Hydrotech HSF2600, HSF2600-2F PFC, HSF2600-3F PFC Operation & Maintenance Manual
Operation & Maintenance Manual
Discfilter HSF2600 series
PFC
Type: 2F, 3F
Serial no: ………………………………
Revised: 2015-08-26 EN
2
LIST OF CONTENTS
. INTRODUCTION
. SAFETY INSTRUCTIONS
2.1 Warning symbols 5
2.2 CE marking 5
2.3 Conversion 5
2.4 Personnel requirements 5
2.5 Emergency stop 6
2.6 Electrical safety 6
2.7 Safety instructions 6
. HYDROTECH DISCFILTER HSF SERIES
3.1 Overview 7
3.2 Identifying the filter 9
. START UP AND OPERATION
4.1 Check procedures during start-up 10
4.2 Automatic settings 11
4.2.1 Level differences 13
4.2.2 Operating mode HAND –
Continuous rotation/backwash 13
4.2.3 Operating mode AUTO – Automatic level control 13
4.2.4 Adjusting the level sensor 14
4.2.5 Setting of level relay 14
4.3 Backwash system 14
. FUNCTION
5.1 Intended use 15
5.2 Non-intended use 15
5.3 Filtration and backwash process 15
. MAINTENANCE/SERVICE
6.1 Filter cover 16
6.1.1 Hinge 16
6.1.2 Operating the filter cover 17
6.2 Operating the backwash pipe 17
6.3 Backwash system 18
6.3.1 Servicing nozzles 18
6.4 Backwash pipe position 20
6.4.1 Checking backwash pipe position 20
6.4.2 Adjusting backwash pipe position 21
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
6.5 Cleaning the wash water filter 22
6.6 Bearings 23
6.6.1 Lubrication of swivel 23
6.6.2 Lubricating drum bearings 23
6.6.3 Checking drum bearing wear 24
6.7 Filter panels 25
6.7.1 High pressure cleaning 25
6.7.2 Chemical cleaning of filter panels 26
6.7.3 Changing filter panels 27
6.8 Drive chain 29
6.8.1 Checking the drive chain 29
6.8.2 Adjusting drive chain tension 30
6.8.3 Replacing the drive chain 30
6.9 Driven unit 31
6.10 Inlet seal 31
6.10.1 Checking inlet seal. 31
6.10.2 Replacing the inlet gasket 31
3
. MAINTENANCE SCHEDULE
APPENDICES
A: Technical specifications
B: Spare parts list
C: Measurement drawings
D: Drive unit
E: Backwash pump (option)
F: Actuators
G: Level sensor (option)
H: Pressostat (option)
I: Wiring diagram for control cabinet (option)
J: Frequency converter (option)
K: Soft start (option)
L: Logic module (option)
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
4
. INTRODUCTION
1.
This manual contains instructions for the operation of Hydrotech Discfilters in the HSF2600
series, types 2F and 3F (standing filter).
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 that work with the equipment.
It is important that:
⊲ The manual and other applicable documents must be kept for the entire duration of the
equipment’s lifespan. The manual and other relevant documents are included as part of
the equipment.
The following documents (manuals) are a part of the equipment:
▹ Reception & Installation Manual
▹ Operation & Maintenance Manual
⊲ The manuals must be read carefully by all relevant personnel.
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
5
Figure 2.1
Figure 2.2
. SAFETY INSTRUCTIONS
2.
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.
⊲ 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.
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 equipment.
Warning labels (see Figure 2.1) are attached to the filter to warn personnel and
act as a reminder 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 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 marking must be attached in such a way that 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
In order to avoid personal injury and damage to the equipment, service and maintenance
may only be carried out by personnel that have been trained to use the equipment and are
conversant in local regulations. 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.
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
6
Figure 2.3 Electrical cabinet, with emergency
stop and safety circuit-breaker highlighted
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 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
Emergency stop
by a qualified electrician and in accordance
with local regulations. Also see Appendix I.
The filter tank must be connected to earth,
Main power switch
see section6.4 in the "Reception & Installation Manual".
The main power switch/emergency switch
must be fitted in accordance with applicable regulations.
2.7 Safety instructions
The filter is activated by turning the main power switch to the ON position (1), then selecting
AUTO or HAND mode using the mode selector located on the front of the electrical cabinet.
