Rotodisk® Automatic

Operating andmaintenanceinstructions

Rotodisk® Automatic

IU4304MAY 2006

2 Copyright ©2006 Irritec srl. All rights reserved.

01.05/200600/

VersioneRevisione

1. Technical characteristics and operating principle 3

1.1 Technical characteristics of the automatic filter 3

1.1.1 Filter components 3

1.1.2 Operating principle of the automatic filter 4

1.1.3 Operating conditions of the filter 5

1.2 Technical characteristics of filtering stations 6

1.2.1 Components of the filtering station 7

1.2.2 Operating principle of the filtering station 8

2. Assembly of the filtering station 9

3. Start-up instructions 12

3.1 General recommendations 12

3.2 Nominal operating conditions 12

4. Manutenzione 13

4.1 Routine maintenance 13

Operating and maintenance instructionsRotodisk® Automatic filter and filtering station

Table of contents

3Copyright ©2006 Irritec srl. All rights reserved.

01.05/200600/

VersioneRevisione


1. Technical characteristics of the automatic filter1.1 Technical characteristics of the automatic filter

1.1.1 Components of the automatic filter

2

4

3

91

5 18

16

71

51

1 11

14

31

12

9

10

8

7

6

1

234

5

6789

10111213141516171819

1

111

1

111111111

3151141

NylonPC

NBRStainless steel

NylonNylon

PPPP

NylonPP

Stainless steelNBRPP

NBRPP

NBRNBR

PE HDNylonNylonNBRNBR

CoverPolycarbonate coverOR cover-filter bodyClampRotodisk base 2” Rotodisk base 3”Filter base cap 2”Filter base cap 3”KnobGuardSpringOR spacer - screw (25.80 x 3.53)SpacerOR bush-pressure plate (45.69x2.62)Pressure plateOR pressure plate-screwOR pressure plate-cartridgeDisksPropellerSupporte disçsLip sealOR cartridge-filter body

Quantità Materiale

0FFCANF00N0000FFCA9F0 0T0000IGCG000000000IFFG00000000

0FT0FG00V200N0FT0FI00V200NIZ60920F0N630IZ60950F0N900

0FMRAN000N0000FCCR2000N0000HMOL000004360HOR2580352A00FDIS2000N0000HOR4569262A00FSDRN000N0NL0HOR2664262A00HOR6944353A00IDIG7000R012OFELIN000N0000FCRAN000N000

0HGUACAR.ROTO0HOR135896990

Ref.Descrizione

The figure below shows all the main components of the Rotodisk® Automatic filter


01.05/200600/

VersioneRevisione

During the filtering phase, the Rotodisk® Automatic fil-ter works like a normal disk filter. The filtering medium,consisting of a set of disks piled onto a sturdy Nylonsupport, filters suspended matter from the flowing waterstream. The progressive accumulation of suspendedparticulate matter on the surface of the filtering mediumincreases the pressure difference between the inlet andthe outlet of the filter (pressure drop).When the pressure drop is too high, the filtering effi-ciency decreases, and the filter must be cleansed. By reversing the flow of water, compared to the normalfiltering stage, the axial pressure on the disks is remo-ved and the disks are made rotate by strong water jets.The impact of the water on the disk surface and thecentrifugal force produced by the rotation of the disksallow a thorough wash of the system. In a filtering sta-tion, each filter is backwashed using the filtered (clean)water from the other filters, that are working normallyand can supply also the other equipment. The backwa-shing phase can be started in manual mode, using thesolenoid valve, or in automatic mode, by programmingthe control unit. For example, the backwashing can beenabled at pre-fixed intervals or as soon as a givenpressure drop is reached between the inlet and outletmanifolds. For further details, please consult themanuals of the control unit and of the differential pres-sure gauge.


Fig.1 - Filtering stage

Fig.2 - Backwashing stage

1. Technical characteristics and operating principle1.1 Technical characteristics of the automatic filter

1.1.2 Operating principle of the automatic filter


01.05/200600/

VersioneRevisione


Maximum working pressure: 10 bar a 20°CCapacity: 2” : 20 m3/h

3” : 30 m3/hMinimum backwashing pressure: 2,8 barFiltering surface: 1400 cm2

Filtration rating: 80 mesh (180 microns)120 mesh (130 microns)155 mesh (100 microns)

0,7

0,6

0,5

0,4

0,3

0,2

0,1

00 10 20 30 40 50 60 70 80 90

*Curves obtained during lab tests with 90° filters, free discharge, 120 meshdisks and clean water at a temperature of 20°C.

