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Grunbeck AH-300 Operation Manual

Waste water lifting system
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Summary of Contents for Grunbeck AH-300

  • Page 1 We understand water. Waste water lifting system | AH-300 Operation manual...
  • Page 2 General Contact Germany International Sales +49 9074 41-145 Service +49 9074 41-333 service@gruenbeck.de Availability Monday to Thursday 7:00 am - 6:00 pm Friday 7:00 am - 4:00 pm We reserve the right to technical modifications. © by Grünbeck Wasseraufbereitung GmbH Original operation manual Edition: April 2022 Order no.: 100164650000_en_075...

  • Page 3: Table Of Contents

    Table of contents Table of contents Checking the product ..... 30 Introduction ........4 Handing over the product to the owner/operator/operating company..31 Validity of the manual ...... 4 Other applicable documents .... 4 Product identification ....... 5 Operation and handling ....32 Symbols used ........

  • Page 4: Introduction

    Illustrations in this manual are for basic understanding and can differ from the actual design. 1.1 Validity of the manual This manual applies to the product below: ● Waste water lifting system AH-300 1.2 Other applicable documents ● Instructions of optional accessories 4 | 56...

  • Page 5: Product Identification

    Introduction 1.3 Product identification You can identify your product based on the product designation and the order no. indicated on the type plate. ► Check whether the products indicated in chapter 1.1 corres- pond to your product. The type plate is located on the collection box. Designation Designation Product designation...

  • Page 6: Symbols Used

    Introduction 1.4 Symbols used Symbol Meaning Danger and risk Important information or requirement Useful information or tip Written documentation required Reference to further documents Work that must be carried out by qualified specialists only Work that must be carried out by qualified electricians only Work that must be carried out by technical service personnel only 1.5 Depiction of warnings This manual contains information and instructions that you must...

  • Page 7: Demands On Personnel

    Introduction Warning symbol and Consequences if the information/ signal word instructions are ignored DANGER Death or serious injuries Personal WARNING Possible death or serious injuries injury CAUTION Possible moderate or minor injuries Possible damage to components, the Damage to NOTE product and/or its functions, or an ob- property ject in its vicinity...
  • Page 8 Introduction Personnel Requirements • Extended product-specific expertise Technical service (Grünbeck's technical • Trained by Grünbeck service/authorised ser- vice company) 1.6.2 Authorisations of personnel The table below describes which tasks may be carried out by whom. User Owner/ Qualified Technical operator/ specialist service operating...

  • Page 9: Safety

    Safety Safety 2.1 Safety measures ● Obey the local regulations on accident prevention and occu- pational safety. ● Obey the following regulations on the treatment and discharge of condensate originating from condensing boilers into the public sewer system: • Work sheet DWA-A 251:2011 "Condensates from con- densing boilers"...
  • Page 10 Safety ● Only operate your product if all components are installed pro- perly. ● Do not make any changes, alterations or extensions on your product. ● Only use genuine spare parts for maintenance or repair. ● Keep the premises locked against unauthorised access to protect imperilled or untrained persons from residual risks.

  • Page 11: Product-Specific Safety Instructions

    Safety Cleaning/Disposal ● Immediately absorb leaked and non-neutralised condensate with disposable towels. ● Dispose of the absorbed condensate with residual waste in an environmentally sound manner. 2.1.4 Groups of persons requiring protection ● This product is not designed to be used by persons (including children) with reduced capabilities, lack of experience or lack of knowledge.

  • Page 12: Conduct In Emergencies

    Safety The affixed information and pictograms must be clearly legible. They must not be removed, soiled or painted over. ► Obey all warnings and safety instructions. ► Immediately replace illegible or damaged symbols and picto- grams. 2.3 Conduct in emergencies 2.3.1 In case of water leaks 1.

  • Page 13: Product Description

    Clear water or slightly polluted industrial water ● The waste water lifting system AH-300 is suitable for continuous operation. ● The waste water lifting system AH-300 is not suitable for the media below: • Salt water (e.g. from water softeners) •...

  • Page 14: Product Components

    Product description 3.2 Product components Designation Designation Hose connection DN 20 Overflow warning switch (alternative) Level switch Locknut with flat seal Electrical connection box Filter cage Non-return valve with flat seal Collection box Hose nipple DN 12 with flat seal Connection DN 25 (inlet) Delivery pump 14 | 56...

