Klargester BIODISC BH Owner's manual

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INSTALLATION & OPERATION
GUIDELINES FOR SINGLE PIECE UNITS
BIODISC®BH – BL & NH – NL
Important
O n c e in s t a ll e d, t h e m o t or s h o u ld b e l e ft o n a n d r u n n in g .
If t h e r e is d e l a y e d e l e c t ri c a l c o n n e c ti o n o r if t h e r e is n o p o w e r
a v a il a b l e t o o p e r a t e t h e u n it, t h e n t h e m o t o r w it h g e a rb o x
m u s t b e r e m o v e d a n d s t or e d in a d r y e n v ir o n m e n t.
T h e m o t or k e e p s dry b y g e n e r a ti n g it s o w n h e a t w h e n
o p e r a tin g. In a n o n -fu n c t io n in g sit u a tio n, w a t e r v a p o ur c a n
e n t e r t h e m o t or a n d c a u s e c o rr o sio n.
T h e m o t o r m u s t n o t b e l e f t n o n-o p e r a t io n a l f or a p e rio d of 7
d a y s o r m o r e .
Issue Description Date
01 Initial Issue November 2004
02 Updated (ECN 0254-05) April 2005
Klargester Environmental
College Road North, Aston Clinton, Buckinghamshire, HP22 5EW
Tel: [phone] Fax: [phone]
Website: www.klargester.com Email: [e-mail]

PD0351 – Installation & Operation Guidelines for BH – BL & NH - NL
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1 HEALTH AND SAFETY
These warnings are provided in the interest of safety. You must read them carefully before installing or using the
equipment.
It is important that this document is retained with the equipment for future reference. Should the equipment be transferred
to a new owner, always ensure that all relevant documents are supplied in order that the new owner can be acquainted
with the functioning of the equipment and the relevant warnings.
Installation should only be carried out by a suitably experienced contractor, following the Guidelines supplied with the
equipment.
We recommend the use of a dust mask and gloves when cutting GRP components.
Electrical work should be carried out by a qualified electrician.
Sewage and sewage effluent can carry micro-organisms harmful to human health. Any person carrying out maintenance
on the equipment should wear suitable protective clothing, including gloves. Good hygiene practice should also be
observed.
Covers must be kept locked.
Observe all hazard labels and take appropriate action to avoid exposure to the risks indicated.
The correct ongoing maintenance is essential for the proper operation of the equipment. Klargester offer a range of
maintenance contracts, details on request.
Should you wish to inspect the operation of the equipment, please observe all necessary precautions, including those
listed below, which apply to maintenance procedures.
BioDisc units contain rotating machinery and associated transmission equipment.
Ensure that you are familiar with the safe working areas and accesses.
Ensure that the working area is adequately lit.
The power supply to the equipment must be isolated at the control panel(s) before lifting the covers. Where a specific
maintenance procedure requires the equipment to be running with the covers off, all care must be taken to avoid contact
with moving parts and electrical components or conductors. Drive guards must be replaced and secured if removed during
maintenance.
Once power has been isolated, the control panel must be kept locked shut to avoid accidental re-connection whilst work or
inspection is being carried out.
Use only the designated access walkways. Do not walk on the cover.
Take care to maintain correct posture, particularly when lifting. Use appropriate lifting equipment when necessary. Keep
proper footing and balance at all times. Avoid any sharp edges.
Desludging should be carried out by a contractor holding the relevant permits to transport and dispose of sewage sludge.
The contractor must refer to the desludge instructions in the Operation section of this manual.

