Kingspan Klargester BioAir DS1398P Guide

1012687 Issue 01 –BioAir 2, 3 & 5 Installation and Maintenance Manual
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DS1398P
BioAir 2 Gravity Sales Drawing
DS1399P
BioAir 3 Gravity Sales Drawing
DS1400P
BioAir 5 Gravity Sales Drawing
DS1407P
BioAir 2 IPS Sales Drawing
DS1408P
BioAir 3 IPS Sales Drawing
DS1409P
BioAir 5 IPS Sales Drawing
Please request copy of specific sales drawing from our
sales department
1012687
01
BioAir 2, 3 & 5 Manual - Initial Issue
January 2023

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HEALTH AND SAFETY
Please read and follow for your own and others safety
You must read these warnings carefully before installing or using the equipment.
Please ensure that you have performed a risk assessment before commencing any
installation. Note that the risk assessment should be performed by a person who
understands the hazards of the work, and the work environment. Note that it must
be suitable and sufficient, i.e. adequately considers risks and ensures controls in
place to mitigate risks.
You must observe all-hazard labels and take appropriate action to avoid exposure to the risks indicated.
Always ensure that all relevant documents are supplied with the equipment when being transferred to a
new owner.
General guidelines
•Only experienced and competent person(s) should carry out the installation.
•The unit must have a Pre-Service Agreement Inspection by an approved engineer.
•Take care to maintain correct posture, particularly when lifting.
•Use appropriate lifting equipment when necessary.
•A qualified electrician should carry out electrical work deemed necessary.
•The covers must be kept locked.
Personal Protective Equipment (PPE)
•We recommend the use of a dust mask and gloves when cutting GRP components.
•Person(s) carrying out maintenance on the equipment should wear suitable PPE.
Maintenance and Inspection Procedures
If you wish to inspect the equipment's operation, please observe all necessary precautions as stated in your
risk assessment; including those listed below.
•The power supply must be isolated at the control panel(s) before lifting the covers.
•If the equipment should run with the covers off, care must be taken to avoid contact with movingparts
and electrical components or conductors.
•Once the power has been isolated, the control panel must be kept locked shut to avoid accidental
reconnection while work or inspection is being carried out.
Working Area
•Ensure that the working area is adequately lit.
•Ensure that you are familiar with the safe working areas and its access and egress.
•Use only the designated access walkways.
•Do not walk on the cover or deep well safety mesh(es).
•Always keep proper footing and your balance, avoid any sharp edges, or restricted points.
Desludging
•Desludging should be carried out by a licensed waste disposal contractor holding the relevant
permits to transport and dispose of sewage sludge in your region/area.

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DESLUDGING
Desludging should be carried out by a licensed waste disposal contractor holding the relevant permits to
transport and dispose of sewage sludge.
Do not empty the entire reactor and FST, as some biology should remain in the system to continue to work.
Desludging frequency is dependent on the incoming organic load, and therefore site specific. As a guide,
using the government figures of 2.4 people per household the desludging frequency will be approximately 12
months.
Reactor
Final Settlement Tank

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CONTENTS
HEALTH AND SAFETY....................................................................................................2
DESLUDGING................................................................................................................3
CONTENTS ...................................................................................................................4
SYSTEM OVERVIEW......................................................................................................5
BioAir® CHECKLIST........................................................................................................6
SELF HELP.....................................................................................................................7
INTRODUCTION............................................................................................................8
TECHNICAL DATA .........................................................................................................8
DESCRIPTION AND PROCESS ........................................................................................9
INSTALLATION............................................................................................................10
ELECTRICAL INSTALLATION ........................................................................................13
MAINTENANCE ..........................................................................................................24
WARRANTY................................................................................................................25
FAULT FINDING..........................................................................................................26
NOTICE.......................................................................................................................27

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SYSTEM OVERVIEW
Pictorial representation below indicates basic requirements for a standard system.
Cross Section
Top View
Outlet
Inlet
Tank Lid
Vent & Air Hose Duct
Reactor
Final Settlement Tank (FST)
Outlet
Inlet
Diffuser
Transfer
Port
Tank Lid
Sludge Return

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BioAir® CHECKLIST
The delivery paperwork will have 2 no. items listed; check that the Tank Code (Item 1) & Blower
Assembly Code (Item 2) are the same as the codes on the units delivered.
Example;
Top Level Product Code - (code)
Item 1 - (code) - (Tank Code)
Item 2 - (code) - (Blower Assembly Code)
The unit will be fitted complete with internal pipework and equipment. Inlet pipework will
be fitted. The unit is supplied strapped to a standard pallet.
Sewage Treatment Tank
Item 1
NB: Storage tanks vary in design and volume (BioAir 1- BioAir 3). Please check
your order and cross reference with relevant sales drawing. (BioAir 1 shown).
Blower Housing Assembly
Item 2
The Blower Assembly consists of the Blower Unit and associated pipework and
fittings.
19 mm Hose Coil - 15 Metres
19 mm Hose required to connect from 3/4” Hose Connector in Blower Housing to Air
Diffuser Manifold located with the Tank (Supplied inside Blower Housing Packaging).

