102-00094-I RIO ZUNI Operators Manual PDF

RIO Zuni™ Series On-Site
Generator 1.0 and 2.0

Installation, Operation, and Maintenance
Manual
1 December 2017
MIOX RIO Zuni™ Operators Manual P/N: 102-00094-I Page 1

MIOX RIO Zuni™ 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
Customer Service
5601 Balloon Fiesta Parkway NE, Suite A
Albuquerque, NM 87113
Phone: 1.505.343.0093
Toll Free: 1.866.MIOX.HLP (1.866.646.9457)
FAX: 1.505.343.0093
MIOXservicedist@Matthey.com
www.MIOX.com
www.Matthey.com
International distributors and sales agents located worldwide
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CONTENTS
CONTENTS .............................................................................................................. 3
List of Figures ......................................................................................................... 4
List of Tables .......................................................................................................... 4
INTRODUCTION AND OVERVIEW ............................................................................ 5
Regulatory Compliance ............................................................................................ 5
U. S. Environmental Protection Agency (US EPA) ..................................................... 5
List of Certifications .............................................................................................. 5
NSF International ................................................................................................. 5
State Approvals ................................................................................................... 5
System Description ................................................................................................. 6
System Specifications .............................................................................................. 7
System Illustrations and Component Descriptions ....................................................... 8
INSTALLATION AND STARTUP .............................................................................. 15
In the Box ......................................................................................................... 15
What you need ..................................................................................................... 15
Tools for install .................................................................................................. 16
Installation Location Requirements ....................................................................... 16
Connections ......................................................................................................... 16
Plumbing........................................................................................................... 16
Electrical ........................................................................................................... 17
Installing the RIO Zuni ........................................................................................... 19
Startup Tips ...................................................................................................... 21
OPERATION AND MAINTENANCE .......................................................................... 22
Normal Operation .................................................................................................. 22
Interface elements ............................................................................................. 22
Communications ................................................................................................ 23
Troubleshooting .................................................................................................... 24
Fault Conditions ................................................................................................. 24
Resolving Software Faults ................................................................................... 24
General Troubleshooting ..................................................................................... 25
Maintenance ......................................................................................................... 27
General Plumbing Checks .................................................................................... 27
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Changing Peristaltic Pump Tubes .......................................................................... 27

Cell Replacement ............................................................................................... 28
APPENDICES ........................................................................................................ 32
Inline Pressure Reducer ......................................................................................... 33
Changing Pump Tubes ........................................................................................... 34
Water Quality Guidelines ........................................................................................ 40
Rio Zuni Spare Parts Identification/Ordering Guide .................................................... 41
List of Figures
Figure 1: RIO Zuni On-Site Generator (tabletop model) .................................................. 6
Figure 2: Generic diagram of a RIO Zuni OSG with necessary components ........................ 8
Figure 3: RIO Zuni 2.0 lb OSG with labeled system components. Cover not shown. .......... 11
Figure 4: RIO Zuni 2.0 lb OSG showing cells, thermowells, and I/O panels ...................... 12
Figure 5: RIO Zuni OSG I/O panels with labeled components ......................................... 13
Figure 6: One of two level switches before being installed in an oxidant tank ................... 14
Figure 7: Inline Pressure Reducer assembly ................................................................. 14
Figure 8: Image showing all connections for full operation of the RIO Zuni OSG. .............. 18
Figure 9: LED Indicator meanings .............................................................................. 22
Figure 10: RIO Zuni OSG with system cover and screw locations .................................... 30
Figure 11: Internal Top View of Zuni Showing Cell Hour Reset Button Location. ............... 31
List of Tables
Table 1: System Specifications .................................................................................... 7
Table 2: Fault conditions descriptions ......................................................................... 24
Table 3: General troubleshooting approaches .............................................................. 26
Table 4: Cell Replacement Tools Required ................................................................... 28
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INTRODUCTION AND OVERVIEW

This manual is intended to provide basic installation, operation, and maintenance guidelines
for the operator of the RIO Zuni™ 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.
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System Description
The MIOX RIO Zuni system is an on-site mixed oxidant generator that creates mixed
oxidant solution from water, salt, and electricity. The system can create either 1.0 lb. or 2.0
lbs. of Free Available Chlorine (FAC) per day, depending on the model ordered. When
producing oxidant the RIO Zuni system is automatically controlled by a pair of level switches
inside the oxidant storage tank.
Mixed oxidant solution is a powerful hypochlorite-based disinfectant with improved biological

kill efficacy that achieves more rapid and thorough inactivation of a wide range of microbial
contaminants.
Figure 1: RIO Zuni On-Site Generator (tabletop model)
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System Specifications
RIO Zuni 1 RIO Zuni 2

1.0 lbs/day 2.0 lbs/day
Rated FAC Capacity
0.45 kg/day 0.9 kg/day
3.0 - 3.5 lb. salt/lb. FAC
Salt Conversion (SCE)*
3.0 - 3.5 kg salt/kg FAC
3.5 kW-hr/lb. FAC
Energy Conversion (ECE)*
7.7 kW-hr/kg FAC
FAC Concentration* 4,000 mg/L (+/- 1,000)
Salt Quality Requirement 99.5% NaCl or better^
Water Hardness 0-17 mg/L
Maximum Silica Limit 20 mg/L
1.3 gph 2.7 gph

