Pentair PR AQUA ROTOFILTER User manual

IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
PR AQUA ROTOFILTER™
DRUM FILTER
INSTALLATION AND
OPERATION MANUAL

2
PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
CUSTOMER SERVICE/TECHNICAL SUPPORT
If you have questions about ordering Pentair replacement parts and products, please contact:
© 2018 Pentair Aquatic Eco-Systems (Canada) Inc. All rights reserved.
This document is subject to change without notice.
2395 Apopka Blvd., Apopka, FL 32703, USA Phone: [phone] Web: PentairAES.com
All Pentair trademarks and logos are owned by Pentair or one of its global afliates. Pentair Aquatic Eco-Systems®,
PR Aqua™and Rotolter™are trademarks of Pentair Aquatic Eco-System, Inc. and/or its afliated companies in the
United States and/ or other countries. Unless expressly noted, names and brands of third parties that may be used in
this document are not used to indicate an afliation or endorsement between the owners of these names and brands
and Pentair Aquatic Eco-Systems (Canada), Inc. Those names and brands may be the trademarks or registered
trademarks of those third parties. Because we are continuously improving our products and services, Pentair reserves
the right to change specications without prior notice. Pentair is an equal opportunity employer.
P/N 450041 Rev. A 8/18
Customer Service
8AM–5PM—Pacic Time
Canada & United States
Toll Free: [phone]
International
Phone: [phone]
Web site
PentairAES.com

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
TABLE OF CONTENTS
Section 1: Foreword.................................................. 5
1.1 Scope.......................................................... 5
1.2 Technical Specication Documents ......... 5
1.3 Serial Number Location............................. 5
1.4 Support Contact ........................................ 5
Section 2: Safety ....................................................... 6
2.1 Safety Summary......................................... 6
2.2 Warning and Information Labels...............6
2.3 Protective Equipment ................................ 7
2.4 Electrical Safety ......................................... 7
2.5 Jewelry ....................................................... 7
2.6 Rotating Equipment...................................7
2.7 UV Radiation ..............................................7
Section 3: Shipping and Storage ............................ 8
3.1 Arrival on Site............................................. 8
3.2 Lifting.......................................................... 8
3.3 Storage ..................................................... 10
Section 4: Introduction........................................... 11
4.1 Overview ................................................... 11
4.2 Location of Major Components .............. 11
4.3 Operational Mechanics ........................... 12
Section 5: Pre-Installation ..................................... 13
5.1 Overview................................................... 13
5.2 Site Requirements and Preparation ....... 13
5.3 Foundation and Service
Access Requirements.............................. 13
5.4 Sump Requirements ................................ 14
5.5 Hydraulic Controls ................................... 15
5.6 Backwash System Considerations......... 16
5.7 Control Panel Considerations ................. 18
5.8 Electrical Power Requirements............... 18
5.9 Flushing Plumbing ................................... 18
5.10 Pre-Installation Checklist .......................... 19
Section 6: Installation.............................................20
6.1 Tools Required ......................................... 20
6.2 Installing the Rotolter ............................20
6.3 Installing the Backwash System............. 21
6.4 Connecting the Plumbing........................ 22
6.5 Installing the Control Panel .....................22
6.6 Control Panel Installation Checklist .......22
6.7 UV Installation (RFUV Only).....................23
Section 7: Pre-Operation .......................................24
7.1 Over vi ew ................................................... 24
7.2 Checking Fasteners................................. 24
7.3 Checking the Drum Seal.......................... 25
7.4 Checking Flow Levels.............................. 25
7.5 Adjusting Drive Tension
(Chain-Drive Models) ...............................26
7.6 Checking the Housing and
Drum Enclosure .......................................27
7.7 Pre-Operation Checklist.......................... 27
7.8 Performing a Test Run ............................. 27
7.9 Performing a 24-Hour Run ......................28
7.10 Post 24-Hour Inspection ......................... 28
7.11 Calibrating Float Switches ......................29
Section 8: Startup and Shutdown.........................30
8.1 Filling the Rotolter.................................. 30
8.2 Startup Procedure ...................................30
8.3 Shutdown Procedure
(24 Hours or Less) .................................... 31
8.4 Shutdown Procedure
(24 Hours or More) ................................... 31
Section 9: Maintenance .........................................32
9.1 Maintenance Schedule............................ 32
9.2 Maintenance Considerations .................. 32
9.3 Checking Flow and Water Levels............ 32
9.4 Inspect Mechanical Parts .......................33
9.5 Combined Maintenance Procedure........34
Section 10: Spray Bar Maintenance .....................39
10.1 Spray Bar Overview ................................. 39
10.2 Spray Bar Assembly ................................39
10.3 Removing the Nozzle Cap .......................39
10.4 Cleaning the Nozzle Tip...........................39
10.5 Removing the Nozzle Body ..................... 39
10.6 Gaskets and O-rings................................ 39
10.7 Nozzle Reassembly ................................. 39

