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Summary of Contents for De Nora MIOX AE Series
- Page 1 AE™ SERIES ON-SITE GENERATOR AE4, AE6 and AE8 Installation, Operation, and Maintenance Manual March 26, 2019...
- Page 2 MIOX AE Series Operators Manual AE™ SERIES ON-SITE GENERATOR AE4, AE6 and AE8 Installation, Operation, and Maintenance Manual 102-00085-E Page 1...
- Page 3 MIOX AE Series Operators Manual 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...
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Page 4: Table Of Contents
MIOX AE Series Operators Manual CONTENTS CONTENTS ......................3 List of Figures ......................5 List of Tables ......................5 INTRODUCTION AND OVERVIEW ................6 Regulatory Compliance ....................6 U. S. Environmental Protection Agency (US EPA) ............6 ... - Page 5 MIOX AE Series Operators Manual Level Switch Installation ..................24 Oxidant Tank Lid ....................26 Feed Line Connection/Injection System ..............26 Overflow Port ......................26 Operation ......................27 Initial Settings and Start-Up Checks ................28 ...
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Page 6: List Of Figures
MIOX AE Series Operators Manual List of Figures Figure 1 AE System ........................8 Figure 2 Strut Bolt Pattern ......................12 Figure 3 AE Series OSG Compartments ..................14 Figure 4 System Side Panel Connections ..................15 ... -
Page 7: Introduction And Overview
MIOX AE Series Operators Manual 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. -
Page 8: Components Of The System
MIOX AE Series Operators Manual 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. -
Page 9: Figure 1 Ae System
MIOX AE Series Operators Manual 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... -
Page 10: Ae Series Osg System Optional Equipment
MIOX AE Series Operators Manual 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. -
Page 11: Receiving And Unpacking The Ae Series Osg
MIOX AE Series Operators Manual 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. -
Page 12: Installation
MIOX AE Series Operators Manual 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. -
Page 13: Control Panel And Cell Installation
MIOX AE Series Operators Manual 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. - Page 14 MIOX AE Series Operators Manual 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.
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Page 15: System Description
MIOX AE Series Operators Manual 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. -
Page 16: Electronic Connections Required For Start-Up
MIOX AE Series Operators Manual 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’... -
Page 17: Wiring Of The Control Box Interface Block
MIOX AE Series Operators Manual 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. -
Page 18: Plumbing Connections Required For Start-Up
MIOX AE Series Operators Manual 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. -
Page 19: Brine Feed Connection
MIOX AE Series Operators Manual 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”... -
Page 20: Oxidant Discharge
MIOX AE Series Operators Manual 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. -
Page 21: Brine Generator Installation (Optional)
MIOX AE Series Operators Manual Brine Generator Installation (Optional) Plumbing Connections Place the brine generator on a flat surface that is capable of handling the load of a fully loaded tank. A 1,000 gallon tank can hold up to 9,000 lbs. of salt. Sweep the floor prior to installation. Debris left under a tank can permanently damage the tank. -
Page 22: Figure 7 Internal View Float Valve Assembly And Detail
MIOX AE Series Operators Manual The spray ring assembly provides a more consistent means of mixing the salt and water to meet the brine saturation requirement. The spray ring at the top of the tank eliminates possibility of channeling (or short circuiting) the water through the outlet of the tank. Adding a quartz rock bed at the bottom the tank also reduces the possibility of brine channeling for any application. -
Page 23: Oxidant Storage Tank Installation
MIOX AE Series Operators Manual Oxidant Storage Tank Installation THE SPECIFICATIONS IN MIOX CORPORATION’S HYDROGEN SAFETY WHITE PAPER MUST BE READ BEFORE INSTALLATION OF OXIDANT STORAGE TANKS BEGINS. ANY DEVIATION FROM THESE SPECIFICATIONS MAY RESULT IN DAMAGE TO PERSON OR PROPERTY. -
Page 24: Figure 9 Safety Placards
MIOX AE Series Operators Manual All oxidant tanks must have a properly installed LBS Vent and Oxidant Tank Vent to operate safely. An optional Dilution Air System can be supplied upon request or on large installations, a combination stand pipe and Dilution Air System can be used. Refer to MIOX’s Hydrogen Safety White Paper. -
Page 25: Level Switch Installation
MIOX AE Series Operators Manual Figure 10 Ventilation Requirements Level Switch Installation For MIOX-supplied oxidant storage tanks, the level switch is shipped loose in the tank. If the oxidant storage tank is not shipped with the AE™ Series OSG, the switch is shipped separately. -
