Grunbeck GENO-G5 Operation Manual
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Grunbeck GENO-G5 Operation Manual

Euro system separation device
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Euro system separation device | GENO-G5
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Summary of Contents for Grunbeck GENO-G5

  • Page 1 We understand water. Euro system separation device | GENO-G5 Operation manual...
  • Page 2 General Contact Germany International Sales +49 9074 41-145 Service +49 9074 41-333 service@gruenbeck.de Availability Monday to Thursday 7:00 am - 6:00 pm Friday 7:00 am - 4:00 pm We reserve the right to technical modifications. © by Grünbeck Wasseraufbereitung GmbH Original operation manual Edition: February 2024 Order no.: 100267570000_en_104...

  • Page 3: Table Of Contents

    Checking the scope of supply ........23 Technical specifications .........62 Water installation ............. 23 Electrical installation ..........29 12.1 System characteristic GENO-G5 ......63 Start-up/commissioning ......... 34 Operation log ............64 Checking and presetting the system ......34 13.1 Start-up/commissioning log ........64 Handing over the product to the owner/operator/operating company ......

  • Page 4: Introduction

    Validity of the manual This manual applies to the product below: ● Euro system separation device GENO-G5 ● Special designs that essentially correspond to the standard products given above. For information on changes, please refer to the respective information sheet that is enclosed, if applicable.

  • Page 5: Product Identification

    Introduction Product identification You can identify your product based on the product designation and the order number shown on the type plate. ► Check whether the products indicated in chapter 1.1 correspond to your product. The type plate is located on the rear. Designation Designation DVGW test mark...

  • Page 6: Symbols Used

    Introduction Symbols used Symbol Meaning Danger and risk Important information or requirement Useful information or tip Written documentation required Reference to further documents Work that must be carried out by qualified specialists only Work that must be carried out by qualified electricians only Work that must be carried out by technical service personnel only Depiction of warnings This manual contains information and instructions that you must obey for your personal...

  • Page 7: Demands On Personnel

    Introduction Demands on personnel During the individual life cycle phases of the product, different people carry out work on the product. This work requires different qualifications. 1.6.1 Qualification of personnel Personnel Requirements • No special expertise required User • Knowledge of the tasks assigned •...
  • Page 8 Introduction 1.6.3 Personal protective equipment ► As an owner/operator/operating company, make sure that the required personal protective equipment is available. The components below fall under the heading of personal protective equipment (PPE): Protective gloves Protective footwear Safety goggles 8 | 72...

  • Page 9: Safety

    Safety Safety Safety measures ● Only operate your product if all components are installed properly. ● Obey the local regulations on drinking water protection, accident prevention and occupational safety. ● Do not make any changes, alterations, extensions or program changes on your product.
  • Page 10 Safety 2.1.3 Electrical hazards There is an immediate danger of fatal injury from electric shock when touching live parts. Damage to the insulation or individual components can be lethal. ● Only have a qualified electrician carry out electrical work on the system. ●...

  • Page 11: Product-Specific Safety Instructions

    Safety Product-specific safety instructions 2.2.1 Safety devices ● Dry-run protection of centrifugal pump of pressure booster system ● Level switch in supply tank 2.2.2 Safety-related components Safety components must be replaced by genuine spare parts only. ► Have safety components and wearing parts replaced by a qualified specialist (refer to chapter 8.6).

  • Page 12: Conduct In Emergencies

    Safety Labels on the product Risk of electric shock Risk of slipping Hot surface The affixed information and pictograms must be clearly legible. They must not be removed, soiled or painted over. ► Obey all warnings and safety instructions. ► Immediately replace illegible or damaged symbols and pictograms. Conduct in emergencies 2.3.1 In the event of water leaks...

  • Page 13: Product Description

    Product description Product description Intended use ● The Euro system separation device GENO-G5 is a safety device to protect the drinking water network against liquids up to and including hazard class 5 in accordance with DIN EN 1717. ● The system offers the highest class of protection and reliably prevents backflow, back pressure and back siphonage of modified drinking water into the drinking water network.

