Grunbeck GENO-mat MN-Z 20/10 User manual

Operating manual
for demanganisation system
GENO-mat MN-Z
Edition July 2018
Order no. 095 153 048-inter

Iron / manganese removal
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Table of contents
A General information ............................................................. 5
1 Preface
2 How to use this operation manual
3 General safety information
4 Shipping and storage
5 Disposal of used parts and materials
B Basic information ................................................................. 9
1 Laws, regulations, standards
2 Designated application/area of application
3 Function
C Product description ............................................................. 11
1 Type plate ............................................................................
2 Technical specifications
3 Intended use
4 Scope of supply
5 Optional accessories
6 Consumables
D Installation and operation .................................................... 17
1 General installation instructions
2 Preliminary work
3 How to connect the system
E Commissioning .................................................................... 23
1 How to start up the system
F Operation .............................................................................. 26
1 How to operate the control unit
G Maintenance and care .......................................................... 29
1 Basic information
2 Inspection (functional check)
3 Maintenance
4 Spare parts
5 Operation log

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All rights reserved.
 © Copyright by Grünbeck Wasseraufbereitung GmbH
Printed in Germany
Effective with the date of edition indicated on the cover sheet.
-Subject to modifications in line with technical advances-
Reprints, translations into foreign languages, electronic storage or
copying of this operating manual - even in part - are only permitted
with the explicit written approval of Grünbeck Wasseraufbereitung
GmbH.
Any type of duplication not authorised by Grünbeck Wasseraufberei-
tung is a copyright violation and subject to legal action.
Responsible for contents:
Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Straße 1  89420 Höchstädt/Do., Germany
Phone [phone]  Fax [phone]
www.gruenbeck.de  [email protected]
Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1, 89420 Höchstädt/Germany

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EU Declaration of Conformity
This is to certify that the devices designated below meet the safety and health requirements of
the applicable European guidelines in terms of 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 Höchstädt
Germany
Responsible for documentation: Markus Pöpperl
Description of the system: Demanganisation system
Device type: GENO-mat MN-Z
Serial no.: Refer to type designation plate
Applicable Directives: Low Voltage (2014/35/EU)
EMC (2014/30/EU)
Applied harmonised standards,
in particular:
DIN EN 61000-6-2:2006-03
DIN EN 61000-6-3:2011-09
Applied national standards
and technical
specifications,
in particular:
DIN 19636-100:2008-02
Location, date and signature Höchstädt, 26/07/2018 p.p.
M. Pöpperl
Dipl.-Ing. (FH)
Function of signatory: Head of Technical Product Design

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A General information
1 | Preface
Thank you for choosing a Grünbeck product. Backed by decades of
experience in the area of water treatment, we provide custom-made
solutions for all kinds 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 ordinance. This
also applies to the treatment of water for industrial use if repercus-
sions for the drinking water cannot completely be excluded.
All Grünbeck systems and devices are made of high-quality materi-
als. This ensures trouble-free operation over many years, provided
you treat your water treatment system with the required care. These
operating instructions assists you with crucial information. Please
read the entire operating instructions carefully before installing, oper-
ating or maintaining the system.
Customer satisfaction is our primary aim, and providing customers
with skilled advice is crucial at Grünbeck. If you have any questions
concerning the present product, possible extensions or general wa-
ter and waste water treatment, our field staff, as well as the experts
at our headquarters in Höchstädt, are available to help you.
Advice and assistance For advice and assistance please contact your local representative
(refer to www.gruenbeck.com). You can also get in touch with our
service centre, which can be reached during business hours:
Phone: [phone]
Fax: [phone]
Email: [email protected]
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 designation plate to
the overview in chapter C-1.

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2 | Notes on using the operation manual
This operation manual is intended for operators of our systems. It is
divided into several chapters (a letter is assigned to each of them)
that are listed in the "Table of contents" on page 2 in alphabetical or-
der. Check for the corresponding chapter on page 2 in order to find
the specific information you are looking for.
The headers and page numbers with chapter information make it
easier to find your way around these operating instructions.
3 | General safety information
3.1 Symbols and
notes
Important information in this operation manual is emphasised 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
impurities in the drinking water.
Warning! Failure to adhere to this information can cause injuries,
damage to property or impurities in the drinking water.
Caution! Failure to adhere to this information can result in damage
to the system or other objects.

