Highland Tank GreaseStopper Series User manual

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User’s Manual
Installation, Operation & Maintenance
Carefully read and follow the instructions in this manual.
Automatic Grease Interceptors
GreaseStopper®
Models 15 to 800
Flush-with-Floor
Proudly made
in America

814.893.5701 | highlandtank.com
Highland Tank
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count on our products. trust in our people.
grease i nterceptors
HT-2810

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Warning and Disclaimer
This manual is intended for use only by persons knowledgeable and
experienced in grease interceptor installation, operation and maintenance.
This manual provides general guidance, and conditions at your site may
render inapplicable some or all of the guidance. If you are uncertain, or
require clarication or further instruction, please contact Highland Tank
prior to commencing any installation, operation or maintenance procedure.
You are solely responsible for ensuring compliance with all applicable
federal, state and local laws, regulations and ordinances applicable to
your installation and operation. Highland Tank disclaims all liability
related to any misuse of the interceptor or failure to follow all guidance
and instruction provided by Highland Tank.

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Introduction 4
Installation 5
Start-up 8
Operation 8
Maintenance 11
Troubleshooting Guide 13
Parts - Repair and Replacement 14
Appendix A: Electronic 24-Hour Timer 19
Appendix B: Large AGI Timers 22
Appendix C: Maintenance Instructions 24
Appendix D: Flush-with-Floor Drawings 25
Appendix E: Large AGI Installation Drawing 26
Appendix F: Best Management Practices 27
Grease Hauler Manifest 29
Sample Inspection & Maintenance Log 30
AGI - Automatic Grease Interceptor
BMP - Best Management Practices
FOG - Fats, Oil & Grease
FSE - Food Service Establishment
GRD - Grease Recovery Device
Contents
Appendices
Forms
Glossary of Terms

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Thank you for purchasing a Highland Tank Automatic Grease
Interceptor (AGI). The AGI combines state-of-the-art technology
with time-tested materials, making it the most reliable automatic
grease recovery device (GRD) in the industry.
The purpose of this manual is to provide instructions on
installation, operation, start-up, maintenance and
troubleshooting of the AGI.
Carefully read and follow the instructions in this booklet. All
plumbing installations must be performed according to state
and/or local requirements. Federal, state and/or local codes
may apply. Check with federal, state and local authority having
jurisdiction (AHJ) prior to installation of an AGI.
The AGI should be installed in a controlled environment.
Enzyme-based cleaners are not recommended since their use
seriously reduces FOG removal efciency. A biodegradable,
non-emulsifying detergent is recommended for use in cleaning
and washing applications.
Locate the AGI in an area with sufcient access (top and side
clearance) for routine maintenance.
The AGI is equipped with an integral ow control device. Optional
external ow controls are available upon request.
Inlet piping should be installed with recommended pitch and
diameter, limiting turns to minimize turbulence.
A second screen basket is recommended for single basket models,
to ease maintenance without having to turn off the AGI or take it
off-line.
Do not modify AGI system in any way. Do not weld on the AGI.
The efuent FOG concentration may exceed desired levels if
the AGI is not properly installed, operated or maintained.
Over a period of time, grease and ne solids can build up on
the walls and bottom of the AGI. It is recommended that any
build-up be cleared out regularly. If improperly maintained, the
AGI may malfunction.
An inspection and maintenance log should be kept and be
available for ready reference.
Introduction
Before you begin
IMPORTANT:
Efuent Notice
General AGI
Cleaning Notice
IMPORTANT:

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All installations are subject to local codes and regulations. The
Highland Tank AGI is available as left-to-right or right-to-left ow
direction depending on the location of the unit in relation to the
xture being serviced and available space for proper operation
and maintenance.
An outlet vent or approved venting device is required on
all installations.
Diagrams are for illustration only. Please refer to applicable
AHJ requirements for direct or indirect connections.
The GreaseStopper AGI is designed for above-oor installation
under sink xtures or other easily accessible area. The interceptor
is designed for direct waste connections.
The Flush-with-Floor GreaseStopper is designed for direct burial
or suspended installation via anchoring anges and cradle. The
interceptor is designed for indirect waste connections and/or
multiple drainage xtures. See Appendix C.
Installation
Typical Plumbing
Installations
Above-oor AGI
Installation
Flush-with-Floor
AGI Installation

