Operation Manual
GENO-mat FE-Z
Deferrisation system
Edition September 2018
Order no. 025 153 940-inter
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Table of contents
A General .................................................................................
1 Preface
2 How to use this operation manual
3 General safety information
4 Shipping and storage
5 Disposal
B Basic information ................................................................ 10
1 Laws, regulations, standards
2 Intended use/field of application
3 Function
C Product description ............................................................. 12
1 Type plate
2 Technical specifications
3 Intended use
4 Scope of delivery
5 Optional accessories
6 Consumables
D Installation and operation ................................................... 17
1 General installation information
2 Preliminary works
3 How to connect the system
E Start-up ................................................................................. 22
1 How to start up the system
F Operation .............................................................................. 23
1 How to operate the control unit
G Maintenance and care ......................................................... 26
1 Basic information
2 Inspection (functional check)
3 Maintenance
4 Spare parts
5 Operation log
5
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All rights reserved.
© Copyright by Grünbeck Wasseraufbereitung GmbH
Printed in Germany
Effective with the date of edition indicated on the cover sheet.
-We reserve the right to modifications, especially with regard to
technical progress-
Reprints, translations into foreign languages, electronic storage or
copying - even in part - of this operation manual are only permitted
with the explicit written approval of Grünbeck Wasseraufbereitung
GmbH.
Any type of duplication not authorised by Grünbeck Wasseraufbereitung is a copyright violation and subject to legal action.
Responsible for contents:
Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1 89420 Hoechstaedt/Do., Germany
Tel. +49 (0) 9074 41-0 Fax +49 (0) 9074 41-100
www.gruenbeck.de service@gruenbeck.de
Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str.1, 89420 Hoechstaedt/Do., Germany
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EC Declaration of Conformity
This is to certify that the systems designated below meets the safety and health requirements of the
applicable European guidelines in terms of its design, construction and execution.
If the systems are modified in a way not approved by us, this certificate is void.
Manufacturer: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str.1
89420 Hoechstaedt/Do., Germany
Responsible for documentation: Markus Pöpperl
Description of the device: Deferrisation system
Device type: GENO-mat FE-Z
Device no.: Refer to type plate
Applicable guidelines: Low Voltage (2014/35/EU)
EMC (2014/30/EU)
Applied harmonised
standards
in particular:
Applied national standards
and technical specifications,
in particular:
Place, date and signature: Hoechstaedt, 10.09.2018 p.p.
Function of signatory: Head of Technical Product Design
DIN EN 61000-6-2:2006-03
DIN EN 61000-6-3:2011-09
DIN 19636-100:2008-02
M. Pöpperl
Dipl.-Ing. (FH)
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A General
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1 | Preface
Thank you for opting for a Grünbeck product. Backed by decades of
experience in the area of water treatment, we provide solutions for
all kind of processes.
Drinking water is classified as food and requires particular care.
Therefore, always ensure the required hygiene in operating and
maintaining systems involved in the drinking water supply. This also
applies to the treatment of water for industrial use if repercussions
for the drinking water cannot completely be excluded.
All Grünbeck systems and devices are made of high-quality materials.
This ensures reliable operation over many years, provided you treat
your water treatment systems with the required care. This operation
manual assists you with important information. Therefore, please read
the complete manual before installing, operating or maintaining your
system.
Customer satisfaction is our prime objective. Providing customers
with qualified advice is crucial to Grünbeck. If you have any questions concerning this system, possible extensions or general water
and waste water treatment, our field staffs, as well as the experts at
our headquarters in Hoechstaedt, are available to help you.
For help and advice
please consult the representatives responsible for your region (see
www.gruenbeck.de) or get in touch with our service centre which
can be reached during office hours:
Phone: +49 9074 41-333
Fax: +49 9074 41-120
Email: service@gruenbeck.de
We can connect you with the appropriate expert more quickly if you
provide the required system data. In order to have the required data
handy at all times, please copy it from the type plate to the overview
in chapter C-1.
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2 | How to use this operation manual
This operation manual is intended for the operators of our systems.
It is divided into several chapters (a letter is assigned to each of
them) which are listed in the “Table of contents” on page 2 in alphabetical order. In order to find the specific information you are looking
for, check for the corresponding chapter on page 2.
The headers and page numbers with chapter information make it
easier to find your way around in the manual.
3 | General safety information
3.1 Symbols and
notes
Important information in this operation manual is characterised by
symbols. Please pay particular attention to this information to ensure
the hazard-free, safe and efficient handling of the system.
Danger! Failure to adhere to this information will cause serious or
life-threatening injuries, extreme damage to property or inadmissible
contamination of the drinking water.
Warning! Failure to adhere to this information may cause injuries,
damage to property or contamination of the drinking water.
Caution! Failure to adhere to this information may result in damage
to the system or other objects.
Note: This symbol characterises information and tips to make your
work easier.
Tasks with this symbol may only be performed by Grünbeck's technical service/authorised service company or by persons expressly
authorised by Grünbeck.
