Outdoor Water Solutions AerMaster DW 7 User manual

AERMASTER ULTIMATE SOLAR AERATOR
DW 7- DW 93/4HP COMPRESSOR

Shipment Delivery Inspection
The aerator unit was properly packaged, secured and accepted by the freight company prior to
shipment. It is the freight company’s responsibility to deliver without damage.
Apparent Damage or Loss
Upon delivery if the equipment or pallet indicates Damage in Transit, such goods should be
refused until freight company agent has been contacted.
Aeration unit pallet contents
•Solar panels
•Cabinet with instructions
•Diffusers (optional)
•Solar Racking with separate instructions
Important Safety Instructions:
•Reduce risk of bodily injury when handling bulky and/or heavy components by using a 2-
person
installation team. A second person should help to lift and handle these components.
•DANGER: RISK OF ELECTRIC SHOCK! DO NOT TOUCH ANY UNINSULATED
PARTS OF THE SOLAR PANEL, OUTPUT WIRING CONNECTED TO THE SOLAR
PANEL OR INSIDE BLACK ELECTRICAL BOX LOCATED IN THE CABINET.
•The solar panel can develop voltages greater than 42V DC, which poses a shock and/or
electrocution hazard. Outdoor Water Solutions recommends wearing electrically non-
conductive gloves when handling the Solar Panel’s output leads.
•To avoid shorting, the Solar Panel’s output does not cross a conductive object such as a
screw driver shaft.
•Install panel and wiring during DRY weather conditions. Never install system while the
weather is raining or in any way, precipitating.
Warnings:
•When preforming ANY maintenance or cleaning on solar panels or cabinet, the system
must be turned
off by the toggle switch located inside the cabinet.
•HIGH WIND AREA: Mount solar panels closer to ground to eliminate flexing of
panels and pole. Clear area from any trees/shrubs obstructing solar panels.
OWS AerMaster Ultimate Solar Aerator
Installation Manual

•Monitor the panels. You don't need to do anything, but keep an eye on them. Make sure
your diffusers are producing water movement on the pond surface at clear sun peak.
•Keep the panels out of the shade. While you're at it, make sure that there are no new
shade issues that weren't there when the system was installed. We here at Outdoor
Water Solutions would never suggest you cut down a tree, but you may need to trim
them back. Shade on solar panels actually works exponentially, not proportionally, to
reduce panel output. So if 1/4 of the panel is shaded, you're not losing 1/4 of the output
for that panel, you're likely losing more than half.
How much sun is required
One common source of confusion with regards to solar powered aerators is the question of how
much sun is
required to successfully power the aerator? Does it have to be perfectly sunny? What if a cloud
blocks the sun? The answer is... it depends. The sun's energy varies throughout the day and at
some point in the day (usually around 12pm), the sun will reach its peak intensity. If it's a clear
day (i.e. no clouds), this is the point at which a solar powered aerator will reach its peak output.
As the day progresses and the sun gets lower in the sky, the power output of a solar panel will
naturally decrease until dark at which point power output will halt altogether. In the same way,
anything that obstructs the sun during the day, such as clouds, trees and buildings, will also have
an effect on the output of the panel. For example, if the sun is obstructed by some light cloud
cover, it is still possible, depending on the time of day, to achieve greater than 50% of the solar
devices direct-solar output. In terms of an aeration system, that means you could still achieve a
reasonable flow rate as long as the clouds don't get too thick, or the sun isn't too low in the sky.

Solar Panels Wired in Series-(amount of panels may vary)
When solar panels are wired in series, the positive terminal of one solar panel is wired to the
negative terminal of the next solar panel. When panels are connected in series:
•Voltage accumulates (adds) for each panel in series.
•Wattage accumulates (adds) for each panel in series.
Current (Amps) remains the same as a single panel in the series
Grounding System
System comes with grounding clamp. Attach ground clamp to solar panel pole see photo below.