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
TABLE OF CONTENTS
Section 11: Screen Maintenance...........................40
11.1 Screen Damage ....................................... 40
11.2 Washing the Screens............................... 41
11.3 Repairing Screen Panels ......................... 41
11.4 Removing Screen Panels and
Gasket Seals ............................................ 42
11.5 Replacing Screen Panels and
Gasket Seals ............................................43
Section 12: Drum Seal Maintenance ....................46
12.1 Over view ...................................................46
12.2 Removing the Drum Seal.........................46
12.3 Replacing the Drum Seal......................... 47
Section 13: Support Wheel Maintenance.............49
13.1 Over view ...................................................49
13.2 Support Wheel Assembly Parts.............. 49
13.3 Greasing the Support Wheels................. 49
13.4 Removing the Support Wheels ............... 50
13.5 Replacing the Support Wheels ............... 51
Section 14: Drive Assembly Maintenance ...........53
14.1 Over view ................................................... 53
14.2 Drive Assembly Parts
(Chain-Drive Models) ...............................54
14.3 Maintaining Oil Bath Levels
(Chain-Drive Models) ...............................54
14.4 Adjusting Chain Tension
(Chain-Drive Models) ...............................54
14.5 Removing the Drive Assembly
(Chain-Drive Models) ...............................55
14.6 Replacing the Drive Assembly
(Chain-Drive Models) ...............................55
14.7 Removing the Drive Assembly
(Direct-Drive Models)...............................56
14.8 Positioning the Set Collar
(Direct-Drive Models)...............................58
14.9 Replacing the Drive Assembly
(Direct-Drive Models)...............................59

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
SECTION 1: FOREWORD
1.1 Scope
This manual contains instructions for installation,
operation, and maintenance of the PR Aqua
Rotolter™Drum Filter.
Personnel should read the entire manual before
installation or operation of the Rotolter. The
manual contains vital information regarding proper
installation, operation, warranty conditions, and
personal safety. Disregarding this information may
cause irreversible damage to the unit or other
equipment, limit the operation, void the warranty,
or may cause bodily injury or death.
Due to the different congurations of Rotolter
models, some information provided in this manual
may not be applicable to your model. If you are
unsure whether certain information applies to your
model, please contact us before proceeding.
All safety information and warnings apply to all
Rotolter models.
A dedicated ultraviolet (UV) reactor manual is
provided with Ultraviolet (RFUV) models. Refer
to the UV reactor manual for operation and
maintenance of UV components.
1.2 Technical Specication Documents
Specication documents containing information
about the unique conguration and components of
your Rotolter are shipped prior to Rotolter arrival.
This information is useful for maintenance and
troubleshooting. You should keep these documents
near this manual and make copies for your records.
Contact us if your specication documents have
been lost or damaged.
1.3 Serial Number Location
The serial number for the Rotolter is stamped
on a product information plate, located to the
left of the drive system. The plate contains the
model number, manufacture date, and company
contact information.
1: Model Number
2: Manufacture Date
3: Serial Number
If you have a technical question, need support, or
require parts, please have the information listed on
the product information plate available when you
contact a service representative at Pentair.
1.4 Support Contact
Additional copies of this manual are available
at no cost from your dealer. For manuals,
parts, service, warranty, or eld support,
please contact us:
Customer Service
8AM–5PM—Pacic Time
Canada & United States
Toll Free: [phone]
International
Phone: [phone]
Web site
PentairAES.com
Figure 1. Product information location

