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MIOX RIO-S™ Operators Manual

102-00130-D

Page 1

RIO-S Series On-Site Generator

Installation, Operation, and Maintenance

Manual

26 March, 2019

Содержание RIO-S Series

Страница 1: ...MIOX RIO S Operators Manual 102 00130 D Page 1 RIO S Series On Site Generator Installation Operation and Maintenance Manual 26 March 2019...

Страница 2: ...ht 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...

Страница 3: ...aterials 14 Tools for Installation 14 Installation Location Requirements 14 Receiving and Unpacking the RIO S OSG 15 INSTALLING the RIO S 16 Securing the Cabinet 16 Plumbing Overview 16 Electrical Ove...

Страница 4: ...Troubleshooting Guide 56 Water Flow Control Valve Re Set Procedure 60 Electrolytic Cell Replacement 61 Maintenance 62 Daily Maintenance 62 Weekly Maintenance 63 Monthly Maintenance 63 Quarterly Mainte...

Страница 5: ...3 External Plumbing Electrical Overview Rear 30 Figure 14 External Plumbing Electrical Overview Right Outlet 31 Figure 15 Modules 3 4 6 M12 Designations 33 Figure 16 Module 5 M12 Designations 34 Figur...

Страница 6: ...els 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 Li...

Страница 7: ...a disinfectant solution from water salt and electricity The system can create 250 1200 lbs of Free Available Chlorine FAC per day for the Mixed Oxidant model and 400 2000 lbs FAC per day on the Sodium...

Страница 8: ...must be at least 30 in 0 76m from the outer face of the enclosure Refer to Figure 2 for a detailed view of clearance requirements Note Additional floor space will be required for an oxidant storage ta...

Страница 9: ...MIOX RIO S Series Operators Manual 102 00130 D Page 9 Figure 2 RIO S OSG Space Requirements...

Страница 10: ...Refer to the Electrical Overview section for more detailed information Switch Gear Cabinet The Switch Gear Cabinet contains all of the major electrical components that relate to supplying monitoring p...

Страница 11: ...pecifications ensure that materials are rated for proper thickness pressure requirements and temperature resistance for the specific application RIO S Series OSG System Optional Equipment Heater or Ch...

Страница 12: ...MIOX RIO S Series Operators Manual 102 00130 D Page 12 Figure 3 Front External View of RIO S with Labeled System Components...

Страница 13: ...not attempt to install or operate MIOX OSGs A liquid barrier system is mandatory Ensure that all hydrogen vent lines slope towards the oxidant tank Ensure that no valves drop legs or P traps are in t...

Страница 14: ...remove crating Pry bar remove crating 2 end wrenches or equivalent connect cell Channel locks or equivalent slip joint pliers tighten plumbing connections Phillips screw driver make main electrical c...

Страница 15: ...the OSG Remove the crate from around the enclosure Check the enclosure for any damage that may have occurred during shipping 2 Unpack Installation Kits Remove the contents from the brine generator an...

Страница 16: ...ismic codes for site specific requirements Plumbing Overview The RIO S OSG comes with all system plumbing pre installed at the factory The only connections made by the customer to the generator itself...

Страница 17: ...water inlet and oxidant outlet of each bank to facilitate draining and acid wash connections Inlet Outlet Plumbing Requirements All water and brine systems are compatible with schedule 80 PVC MIOX str...

Страница 18: ...SI 345 kPa for systems with 1 3 banks and 60 PSI 414 kPA for 4 bank systems is required to ensure stable flow and a continuous supply of 5 25 PSI 34 172 kPa brine feed to the electrolytic cell To prot...

Страница 19: ...ce DO NOT APPLY POWER TO THE UNIT UNTIL INSTALLATION IS 100 COMPLETE Front Main Electrical Cabinets The majority of the major electrical components not including the electrolytic cells for the RIO S a...

Страница 20: ...outed into the OSG for distribution The breaker s amperage rating varies based on the number of cell banks installed with one two three and four bank units being equipped with 100A 200A 300A and 400A...

Страница 21: ...g to all MIOX units should be wired on a separate circuit from other power devices pumps etc MIOX cannot be held responsible for systems wired improperly that do not meet UL or National Electrical Cod...

Страница 22: ...ormation See Figure 3 Front External View of RIO S with Labeled System Components Manual Reset Button o In the event where the system has to be restarted due to an irregular shutdown use of the E Stop...

Страница 23: ...e information Safety Controller o Control System that monitors the various input devices E STOP Leak Detect Door Interlocks etc that correspond with the safe operation of the unit Uninterruptible Powe...

Страница 24: ...ank in the system max 4 Diode Temperature Switch Thermostats o One to three thermostats per unit depending on capacity located between diodes Auto reset and alarm when junction temperature at heatsink...

Страница 25: ...d sends the information back to the PLC Cell Bank Power Connections o The cell power lines exit the Switchgear cabinet via the max eight large liquid tight cord grip fittings on the bottom of the cabi...

Страница 26: ...left hand side of the cabinet Refer to Figure 11 for the locations of all the side panel connections If additional clarification is needed please contact MIOX Customer Support Figure 11 Left View of...

