Grunbeck GENO-mat AK-Z, GENO-mat MS-Z, GENO-mat KF-Z, GENO-mat TE-Z Operation Manual

Operation manual

Filter systems

GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems

GENO-mat TE-Z

Edition September 2018
Order no. 035 129 950-inter

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

Table of contents

1 Preface

B Basic information ................................................................ 9

1 Laws, regulations, standards

C Product description ............................................................. 13

D Installation ............................................................................ 19

E Start-up ................................................................................. 16

F Operation .............................................................................. 27

G Maintenance ......................................................................... 30

A General .................................................................................

2 How to use this operation manual
3 General safety information
4 Shipping and storage
5 Disposal

2 Designated application/area of application
3 Function

1 Type plate ...........................................................................

2 Technical specifications
3 Intended use
4 Scope of delivery
5 Optional accessories
6 Consumables

1 General installation information
2 Preliminary works
3 How to connect the system

1 How to start up the system

1 How to operate the control unit

1 Basic information
2 Inspection (functional check)
3 Maintenance
4 Spare parts
5 Operation log

5

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z

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. [phone]  Fax [phone]
www.gruenbeck.de  [e-mail]

Filtration/Deacidification

Deacidification systems GENO-mat TE-Z

Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1, 89420 Hoechstaedt/Do., Germany

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

EU 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:

Description of the system: Filter systems

Device type: GENO-mat KF-Z / MS-Z / AK-Z

Device no. Refer to type plate
Applicable EC guidelines: Low voltage (2014/35/EU)

Applied harmonised
standards, in particular:

Applied national standards
and technical specifica­tions, in particular:

Place, date and signature: Hoechstaedt, 26.09.2018 p.p.

Markus Pöpperl

Deacidification systems

GENO-mat TE-Z

EMC (2014/30/EU)
DIN EN 61000-6-2:2006-03

DIN EN 61000-6-3:2011-09
DIN 19636-100:2008-02

M. Pöpperl

Dipl.-Ing. (FH)

Function of signatory: Head of Technical Product Design

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A General

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

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, carefully
and thoroughly read the operation manual before installing, operating
or maintaining the 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.

For help and advice

Please consult the representatives responsible for your region (see
www.gruenbeck.com). or get in touch with our service centre which
can be reached during office hours:

Phone: [phone]
Fax: [phone]
Email: [e-mail]
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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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

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 tech-
nical service/authorised service company or by persons expressly
authorised by Grünbeck.

6

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 Intended use

3.4 Protection from
water damage

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

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.

3.5 Indication of
specific dangers

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

damage:
a) a sufficiently dimensioned floor drain system must be available or
b) a safety device (see chapter C Accessories) must be installed.

Warning! Floor drains that discharge to a lifting system do not work
in case of a power failure.

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



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the required tasks are performed on time. You may perform the in­terim inspections yourself.

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

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

Comply with the applicable national regulations.

5.1 Packaging

5.2 Product



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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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

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 filter 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 | Designated application/area of application

Gravel filter KF-Z

Multi-layer filter MS-Z

In general, gravel filter systems are used for the conventional filtra­tion of impurities in cases where a fine filtration by means of car­tridge filters would be too costly due to an exceptionally high degree
of pollution. The quartz gravel used retains undissolved substances
such as sand, etc.

Heavy metal compounds in dissolved form such as iron and manga­nese, however, cannot be removed.

The filter must be backwashed if there is an accumulation of dirt par­ticles and a pressure drop by approx. 0.3 bar (overpressure). The
backwash is carried out from the bottom to the top, opposite to the
regular direction of flow.

Multi-layer filters mostly are used for the conventional filtration of
impurities in cases where a fine filtration by means of cartridge filters
would be too costly due to an exceptionally high degree of pollution.

The hydro-anthrasite H used in addition to quartz gravel is a filter
material composed of carefully sieved, thermally-treated carbon for
the treatment of drinking and process water. The abrasion-resistant
filter material has a rough surface by which a finer filtrate is achieved
compared to a filtration by gravel alone.

