Grunbeck GENO-UV 60 S User manual

Customer Service Section
of the operation manual for
disinfection systems GENO®-UV 60 S
120 S
200 S
This special customer service section contains information that
is essential for the start-up, maintenance resp. repair of the
systems and therefore has to be carried along at all times.
However, this additional information may only be used in
combination with the standard operation manual. Furthermo-
re, it is only designated for the technical customer service.
The customer service section consists of a lose collection of
sheets that should – according to the respective chapter and
page number (refer to header and footer) – be attached to the
corresponding chapters of the standard operation manual.
In order to always be well informed, it is important to keep
the complete customer service section of the operation manual
up to date at all times.
Edition February 2012
Order no. 054 523 950 – inter
-CONFIDENTIAL-
Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Strasse 1
89420 Hoechstaedt/Danube · GERMANY
Phone [phone] · Fax [phone]
www.gruenbeck.com · [e-mail]
A company certified by TÜV SÜD
in accordance with DIN EN ISO 9001, DIN
EN ISO 14001, DIN EN ISO 13485 and SCC

Start-up - Customer Service Section
GENO®UV systems with GENO®-Multi BS
Order no. 044 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB-KD-E.DOC -CONFIDENTIAL-
E-5
E Start-up - Customer Service Section
(GENO®UV systems with GENO®-Multi BS control unit)
Contents
1 Operation of UV systems................................................
1.1 General information .................................................
1.2 How to set the minimum irradiance..........................
E-5
E-5
E-6
1 | Operation of UV systems
1.1 General
information The SAK254 value (specific absorption coefficient at a wave length
of the light of 254 nm) is the parameter relevant for the UV disin-
fection which is used in order to describe the properties of the
water. The value is determined according to DIN 38404, part 3,
without prior filtration of the water. The measuring is made by
means of a spectral photometer in quartz cuvettes of a layer
thickness of at least 40 mm. The SAK254 not only registers the
impact of the substances dissolved in the water (such as iron,
copper, manganese,...) but also of the suspended solids (turbidity
substances) in the water. The following applies: the higher the
SAK254 value, the more light is lost in the water.

Note: The SAK254 can only be determined by means of a labora-
tory measuring device. For determination of the SAK254, please
send a water sample of at least one liter to our internal lab.
The testing of the UV systems for the disinfection of drinking
water is carried out at a design SAK254 of 2.7 m-1. This means
that the UV systems GENO-UV 60 S, 120 S and 200 S are suita-
ble for water with a SAK254 of up to 2.7 m-1. Water that has a
higher SAK254 needs a different, equally suitable UV disinfection
system for the disinfection or the water has to be treated (e.g.
by filtration, deferrization, ..) to an extent that the SAK254 does
not exceed the above mentioned value. In order to guarantee
the disinfection efficiency, the flow indicated in table E-1 for the
respective UV system must not be exceeded and the corre-
sponding minimum irradiance must not be undershot.
As in many water analyses the water transmission is also speci-
fied, the transmissions corresponding to a SAK254 of 2.7 m-1 at a
cuvette thickness of 10 mm, 50 mm and 100 mm are indicated
in table E-1 as well. With transmission, the values must not be
fallen below.
The control unit of the systems is pre-set to the minimum irradi-
ance as indicated in table E-1. This setting must not be modi-
fied. The same applies for the pre-alarm of irradiance which, as
required by worksheet W 294-1, is set to a value of 110 % of
minimum irradiance (e.g. min. irradiance 11.0 W/m², pre-alarm
12.1 W/m²).

