Kasco 3.1EVX User manual

Owners Manual
50Hz Fountains
8400EJ, 3.1EJ, 3.1EVX
2.3E(H)J, 3.3E(H)J, 3.3E(H)VX, 5.3E(H)J
Contents
Important Safety Instructions . . . . . .pg2
Unit Specs . . . . . .pg2
Quick Disconnect Installation . . . . . .pg2
Wire Sizing & Gland Sizing . . . . . .pg4
Parts Included . . . . . .pg5
Assembly Instructions . . . . . .pg5
EVX Pattern Size Chart . . . . . .pg7
J Nozzle Options . . . . . .pg8
3 Phase Startup Procedure . . . . . .pg9
Installation Instructions . . . . . .pg10
Maintenance Recommendations . . . . . .pg10
Troubleshooting Tips . . . . . .pg11
Rev. 12/15/09
Kasco Marine, Inc.
800 Deere Rd.
Prescott, WI 54021
U.S.A.
PH 00+1+715+262+4488
FAX 00+1+715+262+4487
[email protected]
www.kascomarine.com

2
CAUTION
NOTICE (NOTE)
These international safety symbols are used through-
out this manual to inform the end user, installer, and
owner of important safety information and notices for
safe and effective use of the equipment.
Important Safety Instructions
CAUTION
Under NO circumstances should anyone• enter the water with the electrical equipment
plugged in and/or in operation. It is NEVER
recommended to enter the water with the
equipment in operation.
Caution should be used when dealing with any• electrical equipment with moving parts.
NEVER run the unit out of water. It will• damage the seals and create a dangerous
situation for the operator.
Extreme caution should be used around water,• especially cold water, such as in Spring, Fall,
and Winter, which poses a hazard in and of
itself.
NEVER lift or drag the unit by the power or• light cord. If you need to pull the unit to the
side of the pond, use the anchoring ropes.
Do not use waders in deep ponds/lakes or• ponds/lakes with drop-offs, drastic slopes, or
soft bottom material.
Do not use boats that tip easily for fountain• installation, such as a canoe, and follow all
boating safety rules and regulations, including
wearing a PFD. (Personal Flotation Device)
The unit is supplied with an internal grounding• conductor. To reduce the risk of electrical
shock, be certain that the unit is plugged/
connected to an approved RCD (GFCI)
protected circuit.
A properly sized 3 phase motor control• (motor starter) with overload and short
circuit protection must be provided at time of
installation.
3 phase units (2.3, 3.3, 5.3) require a startup•
test after wiring to ensure proper rotation of
the impeller. If the impeller is rotating in the
opposite direction, the unit will not perform
properly and internal damage to the unit may
occur. (See 3 phase startup procedure)
Means for disconnection must be incorporated• in the fixed wiring in accordance with local
and national wiring rules to prevent accidental
start.
Consult a qualified electrician for electrical• installation.
Unit Specs
Model Voltage
range Operating amps lock rotor amps
3.1EVX 208-240 12.5@220V 60@220V
8400EJ 208-240 9.5@220V 40@220V
3.1EJ 208-240 13.2@220V 60@220V
3.3EVX 190 9.6 69
2.3EJ 190 6.4 41
3.3EJ 190 10 69
5.3EJ 190 15.2 98
3.3EHVX 380 4.8 34
2.3EHJ 380 3.3 21
3.3EHJ 380 5 34
5.3EHJ 380 7.7 49
Quick Disconnect Installation
Important – Read Carefully Before Installation
Before using the connector, it is important that these
instructions are carefully read and understood to
ensure the connector system is completely water tight
and electrically safe.
IF IN DOUBT CONSULTA QUALIFIED ELECTRI-
CIAN.
The socket (female) insert of the connector must be
the live part of the connector from the supply. The pin
(male) insert of the connector must lead to the load or
electrical device. On 50Hz units, the pin (male) insert
of the connector is installed at the factory. To ensure
efficient sealing, use only smooth circular cable.