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
SECTION 2: SAFETY
2.1 Safety Summary
This safety summary contains warnings that must
be understood and applied during operation and
maintenance of the Rotolter. Failure to obey these
precautions could result in damage to equipment,
serious injury, or death of personnel.
These are the icons used within the manual:
A Warning icon precedes an
essential operating or maintenance
procedure, practice, condition,
or statement, which, if not strictly observed, could
result in injury to or death of personnel or long-term
health issues
A Caution icon precedes an
essential operating or maintenance
procedure, practice, condition, or
statement, which, if not strictly observed, could
result in damage to or destruction of equipment.
A Note icon precedes an essential
operating or maintenance
procedure, practice, condition,
or statement that should be heeded for maximum
product benet.
Make sure you read all information in the Warnings,
Cautions, and Notes carefully. If any issues
are unclear, consult us. Additional safety
guidelines related to specic components of
the unit are described in the corresponding
component sections.
2.2 Warning and Information Labels
Warning and information labels are posted on the
Rotolter. Read labels and note their locations
before operation, maintenance, or servicing of
the product. Ultraviolet (RFUV) models contain
additional labels. Refer to the UV manual for
applicable warnings and precautions.
Automated Machinery:
This unit may start at any time.
STAY CLEAR.Lockout/tagout
before servicing.
Located on individual lid
panels
Pinch Point:
Do not operate without guards
in place.
Located on drum support
wheel nger guards
Ultraviolet (UV)
Radiation Inside:
Exposure may cause eye
damage. Do not operate
without coverings. Do not look
into UV source. Wear UV eye
protection.
Located on UV chamber
(RFUV only)
Hot Surface:
Contact may cause burn.
Allow to cool before servicing.
Located on UV module light
block shield (RFUV only)
Rotation:
Located on drive assembly
end
NOTE

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
SECTION 2: SAFETY
2.3 Protective Equipment
Protective equipment such
as safety glasses and hearing
protection may be appropriate
or required during installation, operation, and
maintenance of the Rotolter.
It is recommended that suitable personal protective
equipment be selected by a qualied entity prior
to installation and use of the unit. Personnel should
utilize such equipment to avoid bodily injury
or death.
2.4 Electrical Safety
Electrical hazards can cause injury
and death. Always use caution
when working near electricity.
Danger may still exist when the power is set to OFF.
All electrical work should be performed by a
qualied, professional electrician. This includes
installation, inspection, and repair of electrical
components.
A comprehensive lock-out, tag-out procedure
should be observed and followed for installation
and maintenance of the Rotolter. Lock-out/tag-
out procedures often exist as standard operating
procedures within company guidelines. If your
company does not employ a lock-out/tag-out
procedure, please contact your nearest workplace
safety and health administration to obtain one.
Never operate electrical equipment while you are
standing in water.
Remove power, discharge, and ground a circuit
before touching it.
When possible, work in pairs, preferably with basic
life support qualied personnel.
Personnel working with or near dangerous
voltage should be trained in modern methods
of resuscitation.
2.5 Jewelry
Remove rings, watches, chains,
and other metallic objects that
could result in shock, burns, or
may catch on equipment.
2.6 Rotating Equipment
The Rotolter employs rotating
equipment, which can cause
severe injury or death. Be aware of
all rotating parts and keep body and objects away
from these areas.
Never attempt to service the unit while it is in
Automatic Mode. The drum may begin rotating
without warning when it is in Automatic Mode. The
unit should never be operated in Automatic
Mode without lids and access panels installed.
Some operation and service procedures require
rotating the moving parts. These procedures should
always be performed in Manual Mode.
Be aware of any personnel in the area when
attempting to service the unit in Manual Mode.
Do not attempt to manually rotate the drum without
rst observing the area for any personnel or objects
that may be caught in a rotating part.
Never attempt adjustments without powering off
the unit and locking out the control panel unless
otherwise specied by the service procedure.
2.7 UV Radiation
The RFUV emits ultraviolet light.
Never operate the unit without UV
module lids and covers installed.
Shut down the UV reactor prior to maintenance.
UV light can damage eyes and skin. Always wear
appropriate eye protection and protective clothing
when working on or around UV light.

