Grunbeck GENO-OSMO-AVRO 125 RU User manual

Operation manual
Reverse osmosis system
GENO-OSMO-AVRO 125 RU
Edition September 2018
Order no.: 100074900000_en_035

Reverse osmosis system
GENO-OSMO-AVRO 125 RU
Order no. 100074900000_en_035 Edited by: pha-mrie G:\BA_100074900000_EN_035_AVRO_125_RU.DOCX
2
Table of contents

The operation manual consists of several chapters, which are listed
below.
A General
5
1 Preface
2 How to use this operation manual
3 General safety information
4 Shipping and storage
5 Disposal
B Basic information
9
1 Laws, regulations, standards
2 Water
3 Functional principle of reverse osmosis system 
GENO-OSMO-AVRO 125 RU
C Product description
12
1 Type plate 
2 Functional description 
3 Intended use
4 Application limits
5 Scope of supply
D Installation
27
1 General installation instructions
2 Preliminary works
3 Connecting the system on the water side
4 Electrical installation
E Commissioning
34
1 How to flush the system
F Operation
38
1 Preface
2 Operating the control unit
3 Programming levels
4 Operating reverse osmosis system
GENO-OSMO-AVRO 125 RU
G Troubleshooting
47
H Maintenance and care
49
1 Basic information
2 Inspection (functional check)
3 Maintenance
4 Operation log (maintenance checklist)

Reverse osmosis system
GENO-OSMO-AVRO 125 RU
Order no. 100074900000_en_035 Edited by: pha-mrie G:\ BA_100074900000_EN_035_AVRO_125_RU.DOCX
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Publisher's information
All rights reserved.
©Copyright by Grünbeck Wasseraufbereitung GmbH
Printed in Germany
Effective with the date of edition indicated on the cover sheet.-We
reserve the right to modifications, especially with regard to technical
progress-
Reprints, translations into foreign languages, electronic storage or
copying only with explicit written approval of Grünbeck Wasserauf-
bereitung GmbH.
Any type of duplication not authorised by Grünbeck Wasseraufberei-
tung is a copyright violation and subject to legal action.
Responsible for contents:
Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1 | 89420 Hoechstaedt, Germany
Phone [phone] | Fax [phone]
www.gruenbeck.com | [e-mail]
Printing: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1, 89420 Hoechstaedt; Germany

Reverse osmosis system
GENO-OSMO-AVRO 125 RU
Order no. 100074900000_en_035 Edited by: pha-mrie G:\BA_100074900000_EN_035_AVRO_125_RU.DOCX
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EU Declaration of Conformity
This is to certify that the system designated below meets the safety and health requirements of
the applicable European guidelines in terms of its design, construction and execution.
This certificate will become void if the system is modified in a way not approved by us.
Manufacturer: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str.
89420 Hoechstaedt
Germany
Responsible for documentation: Peter Harlander
System designation: Reverse osmosis system
System type: GENO-OSMO-AVRO 125 RU
Serial no.: Refer to type plate
Applicable guidelines: Machinery Directive (2006/42/EC)
EMC (2014/30/EU)
Applied harmonised standards,
in particular:
EN ISO 12100:2011-03, 
EN 61000-6-2:2006-03
EN 61000-6-3:2011-09
Applied national standards and
technical specifications, in particu-
lar:
Place, date and signature: Hoechstaedt, 30 April 2018 i.V .
P. Höß
Function of signatory: Head of Technical Systems & Equipment

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A General
1 | Preface
Thank you for choosing a Grünbeck product. Backed by decades of
experience in the area of water treatment, we provide custom-made
solutions for all kind of processes.
Drinking water is classified as food and requires particular care.
Therefore, always ensure the required hygiene in operating and main-
taining systems involved in the drinking water ordinance. This also
applies to the treatment of water for industrial use if repercussions for
the drinking water cannot completely be excluded.
All Grünbeck systems and devices are made of high-quality materials.
This ensures trouble-free operation over many years, provided you
treat your water treatment system with the required care. This opera-
tion manual assists you with important information. Please read the
entire operation manual carefully before installing, operating or servic-
ing the system.
Customer satisfaction is our primary aim, and providing customers
with qualified advice is crucial at Grünbeck. If you have any questions
concerning this system, possible extensions or general water and
waste water treatment, our field service staff, as well as the experts at
our headquarters in Hoechstaedt, are available to help you.
Advice and assistance
For advice and assistance please contact your local representative
(refer to www.gruenbeck.com). In case of emergency, please get in
touch with our service hotline at [phone]. We can connect
you with the appropriate expert more quickly if you provide the re-
quired system data. To ensure that this information is to hand at all
times, please copy the data indicated on the type plate to the table in
chapter C, paragraph 1.
2 | Notes on using the operation manual
This operation manual is intended for operators of our systems. It is
divided into several chapters (a letter is assigned to each of them)
that are listed in the "Table of contents" on page 2 in alphabetical or-
der. Locate the corresponding chapter on page 2 in order to find the
specific information you are looking for.
The headers and page numbers with chapter information make it eas-
ier to find your way around in the operating instructions.

