ACO Coalisator-R User manual

ACO Light liquid separators NS 3 - 6 - 10
0150.11.55_V3.1_EN_Translation of the original German operating manual.
ACO Separators
For a safe and proper use, read operating manual and further
product-related documents thoroughly.
Hand on to end user and keep up to product disposal.
Coalisator/Curator-R/-RD
Operating manual 2013-04-16 edition
Coalisator/
Curator-R
for free-standing installation
Coalisator/
Curator-RD
for free-standing installation
Direct suction
Official test sign Z-54.3-475
according to DIN EN 858, DIN 1999-100 and DIN 1999-101

2
Welcome
ACO Passavant GmbH
Im Gewerbepark 11c
D 36457 Stadtlengsfeld
Tel.: + 49 36965 819-0
Fax: + 49 36965 819-361
www.aco-haustechnik.de
The ACO Passavant GmbH (hereinafter called ACO) appreciates your confidence and
supplies you with a product which is state-of-the-art technology and which was checked
for its proper condition in line with our quality controls prior to its delivery.
■The texts do not contain abbreviations, exception:
BA = operating manual
e. g. = for example
Fig . = figure
h. = hour(s)
HP = high-pressure
min . = minimum / minute(s)
max. = maximum
nom. = nominal
sec. = second(s)
ST = sludge trap
■Definitions:
Separator plant = Total plant as described in scope of
supply
Welcome

3
Contents
Welcome .................................................................................................... 2
Contents..................................................................................................... 3
1 Preamble .............................................................................................. 7
1.1 ACO service ......................................................................................... 7
1.2 Product identification............................................................................. 7
1.3 Warranty .............................................................................................. 8
1.4 Owner, user ......................................................................................... 8
1.5 Symbols used in the manual................................................................... 8
2 For your safety...................................................................................... 9
2.1 Proper use ........................................................................................... 9
2.1.1 Field of application.................................................................... 9
2.1.2 Improper use............................................................................ 9
2.2 Required qualification .......................................................................... 10
2.3 Personal protective equipment ............................................................ 11
2.4 Depiction of warning notices ................................................................ 12
2.5 Non-approved parts............................................................................. 13
2.6 Material/substance hazards ................................................................. 13
2.7 Responsibility of owner........................................................................ 13
2.8 Warning signs for the separator plant.................................................... 13
3 Transport and storage ......................................................................... 15
3.1 Safety during transport and storage...................................................... 15
3.2 Transport ........................................................................................... 16
3.3 Storage ............................................................................................. 16
4 Product description ............................................................................. 17
4.1 Scope of supply of separator plant ....................................................... 17
4.1.1 Product characteristics ........................................................... 18
4.1.2 Depiction of components ......................................................... 19
4.1.3 Suggested installation ............................................................. 20
4.1.4 Functional principle ................................................................. 20
4.1.5 Type plate.............................................................................. 21
4.1.6 Accessories ........................................................................... 21
Contents

4
Contents
4.2 Securat alarm device V2.0 (optional)..................................................... 22
4.2.1 Components of the Securat alarm device V2.0........................... 23
4.2.2 Functional principle ................................................................. 23
5 Technical data..................................................................................... 25
5.1 Light liquid separator plant Coalisator-R/Curator-R.................................. 25
5.2 Light liquid separator plant Coalisator-RD/Curator-RD.............................. 26
6 Installation .......................................................................................... 27
6.1 Safety during installation...................................................................... 27
6.2 Sanitary installation............................................................................. 28
6.2.1 Assembly of separator plant (if supplied in segments) ................. 29
6.2.2 Assembly of single components in upper part ............................ 29
6.2.3 Assemble housing................................................................... 30
6.2.4 Connect inlet and outlet line ..................................................... 31
6.2.5 Connect vent line .................................................................... 31
6.2.6 Installation/electric installation Securat alarm device (optional) .... 32
7 Commissioning and operation............................................................... 33
7.1 Safety during commissioning and operation ........................................... 33
7.2 Initial commissioning ........................................................................... 34
7.2.1 Prerequisites, presence ........................................................... 34
7.2.2 Realization ............................................................................. 34
7.2.3 Handover of separator plant to user.......................................... 34
7.2.4 ACO maintenance contract (recommendation) ............................ 35
7.3 Operation........................................................................................... 36
7.4 Operating log ..................................................................................... 36
7.5 Sampling ........................................................................................... 36
8 Maintenance ....................................................................................... 37
8.1 Safety during maintenance................................................................... 37
8.2 Maintenance works by the expert user .................................................. 38
8.2.1 Monthly checks....................................................................... 38
8.2.2 Works upon requirement .......................................................... 40
8.3 Maintenance plan for expert ................................................................. 41
9 Fault clearance ................................................................................... 43
9.1 Safety during fault clearance and repair at separator plant ..................... 43
9.2 Fault finding ....................................................................................... 44
9.3 Repair, fault clearance and spare parts ................................................. 44