Flow Rate#
4.9 lph 10.2 lph
Electrical Service Requirement+ 110 VAC to 240 VAC, 1 ph, 2A, 110 VAC to 240 VAC, 1 ph, 4A,
(OSG Only) 50/60 hertz 50/60 hertz
40°F to 110°F
Air Temperature Required
4°C to 43°C
Recommended Feed Water 55° to 80° F
Temperature* 12° to 27° C
Allowable Feed Water 40° to 95° F
Temperature* 4° to 35° C
1 - 75 psi
Feed Water Pressure@
6.8 – 517 kPa
Approximate OSG Dimensions 20.75 x 15.66 x 13.5 inches
(WxDxH) 52.71 x 39.78 x 34.29 cm
25 lbs
Approximate OSG Weight
11.5 kg
Self-Cleaning YES
+For continued protection against risk of fire, replace fuse only with a fuse of the same type and current rating
*Performance may vary depending on salt quality, water quality, and water temperature.
^Refer to MIOX Salt Quality Guidelines for more details.
#Feed water flow rate is subject to +/- 15% variation.
@Feed water pressure for RO Kit and/or Integrated Brine Tank is 40-75 psi
Table 1 : System Specifications
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System Illustrations and Component Descriptions
RIO Zuni
Hydrogen Vent
Inline Pressure Reducer (must vent
(connect to water supply) outside)
Brine Tank
Oxidant
Level Switch
Assembly
Figure 2: Generic diagram of a RIO Zuni OSG with necessary components
RIO Zuni OSG

On-site mixed oxidant generator (OSG).
Water supply
Fresh water supply for the OSG. Runs through Inline Pressure Reducer assembly before
connecting to OSG.
Brine supply
Low-pressure supply of saturated brine to the OSG.
Oxidant Tank
Vented oxidant solution storage tank for OSG output.
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Hydrogen Vents
Upward-sloping piping connected to outside environment for venting potentially dangerous
hydrogen gas (See Hydrogen Safety White Paper).
Level Switch Assembly

Assembly of two level switches and a level switch cable. The level switches control the OSG
when installed in the oxidant tank. The 15’ cable connects the level switches to the OSG.
See Figure 2 for details. Note: The level switches are orientation-sensitive and must be
installed with the arrow pointing upward in order to function properly.
System Cover
A rigid plastic housing that covers and protects the key components of the RIO Zuni.
LCD Display
Visual Display with a cycling menu of system status and operational parameters. See Figure
3 for details.
LED Indicator
A multi-color LED which displays system status. See Figure 3 for details.
Electrical Enclosure
An actively-cooled aluminum box housing the control board, power supplies and other
electronic components of the RIO Zuni System. See Figure 3 for details.
Brine Pump
An automated peristaltic pump which controls the system’s brine flowrate and acts as a
check valve to prevent brine supply dilution. Capable of withstanding up to 10 PSI of
pressure. See Figure 3 for details.
Water Pump
An automated peristaltic pump which controls the overall system flowrate and acts as a
check valve to prevent oxidant from flowing into the water supply. Capable of withstanding
up to 10 PSI of pressure. See Figure 3 for details.
MIOX Zuni Electrolytic Cell

A proprietary electrolytic cell manufactured by MIOX produces 1.0 lbs of FAC per day of
runtime. 1 lb. RIO Zuni OSGs use one cell while 2 lb. RIO Zuni OSGs use two cells. See
Figure 4 for details.
Thermowells
In-line temperature sensors used to evaluate operational efficiency of the system. See
Figure 4 for details.
Electrical Back Panel

All of the unit’s electrical connections, including the power switch, system fuse, IEC power
receptacle, and connectors for the Level Switch Assembly, a USB jump drive, and an
Ethernet cable. See Figure 5 for details.
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Plumbing I/O Panel

3 barb fittings for connecting the water supply, brine supply and oxidant outlet. See Figure
5 for details.
Hydrogen Vent Kit

Kit of parts consisting of an oxidant tank inlet, drop tube assembly, warning labels and a
vent strainer. Refer to the Oxidant Tank Manual for details.
Inline Pressure Reducer Kit

Three (3) piece assembly to reduce line pressure to an appropriate pressure for the OSG.
Kit has a female ¾” NPT inlet connection. See Figure 7 and Appendices for details.
Integrated Brine Tank (Optional)

Optional integrated tank with automatic brine generation system designed explicitly for the
RIO Zuni. See Integrated Brine Tank Manual for installation and operation.
NOTE: For items not listed above see the appendices and
Documentation Kit. Additional items may include, but are not limited
to the oxidant tank, hydrogen vent, oxidant pump, water heater and
water chiller. Contact MIOX for additional details on available options.
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Electrical
Enclosure
Brine Pump
Water
Pump
Check
Valve
LCD Display LED

Indicator
Figure 3: RIO Zuni 2.0 lb. OSG with labeled system components.
(System cover not shown)
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2 MIOX RIO Zuni

Electrolytic Cells
Electrical Back
Panel
Thermowells
Plumbing I/O (T-shaped elements in
plumbing line)
Figure 4: RIO Zuni 2.0 lb. OSG showing cells, thermowells, and I/O panels
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USB Port
for data Ethernet Port
logging
Power ON/OFF
Entry Switch
Module
Fuse
Holder
Water Oxidant
Inlet Outlet
Level Switch
Brine Inlet Assembly
Figure 5: RIO Zuni OSG I/O panels with labeled components
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Figure 6: One of two level switches before being installed in an oxidant tank
Figure 7: Inline Pressure Reducer assembly
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INSTALLATION AND STARTUP

The RIO Zuni OSG has been factory tested and must be properly installed per the
instructions in this manual.
Safety SAFETY PRECAUTIONS AND WARNINGS

