Owners Manual Aerator & Circulators Contents Important Safety Instructions. . . . . . pg2 General Owner’s Instructions. . . . . . pg2 Unit Specs. . . . . . pg3 2400AF, 3400AF/HAF, 4400AF/HAF Parts. . . . . . pg3 2400AF, 3400AF/HAF, 4400AF/HAF Assembly. . . . . . pg4 8400AF, 2.3AF, 3.1AF, 3.3AF, 5.1AF, 5.3AF Parts. . . . . . pg6 8400AF, 2.3AF, 3.1AF, 3.3AF, 5.1AF, 5.3AF Assembly. . . . . . pg6 Mesh Screen Attachment. . . . . . pg9 Installation Instructions. . . . . . pg9 Circulator Parts (CF Models). . . . . . pg10 Circulator (CF Model) Assembly. . . . . . pg10 Control Panel Installation. . . . . . pg12 C-25 Timer Control Instructions. . . . . . pg14 C85 / C95 non-metallic Wiring Diagram. . . . . . pg15 3 Phase Startup Procedure. . . . . . pg16 C85 / C95 non-metallic and 3 Phase Control Panel Timer. . . . . . pg17 2400, 3400, 4400, 8400, 2.3 Replacement Parts Diagram. . . . . . pg18 3HP & 5HP Replacement Parts Diagram. . . . . . pg19 Maintenance Recommendations. . . . . . pg20 Warranty Policy. . . . . . pg20 Troubleshooting Tips. . . . . . pg21 Customer Repair Form. . . . . . pg23 Registration Information. . . . . . pg24 Kasco Marine, Inc. C 800 Deere Rd. Prescott, WI 54021 Intertek PH 715-262-4488 3020379 FAX 715-262-4487 ANSI/UL 778, 5th Ed. 2010 [email protected] CAN/CSA C22.2 No. 108-M89 UL 50, 11th Ed. 1995 www.kascomarine.com Rev. 01/15/15 Thanks! aerator or water circulator is plugged into a GFI We at Kasco Marine, Inc. would like to both thank protected circuit. and congratulate you on your purchase of the Pond • 3 phase aerators (2.3, 3.3, 5.3) require a startup Aerator or Water Circulator model. We appreciate you test after wiring to ensure proper rotation of the choosing Kasco and for your purchase. Your decision propeller. If the propeller is rotating in the op- to purchase Kasco’s Pond Aerator or Water Circulator posite direction, the unit will not perform properly will not disappoint you. The Pond Aerator or Water and internal damage to the unit may occur. (See 3 Circulator will be a great addition to your body of wa- phase startup procedure) ter. It will help improve the water quality by adding • Control panels must be installed a minimum of much needed oxygen and circulation. We thank you 5ft(3m in Canada) from the inside wall of the for choosing Kasco for your aeration needs and want pond, unless separated from the body of water by you to be completely satisfied with your purchase. a fence wall, or other permanent barrier that will make the unit inaccessible to persons in the water. Important Safety Instructions • Control panels must be installed by a qualified electrician. Please read and follow these extremely important • Ground Fault Circuit Interrupters (GFCI) should safety and handling instructions for your Kasco equip- be tested upon each installation and every month ment. Following these instructions will help ensure thereafter to ensure proper operation. your safety and the quality performance of your equip- General Owner’s Instructions ment. • Under NO circumstances should anyone enter the INSPECT THE SHIPMENT water with the electrical equipment plugged in Immediately inspect your Kasco Aerator shipment for and/or in operation. All Kasco equipment is ETL any visible damages. Also cross reference the parts approved to UL and CSA standards for safety in supplied with the Parts Included sheet to check for water. However, it is NEVER recommended to shortages. Shortages should be reported immediately enter the water with the equipment in operation. to your Kasco Marine distributor or representative and • Caution should be used when dealing with any damages reported to your carrier and Kasco Marine. electrical and/or moving equipment. • NEVER run the unit out of water. It will damage CAUTION the seals and create a dangerous situation for the WARNING: Under