Grunbeck GENO-OSMO-X 180 User manual

We understand water.
Reverse osmosis system | GENO-OSMO-X permeate
stage
Operation manual

General Contact
Germany
International Sales
Phone [phone]
Technical Service
Phone [phone]
Fax [phone]
Availability
Monday to Thursday
7:00 am - 6:00 pm
Friday
7:00 am - 4:00 pm
Original operation manual
Edition: November 2022
Order no.: 100115500000_en_074

Table of contents
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Table of contents
Table of contents.............................................................. 3
1Introduction ............................................................. 4
1.1 Validity of the manual ............................................... 4
1.2 Other applicable documents ..................................... 5
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
3Product description............................................... 13
3.1 Intended use .......................................................... 13
3.2 Foreseeable misuse ............................................... 13
3.3 Product components .............................................. 14
3.4 System connections ............................................... 15
3.5 Functional description............................................. 16
3.6 Accessories............................................................ 20
4Transport, placing and storage............................. 23
4.1 Shipping/Delivery/Packaging .................................. 23
4.2 Transport/Placing ................................................... 23
4.3 Storage .................................................................. 23
5Installation ............................................................. 24
5.2 Requirements for the installation site ...................... 25
5.3 Checking the scope of supply ................................. 27
5.4 Water installation.................................................... 27
5.5 Electrical installation............................................... 31
6Start-up/Commissioning ....................................... 37
6.1 Flushing out the preserving agent........................... 37
6.2 Checking the 2-stage system ..................................44
6.3 Setting the control unit ............................................45
6.4 Handing over the product to the owner/operating
company.................................................................45
7Operation/handling ................................................46
7.2 Reverse osmosis system GENO-OSMO-X
2nd stage................................................................47
8Maintenance and repair .........................................49
8.1 Cleaning .................................................................49
8.2 Intervals..................................................................50
8.3 Inspection ...............................................................51
8.4 Maintenance ...........................................................51
8.5 Consumables..........................................................54
8.6 Spare parts .............................................................54
8.7 Wearing parts .........................................................54
9Troubleshooting.....................................................55
10 Decommissioning ..................................................56
10.1 Temporary shutdown ..............................................56
10.2 Decommissioning ...................................................56
10.3 Restart....................................................................56
11 Dismantling and disposal ......................................57
11.1 Dismantling.............................................................57
11.2 Disposal..................................................................58
12 Technical specifications ........................................59
13 Operation log .........................................................61
13.1 Start-up/Commissioning log ....................................61

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 efficient 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 system.
►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
The present operation manual is a supplementary documentation to the operation manual
of reverse osmosis system GENO-OSMO-X (order no. 750 927).
This manual applies to the products below:
●Reverse osmosis system GENO-OSMO-X permeate stage 180
●Reverse osmosis system GENO-OSMO-X permeate stage 360
●Reverse osmosis system GENO-OSMO-X permeate stage 720
●Reverse osmosis system GENO-OSMO-X permeate stage 1100
●Reverse osmosis system GENO-OSMO-X permeate stage 1450
●Reverse osmosis system GENO-OSMO-X permeate stage 2000
●Reverse osmosis system GENO-OSMO-X permeate stage 2700
●Reverse osmosis system GENO-OSMO-X
in optional versions: with membrane degassing
●Special designs that essentially correspond to the standard products given above.
For information on changes, please refer to the respective information sheet that is
enclosed, if applicable.

Introduction
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1.2 Other applicable documents
●Operation manual Reverse osmosis system GENO-OSMO-X
(order no.: 750 927
●Manuals of all accessories used
●Manuals of components from other manufacturers
●Safety data sheets for chemicals
●Electric circuit diagram, order no.: 750 292 and 751 292
1.3 Product identification
You can identify your product based on the product designation and the order number shown
on the type plate.
►Check whether the products given in chapter 1.1 correspond to your product.
The type plate is located on the system rack.
Designation
1
CE mark
2
EAC mark
3
Obey the operation manual
4
Disposal information
5
Product designation
6
Operating weight
7
Order no.
8
Serial no.
9
Date of manufacture
10
Protection/protection class
Designation
11
Power input
12
Power supply
13
Ambient temperature
14
Feed water temperature
15
Recovery
16
Permeate capacity at a feed water
temperature of 15 °C
17
Nominal connection diameter
Permeate/concentrate discharge pipe
18
Nominal connection diameter
Feed water supply pipe

