Grunbeck AVRO 125 TS, AVRO 125 TL Operation Manual

Operation manual

Reverse osmosis system

AVRO 125 TS/TL

Edition January 2018
Order no. 185 752 945-inter

Reverse osmosis system

AVRO 125 TS/TL

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Table of contents



The operation manual consists of several chapters, which are
listed below.

A General information

5

1 Preface

2 How to use this operation manual
3 General safety information
4 Shipping and storage
5 Disposal of used parts and materials

B Basic information 8

1 Laws, regulations, standards

2 Water
3 Functional principle of reverse osmosis

C Product description 10

1 Type designation plate

2 Functional description
3 Intended use
4 Application limits
5 Scope of supply

D Installation 23

1 General installation instructions

2 Preliminary works
3 Connecting the system on the water side
4 Electrical installation

E Commissioning 29

1 How to flush the system

F Operation 33

1 Preface

2 Operating the control unit

3 Programming levels
4 Operating reverse osmosis

G Troubleshooting 41
H Maintenance and care 43

1 Basic information

2 Inspection (functional check)
3 Maintenance
4 Operation log (maintenance checklist)

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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 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-Straße 1  89420 Hoechstaedt/Germany
Phone [phone]  Fax [phone]
www.gruenbeck.de  [e-mail]

Printing: 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 invalid if the system is modified in a way not approved by us.
Manufacturer: Grünbeck Wasseraufbereitung GmbH

Josef-Grünbeck-Strasse

89420 Hoechstaedt/Germany
Responsible for documentation: Markus Pöpperl
System designation: Reverse osmosis system AVRO

125

System type: TL/TS

Serial no.: Refer to type designation

plate

Applicable directives: 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 particular:

DIN 31000/VDE 1000:2011-

05

Place, date and signature: Hoechstaedt, 05.04.2016 i. V.

M. Pöpperl

Dipl. Ing. (FH)
Function of signatory: Head of Product Implementation and Product Launch

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A General information

1 | Preface

Thank you for opting for a Grünbeck product. Backed by decades of
experience in the area of water treatment, we provide customised
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
maintaining systems involved in the drinking water supply. 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. These
operating instructions assist you with important information.
Therefore, please read the entire operation manual before installing,
operating or maintaining the system.

Customer satisfaction is our prime objective. And providing customers
with qualified advice is crucial. 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.de). You can also get in touch with our
service centre, which can be reached during business hours:
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
We can connect you with the appropriate expert more quickly if you
provide the required system data. In order to have the required data
handy at all times, please copy it from the type designation plate to
the overview in chapter C-12.

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. Check for 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 operation manual.

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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 are only allowed to be performed by
Grünbeck's technical service/authorised service company or by
persons expressly authorised by Grünbeck.

Tasks with this symbol are only allowed to 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 are only allowed to be performed by water
suppliers or approved installation companies. In Germany, the
installation company must be registered in an installation directory of
a water supplier as per §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. The safety guidelines are to be
strictly adhered to.

3.3 Intended use

The system is only allowed to be used for the purpose outlined in the
product description (chapter C). The guidelines in this operation
manual as well as the applicable local guidelines concerning the
drinking water protection, accident prevention and occupational safety
must be adhered to.

In addition, appropriate application also implies that the system
is only allowed to be operated when it is in proper working order.
Any malfunctions must be repaired 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 sufficient 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 will 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 system components! Have qualified experts replace
damaged cables immediately.

Danger due to mechanical energy! System components can be
subject to overpressure. Danger of injury and damage to property due
to escaping water and unexpected movement of system parts.
 Check pressure lines regularly. Depressurise the system before
starting repair or maintenance work on the system.

Hazardous to health due to contaminated drinking water!  The
system shall be installed only by a specialist company. Strictly adhere
to the operating instructions! Ensure that there is sufficient flow. The
pertinent guidelines must be followed for starting-up after extended
periods of standstill. Inspections and maintenance must be performed
at the intervals specified!



Note: By concluding a maintenance contract, you ensure that all of
the required tasks are performed on time. You can 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 shipping and storage!

Do not install or store system next to objects which radiate a lot of heat.

5 | Disposal of used parts and consumables

Used parts and consumables are to be disposed of or made available
for recycling purposes according to the applicable local guidelines.

If consumables are subject to specific regulations, adhere to the
corresponding information on the packing.

If in doubt, contact your local waste disposal authority or the
manufacturer for more information.

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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 guidelines 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 specialist companies are permitted to make major

modifications to water supply systems

 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,
are increasingly being released into the natural environment.
These are only partially and slowly broken down by natural effects.
Consequently, these elements build up in the groundwater and
surface water over the course of time. Removing them from
natural water deposits again 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

Concentrate:

Permeate

Fig. B-1: Functional principle

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, aqueous 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 designation plate

The type designation plate can be found on the housing of the reverse

osmosis system AVRO 125 TS/TL. In order to speed up the processing
of your inquiries or orders, please specify the data shown on the type
designation 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 AVRO 125 TS/TL
125

 

Serial number:

     / 

Order number:

     

Fig. C-1: Type designation plate

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2 | Functional description

Via the 5 µm drinking water filter (filter element), the water is directed
to the inlet of the feed water section. The water flows to the high­pressure 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 osmosis 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
osmosis membrane is protected from clogging. Whenever the system
is switched off (tank full) 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 concentrate.

