Grunbeck GENO-Neutra FNH-420-R User manual

We understand water.
Neutralisation system |
GENO-Neutra FNH-420-R
Operation manual

General Contact
Germany
International Sales
[phone]
Service
[phone]
[email protected]
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.: 410838-inter _105

Table of contents
3 | 120
Table of contents
1Introduction ..................................... 5
1.1 Validity of the manual ...................... 5
1.2 Other applicable documents ............ 5
1.3 Product identification ....................... 6
1.4 Symbols used .................................. 7
1.5 Depiction of warnings ...................... 7
1.6 Requirements for personnel ............ 8
2Safety ............................................. 11
2.1 Safety measures............................ 11
2.2 Product-specific safety
instructions..................................... 15
2.3 Conduct in emergencies ................ 18
3Product description ...................... 19
3.1 Intended use.................................. 19
3.2 Product components...................... 20
3.3 Functional description.................... 22
3.4 Accessories ................................... 24
4Transport, set-up and storage ..... 26
4.1 Shipping/Delivery/Packaging ......... 26
4.2 Transport/Set-up............................ 26
4.3 Storage .......................................... 27
5Installation ..................................... 29
5.1 Requirements for the installation
site ................................................. 30
5.2 Checking the scope of supply........ 33
5.3 Water installation ........................... 34
5.4 Electrical installation ...................... 45
6Start-up/commissioning............... 55
6.1 Preliminary work ............................ 55
6.2 Calibrating the pH electrode .......... 57
6.3 Checking the product..................... 66
6.4 Handing over the product to the
owner/ operating company ............ 68
7Operation ....................................... 69
7.1 Control unit GENO-Neutra-matic2.. 69
7.2 GENODOS pump GP .................... 79
8Maintenance and repair................ 82
8.1 Cleaning ........................................ 82
8.2 Intervals ......................................... 84
8.3 Inspection ...................................... 85
8.4 Maintenance .................................. 88
8.5 Consumables................................. 95
8.6 Spare parts .................................... 95
8.7 Wearing parts ................................ 96
9Troubleshooting............................ 98
9.1 GENO-Neutra-matic2 messages .... 98
9.2 Malfunctions of delivery and
circulation pump ............................ 99
9.3 Malfunctions of GENODOS GP... 101
9.4 Malfunctions of neutralisation
system ......................................... 104
10 Decommissioning....................... 105
10.1 Temporary standstill .................... 105
10.2 Restart/recommissioning ............. 105

Table of contents
4 | 120
11 Dismantling and disposal........... 106
11.1 Dismantling .................................. 106
11.2 Disposal ....................................... 107
12 Technical specifications............. 109
13 Operation log............................... 112
13.1 Start-up/commissioning log.......... 112

Introduction
5 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
1 Introduction
This manual is intended for owners/operating companies, opera-
tors/users as well as qualified specialists and ensures the safe and
efficient 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.
●Obey all safety and handling instructions.
●Keep this manual and all other applicable documents, so that
they are available when needed.
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:
●Neutralisation system GENO-Neutra FNH-420-R
1.2 Other applicable documents
●Instructions of optional accessories
●Safety data sheet of neutralising agent GENO-Neutrox

Introduction
6 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
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 side of the neutralisation box.
Designation
1
Product designation
2
Operating weight
1
Order no.
2
Serial no.
3
Date of manufacture
4
Protection/protection class
5
Power input
6
Power supply
7
Ambient temperature
Designation
8
Condensate temperature
9
Boiler capacity
10
Neutralisation capacity
11
Nominal connection diameter
12
Obey the operation manual
13
CE mark
14
EAC test mark
15
Disposal information

Introduction
7 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
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
obey for your personal safety. The information and instructions are
highlighted by a warning symbol and are structured as shown below:
1.1.1.1
1.1.1.2 SIGNAL WORD
1.1.1.3 Type and source of hazard
1.1.1.4
●Possible consequences
►Preventive measures
The signal words below are defined subject to the degree of danger
and might be used in the present document:

Introduction
8 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
Warning symbol and
signal word
Consequences if the information/
instructions are ignored
DANGER
Personal
injury
Death or serious injuries
WARNING
Possible death or serious injuries
CAUTION
Possible moderate or minor injuries
NOTE
Damage to
property
Possible damage to components, the
product and/or its functions, or an object
in its vicinity
1.6 Requirements for personnel
During the individual life cycle phases of the product, different peop-
le carry out work on the product. This work requires different qualifi-
cations.
1.6.1 Qualification of personnel
Personnel
Requirements
Operator/user
•No special expertise required
•Knowledge of the tasks assigned
•Knowledge of possible dangers in case of incorrect
behaviour
•Knowledge of the required protective equipment and
protective measures
•Knowledge of residual risks
Owner/operating
company
•Product-specific expertise
•Knowledge of statutory regulations on work safety
and accident prevention
Qualified specialist
•Electrical engineering
•Sanitary engineering
(HVAC and plumbing)
•Transport
•Professional training
•Knowledge of relevant standards and regulations
•Knowledge of detection and prevention of potential
hazards
•Knowledge of statutory regulations on accident
prevention

