ROTORFLUSH Cobalt 400 User guide

Cobalt Filterpump 400R Range Instruction Manual V.1.0 www.rotorflush.com
Page 1 of 14
ROTORFL SH FILTERP MPS
Cobalt 400 Range Models:
CKC31.5 400AR CKC32.2 400AR CKC42.2 400AR
SE AND MAINTENANCE INSTR CTION MAN AL
TO BE KEPT BY THE SER
For three hase um s it is im erative that electrical connections are made so that the
Filter um “KICKS” in the correct direction. If the um s are run in the wrong direction
for more than a few seconds serious damage may result which will invalidate the
guarantee.
Read aragra h 9.3 before installation for the method of checking correct direction of
rotation.
Although the filters are self-cleaning there may over time be a build-u of detritus in
the ores of the mesh which the self-cleaning mechanism cannot remove.
For stainless steel filter mesh use a ressure washer to very thoroughly clean the
outside of the mesh.
For nylon screens either clean low ressure water or re lacement inserts are available
from Rotorflush Filters Ltd.
If the um is run with the filter screen clogged it may cause the um to overheat
and seriously damage the motor invalidating the guarantee. The use of a ro riate cos
hi load monitoring and dry running rotection is essential with all models.
In most conditions the filter should be ins ected every 2 months. In some situations it
may require more frequent ins ection and if required cleaning.
Stainless steel screens should be thoroughly cleaned with a ressure washer. Nylon
screens should be cleaned with gentle running water or re laced. It is recommended
that nylon screens are re laced at these intervals:
Nylon screens: 300 micron every 5000 hours of use or every year.
Fine Stainless steel screens 315 micron every 5000 hours of use or every year.
1mm mesh ressure washed 6 monthly.
Coarse stainless steel screens Greater than 1mm - ressure washed at least every year
NB: Maintenance is estimated on averagely dirty raw water conditions. Water quality,
and therefore maintenance intervals, can vary greatly

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Contents
1. MAN FACT RER & PROD CT IDENTIFICATION DATA (as per EEC98/37 p.1.7.4a).......................................3
1.1. Manufacturer Data ............................................................................................................................ 3
1.2. Filterpump Data.................................................................................................................................3
2. TECHNICAL ASSISTANCE INFORMATION .......................................................................................................3
3. INTROD CTION ............................................................................................................................................. 3
4. GENERAL SAFETY WARNINGS........................................................................................................................4
4.1. Preventive Measures to be taken by the ser ..................................................................................4
4.2. Significant Protection and Precautions (as per EEC 98/37 p. 1.1.2 and 1.7.2; EN 292-2 p.5). ........... 4
5. DESCRIPTION .................................................................................................................................................5
5.1. General Description ........................................................................................................................... 5
5.2. Technical and Construction Characteristics .......................................................................................5
6. TECHNICAL DATA CARD (as per EEC 98/37 p.1.1.2 and 1.7.2; EN 292-2 p................................................... 5
6.1. Pump Technical Data .........................................................................................................................5
6.2. Self-cleaning Filter Technical Data.....................................................................................................5
7. CONTEMPLATED AND NON-CONTEMPLATED SE ........................................................................................ 6
7.1. Contemplated Conditions of se.......................................................................................................6
7.2. Non-Contemplated Conditions of se ...............................................................................................6
8. HANDLING AND TRANSPORT (as per EEC 98/37 p. 1.7.4.a; EN 292-2 p.5 1.1.a) ...................................... 6
8.1. npacking ..........................................................................................................................................6
8.2. Handling and De-installing.................................................................................................................6
8.3. Transport ........................................................................................................................................... 7
9. PREPARATION FOR SE (as per EEC 98/37 p.1.7.4.a, EN 292-2 p.5.1.3)..................................................... 7
9.1. General information ..........................................................................................................................7
9.2. Electrical Connections........................................................................................................................7