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Carefully remove the AGI covers to avoid damage to the gasket.
Inspect the interior of the AGI to insure that all bafes, heating
elements, skimming devices and internal piping are secure and
have not been damaged during transport.
The AGI must be installed in a level position. It is recommended
that the AGI be located in close proximity to the xture(s) being
serviced to reduce build-up. Check elevations at each end of the
unit with a level, and adjust as necessary.
Piping ow direction is marked at factory as AGI “IN” and “OUT”.
Connect inlet and outlet piping (contractor supplied) to the
provided no-hub connections with a code-approved coupling
device. Keep piping as straight as possible and utilize sweeps
and gradual change in directions.
Inlet and outlet piping must be sloped according to local codes
(typically 1/8 inch to 1/4 inch) to maintain proper gravity ow in
and out of the AGI.
The Highland Tank AGI has an internal deep trap seal.
Install a vent after the unit discharge per local and state
plumbing/building code.
Pre-installation
Inspection
Placement
Piping
IMPORTANT:

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Standard electrical requirements for all AGI models 15 through 100
on-oor and all Flush-with-Floor models is 120 VAC, single phase,
20 amp.
NOTE: AGI models 150, 200, 250, 300, 400, 600 and 800 are
project specic. Please contact factory for power requirements on
optional pump applications.
Follow all local and state electrical and safety codes, the
National Electrical Code (NEC) and the Occupational Safety
Health Act (OSHA).
Disconnect power before installing or servicing.
UNIT MUST BE PLUGGED INTO A GFI PROTECTED
POWER SOURCE.
The Highland Tank AGI is pre-wired at the factory to include one
24-hour digital timer control panel. The timer control device is set
by you to operate daily, based on the size (GPM rating) of
the unit. The digital timer control device operates the disc
skimmer(s) and immersion heater(s). See Appendix A.
Mount the NEMA 3R digital control device (supplied) onto wall.
The power cord (supplied) from the digital control device plugs
into a properly grounded 3-prong, 120VAC, 20 amp circuit. Power
to the unit is indicated by the GREEN light mounted on the digital
timer control panel.
Note: The GREEN light indicates that there is power to the unit,
not that the unit is in operational mode.
Electrical Instructions
IMPORTANT:
CAUTION:

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Electrical equipment, connections and wiring must be
protected from submergence in water and inltration of
water at all times.
You must be certain that nal state of wiring is in
compliance with all applicable electrical and re codes for
location and intended service.
Procedure to ll AGI is as follows:
1. Remove top cover and observe lling of interceptor with
clean, fresh water via xtures.
2. Interceptor is full when water ows through the outlet.
3. After lling the interceptor, verify water ow as follows:
a. Allow water to ow through sink drain leading to unit inlet.
b. Check outlet pipe to make sure water is passing through
the unit and that no blockage or leaks exist.
4. Check inlet pipe and sink drain for any water backup.
The AGI unit MUST be full of water to operate.
The AGI is designed for gravity separation of fats, oils and grease
(FOG) along with food scraps and solids from wastewater
discharged from institutional and commercial kitchens. The
interceptor removes grease automatically, collecting it neatly in
an adjacent container from which it can be disposed and recycled
with other grease by a rendering rm.
The AGI unit is usually connected to the drain lines between the
pot washing sink, pre-rinse station (prior to the dishwasher) sink,
and the sewer drain. AGI models 15-100 can be installed under
a sink or other limited space. Daily screen basket maintenance is
accomplished via the hinged and latched top cover (see Daily
Maintenance for more information).
When greasy water enters the unit, it ows through the screen
basket and strikes the inlet bafe. This slows the water velocity,
keeping it from disturbing the grease in the retention area. As
the water enters the retention area, the grease is separated by
gravity otation.
Start-Up Warnings
CAUTION:
Filling the Interceptor
Operation
IMPORTANT:

