Grunbeck GENO-mat AK-Z User manual

Operation manual
Filter systems
GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems
GENO-mat TE-Z
Edition September 2018
Order no. 035 129 950-inter

Filtration/Deacidification
Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
Order no. 035 129 950-inter Edited by: nkes-mrie G:\BA-129950-INTER_035_FILTERANLAGEN_GENO-MAT.DOCX
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Table of contents
A General................................................................................. 5
1 Preface
2 How to use this operation manual
3 General safety information
4 Shipping and storage
5 Disposal
B Basic information ................................................................ 9
1 Laws, regulations, standards
2 Designated application/area of application
3 Function
C Product description............................................................. 13
1 Type plate...........................................................................
2 Technical specifications
3 Intended use
4 Scope of delivery
5 Optional accessories
6 Consumables
D Installation............................................................................ 19
1 General installation information
2 Preliminary works
3 How to connect the system
E Start-up................................................................................. 16
1 How to start up the system
F Operation.............................................................................. 27
1 How to operate the control unit
G Maintenance......................................................................... 30
1 Basic information
2 Inspection (functional check)
3 Maintenance
4 Spare parts
5 Operation log

Filtration/Deacidification
Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
Order no. 035 129 950-inter Edited by: nkes-mrie G:\BA-129950-INTER_035_FILTERANLAGEN_GENO-MAT.DOCX 3
All rights reserved.
Copyright by Grünbeck Wasseraufbereitung GmbH
Printed in Germany
Effective with the date of edition indicated on the cover sheet.
-We reserve the right to modifications, especially with regard to
technical progress-
Reprints, translations into foreign languages, electronic storage or
copying - even in part - of this operation manual are only permitted
with the explicit written approval of Grünbeck Wasseraufbereitung
GmbH.
Any type of duplication not authorised by Grünbeck Wasseraufberei-
tung is a copyright violation and subject to legal action.
Responsible for contents:
Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1 89420 Hoechstaedt/Do., Germany
Tel. [phone] Fax [phone]
www.gruenbeck.de [email protected]
Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1, 89420 Hoechstaedt/Do., Germany

Filtration/Deacidification
Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
Order no. 035 129 950-inter Edited by: nkes-mrie G:\BA-129950-INTER_035_FILTERANLAGEN_GENO-MAT.DOCX
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EU Declaration of Conformity
This is to certify that the systems designated below meets the safety and health requirements
of the applicable European guidelines in terms of its design, construction and execution.
If the systems are modified in a way not approved by us, this certificate is void.
Manufacturer: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1
89420 Hoechstaedt/Do., Germany
Responsible for documen-
tation: Markus Pöpperl
Description of the system: Filter systems
Deacidification systems
Device type: GENO-mat KF-Z / MS-Z / AK-Z
GENO-mat TE-Z
Device no. Refer to type plate
Applicable EC guidelines: 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 specifica-
tions, in particular:
DIN 19636-100:2008-02
Place, date and signature: Hoechstaedt, 26.09.2018 p.p.
M. Pöpperl
Dipl.-Ing. (FH)
Function of signatory: Head of Technical Product Design

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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A 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. This also
applies to the treatment of water for industrial use if repercussions
for the drinking water cannot completely be excluded.
All Grünbeck systems and devices are made of high-quality materials.
This ensures reliable operation over many years, provided you treat
your water treatment systems with the required care. This operation
manual assists you with important information. Therefore, carefully
and thoroughly read the operation manual before installing, operating
or maintaining the system.
Customer satisfaction is our prime objective and providing custom-
ers with qualified advice is crucial to Grünbeck. If you have any
questions concerning this system, possible extensions or general
water and waste water treatment, our field staff, as well as the ex-
perts at our headquarters in Hoechstaedt, are available to help you.
For help and advice Please consult the representatives responsible for your region (see
www.gruenbeck.com). or get in touch with our service centre which
can be reached during office hours:
Phone: [phone]
Fax: [phone]
Email: [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 plate to the overview
in chapter C-1.