9.3. Checking the Direction of Rotation....................................................................................................7
10. INSTALLATION (as per EEC 98/37 p. 1.7.4.a; EN 292-2 p.5.1.1b) ................................................................7
10.1. Fixed Installation...........................................................................................................................8
10.2. Temporary Installation (for Temporary se) ................................................................................9
11. ASSEMBLY AND DISASSEMBLY
12. ADJ STING AND REGISTERING
(as per EEC 98/37 p.1.7.4.a)....................................................................... 9
(as per EEC 98/37 p.1.7.4.a; EN 292-2 p.5.5.1.d)......................................9
13. SE AND START- P (as per EEC 98/37 p.1.7.4.a; EN 292-2 p. 5.5.1.d) .................................................... 10
13.1. Starting........................................................................................................................................10
14. MAINTENANCE AND REPAIRS (as per EEC 98/37 p.1.6; EN 292-2 p.5.5.1.e) ............................................ 10
14.1. Troubleshooting..........................................................................................................................11
15. TECHNICAL INFORMATION..........................................................................................................................12
15.1. Diagram of Filterpump Dimensions and Weights .......................................................................12
15.2. Diagram for Installation with Minimum Functional Distances....................................................12
15.3. Rating Plate Example ..................................................................................................................13
16. INFORMATION ON AIR-BORNE NOISE (as per EEC 89/392 p. 1.7.4.f)..........................................................14
17. WASTE DISPOSAL......................................................................................................................................... 14
18. DECLARATION OF CONFORMITY .................................................................................................................14

Cobalt Filterpump 400R Range Instruction Manual V.1.0 www.rotorflush.com
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ROTORFLUSH FILTERPUMPS
Cobalt Models CKC31.5 400AR, CKC32.2 400AR & CKC42.2 400AR
1. MANUFACTURER & PRODUCT IDENTIFICATION DATA (as er EEC98/37 .1.7.4a)
1.1. Manufacturer Data
Rotorflush Filters
Langmoor Manor
Charmouth
Bridport
Dorset
DT6 6B
England
Telephone: [phone]
Fax: [phone]
Email: [email protected]
1.2. Filter um Data
Description: Submersible Pump with integral Self-cleaning Intake screen. Referred to as a ‘Filterpump’ within this
document.
Cobalt Models: CKC31.5 400AR CKC32.2 400AR CKC42.2 400AR
2. TECHNICAL ASSISTANCE INFORMATION
If a malfunction of the Filterpump is not covered in the TRO BLESHOOTING table (Section 14.1)
contact Rotorflush Filters at the above address.
3. INTRODUCTION
This publication contains all necessary information and instructions for the use and maintenance of your
Rotorflush Filterpump.
Follow the advice given to ensure correct operation and optimum performance of the Filterpump. For any
other information, please contact Rotorflush Filters
THESE INSTRUCTIONS AND ILLUSTRATIONS ARE SUBJECT TO COPYRIGHT AND MUST NOT BE COPIED IN
WHOLE OR IN PART

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4. GENERAL SAFETY WARNINGS
FAILURE TO OBSERVE THESE WARNINGS AND/OR ANY TAMPERING WITH THE FILTERPUMP EXEMPTS
ROTORFLUSH FILTERS FROM ALL RESPONSIBILITY IN THE EVENT OF PERSONAL INJURY OR DAMAGE TO
EQUIPMENT OR PROPERTY AND/OR TO THE FILTERPUMP
Read this manual carefully and check to ensure that the Filterpump has been properly installed and
connected in accordance with relevant safety standards before starting the Filterpump.
There are no RESID AL RISKS with Rotorflush Filterpumps.
No particular technical skills are required to use Rotorflush Filterpumps, although installation should be
carried out by a qualified electrician.
No personal safety devices (precaution devices) are required to use Rotorflush Filterpumps.
4.1. Preventive Measures to be taken by the User
a) The user must specifically comply with all the accident prevention regulations in
force in the respective countries in which the Filterpump is being used; the
indications given in Section 7 must be scrupulously followed.
b) During o eration make sure that nobody is in the water
b) Before undertaking any repairs or maintenance to the Filterpump, isolate the
electricity supply by removing the plug from the socket and/or turning off the
switch (if provided). This will prevent accidental starting which could cause
personal injury or damage to equipment or property.
c) Any maintenance operation, installation or moving the Filterpump with
the electrical system live may cause serious injury and could prove fatal.
e) During operation, avoid moving the Filterpump.
f) Before using the Filterpump, always check that the cable and all electrical devices are in perfect
working order.
g) When starting up the Filterpump (by turning on the switch, if provided, or by inserting the plug in
the socket) ensure (i) you do not have wet hands (ii) you are not standing in water and (iii) you are
not barefoot.
h) The user must not carry out under his/her own initiative any operations or tasks not contemplated
in this manual.