Ensure that the facility and the installation are in conformance with all codes
and standards.
Please refer to the MIOX Hydrogen Safety White Paper or your local authority
having jurisdiction for more information.
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 the hydrogen vent lines.
Do NOT cross connect vent lines.
Ensure that brine and oxidant tanks are labeled properly.
Disconnect power before working on the system. Do not reconnect the power
to the rear panel until installation is complete.
All MIOX systems require a good earth ground. A neutral is not a substitute
for a proper earth ground. Electrical wiring to all MIOX systems should be
performed by a certified electrician.
In the Box
1) RIO Zuni OSG
2) RIO Zuni Quickstart Guide
3) RIO Zuni Installation, Operation, and Maintenance Manual
4) Documentation Kit
5) Power Cord
6) Standard Parts Kit
a. Level Switch Assembly (comes pre-installed if an Oxidant Storage Tank was
ordered from MIOX)
b. Tubing and hose clamps
7) Integrated Brine Tank (if ordered)
8) Oxidant Storage Tank (if ordered)
9) Inline Pressure Reducer Kit
10) Hydrogen Vent Kit (comes partially pre-installed if an Oxidant Storage Tank was
ordered from MIOX)
What you need

To install the MIOX RIO Zuni, you need:
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1) MIOX RIO Zuni OSG

2) 5 foot by 5 foot indoor environment
3) 110-240 VAC 10A circuit with standard grounded wall plug
4) Saturated Brine Supply (see MIOX Salt Quality Guidelines for salt
specifications)
5) Fresh Water Supply (see Appendices for Water Quality Guidelines)
6) Oxidant Storage Tank with Hydrogen Venting (see Hydrogen Safety White
Paper for details)
7) Tubing and hose clamps (provided with OSG)
8) Level Switch Assembly (provided with OSG)
9) Power Cord (provided with OSG)
Tools for install

The MIOX RIO Zuni can be installed without any tools, although MIOX recommends using a
pair of pliers to tighten the hose clamps on the plumbing I/O panel.
Refer to the Integrated Brine Tank Manual for tools needed to install the Integrated
Brine Tank.
Refer to the Oxidant Tank Manual for tools needed to install the Level Switch Assembly.
Installation Location Requirements

The RIO Zuni OSG must be installed indoors on a flat level surface approximately 5 feet long
by 5 feet wide (1.52m by 1.52m). The ambient air temperature at the installation location
must be between 40°F (5°C) and 110°F (43°C). Additional space may be required for the
water, brine, and oxidant tanks. MIOX recommends placing the OSG and tank near an
available drain for ease of draining the tank or in case of minor overflows. Additionally,
MIOX recommends placing the RIO Zuni near an external wall for ease of hydrogen venting
as described in the Hydrogen Safety White Paper.
NOTE: Failure of the system that can be traced to improper

temperature conditions is not covered under the MIOX warranty.
Connections
Plumbing
The RIO Zuni has three barbed plumbing connections on the plumbing I/O panel: water
inlet, brine in, and oxidant out. The ¼” barbed water inlet must be connected to the
appropriate location on the included Inline Pressure Reducer Kit. The ¼” barbed brine inlet
must be connected to an unpressurized saturated brine supply.
If using the integrated brine tank with the RIO Zuni OSG, the water and brine inlets
will connect to the labeled water and brine outlets on the integrated brine/water
tank. Please refer to the Integrated Brine Tank Manual for more details.
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The 3/8” barbed oxidant outlet must be connected to an oxidant tank and a hydrogen vent
line. All barb fittings must be secured with the included hose clamps.
Safety Only supply the RIO Zuni OSG brine (fully-saturated salt water) and fresh
water. Feeding other solutions instead of brine and water can cause severe
damage to the equipment or operator. Follow MIOX Salt Guidelines for salt
quality used in operating on-site generation equipment.
For direct injection applications, the RIO Zuni OSG can inject into a maximum
of 10PSI.
Electrical
The RIO Zuni requires only power and level switch connections for normal operation. The
included 10 foot power cord connects the system to 110-120 VAC and should be connected
to the standard IEC receptacle on the electrical back panel. For a 220-240 VAC connection,
replace the supplied power cord with a 10A rated 220VAC IEC Cable (220VAC cable not
provided by MIOX).
All RIO Zuni OSG systems ship with a pre-installed 2A or 4A fuse, depending on model. A
spare fuse is also included with the unit.
NOTE: Failure of the system that can be traced to a poor power source
is not covered under the MIOX warranty.
The level switches should be installed in the oxidant tank as described in the GA drawing
or Oxidant Tank Manual. The level switch cable is keyed so there is only one orientation
that matches the connectors on the back panel. Without level switches plugged in, the OSG
will never operate and instead will remain in ‘Standby’ mode.
Safety All MIOX systems require a good earth ground. A neutral is not a substitute for
an earth ground. Electrical wiring to all MIOX units should be wired on a
separate circuit from other power devices, like pumps, etc. MIOX cannot be
held responsible for systems wired improperly that do not meet UL or National
Electrical Code (NEC) requirements. If the system is improperly grounded, the
MIOX warranty is void. If a local code requires a GFI (Ground Fault
Interrupter) circuit breaker, it is the responsibility of the customer to install
the GFI to meet local code requirements.
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Figure 8: RIO Zuni Connections.
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Installing the RIO Zuni

1) Unpack The Boxes
Unpack the RIO Zuni OSG and all included components.
2) Position the OSG

Tabletop configuration: Place the RIO Zuni OSG on a flat, level surface.
Integrated Brine Tank configuration: Place the RIO Zuni OSG on the integrated
brine tank by following instructions in the Integrated Brine Tank Manual.
3) Install Inline Pressure Reducer

Following the instructions in the Appendices for installing the Inline Pressure
Reducer, connect the water source to the water inlet of the OSG through the Inline
Pressure Reducer.
4) Connect Water Source

Tabletop configuration:
Connect water source to brine source.
Integrated Brine Tank configuration:

