Kasco Robust-Aire User manual

ROBUST-AIRE MANUAL 1
800 Deere Rd. Prescott, WI 54021 | 715.262.4488 | [email protected] | kascomarine.com
MOVING WATER FORWARD, SINCE 1968
Installation &
Operation
Manual
Document number 772155
Document version 2022.1.0
DIFFUSED
AERATION
SYSTEM
Robust-Aire™

ROBUST-AIRE MANUAL 1
TABLE OF CONTENTS
715.262.4488
kascomarine.com | [email protected]
QUESTIONS?
Safety First............................................................................................................................................ 2
Unit Specications............................................................................................................................... 2
Diuser Installation............................................................................................................................. 3
Compressor Connections.................................................................................................................... 4
No-Cabinet Installation....................................................................................................................... 5
Suggested Tools & Supplies .......................................................................................................... 5
Installation Conditions & Clearances .......................................................................................... 5
Parts Lists........................................................................................................................................ 6
Base Mount Cabinet Installation ....................................................................................................... 8
Post Mount Cabinet Installation ........................................................................................................ 8
Remote Manifold Installation............................................................................................................. 9
Suggested Tools & Supplies .......................................................................................................... 9
Startup Procedure ............................................................................................................................. 10
Winter Operation............................................................................................................................... 11
Maintenance....................................................................................................................................... 11
Troubleshooting................................................................................................................................. 11
Warranty ............................................................................................................................................. 12
Other Repairs ..................................................................................................................................... 13
Repair Contact Form ......................................................................................................................... 14

ROBUST-AIRE MANUAL 2
IMPORTANT: PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE
• Use caution when dealing with any electrical equipment.
• Use caution around water.
• Running the system in conditions below freezing may create open areas of water at the diuser locations
and thin ice in the surrounding area.
• Some areas require warning signs to be posted. The system owner will assume all risks of operating the
Robust-Aire™ system during winter months. Check your local laws and ordinances.
• Do not use boats that tip easily, such as canoes, for installation. Follow all boating safety rules and
regulations, including wearing a PFD (Personal Flotation Device).
• Consult a qualied electrician for electrical installation.
SAFETY FIRST
WARNINGS:
Compressor(s) Number of
diusers Voltage Compressor HP
Number of 100-ft. rolls
of 3/8” tubing included
No Cabinet, Base Mount, & Post Mount Packages
RA1 KM-60C 1 120 1/4 1
RAH1 KM-60HC 1 208-240 1/4 1
RA2 KM-60C 2 120 1/4 2
RAH2 KM-60HC 2 208-240 1/4 2
RA3 KM-120C 3 120 1/2 3
RAH3 KM-120HC 3 208-240 1/2 3
Additional Base Mount Packages
RA4 KM-60C (x2) 4 120 1/4 N/A
RAH4 KM-60HC (x2) 4 208-240 1/4 N/A
RA5 KM-60C & KM-120C 5 120 1/4 & 1/2 N/A
RAH5 KM-60HC & KM-120HC 5 208-240 1/4 & 1/2 N/A
RA6 KM-120C (x2) 6 120 1/2 N/A
RAH6 KM-120HC (x2) 6 208-240 1/2 N/A
UNIT SPECIFICATIONS
Electrical Shock HazardElectrical Shock Hazard
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ROBUST-AIRE MANUAL 3
DIFFUSER INSTALLATION
The eectiveness of the Robust-Aire™ system depends on the location of the diusers in the pond. Place the
Robust-Aire™ Diusers equidistant from each other at a depth that is representative for most of the pond.
Please contact Kasco with any questions about placement or system operation.
CAUTION: Do not use boats that tip easily for installation (such as a canoe).
Always wear a personal otation device.
1. Kasco recommends marking the location of each diuser at the surface with a buoy.
2. Unroll the SureSink™ Tubing on shore to remove any twists or knots. Performance will decrease if the
tube is not properly uncoiled.
3. Each tubing length is 100 feet. If more than one length of tubing is required to reach a diuser location,
connect any additional tubes according to the SureSink™ Tubing instructions. Unroll these tubes as you
did the rst tube. You can load multiple rolls of tubes into a boat and connect them as needed while
making your way to the proposed diuser location. You can also connect any number of 100’ lengths
together and have someone assist in feeding it from shore. Cut o any excess tubing at the shore before
connecting to the compressor.
