Grunbeck GENO-OSMO RO 125K User manual

Operation manual
Reverse osmosis system
GENO-OSMO RO 125K
Edition September 2018
Order no. 285 752 940-inter

Reverse osmosis system
GENO-OSMO RO 125K
Order no. 285 752 940-inter Edited by: phar-mrie G:\BA-752940-INTER_285_RO_125K.DOCX
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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
C Product description 11
1 Type plate
2 Functional description
3 Intended use
4 Application limits
5 Scope of supply
D Installation 24
1 General installation instructions
2 Preliminary works
3 Connecting the system on the water side
E Commissioning 30
1 How to flush the system
F Operation 34
1 Preface
2 How to operate the control unit
3 Programming levels
4 Operation of reverse osmosis
G Troubleshooting 43
H Maintenance and care 45
1 Basic information
2 Inspection (functional check)
3 Maintenance
4 Operation log (checklist for maintenance work)

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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.
-Subject to modifications in line with technical advances-
Reprints, translations into foreign languages, electronic storage or
copying of this operation manual, including extracts, only with explicit
written approval of Grünbeck Wasseraufbereitung GmbH.
Any type of duplication not authorised by Grünbeck Wasseraufbereitung
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  [email protected]
Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1, 89420 Hoechstaedt, Germany

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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. 1
89420 Hoechstaedt
Germany
Responsible for documentation: Markus Pöpperl
System designation: Reverse osmosis system GENO-OSMO RO 125K
System type: TL; TS
Serial no.: Refer to type plate
Applicable directives: Machinery Directive (2006/42/EC)
EMC (2014/30/EU)
Applied harmonised standards,
in particular:
DIN EN ISO 12100:2011-03
DIN EN 61000-6-2:2006-03
DIN EN 61000-6-3:2011-09
Applied national standards
and technical specifications,
in particular:
Place, date and signature: Hoechstaedt, 30.04.2018 i. V.
M. Pöpperl
Dipl. Ing. (FH)
Function of signatory: Head of Technical Product Design

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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 customised
solutions for all kinds of processes.
Drinking water is classified as food and requires particular care.
Therefore, always ensure the required hygiene in operating and
maintaining 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 reliable operation over many years, provided you treat
your water treatment system with the required care. This operation
manual assists you with important information. Please read the entire
operation manual carefully before installing, operating or servicing
the system.
Customer satisfaction is our primary aim, and providing customers
with qualified advice is crucial at Grünbeck. If you have any questions
concerning the present product, possible extensions or general water
and waste water treatment, our field 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). or get in touch with our service centre
which can be reached during office hours:
Phone: [phone]
Fax: [phone]
Email: [email protected]
We can connect you with the appropriate expert more quickly if you
are able to provide the required system data. In order to have the
required data handy at all times, please copy it from the type plate to
the overview in chapter C-10.
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
order. 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
easier 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, major damage to property or inadmissible
impurities in the drinking water.
Warning! Failure to adhere to this information may 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 characterises information and tips that make your
work easier.
Tasks with this symbol may only be performed by Grünbeck's
technical service/authorised service company or by persons
expressly authorised by Grünbeck.
Tasks with this symbol may only be performed by trained and
qualified 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
company must be registered in the installation directory of a water
supplier as per Section 12(2) AVBWasserV (German Ordinance on
General Conditions for the Supply of Water).
3.2 Operating
personnel
Only allow persons who have read and understood this operation
manual to work with the system. Strictly observe the safety information.
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
protection, 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
eliminated 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
case 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
escaping water and unexpected movement of system parts.  Check
pressure pipes regularly. Depressurise the system before starting
repair or maintenance work on the system.
Hazardous to health due to contaminated drinking water!
 The system 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 intervals specified!

Note: By concluding a maintenance contract, you ensure that all of
the required tasks are performed on time. You may perform the
interim inspections yourself.
4 | Shipping and storage
Caution! The system can 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.
Please inform yourself about the local regulations regarding the
separate collection of electric and electronic products.
Use the available collection facilities for the disposal of your product.

Information about the collection facilities for your product is available
at the town council, the public legal disposal company, an authorized
location for disposal of electrical and electronic products or your
waste disposal.

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B Basic information (reverse osmosis system)
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 regulations stipulate that
 only approved companies are permitted to make major
modifications to water supply facilities
 and that checks, inspections and maintenance on installed devices
are to be performed at regular intervals.
2 | Water
There is no chemically pure water in nature. Even in the
atmosphere, 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,
phosphates 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 biodegradable 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.
Removing 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
Principle:
Pretreated feed
water
Fig. B-1: Functional principle
Concentrate:
Permeate
Osmosis Osmotic pressure Reversed osmosis
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: Reverse osmosis principle
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
referred to as "osmotic pressure" is generated on the side of the
higher original concentration. In case of reverse osmosis, this osmotic
pressure is countered by a higher pressure. 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 removal of dissolved salts,
bacteria, germs, particles, and dissolved organic substances are
also reduced.

