Grunbeck GENO-Neutra KW User manual

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Neutralisation system | GENO-Neutra KW
Operation manual

General Contact
Germany
International Sales
[phone]
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[phone]
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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.: TD3-GS002en_en_045

Table of contents
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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 Conduct in emergencies ............... 12
3Product description ..................... 13
3.1 Intended use................................. 13
3.2 Product components ..................... 14
3.3 Functional description ................... 14
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................................................ 20
5.2 Checking the scope of supply........ 21
5.3 Water installation .......................... 22
6Start-up/commissioning .............. 28
6.1 Filling the box................................ 29
6.2 Checking the product.....................30
6.3 Handing over the product to the
owner/ operating company.............31
7Operation ......................................32
8Maintenance and repair................33
8.1 Cleaning........................................33
8.2 Intervals ........................................34
8.3 Inspection......................................34
8.4 Maintenance..................................36
8.5 Consumables ................................39
8.6 Spare parts ...................................39
8.7 Wearing parts................................39
9Troubleshooting ...........................40
9.1 Observations .................................40
10 Decommissioning.........................42
10.1 Temporary shutdown.....................42
10.2 Restart/recommissioning ...............42
11 Dismantling and disposal.............43
11.1 Dismantling ...................................43
11.2 Disposal ........................................43
12 Technical specifications ..............45
13 Operation log ................................47
13.1 Start-up/commissioning log............47
13.2 Maintenance..................................48

Introduction
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1 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.
●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 products below:
●Neutralisation system GENO-Neutra KW35
●Neutralisation system GENO-Neutra KW65
1.2 Other applicable documents
●Instructions of optional accessories
●Maintenance instructions of maintenance kit
●Safety data sheet of neutralisation granulate

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 front or side of the box.
Designation
1
DVGW test mark
2
EAC test mark
3
Nominal connection diameter
4
Neutralisation capacity
5
Max. boiler capacity
6
Condensate temperature
7
Ambient temperature
Designation
8
Obey the operation manual
9
Fuel:
gas/gas condensing technology
10
Product designation
11
Data matrix code
12
Serial no.
13
Order no.
14
QR code

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:
1.5.1.1
1.5.1.2 SIGNAL WORD
1.5.1.3 Type and source of hazard
1.5.1.4
●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 peo-
ple carry out work on the product. This work requires different quali-
fications.
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 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.
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
1.6.3 Personal protective equipment
►As an owner/operating company, make sure that the re-
quired 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 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, a 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
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 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 may 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 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.
●Children should be supervised to make sure that they do not
play with the product.
2.1.5 Neutralisation granulate (GENO-Neutralit Hz)
●The neutralisation granulate is not considered to be a danger-
ous good in the sense of the German Dangerous Goods Reg-
ulation.
●Keep the neutralisation granulate away from children.
●Only the genuine GENO-Neutralit Hz of the manufacturer may
be used for the neutralisation systems.
●Neutralisation granulate is alkaline and can cause chemical
burns and irritation when coming into contact with the skin or
the eyes. Avoid any skin/eye contact with the neutralisation
granulate.
●Use personal protective equipment when working on the
product.
●Neutralisation granulate may damage surfaces when covering
them.

Safety
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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 neutralisation system GENO-Neutra KW is suitable for
the neutralisation (increase of the pH-value to > 6.5) of gas
condensate originating from gas-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 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. Suitability must be checked by
own tests, if necessary, and regular cleaning of the neutralisa-
tion system with replacement of the granulate must be pro-
vided for.
●In case of condensate containing an extremely high amount
of dirt, we recommend installing an activated carbon filter up-
stream. This increases the service life of the filter material of
the neutralisation system.

Product description
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3.2 Product components
Designation
1
Lid
2
Snap lock
3
Divider for condensate collection
area in the outlet
4
Outlet hose connection DN 20
Designation
5
Box
6
Angle-type inlet connection
DN 20
7
Divider for settling area in the
inlet
3.3 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.

Product description
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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.
The pH value of the discharged condensate can be checked by
means of pH indicator strips.
Neutralisation granulate should be refilled before the pH value falls
below 6.5.
Designation
1
Inlet
2
Settling area in the inlet
3
Filling area with granulate filling
Designation
4
Condensate collection area in
the outlet
5
Outlet

Product description
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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.
Waste water lifting system AH-300
420 150
Lifting system for condensates originating from neutralisa-
tion systems of gas- or oil-fired condensing boilers as well
as non-neutralised gas condensates > pH 3, clear water or
slightly polluted industrial water
Hose DN 20 (5 m)
410 764e
To bridge distances of up to 5 m on the inlet and outlet
side
GENO-Neutralit Hz (8 kg)
410 011
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
KW35
410 810
1 Bag of GENO-Neutralit Hz, 3.3 kg
KW65
410 820

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 neutralisation granulate is packed separately in a bag.
►Upon receipt, immediately check for completeness and
transport damage.
4.2 Transport/Set-up
►Transport the product in its original packaging only.
►The neutralisation granulate is not considered to be a danger-
ous good in the sense of the regulation. Comply with the cur-
rent 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 I
(without siphon in the heat generator)
Designation
1
Heat generator without siphon
2
Inlet hose with backwater loop
Designation
3
Neutralisation system
GENO-Neutra KW
4
Outlet hose

Installation
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Installation example II
(with drain connection and waste water lifting system)
Designation
1
Heat generator with siphon
2
Inlet hose
3
Neutralisation system
GENO-Neutra KW
Designation
4
Connecting hose
5
Drain connection
6
Waste water lifting system
AH-300

Installation
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5.1 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)
●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 ca-
pacity to support the operating weight of the product
Water installation
●Inlet hose with downward slope and siphon in heat generator
•Alternatively with backwater loop
●Outlet hose with a downward slope to the floor drain
●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
●Waste water lifting system in case the drain connection is lo-
cated at a higher level
●Drain connection ≥ DN 40 with possibility of backflow-free dis-
charge of the condensate