Grunbeck fermaliQ:MA2000 Operation Manual
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Grunbeck fermaliQ:MA2000 Operation Manual

Oxidation filter system
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Oxidation filter system | fermaliQ:MA
Operation manual

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Summary of Contents for Grunbeck fermaliQ:MA2000

  • Page 1 We understand water. Oxidation filter system | fermaliQ:MA Operation manual...
  • Page 2 General Contact Germany International Sales Phone +49 9074 41-145 Technical Service Phone +49 9074 41-333 Fax +49 9074 41-120 Availability Monday to Thursday 7:00 am - 6:00 pm Friday 7:00 am - 4:00 pm We reserve the right to technical modifications. ©...

  • Page 3: Table Of Contents

    Table of contents Table of contents Diaphragm expansion tank: Setting the preload Table of contents ..............3 pressure ..............40 Checking the system ..........42 Introduction ............... 4 Flushing the system ..........43 Handing over the product to the owner/operating Validity of the manual ..........4 company ..............43 Other applicable documents ........

  • Page 4: Introduction

    Illustrations in this manual are for basic understanding and can differ from the actual design. Validity of the manual This manual applies to the products below: ● fermaliQ:MA2000 ● fermaliQ:MA3000 ● fermaliQ:MA5000 ● fermaliQ:MA10000 ● Special designs that essentially correspond to the standard products given above.

  • Page 5: Product Identification

    Introduction Product identification You can identify your product based on the product designation and the order no. indicated on the type plate. Check whether the products indicated in chapter 1.1 correspond to your product. The type plate is located on the system rack. Designation Designation CE mark...

  • Page 6: Depiction Of Warnings

    Introduction Symbol Meaning Reference to further documents Work that must be carried out by qualified specialists only Work that must be carried out by qualified electricians only Work that must be carried out by technical service personnel only Depiction of warnings This manual contains information and instructions that you must obey for your personal safety.

  • Page 7: Demands On Personnel

    Introduction Demands on personnel During the individual phases in the service life of the system, different persons carry out work on the system. This work requires different qualifications. 1.6.1 Qualification of personnel Personnel Requirements • No special expertise required Operator/user •...
  • Page 8 Introduction 1.6.3 Personal protective equipment ► As an owner/operating company, make sure that the required personal protective equipment is available. The components below fall under the heading of personal protective equipment (PPE): Protective gloves Protective footwear 8 | 76...

  • Page 9: Safety

    Safety Safety Safety measures ● Only operate your product if all components are installed properly. ● Obey the local regulations on drinking water protection, accident prevention and occupational safety. ● Do not make any changes, alterations, extensions or program changes on your product.
  • Page 10 Safety ● Never bridge electrical fuses. Do not disable fuses. Use the correct current ratings when replacing fuses. ● Keep moisture away from live parts. Moisture can cause short-circuits. 2.1.4 Danger due to chemicals ● Chemicals can be hazardous to health and environment. They can cause skin and eye burns as well as irritation of the respiratory tract or allergic reactions.
  • Page 11 Safety 2.1.5 Persons in need of protection ● Children must not play with the product. ● This product is not designed to be used by persons (including children) with re- duced capabilities, lack of experience or lack of knowledge. Unless they are super- vised, have been instructed on the safe use of the product and understand the re- sulting hazards.

  • Page 12: Product-Specific Safety Instructions

    Safety Product-specific safety instructions Diaphragm expansion tanks operate with a nitrogen cushion and are subject to the Pressure Equipment Directive 97/23/EC. ● In the event of leaks, there is a risk of nitrogen escaping. ► Check the diaphragm expansion tank for leaks at regular intervals (refer to chapter 8.4.2).

  • Page 13: Conduct In Emergencies

    Safety Conduct in emergencies 2.3.1 In case of escaping water 1. De-energise the device – pull the mains plug. 2. Locate the leak. 3. Eliminate the cause of the water leak. 2.3.2 System failure Emergency bypass for emergency supply ● In case of a failure of the treatment system, raw water can be used for fire-fighting purposes and for flushing the toilets (refer to chapter 7.6).

  • Page 14: Product Description

    Product description Product description By a combination of raw water atomisation, aeration and multi-layer filtration, the substances below are fully automatically reduced in the oxidation filter system fermaliQ:MA: ● Iron ● Manganese ● Ammonium ● Solid particles ● Turbidities ● Unpleasant odours (e.g. hydrogen sulphide) An additional effect of the treatment is a moderate deacidification of the raw water.

