Hydrotech HSF2200 Series Manual

Discfilter HSF2200 - 1/2C - PFC
Operation and maintenance manual
Revised: 2019-06-26

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
LIST OF CONTENTS
1. INTRODUCTION 5
2. SAFETY INSTRUCTIONS 6
2.1 Warning symbols 6
2.2 CE marking 6
2.3 Conversion 6
2.4 Personnel requirements 7
2.5 Emergency stop 7
2.6 Electrical safety 7
2.7 Safety instructions 7
3. HYDROTECH DISCFILTER HSF2200 SERIES 9
3.1 Reception 9
3.2 Storage 9
3.3 Overview 10
3.3.1 HSF2200 type 1, filter with tank 10
3.3.2 HSF2200 type 2, filter without tank 11
3.4 Identifying the filter 13
3.4.1 Definition of filter type 13
4. GENERAL INSTALLATION INSTRUCTIONS 14
4.1 Liing the equipment 14
4.2 Installation site 16
I.1.1 Outdoor installation 16
I.1.2 Foundations 16
4.3 Electrical connection 16

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
4.4 Equipotential bonding 16
4.5 Checking drum rotation 17
4.6 Pipe connections 17
5. START UP AND OPERATION 18
5.1 Check procedures during start-up 18
5.2 Automatic seings 19
5.2.1 Level dierences 21
5.2.2 Operating mode HAND – Continuous rotation/backwash 21
5.2.3 Operating mode AUTO – Automatic level control 21
5.2.4 Adjusting the level sensor 21
5.2.5 Seing of level relay 22
5.3 Backwash system 22
6. FUNCTION 23
6.1 Intended use 23
6.2 Non-intended use 23
6.3 Filtration and backwash process 23
7. MAINTENANCE/SERVICE 24
7.1 Backwash system 24
7.1.1 Servicing nozzles 24
7.1.2 Self-cleaning nozzle 25
7.2 Bearings 26
7.2.1 Lubrication of swivel 26
7.2.2 Lubricating drum bearings 27
7.2.3 Drum lier 28
7.3 Filter panels 29

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
7.3.1 High pressure cleaning 29
7.3.2 Chemical cleaning of filter panels 29
7.3.3 Changing filter panels 31
7.4 Drive chain 33
7.4.1 Checking the drive chain 33
7.4.2 Adjusting drive chain tension 34
7.4.3 Replacing the drive chain 34
7.5 Drive unit 34
7.6 Inlet gasket 35
7.6.1 Checking the inlet gasket 35
7.6.2 Replacing the inlet gasket 35
8. MAINTENANCE SCHEDULE 36
Symbols used on Hydrotech filters 37
Manuals & technical information 38

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
1. INTRODUCTION
This manual contains instructions for the operation and maintenance of Hydrotech Discfilter in
the HSF2200 series.
Pay attention to all warning symbols that appear in this manual. If this information is ignored it
may result in serious personal injury and/or damage to equipment.
The manual must always be available to personnel working with the equipment.
It is important that:
⊲The manual and other applicable documents must be kept for the entire duration of the-
nequipment’s lifespan. The manual and other relevant documents are included as part of the
equipment.
⊲All relevant personnel must read the manuals carefully.

