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Veolia HYDROTECH HSF2200-1F-PFC Operation And Maintenance Manual

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Discfilter HSF2200 - 1/2F - PFC
Operataion and maintenance manual

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Summary of Contents for Veolia HYDROTECH HSF2200-1F-PFC

  • Page 1 Discfilter HSF2200 - 1/2F - PFC Operataion and maintenance manual...

  • Page 2: Table Of Contents

    LIST OF CONTENTS 1. INTRODUCTION 2. SAFETY INSTRUCTIONS 2.1 Warning symbols 2.2 CE marking 2.3 Conversion 2.4 Personnel requirements 2.5 Emergency stop 2.6 Electrical safety 2.7 Safety instructions 3. HYDROTECH DISC FILTER HSF2200 SERIES 3.1 Reception 3.2 Storage 3.3 Overview 3.3.1 HSF2200 type 1, filter with tank 3.3.2 HSF2200 type 2, filter without tank 3.4 Identifying the filter...
  • Page 3 4.5 Checking drum rotation 4.6 Pipe connections 5. START UP AND OPERATION 5.1 Check procedures during start-up 5.2 Automatic settings 5.2.1 Level differences 5.2.2 Operating mode HAND – Continuous rotation/backwash 5.2.3 Operating mode AUTO – Automatic level control 5.2.4 Adjusting the level sensor 5.2.5 Setting of level relay 5.3 Backwash system 6.
  • Page 4 7.4.1 High pressure cleaning (HPC) 7.4.1.1 Cleaning with integrated HPC (optional) 7.4.2 Chemical cleaning of filter panels 7.4.3 Changing filter panels 7.5 Drive chain 7.5.1 Checking the drive chain 7.5.2 Adjusting drive chain tension 7.5.3 Replacing the drive chain 7.6 Drive unit 7.7 Inlet gasket 7.7.1 Checking the inlet gasket 7.7.2 Replacing the inlet gasket...

  • Page 5: Introduction

    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.

  • Page 6: Safety Instructions

    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.

  • Page 7: Personnel Requirements

    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.
  • Page 8 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.

  • Page 9: Hydrotech Disc Filter Hsf2200 Series

    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.

  • Page 10: Overview

    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.
  • Page 11 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.

  • Page 12: Hsf2200 Type 2, Filter Without Tank

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

  • Page 14: Identifying The Filter

    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. Figure 3.7 Filter marking plate. Definition of filter type: Operation &...

  • Page 15: General Installation Instructions

    4. GENERAL INSTALLATION INSTRUCTIONS 4.1 Lifting 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.
  • Page 16 ⊲ 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). Operation &...

  • Page 17: Installation Site

    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.

  • Page 18: Checking Drum Rotation

    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%. Operation & maintenance manual, Discfilter HSF2200-1/2F PFC...

  • Page 19: Start Up And Operation

    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.

  • Page 20: Automatic Settings

    5.2 Automatic settings 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”...
  • Page 21 Inside of the control cabinet: A. Motor protection switch, pump. B. Motor protection switch, drive unit. C. Fuse. D. Fuse. E. Transformer. F. Contactor. G. Relays. H. Logic module. I. Level relay. Figure 5.2 Component parts of the Hydrotech control cabinet. J.

  • Page 22: Level Differences

    5.2.1 Level differences The maximum permitted difference between the water levels inside and outside the drum is 250 mm during normal operation (see Figure 5.3). 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 difference.

  • Page 23: Adjusting The Level Sensor

    5.2.4 Adjusting the level sensor NB Prior to servicing, read section 2.7. Place the level sensor 50–100 mm below the overflow wall. The optimal placement depends on the turbulence of the water surface (see Figure 5.4) 5.2.5 Setting of level relay Figur 5.4 Justering av nivågivare.

  • Page 24: Function

    6. FUNCTION 6.1 Intended use The filter is designed and manufactured to remove solid particles in unpressurised water flow systems. The filter is not a pressure vessel. 6.2 Non-intended use Unless approved in writing by Hydrotech, the filter must not be used to filter liquids other than water.

  • Page 25: Maintenance/Service

    7. MAINTENANCE/SERVICE 7.1 Backwash system The most common cause of operating disruptions in the backwash system is clogged nozzles. Clogging is caused by particles in the wash water and/or by biological growth in the pipe system. There are also nozzles that are self-cleaning and less sensitive to blocking than the conventional nozzles, see section 7.1.2 7.1.1 Servicing conventional nozzles 1.
  • Page 26 7. Check whether any of the nozzles are clogged by checking whether water runs through them. Clogged nozzles are cleaned as follows: Figure 7.3 Nozzle components. A. Nozzle attachment B. Rubber seal C. Nozzle tip D. Nozzle nut E. O-ring 8.

  • Page 27: Self-Cleaning Nozzle

    7.1.2 Self-cleaning nozzle Figure 7.4 below shows a self-cleaning nozzle. Figure 7.4 Nozzle components, self-cleaning nozzle. A. Stop screw B. Nozzle attachment C. O-ring D. O-ring E. Nozzle tip F. Nozzle nut Operation & maintenance manual, Discfilter HSF2200-1/2F PFC...

