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
Euro-Norm 1825-1 certified
Quick and easy assembly
Compact / light
100% resistance against
aggressive grease and soil
acids
Transport friendly
Vertically adjustable upper
section
Illustration shows Euro-Norm separator and sampling chamber (load class D)
Subject totechnical amendment
The installation and service of this unit should be carried
out by a licensed professional servicer
Company -TelephoneNo.
stamp
Edition 2009/12 ID-Number. 010-614
1. Safety Precautions
By installation, use, maintenance and repair of this unit please follow all appropriate DIN / VDE /
DVGW safety precautionsandaccident prevention guidelines. Alsopleasefollowany local safety pre-
cautionsand accident prevention guidelinesestablished in your area. Also please observe the follo-
wing:
• BGV C22(formerly VBG37)
• DIN 4124-Safety precautionsfor excavations/ trenches
• DIN EN 1610-Standardproceduresfor theinstallation of drainagepiping
BGR 117(formerly ZH1/77) -Standardproceduresfor workingin confinedspaces
Donot allowany typeof wastewater intotheseparator which couldhinder theproper separation bet-
ween oils/ fuelsandwater.
ACCESS:
NO SMOKING! Smoking is strictly prohibited near or around the separator at 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:
G No access of the separator for unauthorized personnel
G The location of the separator should be chosen carefully as to allow sufficient access
for maintenance, inspection, repair and disposal of the separator.
G 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.
G 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 / cleaner
manufacturer for additional details).
Table of contents
1. Safety precautions ................................................................................. Page 2
2.1 Application................................................................. Page 4
2.2 Separator description ............................................... Page 4
2. General
3. Installation Installation ................................................................ Page 5
4.1 Separator commissioning......................................... Page 10
4.2 Commissioning participants ..................................... Page 10
4. Commissioning
5. Separator contents disposal .............................................................................................. Page 11
6. Maintenance .............................................................................................. Page 11
7. Replacement parts and accessories ............................................................................................ Page 12
8. Guarantee .............................................................................................. Page 13
9. Separator characteristics .............................................................................................. Page 14
10. Important contacts / info .............................................................................................. 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 Userʼs 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 ‚Guaranteeʻ
section of this userʼs manual.
3
2. General
2.1 Application 2.2 Separator description
According to DIN 4040 and EN 1825, the installation of grea- The KESSEL Euro Grease Separator Version G consist of a
se separators is required wherever oils and fats from animals grease separator with integrated sludge trap. The separator
and plants are introduced into waster water systems. Un- is constructed from Polyethylene (PE). Due to the smooth,
collected, oils and fats can cause serious damage to waste- wax like surface of the material Polyethylene, no additional
water piping and private / public waste water treatment protective coating is necessary. The separator is designed to
plants. be installed underground at a predetermined depth (below
the frost level) and with the selected load class manhole
cover (Class A, B or D).
4
3. Installation
The KESSEL grease separator is delivered in ready for ope- Watertightness test
ration condition. If the separator consists of more than one Before the separator is fully backfilled, the upper section and
container, each container will be packed separately on a pal- gasket must be tested for watertight-ness. To perform this
let. Assembly material and accessories will also be packed test, insert inflatable closure balloons into the inlet and out-
on a pallet. In some circumstances the material and acces- let of the separator and inflate to insure a tight seal. Fill the
sories will be inside one of the containers. When the ship- remainder of the separator with fresh water until the water
ment arrives, please inspect it immediately for damages level is toward the top of the upper section (where the man-
which may have been caused during transport / shipping. hole cover is placed). Check to make sure that there are no
The KESSEL Euro Grease Separator Version G should be leaks. If there are no leaks, the inflatable closure balloons
installed underground as close as possible to the fixtures to can be removed and the upper section can be backfilled and
which it is connected. In circumstances where it is not pos- compacted.