Connect pressurized water source to the brine tank using the 1/4” diameter LDPE
tubing. Secure with hose clamps. Leave valves closed.
5) Connect Water & Brine Inputs to OSG

Use the smaller diameter clear vinyl tubing to connect the water and brine feeds to
the OSG. Secure with hose clamps. Leave valves closed.
6) Load Salt
Load the brine tank with salt. If Integrated Brine Tank was ordered from MIOX,
follow instructions in the Integrated Brine Tank Manual.
NOTE: Only use salt that meets or exceeds the salt quality
specifications in the MIOX Salt Guidelines.
7) Connect Oxidant Tank

Connect the oxidant outlet to the oxidant tank using the larger diameter clear vinyl
tubing and hose clamps. If Oxidant Storage Tank was ordered, follow installations
instructions in the Oxidant Tank Manual.
8) Install Level Switch

Plug the level switch assembly cable into the electrical I/O panel of the OSG. Follow
installations instructions in the Oxidant Tank Manual for the Level Switch
Assembly.
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NOTE: Oxidant tank level switches must be installed correctly for the
system to operate.
9) Hydrogen Venting
Install hydrogen venting in the oxidant tank. Hydrogen must be vented outdoors.
Follow the Hydrogen Vent Kit instructions in the Oxidant Tank Manual and MIOX
Hydrogen Safety White Paper.
10) Attached Power Cord

Attach power cord to IEC on the back panel of OSG. Connect to 220-240 VAC. For a
220-240 VAC connection, replace the supplied power cord with a 10A rated 220VAC
IEC Cable (220VAC cable not provided by MIOX).
11) Open Valves on OSG

Open the water and brine feed valves on the OSG.
12) Open Water Source Valve

Open the facility water source valve.
13) Brine Saturation

Wait 30 minutes to 1 hour to allow brine to fully saturate before turning system on.
14) Turn System On

Turn on the unit by switching the power switch on the back panel. The RIO Zuni will
enter into a priming cycle. RIO Zuni will automatically start producing oxidant after
the system has completed the priming cycle.
NOTE: Visually verify that water and brine are being delivered to the
plumbing I/O panel on the back of the OSG.
If water and/or brine are not visibly entering the OSG at the end of the priming
cycle, restart the priming cycle by turning the unit off, waiting 5 seconds, then
turning the unit on again. Wait for the priming cycle to end and then repeat this
process until both water and brine are successfully delivered to the plumbing I/O
panel. Refer to the troubleshooting guide located within this manual if system does
not start after priming cycle.
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Startup Tips
Things to check if any issues arise during the initial system startup:
Brine saturation level

Unsaturated brine may cause the system to fault on initial startup. Adding more salt to the
brine tank and waiting about 30 minutes before restarting the system should resolve this
problem.
Plumbing length
In some installations, the system must go through multiple priming cycles before liquid
reaches the unit. MIOX recommends minimizing the length of hose in between the water
and brine supplies and the OSG.
NOTE: Assure there are no kinks or pinches in the tubing.
Plumbing connections
The pumps in the RIO Zuni are self-priming, but they rely on sealed tube and hose
connections. If any of the connections are leaking, the system will not perform properly.
Level Switch Assembly Installation

Check that the level switches are installed appropriately. Follow the instructions in the
Oxidant Tank Manual to troubleshoot the level switches and the level switch cable.
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OPERATION AND MAINTENANCE

Normal Operation
In normal operation, the RIO Zuni automatically enters ‘Run’ and ‘Standby’ modes based on
the oxidant level in the oxidant tank. The RIO Zuni will also automatically enter a ‘Cleaning’
mode on the first startup after a predefined number of operating cell hours.
Safety The mixed oxidant solution generated by the OSG should be used as quickly as
possible to take advantage of the improved disinfection efficacy. If the mixed
oxidant solution is stored for more than 30 minutes before use, store it in a
vented and covered container made of HDPE. Properly stored mixed oxidant
solution will retain its disinfection efficacy for up to 5 days.
Interface elements
LED
System in Standby
System in Normal Operation
System in Startup or Shutdown
System faulted and needs reset
System faulted and will automatically restart
System operating atypically – check brine and

salt supply
Figure 9: LED Indicator meanings
The colored LED on the front of the OSG indicates the operational mode of the unit. Solid or
flashing green indicates that the system is normal operation conditions and is producing
oxidant. Solid or flashing yellow indicates a fault condition. Flashing blue indicates that
there may be a problem with the brine supply. The system will also flash blue to indicate the
system is about to run out of salt. Refer below for a more detailed breakdown of the various
operating modes and the behaviors associated with them.
Standby
The system is “turned off” and not generating nor attempting to generate oxidant
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Normal Operation
The system is within the normal operating window for oxidant generation and is
running correctly
Startup/Shutdown
During the startup and shutdown modes of operation, the system flushes the lines
and cell with water to remove any excess salt that may crystalize and clog the plumbing
while the system is not in use. After the system enters this mode, it will automatically enter
Normal Operation or Standby after the flush is performed depending on whether or not it
was startup or shutdown.
NOTE: Excessive startups/shutdowns will dilute the oxidant in the storage tank due to the
excess water being added to the tank.
System Fault
The system has encountered an abnormality in the operating parameters and is

either attempting to resolve it automatically (flashing) or needs manual resetting and
inspection (solid). Refer to the Fault Conditions sub-section of the Troubleshooting guide
included in this manual for more information of fault conditions and actions to remove them.
Brine Supply Issues
If the system has an abnormally high brine pump duty, the LED will flash blue. High
brine duty can be caused by a number of things all relating to the amount of salt entering
the cell. Check brine lines for leaks/clogs, brine salt concentration levels, and pump hoses to
ensure that they are all in working order. If the problem persists, contact your customer
support provider for additional troubleshooting assistance.
LCD Display
The display constantly updates with the current operating conditions of the system.
Information including system hours, cell hours, operational mode, cell current, inlet
temperature and outlet temperature cycles continuously through the display when in ‘Run’
mode.
Level Switch Assembly

