Grunbeck GENO-Neutra KW Operation Manual
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Grunbeck GENO-Neutra KW Operation Manual

Neutralisation system
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Neutralisation system | GENO-Neutra KW
Operation manual

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Summary of Contents for Grunbeck GENO-Neutra KW

  • Page 1 We understand water. Neutralisation system | GENO-Neutra KW 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.: TD3-GS002en_en_045...

  • Page 3: Table Of Contents

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

  • Page 4: Introduction

    Introduction Introduction This manual is intended for owners/operating companies, operators/ users as well as qualified specialists and ensures the safe and effi- cient handling of the product. The manual is an integral part of the product. ● Carefully read this manual and the included manuals on the components before you operate your product.

  • Page 5: 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 DVGW test mark...

  • Page 6: 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 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. Operator/ Owner/ Qualified Technical user operating specialist service...

  • Page 9: 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 10 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 11 Safety Cleaning/Disposal ● Immediately absorb leaked and non-neutralised condensate with disposable towels. ● Dispose of the absorbed condensate with the 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 Conduct in emergencies 2.2.1 In case of water leaks 1. Locate the leak. 2. Eliminate the cause of the water leak. 12 | 56...

  • Page 13: Product Description

    DWA-A 251:2011 and DVGW VP 114 up to the speci- fied capacity. 3.1.1 Possible applications ● The neutralisation system GENO-Neutra KW can be used for the neutralisation of condensate containing iron, manganese, aluminium and zinc particles. It is possible that the neutralisa- tion granulate might clog and considerably impair the function of the neutralisation system.

  • Page 14: Product Components

    Product description Product components Designation Designation Angle-type inlet connection Snap lock DN 20 Divider for condensate collection Divider for settling area in the area in the outlet inlet Outlet hose connection DN 20 Functional description The condensate flows unpressurised into the settling area of the neutralisation system.
  • Page 15 Product description The neutralisation granulate is dissolved and the condensate neu- tralised. Afterwards, the condensate flows to the drain via the con- densate collection area. The amount of neutralisation granulate included in the scope of sup- ply corresponds to the initial filling required for 12 months at maxi- mum capacity.

  • Page 16: Accessories

    Refill pack for neutralisation pH indicator strips 170 173 3 Strips to determine pH 4.5 - 10.0 Maintenance kits for GENO-Neutra KW – 1 Foil bag to dispose of the used neutralisation granulate, 2 dividers, 1 pack (3 strips) of indicator strips 1 Bag of GENO-Neutralit Hz, 2.5 kg...

  • Page 17: 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 18: Installation

    The installation of the product must be carried out by a qualified specialist only. Installation example I (without siphon in the heat generator) Designation Designation Neutralisation system Heat generator without siphon GENO-Neutra KW Inlet hose with backwater loop Outlet hose 18 | 56...
  • Page 19 Installation Installation example II (with drain connection and waste water lifting system) Designation Designation Heat generator with siphon Connecting hose Inlet hose Drain connection Neutralisation system Waste water lifting system GENO-Neutra KW AH-300 19 | 56...

  • Page 20: 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 sun- light ● Protection from high radiation temperatures in the immediate vicinity (≤ 40 °C) ●...

  • Page 21: Checking The Scope Of Supply

    Installation Checking the scope of supply Designation Designation Neutralisation system GENO- 2 Dividers Neutra KW as compact system 1 Pack of pH indicator strips (partly pre-assembled) 2 Corrugated hoses of approx. Operation manual 2 m in length (DN 20) Neutralisation granulate 3 Hose clamps GENO-Neutralit Hz 2.5 kg for KW35...

  • Page 22: 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.
  • Page 23 Installation Select an installation site where the inlet and outlet hose can be as short as possible. ► Check that the connection on the heat generator has a downward slope to the inlet connection on the neutralisation system of approximately 3 %. 5.3.2 Connecting the neutralisation system 5.3.2.1 Pre-assembling the neutralisation box 1.
  • Page 24 Installation 4. Bend the dividers into a slightly semi-circular shape. 5. Insert the dividers into the corners of the box. 5.3.2.2 Connecting the inlet and outlet hose Use the hoses supplied with the system to connect the neutralisa- tion system. Should additional hoses and fittings be needed, only approved, cor- rosion-resistant materials according to worksheet DWA A251:2011 (e.g.
  • Page 25 Installation 1. Stretch the respective hose for the inlet and the outlet to the required length. 2. Connect the inlet hose to the inlet IN of the box. Make sure that a downward slope is maintained from the heat generator to the neutralisation system.
  • Page 26 Installation 5.3.2.3 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 27 Installation 5.3.2.4 Connection to 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. Obey the operation manual of the waste water lifting system when installing the waste water lifting system AH-300.

