Hydrotech HSF2600 Series User manual

Discfilter HSF 26 - 1F series PFLC
Operation and maintenance manual
Revised:2018-05-23

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
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 Demands on personnel 7
2.5 Emergency stop 7
2.6 Electrical safety 7
2.7 Safety instructions 7
3. HYDROTECH DISCFILTER HSF2600-1F 9
3.1 Reception 9
3.2 Storage 9
3.3 Overview 10
3.4 Identifying the filter 13
4. GENERAL INSTALLATION INSTRUCTIONS 14
4.1 Liing the equipment 14
4.2 Installation site 15
4.2.1 Outdoor installation 15
4.2.2 Foundations 15
4.3 Electrical connection 15
4.4 Equipotential bonding 15
4.5 Checking the drum rotation and backwash pipe 16
4.6 Pipe connections 16

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
5. START UP AND OPERATION 17
5.1 Check procedures during start-up 17
5.2 Automatic seings 18
5.2.1 Level dierences 19
5.2.2 Operating mode AUTO – Automatic level control 19
5.2.3 Operating mode REMOTE – Remote control 19
5.2.4 Service mode HAND 19
5.3 Backwash system 20
6. FUNCTION 21
6.1 Intended use 21
6.2 Non-approved use 21
6.3 Filtration and backwash process 21
7. MAINTENANCE/SERVICE 23
7.1 Filter cover 23
7.1.1 Hinge 23
7.1.2 Operating the filter cover 24
7.2 Extend the backwash pipe 25
7.3 Backwash system 25
7.3.1 Servicing nozzles 25
7.4 Backwash pipe position 28
7.4.1 Checking backwash pipe position 28
7.4.2 Checking backwash pipe position 29
7.5 Cleaning the backwash water filter 30
7.6 Bearings 31
7.6.1 Lubrication of swivel 31

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
7.6.2 Lubricating drum bearings 31
7.6.3 Checking drum bearing wear 32
7.7 Filter panels 33
7.7.1 High pressure cleaning 33
7.7.2 Chemical cleaning of filter panels 34
7.7.3 Changing filter panels 36
7.8 Drive chain 38
7.8.1 Checking the drive chain 38
7.8.2 Adjusting drive chain tension 39
7.8.3 Replacing the drive chain 39
7.9 Drive unit 40
7.10 Inlet seal 40
7.10.1 Checking inlet seal 40
7.10.2 Replacing the inlet seal 40
8. MAINTENANCE SCHEDULE 41
Symbols used on Hydrotech filters 42
Manuals & technical information 43

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
1. INTRODUCTION
This manual contains instructions for the operation of Hydrotech Discfilter in the HSF2600 se-
ries, type 1F (tank filter).
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 the personnel working with the equipment.
It is important that:
⊲The manual and other relevant documents are kept throughout the life of the equipment. The
manual and other relevant documents are a part of the equipment.
The following documents (manuals) are a part of the equipment:
▹Operation & Maintenance Manual
▹Automation manual
⊲All applicable personnel must read the manuals carefully.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
2. SAFETY INSTRUCTIONS
Hydrotech Discfilters in the HSF2600 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. The machine equipment
is intended for use by multiple operators. You must read the applicable chapters in this manual
prior to using the equipment or performing maintenance.
⊲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 pressurized.
⊲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 while 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 equip-
ment.
Warning decals (see Figure 2.1) are attached to the filter to warn personnel and serve as a remin-
der to keep hands and fingers away from moving parts of the filter.
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 include any components that are not approved by Hydrotech AB and
which are used in conversion/reconstruction of the equipment.
The warning symbols and CE marking must be attached where they are fully visible. If any part of
Figur 2.1
Figur 2.2

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
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.
2.4 Demands on personnel
Only personnel trained for the equipment and conversant with local regulations may perform
service and maintenance, in order to avoid personal injury and damage to the equipment. Ser-
vice and maintenance personnel may only handle those parts of the equipment they have been
trained for.
The operator may need to work inside the safe-
ty barrier and in the safety zone during mainte-
nance and set-up before operation.
2.5 Emergency stop
The filter is equipped with an emergency stop
and a main switch (see the markings in Figure
2.3).
In the event of a power outage, turn the main
switch to the OFF position (0) to prevent the
filter drum from unintentionally starting when
the power returns.
2.6 Electrical safety
Electrical installation must be carried out by
a qualified electrician and in accordance with
local regulations. Also see Appendix A in the
“Automation manual”.
The filter tank must be connected to earth.
The main power switch/emergency switch 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 position (1), then selecting
AUTO, REMOTE or HAND mode using the operating mode selector located on the front of the
electrical cabinet.
NOTE! See instructions in section 5.1.
Turn the main power switch to the OFF (0) position and lock it with a padlock before per-
Figur 2.3 Elskåp
A. Driftlägesomkopplare
B. Huvudbrytare
C. Nödstopp