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SELF HELP
To minimize the need for dealing with emergency situations we recommend that Sewage Treatment Plants
have a Pre-service Agreement Inspection, and then is regularly serviced by us or an approved Service
Engineers. Provided that your plant is installed, operated correctly and serviced, you should not need to get
into much –if any –self-help. However, some of the most likely question and answer situations are listed
below.
Blower Failure
Blower Stopped:
• Check the unit is switched on, the incoming power supply circuit and fuse.
Blower works but no water distribution inside the plant:
• Check hose connections.
• Check distributor heads.
• If the air lift pipes are suspected to be blocked, call for service which number and other details you can find
on the back page of this manual.
• Check regulating valve is not closed.
Plant flooding
• Check for blocked outlet system.
• If pumped outlet is all right, check for pump
operation, check floats and pump power supply.
DO’s ✓
Do take out a service agreement and let the experts look after your plant.
Do contact us for advice if you have any cause for concern. All contact details are at the end of this manual.
Do only flush the 3 P’s (Pee, Poo & Paper)
DON’TS X
Don’t pump feed the plant without seeking advice from Kingspan or installer.
Don’t use a waste disposal unit as you will be adding to the biological load, and your system may not be large
enough to cope with the waste. If you are unsure, please refer to our sales team for guidance.
Don’t throw any medicines down the toilet.
Don’t empty large quantities of bleach or similar cleaning reagents into the system.
Don’t empty cooking oil or similar down the sink.
Don’t cover the plant with soil material or prevent access for service and desludging.
Don’t try to enter the plant.
Don’t discharge backwash from Hot Tubs and Swimming Pools into the plant.
Don’t put sanitary towels, incontinence pads, nappies, tampons, or other non-biodegradable items down the
toilet.
Plant odour
• Check blower working.
• If blower working, plant probably needs desludging.
• Check vent circuit is clear.
• Check that the air duct entering the blower housing
has been sealed with foam.

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INTRODUCTION
Thank you for choosing a Kingspan product. This manual will help you to keep it operating efficiently over a
long service life. Please read this manual thoroughly, preferably before installation.
This manual should be referred to by:
•The installer
•The electrician
•The service engineer
•The maintenance engineer
•The desludge contractor
•The owner/user
TECHNICAL DATA
Unit
BioAir 2
BioAir 3
BioAir 5
Length (mm)
2500
2480
3190
Width (mm)
1540
1690
2010
Inlet Invert depth (mm)
455-755
575-875
645-945
Depth below ground (mm)
1805-2105
2075-2375
2485-2785
Blower
JDK80
JDK80
JDK120
Alternative Blower
LA80
LA80
LA120
Integral Discharge Pump* rating (W)
250
250
250
*Optional
Unit
BioAir 2
BioAir 3
BioAir 5
Max PE
6
9
15
Max Daily BOD (kg)
0.36
0.54
0.9
Maximum Daily Flow (m3)
0.9
1.35
2.25
All surface water must be excluded. These units should be used exclusively for the treatment of
sewage from domestic properties. Contact Kingspan if your sewage results, wholly or partly, from
any commercial function.

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DESCRIPTION AND PROCESS
BioAir systems are designed to accept crude domestic sewage and produce an effluent of suitable quality for
discharge to a watercourse or soak-away system, subject to the approval of the appropriate regulatory
authority. BioAir systems are self-contained single piece units.
The main casing and cover of the BioAir are constructed of Medium Density Polyethylene.
Crude sewage enters the inlet chamber through an inlet pipe in the side of the BioAir. Here, the sewage is
aerated via a diffuser at the bottom of the biozone. Naturally occurring micro-organisms form part of this
aerated mixture and will efficiently break down the pollutants in the sewage.
After a period of time, the aerated solids and liquids are transferred from the biozone to the FST via the
transfer port. Solids will settle in the FST and will be returned to the biozone via the sludge return pipe.
Treated effluent discharges from the FST through a T-pipe (except units with an Integral Discharge Pump).
Periodic desludging of the FST is required when solids build up starts to impact effluent quality.
Optional Integral Discharge Pump
The discharge pump sits within a molded chamber, positioned in the Final Settlement Tank. Treated effluent
flows into the chamber, by gravity from the FST. When the liquid in the chamber reaches a pre-determined
level, a float switches on the pump which then pumps effluent out of the chamber. The same float also
switches off the pump when the liquid level has been sufficiently lowered, thus protecting the pump from
running dry. We do recommend when this option is purchased, that a high level alarm is also fitted to warn
against pump mal-operation or failure.
Reactor
Final Settlement Tank (FST)
Outlet
Inlet
Diffuser
Transfer
Port
Tank Lid
Sludge Return