Tasks with this symbol may only be performed by qualified electrical
experts according to the VDE guidelines or according to the guidelines of a similar local institution.
Tasks with this symbol may only be performed by water companies
or approved installation companies. In Germany, the installation
company must be registered in an installation directory of a water
company as per §12(2) AVBWasserV (German Ordinance on General Conditions for the Supply of Water).
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3.2 Operating
personnel
3.3 Designated
application
3.4 Protection from
water damage
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Only persons who have read and understood this operation manual
are permitted to work with the system. The safety guidelines are to
be strictly adhered to.
The system may only be used for the purpose outlined in the product
description (chapter C). The guidelines in this operation manual as
well as the applicable local guidelines concerning the drinking water
protection, accident prevention and occupational safety must be adhered to.
In addition, appropriate application also implies that the system may
only be operated when it is in proper working order.
Any malfunctions must be repaired at once.
Warning! In order to properly protect the installation site from water
damage:
a) a sufficiently dimensioned floor drain system must be available or
3.5 Indication of
specific dangers
b) a water stop device (see chapter C Accessories) must be in-
stalled.
Danger due to electrical energy! Do not touch electrical parts with
wet hands! Disconnect the system from mains before starting work
on electrical parts of the system. Have qualified experts replace
damaged cables immediately.
Danger due to mechanical energy! System parts may be subject to
overpressure. Danger of injury and damage to property due to escaping water and unexpected movement of system parts. Check
pressure pipes regularly. Depressurise the system before starting
repair or maintenance work on the system.
Hazardous to health due to contaminated drinking water! The
system may only be installed by a specialist company. The operation
manual must be strictly adhered to! Ensure that there is sufficient
flow. The pertinent guidelines must be followed for starting-up after
extended periods of standstill. Inspections and maintenance must be
performed at the intervals specified!
Note: By concluding a maintenance contract, you ensure that all of
the required tasks are performed on time. You may perform the interim inspections yourself.
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4 | Shipping and storage
Caution! The system may be damaged by frost or high tempera-
tures. In order to avoid damage of this kind:
Protect from frost during transportation and storage!
Do not install or store the system next to objects which radiate a lot
of heat.
The system may only be transported and stored in its original pack-
ing. Ensure that it is handled with care and placed the right side up
(as indicated on the packing).
5 | Disposal
5.1 Packaging
5.2 Product
Comply with the applicable national regulations.
Dispose of the packaging in an environmentally sound manner.
If this symbol (crossed out waste bin) is on the product, European Directive 2012/19/EU applies to this product. This means
that this product and the electrical and electronic components
must not be disposed of as household waste.
Find out about local regulations on the separate collection of
electrical and electronic products.
Use the collection points available to you for disposing of your
product.
For information on collection points for your product, contact
your municipality, the public waste disposal authority, an authorised body for the disposal of electrical and electronic products or your waste collection service.
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B Basic information
1 | Laws, regulations, standards
In the interest of good health, rules cannot be ignored when it comes
to the processing of drinking water. This operation manual takes into
consideration the current regulations and stipulates information that
you will need for the safe operation of your deferrisation system.
Among other things, the regulations stipulate that
only approved companies are permitted to make major modifica-
tions to water supply facilities.
and that tests, inspections and maintenance on installed devices
are to be performed at regular intervals.
2 | Intended use/field of application
The GENO-mat FE-Z deferrisation systems are used for the oxida-
tion of dissolved iron in the raw water. The systems are used for private water supply plants up to maximum values of 3.0 mg/l of iron. If
the systems are applied and operated according to the instructions,
pure water values with a concentration of less than 0.1 mg/l of iron
can be obtained.
The following requirements must be observed in order to obtain optimum results:
Hydrogen sulphide and oil may not be detected in the water to be
deferrised.
Organic compounds should preferably not be contained in the
water; however, the maximum allowable value is 4 to 5 mg/l
above the COD.
The oxygen concentration should be proportionally 15 % of the
existing iron concentration and the pH value must be higher than
7.0.
However, should ammonium (> 0.1 mg/l) be detected in the raw
water, an additional treatment step is required.
Should humic acids be contained in the well water, the pure wa-
ter quality to be expected might be affected.
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3 | Function
3.1 Filters
3.2 Backwashing
3.3 First filtrate
The GENO-mat FE-Z deferrisation systems for the removal of iron
work with an active insoluble catalytic filter material. A central control
valve automatically controls the operating cycle’s filtration, backwash
and first filtrate.
The raw water enters the exchanger tank via the raw water inlet and
flows through the catalytic filter material from top to bottom. Thus the
reaction of the oxygen with the iron contained in the water is accelerated.
Bivalent iron is transformed into insoluble, filterable, trivalent iron
(adding air sparingly might be required in order to improve the oxidation process). The filtered pure water is then directed via the lower
distributing nozzle and the rising pipe through the pure water outlet
into the piping system.
During the backwash process, the filter bed is forcibly flushed from
bottom to top and thus loosened up. Impurities retained during the
filtration process are washed out via the drain outlet at the control
valve. The GENO-mat FE-Z deferrisation system must be backwashed every 6 days at the latest (for the setting refer to chapter F).