  • Page 15: Product Components

    Product description Product components Designation Function Coding Closure of filter tank Level 1: Filling & aeration OFF Level probe Level 2: Filling & aeration ON 1MSF1CL01 Level 3: Dry-run protection of filtrate pump Supply of atmospheric oxygen to oxidate iron and manganese Pipe fan 1MSF1AP03 Switch-off delay to outgas moist exhaust air...
  • Page 16 Product description Designation Function Coding Piston valve to separate the filtrate pipe from the interface 13 Filtrate shut-off valve 1MSF1AH05 supplied by the client on site 14 Flow stabiliser Backwash Setting the backwash volume flow 1MSF1AS05 Backwash monitoring Required minimum pressure (adjusta- 15 Pressure switch 1MSF1ACP03 ble: 0.1 –...

  • Page 17: Connections

    Product description Connections Inlet Outlet Designation Designation Raw water inlet Filtrate outlet Supply air Discharge of first filtrate to drain Backwash water inlet Backwash water to drain Exhaust air 17 | 76...

  • Page 18: Functional Description

    Product description Functional description The filter system is operated in 4 steps. ● Filling and aeration ● Filtration ● Backwash ● Discharge of first filtrate 3.4.1 Filling and aeration ● The raw water is delivered into the filter tank by the raw water pump provided by the client on site.
  • Page 19 Product description 3.4.3 Backwash ● The energy stored in pressure cushion of the tank provided by the client on site is used to deliver the filtrate located there into the filter tank. ● The uniform distribution of the backwash water in the filter tank is ensured by the star-shaped nozzle assembly and the support layer consisting of quartz gravel.

  • Page 20: Accessories

    Product description Accessories Your product can be retrofitted with accessories. Please contact your local Grünbeck repre- sentative or Grünbeck’s headquarters in Hoechstaedt/Germany for details. Product Order no. Diaphragm expansion tank DD 33,G¾ 33 l 890 60 304 To prevent water hammer in the inlet if a compressed-air chamber provided by the cli- ent on site is used to store the filtrate.
  • Page 21 Product description Product Order no. Front cover of fermaliQ:MA 530 508 Fine dust filtration for fermaliQ:MA 530800000000 21 | 76...

  • Page 22: Transport, Placing And Storage

    Transport, placing and storage Transport, placing and storage Shipping/Delivery/Packaging The system (system rack and filter tank) is fixed on a pallet each at the factory and secured against tipping. ● The system rack is transported standing up and has a low centre of gravity. ●...

  • Page 23: Storage

    Transport, placing and storage Transporting the filter tank The filter tank is fixed on a pallet at the factory and secured against tipping/rolling off. ● The filter tank is transported in a horizontal position. ► Only transport the filter tank to the installation site (longer distances) when se- cured on the pallet.

  • Page 24: Installation

    Installation Installation The installation of the system represents a major intervention into the water system and must be carried out by a qualified specialist only. Installation example Designation Designation Oxidation filter system fermaliQ:MA3000 Pressurised water tank (supply tank) Front cover of fermaliQ:MA (option) CAUTION Laying cable trays/pipes on traffic routes.
  • Page 25 Installation ● Unimpeded and prompt placing of the system must be possible. ● Disturbing influences and restrictions on site must be indicated in advance and taken into account in the design of the system. ● A drain connection of adequate dimensions (DN 100) must be present. ●...

  • Page 26: Checking The Scope Of Supply

    Installation Checking the scope of supply Designation Designation Profile rail to connect the system rack and the Operation manual filter tank (incl. screws) Non-return flap of pipe fan Level probe Outlet pipe of filter tank System rack fixed on a pallet Inlet pipe of filter tank Filter tank fixed on a pallet ►...

  • Page 27: Removing The Front Cover (Optional Equipment)

    Installation Removing the front cover (optional equipment) The optional front cover must be removed in order to carry out preliminary work (installation, inspection and maintenance) on the technical equipment. Removing the upper cover 1. Push the cover against the system rack at the bottom corners. »...

  • Page 28: Installation

    Installation Installation 5.4.1 Preliminary work 1. Release the system rack from the transport lock. 2. Remove the pallet. 3. Securely place the system at the designated location – take note of the minimum space required. 4. Level out possible unevenness with the levelling feet. 5.
  • Page 29 Installation 5.4.3 Connecting the system rack with the filter tank CAUTION Working at heights (approx. 2 m) during installation ● Risk of injury when falling. ► Use a stable stepladder. 1. Screw the system rack to the filter tank. 2. Connect the inlet and outlet pipes of the filter tank to the system rack. 3.
  • Page 30 Installation 5.4.4 Installing the fine dust filtration (optional equipment) You can install the fine dust filter directly on the system rack or on an even surface on site (e.g. a wall) near the system. The supply air pipe is approx. 5 m long. ►...