NO circumstances should anyone operator. enter the water with the unit in operation. Always • Extreme caution should be used around water, operate the unit in the water and keep people and ob- especially cold water, such as in Spring, Fall, and jects clear of the propeller. Do not lift or pull the unit Winter, which poses a hazard in and of itself. by the electrical cord. Always use extreme caution • NEVER lift or drag the pond aerator or water around electrical equipment and water situations. circulator by the power cord. If you need to pull the unit to the side of the pond, use the anchoring ASSEMBLY & INSTALLATION ropes. Please see the proper Assembly and Installation In- • Do not use waders in deep ponds/lakes or ponds/ structions enclosed in this manual. Each is specific for lakes with drop-offs, drastic slopes, or soft bottom your model and size of Aerator. Note: It is extremely material. important to test the GFI breaker in the control panel • Do not use boats that tip easily for aerator installa- upon each installation/reinstallation of the unit to en- tion, such as a canoe, and follow all boating safety sure proper functioning. rules and regulations, including wearing a PFD (Personal Flotation Device). WARRANTY • Single phase Pond Aerators or Water Circulators Kasco Aerators are the result of over 35 years of are supplied with an internal grounding conductor design and engineering. Kasco products are built to and a grounding-type attachment plug. To reduce withstand the toughest conditions. Kasco Marine the risk of electrical shock, be certain that the pond backs each Pond Aerator and Water Circulator with a 2 2 Year Warranty or 3 Year Warranty depending on the Model Voltage Operating lock rotor model. This warranty covers any and all manufactur- amps amps ers defects within the warranty period from the date 3.3HAF 460 4.1 @ 460V 35 of purchase (See Warranty, Warranty Claim, & Return Policy). Please register your Aerator online at: 5.3HAF 460 6.5 @ 460V 50 www.kascomarine.com (under the technical tab) Single phase circulators USE AND OPERATION 2400CF 115 5@115V 12@115V Kasco Aerators are designed and engineered for 3400CF 115 6.7@115V 18@115V continuous duty, such as on fish farms or other aqua- 3400HCF 208-240 3.4@240V 9@240V culture applications, or on-demand use, as needed in a 4400CF 115 11.3@115V 40@115V recreational water feature. 4400HCF 208-240 5.7@240V 20@240V During flotation operation, the water is pulled from 8400CF 208-240 9.0@240V 40@240V 360O around the unit and from below the unit. The water is pulled upward and thrust through the flotation collar into the air. Your Kasco Marine Aerator is ready for immediate use (after installation). Make sure to keep the motor hous- ing clean from hard water deposits and/or algae. (See Maintenance Recommendations.) 2400AF, 3400AF/HAF, 4400AF/HAF Parts Included: Kasco Pond Aerators and Water Circulators are light- 1. Aerator (Unit with cord or unit with Disconnect(1) weight, energy efficient, and easy to install and oper- 2. Float (with three 50’ mooring ropes attached) (1) ate. We strive to produce products that exceed cus- 3. 1/4-20 x 3 1/2” Phillips Pan Head Screw (4) tomer expectations. We hope you enjoy your Kasco 4. 1/4” split washers (4) Pond Aerator or Water Circulator. 5. 1/4” (3/4” outer diameter) Flat Washer (4) 6. Float Retaining Clips (4) Optional: May be sold separately (bottom screen Unit Specs installation parts 7-12) Model Voltage Operating lock rotor 7. 3/8”-16 x 1-3/4” Hex Head Bolt (2) amps amps 8. 3/8” Flat Washer (4) single phase aerators 9. Bottom Screen cushions (3) 2400AF 115 5 @115V 12@115V 10. Bottom Screen (1) 11. Bottom Screen Clips (2) 3400AF 115 6.7 @115V 18@115V 12. 