Commissioning
GENO®UV systems with GENO® - Multi BS
-CONFIDENTIAL- Order no. 044 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB-KD-E.DOC
E-6

Note: If it is established during the start-up of the system that
the pre-alarm of irradiance does not react at a value of 110 %
of minimum irradiance, the pre-alarm must be set as described
in chapter 5.2.
Combined with the flow stabilizers, it is thus ensured that the
indicator point of the UV disinfection system tested by the
DVGW is maintained.
Table E-1 Indicator points certified by the DVGW
System SAK254 10 50 100 max.
flow
min.
irradiance
m-1 % % % m³/h W/m²
GENO-UV 60 S
2.7 94.0 74.1 55.0
3.3 11.5
GENO-UV 120 S 8.0 14.0
GENO-UV 200 S 12.0 16.0
1.2 How to set the minimum
irradiance
At installation sites at which the system is to be operated without
compliance to DVGW worksheet W 294, a different setting for
minimum irradiance is possible.
In code level 302, the irradiance alarm value can be set under pa-
rameter 1 deviating from the standard value for the system type:
Display 1.xx.xx [W/m²]

Note: The control unit calculates the pre-alarm of irradiance inde-
pendently.

Operation
GENO-Multi BS
Order no. 004 523 950-gb Edited by: KONS-rjau-mrie G:\BA-523950-GB_KD-F.DOC -CONFIDENTIAL-
F-5
F Operation (GENO®-Multi BS)
Contents
1 Preface.........................................................................
2 How to operate the control unit...................................
2.1 Operating panels and display ................................
2.2 Operation programming level ...............................
2.3 Installer level code 290.........................................
2.4 Error memory code 245 .......................................
2.5 Displaying the software version code 999 .............
2.6 Customer service level code 302
2.7 Resetting code 189
F-5
F-6
F-6
F-7
F-8
F-9
F-9
F-10
F-10
1 | Introduction
The GENO®UV disinfection systems are operated and monitored
via the GENO®-Multi BS control unit.
Fig. F-1: GENO®-Multi BS control unit

Operation
GENO-Multi BS
-CONFIDENTIAL- Order no. 004 523 950-gb Edited by: KONS-rjau-mrie G:\BA-523950-GB_KD-F.DOC
F-6
2 | Operating the control unit
2.1 Operating panels and
display
Fig. F-2: Operating panels and display
2.1.1 Displaying the Info level
Key Display Unit LED
Basic display of irradiance XX.XX W/m² X
Operating duration XXXX Days X
Switch on processes XXXX X
Time until service is due XXXd Days --
Back to basic display of irradiance
or optional:
Water temperature XX °C --
Alarm LED
If a malfunction is present or irradiance < limit value, the LED lights
up continuously.
If irradiance < pre-alarm value, the LED flashes.
Mains switch
The mains switch is on the right side of the housing.

Operation
GENO-Multi BS
Order no. 004 523 950-gb Edited by: KONS-rjau-mrie G:\BA-523950-GB_KD-F.DOC -CONFIDENTIAL-
F-7
2.1.2 Programming parameters
Key functions with parameter programming – requirement: Basic
display of irradiance [W/m²].
Key Display
Press the key > 1 sec.: Access to parameter programming
(opt. temperature flushing system).
Open the parameter for reprogramming – the value begins to flash.
Save the parameter – the value stops flashing.
Reduce the opened parameter (while value flashes).
Return to the previous parameter.
Increase the opened parameter (while value flashes).
Return to the next parameter.
Close the opened parameter without saving – the old set value is main-
tained.
Jump back to the basic display of irradiance.
Open the display of the code query "Code C.000" >> access to code-
protected programming levels.
2.2 User programming level The limit value for the optional temperature flushing system is
saved in the user programming level:
Setting range 10 … 60 °C / factory setting 38 °C
When the limit value is reached the rinsing solenoid valve opens
and the display shows Er 3, the zero-potential contact ALARM
opens.
The rinsing solenoid valve remains open until the water has
cooled down by 2 °C.
The malfunction can be manually acknowledged and rinsing is
not stopped by this.
+
+

Operation
GENO-Multi BS
-CONFIDENTIAL- Order no. 004 523 950-gb Edited by: KONS-rjau-mrie G:\BA-523950-GB_KD-F.DOC
F-8
2.3 Installer level
Code 290

Note: The parameters specified below should only be modified by
trained experts as incorrect values may lead to malfunctions or
insufficient disinfected drinking water.
Requirement: The control unit shows the basic display of irradi-
ance.
1. Press keys + at the same time until the display
changes.
The installer level is active. The required menu must be selected
first. The numbers (000) flash. These should be reset so that they
display the code for the menu to be edited. The code for the level
required here is 290.
2. Press key to count upwards until C.290 appears in the
display.
OR
Press key to count downwards until C.290 appears in
the display.
Hold down keys and so that the numbers run faster; press
the keys for fine adjustment.
3. Press key to accept code 290.