Introduction
9 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
Personnel
Requirements
Technical service
(Grünbeck's technical
service/authorised
service company)
•Extended product-specific expertise
•Trained by Grünbeck
1.6.2 Authorisations of personnel
The table below describes which tasks may be carried out by whom.
Operator/
user
Owner/
operating
company
Qualified
specialist
Technical
service
Transport and storage
X
X
X
Installation and mounting
X
X
X
Start-up/commissioning
X
X
Operation and handling
X
X
X
X
Cleaning
X
X
X
X
Inspection
X
X
X
X
Maintenance
X
X
Troubleshooting
X
X
X
X
Repair
X
X
Decommissioning and
restart/recommissioning
X
X
Dismantling and disposal
X
X

Introduction
10 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
1.6.3 Personal protective equipment
►As an owner/operating company, make sure that the requi-
red personal protective equipment is available.
The components below fall under the heading of personal protective
equipment (PPE):
Protective gloves
Protective footwear
Protective overall or
protective apron
Safety goggles
(tightly fitting)

Safety
11 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
2 Safety
2.1 Safety measures
●Obey the local regulations on accident prevention and occu-
pational safety.
●Obey the following regulations on the treatment and dischar-
ge of condensate originating from condensing boilers into the
public sewer system:
•Work sheet DWA-A 251:2011 "Condensates from con-
densing boilers"
•DVGW VP 114 „Neutralisation systems for gas firing sys-
tems; requirements and testing“
2.1.1 Obligation to neutralise in accordance with
DWA-A 251:2011
Excerpt from the standard
Nominal
heat output
Neutralisation for firing systems and motors without catalytic
converter is required for
GAS
Fuel oil
DIN 51603-1
low in sulphur
Alternative fuels
DIN 51603-6
Fuel oil
DIN 51603-1
< 25 kW
no 1), 2)
no 1), 2)
no 1), 2)
yes
25 kW up to
200 kW
no 1), 2), 3)
no 1), 2), 3)
no 1), 2)
yes
> 200 kW
yes
yes
yes
yes
However, neutralisation is nevertheless required:
1) If the domestic waste water is discharged into small sewage treatment plants,
2) in case of buildings and lots whose drainpipes do not meet the material requi-
rements stipulated in paragraph 5.3,
3) in case of buildings which do not meet the requirements for adequate mixing as
per paragraph 4.1.1.

Safety
12 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
●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.
●Be aware of a possible risk of slipping due to leaking water on
the floor.
●Comply with the maintenance intervals (refer to chapter 8.2).
2.1.2 Mechanical hazards
●You must never remove, bridge, or otherwise tamper with sa-
fety equipment.
●Make sure that the product is set up in a way that it cannot tip
over and that its stability is guaranteed at all times.
2.1.3 Danger due to chemicals
●Chemicals can be hazardous to health and environment.
They can cause skin and eye burns as well as irritation of the
respiratory tract or allergic reactions.
●Avoid any skin/eye contact with chemicals.
●Use personal protective equipment.
●Read the safety data sheet before handling chemicals. Obey
the instructions for different activities/situations.
●Current safety data sheets for chemicals are available for
download at www.gruenbeck.de/en/info-centre/safety-
data-sheets.

Safety
13 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
●Obey in-house instructions when handling chemicals. Make
sure that protective and emergency equipment such as
emergency showers and eyewash are available where requi-
red, and functional.
Mixing and residual amounts of chemicals
●Do not mix different chemicals. Unforeseeable chemical reac-
tions posing a lethal danger can occur.
●Dispose of residual amounts of chemicals in accordance with
local regulations and/or in-house instructions.
●Residual amounts from used containers should not be trans-
ferred into containers with fresh chemicals in order not to im-
pair the effectiveness of the chemicals.
Labelling/Minimum shelf life/Storage of chemicals
●Check the labelling of the chemicals. Chemical labels must
not be removed or made illegible.
●Do not use any unknown chemicals.
●Comply with the use-by date (minimum shelf life) stated on
the label.
●If stored incorrectly, chemicals could change their state of
matter, crystallize, outgas, or lose their effectiveness. Store
and use the chemicals at the indicated temperatures only.
Cleaning/Disposal
●Immediately absorb leaked chemicals with suitable binding
agents.
●Wipe up dripping chemicals with disposable cloths.
●Collect and dispose of chemicals in such a way that they can-
not pose any risks to people, animals, or the environment.