sible to install the separator in near proximity to the fixtures Note - When the outlet of the separator is to be installed
to which it is connected, the drainage piping (from fixtures to below the sewer or wastewater piping level, a lifting station
separator) should be equipped with heating elements. The (based on DIN 1986 and prEN1825) must be installed. KES-
inlet of the KESSEL Euro Grease Separator Version G must SEL offers a full line of lifting stations designed for this cir-
be installed below the frost level. This can be achieved by the cumstance.
use of the vertically adjustable upper sections. The manho- Note - Underground separators to be installed below the gro-
le covers for the upper sections are lockable, odour tight and undwater table are available upon request.
available in load classes A (1.5 ton), B (12.5 ton) and D (40.0
ton) and meet EN 124 standards.
Note
Installation The KESSEL Euro Grease Separator Version G is designed
1. The excavation in which the separator is to be installed for locations where:
must be level and capable of handling the appropriate 1) Dispersion of odours during the emptying, cleaning or
loads. maintenance of the separator will not pose a problem.
2. Place the separator in the prepared excavation hole. Make 2) Access of the disposal hose from the disposal truck to the
sure the separator rests at the appropriate level. Fill the separator will not pose a problem.
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 turbulence 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
5
3. Installation
3.1 Installation Illustrations (Class B, 12.5 ton)
Art.#. 93004/120D + 915880D
Dimensioned drawing
T = Installation Depth OD = Outer diameter
Wastewater content
NS DN OD a b h* h1 h2 Sludge trap Separator volume
1 100 110 1380 1106 1050 540 610 140 l 230 l 70 l
Grease storage
2 100 110 1380 1106 1300 790 860 200 l 370 l 120 l
4 100 110 1380 1106 1550 1040 1110 400 l 370 l 160 l
Additional installation depths available upon request.
6
3. Installation
Assembly 2.NS4
Placethelargesealinggasket
Separator insidetherecessed area. After gas-
TheKESSEL separator isshippedfully assembledandready for ope- ket is installed lubricate the upper visual portion of the gasket
ration. Eachchamber isshippedon an individual pallet. Accessories only. Takecautionthat theNS4separatorsaremadeupwithcham-
may either bepacked alongsidetheseparator or possibly bestored ber section with different diameters. Besurethat theproper sized
insideaseparator tank. sealinggasket isused with thecorrespondingsized chamber sec-
tion (seeAbb2).
Notice: 3. Connect thetopandbasesection together with theprovidedclips
Separatorsarepackaged and shipped upsidedown dueto theheavy asillustrated(seeAbb6a/b/c).
weight of thecast iron manholecover. Takecaution when unpacking 4. Placetheoutlet pipeintotheseparator throughtheopeningon the
theseparators. top section until thebasefitsinto theguideslot at thebaseof the
Theseseparatorscan beeasilydissassembledif required. In order to separator. Lubricatedthegasket andconnect outlet pipewith ou-
re-assembletheseparator pleasefollowthesesteps: tlet (seeAbb7). Insert sealinggasket intorecessedholeof topsec-
tion. Lubricate the visible portion of the gasket and then insert
upper section with cast iron manholecover into top section of se-
NS1 and NS2 Separator parator.
1. Placeseparator basesection on floor (seeAbb1). 6. Connect two chamber tankswith another with the supplied cou-
2. Placethelargesealinggasket insidetherecessed area. After gas- pling(seeAbb9)
ket isinstalledlubricatetheupper visual portion of thegasket only
(seeAbb2).
3. Place sludge trap in the appropriate location in the base section
(seeAbb3).
4. Placesludgetrap overflowin thedirection of theoutlet of these-
parator (seeAbb4).
5. Lower topsection of separator ontothebasesection until slotson
topsection insert intoslotson basesection (seeAbb5). Makesure
that thelubricated seal on thebasesection iscompletely inserted
intotherecessedgasket areaof thetopsection.