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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2 | How to use this operation manual
This operation manual is intended for the operators of our systems.
It is divided into several chapters (a letter is assigned to each of
them) which are listed in the “Table of contents” on page 2 in alpha-
betical order. In order to find the specific information you are looking
for, check for the corresponding chapter on page 2.
The headers and page numbers with chapter information make it
easier to find your way around in the manual.
3 | General safety information
3.1 Symbols and notes Important information in this operation manual is characterised by
symbols. Please pay particular attention to this information to ensure
the hazard-free, safe and efficient handling of the system.
Danger! Failure to adhere to this information will cause serious or
life-threatening injuries, extreme damage to property or inadmissible
contamination of the drinking water.
Warning! Failure to adhere to this information may cause injuries,
damage to property or contamination of the drinking water.
Caution! Failure to adhere to this information may result in damage
to the system or other objects.
Note: This symbol characterises information and tips to make your
work easier.
Tasks with this symbol may only be performed by Grünbeck's tech-
nical service/authorised service company or by persons expressly
authorised by Grünbeck.
Tasks with this symbol may only be performed by qualified electrical
experts according to the VDE guidelines or according to the guide-
lines of a similar local institution.
Tasks with this symbol may only be performed by water companies
or approved installation companies. In Germany, the installation
company must be registered in an installation directory of a water
company as per §12(2) AVBWasserV (German Ordinance on Gen-
eral Conditions for the Supply of Water).

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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3.2 Operating person-
nel Only persons who have read and understood this operation manual
are permitted to work with the system. The safety guidelines are to
be strictly adhered to.
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 the drinking water
protection, accident prevention and occupational safety must be ad-
hered to.
In addition, appropriate application also implies that the system may
only be operated when it is in proper working order.
Any malfunctions must be repaired at once.
3.4 Protection from
water damage
Warning! In order to properly protect the installation site from water
damage:
a) a sufficiently dimensioned floor drain system must be available or
b) a safety device (see chapter C Accessories) must be installed.
Warning! Floor drains that discharge to a lifting system do not work
in case of a power failure.
3.5 Indication of
specific dangers Danger due to electrical energy! Do not touch electrical parts
with wet hands! Disconnect the system from mains before starting
work on electrical parts of the system. Have qualified experts re-
place damaged cables immediately.
Danger due to mechanical energy! System parts may be subject to
overpressure. Danger of injury and damage to property due to es-
caping water and unexpected movement of system parts. Check
pressure pipes regularly. Depressurise the system before starting
repair or maintenance work on the system.
Hazardous to health due to contaminated drinking water! The
system may only be installed by a specialist company. The opera-
tion manual must be strictly adhered to! Ensure that there is suffi-
cient flow. The pertinent guidelines must be followed for starting-up
after extended periods of standstill. Inspections and maintenance
must be performed at the intervals specified!
Note: By concluding a maintenance contract, you ensure that all of
the required tasks are performed on time. You may perform the in-
terim inspections yourself.

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Deacidification systems GENO-mat TE-Z
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4 | Shipping and storage
Caution! The system may be damaged by frost or high tempera-
tures. In order to avoid damage of this kind:
Protect from frost during transportation and storage!
Do not install or store the system next to objects which radiate a lot
of heat.
The system may only be transported and stored in its original pack-
ing. Ensure that it is handled with care and placed the right side up
(as indicated on the packing).
5 | Disposal
Comply with the applicable national regulations.
5.1 Packaging Dispose of the packaging in an environmentally sound manner.
5.2 Product If this symbol (crossed out waste bin) is on the product, Euro-
pean Directive 2012/19/EU applies to this product. This means
that this product and the electrical and electronic components
must not be disposed of as household waste.
Find out about local regulations on the separate collection of
electrical and electronic products.
Use the collection points available to you for disposing of your
product.
For information on collection points for your product, contact
your municipality, the public waste disposal authority, an author-
ised body for the disposal of electrical and electronic products
or your waste collection service.

