De Nora MIOX AE4 Installation, Operation and Maintenance Manual

Brand: De Nora

Model: MIOX AE4

Type: Installation, Operation and Maintenance Manual

This manual is also suitable for

AE™ SERIES ON-SITE GENERATOR

AE4, AE6 and AE8

Installation, Operation, and Maintenance Manual

March 26, 2019

MIOX AE Series Operators Manual

102-00085-E Page 1

AE™ SERIES ON-SITE GENERATOR

AE4, AE6 and AE8

Installation, Operation, and Maintenance Manual

MIOX AE Series Operators Manual

102-00085-E Page 2

MIOX maintains a constant product improvement program that may affect design and/or specifications.

The company reserves the right to make these changes without prior notice or liability. Portions of the

MIOX OSGs are covered by U.S. Patent

Customer Service

5601 Balloon Fiesta Parkway NE, Suite A

Albuquerque, NM 87113

Phone: 1.505.343.0090

Toll Free: 1.866.MIOX.HLP (1.866.646.9457)

FAX: 1.505.343.0093

[email protected]

www.MIOX.com

www.DeNora.com

International distributors and sales agents located worldwide

MIOX AE Series Operators Manual

102-00085-E Page 3

CONTENTS

CONTENTS .............................................................................................................. 3

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List of Figures ......................................................................................................... 5

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List of Tables .......................................................................................................... 5

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INTRODUCTION AND OVERVIEW ............................................................................ 6

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Regulatory Compliance .............................................................................................. 6

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U. S. Environmental Protection Agency (US EPA) .......................................................... 6

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List of Certifications .................................................................................................. 6

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NSF International ..................................................................................................... 6

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State Approvals ....................................................................................................... 6

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Components of the System ........................................................................................ 7

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Space Requirements ................................................................................................. 7

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Security .................................................................................................................. 7

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Salt and Water Quality Requirements .......................................................................... 7

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AE Series OSG System Components ............................................................................ 7

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AE Series OSG System Optional Equipment .................................................................. 9

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Receiving and unpacking the AE Series OSG ......................................................... 10

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Installation ........................................................................................................... 11

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Control Panel and Cell Installation ............................................................................. 12

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System Description ................................................................................................. 14

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Electronic Connections Required for Start-Up .............................................................. 15

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Electrical Power Connection ..................................................................................... 15

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Control Box Electrical Connections ............................................................................ 15

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Wiring of the Control Box Interface Block ................................................................... 16

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Connecting Alarm Relay from Control Box .................................................................. 16

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Plumbing Connections Required for Start-Up .............................................................. 17

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Feed Water Connection ........................................................................................... 17

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Brine Feed Connection ............................................................................................ 18

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Oxidant Discharge .................................................................................................. 19

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Brine Generator Installation (Optional) ...................................................................... 20

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Oxidant Storage Tank Installation ............................................................................. 22

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Ventilation Requirements ......................................................................................... 22

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MIOX AE Series Operators Manual

102-00085-E Page 4

Level Switch Installation .......................................................................................... 24

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Oxidant Tank Lid .................................................................................................... 26

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Feed Line Connection/Injection System ..................................................................... 26

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Overflow Port ......................................................................................................... 26

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Operation .............................................................................................................. 27

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Initial Settings and Start-Up Checks .......................................................................... 28

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Operation Controls ................................................................................................. 31

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System Operation .................................................................................................. 31

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Operating Window .................................................................................................. 32

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Fault Conditions ..................................................................................................... 33

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External Controls .................................................................................................... 34

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Maintenance Guide ............................................................................................... 35

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Daily Maintenance .................................................................................................. 36

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Weekly Maintenance ............................................................................................... 36

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Monthly Maintenance .............................................................................................. 36

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Quarterly Maintenance ............................................................................................ 37

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Annual Maintenance ................................................................................................ 37

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Storage of Equipment ............................................................................................. 37

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Troubleshooting Guide .......................................................................................... 38

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Procedures ........................................................................................................... 41

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Brine Pump Replacement ......................................................................................... 41

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Rupture Disk Maintenance ....................................................................................... 41

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Replacing the Rupture Disk Diaphragm ...................................................................... 42

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Acid Washing Cell ................................................................................................... 42

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Oxidant Demand Testing ......................................................................................... 43

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Chlorine Production Testing ..................................................................................... 45

