Hydrotech HSF31 Series User manual
Discfilter
HSF31-series
Operation and
Maintenance Manual
Revised: 07-12-21 EN
TYPE: 2H, 2F, 2H, 2F
SERIAL NO: ....................................
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
Contents
1.1 Safety alert symbols ...................................................................5
1.2 CE Marking ................................................................................5
1.3 Redesigned equipment ..............................................................5
1.4 Personnel requirements .............................................................5
1.5 Emergency shutdown .................................................................6
1.6 Electrical safety...........................................................................6
1.7 Safety instructions ......................................................................6
2.1 Overview .....................................................................................7
2.2 Identication of the lter ..............................................................8
3.1 Receiving ....................................................................................9
3.2 Storage .......................................................................................9
3.3 Lifting ..........................................................................................9
4.1 Installation site ..........................................................................10
4.1.1 Outdoor installation ..........................................................10
4.1.2 Foundation .......................................................................10
4.2 Emergency by-pass ..................................................................10
4.3 Electrical connection .................................................................10
4.4 Equipotential Earth Bonding .....................................................10
4.5 Pipe connections ...................................................................... 11
4.6 Backwash system ..................................................................... 11
5.1 Start-up procedure ....................................................................12
5.2 Control settings .........................................................................13
5.2.1 HAND mode – continuous rotation ..................................14
5.2.2 AUTO mode – automatic level control .............................14
5.2.3 Adjusting the level sensor ................................................15
5.2.4 Setting the time relay .......................................................15
5.2.5 Setting the level relay .......................................................15
5.3 Backwash system .....................................................................15
5.4 Drum rotation ............................................................................15
5.5 Re-tightening of bolts ................................................................15
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
6.1 Intended use .............................................................................16
6.2 Non-foreseen use .....................................................................16
6.3 Filtration and backwash process ..............................................16
7.1 Backwash system .....................................................................17
7.1.1 Removing and cleaning the spray nozzles ......................17
7.1.2 Checking the spray nozzles for wear ...............................18
7.2 Bearings....................................................................................19
7.2.1 Lubrication .......................................................................19
7.3 Filter panels ..............................................................................20
7.3.1 Change the lter panels ...................................................21
7.4 Drive chain ................................................................................22
7.4.4 Check the drive chain for wear ........................................22
7.5 Gear motor................................................................................22
7.6 Rubber sealing..........................................................................22
7.7 Backwash strainer ....................................................................22
7.8 Maintenance schedule ..............................................................23
. Technical specications
. Spare parts list
Dimensional drawing
Circuit diagram for control system (optional)
Control cabinet component list (optional)
The gear motor
Backwash Strainer (optional)
Backwash pump (optional)
Frequency converter
4
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
This manual comprises instructions for operation and maintenance of
Hydrotech Disclter HSF31-series.
The manual should always be available to the personnel who work with the
equipment.
It is important that:
The manual and other applicable documents are preserved during the
whole life span of the equipment. The manual and other applicable
documents constitute a part of the equipment.
This manual is carefully studied by all users of the equipment, and always
kept at hand for future reference
5
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
Hydrotech Disclter HSF31-series are designed for safe operation when
properly in-stalled and used according to the enclosed instructions. The
equipment must be properly installed and adapted according to local
regulations The machine equipment is designed to be handled by several
operators. Before use of or maintenance on this equipment, please read the
applicable parts in the manual.
Pay attention to all warning symbols in this manual. Serious personal injury
or damage to the machine can be inicted if this information is disregarded.
Consider all electric equipment as alive.
Consider all tubes and pipes as pressurised.
Before maintenance, set the safety switch (see Figure 1.7) to OFF and lock
it in the OFF position by means of a padlock.
Only authorised personnel may perform service and maintenance.
In this manual a warning symbol is used to call attention
to potentially hazardous situations:
WARNING!
Information about potential personal injury and/or
damage to the equipment.
Safety warning labels (see Figure 1.1) are afxed to the
Disclter lids to warn personnel to keep hands and ngers
away from moving parts of the lter.
This equipment is CE marked ensuring that the
equipment is designed, manufactured and
described in conformity with the Machine
Directive of EU 98/37/EU (AFS 1994:48).
The CE marking does not cover components not approved by Hydrotech AB,
used in redesigning or rebuilding of the equipment.
