Grunbeck GENO-control User manual

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Hardness control measuring device | GENO-control
Operation manual

Central Contact
Germany
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Availability
Monday to Thursday
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Friday
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Subject to technical modifications.
© by Grünbeck Wasseraufbereitung GmbH
Original operation manual
Edition: May 2021
Order no.: 100198960000_en_034

Table of contents
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Table of contents
1Introduction ............................................................... 4
1.1 Validity of the manual ................................................ 4
1.2 Other applicable documents ...................................... 4
1.3 Product identification ................................................. 4
1.4 Symbols used ............................................................ 5
1.5 Depiction of warnings ................................................ 6
1.6 Personnel requirements............................................. 6
2Safety ......................................................................... 8
2.1 Safety measures........................................................ 8
2.2 Product-specific safety instructions ........................... 9
2.3 Conduct in an emergency.......................................... 9
3Product description ................................................ 10
3.1 Intended use ............................................................ 10
3.2 Product components................................................ 11
3.3 Functional description.............................................. 12
3.4 GENO-control release times.................................... 12
3.5 Accessories ............................................................. 13
4Transport and storage............................................ 14
4.1 Dispatch/delivery/packaging .................................... 14
4.2 Transport ................................................................. 14
4.3 Storage .................................................................... 14
5Installation ............................................................... 15
5.2 Requirements with regard to the installation site ..... 15
5.3 Checking the scope of supply.................................. 16
5.4 Installing the product................................................ 16
5.5 Electrical installation ................................................ 18
6Start-up .....................................................................19
6.1 Checking the product................................................19
6.2 Electrical connection to reverse osmosis system .....19
6.3 Handing over the product to the owner/user ............20
7Operation/handling..................................................21
8Maintenance and repair...........................................22
8.1 Cleaning ...................................................................22
8.2 Intervals ....................................................................22
8.3 Inspection .................................................................23
8.4 Maintenance .............................................................23
8.5 Spare parts ...............................................................25
8.6 Wearing parts ...........................................................25
9Fault ..........................................................................26
10 Shutdown..................................................................27
10.1 Temporary standstill .................................................27
10.2 Restart ......................................................................27
11 Dismantling and disposal .......................................28
11.1 Dismantling...............................................................28
11.2 Disposal....................................................................28
12 Technical specifications .........................................29
13 Operation log............................................................31
13.1 Start-up log ...............................................................31

Introduction
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1 Introduction
This manual is intended for owners/operating companies, operators, users as well as
qualified specialists and ensures the safe and efficient handling of the product. The manual
is an integral part of the product.
►Carefully read this manual and the instructions contained within it on the
components before you operate your product.
►Adhere to all safety instructions and instructions for action.
►Keep this instruction and all other applicable documents, so that they are
available when needed.
Illustrations in this manual are for basic understanding and may differ from the actual
version.
1.1 Validity of the manual
This manual applies to following product:
●Hardness control measuring device GENO-control
1.2 Other applicable documents
●None
1.3 Product identification
You can identify your product by means of the product designation and the order number on
the type plate.
►Check whether the products indicated in chapter 1.1 correspond to your product.

Introduction
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The type plate is located on the control unit in the housing.
Designation
1
“Operation” display
2
“Hard water” display
3
Product designation
4
Order no.
5
Serial no.
6
Observe the Operation Manual
7
CE mark
8
Disposal information
Designation
9
Weight
10
Protection
11
Mains connection
12
Ambient temperature
13
Water temperature
14
Flow rate
15
Operating pressure
16
Nominal pressure
1.4 Symbols used
Symbol
Meaning
Danger and risk
Important information or prerequisite
Useful information or tip
Written documentation required
Reference to further documents
Work that is only allowed to be carried out by qualified specialists
Work that is only allowed to be carried out by qualified electricians
Work that is only allowed to be carried out by technical service personnel