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 following signal words are defined subject to the degree of danger and might be used in
the present document:
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 function or damage to an object in its
vicinity

Introduction
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1.6 Demands on personnel
During the individual phases in the service life of the system, different persons carry out work
on the systems. The respective tasks require different skills.
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 necessary 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 prevention
Technical service
(Grünbeck's technical
service/authorised service
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
Installation and mounting
X
X
Start-up/Commissioning
X
X
Operation and handling
X
X
X
X
Cleaning
X
X
X
Inspection
X
X
X
X
Maintenance
X
Troubleshooting
X
X
X
X
Repair
X
X
Decommissioning and restart/recommissioning
X
X
Dismantling and disposal
X
X

Introduction
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1.6.3 Personal protective equipment
►As an owner/operating company, make sure that the required personal protective
equipment is available.
The components below fall under the heading of personal protective equipment (PPE):
PPE
Protective gloves
Protective footwear
Protective overall
Protective goggles
Hard hat
Mask
Face shield
Protective apron

Safety
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2 Safety
2.1 Safety measures
●Only operate the system if all components are installed properly.
●Obey the local regulations on drinking water protection, accident prevention and
occupational safety.
●Do not make any changes, alterations, extensions or program changes on your
product.
●Only use genuine spare parts for maintenance or repair. If unsuitable spare parts
are used, the warranty for the system will be void.
●Always keep the premises locked against unauthorised access to protect
imperilled/non-trained persons from residual risks.
●Comply with the maintenance intervals (refer to chapter 8.2). Failure to comply can
result in the microbiological contamination of your drinking water system.
2.1.1 Mechanical safety
●You must never remove, bridge, or otherwise tamper with safety equipment
●For all work on the system that cannot be done from the ground, use stable, safe
and self-standing access aids (e.g. stepladders).
●Make sure that the system is set up in a way that it cannot tip over and that the
stability of the system is guaranteed at all times.
2.1.2 Pressure-related hazards
●Components can be under pressure. There is a risk of injuries and damage to
property due to escaping water and unexpected movement of components. Check
the system’s pressure lines at regular intervals.
●Before starting repair and maintenance work, make sure that all affected
components are depressurised.
2.1.3 Electrical hazards
There is an immediate danger of fatal injury from electric shock when touching live parts.
Damage to the insulation or individual components can be life-threatening.
●Only have qualified electricians carry out electrical work on the system.
●In case of damage to live components, switch off the voltage supply immediately
and arrange for repair.
●Switch off the supply voltage before working on electrical system parts. Discharge
residual voltage.

Safety
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●Never bridge electrical fuses. Do not disable fuses. Use the correct current ratings
when replacing fuses.
●Keep moisture away from live parts. Moisture can cause short-circuits.
2.1.4 Danger due to chemicals
●Chemicals can be harmful to the environment and/or to health.
They can cause skin and eye burns as well as irritation of the respiratory tract or
allergic reactions.
●Avoid any skin/eye contact with chemicals.
●Use personal protective equipment.
●Read the safety data sheet prior to handling chemicals and always follow the
instructions for the different activities/situations.
●Current safety data sheets for chemicals are available for download at
www.gruenbeck.de/en/info-centre/safety-data-sheets.
●Obey internal instructions when handling chemicals and make sure that any
protective and emergency equipment such as emergency showers and eye
showers is present and functional.
Mixing and residual amounts of chemicals
●Never mix different chemicals. Unforeseeable chemical reactions posing a lethal
danger can occur.
●Dispose of residual amounts of chemicals in accordance with local regulations
and/or internal instructions.
●Residual amounts from used containers should not be transferred into containers
with fresh chemicals in order not to impair the effectiveness of the chemicals.
Labelling/Minimum shelf life/Storage of chemicals
●Check the labelling of the chemicals - labels must not be removed or rendered
illegible.
●Do not use any unknown chemicals (no labelling or labelling illegible).
●Obey the use-by date (minimum shelf life) stated on the label to ensure the
functionality of the system and the quality of the generated permeate.
●If stored incorrectly, chemicals could change their state of matter, crystallise,
outgas, or lose their effectiveness. Store and use the chemicals at the indicated
temperatures only.
Cleaning/Disposal
●Immediately absorb spilled chemicals with suitable binding agents.
●Collect and dispose of chemicals in such a way that they cannot pose a risk to
people, animals, or the environment.

