Disc Filter Manual
Table of Contents
Manual Overview
Disc Stack Filtration System Manual
1. Machine Installation
1.1 Foundation
The new fully automatic filter occupies significantly less space than traditional sand filters or other mechanical filters and can be placed in corners as needed. The equipment has a low self-weight and has no special foundation requirements, only needing to be level; if the foundation cannot be made level, adjustable feet can be used to secure the equipment. The equipment's operating effectiveness is not affected by installation on sloped bases, side mounting, or even inverted mounting. Small systems can be installed directly on pipelines, while medium and large systems use adjustable feet for connection, with the height adjustable according to site conditions.
1.2 Connections
Both the inlet and outlet pipes of the filter use standard flange connections; small systems use threaded connections.
1.3 Backwashing
The filtration system automatically performs backwashing using filtered water from other filter units or externally supplied flushing water. Due to its low water consumption, it has no significant impact on the equipment's output flow.
2. Machine Features
2.1 Advantages and Characteristics of the Filtration System
- Stable Filtration Efficiency: Uses grooved filter discs as the core component, achieving uniformity at an internationally top standard. Effective for various types of suspended impurities, including both organic and inorganic impurities.
- Modular System, Saves Space: The interchangeability of each filter unit core and interface ensures filter combination diversity. Users can add or remove modules as needed, offering flexibility. The system is compact.
- High-Efficiency Backwashing, Energy and Water Saving: A backwash unit can complete the process in 7-20 seconds. Generally, backwash water consumption is lower than 0.5% of the filtered water volume (single filter unit backwash consumes 50L-100L). Also achieves efficient flushing for viscous impurities, resulting in a wider application range.
- Fully Automatic Control, Continuous Outflow: Filtration and backwashing systems operate simultaneously, with minimal pressure loss and flow loss caused by automatic maintenance. Units are backwashed in rotation while others work normally, ensuring high system efficiency.
- Precise Filtration: Filter discs of different accuracies can be selected based on water requirements. Specifications include 20μ, 50μ, 80μ, 100μ, 120μ, 150μ, 200μ, 300μ, 400μ, 500μ, 600μ, etc.
2.2 Machine Features
- Aesthetically Pleasing Appearance: Features a classic cylindrical design, high-quality materials, and compact structure, enhancing corporate image.
- Microcomputer Control: Built-in microcomputer with powerful functions, using LED indicators for concise display. Improves factory work efficiency, reduces labor intensity, and ensures filtration effectiveness.
- Automatic Control of Flushing and Backwashing: The flushing and backwashing processes are completed automatically, enabling unattended automatic operation without manual adjustment.
3. Working Principle
3.1 Principle of Disc Stack Filtration
The filter core of the disc stack filter uses stacked discs as the impurity treatment medium, consisting of a set of plastic discs with grooves on both sides facing different directions stacked together. The groove edges on adjacent surfaces form numerous intersecting points, which constitute countless cavities and irregular passages, with the passage size continuously decreasing from the outside inward. During filtration, the passages cause water turbulence, prompting impurities in the water to be intercepted at the various intersection points.
The discs are stacked and installed on the filter core frame, forming a filter unit that is loose on the outside and tight on the inside under the action of springs and inlet water pressure. In each filter unit, the discs pressed together by the spring and water pressure form numerous filter screens that impurity particles cannot pass through. The disc width is 12-14mm, made of high-quality engineering plastic with extremely high wear resistance, supported by stainless steel springs, resulting in a sturdy structure.
During backwashing, the water flows tangentially along the inner wall of the discs from the inside out, flushing away various impurities adhering to the disc surfaces. The discs rotate under the action of the backwash water flow, ensuring all dirt is effectively cleaned and discharged. All steps of backwashing can be controlled by time interval and pressure differential. Once set, it can be used long-term. The automatic backwash filter can complete the entire automatic backwashing process within seconds without interrupting operation.