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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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 filter system.
Among other things, the regulations stipulate that
only approved companies are permitted to make major modifica-
tions to water supply facilities
and that tests, inspections and maintenance on installed devices
are to be performed at regular intervals.
2 | Designated application/area of application
Gravel filter KF-Z In general, gravel filter systems are used for the conventional filtra-
tion of impurities in cases where a fine filtration by means of car-
tridge filters would be too costly due to an exceptionally high degree
of pollution. The quartz gravel used retains undissolved substances
such as sand, etc.
Heavy metal compounds in dissolved form such as iron and manga-
nese, however, cannot be removed.
The filter must be backwashed if there is an accumulation of dirt par-
ticles and a pressure drop by approx. 0.3 bar (overpressure). The
backwash is carried out from the bottom to the top, opposite to the
regular direction of flow.
Multi-layer filter MS-Z Multi-layer filters mostly are used for the conventional filtration of
impurities in cases where a fine filtration by means of cartridge filters
would be too costly due to an exceptionally high degree of pollution.
The hydro-anthrasite H used in addition to quartz gravel is a filter
material composed of carefully sieved, thermally-treated carbon for
the treatment of drinking and process water. The abrasion-resistant
filter material has a rough surface by which a finer filtrate is achieved
compared to a filtration by gravel alone.
The multi-layer filter is able to retain undissolved substances such
as sand, etc. Heavy metal compounds in dissolved form such as iron
and manganese, however, cannot be removed. The filter must be
backwashed if there is an accumulation of dirt particles and a pres-
sure drop by approx. 0.3 bar (overpressure). The backwash is car-
ried out from the bottom to the top, opposite to the regular direction
of flow.

Filtration/Deacidification
Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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Activated carbon
filter AK-Z The activated carbon filter is used to dechlorinate the water. If pos-
sible, the water to be dechlorinated should be free of mechanical
impurities.
Activated carbon is able to react with the available, free chlorine via
surface reaction. The chloride thus produced does not clog up the
activated carbon filter but is discharged with the water. The surface
reaction capacity is reduced over time due to the amount of impuri-
ties present in the water.
For this reason, and to remove any carbon abrasions that might
have occurred, it is essential to backwash the filter on a weekly ba-
sis.
If the residual chlorine concentration exceeds the set admissible
value on leaving the activated carbon filter, the activated carbon
should be replaced. A replacement, however, should take place eve-
ry two years at the latest.

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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Deacidification system
TE-Z Corresponding to its carbonate hardness, all water contains a cer-
tain amount of free carbon dioxide which is necessary to dissolve
the carbonate hardness present in the water. If there is more free
carbon dioxide contained in the water than necessary, the water is
characterised as tending to precipitate lime. This aggressive carbon-
ic acid prevents the formation of protective scale/rust layers in the
piping and is therefore removed by means of a deacidification filter.
At the same time that the acid is removed, minor impurities are also
removed by filtration.
We would like to point out explicitly that due to the limited amount of
filtration material available, only a partial deacidification can be
achieved.
We therefore recommend installing an EXADOS dosing unit down-
stream of the deacidification filter in order to add EXADOS-spezial.
In order to prevent the filter material from clogging and to flush out
impurities, it is necessary to backwash the filter. The backwash is
carried out from the bottom to the top, opposite to the regular direc-
tion of flow.
The Hydrolit-Ca deacidification material used is consumed based on
the hydration of the excess carbon dioxide. (Consumption per g of
converted CO2approx. 2.5 g).
It is therefore necessary to check the filling level from time to time
and to refill, if necessary. The system must be flushed through every
time it is refilled.
If an increased bacterial count is to be expected from the well water,
we recommend to have a disinfection performed at regular intervals
by our technical service.

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3 | Function
The GENO-mat filter systems for the filtration of impurities / partial
deacidification work with an active insoluble catalytic filter material. A
central control valve automatically controls the operating cycles fil-
tration, backwash and first filtrate.
3.1 Filteration The raw water enters the exchanger tank via the raw water inlet and
flows through the filter material from top to bottom. According to the
filter type, the dirty water is filtered from top to bottom. The filtered
pure water is then directed via the lower distributing nozzle and the
riser pipe through the pure water outlet into the piping system.
3.2 Backwash During the backwash process, the filter bed is forcibly flushed from
bottom to top and thus loosened up. Impurities retained during the
filtration process are washed out via the drain outlet at the control
valve. The filter system must be backwashed every 6 days at the
latest (for the setting refer to chapter F).
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
discharged to the drain and afterwards the filter system is ready for
operation once again.
3.4 Control unit The GENO-mat filter systems / deacidification systems are 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 plate
The type plate is located on the control valve of the GENO-mat filter/
deacidification system. In order to speed up the processing of your
inquiries or orders, please specify the data shown on the type plate
when contacting Grünbeck. Please copy the indicated information to
the table below in order to have it readily available whenever neces-
sary.
GENO-mat filter system / deacidification system
KF-Z / MS-Z AK-Z TE-Z
Serial number: 
Order no.: 
Fig. C-1: Type plate of a filter system