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APPENDICES ......................................................................................................... 49

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Appendix A - Water Quality Guidelines ...................................................................... 50

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Appendix B – Salt Quality Guidelines ......................................................................... 51

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Appendix C – AE System Wiring Schematic ................................................................ 52

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Appendix D – MIOX System Log Sheet ...................................................................... 53

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Appendix E – Brine Peristaltic Pump Maintenance Guide ............................................... 54

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MIOX AE Series Operators Manual

102-00085-E Page 5

List of Figures

Figure 1 AE System ................................................................................................................... 8

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Figure 2 Strut Bolt Pattern ........................................................................................................ 12

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Figure 3 AE Series OSG Compartments ....................................................................................... 14

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Figure 4 System Side Panel Connections ..................................................................................... 15

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Figure 5 Brine Feed Connection ................................................................................................. 18

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Figure 6 Float Valve Assembly and Detail .................................................................................... 20

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Figure 7 Internal View Float Valve Assembly and Detail ................................................................. 21

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Figure 8 Oxidant Tank Vents ..................................................................................................... 22

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Figure 9 Safety Placards ........................................................................................................... 23

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Figure 10 Ventilation Requirements ............................................................................................ 24

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Figure 11 Level Switch Installation ............................................................................................. 24

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Figure 12 Oxidant Tank Level Switch Wiring to Control Box ........................................................... 25

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Figure 13 System Display - Primary View .................................................................................... 29

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Figure 14 System Display - Secondary View ................................................................................ 30

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Figure 15 External Controls Relay .............................................................................................. 34

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Figure 16 Rupture Disk ............................................................................................................ 41

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Figure 17 Ruptured Diaphragm .................................................................................................. 42

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List of Tables

Table 1 Feed Water Requirements ............................................................................................. 17

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Table 2 Fault Troubleshooting Guide .......................................................................................... 38

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Table 3 Additional troubleshooting procedures ............................................................................. 40

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MIOX AE Series Operators Manual

102-00085-E Page 6

INTRODUCTION AND OVERVIEW

This manual is intended to provide basic installation, operation, and maintenance guidelines for the

operator of the AE Series on-site generator (OSG). Variations between model types may cause the

images in this manual to not directly reflect the setup of every unit.

Properly operating and maintaining the system will increase cell life and overall system performance. If

you encounter problems or have questions not covered in this manual, please contact MIOX Service at

1-888-646-9457.

Regulatory Compliance

U. S. Environmental Protection Agency (US EPA)

On-site generated oxidants are listed as a compliance technology for water disinfection. To be listed as a

compliance technology, the system must be cost effective and achieve compliance with the regulated

maximum contaminant levels (MCLs), and the operator must be capable of reliably operating the

technology. The on-site oxidant category was added to this list in 1997 primarily based on independent

research of MIOX technology.

List of Certifications

EPA Registration Number: 69723-NM-001

NSF International

MIOX maintains a policy of verification and compliance of MIOX technology for water applications. The

NSF Standard provides the criteria used to evaluate the public health safety of materials, components,

products, or systems that contact drinking water, drinking water chemicals, or both. For details of

specific NSF standards for specific MIOX equipment, please consult with MIOX. NSF listings are also

available through NSF International at (800) NSF-MARK or their web site at www.nsf.org.

State Approvals

MIOX maintains a policy of obtaining state regulatory approval in all states where MIOX equipment is

installed and operated. MIOX has never been rejected for approval in any state. For a complete list of

states currently approving on-site oxidant technology, please contact MIOX.

MIOX AE Series Operators Manual

102-00085-E Page 7

Components of the System

The AE System (Figure 1) is an on-site mixed oxidant generator. The rated capacity of the AE Systems

are as follows: AE-4 is 4 pounds (1.8 kg) FAC per day, AE-6 is 6 pounds (2.7 kg) FAC per day and AE-8

is 8 (3.6 kg) pounds FAC per day. The systems are designed for easy salt loading and can operate for

hundreds of hours on a single loading of salt. The unit operates automatically and is self-diagnosing.

Space Requirements

A minimum floor space of 9 feet (2.75 meters) by 3 feet (1 meter) is required for the brine

generator, on-site generator, and oxidant tank. The system should be installed on a clean and level

surface.

Security

MIOX Corporation equipment must be installed in a building or protected structure that provide shelter

from the weather and extreme temperature variances, and which can be locked or otherwise secured.

