Grunbeck ultraliQ:SB500 User manual

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Ultrafiltration | ultraliQ:SB
Operation manual

General Contact
Germany
International Sales
Phone [phone]
Technical Service
Phone [phone]
Fax [phone]
Availability
Monday to Thursday
7:00 am - 6:00 pm
Friday
7:00 am - 4:00 pm
We reserve the right to technical modifications.
© by Grünbeck Wasseraufbereitung GmbH
Original operation manual
Edition: February 2022
Order no.: 100243460000_en_024

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 ................................................ 4
1.4 Symbols used........................................................... 5
1.5 Depiction of warnings ............................................... 6
1.6 Demands on personnel ............................................ 6
2Safety ....................................................................... 8
2.1 Safety measures ...................................................... 8
2.2 Product-specific safety instructions......................... 10
2.3 Conduct in emergencies ......................................... 11
3Product description............................................... 12
3.1 Intended use .......................................................... 12
3.2 Product components .............................................. 13
3.3 Versions................................................................. 14
3.4 System connections ............................................... 15
3.5 Functional description............................................. 16
3.6 Accessories............................................................ 18
3.7 Optional accessories .............................................. 19
4Transport, set-up and storage .............................. 20
4.1 Shipping/Delivery/Packaging .................................. 20
4.2 Transport/Set-up .................................................... 20
4.3 Storage .................................................................. 20
5Installation ............................................................. 21
5.1 Requirements for the installation site ...................... 22
5.2 Checking the scope of supply ................................. 23
5.3 Water installation.................................................... 24
5.4 Electrical installation............................................... 26
6Start-up/commissioning........................................ 29
6.1 Flushing out the preserving agent........................... 29
6.2 Checking the system .............................................. 32
6.3 Settings in case of an unpressurised filtrate tank .... 33
6.4 Mounting the front cover (optional) ......................... 34
6.5 Handing over the product to the
owner/operator/operating company .........................35
7Operation................................................................36
7.1 Operation of the control unit ....................................36
7.2 Reading the operating data .....................................40
7.3 Setting the time.......................................................40
7.4 Program sequence .................................................41
7.5 Programming level (C 303)..................................42
8Maintenance and repair .........................................44
8.1 Cleaning .................................................................44
8.2 Intervals..................................................................45
8.3 Inspection ...............................................................45
8.4 Maintenance ...........................................................46
8.5 Spare parts .............................................................48
8.6 Wearing parts .........................................................48
9Troubleshooting.....................................................49
9.1 Display messages...................................................49
9.2 Other observations .................................................49
10 Decommissioning ..................................................50
10.1 Temporary standstill................................................50
10.2 Decommissioning ...................................................50
10.3 Restart/recommissioning.........................................50
11 Dismantling and disposal ......................................51
11.1 Dismantling.............................................................51
11.2 Disposal..................................................................51
12 Technical specifications........................................52
12.2 P&ID (flow chart).....................................................54
13 Operation log .........................................................56
13.1 Start-up/commissioning log .....................................56

Introduction
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1 Introduction
This manual is intended for owners/operators/operating companies, users as well as
qualified 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:
●Ultrafiltration ultraliQ:SB500
●Ultrafiltration ultraliQ:SB1000
●Ultrafiltration ultraliQ:SB1500
●Ultrafiltration ultraliQ:SB2000
●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
●Manuals for components from other manufacturers
●Safety data sheets for chemicals
●Electric circuit diagram, order no.: 561 015
1.3 Product identification
You can identify your product based on the product designation and the order number shown
on the type plate.
►Check whether the products indicated in chapter 1.1 correspond to your product.
The type plate is mounted on the rack.

Introduction
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Designation
1
CE mark
2
Obey the operation manual
3
Disposal information
4
Empty weight
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
Nominal filtrate capacity
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
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

Introduction
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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
structured as shown below:
SIGNAL WORD
Type and source of hazard
●Possible consequences
►Preventive measures
The signal words below 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 function or damage to an object in its
vicinity
1.6 Demands on personnel
During the individual life cycle phases of the product, different people carry out work on the
product. The respective tasks require different skills.

