Edition: March 2015 Order no inter. Operation Manual Partial flow filter GENO -VARIO 3000 Software version V2.

Transcription

1 Edition: March 2015 Order no inter Operation Manual Partial flow filter Software version V2.7 with touch panel

2 Table of contents A General Preface How to use this operation manual General safety information Symbols and notes Operating personnel Intended use Protection against water damage Indication of specific dangers Shipping and storage Disposal of used parts and materials... 8 B Basic information Laws, regulations, standards Function Filtration Ion exchange Automatic/manual make-up water feed (optional) C Product description Type designation plate Functional description Technical specifications Intended use Scope of supply Standard equipment Optional accessories Consumables Spare parts Wearing parts D Installation General installation instructions Electrical installation Preliminary work How to connect the partial flow filter system Connection of analogue pressure sensor to with touch panel E Start-up How to set the partial flow filter system How to set the hardness How to set the control unit How to start up the F Operation of the with touch panel How to operate the touch panel Help contents Common help Standard display Help regarding standard display Parameter circulation pump Parameter ball valves Parameter automatic 3-way valve Operation of sand filter module Step times of sand filter module Operation of softening module Step times of softening module Main settings Help regarding main settings System time Help regarding system time Operation of dosing Help regarding operation of dosing Make-up water feed mode Hand-operated make-up water feed Help regarding hand-operated make-up water feed Message window Help regarding message window User log-in ECO mode G Troubleshooting Introduction Troubleshooting H Maintenance and care Basic information Inspection (functional check) How to refill salt Maintenance Operation log Operation log

3 Publisher's information 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 only with explicit written approval of Grünbeck Wasseraufbereitung GmbH. Any type of duplication not authorised by Grünbeck Wasseraufbereitung is a copyright violation and subject to legal action. Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str Hoechstaedt/Germany Tel. +49 (0) Fax +49 (0) service@gruenbeck.de Print: Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str. 1, Hoechstaedt/Germany 3

4 EC Declaration of Conformity This is to certify that the system designated below meets the safety and health requirements of the applicable European guidelines in terms of its design, construction and execution. If the system is modified in a way not approved by us, this certificate is void. Manufacturer: Responsible for documentation: System designation: Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str Hoechstaedt/Germany Markus Pöpperl Partial flow filter System type: System number: Applicable EC guidelines: Applied harmonised standards, in particular: Applied national standards and technical specifications, in particular: Refer to type designation plate EMC Directive 2004/108/EU) Low Voltage Directive (2006/95/EG) RoHs (2011/65/EU) DIN EN , DIN EN , DIN EN st Ordinance on Equipment and Product Safety Law (Ordinance concerning the Marketing of Electrical Equipment for Use within Specific Voltage Limits - 1. GPSGV). Date / Manufacturer s signature: 29/01/2015 p.p. Markus Pöpperl Dipl. Ing. (FH) Function of signatory: Head of Department for Product Implementation and Product Launch 4

5 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 system with the required care. This operation manual assists you with important information. Therefore, please read the entire operation manual before installing, operating or maintaining the system. Customer satisfaction is our prime objective and providing customers with qualified advice is crucial. If you have any questions concerning this system, possible extensions or general water and waste water treatment, our field staff, as well as the experts at our headquarters in Hoechstaedt, are available to help you. Advice and assistance For advice and assistance please contact your local representative (see In case of emergency, please get in touch with our service hotline at We can connect you with the appropriate expert more quickly if you provide the required system data. In order to have this information handy at all times, please copy the data indicated on the type designation plate to the table in chapter C-1, paragraph 1. 2 How to use this operation manual This operation manual is intended for the operators of our systems. It is divided into several chapters, which are listed in the Table of contents on page 2 in alphabetical order. 5

6 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. Attention! 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 technical service/authorised service company or by persons expressly authorised by Grünbeck. Tasks with this symbol may only be performed by trained and qualified 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 supply companies or approved installation companies. In Germany, the installation company must be registered in an installation directory of a water supply company as per 12(2) AVBWasserV (German Ordinance on General Conditions for the Supply of Water). 3.2 Operating personnel Only persons who have read and understood this operation manual are permitted to work with the system. The safety guidelines in particular 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 drinking water protection, accident prevention and occupational safety must be adhered to. In addition, intended use also implies that the system may only be operated when it is in proper working order. Any malfunctions must be repaired at once. 6