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CONTENTS
Page
1HEALTH AND SAFETY ........................................................................................ 2
2Appendices...................................................................................................... 3
3Technical Data ................................................................................................. 4
4Handling & Storage ........................................................................................... 5
5Site Planning.................................................................................................... 6
6Installation ...................................................................................................... 6
6.1 General .................................................................................................... 6
6.2 BioDisc Installation...................................................................................... 7
6.3 Control Panel - Installation ............................................................................ 8
6.4 Control Panel - Connection............................................................................ 8
6.5 Ancillary Equipment..................................................................................... 8
7Start Up.......................................................................................................... 8
7.2 Automatic grease cartridges .......................................................................... 9
7.3 Optional Pump Station ................................................................................. 9
7.4 BioDisc ..................................................................................................... 9
7.5 Switch-on.................................................................................................. 9
7.6 Process Initiation .......................................................................................10
8Operation.......................................................................................................10
8.2 Do’s and Don’ts .........................................................................................10
8.3 Automatic Restart ......................................................................................11
9Running Checks...............................................................................................11
9.2 Loss of Rotation Alarm ................................................................................11
9.3 Customer Checks.......................................................................................11
10 Desludging and Maintenance...........................................................................12
10.2 Sludge Removal.........................................................................................12
10.3 Desludge Volumes......................................................................................13
2 Appendices
General Arrangement Drawings: DS0721 – BH - BL BioDisc
BioDisc Wiring Diagrams: 500212 – BH/BJ Single phase
500214 – BK/BL Single phase
E0143 – BH/BJ Three phase
E0144 – BK/BL Three phase

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Introduction
Thank you for choosing a Klargester product. This manual will help you to keep it operating efficiently over a
long service life. Please read this manual thoroughly, preferably before installation.
This manual should be referred to by :
a) The installer.
b) The electrician.
c) The maintenance engineer.
d) The desludge contractor.
e) The owner/user
These Guidelines represent Best Practice for the installation of these Klargester BioDisc Units. Many years
of specialist experience has led to the successful installation of thousands of BioDisc units. It must be noted,
however, that these Guidelines are necessarily of a general nature. It is the responsibility of others to verify
that they are appropriate for the specific ground conditions and in-service loads of each installation. Similarly,
any information or advice given by employees or agents of Klargester regarding the design of an installation
must be verified by a qualified specialist (e.g. Civil engineering consultant).
3 Technical Data
OPTION - PUMP FED THREE PIECE SYSTEM PST INLET INVERT OPTIONS - 600mm, 1100mm,1500mm
BIODISC
BIODISC
PUMP STATION
H
H
K
F
F
E
G
J
D
D
STANDARD - SINGLE PIECE SYSTEM
G.L.
G.L.
G
Note: Illustrations are
schematic. Refer to
General Arrangement
Drawings for true pipework
orientation.
PRIMARY SETTLEMENT TANK
L
GL = Ground Level

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3.1.1 The loadings given below are representative of typical domestic housing applications. The sizing of
sewage treatment plants requires specialised knowledge and experience. Please consult Klargester
for an assessment of your application.
4 Handling & Storage
4.1.1 Care must be taken to ensure that the unit is not damaged during delivery and handling on site. If
there is any damage it should be reported to Klargester After-Sales within 48 hours of delivery.
4.1.2 The design requirements of Klargester products will frequently mean that the centre of gravity of the
unit is “offset”. Care must therefore be taken to ensure that the unit is stable when lifting. Rainwater
may also collect inside units, particularly if they have been stored on site prior to installation, adding
weight and increasing instability. Check units before lifting and pump out any excess water.
4.1.3 When lifting units, use webbing slings of a suitable specification. When lifting BioDisc units the slings
must be passed through the outer two channels in the base of the unit.
4.1.4 A suitable spreader bar should be used to ensure that the unit is stable and that loads are evenly
distributed during lifting. When lifting BioDisc units the spreader bar length should be equal to the
width of the BioDisc to avoid compression damage to the covers or sides of the unit.
4.1.5 Do not use chains. Do not use the U-bolts or horizontal beams on the BioDisc case for lifting.
4.1.6 Lifting equipment should be selected by taking into account the unit weight, length and the distance
of lift required on site.
4.1.7 Klargester Environmental accepts no responsibility for the selection of lifting equipment.
4.1.8 Whenever Klargester BioDiscs are stored or moved on site, ensure that the storage location is free
of rock, debris and any sharp objects, which may damage the unit. The BioDisc must be placed on
ground, which is flat and level to evenly support the base of the unit.