4.2. Significant Protection and Precautions (as er EEC 98/37 . 1.1.2 and 1.7.2; EN 292-2 .5).
Rotorflush Filterpumps are designed so that all moving parts are shrouded by
protective casings. Rotorflush Filters Ltd declines all responsibility in the event of
injury or damage caused as a result of tampering with these devices.
Each lead or live part is electrically insulated to earth; there is also a further safety
device in that the accessible conductive parts are connected to an earth lead so that
the parts within reach cannot become dangerous in the event of failure of the
principal insulation.

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5. DESCRIPTION
5.1. General Descri tion
Rotorflush Cobalt 400 Series Filterpumps are all similar from the functional and constructive point of view;
the only differences are the following:
- Power
- Flow rate
- Head
- Weight
- Dimensions
Rotorflush Cobalt Filterpumps are used for handling water containing total suspended solids not greater
than 2,000 mg/litre dry weight at temperatures up to 40°C (Section 7.1). nwanted solids are separated by a
self-cleaning filter which is continuously backwashed with filtered water pumped though a dual-headed
rotor by a secondary impeller mounted on an extended impeller shaft attached to the pump.
Thanks to their relatively compact bulk and ease of transport, they may be used for fixed or temporary
installations, with or without automatic start.
Rotorflush Filterpumps are designed for long life and constant performance if used according to the
instructions given in Sections 8, 10 and 15.
5.2. Technical and Construction Characteristics
Rotorflush Filterpumps are designed and built to the following design and construction standards:
Machine 98/037/EEC; EN292 standard
Low Voltage 73/23/EEC and relative additions EN60335-1 and EN 60335-2-41 standards
Electromagnetic Compatibility 89/336/EEC and relative additions EN50081-1 and 2 standards
6. TECHNICAL DATA CARD (as er EEC 98/37 .1.1.2 and 1.7.2; EN 292-2 .
6.1. Pum Technical Data
The Cobalt CKC31.5 400AR, CKC32.2 400AR and CKC42.2 400AR fil erpumps are based on
submersible general dewa ering pumps.
6.2. Self-cleaning Filter Technical Data
Filter Mesh Area 2510 cm
2
Filter Mesh
Stainless steel 100 or 315 microns;
Stainless Steel woven mesh 1, 1.5 or 2mm
Perforated stainless steel mesh 3mm or 6mm
Materials: Filter cage Stainless Steel
Backwash rotor
Acrylonitrile Butadiene Styrene (ABS)
Rotor thrust bearing Silicon Carbide
Rotor impeller AISI304 Stainless Steel
Rotor impeller extension shaft AISI304 Stainless Steel

Cobalt Filterpump 400R Range Instruction Manual V.1.0 www.rotorflush.com
Page 6 of 14
7. CONTEMPLATED AND NON-CONTEMPLATED USE
WARNING
Failure to respect the prescribed limits constitutes a situation of use that is technically improper and may
endanger the safety of persons and thus EXEMPTS ROTORFL SH FILTERS FROM ANY RESPONSIBILITY IN THE
EVENT OF ACCIDENTS TO PERSONS OR DAMAGE TO EQ IPMENT OR PROPERTY AND/OR TO THE
FILTERP MP, THEREBY RENDERING THE G ARANTEE INVALID.
7.1. Contem lated Conditions of Use
Rotorflush Filterpumps are suitable for pumping water, non-aggressive and compatible with materials used
to construct the pump. Max density 1.1 kg/dm3 with a total suspended solids loading not exceeding
2000mg/litre dry weight. Oily/fatty/sticky solids will reduce filter performance. They can be used with
pressurisation units. se the Filterpump in keeping with its technical characteristics (Section 7).