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3 | General safety information
3.1 Symbols and notes
Important information in this operation manual is emphasised by
symbols. Please pay particular attention to this information to ensure
the hazard-free, safe and efficient handling of the system.
Danger! Failure to adhere to this information will cause serious or
life-threatening injuries, extreme damage to property or inadmissible
contamination of the drinking water.
Warning! Failure to adhere to this information can cause injuries,
damage to property or contamination of the drinking water.
Caution! Failure to adhere to this information can result in damage
to the system or other objects.

Note: This symbol emphasises information and tips that make your
work easier.
Tasks with this symbol may only be performed by Grünbeck's tech-
nical service/authorised service company or by persons expressly
authorised by Grünbeck.
Tasks with this symbol may only be performed by trained and quali-
fied electrical experts according to the VDE guidelines or according
to the guidelines of a similar local institution.
Tasks with this symbol may only be performed by water suppliers or
approved installation companies. In Germany, the installation com-
pany must be registered in the installation directory of a water suppli-
er according to Section 12(2) AVBWasserV (German Ordinance on
General Conditions for the Supply of Water).
3.2 Operating person-
nel Only allow persons who have read and understood this operation
manual to work with the system. Strictly observe the safety infor-
mation.
3.3 Intended use
The system may only be used for the purpose outlined in the product
description (chapter C). The instructions in this operation manual as
well as the applicable local guidelines concerning drinking water pro-
tection, accident prevention and occupational safety must be adhered
to.
In addition, intended use also implies that the system may only be
operated when it is in proper working order. Any errors must be elimi-
nated at once.

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3.4 Protection from water damage
Warning! In order to properly protect the installation site from water
damage:
a) a sufficiently dimensioned floor drain system must be available or
b) a safety device (refer to chapter C Optional accessories) must be
installed.
Warning! Floor drains that discharge to a lifting system do not work
in the event of a power failure.
3.5 Indication of
specific dangers
Danger due to electrical energy! →Do not touch electrical parts with
wet hands! Disconnect the system from the mains before starting
work on electrical parts of the system! Have qualified experts replace
damaged cables immediately.
Danger due to mechanical energy! System parts may be subject to
overpressure. Danger of injury and damage to property due to escap-
ing water and unexpected movement of system parts. →Check pres-
sure pipes regularly. Depressurise the system before starting repair
or maintenance work on the system.
Hazardous to health due to contaminated drinking water! →The sys-
tem should be installed by a specialist company only. Strictly adhere
to the operation manual! Ensure that there
is sufficient flow. Adhere to
the pertinent guidelines when starting up the system after extended
periods of standstill. Perform inspections and maintenance at the in-
tervals specified!

Note: By concluding a maintenance contract, you ensure that all of
the required tasks are performed on time. You may perform the inter-
im inspections yourself.
4 | Shipping and storage
Caution! The system may be damaged by frost or high temperatures. In
order to avoid damage of this kind:
Protect from frost during transportation and storage!Do not install or
store the system next to objects which radiate a lot of heat.

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5 | Disposal
Comply with the applicable national regulations.
5.1. Packaging
Dispose of the packaging in an environmentally sound manner.
5.2. Product
If this symbol (crossed out waste bin) is on the product, European
Directive 2012/19/EU applies to this product. This means that this
product or the electric and electronic components are not allowed to
be disposed of in the household waste.
Dispose of electrical and electronic products or components in an en-
vironmentally sound manner.

For information on collection points for your product, contact your
municipality, the public waste disposal authority, an authorised body
for the disposal of electrical and electronic products or your waste
collection service.