Pressure drop diagram - Automatic filter

Flow rate [m3/h]

ΔP

[ba

r]

2”3”

10

9

8

7

6

5

4

3

2

1

0

5 6 7 8 9 10 11 12 13 14 15

*Curves obtained during lab tests, free discharge, 120 mesh disks and clean water at a tem-perature of 20°C.

Backwashing flow rate

Flow rate [m3/h]

ΔP

[ba

r]1. Technical characteristics and operating principle

1.1 Technical characteristics of the automatic filter1.1.3 Operating conditions of the automatic filter


01.05/200600/

VersioneRevisione

1. Technical characteristics and operating principle1.2 Technical characteristics of the filtering station


The figure below shows the characteristics of the filtering station and the most importantdimensions for installation purposes.

IFRSL202LVPEL

IFRSL203LVPEL

IFRSL204LVPEL

IFRSL205PFPEL

IFRSL206PFPEL

IFRSL207RFPEL

IFRSL208RFPEL

40

60

70

90

110

140

160

2

3

4

5

6

7

8

4” – 110

4” – 110

4” – 110

6” – 160

6” – 160

8” – 200

8” – 200

284

284

284

284

284

284

284

720

720

720

720

720

720

720

1720

1720

1720

1790

1790

1830

1830

630

845

1120

1512

1787

2093

2318

E[mm]

831

831

831

856

856

876

876

A[mm]

783

783

783

808

808

828

828

B[mm]

G[mm]

H[mm]

L[mm]2”

IFRSL302LVPEL

IFRSL303PFPEL

IFRSL304PFPEL

IFRSL305PFPEL

IFRSL305RFPEL

IFRSL306RFPEL

IFRSL307RFPEL

IFRSL308RFPEL

60

90

120

120

150

180

210

220

2

3

4

5

5

6

7

8

4” – 110

6” – 160

6” – 160

6” – 160

8” – 200

8” – 200

8” – 200

8” – 200

284

284

284

284

284

284

284

284

720

720

720

720

720

720

720

720

1720

1790

1790

1790

1830

1830

1830

1830

630

962

1195

1510

1510

1775

2050

2325

E[mm]

831

856

856

856

876

876

876

876

A[mm]

783

808

808

808

828

828

828

828

B[mm]

G[mm]

H[mm]

L[mm]3”

No. offiltersCode ØC

Manifold diam.Capacity [m3/h]

No. offiltersCode ØC

Manifold diam.Capacity [m3/h]


01.05/200600/

VersioneRevisione



1.2.1 Components of the filtering station

123456789

1011121314151617181920212223

0HPDA0707116A-

0FC0L7HVLI02AOHVIC00000900IAVCL0000039GIAG0M00000Z46IQ21920M0N63GIR62220D0N25BIARMF00000CZ0IAFLS00000ZY0IR62720D0N250IV3MF11D0N250IIFLC2SM2PC15IR62120F0N25BIARMF00000CZ0IATCM00000Y68IISSE00000320

IR62520D0N25DIFTAFIELV2F0NIIPGG000001000FC0L7HVLI02A

-0HPDA0707500P

Front footLock boltsInlet manifoldVictaulic connection 3”3-way water valve 3”Elbow 1/4 x 6x8Compression elbow with male threaded by-passM/F adapter 3/4” x 1/2”M/F adapter 1/2” x 1/4”Finger filter 1/4" x 1/8”Street elbow ¾” x ¾”Single-union PVC valve - male/femaleSolenoid valve filterAdapted elbow 3/4" x 1/2"M/F adapter 1/2” x 1/4”T 1/8 x 6/8 x 6/8Air valve SE 1”Male/female enlarging pieceRotodisk Automatic filter 3”Glycerol pressure gauge 0–10 barOutlet manifoldAutomation unitRear foot

Ref.Descrizione

The figure below shows all the main components of the Rotodisk® Automatic filtering sta-tions.