4. Drop the loose end of the tubing near the compressor cabinet. Allow a few extra feet of tubing to work
with so the tube will reach the cabinet after trenching between the shore and the compressor.
5. Drive the boat in reverse to keep tubing clear of the propeller and slowly make your way to the marking
buoy, placing the tubing as you go.
6. Once you reach the marked buoy, thread a rope through the two holes of the diuser base. Pull through
until the midpoint of the rope is at the diuser base.
7. While holding the two ends of the rope, gently lower the diuser assembly into the water.
8. Continue slowly lowering the assembly until it reaches the bottom of the pond. The diuser will always
land right side up.
9. The Robust-Aire™ Diuser should now be seated properly on the bottom of the pond. You can remove
the rope by pulling on one end. For ease of future maintenance, Kasco recommends leaving the rope
looped through diuser base and tying both ends to a marker buoy or duck decoy. This will allow you to
easily locate diusers and pull them to the surface for maintenance.
10. Repeat the process for additional Robust-Aire™ Diuser locations.
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ROBUST-AIRE MANUAL 4
COMPRESSOR CONNECTIONS
3/8" lead hose from compressor
3/8" clamp
3/8" x 3/8" barb tting
or 3/8" x 5/8" barb tting
3/8" or 5/8" clamp
3/8" or 5/8" tubing
1. Finish connecting the tubing to the lead hose
from the compressor with the supplied barb
tting. Tighten clamps to both supply tubing and
compressor hose.
2. Bury tubing from the shore to the compressor.
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ROBUST-AIRE MANUAL 5
Suggested Tools & Supplies
• Phillips-head screwdriver
• Flat-head screwdriver
• 5/16” socket or nut driver
• 1/4” socket or nut driver
• 9/32” socket or nut driver
• 3/8” socket or nut driver (#10 nuts)
• 7/16” socket or nut driver (1/4” nuts)
• Thread sealant (Teon tape)
NO-CABINET INSTALLATION
Installation Conditions & Clearances
• Install compressor in a clean, dry location.
• Protect the compressor from dirt, moisture, and any harmful elements of the outdoor environment.
• Ambient air temperature must not exceed 104 °F (40 °C).
• Adequate ventilation and cooling air (airow across the compressor) is essential to prevent damage to
the compressor from overheating. A fan is included for this purpose.
• Easily mount the unit to a wall, oor, or bench with the included bracket.
Packages containing 120V compressors have a NEMA 5-15 plug. Packages containing 240V compressors
have ying leads. Hard-wire the leads into 240V service or install an appropriate plug.
Brown Black
Blue White
Green w/ stripe Green
Wiring Connections
Electrical wiring color codes may vary by country/region.
Check local codes before making connections.
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ROBUST-AIRE MANUAL 6
RA(H)1-NC Parts Included Qty.
Robust-Aire™ Diuser Assembly 1
3/8” x 100’ SureSink™ Tubing w/tting kit 1
Single head compressor 1
1/4” NPT x 3/8” barb brass elbow 2
Compressor vibration isolation feet 4
1/4” at washer 4
1/4” locknut 4
Cooling fan assembly (either 115V with plug or
230V without plug)
1
#10 x 3/4” bolt 4
#10 split washer 4
#10 nut 4
3’ length of 3/8” hose 1
Hose clamp 3
Intake hose 1
Intake block 1
Filter minder 1
Air lter 1
RA(H)2-NC Parts Included Qty.
Robust-Aire™ Diuser Assembly 2
3/8” x 100’ SureSink™ Tubing w/tting kit 2
Single head compressor 1
1/4” NPT x 3/8” barb brass elbow 3
Compressor vibration isolation feet 4
1/4” at washer 4
1/4” locknut 4
Cooling fan assembly (either 115V with plug or
230V without plug)
1
#10 x 3/4” bolt 4
#10 split washer 4
#10 nut 4
Hose clamp 3
Intake hose 1
Intake block 1
Filter minder 1
Air lter 1
Two station manifold assembly 1
Manifold mounting screw 2
RA(H)3-NC Parts Included Qty.