3
Pin Insert (Installed on Stub Cord)
Pin Insert Main Body Gland Gland Nut
Socket Insert (User Installed)
Socket insert Main Body Gland Gland Nut
Note:
White gland for 9-11mm O.D.
Yellow gland for 13-15mm O.D.
Assembly/Wiring Instructions
STEP ONE
Remove the socket insert from the housing of the con-
nector. There is a slot for a flat blade screwdriver in
the center of the insert.
Note: The inserts have a LEFT HAND THREAD and
should be turned clockwise to remove.
STEP TWO
Remove the gland nut and gland from the rear of the
housing and slide on to the cable. Make sure the gland
is orientated with the stepped edge facing the gland
nut (see picture). Stepped Edge
STEP THREE
Prepare the cable and strip wire ends as shown.
Wire Stripping
Wire Stripping
STEP FOUR
Insert the stripped wire ends into the terminals on the
back of the Pin/Socket insert and fully tighten the
wire retention screws. (Refer to figure for correct wire
orientation).
Single phase wiring:
Figure 5:
Wire Connections
Brown wire to terminal L
Blue wire to terminal N
Green/Yellow wire to terminal E
3 phase wiring:
Figure 6:
Wire Connections
Brown wire to terminal 1
Black wire to terminal 2
Grey wire to terminal 3
Green/Yellow wire to terminal E
After the wires have been connected securely, pull the
cable and insert back into the housing and tighten with
a screwdriver to ensure the insert is seated correctly.
Note: LEFT HAND THREAD, turn the insert counter
clockwise to tighten.
STEP FIVE
Prepare your supplied Resin Kit by removing the cap
from the resin tube and pushing the resin nozzle onto
the tube. Then twist the nozzle to lock in place.

4
nect and insert the sealing cover into the large blue nut
half and tighten firmly.
Strain Relief
The Strain Relief must be installed to protect the
Quick Disconnect from damage due to excessive
strain. The Strain Relief should be installed on the
user supplied cord length (not on the Kasco supplied
stub cord). It should be position about 15cm from the
Quick Disconnect. To install, insert the narrow end of
the elongated clamp with the chain connected into the
wide end of the short clamp. Use a rubber mallet to
tap the two pieces together securely. A Nylon Tie can
be used to keep it attached to the cord. The chain can
then be attached to the float.
Wire Sizing & Gland Sizing
The chart below shows the proper Gland to be used
with different cord sizes. The measurements are based
on the Outside Diameter (O.D.) of the cord. Smooth,
round cords should be used. (HAR H07RN-F)
Kasco Quick Disconnect 50 Hz Size Chart:
Gland O.D. of Cord
Grey 7-9mm
White 9-11mm
Black 11-13mm
Yellow 13-15mm
Kasco 50 Hz Equipment Wire Size Chart
Model Cord Length
10m 30m 60m 90m
8400EJ 1.5mm22.5mm24mm26mm2
3.1EVX 1.5mm22.5mm26mm26mm2
3.1EJ 1.5mm22.5mm26mm26mm2
2.3EJ 2.5mm22.5mm22.5mm24mm2
Plunger Resin Tube Nozzle
Before applying to the quick disconnect, use the
plunger to evenly push out a small amount of resin to
get a proper mix of of the 2-part epoxy. Then apply
resin into the housing, enough to cover the wires and
contacts. The resin should be about 3mm onto the
cord jacket. Note: Adding too much resin may cause
excess to be forced into the female end of the pin
connector, preventing proper connection of the two
halves.
Cut-Away
disconnect shown
with clear resin.
Note amount that
is covering cord
STEP SIX
Slide the gland and gland nut along the cable into the
body and tighten the gland nut securely. No drying
time is needed for the epoxy before full assembly.
STEP SEVEN
Once the two subassemblies have been completed,
they can be joined together. Plug pin assembly into
the socket assembly and tighten the large blue nut
securely. The blue nut should be hand tightened only.
(See figure below).
Note: There is a small gap after tightening
For sea- son-
al removal, your quick disconnect includes an optional
water tight cover. Simply separate the quick discon-