The filter stops if the mode selector is turned to the 0 (OFF) position.
NB See instructions in section 4.1.
Turn the main power switch to the OFF (0) position 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 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
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.
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
7
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).
. HYDROTECH DISCFILTER HSF SERIES
3.
3.1 Overview
A. Inlet side
A
C
B. Inlet
D
passage
C. Filter cover
B
D. Outlet
side
G H
C
J
I
E
F
E. Backwash pump
(option)
F. Backwash water filter
G. Actuator for
opening cover
H. Pressostat (protects
L
M
N
O
P
Q
R
P
T
U
V
pump from running
dry) (option)
I. Electrical connection
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 sen-
sor, inlet water
Q. Holder for level sen-
sor, outlet water
R. Sludge outlet
S. Filter panel
T. Filter segment
U. Drum
V. Drum bearing,
inlet side
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
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Figure 3.3 Hydrotech Discfilter in HSF2600 series type 2F (from inlet side).
Figure 3.4 Drum lifter.
BA
A. Actuator for
C
D
backwash
system
servicing
E
F
G
H
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
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.
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
3.2 Identifying the filter
Figure 3.5 Filter marking plate
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.
Mejselgatan 6, 235 32 Vellinge, Sweden
Website: www.hydrotech.se E-mail: mailbox@hydrotech.se
9
xxxxFilter type:x
xxxxSerial No.x xx
xxxxYear:xxxxx xx
Definition of filter designation:
Filter type
HSF = Hydrotech Disc Filter
Disc diameter:
26 = 2.6 m
Max. no. of discs
12 = Drum can hold 12 discs
No. of installed discs
8 = 8 discs are installed
HSF2612/8-2F
9568
2011
HSF 26 12/8 - 2 F
Model
F = Industrial model
Disc filter type
1 = Filter with tank
2 = Filter without tank
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
10
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 pump switch to the 0 (OFF) position, see Figure 4.1.
3. Set the main power switch to the 1 (ON) position.
4. Set the mode selector to HAND mode.
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 4.2.1). If the filter cover becomes clogged, it may be necessary to fill the filter tank with water from an external source or to remove a filter panel
and allow unfiltered water to fill the filter tank.
A difference in water level between the inside and outside of the filter drum greater than
450mm will damage the filter.
6. When the water level inside the filter tank is above the pump suction pipe (or the pump if
a CRK or MTR pump is installed), the pump must be started by turning the pump switch
to the 1 (ON) position.
NOTE Also read section 2.7 (Safety instructions).
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. If the water level inside the filter tank reaches the overflow wall, set the mode selector to
the AUTO position (see section 4.2).
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.
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
4.2 Automatic settings
Figure 4.1 Front side of electrical cabinet.
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 Hydrotech’s control system, the filter has two operation modes:
1. Continuous rotation (HAND mode)
2. Automatic level control (AUTO mode).
Turn the mode selector to select the operating mode.
A. DRUM DRIVE TRIPPED. Lamp that
indicates when the frequency
A B
E F
K
J
O
C
G
L
D
H I
M N
converter has tripped.
B. PUMP TRIPPED. Lamp that
indicates when the backwash
water pump’s motor protection
device has tripped.
C. DRY RUNNING. Lamp that
indicates when the dry running
protection device for the backwash water pump has tripped.
D. RESET DRY RUNNING. Resetting
the backwash water pump’s dry
running protection.
E. OPERATION MODE. Mode
selector
F. PUMP. Pump switch.
G. CLEANING SEQUENCE.
Selector for number of
sequences, chemical cleaning.
H. CLEANING. Lamp that indicates
when the chemical wash is in
progress.
I. CLEANING START. Chemical wash
switch, key operated.
J. EMERGENCY STOP. Emergency
stop.
K. RESET E-STOP. Resetting the
emergency stop.
L. COVER OPEN SERVICE. Lamp that
indicates when the cover is open
so that the backwash ramp can
be extended.
M. COVER NOT OPEN/CLOSED.
Switch for operating the cover.
Lamp that indicates when the
cover is not fully opened nor
fully closed.
N. SPRAYBAR NOT IN. Switch for
operating the backwash ramp.
Lamp that indicates when the
backwash pipe is not retracted.
O. MAIN SWITCH. Main power
switch.
11
“Operation & Maintenance Manual”, “Discfilter HSF2600 series”
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