Filters using this filtration principle have dynamically variable gaps between discs during both filtration and backwashing. This not only helps improve filtration performance and water quality but also greatly reduces backwash water consumption, typically self-consumption is about 50L-100L (single filter unit backwash consumption). The depth and number of grooves on the discs determine the filtration accuracy of the filter unit.
3.2 Working Principle of the Filtration Stage
Water flows into the filter through the filtration inlet. The filter discs are pressed tightly together under spring force and hydraulic pressure. Impurity particles are intercepted at the disc intersection points. Filtered water flows out from the main channel of the filter. At this time, the one-way diaphragm valve is in the open state.
3.3 Principle of the Backwashing Stage
When a certain pressure differential or set time is reached, the system automatically enters the backwashing state. The controller controls the valve to change the water flow direction. The one-way diaphragm at the bottom of the filter closes the main channel, and backwashing water enters the four sets of nozzle channels. The water pressure in the piston chamber connected to the nozzle channels rises, pushing the piston upward to overcome the spring pressure on the discs and releasing the piston space at the top of the disc stack. Simultaneously, backwash water is sprayed at high speed from the 35*4 nozzles above the four sets of nozzle channels along the tangential direction of the discs, causing the discs to rotate and separate uniformly. The spray water washes the disc surfaces, flushing away the intercepted impurities.
When backwashing ends, the water flow direction changes again, the discs are pressed tight again, and the system re-enters the filtration state.
3.4 Filtration and Backwashing Principle of Internal Source Backwashing Equipment
Internal source backwash screen-type filters require frequent cleaning. If the screen-type filter is clogged with impurities, backwashing will completely fail.
Water to be treated enters via the inlet pipe into a two-position three-way valve. Controlled by the valve, water flows into each unit for filtration. Filtered water flows from the internal channels of the filter unit to the outlet. As filtration proceeds, impurities adsorbed by the filter increase. When the pressure difference reaches the set value or the set time, the system enters backwash mode.
The controller first sends a signal to the three-way valve corresponding to the first filter unit. This valve changes the water flow direction, closing the inlet and opening the drain port. Backwash water, under pressure, rushes into the filter via the outlet pipe for washing, and wastewater is discharged from the drain port. After washing, that unit returns to filtration mode. The system then backwashes the next unit until all units are flushed, then the system returns to filtration mode.
Depending on outlet pipe pressure, if pressure is insufficient to support backwashing, an electric solenoid valve will be installed on the outlet pipe to control water flow to meet flushing requirements.
3.5 Two-Position Three-Way Valve Schematic
- 3-inch outlet, 3-inch inlet, drain port (specifications include 3-inch, 2.5-inch, 2-inch)
- Normal inlet/outlet state: Inlet/outlet unobstructed, drain closed.
- Water or air pressure above diaphragm: Valve outlet and drain are connected.
4. Controller Operation
4.1 Input / Output Point Function Description
- Power Input: 220V A
- Input Signals: 4 (Normally Open Passive Contacts)
- Differential Pressure Signal Input (X3)
- Inlet Pressure Upper Limit (X0)
- Outlet Pressure Upper Limit (X1, valid only for internal source backwash)
- Outlet Pressure Lower Limit (X2, valid only for internal source backwash)
- Output Signals: 18 (3A/24V)
- 16 points control washing solenoid valves: Each controls 4 DC 24V solenoid valves.
- 2 points control valves: Control single-phase AC motorized valves or solenoid valves.
- During external source backwashing, the action of output points synchronizes with the backwash valve action. When the backwash solenoid valve acts, the inlet valve opens; when the backwash solenoid valve stops, the inlet valve closes.