6. Connect thetopandbasesection together with theprovidedclips
asillustrated(seeAbb6a/b/c). Placetheoutlet pipeintothesepa-
rator throughtheopeningon thetopsection until thebasefitsinto
the guide slot at the base of the separator. Lubricated the gasket
andconnect outlet pipewith outlet (seeAbb7). Insert sealinggas-
ket intorecessedholeof topsection. Lubricatethevisibleportion
of thegasket and then insert upper section with cast iron manho-
lecover intotopsection of separator.
1. Placeseparator basesection on floor (seeAbb1).
7
3. Installation
A-A
햲 햳
햴 햵 햶
max. 7 Nm
6a
쎻 6b
쎻 6c
쎻 햸
8
3. Installation
Installation Illustrations (Class D)
15 cm thick concrete load support plate
햲 KESSEL-Grease
6-8 cm support layer 4 cm Asphalt
Separator G NS 2
햲 Sludge trap
햳 Grease separation
area
햴 Upper section with
cover (load clas B/D)
INLET
OUTLET
Earth Earth
5-10 cm sand
30 cm gravel/process Dimensions in cm
0/32 compacted
Illustration shows NS 2
Dimensioned Drawing NS 1 und NS 2
햲 Inlet
햳 Outlet
햴 Sludge trap
햵 Grease separation area
햶 Upper section with
cover (load clas B/D)
wastewater content
100 1055 1020 1020 1120 650 720 120 l 405 l 145 kg
NS DN a b h1 h2 h3 h4 Sludge trap Grease Storage Weight ca. kg
100 1355 1300 1136 1236 750 750 200 l 935 l 195 kg
1
2
9
3. Installation
Dimensioned Drawing NS 4
햲 Inlet
햳 Outlet
햴 Sludge trap
햵 Grease separation area
햶 Upper section with
cover (load clas B/D)
햷 Chamber connection
4. Commissioning
4.1 Separator commissioning -Separator tobecheckedfor watertightnessandfor proper functiona-
lity
Beforetheseparator isput intoservicepleasemakesurethat: -Contentsof thisuser’smanualstobediscussedwith thosepresent
-Theseparator iscompletely clean, includinginlet and outlet, and that 4) Transfer of thismanual totheappropriatepersonnel
theinterior of thechamber isfreeof dirt anddebris.
-Thecleaned separator iscompletely filled with clean cold water up to
theoutlet.
4.2 Commissioningparticipants
Thecommissioningof theseparator isusually handled by a tradesman
although this can be handled by a KESSEL contractor or KESSEL em-
ployeeif desired.
1) Thefollowingpeopleshouldbeon handduringthecommissioning:
Buildingcontractor representative
Plumber / tradesman whowill bemaintainingtheseparator
Buildingmaintenancepersonnel
Disposal company whowill behandlingthedisposal account
2) Commissioningpreparation
Separator iscompletely filledwith clean water
3) Commissioning
10
5. Separator contents disposal
Thefirst emptying(disposal) of theseparator contentsshouldtakeplace •Placedisposal truck’ssuction hoseinsideseparator and removeentire
within 2to3weeksfrom theday theseparator wasplacedintoservice. contectsof chamber.
•Rinseandclean interior wallsof chamber.
Disposal intervals Removecoagulatedfat/oil anddebris.
Accordingto DIN V 4040-2, it isadvised that sludgeand greasesepara- •Refill chamber with coldclean water.
torsshould befully emptied, cleaned and refilled with cold fresh water •Clean andgreaseall accessibleseals. Replacesealsif necessary.
at fourteen day intervals or at least on a monthly basis. In order for a •Replacecover(s) andsecurewith cover clamps.
greaseseparator tofunction asdesigned, it isveryimportant that these-
parator isemptiedat regular intervalsasdescribedabove. Duetothis, it
isrecommendedthat alicenseddisposal companyiscontractedtoempty
theseparator at regular intervalsand duringtimeswhen strongodours
will not present aproblem.
Disposal procedure
•Removemanholecover.
6. Maintenance
Maintenance of the separator Please make sure that:
The separator should be tested to make sure that it is 1. This Installation, Service and Maintenance Guide and
completely watertight before it is placed into operation any other documentation relating to the separator is
and also during periodic intervals thereafter. kept in a safe place accessible to all who work on the
unit.