  • Page 14: Product Components

    Product description Product components Designation Functions/characteristics Supply tank (25 l) With make-up water feed (float valve) and built-in overflow Flow restrictor In the water inlet, to restrict the inlet volume Flow restrictor In the water outlet, to restrict the withdrawal volume Pressure gauge Display of pressure in the inlet Waste water discharge...
  • Page 15 Product description Designation Functions/characteristics Lid of supply tank For cleaning and maintenance purposes Float valve To protect the pump from running dry Level switch To actuate the pump for make-up water feed Overflow As a safety feature in the event of float valve failure Draining valve To drain the supply tank Outlet (HT-DN 50)

  • Page 16: Connections

    Product description Connections For connection dimensions, refer to the Technical Specifications in chapter 12. Designation Designation Raw water inlet Waste water to drain Outlet to consumer A drain connection (at least DN 50) must be available, which is able to discharge the maximum inlet volume in the event of a malfunction.

  • Page 17: Functional Description

    Product description Functional description The system offers the highest class of protection (refer to chapter 3.1.1) and prevents backflow, back pressure and back siphonage of modified drinking water into the drinking water network. The safety device features a free outlet in accordance with DIN EN 13077, Family A, Type B.

  • Page 18: Accessories

    Grünbeck’s headquarters in Hoechstaedt/Germany for details. Illustration Product Order no. Flushing device for GENO-G5 134 805 Solenoid valve with electronic timer pulser and 1.5 m connection cable with Schuko power plug as adapter plug Connection kit for GENO-G5...

  • Page 19: Transport, Set-Up And Storage

    Transport, set-up and storage Transport, set-up and storage Shipping/Delivery/Packaging The product is fixed on a pallet at the factory and secured against tipping. ► Upon receipt, immediately check for completeness and transport damage. NOTE Improper transport ● Damage to system components due to falling components ●...

  • Page 20: Storage

    Transport, set-up and storage Storage ► Protect the product from the impacts below when storing it: • Dampness, moisture • Environmental impacts such as wind, rain, snow, etc. • Frost, direct sunlight, severe heat exposure • Chemicals, dyes, solvents and their vapours •...

  • Page 21: Installation

    The installation of the product represents a major intervention into the drinking water system and must be carried out by a qualified specialist only. Installation example Designation Designation Drinking water filter pureliQ:KD Connection kit GENO-G5 Inlet shut-off valve Drain connection Outlet shut-off valve 21 | 72...

  • Page 22: Requirements For The Installation Site

    Installation Requirements for the installation site Obey the local installation directives, general guidelines and technical specifications. ● Protection from frost, severe heat exposure and direct sunlight ● Protection from chemicals, dyes, solvents and their vapours ● Protection from dust, acids, corrosive and explosive gases ●...

  • Page 23: Checking The Scope Of Supply

    Installation Checking the scope of supply Designation Designation Pre-assembled GENO-G5 system Operation manual Bag with connection material for “Potential equalisation of aluminium rack” ► Check the scope of supply for completeness and damage. Water installation NOTE Impurities and corrosion particles in the water supply line ●...
  • Page 24 Installation 5.3.2 Installing the (optional) flushing device Regarding the setting of the timer pulser, refer to the instructions of the manufacturer. Designation Designation Blind plug Solenoid valve with electronic timer pulser Union nut Seal Connection cable with Schuko power plug as Cable tie adapter plug 1.
  • Page 25 Installation 5.3.3 Connecting the product to the water pipes WARNING Contaminated drinking water due to stagnation ● Infection due to bacterial growth ► Do not connect the product to the drinking water system until immediately before start-up/commissioning. ► Only fill the system with raw water immediately before operation. ►...
  • Page 26 Installation NOTE Incorrect installation of the corrugated connection pipes ● Risk of damage/impairment of the system function in case of incorrect installation ● Make sure that the corrugated connection pipes are not squeezed or kinked when connecting them. ► Firmly hold the corrugated connection pipes when tightening the union nuts. ►...
  • Page 27 Installation 5.3.4 Establishing the waste water connection NOTE Waste water backing up due to incorrect connection ● Water damage ► Route the waste water line with a downward slope to the drain. According to DIN EN 1717, a free outlet and a backflow-free discharge of the waste water must be guaranteed.
  • Page 28 Installation Designation Waste water discharge HT-DN 50 (connection direction can be swivelled variably) ► Route the on-site waste water line with a downward slope to the drain. 28 | 72...