Installation Instructions:
Attach your airline to each of the airlines exiting the AerMaster cabinet. Run each airline out to
the place in the pond where you want your diffuser and attach your diffuser. For diffusers with a
base, lower the diffuser down to the bottom of the pond. Using a rope can help to keep the
diffuser and base upright. You don’t have to tie the rope on, just fold the rope in half, lower the
diffuser, then pull the rope up by pulling on one half.
If your diffuser does not have a base (rubber membrane diffuser or ceramic air stone), then
inserting the diffuser into a bucket can help keep it out of the mud and muck on the bottom.
Adding 3-5 lbs. of sand or rock to the bottom of the bucket prior to inserting your diffuser helps
sink and stabilize your bucket. Note: Teflon tape is recommended, but not required for
threaded connections. If you have a rubber membrane diffuser with the airline coming off
of the side, you can drill a hole in the side of the bucket and run your airline thru the side.
We also suggest installing your diffuser into the deep part of the pond to ensure complete
circulation of your water. The exception to this would be if you’re wanting to keep the water
open for watering livestock in the winter, then you can put the diffuser closer to the shoreline (or
move it there in the fall). You can also place the diffuser in a more shallow area if you are in a
northern climate and have trout, walleye, Northern pike or Muskie in the pond and want the deep
parts of the pond to remain colder in the summer months.
The use of OWS Weighted Air Line will help keep the airline submerged and on the bottom of
the pond. In the absence of using weighted airline, tie rebar, bricks, blocks, etc. to non-weighted
airline to help keep it submerged.
Note: Air will travel to the point of least resistance or to the shallow diffusers first. Adjusting
the airflow so that it goes to the deepest diffusers is usually required.
First time start up
System comes from OWS with the system OFF.
#1 After aeration system is completely installed and panels are connected.
On the yellow box unscrew (4) flat head screws removing cover on yellow box.
#2 Once cover is removed turn toggle switch to the ON position. (Do not
change any factory settings). Lights will turn on at the front of the yellow box.

Troubleshooting-
To reset the unit see toggle switch inside yellow box unscrew (4) flat head screws
removing cover on yellow box. After cover is removed you will need to reset to
OFF then ON. After toggle switch is reset, turn breaker to On position.
Toggle Switch

Troubleshooting - Indicator Lights There are three LED lights on the yellow controller. The
indicator lights and recommended corrective actions are listed below.
AC Power SOLAR WARNING Mode/Issue
ON ON ON -Unit is OFF
FLASHING OFF OFF - Startup
ON OFF OFF - Running
OFF FLASHING OFF - Standby
OFF OFF ON - Over temperature
ON OFF ON - Power deration
FLASHING OFF FLASHING - Over current
OFF FLASHING FLASHING - Short/Open circuit
FLASHING FLASHING FLASHING - Dry well protection

Maintenance
Compressor Routine Maintenance
System should be checked on a regular basis. Suggested every other week check boils in
lake. Once a month clear any grass or weed debris from around cabinet. When compressor has a
loss of compression. The boils “Bubbles” in the lake will be not as visible or the boil area
becomes smaller from shore. At this time the compressor will need a piston maintenance kit. The
kit includes all new seals, flapper valves and piston rings.
Safety first – follow the system on/off procedure in your manual for shutting down the system
before
commencing cleaning.
Cabinet care- Twice a year check the interior cabinet for outside debris and remove if any.
Solar Panel Maintenance
For safety reasons, it’s also wise to clean your panels from the ground if possible. A good quality
soft brush
and a squeegee with a plastic blade on one side and a cloth covered sponge on the other coupled
with a long extension can make for the perfect tool allowing you to stay on the ground. Use a
hose with a suitable nozzle to allow the stream of water to reach the panels.
What to look for when cleaning: Dust, bird droppings, pollution, pollen, tree sap, plant matter
residue, etc., all
reduce the overall effectiveness of solar panel generation capacity. Panels must be cleaned
regularly to maximize system performance and longevity.
When to clean solar panels: Clean your panels on an overcast day, early in the morning or in the
evening. If the
sun is beating down on the panels, any water used can quickly evaporate and dirt will become
smeared. Early morning can be a particularly good time for cleaning as dew that has settled on
the panels overnight will likely have softened grime; meaning you’ll need to use less water and
less energy to clean your solar panels. If the panels are dry, before tackling the modules with
water, brush off any loose materials first – this will make cleaning easier and faster.
Solar panel cleaning warning: DO NOT use common car-wash soaps and window cleaners
which contain
alkalines that promote oxidation and require a deionized water rinse. Never use an abrasive
soap or a cleaning sponge - the goal is to get the glass as clean and clear as possible and you
don't want to scratch it. Outdoor Water Solutions recommends to use warm water and
dishwashing soap.
Drying solar panels after washing: Dry solar panels with a towel making sure the towel does not
scratch the panels. A chamois that you would use for your car is a good choice.