Physical security is required to ensure that unauthorized persons cannot access the unit.

Salt and Water Quality Requirements

See Appendix A for water quality requirements. See Appendix B for salt quality requirements

AE Series OSG System Components

Electrolytic Cell

A proprietary membraneless electrolytic cell that produces a mixture of oxidants and is manufactured by

MIOX.

Water Softener

All MIOX Corporation equipment requires soft water. Hard water will cause severe damage to the cell.

Water hardness must be maintained at less than one grain/gallon (17.1 mg/L of CaCo3).

The softener resin is recharged with brine from the brine generator. The correct sized recharge meter

disc is determined by water hardness.

MIOX AE Series Operators Manual

102-00085-E Page 8

Figure 1 AE System

Brine Generator

Enclosed tanks varying in size from 55 gallons and up. A mechanical float valve assembly is included in

the brine generator and keeps water level constant within the tank. Custom sizes and dimensions are

available upon request

Oxidant Storage Tank

This tank is an integral part of an on-demand system. The oxidant tank is shipped with a drop tube. The

oxidant tank must be vented to the atmosphere to allow the escape of any evolved hydrogen gases.

Refer to the MIOX Hydrogen Safety White Paper for additional information on the required ventilation.

Tubing and Fittings

All tubing and fittings shipped by MIOX Corporation meet Schedule 80 specifications. The U.S.

specifications ensure that materials are rated for proper thickness, pressure requirements, and

temperature resistance for the specific application.

MIOX AE Series Operators Manual

102-00085-E Page 9

AE Series OSG System Optional Equipment

Heater of Chiller

If the OSG feed water temperature is less than 40°F (5°C) or greater than 95°F (35°C), damage to the

electrolytic cell may occur. A water heater or chiller must be used to bring the water temperature into

range.

Water Pressure Boost System

water pressure boost system can be included to insure minimum water pressure for OSG operation and

support of water softener regeneration. A separate electrical circuit is required for the water pressure

boost system.

MIOX AE Series Operators Manual

102-00085-E Page 10

Receiving and unpacking the AE Series OSG

Your AE™ Series OSG has been carefully packed to avoid shipping and handling damage. The OSG

enclosures are shipped in crated pallets. Brine generator tanks, oxidant tanks, water softeners, and

other ancillary equipment are also shipped on pallets. To safely unpack your OSG complete the following

steps:

NOTE: Do not store any portion of the OSG or related equipment outside before, during or

after installation.

Unpack the OSG enclosure - Remove the crate from around the enclosure. Check the enclosure for

any damage that may have occurred during shipping.

Unpack the cell - Check the cell for any damage that may have occurred during shipping. Save the

shipping materials for cell storage and shipping.

Unpack Installation Kits - Remove the contents from the brine generator and oxidant storage tanks

(if provided). These items include the OSG installation kit, the solution tank level switch, the softener

installation kit, and the solution tank drop tube.

Unpack the water softener (if provided) - Remove the water softener towers from their packaging.

Do not turn the softeners over or lay them on their sides as this will disturb the softening resin and

gravel beds inside the softener and affect softener performance.

Unpack all other equipment - Remove any optional components (heaters, chillers, etc.) from their

packaging and inspect for damage. After completing a visual inspection, compare ordered items against

what was delivered. Should you find anything damaged or missing, please contact your MIOX sales

agent or MIOX Customer Service.

MIOX AE Series Operators Manual

102-00085-E Page 11

Installation

Your AE™ Series OSG has been factory tested and must be properly installed by technicians trained by

MIOX Corporation or its representatives. This chapter describes the procedures for unpacking and

installing the AE™ OSG and auxiliary equipment, including all requirements for plumbing and electrical

tie-ins. Specifications and conditions regarding electrical power to the unit, water quality, water line

pressure requirements, and other requirements for installation of your OSG are discussed.

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SAFETY PRECAUTIONS AND WARNINGS

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• Ensure that the facility and the installation are in conformance with all codes and standards. Please refer

to the MIOX Corporation Hydrogen White Paper or your local authority having jurisdiction for more

information. Untrained persons should not attempt to install or operate MIOX Corporation OSGs.

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• A liquid barrier system is mandatory. Ensure that all hydrogen vent lines slope towards the oxidant tank.