Warning signs and the CE marking shall be placed fully visible. If any part of
the equipment with a sign is being replaced, a new sign must be attached at
the same place. Damaged signs and CE markings must be replaced promptly.
In order to avoid personal injury and machine damages only personnel who
are trained in accordance with your local supplier’s instructions may perform
service and maintenance. Service and maintenance personnel may only
handle parts of the equipment for which they are trained.
During maintenance and adjustment before operation, the operator can work
within the safety fence and in the restricted area.
Figure 1.1
Moving parts can
cause injury.
!
Figure 1.2
The CE
marking
6
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The lter is equipped with a safety switch (see Figure 1.7). In an emergency
shutdown situation, set the safety switch to OFF (0).
In the event of a power failure, set the safety switch to OFF to prevent the lter
to accidentally start rotating when power returns.
Electrical connection must be performed by an authorized electrician and in
accordance with local regulations. See also Appendix D.
The lter tank or frame must be connected to earth.
A lockable safety switch must be installed if the control box is mounted far
away from the lter (further away than 7 m within EU countries).
The lter is activated by setting the safety switch to ON (1) and then selecting
HAND or AUTO on the selector switch on the panel front. Setting the selector
switch to 0 stops the lter.
WARNING!
Set the safety switch
to OFF (0) and lock it
in the OFF position by
means of a padlock
before starting any
work on the lter.
WARNING!
Access to the lter by
unauthorised persons
must be strictly
prohibited. An outdoor
installation should be
fenced off.
WARNING!
The lter can suddenly
start rotating if
automatic control is activated. Do not touch any moving parts. Do not
climb up on the lter construction when the lter is activated.
Protection guards are tted around the power transmission. Make sure these
are correctly and rmly tted at all time.
WARNING!
The vapours from the chemical dosage system contain substances that
are harmful. The vapours from the backwash water may also contain
harmful substances. Use suitable personal protection according to local
regulations.
Measured noise level from the lter is less than 74 dB(A). If necessary, use
suitable personal protection according to local regulations.
Safety switch
OFF (0) / ON (1)
Mode selector switch
HAND / AUTO
Figure 1.7 Switches of the control cabinet (optional)
Pump OFF (0)
Pump ON (1)
!
!
!
!
7
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
INLET SIDE
MOTOR SIDE
Figure 2.1 Parts of Disclter HSF31-series
Control cabinet
(optional)
Drive unit
Filter
segment
Backwash
pump
(optional)
Disc Piping
(optional)
8
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
Filter type, serial number and year of manufacture can be found on the afxed
data plate. Filter type and serial number is also specied on the front page of
this manual.
The lter designator denitions are:
Mejselgatan 6, 235 32 Vellinge, Sweden
Web: www.hydrotech.se E-mail: [email protected]
XXxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xx xxx
xxxxFiltertype:xx xi x
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxwxxxxxxxxxxxxxxxxxxxxxxxxx xxxxx xx
xxxxSerial No.x xx
xx xxxx x
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxwxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxx xxx
xxxxYear:xxxxx x x
xxx xxi x
xxxxxxxxxxxxxxxxxxxxx x
HSF3110/8-2F
4634
2008 Figure 2.2
Filter data plate
Type of microscreen lter
HSF = Hydrotech Disc Filter
Drum diameter incl. discs
31 = 3100 mm
Max. number of discs
10 = The drum can hold 10 discs
Number of installed discs
8 = 8 discs are installed
Model
H = Aquaculture model
F = Industrial model
Disclter type
1 = Filter with tank
2 = Filter without tank
HSF 31 10 / 8 -2 F
9
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
When received, the equipment should be thoroughly inspected for any
damage that may have occurred during transport.
The delivery note, manual and the spare part set are attached to the
equipment.
Check all parts against the packing list. For safe transport it is necessary that
some parts are not assembled when delivered. Handle fragile parts with care.
Should it be necessary to store the equipment for a longer period (several
days or more) certain precautions should be taken in order to prevent
unnecessary damage to the equipment:
Preferably, the equipment should be stored inside, in a room with
temperature above freezing.
For outdoor storage it is necessary to protect the lter from direct sunlight
as the heat and UV radiation may damage the lter panels.
Filters are delivered covered by plastic, within the wooden crate. If placed
outdoors, a special type of corrosion may develop, especially in coastal
areas. Humidity on the inside of the
plastic forms the anode, and dry
exposed parts the cathode. Filters
must therefore be unpacked after
delivery in these areas.