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Deacidification systems GENO-mat TE-Z
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2 | Technical specifications
The GENO-mat filter/deacidification systems are individual systems
with integrated bypass for the supply of raw water during the back-
wash process. It is equipped with a timer control. The backwash is
released after a set time interval.
All system data are summarized on the reverse in table C-1. The
data refers to the standard versions of the GENO-mat filter/
deacidification systems. Possible deviations in case of special ver-
sions are listed separately, if applicable.
Caution! Electrically operated valves. In case of a power failure dur-
ing the backwash, water may enter the drain. In case of power fail-
ure, check the system and shut-off the water supply, if necessary.

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
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Table C-1: Technical specifications GENO-mat filter systems
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“)
Nominal pressure PN 10
Min./max. operating pressure [bar] 2.5/6.0
Nominal flow rate max. KF-Z [m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
Nominal flow rate max. MS-Z [m³/h] 1.5 2.0 3.0 4.0 5.0 6.0 8.0
Nominal flow rate max. AK-Z [m³/h] 0.25 0.5 1.0 1.2 1.5 2.0 3.0
Nominal flow rate max. TE-Z [m³/h] 0.5 1.0 1.5 2.0 2.5 3.0 4.0
Filter material KF-Z
Quartz gravel 3.0-5.6 I [kg] 9 15 20 28 20 61 90
Quartz sand 1.0-2.2 II [kg] 4 30 38 50 90 100 160
Filter sand 0.4-0.8 III [kg] 20 30 50 70 90 150 230
Filter material MS-Z
Quartz gravel 3.0-5.6 I [kg] 9 15 20 30 20 67 100
Quartz sand 1.0-2.2 II [kg] 8 25 50 82 90 180 267
Hydro-anthrasite H 0.6-1.6 III [l] 8 17 26 24 64 50 78
Filter material AK-Z
Quartz gravel 3.0-5.6 I [kg] 9 15 20 20 20 30 30
Hydrafin CC 8 x 30 0.5-2.5 II [kg] 10 16 25 40 50 90 140
Filter material TE-Z
Quartz gravel 3.0-5.6 I [kg] 9 15 20 20 20 30 30
Hydrolit-Ca 1.0-3.0 II [kg] 20 25 70 90 120 220 320
Backwash capacity [m³/h] 1.6 2.3 3.4 5.7
Backwash time [min] 10
Water/ambient temperature, max. [°C] 30/40
Power supply [V]/[Hz] 230/50
Connected load [VA] 10
Protection/protection class IP 54/
Min. drain connection DN 50 DN 70
Total empty weight KF-Z [kg] 43 88 124 175 228 351 529
Total empty weight MS-Z [kg] 31 65 99 151 170 312 455
Total empty weight AK-Z [kg] 29 44 61 67 98 160 219
Total empty weight TE-Z [kg] 39 53 106 137 168 290 399
Operating weight* (incl. water) [kg] 67 127 200 272 344 573 833
Operating weight** (incl. water) [kg] 53 100 167 240 268 515 732
Operating weight*** (incl. water) [kg] 45 77 125 164 193 339 462
Operating weight**** (incl. water) [kg] 57 93 163 214 257 456 633
Order no. KF-Z* 129 … 500 505 510 515 520 525 530
Order no. MS-Z** 129 … 550 555 560 565 570 575 580
Order no. AK-Z*** 129 … 800 805 810 815 820 825 830
Order no. TE-Z**** 129 … 850 855 860 865 870 875 880

