Operation Manual Reverse Osmosis System

Transcription

1 , Reverse Osmosis System Operation Manual Reverse Osmosis System Edition March 2014 Order no inter Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Strasse Hoechstaedt/Danube GERMANY Phone Fax info@gruenbeck.com A company certified by TÜV SÜD in accordance with DIN EN ISO 9001, DIN EN ISO 14001, DIN EN ISO and SCC

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) 2

3 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 Hoechstaedt/Germany Phone Fax service@gruenbeck.de Printed by: Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Strasse 1, Hoechstaedt/Germany 3

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: Responsible for documentation: System designation: System type: System number: Applicable EC guidelines: Applied harmonized standards, in particular: Applied national standards and technical specifications, in particular: Date/Signature of manufacturer: Function of signatory: Grünbeck Wasseraufbereitung GmbH Josef-Grünbeck-Strasse Hoechstaedt/Germany Markus Pöpperl Reverse osmosis system TL; TS Refer to type designation plate EC Machine Guideline (2006/42/EC) EC Guideline EMV (89/336/ECC version 92/31/ECC) DIN EN ISO , DIN EN ISO DIN EN , DIN EN , 9 th Guideline on Device and Product Safety (Machine Guideline 9. GPSGV) 1 st Guideline on Device and Product Safety (Ordinance on the Marketing of Electrical Operating Materials to be used within specific voltage limits 1. GPSGV) DIN 1988 DIN 31000/VDE 1000 (03.79) i. V. M. Pöpperl Dipl. Ing. (FH) Head of Engineering Department for Serial Products 4

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 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 ) or get in touch with our service centre which can be reached during office hours: Tel.: Fax: service@gruenbeck.de 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. 5

6 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) 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

7 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. 7

8 4.3 Designated application 4.4 Protection from water damage 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. 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 installed. 4.5 Indication of specific dangers Note: 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! 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 6 Disposal of used parts and materials 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. 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. 8

9 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 modifications 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 (CO 2 ) 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. 9

10 Reverse Osmosis System GENO -OSMO RO 125K 3 Functional principle of reverse osmosis Principle: Concentrate: Pre-treated feed water Permeate Fig. B-1: Functional principle High concentration solution Low concentration solution High concentration solution Low concentration solution High concentration 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. 10

11 C Product description () 1 Type designation plate The type designation plate is located at the housing of the reverse osmosis system. 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 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 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. 11

12 2.1 System components Fig. C-2: Components of reverse osmosis system GENO -OSMO 125K-TS 12

13 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 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 electronics 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 membrane. 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 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 12 Flow sensor Permeate 13 Membrane expansion vessel 14 Pressure switch Pressure booster pump Measures the concentrate volume and supplies the control electronics with pulses. Visual indication of the concentrate volume in the control electronics 10. Measures the permeate volume and supplies the control electronics with pulses. Visual indication of the permeate volume in the control electronics 10. Permeate buffer to reduce the switching cycles of the 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 13

14 2.2 Flow chart of reverse osmosis system GENO -OSMO-RO 125k Fig. C-2.1: Flow chart of reverse osmosis -TS (for corresponding legend, please refer to previous page) 14

15 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] Power supply, approx. [V/Hz] 230 V / 50 Hz Protection IP 54 Performance data Permeate volume at feed water temperature of [l/h] 105/ C / 15 C 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/ /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) [l/h] 160 at a recovery of 75 %, max. Recovery min./max. [%] (adjustable) Dimensions and weights Dimensions w x d x h [mm] 450 x 430 x 1120 Empty weight, approx. [kg] Operating weight, approx. [kg] Ambient data Feed water temperature min./max. [ C] 10/30 Ambient temperature, min./max. [ C] 5/35 Order no

16 3 Designated application The reverse osmosis system GENO -OSMO RO 125 K is designed to demineralise 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). 16

17 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 motor 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 concentrate 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 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

