Grunbeck GENO-Neutra N Operation Manual
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Grunbeck GENO-Neutra N Operation Manual

Neutralisation system
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Summary of Contents for Grunbeck GENO-Neutra N

  • Page 1 We understand water. Neutralisation system | GENO-Neutra N 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.: 410999_en_055...

  • Page 3: Table Of Contents

    11.2 Disposal ........55 Requirements for the installation site..........26 Technical specifications ....57 Checking the scope of supply..27 Water installation ......29 12.1 GENO-Neutra N-14/N-70 ....57 12.2 GENO-Neutra N-210 ..... 59 Start-up/commissioning ....36 3 | 68...
  • Page 4 Table of contents Operation log........ 61 13.1 Start-up/commissioning log ... 61 13.2 Maintenance ......... 62 4 | 68...

  • Page 5: Introduction

    Illustrations in this manual are for basic understanding and can differ from the actual design. Validity of the manual This manual applies to the products below: ● Neutralisation system GENO-Neutra N-14 ● Neutralisation system GENO-Neutra N-70 ● Neutralisation system GENO-Neutra N-210 Other applicable documents ●...

  • Page 6: Product Identification

    Introduction 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 front or side of the box. Designation Designation Fuel:...

  • Page 7: Symbols Used

    Introduction 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 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. Operator/ Owner/ Qualified Technical user operating specialist service...

  • Page 10: Safety

    Safety Safety 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 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: Conduct In Emergencies

    Safety Conduct in emergencies 2.2.1 In case of water leaks 1. Switch off the heat generator. 2. Locate the leak. 3. Eliminate the cause of the water leak. 13 | 68...

  • Page 14: Product Description

    Product description Product description Intended use ● The neutralisation system GENO-Neutra N is suitable for the neutralisation (increase of the pH-value to > 6.5) of gas con- densate originating from gas-fired heat generators (condens- ing boilers) and/or exhaust systems made of stainless steel,...

  • Page 15: Product Components

    Product description Product components Designation Designation Hose connection DN 20 (outlet) Snap lock Hose connection DN 20 (inlet) Designation Designation Hose connection DN 25 (outlet) Plug-in plates Connection nozzle DN 25 or Dividers DN 20 (inlet) 15 | 68...

  • Page 16: Functional Description

    Product description Functional description The condensate flows unpressurised into the settling area of the neutralisation system. The condensate is then distributed via the in- tegrated dividers and flows through the neutralisation granulate. Condensate by-products such as combustion residue or unburnt hy- drocarbons are retained.
  • Page 17 Product description GENO-Neutra N-14 Designation Designation Filling area 1 with Overflow orifice granulate filling Settling area in the inlet Marking for max. filling level Filling area 2 without Plug granulate filling Condensate collection area in the outlet In case of Neutra N-14 and N-70, an overflow orifice is mounted above the outlet piece so that the condensate may exit the system at a predefined place if the condensate outlet is clogged.
  • Page 18 Marking for max. filling level Filling area 2 with Plug granulate filling Condensate collection area in the outlet In case of GENO-Neutra N-70, additional neutralisation granulate is filled into the filling area 2, thus increasing the neutralisation capac- ity. 18 | 68...
  • Page 19 Product description GENO-Neutra N-210 Designation Designation Settling area in the inlet Filling area with granulate filling Condensate collection area in Max. filling level the outlet 19 | 68...

  • Page 20: Accessories

    Product description In case to GENO-Neutra N-210, you can adapt the filling area for the neutralisation granulate according to the capacity of the con- densing boiler to be connected. This is done by repositioning the plug-in plates. In addition, the hose connection for the inlet can be converted from...
  • Page 21 Product description Illustration Product Order no. GENO-alarm delay relay 410 285 To execute a delayed shutdown of the boiler after an alarm signal has been triggered. With voltage-free fault signal output as normally open con- tact or changeover contact. The alarm delay can only be used in combination with the overflow warning switch Hose DN 20 (5 m) 410 764e...

