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Klargester BA to BC Owners Handbook

HEALTH AND SAFETY

These warnings are provided in the interest of safety. You must read them carefully before installing or using the equipment. It is important that this document is retained with the equipment for future reference. Should the equipment be transferred to a new owner, always ensure that all relevant documents are supplied in order that the new owner can be acquainted with the functioning of the equipment and the relevant warnings.
Installation should only be carried out by a suitably experienced contractor, following the guidelines supplied with the equipment.

We recommend the use of a dust mask and gloves when cutting GRP components.
A qualified electrician should carry out electrical work.
Sewage and sewage effluent can carry micro-organisms harmful to human health.
Any person carrying out
maintenance on the equipment should wear suitable protective clothing, including gloves.
Good hygiene practice should also be observed.
Covers must be kept locked.
Observe all hazard labels and take appropriate action to avoid exposure to the risks indicated.
The correct ongoing maintenance is essential for the proper operation of the equipment.
Service contracts are available and recommended.
Please contact Klargester for details of your local service provider.
Should you wish to inspect the operation of the equipment, please observe all necessary precautions, including those listed below, which apply to maintenance procedures.
BioDisc units contain rotating machinery and associated drive belts.
Ensure that you are familiar with the safe working areas and accesses.
Ensure that the working area is adequately lit.
The power supply to the equipment must be isolated at the control panel(s) before lifting the covers. Where a specific maintenance procedure requires the equipment to be running with the covers off, all care must be
taken to avoid contact with moving parts and electrical components or conductors. Drive guards must be replaced and secured if removed during maintenance.
Once power has been isolated, the control panel must be kept locked shut to avoid accidental re-connection
whilst work or inspection is being carried out.
Use only the designated access walkways. Do not walk on the cover or deep well safety mesh(es).
Take care to maintain correct posture, particularly when lifting.
Use appropriate lifting equipment when necessary. Keep proper footing and balance at all times. Avoid any sharp edges.
Desludging should be carried out by a licensed waste disposal contractor holding the relevant permits to transport and dispose of sewage sludge.
The contractor must refer to the desludge instructions in this Handbook, a copy of the instructions are fastened under the covers.
There are separate installation guidelines available to provide full instructions for installations.

Wiring Diagrams

These are included in the BioDisc® Installation Instructions, supplied with the unit. A copy of the standard
single phase BA/BB wiring diagram (510100) is provided at the back of this Handbook.

INTRODUCTION

Thank you for choosing a Klargester product. This manual will help you to keep it operating efficiently over a
long service life. Please read this manual thoroughly, preferably before installation.
This manual should be referred to by:
The installer
The electrician
The commissioning engineer
The maintenance engineer
The desludge contractor
The owner/user
Service contracts are recommended. Details on request.

Section 1
Technical Data

Section 1 - Technical Data


All surface water must be excluded. These units should be used exclusively for the treatment of
sewage from domestic properties. Contact Klargester if your sewage results, wholly or partly, from
any commercial function.


In keeping with the Company policy of continuing research and development Klargester reserve the right to alter specifications and dimensions without notice.


SECTION 2
DESCRIPTION AND PROCESS

1. Introduction
BioDisc systems are designed to accept crude domestic sewage and produce an effluent of suitable quality
for discharge to a watercourse or soakaway system, subject to the approval of the appropriate regulatory
authority. These BioDiscs are self-contained single piece units.
The main casing and cover of the BioDisc are constructed of Glass Reinforced Plastic (GRP). All steel parts
are stainless, galvanised or surface coated to protect against corrosion. The discs are vacuum formed
polyethylene.

Fig. 2 - General Arrangement of BioDisc System


2. Primary Settlement Tank
Crude sewage enters the Primary Settlement Tank (PST), through an inlet pipe in the side of the BioDisc.
Solids are settled out and retained for periodic desludging.
The PST is designed to have sufficient capacity to accept high flows over a short period and the patented
Managed Flow System allows the liquid level to fluctuate to accommodate such surges.

