-CNS
93210.00/SE1-CNS
8
3. Technical Data SE CNS NS 15-25
h2
h1
h3
SE CNS
NS 15-25
b1
b
l
Nominal size
NS 15
NS 20
NS 25
DN
200
200
200
Ø
200
200
200
Access opening
l x b
3600
4100
4600
1200
1300
1400
9
b1
1650
1750
1850
1730
1730
1730
h1
h2
1800
1800
1800
h3
total volume
in liter
weight
in kg
Art. #
2300
2300
2300
2950 l
3650 l
4350 l
485
505
535
93215.00/SE1-CNS
93220.00/SE1-CNS
93225.00/SE1-CNS
4. Installation and Assembly
4.1 Installation information
The separator is shipped in large components for connection
on-site.
This connection is normally handled by a local service company.
On-site set up information
• Safety information in this manual as well as local / international safety regulations should be followed.
• Improperly operating this grease separator may result in
odours escaping which could cause a nuisance. It is recommended that this separator is installed in a separate
ventilated room.
• If building access is limited, the larger components of this
separator (sludge tank and grease tank) can be disassembled if required
• Due to the operational weight of the grease separator – the
floor in which the separator is to be installed should be
capable of handling the required loads.
• This separator should be installed on a flat floor in a frost
free, weather protected room.
• For proper operation of the separator, temperatures in the
room where the separator is to be installed should not be
lower than 15 degrees Celsius.
• Separators containing connection components should be
connected on-site to a maximum torque of 7 Nm.
• The inlet and outlet of the separator must be connected to
the main kitchen drainage pipe (observe DIN 1986 and DIN
4040.
• The main kitchen wastewater pipe should have a slope of
at least 1:50. No vertical drainage pipe should be connected within 1 meter of the separator inlet. Vertical drainage
pipes entering the horizontal drainage pipe before a grease separator should not be connected with T-fittings or 90
degree fitting – these connections should be made with two
45 degree fittings.
Important requirements for odour free grease separator
operation
The inlet and the outlet of a grease separator should be properly ventilated to assure odour free operation of the grease
separator. This ventilation connection should be as close to
the inlet of the separator as possible. If there is no ventilation connection within 10 meters of the separator inlet, then a
ventilation connection must be made. This ventilation should
go directly to ambient air (roof connection).
All floor drains connected to the wastewater pipe entering the
grease separator should be equipped with a sludge / sediment trap. Larger objects such as utensils or bones could
lead to the malfunctioning of the separator’s pumps or valves.
4.2 Assembly
Grease and sludge disposal tanks
• Connect the inlets of the grease storage tank and the sludge storage tank to the see-thru disposal lines provided with
the separator
• Connect the ventilation inlets of the grease storage tank
and the sludge storage tank to the proper connection on the
main body of the separator.
Pipe connection
• Connect the inlet and outlet of the grease separator to the
main wastewater pipe from the kitchen.
Final checks
• Make sure all connections have been installed properly and
are secure. Hand valves connected to the grease and sludge tanks should be in the closed position.
10
5. Electrical Connections
5.1 Wiring diagram
11
5. Electrical Connections
5.2 Control unit
The type plate is on
the right outside of the
control unit.
Fig. 1
Control unit description:
Control unit identification code
Control unit article number
Voltage and frequency
Amperage
Protection class
Control unit serial number
Control unit replacement number
Danger symbol
Electrical protection class
CE symbol
Disposal symbol (do not dispose in normal trash) Hardware status code
FA PV 260
363-322 (363-402)
5.3 Outputs
Potential free contact
• Change-over contact,
center contact
• Closing contact,
Opening contact
• max. 42 VAC / 0,5 Amp
Optional: remote alarm Connection option
(Article Number 20162) for a remotely
installed audible alarm
Fig. 2
12
5. Electrical Connections
5.4 Control unit settings
5.4.1. General
The following functions are controlled by the control unit:
➤ Rinsing (Euro Norm grease separators do not have the
rinsing function)
➤ Heating
➤ Mixing
Manual operation has the priority over automated operation. If
manual operation is activated, the automated operation is deactivated (internally set automated procedures will not start!)