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B Basic information
1 | Laws, regulations, standards
In the interest of good health, rules cannot be ignored when it comes
to the processing of drinking water. This operation manual takes into
consideration the current regulations and stipulates information that
you will need for the safe operation of your water treatment system.
Among other things, the set of rules stipulate that
•only approved companies are permitted to make major modifi-
cations to water supply facilities
•and that tests, inspections and maintenance on installed devic-
es are to be performed at regular intervals.
2 | Water
There is no chemically pure water in nature. Even in the atmos-
phere, rain water absorbs various substances that change the
properties of the water to a greater or lesser degree. This process
continues as the water passes through the ground layers, with the
result that the water is enriched with increasingly large quantities of
materials. Carbon dioxide (CO2) is particularly important here, since
this substance increases the dissolving capability of the water even
more. Consequently, drinking water contains quantities of dissolved
sodium, potassium, calcium, magnesium, iron, manganese, copper,
zinc, chlorides, fluorides, sulphates and also nitrates, nitrites, phos-
phates and silicates that vary greatly from location to location.
Due to dynamic substance and water cycles, harmful elements,
which are only partly and only slowly bi
odegradable are increasingly
released into nature. These are only partially and slowly broken
down by natural effects. Consequently, these elements accumulate
in the groundwater and surface water over the course of time. Re-
moving them from natural water deposits represents a particular
challenge. Grünbeck faces this challenge with the aim of producing
unpolluted drinking and industrial water.
The water works provide us with pure drinking water that is suitable
for consumption. However, if the water is to be used for technical
purposes, further treatment is frequently required.

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3 | Functional principle of reverse osmosis system GENO-OSMO-
AVRO 125 RU
Principle:
Pretreated feed
water
Concentrate:
Permeate
Fig. B-1: Functional principle
Solution of high
concentration
Solution of low
concentration
Solution of high
concentration
Solution of low
concentration
Solution of high
concentration
(concentrate)
Solution of low
concentration
(permeate)
Fig. B-2: Principle of reverse osmosis system GENO-OSMO-AVRO 125 RU
In the osmosis process, watery solutions of different concentrations
are separated by a semi-permeable membrane. In keeping with the
law of nature, the concentrations will tend to equalise. What is re-
ferred to as "osmotic pressure" is generated on the side of the higher
original concentration. In the reverse osmosis system GENO-OSMO-
AVRO 125 RU, this "osmotic pressure" is countered by a higher pres-
sure. The consequence: The process runs in the opposite direction. A
particular advantage of the reverse osmosis technology compared to
other water treatment processes is the fact that apart from the remov-
al of dissolved salts, bacteria, germs, particles, and dissolved organic
substances are also reduced.

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3.1 Functional princi-
ple of the AVRO
system
AVRO is an alternative anti-scaling process to the common traditional
processes of "softening" or "antiscalant dosing". Contrary to these
processes, AVRO does not require any addition of auxiliary additives.
The chemical composition of the generated concentrate is not modi-
fied. There is only a doubling of the concentration (standard recovery
50%).
Hydraulically, the AVRO is installed in the concentrate pipe down-
stream of the membrane.
The treatment unit consists of two inert special electrodes to which a
low current is applied. Seed crystals (calcium carbonate) are generat-
ed at the cathode and are permanently directed via the concentrate
recirculation. The salts of the supersaturated concentrate continue to
grow on these seed crystals, and they are finally washed out to the
drain with the residual concentrate flow. This reliably prevents scaling
(deposits of insoluble salts on the membrane). Some of the calcium
carbonate remains on the cathode of the AVRO and due to increasing
electrical resistance, limits the service life of the AVRO treatment unit
to 3000 operating hours (permeate production) or 5 years.

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C Product description
1 | Type plate
The type designation plate can be found on the housing of the re-
verse osmosis system GENO-OSMO-AVRO 125 RU. In order to
speed up the processing of your inquiries or orders, please specify
the data shown on the type plate of your system when contacting
Grünbeck. Please copy the indicated information to the table below in
order to have it handy whenever necessary.
Reverse osmosis system GENO-OSMO-AVRO 125 RU
Serial number:
n
n
n
n
n
n
/
n
Order number:
n
n
n
n
n
n
Fig. C-1: Type plate

