Grunbeck AVRO-flex 400 Operation Manual








Operation Manual

Mobile reverse osmosis system

AVRO-flex 400

Starting from software version V1.33

Edition November 2018
Order no. 095 752 946-inter

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

2

Table of contents

AGeneral .................................................................................................................................................................. 5



1 | Preface ..........................................................................................................................................................................................................5



2 | How to use this operation manual .................................................................................................................................................................6



3 | General safety information ............................................................................................................................................................................6



3.1Symbols and notes ..................................................................................................................................................................................6



3.2Operating personnel ...............................................................................................................................................................................7



3.3Intended use ............................................................................................................................................................................................7



3.4Protection from water damage ................................................................................................................................................................7



3.5Indication of specific hazards ..................................................................................................................................................................7



4 | Shipping and storage .....................................................................................................................................................................................8



5 | Disposal .........................................................................................................................................................................................................8



5.1Packaging ................................................................................................................................................................................................8



5.2Product ....................................................................................................................................................................................................8



BBasic information ................................................................................................................................................. 9



1 | Laws, regulations, standards .........................................................................................................................................................................9



2 | Water .............................................................................................................................................................................................................9



3 | Functional principle of reverse osmosis ......................................................................................................................................................10



3.1Functional principle of the AVRO system ..............................................................................................................................................11



CProduct description ........................................................................................................................................... 12



1 | Type designation plate ................................................................................................................................................................................12



2 | Functional description ..................................................................................................................................................................................13



3 | Technical specifications ...............................................................................................................................................................................17



4 | Intended use ................................................................................................................................................................................................18



5 | Application limits ..........................................................................................................................................................................................19



6 | Scope of supply ...........................................................................................................................................................................................20



6.1Standard equipment ..............................................................................................................................................................................20



6.2Optional accessories .............................................................................................................................................................................21



6.3Consumables .........................................................................................................................................................................................22



6.4Wearing parts ........................................................................................................................................................................................22



DInstallation .......................................................................................................................................................... 23



1 | General installation instructions ...................................................................................................................................................................23



1.1Water connection ...................................................................................................................................................................................23



EStart-up................................................................................................................................................................ 24



1 | How to connect the system to the water supply ..........................................................................................................................................24



2 | How to flush the system ..............................................................................................................................................................................26



2.1How to flush off the preserving agent ....................................................................................................................................................26



2.2Filling mode ...........................................................................................................................................................................................26



2.3Workshop mode ....................................................................................................................................................................................28



FOperation (control unit) ..................................................................................................................................... 29



1 | Preface ........................................................................................................................................................................................................29



2 | How to operate the control unit....................................................................................................................................................................30



2.1Reading the operating status ................................................................................................................................................................31



2.2How to set the time ................................................................................................................................................................................31



2.3Access to the programming levels - change parameters ......................................................................................................................32



2.4Software version Code 999 ...................................................................................................................................................................32



3 | Programming levels .....................................................................................................................................................................................33



3.1 Input logic Code 113 .............................................................................................................................................................................33



3.2 System parameters Code 290 ..............................................................................................................................................................33



3.3Reference values / times Code 302 ......................................................................................................................................................34



3.4Error memory / water volumes Code 245 ..............................................................................................................................................35



3.5Diagnosis Code 653 ..............................................................................................................................................................................35



4 | Wiring diagram of mobile reverse osmosis system AVRO-flex 400 ............................................................................................................36



5 | Operation of reverse osmosis system AVRO-flex 400 ................................................................................................................................38



5.1How to set the system recovery ............................................................................................................................................................38



GTroubleshooting ................................................................................................................................................. 40



HMaintenance and care ........................................................................................................................................ 42



1 | Basic information .........................................................................................................................................................................................42



2 | Inspection (functional check) .......................................................................................................................................................................42



3 | Maintenance ................................................................................................................................................................................................43



3.1Operation log .........................................................................................................................................................................................44



4 | Operation log ...............................................................................................................................................................................................45



Maintenance work on mobile reverse osmosis system AVRO-flex 400 .................................................................... 46



Maintenance work on mobile reverse osmosis system AVRO-flex 400 .................................................................... 48



Maintenance work on mobile reverse osmosis system AVRO-flex 400 .................................................................... 50



Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

3

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-Str. 1  89420 Hoechstaedt/Germany
Tel. [phone]  Fax [phone]
www.gruenbeck.com  [e-mail]

Print: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Str. 1, 89420 Hoechstaedt/Germany

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

4

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.