0 System info
5.5 Operation
The control unit has a `Start`and `Stop` button ➄ for manually controlling the disposal and a button for acknowledging any alarms ➂. The current operating status of the separator is displayed by an LED , an alarm / malfunction
LED ➁ and a function LED ➃. The control unit can be operated by using the „Up▲▲“, „Down▼“, „ESC“ and ‘OK’ buttons
➆.
Please follow the operating manual ➇. Before conducting
any work on the control unit be sure to disconnect it from its
power source ➈ (see safety instructions)
➀
➁
➂
➃
➄
➈ ➇
➆➅
Operation-LED
Alarm-LED
Alarm-button
Pump operation-LED
START/STOP
digital display
Navigation buttons
“Up/down” + “ESC/ OK”
Operating instructions
Disconnect control unit
from power
5.6 Functions / Steps of the disposal procedure
The control unit is set up for automated or manual operation.
13
2 Maintenance
3 Settings
These functions are automatically started and ended according to the programmed settings. The systems components
(electronic parts) can also be operated manually by using the
control unit (See Menu 2.1).
5.4.2 Programming the functions
The time of day, date and disposal program has been factory
set.
1 Information
2.1 Manual operation
2.2 automated operation
2.3 SDS (Self Diagnosis System)
2.4 Service dates
2.5 Activating the RemoteControl
Note: For proper disposal of collected grease, the heating
function should berun 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.
5.7 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 Parameters 3.1.1 Heating
3.1.1.1 Every day
3.1.1.2 Monday
3.1.1. ...........
3.1.1.8 Sunday
Setting the mixing function
In Menu 3.1.2 (mixing), the mixing duration can be set.
3. Settings
3.1 Parameters 3.1.2 Mixing
3. Settings
3.1 Parameters 3.1.3 Rinsing
3.1.2.1 Duration
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 be begin and also the duration of the
rinsing.
3.1.3.1 Every day
3.1.3.2 Monday
3.1.3.3 ..........
3.1.3.8 Sunday
6. Commissioning
The following steps must be taken before the grease separator is placed in operation.
6. 1. Cleaning
All debris should be removed from the separator
6.2. Filling
Insure that both hand valves connected to the grease and
sludge storage tanks are in the closed position. Completely
fill the grease separator with clean cold water – when water
begins flowing out of the outlet the separator is completely
full of water. The separator is normally filled by simply running a faucet which is connected to the grease separator.
6.3. Ventilation
The heating dome of the separator must be ventilated. This
is accomplished (after the separator has been completely
filled with water) by opening the hand valve of the disposal
pipe connected to the grease storage tank. As soon as
water begins flowing into the grease storage tank the hea-
ting dome has been ventilated and the hand valve can be closed again.
6.4. Electrical connection
The electrical connection to the heating dome must be made
on-site. This is accomplished by simply plugging in the supplied connection cable.
6.2 Hand-over instructions
Before the separator is handed over to the customer the
following steps should be taken.
• Visual inspection of the entire system to insure the system
has been properly connected and that the system is watertight
• Customer should be advised about the operation, maintenance and disposal of the grease separator
• A ‘mock’ disposal should be demonstrated so that the
customer is aware of how grease and sludge should be
disposed into the storage tanks.
14
7. Disposal
Tips to reduce odour release during operation and disposal of the grease separator
1. When changing disposal tanks, the cover should be switched
and properly connected as fast as possible
2. Insure that the covers, inlet connection and ventilation
connection are properly connected
Barrel change
Exchange barrel with
screwed cap used as
a closure for transport
� Screwed cap
I
Exchange barrel fitted with filling head
for sludge
� Ventilation stub
� Filling connection
� Filling head
II
III
Exchange barrel fitted with filling head
for fat
� Ventilation stub
� Filling connection
� Filling head
� Cap nut
Exchange barrel with
filling head raised.
The space released
is sufficient for residual liquid from the
hose to run into the
top of the barrel.
IV
15
3. Any spills should be cleaned as soon as possible
4. Full storage tanks should be taken away as soon as possible.
Recommended is that the tanks are not stored for longer than
4 weeks.
