Veolia Hydrotech Discfilter HSF 26-2F Series User manual

Discfilter HSF 26 - 2-3F series with PFLC
Operation and maintenace manual
Revised:2019-05-24

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
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 Demands on personnel 7
2.5 Emergency stop 7
2.6 Electrical safety 7
2.7 Safety instructions 7
3. HYDROTECH DISCFILTER HSF2600 SERIES 9
3.1 Overview 9
3.2 Identifying the filter 11
4. START UP AND OPERATION 12
4.1 Check procedures during start-up 12
4.2 Automatic seings 13
4.2.1 Level dierences 14
4.2.2 Operating mode AUTO – Automatic level control 14
4.2.3 Operating mode REMOTE – Remote control 14
4.2.4 Service mode HAND 15
4.3 Backwash system 15
5. FUNCTION 16
5.1 Intended use 16
5.2 Non-intended use 16

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
5.3 Filtration and backwash process 16
6. MAINTENANCE/SERVICE 17
6.1 Filter cover 17
6.1.1 Hinge 17
6.1.2 Operating the filter cover 18
6.2 Extend the backwash pipe 19
6.3 Backwash system 19
6.3.1 Servicing nozzles 19
6.4 Backwash pipe position 22
6.4.1 Checking backwash pipe position 22
6.4.2 Checking backwash pipe position 23
6.5 Cleaning the backwash water filter 24
6.6 Bearings 25
6.6.1 Lubrication of swivel 25
6.6.2 Lubricating drum bearings 25
6.6.3 Checking drum bearing wear 26
6.7 Filter panels 27
6.7.1 High pressure cleaning 27
6.7.2 Chemical cleaning of filter panels 28
6.7.3 Changing filter panels 30
6.8 Drive chain 32
6.8.1 Checking the drive chain 32
6.8.2 Adjusting drive chain tension 33
6.8.3 Replacing the drive chain 33
6.9 Drive unit 34

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
6.10 Inlet seal 34
6.10.1 Checking inlet seal. 34
6.10.2 Replacing the inlet seal 34
7. MAINTENANCE SCHEDULE 35
Symbols used on Hydrotech filters 36
Manuals & technical information 37

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
1. INTRODUCTION
This manual contains instructions for the operation of Hydrotech Discfilters in the HSF2600 se-
ries, types 2F and 3F (filter with frame).
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 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:
▹Handling & Installation Manual
▹Operation & Maintenance Manual
▹Automation manual
⊲All applicable personnel must read the manuals carefully.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
2. SAFETY INSTRUCTIONS
Hydrotech Discfilters in the HSF2600 series are designed for safe operation provided that they are
installed correctly and used in accordance with the enclosed instructions. The equipment must
be installed correctly and adapted in accordance with local regulations. The machine equipment
is intended for use by multiple operators. You must read the applicable chapters in this manual
prior to using the equipment or performing maintenance.
⊲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 pressurized.
⊲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.
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
Figure 2.1
Figure 2.2

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
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 Demands on personnel
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 mainte-
nance and set-up before operation.
2.5 Emergency stop
The filter is equipped with an emergency stop and a main switch,
see Figure 2.3.
In the event of a power outage, turn the main switch to the OFF
position (0) to prevent the filter drum from unintentionally star-
ting when the power returns.
2.6 Electrical safety
Electrical installation must be carried out by a qualified electrici-
an and in accordance with local regulations. Also see Appendix A
in the “Automation manual”.
The filter frame must be connected to earth, see section 6.4 in the “Handling” & Installation
Manual”.
The main power switch/emergency switch must be fitted in accordance with applicable regula-
tions.
2.7 Safety instructions
The filter is activated by turning the main power switch to the ON position (1), then selecting
AUTO, REMOTE or HAND mode using the mode selector located on the front of the electrical
cabinet.
NOTE! See instructions in section 4.1.
Turn the main power switch to the OFF (0) position and lock it with a padlock before per-
forming any work on the filter.
Access to the filter by unauthorized persons is strictly prohibited. Outdoor installations
Figur 2.3 Elskåp
A. Driftlägesomkopplare
B. Huvudbrytare
C. Nödstopp

