Veolia HYDROTECH 12 Series User manual

Drumfilter HDF - 12/16/20/24 -series
Operation and maintenance manual
Revised:2019-03-19

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
LIST OF CONTENTS
1. INTRODUCTION 5
2. SAFETY INSTRUCTIONS 6
2.1 Warning symbols 6
2.2 CE marking 6
2.3 Conversion 6
2.4 Personnel requirements 7
2.5 Emergency stop 7
2.6 Electrical safety 7
2.7 Safety instructions 7
3.1 Overview 9
3.2 Identifying the filter 11
4. RECEPTION AND HANDLING 12
4.1 Reception 12
4.2 Storage 12
4.3 Liing the equipment 12
5. GENERAL INSTALLATION INSTRUCTIONS 13
5.1 Installation site 13
5.1.1 Outdoor installation 13
5.1.2 Foundations 13
5.2 Emergency overflow 13
5.3 Electrical connection 14
5.4 Equipotential bonding 14
5.5 Checking drum rotation 14

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
5.6 Pipe connections 14
5.7 Backwash system 14
5.8 Filter placement 14
6. START-UP AND OPERATION 15
6.1 Check procedures during start-up 15
6.2 Automatic seings 16
6.2.1 Level dierences 17
6.2.2 Operating mode HAND – continuous rotation/washing 18
6.2.3 Operating mode AUTO – automatic level control 18
6.2.4 Adjusting the level sensor 18
6.2.5 Adjusting delay time 18
6.2.6 Seing the level relay 18
6.3 Backwash system 19
6.4 Retightening bolts 19
7. FUNCTION 20
7.1 Intended use 20
7.2 Non-intended use 20
7.3 Filtration and backwash process 20
8. MAINTENANCE/SERVICE 21
8.1 Backwash system 21
8.1.1 Servicing conventional nozzles 21
8.1.2 Self-cleaning nozzle 22
8.2 Wash water filter 24
8.3 Bearings 25
8.3.1 Lubrication 25

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
8.3.2 Checking centre bearings for wear 25
8.4 Filter element 26
8.4.1 High pressure cleaning 26
8.4.2 Chemical cleaning of filter elements 26
8.4.3 Replacing filter elements 28
8.5 Drive chains, drives with roller chains 29
8.5.1 Checking the drive chain for wear 29
8.5.2 Checking drive chain tension 29
8.5.3 Adjusting drive chain tension 30
8.5.4 Replacing the drive chain 31
8.6 Drive chain, drive with chain type H78 32
8.6.1 Checking the drive chain for wear 32
8.6.2 Checking drive chain tension 32
8.6.3 Adjusting drive chain tension 33
8.6.4 Replacing the drive chain 34
8.7 Worm gear motor 34
8.8 Rubber seal 34
8.9 Maintenance chart 35
9. TROUBLESHOOTING 37
Symbols used on Hydrotech filters 38
Manuals & technical information 39

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
1. INTRODUCTION
This manual contains instructions for operation and maintenance of Hydrotech Drum Filter
HDF12, in the 16, 20 and 24 series, with the exception of HDF16-1G. Pay attention to all warning
symbols that appear in this manual. If this information is ignored it may result in serious per-
sonal injury and/or damage to equipment. The manual must always be available to personnel
working with the equipment. It is important that:
⊲ The manual and other applicable documents are retained throughout the equipment’s entire
service life. The manual and other relevant documents are included as part of the equipment.
⊲ The manual is carefully read by all who use the equipment, and that it is always available for
future use.