18 Conductivity meter for As plug-on circuit board for the control electronics. Indication at the display with limit value and delay incl. connection line and conductivity measuring cell, installed in combi-cap pressure pipe. Solenoid valve forced withdrawal for RO 125K Solenoid valve adaptable to permeate outlet of hydro module for forced withdrawal from the tank of the in case of longer periods of standstill. Electrically triggered by the control electronics of the GENO -OSMO RO 125K. Blending unit for GENO -MSR system 200 Control unit adaptable to hydraulic unit GENO - OSMO RO 125K consisting of: Connection G ¾ for feed water, solenoid valve; needle valve, flow sensor to display the total blended water in the control electronics GENO - OSMO RO 125K, connection available for blended water in and/or tank (provided by others) Fine filter BOXER K 1 80 μm cartridge fine filter for pre-filtration Euro system separator GENO -DK 2 Mini To protect the water supply system from installations and systems endangering the drinking water, as per DIN 1988 part 4 (DIN EN 1717) GENO -DK 2 Mini. Water softener Weichwassermeister GSX 10 I in industrial design Twin softening unit for alternating operation, with connection block and flexible connection hoses GENO -softwatch Komfort for automatic monitoring of the residual/total hardness (water hardness)

19 GENO -activated carbon filter AKF 250 To reduce the chlorine concentration in the water GENO-STOP for optimum protection from water damage. The new safety device GENO-STOP provides reliable and comprehensive protection from water damage. The GENO-STOP can be equipped with up to 2 wired water sensors and 5 wireless water sensors. GENO-STOP 1 For additional models, please inquire Note: Pure water tank for the intermediate storage of the unpressurised permeate from the GENO reverse osmosis systems Tank version: All tanks are pre-assembled and feature a PVC overflow pipe as well as connections for permeate inlet and suction line of pressure booster system. Grey PE. Hand hole with removable screw lid and external level control system GENO -Multi Niveau (switching level). Basic pure water tank RT sterile, complete Usable volume approx. 850 l l 780 / w 990 / total height 2000 mm* Additional tank RT for basic pure water tank Usable volume approx. 850 l l 780 / w 780 / total height 2100 mm* Basic pure water tank RT standard Usable volume approx. 850 l l 780 / w 1000 / total height 2050 mm** * Tank height incl. connection pieces; for larger tanks, please inquire ** No sterile overflow as siphon overflow designed as down-pipe Additional tank, level control and overflow loop not included, 2 connection pipes included, inside diameter =36 mm. A maximum supply battery of 4 tanks may be realised

20 Pressure booster system GENO FU 2/40-1 N 10 Compact, pressure-controlled pump aggregate, consisting of a centrifugal pump, completely made of stainless steel as well as integrated pressure and flow sensor for pump control and an integrated dry run protection. Special version to deliver permeate. Delivery rate: max m³/h Delivery height: max m Power supply: 230 V / 50 Hz Connected load: 1 kw Connections: DN 25 / DN 32 Protection: IP 55 Pressure booster system GENO FU 2/40-2 N 10 As for single pressure booster system, however, featuring the possibility for a time/load switchover Switch cabinet for time/load switch-over in case of GENO -FU 2/40-2 N 10 Rotary power switching point (1.25-5A) 1) Power unit for single pressure booster AC power switching point (2.2 kw) 1) Power unit for single pressure booster ) Level control - to be provided by others on site for dry-run protection in permeate tank is required. 5.3 Consumables To ensure reliable system operation, only genuine consumables should be used. GENO -replacement filter element 5 μm with protective cylinder Packing unit: 2 pcs Reverse osmosis membrane with seal Packing unit: 1 pc Water test kit Total hardness 1 pc 10 pcs

21 5.4 Wearing parts Seals and valves are subject to a certain wear and tear. Wearing parts are listed below. Note: Although these are wearing parts, we grant a limited warranty of 6 months. The same applies for electrical components. a) Solenoid valves, regulating valves, concentrate, seals b) High pressure pump Fig. C-3: Valves Fig. C-4: High pressure pump 21