7 3.4 Protection against water damage Warning! In order to protect the installation site from water damage, a sufficiently dimensioned floor drain must be available. Warning! Floor drains leading to a lifting system do not work in case of a power failure. 3.5 Indication of specific dangers Note: 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 replace damaged cables immediately. Danger due to mechanical energy! System parts may be subject to overpressure. Danger of injury 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! Arrange for the system to be installed and operated by a specialist company. The operation manual must be strictly adhered to! Ensure that there is sufficient 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! Specific dangers! By concluding a maintenance contract, you ensure that all of the required tasks are performed on time. You may perform the interim inspections yourself. 7

8 4 Shipping and storage Attention! The system may be damaged by frost or high temperatures. 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 packing. Ensure that it is handled with care and placed the right side up (as indicated on the packing). 5 Disposal of used parts and materials Used parts and materials are to be disposed of, or made available for recycling purposes, according to the applicable local guidelines. If a material is subject to specific regulations, adhere to the instructions indicated on the packing. If in doubt, contact your local waste disposal authority or the manufacturer for more information. 8

9 B Basic information 1 Laws, regulations, standards Treatment of the filling and make-up water for warm water heating systems according to VDI guideline 2035 as well as for hot and warm water heating systems (industrial and remote heating networks) according to VdTÜV guideline Tch 1466 respectively AGFW work sheet FW 510. Proper application, interpretation and execution provided, these ensure corrosion safety and prevention of furring. Our recommendations in excess thereof are based on our long-time experience in water treatment, taking into consideration the VDI and VdTÜV guidelines. 2 Function The partial flow filter is designed for the continuous improvement of the heating circulation water of closed heating or cooling networks. The circulation water is treated in two steps: First of all, the sand filter module removes all insoluble elements such as scale, rust or dirt particles. Then, the ion exchanger system installed downstream completely softens the water and generates a water quality complying with the applicable guidelines VDI 2035 and AGFW 510 (VdTÜV 1466) without the need for a replacement of the system content. The built-in circulation pump ensures the simple hydraulic integration. At the same time, the make-up water may also be treated by means of the partial flow filter system. The fully automatic control unit monitors all system functions: The differential pressure-controlled backwash of the filter stage with drinking water (no water loss in the heating circuit!), the regeneration of the softening module and the fully automatic make-up water feed (optional). Consequently, during the entire cleaning cycle, neither the filter material nor the ion exchanger resin needs to be replaced and the operating costs and the maintenance efforts are reduced. 9

10 3 Filtration 4 Ion exchange The sand filter module is flown through from top to bottom - through the various filter layers. This way, the heating water is filtered and various solid substances such as corrosion particles and calcareous elements are removed. Afterwards, the hardness formers are removed from the treated heating water by means of the softening module and the treated water is then fed into the heating circuit again. During the backwash process, the filter layers are thoroughly flushed from bottom to top and thereby loosened up in order to wash out particles retained during the depth filtration via the drain outlet at the control valve. Program sequence: Release via differential pressure switch or by hand or via time Circulation pump switches off Ball valve at system outlet closes 3-way valve switches to raw water Control valve of sand filter module switches to backwash Raw water ball valve opens After completion of the backwash and subsequent first filtrate, the system fittings inversely switch the partial flow filter to operation again The exchange of calcium and magnesium ions for sodium ions causes the water to become soft. Principle The hard raw water flows through an exchanger. This tank is filled with an ion exchanger resin, to which sodium ions are bonded (see fig. B-1). Since the bonding positions at the ion exchanger resin prefer calcium and magnesium ions to sodium ions, these ions are retained while the ion exchanger resin discharges sodium ions into the water (exchange reaction). This way, all substances causing hardness remain in the exchanger. Soft water loaded with sodium ions leaves the exchanger (fig. B-2). This process continues until the sodium ions are used up. 10

11 The exchange reaction can be reversed if a large amount of sodium ions (salt solution = brine) is added (fig. B-3). By their sheer number, the sodium ions displace the calcium and magnesium ions at the docking positions of the ion exchanger resin. This process restores the initial state. The ion exchanger resin is regenerated and is ready for softening once again. Program sequence: Release via volume (contact water meter), by hand or via time Circulation pump switches off Ball valve at system outlet closes 3-way valve switches to raw water Control valve of softening module switches to backwash Raw water ball valve opens After the regeneration steps backwash, salting, slow rinse, washing out and fill brine tank, the system fittings inversely switch the partial flow filter system to operation again Hard water Brine Resin Resin Resin Soft water Waste water Fig. B-1: Initial position Fig. B-2: Operation Fig. B-3: Regeneration Sodium ions Calcium ions Magnesium ions 11