By an automatic switch-over of the central control valve, the filter
bed will forcibly be flushed from top to bottom. This first filtrate is
discharged to the drain and afterwards the deferrisation system is
ready for operation once again.
3.4 Regeneration/
disinfection
3.5 Control unit
For operating and hygienic reasons, the deferrisation system must
be regenerated every 6 months with the special granulate GENOSpezialgranulat or GENO-oxi plus.
The GENO-mat FE-Z deferrisation systems are time-controlled via
an electrical timer.
In order to properly use the automatic timer control, the time interval
between two filter sequences (backwash interval in days) must be
set.
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C Product description
1 | Type plate
The type plate is located on the GENO-mat FE-Z control valve. Que-
ries and orders will be processed faster if you are able to provide the
information listed on your system's type plate. Please copy the indicated information to the table below in order to have it readily available whenever necessary.
GENO-mat FE-Z Deferrisation system
Serial number: /
Order no.:
Fig. C-1: Type plate GENO-mat FE-Z deferrisation system
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2 | Technical specifications
The GENO-mat FE-Z deferrisation system is a single system with
integrated bypass for the supply of raw water during the backwash
process. It is equipped with a timer control. The backwash is released after a set time interval.
All system data are summarized on the reverse in table C-1. The
data refers to the standard versions of the GENO-mat FE-Z deferrisation systems. Possible deviations in case of special versions are
listed separately, if applicable.
Caution! Electrically operated valves. In case of a power failure during the backwash, water may enter the drain. In case of power failure, check the system and shut-off the water supply, if necessary.
Table C-1: Technical specifications GENO-mat FE-Z deferrisation system
20/10 25/13 30/14 40/17 40/18 50/19 60/20
Connection data
Nominal connection diameter DN 25 (1") DN 40 (1½“)
Min. drain connection DN 50 DN 70
Nominal flow rate (depending on the iron
concentration)
Power supply [V]/[Hz] 230/50
Connected load [VA] 10
Protection/protection class IP 54/
Performance data
Nominal pressure PN 10
Min./max. operating pressure [bar] 2.5/6.0
Pressure loss at nominal flow [bar] 0.5 1.1 1.0 1.1 1.0 0.8 1.1
Dimensions and weights1)
Total height [mm] 1360 1620 1620 1900 1900 1870 2100
Exchanger tank
Regeneration tank
Height regeneration tank [mm] 840 1010
Connection height/raw water piping [mm] 1160 1420 1420 1710 1710 1680 1910
Connection height/pure water piping [mm] 1210 1470 1470 1735 1735 1705 1935
Distance to wall [mm] 200 230 280 280 300 365 405
Depth of foundation [mm] 400 450 500 500 550 600 650
Length of foundation [mm] 1850 1950 2050 2050 2100 2250 2350
Operating weight (incl. water) [kg] 50 85 150 200 240 425 580
Filling volumes and consumption data1)
Bottom filter layer I, quartz gravel 3.0 - 5.6T [kg] - - 25 25 25 50 50
Bottom filter layer I, quartz gravel 3.0 - 5.6T
Bottom filter layer I, quartz gravel 3.0 - 5.6T
(dimension a)
Top filter layer II GENO-Ferrocat [l] 28 52 72 100 112 224 308
Top filter layer II GENO-Ferrocat
(dimension b)
Free board [l] 5 8 15 18 36 45 88
[m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
[mm] 210 260 340 370 420 550 620
[mm] 465 680
[l]
- - 18 18 18 36 36
[mm] - - 1100 1400 1430 1320 1570
[mm] 290 360 270 460 570 390 520
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Amount of regeneration agent required
Preparation amount [l] 302) 502) 602) 1002) 1002) 2002) 3002)
GENO-oxi plus [l] 5 9 11 17 17 35 53
GENO-Spezialgranulat (special granulate) [g] 105 175 210 350 350 700 1050
Regeneration/disinfection interval Regeneration as required / disinfection
at the latest after 6 months
Concentration of preparation [%] 0.35
Total waste water volume per regeneration
at 3 bar approx.
Duration of washing out (regeneration) [min.] 30
Duration of backwash [min.] 10
Backwash capacity [m³/h] 1.6 3.4 5.7
Ambient data
Max. water temperature [°C] 30
Max. ambient temperature [°C] 40
Order no. 153 … 210 220 230 240 250 260 270
[m³]
1 1.3 1.7 2 2.7 3.4 5.4
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Continuation Table C-1:
Spare filter fillings1)
GENO-Ferrocat (28 l per bag) 1x
170170
GENO-Ferrocat (4 l per bucket) - 6x
Quartz gravel SB 3.0 - 5.6 T (25 kg per
sack)
1)
All indications are approximate.
2)
If the liquid product GENO-oxi plus is used,
the GENO-oxi plus amount bust be subtracted from the
preparation amount.
