Veolia Hydrotech Discfilter HPF2200 Series User manual

Discfilter HPF2200 - series , PFLC
Operation and maintenance manual
Revision: 2020-08-26

2
Operation and maintenance, Discfilter HPF2200-series PFLC
Table of contents
1. INTRODUCTION 5
2. SAFETY INSTRUCTIONS 6
2.1 Warning symbols 6
2.2 CE marking 6
2.3 Conversion 7
2.4 Personnel requirements 7
2.5 Emergency stop 7
2.6 Electrical safety 7
2.7 Safety instructions 8
3. HYDROTECH DISCFILTER HPF2200 SERIES 9
3.1 Reception 9
3.2 Storage 9
3.3 Overview 10
3.3.1 HPF2200 type 1, filter with tank 10
3.3.2 HPF2200 type 2, filter without tank 12
3.4 Identifying the filter 14
3.4.1 Definition of filter type 14
4. GENERAL INSTALLATION INSTRUCTIONS 15
4.1 Liing the equipment 15
4.2 Installation site 17
4.2.1 Outdoor installation 17
4.2.2 Foundations 17
4.3 Electrical connection 17

3
Operation and maintenance, Discfilter HPF2200-series PFLC
4.4 Equipotential bonding 18
4.5 Checking drum rotation 18
4.6 Pipe connections 18
5. START UP AND OPERATION 19
5.1 Check procedures during start-up 19
5.2 Automatic seings 20
5.2.1 Level dierences 21
5.2.2 Operating mode AUTO – Automatic level control 21
5.2.3 Operating mode REMOTE – Remote control 21
5.2.4 Service mode HAND 22
5.3 Backwash system 22
6. FUNCTION 23
6.1 Intended use 23
6.2 Non-intended use 23
6.3 Filtration and backwash process 23
7. MAINTENANCE/SERVICE 24
7.1 Backwash system 24
7.1.1 Servicing conventional nozzles 24
7.2 Cleaning the Hydrotech strainer 26
7.3 Bearings 27
7.3.1 Lubrication of swivel 27
7.3.2 Lubricating drum bearings 27
7.3.3 Checking drum bearing wear 28
7.4 Filter panels 29
7.4.1 Additional cleaning 29

4
Operation and maintenance, Discfilter HPF2200-series PFLC
7.4.2 Chemical cleaning of filter panels 30
7.4.4 Changing filter panels 32
7.5 Drive chain 35
7.5.1 Checking and tensioning the drive chain 35
7.5.2 Using the chain tensioner to achieve correct tension 36
7.5.3 Replacing the drive chain 38
7.6 Drive unit 38
7.7 Inlet gasket 38
7.7.1 Checking the inlet gasket 38
7.7.2 Replacing the inlet gasket 39
7.8 Liing the drum 39
7.8.1 Use of the front drum lier 39
7.8.1 Use of the rear drum lier 40
7.8.2 Liing the drum on filters with tank 41
8. MAINTENANCE SCHEDULE 42
Symbols used on Hydrotech filters 43
Manuals & technical information 44

5
Operation and maintenance, Discfilter HPF2200-series PFLC
1. INTRODUCTION
This manual contains instructions for the operation and maintenance of Hydrotech Discfilters in
the HPF2200 series with PFLC automation.
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.
The manual must always be available to the personnel working with the equipment.
It is important that:
⊲ The manual and other relevant documents are kept throughout the life of the equipment.
The manual and other relevant documents are a part of the equipment.
The following documents (manuals) are a part of the equipment:
▹Operation & Maintenance Manual
▹Automatic System Manual
⊲ All applicable personnel must read the manuals carefully.

6
Operation and maintenance, Discfilter HPF2200-series PFLC
2. SAFETY INSTRUCTIONS
Hydrotech Discfilters in the HPF2200 series are designed for safe operation provided they are in-
stalled correctly and used in accordance with the enclosed instructions. The equipment 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.
⊲Assume 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 while operating the filter and when working in close prox-
imity to 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 attached to the filter to warn personnel and act as a remin-
der 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.
Figur 1
Figur 2.1
Figur 2.2

7
Operation and maintenance, Discfilter HPF2200-series PFLC
2.3 Conversion
The CE marking does not include any components that are not approved by Hydrotech AB and
which are used in conversion/reconstruction of the equipment.
The warning symbols and CE marking 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.
2.4 Personnel requirements
Only personnel trained for the equipment and conversant with local regulations may perform
service and maintenance, in order to avoid personal injury and damage to the equipment. Ser-
vice 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 an emergency stop and a
main power switch (see Figure 2.3).
In the event of a power outage, turn the main power
switch to the OFF (0) position to prevent the filter
drum from unintentionally starting when the power
returns.
2.6 Electrical safety
Electrical installation must be carried out by a qua-
lified electrician and in accordance with local regu-
lations.
The filter tank or the frame must be connected to ground. Also see section 4.4.
The main power switch/emergency stop must be fitted in accordance with applicable regula-
tions.
Figure 2.3 Hydrotech control cabinet PFLC.
A. Mode selector
B. Emergency stop
C. Main power switch