Introduction
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1.6.1 Qualification of personnel
Personnel
Requirements
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/operator/
operating company
•Product-specific expertise
•Knowledge of 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 potential hazards
•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 may be carried out by whom.
User
Owner/operator/
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
Repair
X
X
Decommissioning and
restart/recommissioning
X
X
Dismantling and disposal
X
X
1.6.3 Personal protective equipment
►As an owner/operator/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
Protective overall
Safety goggles
Mask
Protective apron

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.
●Only use genuine spare parts for maintenance or repair.
●Keep the premises locked against unauthorised access to protect imperilled or
untrained persons from residual risks.
●Comply with the maintenance intervals (refer to chapter 8.2). Failure to comply can
result in the microbiological contamination of your drinking 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
stability of the system is guaranteed at all times.
2.1.2 Pressure-related hazards
●Components may be under pressure. Risk of injuries and damage to property due
to escaping water and unexpected movement of components. Check the system’s
pressure lines for leaks at regular intervals.
●Make sure that all system components concerned are depressurised before
starting any repair and maintenance work.

Safety
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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 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 and
arrange for repair.
●Switch off the supply voltage before working on electrical system parts. Discharge
residual voltage.
●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 chemical 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 and always obey the
instructions for the different actions/situations.
●Current safety data sheets for chemicals are available for download at
www.gruenbeck.de/en/info-centre/safety-data-sheets.
●Obey internal instructions when handling chemicals and make sure that any
protective and emergency equipment such as emergency showers and eye
showers is present and functional.
Mixing and residual amounts of chemicals
●Never 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.

Safety
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Labelling/Minimum shelf life/Storage of chemicals
●Check the labelling of the chemicals - labels must not be removed or rendered
illegible.
●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
functionality of the system and the quality of the generated filtrate.
●If stored incorrectly, chemicals could change their state of matter, crystallise,
outgas, or lose their effectiveness. Store and use the chemicals at the indicated
temperatures only.
Cleaning/Disposal
●Immediately absorb leaked chemicals with suitable binding agents.
●Collect and dispose of chemicals in such a way that they cannot pose a risk to
people, animals, or the environment.
2.1.5 Groups of persons requiring protection
●This product is not designed to be used by persons (including children) with
reduced capabilities, lack of experience or lack of knowledge. Unless they are
supervised, have been instructed on the safe use of the product and understand
the resulting hazards.
2.2 Product-specific safety instructions
Diaphragm expansion tanks operate with a nitrogen or compressed air 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(s) regularly for leaks (refer to chapter 8.4.2).

Safety
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2.2.1 Signals and warning devices
Warnings/pictograms
Danger of electric shock (attached to the switch box)
►Disconnect the system from the power supply before working
on electrical system parts
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.
2.3 Conduct in emergencies
2.3.1 In case of water leaks
1. De-energise the system –unplug the power plug.
2. Locate the leak.
3. Eliminate the cause of the water leak.

Product description
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3 Product description
3.1 Intended use
The ultrafiltration system ultraliQ is designed for the fully automatic reduction of solid
particles, turbidities and micro-organisms in the raw water.
The ultrafiltration system is suitable for use in private water supply systems.
If the ultrafiltration system ultraliQ is used for drinking water supply, the provisions of
DIN 2001-1, DIN 1988 as well as DIN EN 1717 must be complied with.
3.1.1 Application limits
Parameters
SB500
SB1000
SB1500
SB2000
Turbidity (on average)
NTU
< 15.0
Turbidity (short-term)
NTU
< 30.0
TOC
mg/l
< 5.0
Oils/greases/hydrocarbons
not detectable
For all other water constituents contained in the raw water, with the exception of the
microbiological parameters, the limit values of the German Drinking Water Ordinance
(TrinkwV 2001) do apply.
Any required preliminary treatment stages (such as the oxidation filter system
fermaliQ:MA for the reduction of iron, manganese and ammonium) are available from
Grünbeck upon request.