Introduction
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1.5 Depiction of warnings
This manual contains information that you must comply with for your personal safety. The
information is marked with a warning sign and has the following structure:
1.5.1.1
1.5.1.2 SIGNAL WORD
1.5.1.3 Type and source of danger
1.5.1.4
●Possible consequences
►Preventive measures
The following signal words are defined depending on the degree of danger and may be used
in this document:
Warning sign and
signal word
Consequences when disregarding the
information/instructions
DANGER
Personal
injury
Death or serious injuries
WARNING
Possible death or serious injuries
CAUTION
Possible moderate or minor injuries
NOTE
Property
damage
Possible damage to components, the product
and/or its functions, or anything in its vicinity
1.6 Personnel requirements
During the individual life cycle phases of the product, different people carry out work tasks on
the product. The work tasks require different qualifications.
1.6.1 Qualification of personnel
Personnel
Prerequisites
Operator/user
•No special expertise
•Knowledge of the tasks assigned
•Knowledge of possible dangers in the case of inappropriate conduct
•Knowledge of the necessary protective equipment and protective
measures
•Knowledge of residual risks
Owner/operating company
•Product-specific expertise
•Knowledge of statutory regulations for safety and accident prevention
Qualified specialist
•Electrical engineering
•Sanitary engineering (SHK)
•Transport
•Professional training
•Knowledge of relevant standards and regulations
•Knowledge of detection and prevention of possible risks
•Knowledge of statutory regulations on accident prevention
Technical service
(Grünbeck's technical
service/authorised service
company)
•Extended product-specific expertise
•Trained by Grünbeck

Introduction
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1.6.2 Authorisations of personnel
The following table describes which activities are allowed to be performed by whom.
Operator/
user
Owner/op
erating
company
Qualified
specialist
Technical
service
Transport and storage
X
X
Installation and mounting
X
X
Start-up
X
X
X
X
Operation and handling
X
X
X
X
Cleaning
X
X
X
X
Inspection
X
X
X
X
Maintenanc
e
X
X
X
X
Troubleshooting
X
X
X
X
Repair
X
X
X
Shutdown and restart
X
X
X
Dismantling and disposal
X
X
1.6.3 Personal protective equipment
►As an owner/operating company, ensure that the required personal protective
equipment is available.
The following components fall under the heading of personal protective equipment (PPE):
Protective gloves
Protective goggles

Safety
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2 Safety
2.1 Safety measures
●Only operate your product if all components are installed properly.
●Adhere to the applicable local guidelines on drinking water protection, accident
prevention and occupational safety.
●Do not make any changes, conversions, extensions or program modifications to
your product.
●Only use genuine spare parts for maintenance or repair.
●Keep the premises locked to prevent unauthorised access and to protect
endangered/non-instructed people from residual risks.
●Observe the maintenance intervals (refer to chapter 8.2). Failure to comply can
result in microbiological contamination of your drinking water system.
2.1.1 Mechanical dangers
●Safety devices must never be removed, bridged, or otherwise tampered with.
●For all work on the product that cannot be carried out from the ground, use stable,
safe, independently standing climbing aids.
●Ensure that the product is solidly fixed to the wall surface and that the accessibility
and safety of the product is guaranteed at all times.
2.1.2 Pressure-related hazards
●Components can be under pressure. There is a risk of injuries and damage to
property due to escaping water and unexpected movement of components. Check
the pressure pipes on the system regularly for leaks.
●Before starting repair and maintenance work, make sure that all affected
components are depressurised.

Safety
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2.1.3 Electrical dangers
There is an immediate danger of fatal injury from electric shock when touching live
components. Damage to the insulation or individual components can be life-threatening.
●Only have a qualified electrician carry out electrical work on the product.
●In case of damage to live components, switch off the voltage supply immediately
and arrange for repair.
●Switch off the supply voltage before working on electrical components. Discharge
the residual voltage.
●Never bypass electrical fuses. Do not put fuses out of operation. Observe the
correct current rating when replacing fuses.
●Keep moisture away from live parts. Moisture can cause a short-circuit.
2.1.4 Group of persons requiring protection
●Children must not play with the product.
●This product can be used by children over 8 years of age and persons with limited
abilities or lack of experience if they are supervised or instructed in the safe use of
the product and understand the resulting hazards.
●Cleaning and maintenance must not be carried out by children.
2.2 Product-specific safety instructions
Identification marks on the product
Risk of electric shock
The attached information/instructions and pictographs must be clearly legible.
They must not be removed, soiled, or painted over.
►Comply with all warnings and safety instructions.
►Immediately replace illegible or damaged symbols and pictograms.
2.3 Conduct in an emergency
2.3.1 If there is a water leak
1. Deenergise the device –pull out the mains plug.
2. Locate the leak.
3. Eliminate the cause of the water leak.