Safety
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2.1.5 Groups of persons requiring protection
●This product can be used by persons with limited abilities or lack of experience if
they are supervised or instructed in the safe use of the system and understand the
resulting hazards.
●Operation, cleaning and maintenance must not be carried out by children.
2.2 Product-specific safety instructions
WARNING
Contamination of drinking water due to improper handling.
●Risk of infectious diseases
►Have installation, start-up/commissioning and annual maintenance carried out by
a qualified specialist.
The system features a main switch. Via the main switch, the system and the components
installed downstream are de-energised.
►Completely switch off the system in an emergency situation.
Designation
1
Lockable main switch.
►In case of maintenance and repair work, de-energise the system by switching off
the main switch –secure against unintentional restart.

Safety
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2.2.1 Signals and warning signs
Warnings/pictograms
Risk of electric shock
(attached to the distributor cover and in the power
distribution/electrical switch cabinet)
►Disconnect the system from the power supply before
working on electrical system parts
Risk of electric shock due to residual voltage
High voltage can be present even if the LED warning indicator is not
illuminated.
(attached to the frequency converter and HP pump)
►Wait for 15 minutes after switching off the main switch.
Hazardous material
(attached to the packaging)
Environmental damage due to lithium batteries
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 pictograms.

Product description
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3 Product description
The reverse osmosis system GENO-OSMO-X permeate stage (2nd stage) is mounted on
an aluminium system rack and ready for connection.
The reverse osmosis system GENO-OSMO-X permeate stage (2nd stage) features
connecting pipes to the 1st stage. A transfer unit with transfer station for feed water,
concentrate and permeate is installed in the 1st stage.
The control unit of the 2nd stage (without touch screen) is operated from the 1st stage (with
touch screen).
3.1 Intended use
●A reverse osmosis system GENO-OSMO-X (1st stage) must necessarily be
installed upstream of the GENO-OSMO-X permeate stage. The 2nd stage further
improves the permeate quality.
●The respective pretreatment and the limit values of the GENO-OSMO-X (1st stage)
must be complied with.
●The reverse osmosis system GENO-OSMO-X permeate stage is designed
exclusively for use in industrial and commercial applications.
●For a defined, temperature-dependent continuous permeate capacity (at 15 °C).
The continuous permeate capacity decreases by up to 3 % per degree centigrade
of the feed water temperature.
3.1.1 GENO-OSMO-X permeate stage with membrane degassing
●Carbon dioxide gas (CO2) dissolved in the inlet water is not retained by either of
the two reverse osmosis stages and enters the permeate of the 2nd stage as
conductivity.
●The gases affect the permeate conductivity of the entire system. If quality
requirements are placed on the permeate, these must be taken into account and
additional treatment steps (e.g. membrane degassing) might be necessary.
3.2 Foreseeable misuse
The reverse osmosis system GENO-OSMO-X permeate stage is not suitable for the
applications indicated below:
●Demineralisation of salt water (sea water)
●Strongly deviating and/or fluctuating flow rates of the feed water

