Grunbeck GENO-flushing compressor 1988 K Operation Manual

GENO®-flushing compressor 1988 K

operation manual

Date April 2013
Order no. 015 151 963-inter

Grünbeck Wasseraufbereitung GmbH

Josef-Grünbeck-Strasse 1
89420 Hoechstaedt/Danube · GERMANY
Phone [phone] · Fax [phone]
www.gruenbeck.com · [e-mail]

A company certified by TÜV SÜD

in accordance with DIN EN ISO 9001, DIN
EN ISO 14001, DIN EN ISO 13485 and SCC

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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Table of contents

A General .......................................................................... 5

1 Preface
2 Warranty
3 How to use this operation manual
4 General safety information
5 Shipping and storage
6 Disposal of used parts and materials

B Basic information .......................................................... 11

1 Laws, regulations, standards

2 Flushing, disinfection and sanitation of installations

C Product description ....................................................... 14

1 Type designation plate

2 Flushing compressor components
3 Function
4 Designated application
5 Application limits

6 Technical specifications

7 Scope of supply

D Installation for flushing and disinfection of drinking

water installations ........................................................

28

1 General installation instructions

2 Installation of the flushing compressor in pipelines
3 Installation of accessories for draining the flushing
water
4 Preparation of the drinking water installation for rinsing
5 Preparation of the drinking water installation for
disinfection as per DVGW (German Association for Gas
and Water) work sheet 557

E Flushing and disinfection of drinking water

installations ...................................................................

45

1 General notes

2 Flushing of pipes with a mixture of water and air

3 Performing system installation as per
DIN EN 806-4 and DVGW work sheet 557

F Rinsing of silted up floor heating systems .................. 49

1 General

2 Preparation for rinsing
3 Rinsing of floor heating systems with water and a
mixture of water and air

G Troubleshooting ............................................................ 52

1 Introduction

2 Error messages

H Maintenance and care .................................................. 54

1 Basic information

2 Care work

3 Inspection

4 Maintenance
5 Operation lo

g

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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Publisher's information

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 only with 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-Strasse 1  89420 Hoechstaedt/Germany
Phone [phone]  Fax [phone]
www.gruenbeck.de  [e-mail]

Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Strasse 1, 89420 Hoechstaedt/Germany

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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EC Declaration of Conformity

This is to certify that the system designated below meets the safety and health requirements of the
applicable European guidelines in terms of its design, construction and execution.

If the system is modified in a way not approved by us, this certificate is void.
Manufacturer: Grünbeck Wasseraufbereitung GmbH

Josef-Grünbeck-Strasse 1

89420 Höchstädt/Do., Germany
Responsible for documentation: Markus Pöpperl
System designation: GENO®-flushing compressor
System type: 1988 K
System number: Refer to type designation plate
Applicable EC guidelines: Machinery Directive (2006/42/EC)

EMC Directive (2004/108/EC)

EC Low-Voltage Directive (2006/95 EC)
Applied harmonised standards

in particular:

DIN EN ISO 12100 - 1, DIN EN ISO 12100 - 2

DIN EN 61000-6-2, DIN EN 61000-6-3,

first regulation concerning the Product and Devices Safety Act

(regulation concerning the marketing of electrical equipment

for use within specific voltage ranges

- 1. GPSGV).

Applied national standards and
technical specifications,
in particular:

DIN 31000/VDE 1000 (03.79)

Date / Manufacturer signature: 17.04.13 p.p.

Markus Pöpperl

Dipl. Ing. (FH)
Function of signatory: Head of Design Department for Serial Products

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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A General

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 and 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 staff, as well as the experts at our
headquarters in Hoechstaedt, are available to help you.

Please consult the

representatives

responsible for your region for help and advice (see
www.gruenbeck.de). In case of emergency, please get in touch with our
service hotline at [phone]. We can connect you with the
appropriate expert more quickly if you provide the required system data.
In order to have access to this data at all times, please insert the
information from the type designation plate into the overview in chapter
C, section 1

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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2 | Warranty

All Grünbeck Wasseraufbereitung GmbH devices and systems are
produced using state-of-the-art production methods and are subjected
to comprehensive quality controls. All warranty claims are subject to our
General Terms and Conditions.

Terms and Conditions of Sale and Delivery (excerpt)

. . . . . . . .