- - 1x
GENO-mat FE-Z deferrisation system
20/10 25/13 30/14 40/17 40/18 50/19 60/20
1x
170170
153610
Filter layer III Top
2x
170170
4x
153610
170208
3x
170170
4x
153610
1x
170208
4x
170170
- - -
1x
170208
8x
170170
2x
170208
11x
170170
2x
170208
Filter layer I Bot-
tom
Fig. C-2: Filling of filter layers
3 | Intended use
The system is adjusted to the water demand to be expected at the
installation site. It is not suitable for considerably differing performances. The maximum flow must not be exceeded under any circumstances.
The system may only be operated if all components are installed
properly. Safety devices must never be removed, bridged or otherwise tampered with.
Designated application of the system also implies that the information contained in these operating instructions and all safety guidelines applying at the installation site be observed. Furthermore, the
maintenance and inspection intervals have to be observed.
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4 | Scope of supply
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4.1 Basic configuration
Exchanger tank in double walled plastic housing.
Filter materials (gravel, GENO-Ferrocat, quartz gravel).
Control valve made of red bronze with integrated timer control.
Water test kit for iron.
Operation manual.
5 | Optional accessories
Note: It is possible to retrofit existing systems with optional compo-
PE tank 100 litre or 300 litre with litre scale and hand mixer to pre-
nents. Please contact your local Grünbeck representative or
Grünbeck’s headquarters in Hoechstaedt for details.
pare the regeneration solution. Tank has integrated suction device.
Regeneration device 100 litre
(FE-Z 20/10 – FE-Z 40/18)
Regeneration device 300 litre
(FE-Z 50/19 – FE-Z 60/20)
153 094
153 095
Mounting kit 1:
for convenient hydraulic connection,
Compact valve block R 1’’ internal thread,
integrated bypass with shut-off valve, shutoff valves for hard and soft water, outlet for
raw water (e.g. garden hose), 2 connection
hoses
Mounting kit R 1“ (up to size 30/14) 125 845
6 | Consumables
6.1 Oxidising agents for the regeneration/disinfection of deferrisation systems
Only use genuine consumables in order to ensure the reliable operation of the system.
GENO-Spezialgranulat1) (1 kg) 170 016
GENO-Spezialgranulat1) (5 kg) 170 017
GENO-oxi plus (20 kg/19.7 litre) 170 029
1)
Note: Registration by the Federal Surveillance Authority for Opium
according to the Controlled Substances and Precursors Act required.
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6.2 Test device for iron measuring range 0.0 mg/l - 0.8 mg/l
or 1.0 mg/l - 10.0 mg/l respectively
For the quantitative, colorimetric determination of dissolved iron in
the measuring range of 0.0 mg/l – 0.8 mg/l respectively
1.0 mg/l – 10 mg/l. Quick test kit consisting of:
Iron test device
1 test glass with 3 chambers and scale;
Test tablets (0.0 mg/l-0.8 mg/l) 30 tablets;
Test tablets (0.1 mg/l-10 mg/l) 30 tablets;
6.3 Spare filter filling, complete
Refer to table C-1 „Technical specifications“
6.4 Wearing parts
In case of heavy duty, seals and control pistons are subject to a certain wear and tear. Wearing parts are listed below.
Note: Although these are wearing parts, we grant a limited warranty
period of 6 months. The same applies for electrical components.
Seals, control piston, injector, actuator
170 150
Fig. C-3: Control valve
Nominal connection diameter DN 25 (1“)
Fig. C-4: Control valve
Nominal connection diameter DN 40
(1½“)
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D Installation and operation
1 | General installation instructions
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The installation site must provide adequate space. A foundation of a
sufficient size and adequate carrying capacity must be provided. The
required connections must be provided prior to the installation. For
dimensions and connection data, please refer to table D-1.
Table D-1: Installation data GENO-mat FE-Z deferrisation system
Connection data
Nominal connection diameter DN 25 (1") DN 40 (1½“)
Min. drain connection DN 50 DN 70
Nominal flow rate (depending on the iron
concentration)
Power supply [V]/[Hz
Connected load [VA] 10
Protection/protection class IP 54/
Dimensions and weights1)
Total height [mm] 1360 1620 1620 1900 1900 1870 2100
Exchanger tank
Regeneration tank
Height regeneration tank [mm] 840 1010
Connection height/raw water piping [mm] 1160 1420 1420 1710 1710 1680 1910
Connection height/pure water piping [mm] 1210 1470 1470 1735 1735 1705 1935
Distance to wall [mm] 200 230 280 280 300 365 405
Depth of foundation [mm] 400 450 500 500 550 600 650
Length of foundation [mm] 1850 1950 2050 2050 2100 2250 2350
Operating weight (incl. water) [kg] 50 85 150 200 240 425 580
1)
All indications are approximate.
[m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
20/10 25/13 30/14 40/17 40/18 50/19 60/20
230/50
]
[mm] 210 260 340 370 420 550 620
[mm] 465 680
Note: For the installation of systems with optional accessories (see
chapter C, item 5), also observe the operation manuals supplied with
these components.