  • Page 31: Water Installation

    Installation Water installation 5.5.1 Connecting the system WARNING Incorrect routing of the exhaust air pipe ● Irritation/chemical burns of the respiratory tract due to harmful gases (H S, CH escaping – only applicable if these gases are dissolved in the raw water. ►...

  • Page 32: Electrical Installation

    Installation Electrical installation DANGER Life-threatening voltage of 230 V ● Risk of severe burns, cardiovascular failure, fatal electric shock ► The electrical installation must be carried out by a qualified electrician only. ► Check the system for proper condition before start-up/commissioning. ►...
  • Page 33 Installation 5.6.1 Establishing potential equalisation In normal operation, the speed-controlled filtrate pump can have a ground leakage current > 10 mA. ► Proceed as follows to establish the connection to the potential equalisation: Designation Designation Hammer head screw Earth screw Ribbon cable 1.
  • Page 34 Installation 5.6.2 Connecting the raw water pump The raw water pump provided by the client on site is enabled from switch cabinet 1MSF1AE02. 1. Open the cover of the control unit. 2. Using a cross-headed screw- driver, loosen the four screws at the corners under the cover.
  • Page 35 Installation 5.6.3 Connecting the options ► Open the cover (refer to chapter 5.6.2, steps 1 – 3). Designation Function If signal at input FALSE (0 V at input), all running processes are “Enable system” aborted and the system returns to basic mode. voltage-free, max.

  • Page 36: Installing The Front Cover (Optional Equipment)

    Installation Connecting “Enable dosing” ► Connect “Enable dosing” to output terminals Q4 of the right-hand module 4A2. Connecting “Backwash signal” ► Connect “Backwash signal” to output terminals Q5 of the right-hand module 4A2. 5.6.4 Connection to the power supply 1. Install the cover and close the control unit. 2.

  • Page 37: Start-Up/Commissioning

    Start-up/Commissioning Start-up/Commissioning The start-up/commissioning of the system must be carried out by a qualified specialist only. Filling in filter material CAUTION The containers/bags containing the filter material are heavy. ● Risk of injury when lifting heavy containers/bags ● When using lifting gear (e.g. cranes), there is a risk caused by suspended loads ►...
  • Page 38 Start-up/Commissioning 1. Loosen the screw connections of the lid. 2. Remove the lid of the filter tank (weight approx. 5 kg) and put it down adjacent to the system. 3. Check the nozzle and the star-shaped nozzle assembly for completeness and in- tegrity –...
  • Page 39 Start-up/Commissioning 6.1.2 Filter filling for deferrisation/demanganisation Filter material 2000 3000 5000 10000 a Filling height 1150 1425 1410 1660 Quartz gravel Filling volume SB 3.15 – 5.6 T Layer height b Filling height 1075 1375 1340 1605 Quartz sand Filling volume SB 1.0 –...

  • Page 40: Diaphragm Expansion Tank: Setting The Preload Pressure

    Start-up/Commissioning 6.1.3 Filter filling for solid particle filtration Filter material 2000 3000 5000 10000 a Filling height 1150 1425 1410 1660 Quartz gravel Filling volume SB 3.15 – 5.6 T Layer height b Filling height 1075 1375 1340 1605 Quartz sand Filling volume SB 1.0 –...
  • Page 41 Delivery head in m Characteristic curve of fermaliQ:MA3000/MA5000 Delivery rate in m³/h Characteristic curve of fermaliQ:MA10000 Characteristic curve of fermaliQ:MA2000 2. Set the operating pressure (set pressure) using the buttons on the op- erating panel of the centrifugal pump. 3. Determine the required preload pressure.

  • Page 42: Checking The System

    Start-up/Commissioning 4. Adjust the preload pressure of the dia- phragm expansion tank. a Close shut-off valves 1 and 4. b Drain the diaphragm expansion tank via sampling valve 3. c Measure the set preload pressure on gas filling valve 2 with a hand- held pressure gauge.

  • Page 43: Flushing The System

    Start-up/Commissioning Flushing the system 1. Completely open all valves except for filtrate shut-off valve (1MSF1AH05). 2. Switch on the system (refer to chapter 7). 3. Initiate the manual discharge of first filtrate (refer to chapter 7.2). Repeat this pro- cess until clear water runs off. »...
  • Page 44 Start-up/Commissioning 6.5.1 Disposal of packaging ► Dispose of the packaging as soon as it is no longer needed. NOTE Danger to the environment due to incorrect disposal ● Packaging materials are valuable raw materials that can be reused in many cases.

