Grunbeck GENO AF-5 User manual

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Activated carbon filter | GENO AF-5
Operation manual

General Contact
Germany
International Sales
[phone]
Service
[phone]
[email protected]
Availability
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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

Table of contents
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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 Demands on personnel.................... 8
2Safety ............................................. 10
2.1 Safety measures............................ 10
2.2 Conduct in emergencies ................ 12
3Product description ...................... 13
3.1 Intended use.................................. 13
3.2 Product components...................... 14
3.3 Functional description.................... 15
3.4 Accessories ................................... 16
4Transport, set-up and storage ..... 18
4.1 Shipping/Delivery/Packaging ......... 18
4.2 Transport/Set-up............................ 18
4.3 Storage .......................................... 18
5Installation ..................................... 19
5.1 Requirements for the installation
site ................................................. 21
5.2 Checking the scope of supply........ 22
5.3 Water installation ........................... 22
6Start-up/commissioning............... 29
6.1 Filling the activated carbon filter
box................................................. 29
6.2 Checking the product..................... 31
6.3 Handing over the product to the
owner/ operator/operating
company ........................................ 32
7Operation ....................................... 33
8Maintenance and repair................ 34
8.1 Cleaning ........................................ 34
8.2 Intervals ......................................... 35
8.3 Inspection ...................................... 36
8.4 Maintenance .................................. 37
8.5 Consumables................................. 39
8.6 Spare parts .................................... 39
8.7 Wearing parts ................................ 39
9Troubleshooting............................ 40
9.1 Observations ................................. 40
10 Decommissioning......................... 41
10.1 Temporary standstill ...................... 41
10.2 Restart/recommissioning ............... 41
11 Dismantling and disposal ............ 42
11.1 Dismantling.................................... 42
11.2 Disposal......................................... 43
12 Technical specifications .............. 45
13 Operation log................................. 46

Table of contents
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13.1 Start-up/commissioning log............ 46
13.2 Maintenance .................................. 47

Introduction
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1 Introduction
This manual is intended for owners/operators/operating companies,
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.
●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:
●Activated carbon filter GENO AF-5
1.2 Other applicable documents
●Instructions of optional accessories
●Maintenance instructions for maintenance kit
Order no. 410 824
●Safety data sheet for activated carbon

Introduction
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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.
Designation
1
Product designation
2
Order no.
3
Serial no.
4
Date of manufacture
5
Ambient temperature
Designation
6
Condensate temperature
7
Fuel: oil/condensing technol-
ogy, max. boiler capacity
8
Filter capacity
9
Nominal connection diameter
10
Obey the operation manual

Introduction
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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
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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 ob-
ject in its vicinity
1.6 Demands on personnel
During the individual life cycle phases of the product, different people
carry out work on the product. This work requires different qualifica-
tions.
1.6.1 Qualification of personnel
Personnel
Requirements
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/operator/
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 pre-
vention

Introduction
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Personnel
Requirements
Technical service
(Grünbeck's technical
service/authorised ser-
vice 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.
User
Owner/
operator/
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
1.6.3 Personal protective equipment
►As an owner/operator/operating company, make sure that
the required personal protective equipment is available.
The components below fall under the heading of personal protective
equipment (PPE):
Protective gloves
Safety goggles

Safety
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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 dis-
charge 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 on sulphur
Alternative fuels
DIN 51603-6
Fuel oil
DIN 51603-1
< 25 kW
No1), 2)
No1), 2)
No1), 2)
Yes
25 kW up to
200 kW
No1), 2), 3)
No1), 2), 3)
No1), 2)
Yes
> 200 kW
Yes
Yes
Yes
Yes
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 drainage pipes do not meet the material
requirements 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
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●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.
●Comply with the maintenance intervals (refer to chapter 8.2).
2.1.2 Mechanical hazards
●You must never remove, bridge, or otherwise tamper with
safety 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 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.

Safety
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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.
●Children should be supervised to make sure that they do not
play with the product.
2.1.5 Activated carbon granulate
●The activated carbon is not considered to be a dangerous
good in the sense of the German Dangerous Goods Regula-
tion.
●Keep the activated carbon away from children.
2.2 Conduct in emergencies
2.2.1 In case of water leaks
1. Locate the leak.
2. Eliminate the cause of the water leak.