3. Biozone
The Biozone contains the Rotor, which consists of corrugated polyethylene discs mounted on a horizontal
shaft, supported by a bearing at each end. The rotor is slowly rotated by an electric motor and reduction
gearbox with a belt drive.
A flat GRP walkway along either side of the Biozone contains a number of ports which give desludge access
to the Primary Settlement Tank.
The surface of the discs becomes colonised by naturally occurring micro-organisms, which form a visible
coating known as the Biomass. As the discs rotate, the Biomass is alternately submerged in the settled
sewage and aerated by exposure to the atmosphere. Under these conditions the Biomass can efficiently
break down the pollutants in the sewage.
The Biozone and discs are divided into two stages, separated by a fixed baffle. Settled sewage enters the
first stage of the Biozone through a submerged transfer slot. The liquid level in this stage will fluctuate in the
same way as in the PST and the bacteria are exposed both to the fluctuating liquid level and to fluctuations
in sewage strength and concentration of domestic chemicals such as washing powders. One of the functions
of this stage is to minimise the effect of such shock loads, which could otherwise inhibit the process.
The second stage of the Biozone is hydraulically sealed from the first stage and maintains a constant liquid
level. Liquid is transferred from the first to the second stage, at a steady rate, by a series of buckets
attached to the rotor. This controlled flow of effluent is at the heart of the patented Managed Flow System,
which promotes healthy and balanced growth of the micro-organisms essential for efficient treatment.
Excess Biomass (also referred to as humus) sloughs off the surface of the discs and passes with the flow, to
the Final Settlement Tank.

4. Final Settlement Tank
The Final Settlement Tank (FST) is situated under the drive motor and receives a steady flow of treated
effluent from the Biozone. The humus settles out and is retained for periodic desludging.
In NB and NC units the settled humus is periodically returned to the Primary Settlement Tank, for cosettlement,
by a timer controlled pump system.
Final treated effluent discharges from the FST through a dip pipe (excepting units with an Integral Discharge
Pump).

5. Optional Integral Discharge Pump (BA/BB only)
The discharge pump sits within a moulded chamber, positioned in the Final Settlement Tank. Treated
effluent flows into the chamber, by gravity from the FST. When the liquid in the chamber reaches a predetermined
level, a float switches on the pump which then pumps effluent out of the chamber. The same
float also switches off the pump when the liquid level has been sufficiently lowered, thus protecting the
pump from running dry. We do recommend when this option is purchased, that a high level alarm is also
fitted to warn against pump mal-operation or failure.

6. Control Panel
The weatherproof control panel should be mounted adjacent to the BioDisc. All Klargester control panels are
year 2000 compliant. Panel options are :
·  Standard Control Panel: (and all panels) include a 3 amp circuit breaker which protects the installation
wiring should there be an electrical problem within the BioDisc.
·  Loss of Rotation Alarm Control Panel: This replaces the Standard Control Panel and also includes a
Loss of Rotation (LOR) Alarm, which will activate if the rotor stops turning after a delay of 2-3 minutes
(other than a failure in the power supply.) It has stop and run lights on the door, and where specified an
optional alarm beacon on top. An additional remote slave beacon may also be fitted. The loss of
rotation of the rotor is sensed by a reed switch mounted near the BioDisc motor in conjunction with a
magnet attached to the rotor.
·  Integral Discharge Pump Panel also includes an isolation switch for the discharge pump.
·  Nitrification Unit Panels contain a timer and relay to control the operation of the sludge return pump and
current overload protection for the pump motor.
All units will restart following a power cut, unless there has been a power surge greater than the pre-set limit
of 3 amps. See Section 5, paragraph 3.

7. Alarms
Optional independent alarms are available, suitable for placing in any indoor location, up to 100 metres from
the BioDisc and would usually be connected to a power supply independent of the BioDisc. They have an
audible alarm, with mute button and a warning light; some independent alarms are fitted with a flashing
beacon.
·  Independent Remote Loss of Rotation Alarm Panel: This is fitted in addition to the Standard Control
Panel and gives warning if the rotor stops turning for any reason.
·  Independent High level Alarm: This may be fitted to units with an Integral Discharge Pump and gives
warning if the level in the FST rises abnormally, indicating a pump failure.