1. Surface care - the interior walls of the separator should 2. Disposal of the contents of the separator follows the
be cleaned and checked for problems at regular inter- exact guidelines stated in this guide.
vals. 3. The disposal of the separator is carried out by a quali-
2. The separator should be thoroughly checked two times fied, licensed company.
per year. During these inspections the separator should
be completely emptied and thoroughly cleaned.
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.
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.
11
7. Replacement parts and accessories
KESSEL-Sampling Chamber B=400 for connection
For underground installation, free flowing sample availability.
to separator systems
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.
Installation Inlet Outlet [Link].
height T (mm) DN OD Class A Class B Class D
*400-1300 100/150 110/160 915 880 A 915 880 B 915 880 D
1330-1660 100 110 915 813 A 915 813 B 915 813 D
1330-1660 150 160 915 823 A 915 823 B 915 823 D
* 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
for deeper installation
KESSEL-Extension section for sampling chambers
Max. extension height. 600 mm
Manufacturer: KESSEL
[Link].
- 915 402
KESSEL-Extension section for underground
KESSEL separator systems, polyethylene material, includes gasket
Extension height [Link].
512 mm 917 406
1012 mm 917 407
12
7. Replacement parts and accessories
KESSEL-Sampling chamber Ø 1000 mm
in polyethylene synthetic material, for separa-
tion systems, for underground installation
Inlet and outlet Ø ..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 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
8. Guarantee
1. In the case that a KESSEL product is defective, KESSEL has products. Additional information can be found in section 377
the option of repairing or replacing the product. If the product and 378 of the HGB.
remains defective after the second attempt to repair or repla- In addition to the standard warranty, KESSEL offers an addi-
ce the product or it is economically unfeasible to repair or re- tional 20 year warranty on the polymer bodies of class I / II
place the product, the customer has the right to cancel the fuel separators, grease separators, inspection chambers, wa-
order / contract or reduce payment accordingly. KESSEL stewater treatment systems and rainwater storage tanks.
must be notified immediately in writing of defects in a product. This additional warranty applies to the watertightness, usabi-
In the case that the defect is not visible or difficult to detect, lity and structural soundness of the product.
KESSEL must be notified immediately in writing of the defect A requirement of this additional warranty is that the product is
as soon as it is discovered. If the product is repaired or re- properly installed and operated in accordance with the valid
placed, the newly repaired or replaced product shall receive installation and user's manual as well as the corresponding
a new warranty identical to that which the original (defective) norms / regulations.
product was granted. The term defective product refers only
to the product or part needing repair or replacement and not 2. Wear and tear on a product will not be considered a defect.
necessarily to the entire product or unit. KESSEL products Problems with products resulting from improper installation,
are warranted for a period of 24 month. This warranty period handling or maintenance will also be considered a defect.
begins on the day the product is shipped form KESSEL to its
customer. The warranty only applies to newly manufactured 10.11.2009
13
9. Separator characteristics
Bahnhofstr. 31
D-85101 Lenting
Article _____________________________________________________________________________________
Type _____________________________________________________________________________________
Art.-# _____________________________ Ser.#. _______________________Year__________________________
EN ______________________________________________Approval___________________________________
l x w x h _____________________________________________________________________________________
Sludge trap volume l_____________________________Grease storage volume/l___________________________
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
14
Important contacts / Info
Separator Type: __________________________________________________________
Day / Hour __________________________________________________________
Project description /Building services supervisor __________________________________________________________
Address __________________________________________________________
Telephone / Fax __________________________________________________________
Builder __________________________________________________________
Address __________________________________________________________
Telephone / Fax __________________________________________________________
Planner __________________________________________________________
Address __________________________________________________________
Telephone / Fax __________________________________________________________
Contracted plumbing company __________________________________________________________
Address __________________________________________________________
Telephone / Fax __________________________________________________________
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
15
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