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2 | Functional description
Via a fine filter, the water is directed to the inlet of the feed water sec-
tion. The water flows to the high-pressure pump via the inlet solenoid
valve with a downstream pressure switch for minimum pressure. By
means of an adjusting valve, the pressure generated by the pump is
reduced to the required operating pressure and the water is directed
to the membrane. The membrane separates the water into the partial
flows permeate and concentrate. A partial flow of the concentrate is
returned to the feed water via an orifice regulating independently of
pressure and thus ensures a steady flow over the reverse osmosis
membrane and increases the economic efficiency of the reverse os-
mosis system.
At the same time, the concentrate volume flow is run via an AVRO
treatment module. where seed crystals are formed at a cathode due
to the application of direct current. These seed crystals are then
washed out with the residual concentrate and thus the reverse osmo-
sis membrane is protected from clogging. Whenever the system is
switched off or in case of disturbances, the substances retained on
the membrane are flushed off by means of the inlet solenoid valve
and a solenoid valve switched in parallel to the control valve for con-
centrate.
The hydraulic set-up of the system is designed in a way that the con-
centrate volume and the permeate volume are registered by means of
flow sensors and are displayed in the control unit. The system recov-
ery can also be called up in the control unit.
With optional features, the permeate produced can be stored in a tank
or can also be supplied to a consumer via Online skid.

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1
Safety device (option)
(AVR1V3)
Closes when a leak occurs to protect against water damage and
serves as a shut-off valve for the system (e.g. when changing filters).
2
Euro system separator
GENO-DK 2 Mini (option)
(AVR1S4)
To secure devices and systems endangering the drinking water ac-
cording to DIN 1988-100 (DIN EN 1717).
3
GENO activated carbon
filter AKF 300 (AVR1F2)
(option)
To reduce the chlorine concentration in the water.
4
Fine filter incl. pressure
reducer (AVR1F1)
Pressure reducer preset to 2.5 bar, incl. pressure gauge.
5
Inlet solenoid valve
(AVR1V1)
During permeate output, this valve is always open. Following the sys-
tem stop (tank full), the valve remains open for the programmed flush-
ing time of the membranes. Visual indication in the control unit
13
.
6
Pressure switch
High-pressure pump
(AVR1CP1)
To prevent the high-pressure pump from running dry. Switches time-
delayed after the solenoid valve has opened
5
. Visual indication in
the control unit
13
.
7
Flushing solenoid valve
(AVR1V2) Opens after the switch-off pressure
17
has been reached for a set
time. The solenoid valve also opens for forced flushing, in the event of
system malfunctions and always in conjunction with the inlet solenoid
valve
5
.
8
Needle valve concentrate
(AVR1H1)
To set the feed water-dependent "concentrate" volume flow to the
drain. During permeate output, this portion of the water flows constant-
ly to the drain.
9
High-pressure pump
(AVR1P1)
Pump unit that generates the operating pressure required for the
membrane. Pump starts after permeate request from the permeate
pressure switch
17
. A control valve for adjusting the operating pres-
sure is integrated in the pump head. 
Visual indication in the control unit
13
.
10
Membrane (AVR1B1)
Reverse osmosis membrane for generating the permeate.
11
AVRO treatment unit
(AVR1B2)
AVRO treatment unit to generate seed crystals.
12
Solenoid valve for perme-
ate relief ("Online-skid" op-
tion) (AVR1V4)
Used to relieve the RO membranes during START and STOP of the
RO system and during forced flushing of the system.
13
Control unit (AVR1E1)
Microprocessor controller that in conjunction with the respective units,
regulates the permeate production and the supply of consumers down-
stream.
14
Flow sensor 
concentrate (AVR1CF1)
Registers the concentrate volume and sends pulses to the control
unit.Visual indication of the concentrate volume in the control unit
13
.
15
Flow sensor 
permeate (AVR1CF2)
Records the permeate volume and sends pulses to the control unit. 
Visual indication of the permeate volume in the control unit
13
.
16
Diaphragm expansion tank
("Online-skid" option)
(AVR1B3)
Permeate buffer to reduce the switching operations of the reverse os-
mosis system GENO-OSMO-AVRO 125 RU
17
Pressure switch 
("Online-skid" option)
(AVR1CP3)
Switches the reverse osmosis system GENO-OSMO-AVRO 125 RU on
when water is required, and off again after water withdrawal ends.

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18
Connection HT50 (option)
Drain connection
19
Connection ½" (DN 15)
male thread
Feed water.
20
Connection ½" (DN 15)
male thread
Permeate/consumer.
21
Pressure gauge
(AVR1CP2) To display the operating pressure of the HP pump
9
.
22
Pressure gauge
("Online skid" option)
(AVR1CP4)
To display the current permeate pressure to the consumer.
23
Collecting water (option)
For sensitive installation sites in conjunction with the option of a safety
device protectliQ:A20.