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1.1 Water installation
When installing the GENO-mat FE-Z deferrisation system, certain
rules must be strictly complied with. Additional recommendations are
given in order to facilitate the handling of the systems. The installation information described below is also illustrated in fig. D-2.
Binding rules
The installation of the GENO-mat FE-Z deferrisation system represents a major interference with the drinking water system. Therefore,
only authorised experts may install such systems. In Germany, the
installation company must be registered in an installation directory of
a water company as per §12(2) AVBWasserV (German Ordinance
on General Conditions for the Supply of Water).
1.2 Electrical
installation
Observe local and general installation guidelines.
Provide a drain connection to discharge the backwash water.
The installation room must have a floor drain (DN 100). If no floor
drain is available, a corresponding water stop device has to be installed.
Observe the flow direction!
Recommendations
Provide a sampling valve and a pressure gauge directly upstream
and downstream of the GENO-mat FE-Z deferrisation system (0 10 bar). This simplifies the sampling for the regular determination
of the iron concentration (functional check).
A shock-proof plug is adequate for the electrical connection. However, it must comply with the specifications given in table D-1, may not
be further than 1.20m away from the GENO-mat FE-Z deferrisation
system and must carry constant voltage (do not couple with light
switch)!
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2 | Preliminary Work
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1. Unpack all system components.
2. Check for completeness and perfect condition.
3. Place the filter tank at the designated location.
Extract from Table D-1
Table D-2: Fill volumes
Filling volumes and consumption data
Bottom filter layer I, quartz gravel 3.0 - 5.6T [kg] - - 25 25 25 50 50
Bottom filter layer I, quartz gravel 3.0 - 5.6T
Bottom filter layer I, quartz gravel 3.0 - 5.6T
(dimension a)
Top filter layer II GENO-Ferrocat [l] 28 52 72 100 112 224 308
Top filter layer II GENO-Ferrocat (dimension
b)
Free board [l] 5 8 15 18 36 45 88
1)
All indications are approximate.
1)
GENO-mat FE-Z deferrisation system
20/10 25/13 30/14 40/17 40/18 50/19 60/20
[l]
- - 18 18 18 36 36
[mm]
[mm] 290 360 270 460 570 390 520
- - 1100 1400 1430 1320 1570
Centre rising pipe,
Fill with filter material
Remove protective cap,
secure control valve
Filter layer III Top
Filter layer I Bottom
Fig. D-1: Filling of filter layers
1. Fill filter tank up to 50 % with water.
2. Check whether the rising pipe is covered by a protective cap, plug
on the protective cap, if necessary. The protective cap prevents
material from entering the rising pipe.
3. Centre the filter tank in the rising pipe.
4. Centre the rising pipe in the filter tank. Use the funnel supplied
with the system (refer to figure). Refer to Table D-2 for fill volumes.
5. Fill up the filter tank with water
6. Centre the rising pipe properly and exactly.
7. Clean the filter tank’s screw thread and the sealing surface for the
connection of the control valve from any filter material that might be
clinging to them.
8. Remove the protective cap from the rising pipe.
9. Put the control valve from above onto the rising pipe and fasten it
by turning it to the right.
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3 | How to connect the system
1. Establish water connection as described in the erection drawing
(fig. D-2 (a) (b) while observing the guidelines and recommendations given in section 1.
Raw water
Pure water
Grünbeck‘s
limits of supply
diagram
Pump (provided by others)
Membrane expansion vessel
(provided by others)
Pressure gauge inlet pressure
(by others on site)
Fig. D-2 (a) : Erection drawing GENO-mat
Dimensions in Fig. D-2 (a); Extract from table D-1
Dimensions and weights1)
A Total height [mm] 1360 1620 1620 1900 1900 1870 2100
B Exchanger tank
C Regeneration tank
D Height regeneration tank [mm] 840 1010
E Connection height/raw water piping [mm] 1160 1420 1420 1710 1710 1680 1910
F Connection height/pure water piping [mm] 1210 1470 1470 1735 1735 1705 1935
G Distance to wall [mm] 200 230 280 280 300 365 405
H Foundation depth [mm] 400 450 500 500 550 600 650
I Foundation length [mm] 1850 1950 2050 2050 2100 2250 2350
K Operating weight (incl. water) [kg] 50 85 150 200 240 425 580
1 )
All indications are approximate.
Regeneration tank
for deferrisation (option)
Sampling valve
(by others on site)
Control valve operating voltage
FE-Z deferrisation system
GENO-mat FE-Z deferrisation system
20/10 25/13 30/14 40/17 40/18 50/19 60/20
[mm] 210 260 340 370 420 550 620
[mm] 465 680
GENO-mat FE-Z deferrisation
system incl. filter material
Pressure gauge outlet pressure
(by others on site))
Drinking water filter BOXER K
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GENO-mat FE-Z Deferrisation System
Caution! Dirt and corrosion particles might damage the system
(control valve). Flush the supply pipe prior to start-up.
2. Establish waste water connection as per DIN EN 1717. Shorten
the rinse water hose to the correct length and guide it to the drain.