The multi-layer filter is able to retain undissolved substances such
as sand, etc. Heavy metal compounds in dissolved form such as iron
and manganese, however, cannot be removed. The filter must be
backwashed if there is an accumulation of dirt particles and a pres­sure drop by approx. 0.3 bar (overpressure). The backwash is car­ried out from the bottom to the top, opposite to the regular direction
of flow.

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

Activated carbon
filter AK-Z

The activated carbon filter is used to dechlorinate the water. If pos­sible, the water to be dechlorinated should be free of mechanical
impurities.

Activated carbon is able to react with the available, free chlorine via
surface reaction. The chloride thus produced does not clog up the
activated carbon filter but is discharged with the water. The surface
reaction capacity is reduced over time due to the amount of impuri­ties present in the water.

For this reason, and to remove any carbon abrasions that might
have occurred, it is essential to backwash the filter on a weekly ba­sis.

If the residual chlorine concentration exceeds the set admissible
value on leaving the activated carbon filter, the activated carbon
should be replaced. A replacement, however, should take place eve­ry two years at the latest.

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Deacidification system
TE-Z

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Corresponding to its carbonate hardness, all water contains a cer­tain amount of free carbon dioxide which is necessary to dissolve
the carbonate hardness present in the water. If there is more free
carbon dioxide contained in the water than necessary, the water is
characterised as tending to precipitate lime. This aggressive carbon­ic acid prevents the formation of protective scale/rust layers in the
piping and is therefore removed by means of a deacidification filter.
At the same time that the acid is removed, minor impurities are also
removed by filtration.

We would like to point out explicitly that due to the limited amount of
filtration material available, only a partial deacidification can be
achieved.

We therefore recommend installing an EXADOS dosing unit down­stream of the deacidification filter in order to add EXADOS-spezial.

In order to prevent the filter material from clogging and to flush out
impurities, it is necessary to backwash the filter. The backwash is
carried out from the bottom to the top, opposite to the regular direc­tion of flow.

The Hydrolit-Ca deacidification material used is consumed based on
the hydration of the excess carbon dioxide. (Consumption per g of
converted CO2 approx. 2.5 g).

It is therefore necessary to check the filling level from time to time
and to refill, if necessary. The system must be flushed through every
time it is refilled.

If an increased bacterial count is to be expected from the well water,
we recommend to have a disinfection performed at regular intervals
by our technical service.

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

3 | Function

3.1 Filteration

3.2 Backwash

3.3 First filtrate

3.4 Control unit

The GENO-mat filter systems for the filtration of impurities / partial
deacidification work with an active insoluble catalytic filter material. A
central control valve automatically controls the operating cycles fil­tration, backwash and first filtrate.

The raw water enters the exchanger tank via the raw water inlet and
flows through the filter material from top to bottom. According to the
filter type, the dirty water is filtered from top to bottom. The filtered
pure water is then directed via the lower distributing nozzle and the
riser 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 filter 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 filter system is ready for
operation once again.

The GENO-mat filter systems / deacidification systems are time­controlled 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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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

C Product description

1 | Type plate

The type plate is located on the control valve of the GENO-mat filter/

deacidification system. In order to speed up the processing of your
inquiries or orders, please specify the data shown on the type plate
when contacting Grünbeck. Please copy the indicated information to
the table below in order to have it readily available whenever neces­sary.

GENO-mat filter system / deacidification system

 KF-Z /  MS-Z  AK-Z  TE-Z

Serial number:      
Order no.:      

Fig. C-1: Type plate of a filter system

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

2 | Technical specifications

The GENO-mat filter/deacidification systems are individual systems

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 filter/
deacidification 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.