The level switches in the oxidant tank act as the ‘Run/Stop’ switch for the unit. When both
level switches are low, the OSG enters ‘Run’ mode and makes oxidant until both level
switches are high. Once both level switches have been triggered high, the unit enters
‘Standby’ until both level switches are again in the low position.
If desired, the unit may be put into constant run mode by connecting together the two
halves of the level switch cable on the back I/O panel. This will bypass the level switches
and prevent the unit from ever going into standby.
Communications
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USB
A USB memory stick can be plugged into the USB port on the back panel at any time to log
the system’s status and operational parameters. The log is stored in a dated text file on the
memory stick and any readily available memory stick should be able to log months of
operation without any issues. The headers for the log are not included but are available
through your sales representative or service provider. MIOX recommends always restarting
the unit after plugging in a USB memory stick.
NOTE: MIOX recommends using a new, dedicated USB memory stick

for any data logging to prevent any unexpected file interactions with
the RIO Zuni OSG.
Ethernet
To remotely monitor the system over Ethernet, an Ethernet cable must be connected from
the back of the unit to an existing Ethernet network that supports DHCP. The system will
periodically display its assigned IP address after the priming cycle completes. System data
may be viewed remotely through any modern web browser; enter the IP address
periodically displayed by the system into your web browser’s address bar. The webpage is
served with data in the form of an .xml file, while it is possible to parse this data with some
modern SCADA systems this feature is not supported.
Troubleshooting
Fault Conditions
The RIO Zuni is preprogrammed with a number of fault conditions which trigger whenever
the system is running atypically. The faults are classified as either hard or soft faults. Hard
faults automatically shut the system down and require a power cycle to reset the system.
Soft faults try to resolve themselves and automatically restart the system a number of
times before requiring a power cycle reset.
Fault # of
Fault Type Restarts Cause
Oxidant Tank Level Hard 0 Level Switches are in an invalid position (Low level
Error switch is low while high level switch is high)
Very High Current Hard 0 Cell current has surpassed 125% of target current
Very High Oxidant Temp Hard 0 Oxidant temp measured above 145°F (62°C)
Soft 3 Measured temperature rise across cell has surpassed
Delta Temp
50°F (27°C)
Low Feed Water Temp Soft 1 Inlet water temp measured below 33°F (1°C)
High Brine Pump Duty Soft 3 Brine pump usage over 250% of normal
Table 2: Fault conditions descriptions
Resolving Software Faults

The only way to clear a fault from the system is to reset it by cycling power as described in
step 14) of the installation instructions. This resetting will rerun the priming cycle and flush
the cell before restarting. Please note that restarting the system does not necessarily mean
the problem will go away, only that the unit will try to resume normal operation. If the unit
still cannot resume normal behavior, the system will continue to fault after the
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restart/priming cycle. Refer to Table 3 and the rest of the General Troubleshooting section
for assistance in resolving faults. If the cause of the fault cannot be resolved, contact your
service provider for more advanced troubleshooting.
General Troubleshooting
Every RIO Zuni is fully tested before leaving the factory, but sometimes things do go wrong.
The table below lists common potential problems, their possible causes, and how to resolve
them.
Problem Probable Cause(s) Remedial Action

System primes but never 1. Failure in the level switch 1. Confirm level switches are
starts. assembly. installed and oriented
2. Too much conductivity in properly and all electrical
cell. connections are solidly
connected.
2. Close the brine feed. Toggle
3X for 30 seconds each, let
third restart complete and
open brine feed.
No display visible when switch 1. Correct power not getting to 1. Confirm power is available
turned on. system. from the wall, power cord is
2. Power Supply Failure properly connected to unit,
and fuse is not blown.
2. Contact Customer Support
for guidance on
troubleshooting and/or
getting the power supply
replaced.
MIOX system chlorine 1. High flow through cell. 1. Measure flow.
production lower than normal, 2. Cell exit ports blocked. 2. Clear blockage. If blockage
or chlorine residual in water 3. Injection system cannot be removed, replace
system below normal. malfunction. cell.
4. Cell life depleted. 3. Check cell amperage, flow,
5. Break in water distribution chlorine production, and salt
lines. consumption. Replace cell if
6. Mixed oxidants stored too necessary.
long before use. 4. Check for leaks and repair.
7. System Running outside of 5. Call sales agent or MIOX
specifications. Customer Support.
6. Verify measurements with
demand free water.
7. Confirm all parameters are
within system specifications
outlined in Table 1. If the
problem persists, contact
your service provider.
System faults immediately on 1. Brine is not fully saturated. 1. Add more salt and wait 30-
startup. 2. Water or Brine feed not 60 minutes to allow brine to
getting to system fully saturate. Then restart
the system.
2. Confirm brine and water
feeds are connected and all
valves in between supplies
and inlets are open. Check
for and remove salt crystals
P/N: 102-00094-I Page 25