7.2. Non-Contem lated Conditions of Use
Rotorflush Filterpumps must not be installed in swimming pools, garden ponds and similar environments
where and when people are in the water. For pumping fluids having total suspended solids loading of
more than 2,000 mg/litre dry weight. Rotorflush Filter um s must never be run without water.
8. HANDLING AND TRANSPORT (as er EEC 98/37 . 1.7.4.a; EN 292-2 .5 1.1.a)
8.1. Un acking
Check that there are no breakages or severe dents in the packing; if there are, point this out immediately to
the person who delivers the material. After removing the Filterpump from the package, check that it has not
suffered any damage during transit; if damage is found, inform the dealer within 8 days of delivery. Check
that the specifications stated on the plate of the Filterpump are the same as you requested in your order.
8.2. Handling and De-installing
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY CAUSE THE FILTERPUMP TO FALL
AND SUFFER SEVERE DAMAGE. NEVER UNDER ANY CIRCUMSTANCES USE THE
POWER CABLE TO LIFT OR DRAG THE FILTERPUMP. USE THE CORRECT LIFTING
GEAR REQUIRED FOR WEIGHT IN EXCESS OF 65 KGS DRY WEIGHT
To handle or de-install the Filterpump you must:
- remove the plug from the power socket and/or switch off the switch, if provided;
- roll up and hold the electric power cable to avoid cable damage;
- lift the Filterpump and the delivery pipe using appropriate PPE and lifting gear.
If the Filterpump is set up for fixed applications, perform the following operations before handling it:
- remove the plug from the power socket and/or switch off the switch, if provided;
- unscrew any clamps and remove the delivery pipe;
- roll up and hold the electric power cable to avoid cable damage;
- lift the Filterpump and the delivery pipe using appropriate PPE and lifting gear.
8.3. Trans ort
The Filterpump is packed on a pallet for transport; check the gross weight before moving or transporting
these Filterpumps

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9. PREPARATION FOR USE (as er EEC 98/37 .1.7.4.a, EN 292-2 .5.1.3).
9.1. General information
Before beginning to work on the electrical pump, make sure that you have disconnected
the electricity from the power supply mains and that it cannot be accidentally
reconnected.
The voltage variation allowed +/- 5% (3-phase 380-415 V)
9.2. Electrical Connections
Connections must only be performed by an authorised electrician in compliance with the law in force. Verify
that the data on the name plate match the nominal values for the power line. Make the connection after
verifying the existence of a working grounding circuit.
It is the Installer’s responsibility to perform the connection in compliance with regulations in
force in the country of installation.
The 3-phase versions need external protection (rapid disconnect magnetic overload cut-out)
with intervention time calibrated to:
• Less than 10 seconds with 5 times IN
• Less than 10 minutes with 1.5 times IN
IN = maximum value of current shown on the name plate
The installation of a differential switch is highly recommended
9.3. Checking the Direction of Rotation
After connecting the power supply, the direction of rotation can be inverted in the three phase versions; in
this case performance will be significantly lower than the nominal values and will cause substantial damage
to the Filter um if run in the wrong direction for more than a few seconds and will invalidate any
guarantee.
To verify a correct connection, proceed as follows:
Start the pump before it is installed. By reaction, it must tend to rotate (“kick”) in an ANTI-CLOCKWISE
direction viewed from above (discharge end).
CAUTION! This o eration will be erformed dry and must not last more than a few seconds.
10. INSTALLATION (as er EEC 98/37 . 1.7.4.a; EN 292-2 .5.1.1b)
WARNING
TO LIFT OR LOWER THE FILTERPUMP, USE A STRONG ROPE OR CHAIN AND APPROPRIATE LIFTING
GEARFIXED TO THE EYELETS; NEVER USE THE ELECTRIC POWER CABLE.
Before beginning to work on the electrical pump make sure that you have disconnected the power supply
from the power supply mains and that it cannot be accidentally reconnected.
The installation of the electrical pump can involve a certain amount of complexity. For this reason, it must
be performed by competent and authorised installers.