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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. The maximum flow must not be exceeded under any cir-
cumstances.
The system may only be operated if all components are installed
properly. Safety devices must never be removed, bridged or other-
wise tampered with.
Designated application of the system also implies that the infor-
mation contained in these operating instructions and all safety guide-
lines applying at the installation site be observed. Furthermore, the
maintenance and inspection intervals have to be observed.
4 | Design
5-cycle control valve made of red bronze with time-dependent con-
trol via timer. Control valve top with rotating disks to set the back-
wash intervals; cover for protection against splash water and unau-
thorised access.
Exchanger tank made of pressure resistant plastic with fixtures for
water flow control and retention of filter material.
The control unit is interference-free. Power supply by means of a
transformer plug with 1.5 m feed line.
5 | Scope of supply
5.1 Basic configuration Exchanger tank in double walled plastic housing
Filter materials (quartz gravel, quartz sand, filter sand,
Hydrafin CC 8 x 30, Hydrolit-Ca, Hydroanthrasit H).
Control valve made of red bronze with integrated timer control.
Operation manual

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6 | Optional accessories
Note: It is possible to retrofit existing systems with optional compo-
nents. Please contact your local Grünbeck representative or
Grünbeck’s headquarters in Hoechstaedt for details.
Mounting kit 1:
for convenient hydraulic connection,
Compact valve block R 1’’ internal thread,
integrated bypass with shut-off valve, shut-
off valves for hard and soft water, outlet for
raw water (e.g. garden hose), 2 connection
hoses
Mounting kit R 1“ (up to size 30/14) 125 845
protectliQ safety device 126 400
Product for the protection against water damage in
one- and two-family homes.
For additional types, please inquire

Filtration/Deacidification
Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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7 | Consumables
Only use genuine consumables in order to ensure the reliable opera-
tion of the system.
7.1 Wearing parts
In case of heavy duty, seals and control pistons are subject to a cer-
tain wear and tear. Wearing parts are listed below.
Note: Although these are wearing parts, we grant a limited warranty
period of 6 months.
Seals, control piston, injector, actuator
Fig. C-3: Control valve
Nominal connection diameter
DN 25 (1“)
Fig. C-4: Control valve
Nominal connection diameter
DN 40 (1½“)

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Filter systems GENO-mat KF-Z / MS-Z / AK-Z
Deacidification systems GENO-mat TE-Z
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D Installation and operation
1 | General installation instructions
The installation site must provide adequate space. A foundation of a
sufficient size and adequate carrying capacity must be provided. The
required connections must be provided prior to the installation. For
dimensions and connection data, please refer to table C-1.
Note: For the installation of systems with optional accessories (see
chapter C, item 5), also observe the operation manuals supplied with
these components.
1.1 Water installation When installing the filter/deacidification systems, certain binding
rules must be observed. Additional recommendations are given in
order to facilitate the handling of the systems. The installation infor-
mation described below is also illustrated in fig. D-2.
Binding rules
The installation of the GENO-mat filter/deacidification systems rep-
resents a major interference with the drinking water system. There-
fore, only authorised experts may install such systems. In Germany,
the installation company must be registered in an installation directo-
ry of a water company 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 safety device has to be in-
stalled.
Observe the flow direction!
Warning! Floor drains that discharge to a lifting system do not work
in case of a power failure.
Recommendations
Provide a sampling valve and a pressure gauge (0-10 bar) directly
upstream and downstream of the filter/deacidification systems.
This simplifies the sampling for the regular determination of the
iron concentration (functional check).

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Deacidification systems GENO-mat TE-Z
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1.2 Electrical installa-
tion A shock-proof plug is adequate for the electrical connection. Howev-
er, it must comply with the specifications given in table C-1, may not
be further than 1.20 m away from the GENO-mat filter/
deacidification systems and must carry constant voltage (do not
couple with light switch)!
2 | Preliminary Work
1. Unpack all system components.
2. Check for completeness and perfect condition.
3. Place the filter tank at the designated location.
Note: Filter/deacidification systems must be filled on site.
4. Unscrew control valve from pressure cylinder.
5. Centre the nozzle jet in the pressure cylinder and close if off by
means of adhesive tape or paper wadding.
6. Fill in the filter layers according to the filter/deacidification system
type
Filter layer I Bottom KF-Z, MS-Z, AK-Z, TE-Z
Filter layer II Middle KF-Z, MS-Z, AK-Z, TE-Z
Filter layer III Top KF-Z, MS-Z
Filter layer III Top
Filter layer II Middle
Filter layer I Bottom
Fig. D-1: Filling of filter layers