Product description
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3 Product description
3.1 Intended use
●The GENO-control automatic hardness control measuring device is used to
monitor fully softened water. The hardness control measuring device protects
downstream systems from hard water.
●The GENO-control hardness control measuring device continuously monitors the
residual hardness without using chemicals or water.
●The GENO-control hardness control measuring device is intended exclusively for
use in industrial and commercial applications.
3.1.1 Foreseeable misuse
●Use of the GENO-control hardness control measuring device in systems/processes
that constantly require water with total hardness < 0.1 °dH.
Application limits
●The GENO-control hardness control measuring device has correspondingly slow
release times depending on the withdrawal quantity and hardness (refer to Section
3.4).
●Short-term, minor hardness breakthroughs do not result in a false trip (e.g. when
starting up the entire system).

Product description
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3.2 Product components
Designation
Function
1
Mains plug
for Schuko socket, 230 V/50 Hz
2
Cover
for line connections
3
Lid
made of transparent plastic
4
Shut-off valve
Measuring water inlet
5
Transmitter unit
with reed contact
6
Hardness sensor
with special resin on a resin expansion/shrinkage basis to check the measuring
water for hardness breakthrough
7
Control unit
Controlled via a transmitter unit with reed contact and display of the operating
state via two LEDs.
Possibility of an error message output to a Central Control Station (CCS).
8
Shut-off valve
Measuring water outlet
9
Housing
lockable
10
Spare sensor
for replacement during maintenance
11
Sampling lines
for the inlet and outlet of soft water
12
Differential pressure
sensor
for discharging and returning the required measuring water to the soft water
pipe

Product description
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3.3 Functional description
The differential pressure sensor installed in the soft water pipe generates a lower differential
pressure when there is flow. This means that a partial flow is routed through the hardness
sensor installed in the bypass and returned to the main flow.
The sensor is triggered when there is a break-through of hardness. This causes the special
resin in the hardness sensor to shrink. The visual "hard water" indicator is activated via a
transmitter unit with Reed contact. At the same time, the voltage-free contact can be used to
activate a visual or acoustic alarm signal or to switch off a reverse osmosis system.
3.4 GENO-control release times
The GENO-control hardness control measuring device is not, or only conditionally,
applicable upstream from systems/processes that constantly require water with a total
hardness < 0.1 °dH.
►Observe the following table with release times:
Withdrawal
volume
l/h
Water hardness
°dH
Inlet pressure
bar
Outlet pressure
bar
Activation
time
Min.
30
30
3
15
3
3.1
2.9
2.9
110 –270
15 –25
100
100
3
15
3
3.2
2.9
3.1
90 –120
10 –20
500
500
3
15
3
3
2.9
2.9
70 –110
8 –20
1000
1000
3
15
3
2.9
50 –90
10 –20
2000
2000
3
15
3.5
2
3.3
1.8
60 –120
6 –16

Product description
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3.5 Accessories
Your product can be retrofitted with accessories. Please contact your local Grünbeck
representative or Grünbeck's headquarters in Hoechstaedt for details.
Illustration
Product
Order no.
Spare sensor
172 304
as hardness sensor for the GENO-control hardness control measuring
device
Differential pressure sensor
made of brass
with straight screw connections (male thread 1/4") for sampling lines,
non-return valve type RV 281 and
with additional PVC union nuts and adhesive sockets DN 20
(Ø 25 mm) for plastic line
3/4"
Max. flow rate: 3.3 m³/h
172 303
11/4"
Max. flow rate: 10.1 m³/h
172 305
2"
Max. flow rate: 25.0 m³/h
172 309

Transport and storage
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4 Transport and storage
4.1 Dispatch/delivery/packaging
►Check immediately upon receipt for completeness and transport damages.
►Proceed as follows if there is visible transport damages:
•Do not accept the delivery or only under subject to reservation.
•Note the extent of damage on the transport documents or on the delivery note
of the forwarder.
•Initiate a complaint.
4.2 Transport
►Transport the product in its original packaging only.
4.3 Storage
►Protect the product from the following impacts when storing it:
•Moisture, wetness
•Environmental impacts such as wind, rain, snow, etc.
•Frost, direct sunlight, severe heat exposure
•Chemicals, dyes, solvents and their vapours