Product description
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3.2 Product components
Designation
Function
Coding
1
Switch box
GENO-matic control unit
1UF1AE01
2
System rack
Made of anodised aluminium with adjustable feet
–
3
Sampling valve
Flushing waste water
Flame-sterilisable sampling valve for taking water
samples and flushing out the preserving agent
1UF1AH53
4
Solenoid valve
Flushing waste water
Automatic valve to discharge the flushing waste water
1UF1AV02
5
Shut-off valve
Flushing waste water
Piston valve to separate the system from the on-site
pipe network
1UF1AH07
6
Solenoid valve
Filtrate
Automatic valve to discharge the filtrate
1UF1AV03
7
Shut-off valve
Filtrate
Piston valve to separate the system from the on-site
pipe network
1UF1AH06
8
Non--return valve
Filtrate
To prevent the backflow of filtrate from the on-site buffer
tank during backwash and forward flush
1UF1AS03
9
Flow stabiliser
To set the filtrate volume flow
1UF1AS02
10
Shut-off valve
Raw water
Piston valve to separate the system from the on-site
pipe network
1UF1AH01
11
Solenoid valve
Raw water
Automatic valve to supply the raw water
1UF1AV01
12
Non-return valve
Raw water
To prevent the backflow of filtrate from the diaphragm
expansion tank during backwash
1UF1AS01
13
Flow meter
Filtrate
Flow measurement of the filtrate flow during filtration
operation
1UF1ACF01

Product description
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Designation
Function
Coding
14
Sampling valve
Raw water
Flame-sterilisable sampling valve for taking water
samples
1UF1AH51
15
Pressure indicator
Raw water
Pressure gauge for visual indication of the
raw water pressure applied
1UF1ACP01
16
Sampling valve
Filtrate
Flame-sterilisable sampling valve for taking water
samples and flushing out the preserving agent
1UF1AH52
17
Pressure indicator
Filtrate
Pressure gauge for visual indication of the
filtrate pressure applied
1UF1ACP02
18
Ultrafiltration module(s)
Pressure pipe with membrane
1UF1AB01
(1UF1AB02,
1UF1AB03,
1UF1AB04)
19
Shut-off valve(s)
Backwash
Piston valve to separate the system from the diaphragm
expansion tank
1UF1AH03
(1UF1AH04)
20
Diaphragm expansion tank(s)
Tank to backwash the UF module
1UF1AB05
(1UF1AB06,
1UF1AB07,
1UF1AB08)
21
Shut-off valve
Draining
Mini ball valve to drain the diaphragm expansion tank
1UF1AH02
(1UF1AH05)
3.3 Versions
SB500
SB1000
SB1500
SB2000

Product description
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3.3.1 With front cover (optional)
Designation
1
Control panel of GENO-matic control unit
2
Upper cover
Designation
3
Lower cover
●In case of the optional front cover, the control unit is moved to the front.
●The front cover consists of 2 covers.
3.4 System connections
Designation
A
Raw water inlet
B
Filtrate outlet
Designation
C
Flushing waste water outlet
D
Draining outlet

Product description
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3.5 Functional description
Filtration
Backwash
Forward flush
1
Ultrafiltration membrane
(schematic)
1
Ultrafiltration membrane
(schematic)
1
Ultrafiltration membrane
(schematic)
2
Raw water inlet
2
Backwash with filtrate
2
Raw water inlet
3
Filtrate
3
Flushing waste water to the
drain
3
Flushing waste water to the
drain
4
Principle of particle deposition
during filtration
4
Principle of flushing out
particles during a backwash
4
Principle of flushing out
particles during a forward flush
Filtration
Raw water is delivered into the ultrafiltration system and then pressed through the capillary
membranes of the ultrafiltration elements installed in the pressure pipes. The pores of the
semi-permeable membrane have a cut-off of 0.02 µm. Almost all undissolved substances
contained in the water such as particles, bacteria or viruses are reliably retained on the raw
water side of the membranes and a particle and germ-reduced filtrate is generated.
During the filtration process, the filtered particles are deposited on the membrane surface
and increase the differential pressure (transmembrane pressure) between the raw water side
and the filtrate side. This layer grows as the filtration time progresses and must be flushed
from the membrane surface after each filtration interval.
Flushing the system
After each filtration interval, the ultrafiltration system is automatically flushed in 2 phases:
●Backwash with filtrate from a diaphragm expansion tank installed in the
ulltraliQ:SB: The backwash process removes retained dirt particles and micro-
organisms from the UF membrane.
●Forward flush with raw water: During the forward flush with raw water, the removed
dirt particles and micro-organisms are flushed to the drain.