Note: This symbol emphasises information and tips that facilitate
your work.
Tasks with this symbol may only be performed by Grünbeck's tech-
nical service/authorised service company or by persons expressly
authorised by Grünbeck.
Tasks with this symbol may only be performed by trained and quali-
fied 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 suppliers or
approved installation companies. In Germany, the installation com-
pany must be registered in a water company installation directory as
per §12(2) AVBWasserV (German Ordinance on General Conditions
for the Supply of Water).
3.2 Operating per-
sonnel
Only allow persons who have read and understood this operation
manual to work with the system. Strictly observe the safety infor-
mation.

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3.3 Intended use 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 drinking water pro-
tection, accident prevention and occupational safety must be ob-
served.
In addition, intended use also implies that the system may only be
operated when it is in proper working order.
Any errors must be eliminated at once.
3.4 Protection from
water damage
Warning! To properly protect the installation site from water dam-
age:
a) a sufficient floor drain system must be available or
b) a water stop device (see chapter C Accessories) must be in-
stalled.
Warning! Floor drains that discharge to a lifting system will not work
in case of a power failure.
3.5 Indication of
specific dangers
Danger due to electrical energy!  Do not touch electrical compo-
nents with wet hands! Disconnect the system from the mains before
starting work on electrical system components! Have qualified ex-
perts replace damaged cables immediately.
Danger due to mechanical energy! System components can be sub-
ject to overpressure. Risk of injuries 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 should be installed by a specialist company only. Strictly ad-
here to the operation manual! Ensure that there is sufficient flow,
and observe the relevant guidelines when starting up the system af-
ter extended periods of standstill. Perform inspections and mainte-
nance at the intervals specified!

Note: By concluding a maintenance contract, you ensure that all of
the required tasks are performed on time. The intermediate inspec-
tions can be performed in-house.

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4 | Shipping and storage
Caution! The system can 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 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 treated with care and placed the right side up
(as indicated on the packaging).
5 | Disposal of used parts and consumables
Used parts and consumables should be disposed of or made availa-
ble for recycling purposes according to the applicable local guide-
lines.
If consumables are subject to specific determination, observe the
corresponding instructions on the packaging.
If in doubt, contact your local waste disposal authority or the manu-
facturer for more information.

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B Basic information
1 | Laws, regulations, standards
In the interest of good health, rules cannot be ignored when it comes
to the processing of drinking water. This operation manual takes into
consideration the current regulations and stipulates information that
you will need for the safe operation of your demanganisation sys-
tem.
Among other things, the set of rules stipulates 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
The GENO-mat MN-Z demanganisation systems are designed for
the reduction of iron and/or manganese. They are used in the resi-
dential sector for private water supply plants with maximum values
of up to 3.0 mg/l of iron and 1.0 mg/l of manganese. If the systems
are operated properly and handled according to the operation man-
ual, pure water values as required by the German Drinking Water
Ordinance (TrinkwV) can be achieved.
For an optimum reduction of iron and manganese, a pH value > 7.2
is required. A dosing system for oxidants has to be provided up-
stream of the demanganisation system.
However, should ammonium (> 0.1 mg/l) be detected in the raw wa-
ter, an additional treatment step is required.
3 | Function
The demanganisation system GENO-mat MN-Z is operated with the
natural, catalytic filter material Fermanit. A central control valve auto-
matically controls the operating cycles filtration - backwash - and first
filtrate.

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3.1 Filters The raw water flows into the filter tank via the raw water inlet and
then, from top to bottom, through the catalytic filter material. By
means of an oxidation process, dissolved iron and manganese salts
are transformed into insoluble oxides and are deposited on the Fer-
manit material.
In this oxidation process, the Fermanit releases electrons to the iron
and manganese until the supply is exhausted. The electrons have to
be replaced continuously by dosing GENO-oxi plus (refer to product
data sheet).
By dosing oxidants, the oxidation and precipitation of iron and man-
ganese already takes place prior to their contact with the Fermanit
material. Thanks to its catalytic properties a complete oxidation and
due to the excellent filtration characteristics, an optimum filtration are
achieved. The filtered pure water is then directed via the lower dis-
tributing nozzle and the riser pipe through the pure water outlet into
the piping system.
3.2 Backwashing 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 demanganisation system must be backwashed every 6
days at the latest (for the setting refer to chapter F).
3.3 First filtrate 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 dis-
charged to the drain and afterwards, the demanganisation system
GNEO-mat MN-Z is ready for operation once again.
3.4 Regenera-
tion/disinfection
For operating and hygienic reasons, the demanganisation system
must be regenerated every 6 months with GENO special granulate
or GENO-oxi plus.
3.5 Control unit The demanganisation system GENO-mat MN-Z is time-controlled
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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C Product description
1 | Type designation plate
The type designation plate is located on the control head of the de-
manganisation system. In order to speed up the processing of your
inquiries or orders, please specify the data shown on the type desig-
nation plate of your system when contacting Grünbeck. Please add
the necessary information to the table below to have it readily availa-
ble whenever necessary.
Demanganisation system GENO-mat MN-Z
Serial number:       / 
Order number:      
Fig. C-1: Type plate for demanganisation system GENO-mat MN-Z
2 | Technical specifications
The GeNO-mat MN-Z demanganisation system is a single system
with integrated bypass for the supply of raw water during the back-
wash process. It is equipped with a timer control. The backwash is
initiated after a set time interval.
All system data is summarised in table C-1. The data refers to the
standard versions of the GeNO-mat MN-Z demanganisation system.
Possible deviations in case of special versions are communicated
separately, if applicable.
Caution! Electrically operated valves. In case of a power failure dur-
ing the backwash, water may enter the drain. In the event of power
failure, check the system and shut-off the water supply, if necessary.

