Grunbeck GENO-OSMO RO 125K Operation Manual

Reverse Osmosis System

GENO

®

-OSMO RO 125K

,

Operation Manual

Reverse Osmosis System

GENO

®

-OSMO RO 125K

Edition March 2014
Order no. 195 752 940 - inter

GrünbeckWasseraufbereitung GmbH

Josef-Grünbeck-Strasse 1
89420 Hoechstaedt/Danube · GERMANY
Phone [phone] · Fax [phone]
www.gruenbeck.com · [e-mail]

A company certified by TÜV SÜD

in accordance with DIN EN ISO 9001, DIN
EN ISO 14001, DIN EN ISO 13485 and SCC

Reverse Osmosis System

GENO

®

-OSMO RO 125K

Order no. 195 752 940-inter Edited by: KONS-phar-mrie G:\BA-752940-INTER_RO_125K.DOC

2

Table of contents



This operation manual consists of several parts as shown in the table
below.

A General

5

1 Preface

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

B Basic information 9

1 Laws, guidelines, standards

2 Water
3 Functional principle of reverse osmosis

C Product description 11

1 Type designation plate

2 Functional description
3 Designated application
4 Application limits
5 Scope of supply

D Installation 22

1 General installation instructions

2 Preliminary works
3 System connection on water side

E Start-up 28

1 System rinsing

F Operation 32

1 Preface

2 How to operate the control unit

3 Programming levels

4 How to operate the reverse osmosis

G Troubleshooting

41

H Maintenance and care

43

1 Basic information

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

Reverse Osmosis System

GENO

®

-OSMO RO 125K

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Publisher’s information

All rights reserved.
 Copyright by Grünbeck Wasseraufbereitung GmbH

Printed in Germany
Effective with the date shown on the cover sheet.
– We reserve the right to modification, especially with regard to technical
progress -

Reprints, translations into foreign languages, electronic storage or copying
only with 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]

Printed by: Grünbeck Wasseraufbereitung GmbH
Josef-Grünbeck-Strasse 1, 89420 Hoechstaedt/Germany

Reverse Osmosis System

GENO

®

-OSMO RO 125K

Order no. 195 752 940-inter Edited by: KONS-phar-mrie G:\BA-752940-INTER_RO_125K.DOC

4

EC 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-Strasse 1

89420 Hoechstaedt/Germany
Responsible for documentation: Markus Pöpperl
System designation: Reverse osmosis system GENO®-OSMO RO 125K
System type: TL; TS
System number: Refer to type designation plate
Applicable EC guidelines: EC Machine Guideline (2006/42/EC)

EC Guideline EMV (89/336/ECC version 92/31/ECC)
Applied harmonized standards, in

particular:

DIN EN ISO 12100 - 1, DIN EN ISO 12100 - 2

DIN EN 61000-6-2, DIN EN 61000-6-3,

9

th

Guideline on Device and Product Safety
(Machine Guideline – 9. GPSGV)
1st Guideline on Device and Product Safety
(Ordinance on the Marketing of Electrical Operating Materials
to be used within specific voltage limits – 1. GPSGV)

Applied national standards and
technical specifications,
in particular:

DIN 1988

DIN 31000/VDE 1000 (03.79)

Date/Signature of
manufacturer:

12.08.11 i. V.
M. Pöpperl

Dipl. Ing. (FH)

Function of signatory: Head of Engineering Department for Serial Products

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-OSMO RO 125K

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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 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
for drinking water treatment. This also applies to the treatment of water
for industrial or domestic 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 the
systems with the required care. This operation manual assists you with
important information. Therefore, read the complete manual before
installing, operating or maintaining your 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 customer service staffs, as well as the experts at our head­quarters in Hoechstaedt, are available to help you.

Advice and assistance

For advice and assistance please contact your local representative (refer
to www.gruenbeck.com ) or get in touch with our service centre which
can be reached during office hours:

Tel.: [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 this data handy at all
times, please copy it from the type designation plate to the overview on
page C-11.