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The Delivery Pi e
The diameter of the delivery pipe depends on the flow rate and pressure available at the points of use. For
installations with long lengths of delivery pipe, friction loss can be reduced by using a pipe diameter larger than
the discharge outlet of the pump. It is advisable to install a check valve after the discharge outlet to avoid
dangerous water hammers in the event the electrical pump should stop suddenly. Do not use excessive force
when connecting the pipe to the discharge outlet in order to avoid damage. The electrical pump can be installed
for use with either a metal pipe (which can be used to support the pump) or flexible tubing. In the latter case the
electrical pump must be supported by a cable made of a material with long lasting resistance, passing through
the eyelets at the top of the pump. Fix the power cable to the delivery pipe using suitable straps.
CAUTION! Do not underestimate the risk of drowning if the installation must be performed in a well of a certain
depth. Make sure there is no danger of toxic vapours or harmful gases in the work atmosphere.
10.1. Fixed Installation
We strongly recommend that the um is fitted with dry run rotection, so that if the filter blocks for any
reason or there is insufficient water the pump is automatically stopped to prevent damage from dry running
10.1.1. The Filterpump may be installed upright or horizontally although the self-cleaning filter will
work better in the upright position.
10.1.2. The Filterpump should be fully submerged if possible although this is not necessary except
for frost protection. The Filterpump will operate continuously if at least 450mm of the filter
unit and suction end of the pump are submerged in water at a temperature of less than 40°C.
There must be a gap of at least 200mm around and 100mm underneath the filter unit,
although there is no need for a gap under the Filterpump when operated in the upright
position if there is a flow of fluid past the filter pump to take detritus away from the screen
(e.g. when installing in a flowing river or flume the filter unit at the suction end of the
Filterpump) at all times to allow solid particles to fall or be washed clear of the filter screen.
Due allowance must the made to allow for any build-up of solids underneath the filter and
any detritus, sludge etc. must be removed from time to time to ensure this does not come
within 100mm of the filter.
When lowering the Filterpump into a well or tank, ensure that it is at least 100mm above the
bottom.
Be careful with the power cable when lowering the Filterpump. It is advisable to tie the
power cable to the delivery pipe every two or three metres.
10.1.3. When positioning the Filterpump, observe the minimum required distances (fig. 2) from walls,
from the sides of the drain, tank or other location, so as to allow functioning, use and
maintenance operations in safe conditions (as per EN 292-2 p.5.5.1.b).
10.1.4. It is recommended that standard size rigid pipes (metal or plastic) be attached to the
Filterpump with clamps of a suitable size.
10.1.5. Anchor the pipes to the edge of the basin or tank with a pipe clamping bracket.
10.1.6. If there is the need to install a non-return valve onto the delivery pipes, make sure it is placed
away from the Filterpump filter screen to avoid priming problems when first starting or after
emptying.
10.2. Tem orary Installation (for Tem orary Use)
10.2.1. The Filterpump may be installed upright or horizontally. (As above).
The Filterpump should be fully submerged if possible (as above) but it will operate
continuously if at least 450mm of the filter unit and suction end of the pump are submerged
in water at a temperature of less than 40°C

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Page 9 of 14
10.2.2. There must be a gap of at least 200mm around and 100mm underneath the filter unit,
although there is no need for a gap under the Filterpump when operated in the upright
position if there is a flow of fluid past the filter pump to take detritus away from the screen
(e.g. when installing in a flowing river or flume at the suction end of the Filterpump) at all
times to allow solid particles to fall or be washed clear of the filter screen. Due allowance
must the made to allow for any build-up of solids underneath the filter and any detritus,
sludge etc. must be removed from time to time to ensure this does not come within 100mm
of the filter.
10.2.3. When lowering the Filterpump into a well or tank, ensure that it is at least 100mm above the
bottom.
10.2.4. Be careful with the power cable when lowering the Filterpump. It is advisable to tie the
power cable to the delivery pipe every two or three metres.
10.2.5. When positioning the Filterpump, observe the minimum required distances (fig. 2) from walls,
from the sides of the drain, tank or other location, so as to allow functioning, use and
maintenance operations in safe conditions (as per EN 292-2 p.5.5.1.b).
10.2.6. It is recommended that standard size rigid pipes (metal or plastic) be attached to the
Filterpump with clamps of a suitable size.