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
2. SAFETY INSTRUCTIONS
Hydrotech Drum Filter HDF12 in the 16, 20 and 24 series is designed for safe operation provided
that it is installed correctly and used in accordance with the enclosed instructions. The equipme-
nt must be installed correctly and adapted in accordance with local regulations. This equipment
is designed for use by one or more operators. You must read the relevant sections of this manual
before using the equipment or carrying out maintenance work.
⊲ Pay attention to all warning symbols that appear in this manual. If this information is ignored
it may result in serious personal injury and/or damage to equipment.
⊲ Assume all electrical equipment to be live.
⊲ Consider all hoses and pipes to be pressurised.
⊲ Before carrying out maintenance work, the main power switch (see Figure 2.3) must be turned
to the OFF (0) position and locked with a padlock.
⊲ Maintenance and service may only be performed by authorised personnel.
⊲ Adequate lighting should be used when working and operating the filter.
2.1 Warning symbols
Warning symbols are used in this manual to draw attention to potentially dangerous situations:
Information that warns you of a potential risk of personal injury and/or damage to equip-
ment.
Warning stickers (see Figure 2.1) are affixed to the filter to warn personnel and act as reminders
to keep hands and fingers away from the filter’s moving parts.
2.2 CE marking
This equipment is CE marked (see Figure 2.2), which guarantees that the equipment is designed,
manufactured and described in accordance with the requirements set out in the EU Machinery
Directive 98/37/EU (AFS 1994:48).
2.3 Conversion
The CE marking does not extend to any components that are not approved by Hydrotech AB and
that are used in conversion/reconstruction of the equipment. The warning symbols and CE mar-
king must be attached where they are fully visible. If any part of the equipment with a warning
symbol is replaced, a new symbol must be attached in the same position. Damaged symbols and
CE markings must be replaced immediately.
Figure 2.1 Figure 2.2

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
2.4 Personnel requirements
In order to avoid personal injuries and damage to the equipment, service and maintenance may
only be carried out by personnel that are trained on the equipment and conversant in local regu-
lations. Service and maintenance personnel may only handle those parts of the equipment they
have been trained for. The operator may need to work inside the safety barrier and in the safety
zone during maintenance and set-up before operation.
2.5 Emergency stop
The filter is equipped with a main power
switch (see Figure 2.3). To perform an emer-
gency stop, turn the main power switch to the
OFF (0) position. In the event of a power fai-
lure, turn the main power switch to the OFF
(0) position to prevent the filter drum from
unintentionally rotating once the power is re-
stored.
2.6 Electrical safety
Electrical installation must be carried out by
a qualified electrician and in accordance with
local regulations. Also see Appendix D. The fil-
ter tank or the frame must be connected to
ground. Also see section 5.4. The main power
switch/emergency stop must be fitted in ac-
cordance with applicable regulations.
2.7 Safety instructions
The filter is activated by turning the main power
switch to the ON (1) position and then selecting
HAND or AUTO with the mode selector on the
front of the panel. The filter stops if the mode selector is turned to the 0 (OFF) position.
NB. See the instructions in section 6.1 (Check procedures during start-up).
Turn the main power switch to the OFF (0) position and lock it with a padlock before perfor-
ming any work on the filter.
Access to the filter by unauthorised persons is strictly prohibited. Outdoor installations
must be fenced in.
The drum can begin rotating without warning if automatic control is activated. Moving
parts must not be touched.
Figure 2.3 Switches in control cabinet (optional)
A. Pump OFF (0) position
B. Pump ON (1) position
C. Pump switch
D. Mode (0) position
E. Mode (AUTO) position
F. Mode (HAND) position
G. Mode selection switch
H. Main power switch (ON (1) / OFF(0))

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
Safety guards are fitted around the power transmission and in front of the support wheels.
Always make sure these are secured and correctly fitted.
The aerosols from the backwash water may contain harmful substances.
Measured noise levels from the filter are less than 74 dB (A). Personnel should use appropriate
protection, when necessary, in accordance with local regulations.

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
3. HYDROTECH DRUM FILTER 12, 16, & 20 -SERIES
3.1 Overview
Figure 3.1 HDF12/16/20/24 series components, filter with stand

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
Figure 3.2 HDF12/16/20/24, filter with tank

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
3.2 Identifying the filter
The filter type, serial number and year of manufacture are stated on the identification plate. The
filter type and serial number are also stated on the front of this manual.
Figure 3.3 Filter identification plate
Figure 3.4 Defitition of filter type