Reverse Osmosis System

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®

-OSMO RO 125K

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2 Warranty

All devices and systems supplied by Grünbeck Wasseraufbereitung
GmbH are manufactured according to the most recent technical stand­ards and subjected to a comprehensive quality assurance system. All
warranty claims are subject to our General Terms and Conditions:

Terms and Conditions of Sale and Delivery (excerpt)

. . . . . . . .

11. Warranty
a) If goods and services are supplied which are obviously

defective, the Customer must report such defects
within 8 (eight) days after receipt of such goods and
services in order to maintain the liability claims.

b) If the defect is of such a nature that only a spare part

needs to be replaced, Grünbeck shall have the right to
request the Purchaser to replace the new part deliv­ered by us if the costs for sending a technician to the
Purchaser's site are unreasonably high.

c) The warranty periods are:

- two years: for devices for private use (natural per­sons)

- one year: for devices for industrial or commercial
use (companies)

- two years: for all DVGW-certified devices, also for
industrial or commercial use within the framework
of the liability agreement with the ZVSHK.

after delivery/acceptance. This excludes electrical parts

and parts which are subject to wear and tear. The
warranty period shall only apply if the operating in­structions are observed meticulously, if the device is
mounted, commissioned, operated and maintained
properly, and/or if a maintenance contract is made
within six months. If these requirements are not met,
the warranty shall be void. The warranty shall be void
if the purchaser uses dosing agents or chemicals sup­plied by other manufacturers and if the quality and
composition of such dosing agents or chemicals is be­yond Grünbeck's control.

Grünbeck shall not be liable for defects or damage

resulting from inept handling or operation.

d) Grünbeck shall only be liable if the Customer performs

the maintenance work as stated in the operating in­structions or has the maintenance work performed in
such a way and if the Customer uses spare parts sup­plied or recommended by Grünbeck.

e) Grünbeck shall not be liable for damage resulting from

frost, water or electrical over-voltage or from parts
which are subject to wear and tear. This applies in par­ticular to electrical parts.

f) The claims of the Purchaser are limited to repair or

replacement, as the case may be, at the discretion of
Grünbeck. Grünbeck shall have the right to several at­tempts to repair. If Grünbeck fails to repair or re-place
the defective delivery within a reasonable time, the
customer shall have the right to either cancel the con­tract or demand an appropriate reduction of the pur­chase price.

g) In case of complaints with regard to systems that are

not installed in Germany, the warranty claim will be
settled by the local technical customer service author­ised by Grünbeck. If no technical customer service is
designated in the specific country, the assignment of
Grünbeck’s technical customer service shall end at the
German border. All additional cost, apart from the ma­terial required, shall be borne by the customer.

. . . . . . . .

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®

-OSMO RO 125K

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3 How to use this operation manual

This operation manual is intended for the operators of our systems. It is
divided into several chapters (a letter is assigned to each of them) 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.

4 General safety information

4.1 Symbols and
notes

Important notes in this operation manual are characterised by symbols.
Please pay particular attention to these notes in order to ensure a dan­ger-free, safe and productive system operation.

Danger! Failure to adhere to these notes will cause serious or life­threatening injury, extreme damage to property or inadmissible con­tamination of drinking water.

Warning! Failure to adhere to these notes may cause injury, damage to
property or contamination of the drinking water.

Attention! Failure to adhere to these notes may result in damage to
the system or other objects.



Note: This symbol characterises notes and tips to make your work easi­er.

Tasks with this symbol may only be performed by Grünbeck's technical
service or by persons expressly authorised by Grünbeck.

Tasks with this symbol may only be performed by qualified electrical
experts according to the VDE guidelines or according to the guidelines
of a similar local institution.

Tasks with this symbol may only be performed by water companies or
approved installation companies. In Germany, the installation company
must be registered in a water company installation directory as per

§12(2) AVBWasserV (German Ordinance on General Conditions for the
Supply of Water).

4.2 Operating
personnel

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

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-OSMO RO 125K

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4.3 Designated
application

The system may only 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 may
only be operated when it is in proper working order. Any malfunctions
must be repaired at once.

4.4 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 (see chapter C Optional equipment) must be in-

stalled.