- The housing uses an IP65 waterproof junction box. The display uses a 240×128 dot matrix LCD. Buttons are tactile switches.
| Function Name | Function Code (CD) | Setting Range | Unit | Default Value | Content Description |
| ------------- | ------------------ | ------------- | ---- | ------------- | ------------------- |
| Backwash Mode Selection | 000 | 0-1 | - | 0 | 0 - Internal Source Backwash; 1 - External Source Backwash |
| Number of Backwash Units | 001 | 0-30 | unit | 16 | - |
| Filtration Working Time | 002 | 0-9999 | minute | 720 | - |
| Backwash Time | 003 | 0-9999 | second | 10 | - |
| Backwash Preset Time (Valve) | 004 | 0-9999 | second | 30 | - |
| Backwash Reset Time (Valve) | 005 | 0-9999 | second | 30 | - |
| Unit Interval Time | 006 | 0-9999 | second | 2 | - |
| Differential Pressure Delay Time | 007 | 0-9999 | second | 5 | - |
| Outlet Valve Action Cycle | 008 | 0-9999 | second | 30 | - |
| Differential Pressure Alarm Delay | 009 | 0-9999 | second | 600 | 0 - Alarm Function Cancelled |
| First Filtration Working Time | 010 | 0-9999 | minute | 30 | - |
| Working Mode Selection | 011 | 000-111 | - | 000 | |
| Chinese/English Mode Selection | 100 | 0-1 | - | 0 | 0 - Chinese; 1 - English |
| Backlight Delay Off Time | 199 | 0-9999 | second | 0 | 0 - Backlight Always On |
| Help Screen Text Setting | 101-149 | - | - | - | - |
| Startup Screen Text Setting | 150-198 | - | - | - | - |
4.3 Control Requirements Description
4.3.1 Internal Source Backwash Control Program Function
During the filtration working state, the outlet valve is opened, and all backwash solenoid valves are closed. When the differential pressure reaches the set differential pressure delay value, the backwash valve for filter head 1# is opened, and simultaneously the valve preset time starts counting. When time elapses, closing of the outlet valve begins. When the outlet pressure reaches the upper limit (backwash pressure) or the valve closing time exceeds the valve action cycle, valve closing stops, and the backwash time starts counting.
When backwash time elapses, the backwash solenoid valve is closed, and the valve reset time starts counting. When the valve reset time elapses, opening of the outlet valve begins. It stops when the pressure lower limit is reached or the valve action cycle time elapses, completing the backwash for filter head 1#.
The unit interval time starts counting. When time elapses, the backwash process for filter head 2# begins, and so on. When the number of backwashed heads exceeds the set number of backwash units, the program enters the filtration working state.
If the differential pressure signal persists longer than the set differential pressure alarm delay value, an alarm is triggered, and fault code E1 (Discs Clogged) is displayed.
4.3.2 External Source Backwash Control Program Function
During the filtration working state, all backwash solenoid valves are closed. When the differential pressure reaches the set differential pressure delay value, the backwash valve for filter head 1# and the external valve (external source flush water valve) are opened simultaneously, and the valve preset time starts counting. When the counting time elapses, the backwash time starts counting. When backwash time elapses, the backwash valve for filter head 1# and the external valve (external source flush water valve) are closed, and the valve reset time starts counting. When time elapses, the unit interval time starts counting. When it elapses, the backwash process for filter head 2# begins, and so on. When the number of backwashed heads exceeds the set number of backwash units, the program enters the filtration working state.
If the differential pressure signal persists longer than the set differential pressure alarm delay value, an alarm is triggered, fault code E1 is displayed, and the program continues to run; when the differential pressure alarm delay setting = 0, this function is cancelled.
During internal source backwash operation, if the backwash upper limit pressure is still not reached after the valve action cycle time elapses, fault code E2 (Low Outlet Pressure) is displayed, and the program continues to run.
4.4 Controller Adjustment Method[(Optional)]{.mark}
- Turn on the power switch. The internal source backwash filter control screen is displayed, containing information such as system working status, filtration working time, backwash working time, valve preset time, valve reset time, unit interval time, number of filter units, etc.