Robust-Aire™ Diuser Assembly 3
3/8” x 100’ SureSink™ Tubing w/tting kit 3
Double head compressor 1
1/4” NPT x 3/8” barb brass elbow 3
Compressor vibration isolation feet 4
1/4” at washer 4
1/4” locknut 4
Cooling fan assembly (either 115V with plug or
230V without plug)
1
#10 x 3/4” bolt 4
#10 split washer 4
#10 nut 4
Hose clamp 3
Intake hose 1
Intake block 1
Filter minder 1
Air lter 1
Three station manifold assembly 1
Manifold mounting screw 2
NO-CABINET INSTALLATION (CONT.)
Parts Lists
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ROBUST-AIRE MANUAL 7
NO-CABINET INSTALLATION (CONT.)
RA(H)1-NC RA(H)3-NC
PTFE
thread
sealant
Outlet
Remove outlet plug
using 1/4" hex key
Inlet
Connect to
SureSink™ Tubing
For your protection, Kasco recommends that the site service providing system power is equipped with a
human-rated ground fault circuit interrupter outlet (120V) or human-rated ground fault breaker (240V).
Contact a licensed electrician to install either 120V or 240V (depending on model) single-phase power at the
compressor location with appropriate human-rated ground fault protection.
No-cabinet systems arrive assembled. To prepare for installation:
1. Thread the lter maintenance indicator into the top port of the intake manifold block. Hand-tighten and
DO NOT OVER-TIGHTEN. The tting is made from corrosion-resistant plastic and can be damaged from
excessive force. Thread until snug.
2. Thread the air lter into the front port of the intake manifold block. Hand-tightening is sucient.
1 2
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ROBUST-AIRE MANUAL 8
BASE MOUNT CABINET INSTALLATION
Choose a location far enough from shore to avoid
potential ooding. If you use plantings to help hide
the cabinet, be sure that both the inlet and the outlet
vents are clear, as the compressor requires airow to
prevent overheating.
Place the assembly directly on the ground or attach
it to a concrete pad. Use the holes on the bottom
anges to anchor the cabinet.
Place the cabinet adjacent to the electrical service
which will power the system. The cabinet has 6-foot
power cord(s) with plugs. DO NOT USE EXTENSION
CORDS.
POST MOUNT CABINET INSTALLATION
Attach the post mount cabinet to a post or vertical
wall (shed) with electrical service.
Use the two provided lag screws to mount the cabinet
to the wall or post. Drill two 3/16” holes vertically
spaced 2-3/8” apart. Using a standard 7/16" socket
wrench, install one lag screw into the wall or post,
leaving the hex head out about 1/4". Hang the cabinet
from this screw using the bottom keyhole slot. You
may need assistance from a second person to help
hold the cabinet. Install the second lag screw in the
top mounting hole. Tighten both lag screws.
Optional Foundations
• Pea gravel
• Rubber mulch
• Cement
6 holes
7/16" DIA
24" 18"
No key is required to open either cabinet.
Simply use a at-head screwdriver.
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ROBUST-AIRE MANUAL 9
REMOTE MANIFOLD INSTALLATION
Robust-Aire™ systems with the optional remote manifold have a single air line exiting each compressor.
Follow the instructions below to assemble and install the remote manifolds.
• 3/4” Sch. 40 PVC pipe (amount to be determined by user)
• 3/4” Sch. 40 PVC pipe Couplings (as needed)
• PVC primer and glue
• PVC pipe cutter
• Shovel or other trenching tools
• Pliers (for hose clamp installation)
• Thread sealant
You will need to excavate a trench to bury the PVC air line. Start by determining the path of the trench from
the Robust-Aire™ system to an area near the shore. The path should be as straight as possible, with a gentle
downward slope from the Robust-Aire™ system towards the water. Dig the trench 6” to 8” deep.
For two or three station valve manifolds, excavate an area large enough to bury the included valve box. You
will need an area at least 18” wide x 25” long x 13” deep. Dig the area deeper and add crushed rock to allow
for necessary drainage.
Suggested Tools & Supplies
3/8" or 5/8"
tubing
to diuser
RM1
from
compressor
RM2
from
compressor
to diusers
valve box
RM3
from
compressor
valve box
to diusers
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ROBUST-AIRE MANUAL 10
REMOTE MANIFOLD INSTALLATION (CONT.)
CAUTION: In northern climates where the ground freezes during winter, be sure there are no high or low
spots in the PVC air line. Condensation in the air line may pool, freeze, and block the ow of air to your
diuser. This can also damage your compressor.