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
2. SAFETY INSTRUCTIONS
Hydrotech Discfilters in the HSF2200 series are designed for safe operation provided that they
are installed correctly and used in accordance with the enclosed instructions. The equipment
must be installed correctly and adapted in accordance with local regulations. This equipment is
designed for use by one or more operators. You must read the relevant sections of this manual
before using the equipment or carrying out maintenance work.
⊲Pay attention to all warning symbols that appear in this manual. If this information is ignored
it may result in serious personal injury and/or damage to equipment.
⊲Assume all electrical equipment to be live.
⊲Assume all hoses and pipes to be pressurised.
⊲Before carrying out maintenance work, the main power switch (see Figure 2.3) must be turned
to the OFF (0) position and locked with a padlock.
⊲Maintenance and service may only be performed by authorised personnel.
⊲ Adequate lighting should be used when operating the filter and when working in close prox-
imity to the filter.
2.1 Warning symbols
Warning symbols are used in this manual to draw attention to potentially dangerous situations:
Information that warns you of a potential risk of personal injury and/or damage to equipment.
Warning stickers (see Figure 2.1) are affixed to the filter to warn personnel and act as reminders
to keep hands and fingers away from the filter’s moving parts.
2.2 CE marking
This equipment is CE marked (see Figure 2.2), which guarantees that the equipment is designed,
manufactured and described in accordance with the requirements set out in the EU Machinery
Directive.
2.3 Conversion
The CE marking does not extend to any components that are not approved by Hydrotech AB and
that are used in conversion/reconstruction of the equipment. The warning symbols and CE mar-
king must be attached in such a way that they are fully visible. If any part of the equipment with
a warning symbol is replaced, a new symbol must be attached in the same position. Damaged
symbols and CE markings must be replaced immediately.
Figure 1 Figure 2.1
Figure 2.2

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
2.4 Personnel requirements
In order to avoid personal injury and damage to the
equipment, service and maintenance may only be car-
ried out by personnel that have been trained to use the
equipment and are conversant in local regulations. Ser-
vice and maintenance personnel may only handle tho-
se parts of the equipment they have been trained for.
The operator may need to work inside the safety barrier
and in the safety zone during maintenance and set-up
before operation.
2.5 Emergency stop
The filter is equipped with a main power switch (see Fi-
gure 2.3).
To perform an emergency stop, turn the main power
switch to the OFF (0) position.
In the event of a power failure, turn the main power
switch to the OFF (0) position to prevent the filter drum from unintentionally starting to rotate
when the power is reconnected.
2.6 Electrical safety
Electrical installation must be carried out by a qualified electrician and in accordance with local
regulations. Also see Appendix D.
The filter tank or the frame must be connected to ground. Also see section 4.4.
The main power switch/emergency stop must be fitted in accordance with applicable regula-
tions.
2.7 Safety instructions
The filter is activated by turning the main power switch to the ON (1) position and then selecting
HAND or AUTO with the mode selector on the front of the control cabinet. The filter stops if the
mode selector is turned to the 0 (OFF) position.
NB See instructions in section 5.1.
Turn the main power switch to the OFF (0) position and lock it with a padlock before perfor-
ming any work on the filter.
Figure 2.3
A. Pump OFF (0) position
B. Pump ON (1) position
C. Pump switch
D. Mode (0) position
E. Mode (AUTO) position
F. Mode (HAND) position
G. Mode selection switch
H. Main power switch (ON (1) / OFF(0))

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
Access to the filter by unauthorised persons is strictly prohibited. Outdoor installations must
be fenced in.
The drum can start rotating without warning if automatic control is activated. Moving parts
must not be touched.
Safety guards are fitted around the power transmission. Make sure these are secured and cor-
rectly fitted.
The aerosols from the backwash water may contain harmful substances.
Measured noise levels from the filter are less than 74 dB (A). Personnel should use appropriate
protection, when necessary, in accordance with local regulations.

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
3. HYDROTECH DISCFILTER HSF2200 SERIES
3.1 Reception
Once the equipment has been delivered and received it must be checked for transport damage.
Document any transport damage before further handling of the equipment.
The consignment note, manual and spare part kit are attached to the equipment.
Check all parts against the consignment note. Some parts may be delivered unassembled. Hand-
le fragile parts with care. Before lifting the equipment, see section 4.1.
3.2 Storage
Some precautions must be taken to prevent damage to equipment if a long storage time is ne-
cessary (several weeks or more):
⊲The equipment should preferably be stored indoors, in a frost-free area.
⊲The filter must be protected against direct sunlight if stored outdoors. Heat and UV radiation
can damage the filter panels.
⊲If the filters are delivered inside plastic covered wooden crates, a special type of corrosion can
occur if stored outdoors, especially in coastal areas. The moisture inside the plastic acts as an
anode and the exposed dry components as a cathode. In these areas, the filters must therefore
be unpacked immediately upon delivery.