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2.1 | Product components
Fig. C-2: Product components of reverse osmosis system GENO-OSMO-AVRO 125 RU

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2.2 Flow chart of reverse osmosis system GENO-OSMO-AVRO 125 RU
Fig. C-3: Flow chart of reverse osmosis system GENO-OSMO-AVRO 125 RU with options

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Technical specifications Reverse osmosis system
GENO-OSMO-AVRO 125 RU
Connection data
Nominal connection diameter of feed water pipe
DN 15 (½" male thread)
Nominal connection diameter of permeate outlet
DN 15 (½" male thread)
Nominal connection diameter of concentrate outlet
DN 15 (½" male thread)
Min. drain connection
DN 50
Connected load approx.
[kW]
0.7
Power supply
[V/Hz]
230/50
Performance data
Permeate output at a feed water temperature
10 °C/15 °C
[l/h] 105/125
Electrical capacity of pump at operating pressure
[kW]
0.55
Permeate output per day (max. 24 h) approx. min./max.
[m³/d]
2.5/3.0
Inlet flow pressure of feed water, min.
[bar]
2.5
Nominal pressure
PN 16
Salt rejection
95 – 99 %
Total salt concentration of the feed water as NaCl, max.
[ppm]
1000
Concentrate volume flow (at 15 °C)
[l/h]
125
1)
Feed water volume flow 
(fresh water 15 °C) at a recovery of 50%, max.
[l/h] 250
System recovery [%]
50 – 75
(default setting 50
1)
)
Dimensions and weights
A System width
[mm]
900
B System height
[mm]
600
C System depth
[mm]
500
Operating weight, approx.
[kg]
50
Shipping weight, approx.
[kg]
50
General
Feed water temperature min./max.
[°C]
10/30
Ambient temperature, min./max.
[°C]
5/35
Order no.
750 570
1) After a water analysis, the technical customer service can set a higher recovery.
2) For feed water temperatures > 20 °C, a separate design of the system is required.

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3 | Intended use
The reverse osmosis system GENO-OSMO-AVRO 125 RU is used to
demineralise drinking water for:
•Technical applications in trade
•Industry
•Medical technology
The permeate capacity of the system depends on the temperature
and is defined at 15°C. The permeate outputs can fall (falling temper-
ature) or rise (rising temperature) by up to 3% for each °C rise or fall
in the feed water temperature.
The system is adjusted to the permeate requirements to be expected
at the installation site, it is not suitable for major deviations.
Only operate the system if all components are properly installed.
Safety devices and equipment must NEVER be removed, bridged or
tampered with.
Intended use of the device also implies that the information contained
in this operation manual and all safety guidelines applying at the in-
stallation site be observed. Furthermore, the maintenance and in-
spection intervals must be respected.
The reverse osmosis system GENO-OSMO-AVRO 125 RU is de-
signed exclusively for use in industrial and commercial applications.
3.1 | System shut-down
If the system is shut down for more than 14 days, the reverse osmo-
sis system must be preserved by Grünbeck's technical customer ser-
vice/authorised service company. The maximum time, the system can
remain in the preserved condition is 6 months.
In case the down time is longer, the system must be preserved again
in regular intervals by Grünbeck's technical customer ser-
vice/authorised service company. Prior to resuming operation, the
preserving agent must be flushed from the system.

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4 | Application limits
For the application of the reverse osmosis system GENO-OSMO-
AVRO 125 RU, the limit values stipulated in the German Drinking Wa-
ter Ordinance represent the upper limits for the admissible substanc-
es contained in the water.
•< 22°dH (39.2° f; 3.92 mmol/l) without water analysis
•free chlorine max. 0.2 mg/l
•Iron < 0.10 mg/l
•Manganese < 0.05 mg/l
•Silicate < 15 mg/l
•Chlorine dioxide not detectable
•Turbidity < 1 FTU
•Colloid index < 3
•pH range 3 – 9
For total hardness > 22 °dH or sulphate > 250 mg/l a water analysis is
required.

Note: The permeate originating from the reverse osmosis system is
not potable but requires additional treatment (blending, hardening) if it
is to be used as drinking water.
Caution! In case of an admissible excess of the sulphate concentra-
tion due to geogenic conditions, the recovery with regard to the
standard settings according to layout might need to be reduced.