  • Page 28: 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 29: Filling The Box

    Start-up/commissioning Filling the box Designation Designation Settling area Condensate collection area Filling area for neutralisation granulate 1. Carefully fill the neutralisation granulate into the filling area between the dividers. 2. Fill water into the settling area in the inlet. 29 | 56...

  • Page 30: Checking The Product

    Start-up/commissioning Checking the product 1. Check the inlet and outlet hose for leaks. 2. Close the box with the lid. 3. Put the heat generator into operation. 4. Check the entire installation for leaks. 5. Check that the condensate flows freely into the drain or floor drain.

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

    Start-up/commissioning Handing over the product to the owner/ operating company ► Explain to the owner/operating company how the product works. ► Use the manual to brief the owner/operating company and answer any questions. ► Inform the owner/operating company about the need for in- spections and maintenance.

  • Page 32: 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 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/operating company is re- sponsible for compliance with the prescribed maintenance and re- pair work.

  • Page 34: 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 35 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 36: Maintenance

    Maintenance and repair 6. Check the water level in the box – refill water up to the outlet height, if needed. 7. Check the box and the hoses for leaks. 8. Close and lock the box with the lid. 9. Record the inspection carried out in the operation log (refer to chapter 13.2).
  • Page 37 Maintenance and repair Designation Designation Dividers pH indicator strips Neutralisation granulate Maintenance instructions GENO-Neutralit Hz 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. Open the lid of the box. 3.
  • Page 38 Maintenance and repair 6. Clean the box. 7. Check the inlet and outlet hoses for deposits – clean them, if needed. 8. Insert new dividers. 9. Fill new neutralisation granulate into the box (refer to chapter 6.1). 10. Fill the box with water up to the outlet height. 11.

  • Page 39: Consumables

    Maintenance and repair Consumables Depending on the operating conditions (season, operating hours of the burner, temperature of heat supply and return, ...), the con- sumption of neutralisation granulate may vary considerably. This is normal and due to technical reasons. Product Quantity Order no.

  • Page 40: 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 settings of the burner ►...
  • Page 41 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 42: 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 neutrali- sation system: 1.

  • Page 43: 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 44 Dismantling and disposal Neutralisation granulate ► Dispose of the used neutralisation granulate via local waste disposal companies using waste code number 19 02 99 – do not dispose of it with residual waste or household waste. Hydroxide sludge During system cleaning, hydroxide sludge containing metal might be produced and must be disposed of as hazardous waste.

  • Page 45: Technical Specifications

    Technical specifications 12 Technical specifications Dimensions and weights KW35 KW65 Width Height Length Connection height of inlet and outlet Total length with connections Operating weight ~ 6.2 ~ 7.0 Empty weight ~ 5.0 ~ 5.8 Connection data KW35 KW65 Nominal connection diameter of inlet and outlet DN 20 ≥...
  • Page 46 Technical specifications Performance data KW35 KW65 Fuel/process (generation of condensate) gas/condensing technology ≤ 4.9 ≤ 9.1 Neutralisation capacity ≤ 35 ≤ 65 At 0.14 l/kWh, this corresponds to a boiler capacity of Filling volumes and consumption data KW35 KW65 Neutralisation granulate GENO-Neutralit Hz Service life in case of standard condensate as per 12 months DVGW VP 114, pH 3...

  • Page 47: Operation Log

    Operation log 13 Operation log ► Document the initial start-up/commissioning and all mainte- nance activities. Neutralisation system GENO-Neutra KW_______ 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 Accessories Materials Material(s) of boiler...

  • Page 48: Maintenance

    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: 48 | 56...
  • 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 | 56...
  • Page 50 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: 50 | 56...
  • Page 51 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: 51 | 56...
  • Page 52 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: 52 | 56...
  • Page 55 Publisher's information Technical documentation Should you have any questions or suggestions regarding this operation manual, please contact Grünbeck Wasseraufbereitung GmbH’s Department for Technical Documentation directly. 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...

This manual is also suitable for:

Geno-neutra kw35Geno-neutra kw65410 335410 345

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