Grunbeck AH-300 User manual

We understand water.
Waste water lifting system | AH-300
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.: 100164650000_en_075

Table of contents
3 | 56
Table of contents
1Introduction ..................................... 4
1.1 Validity of the manual ...................... 4
1.2 Other applicable documents ............ 4
1.3 Product identification ....................... 5
1.4 Symbols used .................................. 6
1.5 Depiction of warnings ...................... 6
1.6 Demands on personnel.................... 7
2Safety ............................................... 9
2.1 Safety measures.............................. 9
2.2 Product-specific safety instructions. 11
2.3 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 ..... 17
4.1 Shipping/Delivery/Packaging ......... 17
4.2 Transport/Set-up............................ 17
4.3 Storage .......................................... 17
5Installation ..................................... 18
5.1 Requirements for the installation site . 19
5.2 Checking the scope of supply........ 20
5.3 Water installation ........................... 21
5.4 Electrical installation ...................... 25
6Start-up/commissioning............... 29
6.1 Checking the product ..................... 30
6.2 Handing over the product to the
owner/operator/operating company.... 31
7Operation and handling................ 32
8Maintenance and repair ................ 33
8.1 Cleaning......................................... 33
8.2 Intervals ......................................... 34
8.3 Inspection....................................... 35
8.4 Maintenance .................................. 37
8.5 Spare parts .................................... 42
8.6 Wearing parts................................. 42
9Troubleshooting............................ 43
9.1 Observations.................................. 43
10 Decommissioning ......................... 45
10.1 Temporary standstill....................... 45
10.2 Restart/recommissioning ............... 45
11 Dismantling and disposal............. 46
11.1 Dismantling .................................... 46
11.2 Disposal ......................................... 47
12 Technical specifications............... 48
13 Operation log................................. 51
13.1 Start-up/commissioning log............ 51

Introduction
4 | 56
BA_100164650000_en_075_AH-300.docx
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:
●Waste water lifting system AH-300
1.2 Other applicable documents
●Instructions of optional accessories

Introduction
5 | 56
BA_100164650000_en_075_AH-300.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 collection 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
Maximum delivery head
10
Pump capacity
11
Nominal connection diameter
12
Obey the operation manual
13
CE mark
14
EAC test mark
15
Disposal information

Introduction
6 | 56
BA_100164650000_en_075_AH-300.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
7 | 56
BA_100164650000_en_075_AH-300.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 ob-
ject in its vicinity
1.6 Demands on personnel
During the individual life cycle phases of the product, different pe-
ople carry out work on the product. This work requires different qua-
lifications.
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
8 | 56
BA_100164650000_en_075_AH-300.docx
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
9 | 56
BA_100164650000_en_075_AH-300.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
discharge 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
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
10 | 56
BA_100164650000_en_075_AH-300.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 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
11 | 56
BA_100164650000_en_075_AH-300.docx
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.
2.2 Product-specific safety instructions
2.2.1 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.
●Overflow warning switch
2.2.2 Signals and warning devices
Labels on the product
Risk of electric shock
Hot surface

Safety
12 | 56
BA_100164650000_en_075_AH-300.docx
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.
2.3 Conduct in emergencies
2.3.1 In case of water leaks
1. De-energise the system –unplug the mains plug.
2. Locate the leak.
3. Eliminate the cause of the water leak.
2.3.2 When coming into contact with condensate
WARNING
Acidic condensate
●Chemical burns of eyes and body parts
►Use personal protective equipment (refer to chapter 1.6.3).
►Thoroughly rinse your eyes with water if condensate gets
into your eyes.
►Consult a physician, if necessary.

Product description
13 | 56
BA_100164650000_en_075_AH-300.docx
3 Product description
3.1 Intended use
●The waste water lifting system AH-300 is an automatically
operating system for delivering the media below:
•Neutralised condensate originating from
condensing boilers
•Gas condensate with a pH value > 3 originating
from condensing boilers
•Clear water or slightly polluted industrial water
●The waste water lifting system AH-300 is suitable for
continuous operation.
●The waste water lifting system AH-300 is not suitable for the
media below:
•Salt water (e.g. from water softeners)
•Water containing chlorine (e.g. swimming pool water)
•Non-neutralised oil condensate originating from
condensing boilers
•Dirty water containing textile or paper particles
•Aggressive liquids, chemicals
•Corrosive, flammable, explosive or gassing liquids

Product description
14 | 56
BA_100164650000_en_075_AH-300.docx
3.2 Product components
Designation
1
Overflow warning switch
2
Level switch
3
Lid
4
Filter cage
5
Collection box
6
Connection DN 25 (inlet)
Designation
7
Hose connection DN 20
(alternative)
8
Locknut with flat seal
9
Electrical connection box
10
Non-return valve with flat seal
11
Hose nipple DN 12 with flat
seal
12
Delivery pump