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
must be fenced in.
The filter 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.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
3. HYDROTECH DISCFILTER HSF2600 SERIES
3.1 Overview
Figure 3.1 Hydrotech Discfilter in HSF2600 series type 1F (side view).
Figure 3.2 Hydrotech Discfilter in HSF2600 series type 2F (from inlet side).
E. Backswash pump (option)
F. Backwash water filter
G. Actuator for opening cover
H. Pressostat (protects pump from running dry) (option)
I. Junction box
J. Shut-off valve, backwash pipe
K. Manometer
L. Lubrication point
M. Bypass valve for nozzle check
N. Connection, chemical cleaning
O. Sludge trough
P. Holder for level sensor, inlet water
Q. Holder for level sensor, outlet water
R. Sludge outlet
S. Filter panel
T. Filter segment
U. Drum
V. Drum bearing, inlet side
A. Inlet side
B. Inlet passage
C. Filter cover
D. Outlet side

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
A. Actuator for backwash system servicing
B. Actuator for opening cover
C. Drive unit
D. Lubrication point
E. Backwash pipe drive
F. Drive chain
G. Drum bearing, outlet side
H. Drum
Figure 3.3 Hydrotech Discfilter in HSF2600 series type 2F (from inlet side).
Two drum lifters are supplied unassembled for each installation, see Figure 3.4. These are only
used when servicing drum bearings. The supplier should be contacted when servicing bearings.
Figure 3.4 Drum lifter.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
3.2 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.
Definition of filter designation:
Figure 3.5 Filter marking plate

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
4. START UP AND OPERATION
4.1 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 4.2)
3. Set the main power switch to the ON (1) posi-
tion (see I in Figure 4.2)
4. Start drum rotation on the operator panel
main menu (see Figure 4.1 and Figure 4.2).
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 4.2.1). If the fil-
ter cloth becomes clogged, it may be necessary
to fill the filter basin with water from an exter-
nal source or to remove a filter panel and allow
unfiltered water to fill the filter basin.
6. When the water level inside the filter tank is above the pump suction pipe (or, if a CRK or MTR
pump has been installed, the pump), the pump must be started by pressing “Start” on the ope-
rator panel main menu (see Figure 4.1). NOTE Also read section 2.7 (Safety instructions).
7. If the water level inside the filter tank reaches the overflow wall, set the mode selector to either
REMOTE or AUTO (see section 4.2).
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 “Automation manual HSF2600”).
Figure 4.1 Main menu on electrical cabinet operator panel.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
4.2 Automatic seings
The control system for the HSF2600 series must always be equipped with a frequency converter
for 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 as standard.
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 4.2, detail F).
Figure 4.2 Front side of electrical 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. Operation mode switch (Auto/Hand/Remote)
G. Main power switch
H. Emergency stop
I. Reset button following emergency stop