22 D Installation () 1 General installation information The installation site must provide adequate space. A foundation of sufficient size and load carrying capacity must be provided. The required connections must be provided prior to the installation of the system. Please refer to table C-1 for dimensions and connection data. Note: When installing systems with optional equipment (refer to chapter C, 5.2), you must also observe the operation manuals supplied with such equipment. 1.1 Sanitary installation When installing the reverse osmosis system, certain rules MUST always be observed. Additional recommendations facilitate your work with the system. The installation instructions described herein are illustrated in fig. D-4. Binding rules The installation of a reverse osmosis system is a major interference with the drinking water system. Only authorised companies may install such systems. Note: Observe the local installation guidelines and the general guidelines. The system must be preceded by a fine filter (e.g. BOXER KD) (option) The system must be preceded by a system separator (option). The system must be preceded by a water softener (option). If necessary, install an activated carbon filter (option) Provide a drain connection (at least DN 50) to discharge the concentrate. If the concentrate is directed to a lifting system, the delivery rate of the lifting system should at least amount to 500 l/h. Warning! A floor outlet must be available in the installation room. If this is not the case, an appropriate safety device must be installed (refer to option C-6). Recommendations Provide a sampling valve directly upstream and downstream of the reverse osmosis system GENO -OSMO RO 125 K. This will facilitate the sampling for the regular quality control (functional check). 22

23 1.2 Electrical installation Internal wiring of the GENO-OSMO-RO125K control unit The system is completely wired (if necessary, incl. optional equipment) at the factory and will be delivered ready-to-plug-in. During start-up, the parameter ECL: 1 must be changed to ECL: 0 in Code level 113 (normally closed contact >>normally open contact). This is a safety measure, so that the system cannot be switch-on accidentally after plugging in the mains cable without the system being properly deaerated first. Jumpers must be plugged this way Pumps Solenoid valve Conductivity module Mains Mains cable PS-pump (pressure booster) HP-pump Release of analysis Hardness monitoring device Thermal circuit breaker of HP-pump Fig. D-1: PCB configuration of GENO - OSMO RO 125K Terminal no. Terminal Function (colour of wire) Remarks All protective conductors are connected with the 7 pole protective conductor terminal on the left mounting rail X1 3 L 230 V / 50 Hz phase 2 N Neutral conductor 1 PE Protective earth conductor Mains cable, protection provided by others on site at least 6 A X2 6 MVW 230 V / 50 Hz phase Solenoid valve rinsing Joint neutral terminal 5 N Neutral conductor 7 MVE 230 V / 50 Hz phase Inlet solenoid valve 10 MVR 230 V / 50 Hz phase Option: 9 N Neutral conductor Solenoid valve forced withdrawal 23

24 Terminal no. Terminal Function (colour of wire) Remarks X3 12 PS 230 V / 50 Hz phase -TS 13 N Neutral conductor Triggering of high pressure pump via relay K2, protection via fuse F3 (T3, 15A) -TL Triggering of high pressure pump volt.-free contact, relay K2, terminals Control voltage for external power unit 230 V~: relay K2, terminals 14-A2 14 HP 230 V / 50 Hz phase Option: 13 N Neutral conductor Solenoid valve blending unit 14 HP 230 V / 50 Hz phase Triggering of high pressure pump via relay 2 N Neutral conductor K1, protection via fuse F2 (T 4,0 A) X AVRO electrode line Only used for AVRO 125 TS/TL! 34 GND X5 15 COM Joint root Volt.-free contacts N. C. 250 V~ / 3 A with 16 SAMS Fault signal contact joint root COM 17 MELD Signal contact X6 28 GND Joint mass (brown) 29 WZ0 Pulse input permeate 30 WZ1 Pulse input concentrate green 31 WZ2 Option: Hall pulse cable of turbine water meter Pulse input blending unit V Joint source voltage 12 VDC (white) X7 24 Level a Switch-off level high pressure Level control permeate tank brown pump 25 Level b Switch-on level high pressure green L1 pump a N.C. 26 Level c Dry-run protection pressure yellow booster pump b N.O V Joint source voltage 24 VDC white c N.O. X8 18 DS_HP Pressure switch high pressure pump Low pressure of feed water, dry-run protection V Source voltage 24 VDC high pressure pump 20 DS_PS Pressure switch pressure booster pump Pressure switch to control pressure booster V Source voltage 24 VDC pump (-TS resp. AVRO 125 TS integrated in system) In case of the RO/AVRO 125-TL version, a jumper must be set at terminals X8 20/ CLOSE Release input Close System switches off if thermal circuit V breaker of HP pump is triggered Source voltage 24 VDC Lock system externally, eg. pretreatment, residual hardness... For this purpose, a normally closed contact (NCC) provided by others must be switched in series with the thermal circuit breaker. 24