  • Page 29: Electrical Installation

    Installation Electrical installation The electrical installation must be carried out by a qualified electrician only. DANGER Lethal voltage ● Severe burns, cardiovascular failure, fatal electric shock ● Voltage may be present at terminals L, N and PE as well as at the feed lines to voltage-free contacts.
  • Page 30 Installation Function of the centrifugal pump ● Start and stop of the centrifugal pump depend on the adjustable setpoint (operating pressure) of the frequency converter. ● Upon request by the consumer (opened water tap), water flows from the diaphragm expansion tank. ●...
  • Page 31 Installation 5.4.2 Establishing potential equalisation During operation as intended, the speed-controlled centrifugal pump can have a ground leakage current of > 10 mA. ● Connection to the potential equalisation provided by the client is required. The protective earth conductor must have a minimum cross-section of 6 mm² Cu or 10 mm²...
  • Page 32 Installation 5.4.3 Connection terminals on the frequency converter WARNING External voltage on voltage-free contacts ● Risk of electric shock ► Do not open any switch boxes or other parts of the electrical equipment if you are not a qualified electrician. ►...
  • Page 33 Installation Connection Des. Terminal Description Comments COM – Error status relay Error signal NO – Error status relay 15 VDC, Ʃ max. 100 mA External External power supply sensor +15 VDC pressure sensor External sensor 4-20 mA input (differential pressure) External START External ON/OFF input...

  • Page 34: Start-Up/Commissioning

    Start-up/commissioning Start-up/commissioning The initial start-up of the system must be carried out by technical service personnel only. Checking and presetting the system Risk of centrifugal pump running dry due to entrapped air ● The system's power plug must only be plugged in after the system has been filled with water and the centrifugal pump has been vented.
  • Page 35 Start-up/commissioning 4. Check whether the supply tank is empty. a Open the lid and check. 6.1.1 Check the preload pressure of the diaphragm expansion tank The target pressure is 2.5 bar (default pressure setting). The pressure was preset at the factory. As a longer period of time might have passed between manufacturing and start-up, however, the pressure needs to be checked.
  • Page 36 Start-up/commissioning Adjusting the pressure ► If the pressure in the diaphragm expansion tank is too high (> 2.5 bar): d Depressurise to the target pressure of 2.5 bar. Carefully press the pin in the filling valve using a narrow object/tool. e Check the pressure again.
  • Page 37 Start-up/commissioning 6.1.3 Filling the system with water and venting it 1. Slowly open the shut-off valves in the water inlet of the system. » The supply tank is filled via the float valve. 2. Fill the system and the pump until the water emerging from the sampling valve is free of bubbles.
  • Page 38 Start-up/commissioning 5. Slowly open the shut-off valves in the system’s water outlet. 6. Vent the system via one of the water withdrawal points. a Fully open the water tap and let the water run for a few minutes until no more air escapes.
  • Page 39 Start-up/commissioning 6.1.4 Checking the system for function and safety 6.1.4.1 Flow restrictor Designation Designation Flow restrictor in the water inlet Flow restrictor in the water outlet (with black bypass bore) (without black bypass bore) Flow restrictor in the water inlet The flow restrictor installed in the water inlet must not be removed.

  • Page 40: Handing Over The Product To The Owner/Operator/Operating Company

    Start-up/commissioning 6.1.4.2 Function and setting of frequency converter ► Check the setting of the frequency converter, if necessary (refer to chapter 7.1). ► Check the optional flushing device for function. 6.1.4.3 Safety ► Check that the electric lines are protected against high temperatures, vibrations and mechanical damage.

  • Page 41: Operation

    Operation Operation The operation of the system is automatic and does not require any manual operation. The display and the LEDs on the control/operating panel of the frequency converter provide information on the voltage supply, the status of the centrifugal pump and the operating state. ●...
  • Page 42 Operation 7.1.1 Status LED The status LED indicates the operating state of the pump and signals any faults. Description Pump stopped Steady green light Pump in operation Flashing green/orange Non-locking alarm during operation of the pump light Steady orange light Non-locking alarm when pump is stopped Locking error –...
  • Page 43 Operation 7.1.4 Display The display indicates operating state, operating values, menu and error codes. The OFF mode has a lower display priority than the STOP mode. Display Mode Description Pump is off Contacts 11 and 12 are not short-circuited STOP Pump stopped manually Pump is on The motor starts depending on the selected control mode –...