11. Warranty
a) If goods and services are supplied which are obviously

defective, the Customer must report such defects
within 8 (eight) days after receipt of such goods and
services in order to maintain the liability claims.

b) If the defect is of such a nature that only a spare part

needs to be replaced, Grünbeck shall have the right to
request the Purchaser to replace the new part
delivered by us if the costs for sending a technician to
the Purchaser's site are unreasonably high.

c) The warranty periods are:

- two years: for devices for private use (natural

persons)

- one year: for devices for industrial or commercial use

(companies)

- two years: for all DVGW-certified devices, also for

industrial or commercial use within the framework

of the liability agreement with the ZVSHK
after delivery/acceptance. This excludes electrical parts
and parts which are subject to wear and tear. The
warranty period shall only apply if the operation
manual is observed meticulously, if the device is
mounted, commissioned, operated and maintained
properly, and/or if a maintenance contract is
concluded within the first six months. If these
requirements are not met, the warranty shall be void.
The warranty shall be void if the purchaser uses
dosing agents or chemicals supplied by other
manufacturers and if the quality and composition of
such dosing agents or chemicals is beyond

Grünbeck's control. Grünbeck shall not be liable for
defects or damage resulting from inept handling or
operation.

d) Grünbeck shall only be liable if the Customer performs

the maintenance work as stated in the operation
manual or has the maintenance work performed in
such a way and if the Customer uses spare parts
supplied or recommended by Grünbeck.

e) Grünbeck shall not be liable for damage resulting from

frost, water or electrical over-voltage or from parts
which are subject to wear and tear. This applies in
particular to electrical parts.

f) The claims of the Purchaser are limited to repair or

replacement, as the case may be, at the discretion of
Grünbeck. Grünbeck shall have the right to several
attempts to repair. If Grünbeck fails to repair or replace
the defective delivery within a reasonable time, the
Customer shall have the right to either cancel the
contract or demand an appropriate reduction of the
purchase price.

g) In case of complaints with regard to systems that are

not installed in Germany, the warranty claim will be
settled by the local technical service authorised by
Grünbeck. If no technical service is designated in the
specific country, the assignment of Grünbeck’s
technical service shall end at the German border. All
additional cost, apart from the material required, shall
be borne by the customer.

. . . . . . . .

3 | 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.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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4 | General safety information

4.1 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 life­threatening 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.

Attention! 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 the technical customer
service/authorised service company or by persons who have been
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).

4.2 Operating
personnel

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.

4.3 Designated
application

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.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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4.4 Protection from water damage

Warning! In order to properly protect the installation site from water

damage:

1. a sufficiently dimensioned floor drain system must be available or

2. work must be continually supervised.

4.5 Indication of
specific dangers

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!
Have the system installed and operated by a specialist company. The
operation manual must be strictly adhered to! Inspections and
maintenance must be performed at the intervals specified!

Particular dangers on the compressor aggregate!

Warning!

1. Do not operate the flushing compressor below 5°C. If the flushing

compressor is undercooled – without connection voltage – wait until
the temperature has adjusted.

2. The compressor aggregate and lines become very hot when

operated and remain hot for some time after being switched off.
Contact with hot parts results in burns. It must be ensured that no
flammable materials are allowed to come into contact with these
parts.

3. The flushing compressor may only be operated in a well-ventilated

and dust-free room. The air sucked in by the compressor aggregate
must not contain flammable vapours or mist, e.g., paint solvents,
which could lead to a fire or explosion.

4. The cooling air flow on the compressor aggregate must not be

blocked. The system must thus be set up a distance of at least 50 cm
from any obstacles.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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5. Use the accessories suitable for the specific application and

operating pressure and observe the relevant safety information.

6. Regularly check that the safety devices, electrical lines, safety valve

and tubes are in perfect condition.

7. In the case of any damage to electrical or pressurised components,

disconnect these from the mains or depressurise them and have
them checked/repaired by a specialist.

8. Hold or secure free tube ends as these could cause injuries by

whipping around. When releasing the tube coupling, the coupling
piece is to be held securely in order to avoid injuries caused by the
tube whipping back quickly.

9. Do not "play" with compressed air or aim it at others! Do not use

compressed air to clean clothes.

10. Ear protection must be used when working with the flushing

compressor.

11. Depressurise the pressure vessel via the drain valve prior to

transporting the flushing compressor.

12. Do not make any changes to the safety valve and pressure vessel.

13. The compressor aggregate features a motor circuit breaker which

automatically interrupts the current supply in the event of an
overload. In this case, pull the plug out of the mains and wait a few
minutes before resetting the motor circuit breaker and then put the
plug back in. If the motor circuit breaker should be triggered again,
disconnect the power supply and contact the Grünbeck technical
customer service/authorised service company.