If the system is modified in a way not approved by us, this certificate is void.

Manufacturer: Grünbeck Wasseraufbereitung GmbH

Josef-Grünbeck-Str. 1
89420 Hoechstaedt/Germany

Responsible for documentation: Markus Pöpperl

System designation: Mobile reverse osmosis system

System type: AVRO-flex 400

Serial no.: Refer to type designation plate

Applicable directives: Machinery Directive (2006/42/EU)

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

Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

5

A General

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 when 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 reliable operation over many years, provided you treat
your water treatment systems with the required care. This operation
manual assists 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 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
(see www.gruenbeck.com) or get in touch with our service centre
which can be reached during office hours:

Phone: [phone]

Fax: [phone]

Email: [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-1.

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

6

2 | How to use this operation manual

This operation manual is intended for the operators of our systems. It
is divided into several chapters which are listed in the “Table of con­tents” on page 2 in alphabetical order. In order to find the specific in­formation you are looking for, check for the corresponding chapter on
page 2.

The headers and page numbers with chapter information make it eas­ier to find your way around in the manual.

3 | General safety information

3.1 Symbols and notes

Important information in this operation manual is characterised 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, extensive damage to property or inadmissi­ble contamination of the drinking water.

Warning! Failure to adhere to this information may cause injuries,
damage to property or contamination of the drinking water.

Attention! Failure to adhere to this information may result in damage
to the system or other objects.



Note: This symbol characterises information and tips to 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 the local water sup­ply companies or approved installation companies. In Germany, the
installation company must be registered in an installation directory of
a water company as per §12(2) AVBWasserV (German Ordinance on
General Conditions for the Supply of Water).

Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

7

3.2 Operating
personnel

Only persons who have read and understood this operation manual
are permitted to work with the system. The safety information in par­ticular is to be strictly adhered to.

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 malfunctions must be
repaired at once.

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 with discharge to a lifting system do not work
in case of a power failure.

3.5 Indication of
specific hazards

Danger due to electrical energy!  Do not touch electrical parts with
wet hands! Unplug the mains plug 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 may only be installed by a specialist company. The operation
manual must be strictly adhered to! Ensure that there is sufficient
flow. The pertinent guidelines must be followed for start-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 may perform the in­terim inspections yourself.

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

8

4 | Shipping and storage

Attention! The system may be damaged by frost or high tempera-

tures. In order to avoid damage of this kind:

Protect from frost during transportation and storage!
Do not install or store system next to objects which radiate a lot of
heat.

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 and the electrical and electronic components must not be
disposed of as household waste.

Dispose of electrical and electronic products or components in an
environmentally sound manner.



For information on collection points for your product, contact your
municipality, the public waste management authority, an authorised
body for the disposal of electrical and electronic products or your
waste collection service.

Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

9

B Basic information

1 | Laws, regulations, standards

In the interest of good health, rules cannot be ignored when it comes

to the processing of drinking water. This operation manual takes into
consideration the current regulations and stipulates information that
you will need for the safe operation of your water treatment system.

Among other things, the regulations stipulate that

only approved companies are permitted to make major modifications
to water supply facilities

and that tests, 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. Over time, these elements therefore accumulate
in ground and surface water. Removing them from natural water bod­ies again represents a particular challenge. Grünbeck rises to this
challenge and aims at generating 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.

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

10

3 | Functional principle of reverse osmosis

Principle:
Pretreated

feed water

Concentrate:

Permeate

Fig. B-1: Functional principle

Solution of high
concentration

Solution of low
concentration

Solution of high
concentration

Solution of low
concentration

Solution of high
concentration
(concentrate)

Solution of low
concentration
(permeate)

Fig. B-2: 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 try to equalise. On the side of the
higher original concentration, the so-called "osmotic" pressure is gen­erated. In case of reverse osmosis, this osmotic pressure is coun­tered by a higher pressure. The consequence: the process proceeds
in the reverse 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.

Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

11

3.1 Functional princi­ple of the AVRO
system

AVRO is an alternative anti-scaling process to the common traditional
processes of "softening" or “antiscalant dosing”. Contrary to these
processes, AVRO does not require any addition of auxiliary additives.
The chemical composition of the generated concentrate is not modi­fied. There is only a doubling of the concentration (standard recovery
50 %).