4.5 Indication of
specific dangers

Danger due to electricity!  Do not touch electrical parts with wet
hands! Disconnect the system from mains before starting work on elec­trical parts of the system. Have qualified experts replace damaged cables
immediately.

Danger due to mechanical energy! System parts may be subject to
overpressure. Danger of injury and damage to property due to escaping

water and unexpected movement of system parts.  Check pressure
pipes regularly. Depressurise the system before starting repair or
maintenance work on the system.

Hazardous to health due to contaminated drinking water!  The sys­tem may only be installed by a qualified company. The operation manu­al must be strictly adhered to! Ensure that there is sufficient flow. The
pertinent guidelines must be followed for starting-up after long 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.

5 Shipping and storage

Attention! The system may be damaged by frost or high temperatures.

In order to avoid damage of this kind:
Protect from frost during transportation and storage! Do not install or
store system next to objects which radiate a lot of heat.

6 Disposal of used parts and materials

Used parts and materials are to be disposed of, or made available for
recycling purposes, according to the applicable local guidelines.
If a material is subject to specific regulations, adhere to the notes indi­cated on the packing.
If in doubt, contact your local waste disposal authority or the manufac­turer for more information.

Reverse Osmosis System

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®

-OSMO RO 125K

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B Basic information (reverse osmosis system)

1 Laws, guidelines, standards

In the interest of good health, rules cannot be ignored when it comes to
the processing of drinking water. This operation manual takes the appli­cable German guidelines into account and provides all the information
you need to safely operate your water treatment system.

Among other things, the regulations stipulate

 that only approved companies are permitted to make major modifica-

tions to water supply systems.

 and that tests, inspections and maintenance on installed devices are

to be performed at regular intervals.

2 Water

In nature, chemically pure water does not exist. Rain water already takes
up various substances from the air which change the properties of the
water to a larger or lesser extent. This process continues while the water
flows through the ground layers and takes up increasing amounts of
substances. In this context, carbon dioxide (CO2) is of major importance
as this substance further increases the dissolving power of the water.
Consequently, the concentrations of dissolved sodium, potassium, calci­um, magnesium, iron, manganese, copper, zinc, chlorides, fluorides, sul­phates but also nitrates, nitrites, phosphates and silicates contained in
the drinking water differ regionally.

For many decades, the ground water has been polluted with substances
originating from agricultural, industrial and other sources. As these pollu­tants can only be degraded over long periods of time, increasingly sophisti­cated technologies are required to remove high salt concentrations, hydro­carbons, nitrates, pesticides, heavy metals, etc.

The water works supply clean 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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®

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3 Functional principle of reverse osmosis

Principle:

Pre-treated feed
water

Fig. B-1: Functional principle

Concentrate:

Permeate

High concen-

tration solution

Low concentration

solution

High concen-

tration solution

Low concentration

solution

High concen-

tration solution

(concentrate)

Low concentration

solution

(permeate)

Fig. B-2: Principle of reverse osmosis

In the osmosis process, watery solutions of different concentrations are
separated by means of a semi-permeable membrane. In keeping with the
law of nature, the concentrations try to equalize. On the side of the higher
original concentration, the so-called “osmotic” pressure is generated. In
the 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 procedures is the fact that in addition to the remov­al of dissolved salts, also bacteria, germs, particles and other dissolved or­ganic matter are reduced.

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®

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C Product description (GENO®-OSMO RO 125K)

1 Type designation plate

The type designation plate is located at the housing of the reverse os-

mosis system GENO®-OSMO RO 125K. Please specify the data shown on
the type designation plate in order to be able to faster proceed your
inquiries or orders. Simply copy the information from the type designa­tion plate to the form below so that all the required information is avail­able when needed.