Note: In contrast to the Info level, it is possible to move backwards
and forwards between the individual parameters in the installer
level using keys and .
Index Parameter, Unit Factory
setting
Setting
range Note
0 System type 0 60 60/120/
200/201 60 = UV60 120 = UV120
200 = UV200 with SAK254 = 2.7
201 = UV200 with SAK254 = 5.1
1 Option temperature flush-
ing system 1 0 0 … 1 0 = deactivated 1 = activated
2 Service interval [days] 2 0 0 … 730 Restart the service interval by
reprogramming

Operation
GENO-Multi BS
Order no. 004 523 950-gb Edited by: KONS-rjau-mrie G:\BA-523950-GB_KD-F.DOC -CONFIDENTIAL-
F-9
2.4 Error memory
Code 245
The FIFO error memory covers the last 20 malfunctions including
the time stamp of how many operating hours ago the malfunction
occurred. The malfunction no. 20 lying furthest back is deleted
from the memory in each case when a new malfunction occurs.
Requirement: The control unit shows the basic display of irradi-
ance.
1. Press keys + at the same time until the display
changes.
The installer level is active. The required menu must be selected
first. The numbers (000) flash. These should be reset so that they
display the code for the menu to be edited. The code for the level
required here is 245.
2. Press key to count upwards until C.245 appears in the
display.
OR
Press key to count downwards until C.245 appears in
the display.
Hold down keys and so that the numbers run faster; press
the keys for fine adjustment.
3. Press key to accept code 245.

Note: In contrast to the Info level, it is possible in the error
memory to move backwards and forwards between the individual
parameters using keys and .
Index Parameter, Unit Note
1 1Ex Latest error occurring (X hours ago)
Xh
2 2Ey Second-latest error occurring (Y hours ago)
Yh
…
20 20Ez Error occurring the longest time ago
(Z hours ago)
Zh
2.5 Displaying the software
version code 999
Display of the software version programmed into the control unit,
e.g. "u1.04".

Operation
GENO-Multi BS
-CONFIDENTIAL- Order no. 004 523 950-gb Edited by: KONS-rjau-mrie G:\BA-523950-GB_KD-F.DOC
F-10
2.6 Customer service level
code 302
Index Parameter, Unit Factory
setting
Setting
range Note
0 Calibration of UV sensor
[W/m²] Current irradiance 0 … 45.0 see chapter H, 2.1
1 Irradiance limit value
[W/m²] According to currently
set data set
0 … 45.0 see chapter E, 1.2
2.7 Resetting code 189
Index Parameter, Unit Factory
setting
Setting
range Note
0 Reset 0 0 … 1 see chapter H, 3

Troubleshooting - Customer Service Section
GENO®UV systems with GENO®-Multi BS
Order no. 024 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB_KD-G.DOC -CONFIDENTIAL-
G-5
G Troubleshooting - Customer Service Section
(GENO®UV systems with GENO®Multi BS control unit)
The causes of errors are tabulated in the order of their probable
frequency. To find an error, go through the list from top to bot-
tom.
Attention! Only open the cover of the terminals or lamps when
the system is switched off. Do not measure the lamp’s burning
voltage under any circumstances as the high-frequency signal
could destroy the measuring device.
Warning! The lamp is ignited by means of a high voltage pulse
generated by the ballast. Do not measure this pulse under any
circumstances as it represents a serious hazard to human beings.
Table G-1: Troubleshooting
This is what you observe This is the cause This is what to do
Er 1 and UV lamp light up. Irradiance < limit value.
System is dirty inside.
Service life (730 days or
18,000 h) of UV lamp has been
exceeded.
Clean the system (rinse).
Replace the UV lamp
Recalibrate the system sensor.
Er 1 and UV lamp do not light up. UV lamp is defective.
Ballast is defective.
Replace the UV lamp.
Replace the ballast.
Er 2 and LED ALARM flash Irradiance is now only 10% above
the limit value (Er 2 only displayed
in the error memory).
After switching on the cold UV
lamp, Er 2 is most probably in the
error memory because the irradi-
ance only slowly increases.
When the LED ALARM flashes
continuously:
Clean the system (rinse).
Replace the UV lamp.
Recalibrate the system sensor.
Er 3 Temperature flushing (only when
the optional temperature flushing
system is installed).
Is a normal operating response
after a longer time period without
water withdrawal.
Water temperature > 38 °C. Set rinsing temperature lower.
Check the functionality of the
rinsing valve.