5
Contents
10 Decommissioning and disposal ............................................................. 45
10.1 Safety during decommissioning and disposal ......................................... 45
10.2 Decommissioning of the separator plant................................................ 46
10.3 Stop separator plant ........................................................................... 46
10.4 Disposal ............................................................................................ 46

6

7
Preamble
1 Preamble
This operating manual for the separator plant was issued with high diligence and
contains information which guarantees safe and long-lasting operation.
If, however, some mistakes have slipped in or if some information is missing, please
advise us accordingly.
1.1 ACO service
In the case of questions on the product and this operating manual, please contact our
ACO Service.
ACO Service
Im Gewerbepark 11c
36457 Stadtlengsfeld
Tel.: + 49 (0) 369 65 /81 9-0
Fax: + 49 (0) 369 65 /81 9-3 61
[email protected]
1.2 Product identification
The plant can be identified and marked by means of following table. The year built can
be taken from type plate of plant.
Table 1: Characteristics for product identification
Art. no.
Right
Art. no.
Left
Type Nominal
size
Illustra-
tion
Year built Serial no.
7603.00.50
Coalisator-R
NS 3
7606.00.50 NS 6
7610.00.50 NS 10
7603.10.50 7603.11.50
Coalisator-RD
NS 3
7606.10.50 7606.11.50 NS 6
7610.10.50 7610.11.50 NS 10

8
Preamble
1.3 Warranty
For full particulars on warranty refer to ACO's Terms and Conditions under
www.aco-haustechnik.de/agb.html.
1.4 Owner, user
The owner is responsible for the design (planning and dimensioning) of the separator
plant.
If the separator plant is not operated by the owner, the following coordinations with the
user are required:
■Who is responsible for current operation?
■Who initiates maintenance or repair works of the separator plant?
■Who reacts in the case of malfunction?
■...
1.5 Symbols used in the manual
For better differentiation of information, it is marked by following symbols in the manual:
Useful hints and additional information facilitating work
Steps to be carried out
References to further information in this operating manual or to other documents
Illustration of warning notices, chapter 2.4

9
For your safety
2 For your safety
Please read the safety notes in this chapter prior to using the product. Severe damages
may occur in the case of misuse.
If owner or user of plant changes, documents have to be handed on.
2.1 Proper use
2.1.1 Field of application
The separator plant is intended exclusively for separation of light liquids (oil and petrol).
The following criteria are prerequisites for the installation:
■Only for separation of light liquids (oil and petrol)
■Light liquid separator has an incline to sewers
■Stable emulsions may not be fed into separator plant for light liquids
Different use and application options as well as alterations are prohibited.
The owner is responsible for planning, installation and operation of the light liquid
separator, ACO K9/chapter 12/planning notes/dimensioning.
2.1.2 Improper use
Improper use is e. g.:
■Operation of separator plant outside the limitations of use, K9/chapter 12
■Feeding of stable emulsions into the separator plant for light liquids
■Use of worn components (omitted servicing works)
■Disregard of this operating manual and product-related documents
■Feeding of harmful substances

10
For your safety
2.2 Required qualification
All works at separator plant must be carried out by specialists, if not expressly
mentioned that different persons (owner, user) are allowed to do so.
Besides a perennial work experience, specialists must have proof of the following
knowledge:
Table 2: Required staff qualification
Activities Person Knowledge
Design
Operational alterations
New context of use
Planner ■Knowledge of building, sanitary and house
technique
■Evaluation of applications of wastewater
technology and proper dimensioning of light
liquid separators
Transport/storage Forwarders, dealers ■Proof of load securing education
■Safe handling of lifting accesories
Installation sanitary/
electrical works
initial commissioning,
maintenance,
repair works,
decommissioning,
dismantling
Specialists ■Safe handling of tools
■Laying and connection of pipelines and connec-
tions
■Laying of elecric lines
■Assembly of distribution boards, fault-current
circuit breakers, automatic cutouts, electrical
machines, switches, buttons, power sockets etc.
■Measuring of efficiency of electric protective
measures
■Product-specific knowledge
Check Competent persons ■Staff members of user-independent plants, autho-
rised experts or other institutions
■Verifiably required expert knowledge for
operation, maintenance and check of separator
plant
■Device-related equipment for check of separator
plants
Operation, operation
monitoring,
easy maintenance and
fault remedy
Owner, user ■Experience in operation, maintenance and check
of separator plant
■Experience in expert handling and evaluation of
works carried out at separator plants
Disposal Specialists ■Proper and environmentally friendly disposal of
materials and substances
■Decontamination of harmful substances
■Knowledge about recycling