When lifting the unopened crate a
fork lift with fork extensions should
be used.
Unpacked lters without tank (type 2)
can be lifted using a crane or overhead
gantry, and straps. The straps should be
positioned as shown in Figure 3.3.
NOTE! The lters must be put down on
their nal (operational) site.
WARNING!
Before unloading, the working area
should be fenced off according to
local regulations to prohibit access by
unauthorised persons.
Figure 3.3 Lifting points for lters
without tank (type 2/3)
!
10
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The following requirements must be met before installation can begin
The electrical specications of the equipment corresponds to the available
line current specications
The equipment is undamaged (no damages from transport or storage)
For outdoor installations it is necessary to protect the lter from direct sunlight
as the heat and UV radiation may otherwise destroy the lter panels.
Protect the lter from freezing. At water temperatures of +5 °C and air
temperatures warmer than -10 °C, the lids of the lter is enough for protection.
At lower water and air temperatures, the lter should be installed indoors.
Lift the lters into their nal (operational) site
Fit the inlet channel on the lter frame.
Position the lter.
Check the parallelism of the lter frame. Maximum deviation of the diagonal
measures are: ± 2 mm (See gure 4.1.2.1 below).
The lters must be properly levelled in both directions. Maximum deviation:
3 mm/m.
The inlet channel should be bolted to the concrete wall. The lter frame
should be bolted to the concrete oor with 6 expansion-shell bolts.
Check the alignment of the drum. The distance between inlet side (the open
side) of the drum and the lter frame should be approx. 10 mm.
Figure 4.1.2.1
Check the parallelism of the
lter frame
11
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The lter should be tted on an even
surface with appropriate torsional and
structural strength.
Foundation bolting is required
The lter must be properly levelled in both
directions (see gure 4.1).
600 mm wide walkways should be tted
around the lter in order to provide easy
access to the lter for service work.
Open areas between the lter frame and
the concrete chamber must be covered to
avoid access to moving parts and to stop
objects from falling into the lter.
A special inlet channel (optional) can be used for the emergency by-pass.
In some applications an external by-pass must be arranged in case of e.g. a
power failure to avoid a too high differential pressure across the lter cloth.
Electrical connection must be performed according to local regulations. Check
the settings of the motor protectors against amperage readings on the motors
(see Appendix A & D).
The Hydrotech Disclter and its associated equipment should be protected
using a suitable Equipotential Earth Bonding system. This is very important to
avoid galvanic corrosion. Typically use a cable with an area of 10-16 mm2. The
cable should be attached to the same electrical potential as the drive system.
WARNING!
All electrical works should be installed by a qualied and competent
electrically trained person.
Figure 4.1 Filter installation
!
12
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
Nominal pipe sizes are indicated in the Technical specications, Appendix A.
The inlet water velocity should not exceed 1 m/s.
Piping from the sludge channel must have an inclination of at least 1%.
A new rinse water pipe system should be ushed for at least 10 min. before
connecting it to the lter. Thoroughly check that no rinse nozzles are clogged.
Any particles in the rinse water supply must be removed. A standard in-line
strainer can normally be used to remove particles (see section 7.7).
Figure 4.6
In line strainer (optional)
13
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
1. Make sure that the drive unit cover is rm and correctly tted.
2. Set the pump switch to 0 (see 6 in Figure 5.2).
3. Set the safety switch to ON (see 7 in Figure 5.2).
4. Set the selector switch to HAND (see 5 in Figure 5.2).
5. Open the main valve partly to make the water slowly enter into the lter
drum. Make sure that the water level difference between the inside and
outside of the lter does not exceed 300 mm (see section 5.2.1).
If the lter clogs it may be necessary to ll up the tank or concrete chamber
with water from an external source or to remove a lter panel and let
unltrated water ow into the chamber.
6. When the water level inside the tank or concrete chamber goes above the
suction pipe or the pump (if a CRK or MTR pump is installed), the pump
switch should be set to 1.
WARNING!
The backwash pump must not be started before the water level has risen
above the suction pipe or the pump, otherwise the pump will run dry and
break down.
7. When the water level inside the tank or concrete chamber reaches the
level weir, set the selector switch from HAND to AUTO.
8. Open the main valve completely.
The lter is now running in automatic level control mode. It may be needed to
adjust the level sensor to make the lter run optimally (see section 5.2.2).