25 Reverse Osmosis System GENO -OSMO RO 125K Terminal no. Terminal Function (colour of wire) X9 Screen LF E LF V Conductive measuring cell with 2 electrodes, not temperature compensated, cell constant 0,1 or 1.0 Release signal/analysis start hardness monitoring device Relais 31 K1 34 Remarks white brown Option: Conductivity meter Contact is closed if system produces permeate. Connect GENO -Softwatch Komfort: to terminals 16/17. Configuration of the components on the mounting rails, accessible after the control unit has been dismantled: Protective conductor terminal, mounted below the two fuses F2 and F3 Fig. D-2: Position of protective conductor terminal 2 Preliminary works 1. Unpack all system components. 2. Check for completeness and perfect condition. 3. Set up the reverse osmosis system GENO -OSMO RO 125 K at the designated installation site. 25

26 3 System connection on water side Connect the feed water to the system (refer to fig. D-4) Connect the permeate pipe to the system. In case of GENO -OSMO RO 125K-TL connect to tank provided by others on site. Attention! If withdrawal/feed points (e. g. tank provided by others on site) of permeate originating from the RO-125K are located below the connection level of the system, a pressure maintaining valve must be installed into the permeate pipe in order to protect the permeate tank from being siphoned. Fig. D-3: Withdrawal point below system level 26

27 A BOXER -KD B Euro system separator DK 2-Mini C Water softener Weichwassermeister 2 GSX I D Activated carbon filter AKF Concentrate connection Permeate connection Feed water connection E GENO -OSMO-RO 125K-TS Fig. D-4 Installation drawing of reverse osmosis system Fig. D-4(a) Installation drawing of reverse osmosis system 27

28 E Start-up (reverse osmosis system ) 1 System rinsing The work described below may only be performed by trained experts. For safety reasons, we recommend to have the start-up performed by Grünbeck s customer service/authorised service. 1.1 Mounting of rinsing line Disassemble permeate line from supply tank (refer to fig. E-1, E-2, item 1) and route to drain by means of a separate hose. Fig. E-1: Permeate line RO 125 K-TS Fig. E-2: Permeate line RO-125 K-TL 28

29 1.2 Rinsing of preservative Note: A special preservative is used to protect the membrane during storage and shipping. The first step is to rinse this preservative from the system. To prevent the system from being accidentally started before this agent has been removed, the system is locked electronically. Please refer to chapter F for detailed information on the controller. Release system via Code 113, (refer to table E-1: excerpt from ), parameter ECL: To do so, open parameter by means of key, set ECL: 1 by means of key and confirm by means of key Via Code 113, (rever to table E-1: excerpt from ), parameter EnL: 1 open both solenoid valves ( DEAERATION ) and rinse preservative from system for 30 min. To do so, access the parameter by means of key and set EnL: 1 with key. Confirm with key To terminate program step DEAERATION : access parameter with key, set EnL:0 by means of key and confirm with Quit programm EnL by simultaneously pressing keys and 29