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INSTALLATION
Our domestic treatment plants are structurally tested in accordance with EN 12566-3, which specifies
structural stability testing for both wet and dry sites using granular backfill 3-8mm. However, in GB & IRE it
would be typical for tanks to be installed in concrete due to rising water table, and it can generally be
assumed that buoyancy prevention of concrete backfill is more advantageous than the granular backfill
materials used in testing.
During installation, care must be taken to ensure the body of the unit is uniformly supported to avoid
point loads on the unit.
A water supply must be available on site to enable the unit to be ballasted during backfilling.
When units are installed in unstable ground conditions where movement of the surrounding material
and/or unit may occur, the connecting pipework must be designed to minimise the risk of damage from
differential movement of the unit(s) and/or surrounding material.
In situations where the excavation will not maintain a vertical wall, it will be necessary to supportside walls
of the excavation (E.g., with suitable trench sheets and bracing systems) from the bottomto the top. DO
NOT completely remove the shoring system until after the backfilling is complete, but before the concrete
fully hardens.
If there is a risk of a high-water table or of the site flooding, a structural design by a suitable specialist will
be required to hold the tank in place.
In areas where the water table is above the bottom of the excavation and/or the excavation is liable to
flood, the excavation must be de-watered, using suitable pumping equipment, until the installation is
complete. Ensure that the pump discharge does not saturate the ground in the immediate vicinity. In such
conditions it may be advisable to line the excavation with polythene sheeting, to prevent cement being
washed out of the concrete surround/base.
Concrete Specification below is a general specification. It is not a site-specific installation design.
GENERAL CONCRETE SPECIFICATION
IN ACCORDANCE WITH BS EN 206-1 (BS 8500-1)
TYPE OF MIX
(DC) DESIGN
PERMITTED TYPE OF CEMENT
BS 12 (OPC): BS 12 (RHPC): BS 4027 (SRPC)
PERMITTED TYPE OF AGGREGATE
(coarse & fine)
BS 882
NOMINAL MAXIMUM SIZE OF AGGREGATE
20 mm
GRADES:
C25 /30
REINFORCED & ABOVE GROUND WITH HOLDING DOWN BOLTS
C25 /30
REINFORCED (EG. FOR HIGH WATER TABLE)
C16 /20
UNREINFORCED (NORMAL CONDITIONS)
MINIMUM CEMENT
CONTENT:
C30 C20
270 - 280 Kg/M3
220 - 230 Kg/M3
SLUMP CLASS
S1 (25mm)
RATE OF SAMPLING
READY MIX CONCRETE SHOULD BE SUPPLIED COMPLETE WITH
APPROPRIATE DELIVERY TICKET IN ACCORDANCE WITH BS EN
12350-1
NOTE: STANDARD MIXES SHOULD NOT BE USED WHERE SULPHATES OR OTHER AGGRESSIVE CHEMICALS EXIST
IN GROUND WATER

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1. Excavate Hole & Lay Concrete Bed
•Approximate dimensions of units:
Unit
Inlet Invert
(mm)
Diameter
(mm)
Unit Height
(mm)
Length
(mm)
Water Fill
Volume
(m3)
BioAir 2
455 –755
1540
1805 –2105
2500
3.172
BioAir 3
575 –875
1690
2075 –2375
2480
4.065
BioAir 5
645 –945
2010
2485 –2785
3190
7.473
•Excavate a hole with clearance on all sides and base of the unit
of 150 –200 mm, depending on site conditions.
•If shuttering is required to maintain a vertical wall, increase the
width of the excavation to accommodate.
•If the excavation has an unstable base, excavate an additional
250 –300 mm and fill with compacted hard-core.
•If water is present in the excavation, de-water using suitable
pumping equipment. Place a sheet of polythene over the base
and up the sides of the excavation before creating the concrete
slab.
•A minimum base of 150 –200 mm of lean mix concrete is
required for all ground conditions. The installer must ensure that the base is adequate to support the
weight of the tank and its contents.
•It is recommended to backfill with C25 SEMI-DRY MIX.
2. Lower Unit onto Concrete & Ensure Level
•Approximate weights of units in kilograms, depending on inlet invert:
•Lower the tank into the hole. A suitable spreader bar must be
used with lifting slings located through the lifting points
provided on the tank.
•The slings must not be attached to the inlet or the outlet pipe.
•Tank must not be lifted with any water inside.
•Check the Inlet and Outlet pipe orientation is correct.
•Check the unit is levelled.
Unit
Weight (kg)
BioAir 2
170
BioAir 3
200
BioAir 5
650