Safety
14 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
2.1.4 Danger due to condensate
●Non-neutralised condensate is acidic and can cause chemical
burns and irritation when coming into contact with the skin or
the eyes.
●Avoid any skin/eye contact with the condensate.
●Use personal protective equipment when working with con-
densate.
●The condensate can damage surfaces when covering them.
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.
2.1.5 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.
●Children should be supervised to make sure that they do not
play with the product.

Safety
15 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
2.2 Product-specific safety instructions
2.2.1 Neutralising agent (GENO-Neutrox)
►Brief/train the owner/operating company in handling the sys-
tem and inform the owner/operating company about possible
risks/sources of danger when handling chemicals.
►Always use personal protective equipment when handling
chemicals (refer to chapter 1.6.3).
►Obey the safety data sheet of the neutralising agent GENO-
Neutrox.
●The neutralising agent is a hazardous substance and is sub-
ject to the German Ordinance on Hazardous Substances.
●Keep the neutralising agent away from children.
●For neutralisation systems GENO-Neutra FNH-420-R, only
the manufacturer’s original GENO-Neutrox must be used.
●The neutralising agent is alkaline and can cause chemical
burns and irritation when coming into contact with the skin or
the eyes. Avoid any contact of eyes/skin with the neutralising
agent.
●Use personal protective equipment when working on the pro-
duct.
●The neutralising agent can damage surfaces when covering
them.

Safety
16 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
2.2.2 Safety devices
●Delivery pump featuring a protective temperature limiter with
automatic reset.
●The pump motor is switched off in the event of overheating
and restarts automatically after it has sufficiently cooled down.
●Level probe to monitor the filling level
●Overflow warning switch for switch-off
●pH electrode and pH measuring transducer to monitor the pH
value
2.2.3 Safety-related components
Safety components must be replaced by genuine spare parts only.
●Dosing pump
●Dosing valve
●Delivery pump
●Level probe
●pH electrode
●pH measuring transducer (GENO-Neutra-matic2)

Safety
17 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
2.2.4 Signals and warning signs
Labels on the product
Risk of electric shock
Risk of chemical burns
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.
2.2.5 Line routing
►Always route lines such as suction and return hose, mains
cables, electrical connecting cables away from traffic routes
in order to prevent tripping and tearing off.
►Secure the lines of the neutralisation system at the installati-
on site where public traffic can be expected.
►Mark possible tripping hazards, if necessary.

Safety
18 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
2.4 Conduct in emergencies
WARNING
Pressurised media lines
●After the mains plug is unplugged, media lines on the pres-
sure side are still under pressure.
●Dosing media splashing out
►Use personal protective equipment.
►Relieve the pressure on the pressure side of the dosing
pump before working on the dosing pump, its equipment
parts or the dosing lines.
2.4.1 In case of escaping dosing medium/condensate
1. De-energise the system –pull the mains plug.
2. Locate the leak.
3. Eliminate the cause of dosing medium or condensate es-
caping.
4. Contact the technical service.
WARNING
Acidic condensate
●Chemical burns of eyes and body parts
►Thoroughly rinse your eyes with water if condensate or do-
sing medium gets into your eyes.
►Consult a physician, if needed.
2.4.2 In case of incorrect dosing/overdosing
1. De-energise the system –pull the mains plug.
2. Contact the technical service.

Product description
19 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
3 Product description
3.1 Intended use
●The neutralisation system GENO-Neutra FNH is suitable for
the neutralisation (increase of the pH-value to > 6.5) of con-
densate originating from gas or oil-fired heat generators (con-
densing boilers) and/or exhaust systems made of stainless
steel, plastic, glass, graphite and ceramics according to work
sheets DWA A 251:2011 and DVGW VP 114 up to the spe-
cified capacity.
3.1.1 Possible applications
●The neutralisation system GENO-Neutra FNH-420-R is de-
signed exclusively for use in industrial and commercial appli-
cations.
●The condensate can also contain impurities, combustion resi-
dues and, in case of oil operation, unburnt hydrocarbons or
oil.
●In case of condensate containing an extremely high amount
of impurities, we recommend installing condensate prefiltrati-
on box upstream. This increases the service life of the neutra-
lisation system.

Product description
20 | 120
BA_410838-inter_105_GENO-Neutra_FNH-420-R.docx
3.3 Product components
Designation
1
Neutralising agent GENO-
Neutrox (optional, not included
in the scope of supply)
2
Suction lance with pre-alarm
and empty signal
3
Suction and return pipe
4
Control unit GENO-Neutra-
matic2
5
Delivery pump
6
Level probe
Designation
7
pH electrode
8
Dosing hose
9
Dosing pump GENODOS GP
10
Lid
11
Connection DN 25 (inlet)
12
Connection DN 25 (overflow)
13
Neutralisation box