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
forming any work on the filter.
Access to the filter by unauthorized persons is strictly prohibited. Outdoor installations
must be fenced in.
The filter 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 & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
3. HYDROTECH DISCFILTER HSF2600-1F
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 panel and the control panel touch screen.
⊲If the filters are delivered inside plastic covered wooden crates, a special type of corrosion may
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, filters must therefore be
unpacked immediately upon delivery.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
3.3 Overview
Figure 3.1 Hydrotech Discfilter in HSF2200 series type 1F (side view).
A. Inlet side
B. Filter cover
C. Outlet side
Figure 3.2 Hydrotech Discflter in HSF2600 series type 1F (from inlet side).
D. Actuator for opening cover
E. Actuator for backwash system servicing
F. Connection, chemical cleaning
G. Lubrication point
H. Inlet
I. Sludge outlet
J. Sludge trough
K. Drum bearing, inlet side
L. Outlet, separate emergency overflow (bypass) (option)

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
Figure 3.3 Hydrotech Discflter in HSF2600 series type 1F (from outlet side).
A. Bypass valve for nozzle check
B. Manometer
C. Shut off valve for wash pipe
D. Pressostat - dry run protector for pump
E. Backwash water filter
F. Actuator for opening cover
G. Junction box
H. Drive unit
I. Backwash pump
J. Lubrication point
K. Outlet
L. Drain (tank)
Figure 3.4 Hydrotech Discfilter in HSF2600 series type 1F from outlet side with a chequered plate and a cover plate
removed.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
Figure 3.5 Hydrotech Discfilter in HSF2600 series type 1F with a chequered plate removed on the inlet side and a trans-
parent side plate. The level sensor behind the transparent side plate will be available once you lift the cover on the
backwash pipe side.
Two drum lifters are supplied unassembled for each installation, see Figure 3.6. These are only
used when servicing drum bearings. The supplier should be contacted when servicing bearings.
Figure 3.6 Drum lifter.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
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.
Definition of filter designation:
Figure 3.7 Filter marking plate.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
4. GENERAL INSTALLATION INSTRUCTIONS
4.1 Liing the equipment
When lifting the tank, we recommend that you use the four lifting points on the tank, the place-
ment of which is shown in Figure 4.1. The greatest permitted lifting angle is shown in Figure 4.2.
Figure 4.1 Placement of lifting points.
Figure 4.2 Largest permitted angle when lifting.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
4.2 Installation site
4.2.1 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 can otherwise cause damage to the filter panels. The same applies
to the control panel touch screen.
The filter must be protected against frost. The filter cover provides sufficient protection at water
temperatures above +5 °C and air temperatures above -10 °C. At lower water and air temperatu-
res, the filter installation must be carried out indoors.
4.2.2 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 4.3).
⊲600 mm wide aisles should be placed
around the filter to permit easy access to the
filter during servicing.
⊲For reasons of safety, the space between the
filter and the concrete structure must be cove-
red.
4.3 Electrical connection
Qualified electricians must perform all
electrical work.
Electrical connection must be done in accor-
dance 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-
Figur 4.3 Filterinstallation.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
ble with a cross section of 10-16 mm2. The cable should be connected to the same electrical po-
tential as the drive system.
4.5 Checking the drum rotation and backwash pipe
Start up after electrical connection may only be carried out with a completely extended
backwash pipe.
1. Before starting the filter drum rotation, the backwash pipe should be extended as set out in
section 6.2.
2. Start drum rotation and check that the drum rotates in the same direction as the rotation ar-
row on the drive unit cover, see Figure 4.4.
3. Reset the backwash pipe to operating mode.
4. Start drum rotation.
5. If necessary, check and adjust the height of the backwash pipe above the drum as set out in
section 7.4.
4.6 Pipe connections
Piping for reject should have a minimum inclination of 1%
Figure 4.4 Rotation arrow on the drive unit.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
5. START UP AND OPERATION
5.1 Check procedures during start-up
1. Check that the drive unit cover is installed correctly.
2. Set the mode selector to the HAND position (see F in Figure 5.2)
3. Set the main power switch to the ON (1) position (see I in Figure 5.2)
4. Start drum rotation on the operator panel
main menu (see Figure 5.1 and Figure 5.2).
5. Open the water supply a little so that the
water can slowly run into the filter drum. Make
sure that the difference in water level between
the inside and outside of the filter drum does
not exceed 450 mm (see section 5.2.1). If the fil-
ter cloth becomes clogged, it may be necessary
to fill the filter tank with water from an exter-
nal source or to remove a filter panel and allow
unfiltered water to fill up the filter tank.
6. When the water level inside the filter tank exceed the pump suction pipe (or, if a CRK or MTR
pump has been installed, the pump), the pump must be started by pressing “Start” on the ope-
rator panel main menu (see Figure 5.1). NB Also read section 2.7.
7. When the water level inside the filter tank reaches the overflow wall, set the mode selector to
either REMOTE or AUTO (see section 5.2).
8. Open the water supply fully.
If the filter is operated using automatic level control, it may be necessary to calibrate the level
sensor in order for the filter to be run optimally (see “Automation manual HSF2600”).
Figure 5.1 Main menu on electrical cabinet operator panel.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
5.2 Automatic seings
The control system for the HSF2600 series must always be equipped with a frequency converter
for the drive unit. This is factory calibrated if delivered from Hydrotech. To perform a soft start of
the drive motor, the frequency converter settings must be min. 5 sec “ramp up” and min. 3 sec
“ramp down”. The filter works with 50 Hz as standard.
If the filter is equipped with a Hydrotech standard control, the filter has three operating modes:
1. Automatic level control (AUTO mode).
2. Remote control (REMOTE mode).
3. Service mode (HAND mode).
Turn the mode selector to select the appropriate operating mode (see Figure 5.2, detail F).
Figure 5.2 Front side of electrical cabinet.
A. Operator panel
B. Warning lamp: Fault indicator
C. Warning lamp: Chemical cleaning
D. Indicator lamp: Drum operation
E. Indicator lamp: Pump operation
F. Mode selector (Auto/Hand/Remote)
G. Main power switch
H. Emergency stop
I. Reset button following emergency stop