  • Page 44: Software Parameters

    Operation Software parameters The software parameters are preset at the factory. Designation Function Main display • To increase the selected control mode Parameter menu • To increase the indicated parameter directory Plus Parameter indication/editing • To increase the parameter value Zero pressure auto-calibration (P44) •...
  • Page 45 Operation 7.2.1 Parameters of sensor configuration You can set and adjust the following parameters of the pressure sensor: = global parameter Parameters Unit Description Pressure Sensor Unit Of bar/psi To set the measuring unit (BAR, PSI) of the pressure Measure [BAR, PSI] sensor •...

  • Page 46: Maintenance And Repair

    Maintenance and repair Maintenance and repair Maintenance and repair includes cleaning, inspection and maintenance of the product. The responsibility for inspection and maintenance is subject to local and national requirements. The owner/operator/operating company is responsible for compliance with the prescribed maintenance and repair work. By concluding a maintenance contract, you make sure that all maintenance work will be carried out on time.
  • Page 47 Maintenance and repair 8.1.1 Exterior cleaning ► Use personal protective equipment. ► Only clean the outside of the system. ► Do not use any strong or abrasive cleaning agents. ► Wipe the surfaces with a damp cloth. ► Dry the surfaces with a cloth. 8.1.2 Special cleaning/disinfection As a "Free outlet"...

  • Page 48: Intervals

    Maintenance and repair Intervals By way of regular inspections and maintenance, malfunctions can be detected in time and product failures might be prevented. ► As owner/operator/operating company determine which components must be inspected and maintained at which intervals (load-dependent). These intervals are subject to the actual conditions such as: water condition, degree of contamination, environmental impacts, consumption, etc.

  • Page 49: Inspection

    Maintenance and repair Inspection You as owner/operator/operating company can carry out the regular inspections yourself. Initially, we recommend inspecting the product at shorter intervals and later on as required. ► Carry out an inspection at least every 2 months. 1. Check the installation for leaks. a Pay attention to leaks and puddles on the floor.
  • Page 50 Maintenance and repair 8.4.1 Semi-annual maintenance 1. Check the outside of the entire system for damage and corrosion. 2. Check the diaphragm expansion tank for escaping water on the filling valve. a Briefly operate the filling valve. b Replace the diaphragm expansion tank if water escapes from the filling valve. 3.

  • Page 51: Spare Parts

    Maintenance and repair 8.4.2 Annual maintenance Annual maintenance work requires expert knowledge. This kind of maintenance work must be carried out by technical service personnel only. ► Carry out the work below in addition to the semi-annual maintenance work: 1. Check the setting pressure (operating pressure) of the centrifugal pump on the pressure gauge –...

  • Page 52: Wearing Parts

    Maintenance and repair Wearing parts Wearing parts must be replaced by qualified specialists only. The wearing parts are listed below: Designation Designation Flow restrictor in the water outlet Sealing elements of circulation pump Flow restrictor in the water inlet Pressure sensor Float valve Solenoid valve of flushing device (optional) Pressure gauge...
  • Page 53 Maintenance and repair ► Have the seals replaced in the event of leaks, damage or deformations. ► Have defective or worn components replaced. Diaphragm expansion tank ► Replace the diaphragm expansion tank in case of damage and corrosion. Centrifugal pump with pressure control ►...

  • Page 54: Troubleshooting

    Troubleshooting Troubleshooting WARNING Contaminated drinking water due to stagnation ● Infectious diseases ► Have faults eliminated immediately. Messages The product displays faults in the display of the frequency converter. The fault display remains active until the condition has been rectified. Designation/meaning Standby mode –...

  • Page 55: Other Observations

    Troubleshooting Other observations Observation Explanation Remedy ► Check the system for leaks Water withdrawal is closed. Water leaks on the non-return valve or within the system ► Repair or replace Pump is in operation with cyclical defective/worn components increase/decrease of speed ►...