5
Redwood & Spruce Nozzle (1)7. Sequoia Nozzle (3.1EJF only)8. 3/8” x 2.5” Bolt (1) (3.1EJF only)9.
Note: Extra hardware may be included.
TOOLS & SUPPLIES NEEDED
A. Anchors or stakes for installing unit (3)
B. 240V Electrical Supply near pond on a post
C. Three 30cm pieces of 2.54cm galvanized pipe for
weighting ropes (optional)
D. 7/16” (11mm) Socket & Wrench (1)
E. 7/16” (11mm) Wrench (1)
F. 9/16” (14mm) Socket & Wrench (1)
F. 9/16” (14mm) Wrench or adjustable crescent
wrench (1)
G. Flat head screw driver (1)
Assembly Instructions
STEP ONE
Remove all contents from package and place on a
clean, flat surface. Inspect the shipment for any dam-
ages. Make sure you have all the parts needed.
STEP TWO
Arrange the three Float Sections (Part B1) upright
(plug on bottom) so the overlap of one section aligns
with the next section and loosely push the three sec-
tions together to form a continuous ring.
Float up Float down
(plug)
Model Cord Length
10m 30m 60m 90m
3.3EVX 2.5mm22.5mm24mm26mm2
3.3EJ 2.5mm22.5mm24mm26mm2
5.3EJ 2.5mm24mm26mm26mm2
2.3EHJ 2.5mm22.5mm22.5mm22.5mm2
3.3EHVX 2.5mm22.5mm22.5mm22.5mm2
3.3EHJ 2.5mm22.5mm22.5mm22.5mm2
5.3EHJ 2.5mm22.5mm22.5mm22.5mm2
Parts Included
INCLUDED
A. Aerating Fountain (Unit with stub cord) (1)
B. Float in separate box (1)
1. Float Section (3)
2. Top Float Bracket (3)
3. Bottom Float Bracket w/ 50’ rope (3)
4. 9” x 3/8” Black Coated Bolt (6)
5. 3/8” Lock Nut (9)
6. Unit Mounting Bracket (3) (not in
cluded with 3.1EVFX, 5.1EJF)
7. 1/4” x 3/4” Bolt (6)
8. 1/4” Lock Washer (9)
9. Bottom Screen (1)
10. Top Screen (1)
11. Top Screen Clip (3)
12. 1/4” Nut (6)
13. Bottom Screen Clips (3)
14. 1/4-20 x 3/4” Brass Screw (3)
15. 3/8” x 1” Bolt (3)
16. 3/8” Lock Washer (3) (5.3 only)
C. Set of Five Interchangeable Nozzles (5)
#6 x 1/2” Phillip Pan Head Self Tapping Screw (3)1. 3/8” x 4” bolt (1)2. Linden Nozzle (1)3. Redwood Nozzle Y Insert (comes installed in #7)4. (1)
Juniper Nozzle (1)5. Willow Nozzle (1)6.

6
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” Black
Coated Bolts (Part B4) through the assembly. This
may require some minor repositioning of the float sec-
tions as you push the bolt all the way through. Do not
force the bolt through. Repeat for the remaining two
joints.
STEP FOUR
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 Lock Nuts (Part B5) on the ends
of the bolts (do not tighten yet).
(For 8400, 2.3, 3.1, 3.3)
Connect the top and bottom brackets using three 3/8”
x 1” Bolts (Part B15) with the three 3/8” Nuts (Part
B5) and tighten using the 9/16” (14mm) wrench and
socket.
STEP FIVE (For 8400EJ, 2.3EJ & 3.1EJ, 3.3EJ)
Return the assembly to the upside down position and
place the motor assembly (Stainless Steel can side
up, black pump down) in the center of the float. At-
tach the motor to the float using the Unit Mounting
Brackets (Part B6). The notch in the center of the Unit
Mounting Brackets should be positioned over the top
ring of the cage and should be attached to the float
bracket using the two middle holes of the float bracket
on 8400EJ & 3.1EJ.
Tighten using the 1/4” x 3/4” Bolts with 1/4” Lock
Washers using the 7/16” socket and wrench. (See pic-
tures) Note: If you have trouble positioning the Unit
Mounting Bracket between the Cage and Fountain
Housing, you can use a screwdriver to gently pry open
enough space.
STEP FIVE (for 5.3E(H)JF)
Rest the float on the base plate of the unit. Connect
the float to the base plate using the 3/8” x 1” bolt (Part
#B15) and 3/8” lock washer (Part #B16). Tighten us-
ing a 9/16” wrench.
STEP FIVE (For 3.1EVFX, 3.3E(H)VFX models)
Return the assembly to the upside down position and
place the motor assembly (Stainless Steel can side
up, black tube down) in the center of the float. Align
the 3 taller legs of the black fountain tube with the 3
float brackets. Attach the motor to the float using the
1/4” x 1” bolts. Attach to the float bracket using the
two middle holes of the float bracket. Tighten us-
ing the 1/4” x 1” Bolts with 1/4” Lock Washers using
the 7/16” socket and wrench. The 1” bolts will screw
directly into the legs of the black fountain tube.