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Table C-1: Technical specifications Demanganisation system GENO-mat MN-Z
20/10 25/13 30/14 40/17 40/18 50/19 60/20
Connection data
Nominal connection diameter DN 25 (1") DN 40 (1½“)
Min. drain connection DN 50 DN 70
Nominal flow rate (depending on the iron concen-
tration)
[m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
Power supply [V/Hz] 230 V, 50 Hz
operation with protective low voltage 24 V/50 Hz
Connected load [VA] 10
Protection type IP 54
Performance data
Nominal pressure (PN) 8.0
Min./max. operating pressure [bar] 2.5/6.0
Pressure loss at nominal flow [bar] 0.5 1.1 1.0 1.1 1.0 0.8 1.1
Dimensions and weights
1)
Total height [mm] 1360 1620 1620 1900 1900 1870 2100
Exchanger tank  [mm] 210 260 340 370 420 550 620
Regeneration tank  [mm] 465 680
Height of regeneration tank [mm] 840 1010
Connection height/raw water piping [mm] 1160 1420 1420 1710 1710 1680 1910
Connection height/pure water piping [mm] 1210 1470 1470 1735 1735 1705 1935
Distance to wall [mm] 200 230 280 280 300 365 405
Depth of foundation [mm] 400 450 500 500 550 600 650
Length of foundation [mm] 1850 1950 2050 2050 2100 2250 2350
Operating weight (incl. water) [kg] 76 135 213 311 361 642 947
Filling volume and consumption data
1)
Filter layer I, bottom, gravel 3.0 - 5.6 [kg] 10 10 25 25 25 50 50
Filter layer I, bottom, gravel 3.0 - 5.6 [l] 7 7 18 18 18 35 35
Filter layer I, bottom, gravel 3.0 - 5.6 (dimension a) [mm] 860 1170 1100 1400 1430 1320 1570
Filter layer II, middle, GENO Fermanit [kg] 25 50 50 100 125 200 325
Filter layer II, middle, GENO Fermanit [l] 12.5 25 25 50 63 100 163
Filter layer II, middle, GENO Fermanit (dimension b) [mm] 500 690 810 930 950 900 1020
Filter layer III, top, with quartz sand 0.4 – 0.8 [kg] 10 25 50 75 75 150 250
Filter layer III, top, with quartz sand 0.4 – 0.8 [l] 7 17 33 50 50 100 167
Filter layer III, top, with quartz sand 0.4 – 0.8 (dimen-
sion c) [mm] 300 370 430 460 560 490 450
Free board [l] 7 12 30 22 40 74 71
Amount of regeneration agent required
Preparation amount [l] 30
2
) 50
2
) 60
2
) 100
2
) 100
2
) 200
2
) 300
2
)
GENO special granulate [g] 105 175 210 350 350 700 1050
GENO-oxi plus [l] 5 9 11 17 17 35 53
Total waste water volume per regeneration (3 bar) [m³] 1 1.3 1.7 2 2.7 3.4 5.4
Ambient data
Duration of washing out (regeneration) [min.] 30
Duration of backwash [min.] 10
Backwash capacity [m³/h] 1.6 2.3 3.4 5.7
Max. water temperature [°C] 30
Max. ambient temperature [°C] 40
Order no. 153 … 410 420 430 440 450 460 470
Spare filter filling
3)
Order no. 153 … 020 022 024 026 028 030 032
1)
All indications are approximate.
2)
If the liquid product GENO-oxi plus is used, the GENO-oxi plus amount must be subtracted from the batch size.
3)
all three filter layers

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Filter layer III top
Filter layer II middle
Filter layer I Bottom
Fig. C-2: Filling of filter layers
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 perfor-
mances. Do not exceed the peak flow under any circumstances.
The system may only be operated if all components are installed
properly. Safety devices and equipment must NEVER be removed,
bridged or tampered with.
Intended use of the device also implies that the information con-
tained in this operation manual and all safety guidelines applying at
the installation site be observed. Furthermore, the maintenance and
inspection intervals must be respected.