UNIT BH NH BJ NJ BK NK BL NL
Maximum Daily BOD kg 4.5 3.6 6.0 4.5 7.5 5.7 9.0 6.6
Maximum Daily Flow m315 12 20 15 25 19 30 22
Peak Flow Rate m3 / hr 1.8 1.5 2.5 1.8 3.1 2.3 3.7 2.7
Primary Settlement Tank
Please refer to Klargester Sales for applications requiring a primary settlement tank for sizing and
dimensional information.
BioDisc
Length D mm 7755 7755 7755 7755
Width mm 2455 2455 2455 2455
Inlet Invert depth E mm 600 600 600 600
Depth below inlet invert L mm 1790 1790 1790 1790
Outlet Invert Depth F mm 750 750 750 750
OA Height G mm 2830 2830 2830 2830
Height to rim of cover H mm 2390 2390 2390 2390
Empty Weight Kg 3000 3100 3200 3300
Standard Power Supply 3 phase 3 phase 3 phase 3 phase
Optional Power Supply 1 phase 1 phase 1 phase 1 phase
Motor Rating 1phase/3phase watts 250 250 370 370
Full load current 1 phase amps 1.95 1.95 2.35 2.35
Full load current 3 phase amps 0.88 0.88 1.35 1.35
Sludge Return Pump Rating watts 250 250 250 250
Pump Station
Diameter J mm 900 900 900 900
Flange height K mm 2530 2530 2530 2530
Standard Power Supply 1 ph 1 ph 1 ph 1 ph
Pump Rating watts 250 250 250 250

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5 Site Planning
The following points should be considered before installation of the equipment:
5.1.1 The discharge must have the consent of the relevant Environmental Regulator.
5.1.2 The installation should have Planning and Building Control approval.
5.1.3 Ground conditions and water table level should be assessed. If the water table will be above the
base of the unit at any time of the year, adequate concrete backfill must be provided to avoid
flotation. In poorly draining ground, consideration should also be given to the likelihood of flotation
due to surface water collecting in the backfill. It should be borne in mind that the inlet drain trench will
act as a land drain, directing surface water to the backfill around the unit.
5.1.4 If discharge is to a soakaway, a porosity test should be carried out in accordance with BS 6297 to
assist in assessing sub-soil drainage and designing the sub-surface irrigation system.
5.1.5 The BioDisc system must be installed at a level, which will allow connection to the incoming drain
and a free discharge at the system outlet. Effluent pumping station are available to lift the discharge
to a higher level and/or pump to remote discharge points.
5.1.6 The unit should be installed so that the bottom lip of the cover is 65mm or more above local ground
level. If the unit has to be recessed, measures must be taken to ensure that it cannot be flooded by
surface water run-off.
5.1.7 There must be at least 1 metre of clear, level ground all around the unit to allow for routine servicing,
plus adequate space to allow complete removal of the covers.
5.1.8 Adequate access must be provided for routine de-sludging and maintenance, including crane
access. Vehicles should not be permitted within a distance equal to the depth of the unit, unless
suitable structural protection is provided to the installation.
5.1.9 BioDisc covers are not suitable for walking on. Where necessary the BioDisc should be fenced off or
otherwise protected. Maintenance access must be maintained as above.
5.1.10 The drainage system connected to the BioDisc must be adequately vented in accordance with the
Building Regulations. The head of the drainage system should be connected to a stack pipe, open at
high level, so as to draw foul air from the system and sited with consideration to prevailing wind
direction. Tile vents & Air admittance valves should not be used as the sole drainage ventilation
facility, but if this cannot be avoided, the BioDisc should be independently ventilated. All inspection
points within the drain system should be sealed so as to enable ventilation at high level.
5.1.11 An adequate electrical supply must be provided, complying with current electrical regulations. The
electrical details in section Error! Reference source not found. will enable selection of suitable
cable and current overload protection, taking into account the distance from the power source to the
control panel and any other relevant factors. In most cases steel wire armoured (S.W.A) cable,
minimum 2.5 mm²will be suitable, but this is a minimum recommendation and selection is the
responsibility of the installing electrician. Although not obligatory for an installation of this type, RCD
protection is suggested as an extra precaution.