30 Table E-1: Excerpt from pagaragraph F-3.1 Input logiccode 113 Display Factory setting Parameter Setting range E-A: 1 Contact type level a = NOC 1 = NCC E-b: 0 Contact type level b = NOC 1 = NCC E-c: 0 Contact type level c = NOC 1 = NCC EHP: 2 EPS: 0 ECL: 0 EnL: 0 A.PF:0 Contact type pressure switch low pressure HP (High pressure pump). Contact type pressure switch PS (Pressure booster pump). Contact type input Close. Rinse system (Solenoid valves inlet and rinsing). Function signal contact terminals 15/17. Remarks = NOC 1 = NCC 2 = NOC with autom. restart 1) 3 = NCC with autom. restart 1) = NOC 1 = NCC = NOC 1 = NCC = opens solenoid valves (only possible if system is switched off via key ). 0 = closes solenoid valves again = Contact opens in case of deactivation of HP pressure, pre-alarm conductivity, level c undershot, maintenance interval expired. 1 = Contact is closed when HP pump is running.. 30

31 1.3 Permeate production / deaeration of pressure pump Note: Note: Remount permeate line to supply tank (refer to fig. E-1). Switch on the reverse osmosis system RO 125 K by means of The system produces permeate in the tank. The following only applies to reverse osmosis system RO-125 K-TS key. The pressure booster pump is deaerated if permeate flows from the deaeration/sampling valve (refer to fig. E-3, item 1) (it will takes approx. 15 minutes for the permeate to start flowing). Close deaeration valve. Plug the plug of the pressure switch (refer to fig. E-4, item 1) onto the presure switch pressure booster pump starts delivering. In order for the pressure pump to reach ist bearing pressure, the pipe downstream must also be deaerated, therefore it is essential to establish permeate consumption. Switch-on pressure approx. 1.8 bar; switch-off pressure approx. 3.0 bar. Fig. E-3: Deaeration of pressure booster Fig. E-4: Pressure switch of pressure booster 31

32 F Operation 1 Preface Note: Instructions printed in bold letters are absolutely necessary for the continuation of the operation. All other instructions may be omitted, if the value shown in the display remains unchanged. Settings in the customer service programming level may only be performed by Grünbeck s technical customer service/authorised service or by trained experts explicitly authorised by Grünbeck. Warning! Incorrect settings may result in dangerous operating states which may cause damage to persons, health or property. Strictly observe the operation manual! Only make settings that are described in this manual! Fig. F-1: Control unit 32

33 2 How to operate the control unit Display symbols: Operating mode display appears when the system is switched on via key (> 5 sec. in basic display time ) High pressure pump appears when high pressure pump produces permeate (blinking in case of malfuntion Er1) Pressure booster pump appears when the pressure booster pump delivers permeate resp. the power unit K2 is active. Solenoid valve inlet appears when permeate is being produced resp. when the system is being rinsed Solenoid valve rinsing appears when the system is being rinsed Solenoid valve forced withdrawal appears when the content of the permeate tank is discharged to the drain Filling level indication permeate tank Upper wave: Switch-off level for high pressure pump Wave in the middle: Switch-on level for high pressure pump Lower wave: Dry-run protection for pressure booster pump Bars for water meter pulses blink with every 5th pulse of the water meter Permeate resp. Konzentrat (concentrate) Bar for operation standby of high pressure pump (HP) and pressure booster pump (PS) indicates the state of the pressure switch feed water inlet (bar appears when pressure is pending) and operation release of PS pump (bar appears when operation is released) Bar for input Close appears when the release signal Close is pending at the input, i. e. the system is locked appears when high pressure pump is overheated ± Fig. 2: Operating panel of GENO - OSMO RO 125K control unit P Display Numerical values indicates time and operating parameters in the Info level indicates the parameters of the Code levels indicates symbols in addition to the error signal Point appears as long as pressure booster pump is locked (after ON via key, when the lower wave permeate tank was exceeded, acknowledge after malfunction) Is blinking, if during the permeate production the pressure switch of the high pressure pump is de-energised (lack of pressure in the feed water) Bar for signal and fault signal contact appears when the maintenance interval has expired, pressure switch high pressure pump has dropped out, conductivity pre-alarm, permeate tank empty. Er appears in case of malfunctions Er0 Er6 Symbol not relevant for GENO -OSMO RO 125K TL/TS 33