  • Page 22: Transport, Set-Up And Storage

    Transport, set-up and storage Transport, set-up and storage Shipping/Delivery/Packaging The product is packed in a cardboard box at the factory. The neutralisation granulate is packed separately in a bag. ► Upon receipt, immediately check for completeness and transport damage. Transport/Set-up ►...

  • Page 23: Installation

    The installation of the product must be carried out by a qualified specialist only. Installation example I (with siphon in the heat generator) Designation Designation Heat generator with siphon Outlet hose Neutralisation system Inlet hose GENO-Neutra N-14/N-70 23 | 68...
  • Page 24 Installation Installation example II (without siphon in the heat generator) Designation Designation Heat generator without siphon Outlet hose Neutralisation system Inlet hose with backwater loop GENO-Neutra N-14/N-70 24 | 68...
  • Page 25 Installation Installation example III (with drain connection and waste water lifting system) Designation Designation Heat generator with siphon Connecting hose Waste water lifting system Inlet hose AH-300 Neutralisation system Drain connection GENO-Neutra N-210 25 | 68...

  • Page 26: Requirements For The Installation Site

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

  • Page 27: Checking The Scope Of Supply

    Installation Checking the scope of supply 5.2.1 GENO-Neutra N-14/N-70 Designation Designation Neutralisation system GENO- Hose, 5 m in length (DN 20) Neutra N-14 or N-70 as com- 1 Pack of pH indicator strips pact system (partly pre-assem- bled) 3 Hose clamps...
  • Page 28 Installation 5.2.2 GENO-Neutra N-210 Designation Designation Neutralisation system GENO- Hose, 5 m in length (DN 25) Neutra N-210 as compact sys- 1 Pack of pH indicator strips tem (partly pre-assembled) Inlet hose connection DN 20 3 Hose clamps with locknut and seal...

  • Page 29: Water Installation

    Installation Water installation 5.3.1 Setting up the neutralisation system Take into consideration that in standard operation the condensate is accumulated to a level of the height of the outlet connection. If the condensate from the heat generator or the exhaust system is to drain off completely, the installation surfaces and the condensate outlets must be provided for accordingly The neutralisation system does not feature a siphon at the inlet...
  • Page 30 3 %. 5.3.2 Connecting the neutralisation system 5.3.2.1 Installing the (optional) overflow warning switch Obey the mounting instructions of the accessory overflow warning switch (refer to chapter 3.4). GENO-Neutra N-14/N-70 Designation Overflow warning switch (optional) 30 | 68...
  • Page 31 Designation Overflow warning switch (optional) 5.3.2.2 Converting the connection to DN 20 (for GENO-Neutra N-210 only) Converting the inlet to DN 20 is only required if the inlet hose has a nominal diameter of DN 20. 1. Unlock and open the lid.
  • Page 32 Use the hose supplied with the system to connect the neutralisation system. GENO-Neutra N-14/N-70 1. Shorten the hose to the required length for inlet and outlet. 2. Connect the inlet hose to the inlet of the box. Make sure that a downward slope is maintained from the heat generator to the neutralisation system.
  • Page 33 Installation 7. Secure the outlet hose against mechanical damage, if needed. Do not step on the outlet hose. The end of the outlet hose must be freely visible in order to be able to check the functioning of the neutralisation system at any time. Should additional hoses and fittings be needed, only approved, cor- rosion-resistant materials according to worksheet DWA A251:2011 (e.g.
  • Page 34 Installation 5.3.2.4 Connecting the outlet to the drain connection Comply with the following if you connect 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.
  • Page 35 Installation GENO-Neutra N-210 with waste water lifting system AH-300 ► Connect the inlet hose to the inlet connection IN. ► Connect the outlet hose to the outlet connection OUT and to the waste water lifting system. When installing the waste water lifting system AH-300, obey the op- eration manual of the waste water lifting system.