12 5 Automatic/manual make-up water feed (optional) Due to small leakages, steam diffusion at sealing points, bleeding processes or after repair and retrofitting work, water losses may occur in the heating circuit. This water loss must be made up for by adding water of appropriate quality to the heating circuit again. A module for an automatic make-up water feed is available as an option. The pressure transducer (switching points min./max.) which is installed in the return provided by others and which can be adjusted at the control unit, signals if there is too little pressure available in the return. During manual make-up water feed, the following program sequence is started manually via the control unit. Program sequence: Circulation pump switches off 3-way valve switches to raw water Raw water ball valve opens The set water volume (adapt to system volume on site) is made up After completion of the make-up water feed, the system fittings inversely switch the partial flow filter to operation again After a set time, the pressure transducer will be called up again. If the pressure in the heating return once again is below the set pressure, another make-up water feed process will start. Note: If the water volume in the heating return is not attained after a set time, the make-up water feed mode will be aborted. By setting a maximum make-up water feed volume (subject to the system volume), the unintentional make-up water feed in case of leakages can be prevented. 12

13 C Product description 1 Type designation plate In order to speed up the processing of your inquiries or orders, please specify the data shown on the type designation plate (fig. C-1) of your partial flow filter when contacting Grünbeck. Please add the serial number to the table below in order to have the required data handy at all times. Partial flow filter Serial number: Order number: Fig. C-1: Type designation plate of partial flow filter 13

14 2 Functional description Differential pressure switch: Adjustable differential pressure switch to monitor the pressure gradient above the sand filter module. Setting range bar - releases the automatic backwash of the sand filter module. Euro system separator: Euro system separator, BA design - prevents back-flow, backpressure and back-suction of modified water into the drinking water (protection up to danger class 4 according to DIN EN 1717). Automatic 3-way valve: Switches from heating circulation operation to raw water during regeneration, backwash or make-up water feed. Softening module: Softens the heating circulation water to < 0.1 dh by way of the ion exchanger principle. Automatic regeneration via treated volume or time (freely adjustable, recommendation: 30 days). Sand filter module: For the filtration of particles in the heating circulation water by means of depth filtration - three gravel layers. Automatic backwash after differential pressure measurement or via time (freely adjustable, recommendation: 14 days). Brine tank: To store regeneration salt as per DIN EN 978 for the automatic regeneration of the softening module. Drinking water filter BOXER KD incl. pressure reducer: 80 µm prefiltration of the raw water to prevent malfunctions during backwash/regeneration. Ball-type inlet valve for raw water raw water connection 1 water meter screw connection: Opens after the 3-way valve (item 3) of the sand filter module or the softening module received a raw water request. Ball-type shut-off valve with motor drive and integrated manual override to shut off the partial flow filter. 14

15 Type designation plate: Filtrate connection outlet to the heating circuit 1 water meter screw connection. Control unit: To operate the partial flow filter system via touch panel. System wiring as well as electrical connections for external use completely integrated in switch cabinet. Ball-type shut-off valve with motor drive and integrated manual override to shut off the partial flow filter. Shock-proof socket: To supply the optional dosing pump (continuous voltage) with power. Waste water connection: Central connection for occurring waste water. Inlet connection from heating circuit - including ball-type shut-off valve - 1 flat seal Circulation pump: For circulation via the partial flow filter system. Pressure switch: Circulation pump de-energised in case of low pressure. Contact water meter: To register the volume flown-through to regenerate the softening module volume-dependently or in case of make-up water feed mode. Deaeration: On outlet side, on sand filter module and softening module. 15

16 Fig. C-2: Exploded drawing of 3 Technical specifications All system data for the partial flow filter are summarised on the reverse in table C-1. Possible deviations in case of special versions are communicated separately, if applicable. Attention! Electrically operated valves. In case of a power failure during the regeneration, water may flow into the drain or brine tank. In case of a power failure, check the partial flow filter system and shut-off the water supply, if necessary. 16