!
14
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The control system for the HSF31-series must be provided with a
frequency converter. It is pre-calibrated at factory if delivered from Hydrotech.
For soft start of the drive motor, the settings on the frequency converter must
be adjusted to min. 3s ramp up and min. 1s ramp down.
The lter operates with 50 Hz as standard.
If the lter is equipped with a Hydrotech standard control, the lter has two
operation modes:
1. Continuous rotation (HAND mode)
2. Automatic level control (AUTO mode).
Use the selector switch to select operation mode (see 5 in Figure 5.2).
Warning lamps:
1 Drum drive tripped
2 Warning lamp: Pump tripped
3 Warning lamp: Dry running of
pump
Other items:
4 Reset button for dry running
5 Selector switch (Hand/Auto)
6 Pump switch
7 Safety switch
8 Time relay
9 Level relay
10 Fuse
11 Frequency converter
12 Safety switch
13 Motor protection: Pump
14 Motor protection: Drive motor
8
11
9
10
12
13 14
1 42 3
5
7
6
Figure 5.2 Hydrotech standard control cabinet (optional)
(The design of the control cabinet is often adapted to each application)
15
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
During continuous drum rotation and backwash, the water level inside the
discs is kept nearly constant.
The maximum allowed difference
of the water level inside and outside
the discs is 250 mm during con-
tinuous operation (see Figure 5.2.1).
The recommended operational
difference is 100-200 mm. Long-
term operations with a pressure
differential exceeding the indicated
maximum will reduce life span for
and bearings and ltration media.
WARNING!
The lter should be installed so
that the differential pressure will
under no circumstances exceed
a maximum of 380 mm. The lter can withstand maximum pressure for a
limited period of time and only if the lter is stationary.
The level sensor and the automatic control system are disabled when HAND
mode is selected.
With level control, the disc rotation and the backwash pump is activated when
the water level inside the discs reaches the level sensor. If an independent
rinse water supply is used, the level sensor controls a solenoid valve instead
of the pump.
The water level inside the centre discs will vary when AUTO mode is selected.
The lowest level is just after a backwash cycle, and rises until the level sensor
is reached.
The maximum allowed difference
of the water level inside and outside
the discs is 300 mm during continu-
ous operation (see Figure 5.2.1).
The recommended operational
difference is 100-200 mm. Long
term operations with a pressure
differential exceeding the indicated
maximum will reduce life span for
and bearings and ltration media.
WARNING!
The lter should be installed so
that the differential pressure will
under no circumstances exceed
a maximum of 380 mm. The lter can withstand maximum pressure for a
limited period of time and only if the lter is stationary.
If a constant water level inside the drum is required, the lter should run
continuously (HAND mode).
Figure 5.2.1 Maximum allowed differential
pressure at continuous operation
Max. 250 mm
!
Figure 5.2.2 Maximum allowed differential
pressure in AUTO mode
Max. 300 mm
!
16
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
Place the level sensor 50–100 mm
below the emergency overow weir.
The optimal position depends on
how turbulent the water surface is
(see Figure 5.5.2).
A time relay (see 8 Figure 5.2) is
used to delay the backwash stop
when the water level is below the
level sensor. The time relay is set so
that the drum is backwashed during
a half rotation.
In some applications it might be necessary to increase the backwash time
delay to avoid long term clogging. In cases where low rinse water consumption
is essential, the set backwash time delay can be reduced.
The sensitivity of the level sensor can be set from MIN to MAX on the level
relay and three different sensitivity ranges can be selected on the lower level
relay switch (see 9 in Figure 5.2).
If the appropriate sensitivity is not within the selected range change it to
another sensitivity range. For water with a high conductivity (= low resistance)
chose setting 1. For water with a low conductivity (= high resistance) chose
setting 3. Sea water, for example, has a high conductivity. See also appendix
E, level sensors.
The standard backwash nozzles (TeeJet 6505) have an equivalent opening
size of 1.4 mm. For some applications it may be necessary to use a lower
rinse water ow. This can be achieved by installing nozzles with a smaller
opening size. Contact the supplier or Hydrotech for more information. The
backwash system pressure is set to 7-8 bars.
The lter is powered by a gear motor that rotates the drum by means of a
drive chain. The rotation speed can be altered using the frequency converter
installed in the control cabinet.