8
Operation and maintenance, Discfilter HPF2200-series PFLC
2.7 Safety instructions
The filter is activated by turning the main power switch to the ON (1) position and then selecting
AUTO, REMOTE or HAND with the mode selector on the front of the control cabinet.
NB See instructions in section 5.1.
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 start rotating without warning if automatic control is activated. Moving
parts must not be touched.
Safety guards are fitted around the power transmission. Make sure these are secured and cor-
rectly fitted.
Spray 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.

9
Operation and maintenance, Discfilter HPF2200-series PFLC
3. HYDROTECH DISCFILTER HPF2200 SERIES
3.1 Reception
Once the equipment has been delivered and received it must be checked for transport damage.
Document any transport damage before further handling of the equipment. The consignme-
nt 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.
Refer to section 4.1 before lifting the equipment.
3.2 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 panels and the control panel touch screen.
⊲If the filters are delivered inside plastic covered wooden crates, a special type of corrosion can
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, filters must therefore be
unpacked immediately upon delivery.

10
Operation and maintenance, Discfilter HPF2200-series PFLC
3.3 Overview
3.3.1 HPF2200 type 1, filter with tank
NB Also see section 3.3.2 (HPF2200 type 2, filter without tank) where several filter parts are shown.
Figure 3.1 Hydrotech Discfilter in HPF2200 series type 1 (side view).
A. Inlet side
B. Filter cover
C. Drive side
Figure 3.2 Hydrotech Discfilter in HPF2200 series type 1 (inlet side).
A. Linnear actuators, for opening the cover and unfolding the spray bar ramp
B. Connection, chemical cleaning
C. Lubrication point
D. Sludge outlet
E. Inlet
F. Outlet, separate emergency overflow (bypass) (optional)

11
Operation and maintenance, Discfilter HPF2200-series PFLC
Figure 3.3 Hydrotech Discfilter in HPF2200 series type 1 (outlet side).
A. Drain valve
B. Bypass valve for nozzle check
C. Manometer
D. Lubrication point
E. Shut off valve for backwash pipe
F. Pressure transmittor - dry running protection for pump
G. Strainer
H. Drive unit
I. Backwash pump
Figure 3.4 Level transmittors located in the pipes marked red.

12
Operation and maintenance, Discfilter HPF2200-series PFLC
3.3.2 HPF2200 type 2, filter without tank
Figure 3.5 Hydrotech Discfilter in HPF2200 series type 2 (side view).
A.Inlet side
B. Inlet passage
C. Filter cover
D. Outlet side
Figure 3.6 Hydrotech Discfilter in HPF2200 series type 2 (inlet side).
A. Mounts for level transmittors
B. Linear actuator for opening cover
C. Linear actuator for unfolding the spray bar ramp
D. Connection for chemical cleaning
E. Lubrication point
F. Inlet channel
G. Sludge through
H. Sludge outlet
I. Filter panel

13
Operation and maintenance, Discfilter HPF2200-series PFLC
Figure 3.7 Hydrotech Discfilter in HPF2200 series type 2 (outlet side).
A. Manometer
B. Bypass valve for nozzle check
C. Shut off valve for nozzle check
D. Pressure transmittor - dry running protection for pump
E. Strainer
F. Linear actuator for opening filter cover
G. Lubrication point
H. Drive motor
I. Backwash pump
J. Drum lifter

14
Operation and maintenance, Discfilter HPF2200-series PFLC
3.4 Identifying the filter
Filter type, serial number and year of manufacture are stated on the marking plate. The filter
type and serial number are also stated on the front of this manual.
3.4.1 Definition of filter type
Figure 3.8 Filter marking plate.
Figure 3.9 Definition of filter type.

15
Operation and maintenance, Discfilter HPF2200-series PFLC
4. GENERAL INSTALLATION INSTRUCTIONS
4.1 Liing the equipment
⊲A forklift truck with long forks must be used when lifting filters in wooden crates.
⊲Filters with a tank can be lifted using a crane or overhead crane by using the filter’s lifting lugs,
or with a forklift truck.
WARNING! The work area must be fenced off before unloading, in accordance with local
regulations, to prevent unauthorised access.
Figure 4.1 Lifting Hydrotech Discfilter in HPF2200 series type 1 (with tank).