NOTE: These codes refer to the filtering station model IFRSL302LVPEL, as shown in thefigure. For a detailed list of the available components and spare parts, please consult the catalogue of filtering systems.


01.05/200600/

VersioneRevisione


1.2.2 Operating principle of the filtering station


During the filtering stage the automatic filter battery works like a standard manual disk filterbattery: the water is filtered (from the outside of the filtering medium) by filters grass, accor-ding to the following diagram (suspended matter is stopped by the external surface of thedisks).

For example, in case of backwashing of the filter n. 1, the 3-way valve positioned on the filter n. 1 is activated by the con-trol unit and reverse the flow of water passing through the fil-ter n. 1. The clean water from filter n. 2 and 3 crosses the filtern. 1 (from the inside of the filtering medium), so as to removethe dirt from the external surface of the disks.

The backwashing stage, which makes it possible to clean every single filter, requires theinstallation of 3-way valves on the inlet manifold, so as to reverse the flow of water pas-sing through the filters. The 3-way valves are controlled by the control unit, that makes itpossible to preset:1) the interval between a complete backwashing cycle and the next one;2) the duration of the backwashing stage for every single filter;3) the interval between the backwashing of a single filter and the next one

(during the same cycle).


01.05/200600/

VersioneRevisione


2. Assembly of the filtering station

Identify the different parts of the filtering stations, as shown in the figure on page 7 and plea-se refer to these instructions for a correct assembly and start-up of the system.

When delivered, the filtering station is partially assembled. To complete mounting, proceedas follows:1) Remove all parts from their original package.2) Insert the feet into the relevant seats of the manifolds and secure them with the screws

provided. The front and rear feet have not the same length: the longer feet shall beinserted in the manifold connected to the 3-way valves, while the shorter feet shall beinserted in the manifold connected to the filters.

3) Insert the filtering media inside the filter bodies, after greasing the seals with silicone grease.4) Grease the seal positioned at the base of the cover and close the filter. Clamp the

mounted parts with the metal band.5) Prepare the drain by connecting the relevant PE tubing (Ø 63 mm) to the elbows on the

3-way valves. Make sure that the drain piping is free and not under pressure (fig. 5), and that the distance between the valve outlet and the drain pipe outlet (h min.) is at least70 cm (fig. 3) Please respect this distance also when, due to the overall dimensions of thesystem, the manifolds’ feet must be shortened (fig. 4).

Fig.3

Fig.4 Fig.5

WARNING:The filtering station shall be installed on a sturdy flat horizontal surface, if possible indo-or. Make sure that the place of installation does not hinder the assembly and maintenanceoperations.


01.05/200600/

VersioneRevisione


6) Install the filtering station on a flat surface, if possible (fig. 6), and do not tilt it in such a waythat the 3-way valves’ outlets are facing upwards (fig. 8).7) Connect the inlet and outlet manifolds of the filtering station to the system. Secure the feetto the ground, after checking that the selected position is compatible with any future mainte-nance operations (see chapter 4).8) If necessary, use a safety valve on the inlet manifold and/or a check valve downstreamfrom the outlet manifold. Furthermore, it is advisable to install a safety filter downstream fromthe filtering station or upstream of the different sectors of use.

WARNING:Please adopt the necessary precautions to make sure that filters are NEVER subject towater hammer phenomena and pressure peaks exceeding the maximum recommendedpressure.

Fig.6Fig.7 Fig.8


01.05/200600/

VersioneRevisione


NOTE:For further information on the wiring, please refer to the manual of the control unit. If the filte-ring station is delivered without the automation unit, please refer to the documentation dealingwith the electric and electronic components to be used. Anyway, make sure that the hydraulicconnections indicated in fig. 9 are performed properly.

Fig.9

Fig.10

If the automation kit is delivered toge-ther with the filtering station, the neces-sary wiring and hydraulic connectionsbetween the control unit, the solenoidvalves and the differential pressuregauge are already preset. Simply com-plete them, as shown schematically inthe figures below.For a proper execution of the hydraulicconnections, follow the diagram andrefer to the labels stuck on micro-pipesand to the symbols available on the dif-ferential pressure gauge and on the val-ves.