- Press 【Main Menu】 or 【MEAN】 to display the disc stack filter control system main menu (Control Screen, Setting Screen, Help Screen). The cursor blinks on 〖Control Screen〗.
- Press the Down arrow key. The cursor blinks on 〖Setting Screen〗. Press 【Confirm】 or 【ENT】 key, and the cursor blinks on Function Code 〖000〗. Press 【Confirm】 or 【ENT】 key again, and the cursor blinks on 〖Setting Value: 00000〗. Press 【￪】【￬】 keys to change the setting value (00000 - Internal Source Backwash, 00001 - External Source Backwash). Press 【Confirm】 or 【ENT】 key to confirm the backwash mode.
- The cursor blinks on 〖Function Code: 000〗. Press the Up 【￪】 key to change the function code to 001 (Number of Backwash Units). Press 【Confirm】 or 【ENT】 key, and the cursor jumps to blink on the setting value. Adjust the value using the 【￪】(increase) and 【￬】(decrease) keys. Press 【Confirm】 or 【ENT】 key to confirm.
- Follow the steps above to adjust parameters in sequence: 002 (Filtration Working Time), 003 (Backwash Time), 004 (Valve Preset Time), 005 (Valve Reset Time), 006 (Unit Interval Time), 007 (Differential Pressure Delay Time), 008 (Outlet Valve Action Cycle), 009 (Differential Pressure Alarm Delay), 100 (Chinese/English Mode Selection), 199 (Backlight Delay Off Time), etc. Press 【Confirm】 or 【ENT】 key to confirm after adjusting each parameter.
- After all settings are complete, press 【Main Menu】 or 【MEAN】. The cursor blinks on 〖Control Screen〗. Press 【Confirm】 or 【ENT】 key, and the screen returns to the internal source backwash filter control screen, entering the normal filtration state.
- Directly press 【Backwash】 or 【BackF】 key to enter the backwash state; press 【Filter】 or 【Filter】 key to enter the normal filtration state.
- Settings are correct as delivered. If modification is needed, operate according to the above method.
5. Maintenance
5.1 Daily Inspection
- Check if the ambient temperature is too high; maximum water temperature should not exceed 60°C.
- Check the surface of filter units for obvious damage or cracks. Replace immediately if cracks are found.
- Check if clamps are tightened to prevent injury from pressure inside the backwash unit.
- Check bolts of pipe connection clamps for loosening due to vibration, etc., which may cause leakage (potentially leading to insufficient flushing and backwash pressure, affecting work efficiency).
- Check if wiring of two-position two-way solenoid valves is loose (looseness may prevent filter units from automatically completing flushing and backwashing processes).
- Check if all pipes connected to the filter have unobstructed water flow; clean if obstructed.
5.2 Periodic Inspection
- Open the upper half of the filter unit cover barrel and check if the spring in the disc compression cover is deformed.
- Inspect whether the rubber rings inside the clamps connecting to the base are correctly pressed between the two interfaces.
- Check if the internal rubber diaphragm of the two-position three-way valve is seated in its groove, and if the electrical contacts of the two-position two-way solenoid valves are in good condition.
- Check if all pressure gauges connected to the system are working properly.
- Check the controller interior for dust (may prevent automatic control).
- Check all tubing connected to the two-position two-way solenoid valves for damage and ensure connections are secure.
5.3 Component Replacement
- Periodically disassemble and inspect the spring pressing the discs in the upper cover (see Fig. Page 15). Replace if deformed.
- If the rubber sealing ring inside the upper cover is worn, replace it.
- After prolonged use, if inlet water quality is poor and backwash frequency is high, high-speed rotation of discs can cause wear. Replace discs based on wear condition.
6. Precautions
- Ensure the rated voltage of this product matches the AC power supply voltage.
- When installing connecting pipes, ensure measures are taken to prevent water leakage.
- Do not touch controller buttons with wet hands while the system is operating.
- Do not open clamps when there is pressure inside the filter unit.