34 1.3 Permeate production / deaeration of pressure pump Note: Note: Remount permeate line to supply tank (refer to fig. E-1). Switch on the reverse osmosis system RO 125 K by means of The system produces permeate in the tank. The following only applies to reverse osmosis system RO-125 K-TS key. The pressure booster pump is deaerated if permeate flows from the deaeration/sampling valve (refer to fig. E-3, item 1) (it will takes approx. 15 minutes for the permeate to start flowing). Close deaeration valve. Plug the plug of the pressure switch (refer to fig. E-4, item 1) onto the presure switch pressure booster pump starts delivering. In order for the pressure pump to reach ist bearing pressure, the pipe downstream must also be deaerated, therefore it is essential to establish permeate consumption. Switch-on pressure approx. 1.8 bar; switch-off pressure approx. 3.0 bar. Fig. E-3: Deaeration of pressure booster Fig. E-4: Pressure switch of pressure booster 31

35 Key functions: Basic functions: Acknowledgement of malfunctions Access to time programming mode (press key for > 2.5 sec. ) To switch off the system (> 5 sec. in basic display time ) To switch on the system (> 5 sec. in basic display time ), to indicate operating values of the Info level Extended functions in programming levels: Access parameter for editing (value is blinking) Store parameter and close Reduce the value Return to the previous menu item Increase the value Go to the next menu item + Access to the Code protected programming levels (Code request C 000) + Close open parameter without saving (present value is kept) Return to the basic display time 2.1 How to read the operating state Within the Info level, various operating parameters can be displayed. The Info level may be accessed by pressing the key (> 5 sec.) You may access other parameters by tapping the key. As long as the system has not yet been released via the input signal Close, the info level is also still locked. Key Display Parameter 00:00 Basic display time When pressing this key (> 5 sec.) for the first time, the system is being switched on! 365 Remaining time of maintenance interval [days] 0000 Displayed value not relevant for RO 125 K TL/TS LF022 P0200 c0200 Permeate conductivity [μs/cm] (optional displayed value blinks if pre-alarm value is exceed) Permeate flow [l/h] Concentrate flow [l/h] u0320 Blending flow [l/h] (option ) A 050 System recovery [%] 34

36 2.2 How to program the time 2.3 Access to the programming levels modification of parameters Precondition: The basic display time must be indicated. 1. Press key for > 2.5 seconds, only the hours are still displayed 00: 2. Press key to modify the hours (when the value is blinking, set the desired value by means of keys and, and save with the key ) or press to switch to the minutes :00 3. Press key to modify the minutes (when the value is blinking, set the desired value by means of keys and, and save with key ) 4. By simultaneously pressing the keys and, return to the basic display. 1. By simultaneously pressing (> 1 sec.) keys and, the Code request C 000 appears. 2. Set the required Code with keys or and confirm with key. 3. Select the desired parameter in the programming level by keys or and open it for editing with key (the value starts blinking). 4. Change the parameter setting to the desired value by keys or 5. Save the new parameter settings with the key (value stops blinking) or reject the modification by simultaneously pressing keys and and close the parameter again (value stops blinking and the previous setting remains stored). 6. Return to the basic display time by simultaneously pressing keys and. 7. When no keys are operated within the parameter level for more than 5 minutes, the display automatically returns to the basic indication of the time. Parameters that might be open (blinking value) are closed and the previously stored value is kept. 2.4 Software version Display Parameter P1.00 Software version RO-matic control unit 35