Page 26: Figure 12 Oxidant Tank Level Switch Wiring To Control Box
MIOX AE Series Operators Manual 4. Wire the oxidant level switch by feeding wires into the unit through one of the spare feedthrough fittings on bottom of the control box. If all of the feedthrough fittings have wires in them, it is acceptable to feed two wires through one pass-through. -
Page 27: Oxidant Tank Lid
MIOX AE Series Operators Manual Oxidant Tank Lid The oxidant tank lid should cover the tank during operation, which helps reduce volatilization and extends the life of the oxidant solution. Feed Line Connection/Injection System The oxidant tank outlet valve is located at the bottom of the oxidant tank. This oxidant tank outlet provides oxidant solution to the water system for disinfection purposes. -
Page 28: Operation
MIOX AE Series Operators Manual Operation SAFETY PRECAUTIONS AND WARNINGS • The oxidant solution is a disinfectant - NOT DRINKING WATER - and therefore should NOT be consumed without diluting it with water. • The AE™ Series OSG is not a desalinization device for making fresh water from salt water, but instead uses salt water in making disinfectant solution. -
Page 29: Initial Settings And Start-Up Checks
MIOX AE Series Operators Manual Initial Settings and Start-Up Checks Electrical Check Verify that the correct AC power is being used: AE-4: 110 VAC or 220 VAC, 50 to 60 Hz, single-phase AE-6: 110 VAC or 220 VAC, 50 to 60 Hz, single-phase... -
Page 30: Figure 13 System Display - Primary View
MIOX AE Series Operators Manual Water Softener Operation Ensure that the water softener is operating properly before initial startup by testing the water from the water softener for hardness. If hardness is more than 1 grain per gallon (17.1 ppm), the softener is not functioning properly. -
Page 31: Figure 14 System Display - Secondary View
MIOX AE Series Operators Manual Figure 14 System Display - Secondary View NOTE: excessive startups and shutdowns will result in the oxidant solution in the storage tank to become diluted due to the excess flushing cycles. 102-00085-E Page 30... -
Page 32: Operation Controls
MIOX AE Series Operators Manual Operation Controls System Operation Turn on the system using the ON/OFF switch on the front of the control box. The system automatically starts. The following screens will display the following information: Start-up Mode The first line displays “MIOX CORP”. The second line displays the filename of the firmware in the microcontroller that is running the LCD. -
Page 33: Operating Window
MIOX AE Series Operators Manual Display 2: Oxidant tank is draining displays: “TANK DRAINING” Display 3: Oxidant tank done draining: “DRAINING DONE Once the tank is empty, the “DRAINING DONE” screen will be displayed for 5 seconds. The unit then turns on the water solenoid and purges the cell for 20 seconds. -
Page 34: Fault Conditions
MIOX AE Series Operators Manual Fault Conditions The AE controller is designed to diagnose and correct all upset conditions prior to sending the system into a Hard Fault and shutting it down. If the system cannot self-correct, then a Hard Fault is identified. There are eight Hard Fault conditions that can occur. -
Page 35: External Controls
MIOX AE Series Operators Manual No other display information is provided. This condition is the result of the oxidant tank high level float stuck in the high position when it should be low. For example, the tank is full and the unit enters “STANDBY” and displays “TANK FULL”. -
Page 36: Maintenance Guide
MIOX AE Series Operators Manual Maintenance Guide The AE™ Series OSG should be monitored periodically to ensure that the unit is running properly. MIOX Corporation recommends daily, weekly, monthly, and quarterly checks. In order to maintain a history of system performance and assist in troubleshooting and warranty work, it is recommended that a log be kept near the OSG for easy record keeping. -
Page 37: Daily Maintenance
MIOX AE Series Operators Manual Daily Maintenance Check the Salt Level - There must always be ample salt in the brine generator for OSG use, as well as water softener regeneration. MIOX Corporation recommends keeping a minimum of 1 foot (0.3 meters) of salt in the brine generator at all times. -
Page 38: Quarterly Maintenance
MIOX AE Series Operators Manual Quarterly Maintenance Clean Brine Tank – Using a wet rag, wipe down the interior of the brine generator tank wall to remove any dirt or buildup. Clean or Replace the Brine Filter and Water Filter – The brine and water filters are the same 5- micron standard type unit for removal of particulate matter. -
Page 39: Troubleshooting Guide
MIOX AE Series Operators Manual Troubleshooting Guide Table 2 Fault Troubleshooting Guide System Display Fault/Behavior Cause (most likely to Remedial Action least likely) RUNNING Insufficient feed water 1. Sudden loss of 1. Ensure feed water valve WAITING FOR to the system. - Page 40 MIOX AE Series Operators Manual System Display Fault/Behavior Cause (most likely Remedial Action to least likely) HARD FAULT Cell amperage 1. Low water line 1. Verify feed water HIGH CURRENT exceeds maximum pressure (<25 pressure is within system current rating psi).