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3. Backfill the Tank Unit
•The backfilling must start before the base has hardened and
must be a single continuous operation, so the tank has a full
concrete jacket without joins.
•The backfill must be free from organic material, large stones,
brick, or sharp objects.
•Backfilling must be carried out in layers, making sure that voids
are not left under or around the sides of the tank and there are
no localised stress concentrations.
•The installer must progressively fill the tank via a hose while
keeping the water level 300 mm above the backfill to stabilise
pressures on the tank. If the pressures are not stable the tank
can become distorted and damaged.
4. Second Backfill Stage
•Continue to fill the tank with water and backfill evenly around
the tank, consolidating in 300 mm layers.
•DO NOT use vibrating pokers to consolidateconcrete.
•DO NOT discharge concrete directly on to the tank.
•Ensure that the concrete is not too wet and that it’s
tampered in around the tank.
•Continue until just below inlet and outlet pipework.
•Remove covers and connect inlet and outlet pipework.
•A 110mm diameter multipurpose vent and air duct hose is
located on the side of the plant. A T-piece must be connected so
the unit can be vented, and the air hose connected to the blower
housing.
•The vent side of the T-piece to be taken above ground and suitable vent mushroom fitted. Installer must
ensure adequate venting is provided for the treatment plant to work efficiently.
•The air hose side of the T-piece to be run back to the blower housing and sealed with expanding foam to
avoid foul air recirculation into the plant. The ducting for the air hose must connect through an
independent concrete base for blower housing location. The duct must be laid with long radius bends to
enable the hose to be threaded through.
5. Final Stage
•Continue to concrete backfill up to 100 mm below the lip of the
cover.
•Backfill up to lip with soil
•Once the unit has been installed, it must be left filled with
water.
•Complete electrical connections for isolator switch or control
panel as shown in the electrical installation section.

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ELECTRICAL INSTALLATION
General Electrical Installation Information
Your BioAir will either be supplied with an isolator switch or a control panel for electrical control of the unit.
It is imperative that the electrical installation of this equipment is entrusted to a competent qualified
electrician working to the latest IEE regulations.
It is not possible to state a specific installation configuration that would suit all sites. The selection of current
protection devices must remain the responsibility of the installer who should select a suitable cable and
current overload protection, taking into account the distance from the power source to the unit and any
other
relevant factors. (In many cases steel wire armoured (SWA) cable, minimum 1.5 sq mm will be suitable).
When installing the electrical supply to the unit, the following points should be considered:
The electric power supply to the tank should be by means of a dedicated circuit with isolation and protection
devices consistent with the requirements for fixed equipment and in accordance with the latest regulations
of
the Institute of Electrical Engineers. This power supply should be independent of all other household
protection devices other than the supply authority's main fuse and that provided specifically for the power
supply. In particular, earth leakage devices provided for normal domestic protection must not form part of
the supply circuit to the tank.
An earth leakage circuit breaker should be incorporated in the supply to the unit. A device with 30mA
minimum trip current is recommended.
Isolator (Economy Specification)
The Isolator with power failure light (in the blower box) can be mounted externally at a point where it is
easily
visible from the property.
The power supply cable should connect to the IP65 rated isolator socket mounted externally (see sales
drawing). Any terminal shrouds removed during the connection of cable cores must be replaced afterwards.
A separate duct or conduit should be provided by others.
Blower
Isolator
Blower Unit
Mains Power
Entry Point
Diffuser Hose
Entry Point
Diffuser Hose
Connection
Point Ø19mm
Hose Tail
Pump Isolator
(If Applicable)

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Isolator Wiring Diagram - Gravity System:

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Isolator Wiring Diagram - IPS System:

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Control Panel (Premium Specification)
Figure 1: 1002510 Lid & Cover
Figure 2: Enclosure & Mounting Dimensions

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Figure 3: Control Panel Wiring (1)
Figure 4: DTP Control Panel Wiring (2)