11
For your safety
2.3 Personal protective equipment
For different works at the separator plant, personal protective equipment is required.
The specialist company must put a sufficient number of protective equipment at the
disposal of their employees. Supervisors must make sure that the equipment is worn.
Table 3: Personal protective equipment
Signs
giving
orders
Meaning Explanation
Wear safety
shoes
Safety shoes offer good anti-slip property, particularly under wet
conditions, as well as high puncture resistance, e. g. with nails, and they
safeguard the feet against objects falling down, e. g. during transport
Wear safety
helmet
Safety helmets safeguard against head injuries, e. g. in the case of
objects falling down or impacts, particularly with low ceiling heights and
above-head assembly
Wear safety
gloves
Safety gloves safeguard the hands against light crushes, cutting injuries
and infections, particularly during transport, commissioning, mainte-
nance, repair and dismantling
Wear protective
clothing
Protective clothing safeguards the skin against light mechanic impacts
and infections in the case of leaking wastewater
Wear protective
glasses
Protective glasses safeguard the eyes in the case of leaking wastewater,
particularly during commissioning, maintenance, repair, decommissioning
Use breathing
protection
Breathing apparatuses safeguard against inhaling harmful gases and
vapours

12
For your safety
2.4 Depiction of warning notices
For better differentiation, risks and hazards are marked in the operating manual by
following warning signs and signal words:
Table 4: Risk levels
Warning signs and
signal words Meaning
DANGER
Injuries to persons
Refers to a dangerous situation leading to death or severe injuries if it
is not avoided.
WARNING Refers to a dangerous situation possibly leading to death or severe
injuries if it is not avoided.
BEWARE Refers to a dangerous situation possibly leading to medium or light
injuries if it is not avoided.
CAUTION
Property
damage
Refers to a situation possibly leading to damages of components, of
plant and/or its functions or of an object in its work environment, if it is
not avoided
Exemplary warning notices:
SIGNAL WORD
Cause of danger
Consequences of danger
Description/listing of protective measures
(Note and calls for action)

13
For your safety
2.5 Non-approved parts
Prior to its market introduction, the separator plant had to pass all product tests and all
components were checked under high load.
Copies of high-quality spare parts are increasingly available. Installing non-approved
parts affects safety and rules out warranty by ACO.
In the case of an exchange, exclusively use original ACO parts or "spare parts released"
by ACO.
2.6 Material/substance hazards
Contact with light liquids (oil and petrol) may lead to infections.
2.7 Responsibility of owner
It is in the owner's responsibility that the following points are observed:
■The separator plant must be operated in accordance with its intended use and in
proper condition, chapter 2.1.
■Function of protective equipment must not be affected.
■Service intervals must be kept and faults must be remedied promptly. Remedy faults
oneself only if relevant measures are described in this operating manual. For all
other measures, the ACO Service is in charge.
■Sufficient number of required "personal protective equipment" (PPE) must be
available and must be worn, chapter 2.3.
■This operating manual must be available at place of installation legibly and
completely and staff members must have been trained with this manual.
■Only qualified and authorised staff members may be used, chapter 2.2
2.8 Warning signs for the separator
plant
The following warning signs apply to the separator plant.
Table 5: Warning signs
Sign Hazard Plant component
For a safe and proper application, read
operating manual properly. Alarm device of separator plant

14

15
Transport and storage
3 Transport and storage
This chapter holds information on correct transport and accurate storage of the
separator plant.
Supply unit
The separator plant mounted at our works and the loose components are delivered on a
pallet, scope of supply/chapter 4.1.
3.1 Safety during transport and storage
During transport and storage, the following risks may occur:
WARNING
Read the following safety notes thoroughly prior to transport or storage. In the case of
misuse, light or medium injuries may occur.
Make sure that transport and storage personnel have required qualification,
chapter 2.2
Transport with forklift or truck
Severe bruises, impacts and momentous accidents in the case of improper
transport
■Wear personal protective equipment, chapter 2.3
■Transport separator plant as supplied (mounted on pallet) only
■Secure loading sufficiently
■Check suitability and intactness of lifting accessories
WARNING
Transport with crane
Severe bruises and impacts in the case of loads falling down
■Wear personal protective equipment, chapter 2.3
■Transport separator plant as supplied (mounted on pallet) only
■Check max. permissible bearing load of crane and lifting accessories
■Never stand beneath pending loads
■Make sure no other persons are able to enter the entire danger area
■Avoid reciprocating movements during transport