Страница 27: ...the dilution air blowers if equipped The dilution air system dilutes the hydrogen gas produced from the oxidant tank to safe concentrations before venting to the atmosphere Refer to MIOX s Hydrogen Sa...

Страница 28: ...rmation on connecting the cells to power If additional clarification is needed please contact MIOX Customer Support Figure 12 Typical Cell Bank Wiring Diagram Top View Cell Lead Connections o Power co...

Страница 29: ...ont and back of the cell according to the wiring diagram shown in Figure 12 using the provided hex bolts 5 Torque the bolts to 5 5 0 5 ft lbs 7 5 7 N m to insure a solid connection 6 Install cell guar...

Страница 30: ...MIOX RIO S Series Operators Manual 102 00130 D Page 30 Figure 13 External Plumbing Electrical Overview Rear...

Страница 31: ...MIOX RIO S Series Operators Manual 102 00130 D Page 31 Figure 14 External Plumbing Electrical Overview Right Outlet...

Страница 32: ...ds the information to the PLC Water Temperature Sensor o Monitors the temperature of the inlet water connection and sends the information to the PLC Oxidant Temperature Sensors o One per cell bank max...

Страница 33: ...connect all the devices on the plumbing assembly to the PLC There is also a M12 connection module Module 5 located inside Bank 2 that connects all of the panel interlocks These connections are all wir...

Страница 34: ...recommended that an isolation valve be installed on the water line prior to the tank to assist with maintenance Plumb the overflow fitting to a drain Verify the overflow line has an adequate air gap...

Страница 35: ...f 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 chann...

Страница 36: ...the tank Rake it flat and cover the slotted pipe manifold Place 5 inches of x NSF quartz rock on top of the first layer of quartz rock Rake flat Be certain to rinse quartz rock for several minutes to...

Страница 37: ...MIOX RIO S Series Operators Manual 102 00130 D Page 37 Figure 19 Brine Pressure Boost System...

Страница 38: ...tem LBS hydrogen vent and Oxidant Tank hydrogen vent Figure 20 A drop tube assembly and LBS vent assembly are shipped with the oxidant tank The user is responsible for supplying CPVC piping to attach...

Страница 39: ...bination stand pipe and Dilution Air System can be used Refer to MIOX s Hydrogen Safety White Paper for more details on Hydrogen Safety Safety placards are required on oxidant tanks and are attached t...

Страница 40: ...n Safety White Paper and this manual must be followed explicitly to ensure proper hydrogen venting MIOX oxidant tanks require that they be vented to the atmosphere outside the facility Proper configur...

Страница 41: ...cer submersible with digital output Level Float Magnetic Reed Switch High Low Oxidant Level Pressure Transducer Installation Similarly to a brine pressure transducer a GF Signet Pressure Transducer ca...

Страница 42: ...nk into the bulkhead adapter at the top of the tank 2 Feed the electrical cord through the elbow and out of the tank 3 Seal the male end of the liquid level switch with Teflon tape and screw it into t...

Страница 43: ...with two oxidant tanks installed the overflow ports should be piped to each other with a common drain If the customer elects not to run the overflow drain then the outlet must be plugged to prevent ga...

Страница 44: ...e flow of water to the brine generator Observe that the water flow stops at the correct level o After filling the brine generator with salt and softened water allow 60 minutes for the salt to dissolve...

Страница 45: ...e water feed supply must be connected to the proper inlet on the water softener head with the inward pointing arrow Water from the softener to the RIO S OSG must be connected to the outlet with the ou...

Страница 46: ...oo low an amperage is corrected by speeding up the pump The cell amperage will increase until it stabilizes in the optimal operating range the operating window Cell voltage and current are indicated o...

Страница 47: ...colors and states LED State Color OSG Status Flashing Green START UP and RUN mode while not in operating window Solid Green RUN mode in operating window all enabled banks Flashing Yellow SHUT DOWN So...

Страница 48: ...eht wenn das Ger t sofort beendet werden muss nach unten DE Per l uso se un evento si pone in cui l unit deve essere spenta immediatamente IT Dlya vykorystannya v razi vynyknennya podiyi de blok povyn...

Страница 49: ...it avant qu il ne fonctionnera nouveau Ceci est accompli en appuyant sur le bouton de r initialisation FR Si alguno de los enclavamientos del sistema o el bot n de parada de emergencia se activan la u...

Страница 50: ...the unit enters Standby until both level switches are again in the low position Communications Ethernet To remotely control monitor the system over Ethernet a CAT 5 or better cable must be connected f...

Страница 51: ...ne pump speed increase until cell current set point is reached Run Mode In Run mode the brine flow is adjusted to achieve and maintain the current set point to the cell Self Clean Mode For self cleani...

Страница 52: ...shut down without a water flush Immediate shutdown occurs with Leak Detect Hydrogen Monitor Safety Interlock and E Stop activation Bank Enable Setup All RIO S units will come factory set with all ban...

Страница 53: ...e pump Connect a water source to the suction side of the brine proportion pump 4 Start the OSG to flush the pump with brine free water 5 Allow for systems to fault for High Brine Pump Voltage 6 Reset...