- When using this set of equipment, try to place it on relatively flat ground.
- When connecting pipes, pay attention to correct connection of inlet and outlet.
- Before connecting the controller power, ensure the cover plate is closed to avoid personal injury.
- To inspect the inside of a filter unit, wait 3-5 minutes after the system stops, allowing water inside the flushing filter unit to drain completely, before opening the clamp to ensure personal safety.
- Avoid using liquid adhesive as a sealant if possible; if used, absolutely ensure that the adhesive does not flow into the pump body during tightening (otherwise it may cause the impeller and rotor to stick, resulting in a no-pressure fault). If using PTFE tape as a sealing material, absolutely ensure to prevent PTFE tape from breaking off and entering the pump interior (otherwise the above fault may occur).
- All pipes should be selected as specified; do not reduce the diameter.
- Before repairing or replacing any components, the power must be disconnected.
7. Main Technical Specifications
7.1 Filter Unit Technical Specifications
Table 7-1 Filter Unit Technical Specifications
| Item | Specification |
| ---- | ------------- |
| Size | 3" |
| Housing Material | Reinforced Nylon |
| Disc Material | PP |
| Filtration Area (Discs) | Φ131×423mm |
| Filtration Accuracy (μm) | 20, 50, 80, 100, 120, 150, 200, 300, 400, 520, 600 |
| Dimensions (H × W) | 790mm×320mm |
| Weight | 9.8 kg |
7.2 Outlet Water Quality (Disc Accuracy) vs. Unit Flow Rate per Hour Reference Table
Table 7-2 Outlet Water Quality vs. Unit Flow Rate Reference Table
| Water Quality Condition | Disc Design Accuracy (μm) | 20μ | 50μ | 80μ | 100μ | 120μ | 150μ | 200μ | 300μ | >400μ |
| ----------------------- | ------------------------- | --- | --- | --- | ---- | ---- | ---- | ---- | ---- | ----- |
| Excellent Water Quality | Unit Flow Rate (m³/h) | 10 | 20 | 25 | 30 | 33 | 35 | 40 | 45 | 55 |
| Average Water Quality | Unit Flow Rate (m³/h) | 8 | 15 | 18 | 20 | 25 | 28 | 30 | 35 | 45 |
| Poor Water Quality | Unit Flow Rate (m³/h) | 3 | 11 | 13 | 15 | 17 | 19 | 21 | 25 | 35 |
| Very Poor Water Quality | Unit Flow Rate (m³/h) | 2 | 6 | 8 | 10 | 12 | 14 | 16 | 20 | 28 |
7.3 Operating Parameters
Table 7-3 Operating Parameters
| Item | Value / Range |
| ---- | ------------- |
| Water Temperature | <60°C (>65°C must be declared in advance) |
| PH | 5~11.5 |
| Optimal Backwash Pressure | 0.28MPa - 0.35MPa |
| Optimal Backwash Flow Rate | 28~35m³/h |
| Optimal Backwash Time | 10~20 seconds |
| Backwash Water Consumption | 50L-100L (single filter unit per backwash) |
| Control Voltage | 220V AC Input, 24V DC Output |
7.4 Disc Stack Filter System Drawing (Filter Head Parts Diagram)
- Wear Part: Water Seal Ring
- Other Components: Upper Cover, Center Column, Spring, Discs, Rubber Seals, Disc Compression Cover, Lower Spring, Spring Plate
8. JX Filtration System Design Specifications
8.1 Technical Parameters
Table 8-1 System Technical Parameters
| Item | Value / Description |
| ---- | ------------------- |
| Overall Pressure Section | Company Standard Parts |
| Design Pressure | 0.2-1.0Mpa |
| Optimal Working Pressure | 0.35-0.45Mpa |
| Optimal Backwash Pressure | 0.28-0.35Mpa ("Internal Source" refers to outlet pipe pressure) |