17 Table C-1: Technical specifications Partial flow filter Connection data Inlet connection from heating circuit DN 25 (1" male thread) Filtrate connection to heating circuit DN 25 (1" male thread) Connection raw water inlet DN 25 (1" male thread) Power supply [V/Hz] 230 / 50 General performance data Nominal pressure PN 10 Nominal flow [m³/h] 2.5 Min./max. operating pressure of heating circuit [bar] 2.0 / 6.0 Min./max. operating pressure of raw water [bar] 2.0 / 8.0 Pump capacity [kw] 0.5 Performance data of softening module Nominal capacity [mol] [ dh x m³] 26.8 [150] Duration of regeneration [min.] 94 Resin quantity [l] 44 Salt consumption per regeneration, approx. [kg] 6.2 Max. capacity of brine tank [kg] 50 Total waste water volume per regeneration, approx. [l] 150 Max. backwash capacity [m³/h] 0.55 Performance data of sand filter module Quartz gravel I [kg] 6 Quartz gravel II [kg] 22 Quartz gravel III [kg] 22 Max. backwash capacity [m³/h] 2.3 Total waste water volume per backwash [m³] 0.61 Dimensions and weights A Total width [mm] 990 B Total height [mm] 1714 C Total depth [mm] 765 D Height of foundation [mm] 106 E Inlet connection from heating system [mm] 263 F Waste water connection [mm] 560 G Raw water connection [mm] 1012 H Filtrate connection to heating system [mm] 1237 I Distance waste water connection, raw water [mm] 113 connection, filtrate connection to heating J Distance inlet connection from heating [mm] 145 Weight upon delivery [kg] 132 Ambient data Max. water temperature [ C] 80 Max. ambient temperature [ C] 40 Order no

18 Fig. C-3: Dimensional drawing of 4 Intended use The partial flow filter is designed for the continuous improvement of the heating circulation water of closed heating or cooling networks. The ambient temperature as well as the radiation temperature next to the system must not exceed 40 C. The partial flow filter system may only be operated if all components are installed properly. Safety devices must NEVER be removed, bridged or otherwise tampered with. Appropriate use of the device also implies that the information contained in this operation manual and all safety guidelines applying at the installation site be observed. Furthermore, the maintenance and inspection intervals have to be observed. 18

19 5 Scope of supply 5.1 Standard equipment High-quality system rack made of anodised aluminium to house all system components of the partial flow filter Drinking water filter BOXER KD 80 µm to filter the raw water Pipes made of stainless steel press system with built-in control valves, collective waste water pipe made of plastic Euro system separator, BA design, to secure the raw water/ heating water according to EN 1717 Sand filter module, softening module consisting of stainless steel pressure tanks incl. control valves Operation manual 5.2 Optional accessories Note: It is possible to retrofit existing partial flow filter systems with optional components. Please contact your local Grünbeck representative or Grünbeck s headquarters in Hoechstaedt for more information. Optional module for automatic make-up water feed of partial flow filter. Order no Pressure transducer (0-10 bar - ¼ male thread) made of stainless steel with 5 m of cable for installation into the heating circuit by others on site - electrical connection to the switch box of the partial flow filter. Dosing system for selective increase of the ph value to the optimum value of 9.3. Analysis case (ph, conductivity, determination of raw water hardness, determination of hardness B). Please inquire Water sample cooler

20 5.3 Consumables In order to ensure the reliable operation of the partial flow filter, only use genuine consumables. Order no. Regeneration salt 25 kg bag Water test kit Determination of hardness type B (approx. 100 analyses) Calibrating solution ph Calibrating solution ph Calibrating solution for conductivity Spare parts You may order spare parts and consumables from your local Grünbeck representative (see 20

21 5.5 Wearing parts Note: In case of heavy duty, seals and control pistons are subject to a certain wear and tear. Wearing parts are listed below. Although these parts are wearing parts, we grant a limited warranty period of 6 months. The same applies for electrical components. a) Seals, control piston, injector, actuator b) Flat seals, non-return valve Fig. C-4: Control valve Nominal connection diameter DN 25 Fig. C-5: Brine valve c) Floating ring seal Fig. C-6: Circulation pump For wearing parts of the Euro system separator, BA design, and drinking water filter BOXER KD, please refer to attached operation manuals. 21