3/8”-16 Nylon Lock Nut (2) 3400HAF 208-240 3.4 @240V 9@240V 4400AF 115 11.3@115V 40@115V 4400HAF 208-240 5.7@240V 20@240V 8400AF 208-240 9.0 @240V 40@240V 3.1AF 208-240 10.7 @240V 63@240V 5.1AF 208-240 18 @240V 97@240V 3 phase aerators 2.3AF 208-230 4.5 @ 230V 40 3.3AF 208-230 8.2 @ 230V 70 5.3AF 208-230 13 @ 230V 100 2.3HAF 460 2.3 @ 460V 20 3 DWG. NO. XXXX-XXXX-XX REV. ECO# DESCRIPTION DR'N BY DATE DES ENG CH'K BY 1 INITIAL RELEASE tional C-25 (3) or C-85 (4) 3 • 9/16” Socket and Ratchet (for optional bottom screen) • 9/16” Wrench (for optional bottom screen) 4 • Nylon Tie for cord 5 2400AF, 3400AF/HAF, 4400AF/HAF Assembly 7 STEP ONE 8 Make sure you have all the parts needed. If any short- ages are found, contact your Kasco representative immediately. 2 STEP TWO Set motor housing upright (stainless steel can down) 1 on a flat surface. With motor housing upright, slide Float (Part 2) over pump housing making sure the surface with the Kasco logo is up. 6 9 logo 10 Rest the float on the cage top ring. STEP THREE 11 Ensure correct alignment by twisting the float gently around the motor housing until the power cord guide lines up with the cord. See diagram of bottom side of 12 DO NOT SCALE DRAWING UNLESS OTHERWISE SPECIFIED MATERIAL: float. C.A.D. GENERATED DRAWING DIMENSIONS ARE IN INCHES. X power corTdHIS DOCUMENT HAS BEEN ISSBUEoD lt hDoIlMeEsNSIO NTOS LINER [A ]N ACREES MOINLL:IMETERS. X FOR ENGINEERING INFORMATIONAL guide PURPOSES ONLY. ANY REVISIONS .X .02 [.508] .XX .010 [.254] FINISH: Optional Equipment TOM UTHSTE BCEO INNCTEONRTP OOFR TAHTIESD D IONCTOU MTHEEN T X 800 DEERE ROAD • Control Box (C-25 for 120V units or C-85 for 240V ORIGINAL CAD FILE. .XXX .005 [.127] ANGULAR 0.5 X PRESCOTT, WI 54021-1241 units in separate box) (1 - optional) THIRD ANGLE PROJECTION ITNHFISO DRMRAAWTIOINNG ACNODN STHAAINLSL PNROOTP BREI EUTSAERDY, TITLE: SCALE: 1:24 SHEET 1 OF 1 • Bottom Screen with mesh and Hardware for Small REPRODUCED OR DISTRIBUTED WITHOUT FX FLOAT ASSEMBLY W/SCREEN THE PRIOR WRITTEN CONSENT OF XXXX-XXXX-XX Float Ring (1 - optional) KASCO MARINE, INCORPORATED X NOTE: Extra hardware may be included. POND AERATOR TOOLS & SUPPLIES NEEDED • Anchors or stakes for installing unit (2 or 3 depending STEP FOUR on unit) Use one of the 1/4”-20 x 3-1/2” Phillips Pan Head • # 2 Phillips head screw driver Screws (Part 3), one 1/4” split washer (Part 4), and a • Two (or 3 depending on model) 12” pieces of 1” galva- 1/4” Flat Washer (Part 5) to secure the float. Make nized pipe for weighting ropes (optional) sure the split washer goes between the bolt head and • #10 x 1” long or longer screw(s) for mounting the op- 4 the flat washer. Insert screw with washer through bolt STEP SIX (optional bottom screen) hole in float Using a stainless steel Bottom Screen Clip (Part 11), 3/8”-16 x 1-3/8” Bolt (Part 7), two 3/8” Flat Washer Use one float retaining clip (Part 6) under the top ring (Part 8), and 3/8”-16 Nylon Lock Nut (Part 12) to of the cage. There is a U-shaped indent in the clip that secure the screen to the float. Align a clip so the two will fit snug against the top ring of the cage. The 1/4”- prongs straddle a wire on the screen. Insert bolt with 20 x 3-1/2” will then thread into the retaining clip. washer so the top of the bolt is facing the top of float float retaining clip (now in down position). Place the second washer and the locking nut with nylon insert on the end of the bolt and tighten using the 9/16” (14mm) Socket and Ratch- et on the nut end and the 9/16” (14mm) Wrench on the bolt end. Tighten until snug and repeat with remaining clip. Tighten until snug with a Phillips Head screw driver and repeat for 3 remaining screws. STEP SEVEN Turn the assembly upright again. At this time, if the cord contains a metal strain relief, you can use the chain connector and attach it in one of the opening at the rope placement. The chain connector will easily fit if installed from the bottom or top side of