Grunbeck GENO-OSMO-X 200 User manual

We understand water.
Reverse osmosis system | GENO-OSMO-X
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.: 750927-inter_234

Table of contents
3 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
Table of contents
Table of contents.............................................................. 3
1Introduction ............................................................. 4
1.1 Validity of the manual ............................................... 4
1.2Other applicable documents ..................................... 4
1.3 Product identification ................................................ 5
1.4 Symbols used........................................................... 6
1.5 Depiction of warnings ............................................... 6
1.6 Demands on personnel ............................................ 7
2Safety ....................................................................... 9
2.1 Safety measures ...................................................... 9
2.2 Product-specific safety instructions......................... 11
3Product description............................................... 13
3.1 Intended use .......................................................... 13
3.2 Foreseeable misuse ............................................... 14
3.3 Product components .............................................. 15
3.4 System connections ............................................... 18
3.5 Functional description............................................. 19
3.6 Accessories............................................................ 24
4Transport, placing and storage............................. 27
4.1 Dispatch/Delivery/Packaging .................................. 27
4.2 Transport/Placing ................................................... 27
4.3 Storage .................................................................. 27
5Installation ............................................................. 28
5.1 Requirements for the installation site ...................... 30
5.2 Checking the scope of supply ................................. 31
5.3 Water installation.................................................... 32
5.4 Electrical installation............................................... 35
6Start-up/Commissioning ....................................... 44
6.1 Flushing out the preserving agent........................... 44
6.2 Checking the system .............................................. 47
6.3 Setting the control unit............................................ 48
6.4 Handing over the product to the owner/operating
company.................................................................48
7Operation/handling ................................................49
7.1 Operating concept ..................................................49
7.2 Basic settings of control unit GENO-tronic...............53
7.3 Reverse osmosis system GENO-OSMO-X..............58
7.4 Permeate tank ........................................................64
7.5 Antiscalant dosing (option) ......................................65
8Maintenance and repair .........................................67
8.1 Cleaning .................................................................67
8.2 Intervals..................................................................68
8.3 Inspection ...............................................................69
8.4 Maintenance ...........................................................71
8.5 Consumables..........................................................73
8.6 Spare parts .............................................................73
8.7 Wearing parts .........................................................73
9Malfunctions...........................................................74
9.2 Display messages...................................................76
10 Shutdown ...............................................................85
10.1 Temporary standstill................................................85
10.2 Shutdown ...............................................................85
10.3 Restart....................................................................85
11 Dismantling and disposal ......................................86
11.1 Dismantling.............................................................86
11.2 Disposal..................................................................86
12 Technical specifications ........................................88
13 Operation log .........................................................90
13.1 Start-up/Commissioning log ....................................90

Introduction
4 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
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 instructions 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:
●Reverse osmosis system GENO-OSMO-X 200
●Reverse osmosis system GENO-OSMO-X 400
●Reverse osmosis system GENO-OSMO-X 800
●Reverse osmosis system GENO-OSMO-X 1200
●Reverse osmosis system GENO-OSMO-X 1600
●Reverse osmosis system GENO-OSMO-X 2200
●Reverse osmosis system GENO-OSMO-X 3000
●Reverse osmosis system GENO-OSMO-X
in optional versions: Online, AVRO and Antiscalant.
●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.
1.2 Other applicable documents
●Manuals of all accessories used
●Manuals of components from other manufacturers
●Safety data sheets for chemicals
●Electric circuit diagram order no. 750 292

Introduction
5 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
1.3 Product identification
You can identify your product based on the product designation and the order no. 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
Inlet flow pressure Feed water
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 pipe

Introduction
6 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
1.4 Symbols used
Symbol
Meaning
Danger and risk
Important information or requirement
Useful information or tip
Written documentation required
Reference to further documents
Work that must be done by qualified specialists only
Work that must be done by qualified electricians only
Work that must be done 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 have the
structure below:
1.5.1.1
1.5.1.2 SIGNAL WORD
1.5.1.3 Type and source of danger
1.5.1.4
●Possible consequences
►Preventive measures
The signal words below were 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
injuries
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
7 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
1.6 Demands on personnel
During the individual phases in the service life of the system, different persons do activities
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 possible risks
•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 must be done 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
Shutdown and restart/recommissioning
X
X
Dismantling and disposal
X
X

Introduction
8 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
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
9 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
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/untrained persons from residual risks.
●Meet the maintenance intervals (refer to chapter 8.2). If you do not meet these
intervals, there is a risk of microbiological contamination of your drinking water
system.
2.1.1 Mechanical safety
●You must never remove, bridge, or otherwise tampered with safety equipment.
●For all work on the system that cannot be done from the ground, use stable, safe
and self-standing climbing aids.
●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
components. Damage to the insulation or individual components can be life-threatening.
●Have electrical work on the system done by qualified electricians only.
●In case of damage to live components, switch off the voltage supply immediately
and arrange for repair.