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
4.2.1 Level dierences
The maximum permitted difference
between the water levels inside and outsi-
de the drum is 250 mm during normal ope-
ration (see Figure 4.3). The recommended
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 disturbances under no
circumstances exceeds 450 mm.
The filter shall be operated so that the level difference during normal operation does not
exceed 250mm.
Prolonged operation with a greater level difference will significantly shorten the life of the
filter panels and other vital parts.
4.2.2 Operating mode AUTO – Automatic level control
With automatic level control, drum rotation and the backwash pump are activated once the le-
vel difference between filtered and unfiltered water exceeds an adjustable value. The filter is
force-started if the filter has stood still for an extended period of time. If an external backwash
water supply is used, the level sensor controls a solenoid valve instead of a pump.
The water level inside the drum will vary when AUTO mode has been selected. The water le-
vel is at its lowest immediately after a backwash cycle, and then rises until the level difference
between filtered and unfiltered water becomes too high.
4.2.3 Operating mode REMOTE – Remote control
In REMOTE operating mode, the filter can be controlled remotely. In remote control mode, the
filter can either be controlled as if in AUTO operating mode or using an external controller, see
the “Automation manual”.
Figure 4.3 Maximum permitted level difference during level-con-
trolled operation.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
4.2.4 Service mode HAND
HAND is only a service mode.
In order to operate the filter in HAND mode, the following steps must be implemented:
1. Turn the mode selector shown in Figure 4.2 to
the HAND position.
2. Once the mode selector has been turned to
HAND, “HAND” will be shown in the operator
panel main menu, see Figure 4.4. Press the
drum “Start” button - see Figure 4.4.
3. Press the pump “Start” button - see Figure
4.4.
The operator panel main menu also shows the
water levels of unfiltered (In) and filtered water
(Out), as well as the level difference between
them (Level Diff).
4.3 Backwash system
NOTE! Prior to servicing, read section 2.7.
The system pressure for backwashing must be set to 7-9 bar.
Newly connected pipe systems for external backwash water should be rinsed through before
they are connected to the filter. Thoroughly check that the nozzles are not blocked, see section
6.3.
Figure 4.4 Main menu on electrical cabinet operator panel.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
5. FUNCTION
5.1 Intended use
The filter is designed and manufactured to remove solid particles in unpressurised water flow
systems. The filter is not a pressure vessel.
5.2 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.
5.3 Filtration and backwash process
A brief description of the process is given below.
1. The water to be filtered flows with gravity from the inside of the filter drum out to the filter
segments.
2. Solid particles are separated from the water using a filter medium attached to both sides of
the filter segments, whilst clean water passes through the filter medium to the outside of the
filter segment.
3. Operating mode AUTO – The solid particles trapped on the inside of the filter medium gra-
dually reduce the water flow through the filter panel. 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 REMOTE – The filter is controlled as in AUTO operating mode or using external
control (e.g. time-controlled drum rotation and backwashing). Service HAND – Drum rotation
and backwashing are started manually.
4. The backwash nozzles spray wash water on the outside of the filter panels. The solid particles
that accumulate are washed from the filter panels to the sludge channel, at the same time as
the drum rotates.
5. The removed particles and backwash water flow with gravity out of the filter.
Figure 5.1 Disc filter function.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
6. MAINTENANCE/SERVICE
This chapter describes how maintenance and servicing is to be carried out. Chapter 7 describes
how often the various components require servicing.
6.1 Filter cover
NOTE! Prior to servicing, read section 2.7. The filter cover for the Hydrotech Discfilter HSF2600
series is controlled from the operator panel and can be opened from two directions, depending
on which side of the filter needs to be accessed.
6.1.1 Hinge
Before the filter cover is operated from the operator panel, its hinge must be locked on the cor-
rect side. The locking pin (A) must lock the hinge lock (B) securely as shown in Figure 6.1a below.
Make sure that the filter cover is completely closed and that the hinge lock (B) shown in
Figure 6.1a surrounds the shaft (C) in Figure 6.1b.
The locking pin (A) and the hinge lock (B) must ALWAYS sit on the two outermost hinges (E), as
shown in Figure 6.2 or on the opposite side depending on which direction you want the cover to
open in.
In order to access the backwash pipe, the hinges must be locked (E in Figure 6.2) on the side of
the cover on which the drive unit (F) sits (see Figure 6.2), and the hinges must be open (see Figure
6.1b) on the opposite side, i.e. the backwash pipe side.
Figure 6.1 a Locked hinge, b Open hinge
Figure 6.2 Shows the location of the lockable hinges and the drive unit.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
6.1.2 Operating the filter cover
1. In order to operate the filter cover, the
mode selector shown in Figure 6.3 must be in
the “HAND” position. When in HAND mode,
“HAND” is shown in the operator panel main
menu, see Figure 6.4 below.
2. Select “Login” (if the user is not already log-
ged in) and log in using your user name and
password, see Figure 6.5 below.
3. Select “Service”.
4. Select “Cover & Spray”, see Figure 6.5.
5. In the “Service Cover, Spray bar” window, there are 5 position sensors B3.1-B3.3 and B7.1-B7.2,
which indicate the position of the cover, see Figure 6.7. When the cover is closed, the “B3.1 - B7.1
Cover Closed” lights come on. In order to lift the filter cover, press the “Open” button until the
cover is completely open.
Check that the hinges are fully locked before opening the filter cover, see section 6.1.1
“Hinges”.
6. When the cover is completely open on the backwash pipe side, the “B3.2 - B.7.2 Cover Open”
and “B3.3 Cover Open Service” lights come on, making it possible to extend the backwash pipe.
If the cover is fully open on the other side, only the “B3.2 – B7.2 Cover Open” light will come on.
When this is the case, the backwash pipe cannot be extended.
Figure 6.4 Main menu on electrical cabinet operator panel. Figure 6.5 Service menu.
Figure 6.6 Login for service functions. Figure 6.7 Service Cover & Spray bar menu.
Figure 6.3 Mode selector