22 D Installation 1 General installation instructions The installation site must provide adequate space. A foundation of a sufficient size and adequate load carrying capacity has to be provided. The required connections must be provided prior to the installation of the system. For dimensions and connection data, please refer to table C-1. Note: For the installation of partial flow filter systems with optional accessories (refer to chapter C, item 4.2), also observe the operating manuals supplied with these components. 1.1 Electrical installation 2 Preliminary work A shock-proof plug is adequate for the electrical connection. However, it must comply with the specifications given in table C- 1, may not be further away from the partial flow filter than 3 m and must carry continuous voltage (do not couple with light switch)! 1. Transport the partial flow filter to the intended installation site. 2. Unpack all components of the partial flow filter system. 3. Check for completeness and soundness. 22

23 3 How to connect the partial flow filter system A B A B 1 Return of heating circulation water Raw water Dosing system for conditioning chemical (optional) Fig. D-1: Installation example of 23

24 1. Connect the water supply to the 3 different connections. Inlet connection from heating circuit Filtrate connection to heating circuit Raw water connection Note: For connection diameters, refer to chapter C, item 2 as well as table C Make the waste water connection. Attention! Danger of damage and malfunctions due to waste water backing up. In case of backed-up water, level the partial flow filter system by appropriately adjusting the levelling feed. 3. Connect the mains plug to the socket (refer to chapter D, item 1.2). 4 Connection of analogue pressure sensor to with touch panel Applying the analogue pressure sensor to the terminal strip (refer to the electric circuit diagram of, order no , page 19). Terminal connections: Terminal X2:30 white Terminal X2:33 brown Terminal X2:34 green 24

25 E Start-up The work described below may only be performed by trained experts. We recommend having Grünbeck s technical service/ authorised service company start up the system. 1. Remove the lid from the brine tank. 2. Carefully fill in water until the water level is about 30 mm above the sieve bottom. Attention! Impurities in the salt may cause malfunctions at the brine valve and at the injector of the control valve. For the reliable function of the partial flow filter system, a salt quality with defined properties is required. Only use salt tablets as per DIN EN 973 A. 3. Put the salt tablets into the brine tank. You may completely fill the brine tank with tablets. 4. Fill in the operating water volume (22 litres). 5. Close the lid of the brine tank. 1 How to set the partial flow filter system 1.1 How to set the hardness 1.2 How to set the control unit The hardness needs to be set at the partial flow filter GENO - VARIO To do so, check the hardness of the water to be treated as well as the raw water hardness of the raw water for the make-up water feed. 1. Enter the hardness at the control unit (refer to chapter F, item 12). 2. Set the backwash interval (refer to chapter F, item 8). 3. Set the regeneration interval (refer to chapter F, item 10). In case of optional automatic make-up water feed: 4. Set the maximum make-up water feed volume (refer to chapter F, item 15). 5. Set the hysteresis for the make-up water feed (refer to chapter F, item 15). 6. Set the start/stop pressure of the pressure transducer. Observe the system pressure! (refer to chapter F, item 15). 25

26 2 How to start up the 1. Open the raw water inlet at the connection inlet of heating circuit. 2. Perform a visual check. Make sure that no water leaks from the partial flow filter system at any point. 3. Switch on the control unit at the main switch and start up the partial flow filter (refer to chapter F, item 1). 4. Take a water sample at the sampling valve downstream of the partial flow filter system. 5. Determine the hardness by means of the water test kit Total hardness". The partial flow filter system is working properly if the analysis of the water taken directly downstream of the exchanger tank results in 0 dh. 26

27 F Operation of the with touch panel 1 How to operate the touch panel Note: In the following, keys, buttons and fields are described which always have the same function during the operation of the touch panel. Fig. F-1: Key assignment of touch panel, operating elements and display F1 F2 F3 Calling up help function By pressing the F1 key, the help function for the respective operating screen is called up, pressing the F1 key anew closes the help function again. Note: The indication of the software corresponds to the factory-setting. System ON By pressing the F2 key, the system may be switched on, no matter on which screen of the touch panel you are. System OFF By pressing the F3 key, the system may be switched off, no matter on which screen of the touch panel you are. 27

28 F4 Calling up the message window By pressing the F4 key, the message window in which all system and error messages are stored, is called up. Pressing the F4 key anew closes the message window again. In these fields, the set points are entered/emitted. In these fields, values or texts such as current values, control values,... are emitted. Scroll back With this button, you may return to the previous screen. Scroll forward With this button, you may call up additional settings, operator options (if possible). Set the time With this button, you can access the screen where the time is set. Change the language With this button, you may go through the various system languages. Buttons substitute common hardware controls or keys. With these buttons, you can set or control release conditions. Buttons highlighted in grey indicate the state that is currently active. 28