Ensure there is a free outlet (min. 20mm) to the drain. Secure the
hose with suitable fittings to prevent the hose from moving about
(regeneration water is pressurised).
Caution! Danger of damage and malfunctions due to a waste water
backflow. Therefore, do not bend the hose and do not lead it higher
than the system height.
3. Connect the mains plug to the socket (cf. 1.2).
4. Water the system
In order to prevent the filter material from being washed out, it
must be watered for 24 hours.
Deferrisation
Fig. D-2 (b): GENO-mat FE-Z deferrisation system, rear view
Control valve
Filter tank
Drain connection
Raw water inlet
Raw water outlet
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GENO-mat FE-Z Deferrisation System
E Start-up
The work described below may only be performed by trained experts. We recommend having the start-up performed by Grünbeck’s
technical service/authorised service company.
Warning! Danger of contamination due to stagnation! According to
VDI 6023, filling the system with drinking water before normal opera-
1 | How to start up the system
tion commences is prohibited.
The GENO-mat FE-Z deferrisation system must therefore must only
first be connected to the drinking water system immediately prior to
commissioning.
1. Open the valve at the raw water inlet.
2. Open the valve at the pure water outlet.
3. Perform a visual check. Ensure that no water leaks from the system anywhere.
4. Rinse out fine particles
The filter material contains a small amount of fine particles which
must be flushed by means of a backwash prior to start-up. Release a manual regeneration
(refer to chapter F, item 1.4).
Note: The backwash process must be repeated until the backwash
water that flows to the drain in the process step „first filtrate“ is clear.
5. Take a water sample at the sampling valve downstream of the
system.
6. Determine the iron concentration by means of the water test kit.
7. Fill in the cover sheet and column 1 in the operation log.
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F Operation
1 | How to operate the control unit
Deferrisation
GENO-mat FE-Z Deferrisation System
1.1 How to set the time
1.2 How to set the
backwash interval
The control unit regulates the operation of the deferrisation system.
The GENO-mat FE-Z systems are factory-set in a way that the automatic regeneration is always released at 02:00 (at night). Upon
start-up or after a power failure, the current time must be set.
1. Loosen the screw at the housing cover (top right).
2. Open the housing cover.
3. Press and hold the red button (Fig. F-1, Item 6).
4. Turn the 24 hour disk until the reference arrow (Fig. F-1, Item 2)
points to the current time.
5. Release the red button (Fig. F-1, Item 6).
Note: In case the preset time for the backwash (02:00) should be
unfavourable for internal reasons, set a time which deviates from the
current time at the 24 hour disk in order to adjust the starting time for
the backwash.
Example:
Desired starting time of the backwash: 22:00
Move clock forward 4 hours.
The maximum backwash interval is 12 days. Furthermore, an automatic backwash can be carried out after 6, 4, 3, 2 or 1 day(s) (factors of 12). Fig. F-1 indicates the setting for a backwash to be carried out every 2 days.
1. Determination of the backwash interval.
For hygienic reasons, a backwash should be carried out every 6
days (factory-setting).
If the differential pressure of the filter is > 0.3 bar above normal
after 6 days due to a higher concentration of dirt in the water, a
backwash process should be initiated every 4 days or at even
shorter intervals.
The same applies in case of an early breakthrough of dirt parti-
cles.
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Deferrisation
GENO-mat FE-Z Deferrisation System
Backwash wheel
Hour wheel
Reference arrow (red)
Day disk
Steel switching pin (in home position
moved to centre point, in switch position
moved outwards)
Fig. F-1: Control unit and operating elements „front view“
2. Push the switching pin (Fig. F-1, Item 5) outwards for the 1st day.
3. Set the other switching pins as required.
On all days where the switching pins are pushed outwards, the
backwash is released. In order to set, for example, a backwash interval of 3 days, the switching pins in positions 1, 4, 7 and 10 on the
day disk must be pushed outwards (Fig. F-1, Item 4).
Button to set the time
Reference arrow for current time and operating state
(black)
Reference point for operating state (white)
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1.3 Reading the
operating status
Deferrisation
GENO-mat FE-Z Deferrisation System
The current operating state may be read from the position of the reference point (Fig. F-1, Item 8) on the backwash wheel (Fig. F-1, Item
1).
The reference point (Fig. F1, Item 8) lies opposite
the reference arrow (Fig.
F-1, Item 7).
All other settings from the
reference point (Fig. F-1,
Item 8).
The day disk (Fig. F-1, Item 4) turns counter-clockwise once in 12
days. The red reference arrow (Fig. F-1, Item 3) points to the position where a switching pin turned outwards releases a backwash. In
the operating mode, the distance between the reference arrow (Fig.
F-1, Item 3) and the following switching pin which is turned outwards
is an indication for the number of days until the next backwash.
1.4 How to release a
manual backwash
Manual regeneration should be released if
the differential pressure of the deferrisation system is more than
0.3 bar above normal before the timer control releases the backwash.
Operating mode: pure water is available.
Backwash; the backwash wheel (Fig. F1, Item 1) turns clockwise; the progress
of the backwash can be read from the
position of the reference point (Fig. F-1,
Item 8).
the systems are restarted after longer periods of standstill.
maintenance or repair work has been carried out.