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
3.3 Overview
3.3.1 HSF2200 type 1, filter with tank
NB Also see section 3.3.2 (HSF2200 type 2, filter without tank) where several filter parts are shown.
Figure 3.1 Hydrotech Discfilter in HSF2200 series type 1F (side view).
A. Connection side
B. Filter cover
C. Drive side
Figure 3.2 Hydrotech Discfilter in HSF2200 series type 1C (inlet side).
A. Connection, chemical cleaning
B. Backwash ramp lever
C. Lubrication point
D. Sludge outlet
E. Inlet
F. Outlet
G. Outlet, separate emergency
overflow (bypass) (optional)

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
A. Backwash pump
B. Electrical connection
box
C. Shut off valve for
backwash pipe
D. Pressure switch, dry
running protection for
pump (optional)
E. Manometer
F. Lubrication points
G. Drive unit
H. Insulation valve for
pump
I. Drain (tank)
Figure 3.3 Hydrotech Discfilter in HSF2200 series type 1C (drive side).
A.Inlet side
B. Inlet passage
C. Filter cover
D. Drive side
3.3.2 HSF2200 type 2, filter without tank
Figure 3.4 Hydrotech Discfilter in HSF2200 series type 2C (side view).

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
A. Connection, chemical cleaning
B. Backwash ramp lever
C. Support wheel, lubrication
points
D. Sludge outlet
E. Inlet
F. Filter panel
G. Sludge trough
Figure 3.5 Hydrotech Discfilter in HSF2200 series type 2C (inlet side).
Figure 3.6 Hydrotech Discfilter in HSF2200 series type 2C (drive side).
A. Manometer
B. Pressure switch (dry running
protection for pump) (optional)
C. Backwash pump (optional)
D. Drive unit
E. Lubrication point
F. Drive chain
G. Drum bearings
H. Filter drum

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
3.4 Identifying the filter
Filter type, serial number and year of manufacture are stated on the marking plate. The filter
type and serial number are also stated on the front of this manual.
Figure 3.7 Filter marking plate.
3.4.1 Definition of filter type
Figure 3.8 Definition of filter type

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
4. GENERAL INSTALLATION INSTRUCTIONS
4.1 Liing the equipment
⊲A forklift truck with long forks must be used when lifting filters in wooden crates.
⊲Filters with a tank can be lifted using a crane or overhead crane by using the filter’s lifting lugs,
or with a forklift truck.
WARNING! The work area must be fenced off before unloading, in accordance with local
regulations, to prevent unauthorised access.
Figur 4.1 Lyft av Hydrotech Discfilter i HSF2200-serien typ 1 (med tank,).

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
⊲Filters without a tank can be lifted using a crane or overhead crane by using the filter’s lifting
lugs.
Figure 4.2 Shows how lifting devices are attached (filter without tank).
Figure 4.3 Lifting Hydrotech Discfilter in HSF2200 series type 2 (without tank).

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
4.2 Installation site
I.1.1 Outdoor installation
In the event of outdoor installation it is important to protect the filter panels against direct sun-
light, as heat and UV radiation otherwise can cause damage to the filter panels.
The equipment must be protected against temperatures below freezing point. At water tempe-
ratures above +5 °C and air temperatures above -10 °C the filter cover provides sufficient protec-
tion. At lower water and air temperatures, filter installation should be indoors.
I.1.2 Foundations
⊲The filter must be installed on a flat surface
that offers sufficient load bearing capacity.
⊲The filter is to be bolted to the foundation.
⊲The filter must be level in both directions
(see figure 4.4).
⊲600 mm wide aisles should be laid out
around the filter to permit easy access to the
filter during service work.
⊲The gap between the filter and the concre-
te structure must be sealed for safety reasons
and to keep out foreign objects that can cause
blockages in the backwash system.
4.3 Electrical connection
Qualified electricians must perform all
electrical work.
Electrical connection must be done in accordance with local regulations. Check that the settings
on the motor protection correspond with the motor data.
Section 4.5 must be read before starting the filter’s drum rotation.
4.4 Equipotential bonding
The Hydrotech Discfilter and associated equipment should be protected with a suitable system
for equipotential bonding. This is very important to prevent galvanic corrosion. Ideally use a ca-
ble with a cross section of 10-16 mm2. The cable should be connected to the same electrical po-
tential as the drive system.
Figur 4.4 Installation av filter

