Grunbeck GENO AF-5 Operation Manual
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Grunbeck GENO AF-5 Operation Manual

Activated carbon filter
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Activated carbon filter | GENO AF-5
Operation manual

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Summary of Contents for Grunbeck GENO AF-5

  • Page 1 We understand water. Activated carbon filter | GENO AF-5 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.: 100169310000_en_035...

  • Page 3: Table Of Contents

    Table of contents Table of contents Filling the activated carbon filter Introduction ........5 box ..........29 Checking the product ..... 31 Validity of the manual ...... 5 Handing over the product to the Other applicable documents .... 5 owner/ operator/operating Product identification .......
  • Page 4 Table of contents 13.1 Start-up/commissioning log .... 46 13.2 Maintenance ........47 4 | 52...

  • Page 5: 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: ● Activated carbon filter GENO AF-5 1.2 Other applicable documents ● Instructions of optional accessories ● Maintenance instructions for maintenance kit Order no.

  • Page 6: 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 corre- spond to your product. The type plate is located on the narrow side of the activated carbon filter box.

  • Page 7: 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 8: 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 9 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 10: 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 dis- charge of condensate originating from condensing boilers into the public sewer system: • Work sheet DWA-A 251:2011 "Condensates from con- densing boilers"...
  • Page 11 Safety ● Only operate your product if all components are installed properly. ● 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 12: Conduct In Emergencies

    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 13: Product Description

    DWA-A 251:2011 and DVGW VP 114 up to the speci- fied capacity. 3.1.1 Possible applications ● The activated carbon filter GENO AF-5 can be used as a pre- filter upstream of a neutralisation system. ● Experience has shown that in case of gas/oil switch-over op- eration of a condensing boiler, the higher specific amount of condensate in case of gas (0.14 l/kWh with gas, 0.08 l/kWh...

  • Page 14: Product Components

    Product description 3.2 Product components Designation Designation Cover Hose connection DN 20 (inlet) Snap lock Locknut Activated carbon filter box Angle grommet with seal Hose connection DN 20 (outlet) 14 | 52...

  • Page 15: Functional Description

    Product description 3.3 Functional description Designation Designation Filling area 1 Overflow orifice with granulate filling Settling area in the inlet, with Marking for max. filling height siphon (barrier height approx. 46 mm) Plug Filling area 2 Condensate collection area in without granulate filling the outlet The condensate flows into the settling area of the activated carbon...

  • Page 16: Accessories

    Product description condensate outlet to the drain or to the neutralisation system is clogged. The activated carbon filter can be equipped with an optional over- flow warning switch as level switch (refer to chapter 3.4). When the maximum filling height is reached, a fault signal is triggered. Furthermore, there is the option to increase the filling volume of acti- vated carbon and thus extend the service life of the filter.
  • Page 17 Activated carbon filter filling, 3.5 l 410 590 – Additional activated carbon filling to increase the filling volume Maintenance kit for GENO AF-5 410 824 – 2 l of activated carbon and 1 foil bag to dispose of the used activated carbon...

  • Page 18: 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. The activated carbon is included in a separately packed bag. ► Upon receipt, immediately check for completeness and transport damage. 4.2 Transport/Set-up ►...

  • Page 19: Installation

    Installation Installation The installation of the product must be carried out by a qualified specialist only. Installation example (solo) Designation Designation Heat generator Outlet hose Activated carbon filter Inlet hose GENO AF-5 19 | 52...
  • Page 20 Installation Installation example (upstream of a neutralisation system) Designation Designation Neutralisation system Heat generator GENO-Neutra Inlet hose Outlet hose Connecting hose Activated carbon filter GENO AF-5 20 | 52...

  • Page 21: Requirements For The Installation Site

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

  • Page 22: Checking The Scope Of Supply

    Installation 5.2 Checking the scope of supply Designation Designation Activated carbon filter Hose, 5 m in length (DN 20) (partly pre-assembled) 3 Hose clamps Activated carbon filling Operation manual 1 Angle-type inlet hose connec- tion DN 20 with locknut and seal ►...
  • Page 23 Installation Designation Designation Heat generator Inlet connection ► Set up the activated carbon filter in a horizontal position close to the boiler – but away from traffic routes. Select an installation site where the inlet and outlet hoses can be kept as short as possible.
  • Page 24 Installation 5.3.2 Connecting the activated carbon filter Obey the mounting instructions of the accessory Overflow warning switch (refer to chapter 3.4). Designation Overflow warning switch (optional) 5.3.2.1 Mounting the angle-type hose connection 1. Unlock and open the lid. 2. Install the angle-type hose connection. 24 | 52...
  • Page 25 Installation 3. Insert the seal from the inside and tighten the locknut firmly from the outside. 5.3.2.2 Connecting the inlet and outlet hoses Use the hose supplied with the system to connect the activated car- bon filter. 1. Shorten the hose to the required length for inlet and outlet. 2.
  • Page 26 Installation 7. Secure the outlet hose against mechanical damage, if neces- sary. Do not step on the hose. The end of the outlet hose must be freely visible in order to be able to check the functioning of the activated carbon filter at any time. Should additional hoses and fittings be needed, only approved, cor- rosion-resistant materials according to worksheet DWA-A 251:2011 (e.g.
  • Page 27 Installation ► Fix the outlet hose at the drain connection with a distance of at least 20 mm. ► Make sure that the activated carbon filter box is securely set up and fastened. 5.3.3 Connecting the activated carbon filter to the neutralisa- tion system ►...
  • Page 28 Installation Designation Designation Activated carbon filter Connecting hose Neutralisation system, e.g. GENO-Neutra NO 1. Make a connection hose of the required length. a Make sure that the hose connection is kept as short as possible and that the flow of the condensate is en- sured.