that have formed blockages

in the brine lines.
System faults immediately on 1. Water or brine feed not 1. Confirm brine and water
startup. getting to system. feeds are connected and all
valves in between supplies
and inlets are open.
Display Reads: VERY HIGH 1. Loss of water supply. 1. Check water feed line to RIO
CURRENT (Cell #1 or Cell 2. Blockage of cell exit ports. Zuni™ System.
#2) 3. Too much conductivity in 2. Turn system off, remove cell
cell. exit port disconnects, and
remove any obstructions
within ports.
4. Close the brine feed. Toggle
3X for 30 seconds each, let
third restart complete and
open brine feed.
Display Reads: VERY HIGH 1. Loss of water supply. 1. Check water feed line to RIO
CELL OX TEMP (Cell #1 or Cell 2. Blockage of cell exit ports. Zuni™ System.
#2) 3. Temperature sensor failure 2. Turn system off, remove cell
exit port disconnects, and
remove any obstructions
within ports.
Display Reads: LOW FEED 1. Feed water temperature too 1. Increase feed water
WATER TEMP X˚F low. temperature to above 50˚F
2. Temperature sensor failure (10˚C) prior to restarting
system.
2. Temporarily swap the
thermowell assemblies or
otherwise verify correct
temperature is being
displayed on the Rio Zuni,
Display Reads: HIGH BRINE 1. Low brine concentration. 1. Check the salt, water and
PUMP DUTY 2. Brine pump air locked. brine level in the brine tank.
3. Brine pump locked due to Add salt to the brine tank to
debris. salt ﬁll level.
4. Brine line ruptured or 2. Verify brine inlet valve is
clogged. open. Remove the tube on
5. Controller board failure or the inlet to the brine pump
brine pump worn out. and purge the air from the
6. Cell life depleted brine line.
3. Remove debris from brine
pump.
4. Replace peristaltic pump
brine line with provided
tubing.
5. Verify pump turns by
removing the cover and
manually rotating the roller.
6. Replace brine pump.
Display Reads: DELTA TEMP 1. Blockage of ﬂ ow through 1. Turn system off, remove cell
CELL cell (#1 or #2). exit port disconnects and
2. Temperature sensor failure. remove any obstructions
within the ports.
2. Replace temperature sensor.
3. Verify temperature (inlet
oxidant temp).
Table 3 : General troubleshooting approaches
P/N: 102-00094-I Page 26

NOTE: Following any troubleshooting, reset the system by cycling power. If

the suggested remedial action does not resolve the problem and the system
continues to not function properly, contact your service provider for further
assistance.
Maintenance
The MIOX RIO Zuni is designed for minimal maintenance. As long as the water and brine
supplies are within the specifications, there should be almost no maintenance required to
keep the unit running.
Salt Loading
Salt load will be required to maintain saturated brine levels. The conversion efficiency for
the RIO Zuni is 3.0 – 3.5 lb./kg salt per lb./kg FAC. This means 300 lbs of salt will provides
enough brine for up to 100 lbs mixed oxidant production. This equates to 12 to 16 weeks of
continuous operations of a RIO Zuni 1 lb. system or 6 to 8 weeks of continuous operation of
a RIO Zuni 2 lb. system.
General Plumbing Checks

The RIO Zuni comes preassembled with secured plumbing connections which should never
require replacement; however, if any of the internal plumbing connections are broken, the
connections should be resealed with zip ties or hose clamps.
Changing Peristaltic Pump Tubes

Other maintenance which might be necessary is changing the peristaltic pump tubes for the
water and brine pumps. The pump tubes should be changed if overall system flowrate falls
below 50% of the specified flow or if liquid is seen running out of the system housing.
To change the peristaltic pump heads, remove the system cover and find the two peristaltic
pumps. The system cover is held to the base with four screws on the bottom corners of the
cover (See Figure 10). Once the cover is removed and the pumps are accessible, change the
tubes by following the instructions included in the Appendices of this manual, Changing
Pump Tubes.
Safety Caution should be taken to prevent accidental exposure of brine and oxidant to
skin or eyes when servicing the unit. If this occurs, rinse affected areas with
water and apply first aid as needed.
Safety Always disconnect power from unit before removing cover.
P/N: 102-00094-I Page 27

Cell Replacement
In the event that your RIO Zuni needs to have an electrolytic cell replaced, use the following
procedure to replace the cell and reset the cell hour counter to zero.
Tool Purpose Step(s) Used

1/8” Allen Wrench Zuni Cover Removal 3, 10
3/8” Crescent Wrench Cell Mounting Bolt Removal 4, 7
7/64” Allen Wrench Cell Lead Removal 5, 7, 8
5/16” Crescent Wrench Cell Lead Removal 5, 7, 8
Pliers (Optional) Hose Clamp Removal 6, 7
1/4" Wrench (Crescent or Electrical Cover Removal 9, 10
Socket)
Table 4: Cell Replacement Tools Required
1) Disconnect Power
Disconnect power to the unit completely by first turning the power switch to the ‘off’
position and then unplugging the power cord.
2) Disconnect Plumbing
Close the valves that connect to the water and brine inlets, as well as the oxidant
outlet to the OSG. After the unit is isolated from all plumbing lines, remove the three
external plumbing connections from the back of the unit by sliding the vinyl tubing
off of the hose fittings.
Note: The OSG will still contain a small amount of liquid within the internal
plumbing as well as the cell(s). This will begin to drain out of the unit once
the lines are disconnected. Use a bucket placed underneath the hose fittings
to catch this drainage.
3) Remove the Outer Cover From the OSG

Remove the plastic cover from the OSG by removing the 4 screws located near the
base of the cover in the corners and lifting the cover upwards as shown in Figure 10
to gain access to the cell(s).
4) Unmount the Cell

Remove the old cell from its mounting location by removing the four 10-32 hex nuts
holding the cell(s) to the unit at all four corners (shown in Figure 4) and sliding the
mounting hardware and cell off of the threaded studs sequentially.
Note: On 2lb units where the inner-most cell must be replaced it is necessary to
remove the outer cell from the mounting bracket to remove the inner cell.
5) Disconnect Cell Leads

