Grunbeck fermaliQ:MA2000 User manual

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Oxidation filter system | fermaliQ:MA
Operation manual

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We reserve the right to technical modifications.
© by Grünbeck Wasseraufbereitung GmbH
Original operation manual
Edition: May 2021
Order no.: 100086810000-en_034

Table of contents
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Table of contents
Table of contents................................................................ 3
1Introduction ............................................................... 4
1.1 Validity of the manual ................................................ 4
1.2 Other applicable documents ...................................... 4
1.3 Product identification ................................................. 5
1.4 Symbols used ............................................................ 5
1.5 Depiction of warnings ................................................ 6
1.6 Demands on personnel.............................................. 7
2Safety ......................................................................... 9
2.1 Safety measures........................................................ 9
2.2 Product-specific safety instructions ......................... 12
2.3 Conduct in emergencies .......................................... 13
3Product description ................................................ 14
3.1 Intended use ............................................................ 14
3.2 Product components................................................ 15
3.3 Connections............................................................. 17
3.4 Functional description.............................................. 18
3.5 Accessories ............................................................. 20
3.6 Optional accessories ............................................... 20
4Transport, placing and storage ............................. 22
4.1 Shipping/Delivery/Packaging ................................... 22
4.2 Transport/Placing..................................................... 22
4.3 Storage .................................................................... 23
5Installation ............................................................... 24
5.1 Requirements for the installation site....................... 24
5.2 Checking the scope of supply.................................. 26
5.3 Removing the front cover (optional equipment)....... 27
5.4 Installation................................................................ 28
5.5 Water installation ..................................................... 31
5.6 Electrical installation ................................................ 32
5.7 Installing the front cover (optional equipment)......... 36
6Start-up/Commissioning ........................................ 37
6.1 Filling in filter material .............................................. 37
6.2 Diaphragm expansion tank: Setting the preload
pressure....................................................................40
6.3 Checking the system ................................................42
6.4 Flushing the system..................................................43
6.5 Handing over the product to the owner/operating
company ...................................................................43
7Operation/handling..................................................45
7.1 Operation of the control unit .....................................45
7.2 Initiating manual discharge of filtrate ........................49
7.3 Initiating manual backwash ......................................50
7.4 Backwash monitoring ...............................................50
7.5 Operation of filtrate pump .........................................51
7.6 Emergency bypass ...................................................54
8Maintenance and repair...........................................56
8.1 Cleaning ...................................................................56
8.2 Intervals ....................................................................57
8.3 Inspection .................................................................57
8.4 Maintenance .............................................................58
8.5 Consumables............................................................59
8.6 Spare parts, wearing parts .......................................59
9Troubleshooting.......................................................60
9.1 Display messages ....................................................60
9.2 Pump displays ..........................................................61
9.3 Other observations ...................................................63
10 Dismantling and disposal .......................................65
10.1 Dismantling...............................................................65
10.2 Disposal....................................................................65
11 Technical specifications .........................................66
11.1 PID flow chart ...........................................................69
EC Declaration of Conformity ..........................................71
Notes ..................................................................................72

Introduction
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1 Introduction
This manual is intended for owners/operating companies, operators/users as well as quali-
fied specialists and ensures the safe and efficient handling of the product. The manual is an
integral part of the product.
►Carefully read this manual and the included manuals on the components before
you operate your product.
►Obey all safety and handling instructions.
►Keep this manual and all other applicable documents, so that they are available
when needed.
Illustrations in this manual are for basic understanding and can differ from the actual design.
1.1 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.
For information on changes, please refer to the respective information sheet that is
enclosed, if applicable.
1.2 Other applicable documents
●Electrical circuit diagram, drawing no.: 530547E00R01
●The manuals of all accessories used.

Introduction
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1.3 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
1
CE mark
2
Obey the operation manual
3
Disposal information
4
Empty weight (rack + filter tank)
5
Order no.
6
Serial no.
7
Date of manufacture
8
Connected load
Designation
9
Power supply
10
Ambient temperature
11
Water temperature
12
Operating pressure
13
Flow volume
14
Nominal connection diameter of filtrate outlet
15
Nominal connection diameter of raw water inlet
1.4 Symbols used
Symbol
Meaning
Danger and risk
Important information or requirement
Useful information or tip
Written documentation required