  • Page 56: Display Screens Of The Frequency Converter

    Troubleshooting Display screens of the frequency converter In the event of an alarm or error, the display of the pressure booster pump indicates a code, and the status LED lights up. ● Alarms and errors are saved with the date and time. ●...
  • Page 57 Troubleshooting Voltage supply outside the ► Check voltage Grid voltage error operating range ► Check electrical connection ► Check whether there are Thermal contactor of motor Error Motor winding tripped impurities near the impeller and temperature the rotor – remove them, if necessary ►...

  • Page 58: Decommissioning

    Decommissioning Decommissioning It is not necessary to take your product out of operation. In case of longer absences, e.g. holidays, precautionary hygiene measures according to VDI 3810-2 and VDI 6023-2 must be taken in order to maintain drinking water hygiene after downtimes.

  • Page 59: Decommissioning

    Decommissioning 10.2 Decommissioning If a longer standstill of the system is planned, the system must be decommissioned. The work below must be carried out by a qualified specialist only. 1. Completely drain the system. a Let the supply tank drain and clean it inside. 2.

  • Page 60: Dismantling And Disposal

    Dismantling and disposal Dismantling and disposal 11.1 Dismantling The work below must be carried out by a qualified specialist only. 1. Close the shut-off valves of the water inlet. 2. Open a water withdrawal point downstream of the product and wait a few minutes. »...

  • Page 61: Disposal

    Dismantling and disposal 11.2 Disposal ► Obey the applicable national regulations. Packaging ► Dispose of the packaging in an environmentally sound manner. NOTE Danger to the environment due to incorrect disposal ● Packaging materials are valuable raw materials that can be reused in many cases ●...

  • Page 62: Technical Specifications

    Technical specifications Technical specifications Dimensions and weights GENO-G5 System width 890 (885 – 900) System height System depth Connection height Raw water inlet Connection depth Raw water inlet Connection height Outlet to consumer Connection depth Outlet to consumer Connection height Waste water to drain...

  • Page 63: System Characteristic Geno-G5

    ≤ 70 Humidity (non-condensing) DVGW registration number AS-0398BS0294 Order no. 134 100 12.1 System characteristic GENO-G5 Designation Designation Pressure in bar Flow rate in m Note: Valid with built-in flow restrictor in the water outlet (as delivered) 63 | 72...

  • Page 64: Operation Log

    Operation log Operation log ► Document the initial start-up/commissioning and all maintenance activities. ► Copy the maintenance report. Euro system separation device | GENO-G5 Serial no.: ______________________ 13.1 Start-up/commissioning log Customer Name Address Installation/Accessories Drinking water filter (make/type) Drain connection (size)
  • Page 65 Operation log Maintenance No.: ___ Record the measured values and operating data. Confirm the checks with OK or record any repairs done. Operating values Target pressure (operating pressure) of pressure booster system Setting pressure (inlet pressure) of diaphragm expansion tank Water meter reading m³...
  • Page 66 Operation log Annual maintenance work (Yes) Setting pressure (operating pressure) of centrifugal pump checked on the pressure gauge Setting pressure (operating pressure) of the centrifugal pump readjusted Dry-run protection of the centrifugal pump tested Fan and ventilation slots of the centrifugal pump checked to make sure they are free of dust Fan impeller of centrifugal pump cleaned Diaphragm expansion tank replaced in case of leaks Non-return valve checked for leaks...
  • Page 67 Operation log 67 | 72...
  • Page 68 Operation log 68 | 72...
  • Page 69 Operation log 69 | 72...
  • Page 70 EU guidelines in terms of its design, construction and execution. This certificate becomes void if the system is modified in any way not approved by us. Euro system separation device GENO-G5 Serial no.: Refer to type plate The aforementioned system also complies with the following directives and provisions: •...
  • Page 71 Publisher's information Technical documentation Should you have any questions or suggestions regarding this operation manual, please contact Grünbeck Wasseraufbereitung GmbH’s Department for Technical Documentation directly. Email: dokumentation@gruenbeck.de...
  • Page 72 Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str. 1 89420 Hoechstaedt/Germany +49 9074 41-0 +49 9074 41-100 info@gruenbeck.com For more information go to www.gruenbeck.com www.gruenbeck.com...

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