Safety
10 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
●Switch off the supply voltage before working on electrical system parts. Discharge
residual voltage.
●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 hazardous 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 before handling chemicals and always obey the
instructions for the different actions/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 protective
and emergency equipment such as emergency showers and eye showers are
available and functional.
Mixing and residual amounts of chemicals
●Never mix different chemicals. Unforeseeable chemical reactions with mortal
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 filled 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 made
illegible.
●Do not use any unknown chemicals (no labelling or labelling illegible).
●Obey the use-by date (minimum shelf life) shown on the label to ensure the
functionality of the system and the quality of the generated permeate.
●If kept incorrectly, chemicals might change their state of matter, crystallize, outgas,
or lose their effectiveness. Keep and use the chemicals at the given 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
11 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
2.1.5 Groups of persons in need of 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 done 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 done by a
qualified specialist.
The system features a main switch. Via the main switch, the system and the components
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
12 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
2.2.1 Signals and warning devices
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 attached 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
13 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
3 Product description
The reverse osmosis system GENO-OSMO-X is mounted on an aluminium system rack.
The ultra-low-pressure reverse osmosis membranes are installed in PE pressure pipes.
The controller for displaying the operating status and the system values is operated by a
touch screen.
3.1 Intended use
●The reverse osmosis system GENO-OSMO-X is designed for the demineralisation
of water whose composition complies with the quality requirements of the German
Drinking Water Ordinance (TrinkwV).
●The reverse osmosis systems GENO-OSMO-X, GENO-OSMO-X Online, GENO-
OSMO-X AVRO and GENO-OSMO-X Antiscalant are intended for the industrial
and commercial sector only.
●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 Online
●Designed for the steady permeate supply of installations downstream without
pressure fluctuations, intermediate tanks, or pressure booster.
●For on-line supply of connected consumers such as humidifiers, air-conditioning
systems, etc., with permeate.
3.1.2 GENO-OSMO-X AVRO
●To protect the reverse osmosis membranes by means of treatment module(s)
installed in the system.
●To prevent scaling on the membranes.
●Does not require the installation of a water softener/hardness stabilisation
upstream.
3.1.3 GENO-OSMO-X Antiscalant
●To protect the reverse osmosis membranes by dosing-monitored addition of
hardness stabilising agents in proportion to quantity.
●To avoid scaling on the membranes.

Product description
14 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
●Does not require the installation of a water softener/hardness stabilisation
upstream.
3.1.4 Application limits
We assume that the composition of the feed water (raw water) will not change significantly,
that the feed water will always be free of mechanical and organic impurities and that the
limit values given below will not be exceeded:
NOTE
No disinfectant
●Organic polymers are used as material for the RO membranes. They are not
resistant to disinfectants such as chlorine or chlorine dioxide.
●Disinfectants irreversibly destroy the RO membranes.
►Chlorine and oxidants must not be detectable in the feed water. The raw water
must not contain any oxidants.
Parameters
Value
Total hardness
°dH
< 0.1 (0.18 °f; 0.018 mol/m³)
•Option: Antiscalant
not limited
•Option: AVRO (without water analysis)
•Option: AVRO (water analysis required)
< 22 (39.2 °f; 3.92 mol/m³)
> 22 or (sulphate > 250 mg/l)
Free chlorine
mg/l
not detectable
Iron
mg/l
< 0.10
Manganese
mg/l
< 0.05
Silicate
mg/l
< 15
Chlorine dioxide
mg/l
not detectable
Turbidity
NTU
< 1
Silt density index (SDI)
< 3
pH range
3 –9
Total salt content as NaCl
mg/l
< 1000
Feed water temperature
°C
10 –30
●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.
3.2 Foreseeable misuse
The reverse osmosis system GENO-OSMO-X is not suitable for the use given below:
●Demineralisation of salt water (sea water)
●Strongly deviating and/or fluctuating flow rates of the feed water