Danger! Disinfectants are hazardous substances. When using optional
disinfectants, the relevant safety information and safety data sheets are
to be observed and the prescribed protective equipment is to be used.



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.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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5 | Shipping and storage

Attention! The system may be damaged by frost or high temperatures.

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.

6 | Disposal of used parts and materials

Used parts and materials are to be disposed of or made available for
recycling purposes according to the applicable local guidelines.

If a material is subject to specific regulations, adhere to the instructions
indicated on the packing.

If in doubt, contact your local waste disposal authority or the
manufacturer for more information.

Since the compressor does not contain lubricants, the condensation can
be disposed of as waste water.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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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 (raw water). This operation manual
takes into consideration the current regulations and stipulates
information that you will need for the safe operation of your water
treatment system.

Among other things, the regulations stipulate that
only approved companies are permitted to make major modifications to

water supply facilities
and that tests, inspections and maintenance on installed devices are to

be performed at regular intervals.
In order to ensure drinking water quality, the issue of hygiene in

installations is becoming increasingly important. On the one hand, when
commissioning the installation there is the issue of cleaning by means of
flushing and then, depending on water hardness, the implementation of
measures to prevent lime scale. On the other hand, there are sanitation
measures such as sanitation flushing, disinfection, the removal of lime
scale and rust as well as the creation of a protective layer by means of
mineral dosing. These measures result from the latest requirements of
the German drinking water ordinance and standards, in particular DIN
EN 806-4.

The DVGW work sheet W 557 describes the "cleaning and
disinfection of drinking water installations"

It serves as the basis for avoiding and eliminating microbial
contamination and undesired deposits in drinking water installations as
defined by the drinking water ordinance. It describes the cleaning of
drinking water installations and the system disinfection of drinking
water installations or parts thereof and designates which disinfection
methods are to be applied and when as well as preventative measures
for avoiding microbial contamination.
The continuous disinfection of drinking water (drinking water
disinfection) is, in contrast, described in DVGW work sheet W 556
(under preparation).

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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2 | Differentiation between "system disinfection" and
"disinfection of the drinking water"

"System disinfection" is a complete measure for disinfection of a
drinking water installation and, during this time, drinking water is not
available to consumers. "System disinfection" is only a long term
solution if the causes of contamination are remedied.

"Disinfection of the drinking water" is transient long-term disinfection
before and/or during the technical sanitation of the drinking water
installation. The addition of disinfection by the water supplier must be
taken into account.

3 | Basis as per W 557, section 4

Drinking water must not impair the health of consumers. In addition to

the long-term protection of drinking water resources and preparation
and distribution in accordance with the generally recognised codes of
practice this also requires a properly planned, set up and operated
drinking water installation.

In particular, the drinking water installation can become contaminated
when newly constructed and during repairs. Contamination with
pathogens is a key danger. As long as the contamination remains
suspended or dissolved in the water, it is possible to flush it out of the
drinking water installation without any great difficulties. The first step in
remedying pollution is always cleaning. This is also true with microbial
contamination. Micro-organisms embedded in particles or corrosion
products are virtually impossible to kill off with disinfectants as these are
unable to access the micro-organisms. For this reason, the particles or
corrosion products must be removed by flushing or other cleaning
measures. System disinfection may be necessary as an additional safety
measure.

In existing drinking water installations with zinc-coated steel pipelines in
the hot water area, the water can become discoloured after even a brief
stagnation time due to corrosion. Flushing and other cleaning measures
are either not or only briefly effective in such cases. The dosing of
inhibitors can result in an improvement.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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Regardless of whether there is immediate discolouration of the water or

not, corrosion causes deposits to build up. These can be due to
precipitation in the hot water area or from the flushing in of solid
particles from the supply network (e.g., rust particles). If there are
deposits, there is a risk that these will be mobilised when a large
amount of water is withdrawn and, consequently, the water is
discoloured or becomes clouded. Moreover, deposits facilitate the
multiplication of micro-organisms which can, in turn, result in microbial
pollution. In order to prevent this, the installation must be cleaned if it
contains deposits.

In drinking water installation which are planned, built, commissioned,
operated and maintained in accordance with the generally recognised
codes of practice, the microbiological sound quality of the drinking
water is ensured at the withdrawal point. In particular the following
must be ensured:

 Operation as intended (including regular withdrawal of water at all

withdrawal points)

 Temperature of the cold drinking water not in excess of 25°C
 Temperature of the hot drinking water in the entire circulation system

not below 55°C

 Regular maintenance

If the microbiological parameters of the limit values of the drinking
water ordinance are exceeded or if the technical action value of the
drinking water ordinance is reached or exceeded or the requirements of
the UBA (Federal Environmental Agency) recommendations are not
complied with, microbial contamination must be eliminated in the
interests of health protection. In such cases, system disinfection may be
additionally necessary after cleaning.