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C Product description
1 | Type plate
The type designation plate can be found on the housing of the
reverse osmosis system GENO-OSMO RO 125K. 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 RO 125K
125K-   Serial number:      / 
Order number:      
Fig. C-1: Type plate
2 | Functional description
The pretreated feed water is fed to the valve control unit after the fine
filter. A high-pressure pump then brings the feed water to the
operating pressure required for the function of the RO membrane.
The RO membrane separates the water into the partial flows
permeate and concentrate. The permeate is fed into a UV-resistant
storage tank made of PE. A partial flow of the concentrate is fed back
to the membrane via a circulation line by the high-pressure pump,
thus increasing the yield and efficiency of the reverse osmosis system
GENO-OSMO RO 125K and ensuring a uniform outflow on the
membrane. A small portion of the concentrate, in which the water
constituents retained by the membrane are located, is directed to
the drain.

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2.1 System components
Fig. C-2: Exploded drawing of reverse osmosis system GENO-OSMO 125K-TS

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1
Fine filter incl. pressure
reducer
Pressure reducer preset to 2.5 bar, incl. pressure gauge.
2
Inlet solenoid valve During the permeate production, this valve is always open. Following
the system stop (tank full), the valve remains open for the programmed
flushing time of the membrane. Optical display in control electronics .
3
Pressure switch
Pressure booster pump
Switches the pressure booster on when water is required, and off again
after water withdrawal ends.
4
Flushing solenoid valve opens after the level control
8
in the tank reports "FULL" to the control
electronics for a set time. The solenoid valve also opens in the event of
system malfunctions and always in conjunction with the inlet solenoid
valve
2
.
5
Needle valve, concentrate To set the feed water-dependent "concentrate" volume flow to the
drain. During permeate output, this portion of the water flows
constantly to the drain.
6
High-pressure pump Pump unit that generates the operating pressure required for the
membrane. Pump runs according to permeate requirement from the
level control
8
(LB switches) located in the permeate tank. A control
valve for adjusting the operating pressure is integrated in the pump
head. Optical display in control electronics
10
.
7
Membrane Reverse osmosis membrane to generate the permeate.
8
Level control Float level control for controlling the water level in the permeate tank
(TS version only).
9
Pressure booster pump Pressure booster pump with integrated pressure switch. Feeds
permeate into the consumer network (only TS version).
10
Control electronics Microprocessor controller that in conjunction with the respective units,
regulates the permeate production and the supply of consumers
downstream.
11
Flow sensor,
concentrate
registers the concentrate volume and sends pulses to the control
electronics. Optical display of the concentrate volume in the control
electronics
10
.
12
Flow sensor
Permeate
registers the permeate quantity and sends pulses to the control
electronics. Optical display of the permeate quantity in the control
electronics
10
.
13
Diaphragm expansion tank Permeate buffer to reduce the switching operations of the DE pump.
14
Pressure switch
High-pressure pump
to prevent the high-pressure pump from running dry. Switches time-
delayed after the solenoid valve has opened . Optical display in
control electronics
10
.
15
Connection ½" (DN 15)
male thread
Concentrate to drain
16
Connection ½" (DN 15)
male thread
Feed water
17
Connection ½" (DN 15)
male thread
Permeate/consumer
18
Option: Solenoid valve forced withdrawal
19
Option: Conductivity measurement
20
Option: Blending unit

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2.2 Flow diagram reverse osmosis system GENO-OSMO-RO 125k
Fig. C-2.1: Flow chart reverse osmosis system GENO-OSMO RO 125K-TS (for legend see front page)