16
Transport and storage
3.2 Transport
To ensure that the light-oil separators are not damaged during transport, use a forklift
truck, lifting truck or sling ropes.
In the case of transport with a forklift or lifting truck, separator plant must be placed on
an adequate transport means (e. g. wooden pallet which served as transport medium).
In no case underride separator plant directly or lift; risk of damage.
For transporting the separator plant with a crane hook, use a 3-suspension with safety
hooks.
3.3 Storage
CAUTION An improper storage or missing preservation may damage separator plant.
■Store separator plant in a closed, dry, dustproof and frostfree room
■Avoid temperatures outside the range of +1°C to +40°C
In the case of long-term storage:
■In the case of non-rustproof material: apply preservative to all outside and inside
blank metal parts.
■Check preservation after 6 months and renew, if required.

17
Product description
4 Product description
This chapter holds information on design and functioning of separator plant.
4.1 Scope of supply of separator plant
Check intactness and completeness of supply by means of below table.
CAUTION Never fit and operate damaged separator plant.
Inform supplier of possible damages at separator plant in order to ensure that
complaints can be handled speedily.
Table 6: Supply units and single components
Unit Single component Illustration Packing
Housing
■1 x housing
■1 x suction (only with RD) Wooden pallet
Accessories
(optional) alarm
device
■1 x Alarm device –Carton
Documentation ■1 x Operating manual
■1 x Supply documents –PVC bag
Further accessories as sampling pipe, product catalogue, www.aco-haustechnik.de

18
Product description
4.1.1 Product characteristics
This subchapter describes essential features as well as functional principle of the
Coalisator-R/-RD separator plant.
Short description of Curator-R/-RD, Coalisator-R/-RD separator plant
The separator plant is intended for free-standing installation in frostproof rooms. It
separates light liquids (oil and petrol).
Table 7: Characteristics of separator plant
General
■NS 3 - 6 - 10
■Official test sign Z-54.3-475 according to DIN EN 858 and DIN 1999-100
■Separator plant for free-standing installation in frostproof rooms
■Plant components of stainless steel material grade 1.4301 or 1.4571
■Low weight (single components 85 - 100 kg), quick assembly
■High chemical resistance of all components
■Maintenance-friendly thanks to large maintenance/revision opening
Housing
■Segment design (twin design - NS 3, 3-part design - NS 6,10)
■Separator inlet/outlet
■Float/seal
■Coalescence insert (only with Coalisator)
■Sampling connection
■Maintenance opening
■Disposal connection (only -RD)
■Oil suction connection (only -RD)
■Ventilation connection (only -RD)
Alarm device
■Securat alarm device V2.0, SK 2 and SB1 (optional)

19
Product description
4.1.2 Depiction of components
The following illustration shows design and position of single plant components.
Descriptions of the following chapters can be easily assigned.
7
6
8
1 2 4
9
10
11
12
13
35
14
1=Inlet
2=Separator inflow
3=Maintenance opening
4=Disposal connection
fire hose quick coupling
Storz 75 B R 2 1/2"
DIN 14308 (with -RD
type)
5=Securat alarm device
(option)
6=Connection 1/2" for
sampling
7=Outlet
8=Separator outflow
9=Integrated sludge trap
10 =Oil suction connection
fire hose quick coupling
Storz 75 B R 2 1/2"
DIN 14308 (with -RD
type)
11 =Ventilation DN 70
12 =Housing
13 =Coalescence insert
(with Coalisator)
14 =Float
18 =Inlet socket
Fig. 1: Depiction of components
View X
illustrated:
NS 6, right-hand operating side,
in the case of left-hand operating side, the
components (disposal connection, venti-
lation, oil suction) are arranged mirror-
invertedly to centre axis of separator.

20
Product description
4.1.3 Suggested installation
This subchapter describes possible installation situation of the separator plant.
min. 750 mm
5
1
9
3
2
8
6
4
7
1=Inlet
2=Separator inflow
3=Maintenance opening
4=Ventilation DN 70
5=Outlet
6=Separator outflow
7=Integrated sludge trap
8=Coalescence insert
(with Coalisator)
9=Float
Fig. 2: Suggested installation/function
4.1.4 Functional principle
This subchapter describes function of separator plant.
Function of Curator-R/-RD, Coalisator-R/-RD separator plant
The separator plant works purely physically as per the gravity principle (with class II
separator plants) and additionally by using coalescence effects with class I separator
plants.
Heavy wastewater substances (as e. g. sand) sink to the bottom of the integrated
sludge trap, light substances as e. g. oil rise upwards in the separator. Small oil
droplets continue floating and are separated by means of the coalescence effect (with
Coalisator) K9/chapter 12.