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Grunbeck GENO-flushing compressor 1988 K Operation Manual

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Date April 2013
Order no. 015 151 963-inter
®
GENO
-flushing compressor 1988 K
operation manual
Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Strasse 1
89420 Hoechstaedt/Danube · GERMANY
Phone +49 9074 41-0 · Fax +49 9074 41-100
www.gruenbeck.com · info@gruenbeck.com
A company certified by TÜV SÜD
in accordance with DIN EN ISO 9001, DIN
EN ISO 14001, DIN EN ISO 13485 and SCC

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  • Page 1 ® GENO -flushing compressor 1988 K operation manual Grünbeck Wasseraufbereitung GmbH Date April 2013 Josef-Grünbeck-Strasse 1 Order no. 015 151 963-inter 89420 Hoechstaedt/Danube · GERMANY Phone +49 9074 41-0 · Fax +49 9074 41-100 www.gruenbeck.com · info@gruenbeck.com A company certified by TÜV SÜD in accordance with DIN EN ISO 9001, DIN EN ISO 14001, DIN EN ISO 13485 and SCC...

  • Page 2: Table Of Contents

    ® GENO -flushing compressor 1988 K 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 Basic information ............11 1 Laws, regulations, standards 2 Flushing, disinfection and sanitation of installations Product description ............
  • Page 3 ® GENO -flushing compressor 1988 K 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...
  • Page 4 ® GENO -flushing compressor 1988 K 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...

  • Page 5: A General

    ® GENO -flushing compressor 1988 K 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.

  • Page 6: Warranty

    ® GENO -flushing compressor 1988 K 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) .

  • Page 7: General Safety Information

    ® GENO -flushing compressor 1988 K 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 life- threatening injuries, extreme damage to property or inadmissible contamination of the drinking water.
  • Page 8 ® GENO -flushing compressor 1988 K 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. Danger due to electrical energy! 4.5 Indication of Do not touch electrical parts with wet hands.
  • Page 9 ® GENO -flushing compressor 1988 K 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.

  • Page 10: Shipping And Storage

    ® GENO -flushing compressor 1988 K 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.

  • Page 11: B Basic Information

    ® GENO -flushing compressor 1988 K 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.
  • Page 12 ® GENO -flushing compressor 1988 K 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.
  • Page 13 ® GENO -flushing compressor 1988 K 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).

  • Page 14: C Product Description

    ® GENO -flushing compressor 1988 K 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.

  • Page 15: Flushing Compressor Components

    ® GENO -flushing compressor 1988 K 2 | Flushing compressor components Tubular frame Air suction filter Pressure regulator condensate drain valve Compressor aggregate Control unit Pressure display for compressed air vessel Compressed air vessel Solenoid valve Compressed air vessel condensate drain valve Type designation plate Non-return valve...

  • Page 16: Function

    ® GENO -flushing compressor 1988 K 3 | Function Pulse display Disinfection Flow display Water/air mix Continuous air blast ON/OFF Compressed air ® Fig. C-3: Control of the GENO -flushing compressor1988 K Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC...
  • Page 17 ® GENO -flushing compressor 1988 K 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.

  • Page 18: Designated Application

    ® GENO -flushing compressor 1988 K 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. ...

  • Page 19: Application Limits

    ® GENO -flushing compressor 1988 K 5 | Application limits Flushing of drinking water installations prior to commissioning with a mixture of water and air as per DIN EN 806-4 and DVGW work sheet W 557 with a recommended minimum flow speed of 0.5 m/s. ...

  • Page 20: Technical Specifications

    ® GENO -flushing compressor 1988 K 6 | Technical specifications All flushing compressor data is summarised in Table C-1. The data refers to the standard versions of the flushing compressors. Possible deviations in case of special versions are listed separately, if applicable. Table C-1: Technical specifications GENO ®...