RA1 – RA3 systems require a single trench.
RA4 – RA6 systems require either a single trench or two separate trenches, depending on pond size and
diuser locations.
Connect the brass barb tting to the PVC adapter, applying thread sealant to male threads on PVC adapter.
Connect the barb tting to the rubber compressor hose lead and secure with a clamp.
Connect the PVC adapter and PVC pipe with primer and glue. Add pipe sections as needed to reach the
remote manifold.
Prime and glue the manifold assembly to the PVC pipe supplying the compressor. Install 3/8” or 5/8” barb
ttings depending on the size of SureSink™ Tubing to each diuser. Apply thread sealant to the male
threads of the barb ttings. Attach the tubing to each barb tting and secure with a hose clamp.
When applicable, place a valve box over the manifold assembly and ll around the box and the entire length
of the trench with the excavated dirt. The lid of the valve box should be ush with the ground.
Following installation of systems with multiple diusers, use the valves to balance ow to each diuser.
STARTUP PROCEDURE
IMPORTANT INSTALLATION WARNING
Thermal stratication refers to layering that occurs in some lakes and ponds when warmer water sits on top
of colder, denser water toward the lake bottom.
If you install your unit into a body of water that is extremely stratied, use caution when starting the system.
In some cases, colder water sitting on the bottom could hold gases that can be harmful to sh. Often, the
colder bottom water also contains little or no dissolved oxygen.
A simple test for thermal stratication is to use a thermometer to gradually check for water temperature
changes between the top and bottom of the lake or pond. Measure temperature every two feet of depth.
Keep the thermometer at each depth long enough to take an accurate temperature reading. Then quickly
bring the thermometer to the surface and record the temperature at each depth.
If the colder water (anything 4 °F colder than surface) represents more than 30% of the overall volume, start
aeration at a slower pace by running the system for short intervals only. For a stratied lake, a suggested
start-up interval might include running the system one hour per day for one week and gradually increasing
the duration until the system is running continuously. Lakes and ponds react dierently to diused aeration,
so exact time frames can be dicult to predict. Sunny days are preferable to cloudy days for system start-
up, since photosynthesis will supplement oxygen levels as the water is mixed.
If you have questions about this procedure, please contact your distributor or e-mail Kasco Customer
Service at [email protected].
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ROBUST-AIRE MANUAL 11
WINTER OPERATION
The system owner assumes all risks of operating the Robust-Aire™ system during winter months.
MAINTENANCE
Warning! Product surfaces become very hot during operation. Allow compressor to cool before servicing.
Disconnect electrical power before performing maintenance.
• Check lter monthly.
• Clean or replace intake lter when lter minder shows a
red band.
• Reset by pushing the small button on the minder top.
• Failure to maintain clean air lter will lead to excessive
heat and premature failure of the compressor.
• Replacement air lter element part number: 771018 Clean lter Dirty lter
TROUBLESHOOTING
“Compressor and fan are not running.”
• Ensure the power cord is connected. Check if the user supplied GFCI circuit is tripped. Reset as
necessary
“The fan is running but the compressor is not”
• Inspect the compressor and capacitor wiring and connections.
“The compressor and fan are running, but there are no bubbles coming out of any diusers”
• Check for leaks in line connections and at the compressor. Check connections for tightness.
“The compressor and fan are running. There are bubbles coming out of some diusers, but not all of them.”
• The valves in the cabinet may need to be balanced. There may be a clogged diuser that needs to be
cleared. The compressor may be due for a rebuild.
“The compressor stops and restarts”
• Ensure the fan is working properly. Capacitor may need replacement.
Please contact Kasco or your distributor if any problems persist.
Operating the Robust-Aire™ system during the winter or in freezing temperatures may create open areas
of water at the diuser locations. Ice surrounding those areas will be thin. Use extreme caution in the area
to avoid injury or fatality from falling into the water. Use signs to indicate the danger to others. Check your
local laws and ordinances; some areas require warning signs to be posted.
In climates where temperatures fall below freezing, Kasco recommends insulating the air lines from the
compressor cabinet a minimum of 3 feet into the water (use low water level for reference). Prevent ice
buildup in the lines by using closed cell polyurethane foam to insulate. Ice buildup can block the ow of air
to your diuser and cause damage to your compressor. Insulation should pass through the ice, into the
open water below.