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
5.2.1 Level dierences
The maximum permitted difference between
the water levels inside and outside of the drum
is 250 mm during normal operation (see figure
5.3). The recommended level difference is 100-
200 mm.
If an even flow after the filter is required, the
filter must be run with a small level difference.
The filter must be installed so that the
level difference in the event of opera-
ting disturbances under no circumstan-
ces exceeds 450 mm.
The filter shall be operated so that the level difference during normal operation does not
exceed 250mm.
Prolonged operation with a greater level difference will significantly shorten the life of the
filter panels and other vital parts.
5.2.2 Operating mode AUTO – Automatic level control
With automatic level control, drum rotation and the backwash pump are activated once the le-
vel difference between filtered and unfiltered water exceeds an adjustable value. The filter is
force-started if the filter has stood still for an extended period of time. If an external wash water
supply is used, the level sensor can control a solenoid valve instead of a pump.
The water level inside the drum will vary when AUTO mode has been selected. The water le-
vel is at its lowest immediately after a backwash cycle, and then rises until the level difference
between filtered and unfiltered water becomes too high.
5.2.3 Operating mode REMOTE – Remote control
In REMOTE operating mode, the filter can be controlled remotely. In remote control mode, the
filter can either be controlled as if in AUTO operating mode or using an external controller, see
the “Automation manual”.
5.2.4 Service mode HAND
HAND is only a service mode.
In order to operate the filter in HAND mode, the following steps must be implemented:
1. Turn the mode selector shown in Figure 5.2 to the HAND position.
Figure 5.3 Maximum permitted level difference during level
controlled operation.

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Operation & maintenance manual, Discfilter HSF2600 - 1F series with PFLC
2. Once the mode selector has been turned to
HAND, “HAND” will be shown in the opera-
tor panel main menu, see Figure 5.4. Press the
drum “Start” button - see Figure 5.4.
3. Press the pump “Start” button - see Figure
5.4.
The operator panel main menu also shows the
water levels of unfiltered (In) and filtered water
(Out), as well as the level difference between
them (Level Diff).
5.3 Backwash system
NOTE! Prior to servicing, read section 2.7.
The system pressure for backwashing must be set to 7-9 bar.
Newly connected pipe systems for external backwash water should be rinsed through before
they are connected to the filter. Thoroughly check that the nozzles are not blocked, see section
7.3.
Figure 5.4 Main menu on electrical cabinet operator panel.