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• Ensure that no valves, drop legs, or P-traps are in the hydrogen vent lines. Do NOT cross connect vent

lines.

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• Ensure that storage tanks are labeled properly.

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• Disconnect power before working on units. Do not reconnect the power to the switch gear enclosure until

installation is complete.

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• Do not defeat or tamper with electrical interlocks or lockout mechanisms.

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• All MIOX Corporation units require a good earth ground. A neutral is not a substitute for a proper earth

ground. Electrical wiring to all MIOX Corporation units should be performed by a certified electrician.

The circuit feeding the MIOX OSG should be separated from other power devices.



Untrained persons should not attempt to install or operate MIOX equipment.

MIOX AE Series Operators Manual

102-00085-E Page 12

Control Panel and Cell Installation

This section provides information and instructions for installing the AE System mounting plate and

electrolytic cell.

Note: these installation instructions do not apply for units that are pre-mounted on a stand.

Mounting Strut

There are three choices for mounting the strut to a wall, depending on the construction of the wall:

1) Wood screws to mount to a stud wall

2) Toggle bolts for a hollow wall such as cinder block or paneling

3) Expansion anchors for concrete

The strut should be mounted to the wall by drilling suitable holes through them. The vertical distances

from the upper to lower strut and the horizontal distances between holes are shown in Figure 2. The

wall material should be of sufficient strength to hold the control panel, which weighs up to 50 pounds

(22.68 kgs).

Figure 2 Strut Bolt Pattern

MIOX AE Series Operators Manual

102-00085-E Page 13

Installing the Mounting Panel

The panel is mounted to the struts via holes in the four corners of the panel. The mounting panel can be

bolted directly to a wall, but it is usually more convenient to mount struts to the wall and then mount

the control panel to the strut.

Attach the mounting plate by inserting four 3/8” – 16 x 1-1/2” long bolts and lock washers. Tighten the

bolts so that the control panel is adequately supported.

Note: Do not connect power to the mounting plate until installation is complete.

Cell Installation

Remove the cell from its packaging and place it vertically into the cell support bracket on the mounting

panel. Refer to Figure 3 for orientation of cell placement in the support bracket.

Connect the cell electrical leads, matching the red lead to the anode side of the cell (the side facing the

panel), and the black lead to the cathode side of the side of the cell (the side facing the operator). Check

and tighten the ¼ - 20 cell lead/lug flange nuts to 100 inch-lbs. (11.3 N-m) torque.

NOTE: To ensure a good electrical connection, do not use washers. The nuts provided with

integral serrated flange will provide a good connection. Electrical conductive grease, should

also be used and will improve the connection.

MIOX AE Series Operators Manual

102-00085-E Page 14

System Description

The AE™ Series OSG is made up of two major compartments: Controls and Plumbing (Figure 3). While

the cell is shipped independently of the Plumbing compartment, the cell is to be installed inside the

compartment during commissioning of the unit.

Figure 3 AE Series OSG Compartments

Controls

Compartment

Plumbing

Compartment

MIOX AE Series Operators Manual

102-00085-E Page 15

Electronic Connections Required for Start-Up

Normal precautions should be taken with regard to electrical components in the vicinity of a

water source.

Electrical Power Connection

The AE System is pre-wired internally, and equipped with the appropriate power cable that exits the

system on the rear (12’ feet, 3-12AWG). Connections to the Electrical Service Circuit Breaker are to be

made by a qualified electrician per NEC, UL, or Local Electrical Codes. See Appendix G for AE System

Wire Schematic.

Do not apply power to the system until installation is complete.

Control Box Electrical

Connections

Eight electrical feed-through

fittings are provided on the

bottom of the control box to

facilitate field-wiring of the

water solenoid, flow sensor,

brine pump, temperature

sensor, tank level switch,

current transducer and (+/-)

cell leads. One or two

fitting(s) are left blank and

can be used for connecting to

the alarm relay or other

auxiliary relay components.

Refer to Figure 4 for the

location of the interface

points for the electrical

connections entering and

exiting the control box.

Figure 4 System Side Panel Connections

MIOX AE Series Operators Manual

102-00085-E Page 16

Wiring of the Control Box Interface Block

After wiring the electrical components on the mounting plate, the wires must be fed through the fittings

on the bottom of the control box and wired to the Interface Block. The Interface block is the termination

for all electrical components outside of the control box. Refer to Appendix C – AE System Wiring

Schematic for wiring details of the system control board, interface block, and power supplies.