  • Page 15: Functional Description

    Product description 3.3 Functional description The condensate flows into the collection box of the waste water lif- ting system and is pumped to the drain by means of the level-con- trolled delivery pump. The delivery pump is a robust, seal-less centrifugal pump with the shaft being mounted in the motor, which is only immersed into the medium with the corrosion-resistant pumping unit.

  • Page 16: Accessories

    Product description of about 120 mm and is switched off again at a level of about 95 The optional alarm delay (refer to chapter 3.4) for connection to the overflow warning switch allows the heat generator to be switched off either in parallel with the fault signal, or with a time delay.

  • Page 17: Transport, Set-Up And Storage

    Transport, set-up and storage Transport, set-up and storage 4.1 Shipping/Delivery/Packaging The product is packed in a cardboard box at the factory. ► Upon receipt, immediately check for completeness and trans- port damage. 4.2 Transport/Set-up ► Transport the product in its original packaging only. ►...

  • Page 18: Installation

    The installation of the product must be carried out by a qualified specialist only. Installation example Designation Designation Heat generator with siphon Connecting hose Waste water lifting system Inlet hose AH-300 Neutralisation system Drain connection GENO-Neutra N-210 18 | 56...

  • Page 19: Requirements For The Installation Site

    Installation 5.1 Requirements for the installation site Obey the local installation directives, general guidelines and techni- cal specifications. ● Protection from frost, severe heat exposure and direct sun- light ● Protection from high radiation temperatures in the immediate vicinity (≤ 40 °C) ●...

  • Page 20: Checking The Scope Of Supply

    Installation 5.2 Checking the scope of supply Designation Designation Waste water lifting system Outlet hose, 6 m in length AH-300 as compact system (DN 12) (pre-assembled) 1 Hose clamp (12–20) Overflow warning switch 2 Hose clamps (20–32) Hose connection DN 25 with...

  • Page 21: Water Installation

    Installation 5.3 Water installation 5.3.1 Setting up the waste water lifting system Select an installation site where the inlet and outlet hoses can be kept as short as possible. Designation Designation Outlet connection of Inlet connection of waste water neutralisation system lifting system ►...
  • Page 22 Installation 5.3.2 Connecting the waste water lifting system 5.3.2.1 Installing the inlet connection Determine which connection diameter, DN 20 or DN 25, is required – depending on the inlet hose of the neutralisation system. The hose delivered with the neutralisation system can be used as inlet hose.
  • Page 23 Installation 1. Shorten the inlet hose to the required length. 2. Connect the inlet hose to the neutralisation system. 3. Fix the inlet hose by means of the hose clamp. 4. Secure the inlet hose against mechanical damage, if neces- sary.
  • Page 24 Installation Comply with the following when connecting the outlet hose to the drain connection: ● The drain connection must at least have a nominal diameter of DN 40. The drain connection must allow for backflow-free discharge. ● The outlet hose must not be connected directly to the drain pipe in order to prevent a retroactive bacterial contamination from the drain to the system.

  • Page 25: Electrical Installation

    Installation 5.4 Electrical installation The electrical installation must be carried out by a qualified electri- cian only. Life-threatening voltage on the terminal connec- DANGER tions in the electrical connection box ● Severe burns, cardiovascular failure, fatal electric shock ► Only have qualified electrics carry out electrical work on the product.
  • Page 26 Installation The mains cable and the delivery pump are pre-wired in the electri- cal connection box at the factory. Terminal connections of overflow warning switch If required, you can connect the overflow warning switch with vol- tage-free changeover contact for external fault signalling or swit- ching off the heat generator The overflow warning switch switches at a level of about 120 mm and is switched off again at a level of about 95 mm.
  • Page 27 Installation Terminal connections of GENO-alarm delay relay Designation Terminal box provided by the client on site Mains cable 230 V/50 Hz Overflow warning switch Display Brimful (250 V~ / max. 6 A resistive load) GENO-alarm delay relay (accessories) Connections to switch off the boiler: 15 = Common root 16 = Opens in the event of an alarm 18 = Closes in the event of an alarm...
  • Page 28 Installation Obey the mounting instructions of the accessory GENO-alarm delay relay (refer to chapter 3.4). The optional alarm delay for connection to the overflow warning switch allows the heat generator to be switched off either in parallel with the fault signal, or with a time delay. 28 | 56...