the opening. STEP FIVE (optional bottom screen) It will not fit if installed from side of opening. Use the See “Mesh Screen Attachment” section before con- Nylon Cable Tie included to secure the power cord to necting the bottom screen to the float. Turn secured a molded hole in the float to prevent cord damage if assembly upside down so the top of the float (logo there is no strain relief on the cord. If a Strain Relief side) is face down on the flat surface. Place Bottom is present on the cord, you may disregard the Nylon Screen (Part 10) onto the bottom side of the float. Tie. On cords with a Quick Disconnect, the discon- Make sure the wide opening of the screen is against nect should be tightened properly to avoid leaking. the float and the 3 handles on the screen do not in- If installing a new Quick Disconnect, refer to Quick terfere with the rope placements. Fit the 3 Bottom Disconnect Instructions. Screen cushion (Part 9) underneath the screen and on top of the 3 spacing bumps on the bottom of the float. STEP EIGHT(optional) Thread one rope through one Pipe Weight and posi- tion it approximately 6’ from the float. Next, thread the end of the rope back through the opening facing Bottom Screen cushion the float (as shown). Repeat with the second rope and weight. If ready to install in the pond, go to Instal- lation instructions. Light Kits can also be installed at 5 this time, go to Light kit instructions. • 9/16” & 7/16” Nut Driver • 9/16” & 7/16” Socket • Adjustable crescent wrench • Nylon Tie for cord 8400AF, 2.3AF 8400AF, 2.3AF, 3.1AF, 3.3AF, 5.1AF, 5.3AF Parts POND AERATOR PARTS INCLUDED Aerator Unit with cord (Cord may be shipped separately) (1) B. Large Float Ring (8400AF, 2.3AF) 1. Float Sections (3) 2. Top Float Bracket (3) 3. Bottom Float Bracket w/Rope (3) 4. 9.5” x 3/8” Bolt (6) 3.1AF, 3.3AF, 5.1AF, 5.3AF 5. 3/8” Lock Nut (6) 6. Unit Mounting Bracket (3) 7. 1/4” x 3/4” Bolt (6) 8. 1/4” Lock Washer (6) 9. 1/4” x 3/4” Bolt with lock washers and nuts (3) Optional: (parts 10-13) May be sold separately 10. Bottom Screen Clip (3) 11. Bottom Screen (1) 12. Mesh screen (1) 13. Cable ties for mesh (10) B. Large Float Ring (3.1AF, 3.3AF, 5.1AF, 5.3AF) 1. Float Sections (3) 2. Top Float Bracket (3) Tools & Supplies Needed: 3. Bottom Float Bracket w/Rope (3) A. Anchors or stakes for installing unit (2 or 3 de- 4. 9.5” x 3/8” Bolt (6) pending on unit) 5. 3/8” Lock Nut (6) B. 208-240V Electrical Supply near pond on a post 6. 3/8” x 1” Bolt (3) 7. 3/8” Lock Washer (3) C. Two (or 3 depending on model) 30cm pieces of Optional: (parts 8-11) May be sold separately 2.54cm galvanized pipe for weighting ropes (optional) 8. Bottom Screen Clip (3) D. 9/16”(14mm) & 7/16” (11mm) Nut Driver 9. Bottom Screen (1) E. 9/16” (14mm) & 7/16” (11mm) Socket 10. Mesh screen (1) Adjustable crescent wrench 11. Cable ties for mesh (10) Optional Equipment 8400AF, 2.3AF, 3.1AF, 3.3AF, 5.1AF, 5.3AF C. Control Box (1 - optional) Assembly NOTE: Extra hardware may be included. STEP ONE POND AERATOR TOOLS & SUPPLIES NEEDED Remove all contents from package and place on a • Anchors or stakes for installing unit (3) clean, flat surface. Inspect the shipment for any dam- • Philips head screw driver for mounting optional control ages. If damages are found, immediately notify your panel carrier and your Kasco Marine, Inc. representative. • 120V or 240V Electrical Supply near pond on a post • Three 12” pieces of 1” galvanized pipe for weighting Next, cross reference the parts included in the ship- ropes (optional) ment with the Parts Included sheet in this manual. • #10 x 1” long or longer screw(s) for mounting the op- Make sure you have all the parts needed. If any tional C-25 (3) or C-85/95 (4) shortages are found, contact your Kasco representative 6 immediately. Float Brackets (Part #B3) over the bolts, the ends