Product description
15 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
3.3 Product components
3.3.1 GENO-OSMO-X
Designation
Function
Coding
1
Membrane
Reverse osmosis membranes in pressure pipes to generate the
permeate
RO1B1
2
Control unit
Operating unit GENO-tronic with 4.3 touch screen, tiltable
RO1E1
3
Main switch
To switch the entire system and components installed
downstream on and off
4
Power distribution
With automatic circuit breakers and Schuko socket to supply the
Antiscalant dosing system
RO1E2
5
Frequency converter
With the frequency converter, the pump's revolution speed is
adapted in a way that the permeate capacity is achieved.
6
Hydro block
Concentrate (to drain)
BL2
7
Overpressure switch
Prevents the system's operating pressure from exceeding 16 bar
RO1CP3
8
Hydro block
Feed water (as treated soft water)
BL1
9
System rack
Made of anodised aluminium with adjustable feet
10
Piping
High-pressure resistant PE pipes and PP compression fittings
11
High-pressure pump
(HP pump)
Centrifugal pump (frequency-controlled) which generates the
operating pressure required for the membrane
The centrifugal pump operates upon permeate demand from the
level control located in the permeate tank
RO1P1
12
Hydro block
Permeate
BL3

Product description
16 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
3.3.2 GENO-OSMO-X Online
Designation
Function
Coding
1
Diaphragm expansion tank
Flown through as pressurised permeate tank
RO1B4
2
Pressure transducer
For supply pressure; switches the system ON and OFF
Measuring range: 0 - 6 barg, current output: 4-20 mA
RO1CP2
3
Sampling valve
Sampling valve of pressurised permeate tank.
As pressure relief during maintenance of the permeate tank.
RO1H6
4
Piston valve
To shut-off the permeate outlet
RO1H7
3.3.3 GENO-OSMO-X AVRO
Designation
Function
Coding
1
Pressure pipe system
AVRO treatment unit
RO1B5

Product description
17 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
3.3.4 GENO-OSMO-X Antiscalant
Designation
Function
Coding
1
Dosing pump
For Antiscalant dosing in proportion to quantity
Delivers the dosing agent as soon as the feed water flows into
the system.
RO1P2
Pressure maintaining valve DN 8, opening pressure 3 bar
RO1S7
2
Suction lance
Suction lance with electrical switching contacts “pre-alarm” and
“empty” to withdraw the dosing agent.
RO1S8
RO1CL1
RO1CL2
Canister containing dosing agent: MT-4000 / MT-4010
RO1B2
3
Collecting container
Prevents the dosing agent from escaping in case of a leaking
canister (leak and drip protection).
Made of PP plastic (400 x 300 x 325 mm)
RO1B3
4
Dosing point
Injection of the dosing agent into the feed water

Product description
18 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
3.4 System connections
Designation
Function
Coding
A
Inlet connection
Feed water inlet
BL1
B
Discharge connection
Concentrate-to-drain
BL2
C
Outlet connection
Permeate (towards pure water tank)
BL3
D
Outlet connection
Permeate (towards consumer provided by client on site)
BL3
Connections to water meter screw connections 1" or 1¼" (male thread) to be provided by
client.

Product description
19 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
3.5 Functional description
The reverse osmosis system consists of the functional units below:
Designation
19
Pressure pipe with membrane module
(number depends on system size)
20
Hydro block Concentrate-to-drain
Designation
21
Hydro block Permeate
22
Hydro block Feed water
The GENO-OSMO-X system works according to the process of reverse osmosis.
The feed water is directed to the high-pressure pump via an automatic valve and a fine filter
with pressure reducer.
A negative pressure switch protects the pump from running dry. The capacity of the high-
pressure pump is controlled by a frequency converter in such a way that the permeate
capacity is generated depending on the temperature. With the controller, the permeate
capacity can be reduced by up to 25 %.
From the high-pressure pump, the feed water is directed to the reverse osmosis membranes
and divided into the partial flows permeate and concentrate. A partial flow of the concentrate
is measured by a control valve and (automatically) recirculated to the feed water. The
remaining concentrate is directed to the drain via a control valve.
The permeate capacity is subject to the temperature and defined at 15 °C.
It decreases by up to 3 % per degree centigrade of the feed water temperature.

Product description
20 | 96
BA-750927-inter_234_GENO-OSMO-X.docx
The permeate capacity is automatically controlled in relation to the temperature. Control via
flow meters in the feed water, FEED and permeate. The recovery (concentrate-to-drain) as
well as the concentrate recirculation are adapted to the modified permeate output.
Hydro block Feed water
Designation
Function
Coding
1
Connection
Feed water inlet
Water meter screw connection 1" or 1¼" (male thread) with
flat sealing
BL1
2
Drinking water 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
Negative pressure
switch
To prevent the high-pressure pump from running dry.
Switches time-delayed 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.
RO1CF
6
Solenoid valve
Feed water
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