10.2.7. If there is the need to install a non-return valve onto the delivery pipes, make sure it is placed
away from the Filterpump filter screen to avoid priming problems when first starting or after
emptying.
11. ASSEMBLY AND DISASSEMBLY (as er EEC 98/37 .1.7.4.a).
The basic Filterpump has no separate parts or accessories, so no assembly is required for installation. If
the Filterpump is to be used with the Rotorflush Valve Control System, the assembly instructions
provided with the Control Valve system must be followed.
The user must not attem t to disassemble any other com onent not covered in these instructions
and should contact Rotorflush Filters for advice if any further disassembly is required.
FAILURE TO COMPLY WITH THIS RULE RENDERS THE GUARANTEE INVALID.
12. ADJUSTING AND REGISTERING (as per EEC 98/37 p.1.7.4.a; EN 292-2 p.5.5.1.d)
The only thing that needs checking once installation is complete is the length of the cable with float (in
installations that have one) with respect to the minimum and maximum water level.
13. USE AND START-UP (as er EEC 98/37 .1.7.4.a; EN 292-2 . 5.5.1.d)
The water level must never be lower than the filter screen, even when the um is not being used. If you
fail to observe this, the Filterpump will run out of water and you will have great difficulty starting the
Filterpump again.
13.1. Starting
Never continuously run the Filterpump until it is placed and installed in its final operational
position. It is possible to have leakage of the Filterpump oil into the pumped liquid;
however, this is not harmful to health.
To start up the Filterpump, connect the plug and/or turn on the switch. When the water
level reaches the minimum level (fig. 2), disconnect the plug and/or turn off the switch.

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Page 10 of 14
14. MAINTENANCE AND REPAIRS (as er EEC 98/37 .1.6; EN 292-2 .5.5.1.e)
BEFORE CARRYING OUT ANY MAINTENANCE OPERATIONS, DISCONNECT THE PLUG
AND/OR SWITCH OFF.
FOR ANY REPAIR JOBS DURING THE GUARANTEE PERIOD, THE USER MUST CONTACT
ROTORFLUSH FILTERS
FAILURE TO OBSERVE THIS RULE RENDERS THE GUARANTEE INVALID.
AFTER THE GUARANTEE PERIOD, ALL MAINTENANCE OPERATIONS, REPAIR JOBS AND/OR
REPLACEMENTS, MUST BE CARRIED OUT BY SKILLED TECHNICIANS ONLY.
To ensure correct functioning and long life of the Filterpump, the Rotorflush filter unit should be inspected
and every two – six months, depending on mesh type and water conditions. The amount of cleaning
required will depend on the liquid being pumped in some instances more frequent manual cleaning of the
filter screen may be required, for example where biological growth occurs on the filter screen or oily/fatty
deposits are found to build up on the filter screen).
Stainless steel screens should be thoroughly cleaned with a pressure washer. Nylon screens should be
cleaned with gentle running water or replaced. It is recommended that nylon screens are replaced at these
intervals for use in average conditions. Maintenance intervals will vary according to water quality and use.
Nylon screens: 300 micron every 5000 hours of use or every year. 115 nylon and 60 micron every
1000 hours of use or 6 monthly whichever occurs first.
Stainless steel screens: These should be ressure washed at least every year, but may be more
frequently de ending on conditions.
Check the condition of the electric power cable; if it is damaged, contact the dealer or Rotorflush Filters
Ltd to have it replaced.
14.1. Troubleshooting
TYPE OF FAULT: The pump does no work ( he mo or does no urn over)
CAUSE REMEDY
No electric power Check the contactor on the electric line
Plug not inserted Check power connection to the line
Automatic switch has tripped Reset the switch and check the cause
Thermal protection has tripped This resets automatically
Protection fuses are burnt out (three-phase) Replace the fuses with same type
Faulty motor Contact Rotorflush Filters
TYPE OF FAULT: The pump does no work ( he mo or urns over)
CAUSE REMEDY
Intake filter blocked Clean the filter / replace mesh inserts
Non-return valve blocked Clean the valve and check its operation
The pump does not start up
Check minimum water level
Check function of delivery gate valve
Hole in filter screen causing pump to block with
detritus
Return to Rotorflush Filters for repairs