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Operation continued Since grease is lighter than water, it oats and remains in the
retention area between the two bafes. The Diskimmer skims
the liqueed grease off the top surface of the water.
The Diskimmer is an electrically powered grease-skimming
device, which operates on a time or event-controlled basis. The
oleophilic plastic disc rotates and causes the grease to adhere to
it where the disc enters the water. As the disk rotates, the grease
is carried with it until it passes between the scraper blades. The
skimmed grease is scraped from the disk surface, directed into a
trough and drained via a conduit from the interceptor into the
disposal container. Clean water ows under the discharge bafe
and out of the AGI to the sewer drain. If properly sized and
maintained, the AGI is capable of reducing the otable FOG content
in the discharge wastewater to 100 mg/l or less.
The AGI is tted with thermostatically controlled electric immersion
heaters for elevating the temperature in the interceptor to maintain
the contained grease in a liquid state for skimming purposes. The
unit is also tted with a 120 volt/60 hertz gear motor to operate
the Diskimmer and one 24-hour digital clock timer to control
the system.
GreaseStopper AGI
15, 20, 25
GreaseStopper AGI
30, 35, 50, 75, 100
Gear Motor
Digital Timer
Solids
Collection
Basket
INLET OUTLET
Diskimmer
Retention Area Recovered Grease Container
Grease
Recovery
Pipe
Electric
Heater
Dual-sided
Diskimmer
Recovered
Grease
Container

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Mechanical Sequence
of Operation
IMPORTANT:
Digital Timer Operation
VERY IMPORTANT:
One (1) 24-hour digital clock timer is supplied to control the AGI.
The clock timer must be set by you onsite based on the Food
Service Establishment (FSE) and Best Management Practices
(BMPs). The recommended run time is 60 minutes daily, and
adjust accordingly.
For best results, operating temperature should be between
90-110 degrees. The thermostat was set at the factory. Some
applications may require adjustments. (See heater manual
to adjust temperature.)
See Appendix A for complete details for wiring and timer settings.
In case of power failure, the timer has an internal battery
that is designed to maintain clock time and retain operating
presets (NOTE: Periodically check internal battery to ensure
it is not dead).
If the digital control device needs programming, please refer to
Appendix B instructions.
BMPs vary with each FSE. We recommend a minimum of 60
minutes daily and adjust accordingly.
Flush-With-Floor
GreaseStopper AGI
20, 25, 30, 35, 50,
75 & 100
Digital Timer
Solids
Collection
Basket
INLET OUTLET
Diskimmer
Recovered Grease Container
Grease
Recovery
Pipe
Electric
Heater
Electrical
Supply
Connection
Grease
Level
Monitor

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Maintenance
Optimum Performance
IMPORTANT:
Daily Maintenance
The AGI is designed for long-term, trouble-free operation, but daily
maintenance, in addition to keeping the AGI unit free from grease
and solids buildup, is required for optimum performance.
An inspection and maintenance log should be available for
ready reference.
Make sure that pot sinks have permanent strainers and that
the AGI’s screen baskets are always cleaned, undamaged and
properly placed to avoid blockage.
Always disconnect power to AGI before cleaning or
servicing unit.
To avoid blockage, never permit screen basket to become
more than half full.
The following maintenance procedures should be performed daily:
1. Screen basket should be checked and emptied, if required,
throughout each day. Thoroughly clean and clear out all food
particles, then put back in place. If a second screen basket is
not available, this must be performed at off-peak hours, to
prevent wastewater solids from entering the unit.
a. To clean strainer, carefully remove unit cover.
b. Tilt and lift strainer forward until strainer clears intake pipe.
(On top-inlet type AGIs, slide strainer out, clean and replace).
c. Remove strainer lid.
d. Thoroughly clean strainer and replace.
2. Discharge tube/exterior grease container should be checked
daily to verify grease ow without obstructions.
3. If grease is not owing, do the following:
a. Check timer to see if AGI unit is running.
b. Remove large lid to see if there is grease in the AGI.
c. Make sure disc is rotating.
d. Make sure scraper blade assembly is in place on the disc.
e. If disc is rotating, check sump pump discharge tube and
scraper blade area for blockage.
4. If excess water appears in grease container, reset timers to
run for a shorter period of time.