Product description
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●The forced flushing processes programmed in the control unit prevent the
stagnation of raw water in the UF module.
Formation of a surface layer
During operation, a surface layer is formed by the substances contained in the water
(particles, turbidity, micro-organisms) retained on the UF membrane.
The formation of the surface layer (fouling) is divided into 3 categories:
●Inorganic fouling (= scaling)
•Deposits of minerals (exceeding the solubility limit)
●Organic fouling
•Deposits of organic components
(suspended particles, macromolecules, colloidal turbidity, proteins)
●Biofouling: Fouling due to biofilms
As the filtration time progresses, the surface layer grows and leads to the effects below:
●The permeability of the membrane decreases
●The membrane resistance increases
●The transmembrane pressure (TMP) increases
Cleaning process
To remove deposits that cannot be removed by the combination of backwash and forward
flush, chemical cleaning (CIP = Cleaning In Place) must be carried out.
During CIP cleaning, the surface layers on the UF membrane are removed by a combination
of chemicals, heat, mechanical forces and exposure time.
CIP cleaning has the effects below:
●The surface layer is removed
●The transmembrane pressure (TMP) drops
●The membrane resistance decreases
●The permeability of the membrane increases
CIP cleaning is required under the circumstances below:
●TMP has reached 0.7 bar and can no longer be reduced by the automatic flushing
steps (backwash, forward flush)

Product description
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3.6 Accessories
You can retrofit your product with accessories. Please contact your local Grünbeck
representative or Grünbeck’s headquarters in Hoechstaedt/Germany for details.
Illustration
Product
Order no.
Diaphragm expansion tank DD 33,
G¾
To prevent water hammer in the inlet
if a pressurised water tank provided
by the client on site is used to store
the filtrate.
33 l each
890 60 304
Diaphragm expansion tank
As an addition to an existing
diaphragm expansion tank –or for
new installations –for water supply
during the flushing process of the
ultrafiltration 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
As an addition to an existing
pressurised water tank –or for new
installations –for water supply during
the flushing process of the
ultrafiltration system
150 l
530 505
300 l
530 515
500 l
530 525
750 l
530 535
1000 l
530 545
Basic pure water tank GT 1000
For the unpressurised
storage of filtrate
without sterile air filter
712000010000
with sterile air filter
712000020000
Pre-assembled PE tank with PE overflow line, PVC
connections for the inlet and withdrawal of a
pressure booster system (max. withdrawal volume
5 m³/h), control electronics GENO-Multi Niveau and
level probe (in the tank)
Pressure booster systems
Automatically controlled via pressure and flow controller
GENO-HR-X 2/40-1 N
730 460
Speed-controlled by means of a pressure sensor as well as
frequency converter
GENO-FU-X 2/40-1 N
730 640

Product description
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Illustration
Product
Order no.
Mobile cleaning system CIP:UF60
For the chemical cleaning of ultrafiltration systems
778 100
3.7 Optional accessories
You can retrofit your product with optional equipment. Please contact your local Grünbeck
representative or Grünbeck’s headquarters in Hoechstaedt/Germany for details.
Product
Order no.
Front cover ultraliQ:SB
535 138
Control unit S7-1200 for ultraliQ
535 060

Transport, set-up and storage
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4 Transport, set-up and storage
4.1 Shipping/Delivery/Packaging
The system is fixed on a pallet at the factory and secured against tipping.
►Load and unload the system with a forklift or lift truck with suitable pallet forks. Be
aware of the system’s top-heavy centre of gravity.
NOTE
Risk of damage when lifting the system with a crane and lifting strap.
●The system does not feature any lifting points for lifting by a crane and lifting
strap.
►The system must not be loaded/unloaded by crane and lifting strap.
►Dispose of the packaging material in an environmentally sound and appropriate
manner only after installation of the system (refer to chapter 6.5.1).
4.2 Transport/Set-up
WARNING
Risk of tipping in case of improper transport.
●The system’s centre of gravity is top-heavy. The system can tip and crush
persons/limbs.
►Transport the system by means of a forklift or lift truck with appropriate forks only
–obey the marked pick-up direction
►Do not transport the system over inclines or stairs.
►Transport the system to the installation site (longer distances) in its original
packaging and secured on a pallet only.
►Transport the unpacked system (without pallet) in close vicinity of the final
installation site only –do not lift it at the system rack.
►Remove the transport lock, if present.
4.3 Storage
►Protect the product from the impacts below when storing it:
•Moisture, wetness
•Environmental impacts such as wind, rain, snow, etc.
•Frost, direct sunlight, severe heat exposure
•Chemicals, dyes, solvents and their vapours