  • Page 45: Operation/Handling

    Operation/handling Operation/handling Normally, no intervention by owner/operating company/operator/ is required during operation. WARNING Leaking exhaust air pipe, failure of pipe fan ● Irritation/chemical burns of the respiratory tract and risk of asphyxiation due to harmful gases (e.g. hydrogen sulphide, methane) escaping – only applicable if these gases are dissolved in the raw water.
  • Page 46 Operation/handling 7.1.1 Operating concept The menu consists of one level. ► Use the navigation buttons ▼ and ▲ to change the displays. Setting the values 1. Press and hold the ESC button for 3 seconds. » The input field is highlighted in black. 2.
  • Page 47 Operation/handling Display Explanation 3/11 Information: ▲ ● Status at input “Raw water pump Input in operation” Raw water pump in operation: ● On/Off (TRUE/FALSE) ▼ 4/11 Information: ▲ • Initiating backwash manually Initiate manual On/Off backwash? Off In case a backwash is initiated manually, the specified back- ▼...
  • Page 48 Operation/handling Display Explanation 6/11 Information: ▲ ● Backwash active/inactive Backwash: inactive Remaining time: 00:00m ● Remaining time of backwash in First filtrate: inactive minutes Remaining time: 00:00m ● Discharge of first filtrate active/in- ▼ active ● Remaining time of discharge of first filtrate in minutes 7/11 Information:...

  • Page 49: Initiating Manual Discharge Of Filtrate

    Operation/handling Display Explanation 11/11 Information: ● Time and date Tu. 09:00 2020-01-28 Initiating manual discharge of filtrate During start-up/commissioning, it is necessary to thoroughly flush the filter material in the fil- ter tank. ► Proceed as follows to initiate a manual discharge of the filtrate: 1.

  • Page 50: Initiating Manual Backwash

    Operation/handling Initiating manual backwash Under certain circumstances, it might be necessary to initiate a backwash outside the planned intervals. In case a backwash is initiated manually, the specified backwash requirements are ig- nored. The backwash process is started irrespective of pressure, level and flow. ►...

  • Page 51: Operation Of Filtrate Pump

    Operation/handling 7.4.2 Resetting the number of failed attempts NOTE: Repeated manual reset of the counter ● Malfunctions in the event of repeated manual reset of the counter ► Eliminate the cause of failed backwash processes. ► If the backwash processes keep failing, contact the technical service. Resetting the counter is logged and can be followed up by the technical service.
  • Page 52 Operation/handling Designation Function Information on the unit of the rotational speed LED strip and the Measuring unit LEDs display Indication of the current rotational speed in steps of 10 % Rotational speed LED strip (subject to the set min./max. rotational speed) Status LED Indication of the operating state •...
  • Page 53 Operation/handling 7.5.2 Rotational speed LED strip The rotational speed LED strip consists of 10 LEDs. Each LED represents the rotational speed range between parameter P27 (min. speed) and parameter P26 (max. speed) in stages between 10 and 100 %. Description Motor in operation –...

  • Page 54: Emergency Bypass

    Operation/handling Emergency bypass All oxidation filter systems fermaliQ:MA feature an emergency bypass as standard which can optionally be connected. The system is bypassed by means of a drinking water hose. Using raw water (not drinking water quality) as emergency supply (“emergency bypass”) is admissible for the fields of application below: ●...
  • Page 55 Operation/handling 1. Switch off the system (refer to chapter 7). 2. Close the fittings below: • Raw water shut-off valve (1MSF1AH01) • Filtrate shut-off valve (1MSF1AH04) • Shut-off valves on the raw water side provided by client (downstream of dia- phragm expansion tank provided by client) •...

  • Page 56: Maintenance And Repair

    Maintenance and repair Maintenance and repair Maintenance and repair includes cleaning, inspection and maintenance of the product. The responsibility for inspection and maintenance is subject to local and national require- ments. The owner/operating company is responsible for compliance with the prescribed maintenance and repair work.

  • Page 57: Intervals

    Maintenance and repair Intervals By way of regular inspections and maintenance, malfunctions can be detected in time and system failures might be avoided. ► (As owner/operating company) Determine which components have to be in- spected and maintained at which intervals (load-dependent). The interval table below shows the minimum intervals for the tasks to be carried out.

  • Page 58: Maintenance

    Maintenance and repair Maintenance Doing the annual maintenance work requires specialist knowledge. The maintenance work must be carried out by technical service personnel only. DANGER Life-threatening electrical voltage during interventions on the system ● Risk of severe burns, cardiovascular failure, fatal electric shock ●...