of STEP TWO which should now be extending through the assembly. Arrange the three Float Sections (Part #B1) upright Loosely install the six 3/8” Lock Nuts (Part #B5) on (plug on bottom) so the overlap of one section aligns the ends of the bolts (do not tighten yet). Connect the with the next section and loosely push the three sec- Top and Bottom Float Brackets using three 1/4” x 3/4” tions together to form a continuous ring. Bolts (Part #B9) with three lock washer and 1/4” nuts 8400AF, 2.3AF and tighten using the 7/16” wrench and socket. Attach the Unit Mounting Brackets (Part #B6) loosely to the float bracket with (3) 1/4” x 3/4” bolts and 1/4” Lock Washers in the top mounting hole as shown 3.1AF, 3.3AF, 5.1AF, 5.3AF STEP FOUR (3.1, 3.3, 5.1, 5.3) Turn the assembly upside down and place the Bottom Float Brackets (Part #B3) over the bolts, the ends of which should now be extending through the assembly. Loosely install the six 3/8” Lock Nuts (Part #B5) on the ends of the bolts (do not tighten yet). STEP THREE Position one Top Float Bracket (Part #B2) so that the bolt holes in the bracket align with the bolt holes in the two adjoined float sections and insert two 9.5” Coated Bolts (Part #B4) through the assembly. This may require some minor repositioning of the float sections as you push the bolt all the way through. Do not force STEP FIVE the bolt through. Repeat for the remaining two joints. See “Mesh Screen Attachment” section before con- necting the bottom screen to the float. If the optional Bottom Screen (Part#B11) was pur- chased, place the Aerator Assembly inside the bottom Screen as shown. STEP FOUR (8400, 2.3) Turn the assembly upside down and place the Bottom 7 STEP SIX (8400,2.3) Lift Float Assembly and place over Aerator Assembly. Adjust one unit Mounting Bracket at a time and nest STEP SEVEN (Optional Bottom Screen) the cage ring in the lower notch of the Unit Mounting Raise the Bottom Screen and secure with Bottom Bracket for the 3.1, and 5.1 units. Nest the cage ring Screen clips. Remove the center three 3/8” Lock Nuts in the middle notch of the Unit Mounting Bracket for from the 9” Bolts and place the Bottom Screen Clips the 8400. (Part #B10) over the bolts as shown. The power cord 8400, 2.3 can be slid under the bottom screen between the float and screen where two float sections come together before the 3/8” Lock Nuts are replaced. Replace the three inside Lock Nuts and tighten all 3/8” Lock Nuts using the 9/16” wrench and socket. Once all three Unit Mounting Brackets are seated correctly on the cage ring, add remaining 1/4” x 3/4” Bolts and 1/4” Lock Washers to lower mounting hole. Tighten all bolts on the Unit Mounting Bracket with Note: Extra hardware may be included 7/16” socket or wrench. STEP EIGHT On power cord lengths of 100 feet or longer with the watertight Quick Disconnect, the power cord is shipped separately. It should now be attached to the stub cord by lining up the male and female halves of the disconnect and hand tightening the blue collar. On these cords, the Additional Strain Relief should be attached to one of the lower float brackets as pictured. If you receive a 3 chain strain relief (6 or 8 gauge cord), attach one chain to each of the three lower float brackets. If there is not Strain Relief, use the Nylon Cable Tie provided to secure the cord to a rope to STEP SIX (3.1, 3.3, 5.1, 5.3) prevent damage by the propeller. Double check the Lift Float Assembly and place over Aerator Assembly. Quick Disconnect to make sure the threaded collar has Place the 3/8” x 1” Bolts (Part #B6) and 3/8” Lock not come loose in shipping before placing in the water. Washers (Part #B7) through the top float bracket and If installing a new Quick Disconnect, please refer to lower float bracket as shown and screw directly into Quick Disconnect instructions. the aerator mounting ring. Tighten down with a 9/16” wrench. 