5.1.12 Pump stations or any other associated equipment should have a separate power supply.
5.1.13 Proximity to a mains water hosepipe connection point is recommended, for maintenance purposes.
Such a supply should be connected in accordance with water bylaws and regulations. Never leave a
hose connected and immersed in sewage.
5.1.14 Installation should only be carried out by suitably qualified and experienced contractors in
accordance with the Health and Safety at Work Act. Electrical work should be carried out by a
qualified electrician, working to the latest edition of IEE.
6 Installation
6.1 General
6.1.1 When units are installed in unstable ground conditions where movement of the surrounding material
and/or unit may occur, the connecting pipe work should be designed to minimise the risk of damage
from differential movement of the unit(s) and/or surrounding material.

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6.1.2 In situations where the excavation will not maintain a vertical wall, it will be necessary to support
sidewalls of the excavation (E.g. with suitable trench sheets and bracing systems) to maintain a
vertical wall from the bottom to the top of the excavation. DO NOT completely remove the shoring
system until after the backfilling is complete, but before the concrete fully hardens.
6.1.3 In areas where the water table is above the bottom of the excavation and/or the excavation is liable
to flood, the excavation should be de-watered, using suitable pumping equipment, until the
installation is complete. In such conditions it may be advisable to line the excavation with polythene
sheeting, to prevent cement being washed out of the concrete surround/base.
6.1.4 During installation care must be taken to ensure that the body of the unit is uniformly supported so
that point loads through the unit are avoided.
6.1.5 Refer to the drawings attached for dimensions of units.
6.1.6 The Concrete Specification is not a site-specific installation design.
GENERAL CONCRETE SPECIFICATION
IN ACCORDANCE WITH BS EN 206-1 ( BS 8500-1)
TYPE OF MIX (DC) DESIGN
PERMITTED TYPE OF CEMENT BS 12 (OPC): BS 12 (RHPC): BS 4027 (SRPC)
PERMITTED TYPE OF AGGREGATE
(coarse & fine)
BS 882
NOMINAL MAXIMUM SIZE OF AGGREGATE 20 mm
GRADES: C25 /30
C25 /30
C16 /20
REINFORCED & ABOVE GROUND WITH HOLDING
DOWN BOLTS
REINFORCED (EG. FOR HIGH WATER TABLE)
UNREINFORCED (NORMAL CONDITIONS)
MINIMUM CEMENT
CONTENT
C30
C20
270 - 280 Kg/M3
220 - 230 Kg/M3
SLUMP CLASS S1 (25mm)
RATE OF SAMPLING READY MIX CONCRETE SHOULD BE SUPPLIED
COMPLETE WITH APPROPRIATE DELIVERY TICKET
IN ACCORDANCE WITH BS EN 12350-1
NOTE: STANDARD MIXES SHOULD NOT BE USED WHERE SULPHATES
OR OTHER AGGRESSIVE CHEMICALS EXIST IN GROUND WATER
6.2 BioDisc Installation
6.2.1 Excavate a hole of sufficient length and width to accommodate the unit and a minimum of 200mm
concrete surround and to a depth, which allows for the burial depth of the unit plus a minimum
300mm thick concrete base.
6.2.2 Construct a suitable concrete base slab, a minimum of 300mm thick, appropriate to site conditions.
In wet or unstable ground conditions it may be necessary to lay a hard-core sub-base. Ensure that
the slab is flat and level. Allow the slab to set sufficiently to support the installed load.
6.2.3 Ensure that the slab is free of any stones or other material, which could damage the unit. Lower the
unit onto the slab using suitable webbing slings and lifting equipment.
6.2.4 Remove the package tied to the outside of the unit. This contains a copy of the Installation
Guidelines and a cover key.
6.2.5 Remove the covers by undoing the locks and folding the end covers back over the inner covers
before lifting them off. Then unlock and remove the centre cover.