Reverse osmosis system GENO®-OSMO RO 125K
125K-   Serial no.:      / 
Order no.:      

Fig. C-1: Type designation plate

2 Functional description

Downstream of the fine filter 5 μm, the pre-treated feed water is guided
to the valve control unit. A high-pressure pump then brings the feed
water to the pressure required for the osmotic membrane to begin func­tioning. The RO membrane separates the water into the partial streams
of permeate and concentrate. The permeate water is directed to a UV­insensitive reservoir made of PE. The concentrate partial stream is re-fed
to the membrane by means of a circulation line via the high-pressure
pump and thus increases the recovery and the economic efficiency of
the reverse osmosis system GENO

®

-OSMO RO 125K and ensures an
even flow off on the membrane. A small part of the concentrate, con­taining the water soilage retained by the membrane, is run into the
sewage system.

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2.1 System components

Fig. C-2: Components of reverse osmosis system GENO

®

-OSMO 125K-TS

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®

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1

5 μm fine filter
incl. pressure reducer

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

2

Inlet solenoid valve

During the production of permeate, this valve is always open. When the
system stops (tank full), the valve remains open for the set membrane

rinsing time. Visual indication in control electronics

10

.

3

Pressure switch
High pressure pump

To prevent the high pressure pump from running dry. It switches time-delayed after
the solenoid valve

2

has opened. Visual indication in control electronics10.

4

Rinsing solenoid valve

This valve opens for a set period of time after the level control

8

in the
tank signals "FULL" to the control electronics. The valve also opens in
case of malfunctions and always in connection with the inlet solenoid

valve

2

.

5

Needle valve
Concentrate

To set the feed water dependent volume flow of “concentrate” to the
drain. During permeate production, this amount of water is always dis­charged to the drain.

6

High pressure pump Pump aggregate that generates the operating pressure required for the mem-

brane. Pump starts operation upon permeate demand by the level control

8

(LB

switches) in the permeate tank. A control valve to set the operating pressure is
integrated in the pump head. Visual indication in control electronics

10

.

7

Membrane Reverse osmosis membrane for the production of permeate.

8

Level control Float level control for regulating the water level in the permeate supply tank

(only TS version).

9

Pressure booster pump Pressure booster pump with integrated pressure switch. Delivers permeate

to the consumer network (only TS version).

10

Control electronics The microprocessor controller and the corresponding aggregates regulate

the permeate production and the supply of the downstream consumers.

11

Flow sensor
Concentrate

Measures the concentrate volume and supplies the control electronics with
pulses. Visual indication of the concentrate volume in the control electron-

ics

10

.

12

Flow sensor
Permeate

Measures the permeate volume and supplies the control electronics with
pulses. Visual indication of the permeate volume in the control electron-

ics

10

.

13

Membrane expansion
vessel

Permeate buffer to reduce the switching cycles of the pressure booster
pump

14

Pressure switch
Pressure booster pump

Switches the pressure booster on when water is withdrawn and off after
water withdrawal has been completed.

15

Connection ½“ (DN 15) MT Concentrate to drain

16

Connection ½“ (DN 15) MT Feed water

17

Connection ½“ (DN 15) MT Permeate/consumer

18

Option: Solenoid valve for forced withdrawal

19

Option: Conductivity measurement

20

Option: Blending device

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2.2 Flow chart of reverse osmosis system GENO®-OSMO-RO 125k

Fig. C-2.1: Flow chart of reverse osmosis GENO

®

-OSMO RO 125K-TS (for corresponding legend, please refer to previous page)

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®

-OSMO RO 125K

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Table C-1: Technical specifications Reverse osmosis system GENO®-OSMO RO

125K-TS 125K-TL

Connection data

Nominal connection diameter for feed water inlet

½“ (DN 15) male thread

Nominal connection diameter for permeate outlet

½“ (DN 15) male thread

Nominal connection diameter for concentrate outlet

½“ (DN 15) male thread

Required drain connection min.

[DN] 50

Connected electrical load approx.

[kW] 0.85 0.50

Power supply, approx.

[V/Hz] 230 V / 50 Hz

Protection

IP 54

Performance data

Permeate volume at feed water temperature of
10° C / 15 °C

[l/h] 105/125

Electrical pump capacity at operating pressure

[kW] 0.37

Daily permeate volume (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 -

Hydraulic capacity pressure booster max.