Disconnect the red (+) and black (-) wires from the cell by removing the 6-32 socket
head screws (1 each, 2 total) that attach the wires to the cell using an Allen wrench.
It may be necessary to hold onto the 6-32 hex nut on the other side of the
connection with a wrench in order to back the screw out.
6) Disconnect Cell Plumbing
P/N: 102-00094-I Page 28

Remove the inlet (bottom) and outlet (top) plumbing connections from the cell by
sliding the tubing off of the hose fittings on the cell.
Note: liquid may still be present within the cell and plumbing lines, watch
out for leaks and use a cup or similar container to help catch excess liquid.
7) Install the New Cell

Install the new replacement cell by following steps 4 through 6 in reverse order.
Though the unit should be completely disconnected from power at this point, it is
good practice to ensure that the outside of the cell and surrounding area are
completely dry before connecting the cell leads as excess oxidant can corrode the
electrical hardware and/or cause a short once power is restored to the unit.
8) Restore OSG to Operating Condition

Once the new cell is installed and mounted to the unit, ensure the entire area is dry
to avoid damaging electrical components. After drying the area, double check ALL
electrical and cell connections contained within the OSG enclosure to ensure that
nothing came loose during the replacement process. Re-install the plumbing and
electrical connections by performing steps 1 and 2 in reverse order. Once the unit is
back to its normal operating configuration (but with the plastic cover still removed),
turn on the unit and monitor it closely throughout the priming process to ensure
there are no leaks.
9) Reset the Cell Hours

Once the unit has completed the priming process, remove the top cover of the
electrical enclosure by removing the four 8-18 hex head self-drill screws located at
the four corners as shown in Figure3 to gain access to the controls board. With the
unit still powered on, locate and press the small orange button closest to the USB
port for more than 5 seconds to reset the cell hours counter to zero (Figure 11).
Verify this is complete by watching the display, when the ‘Cell Hours’ screen appears,
the counter should be reset.
NOTE: The reset will not work if the system is still in priming mode, make sure to
wait until the unit is in either ‘Run’ or ‘Standby’ modes before performing this step.
Be careful of exposed electrical components that may present a shock hazard.
10) Replace Covers & Resume Normal Operation

Re-install the cover for the electrical enclosure using the hex screws. Replace the
plastic outer cover by performing step 3 in reverse. Monitor the unit closely for the
first hour after replacement to ensure that there are no leaks.
P/N: 102-00094-I Page 29

Figure 10: RIO Zuni OSG with system cover and screw locations
P/N: 102-00094-I Page 30

Brine (Small)
Pump
Cell Hour Reset
↓ Fron t of Un it ↓
Figure 11: Internal Top View of Zuni Showing Cell Hour Reset Button Location.
P/N: 102-00094-I Page 31

APPENDICES
a. Inline Pressure Reducer
b. Changing Pump Tubes
c. Water Quality Guidelines
d. Spare Parts Identification/Ordering Guide
P/N: 102-00094-I Page 32

Inline Pressure Reducer

For all installations a pre-assembled Inline Pressure Reducer Kit is provided.
The Inline Pressure Reducer Kit includes the following:
1) Pressure Reducing Valve (PRV), ¾” NPT that regulates outlet pressure to 4-psi
2) Coupling ¾” PVC, adapts PRV to provided barb fitting
3) Adapter, ¾”MT x ¼” Barb, HDPE, provides connection to ¼” hose and PRV/Coupling
The kit should be provided pre-assembled. If assembly is required, wrap both ¾” NPT
threads on PRV and Adapter with Teflon Tape. The tape should be wrapped 3 times (3X)
around the threads. Screw one end of the Coupling into the PRV and then screw the
adapter into the other end of the Coupling. Connections should be hand tight with an
additional ½ turn utilizing a wrench or channel lock pliers. Connect one end of the ¼” hose
to the ¼” barb on the Adapter and the other end to the ¼” barb water inlet fitting on the
RIO Zuni. Use hose clamp or cable ties to ensure barb connections will not leak. The
pressurized feed water should be connected to the unused end of the PRV, this connection
size is also ¾” NPT. Proper fittings should be utilized that can handle appropriate feed
water pressure.
NOTE: Check all fittings for leaks prior to operating the RIO Zuni.
P/N: 102-00094-I Page 33

Changing Pump Tubes

The following pages show how to change the pump tubes on the RIO Zuni peristaltic pumps.
They are excerpts from the Welco Instruction Manuals.
P/N: 102-00094-I Page 34

P/N: 102-00094-I Page 35

P/N: 102-00094-I Page 36

P/N: 102-00094-I Page 37

P/N: 102-00094-I Page 38

P/N: 102-00094-I Page 39

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. Concentrations or measurements in brine feed water and/or treated
water that are less than the stated limits are not anticipated to have the stated effect.
These factors can affect the oxidant demand of each individual water system, the oxidant
production of the MIOX system, or the life of the cell itself. It is important to use “worst
case” measures since water quality can vary from season to season.
WHAT IS IMPACTED
MEASURE LIMIT Oxidant Chlorine
Cell Life
Demand Production
grains/gal <1 grain
Total Hardness ** • •
(or mg/L) (<17 mg/L)
<1 mg/L
Iron (Fe) **† mg/L • •
**
<50 µg/L
Manganese (Mn) µg/L • • •
**
Fluoride (Fl) mg/L <1 mg/L •
Silica (SiO2) mg/L <20 mg/L • •
Bromide mg/L <50 mg/L •
Cyanide mg/L <1 mg/L •
Lead (Pb) mg/L <2 mg/L •
Dissolved Sulfides (as
mg/L *** •
H2S)
Ammonia Nitrogen (NH3-
mg/L *** •
N)
Organic Nitrogen (Org-N) mg/L *** •
Total Organic Carbon
mg/L *** •
(TOC)
pH - 5-9 • •
Water Temperature 55-80 °F
°F (or °C) • •
Range ^ (12-27°C)
**Caution: water softeners will remove these components up to a limit. See references to maximum
ferrous iron and manganese in water softener documentation. Total hardness affects cell life only in
that higher hardness requires acid washing to remove carbonate deposits from the cell. Use of water
softened to < 1 grain hardness should not require acid washing of the cell.
*** Oxidant demand is affected by any level of H2S, ammonia or organic nitrogen, or TOC.
† Iron may deposit Fe(OH)3 on the anode, causing an electrical “blind”, which would increase the
brine proportion pump signal voltage (brine proportion pump speed) needed for the system to reach
the operating window. Chlorine production would remain the same, but salt conversion efficiency will
decrease. The same effect is true of silica on the cathode.
^ The system will operate with water temperatures outside this range; however, there will be a
performance change. Follow the system specifications for absolute limits.
P/N: 102-00094-I Page 40