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4 | Scope of supply
4.1 Basic equipment  Exchanger tank in double walled plastic housing.
 Filter materials (gravel, GENO Fermanit, quartz sand).
 Control valve made of red bronze with integrated timer control.
 Water test kit for manganese.
 Operation manual.
5 | 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 Höchstädt for more information.
PE tank 100 litre or 300 litre with litre scale and hand mixer to pre-
pare the regeneration solution. The tank features an integrated suc-
tion device.
 Regeneration device 100 litres
(FE/MN-Z 20/10 – FE/MN-Z 40/18)
153 094
 Regeneration device 300 litres
(FE/MN-Z 50/19 – FE/MN-Z 60/20)
153 095
Mounting set 1:
For convenient hydraulic connection.
Compact valve block R 1" female thread, in-
tegrated bypass with shut-off valve, shut-off
valves for hard and soft water, outlet for raw
water (e.g. garden hose), 2 connection
hoses
Mounting set R 1“ (up to type 30/14) 125 845
Complete dosing system consisting of dosing pump GP-2/40 (GP-
6/40), water meter 1" (1½"), dosing point, opaque suction lance,
dosing hose.
 Dosing system suitable for
MN-Z 20/10 – MN-Z 30/14
Dosing system GENODOS DM-oxi 1"
163 420
 Dosing system suitable for
MN-Z 40/17 – MN-Z 60/20
Dosing system GENODOS DM-oxi 1½"
163 430
 Overflow valve GENODOS DM-oxi 1",1 1/2" 163 790

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6 | Consumables
Only use genuine consumables in order to ensure the reliable opera-
tion of the system.
6.1 Oxidants for the regeneration/disinfection of demanganisation systems
GENO special granulate
1)
(1 kg) 170 016
GENO special granulate
1)
(5 kg) 170 017
GENO-oxi plus (20 kg/19.7 litres) 170 029

1)
Note: Registration by the Federal Surveillance Authority for Opium
according to the Controlled Substances and Precursors Act required.
6.2 Test device for manganese measuring range 0.0 mg/l - 0.8 mg/l
and 1.0 mg/l - 10.0 mg/l
For the quantitative, colorimetric determination of dissolved manga-
nese in the measuring range of 0.03 mg/l – 0.5 mg/l. Quick test kit
consisting of:
2 test vials and comparison scale
2 reagent Mn -1 A
1 reagent Mn - 2 A
1 reagent Mn - 3 A
170 124
6.3 Test kit for iron, measuring range 0.0 mg/l - 0.8 mg/l
and 1.0 mg/l - 10.0 mg/l
For the quantitative, colorimetric determination of dissolved iron in
the measuring range of 0.0 mg/l – 0.8 mg/l respectively 1.0 mg/l – 10
mg/l. Quick test kit consisting of:
1 test glass with 3 chambers and scale;
Test tablets (0.0 mg/l-0.8 mg/l) 30 tablets;
Test tablets (0.1 mg/l-10 mg/l) 30 tablets;
170 150
6.4 Spare filter filling, complete
Refer to table C-1 „Technical specifications“

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6.5 Wearing parts
Seals and control pistons are subject to a certain wear and tear in
the event of heavy duty. Wearing parts are listed below.

Note: Although these parts are wearing parts, we grant a limited
warranty period of 6 months. The same applies to electrical compo-
nents.
Seals, control piston, injector, actuator
Fig. C-3: Control head
nominal connection diameter DN 25 (1")
Fig. C4: Control head
Nominal connection diameter DN 40
(1½")