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Table C-1: Technical data Reverse osmosis system GENO-OSMO RO
125K-TS 125K-TL
Connection data
Nominal connection diameter of feed water pipe ½" (DN 15) male thread
Nominal connection diameter of permeate outlet ½" (DN 15) male thread
Nominal connection diameter of concentrate
outlet
½" (DN 15) male thread
Min. drain connection required DN 50
Connected load, approx. [kW] 0.85 0.50
Power supply [V/Hz] 230/50
Protection/protection class IP 54/
Performance data
Permeate output at a feed water temperature of
10 °C/15 °C
[l/h] 105/125
Electrical capacity of pump at operating
pressure
[kW] 0.37
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
Permeate supply approx. [l] 38 -
Pump characteristic curve pressure booster [l/h/bar] 300/3.5 – 1200/1.0 -
Nominal pressure PN 16
Salt rejection 95 – 99 %
Total salt concentration of the feed water as NaCl,
max.
[ppm] 1000
Concentrate volume flow, min./max. (at 15 °C) [l/h] 40/125
Feed water volume flow
(fresh water 15 °C) at a recovery of 75 %, max.
[l/h] 160
Recovery min./max. [%] 50 – 75 (adjustable)
Dimensions and weights
Dimensions (w x d x h) [mm] 450 x 600 x 1130
Empty weight, approx. [kg] 37 30
Operating weight, approx. [kg] 75 30
Ambient data
Feed water temperature min./max. [°C] 10/301)
Ambient temperature, min./max. [°C] 5/35
Order no. 752 100 752 110
1) 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 RO 125K is used for
the demineralisation of feed waters. The water is primarily used for
industrial applications.
The system can be used only after a prior water analysis and
corresponding pretreatment.
The permeate capacity of the system depends on the temperature
and is defined at 15 °C. The permeate outputs can fall (falling
temperature) 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
installation site be observed. Furthermore, the maintenance and
inspection intervals must be respected.
3.1 | System shut-down
If the system is shut down for more than 14 days, the reverse
osmosis system must be preserved by Grünbeck's technical customer
service/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
service/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
RO 125K, the limit values stipulated in the German Drinking Water
Ordinance represent the upper limits for the admissible substances
contained in the water.
 Total hardness < 0.1°dH (0.178°f, 0.0178 mmol/l)
 Free chlorine not detectable
 Iron < 0.1 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

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.

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5 | Scope of supply
5.1 Standard
equipment
 Stand-alone housing made of opaque PE to accommodate all
aggregates and control elements. Stand-alone housing also serves
as supply tank (only GENO-OSMO RO 125K-TS)
 Microprocessor controller with LC display, voltage-free collective
fault signal and voltage-free signal contact (maintenance interval,
various pre-warnings), installed in a stand-alone housing.
 Sliding-vane rotary pump made of corrosion-resistant brass with
motor as high-pressure pump to supply the membrane, incl. control
valve for operating pressure and pressure gauge
 1) External pressure booster with pressure switch and
membrane connection vessel for supplying permeate to
downstream consumers
 Hydro module for the water supply within the membrane system.
Integrated valves and measuring instruments for easier system
calibration.
 Fine filter with integrated pressure reducer preset to 2.5 bar.
 Ultra-low pressure reverse osmosis membrane, installed in
pressure pipe made of high-strength PE
 Flow sensor to measure the volume of the system flows permeate
and concentrate
 Operation manual
1) Only GENO-OSMO RO 125K-TS
5.2 Optional features

Note: It is possible to retrofit existing systems with optional
components. Please contact your local Grünbeck representative or
Grünbeck’s headquarters in Hoechstaedt for more information.
 Connection block for
GENO-OSMO-RO 125 K
Connection block (installation length 190 mm).
Permeate-resistant incl. two shut-off valves –
suitable for connection set
752 840
 Connection set for GENO-OSMO 125K
2 flexible connection hoses DN 15
(L = 600 mm) for feed water and permeate
1 drain hose for concentrate
752 830
 Conductivity measurement for
GENO-OSMO RO 125K
As plug-in board to the control electronics.
Display with limit value and delay, incl.
connecting line and conductivity measuring
cell installed in the combi-cap pressure pipe.
752 820

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 Forced withdrawal solenoid valve for
RO 125K
Solenoid valve can be adapted to the
permeate outlet hydro module for forced
withdrawal with GENO-OSMO RO 125K
from the tank during longer idle times.
Electrically controlled from control electronics
of the GENO-OSMO RO 125K.
752 810
 Blending device for
GENO-MSR system 200
Adaptable control unit to hydraulic unit
GENO-OSMO RO 125K consisting of:
Connection G ¾ for feed water, solenoid
valve, needle valve, flow sensor to display
the total blended water in the control unit
GENO-OSMO RO 125K, connection option
for blended water in GENO-OSMO RO 125K
or on-site tank
752 800

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 Drinking water filter BOXER K
Filter element for prefiltration.
101 210
 Euro system separator GENO-DK 2 Mini
For protecting systems hazardous to drinking
water in accordance with DIN 1988 Part 4
(DIN EN 1717) GENO-DK 2 Mini.
133 100
 Water softener Weichwassermeister
GSX 10 I in industrial version
As a softener with twin units for alternating
operation including connection block and
flexible connection hoses.
187 530
 GENO-softwatch Komfort
for automatic monitoring of the
residual/total hardness (water hardness).
172 500
 GENO activated carbon filter AKF 300
For reducing the chlorine content in water.
109 150
Safety device protectliQ:A20
Product for the protection from water damage in
one and two-family homes.
For other sizes, please inquire.
126 400