Product description
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3 Product description
3.1 Intended use
●The activated carbon filter GENO AF-5 is suitable for the fil-
tration of condensate from oil-fired heat generators (condens-
ing boilers) and/or their exhaust systems according to work-
sheets 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
with oil) cause the release of deposits and other components
from the pipes when the condensing boiler is switched to gas
and these can get into the neutralisation system.
●In case of gas/oil switchover operation of a condensing boiler
or in case of an otherwise increased dirt content (e.g. impuri-
ties entering from the chimney), we recommend installing an
activated carbon filter in the supply line to the neutralisation
system.
●This increases the service life of the filter material of the neu-
tralisation system.
●The activated carbon filter GENO AF-5 can also be used as
sole filtration device for unburnt hydrocarbons.

Product description
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3.2 Product components
Designation
1
Cover
2
Snap lock
3
Activated carbon filter box
4
Hose connection DN 20 (outlet)
Designation
5
Hose connection DN 20 (inlet)
6
Locknut
7
Angle grommet with seal

Product description
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3.3 Functional description
Designation
1
Filling area 1
with granulate filling
2
Marking for max. filling height
3
Plug
4
Condensate collection area in
the outlet
Designation
5
Overflow orifice
6
Settling area in the inlet, with
siphon (barrier height approx.
46 mm)
7
Filling area 2
without granulate filling
The condensate flows into the settling area of the activated carbon
filter unpressurised. The condensate is then distributed via the inte-
grated filter plate and flows through the activated carbon filling.
The activated carbon filling retains impurities, combustion residues
or unburnt hydrocarbons.
A siphon with a barrier height of approx. 46 mm is integrated at the
inlet connection.
An overflow orifice is mounted above the outlet piece, so that the
condensate can exit the system at a predefined location in case the

Product description
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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.
If there is an increased accumulation of dirt and visible dirt residue
on the condensate surface in the inlet settling area, we recommend
additionally equipping this area with and oil binding mat (refer to
chapter 3.4).
The oil binding mat is water-repellent and floats on the condensate
surface.
3.4 Accessories
You can retrofit your product with accessories. Please contact your
local Grünbeck representative or Grünbeck’s headquarters in
Hoechstaedt/Germany for details.
Illustration
Product
Order no.
Neutralisation system GENO-Neutra N
For neutralisation of the gas con-
densate
(Increase of pH value to > 6.5)
N-14
410 440
N-70
410 450
N-210
410320
Neutralisation system GENO-Neutra NO
For neutralisation of the oil
condensate
(Increase of pH value to > 6.5)
NO-5
410 230
NO-12
410 240
NO-24
410250

Product description
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Illustration
Product
Order no.
Waste water lifting system AH-300
420 150
Lifting system for condensates originating from neutrali-
sation systems of gas or oil-fired condensing boilers as
well as non-neutralised gas condensates > pH 3, clear
water or slightly polluted industrial water
Overflow warning switch for GENO-
Neutra
410 680
Level switch with voltage-free changeover contact for
generating a fault signal; for installation in the lid of the
box.
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
contact or changeover contact. The alarm delay can only
be used in combination with the overflow warning switch.
Hose DN 20 (5 m)
410 764e
For connection to the inlet and outlet of the activated
carbon filter
Oil binding mats, 20 pcs
410 585
The oil binding mats have an oil absorption capacity of
100 ml/mat and are water-repellent.
–
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

Transport, set-up and storage
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4 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
►Transport the product in its original packaging only.
►The activated carbon is not considered to be a dangerous
good in the sense of the German Dangerous Goods Reg-
ulation. Obey the current safety data sheet.
4.3 Storage
►Protect the product from the impacts below when storing it:
•Dampness, moisture
•Environmental impacts such as wind, rain, snow, etc.
•Frost, direct sunlight, severe heat exposure
•Chemicals, dyes, solvents and their vapours

Installation
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5 Installation
The installation of the product must be carried out by a qualified
specialist only.
Installation example (solo)
Designation
1
Heat generator
2
Inlet hose
Designation
3
Outlet hose
4
Activated carbon filter
GENO AF-5

Installation
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Installation example (upstream of a neutralisation system)
Designation
1
Heat generator
2
Inlet hose
3
Connecting hose
4
Activated carbon filter
GENO AF-5
Designation
5
Neutralisation system
GENO-Neutra
6
Outlet hose