29 2 Help contents Fig. F-2: Screen displayed: Help contents 29

30 3 Common help Fig. F-3: Screen displayed: Common help 30

31 4 Standard display Indicates the current system state, the state of the sand filter module or softening module. The make-up water feed volume will only be indicated if makeup water feed mode is activated in the main settings. Pressure heating circuit will only be indicted if yes was selected for pressure sensor present in the settings of the makeup water feed mode. Fig. F-4: Standard display of touch panel, overview Calling up settings/operation of main settings. Calling up settings/operation of make-up water feed mode Only visible if make-up water feed mode was selected in the main settings. Calling up settings/operation of dosing pump Only visible if yes was selected for dosing present in the main settings. Calling up time window Only visible if yes was selected for ECO mode in the main settings. 31

32 Calling up settings of circulation pump. Calling up settings of automatic 3-way valve. Calling up settings of ball valves. Calling up settings/operation of sand filter module. Calling up settings/operation of softening module. 4.1 Help regarding standard display Fig. F-5: Screen displayed: Help - overview Calling up help contents 32

33 5 Parameter circulation pump 1) 2) 3) Indicates the current settings of the circulation pump (refer to chapter C, item 2, position 14). Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Note: You may modify the following values via Code 113, refer to chapter F, item 18. Note Regarding ECO mode, refer to chapter F, item 19. Fig. F-6: Screen displayed: Circulation pump 33

34 6 Parameter ball valves Indicates the current settings of the ball valve (refer to chapter C, item 2, position 7.1) - raw water inlet. 1) Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Fig. F-7: Screen displayed: Ball valve - raw water inlet Indicates the current settings of the ball valve - outlet (refer to chapter C, item 2, position 9). Fig. F-8: Screen displayed: Ball valve - outlet 34

35 7 Parameter automatic 3-way valve 1) Indicates the current settings of the automatic 3-way valve (refer to chapter C, item 2, position 3). Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Fig. F-9: Screen displayed: Automatic 3-way valve 35

36 8 Operation of sand filter module Indicates the current state of the differential pressure switch (refer to chapter C, item 2, position 1) of the sand filter module (refer to chapter C, item 2, position 5) and the number of backwashes that have already taken place. 1) Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. 2) Note: You may modify the following values via Code 113, refer to chapter F, item 18. Fig. F-10: Screen displayed: Sand filter module Start button to manually release the backwash of the sand filter module (hold the button for 5 seconds). Forward button to switch the next, individual steps of the backwash process (hold the button for 5 seconds; only visible, if backwash program is active). Calling up the settings of the various step times for the backwash program of the sand filter module. 36

37 9 Step times of sand filter module 1) Indicates the current settings of the various step times of the backwash program of the sand filter module (refer to chapter C, item 2, position 5). Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Fig. F-11: Screen displayed: Step times of the sand filter module 37

38 10 Operation of softening module Indicates the current state of the softening module (refer to chapter C, item 2, position 4) and the number of regenerations that have already taken place. 1) Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Fig. F-12: Screen displayed: Operation of softening module Start button to manually release the regeneration of the softening module (hold the button for 5 seconds). Forward button to switch to the next individual steps of the regeneration process (hold button for 5 seconds; only visible if regeneration program is active). Calling up the settings of the various step times for the regeneration program of the softening module. 38

39 11 Step times of softening module 1) Indicates the current settings for the various step times of the regeneration program of the softening module. Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Fig. F-13: Screen displayed: Step times of softening module 39

40 12 Main settings 1) 2) 3) Settings of fundamental functions/parameters of the partial flow filter Note: Modifications can only be made by Grünbeck's technical service/authorised service company or by persons expressly authorised by Grünbeck. Note: You may modify the following values via Code 113, refer to chapter F, item 18. Note: Regarding ECO mode, refer to chapter F, item 19. Fig. F-14: Screen displayed: Main settings 40

41 12.1 Help regarding main settings Fig. F-15: Screen displayed: Help - Main settings Calling up help contents. 41

42 13 System time Setting the time and the date. Fig. F-16: Screen displayed: System time Button to transfer the time to the system Help regarding system time Fig. F-17: Screen displayed: Help - System time Call up help contents 42