SECTION 3
INITIAL START UP PROCEDURE

1. Introduction
Every care is taken to ensure that all mechanical components are correctly fitted, adjusted and lubricated
prior to leaving the factory. However, subsequent handling during transportation and installation may result
in the movement of components and a subsequent need to re-adjust prior to starting the unit. Your installing
contractor should have thoroughly checked the unit but if, on inspection, you consider that any components
require adjustment, please contact Klargester. We do recommend you purchase a commissioning service
from an approved engineer.
Once the unit has been installed it should be left filled with water. Please switch on the motor, following the
procedure below and leave the unit running, even if there is no sewage being fed into the plant.
If the unit
has been installed with no operational power supply, then remove the motor/gearbox unit and store
it in a dry or heated environment until such time as the unit is ready for permanent operation. The
motor gearbox unit and drive belt should then be replaced and tensioned by Klargester or an
experienced contractor.

We recommend that the system should be commissioned. Please contact Klargester. Where an immediate
start-up is necessary, the following basic procedures should be carried out. Ensure that all Health and
Safety precautions are observed.

2. Water
Check that the BioDisc is full of water to the outlet level.

3. Electrical
Check that the power supply is connected to the control panel. Check that all electrical components and
conductors are earthed.

4. BioDisc
Check that the BioDisc is in order, with no obvious damage or misalignment of parts. If any problems are
discovered, contact Klargester.
Check that all electrical components: Drive Motor, Sludge Return Pump and LOR Alarm sensor, (where
applicable) are connected to the Control Panel.
NB/NC units only: Check that the Sludge Return Timer in the BioDisc Control Panel is set correctly, as
Indicated in the diagram

Fig. 3 - Pump Position


Fig. 3 - Pump Position


Units with optional discharge pump: Check that
the pump float and associated pipework are
positioned as shown and that the float can move
freely.
Fig. 4 - Float SettingFig. 4 - Float Setting

The float cable length is pre-set during assembly
to a dimension of 75mm. Check that this
dimension has not been altered. If for any reason
the cable becomes disconnected from the
retaining clip it should be replaced so that there
is 75mm of cable between the clip and the float.
Note: Setting less free cable will cause the pump
to operate more frequently and may shorten its
working life.
Important: With the pump chamber empty of
water the float must hang clear of the chamber
floor. The correct float position and distance is
essential. The float must not be able to either
trap or tangle, as this will prevent its correct
operation. The float must not jam.

5. Switch On
Open the Panel. Put the isolating switch and/or circuit breaker(s) into the “on” position. Close and lock the
panel. Note: If the unit is fitted with a sludge return pump, this will start immediately and will run for the preset
period.

6. Running Checks
Check that the rotor is running smoothly in the correct direction of rotation and is not contacting any part of
the fixed structure.
Check that the forward feed buckets are discharging correctly from the first to the second stage of the
Biozone.
Units with optional Discharge pump: Once the rotor is turning, a flow through the FST and into the pump
chamber will be generated. Check that the pump switches on at high level and off at low level.
Note: The pump switch-on level must be below the pump chamber inlet.

7. Optional Loss of Rotation Alarm
The alarm sensor (reed switch) is mounted adjacent to the motor/gearbox assembly. The sensor may be
supplied out of position, to allow for possible minor rotor movement during transport. Check the sensor
position and if necessary adjust to provide a gap of 5 - 10 mm between the sensor and the actuator magnet.

Fig. 5 - Alarm Sensor Adjustment


Check operation of the Loss of Rotation (LOR) Alarm as follows:
a) Open the Control Panel and isolate the drive motor whilst maintaining power supply to the alarm circuit.
For units with a combined Alarm Control Panel this can be done either by removing the motor fuse or
by operating the motor overload trip (refer to wiring diagram). Where a remote independent alarm is
fitted, simply isolate power supply at the BioDisc control panel. After a delay of 2-3 minutes the alarm
should activate.
b) Push the reset button on the front of the Panel. The alarm beacon or sounder should cease and the red
indicator light on the panel front should remain illuminated.
c) Re-connect power to the drive motor and close the Control Panel. The alarm should cease after
approximately one minute.
d) Depress and release the “Beacon Off” button to reset it.
Malfunctioning of the LOR Alarm does not prevent operation of the BioDisc System, but it should be
reported to your maintenance engineer for early rectification.

8. Process Initiation
During installation, the unit will have been filled with water. Allow sewage to enter the unit, this will gradually
displace the clean water used during installation.
Colonisation by micro-organisms will commence naturally and an operating biomass will develop on the
discs after approx. 3-6 weeks, depending on individual site conditions and season.