Rio Zuni Spare Parts Identification/Ordering Guide

Below is a list of common parts on the Rio Zuni along with their MIOX part number to aid in
any troubleshooting event where identifying or replacing a part may be necessary.
Additionally, these parts can be ordered and kept on hand as a spare in case a replacement
is needed in a more time sensitive manner. Contact your MIOX Customer Support provider
for additional information on ordering these or any other parts for the Rio Zuni.
Rio Zuni Spare Parts
CELL, RIO ZUNI

201-01251-07
PUMP,WPX1,1/8”,STEP,PHARMED
301-00374
P/N: 102-00094-I Page 41

PUMP,WP11,3/16",STEP,PHARMED
301-00375
TUBE, 1/8"-135, WT6, PHARMED

301-00376
TUBE, 3/16"-2, WT6, PHARMED

301-00377
P/N: 102-00094-I Page 42

TUBING, 1/4" x 3/8"

300-00349
ADAPTER,1/4x1/4x1/4 BARB, HDPE

300-02757
ADAPTER,3/8x3/8BARBx1/4,HDPE
300-02759
BULKHEAD, 1/4" NUTS, STR, NYLO

300-02640
P/N: 102-00094-I Page 43

TUBING 3/8 OD PE
700-00447
TUBING 3/8 ID x 5/8 OD VINYL

700-00447
CLAMP HOSE SNAP 3/8 OD ACETAL

700-01193
CLAMP HOSE SNAP 5/8 OD ACETAL

700-00449
P/N: 102-00094-I Page 44

FUSE, 5x20mm, 4A/250V (2PPD SYSTEM)

400-02548
FUSE, 5x20mm, 2A/250V (1PPD SYSTEM)

400-01199
ASSY, CELL LEAD #1

400-02557-D
ASSY, CELL LEAD #2

400-02558-D
ASSY, TEMP SENSOR. 1/4"DIA

400-02551-B
P/N: 102-00094-I Page 45

CONTROL BOARD ASSY

400-02083-04
POWER SUPPLY, 240W, 15V, 16A

400-02078
P/N: 102-00094-I Page 46

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RIO Zuni™ Series On-Site

Generator 1.0 and 2.0

MIOX RIO Zuni™ Operators Manual P/N: 102-00094-I Page 1

5601 Balloon Fiesta Parkway NE, Suite A

Toll Free: 1.866.MIOX.HLP (1.866.646.9457)

International distributors and sales agents located worldwide

P/N: 102-00094-I Page 2

P/N: 102-00094-I Page 3

Changing Peristaltic Pump Tubes .......................................................................... 27

P/N: 102-00094-I Page 4

INTRODUCTION AND OVERVIEW

U. S. Environmental Protection Agency (US EPA)

P/N: 102-00094-I Page 5

Mixed oxidant solution is a powerful hypochlorite-based disinfectant with improved biological

Figure 1: RIO Zuni On-Site Generator (tabletop model)

P/N: 102-00094-I Page 6

RIO Zuni 1 RIO Zuni 2

FAC Concentration* 4,000 mg/L (+/- 1,000)

Salt Quality Requirement 99.5% NaCl or better^

Water Hardness 0-17 mg/L

Maximum Silica Limit 20 mg/L

1.3 gph 2.7 gph

Table 1 : System Specifications

P/N: 102-00094-I Page 7

System Illustrations and Component Descriptions

Figure 2: Generic diagram of a RIO Zuni OSG with necessary components

RIO Zuni OSG

P/N: 102-00094-I Page 8

Level Switch Assembly

MIOX Zuni Electrolytic Cell

Electrical Back Panel

P/N: 102-00094-I Page 9

Plumbing I/O Panel

Hydrogen Vent Kit

Inline Pressure Reducer Kit

Integrated Brine Tank (Optional)

P/N: 102-00094-I Page 10

LCD Display LED

(System cover not shown)

P/N: 102-00094-I Page 11

2 MIOX RIO Zuni

P/N: 102-00094-I Page 12

Figure 5: RIO Zuni OSG I/O panels with labeled components

P/N: 102-00094-I Page 13

Figure 7: Inline Pressure Reducer assembly

P/N: 102-00094-I Page 14

INSTALLATION AND STARTUP

Safety SAFETY PRECAUTIONS AND WARNINGS

Ensure that brine and oxidant tanks are labeled properly.

What you need

P/N: 102-00094-I Page 15

1) MIOX RIO Zuni OSG

Tools for install

Installation Location Requirements

NOTE: Failure of the system that can be traced to improper

P/N: 102-00094-I Page 16

P/N: 102-00094-I Page 17

Figure 8: RIO Zuni Connections.

P/N: 102-00094-I Page 18

Installing the RIO Zuni

2) Position the OSG

3) Install Inline Pressure Reducer

4) Connect Water Source