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
4.5 Checking drum rotation
Start drum rotation and check that the drum rotates in the same direction as the rotation arrow
on the drive unit cover.
4.6 Pipe connections
Piping for reject should have a minimum inclination of 1%.

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
5. START UP AND OPERATION
5.1 Check procedures during start-up
1. Check that the drive unit cover is installed correctly.
2. Turn the pump switch to the OFF (0) position (see F in Figure 5.1).
3. Set the main power switch to the ON (1) position (see J in Figure 5.1).
4. Set the mode selector to the HAND position (see E in Figure 5.1).
5. Open the water supply partially so that water slowly flows into the filter drum. Make sure that
the difference in water level between the inside and outside of the filter drum does not exceed
550 mm (see section 5.2.1).
If the filter cloth becomes clogged, it may be necessary to fill the filter tank/chamber with water
from an external source or to remove a filter panel and fill the filter tank/chamber with unfilte-
red water.
WARNING! A difference in water level between the inside and outside of the filter drum
greater than 550 mm will damage the filter.
6. When the water level inside the filter tank/chamber reaches the pump suction pipe (or the
pump if a CRK or MTR pump is installed), the pump switch must be set to 1 (ON) position. NB Also
read section 2.7.
WARNING! The backwash pump must not be started until the water level has reached the
suction pipe (or pump if a CRK or MTR pump is installed), otherwise the pump will run dry
and fail.
7. When the water level inside the filter tank/chamber reaches the overflow wall, the mode se-
lector switch should be turned to AUTO mode.
8. Open the water supply fully. The filter is now run in the mode for automatic level control. It
may be necessary to adjust the level sensor so that the filter can be run optimally (see section
5.2.4).

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
5.2 Automatic seings
The control system for the HSF2200 series must be equipped with a frequency converter on the
drive unit. This is factory calibrated if delivered from Hydrotech. The setting on the frequency
converter must be set for a minimum of 5 seconds “ramp up” and a minimum of 3 seconds “ramp
down” to give soft start on the drive motor. The filter works with 50 Hz as standard.
If the filter is equipped with a Hydrotech control system, the filter has two operation modes:
1. Continuous rotation (HAND mode)
2. Automatic level control (AUTO mode).
Turn the mode selector to select the operating mode (see E in Figure 5.1).
A. DRUM DRIVE TRIPPED. LED that indicates
when the frequency converter has tripped.
B. PUMP TRIPPED. LED that indicates when the
backwash water pump´s motor protection
device has tripped,
C. DRY RUNNING. LED that indicates when the
dry running protection device for the back-
wash water pump has tripped.
D. RESET DRY RUNNING. Resetting the dry run-
ning protection for the backwash water pump.
E. OPERATION MODE. Mode selector.
F. PUMP. Pump switch.
G. CLEANING START. Chemical wash swich, key
operated.
H. CLEANING. LED that indicates when the
chemical cleaning wash is in progress.
I. CLEANING SEQUENCE. Selector for the num-
ber of sequences, chemical cleaning.
J. Main power switch.
Figure 5.1 Front of the control cabinet.

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Operation and maintenance manual, Discfilter HSF2200-1/2F PFC
A. Motor protection
switch, pump.
B. Motor protection
switch, drive unit.
C. Fuse.
D. Fuse.
E. Transformer.
F. Contactor.
G. Relays.
H. Logic module.
I. Level relay.
J. Soft start.
K. Frequency converter.
L. Terminal block.
M. Main power switch.
Figure 5.2 Component parts of the Hydrotech control cabinet.