SECTION 4
OPERATION

1. Introduction
The biological treatment process of your BioDisc is self regulating and it requires no specialised operational
knowledge, but it is important that you are aware of the following:
Your BioDisc system uses colonies of live natural micro-organisms (biomass), to break down the pollutants
in the sewage. Many chemicals used in households and commercial establishments can inhibit or kill these
micro-organisms; particularly if used in excessive amounts.
Bear in mind that treatment plants serving small populations do not have the benefit of dilution that occurs
at a large sewage works. A bottle of bleach tipped down the toilet in Birmingham would be virtually lost
amongst the millions of gallons of sewage arriving at the city's treatment works; a bottle of bleach in a plant
serving one or two houses could be a lethal dose for the biomass.
If the biomass is damaged, it will usually recover in time. But in the meanwhile one of the more obvious
symptoms may be an unpleasant smell, so it is in the operators interest to avoid this.
Generally speaking all common household cleaning fluids are acceptable, provided they are used in
accordance with the makers instructions and stipulated concentrations. The following “Do’s and Don’ts“
includes the most common household chemicals, but it is not an exhaustive list and the golden rule is "If in
doubt - leave it out."
Bear in mind too that it isn't only the toilet that is connected to the treatment plant; anything that goes down
the sink, bath etc., also ends up there.

2. Do's and Don't's
Washing machine and dishwasher detergents, washing up liquids:
These are generally all right to use in the normal concentrations and usage found in domestic housing
applications. Problems can occur if, for instance, you are washing the jerseys of the local rugby club's five
teams!
BioDisc incorporates a unique flow management system which enhances its ability to handle shock loads of
detergent waste, but there are limits even to this, so if you have to do unusual amounts of clothes washing it
would be a good idea to spread it over a few days.
Excessive use of Biological washing powders can cause degradation of the biomass. Non-biological
detergents, without enzymes, may be substituted.
Floor cleaners, disinfectants and bleaches:
These are safe to use in accordance with the makers recommendations and in the minimum necessary
concentration. Do not pour neat disinfectant or bleach down sinks or outside gullies. If these are smelly it
usually indicates a build up of decaying material or a plumbing problem and should be dealt with
accordingly.
Nappy disinfectants and bottle sterilising fluids e.g. Milton
When disposing of the used fluid, ensure that it is well diluted with water. The easiest way of doing this is
usually to flush it away down the toilet.
Waste disposal units:
These do not inhibit the biomass, but, depending on use, they can present the treatment plant with
considerable extra load. This can result in the treatment process becoming unbalanced, leading to
problems. Much better to compost your vegetable peelings etc - it's cheaper and environmentally friendly.
Home beer and wine making.
This presents a similar problem to waste disposal units. The BioDisc has to work as hard to treat one pint of
beer tipped down the drain as it does to treat all the normal waste produced by one person in 24 hours. See
also the notes above regarding sterilising fluids.
THE FOLLOWING MUST NOT BE DISCHARGED INTO THE DRAINS
Motor oil, grease, anti-freeze, brake fluid etc.
Cooking oil and fat.
Weed-killers, insecticides, fungicides and other gardening chemicals.
Paint, thinners, white spirit, turpentine, creosote etc.
Chemical drain cleaners.
Acid based brick/stone floor cleaners.
Medicines

Take unused medicines to a pharmacist for safe disposal.
Photographic developing fluids.
Nappies, sanitary towels, rags, soft toys, tennis balls etc.

This may seem obvious, but it is amazing what gets flushed down the loo from time to time. Although such
items are not directly damaging to the biomass they can cause problems, not the least of which is simple
blockage of the drains.
Even so-called disposable nappies and sanitary towels often do not degrade fully in the treatment plant and
can lead to malfunction, so it is best to dispose of them by other means.

3. Desludging and Maintenance
These are vital to the plant's ongoing operation and should be carried out in accordance with the guidelines
in the maintenance section of this manual.
Maintenance contracts are available. Please contact Klargester for your local service provider.


SECTION 5
MAINTENANCE

1. Introduction
Klargester BioDisc units are designed and engineered for the minimum possible maintenance requirements,
consistent with proper performance. Nevertheless, it is important that routine preventive electro/mechanical
maintenance and de-sludging are carried out at the appropriate intervals by suitably qualified persons.
Please contact Klargester for your local service provider.