  • Page 28: Cleaning The Hydrotech Wash Water Filter

    7.2 Cleaning the Hydrotech wash water filter NB Prior to servicing, read section 2.7. If the pressure gauge indicates a pressure that is more than 0.5 bar below normal pressure, it is time to clean the wash water filter. 1. Turn the main power switch to the OFF (0) position and lock with a padlock. 2.

  • Page 29: Bearings

    7.3 Bearings NB Prior to servicing, read section 2.7. Stickers indicating the lubrication points are attached to the filter, see Figure 7.6. Figure 7.6 7.3.1 Lubrication of swivel The swivel makes up the bearing between the wash pipe and the connecting pipe for the wash water (see Figure 7.7).

  • Page 30: Checking Drum Bearing Wear

    7.3.3 Checking drum bearing wear 1. Turn the main power switch to the OFF (0) position and lock with a padlock. 2. Drain filter basin/filter tank. 3. Check the drum bearings with respect to wear. If the distance between the bearing housing (A) and the shaft (B) is less than 22 mm (see Figure 7.8), the drum bearing must be replaced.

  • Page 31: Filter Panels

    7.4 Filter panels NB Prior to servicing, read section 2.7. 7.4.1 High pressure cleaning (HPC) It may be necessary to clean the filter panels manually. If the automatic backwashing starts more frequently, this is a clear indication that manual cleaning is required. Manual cleaning can be performed using HPC.

  • Page 32: Chemical Cleaning Of Filter Panels

    7.4.2 Chemical cleaning of filter panels Long-term clogging of the filter media can be caused by iron, calcium, organic growth or other particulate matter. This clogging can normally be removed through chemical cleaning. Three pro- ducts that have been proven not to affect the life of the filter medium are diluted hydrochloric acid (HCl), diluted sodium hypochlorite (NaClO) and diluted sodium hydroxide (NaOH).

  • Page 33: Changing Filter Panels

    7.4.3 Changing filter panels It is important to maintain the balance of the drum when changing the filter panels. Remo- ve/refit every other filter panel. This prevents unintentional rotation of the drum and redu- ces the load on the drive chain and gearbox. NEVER remove or refit all the filter pa- nels on just ONE side of the disc (see Fi- gure 7.11).
  • Page 34 4. Insert a new filter panel and slide it in until it bottoms. NB Filter panels with steel frames must be po- sitioned with the filter cloth facing inwards (see Figure 7.14). Incorrect installation of the filter panels can cause damage to the filter segments. 5.

  • Page 35: Drive Chain

    7.5 Drive chain NB Prior to a service, read section 2.7. The filter is equipped with a chain drive. See Appendix A and Appendix F for technical data. 7.5.1 Checking the drive chain 1. Turn the main power switch to OFF (0) and lock with a padlock. 2.

  • Page 36: Adjusting Drive Chain Tension

    7.5.2 Adjusting drive chain tension Adjust the drive chain tension as follows: 1. Turn the main power switch to OFF (0) and lock with a padlock. 2. Loosen the four nuts (A) (see Figure 7.16). 3. Loosen the nut (B). 4.

  • Page 37: Replacing The Drive Chain

    7.5.3 Replacing the drive chain 1. Turn the main power switch to the OFF position and lock with a padlock. 2. Lower the drive unit to its lowest position, see section 7.5.2. 3. Split and remove the drive chain. 4. Fit the new drive chain. 5.

  • Page 38: Replacing The Inlet Gasket

    7.7.2 Replacing the inlet gasket 1. Turn the main power switch to OFF (0) and lock with a padlock. 2. Lower the water level in the filter until the whole inlet gasket is accessible. 3. Note how the inlet gasket is fitted before it is dismantled. 4.

  • Page 39: Maintenance Schedule

    8. MAINTENANCE SCHEDULE Check/action Maintenance interval Check whether the wash water filter is clogged. See The interval is based on experience of the applica- section 7.2. tion. (When the wash water pressure has dropped to 0.5 bar below the normal value). Check the filter panels for clogging and damage.

  • Page 40: Symbols Used On Hydrotech Filters

    Symbols used on Hydrotech filters Symbol is displaying equipotential earth bonding points on the filter. Symbol shown at lubrication points on the filter. Read the manual for fur- ther information about lubrication. Symbol displaying moving parts. Neg- ligence to comply with safety regula- tions may lead to injury.

  • Page 41: Manuals & Technical Information

    Manuals & technical information For further information regarding Hydrotech filters or any other product used together with Hydrotech filters, please visit www.hydrotech.se. Click on ”Manuals & technical information”. Locate the desired product manual and select manual by clicking on one of the language options.
  • Page 42 Hydrotech AB A Veolia Solutions & Technologies Company Mejselgatan 6 235 32 Vellinge Sweden Telephone: +46 (0)40 - 42 95 30 Fax: +46 (0)40 - 42 95 31 E-mail: mailbox@hydrotech.se Web: www.hydrotech.se Copyright © All rights reserved...

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