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
4. RECEPTION AND HANDLING
4.1 Reception
Once the equipment has been delivered and received it must be thoroughly checked for trans-
port damage. Document any transport damage before further handling of the equipment. The
consignment note, manual and spare part kit are attached to the equipment. Check all parts
against the consignment note. Some parts may be delivered unassembled. Handle fragile parts
with care. Before lifting the equipment, see section 4.3.
4.2 Storage
Some precautions must be taken to prevent damage to equipment if a long storage time is ne-
cessary (several weeks or more):
⊲ The equipment should preferably be stored indoors, in a frost-free area.
⊲ The filter must be protected against direct sunlight if stored outdoors. Heat and UV radiation
can damage the filter elements.
⊲ If the filters are delivered in plastic-covered wooden crates, a special type of corrosion may
occur if stored outdoors, especially in coastal areas. The moisture inside the plastic acts as an
anode and the exposed dry components as a cathode. In these areas, the filters must therefore
be unpacked immediately upon delivery.
4.3 Liing the equipme-
nt
⊲ A forklift truck with long forks should
be used when lifting filters in wooden
crates.
⊲ An unpacked filter with tank (type 1)
can be lifted with a fork lift truck, stan-
dard crane or with an overhead crane
with lifting straps.
⊲ An unpacked filter without tank (types
2 & 3) can be lifted with a standard crane
or overhead crane and lifting straps. The
straps are positioned as set out in
The work area must be cordoned off befo-
re unloading in accordance with local re-
gulations to prevent unauthorised access.
Figure 4.1 Lifting points for filter without tank (type 2/3)

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
5. GENERAL INSTALLATION INSTRUCTIONS
The following requirements must be fulfilled before installation can begin:
⊲ The electrical specifications for the equipment must be in agreement with the applicable spe-
cifications for the available power grid.
⊲ The equipment is free from damage (no damage incurred during transport or storage).
5.1 Installation site
5.1.1 Outdoor installation
For outdoor installation it is important to pro-
tect the filter elements against direct sunlight,
as heat and UV radiation can otherwise dama-
ge the filter elements. The filter must be pro-
tected against frost. The filter cover provides
sufficient protection at water temperatures
above +5 °C and air temperatures above -10 °C.
At lower water and air temperatures, filter in-
stallation should be indoors.
5.1.2 Foundations
⊲ The filter must be installed on a flat surface
with sufficient load bearing capacity.
⊲ The filter is to be bolted to the foundation.
⊲ The filter must be level in both directions
(see Figure 5.1).
⊲ 600 mm wide aisles should be placed
around the filter to permit easy access to the
filter during servicing.
⊲ On type 2 and 3 filters (without tanks), the space between the filter frame and concrete
structure must be covered to prevent access to moving parts and to prevent loose objects from
falling into the filter.
5.2 Emergency overflow
Filter type 1 (with tank) and filter type 3 (without tank, with inlet pipe) have integrated emergen-
cy overflow walls as standard. For a type 2 filter (without tank, open inlet), an inlet channel can
be used as an emergency overflow.
Figure 5.1 Filter installation

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
In certain configurations, an external emergency overflow is used in the event of electrical power
outages, for example, to avoid subjecting the filter fabric to excessively high pressure differences.
5.3 Electrical connection
Electrical connection must be done in accordance with local regulations. Check that the settings
on the motor protection device correspond with the motor data (see Appendices A and D).
5.4 Equipotential bonding
The Hydrotech Drum Filter and associated equipment should be protected with a sui-
table system for potential equalisation. This is very important to prevent galvanic cor-
rosion. Ideally use a cable with a cross section of 10-16 mm2. The cable should be con-
nected to the same electrical potential as the drive system.
Qualified and skilled electricians must perform all electrical work.
5.5 Checking drum rotation
Start drum rotation and check that the drum rotates in the same direction as the rotation arrow
on the drive unit cover.
5.6 Pipe connections
Nominal pipe dimensions are specified in the section
Technical specifications, Appendix A. The water’s inlet
speed should not exceed 1 m/s. Piping for discharge of
sludge water must have a minimum downward tilt of 1%.
5.7 Backwash system
Newly connected piping systems for wash water should
be flushed for at least 10 minutes before they are con-
nected to the filter. Carefully check that the nozzles are
not blocked. Any particles in the backwash water supply
must be removed. A standard wash water filter can nor-
mally be used to remove these particles (also see section
8.2).
5.8 Filter placement
When placing the filter it´s recommended to have typi-
cally 1000 mm of free space on surrounding the filter to
allow for easy access. In cases where it isn´t possible to
have a free space buffer of 1000 mm it´s advisable to
have not less than 600 mm of free space. Figure 5.2 Filter seen from above

