Veolia HYDROTECH HSF2200-1F-PFC User manual

Discfilter HSF2200 - 1/2F - PFC
Operataion and maintenance manual
Revision: 2021-02-09

2
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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. HYDROTECH DISC FILTER HSF2200 SERIES 9
3.1 Reception 9
3.2 Storage 9
3.3 Overview 10
3.3.1 HSF2200 type 1, filter with tank 10
3.3.2 HSF2200 type 2, filter without tank 12
3.4 Identifying the filter 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
4.4 Equipotential bonding 17

3
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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 22
5.2.2 Operating mode HAND – Continuous rotation/backwash 22
5.2.3 Operating mode AUTO – Automatic level control 22
5.2.4 Adjusting the level sensor 23
5.2.5 Seing of level relay 23
5.3 Backwash system 23
6. FUNCTION 24
6.1 Intended use 24
6.2 Non-intended use 24
6.3 Filtration and backwash process 24
7. MAINTENANCE/SERVICE 25
7.1 Backwash system 25
7.1.1 Servicing conventional nozzles 25
7.1.2 Self-cleaning nozzle 27
7.2 Cleaning the Hydrotech wash water filter 28
7.3 Bearings 29
7.3.1 Lubrication of swivel 29
7.3.2 Lubricating drum bearings 29
7.3.3 Checking drum bearing wear 30
7.4 Filter panels 31

4
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
7.4.1 High pressure cleaning (HPC) 31
7.4.1.1 Cleaning with integrated HPC (optional) 31
7.4.2 Chemical cleaning of filter panels 32
7.4.3 Changing filter panels 33
7.5 Drive chain 35
7.5.1 Checking the drive chain 35
7.5.2 Adjusting drive chain tension 36
7.5.3 Replacing the drive chain 37
7.6 Drive unit 37
7.7 Inlet gasket 37
7.7.1 Checking the inlet gasket 37
7.7.2 Replacing the inlet gasket 38
8. MAINTENANCE SCHEDULE 39
Symbols used on Hydrotech filters 40
Manuals & technical information 41

5
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
1. INTRODUCTION
This manual contains instructions for the operation and maintenance of the Hydrotech Disc filter
in the HSF2200 series.
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.
Personnel who work on the equipment must have access to the manual at all times.
It is important that:
⊲The manual and other relevant documents are kept carefully throughout the life of the equip-
ment. The manual and other relevant documents are part of the equipment.
⊲The manuals are read carefully by all personnel who handle the equipment.

6
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
2. SAFETY INSTRUCTIONS
Hydrotech Disc filters in the HSF2200 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 in accordance with local regulations. The 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. Failure to do so may result in
serious personal injury and/or damage to the equipment.
⊲Assume all electrical equipment to be live.
⊲Assume all hoses and pipes to be pressurised.
⊲The main power switch (see Figure 2.3) must be turned to OFF (0) and locked with a padlock
before maintenance work is performed.
⊲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 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.
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 1 Figure 2.1
Figure 2.2

7
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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
To prevent personal injury and damage to the equipment, only personnel who have been trained
in the equipment and local codes and regulations are allowed to perform service and mainte-
nance work. Service and maintenance personnel may only handle those parts of the equipment
they have been trained for.
The operator may 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 Fi-
gure 2.3).
To perform an emergency stop, turn the main power
switch to OFF (0).
In the event of a power failure, turn the main power
switch to OFF (0) to prevent the filter drum from unin-
tentionally starting to rotate when the power is recon-
nected.
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 filter tank or the frame must be connected to earth. Also see section 4.4. The main power
switch/emergency stop must be fitted in accordance with applicable regulations.
2.7 Safety instructions
The filter is activated by turning the main power switch to ON (1) and then selecting HAND or
AUTO with the operating mode switch on the front of the control cabinet. The filter stops if the
operating mode switch is turned to 0 (OFF).
NB See instructions in section 5.1.
Figure 2.3
A. Mode selector
B. Main power switch

8
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
Turn the main power switch to OFF (0) and lock it with a padlock before performing 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.
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.

9
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
3. HYDROTECH DISC FILTER HSF2200 SERIES
3.1 Reception
The equipment must be inspected for transit damage upon delivery. Document any transit da-
mage before further handling of the equipment.
The consignment note, manual and spare part kit are attached to the equipment.
Check that all parts have been delivered as listed on the consignment note. Some parts may be
delivered unassembled. Handle fragile parts with care. Before lifting the equipment, see section
4.1.
3.2 Storage
Some precautions must be taken to prevent damage to the equipment if a long storage time is
necessary (several weeks or more):
⊲The equipment should preferably be stored indoors, in a frost-free area.
⊲If stored outdoors, protect the filter from direct sunlight. Heat and UV radiation can damage
the filter panels.
⊲ 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 & maintenance manual, Discfilter HSF2200-1/2F PFC
3.3 Overview
3.3.1 HSF2200 type 1, filter with tank
NB Also see section 3.3.2 (HSF2200 type 2, filter without tank) where several filter parts are shown.
Figure 3.1 Hydrotech Disc filter in the HSF2200 series type 1 (side view).
A. Inlet side
B. Filter cover
C. Outlet side
Figure 3.2 Hydrotech Disc filter in the HSF2200 series type 1 (inlet side).
A. Connection, chemical cleaning
B. Lubrication point
C. Sludge outlet
D. Inlet
E. Outlet, separate emergency overflow (bypass) (optional)