Connecting Alarm Relay from Control Box

The AE System comes wired from the factory with an alarm control circuit. This circuit can be connected

to a relay circuit to lock-out water system pumps, sound an alarm, and/or turn on some sort of visual

signal or control.

MIOX AE Series Operators Manual

102-00085-E Page 17

Plumbing Connections Required for Start-Up

All water and brine systems are compatible with schedule 80 PVC. MIOX Corporation requires Schedule

80 CPVC for all mixed-oxidant or sodium hypochlorite solutions and hydrogen venting. Where possible,

all connections should be solvent weld rather than threaded to prevent the possibility of leaks. All piping

should be supported at 3 - 4 ft. (1 m) intervals. Isolation valves should be included on all inlet lines

external to the AE™ Series OSG.

Feed Water Connection

NOTE: Consult water softener specifications for required flow rates.

Feed water requirements for the AE™ Series OSG are given in Table 1. Additional feed water is based on

water softener requirements. A minimum of 25 psi (172 kPa) feed water pressure at the OSG is

required to ensure stable flow and a continuous supply to the electrolytic cell. Maximum supply pressure

to the AE™ Series OSG should not exceed 100 psi (689 kPa). For supply pressure above 100 psi (689

kPa), a pressure regulator must be added to lower the pressure to a range of 25-100 psi (172-689 kPa).

Table 1 Feed Water Requirements

AE Model GPH GPM LPH

AE4 6 0.1 22.7

AE6 9 0.15 34.1

AE8 9 0.15 34.1

The feed water connection to the AE™ Series OSG comes from the water softener. The feed water

temperature is recommended to be between 50-85° F (10-29° C) to avoid damage to the cell.

Glue the

supplied PVC reducer bushings into the water softener adapter fitting. Apply Teflon tape on both ends of the

gray plastic 3/4” nipple pipe (approximately 1 3/4” long) and then insert the pipe into one end of the tee.

Insert the other end of the nipple pipe into the adapter fitting for the outlet connection, with the outward-

pointing arrow. Tape the male end of the two metal 3/4” hose bibbs with Teflon tape and place one hose bibb

into each of the remaining two openings of the tee. Cut the 1/2” clear braided hose long enough to allow

flexibility of movement for the softener and MIOX system. Attach a piece of hose to each hose bibb with the

green plastic connectors, clamping each hose securely with the green plastic clamshell. Before connecting

one of the hoses to the MIOX system, turn on the main water supply and flush water through the softener

until the water is clean and clear.

making sure no pipe shavings enter into the plumbing manifold.

MIOX AE Series Operators Manual

102-00085-E Page 18

Brine Feed Connection

The brine feed connection to the AE™ Series OSG is 3/8” tube with the appropriate adapter fitting. The

OSG is equipped with a 3/8” barb fitting on the inlet of the brine filter assembly. Connection to the barb

fitting is made with 3/8” ID x 5/8” OD flexible clear tubing supplied in the operations kit. A primer bulb

is also included in the operations kit and should be placed in-line upstream of filter assembly but as

close to the unit as possible. The primer bulb will aid in removing air bubbles for brine delivery to the

cell. (Figure 5)

Figure 5 Brine Feed Connection

Note: On initial start-up, cell replacement or when brine plumbing connections are modified,

air is introduced to the brine line. This air must be removed for proper operation of the brine

pump. Air locks in the brine line will prohibit consistent brine flow to the cell.

Brine Inlet

Primer Bulb

MIOX AE Series Operators Manual

102-00085-E Page 19

Oxidant Discharge

The standard oxidant discharge connection from the AE™ Series OSG is a 3/8” hose barb fitting, which is

provided to connect directly to the oxidant tank. An optional check valve and 3-way valve (for sampling)

may be included in the plumbing from OSG to Oxidant Tank.

Do not use any valves in the mixed-oxidant or sodium hypochlorite lines other than the

three-way valve provided by MIOX Corporation. These valves have an open center

configuration that prevents the blockage of flows from the cell. Failure to use MIOX Corporation supplied

three-way valves may void the system and cell warranty.

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De Nora MIOX AE4 Installation, Operation and Maintenance Manual

Brand: De Nora

Model: MIOX AE4

Type: Installation, Operation and Maintenance Manual

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