7
To install the Redwood nozzle, make sure the Y Insert
(Part D4) is installed and seated properly into the
nozzle. Push the nozzle down over the cone assembly
(it may require light taps with a rubber mallet to seat
properly). Next, use the 3 Self Tapping Screws (Part
D1) provided in the 3 holes on the nozzle and tighten
the screws into the cone assembly. Once you feel
resistance, two more turns will be sufficient. To install
the Spruce nozzle, follow the same steps, but do not
install the Y Insert.
STEP NINE
The power cord 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 there is not Strain Relief, use the Nylon Cable Tie
provided to secure the cord to a rope to prevent dam-
age by the propeller. If installing a new Quick Dis-
connect, please refer to Quick Disconnect instructions.
EVX Pattern Size Chart
V-shaped display.
Model Height Width
3.1EVX,
3.3EVX 2.0 m 7.3 m
STEP SIX
Center the Top Screen (Part B10) inside the three Top
Float Brackets. Attach the screen by spanning each
Top Screen Clip (Part B11) across the two innermost
rings on the screen and the hole in the float bracket.
Insert the Brass Screws (Part B14) and attach with
1/4” Lock Washers and 1/4” Nuts to secure the screen
to the float assembly.
STEP SEVEN
Position the Bottom Screen (Part B9) over the float so
the motor housing (can) passes through the large hole
in the center of the screen. Remove the center three
Lock Nuts from the 9” Bolts and place the Bottom
Screen Clips (Part B13) over the bolts as shown. The
power cord can be slid under the bottom screen where
two float sections come together before the Lock Nuts
are replaced. Replace the three inside Lock Nuts and
tighten all 3/8” Lock Nuts using the 9/16” (14mm)
wrench and socket.
Note: Extra hardware may be included
STEP EIGHT
Return the unit to its upright position and select a
nozzle (See Nozzle and Pattern Options). Select the
proper Shaft Bolt (Part D2) and insert the Shaft Bolt
into the Nozzle Head so it fits snugly into the molded
socket. Install the Nozzle by threading it into the inner
cone of the pump. Make sure to tighten the Nozzle all
the way down.

8
The Willow nozzle (marked W on the inside of the
cone) uses the 3/8” x 4” bolt.
Model HP Height Width
8400, 2.3 2 3.4 m 10.4 m
3.1, 3.3 3 3.6 m 8.2 m
The Juniper nozzle (marked with J on in inside of the
nozzle cone) uses the 3/8” x 4” bolt.
Model HP Height Width
8400, 2.3 2 1.8 m 13.4 m
3.1, 3.3 3 2.7 m 12.2 m
The Spruce nozzle uses the three self tapping screws
to attach over the pump housing and the Y Insert must
be removed.
Model HP Height Width
8400, 2.3 2 5.5 m 3 m
3.1, 3.3 3 5.8 m 2.1 m
J Nozzle Options
NOTE: Pattern sizes listed are approximate. Varia-
tions in voltage caused by regional electrical differenc-
es or voltage drop due to long power cords may result
in reduced pattern sizes.
The Redwood nozzle uses the 3 self tapping screws to
attach over the pump housing and the Y Insert must be
installed.
Model HP Height Width
8400, 2.3 2 5.5 m 1.5 m
3.1, 3.3 3 6.1 m 0.9 m
The Linden nozzle (marked L inside one of the fins)
uses the 3/8” x 4” bolt.
Model HP Height Width
8400, 2.3 2 4.7 m 10.4 m
3.1, 3.3 3 4.1 m 9.8 m
5.3 5 4.9 m 8.5 m