11
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
Figure 3.3 Hydrotech Disc filter in the HSF2200 series type 1 (outlet side).
A. Bypassvalve for nozzle check
B. Manometer
C. Lubrication point
D. Shut off valve for wash pipe
E. Wash ramp lever
F. Drive unit
G. Pressure switch - dry running protection for pump (optional)
H. Wash water filter
I. Backwash pump
J. Electrical connection box
K. Drain valve
L. Outlet
M. Drain (tank)

12
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
3.3.2 HSF2200 type 2, filter without tank
Figure 3.4 Hydrotech Disc filter in the HSF2200 series type 2 (side view).
A. Inlet side
B. Inlet passage
C. Filter cover
D. Outlet side
Figure 3.5 Hydrotech Disc filter in the HSF2200 series type 2 (inlet side).
A. Backwash pump (optional)
B. Drain valve
C. Wash water filter
D. Pressure switch (protects pump from running dry) (optinal)
E. Connection, chemical cleaning
F. Shut off valve for wash pipe
G. Manometer
H. By-pass valve for nozzle check
I. Lubrication point
J. Drum lifter
K. Sludge trough
L. Sludge outlet
M. Drum bearing, inlet side
N. Inlet
O. Filter panel

13
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
Figure 3.6 Hydrotech Disc filter in the HSF2200 series type 2 (outlet side).
A. Wash ramp lever
B. Lubrication point
C. Drive unit
D. Drum lifter
E. Drive chain
F. Drum bearing, outlet side
G. Drum
H. Filter panel

14
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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.
Definition of filter type:
Figure 3.7 Filter marking plate.

15
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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 Disc filter in the HSF2200 series type 1 (with tank).

16
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
⊲Filters without a tank can be lifted using a crane or overhead crane by using the filter’s lifting
lugs.
Figure 4.2 Shows how lifting devices are attached (filter without tank).
Figure 4.3 Lifting Hydrotech Disc filter in the HSF2200 series type 2 (without tank).

17
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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 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 wash water system.
4.3 Electrical connection
All electrical work must be carried out by suitably qualified personnel.
Electrical installations must be properly connected in accordance with local codes and standards.
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.
4.4 Equipotential bonding
The Hydrotech Disc filter and related equipment should be protected with a suitable system for
equipotential bonding. This is very important to prevent galvanic corrosion. Ideally use a cable
with a cross section of 10-16 mm2. The cable should be connected to the same electrical potential
as the drive system.
Figure 4.4 Filter installation

18
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
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 & maintenance manual, Discfilter HSF2200-1/2F PFC
5. START UP AND OPERATION
5.1 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 5.1).
3. Set the main power switch to the ON (1) position (see J in Figure 5.1).
4. Set the operating mode switch to the HAND position (see E in Figure 5.1).
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 5.2.1).
If the filter 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 unfilte-
red water.
WARNING! A difference in water level between the inside and outside of the filter drum gre-
ater than 450 mm will damage the filter.
6. When the water level inside the filter tank/chamber reaches the pump suction pipe (or the
pump if a CRK or MTR pump is installed), the pump switch must be set to 1 (ON) position. NB Also
read section 2.7.
WARNING! The backwash pump must not be started until the water level has reached the
suction pipe (or pump if a CRK or MTR pump is installed), otherwise the pump will run dry
and fail.
7. When the water level inside the filter tank/chamber reaches the overflow wall, the operating
mode switch should be turned to AUTO mode.
8. Open the water supply fully.
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 5.2.4).

20
Operation & maintenance manual, Discfilter HSF2200-1/2F PFC
5.2 Automatic seings
The control system for the HSF2200 series must be equipped with a frequency converter on the
drive unit. This is factory calibrated if delivered from Hydrotech. The setting on the frequency
converter must be set for a minimum of 5 seconds “ramp up” and a minimum of 3 seconds “ramp
down” to give soft start on the drive motor. The filter works with 50 Hz as standard.
If the filter is equipped with a Hydrotech control system, the filter has two operation modes:
1. Continuous rotation (HAND mode)
2. Automatic level control (AUTO mode).
Turn the operating mode switch to select the operating mode (see E in Figure 5.1).
A. DRUM DRIVE TRIPPED. LED that indicates
when the frequency 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 the dry run-
ning protection for the wash water pump.
E. OPERATION MODE. Operating mode switch.
F. PUMP. Pump switch.
G. CLEANING START. Chemical wash switch,
key operated.
H. CLEANING. LED that indicates when the che-
mical wash is in progress.
I. CLEANING SEQUENCE. Selector for the num-
ber of sequences, chemical cleaning.
J. Main power switch.
Figure 5.1 Front of the control cabinet.