7. Disposal
Sludge separator
II
Grease separator
Step I: Grease disposal
Turn on the heating dome (12) by pressing the heating
START button on the control unit (6). The heating cycle will
run automatically for the pre-programmed amount of time (recommended heating time of 2 hours)
• After the heating cycle is finished, manually turn the hand
lever (10) for approximately 1 minute.
• Open the hand valve on the grease storage tank (12).
• Allow grease to flow into the grease storage tank until either the tank is full or clear water begins flowing into tank.
• Close hand valve.
• In the case that the first grease tank is full, close the hand
valve, change the grease storage tank, re-open the hand
valve and continue disposal.
I
III
(which may have entered the grease separation area of the
separator) is pumped back into the sludge tank. This is
done by simply pressing the RINSING button on the control
unit.
The sludge transfer pump will run as long as the button is
pressed. Keep the button pressed for approximately 10
seconds and then release the button. The sludge transfer
process is now complete.
➀ Inlet DN 150/DA160 mm
➁ Outlet DN 150/
DA160 mm
➂ Connection for heating
rod (heating road is
optional)
➃ Sludge transfer pump
➄ Sludge and Grease tank
➅ Unit control
➆ Access
➇ Grease disposal pipe
➈ Sludge disposal pipe
➉ Grease mixing lever
11 Internal ventilation
12 Grease disposal valve
13 Sludge disposal valve
14 Heating dome
Step II: Sludge disposal
• Open the hand valve (13) on the sludge storage tank
• Allow sludge to flow into the sludge storage tank (5) until either the tank is full or clear water begins flowing into tank.
• Close hand valve (13),
• In the case that the first sludge tank is full, close the hand
valve, change the sludge storage tank, re-open the hand
valve and continue disposal
Step III: Sludge transfer (not for version Euro SE)
• After the grease and sludge have been emptied in their appropriate storage tanks, it is recommended that sludge
16
8. Malfunction
The following information may be helpful in troubleshooting problems on-site
Grease disposal:
Problem
little or no grease flows into
storage tank
Reason
preheating of the grease was too short or
not done at all
Solution
lengthen grease heating time
preheating of the grease was too short or
not done at all
lengthen grease heating time
debris in grease disposal hose
install sediment trap in floor drains and
sinks connected to grease separator
room temperature under 15 degrees Celsius increase room temperature or increase
heating time
air trapped in heating dome area
ventilate heating dome according to this
manual
Sludge disposal:
Problem
little or no sludge flows into
storage tank
Reason
sludge disposal hose blocked
debris blocking valve or disposal hose
grease layer in sludge
separator
very little wastewater amount, high amount
of grease
Problem
Reason
Odour nuisance:
odours
drainage pipe not completely tight
ventilation not in place /
ventilation pipe too small
Soulution
disassemble and clean disposal hose
dispose of sludge more frequently
completely empty sludge tank and clean
install sediment trap in floor drains and sinks
connected to grease separator
sludge should be transferred more frequently using the RINSING button on control unit
Solution
inspect drainage piping and replace
gaskets if necessary
install proper ventilation
separator cover, storage tank
cover not odour tight
inspect covers and gaskets,
replace if necessary
room air tight – not ventilated
equip room with proper ventilation
full storage tank not disposed of timely
17
remove full storage tanks more frequently
9. Maintenance
1. The system must be checked for leaks at start-up and at
regular intervals afterwards (e.g. every month or during disposal).
2. The transparent hoses must be cleaned at regular intervals. For this purpose, they can be removed and rinsed out
with warm water.
3. The sludge trap and the overflow must be checked for the
build-up of layers of fat (visual inspection through the cover
of the sludge trap and the cleaning ports). If necessary, the
running periods of the circulation system will have to be increased.
4. An inspection must be carried out once per year, as the
need arises or more often. For this purpose, the plant must
be completely emptied and cleaned out. The condition of the
sludge trap and the separator must be checked from inside
and outside. We recommend having this work done by a
company specialising in this type of work. Our Customer Service Department can arrange contact with an appropriate
company for you.