6.2.6 Remove the Control Panel, from the walkway inside the unit.
6.2.7 Check that the inlet and outlet orientation is correct and that the unit is level. It is essential that the
unit is installed in a level plane to avoid undue stress on the bearings. The unit must be level to
within ±5mm from side to side, measured at the walkway on either side of the rotor. If necessary, lift
the unit off the base and apply further concrete as needed to level up.
Note: The top flange of the BioDisc should not be used for levelling as manufacturing
tolerances may result in it not being parallel with the rotor shaft.

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6.2.8 It is essential that the unit levels are checked regularly throughout the installation process. Should
the unit become out of level, immediate remedial action is advised, to maintain the unit within the
levels stated in section 6.2.7.
6.2.9 Pour no more than 1 metre depth of water into both primary (inlet) chambers and the final (outlet)
chamber ensuring that there is never more than 250mm difference in water level between any of the
sections.
6.2.10 Place concrete backfill to approximately 500mm depth around the unit ensuring good compaction to
avoid voids. Do not use vibrating pokers.
6.2.11 Continue backfilling with concrete to just below the level of the inlet spigot. Keep the concrete at an
even level all round the unit, compacting in layers. As backfilling progresses keep the ballast water
level inside the unit 250-500mm above the concrete backfill level, but do not attempt to fill the unit
with water above the outlet level.
6.2.12 Remove blanking cap from the cable duct at the outlet end of the unit.
6.2.13 Continue to backfill, with concrete or free flowing granular material, up to ground level. Do not use
sand. The finished surface should be 65 mm minimum lower than the lip of the cover.
Important: Refer to Front Page regarding delayed electrical installation.
6.3 Control Panel - Installation
6.3.1 The control panel is supplied fixed to the pedestrian walkway at the outlet end of the unit, cut cable
ties to remove.
6.3.2 The control panel is suitable for internal or external wall mounting, with volt-free contacts for an
optional beacon or telemetry. Kiosks are available as an option on request.
6.3.3 It is important that the control panel is situated in an accessible location for servicing and
maintenance.
6.3.4 The panel key is in the protective bag on the front of the panel.
6.4 Control Panel - Connection
6.4.1 It is necessary to supply (by others) SWA cable to connect the control panel with the internal junction
box inside the unit.
6.4.2 The gearbox, loss of rotation alarm and sludge return pump are all pre-wired into the internal junction
box within the unit.
6.4.3 The SWA cable connecting the control panel and internal junction box must be ducted through the 4”
port at the outlet end of the unit.
6.4.4 Refer to the wiring diagram inside the panel for connection details.
6.5 Ancillary Equipment
6.5.1 Ancillary items should be installed in accordance with the Installation Guide supplied e.g.
• Primary Settlement Tank
• Sewage Pump Station
• Effluent Pump Station
• Sample Chamber
• Grease Trap
7 Start Up
7.1.1 Every care is taken to ensure that all mechanical components are correctly fitted, adjusted and
lubricated prior to leaving the factory. However, subsequent handling during transportation and
installation may result in the movement of components and a subsequent need to re-adjust prior to
starting the unit. If, on inspection, you consider that any components require adjustment, please
contact Klargester.

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7.1.2 Once the unit has been installed it should be left filled with water. Please switch on the motor,
following the procedure below and leave the unit running, even if there is no sewage being fed into
the plant. If the unit has been installed with no operational power supply, then remove the
motor/gearbox unit and store it in a dry or heated environment until such time as the unit is
ready for permanent operation. Klargester or an experienced contractor should then replace the
motor gearbox unit.
7.1.3 We recommend that Klargester should commission the system: details on request.
7.1.4 Where circumstances dictate an immediate start-up the following basic procedures should be carried
out.
7.1.5 Check that the Primary Settlement Tank (where applicable) and the BioDisc are full of water to their
outlet levels.
7.1.6 Check that the power supply is connected to the control panel. Check that all electrical components
and conductors are earthed.
7.2 Automatic grease cartridges
7.2.1 The shaft roller bearings are fitted with
pressurised grease cartridges. These
should be activated before the unit is
started.