[l/h/bar] 900/3.8 -

Pump capacity curve – pressure booster [l/h/bar] 170/4.0 – 250/3.7 ­Nominal pressure

PN 16

Salt retention

95-99%

Total salt concentration in feed water, as NaCl max.

[ppm] 500

Concentrate volume flow, min./max. (at 15 °C)

[l/h] 40/125

Feed water volume flow (fresh water at 15 °C)
at a recovery of 75 %, max.

[l/h] 160

Recovery min./max.

[%] 50-75 (adjustable)

Dimensions and weights

Dimensions w x d x h [mm] 450 x 430 x 1120
Empty weight, approx. [kg] 37 30
Operating weight, approx. [kg] 75 30

Ambient data

Feed water temperature min./max. [°C] 10/30
Ambient temperature, min./max. [°C] 5/35

Order no. 752 100 752 110

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3 Designated application

The reverse osmosis system GENO®-OSMO RO 125 K is designed to de-

mineralise feed water. The water is primarily used for industrial applica­tions.

The system may only be used after a prior water analysis and an appro­priate pre-treatment of the water have been performed.

The continuous permeate capacity of the system depends on the tem­perature. It was defined at a temperature of 15°C. In case of an increas­ing resp. decreasing feed water temperature, the permeate output may
decrease (decreasing temperature) or increase (increasing temperature)
by up to 3 % per °C.

The system is adapted to the permeate requirements to be expected at
the installation site. It is not suitable for strongly deviating output.

The system may only be operated if all components are installed proper­ly. You MUST NOT remove bridge or in any other way tamper with safe­ty devices.

The designated application of the system also implies that the infor­mation contained in this manual and all safety guidelines applying at the
installation site be observed. Finally, the system must be maintained and
inspected at the specified intervals.

4 Application limits

The upper limit values concerning substances in the water as stipulated

by the German Drinking Water Ordinance constitute the application lim­its for the reverse osmosis system GENO®-OSMO RO 125 K.

 < 22°dH (39,2° f; 3,96 mmol/l) without water analysis
 Free chlorine, unverifiable)
 Iron < 0.2 mg/l
 Manganese < 0.05 mg/l
 Silicic acid < 15 mg/l
 Chlorine dioxide, unverifiable
 Turbidity < 1 TE/F
 Silt density index < 3
 pH range 3 - 9



Note: The permeate produced by the reverse osmosis system is no
drinking water. If it is to be used as drinking water, additional treatment
is required (blending, hardening).

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®

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5 Scope of delivery

5.1 Standard
equipment

 Free-standing casing made of photo-resistant PE for the integration of

all aggregates and control elements. The casing also serves as supply
tank (only in case of GENO®-OSMO RO 125 K-TS).

 Microprocessor controller with LC display, volt.-free collective fault

signal and volt.-free signal contact (maintenance intervals, various
pre-alarms), integrated in the free-standing casing.

 Sliding vane rotary pump made of corrosion-resistant brass with mo-

tor as high pressure pump to supply the membrane, incl. control valve
for operating pressure and pressure gauge.



1)

External pressure booster pump with integrated pressure switch and
membrane connection tank for permeate supply of consumers down­stream

 Hydro distribution block for the water supply within the membrane

system. Integrated valves and measuring instruments for an easier sys­tem adjustment.
The hydro module features a 5 μm fine filter with integrated pressure
reducer that is preset to 2.5 bar

 Ultra-low pressure reverse osmosis membrane, installed in a pressure

pipe made of high-duty PE

 Flow sensor for measuring the volumes of the permeate and concen-

trate flows

 Operation manual

1)

only in case of GENO®-OSMO RO 125 K-TS

5.2 Optional equipment



Note: It is possible to retrofit existing systems with optional compo­nents. Please contact your local Grünbeck representative or Grünbeck’s
headquarters for details.



Connection block for GENO

®

-OSMO-RO 125K

Connection block (installation length 190 mm).
Permeate-resistant, incl. two shut-off valves -
suitable for connection set

752 840

 Connection set for GENO

®

-OSMO 125K

2 flexible connection hoses DN 15

(l = 600 mm) for feed water and permeate

1 drain hose for concentrate

752 830