8 to the top ring of the screen in (3) equally spaced locations using cable ties. Attach 3 cable ties to top ring equally spaced 1 chain strain relief Chain Bottom Float Bracket 3 chain strain relief 2 inch overlap Mesh Screen Attachment 1. Take flat mesh pattern and wrap into cone shape 3. Flip mesh and screen assembly over and use by overlapping both vertical edges by approximately remaining cable ties to secure mesh to small bottom 1 inch and aligning top and bottom edges of mesh. diameter of the stainless steel ring. Secure mesh vertical seam at the top, bottom and middle using (3) cable ties. Attach 2 cable ties to bottom ring equally spaced Overlap vertical edges Attach 3 cable ties 4. Clip off excess cable tie material once mesh is secured into place. Go back to assembly instructions to continue with connecting the bottom screen to the float. 1 inch overlap Installation Instructions Before installing 3 phase units (2.3, 3.3, 5.3) into the pond, please refer to 3 phase startup procedure. STEP ONE Use the ropes to position the Aerator in the desired location in the pond/lake. Anchor the ropes or secure 2. Insert existing stainless steel screen centered inside them to the shoreline so the ropes are free of slack, but mesh cone with approximately 2 inches of mesh not tight. To prevent twisting of the unit due to torque, overlap to the top ring of the screen. Attach mesh you should place the anchor at least 3 feet from the 9 float for each foot of depth (Ex. A 6 foot deep pond 3. Adjustment Bracket (1) would require an anchor 18 feet horizontally from the 4. Angle Bracket (3) float.) 5. Draw Band (1) 6. U-Bracket (2) For ease of removal, you may choose to keep at least 7. Spacer Bracket (2) one anchor within reach from shore, just below the 8. 1/4” x 1/2” Stainless Steel Bolt (8) water’s surface. 9. 1/4” x 1” Stainless Steel Bolt (3) Correct Anchoring 10. 1/4” x 1-1/4” Stainless Steel Bolt (2) 11. 1/4” Stainless Steel Lock Nut (8) 12. 1/4” Stainless Steel Hex Nut (2) 13. 1/4” Stainless Steel Lock Washer (5) 14. 50’ Black Nylon Ropes (2) 15. Nylon Tie (1) Incorrect Anchoring STEP TWO (ALTERNATE INSTALLATION) In ponds where the water level fluctuates significantly, you may need to suspend a small weight (12” of 1” galvanize pipe works well) at the mid-point of the rope to take up any slack as the water level drops. The weight should be light enough so the Aerator can rise as the water level rises. This can also help hide ropes by sinking them further below the surface. Normal Water level Kasco Power Circulator Tools & Supplies Needed Control Box Anchor Rope Power Cord A. Anchors or stakes for installing unit (2) B. 120V or 240V Electrical Supply near pond on a Secondary Weight post (1) C. 12” pieces of 1” galvanized pipe for weighting Low Water Level ropes (optional) (2) D. 9/16” (14mm) & 7/16” (11mm) Nut Driver E. 9/16” (14mm) & 7/16” (11mm) Socket F. Adjustable crescent wrench G. 7/16” Wrench (1) High Water Level H. 7/16” Socket & Wrench (1) I. Felt-tip marker (1) Circulator (CF Model) Assembly STEP THREE At this time the Aerator is ready for operation. It can STEP ONE be plugged into the power supply at the pond edge. Remove all contents from package and place on a clean, ENJOY YOUR NEW KASCO EQUIPMENT! flat surface. Inspect the shipment for any damages. Make sure you have all the parts needed. Circulator Parts (CF Models) STEP TWO Circulator (Unit with cord or stub cord) (1) Position the Float (Part B1)upside down (lengthwise chan- Float in separate box (1) nels facing up) and place the Base Strap (Part B2) so the 1. Float (1) three holes in the Base Strap align with the three threaded 2. Base Strap (1) holes that comprise the lengthwise midline of the Float. 10
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