Air Filter replacement/Cleaning
Air filter replacement or cleaning: Unplug system from power source. Remove
compressor air intake filter and wash with soap and water or replace with new filter cartridge.
Washing or replacing should be completed 2-4 times per year. Ideally every three months for
changing filter and cleaning inside of cabinet. Do not reinstall a wet or damp filter cartridge.
Twist to unlock
Remove top of filter housing
Line the notches twist and lock clean or replace

Repair Kit Instructions
1.
3.
4.
2.
*Repair kit contents may vary depending on your
compressor.
5.
WARNING: Electrical shock hazard. Disconnect electrical
supply before performing maintenance. Vent all air lines to
release vacuum or pressure. Failure to follow these instructions may result
in death, fire or electrical shock.
WARNING: Injury hazard. Product surfaces become very hot during
operation, allow surfaces to cool before handling.
WARNING: Do not use oil to lubricate parts. Compressors use an oil
less design. Using oil may result in failure of the unit.
Before beginning, you willneed:
1. T15 and T25 Torx driver
2. Torque driver
3. Utillity knife
4. Clean work space
1.
2.
3.
Remove screws from the head of
compres- sor using T25 Torx driver,
remove the head
Mark the orientation of head
plate(s) and re- move. Mark the
orientation of valve plate(s),
remove valve plate(s). Clean valve
plates with water based solvent,
Remove old cylinders and
discard.
4.
Remove screws from cup retainer
plate with T15 Torx driver. Discard
old cups and retainer screws.
5.
Set new cylinder(s) on
piston(s).
6.
Remove new piston cup(s) from
protective cardboard packaging.
Set new piston cups ontoretainer
A
AA

7.
Press retainer plate with piston
cup into cylinder all the way to the
piston. The cylinder can be rotated
to align the screw holes. Apply
thread locking compound (Loctite
®
222) to retainer screws, torque
screws to 10-13 inch-pounds.
9.
Inspect the leaf valves for damage
or wear. NOTE: There is one
intentionally “bent” leaf valve per
set. If leaf valves need to be
replaced, a complete leaf valve
8.
Remove the cylinder o-ring(s) from
the bot- tom of valve plate(s) and
install new o-rings.
11.
Remove old and install new
head o-rings in the o-ring grooves
on top of valve plate
12.
Reinstall head over valve plate(s)
checking that orientation with ports
is correct. Torque screws to 50 inch
-
pounds
10.
Check that orientation of the valve
plate(s) with ports is correct and
place over cylinders.
Check that all external accessories such as relief valves and gauges are not damaged before re-operating product.
Unit must be unplugged
before servicing
13. Beforeputtingtheunitbackintoserviceitshouldberunforfiveminutesandthecylinderhead
screwsshouldbecheckedfor tightness. If these screws come loose during operation the unit will
experience extensive damage and voids the warranty of the unit.
• Install the air intake filter into inlet port and leave outlet port open. It is not necessary to
connect outlet plumbing connections at this point.
• Pluginunitandrunforfiveminuteslisteningforanyoddnoisesorclickingsounds.Ifanyof
thesenoisesareheard,unplugunit immediately.
• After running for five minutes, remove head and valve plate and check the cylinder head
screws. Tighten the screws to 10-13 inch-pounds and reassemble valve plate and head to put unit
back into service.