7.2.2 Turn the control knob and it’s linked dial until
the figure 6 is against the arrow on the
casing, as opposite (this will give a
lubrication period of 12 months at the
temperature in the BioDisc).
7.2.3 Depress the red button. This secures the
setting and releases the control knob from
dial.
7.2.4 Rotate the knob clockwise to activate the
unit.
Note: Grease cartridges must be changed
every 12 months.
7.3 Optional Pump Station
7.3.1 Check that the pumps have been installed and wired to the Pump Control Panel.
7.3.2 The pumps should be set to pump little and often in order to prevent excessive loading on the
BioDisc.
7.3.3 Check the setting of the high level float in the pump chamber. This must be set to operate the
pumps so as not to exceed the balancing volume of the unit. To ensure this the float must operate
below the level of the inlet of the unit. Ensure that the float(s) can operate freely without risk of
entanglement. Check that the Pump Control Panel timer is set correctly, as shown on the wiring
diagram.
7.4 BioDisc
7.4.1 Check that the BioDisc is in order, with no obvious damage or misalignment of parts. If any possible
problems are discovered, contact Klargester.
7.4.2 Check that all electrical components: Drive Motor, Sludge Return Pump and LOR Alarm sensor, are
connected to the Control Panel.
7.4.3 Check that the Sludge Return Timer in the BioDisc Control Panel is set correctly, as indicated on the
wiring diagram.
7.5 Switch-on
7.5.1 Open the BioDisc control panel, check that all circuit breakers are in the “on” position and switch on
the main isolator switch. Close and lock the panel. Immediately upon switching on the sludge return
pump should start and run for the set time.
Setting a discharge duration of 12 months

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7.5.2 Open the Pump Control Panel (where installed), check that all circuit breakers are in the “on”
position and switch on the main isolator switch. Close and lock the panel. Immediately upon
switching on the isolator, one of the pumps may start and run for the set time.
7.6 Process Initiation
7.6.1 During installation, the unit will have been filled with water to prevent flotation in the concrete
surround. Allow sewage to enter the unit, this will gradually displace the clean water used during
installation.
7.6.2 The colonisation by micro-organisms will commence naturally and a full operating biomass will
establish itself on the discs in 4-8 weeks, depending on individual site circumstances.
8 Operation
8.1.1 The biological treatment process of your BioDisc is self-regulating and it requires no specialised
operational knowledge, but it is important that you are aware of the following points.
8.1.2 Your BioDisc system uses colonies of live natural micro-organisms (biomass), to break down the
pollutants in the sewage. Many chemicals used in households and commercial establishments can
inhibit or kill these micro-organisms; particularly if used in excessive amounts.
8.1.3 Bear in mind that treatment plants serving small populations do not have the benefit of dilution that
occurs at a large sewage works. A bottle of bleach tipped down the toilet in Birmingham would be
virtually lost amongst the millions of gallons of sewage arriving at the city's treatment works; a bottle
of bleach in a plant serving a hotel could be a lethal dose for the biomass.
8.1.4 If the biomass is damaged, it will usually recover over time. But in the meanwhile one of the more
obvious symptoms is an unpleasant smell, so it is in the users interest to avoid this.
8.1.5 Generally speaking all common household cleaning fluids are acceptable, provided they are used in
accordance with the makers instructions and stipulated concentrations. The following “Do’s and
Don’ts” includes the most common household chemicals, but it is not an exhaustive list and the
golden rule is "If in doubt - leave it out."
8.1.6 Bear in mind too that it isn't only the toilet that is connected to the treatment plant; anything that goes
down the sink, bath etc. also ends up there.
8.2 Do’s and Don’ts
8.2.1 Washing machine and dishwasher detergents, washing up liquids:
These are generally all right to use in the normal concentrations and usage found in domestic
housing applications. All commercial applications are individually assessed before installation for
their laundry load. Please contact Klargester for advice if any changes are contemplated e.g.
addition of extra laundry facilities.