Страница 54: ...t Fails to Close No contact status signal when contact enable signal on 1 NO NO NO Contact Fails to Open Contact status signal on then contact enable signal off 5 YES NO NO High Cell Current Cell curr...

Страница 55: ...ile running 1 NO NO NO Hydrogen Monitor Fault Hydrogen monitor trips while running 1 YES YES NO Low Ext Dilution Air Flow Dilution air status signal off when Dilution air enable signal on 1 YES NO NO...

Страница 56: ...max limit 1 Excessive flow or pressure fluctuations 2 Main water flow control valve failure 1 Verify adequate water flow and consistent pressure 2 Contact MIOX Customer Service Low Cell Voltage Bank 1...

Страница 57: ...llow Reset pg 53 Low Water Flow Bank 1 4 20 decrease in water flow rate for 45 seconds 1 Low water pressure 2 Water boost pump failure 1 Verify water flow and pressure is within specification 2 Verify...

Страница 58: ...vice Hydrogen Monitor Fault Hydrogen monitor trips while running 1 Hydrogen monitor state change 2 Hydrogen monitor failure 1 Correct hydrogen monitor failure 2 Contact MIOX Customer Service Low Ext D...

Страница 59: ...Module lost signal 2 2 Module failed 1 Loose wiring 2 Contact MIOX Customer Service Turck Module 4 Fault Invalid or no signal from 4 Turck Module 1 4 Module lost signal 2 4 Module failed 1 Loose wiri...

Страница 60: ...ting plugs 3 On the male DIN plug the center control signal plug on the actuator create a short circuit between pin 1 and ground Looking at the male DIN plug head on pin 1 is the pin in the 3 o clock...

Страница 61: ...igh brine pump voltage 3 Chlorine production is significantly below normal level 4 Salt consumption is increased Returning an Old Damaged Cell You may return a defective product to your original point...

Страница 62: ...s or ignition sources in or around the oxidant tank Use confines space procedures prior to entry to the oxidant tank Do not add other chemicals to the oxidant tank Always follow the plumbing and venti...

Страница 63: ...meter bolts to 82 5 in lbs 9 3 0 6 N m Check the brine proportion pump fittings regularly for seepage and check the connections to verify that there is no salt around the flange sealing area Check for...

Страница 64: ...flow is restricted the filter should be replaced Reinstall the filter Discard the old filters according to local environmental codes Cell Bank Acid Wash Refer to 102 00012 for procedure for cleaning c...

Страница 65: ...ct Bank X is displayed In the event of a Leak Detect Fault the moisture detected on the sensing band could be the result of the rupture disk bursting or a leak from within the cell bank Always check t...

Страница 66: ...he OSG operations kit If more disks are needed contact MIOX customer service or other appropriate service representative 7 Carefully thread the union back together with the disk centered inside 8 Blow...

Страница 67: ...ove both water and oxidant side panels for faulted bank 3 Locate the source of the leak by checking all plumbing assemblies and inspecting the integrity of each cell within the faulted bank Also check...

Страница 68: ...cid Wash Procedure documentation PN 102 00012 2 Ensure that the water supplied to the cell meets hardness and purity requirements under Appendix A 3 Ensure that the salt supplied to the cell meets wit...

Страница 69: ...the volume of oxidant and sample water to be used based on X mL of Oxidant 100 X 100 50 2 mL mL of Sample Water 100 100 X 100 100 50 100 2 98 mL Thus add 2 mL of oxidants to 98 mL of sample water for...

Страница 70: ...0 minutes and 90 minutes Readings beyond 90 minutes are determined by interpretation of data from the first 90 minutes Accurately measure the volume mL of calculated sample water and place in a glass...

Страница 71: ...bottom row t 90 minutes of the chart filled out above note that Sample B at 1 8 ppm is closest to the desired residual The initial FAC dose in this case was 3 ppm so the oxidant demand of this water i...

Страница 72: ...ified to account for the excess chlorine residual in the water Note Distilled water whether purchased at the store or made in a lab cannot be trusted to be demand free Method One 1 Add 5mL of 5 25 ble...

Страница 73: ...discarding it 4 With the pipette accurately measure the solution sample needed according to the dilution technique used above and add to the jar containing demand free water 5 Cap and shake the jar s...

Страница 74: ...ten erroneously associated with low production In order to calculate the total production for the system the flow rate must also be determined and adjusted if necessary 1 Remove the tubing that feeds...

Страница 75: ...MIOX RIO S Series Operators Manual 102 00130 D Page 75 X mg L chlorine concentration Y gph flow...

Страница 76: ...ary from season to season MEASURE LIMIT WHAT IS IMPACTED Oxidant Demand Chlorine Production Cell Life Total Hardness grains gal or mg L 1 grain 17 1 mg L Iron Fe mg L 1 mg L Manganese Mn g L 50 g L Fl...

Страница 77: ...temperatures outside this range however there will be a performance change Follow the system specifications for absolute limits Appendix B Salt Quality Guidelines MIOX requires that all Self Cleaning...

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