  • Page 29: Start-Up/Commissioning

    Start-up/commissioning Start-up/commissioning The initial start-up/commissioning of the product must be carried out by technical service personnel only. WARNING Acidic condensate ● Chemical burns of eyes and body parts ► Use personal protective equipment (refer to chapter 1.6.3). ► Avoid any skin and eye contact with the condensate. ►...

  • Page 30: Checking The Product

    Start-up/commissioning 6.1 Checking the product Designation Designation Level switch Overflow warning switch 1. Check the inlet and outlet hoses for leaks. 2. Check the entire installation for leaks. 3. Check the level switch and the optional overflow warning switch for function. ►...

  • Page 31: Handing Over The Product To The Owner/Operator/Operating Company

    Start-up/commissioning 6. Record the start-up/commissioning in the operation log (refer to chapter 13). 6.2 Handing over the product to the owner/operator/operating company ► Explain to the owner/operator/operating company how the product works. ► Use the manual to brief the owner/operator/operating com- pany and answer any questions.

  • Page 32: Operation And Handling

    Operation and handling Operation and handling The product is operated automatically and does not require any ma- nual operation. WARNING Acidic condensate ● Chemical burns of eyes and body parts ► Use personal protective equipment (refer to chapter 1.6.3). ► Avoid any skin and eye contact with the condensate. ►...

  • Page 33: Maintenance And Repair

    Maintenance and repair Maintenance and repair Maintenance and repair includes cleaning, inspection and mainte- nance of the product. The responsibility for inspection and maintenance is subject to local and national requirements. The owner/operator/operating company is responsible for compliance with the prescribed maintenance and repair work.

  • Page 34: Intervals

    Maintenance and repair 8.2 Intervals By way of regular inspections and maintenance, malfunctions can be detected in time and product failures might be prevented. ► As owner/operator/operating company determine which com- ponents must be inspected and maintained at which intervals (load-dependent).

  • Page 35: Inspection

    Maintenance and repair 8.3 Inspection You as owner/operator/operating company can do the regular in- spections yourself. Initially, we recommend inspecting the product at shorter intervals and later on as required, but at least every 6 mon- ths. ► Use personal protective equipment (refer to chapter 1.6.3). ►...
  • Page 36 Maintenance and repair 5. Check the fastening of the inlet hose and the outlet hose for a tight fit. 6. Close the lid of the system. 7. Plug the mains plug into the socket. 8. Check the level switch and the overflow warning switch for a proper fit.

  • Page 37: Maintenance

    Maintenance and repair 8.4 Maintenance Regular work is required in order to ensure the proper functioning of the product in the long term. Maintenance must be carried out at regular intervals depending on the volume and the contamination of the condensate, but at least once a year.
  • Page 38 Maintenance and repair 1. Stop the inflow of condensate or divert it into a suitable collec- tion vessel. 2. Unplug the mains plug. 3. Pull the overflow warning switch from the lid or de-energise the overflow warning switch. 4. Make sure that the system is de-energised. 8.4.1.2 Cleaning the components Designation Designation...
  • Page 39 Maintenance and repair 3. Remove the non-return valve and clean it - replace it, if ne- cessary. 4. Open the lid of the system. 5. Clean the filter cage – replace it, if needed. 6. Clean the collection box, if necessary. 8.4.1.3 Cleaning the delivery pump The delivery pump is maintenance-free when used as intended.
  • Page 40 Maintenance and repair Designation Designation Seal (O-ring) Cover Screws Impeller a Remove the cover of the impeller. b Clean the inside of the impeller and the cover. c Carefully clean the sealing surfaces. d Properly put on the cover again with the seal in place – pressure chamber above pressure socket.
  • Page 41 Maintenance and repair NOTE The cover must be mounted tightly ● Leaks at the cover of the impeller result in a reduction of the delivery pump’s capacity. ● Large amounts of leakage directed into the collection box overload the pump’s motor and result in a pump failure. ►...