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
6.2 Extend the backwash pipe
NOTE! Prior to servicing, read section 2.7.
1. Turn the mode selector to “HAND” and lift
the filter cover on the backwash pipe side, see
section 6.1.
2. When the cover is fully opened on the back-
wash pipe side, B3.2, B3.3 and B7.2, as shown
in Figure 6.7 will be on. The backwash pipe
can now be extended, keep the “Out” button
as shown in Figure 6.7 pressed until the “B4.2
Spray bar Out” light comes on.
6.3 Backwash system
NOTE! Prior to servicing, read section 2.7.
The most common cause of disruption in the backwash system is nozzle clogging. Clogging is
caused by particles in the wash water and/or by e.g. biological fouling in the pipe system.
6.3.1 Servicing nozzles
1. Open the cover on the side of the rinser header according to section 6.1.
2. Open the bypass valve (B), see Figure 6.9.
3. Click the Back arrow to go back a step, see Figure 6.10.
4. Select “Pump & Drum”, see Figure 6.11.
Maintain a safe distance from the filter whilst the drum is rotating.
5. Select “Start” in the “Drum” window, see Figure 6.12.
Figure 6.8 Filter cover open and backwash pipe extended.
Figure 6.9 Main valve A and bypass valve B.

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Operation and maintenance, Discfilter HSF2600 - 2,3 series with PFLC
6. Select “Start” in the “Pump” window, see Figure 6.12.
7. Close the main valve (A), see Figure 6.9.
8. Adjust the backwash water flow using the by-
pass valve so that there is a small but constant
flow through the nozzles. This makes it easy to
identify which nozzles need to be cleaned.
9. Press the back arrow
10. Select “Cover & Spray”, see Figure 6.12.
11. Extend the wash ramp as described in sec-
tion 6.2, item 2.
The operating time in this mode must be minimised in order to not risk the pump over-
heating.
12. Fully or partially clogged nozzles must be cleaned.
13. Remove the nozzle nut by turning it a ¼ turn anticlockwise. Do not lose the rubber seal
14. Clean the nozzle using compressed air or a plastic brush. Never use a steel brush or metal pins
as these may damage the nozzle.
15. Fit the nozzle in reverse order. Check that the nut has reached the stop position once it has
been tightened a ¼ turn clockwise.
16. Stop drum rotation, (the pump stops automatically).
17. Open the backwash water main valve and close the bypass valve.
18. Reset the backwash pipe to operating mode.
Figure 6.10 Service Cover & Spray bar menu. Figure 6.11 Service menu.
Figure 6.12 Service Backwash Pump & Drum window.