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Table C-1: Technical specifications GENO-mat filter systems

Connection data

Nominal connection diameter DN 25 (1") DN 40 (1½“)
Nominal pressure PN 10
Min./max. operating pressure [bar] 2.5/6.0
Nominal flow rate max. KF-Z
Nominal flow rate max. MS-Z

[m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0

[m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
Nominal flow rate max. AK-Z [m³/h] 0.25 0.5 1.0 1.2 1.5 2.0 3.0
Nominal flow rate max. TE-Z [m³/h] 0.5 1.0 1.5 2.0 2.5 3.0 4.0

Filter material KF-Z

Quartz gravel 3.0-5.6 I [kg] 9 15 20 28 20 61 90
Quartz sand 1.0-2.2 II [kg] 4 30 38 50 90 100 160
Filter sand 0.4-0.8 III [kg] 20 30 50 70 90 150 230

Filter material MS-Z

Quartz gravel 3.0-5.6 I [kg] 9 15 20 30 20 67 100
Quartz sand 1.0-2.2 II [kg] 8 25 50 82 90 180 267
Hydro-anthrasite H 0.6-1.6 III [l] 8 17 26 24 64 50 78

Filter material AK-Z

Quartz gravel 3.0-5.6 I [kg] 9 15 20 20 20 30 30
Hydrafin CC 8 x 30 0.5-2.5 II [kg] 10 16 25 40 50 90 140

Filter material TE-Z

Quartz gravel 3.0-5.6 I [kg] 9 15 20 20 20 30 30
Hydrolit-Ca 1.0-3.0 II [kg] 20 25 70 90 120 220 320

Backwash capacity [m³/h] 1.6 2.3 3.4 5.7
Backwash time [min] 10
Water/ambient temperature, max. [°C] 30/40
Power supply [V]/[Hz] 230/50
Connected load [VA] 10
Protection/protection class IP 54/
Min. drain connection DN 50 DN 70

Total empty weight KF-Z
Total empty weight MS-Z
Total empty weight AK-Z
Total empty weight TE-Z

Operating weight* (incl. water)
Operating weight** (incl. water)
Operating weight*** (incl. water)
Operating weight**** (incl. water)

Order no. KF-Z* 129 … 500 505 510 515 520 525 530
Order no. MS-Z** 129 … 550 555 560 565 570 575 580
Order no. AK-Z*** 129 … 800 805 810 815 820 825 830
Order no. TE-Z**** 129 … 850 855 860 865 870 875 880

20/10 25/13 30/14 40/17 40/18 50/19 60/20

[kg] 43 88 124 175 228 351 529
[kg] 31 65 99 151 170 312 455
[kg] 29 44 61 67 98 160 219
[kg] 39 53 106 137 168 290 399

[kg] 67 127 200 272 344 573 833
[kg] 53 100 167 240 268 515 732
[kg] 45 77 125 164 193 339 462
[kg] 57 93 163 214 257 456 633

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

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.

4 | Design

5-cycle control valve made of red bronze with time-dependent con-

trol via timer. Control valve top with rotating disks to set the back­wash intervals; cover for protection against splash water and unau­thorised access.

Exchanger tank made of pressure resistant plastic with fixtures for
water flow control and retention of filter material.

The control unit is interference-free. Power supply by means of a
transformer plug with 1.5 m feed line.

5 | Scope of supply

5.1 Basic configuration

 Exchanger tank in double walled plastic housing
 Filter materials (quartz gravel, quartz sand, filter sand,

Hydrafin CC 8 x 30, Hydrolit-Ca, Hydroanthrasit H).

 Control valve made of red bronze with integrated timer control.
 Operation manual

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

6 | Optional accessories

Note: It is possible to retrofit existing systems with optional compo-



nents. Please contact your local Grünbeck representative or
Grünbeck’s headquarters in Hoechstaedt for details.

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

protectliQ safety device

Product for the protection against water damage in
one- and two-family homes.

For additional types, please inquire

126 400

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

7 | Consumables

Only use genuine consumables in order to ensure the reliable opera­tion of the system.

7.1 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.
Seals, control piston, injector, actuator

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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Filter systems GENO-mat KF-Z / MS-Z / AK-Z

D Installation and operation

1 | General installation instructions

Filtration/Deacidification

Deacidification systems GENO-mat TE-Z



1.1 Water installation

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 C-1.

Note: For the installation of systems with optional accessories (see
chapter C, item 5), also observe the operation manuals supplied with
these components.