  • 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 Start-up/commissioning 3. Remove the lid and place it safely away from damage. 4. Remove any transport protection from the activated carbon fil- ter box (e.g. cardboard packaging). Designation Designation Activated carbon area Condensate collection area 5. Carefully fill the activated carbon into the chamber for acti- vated carbon.

  • Page 31: Checking The Product

    Start-up/commissioning 6.2 Checking the product 1. Check the inlet and outlet hoses for leaks. 2. Close the activated carbon filter box with the lid. 3. Put the heat generator into operation. 4. Check the entire installation for leaks. 31 | 52...

  • Page 32: Handing Over The Product To The Owner/ Operator/Operating Company

    Start-up/commissioning 5. Check the optional overflow warning switch for function (refer to the instructions of the accessory). 6. Check that the condensate flows freely into the drain or floor drain. In case of installation as a prefilter to the neutralisation system 7.

  • Page 33: Operation

    Operation Operation The product is operated automatically and does not require any manual 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 34: 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 35: 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 36: 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 months. ► Use personal protective equipment (refer to chapter 1.6.3). ►...

  • Page 37: Maintenance

    8.4.1 Annual maintenance Annual maintenance work requires expert knowledge. The work below must be carried out by qualified specialists only. ► Use the maintenance kit for GENO AF-5 (refer to chapter 8.5). Designation Designation Activated carbon, 2 l...
  • Page 38 Maintenance and repair 1. Stop the inflow of condensate or divert it into a suitable collec- tion vessel. 2. Disconnect the overflow warning switch (optional accessory) from the power supply. 3. Open the lid of the activated carbon filter box. 4.

  • Page 39: Consumables

    3.5 l 410 590 Oil binding mats 20 pieces 410 585 Maintenance kit for GENO AF-5 1 kit 410 824 8.6 Spare parts For an overview of the spare parts, refer to our spare parts cata- logue at www.gruenbeck.com. You can order the spare parts from your local Grünbeck representative.

  • Page 40: Troubleshooting

    Troubleshooting Troubleshooting 9.1 Observations Observation Explanation Remedy ► Absorb the oil film Oil residue on the con- Poor combustion in the densate surface condensing boiler using oil binding mats ► Clean the activated carbon filter box more frequently and replace the activated carbon ►...

  • Page 41: Decommissioning

    Decommissioning 10 Decommissioning If a longer period of standstill is planned for the heat generator, the activated carbon filter must be decommissioned. 10.1 Temporary standstill If the heat generator is to be switched off temporarily (e.g. for 3 months in summer), carry out the following activities on the activated carbon filter: 1.

  • Page 42: 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. 2. Remove the condensate from the activated carbon filter box. 3.

  • Page 43: Disposal

    Dismantling and disposal 11.2 Disposal ► Obey the applicable national regulations. Packaging ► Dispose of the packaging in an environmentally sound manner. Danger to the environment due to incorrect dis- NOTE posal ● Packaging materials are valuable raw materials that can be reused in many cases.
  • Page 44 Dismantling and disposal Product If this symbol (crossed-out wheelie bin) is on the product, this prod- uct or its electrical and electronic components must not be dis- posed of as household waste. ► Find out about the local regulations on the separate col- lection of electrical and electronic products.

  • Page 45: Technical Specifications

    Technical specifications 12 Technical specifications Dimensions and weights GENO AF-5 Width Height Length Connection height of inlet and outlet Total length with connections Height of overflow/lower edge Operating weight ~ 10 Empty weight ~ 4.5 Connection data GENO AF-5 Nominal connection diameter of inlet and outlet DN 20 ≥...

  • Page 46: Operation Log

    Operation log 13 Operation log ► Document the initial start-up/commissioning and all mainte- nance activities. Activated carbon filter GENO AF-5 Serial no.: _______________ 13.1 Start-up/commissioning log Customer Name Address Installation/Accessories Manufacturer of condensing boiler Type of condensing boiler Fuel Capacity of condensing boiler...
  • Page 47 Operation log 13.2 Maintenance Work performed ☐ Inspection ☐ Maintenance ☐ Repair Description Execution confirmed Company: Name: Date: Signature: Work performed ☐ Inspection ☐ Maintenance ☐ Repair Description Execution confirmed Company: Name: Date: Signature: 47 | 52...
  • Page 48 Operation log Work performed ☐ Inspection ☐ Maintenance ☐ Repair Description Execution confirmed Company: Name: Date: Signature: Work performed ☐ Inspection ☐ Maintenance ☐ Repair Description Execution confirmed Company: Name: Date: Signature: 48 | 52...
  • Page 49 Operation log Work performed ☐ Inspection ☐ Maintenance ☐ Repair Description Execution confirmed Company: Name: Date: Signature: Work performed ☐ Inspection ☐ Maintenance ☐ Repair Description Execution confirmed Company: Name: Date: Signature: 49 | 52...
  • Page 51 Publisher's information Technical documentation Should you have any questions or suggestions regarding this operation manual, please contact Grünbeck Was- seraufbereitung GmbH’s Department for Technical Docu- mentation directly. Email: dokumentation@gruenbeck.de...
  • Page 52 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 www.gruenbeck.com to www.gruenbeck.com...

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