8.2.2 Floor cleaners, disinfectants and bleaches:
These are safe to use in accordance with the makers recommendations and in the minimum
necessary concentration. Do not pour neat disinfectant or bleach down sinks or outside gullies.
If these are smelly it usually indicates a build up of decaying material or a plumbing problem and
should be dealt with accordingly.
8.2.3 Nappy disinfectants and bottle sterilising fluids E.g. Milton:
When disposing of the used fluid, ensure that it is well diluted with water. The easiest way of doing
this is usually to flush it away down the toilet.
8.2.4 Waste disposal units:
These do not inhibit the biomass, but, depending on use, they can present the treatment plant with
considerable extra load. This can result in the treatment process becoming unbalanced, leading
to problems. Much better to compost your vegetable peelings etc - its cheaper and
environmentally friendly.
8.2.5 Home beer and wine making.
This presents a similar problem to waste disposal units. The BioDisc has to work as hard to treat
one pint of beer tipped down the drain as it does to treat all the normal waste produced by one
person in 24 hours. See also the notes above regarding sterilising fluids.

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8.2.6 THE FOLLOWING MUST NOT BE DISCHARGED INTO THE DRAINS
Motor oil, grease, anti-freeze, brake fluid etc.
Cooking oil and fat.
Weed-killers, insecticides, fungicides and other gardening chemicals.
Paint, thinners, white spirit, turpentine, creosote etc.
Medicines
Take unused medicines to a pharmacist for safe disposal.
Photographic developing fluids.
Nappies, sanitary towels, rags, soft toys, tennis balls etc.
This may seem obvious, but it is amazing what gets flushed down the loo from time to time.
Although such items are not directly damaging to the biomass they can cause problems, not
the least of which is simple blockage of the drains.
Even so-called disposable nappies and sanitary towels often do not degrade fully in the treatment
plant and can lead to malfunction, so it is best to dispose of them by other means.
8.3 Automatic Restart
8.3.1 BioDiscs are designed to re-start automatically when power is resumed, but the re-start may not
succeed in some circumstances, such as extended power cuts. This will cause the alarm to activate
when power is re-established after power cuts, check that the rotor is turning correctly. In the event
of any difficulties, contact Klargester.
9 Running Checks
9.1.1 Check that the rotor is running smoothly in the correct direction of rotation (see section 9.1.2) and is
not contacting any part of the fixed structure.
9.1.2 Check that the forward feed buckets are discharging correctly from the first to second stage Biozone.
9.2 Loss of Rotation Alarm
9.2.1 Check operation of the Loss of Rotation (LOR) Alarm as follows:
9.2.1.1 Open the Control Panel and switch off the drive motor circuit breaker. After a delay of 2-3
minutes the alarm should activate.
9.2.1.2 Push the “Beacon Off” button on the front of the Control Panel. The alarm beacon should
stop flashing and the red indicator light on the panel front should remain illuminated.
9.2.1.3 Switch on the drive motor circuit breaker and close the Control Panel. The alarm should
cease after approximately one minute.
9.2.1.4 Depress and release the “Beacon Off” button to reset it.
9.2.2 Malfunctioning of the LOR Alarm does not prevent operation of the BioDisc System, but it should be
reported to your maintenance engineer for early rectification.
9.3 Customer Checks
9.3.1 The following periodic checks should be carried out monthly. Your attention is specifically drawn to
the Health and Safety section of this manual.
9.3.1.1 Visually check the general condition of the plant and listen for any unusual noises. Report
any aspects of concern to your maintenance engineer.

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9.3.1.2 Check the appearance of the Biomass. It should be light grey to grey at the first bank,
gradually changing to brown in the second stage and dark brown at the drive end of the
rotor. If the growth is excessively thick and the colour predominantly grey throughout, an
overload condition is indicated.
9.3.1.3 Visually check that all fixings are secure.
9.3.1.4 Clear any debris from inlet and outlet pipes.
9.3.1.5 Check dosing buckets and transfer pipe for any build up of debris. Clean, if required, using a
stiff bristled brush.
9.3.1.6 Check the Loss of Rotation Warning Device for correct operation (see section 9.2). If the
alarm does not operate properly, contact your maintenance engineer.