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Annual or
Semi-Annual
Maintenance
General Maintenance
Water Discharge
Waste Disposal
Recommend total pump-out of automatic grease interceptor
annually or semi-annually to remove any accumulation on
bottom or walls of interceptor. Rell with fresh water and
continue recommended operation (NOTE: Monitor usage. Total
pump-out and removal of accumulated FOG may need performed
more often).
Remove cover and oil disc shaft bearings yearly. Inspect and
replace gasket(s) on cover as necessary. Inspect and replace
scraper blades as necessary (NOTE: Monitor usage. Replacement
of worn or damaged parts may need performed more often).
The plastic disc within the AGI unit is oleophilic (oil attracting).
When revolving through only a thin sheen of grease, small droplets
of water may adhere to disc and discharge into the container.
If the disc is picking up a lot of water, the skimmer motor is running
too long. Reduce run time by reprogramming timer.
See Appendix B.
A certied waste disposal company should handle disposal of all
waste products.

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Troubleshooting Operating problems can be caused by many factors. The following
troubleshooting guide lists the most common problems along with
their possible causes and suggested remedies. Specic questions
can always be directed to Highland Tank at (814)-443-6800.
Problem Possible Cause Remedy
No evident grease in Clog in sump discharge tube Check tube and remove
AGI discharge clog if necessary.
Floating solids near disc in Check screen basket.
grease retention area Clean and replace
screen basket before
draining pot sinks.
A second screen basket
is recommended for
single basket units.
Smoking grease or Starting the AGI without water in Fill AGI with clean,
disc burn the AGI fresh water. See
Start-up Instructions.
Grease buildup extends down Check for obstructions,
to heating element remove accumulated
FOG and rell with clean
fresh water. See
Start-up Instructions.
Excessive FOG Flow rate exceeds rated capacity Decrease ow rate.
in efuent
Chemical emulsication Remove sources of
harmful chemicals.
Grease levels are greater than storage Remove grease.
capacity causing separated grease to
carry over
Excessive ow turbulence within AGI Check for trash in
screen basket or
inlet piping.
System back-up Excessive sludge or debris back-up Clean out AGI.
Closed inlet on efuent piping valve Open piping
valves completely.
Trash Clean catch basin,
trench drains
or interceptor.
High suspended solids Excessive sludge or debris build-up Clean out AGI.
content in efuent

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Parts
Repair and Replacement
All models AGI-15 —100
Front View
Parts Listing
1. Scraper Bar Assembly
2. Nylon Disc Guides (2 required)
3. Scraper Blades with Nuts & Bolts (2 required)
4. Stainless-steel Hold-down Plates (2 required)
5. Stainless-steel Nuts & Bolts (to attach scraper blades)
6. DWV Street 45º Copper Elbow
7. Plastic Skimmer Disc with Hub
8. 3/4 inch Diameter Solid Stainless-steel Drive Shaft
9. Stainless-steel Shaft Bracket & Flange Assembly
with Gasket
10. SCH 40 Stainless-steel Pipe Stub (inlet & outlet)
11. Stainless-steel Grease Sump
12. Removable Stainless-steel Screen Basket with
Lid & Latches
13. Closed-cell Foam Lid Gasket
14. Removable Stainless-steel Hinged Lid
15. Twist Lock Connector
16. Digital Timer with Control Box
17. Woodruff Key - Machined into Driveshaft
18. Scraper Bar Assembly Stainless-steel Support Brackets
19. Stainless-steel Lid Clamps
20. Plastic Grease Pail with Lid
21. Stainless-steel Underow Bafe
22. Tank Shell - 304 Stainless-steel
23. Stainless-steel Deep Trap Seal
24. Immersion Heater ( 1500 Watt 115 Volt)
25. Thermostat with Bracket
26. Direct Drive Gear Motor
27. Junction Box with Gasket
28. Cleanout Fitting with Plug

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Scraper Bar Assembly
Rear View