Direction of rotation is marked on the motor cover.
After two working weeks or 80 production hours, all bolted joints must be re-
tightened.
Figure 5.5.2 Adjusting the level sensor
17
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The lter is designed and manufactured to remove suspended solids from
non-pressurised water. The lter is not a pressure vessel.
If not approved by Hydrotech, the lter may not be used for other liquids than
water. The lter must not be installed in an area where there is an explosive
atmosphere or any other risk of explosion, e.g. high dust load.
1. Water to be ltered ows by gravity into the lter panels from the centre
drum.
2. Solids are separated from the water by a microscreen cloth tted on the
two sides of the lter panels while the clean water passes through the cloth
to the outside of the disc.
3. AUTO mode - The solids collected on the inside of the lter cloth is
gradually impeding the ow of water through the disc. The water level
inside the disc begins to rise. When the water level reaches the level
sensor the disc rotation and the backwash starts.
HAND mode - Disc rotation and backwash is continuous.
4. Backwash nozzles spray clean rinse water from the outside of the lter
panels. The collected solids are washed off the lter panels into the solids
collection trough as the disc rotates.
The lter is equipped with a moving backwash header system that reduces
the need for backwash. Therefore only a small portion of the ltered water
is required for backwash.
5. The removed solids ow together with the backwash water out of the lter
by gravity.
Filter disc
Filtered water
outlet
Backwash outlet
Spray bar
Filtered water
Washed off solids
Spraying nozzle
Inlet
18
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The most frequent reason for a malfunctioning rinse system is clogging of the
spray nozzles. Clogging is due to particles in the rinse water supply or e.g. to
biological growth in the rinse piping system.
The nozzles should be checked for clogging every week or as often as the
application requires.
1. Set the safety switch to OFF and the selector switch to 0. If a backwash
pump not supplied by Hydrotech is used, make sure that the rinse water
supply is shut off.
2. Remove the lids on the side where the backwash pipe is located.
3. Fold out the spray bar.
.
4. Remove the bayonet nut by turning it ¼ of a revolution counter clockwise.
Be careful not to loose the rubber seal.
5. Clean the nozzle with compressed air or a plastic brush. use a steel
brush or steel pin, as this will damage the nozzle.
6. Assemble the nozzle in the reverse order. Make sure that the nut has
come to a full stop after tightened it ¼ of a revolution clockwise.
Figure 7.1.1
Spray bar lever lifted and
a nozzle removed
Figure 7.1.1d
Spray nozzle parts:
1 Bayonet nut
2 Nozzle tip
3 Rubber seal
4 Nozzle body
5 O-seal
2
1
4
5
3
19
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
7. Place the spray bar to its initial position.
8. Put back the removed lids.
9. Set the safety switch to ON and the selector switch to AUTO
WARNING!
It is important that the bayonet nozzle nuts (see gure 7.1.1d) are
reassembled correctly after cleaning of the nozzles. If a nut loosens, the
nozzle will fall out and the resulting water jet can destroy the lter cloth.
The nozzles will eventually be worn out and a replacement will be necessary.
The life length depends on the quality of the rinse water. If the rinse water
contains coarse sand or similar particles, the nozzles will be worn out faster
than a nozzle that operates in “clean” rinse water. When a nozzle becomes
worn out, the nozzle tip opening becomes enlarged (see Figure 7.1.2b). This
leads to a less efcient back wash (changed dispersion) and higher rinse
water consumption. Therefore it is important to regularly check the functionality
of the nozzles (at least once every year) and change the nozzles if needed.
A comparison between a worn
out nozzle and a brand new
nozzle is shown in Figure 7.1.2.
In the worn out nozzle, a change
in the nozzle opening can be
seen.
!
Figure 7.1.2 a
New nozzle
Figure 7.1.2 b
Worn out nozzle
20
Operation and maintenance manual for
Hydrotech Disclter HSF31-series
The drum main shaft has ball bearings that should be
greased every second week.
The ball bearings of the support wheels should also be
greased every second week.
The grease nipples of the bearings are tted on the outside
of the lter. Lubrication labels identifying the lubrication
points are attached to the lter housing (see Figure 7.2.1
and Figure 2.1).
The bearings should be lubricated with the grease recom-
mended in the maintenance schedule (see section 7.9).
Figure 7.2.1
Lubrication label
This manual suits for next models
4
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