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
6. START-UP AND OPERATION
6.1 Check procedures during start-up
1. Check that the drive unit cover is installed correctly.
2. Turn the pump switch to the OFF (0) position (see F in Figure 6.1).
3. Set the main power switch to the ON (1) position (see J in Figure 6.1).
4. Set the mode selector to the HAND position (see E in Figure 6.1).
5. Open the water supply partially so that water slowly flows into the filter drum. Make sure that
the difference in water level between the inside and outside of the filter drum does not exceed
450 mm (see section 6.2.1). If the filter fabric becomes clogged, it may be necessary to fill the
filter tank/chamber with water from an external source or to remove a filter element and allow
unfiltered water to run into the filter tank (chamber).
A greater difference in water level between the inside and outside of the filter drum than
450 mm will damage the filter.
6. When the water level inside the filter tank (or concrete chamber) has risen above the pump
suction pipe (or the pump if a CRK or MTR pump is installed), the pump switch must be set to
position 1 (ON).
NB. Also read section 2.7 (Safety instructions).
The backwash pump must not be started until the water level has risen above the suction
pipe (or pump if a CRK or MTR pump is installed), otherwise the pump can run dry and
fail.
7. When the water level inside the tank (or concrete chamber) reaches the overflow wall, turn the
operation mode selector from the HAND to AUTO position.
8. Fully open the water supply. The filter is now run in the mode for automatic level control. It
may be necessary to adjust the level sensor so that the filter can be run optimally (see section
6.2.4).

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
6.2 Automatic seings
The control system for HDF16, 20 and 24 series, must always be equipped with a frequency con-
verter. This is factory calibrated if delivered from Hydrotech. To perform a soft start of the drive
motor, the frequency converter settings must be min. 5 sec “ramp up” and min. 3 sec ”ramp
down”. The filter works with 50 Hz as standard.
Hydrotech control systems are available in various configurations.
If the filter is equipped with a Hydrotech standard controller, the filter has two operating modes:
1. Continuous rotation (HAND mode)
2. Automatic level control (AUTO mode).
Turn the mode selector to select the operating mode (see E in Figure 6.1).
Figure 6.1 Hydrotech control cabinet type PFC (option)
A. DRUM DRIVE TRIPPED. LED that indicates when the fre-
quency converter has tripped.
B. PUMP TRIPPED. LED that indicates when the wash water
pump’s motor protection device has tripped.
C. DRY RUNNING. LED that indicates when the dry running
protection device for the wash water pump has tripped.
D. RESET DRY RUNNING. Resetting of wash water pump’s
dry running protection device.
E. OPERATION MODE. Mode selector.
F. PUMP. Pump switch.
G. CLEANING START. Chemical wash switch, key operated.
H. CLEANING. Lamp that indicates when the chemical wash
is in progress.
I. CLEANING SEQUENCE. Selector for number of sequences,
chemical cleaning.
J. Main power switch

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
Figure 6.2 Hydrotech standard control cabinet, type PFC (option). (The control cabinet’s construction is in general adap-
ted to the respective application).
A. Motor protection pump
B. Fuses
C. Logic module
D. Contactor, pump
E. Control relays
F. Level relays
G. Frequency converter
H. Main power switch
Hydrotech control cabinet type PF has a simpler control system with a logic module.
6.2.1 Level dierences
The maximum permitted difference
between the water level inside and out-
side the drum is 250 mm during normal
operation (see Figure 6.3). The recommen-
ded level difference is 100–200 mm. If an
even flow after the filter is required the
filter must be run with a small level dif-
ference.
The filter must be installed so that the level
difference in the event of operating distur-
bances under no circumstances exceeds
450 mm.
The filter must be run so that the level dif-
ference during normal operation does not
exceed 250 mm.
Prolonged operation with a greater level difference will significantly shorten the life of the filter
panels and other vital parts.
Figure 6.3 Maximum permitted pressure difference during conti-
nuous operation.