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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
1.5 Depiction of warnings
This manual contains information and instructions that you must obey for your personal
safety. The information and instructions are highlighted by a warning symbol and are struc-
tured as shown below:
SIGNAL WORD
Type and source of hazard
●Possible consequences
►Preventive measures
The following signal words are defined subject to the degree of danger and might be used in
the present document:
Warning symbol
and signal word
Consequences if the information/instructions are ignored
DANGER
Personal
injury
Death or serious injuries
WARNING
Possible death or serious injuries
CAUTION
Possible moderate or minor injuries
NOTE
Damage to
property
Possible damage to components, the product
and/or its functions, or an object in its vicinity

Introduction
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1.6 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
Operator/user
•No special expertise required
•Knowledge of the tasks assigned
•Knowledge of possible dangers in case of incorrect behaviour
•Knowledge of the required protective equipment and protective
measures
•Knowledge of residual risks
Owner/operating company
•Product-specific expertise
•Statutory regulations on work safety and accident prevention
Qualified specialist
•Electrical engineering
•Sanitary engineering
(HVAC and plumbing)
•Transport
•Professional training
•Knowledge of relevant standards and regulations
•Knowledge of detection and prevention of possible dangers
•Knowledge of statutory regulations on accident prevention
Technical service
(Grünbeck's technical service/
authorised service company)
•Extended product-specific expertise
•Trained by Grünbeck
1.6.2 Authorisations of personnel
The table below describes which tasks must be carried out by whom.
Operator/
user
Owner/
operating
company
Qualified
specialist
Technical
service
Transport and storage
X
X
Installation and mounting
X
X
Start-up/Commissioning
X
X
Operation and handling
X
X
X
X
Cleaning
X
X
X
Inspection
X
X
X
X
Maintenance
annually
X
Troubleshooting
X
X
X
Repair
X
X
Decommissioning and restart/recommissioning
X
Dismantling and disposal
X
X

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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

Safety
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2 Safety
2.1 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.
●Keep the premises locked against unauthorised access to protect imperilled or un-
trained groups of persons from residual risks.
●Lay pipes and cable trays away from traffic routes, escape/rescue routes and ac-
cesses to the system.
●Comply with the maintenance intervals (refer to chapter 8.2). Failure to comply can
result in the microbiological contamination of your water system.
2.1.1 Mechanical hazards
●You must never remove, bridge, or otherwise tamper with safety equipment.
●For all work on the system that cannot be carried out from the ground, use stable,
safe and self-standing access aids (e.g. stepladders).
●Make sure that the system is set up in a way that it cannot tip over and that the sta-
bility of the system is guaranteed at all times.
2.1.2 Pressure-related hazards
●Components can be under pressure. There is a risk of personal injury and damage
to property due to escaping water and/or compressed air as well as unexpected
movement of components. Check the system’s pressure lines at regular intervals.
●Before starting repair and maintenance work, make sure that all affected compo-
nents are depressurised.
2.1.3 Electrical hazards
In case of contact with live components, there is an immediate risk of death due to electric
shock. Damage to the insulation or individual components can be life-threatening.
●Only have qualified electricians carry out electrical work on the system.
●If live components are damaged, immediately switch off the power supply. Arrange
for repair.
●Switch off the supply voltage before working on electrical system parts. Discharge
residual voltage.

Safety
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●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.
●Avoid any skin/eye contact with chemicals.
●Use personal protective equipment.
●Read the safety data sheet before handling chemicals. Always obey the instruc-
tions for different activities/situations.
●Current safety data sheets for chemicals are available for download at
www.gruenbeck.de/en/info-centre/safety-data-sheets.
●Obey in-house instructions when handling chemicals. Make sure that protective
and emergency equipment such as emergency showers and eyewash are availa-
ble where required, and functional.
Mixing and residual amounts of chemicals
●Do not mix different chemicals. Unforeseeable chemical reactions posing a lethal
danger can occur.
●Dispose of residual amounts of chemicals in accordance with local regulations
and/or internal instructions.
●Residual amounts from used containers should not be transferred into containers
with fresh chemicals in order not to impair the effectiveness of the chemicals.
Labelling/Minimum shelf life/Storage of chemicals
●Check the labelling of the chemicals - labels must not be removed or rendered il-
legible.
●Do not use any unknown chemicals (no labelling or labelling illegible).
●Obey the use-by date (minimum shelf life) stated on the label to ensure the func-
tionality of the system and the quality of the treated water.
●If stored incorrectly, chemicals could change their state of matter, crystallise, out-
gas, or lose their effectiveness. Store and use the chemicals at the specified tem-
peratures only.
Cleaning/Disposal
●Immediately absorb spilled chemicals with suitable binding agents.
●Collect and dispose of chemicals in such a way that they cannot pose a risk to peo-
ple, animals, or the environment.