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General Installation
The control panel must not be adjacent to the plant. It can be mounted in the blower housing (supplied with
BioAir), wall mounted or fixed to the mounting frame (available separately). It should be positioned so it
cannot be reached by someone standing in or on the unit. It would be advisable to situate the control panel
and beacon in a frequently viewed position, so if a fault alarm appears it will be seen.
Mounting Frame Installation (where applicable)
Set the frame legs in a concrete base, minimum 250mm thick and prop the frame to prevent movement until
the concrete has set. Allow 350mm minimum clearance from finished ground level to the bottom of the
panel.
Installation of Integral Discharge Pump (where applicable)
Using a suitable M20 gland, feed the pump power cable through Gland Hole and terminate to connections 1
& 2 (J6) according to Figure 3 & Figure 4
Installation of High-Level Alarm –HLA (where applicable)
Fix the black plastic bracket to the side wall of the baffle (the exact position is on the drawing included with
the HLA kit). Secure the float cable in the cable gland as shown on the drawing in the HLA kit. Pull the float
cable through any installed ducting into the blower housing. Complete wiring according to Figure 3 & Figure
4.
Beacon units - P.No.1009254 (where applicable)
The Beacons provides an external visual indication which is used to indicate Failure & Service Reminders and
may be included in the Power and Pressure Failure Detection System (PPFDS). The beacon is provided with a
5m cable which can be extended to 30m. As supplied, the unit is protected against rain to IP65 and is
supplied ready to mount on a suitable surface. Complete wiring according to Figure 3 & Figure 4
This unit is designed to be simple to install and safe in operation. Any modification may adversely affect its
weather resistance in operation. If in any doubt, please consult us for advice. This is a sealed unit and not
serviceable.
Power & Pressure Failure Detection System –PPFDS (where applicable)
The panel is designed to be used in conjunction with the Beacon unit to provide warning of either loss of
power or air pressure failure. For panels mounted outside the blower housing, additional tubing can be
purchased, contact your local sales team for details. The panel can be mounted up to 30m away from the
blower with no effect on the performance of the pressure failure detection system.
Blower
Control Panel
Blower Unit
Mains Power
Entry Point
Diffuser Hose
Entry Point
Diffuser Hose
Connection Point
Ø19mm Hose Tail
Loss of Pressure
Hose

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To prevent damage to the PPFDS hole, a nylon bolt and nut are fitted. If the PPFDS is to be used, replace the
bolt with the air inlet bulkhead fitting supplied inside the control unit. A short length of 4mm silicone tubing
and a cable tie is also supplied. Connect the tubing from the bulkhead fitting to the Top Port of the pressure
switch, SW2, see Figure 5. Tie the cable tie on the pressure switch to prevent the tubing slipping off as it is
not barbed.
Figure 5: Pressure switch tubing
Completing the Installation
Complete all wiring according to Figure 4 DTP Control Panel Wiring (2). Plug the lead from the battery into
the small white socket below the battery on the PCB marked J3. After finishing wiring, replace the isolator
cover and screw. Turn the mains supply on at the source. Turn on the panel using the isolation switch. It
should now be illuminated RED. The display should now show text.
Replace the top cover and screws carefully so as not to damage buttons, ensuring the lid is fixed correctly.
Follow Guide in Section 3.3.11 Configuration Programming to enable programming.
Ancillary Equipment
Ancillary items should be installed in accordance with the Installation Guide supplied e.g. Sewage Pump
Station/Effluent Pump Station/Effluent Sample Chamber.
Configuration Programming
Start Up
When the control unit is powered up for the first time, the display will prompt for the country to be selected.
Figure 6: Keys for Configuration
Figure 6: Initialisation

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Detailed Operation
Once the initialisation is complete the operating screen will appear as follow. Page 1 to 6 can be navigated
using ◄& ►key. Current time will start from 00:00:00 after unit start / restart.
Figure 7: Main Screen Page 1
Figure 8: Main Screen Page 2
Page 3 to 6 are like the above, for Motor / Blower & Chemical Dosing Pump.
Alarms
The conditions shown below cause an alarm message to appear on the display, the beeper sounds, the
beacon flashes, and the common alarm telemetry relay is de-energised. Some alarm conditions are recorded
in the event log, along with the date and time. The display will cycle through messages if multiple alarms
exist at the same time. The alarm message(s) will disappear when the alarm condition(s) have been cleared.
•Mains failure
•Low battery
•Loss of rotation
•High level float probe
•Auxiliary input
•Blower pressure
•Pumped outlet fuse
•De-sludge pump fuse
•Motor/blower fuse
•Chemical dosing pump fuse
The beeper can be muted by pressing the ‘’ button. The beeper will sound again after SIX HOURS if any
alarm condition still exists.
Telemetry Relays Outputs
There are three volt-free contacts available for alarm reporting to external systems. Follow Guide on Figure 4
for wiring.