Note: Cleaning measures and system disinfection are only effective in
the long term if the causes of pollution, in particular in connection with
microbial contamination, have been remedied.

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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C Product description

1 | Type designation plate

Queries and orders can be processed more quickly if you quote the data

on the type designation plate (fig. C-1) of your flushing compressor.
Please amend the serial number in the overview below in order to
always have the data required at hand.

GENO®-flushing compressor 1988 K
Serial number:      
Order no.: 151 200

Fig. C-1: GENO®-flushing compressor 1988 K type designation plate

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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2 | Flushing compressor components

1

Tubular frame

8

Air suction filter

15

Pressure regulator condensate drain
valve

2

Compressor aggregate

9

Control unit

16

Pressure display for
compressed air vessel

3

Compressed air vessel

10

Solenoid valve

17

Compressed air vessel condensate drain
valve

4

Type designation plate

11

Non-return valve

18

Safety valve

5

Dosing connection for
optional dosing system

12

Pressure display
for air pulses

19

Pressure switch

6

Control connection for
optional dosing system

13

Flushing air pressure
regulator
with filter

20

Motor circuit breaker

7

Mains cable

14

Compressed air
connection
quick coupling

Fig. C-2: GENO®-flushing compressor1988 K components

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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3 | Function

m3/h

8.8

1

Pulse display

4

Disinfection

2

Flow display

5

Water/air mix

3

Continuous air blast ON/OFF

6

Compressed air

Fig. C-3: Control of the GENO®-flushing compressor1988 K

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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Compressed air

To use as a compressed air supply, the flushing compressor must be
fitted with a standard compressed air connection with quick coupling.
With this function, no air or dosing agent is added to the water.

Water/air mix

For the flushing of pipes with a water/air mix.
The flushing compressor is flushed through with water from an on-site

source. Volume-controlled addition of compressed air in periodic pulses
in order to increase the flushing efficiency. The flushing air pressure
automatically adjusts to a value which exceeds the existing water
pressure. The water flow is indicated in the LED display in m³/h.

If the disinfectant GENO

®

-Baktox (chlorine dioxide) is to be used, the
separate, independent dosing system MOBIdos (without flushing
compressor) is used.

Continuous air blast

In order to increase the efficiency of cleaning, this function can be
connected to the water/air mix, e.g., with sanitation flushing.

Disinfection

For system disinfection (disinfection of a drinking water installation) with
GENO®-Chlor A or GENO®-perox using the optional dosing system
GENODOS® DM-SK (see note below).

The GENO®-flushing compressor 1988 K is flushed through with water
from an on-site source. Volume-controlled supply of disinfectant to the
dosing connection on the flushing compressor. The dosing pump is
controlled by the controller of the flushing compressor and the dosing
pulses are indicated on the LED display (for dosing systems and
disinfectants, please refer to Accessories).



Note: For system disinfection we recommend the independent and
mobile dosing system MOBIdos (order no. 160 150) which comes
complete with a system divider and is suitable for all three disinfectants
listed in the DVGW work sheet W 577; GENO®-perox (hydrogen
peroxide) GENO+-Baktox (chlorine dioxide) and GENO®-Chlor A (sodium
hypochlorite or chlorine).

GENO®-flushing compressor 1988 K

Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC

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4 | Designated application

The GENO®-flushing compressor 1988 K is suitable for the following

applications:

Flushing of pipes

with a water/air mix

 prior to the commissioning of drinking water installations

as per DIN EN 806-4 and DVGW work sheet W 557.

 prior to disinfection of drinking water installations

as per DIN EN 806-4 and DVGW work sheet W 557.

 in the case of corroded and silted up pipes lines prior to mineral

dosing.

 of silted up floor heating systems.

system disinfection

Disinfection of drinking water installations as per DIN EN 806-4 and
DVGW work sheet W 557 with GENO®-Chlor A or GENO®-perox, using
the optional dosing system GENODOS® DM-SK.

The GENO®-flushing compressor 1988 K may only be operated once all
components have been properly installed. Safety devices must NEVER be
removed, bridged or otherwise tampered with.

Designated application also involves following the information given in
this operation manual and the safety regulations which apply at the site
of operation as well as compliance with the maintenance and inspection
intervals.