Product description
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3.3 Product components
3.3.1 GENO-OSMO-X permeate stage
Designation
Function
Coding
1
Transfer unit
Piping with connections: Feed water inlet, concentrate-to-
drain and permeate outlet are installed on the system rack
2
Pressure transducer
Installed in the hydro block Permeate of the 1st stage. For
constant pressure control of the 1st stage
RO1CP2
3
Frequency converter
By means of the frequency converter, the pump's revolution
speed is adapted in a way that the permeate output is
achieved
4
Control unit
Without graphic touch screen, mounted tiltable. Is operated
from the 1st stage.
RO1E3
5
Power distribution
With automatic circuit breakers and main switch to switch the
entire system on and off .
RO1E4
6
Hydro block
Permeate
7
Membrane
Reverse osmosis membranes in pressure pipes to generate
the permeate
RO1B9
8
System rack
Made of anodised aluminium with adjustable feet
9
High-pressure pump
(HP pump)
Centrifugal pump (frequency-controlled) which generates the
operating pressure required for the membrane(s)
RO1P4
10
Hydro block
Permeate inlet from the 1st stage
11
Pressure switch for
maximum pressure
Prevents the system's operating pressure from exceeding
16 bar
RO1CP3
12
Hydro block
Concentrate (to drain)

Product description
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3.3.2 GENO-OSMO-X with
GENO-OSMO-X permeate stage
Designation
1
GENO-OSMO-X (1st stage)
Designation
2
GENO-OSMO-X permeate stage (2nd stage)
3.4 System connections
Designation
1
GENO-OSMO-X (1st stage)
2
GENO-OSMO-X permeate stage (2nd stage)
Designation
A
Feed water inlet BL1 (1" m. thr. or 1¼" m. thr.)
B
Concentrate outlet to drain BL2 (1" m. thr.)
C
Permeate outlet to permeate tank
BL3 (1" m. thr.)
Connections to water meter screw connections 1" or 1¼" (male thread) to be provided by
client.

Product description
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3.5 Functional description
The reverse osmosis system consists of the functional units below:
Feed water
Concentrate-to-drain
Permeate
Designation
1
Pressure pipe with membrane module
(1st stage)
(number subject to system size)
2
Hydro block Permeate (1st stage)
3
Hydro block Permeate (2nd stage)
4
Pressure pipe with membrane module
(2nd stage)
Designation
5
Hydro block Concentrate-to-drain
(2nd stage)
6
Hydro block Concentrate-to-drain (1st stage)
7
Hydro block Feed water (1st stage)
8
Hydro block Permeate inlet from the
1st stage into the 2nd stage
The reverse osmosis system GENO-OSMO-X (1st stage) is completely piped and wired with
the GENO-OSMO-X permeate stage (2nd stage).
By means of a constant, adjustable pressure, the permeate of the 1st stage is directed to the
2nd stage (treatment stage).
The permeate of the 1st stage is further demineralised in the 2nd stage using identical
process steps.
In the 2nd stage, however, the concentrate is not discharged to the drain via the control
valve (motor-driven) but is once again directed to the feed water inlet of the 1st stage of the
reverse osmosis.
In the 2nd stage, a recovery of 90 % can be achieved.

Product description
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Hydro block Feed water 1st stage
Designation
Function
Coding
1
Connection
Feed water inlet
Water meter screw connection 1" or 1¼" (male thread) with flat
sealing
BL1
2
Fine filter
Prefiltration of the feed water incl. pressure reducer (preset)
4.0 bar and integrated pressure gauge.
Osmosis version with black filter cylinder and filter element.
RO1F1
3
Flow sensor
FEED
Via pulse signal to the control unit.
FEED = Concentrate recirculation + Permeate + Concentrate-to-
drain
RO1CF2
4
Low pressure switch
To prevent the high-pressure pump from running dry. Switches
time-delayed after the feed water solenoid valve has opened.
RO1CP1
5
Flow sensor
Feed water
Via pulse signal to the control unit.
Feed water = Permeate + Concentrate-to-drain.
RO1CF1
6
Feed water solenoid
valve
During the permeate production, this valve is always open.
After a system stop, the valve remains open for the programmed
flushing volume of the membrane(s).
RO1V1
Hydro block Permeate inlet 2nd stage
Designation
Function
Coding
1
Sampling valve
Permeate inlet
Allows for manual quality determination via sampling valve
RO1H12
2
Flow sensor
Permeate
Via pulse signal to the control unit.
FEED Permeate stage = Recirculated permeate + Permeate +
Concentrated permeate back to 1st stage
RO1CF6