Product description
15 | 56
BA_100164650000_en_075_AH-300.docx
3.3 Functional description
The condensate flows into the collection box of the waste water lif-
ting system and is pumped to the drain by means of the level-con-
trolled delivery pump.
The delivery pump is a robust, seal-less centrifugal pump with the
shaft being mounted in the motor, which is only immersed into the
medium with the corrosion-resistant pumping unit. The delivery
pump features a protective temperature limiter with automatic reset.
The pump motor is switched off in the event of overheating and
restarts automatically after it has cooled down sufficiently.
The delivery pump switches on at a level of about 80 mm and off
again at a level of about 55 mm.
The integrated filter cage protects the delivery pump from coarse im-
purities.
The non-return valve prevents any backflow into the collection box
when the delivery pump is off.
All electrical components are aligned on the lid and can be comple-
tely when comes to cleaning the collection box.
Level switch and overflow warning switch
The level switch for switching the pump on and off as well as the
voltage-free overflow warning switch are actuated without contact
via an air cushion. This operationally safe level detection prevents
malfunctions caused by corrosion and deposits on mechanical com-
ponents.
A second overflow warning switch with voltage-free changeover
contact can be used for external fault signalling or for switching off
the heat generator. The overflow warning switch switches at a level

Product description
16 | 56
BA_100164650000_en_075_AH-300.docx
of about 120 mm and is switched off again at a level of about 95
mm.
The optional alarm delay (refer to chapter 3.4) for connection to the
overflow warning switch allows the heat generator to be switched off
either in parallel with the fault signal, or with a time delay.
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.
Condensate prefiltration box DN 25
410 135
In case of gas/oil switchover operation of a condensing
boiler or in case of an otherwise increased dirt content
(e.g. impurities entering from the chimney), we recom-
mend installing a condensate prefiltration box in the supply
line to the neutralisation system.
GENO-alarm delay relay
410 285
To execute a delayed shut-off 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.
Safety package for caustic substances:
180 810
Consisting of the required PPE equipment and symbol
signs necessary for the safe operation of dosing systems
with caustic dosing agents.
Hose DN 20 (5 m)
410 764e
To bridge distances of up to 5 m on the inlet and outlet
side.
Hose DN 25 (5 m)
410 774e
To bridge distances of up to 5 m on the inlet and outlet
side.

Transport, set-up and storage
17 | 56
BA_100164650000_en_075_AH-300.docx
4 Transport, set-up and storage
4.1 Shipping/Delivery/Packaging
The product is packed in a cardboard box at the factory.
►Upon receipt, immediately check for completeness and trans-
port damage.
4.2 Transport/Set-up
►Transport the product in its original packaging only.
►Place the product on a level and stable surface. Take the
weight of the product into account.
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
18 | 56
BA_100164650000_en_075_AH-300.docx
5 Installation
The installation of the product must be carried out by a qualified
specialist only.
Installation example
Designation
1
Heat generator with siphon
2
Inlet hose
3
Neutralisation system
GENO-Neutra N-210
Designation
4
Connecting hose
5
Waste water lifting system
AH-300
6
Drain connection

Installation
19 | 56
BA_100164650000_en_075_AH-300.docx
5.1 Requirements for the installation site
Obey the local installation directives, general guidelines and techni-
cal specifications.
●Protection from frost, severe heat exposure and direct sun-
light
●Protection from high radiation temperatures in the immediate
vicinity (≤ 40 °C)
●Protection from chemicals, dyes, solvents and their vapours
●Access for maintenance work (take note of space required)
●Sufficiently illuminated as well as aerated and ventilated
●Horizontal installation surface with sufficient load-bearing
capacity to support the operating weight of the product
Space required
●There must be a clearance of at least 800 mm in front of the
system for operation.
●Above the system, there must be a clearance of at least
600 mm for installation and maintenance work.
Water installation
●Inlet hose with a downward slope
●Floor drain or an alarm device which, in the event of a mal-
function, clearly indicates the alarm and switches off the heat
generator, if necessary
●Drain connection ≥ DN 40 with possibility of backflow-free
discharge of the condensate
●The drain connection must allow for a resistance-free
discharge of ≥ 41.5 l/min

Installation
20 | 56
BA_100164650000_en_075_AH-300.docx
5.2 Checking the scope of supply
Designation
1
Waste water lifting system
AH-300 as compact system
(pre-assembled)
2
Overflow warning switch
3
Hose connection DN 25 with
union nut and seal
4
Hose connection DN 20
Designation
5
Outlet hose, 6 m in length
(DN 12)
6
1 Hose clamp (12–20)
7
2 Hose clamps (20–32)
8
Operation manual
The small parts are located in the collection box.
►Remove the lid and take out the small parts.
►Check the scope of supply for completeness and damage.