43 14 Operation of dosing Indicates the current state of the dosing pump. Setting of the dosing time for one start cycle. off Fig. F-18: Screen displayed: Dosing Start button to start a dosing cycle (hold button for 5 seconds). Stop button to terminate a current dosing cycle (hold button for 5 seconds; only visible if dosing is active) Help regarding operation of dosing Fig. F-19: Screen displayed: Help - Dosing Call up help contents. 43

44 15 Make-up water feed mode This level will only be indicated if the make-up water feed mode is activated in the main settings. The total hardness of the raw water has definitely to be set in order to enable the automatic release of a backwash or a regeneration. Automatic make-up water feed: For automatic make-up water feed with integrated leakage monitoring, the corresponding optional module has to be installed into the heating circuit by others on site and the parameter pressure sensor 0-10 V present has to be changed to yes. Afterwards, the following parameters need to be set as well: Delay start filling Limit value start pressure Limit value stop pressure 2) Limit value filling volume malfunction leakage Note: These values are subject to the respective system and have to be provided by the person in charge/operator of the system. Note: The parameters delay start filling, limit value start pressure, limit value stop pressure, limit value filling volume malfunction leakage are only visible, if for pressure sensor present yes was selected. Note: You may modify the following values via Code 113, refer to chapter F, item

45 Fig. F-20: Screen displayed: Make-up water feed Calling up manual operation of make-up water feed 45

46 16 Hand-operated make-up water feed Indicates the current state of the system as well as the number of make-up water feed processes that have already taken place. Fig. F-21: Screen displayed: Hand-operated make-up water feed Start button to start hand-operated make-up water feed (hold button for 5 seconds). Stop button to terminate hand-operated make-up water feed (hold button for 5 seconds; only visible if make-up water feed is active) Help regarding hand-operated make-up water feed Fig. F-22: Screen displayed: Help Hand-operated make-up water feed Calling up help contents. 46

47 17 Message window Fig. F-23: Screen displayed: Messages Button to acknowledge malfunctions. Calling up additional information on malfunctions (if available) 17.1 Help regarding message window Fig. F-24: Screen displayed: Help - Message window Calling up help contents. 47

48 18 User log-in Operator codes: Code: 113 (installer) Fig. F-25: Screen displayed: User log-in 48

49 19 ECO mode By means of the ECO mode, the operation of the partial flow filter can be set individually for a certain time each weekday. Fig. F-26: Screen displayed: Timer Calling up the settings of the timer for the respective weekday. Fig. F-27: Screen displayed: Timer weekdays Release button to activate or deactivate the timer for the weekday. 49

50 G Troubleshooting 1 Introduction Even carefully designed and manufactured partial flow filters that are operated properly, may experience malfunctions. Table G-1 provides an overview of possible problems that may occur during the operation of the partial flow filter GENO - VARIO 3000 and indicates the possible causes and their elimination. Note: Grünbeck's technical customer service/authorised service company definitely must be notified in case of malfunctions that cannot be remedied with the information given in table G-1! Please indicate designation, order no. and serial number of the partial flow filter when contacting Grünbeck. 50

51 2 Troubleshooting Table G-1: Troubleshooting This is what you observe This is the cause This is what to do Increased hardness in blending or soft water Ion exchanger resin in drain pipe Pressure loss too high Partial flow filter system does not suck in brine a) Partial flow filter system overrun Partial flow filter system does not carry continuous current (coupled with light switch). Partial flow filter system does not suck in brine. No salt in brine tank. Not enough water in brine tank. b) Other causes Water supply interrupted. Water withdrawal too high (higher than peak flow indicated on type designation plate). Not enough salt in brine tank. Defective jet system. Ion exchanger resin or sand filter module polluted by undissolved substances. Water pressure is too low. Injector clogged. Injector sieve clogged. Brine valve clogged. Check power supply and adjust, if necessary. Clean injector; check inlet pressure and adjust if necessary. Refill salt. Check BVO valve and brine valve for impurities and clean, if necessary. Open the shut-off valves. Reduce water withdrawal. Check salt level as per mark and refill, if necessary. Notify Grünbeck s technical customer service/authorised service company. Notify Grünbeck s technical customer service/authorised service company. Increase flow pressure to at least 2.0 bar. Clean injector. Clean injector sieve. Remove brine valve and thoroughly clean it. 51