37 3 Programming levels 3.1 Input logic Code 113 Display Factorysetting A.PF:0 Parameter Setting range E-A: 1 Contact type level a = NOC 1 = NCC E-b: 0 Contact type level b = NOC 1 = NCC E-c: 0 Contact type level c = NOC 1 = NCC EHP: 2 EPS: 0 ECL: 0 EnL: 0 Contact type pressure switch low pressure HP (high pressure pump) Contact type pressure switch PS (pressure booster pump) Contact type input Close Rinse system (solenoid valves inlet and rinsing) Function signal contact terminals 15/17. Remarks = NOC 1 = NCC 2 = NOC with autom. restart (1) 3 = NCC with autom. restart (1) = NOC (RO/AVRO 125-TS) 1 = NCC (RO/AVRO 125-TL) = NOC 1 = NCC = opens solenoid valves (only possible, if system is switched off via key ) 0 = closes solenoid valves again = Contact opens in case of deactivation of HP pressure, pre-alarm conductivity, level c undershot, maintenance interval expired. 1 = Contact is closed when HP pump is running. 36

38 (1) If the error Er1 occurs while the permeate production is running (pressure switch low pressure high pressure pump), the system tries to restart in the following time intervals: minutes If sufficient pressure is available, permeate is being produced until level a is reached and the error quits itself. During the wait time between the start attempts, the symbol P is blinking in the display. 2) Pressure switch: Switch-on pressure 1.8 bar Switch-off pressure 3.0 bar The hysteresis of the pressure switch may be adjusted in parallel by means of the screw. 3.2 System parameters Code 290 Display Parameter Factorysetting 1. 0 Cell constant conductivity measurement (optional) Limit value conductivity for malfunction Er 3 [μs/cm] Conductivity pre-alarm [μs/cm] (display in the info level starts blinking and signal contact switches) Switch-off delay in case of Er 3 [minutes] Setting range 0.0 / 0.1 / Remarks 0.0 = Conductivity measurement deactivated, i. e. parameter not effective 0.1 = Measuring range μs/cm 1.0 = Measuring range μs/cm Note: Setting value must be chosen according to the cell constant (i. e. measuring range)! Also delay time for the release of the status signal in case the conductivity pre-alarm is exceeded 37

39 Display Parameter Factorysetting 5. 0 Return of power reaction for malfunction Er 0 (power failure > 5 minutes) 6. 1 Interval in days for forced operation / forced withdrawal [days] 7.18:00 Time for forced operation / forced withdrawal 8. 0 Duration of forced operation [hours] Opening period of solenoid valve forced withdrawal [minutes] A. 0 Monitoring or recovery (Er 5) b. 80 Upper limit value for recovery [%] c. 060 Delay time for recovery switch off [min.] Setting range Remarks = No matter whether the system was off or on prior to the power failure, after return of power, it remains switched off and malfunction Er 0 is indicated 1 = Malfunction Er 0 is deactivated 2 = After return of power, the system is on or off such as it was before the power failure and the malfunction Er 0 is indicated If the interval in days since the last permeate production is reached at the programmed time, forced 00: : operation or forced withdrawal takes place, depending on which of the two has been activated In case of RO125K, forced withdrawal is only admissible in combination with the option solenoid valve forced withdrawal! 0 1 For AVRO 125 TS/TL, the recovery monitoring must be activated! 1 99 Attention! In case of AVRO 125 TS/TL, the recovery must be set to 50 %!

40 4 Operation of reverse osmosis 4.1 How to set the system recovery In order to prevent the membrane from clogging (scaling), a certain amount of feed water has to be rejected. The ratio between the permeate volume produced and the concentrate volume flowing to the drain is called recovery How to set the permeate volume Switch on the system via key (refer to chapter F-2) at the control electronics. Throttle the pump by means of the setting valve (refer to fig. F-3, item 1) for operating pressure (refer to fig. E-2) in a way that the system specific permeate flow of 125 l/h is obtained. Note: The current permeate flow may be indicated at the control unit (refer to chapter F, paragraph 2.1, How to read the operating state ). Fig. F-3: pump 39