Rebuild kit for piston compressor
In normal continuous year-round usage, the compressor piston cups typically last 24-
36 months. As the piston cups wear out you will notice a drop in airflow resulting in a
smaller surface boil at the diffuser. At this time complete a rebuild piston kit and replace or
clean filter element.
Note: The compressor has working parts that must be serviced. By scheduling routine
maintenance this will increase the life of your compressor.
The Outdoor Water Solutions Limited Warranty
This warranty covers all AerMaster aeration systems from purchase date against defects in workmanship.
1. Outdoor Water Solutions, Inc. (OWS) will replace or repair any part deemed to be defective
by Outdoor Water Solutions, Inc., due to defects in quality and/or workmanship Note:
Wearable parts are considered routine maintenance.
2. Warranty does not apply to OWS products which were installed incorrectly, subject to an
accident or neglect.
3. Product returned must have a return merchandise authorization number. Warranty repair
must be returned to the address specified by the Manufacturer freight prepaid, and any
warranty product sent to the customer will be sent freight prepaid;
4. Warranty coverage may be void if parts other than genuine Outdoor Water Solutions parts
are utilized for repair or attached to an Outdoor Water Solutions Aeration system.
5. Proof of purchase date is required for warranty repairs.
6. If you have any warranty concerns, please contact Outdoor Water Solutions Windmills Inc.
at 1-866-471-1614 in Canada or USA. International customers can call 1-479-756-1614
with any warranty concerns.
Return Materials Authorization
•A return materials authorization (RMA) number must be obtained prior to returning any product
for warranty work.
•You can call the Outdoor Water Solutions warranty department at the following numbers:
oCanada and USA – 1-866-471-1614
oInternational (outside Canada and USA) –1-479-756-1614
Note: Serial Numbers are located under the top plate so they are protected from weather.
Outdoor Water Solutions Inc. recommends that, for future reference,
you should keep this Installation Manual in a convenient location.
Serial number: _______________ Date of Purchase: __________________

Troubleshooting Guide
Problem What to look for Usual Cause How to Correct Problem
Compressor shakes
erratically and makes
unusual noises
Check for low voltage
while compressor is
under load
Gauge of supplied
wires to circuit
possibly undersized or
cabinet is plugged into
extension cord
If the gauge of wire is
incorrect, have an
electrician correct.
NEVER use an extension
cord to operate system
Evaluate intake filter for
blocked or clogged
silencer tube in top of
filter housing
Filter needs to be
replaced or blockage in
silencer tube in filter
housing
Clean or replace filter
never use a wet filter.
Remove any debris that
maybe clogging silencer
tuber
Compressor stops
working for periods of
time, then restarts
Inspect cabinet cooling
fan for proper function
Compressor
overheating from non-
working fan
Contact Outdoor Water
Solutions or your local
dealer. Leave lid open if
possible if not unplug
system until fan is replaced
No bubbles from any
diffuser or airstone, but
compressor and fan are
running
Check for air leaks,
Compressor is running
louder and excessive
vibration
Compressor intake
filter is dirty/clogged
or silencer tube is
blocked
Clean or replace filter.
Compressor operating
normally or making
usual noises. Reduced
pressure/ airflow
Compressor needs
pistons rebuild kit and
new intake filter
Contact Outdoor Water
Solutions or your local
dealer
No bubbles at one or
more diffuser or airstone,
compressor and fan are
running
Are all valves in cabinet
wide open?
Improper balancing of
airstones or diffusers
Adjust valves on manifold
in cabinet until all diffuser
or airstones operate
properly
Valves in cabinet
manifold properly
balanced and no leaks.
Compressor is
beginning to lose
compression and needs
a rebuild kit.
Contact Outdoor Water
Solutions or your local
dealer
Part Reordering
OWS Part # OWS Description Quantity
EAU0393 Large washable Filter 1
EAU0395 Pack of 6 Large washable filters 1
EAU0405 Compressor repair/maintenance kit 1