52 H Maintenance and care 1 Basic information In order to guarantee the reliable function of the partial flow filter over a long period of time, some maintenance work has to be performed at regular intervals. All regulations and guidelines, which apply at the installation site must be strictly adhered to. DIN 806, part 5, stipulates that an inspection must be performed at least every two months. According to DIN EN 806-5, filter and ion exchanger systems routinely require a functional check to be performed by the operator and maintenance to be performed by an authorised customer service company. Maintenance must be performed by the Grünbeck s technical service/authorised service company or by an approved specialist company. An operation log must be kept in order to document the maintenance work performed. Notes: By concluding a maintenance contract you ensure that all maintenance work will be performed in due time. The operation log is attached to this operation manual. 52

53 2 Inspection (functional check) You may perform the regular inspections yourself. We recommend inspecting the partial flow filter at shorter intervals after installation, and later on as required. However, an inspection is compulsory at least every two months. Please refer to the following summary for the tasks to be performed within the framework of an inspection. Summary: Inspection work Determine the raw water hardness. (Water test kit "Total hardness ) Check controller settings: a) System time b) Water hardness of the heating circulation water c) Raw water hardness (when using optional modul for automatic make-up water feed) Check salt level in brine tank. Refill salt, if required (refer to chapter H, item 2.1). Attention! If the salt level falls below the minimum salt filling level, hardness may break through. Observe the minimum salt filling level (refer to chapter C, Technical specifications). Check control valve to drain for tightness (in operating mode). Replace the filter element of the drinking water filter BOXER KD. 53

54 2.1 How to refill salt Warning! Impurities in the salt tank may adversely affect the water quality. For hygienic reason, be very careful when refilling salt. Attention! Insoluble impurities in the salt may cause malfunctions at the brine valve and at the injector of the control valve. For the reliable function of the partial flow filter GENO - VARIO 3000, a salt quality with defined properties is required. Only use salt tablets as per DIN EN 973 type A. A few precautionary measures ensure hygienically and technically perfect conditions: Only store the salt in dry and clean rooms. Do not use salt from bags that are already open. Clean the outside of the bags before opening them. Fill the regeneration salt directly from the bag into the brine tank Close the brine tank immediately after refill. 3 Maintenance According to DIN EN 806, part 5, maintenance work on the partial flow filter may only be performed by Grünbeck s technical service/authorised service company or an approved specialist company. For the partial flow filter as well as for filter systems, an operation log must be kept. In this operation log, the customer service technician records all maintenance and repair work performed. In case of malfunctions, this log helps to identify possible sources of error. In addition, the log documents the proper system maintenance. Note: Make sure that all maintenance work is recorded in the operation log. 54

55 Summary: Maintenance work Read the water pressure, flow pressure and water meter value. Determine the hardness: Raw water hardness, 0 dh ( f, mmol/l) test Align the measured hardness values with settings in the electronics. Check the programming of the control unit. Check the brine regulation (salting, filling of brine tank) and program settings; readjust them, if necessary. Check release of regeneration. Check sand filter module and backwash, if necessary. Check start of contact water meter. Check control valve for tightness, replace wearing seals if necessary, check the proper function of the drive motor of the control valve, clean injector and sieve - typical hydraulic values. Clean brine tank and brine valve. Check regeneration salt supply (quantity and quality). Check hose connections and seals and replace, if necessary. Attention: Danger of water damage! Damaged or worn hose connections may tear. Therefore, DIN EN 806, part 5 recommends checking and if necessary, replacing the flexible connection hoses. Replace the filter element of the drinking water filter BOXER KD. Check the function of the safety fitting (e.g. A Euro system separator, BA design) against back-flow. Check the pressure switch for minimum pressure. Record all data and activities, including repair work, in the operation log. Hand over the partial flow filter and the filled out operation log to the operator. 3.1 Operation log An operating log must be kept to document care, inspection and maintenance work (for the operating log, please see appendix). In case of operational malfunctions, the operation log helps to identify possible sources of error and proves the proper monitoring of the partial flow filter. 55

56 4 Operation log Partial flow filter Order no.: Serial no.: Work performed Care work Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Description: Description: Description: Description: Description: Execution confirmed Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: 56

57 Work performed Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Description: _ Description: _ Description: _ Description: _ Description: _ Execution confirmed Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: 57

58 Work performed Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Description: Description: Description: Description: Description: Execution confirmed Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: 58

59 Work performed Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Care Inspection Maintenance Repair Description: Description: Description: Description: Description: Execution confirmed Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: Company: Name: Date/ Signature: 59