  • Page 36: 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 37: Filling The Box

    Start-up/commissioning Filling the box GENO-Neutra N-14/N-70 1. Unlock the locks on both sides of the lid. 2. Lift the lid a little. 3. Remove the lid and place it safely away from damage. 4. Remove any transport protection from the box (e.g.
  • Page 38 Start-up/commissioning Designation Designation Filling area for Settling area neutralisation granulate 5. Carefully fill the neutralisation granulate into the respective chambers. 6. Fill water into the settling area in the inlet – pay attention to the max. marking. 38 | 68...
  • Page 39 Start-up/commissioning GENO-Neutra N-210 Designation Designation Filling areas for Settling area neutralisation granulate 1. Unlock and open the lid. 2. Remove the lid and place it safely away from damage. 3. Remove any transport protection from the box (e.g. cardboard packaging).

  • Page 40: Checking The Product

    Start-up/commissioning Checking the product 1. Check the inlet and outlet hoses for leaks. 2. Close the box with the lid. 3. Put the heat generator into operation. 4. Check the entire installation for leaks. 40 | 68...

  • Page 41: Handing Over The Product To The Owner/ Operating Company

    Start-up/commissioning 5. Check the optional overflow warning switch for function (refer to the instructions of the accessories). 6. Check that the condensate flows freely into the drain or floor drain. Handing over the product to the owner/ operating company ► Explain to the owner/operating company how the product works.
  • Page 42 Start-up/commissioning 6.3.1 Disposal of packaging ► Dispose of packaging material as soon as it is no longer needed (refer to chapter 11.2). 6.3.2 Storage of accessories/consumables ► Store accessories and consumables properly (refer to chapter 4.3). 42 | 68...

  • Page 43: 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 44: 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/operating company is re- sponsible for compliance with the prescribed maintenance and re- pair work.

  • Page 45: Intervals

    Maintenance and repair Intervals By way of regular inspections and maintenance, malfunctions can be detected in time and product failures might be prevented. ► As owner/operating company determine which components must be inspected and maintained at which intervals (load-de- pendent). These intervals are subject to the actual conditions such as: degree of impurities, environmental impacts, con- sumption, etc.
  • Page 46 Maintenance and repair ► Use personal protective equipment (refer to chapter 1.6.3). ► Carry out an inspection at least every 6 months. 1. Open the lid of the box. Designation Designation Condensate outlet pH indicator strips 2. Check the pH value at the condensate outlet using the indica- tor strips.

  • Page 47: Maintenance

    8.4.1 Annual maintenance Annual maintenance work requires expert knowledge. The mainte- nance work must be carried out by technical service personnel only. ► Use the corresponding maintenance kit for GENO-Neutra N-14/N-70/N-210 (refer to chapter 8.5). 47 | 68...
  • Page 48 Maintenance and repair Designation Designation Neutralisation granulate pH indicator strips GENO-Neutralit Hz Maintenance instructions Foil bag to dispose of the used neutralisation granulate 1. Stop the inflow of condensate or divert it into a suitable collec- tion tank. 2. Switch off the power supply to the overflow warning switch (optional accessory) –...
  • Page 49 Maintenance and repair 7. Check the inlet and outlet hoses for deposits – clean them, if needed. 8. Fill new neutralisation granulate into the box (refer to chapter 6.1). 9. Fill the box with water up to the outlet height. 10.

  • Page 50: Consumables

    Order no. pH indicator strips (1 package) 3 strips 170 173 GENO-Neutralit Hz 8 kg 410 011 Maintenance kit for GENO-Neutra N-14 410 801 Maintenance kit for GENO-Neutra N-70 410 802 Maintenance kit for GENO-Neutra N-210 410 803 Spare parts For an overview of the spare parts, refer to our spare parts cata- logue at www.gruenbeck.com.