5. In regard to the implementation of the legal requirements
and controls, we recommend that all operators document all
work carried out on, and all events taking place at the separator in an operator’s log book and that they keep all paperwork relating to disposal as evidence.
Notes:
 Fix the operating instructions in the vicinity of the separator.
 Follow the safety instructions.
 Follow the accident prevention regulations.
 Dispose of the collecting barrels using an approved effluent disposal company.
 An application form for a maintenance contract is available from the KESSEL Customer Service Department.
 Subject to technical alterations
18
Maintenance instructions for KESSEL „SE“ grease separator plants
The person carrying out maintenance must be familiar with
the operation of the plant.
A spare seal for the heating cover of the corresponding „SE“
plant should be taken to the site so that this can be changed
if necessary.
When opening the fat separator, bad odours must be expected.
Preparation
1.) It must be ensured that no wastewater runs into the fat
separator during maintenance work (inform the operator).
2.) Dispose of fat and sludge in accordance with the operating instructions (abide by the heating times).
19
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 blockages 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 necessary.
Maintenance instructions for KESSEL „SE“ grease separator plants
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 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 water and clean them, carefully removing any deposits.
5.) Flush through the transparent hoses with warm water
and clean them.
6.) Clean the pipe connections between the sludge trap and
the fat separator tank, rinse and clean the discharge valves, rinse pump and special covers for the disposal barrels and check for obstructions.
Maintenance work on the rinsing pump
WARNING: Isolate the control box from the power supply.
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, open the valve and check that
the pump is operating properly (check flow).
Re-commissioning
1.) Check the whole plant for leaks.
2.) Re-start the KESSEL „SE“ grease separator plant in
accordance with Section 4.1
7.) Check the heating cover seal for any possible damage
and exchange if necessary. Clean and grease the surface of the seals and re-install the heating cover.
8.) Reassemble the plant.
20
10. Warranty
1. In the case that a KESSEL product is defective, KESSEL has
the option of repairing or replacing the product. If the product
remains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair or replace the product, the customer has the right to cancel the
order / contract or reduce payment accordingly. KESSEL
must be notified immediately in writing of defects in a product.
In the case that the defect is not visible or difficult to detect,
KESSEL must be notified immediately in writing of the defect
as soon as it is discovered. If the product is repaired or replaced, the newly repaired or replaced product shall receive
a new warranty identical to that which the original (defective)
product was granted. The term defective product refers only
to the product or part needing repair or replacement and not
necessarily to the entire product or unit. KESSEL products are
warranted for a period of 24 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.
21
In addition to the standard warranty, KESSEL offers an additional 20 year warranty on the polymer bodies of class I / II
fuel separators, grease separators, inspection chambers, wastewater 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.
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 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
Separator Type
11. Important contacts / Info
KESSEL Art. #
Production Date
Project description /
Building services supervisor
Address
Telephone / Fax
Planner
Address
Telephone / Fax
Contracted plumbing company
Address
Telephone / Fax
System operator / owner
Address
Telephone / Fax
Other remarks
The system operator, and those responsible, were present during the commissioning of this system.
Place and Date
22
A) General information
12. Separator characteristies
Installation area :
Type
:
Production number :
Production Year:
B) Technical data
Weight / kg
:
Length x width x height
:
Size
:
Sludge trap volume
:
EN
Material
:
Approval
:
total volume
C) Electrical data
Voltage
:
:
:
Connection value :
Protection rating :
Fuse requirements:
D) Equipment
Pump
:
Valves
:
Accessories
:
Control unit
:
Grease/sludge
storage tanks
:
Grease level sensor:
Sampling device :
Heating element :
:
:
:
E) Final inspection
This unit hs been checked before leaving the factory.
Watertightness
Function
Date
:
Electricity
:
:
Completeness
of System
:
Name of examiner
23
Stamp
Date
Name of examiner
This unit has been checked for watertightness to be sure that it is fully operational before leaving the factory.
Description 2
Description 1
Density
Volume
Dimensions
EN/Approval
Ref.No./Material/Weight
Mat.-No./Order-No./Prod. Date
Mat.-Description
Separator characteristics

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