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06-1159
06-1008
06-1096
06-1075
06-1074
06-1076
06-1186
06-1186
06-1031
06-1077
06-1106
06-1006
06-1144
06-1145
06-1146
06-1032
06-1025
06-1094
06-1030
06-1147
06-1175
06-1005
06-1092
06-1062
06-1105
06-1027
06-1027
06-1101
06-1101
06-1101
06-1124
06-1065
06-1059
02-0300
06-1033
06-1004
06-1056
Alarm – High Grease (For Grease Waste Container)
Digital Timer with Control Box (Including Box Timer, Wiring & Light Indicator)
Disc Guides (Pair)
Disc with Hub (Models 15,20,25,25H,35)
Disc with Hub (Models 25L)
Disc with Hub (Models 50 – 800)
Dolly: Used with 5 gallon bucket
Dolly: Used with 55 gallon drum
Drive Shafts: (Models 15 up to 100)
Drive Shafts: (Models 150 up to 800)
Flow Control – Cast Iron
Gasket – Junction Box
Gasket – Lid (Models 15, 20 ,25 ,20)
Gasket – Lid (Models 35, 50, 75, 100)
Gasket – Lid (Models 150 – 800)
Gasket – Shaft Bracket
Gasket – Sump Bracket
Gearmotor – Direct Drive
Gearmotor – Chain Driven
Gearmotor Transistor
Grease Waste Container – (5 QT Pail with Lid for Model 15)
Grease Waste Container – (8 QT Pail with Lid for Models 20, 25)
Grease Waste Container – (5 Gallon Bucket with Lid for Models AGI 50 – 100)
Grease Waste Container – (55 Gallon Drum)
Green Indicator Light (Used in digital timer box)
Heating Element: (Model 15-50: 3500 Watt) Uses 1 Heater
Heating Element (Model 75-100: 3500 Watt) Uses 2 Heaters
Heating Element (Model 150-300: 4500 Watt) Uses 4 Heaters
Heating Element (Model 400, 600: 4500 Watt) Uses 6 Heaters
Heating Element (Model 800: 4500 Watt) Uses 8 Heaters
Heater – Mat (For collection tank)
Hold Downs (Pair) Stainless Steel
Junction Box
Label Kit (Includes all standard labels/stickers for AGIs)
Latches – Basket Clamps
Latches – Lid Clamps (AGI 15 – 30)
Latches – Compression (AGI 35 and up)
Automatic Grease Interceptor Accessories
Product
Codes
Description

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06-1051
06-1070
06-1071
06-1002
06-1072
06-1009
06-1087
06-1088
06-1089
06-1090
06-1148
06-1082
06-1034
06-1078
06-1079
06-1157
06-1125
06-1021
06-1035
06-1109
06-1103
06-1135
06-1029
06-1069
06-1099
06-1095
Scraper Bar Assembly: (Models 15-35)
Scraper Bar Assembly: (Models 50 -100)
Scraper Bar Assembly: (Models 150-800)
Scraper Blades with Nuts & Bolts: (Models 15 – 75)
Scraper Blades with Nuts & Bolts: (Models 100 – 800)
Screen Basket (Includes Lid): (Models 15, 20, 25, 25H)
Screen Basket (Includes Lid): (Models 25L)
Screen Basket (Includes Lid): (Models 35, 50, 75, 100)
Screen Basket (Includes Lid): (Models 150 – 600)
Screen Basket (Includes Lid): (Model 800)
Seal / Plug (Inside AGI Units)
Shaft Bearing – Nylon
Shaft Bracket Assembly: (Models 20, 25, 25H)
Shaft Bracket Assembly: (Models 25L, 35, 50, 75, 100)
Shaft Bracket Assembly: (Models 150 – 800)
Shaft Bracket Plate
Stand Coated Carbon Steel (Up to 36” high)
Stand – Stainless Steel (Up to 36” high)
Sumps (Models 150 & Up / Stainless Steel)
Sump Tube (Plastic)
Thermal Overload (Mounted in Timer Box)
Thermocouple
Thermostat with Bracket
Twist Lock Connectors
Vent Filter – Carbon (Used in 55 Gallon Drum)
Woodruff Key (For Direct Drive Shafts)
Automatic Grease Interceptor Accessories
Product
Codes
Description

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Disc replacement as follows:
1. Remove 3/16 inch stainless stud #15 from hub and slide shaft
out of tank about 2 inches.
2. Remove disc and replace with new disc.
Scraper blade replacement as follows:
1. Remove large lid.
2. Lift scraper blade assembly from tank
(#1 on Parts Diagram).
3. Remove 6-32 at head screws (#5) and scraper blade
hold downs (#4) to replace scraper blades (#3).
4. Straddle scraper blades over disc.
Keep scraper blades in proper position.
Disc Replacement
Scraper Blade
Replacement
IMPORTANT:

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