  • Page 59: Consumables

    Correct it, if necessary. ► Use nitrogen for gas filling. The water side must be non-pressurised. Consumables Filter filling for deferrisation/demanganisation Product Order no. Filter filling fermaliQ:MA2000, FE/MN 530 501 Filter filling fermaliQ:MA3000, FE/MN 530 511 Filter filling fermaliQ:MA5000, FE/MN 530 521...

  • Page 60: Troubleshooting

    Troubleshooting Troubleshooting WARNING Contaminated water due to stagnation. ● Infectious diseases ► Have malfunctions repaired immediately. Display messages In case of a malfunction, the display of the control 2020-01-28 unit flashes in red. Tu 10:00 The following appears on the display: Time when the fault occurred and error code of the fault.

  • Page 61: Pump Displays

    Troubleshooting Code Meaning Causes Remedy • The existing com- ► Check pressure switch 1MSF1AP03 for function. pressed air cushion was not sufficient for the backwash process (error only appears after repeated occurrence of the cause of the error). • Backwash does not ►...
  • Page 62 Troubleshooting Code Meaning Causes Remedy • Data memory corrupted ► Stop the pump for 5 min EEPROM and then restart it Internal alarm If the problem persists: ► Forward error message to technical service • Faulty multi-pump ► Check the condition of the Multi-pump connection cables connection...

  • Page 63: Other Observations

    Troubleshooting Code Meaning Causes Remedy ► Check condition of instal- lation as well water and air temperature ► Wait until the motor has cooled down If the problem persists: ► Stop the pump for 5 min and then restart it If the problem persists: ►...
  • Page 64 Troubleshooting Observation Meaning Remedy • Intervention of amperometric ► Check motor thermal protection or protec- tion device because current consumption is too high • A power supply phase is ► Check supply missing • Foreign matter inside the ► Clean the pump pump blocks the impellers •...

  • Page 65: Dismantling And Disposal

    Dismantling and disposal Dismantling and disposal 10.1 Dismantling Have this work carried out by qualified specialists only. 1. Flush the system with raw water. 2. Disconnect the system from mains – discharge residual voltage. 3. Close the shut-off valves provided by the client on the raw water and filtrate (upstream and downstream of the system).

  • Page 66: Technical Specifications

    Technical specifications Technical specifications 66 | 76...
  • Page 67 Technical specifications Dimensions and weights MA2000 MA3000 MA5000 MA10000 1060 1340 Width of entire system 1540 1630 1800 2430 Depth of entire system Depth of entire system with front 1600 1690 1860 2490 cover 1730 Height of system rack Height of system rack with front 1750 cover 1700...
  • Page 68 Technical specifications General data MA2000 MA3000 MA5000 MA10000 5 – 20 Water temperature (drinking water) °C 5 – 25 Ambient temperature (drinking water) °C Water temperature °C 5 – 35 (technical applications) Ambient temperature °C 5 – 35 (technical applications) 6.5 –...

  • Page 69: Pid Flow Chart

    Technical specifications 11.1 PID flow chart * Only fermaliQ:MA10000, order no. 530 530 69 | 76...
  • Page 70 Technical specifications No./Coding Designation No./Coding Designation Emergency bypass 1MSF1AH52 Filtrate sampling valve Discharge of first filtrate 1MSF1AP02 Filtrate pump Pressurised water tank (accessory) 1MSF1AP03 Pipe fan 1MSF1AB01 Filter tank 1MSF1AS01 Raw water non-return valve 1MSF1AB02 Diaphragm expansion tank 1MSF1AS02 Hollow cone spray nozzle 1MSF1ACF01 Flow sensor 1MSF1AS03...

  • Page 71: Ec Declaration Of Conformity

    EU Declaration of Conformity EC Declaration of Conformity In accordance with the EC Machinery Directive 2006/42/EC This is to certify that the system designated below meets the safety and health protection requirements of the applicable EC/EU guidelines in terms of its design, construction and execution. This certificate becomes void if the system is modified in any way not approved by us.

  • Page 72: Notes

    Notes Notes 72 | 76...
  • Page 73 Notes 73 | 76...
  • Page 74 Notes 74 | 76...
  • Page 76 Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str. 1 89420 Hoechstaedt/Germany +49 9074 41-0 +49 9074 41-100 info@gruenbeck.com For more information go www.gruenbeck.com to www.gruenbeck.com...

This manual is also suitable for:

Fermaliq:ma3000Fermaliq:ma5000Fermaliq:ma10000

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