  • Page 21: Scope Of Supply

    ® GENO -flushing compressor 1988 K 7 | Scope of supply 7.1 Basic configuration GENO ® -flushing compressor 1988 K, complete, packed in a box with operation manual and 2 flexible connection tubes DN 25 (1" excess), each 1.5 m in length with spare O-rings. 7.2 Accessories ...
  • Page 22 ® GENO -flushing compressor 1988 K Connection fitting cases ¾", 1", 1¼", 1½", 2" For integration of the flushing compressor in the pipelines, e.g., in place of an existing filter, adjusting piece, softening system, dosing system Consisting of:  Connection fittings to be fitted, for example, in place of an adjusting piece, for ¾"...
  • Page 23 ® GENO -flushing compressor 1988 K ® GENODOS DM-SK dosing system As an accessory for the flushing compressor, for disinfection of piping with GENO ® -Chlor A or GENO ® -perox comprising:  Dosing pump GP 10/40, self-deaerating, for degassing media, controlled via contact water meter of flushing compressor, power supply 230 V, 50 - 60 Hz.
  • Page 24 ® GENO -flushing compressor 1988 K Closing plug case, 60 x ½" closing plugs Closing plugs to be fitted at withdrawal points, also suitable for leakage tests and to deaerate the drinking water installation. The closing plug can be equipped with an optional flushing fitting (see case with flushing fittings) to perform the flushing.
  • Page 25 ® GENO -flushing compressor 1988 K Case with flushing fittings, 20 flushing fittings with accessories In order to use these flushing fittings, the above mentioned closing plugs are needed. See case with closing plugs or set of closing plugs. The flushing fitting is connected to the closing plug for flushing and serves to drain off the flushing water when flushing through piping.
  • Page 26 ® GENO -flushing compressor 1988 K Flushing water calming tank When flushing though drinking water installations, the flushing water calming tank serves to ensure steady draining of the flushing water into a floor drain or toilet. As per DVGW work sheet W 557 when flushing with a mixture of air and water, the withdrawal points must be fitted with the relevant equipment in order to separate the air from the flushing water.
  • Page 27 ® GENO -flushing compressor 1988 K To ensure reliable operation of the flushing compressor, only use 7.3 Consumables original consumables.  Air suction filter for the compressor aggregate. 151 665e  Filter insert for the flushing air pressure regulator. 899 50 943 Spare parts and consumables are available from the representatives 7.4 Spare parts responsible for your region.

  • Page 28: D Installation For Flushing And Disinfection Of Drinking Water Installations

    ® GENO -flushing compressor 1988 K D Installation for flushing and disinfection of drinking water installations 1 | General installation instructions  Note: The general and safety instructions in chapter A as well as the designated application, application limits and technical specifications in chapter C must be observed.
  • Page 29 ® GENO -flushing compressor 1988 K 1.2 Sanitary Installation ® When installing the GENO -flushing compressor 1988 K certain rules must always be followed. Additional recommendations facilitate work with the GENO ® -flushing compressor 1988 K. Binding rules The installation of a flushing compressor represents a major intervention in the drinking water installation and thus must only be performed by an approved installation company.
  • Page 30 ® GENO -flushing compressor 1988 K Suitable connections must be ensured on-site for integration of the flushing compressor into the installation. That's why, during planning and installation, an adjusting piece should be fitted immediately downstream of the filter (see chapter C, accessories) in order, when commissioning, to have the option of temporarily connecting the relevant devices, such as a pressure booster, flushing compressor or disinfection device.

  • Page 31: Installation Of The Flushing Compressor In Pipelines

    ® GENO -flushing compressor 1988 K 2 | Installation of the flushing compressor in pipelines The flushing compressor is integrated into the installation using the flexible connection tubes included in the scope of supply.  Note: The information on flow direction must be followed when installing the flushing compressor in the piping.
  • Page 32 ® GENO -flushing compressor 1988 K 2.1 Integration of a flushing compressor in place of a filter with an installation length of 100 mm Warning! When using the filter from the connection fitting case, a new filter cartridge must be used for each flushing operation. For this connection type, the parts for the nominal widths ¾", 1"...
  • Page 33 ® GENO -flushing compressor 1988 K 2.2 Integration of a flushing compressor in piping in place of, for example, an adjusting piece For this connection type, the parts for the nominal widths 1", 1 ¼", 1 ½" and 2" are included in the connection fitting cases ¾" - 2". The installation length of these fittings is variable and in conjunction with the connection bracket they can be used as of an installation length of approx.
  • Page 34 ® GENO -flushing compressor 1988 K With longer distances, installation without a connection bracket (e.g., in place of a 1 ½" and 2" adjusting piece with 330 mm). Fig. D-5: Installation example of a flushing compressor without connection bracket Order no. 015 151 963-inter Created: KONS-gmei-mrie G:\BA-151963-INTER_GENO-SPUELKOMP-1988_K.DOC...
  • Page 35 ® GENO -flushing compressor 1988 K 2.3 Integration of several parallel-connected flushing compressors in piping in place of, for example, an adjusting piece For this connection type, the parts for the nominal widths 1½", 2", DN 65 and DN 80 are included in the connection fitting cases 1½" - DN 80. With 1½", 2"...
  • Page 36 ® GENO -flushing compressor 1988 K 2.4 Additional assembly of an optional system divider on the flushing compressor for disinfection of pipelines System divider on the flushing compressor inlet The components necessary for this connection version are included in the connection fitting cases ¾" - 2". ...