| Optimal Backwash Flow Rate | 28m³/h - 35m³/h |
| Design Water Temperature | 0-60°C |
| Filtration Accuracy | See 7.1 Filter Unit Technical Specifications |
| Number of Units | 5 units |
| Pipe Material | Seamless Steel Pipe, Internally Lined with Plastic |
| Filter Head Housing | Reinforced Nylon |
| Disc Material | PP |
| Inlet / Outlet Pipes | Flange Interface |
| Unit Filtration Area | Φ131×423mm |
| System Net Pressure Drop | Less than 0.02Mpa |
| Maximum Filtration Pressure Drop | Less than 0.1Mpa |
| Backwash Type | Internal Source Backwash |
| System Backwash Cycle | 1-9999 minutes (adjustable) |
| System Backwash Sequence | Backwash units one by one |
| Backwash Time per Unit | 10 seconds ~ 20 seconds |
| Backwash Interval per Unit | 1-9999 seconds (adjustable) |
| Backwash Initiation Type | Pressure / Differential Pressure / Time Control |
| Control Logic | Automatic / Manual Control |
| Control Box Location | Beside Filtration System |
| Control System Power Supply | 220V 50HZ |
| Controller Dimensions | 390mm×280mm×160mm |
| Controller Stand Height | 750㎜ |
8.2 Main Equipment List for Internal Source Filtration System
Table 8-2 Main Equipment List
| No. | Name | Quantity | Specifications and Description |
| --- | ---- | -------- | ------------------------------ |
| 1 | Filter Unit | 5 units | Standard 3-inch Filter Unit |
| 2 | Inlet/Outlet Pipes | 1 set | Flange Interface |
| 3 | Drain Pipe | 1 piece | Flange Interface |
| 4 | CPM Computer Controller | 1 unit | Chip, LCD Screen, Anti-interference Series, Multi-channel Control |
| 5 | Two-Position Three-Way Valve | 5 sets | In-house produced Two-Position Three-Way Changeover Valve, All-Plastic, Durable |
| 6 | Solenoid Valve | 5 units | Two-Position Two-Way Solenoid Valve, Voltage 24V |
| 7 | Pressure Gauge | 2 units | Electric Contact Pressure Gauge, Vibration-Resistant Pressure Gauge |
| 8 | Differential Pressure Gauge | 1 unit | Yu Yi (Brand) |
| 10 | Spare Parts | 1 set | Rubber Rings (See 8.3 Spare Parts List) |
| 11 | Manual | 1 copy | Equipment Manual with Drawings (One Set) |
8.3 Spare Parts List
Table 8-3 Spare Parts List
| No. | Name | Quantity | Remarks |
| --- | ---- | -------- | ------- |
| 1 | Pipe Rubber Gasket | 3 pieces | Spare Part |
| 2 | Upper & Lower Center Column Rubber Rings | 4 pieces | Spare Part |
| 3 | Nut Rubber Ring | 2 pieces | Spare Part |
| 4 | Filter Middle Section Rubber Ring | 2 pieces | Spare Part |
8.4 Customer Responsibility Section
Table 8-4 Customer Responsibilities
| No. | Item | Requirement |
| --- | ---- | ----------- |
| 1 | Filtration System Foundation | Installation ground: cement floor, flatness less than 0.5cm/m², load-bearing capacity 5t/m². |
| 2 | Controller Power Supply | 220V, 50HZ, supplied to the vicinity of the controller. |
| 3 | External Outlet Pipe | Flange interface (including butterfly valve at connection point). |
| 4 | External Inlet Pipe | Flange interface (including butterfly valve at connection point). |
| 5 | Drain Connection Pipe | Flange interface, connecting to the main drain header of the filtration system. |
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8(1)+150-Disc Filter
18+200-Disc Filter
8+250-Disc Filter
10+250Disc Filter
10+250-Disc Filter
4+100 Disc Filter
3+80-Disc Filter
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