When installing the filter/deacidification systems, certain binding
rules must be observed. 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 filter/deacidification systems 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).

 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 safety device has to be in­stalled.

 Observe the flow direction!

Warning! Floor drains that discharge to a lifting system do not work
in case of a power failure.

Recommendations

 Provide a sampling valve and a pressure gauge (0-10 bar) directly

upstream and downstream of the filter/deacidification systems.
This simplifies the sampling for the regular determination of the
iron concentration (functional check).

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

1.2 Electrical installa-

tion

2 | Preliminary Work

A shock-proof plug is adequate for the electrical connection. Howev­er, it must comply with the specifications given in table C-1, may not
be further than 1.20 m away from the GENO-mat filter/
deacidification systems and must carry constant voltage (do not
couple with light switch)!

1. Unpack all system components.

2. Check for completeness and perfect condition.

3. Place the filter tank at the designated location.
Note: Filter/deacidification systems must be filled on site.



4. Unscrew control valve from pressure cylinder.

5. Centre the nozzle jet in the pressure cylinder and close if off by
means of adhesive tape or paper wadding.

6. Fill in the filter layers according to the filter/deacidification system
type

Filter layer I Bottom KF-Z, MS-Z, AK-Z, TE-Z
Filter layer II Middle KF-Z, MS-Z, AK-Z, TE-Z
Filter layer III Top KF-Z, MS-Z

Filter layer III Top

Filter layer II Middle

Filter layer I Bottom

Fig. D-1: Filling of filter layers

20

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Table D-1: Filling volumes

Filling volumes and consumption data

Bottom filter layer I, quartz gravel 3.0 - 5.6T [kg] 9 15 20 28 20 61 90
Bottom filter layer I, quartz gravel 3.0 - 5.6T
Bottom filter layer I (dimension a) [mm] 870 1110 1140 1380 1460 1290 1480
Middle filter layer II with quartz sand 1.0 – 2.2 [kg] 4 30 38 50 90 100 160
Middle filter layer II with quartz sand 1.0 – 2.2 [l] 3 20 25 33 60 67 107
Middle filter layer II (dimension b) [mm] 800 720 850 1070 1000 1010 1110
Top filter layer III with quartz sand 0.4 – 0.8 [kg] 20 30 50 70 90 150 230
Top filter layer III with quartz sand 0.4 – 0.8 [l] 13 20 33 47 60 100 153
Top filter layer III with quartz sand 0.4 – 0.8 [mm] 410 330 470 630 540 600 590
Free board, approx. [l] 10 9 32 36 32 95 107

1)

All indications are approximate.

Table D-2: Filling volumes

Filling volumes and consumption data

Bottom filter layer I, quartz gravel 3.0 - 5.6T [kg] 9 15 20 30 20 67 100
Bottom filter layer I, quartz gravel 3.0 - 5.6T
Bottom filter layer I (dimension a) [mm] 880 1110 1140 1360 1460 1270 1450
Middle filter layer II with quartz sand 1.0 – 2.2 [kg] 8 25 50 82 90 180 267
Middle filter layer II with quartz sand 1.0 – 2.2 [l] 5 17 33 55 60 120 178
Middle filter layer II (dimension b) [mm] 720 780 760 850 1000 770 840
Top filter layer III with Hydroanthasit H 0.6–1.6 [kg] 4 9 13 12 32 25 39
Top filter layer III with Hydroanthasit H 0.6–1.6 [l] 8 18 26 24 64 50 78
Top filter layer III (dimension c) [mm] 490 440 460 630 510 560 580
Free board, approx. [l] 13 14 31 36 28 87 104

1)

All indications are approximate.

Table D-3: Filling volumes

Filling volumes and consumption data

Bottom filter layer I, quartz gravel 3.0 - 5.6T [kg] 9 15 20 20 20 30 30
Bottom filter layer I, quartz gravel 3.0 - 5.6T [l] 6 11 14 14 14 21 21
Bottom filter layer I (dimension a) [mm] 880 1100 1130 1430 1460 1380 1620
Top filter layer II with Hydrafin CC (0.5 – 2.5) [kg] 10 16 25 40 50 90 140
Top filter layer II with Hydrafin CC (0.5 – 2.5) [l] 21 33 52 83 104 188 292
Top filter layer II (dimension b) [mm] 270 460 540 650 660 600 630
Free board, approx. [l] 6 16 39 38 48 96 119

1)

All indications are approximate.