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
6.2.2 Operating mode HAND – continuous rotation/washing
Operation with continuous drum rotation and backwash. In this mode, the water level inside the
drum is kept virtually constant. The level sensor and the automatic control system are disabled
when the HAND operating mode is selected.
6.2.3 Operating mode AUTO – automatic level control
With level control enabled, drum rotation and the backwash pump are activated when the water
level inside the drum reaches the level sensor. If an external wash water supply is used, the level
sensor can control a solenoid valve instead of a pump. The water level inside the drum will vary
when AUTO mode has been selected. The water level is at its lowest immediately after a back-
wash cycle and then rises until it reaches the level sensor. If a constant water level is required
inside the drum, the filter should be run continuously (HAND mode).
6.2.4 Adjusting the level sensor
Place the level sensor 50–100 mm below the overflow wall. The optimal placement depends on
the turbulence of the water surface (see Figure 6.4).
NB. Prior to service, read section 2.7 (Safety instruc-
tions).
6.2.5 Adjusting delay time
A time relay/logic module is used to delay the back-
wash stop after the water level has dropped below
the level sensor. The time relay/logic module is pre-
set so that the drum is backwashed for one revo-
lution after the water level has dropped below the
level sensor. In certain applications it can be necessary to increase the time that the filter is back-
washed after the water level has dropped below the level sensor to prevent future clogging.
NB. Prior to service, read section 2.7 (Safety instructions).
6.2.6 Seing the level relay
The sensitivity of the level sensor can be set from MIN to MAX at the level relay’s upper adjust-
ment screw (see F in Figure 6.2). The lower adjustment screw must always point to the side mar-
ked EMPTY. On this side there are three different sensitivity ranges, H, S and L. If appropriate
sensitivity cannot be set using the selected sensitivity range, another sensitivity range can be
chosen:
⊲ For water with high conductivity (low resistance), choose setting L.
⊲ For water with low conductivity (high resistance), choose setting H.
Figure 6.4 Adjusting the level sensor

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
Salt water for example, has high conductivity (setting L).
NB. Prior to service, read section 2.7 (Safety instructions).
6.3 Backwash system
The system pressure for backwashing must be set to 7-9 bar.
Newly connected pipe systems for external wash water should be flushed before they are con-
nected to the filter. Check that the nozzles are not blocked; see section 8.1.
6.4 Retightening bolts
After two working weeks or 80 hours of operation, all bolted joints should be checked for tight-
ness.
NB. Prior to service, read section 2.7 (Safety instructions).

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Operation & maintenance manual, Drum filter HDF 12/16/20/24 -series
7. FUNCTION
7.1 Intended use
The filter is designed and manufactured to remove solid particles in unpressurised water flow
systems. The filter is not a pressure vessel.
7.2 Non-intended use
Unless approved in writing by Hydrotech, the filter must not be used to filter liquids other than
water. The filter must not be installed in an environment with an explosive atmosphere or
another risk of explosion, such as high concentrations of dust.
7.3 Filtration and backwash process
1. The water to be filtered flows with gravity from the inside of the filter drum out through the
filter elements.
2. Solid particles are separated from the water by the filter fabric that is mounted on the outside
of the filter elements, while the clean water passes through the fabric to the outside of the drum.
3. Operating mode AUTO – The solid particles entrapped on the inside of the filter fabric gradual-
ly reduce the water flow through the drum. The water level on the inside of the drum begins to
rise. Once the water reaches the level sensor, drum rotation and backwashing begin. Operating
mode HAND – Drum rotation and backwash are continuous.
4. The backwash nozzles spray clean wash water from the outside of the filter drum. The solid
particles that accumulate are washed away from the filter elements to the sludge trough, at the
same time as the drum rotates.
5. With the help of gravity, the removed particles run out from the filter along with the backwash
water.