9
marked value or the service factor amperes, shown on
the namplate.
3 phase
190 volt 2.3EJ 3.3EJ 3.3EVX 5.3EJ
Full load
amps 6.4 10 9.6 15.2
3 phase
380 volt 2.3HEJ 3.3HEJ 3.3HEVX 5.3EHJ
Full load
amps 3.3 5 4.8 7.7
Control panels must be installed by a qualified
electrician.
If unit is connected to a circuit protected by a fuse, use
a time-delay fuse with this pump.
You must verify motor rotation before installing
the unit in the water.
3phase Kasco units will run in a clockwise rotation
when looking down at the propeller/impeller. On J
series units the upper pump housing must be removed
to see the propeller/impeller. Stand clear of the
propeller/impeller while verifying rotation. Follow
the steps below.
Electrician:
Verify all screw terminal connections are tightened to1. specified torque setting prior to energizing the panel.
Verify the electrical service (voltage and Phase)2. matches the control panel and aerator nameplates
ratings. Refer to your control panel instructions and
schematics for installation details.
Verify all switches, circuit breakers, and motor starters3. are in the OFF position
Connect electrical service to your control panel as4. shown in the electrical schematic that came with the
panel.
Connect the unit power cord to the panel as shown in5. the electrical schematic with your panel
Set the motor starter overload to the FLA rating on the6. aerator nameplate.
Pump rotation: Remove the upper pump housing (if7. you have a J series aerator) by removing the three
screws attaching it to the lower pump housing. The
pump rotation is clockwise when looking down at the
propeller/impeller. Apply power to the control panel.
Turn on the 15amp control circuit breaker, and motor
starter.
Momentarily turn the Hand-Off-Auto switch to Hand.8.
The Birch display does not use a nozzle or bolt. It is
the fountain unit running without any nozzle and al-
lows for the best flow rate and oxygen transfer!
Model HP Height Width
8400, 2.3 2 3.5 m 1.8 m
3.1, 3.3 3 3.0 m 4.0 m
5.3 5 3.0 m 3.0 m
The Sequoia nozzle (marked S on the inside of the
cone) uses the 3/8” x 2.5” bolt.
3.1EJF, 3.3E(H)JF, 5.3E(H)JF ONLY
Model HP Height Width
3.1, 3.3 3 4.6 m 3.0 m
5.3 5 5.8 m 3.0 m
3 Phase Startup Procedure
A Control Panel is not provided with your unit, please
refer to the following warnings:
When inherent overheating protection is not provided:
use with approved motor control that matches motor
input in full load amperes with overload element(s)
selected or adjusted in accordance with control
instructions.
Proper ground fault protection (RCD) must be
provided at time of installation in your control panel
Note: The motor input in full load amperes is the

10
Correct Anchoring
Incorrect Anchoring
STEP TWO (ALTERNATE INSTALLATION)
In ponds where the water level fluctuates significantly,
you may need to suspend a small weight (30cm of
2.54cm 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 Unit can rise
as the water level rises. This can also help hide ropes
by sinking them further below the surface.
Normal Water level
Power Cord
Anchor Rope
Secondary Weight
Low Water Level
Kasco Power
Control Box
High Water Level
STEP THREE
At this time the Fountain is ready for operation. It can
be plugged into the power supply at the pond edge.
ENJOYYOUR NEW KASCO EQUIPMENT!
Maintenance Recommendations
Under No Circumstances should anyone enter
the water while a unit is operating. Turn Off and Dis-
connect electrical power prior to any Maintenance or
Servicing
RCD (Residual Current Device) or GFCI are a safety
feature that can also alert you to electrical leaks in the
equipment. It is extremely important to test the RCD
upon installation, each reinstallation, and monthly
This will run the aerator. Do not run the aerator for
more than a few seconds on shore. If the rotation is
not correct. Disconnect and lock out power from the
control panel. Swap any two of the aerator power cord
wires in the panel. This will cause the motor to reverse
direction. Reapply power to the panel and verify the
rotation is clockwise.
Once rotation is verified, with the power disconnected9. and locked out again, reinstall the upper pump housing.
Run the aerator one more time momentarily on
shore to ensure the housing was reinstalled correctly.
Disconnect and lock out power again and continue with
installation of the aerator as detailed in the aerator
owner’s manual.
Record the following data while the unit is operating
in the water under load:
Voltage: Amperage:
L1-L2 ____________ L1_______________
L1-L3 ____________ L2_______________
L2-L3 ____________ L3_______________
Current unbalance should not exceed 5% at full load
Installation Instructions
STEP ONE
Use the ropes to position the Unit in the desired loca-
tion in the pond/lake (secure the cord near power
source to prevent it from being dragged into the wa-
ter). Anchor the ropes or secure them to the shoreline
so the ropes are free of slack, but not tight. To prevent
twisting of the unit due to torque, you should place
the anchor at least 3m from the float for each meter of
depth (Ex. A 3m deep pond would require an anchor
9m horizontally from the float.) For ease of removal,
you may choose to keep at least one anchor within
reach from shore, just below the water’s surface.