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
SECTION 3: SHIPPING AND STORAGE
3.1 Arrival on Site
The Rotolter is shipped fully enclosed and secured
in a wooden crate. It may be packaged as a single
unit or transferred with other system components.
UV modules for the Ultraviolet (RFUV) models
are always shipped separately because they are
extremely fragile.
There may be cardboard boxes on the oor of the
crate containing the backwash pump, plumbing kit,
or other items.
Inspect all crates for visible signs of damage before
acceptance from the shipping contractor. If damage
has occurred, the recipient should contact us
prior to acceptance in case an insurance claim
is required.
Verify the correct screen pore size from the
specication documents.
3.2 Lifting
The approximate dry and wet weights of the
Rotolters are listed below:
Molded (RFM) Models
Size Weight Dry/Wet (kg) Weight Dry/Wet (lbs)
20014 90/200 kg 190/435 lbs
32018 185/670 kg 400/1,470 lbs
32036 295/1,225 kg 650/2,700 lbs
32054 355/1,470 kg 775/3,240 lbs
48048 545/2,495 kg 1,200/5,500 lbs
48072 820/3,585 kg 1,800/7,900 lbs
60096 1,136/5,545 kg 2,500/12,200 lbs
Ultraviolet (RFUV) Models
Size Weight Dry/Wet (kg) Weight Dry/Wet (lbs)
32036 545/1,955 kg 1,200/4,300 lbs
48048 1,275/4,380 kg 2,800/9,650 lbs
Frame (RFF) Models
Size Weight Dry/Wet (kg) Weight Dry/Wet (lbs)
32018 175/365 kg 385/800 lbs
32036 190/410 kg 415/900 lbs
32054 280/475 kg 615/1,040 lbs
48048 335/685 kg 730/1,500 lbs
48072 345/910 kg 760/2,000 lbs
60072 775/1,680 kg 1,700/3,700 lbs
60096 910/2,635 kg 2,000/5,800 lbs
60120 1135/3,290 kg 2,500/7,250 lbs
The Rotolter can be extremely heavy. For
mechanically assisted lifting, use an appropriately-
sized lifting device capable of safely lifting the unit.
Follow proper rigging procedures at all times. Never
allow the unit to swing out of control.
To safely lift the unit, you should use a spreader
bar accompanied with approved nylon slings. See
Figure 2.
External or internal lifting lugs may be provided
depending upon the unit.

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
SECTION 3: SHIPPING AND STORAGE
1: Lifting Lug
2: Sling (Nylon or Canvas)
3: Spreader Bar
Slings should always be made of nylon or canvas,
and should be attached to the Rotolter in one of
three ways:
• Passed through a shackle securely connected to
the lifting lug
• Passed directly through the lifting lug
• If lugs are not present, passed beneath the
underside of the frame
1: Distance Between the Lifting Points (D)
2: 1.5 Times the Distance Between the Lifting
Points (1.5 x D)
Do not attempt to lift using slings around the drum
or any plumbing ttings. Doing so will damage the
Rotolter and void the warranty.
Use a pad between the sling and the Rotolter, as
pressure from the sling may mar the surface nish
of the unit.
Rotolter Frame (RFF) models have external lifting
lugs provided on each corner of the unit, each with
a hole to provide enough room to insert a shackle
or sling.
Molded (RFM) 48-series and 60-series models
should be lifted by the support bridge at the front
of the unit, and internally-mounted lifting lugs at the
back of the unit.
Molded (RFM) 32-series models should be lifted
using two 75mm (3 in) wide slings at a minimum,
looped underneath the housing and placed as close
to each end as possible.
Ultraviolet (RFUV) models: Do not install UV
Modules until the Rotolter has been installed and
properly anchored.
The minimum length of the sling should allow
the distance between the spreader bar and the
Rotolter lifting points to be 1.5 times the distance
between the lifting points. See Figure 3.
Figure 2. Proper lifting procedure Figure 3. Proper sling length (not to scale)

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PR Aqua Rotolter™ Drum Filter Installation and Operation Manual
SECTION 3: SHIPPING AND STORAGE
3.3 Storage
The Rotolter should always be stored on a at and
level foundation.
The Rotolter should remain in its crate until time
of installation.
The unit should always be stored in a clean, heated,
and ventilated area.
If these conditions are not available, the Rotolter
should be fully covered by a UV-treated, waterproof
material such as a tarpaulin or plastic shroud.
Provide ventilation if the unit is covered. The
ventilation should not allow moisture in and should
not be located at the top of the unit.
Condensation can occur in the Rotolter, both
during shipping and storage. Ensure that the unit
is fully dry before applying power.
Perform a systematic inspection on the Rotolter
and implement a maintenance schedule during
longer storage periods.
Actions that should be performed every 40 days if
the unit is in storage:
Visually inspect the storage area and storage
materials for potentially damaging issues, such as
leaks in the roof or tears in the covering.
Visually inspect the Rotolter for any damage.
Actions that should be performed every 90 days if
the unit is in storage include:
Visually inspect the storage area and storage
materials for potentially damaging issues, such as
leaks in the roof or tears in the covering.
Visually inspect the Rotolter for any damage.
Add oil to the chain bath of the drive assembly for
Frame (RFF) models. Add only Clarity® Synthetic
Hydraulic Oil AW. Oil should cover the bottom links
of the chain and lower sprocket.
Perform a megger test of the electrical system, and
keep a record of insulation values, temperature,
time, humidity, and length of voltage application to
show winding conditions prior to start up. The unit
must be fully dry before applying any power.
All electrical work should be
performed by a qualied,
professional electrician.
Please contact us with any questions concerning
proper storage of the Rotolter.