1)

Gravel filter system GENO-mat KF-Z

20/10 25/13 30/14 40/17 40/18 50/19 60/20

[l]

6 11 14 20 14 44 64

1)

Multi-layer filter GENO-mat MS-Z

20/10 25/13 30/14 40/17 40/18 50/19 60/20

[l]

6 11 14 21 14 48 71

1)

Activated carbon filter GENO-mat AK-Z

20/10 25/13 30/14 40/17 40/18 50/19 60/20

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21

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

Table D-4: Fill volumes

Filling volumes and consumption data

Bottom filter layer I, quartz gravel 3.0 - 5.6T [kg] 9 15 20 20 20 30 30
Bottom filter layer I, quartz gravel 3.0 - 5.6T [l] 6 11 14 14 14 21 21
Bottom filter layer I quartz gravel (dimension

a)
Middle filter layer II Hydrolit CA [kg] 20 25 70 90 120 220 320
Middle filter layer II Hydrolit CA [l] 20 25 70 90 120 220 320
Middle filter layer II Hydrolit CA (dimension b) [mm] 300 620 340 590 540 460 530
Free board, approx. [l] 6 24 21 32 32 64 90

1) All indications are approximate.

Centre riser pipe,
fill with filter material

1)

GENO-mat TE-Z deacidification system

20/10 25/13 30/14 40/17 40/18 50/19 60/20

[mm] 880 1100 1130 1430 1460 1380 1620

1. Fill filter tank up to 50 % with water.

2. Check whether the riser pipe is covered by a protective cap, plug
on the protective cap, if necessary. The protective cap prevents
material from entering the riser pipe.

3. Centre the filter tank in the riser pipe.

4. Fill the tank with filter material. By using the funnel supplied with
the system (refer to figure). Refer to Table D-2 for fill volumes.

Remove protective cap,
secure control valve

5. Fill up the filter tank with water.

6. Centre the riser 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 riser pipe.

9. Put the control valve from above onto the riser pipe and fasten it
by turning it to the right.

22

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y

3 | How to connect the system

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Raw water

1. Establish the water connection as described in the erection draw­ing (fig. D-2 (a) (b). Observe all requirements and general installa­tion instructions.

Pure water

Grünbeck
Limits of suppl
diagram

Pump (provided by others)



Membrane expansion vessel (provided by others)



Pressure gauge inlet pressure (by others))



Fig. D-2 (a) : GENO-mat filter/deacidification systems erection drawing

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Control valve operating voltage



GENO-mat filter system incl. filter material



Pressure gauge outlet pressure (by others)



23

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

Table D-5: Installation dimensions1) GENO-mat filter systems

A Total height [mm] 1360 1620 1620 1900 1900 1870 2100
B Pressure cylinder 
E Connection height/

raw water piping
F Connection height/

pure water piping
H Distance to wall [mm] 200 230 280 280 300 365 405
I Foundation depth [mm] 400 450 500 500 550 600 650
K Foundation length [mm] 705 755 860 860 900 1030 1110

1)

All indications are approximate.

20/10 25/13 30/14 40/17 40/18 50/19 60/20

[mm] 210 260 340 370 420 550 620
[mm] 1160 1420 1420 1710 1710 1680 1910

[mm] 1210 1470 1470 1735 1735 1705 1935

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 (see 1.2).

4. Water the system (not the KF-Z)

In order to prevent the filter material from being washed out, it
must be watered for 24 hours.

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z




Control valve



Raw water inlet



Fig. D-2 (b): GENO-mat filter system, rear view

Filter tank



Drain connection



Pure water outlet



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25

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

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 filter/deacidification systems must therefore 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

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

1.1 How to set the time



1.2 How to set the
backwash interval

The control unit regulates the operation of the filter/deacidification sys­tems.