16
Operation and maintenance, Discfilter HPF2200-series PFLC
⊲Filters without a tank can be lifted using a crane or overhead crane by using the filter’s lifting
lugs or by the use of a forklift.
Figure 4.2 Shows how lifting devices are attached (filter without tank).

17
Operation and maintenance, Discfilter HPF2200-series PFLC
4.2 Installation site
4.2.1 Outdoor installation
In the event of outdoor installation it is important to protect the filter panels against direct sun-
light, as heat and UV radiation otherwise can cause damage to the filter panels. The same applies
to the control panel touch screen.
The equipment must be protected against temperatures below freezing point. At water tempe-
ratures above +5°C and air temperatures above -10°C the filter cover provides sufficient protec-
tion. At lower water and air temperatures, filter installation should be indoors.
4.2.2 Foundations
⊲The filter must be installed on a flat surface
that offers sufficient load bearing capacity.
⊲The filter is to be bolted to the foundation.
⊲The filter must be level in both directions
(see Figure 4.4).
⊲600 mm wide aisles should be laid out
around the filter to permit easy access to the
filter during service work.
⊲The gap between the filter and the concre-
te structure must be sealed for safety reasons
and to keep out foreign objects that can cause
blockages in the backwash system.
4.3 Electrical connection
Qualified electricians must perform all electrical work.
Electrical connection must be done in accordance with local regulations. Check that the settings
on the motor protection correspond with the motor data.
Section 4.5 must be read before starting the filter’s drum rotation.
Figure 4.4 Installation av filter

18
Operation and maintenance, Discfilter HPF2200-series PFLC
4.4 Equipotential bonding
The Hydrotech Discfilter and associated equipment should be protected with a suitable system
for equipotential bonding. This is very important to prevent galvanic corrosion. Ideally use a ca-
ble with a cross section of 10–16 mm2. The cable should be connected to the same electrical
potential as the drive system.
4.5 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.
4.6 Pipe connections
Piping for reject should have a minimum inclination of 1%.

19
Operation and maintenance, Discfilter HPF2200-series PFLC
5. START UP AND OPERATION
5.1 Check procedures during start-up
1. Check that the drive unit cover is installed correctly.
2. Set the mode selector to the HAND position (see F in Figure 5.2).
3. Set the main power switch to the ON (1) position (see I in Figure 5.2).
4. Start the drum rotation on the operator pa-
nel main menu (see Figure 5.1 and Figure 5.2).
5. Open the water supply a little so that the
water can slowly run 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 5.2.1). If the fil-
ter cloth becomes clogged, it may be necessary
to fill the filter tank/chamber with water from
an external source or to remove a filter panel
and fill the filter tank/chamber with unfiltered
water.
WARNING! 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/chamber exceeds the suction pipe of the pump (or,
the suction pipe if a CR- pump has been installed), the pump must be started by pressing “Start”
on the operator panel main menu (see Figure 5.1). NB Also read section 2.7.
WARNING! The backwash pump must not be started until the water level has reached the
suction pipe of the pump (or, the suction pipe connected to the pump if using a CR- pump),
otherwise the pump will run dry and fail.
7. If the water level inside the filter tank/chamber reaches the overflow wall, turn the mode se-
lector from HAND position to either REMOTE or AUTO (see section 5.2).
8. Open the water supply fully.
If the filter is operated using automatic level control, it may be necessary to calibrate the level
sensor in order for the filter to be run optimally (see “Automatic System Manual HPF2200”).
Figure 5.1 Main menu on electrical cabinet operator panel.
(Indication of current backwash pressure is an option.)

20
Operation and maintenance, Discfilter HPF2200-series PFLC
5.2 Automatic seings
The control system for the HPF2200 series must be equipped with a frequency converter on the
drive unit. 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 or 60 Hz as standard, depending on region of delivery.
If the filter is equipped with a Hydrotech standard control, the filter has three operating modes:
1. Automatic level control (AUTO mode).
2. Remote control (REMOTE mode).
3. Service mode (HAND mode).
Turn the mode selector to select the appropriate operating mode (see Figure 5.2, detail F).
Figure 5.2 Front of the control cabinet.
A. Operator panel
B. Warning lamp: Fault indicator
C. Warning lamp: Chemical cleaning
D. Indicator lamp: Drum operation
E. Indicator lamp: Pump operation
F. Mode selector (Auto/Hand/Remote)
G. Emergency stop
H. Reset button for emergency stop
I. Main power switch