  • Page 37: Installation Of Accessories For Draining The Flushing Water

    ® GENO -flushing compressor 1988 K 3 | Installation of accessories for draining the flushing water  Note: For the installation examples shown below, the optional closing plug and flushing fitting cases as well as the flushing water calming tank are required (see chapter C, accessories) Warning! The flushing tube to the drain must be secured during flushing as the water flows out in a pressurised and pulsating manner.
  • Page 38 ® GENO -flushing compressor 1988 K Fig. D-10: Example of installation of the flushing water Fig. D-11: Example of installation with toilet bowl calming tank with floor drain Fig. D-12: Withdrawal point on bath fitting with closing plug and flushing fitting as well as flushing insert from the manufacturer in the flush-mounted device for separate flushing of hot and cold water lines.

  • Page 39: Preparation Of The Drinking Water Installation For Rinsing

    ® GENO -flushing compressor 1988 K Fig. 13: Toilet tank (disassembled angle Fig. D-14: Toilet tank – flushing without valve) with closing plug and flushing angle valve disassembly as stipulated by fitting manufacturer 4 | Preparation of the drinking water installation for rinsing Proper planning of the flushing process pays off during implementation.
  • Page 40 ® GENO -flushing compressor 1988 K 4. Drinking water heaters and water treatment devices (e.g., softening and dosing systems) must be removed or avoided. 5. Flushing of circulation lines. Prepare installation (e.g., see Fig. 15) and flush the hot water line in the same way as described in point 8.
  • Page 41 ® GENO -flushing compressor 1988 K 6. In the case of low water pressure, it may be necessary to integrate a pressure booster when flushing in order to achieve the necessary minimum flow speed. A sufficient flow speed and the correct inlet pressure are important for the success of flushing.
  • Page 42 ® GENO -flushing compressor 1988 K 9. Determine the minimum flow speeds of the flushing sections. DIN EN 806-4 6.2.3 recommends a minimum flow speed of 0.5 m/s in each piping section when flushing drinking water installations prior to commissioning. With sanitation flushing of corroded piping, we recommend a minimum flow speed of 1.5 m/s.

  • Page 43: Preparation Of The Drinking Water Installation For Disinfection As Per Dvgw

    ® GENO -flushing compressor 1988 K 5 | Preparation of the drinking water installation for disinfection as per DVGW work sheet W 557 Danger! During disinfection of the system, drinking water is not available to consumers from the drinking water installation. It must be ensured that no water intended for drinking can be withdrawn from the treated system by taking suitable measures.
  • Page 44 ® GENO -flushing compressor 1988 K  Dead lines must be removed from the drinking water installation prior to disinfection.  By way of principle, it is said that micro-organisms can only be effectively killed or inactivated when the disinfectant can act directly on the later.

  • Page 45: E Flushing And Disinfection Of Drinking Water

    ® GENO -flushing compressor 1988 K Flushing and disinfection of drinking water installations  Note: The DVGW work sheet W 557 Cleaning and Disinfection of Drinking Water Installations and ZVSHK (German Central Association Plumbing, Heating, Air Conditioning) instruction sheet "Flushing, disinfection and commissioning of drinking water installations"...
  • Page 46 ® GENO -flushing compressor 1988 K 7. The volumetric flow is shown on the control unit of the flushing compressor. If the recommended minimum volumetric flow as per the table in chapter D 4 point 9 is not reached, this can be optimised by taking suitable measures, e.g., integration of a pressure booster (also see chapter D 4).