Safety
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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.
●Children must be supervised to make sure that they do not play with the product.
●Cleaning and maintenance must not be carried out by children.

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2.2 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).
2.2.1 Signals and warning signs
Warnings/pictograms
Danger of electric shock (attached to the switch box)
►Disconnect the system from the power supply before work-
ing on electrical system parts.
Warning label (attached to the tank)
►Keep the lid of the filter tank closed during operation.
The affixed information and pictograms must be clearly legible.
They must not be removed, soiled or painted over.
►Obey all warnings and safety instructions.
►Immediately replace illegible or damaged symbols and pictograms.
2.2.2 Availability of drinking water.
According to DIN 2001-1, the following prerequisites apply to the availability of drinking wa-
ter:
●When supplied from small units, drinking water must be available at the withdrawal
point at all times, in the required quality and sufficient quantity as well as with
enough pressure.
●In the event the supply is interrupted, remedial action to eliminate the malfunction
must be taken without delay.
●For small units that supply drinking water to third parties or that are used in the
scope of commercial or public activities, the owner/operating company must draw
up an action plan in accordance with the German Drinking Water Ordinance.
►As the owner/operating company, draw up an action plan in accordance with the
German Drinking Water Ordinance which contains, for example, information on
how to change to another supply in the event of an emergency or malfunction.

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2.3 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).
●The emergency bypass must not be used for the supply of drinking water under
any circumstances.

Product description
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3 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.
3.1 Intended use
The system is designed for the treatment of well and spring water.
The oxidation filter system fermaliQ:MA only is the first treatment step in the drinking water
supply as per DIN 2001-1.
For complete and safe production of drinking water, the filtration stage must always be fol-
lowed by a disinfection stage (e.g. UV disinfection).
3.1.1 Application limits
The following application limits must not be exceeded/undershot.
Application limits
Manganese
mg/l
≤ 1.0
Iron
mg/l
≤ 15.0
pH range
6.5 –8.5
Ammonium
mg/l
≤ 3.0
3.1.2 Foreseeable misuse
●Using the system for complete drinking water treatment.

Product description
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3.2 Product components
Designation
Function
Coding
1
Lid
Closure of filter tank
-
2
Level probe
Level 1: Filling & aeration OFF
Level 2: Filling & aeration ON
Level 3: Dry-run protection of filtrate pump
1MSF1CL01
3
Pipe fan
Supply of atmospheric oxygen to oxidate iron and manganese
Switch-off delay to outgas moist exhaust air
1MSF1AP03
4
Air backflow flap
Moist air in the filter tank is retained and does not penetrate
into the installation room.
-
5
Switch box with oper-
ating unit
Control of the filter system
1MSF1AE01
6
Air filter box
Contains a particle filter to filter the intake supply air
1MSF1AF01
7
Filtrate pump
To perform the filtration and the discharge of first filtrate
1MSF1AP02
For fermaliQ:MA10000:
2 x Filtrate pump
1MSF1BP02
8
Filtration/backwash
shut-off valve
Automatic 3-way ball valve to control filtration and backwash
1MSF1AV01
9
Tank shut-off valve
Piston valve to separate the filter tank from the rack with the
technical equipment
1MSF1AH03
10
Handhole
Enables lateral access into the filter tank for maintenance work
-
11
Raw water sampling
valve
Flame-sterilisable sampling vale to withdraw water samples
1MSF1AH51
12
Filter tank
Tank including fixtures and filter materials
1MSF1AB01

Product description
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Designation
Function
Coding
13
Filtrate shut-off valve
Piston valve to separate the filtrate pipe from the interface
supplied by the client on site
1MSF1AH05
14
Flow stabiliser Backwash
Setting the backwash volume flow
1MSF1AS05
15
Pressure switch
Backwash monitoring Required minimum pressure (adjusta-
ble: 0.1 –1.0 bar) must be reached during backwash
1MSF1ACP03
16
Flow stabiliser Filtration
Setting of filtrate volume flow
1MSF1AS04
17
Flow sensor
Indication of actual flow rate in the display of the control unit
and archiving of total flow
1MSF1ACF01
18
Filtrate pressure gauge
Indication of filtration pressure
1MSF1ACP02
19
Filtrate sampling valve
Flame-sterilisable sampling valve to withdraw water samples
1MSF1AH52
20
Diaphragm expansion
tank
To absorb water hammer
Autonomous switch-off of filtrate pump (no interference from
client on site)
Protection of the filtrate pump against frequent switching
changes
1MSF1AB02
21
Shut-off valve
Filtration/discharge of first
filtrate
Automatic 3-way ball valve to switch filtration and discharge
of first filtrate
1MSF1AV02
22
Overflow loop
Discharge of backwash water to drain and upward discharge
of exhaust air
-
23
Raw water shut-off valve
Piston valve to separate the raw water pipe from the inter-
face supplied by the client on site
1MSF1AH01