  • Page 42: Spare Parts

    Maintenance and repair 10. Check the delivery pump for function and check the delivery rate by gauging. 11. Check the function of the overflow warning switch for emis- sion of a fault signal. 12. Put the system into operation. 13. Record the maintenance carried out in the operation log (refer to chapter 13).

  • Page 43: Troubleshooting

    Troubleshooting Troubleshooting WARNING Delivery pump overloaded ● Risk of burns on hot surfaces ● Overheating of pump motor and failure of delivery pump ● If the protective temperature limiter responds, this means that there is an irregularity that overloads and overheats the pump motor.
  • Page 44 Troubleshooting Observation Explanation Remedy ► Check the delivery The condensate inflow exceeds the system rate of the delivery capacity pump by gauging ► Install a larger or an additional waste wa- ter lifting system, if necessary ► Check the delivery Delivery head at the out- let is too high rate and/or the...

  • Page 45: Decommissioning

    Decommissioning 10 Decommissioning If a longer period of standstill is planned for the heat generator and the neutralisation system, the waste water lifting system must be de- commissioned. 10.1 Temporary standstill If the heat generator and the neutralisation system are to be swit- ched off temporarily (e.g.

  • Page 46: Dismantling And Disposal

    Dismantling and disposal 11 Dismantling and disposal 11.1 Dismantling ► Have this work carried out by qualified specialists only. 1. Make sure that the heat generator is out of operation and no condensate is produced by the neutralisation system. 2. Unplug the mains plug. 3.

  • Page 47: Disposal

    Dismantling and disposal 11.2 Disposal ► Obey the applicable national regulations. Packaging ► Dispose of the packaging in an environmentally sound manner. NOTE Danger to the environment due to incorrect disposal ● Packaging materials are valuable raw materials that can be reused in many cases.

  • Page 48: Technical Specifications

    Technical specifications 12 Technical specifications Dimensions and weights AH-300 Width Height Length Inlet connection Total length with connections Height of switch-on/switch-off level of delivery 80/55 pump (condensate backwater height in normal operation) Height of switching point/reset point of over- 120/95...
  • Page 49 Technical specifications Connection data AH-300 Nominal connection diameter of inlet DN 20/DN 25 Nominal connection diameter of outlet hose to DN 12 drain ≥ DN 40 Drain connection provided by the client on site ≥ 41.5 with delivery rate l/min...
  • Page 50 Technical specifications Characteristic curve of delivery pump Designation Designation Delivery head in m Delivery rate in l/min Note: Pump capacity at a hose length of 6 m (line extensions and reduc- tions in the cross sections of the outlet hose cause a decrease in performance).

  • Page 51: Operation Log

    Operation log 13 Operation log ► Document the initial start-up/commissioning and all mainte- nance activities. Waste water lifting system AH-300 Serial no.: ________________ 13.1 Start-up/commissioning log Customer Name Address Installation/Accessories ☐ Yes ☐ No Neutralisation system Type of neutralisation system...
  • Page 52 Operation log Remarks Start-up/commissioning Company Service technician Work time certificate (no.) Date/signature 52 | 56...
  • Page 53 Operation log Maintenance no.___ Work performed Inspection Maintenance Repair Activities ☐ cleaned ☐ replaced Non-return valve ☐ cleaned ☐ replaced Inlet hose ☐ cleaned ☐ replaced Delivery pump ☐ cleaned ☐ replaced Filter cage on the delivery pump ☐ done Check level switch and overflow warning switch for a proper fit ☐...
  • Page 54 EU guidelines in terms of its design, construction and execution. This certificate becomes void if the system is modified in any way not approved by us. Waste water lifting system AH-300 Serial no.: Refer to type plate The aforementioned system also complies with the following directives and provisions: •...
  • Page 55 Publisher's information Technical documentation Should you have any questions or suggestions regarding this operation manual, please contact Grünbeck Wasseraufberei- tung GmbH’s Department for Technical Documentation di- rectly. Email: dokumentation@gruenbeck.de...
  • Page 56 Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str. 1 89420 Hoechstaedt/Germany +49 9074 41-0 +49 9074 41-100 info@gruenbeck.com For more information go to www.gruenbeck.com www.gruenbeck.com...

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