Maintenance and Care - Customer Service Section
GENO®UV systems with GENO®-Multi BS
-CONFIDENTIAL- Order no. 024 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB_KD-G.DOC
G-6
Continuation Table 1:
This is what you observe This is the cause This is what to do
Er 4 Excess temperature (only when the
optional temperature flushing sys-
tem is installed).
Water temperature > 40 °C.
Set rinsing temperature lower.
Check the functionality of the
rinsing valve.
Er 5 or display EEEE. Wire fracture of UV sensor or sen-
sor signal 4-20 mA interrupted.
UV sensor connection plug in-
serted correctly?
Optional USB data recording
device wired incorrectly?
Er 6 or Er 7 Wire fracture or short circuit of the
temperature sensor (only when the
optional temperature flushing sys-
tem is installed).
Temperature sensor = PT100,
meaning sensor resistance is ap-
prox. 125 ohms at 25 °C.
Display and all LEDs dark. Mains switch is switched off.
Power supply is interrupted (inte-
grated fuse, supply line).
Switch on mains switch.
Replace the glass tube microfuse
T 2 A (see chapter D). For this
the fuse terminals are folded out
downwards and then to the
right.
"Operating duration" LED flashes. Service interval has elapsed. Carry out maintenance and restart
the service interval.

Maintenance - Customer Service Section
GENO®UV systems with GENO®-Multi BS
Order no. 034 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB_KD-H.DOC -CONFIDENTIAL-
H-5
H Maintenance - Customer Service Section
(GENO®UV systems with GENO®-Multi BS)
Contents
1 Overview of service and maintenance work .................
2 Calibration of the system sensor ..................................
3 Resetting......................................................................
H-5
H-7
H-8
1 | Overview of service and maintenance work
1.1 Overview of service work (every 4,500 operating hours)
Check UV system sensor and calibrate, if necessary
Check sensor shell and replace, if necessary
Check lamp plug and replace, if necessary
Check seals and replace, if necessary
Check functioning of the safety device
Check functioning of a possibly existing rinsing valve
Rinse UV disinfection system, if required
Clean protective pipes, if necessary
Record all data and work performed, including repair work, in
the operation log.
Turn over the system and operation log to operator.
1.2 Overview of maintenance work (every 365 days of operating duration or every 9,000
operating hours)
Replace sensor shell
(only applies to hot water (30-70 °C) UV systems).
Replace flow stabilizer
(only applies to hot water (30-70 °C) UV systems)
Record all data and work performed, including repair work, in
the operation log.
Turn over the system and operation log to operator.
Only for UV 200 S: Check the functionality and effectiveness of
the housing fans.