Product description
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Hydro block Concentrate 1st stage
Designation
Function
Coding
1
Connection
Concentrate-to-drain
Water meter screw connection 1" (male thread) with flat sealing
BL2
2
Adjusting valve
Concentrate-to-drain
with drive
To automatically adjust the volume flow Concentrate-to-drain
(recovery). During the production of permeate, this portion of the
water permanently flows to the drain. In case of a system stop
and in case of a system failure, the valve opens the entire cross
section always in combination with the feed water solenoid valve
RO1V3
3
Pressure reducer
Concentrate
To improve the control accuracy of the adjusting valves
(set to 6 bar)
RO1H4
4
Adjusting valve
Concentrate
recirculation with drive
For automatic adjustment of the volume flow Concentrate
recirculation
The volume flow depends on the system size
RO1V2
5
Sampling valve
Concentrate
Allows for manual quality determination via the sampling valve
RO1H1
Hydro block Concentrate 2nd stage
Designation
Function
Coding
1
Adjusting valve
Concentrate of permeate
stage
To automatically adjust the volume flow Concentrate back into
the 1st stage
RO1V10
2
Pressure reducer
Concentrate of permeate
stage
To improve the regulation accuracy of the adjusting valves
(set to 6 bar)
RO1H13

Product description
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Designation
Function
Coding
3
Sampling valve
Concentrate of permeate
stage
Allows for manual quality determination via the sampling valve
RO1H11
4
Adjusting valve
Concentrate recirculation
with drive
For automatic adjustment of the volume flow Concentrate
recirculation. The volume flow depends on the system size
RO1V9
Hydro block Permeate 1st stage
Designation
Function
Coding
1
Connection
Permeate
Water meter screw connection 1" (male thread) with flat sealing
BL3
2
Flow sensor
Permeate
Via pulse signal to the control unit
RO1CF3
3
Sampling valve
Permeate
Allows for manual quality determination via the sampling valve
RO1H5
4
Conductivity meter
Conductivity sensor according to the 2-electrode principle
(temperature-compensated (RO1CT1)) for the continuous
measurement of the permeate conductivity
The measuring results are shown in the control unit
RO1CQ1
5
Pressure transducer
For constant pressure control of the 1st stage
RO1CP2
Hydro block Permeate 2nd stage
Designation
Function
Coding
1
Flow sensor
Permeate of permeate
stage
Via pulse signal to the control unit
RO1CF7
2
Sampling valve
Permeate of permeate
stage
Allows for manual quality determination via the sampling valve
RO1H14
3
Conductivity meter
Permeate stage
Conductivity sensor acc. to the 2-electrode principle (tempera-
ture-compensated (RO1CT1)) for the continuous measure-
ment of the permeate stage conductivity. The measuring result
is shown in the control unit of GENO-OSMO-X 1st stage
RO1CQ2

Product description
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3.6 Accessories
Your product can be retrofitted with accessories. Please contact your local Grünbeck
representative or Grünbeck’s headquarters in Hoechstaedt/Germany for details.
Illustration
Product
Order no.
Drinking water filter BOXER KX 1"
101 835
80 µm filter element for prefiltration
Drinking water filter BOXER KDX 1"
101 820
with additional pressure reducer
EURO system separator GENO-DK 2 DN 15 (½")
132 510
Euro system separator GENO-DK 2 DN 20 (¾")
132 520
To secure systems and devices that might endanger the drinking water as per
DIN EN 1717-part 4.
GENO-activated carbon filter AKF 1600
109 460
To reduce the chlorine concentration in the water.
For larger activated carbon filters, please inquire.
Water softener GENO-mat duo WE-X
186 100
Fully automatic twin water softener working according to the ion exchange
principle. Generation of fully softened water with volume-controlled regeneration.
For larger systems, please inquire.
Water softener Delta-p-I
185 200
Fully automatic triple water softener working according to the ion exchange
principle. Generation of fully/partially softened water with volume-controlled
regeneration.
For larger systems, please inquire.
Hardness control measuring device softwatch
172600000000
Automatic limit value monitoring of residual/total hardness via limit value
indicator