Moving the diusers closer to shore in winter will allow a small area of the shoreline to remain open,
preventing winter kill.
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ROBUST-AIRE MANUAL 12
Warranty Period
• Diuser assembly = Lifetime
• Teich-Aire compressor = 3 years
• Exterior cabinet = Lifetime
• SureSink™ Tubing = 15 years
Kasco® Marine, Inc. warrants this system to be free from defects in material or workmanship under normal
use and service. The Kasco Marine, Inc. obligation under this warranty is limited to replacing or repairing
free of charge any defective part within the warranty period. The customer shall pay shipping charges for
returning the unit to Kasco or an Authorized Repair Center.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED, AND ANY OTHER OBLI-
GATION OR LIABILITY WHATEVER ON THE PART OF KASCO MARINE, INC. AND IN NO EVENT SHALL KASCO
MARINE, INC. BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES.
Warranty is void if:
• The system is not maintained properly according to the maintenance recommendations supplied in this
manual.
• The system is damaged by unauthorized tampering.
Warranty Claim Procedure
The best method for establishing warranty period is via the original receipt. Also, register the unit online at:
www.kascomarine.com. Once the warranty coverage has been established, the unit may be sent to any Kas-
co Authorized Repair Center for evaluation and repair. Please call Kasco at 715-262-4488 prior to shipping
to receive any updated information and/or Repair Form, or call to locate your nearest Authorized Repair
Center. You can also email Kasco at [email protected].
Please include the repair form received from Kasco or your local distributor with the shipment. If no repair
form is available, include your name and physical address for return delivery of the repaired unit and a day-
time phone number and/or email address for correspondence regarding the warranty claim. Any expedited
shipping method for the return of the unit is at the customer’s expense. Kasco will return units repaired
under warranty at our expense via ground freight within the continental United States.
WARRANTY
Please attach a repair form with the shipment. The repair form must include a name, physical
address (for return delivery of the repaired unit), daytime phone number, and an e-mail address
for correspondence regarding the warranty claim.
Any expedited shipping method for the return of the unit is at the customer’s expense. Kasco will
return units repaired under warranty at our expense via ground freight within the continental
United States.
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ROBUST-AIRE MANUAL 13
Most failed equipment can be repaired at substantially lower costs than replacement with new equipment.
Please ship according to the instructions provided.
Kasco does estimates on repairs at the request of the customer. The request for an estimate should be
included in the letter that accompanies the returned unit and must include a daytime phone number and/or
email address. Estimate options are as follows:
• We will contact the customer with a total estimated cost for repairs after we have evaluated the unit but
before we perform the work.
• We will repair the unit only if repair costs are under a dollar amount stated by the customer. Example:
“Please repair if total is under $150.00 before shipping charges.”
All estimates that are rejected for repair will be destroyed unless otherwise directed by the customer. If
the customer would like the unit returned, we will restore the unit as closely as possible to the condition in
which we found it and ship at the customer’s expense (including shipping and handling charges).
Billing: Kasco accepts Visa and MasterCard credit card payments. Kasco will call for credit card information
upon completion of the estimate at the customer’s request. All other warranty and repair inquiries should
be directed to Kasco at 715-262-4488 or [email protected]
OTHER REPAIRS
715.262.4488
Kasco Marine
800 Deere Road
Prescott, WI 54021
kascomarine.com | [email protected]
CONTACT US
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ROBUST-AIRE MANUAL 14
REPAIR CONTACT FORM
Company name
Contact name
First name Last name
Address
Street
City
State
ZIP code
Phone number
Primary Alternate
Email address
Preferred method of
contact (circle one) Phone Email
Purchase order
number
Additional product
information
Serial Number Cord Length
Information for Repair Technician
Was this unit used in a chemical treatment or wastewater
application? (circle one) Yes No
Additional notes
Kasco Marine
800 Deere Road
Prescott, WI 54021
Attn: Repairs
• Kasco requires that all equipment sent for repair MUST be
accompanied by this form and marked to Repairs attention.
• Unit should be cleaned before shipping.
• Kasco is NOT responsible for shipping damage accrued in
return shipment.
• It is the responsibility of the customer to ship and pay freight
to Kasco.
Note: Contact information should be that of the person or company to contact for repair information.
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