V4 – PA0016 ACO, 134-140 Old Bathurst Road, Emu Plains, NSW 2750

Tel: +61 2 4747 4000 | Fax: +61 2 4747 4029 | Email: sales@acoaus.com.au

ACO Passavant

Installation guide

LIPUMAX-G GREASE SEPARATOR

VERSION NO. IMPLEMENTED BY REVISION DATE REASON 1 Kate Jennings 29 September 2017 Amendments Water Corp

2 Kate Jennings 31 October 2017 Amendments Water Corp

3 Kate Jennings 19 March 2018 Product table update

4 Kate Jennings 12th April 2018 Ventilation requirement (Water Corp)

LIPUMAX-G GREASE SEPARATOR - Installation guide | Kate Jennings

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Contents

1 GENERAL .............................................................................................................................................. 3 2 SAFETY CONSIDERATIONS ......................................................................................................... 3 3 INSTALLATION ................................................................................................................................. 4 4 MAINTENANCE ................................................................................................................................ 12 5 WATER AUTHORITY APPROVALS ........................................................................................... 12 6 CONTACT INFORMATION ........................................................................................................... 12

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1 GENERAL

The ACO Passavant Lipumax-G grease separator is designed for below ground installation

only. Lipumax-G grease separators are designed to remove waste Fats, Oils and Grease

(FOG) from commercial tradewaste from applications such as commercial kitchens and

food processing factories. They are not anticipated for use in residential applications.

When discharging tradewaste into the public sewer system, local water authority

requirements must be adhered to.

2 SAFETY CONSIDERATIONS

All work in installing and maintaining this grease separator shall comply with

requirements of the relevant authorities.

2.1 Site handling

Inspect the Lipumax-G upon delivery and prior to installation, check for damage that

may have occurred during transportation or at the job site prior to installation.

Grease separators can be extremely large. To avoid damage to the grease separator,

ensure that correct equipment (e.g. forklift, crane or sling ropes) is available for proper

unloading and manoeuvring on site. Use lifting provisions (shown below).

Note: separators may require a 3 tonne excavator to dig the required depth.

2.2 Foreseeable misuse

No substances that pollute the water or limit the functionality of the grease separator

should be introduced into the grease separator. This is particularly important in regard

to:

Wastewater containing faeces

Wastewater containing light liquid oil (e.g. petrol)

Wastewater in which a considerable amount of stable emulsions is present (e.g.

dairy)

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Lipumax-G is not designed for waste oil to be tipped into it and macerators must not be

discharged into it. Note that only wastewater from specific fixtures from commercial

kitchen and food processing facilities should be connected to the grease separator.

Good work practices are vital to ensure the correct functioning of the grease separator.

Before plates and dishes are washed, they should be scraped of food scraps into a bin.

Waste oil must never be poured down the sink and it should be set aside and removed

by an appropriate disposal company.

2.3 Owners responsibilities

All work performed on the grease separator equipment is to be carried out by trained

and approved personnel, in accordance with local water authority regulations.

The owner is responsible for complying with the following points and must ensure that:

• The grease separator is in proper condition.

• Personnel are qualified and authorised to operate and maintain the grease

separator.

• Adequate personal safety equipment is used.

• The grease separator is operated according to relevant regulations.

• There is adherence to a scheduled maintenance program (as per individual

tradewaste agreement with the local water authority) and faults are repaired

immediately. Contact ACO for information on replacement parts.

• Complete and legible operating instructions are displayed at the grease

separator’s site of installation and training is provided for relevant personnel.

2.4 Workplace Health and Safety (WHS)

Safety instructions are intended to prevent damage to equipment or injury to personnel

and must be read before any maintenance is performed.

• All safety instruction labels must be replaced if they become detached or illegible

• Installed devices (e.g. baffles, inlets, outlets etc.) are not load bearing. They must

not be used as steps, footholds or resting places for cleaning equipment etc.

• Grease separators should be not be installed where a danger to health is possible

from the grease separator leaking, blocking or surcharging

3 INSTALLATION

The Lipumax-G grease separator must be installed in compliance with local water

authority regulations, Safe Work Australia and all other codes of practice. Prior to

installation, ensure that the local water authority approves each installation.

Sydney Water requirement Sydney Water requires a certificate of compliance from a licensed plumber when a grease separator is being installed.