The hydraulic set-up of the system is designed in a way that the
concentrate volume and the permeate volume are registered by
means of flow sensors and are displayed in the control unit.
The system recovery can also be called up in the control unit.

1)

The permeate produced is fed into a light-tight reservoir. A level
control with three switching contacts is integrated in the tank. In order
to supply the consumers with permeate, a centrifugal pump made of
high-performance plastics including pressure switch and diaphragm
expansion tank is integrated in the system as pressure booster
system.

1)

Only AVRO 125 TS

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Fig. C-2: Exploded drawing reverse osmosis system AVRO 125 TS/TL-TS

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5 µm fine filter incl.
pressure reducer

Pressure reducer preset to 2.5 bar, incl. pressure gauge.

Inlet solenoid valve During permeate output, this valve is always open. Following the system

stop (tank full), the valve remains open for the programmed flushing time
of the membranes. Visual indication in the control unit .

Pressure switch
Pressure booster pump

Switches the pressure booster on when water is required, and off again
after water withdrawal ends.

Flushing solenoid valve

Opens after the level control in the tank reports "FULL" to the control
unit for a set time. The solenoid valve also opens in the event of
system malfunctions and always in conjunction with the inlet solenoid
valve .

Needle valve, concentrate To set the feed water-dependent "concentrate" volume flow to the drain.

During permeate output, this portion of the water flow permanently flows
to the drain.

High-pressure pump Pump unit that generates the operating pressure required for the

membrane. Pump operates on permeate request from the level
control (LB switches) located in the permeate tank. A control valve
for adjusting the operating pressure is integrated in the pump head.

Visual indication in the control unit .
Membrane Reverse osmosis membrane to generate the permeate.
AVRO treatment unit AVRO treatment unit to generate seed crystals.
Level control Float level control for controlling the water level in the permeate tank

(TS version only).
Booster pump Pressure booster pump feeds permeate into the consumer network

(only TS version).
Control unit Microprocessor controller that in conjunction with the respective units,

regulates the permeate production and the supply of consumers

downstream.
Flow sensor, concentrate Registers the concentrate volume and sends pulses to the control unit.

Visual indication of the permeate volume in the control unit .
Flow sensor

Permeate

Records the permeate volume and sends pulses to the control unit.

Visual indication of the permeate volume in the control unit .
Diaphragm expansion tank Permeate buffer to reduce the switching operations of the DE pump.
Pressure switch

High-pressure pump

To prevent the high-pressure pump from running dry. Switches time-

delayed after the solenoid valve has opened . Visual indication in the

control unit .
Connection ½" (DN 15)

male thread

Concentrate to drain.

Connection ½" (DN 15)
male thread

Feed water.

Connection ½" (DN 15)
male thread

Permeate/consumer.

Option: Solenoid valve forced withdrawal.
Option: Conductivity measurement.
Option: Blending unit.

1

2

11

3

4

9

2

5

6

9

11

7
8
9

10

11

12

11

13

11

14
15

2

11

16

17

18

19

20
21

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2.1 Flow chart of reverse osmosis system AVRO 125 TS/TL

Fig. C-2.1: Flowchart of reverse osmosis system AVRO 125 TS/TL-TS

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Technical specifications Reverse osmosis system
AVRO 125 TS AVRO 125 TL

Connection data

Nominal connection diameter of feed water pipe ½" (DN 15) male thread
Nominal connection diameter of permeat e 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] 0.7 0.6
Power supply [V/Hz] 230 V / 50 Hz
Protection/protection class IP 54 / I
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] 0.55
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
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 (at 15 °C) [l/h] 1251)
Feed water volume flow

(fresh water 15 °C) at a recovery of 50 %, max.

[l/h] 250

Recovery [%] 501)
Dimensions and weights
Dimensions (w x d x h) approx. [mm] 600 x 550 x 1120
Empty weight, approx. [kg] 45 38
Operating weight, approx. [kg] 85 40
Ambient data
Temperature of feed water, min./max. [°C] 10 / 30
Ambient temperature, min./max. [°C] 5 / 35

Order no. 752 105 752 115

1)

After a water analysis, the technical customer service can set a higher recovery.

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3 | Intended use

The reverse osmosis system AVRO 125 TS/TL is used for

demineralising drinking water. The water is primarily used for
industrial applications.

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.

Appropriate application 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 have to be observed.

3.1 System shutdown

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 AVRO 125 TS/TL,

the limit values stipulated in the German Drinking Water Ordinance
represent the upper limits for the admissible substances contained in
the water.

 < 22°dH (39.2° f; 3.92 mmol/l) without water analysis
 Free chlorine not detectable

 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
concentration due to geogenic conditions, the recovery with regard to
the standard settings according to layout might need to be reduced.

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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 (AVRO 125 TS/TL-TS only).

 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.

 5 µm drinking water 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.

 AVRO treatment unit, installed in a pressure pipe made of high-

strength PE.

 Flow sensor to measure the volume of the system flows permeate

and concentrate.

 Operation manual.

1)

only AVRO 125 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 RO 125 K/AV RO 125

Connection block (installation length 180 mm).
Permeate-resistant incl. two shut-off valves –
suitable for connection set

752 840

 Connection set for RO 125 K/AVRO 125

2 flexible connection hoses DN 15
(L = 600 mm) for feed water and permeate
1 drain hose for concentrate

752 830