Irrespective of the set backwash interval and the time, the backwash
can be released manually at any time.
1. Check operating state.
Only in operating mode:
2. Turn backwash wheel (Fig. F-1, Item. 1) to the right by one catch
(pay attention to the snap!).
The deferrisation system starts the backwash process, the backwash wheel (Fig. F-1, Item 1) slowly turns clockwise. After approx. 3
hours, the backwash is terminated and the white reference point
(Fig. F-1, Item 8) is located opposite of the black reference arrow for
the current time again (Fig. F-1, Item 7).
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Deferrisation
GENO-mat FE-Z Deferrisation System
G Maintenance and care
1 | Basic information
In order to guarantee the reliable function of the GENO-mat FE-Z
deferrisation systems over a long period of time, some maintenance
work has to be performed at regular intervals. This applies in particular to the backwash in the drinking water sector where the required
measures are defined in the pertinent regulations and guidelines. All
regulations and guidelines which apply at the installation site must
be strictly adhered to.
DIN EN 806-5 stipulates:
Inspection every 2 months
Maintenance every 6 months
Maintenance must be performed by the Grünbeck’s customer
service/authorised service company or by a specialised company.
An operation log must be kept in order to document the mainte-
nance work performed.
Note: A maintenance contract ensures that all the required maintenance work will be performed in due time.
The operation log is attached to this operation manual.
2 | Inspection (functional check)
You may perform the regular inspections yourself.
Summary: Inspection work
Determine inlet water (iron concentration).
(Water test kit)
Determine pure water (iron concentration).
(Water test kit)
Differential pressure of the system
Check controller settings:
a) Time
b) Check backwash interval
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GENO-mat FE-Z Deferrisation System
Note: Minor deviations are normal and cannot be prevented techni-
cally. If you detect major deviations, please contact Grünbeck’s customer service/authorised service company.
3 | Maintenance
Check the entire system for outward tightness.
Check control valve to drain for tightness (in operating mode).
Maintenance work on the GENO-mat FE-Z deferrisation systems
may only be performed by Grünbeck’s technical service/authorised
service company or by an approved specialist.
An operation log must be kept for GENO-mat FE-Z deferrisation systems. In this operation log, the customer service technician records
all maintenance and repair work performed. In case of malfunctions,
this log helps to identify possible sources of error. In addition the log
documents the proper system maintenance.
Make sure that all maintenance work is recorded
in the operation log.
Summary: Maintenance work
Read water pressure, flow pressure and if necessary water meter
reading.
Determine iron concentrations.
Check release of backwash.
Check control valve for tightness, replace wearing seals if neces-
sary, check the proper function of the drive motor of the control
valve, clean injector and sieve.
Regenerate and disinfect the system.
Check the level of the filter material in the filter tank. Refill filter
material, if required.
3.1 Regeneration/disinfection of the GENO-mat FE-Z deferrisation system
Note: We recommend having the regeneration/disinfection per-
formed by Grünbeck’s authorised technical service/authorised service company.
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Deferrisation
GENO-mat FE-Z Deferrisation System
3.1.1 Oxidising agents
Designated area of application:
Oxidising agents are used for the regeneration and disinfection of
GENO-mat FE-Z deferrisation systems. Furthermore, they are dosed
upstream of GENO-mat FE-Z deferrisation systems in order to completely oxidise iron II compounds.
The dosing and the dosing volumes depend on the iron concentrations contained in the raw water.
You can use either our GENO-Spezialgranulat1) agent or
GENO-oxi plus (liquid).
3.1.2 Preparing the regeneration agent
Fill the regeneration tank with filtered water (for respective quanti-
ties refer to Table G-1). We recommend installing a filling tap in the
pure water pipe for this purpose.
Pour the GENO-Spezialgranulat (special granulate)1) or GENO-oxi
plus into the tank and mix by means of the integrated hand mixer
until the special granulate has dissolved completely.
Install a suction hose between the regeneration tank and the ball
valve at the control valve.
1)
Note: Registration by the Federal Surveillance Authority for Opium
Table G-1: Amount of regeneration agent
according to the Controlled Substances and Precursors Act required.
GENO-mat FE-Z deferrisation system
required
Preparation amount [l]
GENO-oxi plus [l] 5 9 11 17 17 35 53
GENO-Spezialgranulat1)
2)
If the liquid product GENO-oxi plus is used, the GENO-oxi plus amount must be subtracted from the preparation amount.
20/10 25/13 30/14 40/17 40/18 50/19 60/20
2)
502) 602) 1002) 1002) 2002) 3002)
30
[g] 105 175 210 350 350 700 1050
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3.1.3 Timer settings
Deferrisation
GENO-mat FE-Z Deferrisation System
For the regeneration/disinfection the corresponding regeneration
tank and the appropriate regeneration agent are required (refer to
3.1 preparation of the regeneration agent).
Flip the cover of the control valve to the side.
Release a manual regeneration (refer to chapter F, item 1.4).