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D Installation and operation
1 | General installation information
The installation site must offer adequate space. A foundation of a
sufficient size and adequate load carrying capacity has to be pro-
vided. The required connections must be provided prior to the instal-
lation. For dimensions and connection data, please refer to table D-
1.
Table D-1: Installation data Demanganisation system GENO-mat MN-Z
20/10 25/13 30/14 40/17 40/18 50/19 60/20
Connection data
Nominal connection diameter DN 25 (1") DN 40 (1½“)
Min. drain connection DN 50 DN 70
Nominal flow rate (depending on the iron con-
centration)
[m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
Power supply [V/Hz] 230 V, 50 Hz
operation with protective low voltage 24 V/50 Hz
Connected load [VA] 10
Protection type IP 54
Dimensions and weights1)
Total height [mm] 1360 1620 1620 1900 1900 1870 2100
Exchanger tank  [mm] 210 260 340 370 420 550 620
Regeneration tank  [mm] 465 680
Height of regeneration tank [mm] 840 1010
Connection height/raw water piping [mm] 1160 1420 1420 1710 1710 1680 1910
Connection height/pure water piping [mm] 1210 1470 1470 1735 1735 1705 1935
Distance to wall [mm] 200 230 280 280 300 365 405
Depth of foundation [mm] 400 450 500 500 550 600 650
Length of foundation [mm] 1850 1950 2050 2050 2100 2250 2350
Operating weight (incl. water) [kg] 76 135 213 311 361 642 947
1)All indications are approximate.

Note: For the installation of systems with optional accessories (refer
to Chapter C, item 5), also observe the operation manuals supplied
with these components.

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1.1 Water installa-
tion
It is imperative that you comply with certain regulations when in-
stalling the GENO-mat MN-Z demanganisation system. Additional
recommendations are given in order to facilitate the handling of the
system. The installation instructions described below are also illus-
trated in fig. D-2.
Mandatory regulations
The installation of the GeNO-mat MN-Z demanganisation system
represents a major interference with the drinking water system.
Therefore, only authorised experts may install such systems. In Ger-
many, the installation company must be registered in a water com-
pany installation directory as per §12(2) AVBWasserV (German Ordi-
nance 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 water stop device has to be in-
stalled.
 Observe the flow direction!
Warning! Floor drains that discharge to a lifting system will not work
in case of a power failure.
Recommendations
 Provide a sampling valve and a pressure gauge directly upstream
and downstream of the GeNO-mat MN-Z demanganisation system
(0 -10 bar). This simplifies the sampling for the regular determina-
tion of the iron concentration (functional check).
1.2 Electrical instal-
lation
A shock-proof plug is adequate for the electrical connection. How-
ever, it must comply with the specifications given in table D-1, may
not be further than 1.20m away from the GeNO-mat MN-Z deman-
ganisation system and must carry constant voltage (do not couple
with light switch)!

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2 | Preliminary work
1. Unpack all system components.
2. Check for completeness and undamaged condition.
3. Place the filter tank at the designated location.
Extract from Table D-1
Table D-2: Filling volumes
1)
Demanganisation system GENO-mat MN-Z
20/10 25/13 30/14 40/17 40/18 50/19 60/20
Filling volumes and consumption data
Bottom filter layer I, gravel 3.0 - 5.6 [kg] 10 10 25 25 25 50 50
Bottom filter layer I, gravel 3.0 - 5.6 [l] 7 7 18 18 18 35 35
Filter layer I, bottom, gravel 3.0 - 5.6 (dimen-
sion a)
[mm] 860 1170 1100 1400 1430 1320 1570
Filter layer II, middle, GENO Fermanit [kg] 25 50 50 100 125 200 325
Filter layer II, middle, GENO Fermanit [l] 12.5 25 25 50 63 100 163
Filter layer II, middle, GENO Fermanit (dimen-
sion b)
[mm] 500 690 810 930 950 900 1020
Filter layer III, top, with quartz sand 0.4 – 0.8
[kg]
10 25 50 75 75 150 250
Filter layer III, top, with quartz sand 0.4 – 0.8
[l]
7 17 33 50 50 100 167
Filter layer III, top, with quartz sand 0.4 – 0.8
(dimension c)
[mm]
300 370 430 460 560 490 450
Free board, approx. [l] 7 12 30 22 40 74 71
1)All indications are approximate.
Filter layer III Top
Filter layer II Middle
Filter layer I Bottom
Fig. D-1: Filling of filter layers

Iron / manganese removal
Demanganisation system GENO-mat MN-Z
Order no. 095 153 048-inter Edited by: nkes-mrie G:\BA-153048-INTER_095_GENO-MAT_MN-Z.DOCX
20
Centre rising pipe,
Fill with filter material
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 rising 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 the protective cap,
fix the control head in place.
5. Fill up the filter tank with water
6. Centre the riser pipe precisely.
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 rising pipe and fasten it
by turning it to the right.