The filter/deacidification systems are factory-set in a way that the
automatic regeneration is always released at 2:00 am (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 (2:00 am) 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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27

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

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

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

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).

1.4 How to release a
manual backwash

The reference point (Fig.
F-1, Item 8) lies opposite
the reference arrow (Fig.

Operating mode: pure water is available.

F-1, Item 7).
All other settings from the

reference point (Fig. F-1,
Item 8).

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 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.

Manual regeneration should be released if
 the differential pressure of the filter/deacidification systems is

more than 0.3 bar above normal before the timer control releases
the backwash.

 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 filter/deacidification systems start 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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29

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

G Maintenance and Care

1 | Basic information



In order to guarantee the reliable function of filter/deacidification 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 system pressure differential
 Check controller settings:

a) Time
b) Check backwash interval

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.

 Check the entire system for outward tightness.
 Check control valve to drain for tightness (in operating mode).

30

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3 | Maintenance

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Maintenance work on the filter/deacidification systems may only be
performed by Grünbeck’s technical service/authorised service com­pany or by an approved specialist.

3.1 Disinfecting the GENO-mat filter/deacidification systems

An operation log must be kept for the filter/deacidification 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.

 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.

 Disinfect the system if required.
 Check the level of the filter material in the filter tank. If necessary,

refill the filler material.

Note: We recommend having the disinfection performed by



Grünbeck’s authorised technical service/authorised service compa­ny.

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31

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

3.1.1 Timer settings

 For the 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.

Limit switch 1

 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 disinfection agent from the filter bed.

 Reconnect mains.
 The filter/deacidification systems are ready for operation again

when the limit switches 1 and 2 are free (Fig. G-1, picture 3).

 Screw cover back on.

Programmer dial Programmer dial

Limit switch 1

Limit switch 1

Programmer dial

Limit switch 2

Fig. 1

Fig. G-1: Rear of timer

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32

Limit switch 2

Fig. 2

Limit switch 2

Fig. 3

3.2 Operation log

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

4 Spare parts

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.

You may order spare parts and consumables from your local
Grünbeck representative (refer to www.gruenbeck.com).

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Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

34

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5 Operation log

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Customer

Name: ...............................................................................

Address: ............................................................................

..........................................................................................

..........................................................................................

GENO-mat filter/deacidification systems

KF-Z / MS-Z AK-Z  TE-Z

(please check appropriate box)

Serial number: ................ .........................................

Installed by ...................... .........................................

Filter: Make/Type/ .......................

20/10
25/13
30/14
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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35

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

Maintenance work required on filter/deacidification systems

GENO-mat KF-Z, MS-Z, AK-Z, TE-Z

Checklist

Please enter measured values. Confirm checks with OK or enter repair work performed.
Maintenance performed (date) Start-up

Measured values

Water pressure [bar] upstream
and downstream of the system

Flow pressure [bar] upstream and
downstream of the system

Water meter reading [m³]

Inspections and checks of control unit and control valve

Release of backwash checked
Injector and sieve cleaned
Control valve checked for tight-

ness
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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36

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Maintenance work required on filter/deacidification systems

GENO-mat KF-Z, MS-Z, AK-Z, TE-Z

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]

Inspections and checks of control unit and control valve

Release of backwash checked
Injector and sieve cleaned
Control valve checked for tight-

ness
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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37

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z

Maintenance work required on filter/deacidification systems

GENO-mat KF-Z, MS-Z, AK-Z, TE-Z

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]

Inspections and checks of control unit and control valve

Release of backwash checked
Injector and sieve cleaned
Control valve checked for tight-

ness
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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38

Filtration/Deacidification

Filter systems GENO-mat KF-Z / MS-Z / AK-Z

Deacidification systems GENO-mat TE-Z

Maintenance work required on filter/deacidification systems

GENO-mat KF-Z, MS-Z, AK-Z, TE-Z

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]

Inspections and checks of control unit and control valve

Release of backwash checked
Injector and sieve cleaned
Control valve checked for tight-

ness
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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39