  • Page 51: Troubleshooting

    Troubleshooting Troubleshooting Observations Observation Explanation Remedy ► Clean the box more Deposits of condensate Poor combustion in the by-products on the sur- condensing boiler frequently and re- face of the condensate place the neutralisa- tion granulate ► Check the setting of the burner ►...
  • Page 52 Troubleshooting Observation Explanation Remedy ► Loosen up the neu- Neutralisation granulate Due to a large amount of stuck together or clogged deposits from conden- tralisation granulate sate by-products by adding water ► Check whether an activated carbon filter needs to be installed upstream ►...

  • Page 53: Decommissioning

    Decommissioning 10 Decommissioning If a longer period of standstill is planned for the heat generator, the neutralisation system must be shut down. 10.1 Temporary shutdown If the heat generator is to be switched off temporarily (e.g. for 3 months in summer), carry out the following activities on the neu- tralisation system: 1.

  • Page 54: Dismantling And Disposal

    Dismantling and disposal 11 Dismantling and disposal 11.1 Dismantling ► Have this work carried out by qualified specialists only. 1. Check that the heat generator is out of operation and no con- densate is produced. 2. Remove the condensate from the box. 3.

  • Page 55: Disposal

    Dismantling and disposal 11.2 Disposal ► Obey the applicable national regulations. Packaging ► Dispose of the packaging in an environmentally sound man- ner. Danger to the environment due to incorrect dis- NOTE posal ● Packaging materials are valuable raw materials that can be reused in many cases.
  • Page 56 Dismantling and disposal disposal companies using waste code number 10 01 21 – do not dispose of it with residual waste or household waste. 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.

  • Page 57: Technical Specifications

    Technical specifications 12 Technical specifications 12.1 GENO-Neutra N-14/N-70 Dimensions and weights N-14 N-70 Width Height Length Connection height of inlet and outlet Total length with connections Height Overflow/lower edge Operating weight ~ 12 ~ 15 Empty weight ~ 12 Connection data...
  • Page 58 Technical specifications Performance data N-14 N-70 Fuel/process (generation of condensate) gas/condensing technology ≤ 14 ≤ 70 Neutralisation capacity ≤ 100 ≤ 500 At 0.14 l/kWh, this corresponds to a boiler capacity of Filling volumes and consumption data N-14 N-70 Neutralisation granulate GENO-Neutralit Hz Service life in case of standard condensate as per 12 months DVGW VP114, pH 3...

  • Page 59: Geno-Neutra N-210

    Technical specifications 12.2 GENO-Neutra N-210 Dimensions and weights N-210 Width Height Length Connection height of inlet and outlet Total length with connections Operating weight ~ 45 Empty weight ~ 33 Connection data N-210 Nominal connection diameter of inlet and outlet DN 25 ≥...
  • Page 60 Technical specifications Performance data N-210 Fuel/process (generation of condensate) gas/condensing technology ≤ 210 Neutralisation capacity ≤ 1500 At 0.14 l/kWh, this corresponds to a boiler capacity of Filling volumes and consumption data N-210 Neutralisation granulate GENO-Neutralit Hz 24.0 Service life in case of standard condensate as per 12 months DVGW VP 114, pH 3 Neutralisable condensate volume...
  • Page 61 Operation log 13 Operation log ► Document the initial start-up/commissioning and all mainte- nance activities. Neutralisation system GENO-Neutra N-_______ 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 62 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: 62 | 68...
  • Page 63 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: 63 | 68...
  • Page 64 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: 64 | 68...
  • Page 65 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: 65 | 68...
  • Page 67 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 directly. Email: dokumentation@gruenbeck.de...
  • Page 68 Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Str. 1 89420 Hoechstaedt/Germany +49 9074 41-0 +49 9074 41-100 For more information info@gruenbeck.com go to www.gruenbeck.com www.gruenbeck.com...

This manual is also suitable for:

Geno-neutra n-14Geno-neutra n-70Geno-neutra n-210

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