  • Page 47: Performing System Installation As Per

    ® GENO -flushing compressor 1988 K 3 | Performing system installation as per DIN EN 806-4 and DVGW work sheet W 557 Danger! Dosing of the disinfectant may only be performed in cold water, for this reason the warm water heater must be switched off and prevented from being accidentally turned on again.
  • Page 48 ® GENO -flushing compressor 1988 K Table 1: ® Disinfectants Water meter GENODOS dosing system Application Size of the Dosing pump setting ® concentration GENODOS Stroke Operat Facto as per DVGW pump setting work sheet W mode ® GENO -Chlor A 50 mg/l Flushing DM-SK 10/40...

  • Page 49: F Rinsing Of Silted Up Floor Heating Systems

    ® GENO -flushing compressor 1988 K Rinsing of silted up floor heating systems 1 | General Attention! The prerequisite for flushing a heating system is a sufficiently large free flow cross section. If the free flow cross section is too small, the deposits which are loosened can block the cross section. Attention! Please note the maximum permissible operating pressure of the heating system to be flushed as well as the additional load which occurs due to the pulsatile flushing with the water/air mix, in particular...

  • Page 50: Rinsing Of Floor Heating Systems With Water And A Mixture Of Water And Air

    ® GENO -flushing compressor 1988 K  Fit an outlet tube to the return connection of the heating system to be flushed, guide this to the drain and fix in place or use a flushing water calming tank (see accessories). ...
  • Page 51 ® GENO -flushing compressor 1988 K  Flush out all the heating systems to be cleaned one after the other as described above.  On conclusion of flushing, disconnect the flushing compressor from the mains, disassemble the water connections, remove any remaining water and drain off the condensate on the flushing compressor (also see chapter 11, point 2, care work).

  • Page 52: G Troubleshooting

    ® GENO -flushing compressor 1988 K Troubleshooting 1 | Introduction Operational errors cannot be completely ruled out even when the flushing compressors have been designed and produced with care and operated as intended. Table G-1 provides an overview of the possible errors when operating the flushing compressor, their causes and remedying.

  • Page 53: Error Messages

    ® GENO -flushing compressor 1988 K 2 | Error messages Table G-1: Troubleshooting This is what you observe This is the cause This is what to do The compressor aggregate Motor voltage is too low For cables measuring 50 m in length, the does not start.

  • Page 54: H Maintenance And Care

    ® GENO -flushing compressor 1988 K Maintenance and care 1 | Basic information Some regular work is necessary in order to ensure the proper functioning of the flushing compressor in the long term. All regulations and guidelines which apply at the installation site must be strictly adhered to.

  • Page 55: Care Work

    ® GENO -flushing compressor 1988 K 2 | Care work This work must be performed regularly by a specialist regardless of how often the system is used. Perform before use: Flush out the water path with drinking water directly into the drain. If necessary, disinfect the water path, depending on the period of time since the system was last used and application type (drinking water or heating system).

  • Page 56: Maintenance

    ® GENO -flushing compressor 1988 K 4 | Maintenance Maintenance work must be performed regularly after use, or at least once per year, as otherwise the warranty claim will become void. Maintenance work must be carried out by properly trained specialists or the Grünbeck technical customer service/authorised service company.

  • Page 57: Operation Log

    ® GENO -flushing compressor 1988 K 5 | Operation log ® ......System type: GENO -flushing compressor 1988 K Order no. 151 200 Serial no.: Work performed Execution confirmed .......... Care work Description ____________________________________ Company: ________________________________________________ ............Inspection ________________________________________________ ............________________________________________________ ..........
  • Page 58 ® GENO -flushing compressor 1988 K ......® System type: GENO -flushing compressor 1988 K Order no. 151 200 Serial no.: Work performed Execution confirmed .......... Care work Description ____________________________________ Company: ............________________________________________________ Inspection ________________________________________________ ............________________________________________________ ..........Maintenance Name: ________________________________________________ Repair ________________________________________________...
  • Page 59 ® GENO -flushing compressor 1988 K ......® System type: GENO -flushing compressor 1988 K Order no. 151 200 Serial no.: Work performed Execution confirmed .......... Care work Description ____________________________________ Company: ............________________________________________________ Inspection ________________________________________________ ............________________________________________________ ..........Maintenance Name: ________________________________________________ Repair ________________________________________________...

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