Solenoid valve

Discharge

Differentialpressure gauge

Differentialpressure gauge

Solenoid valve 1 Solenoid valve 2 Solenoid valve n


01.05/200600/

VersioneRevisione


3. Start-up instructions 3.1 General recommendations

- Before starting the system, make sure that all its components have been assembledproperly.

- Use the transparent polycarbonate cover (if provided) only for short inspections ormaintenance operations. Do not keep the transparent cover on the filter when the stationis off: the exposure of the disks to sunlight is likely to facilitate the growth of algae,reducing the filtration efficiency.

- Make sure that the filters’ metal bands are closed.

- Set the pressure difference on the differential pressure gauge so that it exceeds by approx.0.3 bar the value detected by the differential pressure gauge under normal workingconditions, with clean filters (the ideal value depends on the quality of the water to betreated and the number of available filters).

- Set a backwashing time sufficient for a thorough cleansing of the filtering media. As a rulea 60-90 sec. backwashing is recommended for a thorough cleansing of the filter. Conductsome tests in order to determine the best conditions, according to the type of water to betreated.

Maximum working pressure: 10 bar a 20°CMinimum backwashing pressure: 2,8 barRecommended backwashing time: > 60 secBackwashing flow rate (at 3 bar): 145 l/min (8,7 m3/h)

3.2 Nominal operating conditions


01.05/200600/

VersioneRevisione


4. Maintenance4.1 Routine maintenance

The Rotodisk® Automatic filtering station requires a regular maintenance according to thewater quality and the working conditions, so as to ensure perfect and continuous operationover time. The water quality may change over the time, and the filter’s operating conditionsmay change accordingly, as well as the frequency of maintenance operations. It is recom-mended to have maintenance operations performed by qualified personnel, according to theinstructions given throughout this manual.

WARNING:Every single maintenance operation shall be carried out with the system stopped, afterreleasing the pressure inside the filters.

1) Cleaning the filtering mediuma) Release the metal band and remove the cover of the filter. Remove the disk medium.

During this operation, be sure that no waste matter falls inside the filter, as it could be recir-culated after the subsequent start-up. To prevent this problem, it is recommended to carryout a backwashing phase just before proceeding with this operation; after removing the covertake the waste matter away from the cartridge base, using a jet of clean water.

b) Unscrew the screw in the upper part of the filtering medium, being careful with the spring tensioned inside the system.Do not compress the propeller.

>

>


01.05/200600/

VersioneRevisione



c) Take the screw out of the pressure plate, disengaging the guard, the spring and the spacer.

d) Take the pressure plate and the disks out of the support. Wash all components with plenty of clean water. Remove the scale, if any, with a soft brush.

>

>e) Grease the head of the cartridge, the screw shank and all seals with silicone grease.

f) Reassemble the medium, according to the diagram shown on page 3, and make surethat the initial configuration of the whole unit is restored. Grease the seat of thecartridge and its seal. Grease the seal located on the cover.

>

>


01.05/200600/

VersioneRevisione



2) Cleaning the valve filterThe filter positioned on the inlet manifold supplies the water for thehydraulic control of the valves and the differential pressure gauge.Clean it regularly in order to prevent any malfunctions of the sole-noid valves. Unscrew the cover of the filter positioned on the bottomor on the side of the manifold. Take out the filtering medium andwash it thoroughly. Clean the cover and the interior of the filter witha jet of clean water. Reintroduce the medium into the filter body,

being careful with the direction of insertion: the part to be fitted into the cover has the shor-ter inside diameter. Screw up the cover, and place the seal in the correct position.

3) Cleaning the air valveUnscrew the valve from the filter cover. Open the valve, by unscre-wing its two parts. Take out the float by removing the seal from thevalve body. Wash all components with plenty of clean water.

Check that the drain hole is free.Reassemble the valve being careful with the correct positioning of allcomponents. Clean the threaded part (3/4”) and attach the valve tothe cover again using a teflon tape.

WARNINGAt the end of each maintenance operation requiring the disassembly of anycomponents, restore the initial configuration.

www.irritec.com

Documents

Rotodisk® Automatic