Installation
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5 Installation
The installation of the system represents a major intervention in the drinking water system
and only a qualified specialist may install such systems.
Installation example
Designation
1
Safety device protectliQ
2
Drinking water filter pureliQ
3
System separator GENO-DK 2
Designation
4
Activated carbon filter AKF
5
Water softener such as Delta-p
5.2 Requirements with regard to the installation site
Observe local installation directives, general guidelines and technical specifications.
●The required wall surface must be level and have sufficient strength and load-
bearing capacity to support the product's weight.
●The installation site must be frost-proof and ensure the product's protection from
chemicals, dyes, solvents and their vapours.

Installation
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●A floor drain suitable for the system size must be available at the installation site or
a protection device e.g. protectliQ or a protection device with water stop of the
same quality must be installed.
●A Schuko socket is required for the electrical connection at a distance of approx.
1.2 m from the system.
5.3 Checking the scope of supply
Designation
1
Complete hardness control measuring device
2
Spare sensor in the housing
Designation
3
2x sampling lines 1 m long (id=4/od=6 mm)
4
Operation manual
►Check the scope of supply for completeness and damage.
5.4 Installing the product
►Install the product in a dry, easily accessible and clearly visible location.
5.4.1 Mounting the housing
A solid fastening of the product must be provided on site according to the wall situation.
Fixing accessories are not included in the scope of delivery.
►Determine the on-site fixing accessories - according to the local wall situation.

Installation
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1. Remove the cover for line connections - loosen 2 screws.
2. Position the hardness control measuring device near the flow fitting - in doing so
take note of the lengths for mains power cables and sampling lines.
3. Fasten the housing vertically to the wall using fastening accessories
(recommendation:
stainless steel flat head screws) - take note of the dimensions and size of the
holes.
5.4.2 Installing the differential pressure transmitter
Designation
1
2x PVC union nuts with insert DN20
(Ø 25 mm)
Designation
2
Differential pressure transmitter with non-
return valve
3
Sampling lines

Installation
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1. Install the differential pressure transmitter in the soft water pipe immediately after
the softening system.
a Take note of the flow direction on the differential pressure transmitter.
b Ensure that the hose connections are pointing upwards.
2. Connect the sampling lines to the differential pressure transmitter.
3. Shorten the sampling lines if necessary.
4. Connect the sampling lines to the shut-off valves for the sampling water inlet and
outlet.
5.5 Electrical installation
The electrical installation may only be carried out by a qualified electrician.
WARNING
Electrical voltage at the control unit
●Electric shock
►Disconnect the unit from the power supply before opening the control unit.
5.5.1 Connecting the voltage-free contact
Possibility of an error message output to a Central Control Station (CCS).
1. Open the control unit.
2. Connect a voltage-free signal contact to terminals 1, 2, 3.
3. Close the control unit.

Start-up
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6 Start-up
The initial start-up of the product is only allowed to be carried out by the customer service.
6.1 Checking the product
1. Check whether there is soft water.
2. Plug the mains plug into the socket.
» Operation display lights up.
3. Slowly open both shut-off valves.
4. Check all joints for leak tightness.
6.2 Electrical connection to reverse osmosis system
►Connect the contact to the terminals of the reverse osmosis system.
Device/system
Terminals
GENO-control
1
2
3
GENO-OSMO-MSR
X1/116
3K1 42
HL-300 resp. HL-X
X1/21
X1/29
RO/AVRO 125 K
X8/22
X8/23
GENO OSMO-X
67
66

Start-up
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When connecting to a GENO-OSMO-X reverse osmosis system, set the residual hardness
logon in the reverse osmosis system control to "Comfort" (refer to customer service
instructions order no. 750 929).
►Place the spare sensor in the device.
►Close the cover for line connections and the lid.
» The device is ready for operation.
6.3 Handing over the product to the owner/user
►Explain to the owner/user how the product works.
►Use the manual to brief the owner/operator and answer any questions.
►Inform the owner/user about the need for inspections and maintenance.
►Hand over all documents to the owner/operator for storage.
6.3.1 Disposal of packaging
►Dispose of packaging material as soon as it is no longer needed.