Maintenance - Customer Service Section
GENO®UV systems with GENO®-Multi BS
-CONFIDENTIAL- Order no. 034 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB_KD-H.DOC
H-6
1.3 Overview of maintenance work (every 730 days of operating duration or every 18,000
operating hours)
All service work and in addition:
Replace UV lamp with GENO®-UV 60 S, 120 S, 200 S.
Replace the system sensor and sensor shell (every 730 days of
operating duration or every 18,000 operating hours, at the
latest after 2 years).
Replace the flow stabilizer (every 730 days of operating
duration or every 18,000 operating hours) with operating
systems with water temperatures between 5 – 30°C.
Record all data and work performed, including repair work, in
the operation log.
Hand over the system and operation log to the operator.
If possible, if dust deposits have collected remove these from
the left housing fan carefully from inside to outside with
pressurised air.
Table H-1: Maintenance work
Type of maintenance work What must be done
Check the UV system sensor
and calibration of the UV
system sensor Chapter H-2.
Enter the irradiance indicated in the capacity display into the
operation log. Check the operating time of the sensor.
If the operating time of the sensor is > 730 days of operating
duration or 18,000 operating hours, or the last sensor replacement
took place longer than 2 years ago, the sensor must be replaced.
Check the functioning of a
safety device that might be
installed.
If the system is switched off, the safety device must close; check
the water flow.
Check the functioning of a
temperature flushing system
that might be installed.
Dip the temperature sensor into a beaker with warm water with a
temperature > the set limit value the valve must open.
UV 200: Check the housing
fan. If filter elements have been added and cannot be cleaned with pressurised air, then replace the housing fan (not the ventilator!).
Replace the UV lamp. Replace the UV lamp after 730 days of operating duration or
18,000 operating hours (see G-1).
Check the lamp plug. Check the lamp plug for fractures and fissures and replace if
necessary.
Rinse the UV disinfection
system. Clean the UV system according to the operation manual of the flushing set and check the efficiency of cleaning by removing the
protective quartz tubes and the sensor shell when the system is
empty.
Check the seals. Check the Viton seal at the protective quartz tube and the O-ring at
the sensor shell for fractures and fissures and replace if necessary.
Check the limit value of the
irradiance. Check the limit value of the irradiance according to table E-1 and set it as specified in the customer service section, chapter E-6 if necessary.
Check the pre-alarm of the
irradiance. If the limit value is o. k., slowly pull the sensor out of the sensor shell. With 10% above the set limit value the red pre-alarm LED
must start to light up. Reset if necessary as specified in the
customer service section, chapter E-6.
Documentation. Record all data and work performed, including repair work, in the
operation log.

Maintenance - Customer Service Section
GENO®UV systems with GENO®-Multi BS
Order no. 034 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB_KD-H.DOC -CONFIDENTIAL-
H-7
2 | Calibration of the UV system sensor
If the deviation between the UV system sensor and the reference
measuring device is in a range of ± 5 – 10 %, the system sensor
may be recalibrated. The calibration value must be recorded in the
operation log as an absolute deviation and as deviation in percent.
In addition, the deviations in percent must be added up and
recorded in the operation log as well.
Note: If the sum of all deviations in percent results in a value > 20
%, the sensor must be replaced.
In order not to interrupt the water flow when checking the
irradiance display with the reference sensor, the following
procedure must be observed:
Record the measured value for the irradiance in the operation
log.
On the GENO®-Multi BS control unit, change to calibration level
code 302 and open the parameter 0.XX.X with the key P for
editing (0.XX.X flashes).
Remove the system sensor, insert the reference sensor into the
sensor shell and wait for uniformity of the measured value.
Note the value measured by the reference sensor and compare
the measured values:
- Deviation less than ± 5 % no further steps required
- Deviation less than ± 5 … 10 % Carry out recalibration
(see below)
- Deviation greater than ± 10 % Replace the system sensor
Remove the reference sensor from the sensor shell and re-insert
the system sensor.
Recalibration required:
- Set the measured value of the reference sensor at parameter
0.XX.X and save with key P, then exit the code level.
No recalibration required:
- Close the parameter 0.XX.X with the key combination +
without saving and exit the code level again.
Attention! For monitoring the irradiance, only UV sensors from
the manufacturer IL-Metronic with a measuring field angle of 40°
are permitted. They are marked accordingly by an imprint on the
sensor.

Maintenance - Customer Service Section
GENO®UV systems with GENO®-Multi BS
-CONFIDENTIAL- Order no. 034 523 950-gb Edited by: KONS-mhug-mrie G:\BA-523950-GB_KD-H.DOC
H-8
3 | Resetting the operating hours and the switch-on counter
After replacing the lamp, the operating duration and switch-on
counter should be reset:
Reprogramme the code level 189, par. 0…0 to 0…1 
operating duration, switch-on counter and error memory are
deleted.