Hydraulically, the AVRO is installed in the concentrate pipe down­stream of the membrane.

The treatment unit consists of two inert special electrodes to which a
low current is applied. Seed crystals (calcium carbonate) are gener­ated at the cathode and are permanently directed via the concentrate
recirculation. The salts of the supersaturated concentrate continue to
grow on these seed crystals, and they are finally washed out to the
drain with the residual concentrate flow. This reliably prevents scaling
(deposits of insoluble salts on the membrane). Some of the calcium
carbonate remains on the cathode of the AVRO and due to increasing
electrical resistance, limits the service life of the AVRO treatment unit
to 3000 operating hours (permeate production) or 5 years.

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

12

C Product description

1 | Type designation plate

You may find the type designation plate at the housing of the mobile

reverse osmosis system AVRO-flex 400. 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.

Mobile reverse osmosis system AVRO-flex 400
Serial number:      
Order number:      

Fig. C-1: Type designation plate

Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

13

2 | Functional description

Via a fine filter (filter element), the water is directed to the inlet of the

feed water section. The water flows to the high-pressure pump via the
inlet solenoid valve with a downstream “pressure switch for minimum
pressure”. By means of a control valve, the pressure generated by the
high-pressure 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 membrane and increases the economic efficiency of the re­verse osmosis.

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 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.

Downstream of the membrane, the permeate produced can be deliv­ered into the heating system with a counter-pressure of up to 3.5 bar.



Note: If the counter-pressure on the permeate side increases, the
permeate output decreases.

Filling mode:

If "filling mode" is selected via the selector switch on the controller,

three waves are visible in the controller. The pressure switch is inter­rogated as the start criterion.

Workshop mode:

If "workshop mode" is selected via the selector switch on the control-

ler, one wave is visible in the controller. Selection of the operating
switch is used as the start criterion. After 24 hours, permeate is pro­duced over time. The workshop mode prevents germs from infecting
the system, thereby ensuring a constant permeate quality.

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

14

Fig. C-2: Exploded drawing of mobile reverse osmosis system AVRO-flex 400

Mobile reverse osmosis system

AVRO-flex 400



Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

15

Fine filter incl.
pressure reducer

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

Inlet solenoid valve During the permeate production, this valve is always open. Fol-

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

Pressure switch for mini­mum pressure of high­pressure 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 .

Flushing solenoid valve Opens after the pressure switch “switch-off pressure” has

reached the set pressure. The solenoid valve also opens in the
event of system malfunctions and always in conjunction with the
feed water inlet solenoid valve . Visual indication in the con­trol unit .

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

the drain. During permeate production, this water constantly
flows to the drain.

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

the membrane and for the filling of heating water systems.

Membrane Reverse osmosis membrane to generate the permeate.

AVRO treatment unit AVRO treatment unit to generate seed crystals.

Control unit Microprocessor controller that in conjunction with the respective

units, regulates the permeate production and the supply of con­sumers downstream.

Flow sensor, concentrate Records the concentrate volume and sends pulses to the con-

troller. Visual indication of the concentrate volume in the con­troller .

Flow sensor, permeate Records the permeate volume and sends pulses to the control-

ler. Visual indication of the permeate volume in the controller .

Diaphragm expansion tank Permeate buffer to reduce the switching operations.

Pressure switch switch-off
pressure

Switches the reverse osmosis on when water is required, and
off again after water withdrawal ends.

Connection ¾“ (DN 20)
male thread or GEKA

Concentrate to drain.

Connection ¾“ (DN 20)
male thread or GEKA

Feed water.

Connection ¾“ (DN 20)
male thread or GEKA

Permeate/consumer.

Control valve for operating
pressure with pressure
gauge

To set the operating pressure, with pressure gauge as visual in­dicator.

1

2

9

3

2

9

4

2

9

5

6

7

8

9

10

9

11

9

12

13

14

15

16

17

Mobile reverse osmosis system

AVRO-flex 400











Order no. 095 752 946-inter Edited by: phar-mrie G:\BA-752946-INTER_095_AVRO-FLEX_400.DOCX

16

Fig. C-3: Flow chart of mobile reverse osmosis system AVRO-flex 400