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3.1 Sizing

The correct sizing and regular emptying of a grease separator is vital to its correct and

on-going functioning.

Refer to local water authority and council guidelines for sizing.

Icon Water and Water Corporation requirement A cap is required on top of each baffle (inlet and outlet) to prevent surcharge. Ensure each grease separator is installed with a baffle cap on the inlet and outlet baffle. Part no: 142103

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*To suit engineered slab details

ACO Passavant can be used in conjunction with a number of different pipe materials. The

most commonly used pipe materials are HDPE (High Density Polyethylene) and PVC (Poly

Vinyl Chloride). These pipe materials have various connection methods. The most

commonly used methods are detailed below.

a) HDPE pipe

HDPE pipe is commonly

used in applications where

the temperature of

discharging water is high.

There are three options

available for connecting the

ACO Passavant inlet and

outlet with HDPE pipe:

HDPE connector

(left)

Flexible coupling (middle)

Flex seal shielded coupling (right)

The HDPE connector (pictured left) allows the ACO Passavant inlet or outlet to be butt-

welded to the connector, and the other end of the connector is a push-fit connection to

the connecting HDPE pipe.

Flexible couplings are designed to fit two pipes of a similar outside diameter together.

The flexible connector (pictured middle) is placed over the inlet or outlet and over the

connecting HDPE pipe. The stainless steel hose clamps are tightened to achieve the seal.

Note: some authorities do not permit the use of flexible couplings in ground slabs.

Alternatively, a flex seal shielded coupling (pictured right) can be used. This coupling is

also a flexible coupling, but has a layer of stainless steel and is designed for below

ground applications. Check manufacturers’ approvals for use in ground slab applications

prior to use.

b) PVC pipe

PVC pipe is used in

projects where cost

requirements exceed the

importance of hygiene,

heat and corrosion

resistance.

To connect the ACO Passavant inlet or outlet to PVC pipe, a flexible coupling can be used

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(pictured left). The flexible connector is placed over the inlet/outlet and over the

connecting PVC pipe. The stainless steel hose clamps are tightened to achieve the seal.

Note: some authorities do not permit the use of flexible couplings in ground slabs.

Another option is a flex seal shielded coupling (pictured middle). This is also a flexible

coupling, but has a layer of stainless steel and is designed for below ground applications.

Ensure to check manufacturers’ approvals for use in ground slab applications prior to

use.

A slip coupling (pictured right) is another option for connecting PVC pipe below ground.

The inlet/outlet push-fits into one end of the slip coupling and the connecting PVC pipe

the other. This method can also be used in ground slabs.

Please note, couplings are not supplied by ACO.

3.2 Identification

The grease separator model and size can be identified on the inside lip of the separator.

3.3 Location

Ensure the location of the grease separator is positioned where a maintenance contractor

can easily access for pump out. If in doubt, contact a grease removal contractor and

obtain a written agreement that the grease separator is able to be serviced.

To minimise sedimentation in long runs, grease separators should be installed as close to

the source of the grease as possible. Due to hygiene, grease separators should not be

installed directly in the kitchen.

A hose tap fitted with a backflow prevention device must be located within 5 metres of

the grease separator for cleaning purposes (as per AS/NZS 3500).

3.3 Connecting pipes

Connecting pipes and pipe materials should be installed in accordance with AS/NZS 3500

and local plumbing codes. The grease separator has moulded outlet and inlet points,

marked respectively.

A calming region of 10 metres of straight pipe upstream is recommended of the inlet to

reduce turbulent wastewater from entering the grease separator and disrupting

separation. Any angled pipes to the inlet should not exceed 45°.

Adequate backflow prevention must be in place.

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3.4 Sampling

To test the quality of the influent and effluent, some water authorities have a

requirement for a Trade Waste Sampling Point (TWSP) to be installed at the outlet of the

grease separator to test the quality of effluent.

Pipework must be a minimum DN100.

3.5 Disconnector Gully

Disconnector gullies shall be installed where required in accordance to the local water

authority. Refer to AS/NZS 3500 part 2 for typical detail.

3.6 Ventilation

Grease separators should be adequately ventilated using the marked vent connection in

accordance with Australian Standards and local building and plumbing codes.

To fit the vent, remove the cap. Fasten the vent pipe (minimum DN100).

Water Corporation requirement Refer to section 3.4.

Water Corporation requirement Refer to Information Sheet 23B.