2. Customer Checks
As a back-up to routine servicing and to assist trouble-free operation, we recommend that you familiarise
yourself with the operation of your BioDisc and make the following checks from time to time: (Refer to Fig. 6
for positions of parts mentioned.)
Your attention is specifically drawn to the Health and Safety section of this manual.
·  Review the appearance of the Biomass. It may be light grey to grey at the first bank, gradually
changing to brown in the second stage and dark brown at the drive end of the rotor. If the growth is
excessively thick and the colour predominantly grey throughout, an overload condition is indicated.
·  Visually check the general condition of the BioDisc.
·  Check that the inlet and outlet pipes (C) are clear. Remove any debris if necessary.
·  Check that the dosing bucket(s) (D) are transferring liquid consistently from the first to second biozone
section.
·  Units with an Integral Discharge Pump: Check that the pump float can move freely and switches the
pump on and off as the level in the pump chamber rises and falls. If a high level alarm is fitted check
that the alarm float can move freely.
·  Units with Loss of Rotation Warning Device: Check for correct operation (see Initial Start Up Section).
·  Familiarise yourself with the normal operating sound of your BioDisc. Report any unusual noises to
your maintenance engineer.
If any malfunction is discovered, contact your maintenance engineer.

3. Failure of Power Supply or of Discharge Pump
BioDiscs with gravity discharge: In the event of a power failure, flow through the BioDisc will continue by
gravity, although the quality of the discharge will gradually deteriorate. When power is re-established, check
that the rotor has re-started and is turning correctly (see Section 3.0 paragraphs (5) and (6)). If the BioDisc
has not been working for some time, the rotor may become unbalanced. This can cause the rotor to turn
unevenly or prevent the unit restarting. In the event of any difficulties, contact your local service provider.

4 Low Voltage Power Supply
Motors may burn out if this condition is experienced. Consult electrician.
IMPORTANT - READ THIS. TAKE IMMEDIATE ACTION IF A PROBLEM ARISES
BioDiscs with pumped discharge (Integral or external pumps): During power cuts, or in the event of pump
failure, the level of sewage in the BioDisc will rise and if unchecked will lead to overflowing and/or possible
damage to the motor/gearbox. At normal flow rates, sewage will reach the level of the motor in about 40
hours (6 people) or 20 hours (12 people). If pump operation cannot be re-established within this time the
sewage level in the BioDisc must be carefully monitored and incoming flow restricted. If necessary the
BioDisc should be emptied by a licensed waste contractor to avoid sewage overflowing the internal baffles
or damaging the motor. Do not allow the motor/gearbox to come into contact with sewage.
When normal operation is resumed, check for solids in the Biozone and FST and de-sludge if necessary.
Check rotor rotation as above.

4. Sludge Removal from BioDiscs BA, BB, NB, BC AND NC.
Refer to the illustration below for recommended desludge positions.
(Note: Illustration is typical; individual units may vary).

Fig. 6 - Desludge Positions


a) Isolate power to the BioDisc.
b) Undo the BioDisc cover latches and remove the cover. Hinged covers should be folded before
removal.
c) Remove surface scum and about half the contents of the Primary Settlement Tank through the
desludge ports [A] on either side of the rotor. Use the ports alternately. If port covers are fitted, keep
the port not in use covered.
d) Empty the Final Settlement Tank [B]. DO NOT attempt to remove liquid from the discharge pump
chamber (if fitted).
e) Remove remaining matter from the Primary Settlement tank.
f) DO NOT attempt to remove any liquid from the rotor section.
g) DO NOT attempt to clean off the gelatinous biomass growth on the rotor.
h) Ensure that the BioDisc inlet and outlet pipes [C] and the forward feed buckets [D] are free of debris.
Ensure that the desludge port covers, if fitted, are replaced, then close and lock the BioDisc covers.
i) Re-connect the power supply. Ensure that the control panel door is locked shut.
j) Units with Loss of Rotation Alarms only: Wait for two minutes. If the alarm on the control panel does
not activate, this indicates that the rotor has successfully re-started. If the alarm activates, switch off
the power at the control panel and immediately switch on again. If the alarm continues to activate,
isolate the power supply and notify the plant owner so that the problem can be investigated.

5. Desludge Volumes


Desludge Volumes



TROUBLE SHOOTING GUIDE FOR BIODISC UNITS BA/BB/NB/BC/NC

Troubleshooting

1. Refer to Section 5 of this manual for guidance on the appearance of a healthy Biomass.


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