10 Desludging and Maintenance
10.1.1 These are vital to the plant's ongoing operation and should be carried out in accordance with the
guidelines in this manual.
10.1.2 Mechanical and electrical maintenance must be performed by properly trained engineers, with
reference to the appropriate Maintenance Manual. Klargester offer a range of maintenance
packages, details on request.
10.1.3 Klargester BioDiscs are designed and engineered for the minimum possible maintenance
requirements, consistent with proper performance. Nevertheless, it is important that routine
preventive electro/mechanical maintenance and de-sludging are carried out at the appropriate
intervals by suitably qualified persons.
10.1.4 Klargester offer various levels of contract maintenance of all BioDisc Systems through our service
company Tekserv who can be contacted on 0845 3550555 or by e-mail at [e-mail].
10.2 Sludge Removal
10.2.1 Refer to the illustration below for recommended de-sludge positions. (Note: Illustration is typical;
individual units may vary).
10.2.2 Isolate power to the BioDisc (and Pump Station if applicable) at the Control Panel(s).
10.2.3 Undo the BioDisc cover latches and fold back the hinged cover sections as required to gain access.
Alternatively the covers can be completely removed if wished. Hinged sections should be folded
back before lifting off.
B C
A
D
D E

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10.2.4 Remove any surface scum from the Final Settlement Tank [A]. The steel mesh may be removed for
access if required. Lower the hose to the bottom of the tank and remove any settled sludge.
Replace the steel mesh.
10.2.5 Remove surface scum from the BioDisc Primary Settlement Zone at point [B] and de-sludge at
points [C] on either side of the rotor. De-sludge along the length of the rotor to prevent ‘rat-holing’.
The steel mesh over point [B] may be removed for access if required.
10.2.6 Note: While de-sludging the Primary Settlement Zone, ensure that there is never more than 250mm
difference in water levels between points [A] and [C].
10.2.7 DO NOT attempt to remove any liquid from the Rotor Section.
10.2.8 DO NOT attempt to clean off the gelatinous growth on the rotor.
10.2.9 Ensure that the BioDisc inlet and outlet pipes [D] and the Forward Feed Buckets [E] are free of
debris.
10.2.10 Ensure that all safety meshes are replaced, then close and lock the BioDisc covers.
10.2.11 Units with separate Primary Tank only - Remove the covers from Primary Settlement Tank. Remove
any surface scum in the Primary Settlement Tank, then lower the hose into the bottom of the tank
and completely remove settled sludge. It may be necessary to empty the tank completely to ensure
full sludge removal. Ensure that the inlet and outlet pipes are clear of debris, and then replace the
covers.
10.2.12 All units - Re-connect the power supply. Wait for two minutes. If the alarm on the control Panel
does not activate, this indicates that the Rotor has successfully re-started. If the alarm activates,
switch off the power at the Control Panel and immediately switch on again. If the alarm continues to
activate, isolate the power supply and notify the plant owner so that the problem can be investigated.
10.3 Desludge Volumes
10.3.1 The minimum volumes shown here are those which can be anticipated under full loading at the de-
sludge period indicated. If the system is not loaded to full capacity, the de-sludge period and
volumes removed may be adjusted, but it is essential that a) sludge is not allowed to accumulate to
the detriment of the process and b) all settled sludge and floating matter are removed at each de-
sludge visit.
Note: Volume is in litres (gallons below in brackets)
BioDisc
Primary Settlement Zone
BioDisc
Final Settlement ZoneUNIT
De-sludge
Period
Min Max Min Max
15,000 19,650 1,500 4,400
BH & NH 5 – 6 months
(3,300) (4,250) (330) (970)
14,800 19,650 1,500 4,400
BJ & NJ 3 – 4 months
(3,200) (4,250) (330) (970)
13,250 17,950 1,500 6,100
BK & NK 3 months
(2,900) (3,950) (330) (1,350)
13,250 17,950 1,500 6,100
BL & NL Approx. 3
months (2,900) (3,950) (330) (1,350)