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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