Flip the timer to the right and wait for 10 minutes until limit switch
1 is free (Fig. G-1, picture 1) and the actuator of the control piston
has stopped.
Unplug mains plug.
Open the ball valve on the back of the control valve and suck the
regeneration agent from the connected regeneration tank.
Close the ball valve again after the regeneration agent has been
completely sucked off.
Reconnect mains.
Wait until limit switch 1 is pressed again (Fig. G-1,
picture 2) and the actuator of the control piston has stopped.
Unplug mains plug.
Flush for at least 30 minutes in order to wash out all residues of
the regeneration agent from the filter bed.
Reconnect mains.
The deferrisation system is ready for operation again when the
limit switches 1 and 2 are free (fig. G-1, picture 3).
Screw cover back on.
Fig. G-1: Rear of timer
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GENO-mat FE-Z Deferrisation System
3.2 Operation log
4 Spare parts
You may order spare parts and consumables from your local
The operation log is located in chapter G, item 5 of this operation
manual. When starting up the system, make sure to record all data
on the cover sheet of the operation log and fill in the first column of
the check list.
The customer service technician will fill in a column of the check list
whenever maintenance is performed. This document provides evidence of proper maintenance.
Grünbeck representative (refer to www.gruenbeck.de).
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5 Operation log
Deferrisation
GENO-mat FE-Z Deferrisation System
Customer
Name: ...............................................................................
Address: ............................................................................
..........................................................................................
..........................................................................................
GENO-mat FE-Z deferrisation system
(Please check appropriate box)
Serial number ................. .........................................
20/10
25/13
30/14
Installed by ...................... .........................................
Filter: Make/Type/ .......................
40/17
40/18
50/19
60/20
Connection data: Drain connection DIN EN 1717 yes no
(Please check appropriate
box)
Floor drain available yes no
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Deferrisation
GENO-mat FE-Z Deferrisation System
Maintenance work required on the GENO-mat FE-Z deferrisation system
Checklist
Please enter measured values. Confirm checks with OK or enter repair work performed.
Maintenance performed (date)
Measured values
Water pressure [bar] upstream
and downstream of the system
Flow pressure [bar] upstream and
downstream of the system
Water meter reading [m³]
Iron inlet (measured)
Iron pure water (measured)
Inspections and checks of control unit and control valve
Release of backwash checked
Injector and sieve cleaned
Start-up
Control valve checked for tightness
Function of driving motor checked
System "regeneration and disinfection"
System treated with special granulate
Connections, hose connections, seals
Seals and hose connections
checked
Miscellaneous
Notes
Customer service technician
Company
Work time certificate (no.)
Signature
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Deferrisation
GENO-mat FE-Z Deferrisation System
Maintenance work required on the GENO-mat FE-Z deferrisation system
Checklist
Please enter measured values. Confirm checks with OK or enter repair work performed.
Maintenance performed (date)
Measured values
Water pressure [bar] upstream
and downstream of the system
Flow pressure [bar] upstream and
downstream of the system
Water meter reading [m³]
Iron inlet (measured)
Iron pure water (measured)
Inspections and checks of control unit and control valve
Release of backwash checked
Injector and sieve cleaned
Control valve checked for tightness
Function of driving motor checked
System "regeneration and disinfection"
System treated with special granulate
Connections, hose connections, seals
Seals and hose connections
checked
Miscellaneous
Notes
Customer service technician
Company
Work time certificate (no.)
Signature
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Deferrisation
GENO-mat FE-Z Deferrisation System
Maintenance work required on the GENO-mat FE-Z deferrisation system
Checklist
Please enter measured values. Confirm checks with OK or enter repair work performed.
Maintenance performed (date)
Measured values
Water pressure [bar] upstream
and downstream of the system
Flow pressure [bar] upstream and
downstream of the system
Water meter reading [m³]
Iron inlet (measured)
Iron pure water (measured)
Inspections and checks of control unit and control valve
Release of backwash checked
Injector and sieve cleaned
Control valve checked for tightness
Function of driving motor checked
System "regeneration and disinfection"
System treated with special granulate
Connections, hose connections, seals
Seals and hose connections
checked
Miscellaneous
Notes
Customer service technician
Company
Work time certificate (no.)
Signature
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Deferrisation
GENO-mat FE-Z Deferrisation System
Maintenance work required on the GENO-mat FE-Z deferrisation system
Checklist
Please enter measured values. Confirm checks with OK or enter repair work performed.
Maintenance performed (date)
Measured values
Water pressure [bar] upstream
and downstream of the system
Flow pressure [bar] upstream and
downstream of the system
Water meter reading [m³]
Iron inlet (measured)
Iron pure water (measured)
Inspections and checks of control unit and control valve
Release of backwash checked
Injector and sieve cleaned
Control valve checked for tightness
Function of driving motor checked
System "regeneration and disinfection"
System treated with special granulate
Connections, hose connections, seals
Seals and hose connections
checked
Miscellaneous
Notes
Customer service technician
Company
Work time certificate (no.)
Signature
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