Water Corporation requirement Refer to drawing HX33-11-30 for precise construction requirements for Trade Waste Sampling Point (TWSP).

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The high level vent on the inlet line must terminate above the roofline and the vent from

the outlet shall be installed to AS/NZS 3500.

3.7 Site works

Excavation should comply with Work Health and Safety (WHS) regulations and Safe Work

Australia.

Excavate to the required depth, allowing for the separator depth and an additional

300mm. Concrete is to be used to bed the separator. The separator bed must be applied

on to a well compacted foundation.

The width of excavation should be sufficient for the compactor to access. Ensure the

angle of excavation is suitable for the soil type. Backfill with compacted sand and gravel

or non-binding soil in 300mm layers.

3.8 Load class, cover and collar/load distribution plate installation

Each Lipumax-G separator requires a gas and water tight access cover (complaint to AS

3996) to close the system and offer access for maintenance purposes. A range of Class

B and Class D covers are available.

Class B covers are supplied with a reinforced concrete collar.

For Class D applications, there is a fully engineered solution including: Class D cover and

reinforced collar, load distribution plate and raising tube. An alternative, for use in a

structural slab where the load is distributed through the slab, is to purchase a Class D

cover and reinforced collar only. Refer to engineers detail for design preference.

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Note: Lipumax-P pictured

When installed, the tops of the cover and collar assembly should be flush with the

finished surface level.

A load distribution plate is available separately and with Class D assembled solutions,

where a structural slab is not present, to distribute load. A load distribution plate can

also be used for Class B applications where buoyancy is a concern in high water tables. If

in doubt, seek specific engineering advice.

An optional riser tube can be ordered (part no. 142350) to achieve a greater depth in

installation and comes with Class D assembled solutions. For Class B installations, the

minimum height the riser tube adds is 367mm and maximum height 607mm. For Class D

installations, the minimum height the riser tube adds is 170mm and maximum height

411mm.

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When the raising tube is used in conjunction with a load distribuion plate, the rebate

must be cut to off the top of the raising tube (prior to installation) using the groove

provided and a saw, as per the diagrams below.

To achieve a variable height, the riser tube can be cut.The riser tube uses two o-rings: a

retaining ring to prevent the raising tube sliding into the separator and a sealing ring to

seal between the separator and riser to stop odours escaping.

Prepare shaft by cutting it to the required height and fitting the sealing ring (supplied)

and position the retaining ring one notch above to bring the riser to the desired height.

To ensure water tightness, apply acid free grease to the seal and collar seating. Before

installing the concrete collar and cover, ensure the riser tube has been backfilled.

For downloadable installation details, visit www.acopassavant.com.au.

3.9 Start-up

Before using the grease separator for the first time, fill with clean water.

Retaining ring

Sealing ring

L1

Ø 836

L2

Ø 836

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4 MAINTENANCE

4.1 Disposal and cleaning

The cleaning interval must be agreed with the local water authority and in compliance

with AS 4494. A proper disposal and cleaning procedure is critical to the ongoing efficient

function of the grease separator.

Before disposal and cleaning, kitchen operation must stop. The entire contents of the

grease separator should be removed by a disposal truck with a suction hose through the

maintenance openings. Once emptied, the tank must be cleaned manually using a

hose/high pressure hose to completely remove residual FOG from the walls of the grease

separator. Scraping may also be required to achieve this. The cleaning water must be

completely removed from the grease separator. Finally, the grease separator must be

refilled at least two thirds of the entire volume with hosepipe from an on-site water

supply.

4.2 General inspection

4.2 General inspection

A general inspection should be carried out regularly by qualified personnel, including a

visual check of the grease separator and its connections. If any defects are found, they

must be remedied without delay (refer to 2.3).

5 WATER AUTHORITY APPROVALS

Please refer to www.acopassavant.com.au/approvals for a list of the approved ACO

grease separator water authority approvals.

6 CONTACT INFORMATION

For queries, servicing assistance and spare parts, contact ACO.

ACO Pty Ltd

134-140 Old Bathurst Road

Emu Plains

NSW 2750

Australia

e: sales@acoaus.com.au p: +61 2 4747 4000

_______________________________________________________________________

Original manufacturer document ACO Haustechnik HT 869 subject number 3300.11.50.

Water Corp requirement Only camlock fittings are to be used for pump out line and no fixed suction is to be installed.