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Page 41: Table 3 Additional Troubleshooting Procedures
MIOX AE Series Operators Manual Table 3 Additional troubleshooting procedures Problem Explanation Cause (most likely to Remedial Action least likely) Solution tank overflow OSG not shutting down 1. Level switch 1. Verify level once tank is full malfunction switch is wired/ 2. -
Page 42: Procedures
MIOX AE Series Operators Manual Procedures Brine Pump Replacement Refer to Appendix E – Brine Peristaltic Pump Maintenance Guide for assistance on replacing the peristaltic pump and/or work tubing within the pump. Rupture Disk Maintenance The rupture disk is designed to prevent excessive pressure to be built up inside of the cell. If the cell pressure exceeds 25 psi then a diaphragm inside of the rupture disk union bursts. -
Page 43: Replacing The Rupture Disk Diaphragm
MIOX AE Series Operators Manual Replacing the Rupture Disk Diaphragm 1. Turn off system by toggling ON/OFF switch to OFF. 2. From the front of the system and facing the cell a union with soft tubing will be located. (Figure 3. -
Page 44: Oxidant Demand Testing
MIOX AE Series Operators Manual Oxidant Demand Testing The oxidant demand of water is a measure of the amount of oxidant needed to properly disinfect water. This value is extremely important for accurately sizing and maintaining MIOX equipment. Oxidant demand is determined by adding oxidants in several concentrations to raw untreated (sample) water and measuring the FAC over time. - Page 45 MIOX AE Series Operators Manual Thus, add 2 mL of oxidants to 98 mL of sample water for the first FAC reading 3. Determine the doses for subsequent measurements. Dilute the oxidant as determined above and after 30 minutes, take an FAC reading. If FAC is unmeasurable, all of the oxidants have been consumed and you need doses of 10, 15, and 20 ppm for subsequent testing;...
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Page 46: Chlorine Production Testing
MIOX AE Series Operators Manual • Repeat the above steps for the other dilutions, measure each at time = 0 before preparing the next dilution, and then take FAC readings at 30, 60, and 90 minutes. Generate a table similar to the one given in the example below. - Page 47 MIOX AE Series Operators Manual • 250 mL glass beaker • 3000 mL, or 5000 mL glass jar with lid (depending on MIOX OSG being tested) • Pipette that can accurately measure 0.5 mL or 1 mL samples • Chlorine Test Kit (i.e. DPD, Color Wheel, Colorimeter or AccuVac) •...
- Page 48 MIOX AE Series Operators Manual 5. If there is no chlorine residual in the water, add another 3 mL, and wait another thirty minutes. 6. If there is a chlorine residual, record the value and wait another 15 minutes. 7. Check the chlorine residual again. If the chlorine value is the same as the last reading, the chlorine demand in the water has been met and the water is stable.
- Page 49 MIOX AE Series Operators Manual 1.75 mg/L x 2500 = 4375 mg/L 8. Repeat this process three times, take the average of these readings and assign this value to X to calculate chlorine production. Measuring Flow Total production of a system is the product of the concentration of the solution (determined above) and the volumetric flow of the solution over a period of time.
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Page 50: Appendices
MIOX AE Series Operators Manual APPENDICES A. Water Quality Guidelines B. Salt Quality Guidelines C. AE Wiring Schematic D. MIOX System Log Sheet E. Brine Peristaltic Pump Maintenance Guide 102-00085-E Page 49... -
Page 51: Appendix A - Water Quality Guidelines
MIOX AE Series Operators Manual Appendix A - Water Quality Guidelines Knowing what to look for when sizing a system will help remove hidden surprises after installation. Most of the items on the following list will be below the limits but should be checked nonetheless. -
Page 52: Appendix B - Salt Quality Guidelines
MIOX AE Series Operators Manual Appendix B – Salt Quality Guidelines MIOX requires that all Self Cleaning RIO-S Systems use a granular salt that meets or exceeds the purity percentages listed below. For additional information consult the MIOX Salt Guidelines white paper (P/N: 106-00008). -
Page 53: Appendix C - Ae System Wiring Schematic
MIOX AE Series Operators Manual Appendix C – AE System Wiring Schematic 102-00085-E Page 52... -
Page 54: Appendix D - Miox System Log Sheet
MIOX AE Series Operators Manual Appendix D – MIOX System Log Sheet 102-00085-E Page 53... -
Page 55: Appendix E - Brine Peristaltic Pump Maintenance Guide
MIOX AE Series Operators Manual Appendix E – Brine Peristaltic Pump Maintenance Guide 102-00085-E Page 54...
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