Product description
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3.3 Connections
Inlet
Outlet
Designation
Designation
A
Raw water inlet
C
Filtrate outlet
B
Supply air
D
Discharge of first filtrate to drain
C
Backwash water inlet
E
Backwash water to drain
F
Exhaust air

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3.4 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.
●Afterwards the raw water is atomised (increase of the water’s surface to optimise
the oxidation process).
●At the same time, ambient air is introduced into the upper part of the tank by
means of a pipe fan (increase of oxygen supply for improved oxidation of iron/man-
ganese and for outgassing odorous substances).
●The raw water pump and the pipe fan are switched on and off by the level control
in the filter tank.
●The pipe fan switches off time-delayed to outgas the moist exhaust air generated
by the atomisation process from the filter tank.
» Oxygenated raw water is located in the filter tank.
3.4.2 Filtration
●The raw water contained in the filter tank is drawn off through the various filter lay-
ers and the star-shaped nozzle assembly.
» Filtrate was generated.
●A pressure booster system delivers the filtrate to a pressurised water tank provided
by the client on site or a diaphragm expansion tank provided by the client on site.
This on-site tank on the one hand serves as buffer tank to meet short-term peak
consumption and on the other hand, the filtrate volume stored in it is used to back-
wash the filter tank.
●Via a frequency converter, the filtrate pump is controlled to an adjustable constant
pressure. When this pressure is reached permanently (e.g. when all withdrawal
points of the consumer are closed), the pump is switched off.
» Filtrate is available.

Product description
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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.
●During the backwash process, the filter material is loosened and the substances
that have been deposited on the surface of the filter material during filtration are re-
moved. Via the overflow funnel, the substances are then flushed to the drain.
●A backwash process is triggered when a certain fixed time (weekday and time) has
been reached. The duration and time of the work step can be preset.
●For hygiene reasons, a backwash takes place at least once a day.
●An automatic backwash monitoring system with backwash counter checks whether
the backwash has taken place. Backwash processes that have not been completed
properly are detected by the control unit. When a preset counter value (e.g. 3) is
reached, an error signal and a visual signal on the display of the control unit indi-
cate an error.
» The filter tank was backwashed.
3.4.4 Discharge of first filtrate
●The first filtrate is always discharged fully automatically after a backwash process.
●The discharge of first filtrate corresponds to filtration into the waste water drain with
corresponding filtration volume flow.
●The duration of this work step can be preset.
●This process is designed to compress the filter material and to prevent particles/tur-
bidities from entering into the filtrate.
» Backwash and discharge of first filtrate were carried out.
» Filling & aeration as well as filtration are continued.

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3.5 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
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.
33 l
890 60 304
Diaphragm expansion tank
In addition to an existing diaphragm expan-
sion tank or for new installations as water
supply during the flushing process of the filter
system
25 l
535 105
60 l
535 115
80 l
535 125
100 l
535 135
300 l
535 155
500 l
535 165
Pressurised water tank, 6 bar
In addition to an existing pressurised water
tank or for new installations as water supply
during the flushing process of the filter sys-
tem
150 l
530 505
300 l
530 515
500 l
530 525
750 l
530 535
1000 l
530 545
Water test kit for iron
Measuring range 0 –0.8 mg/l and 1 –10 mg/l
(30 determinations)
170 150
Water test kit for manganese
Measuring range 0.03 –0.5 mg/l
(100 determinations)
170 097
Refill pack of reagents
for water test kit for manganese
170 193
Water test kit for pH value
Measuring range 4.5 –10
(100 test strips)
170 148
3.6 Optional accessories
Your product can be retrofitted with additional accessories. Please contact your local
Grünbeck representative or Grünbeck’s headquarters in Hoechstaedt/Germany for details.