Wilo Wilo-Sevio AIR User manual

Wilo-Sevio AIR
Pioneering for You
6068088 Ed.0.5-11/2012 no ofcial version
de Einbau- und Betriebsanleitung
US Installation and operating instructions
hu Beépítési és üzemeltetési utasítás

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Installation and operating instructions Wilo-Sevio AIR 43
English
1. Introduction 44
1.1. About this document 44
1.2. Structure of the manual 44
1.3. Personnel qualications 44
1.4. Abbreviations 44
1.5. Illustrations 45
1.6. Copyright 45
1.7. Rights of alteration 45
1.8. Warranty 45
2. Safety 46
2.1. Instructions and safety information
47
2.2. General safety information 48
2.3. CE marking 49
2.4. Ground connection 49
2.5. Safety rules during operation 49
2.6. Liquids 49
2.7. Sound pressure 50
3. Transport and storage 50
3.1. Delivery 50
3.2. Transport 50
3.3. Storage 50
4. Product description 51
4.1. Proper use 51
4.2. Construction 51
4.3. Function 53
4.4. Technical data 53
4.5. Scope of delivery 53
5. Installation 54
5.1. General requirements 54
5.2. Types of installation 55
5.3. The operating area 55
5.4. Work steps 56
6. Start-up 63
6.1. Initial start-up 63
6.2. Before switching on 65
6.3. Starting up the aeration 65
6.4. After switching on 65
7. Shutdown/disposal 66
7.1. Temporary shutdown 66
7.2. Shutdown for maintenance work or
storage 66
7.3. Starting up again 67
7.4. Disposal 67
8. Maintenance 68
8.1. Maintenance intervals 69
8.2. Maintenance tasks 70
8.3. Repairs 71

44 WILO SE 11/2012 Ed.03 DIN A5
English INTRODUCTION
1. Introduction
1.1. About this document
The language of the original operating manual is German. All other language versions
are translations of the original German manual.
The operating manual contains a copy of the EC Declaration of Conformity.
Any unauthorized or unapproved changes made to the design specied in it will nullify
this declaration.
1.2. Structure of the manual
The manual is divided into individual sections. Each section has a heading which clearly
describes its content.
The table of contents also serves as a brief reference, since all the important sections
have their own headers.
All the important operating and safety instructions are highlighted. For detailed infor-
mation on the structure of these texts, see “Safety” in section 2.
1.3. Personnel qualications
All personnel who work on or with the product must be qualied for such work; elec-
trical work, for example, may only be carried out by a qualied electrician. All personnel
must be of legal age.
Operating and maintenance personnel must also observe national accident prevention
regulations.
It must be ensured that the personnel have read and understood the instructions in this
operating and maintenance handbook; if necessary, this manual must be ordered from
the manufacturer in the required language.
This product is not intended to be used by persons (including children) with limited
physical, sensory or mental capacities or without the relevant experience or knowledge,
unless they are supervised by a person responsible for their safety and receive instruc-
tions from this person on how to use the product.
Children must be supervised in order to ensure that they do not play with the product.
1.4. Abbreviations
• p.t.o. = please turn over
• re. = regarding
• approx. = approximately
• i.e. = that means
• incl. = including
• min. = minimum
• max. = maximum
• etc. = and so on
• s.a. = see also
• e.g. = for example

Installation and operating instructions Wilo-Sevio AIR 45
INTRODUCTION English
1.5. Illustrations
Dummies and original drawings of the products are used in the illustrations. This is the
only sensible solution given our wide range of products and the differing sizes offered
by the modular system. More exact drawings and specications can be found on the
dimension sheet, the planning information and the installation plan.
1.6. Copyright
This operation and maintenance manual has been copyrighted by the manufacturer.
The operation and maintenance handbook is intended for use by assembly, operating
and maintenance personnel. It contains technical specications and diagrams which
may not be reproduced or distributed, either completely or in part, or used for any other
purpose without the express consent of the manufacturer.
1.7. Rights of alteration
The manufacturer reserves the right to make technical alterations to systems or com-
ponents. This operating and maintenance manual refers to the product indicated on the
title page.
1.8. Warranty
This section contains the general information on the warranty. Contractual agreements
have the highest priority and are not superseded by the information in this section.
The manufacturer is obliged to correct any defects found in the products it sells, provid-
ed that the following requirements have been fullled:
1.8.1. General requirements
• The defects are caused by the materials used or the way the product was manufactured
or designed.
• The defects were reported in writing to the manufacturer within the agreed warranty
period.
• The product was used only as prescribed.
• All safety and control devices were connected and inspected by qualied personnel.
1.8.2. Warranty period
If no other provisions have been made, the warranty period covers the rst 12 months
after initial start-up or up to 18 months after the delivery date. Other agreements must
be made in writing in the order conrmation. These remain valid at least until the agreed
warranty period of the product has expired.
1.8.3. Spare parts, add-ons and modications
Only genuine spare parts from the manufacturer may be used for repairs, replacements,
add-ons and modications. These are the only parts that guarantee a long service life
and maximum safety. These parts have been specially designed for our products. Unau-

46 WILO SE 11/2012 Ed.03 DIN A5
English SAFETY
thorized add-ons and modications or the use of non-original spare parts can seriously
damage the product and injure personnel.
1.8.4. Maintenance
The prescribed maintenance and inspection work should be carried out regularly. This
work may only be carried out by qualied, trained and authorized personnel. Mainte-
nance not listed in this operation and maintenance manual, and any type of repair work
may only be performed by the manufacturer and authorized service centers.
1.8.5. Damage to the product
Damage and malfunctions that endanger safety must be eliminated immediately by
trained personnel. The product may only be operated if it is in proper working order.
During the agreed warranty period, the product may only be repaired by the manufac-
turer or an authorized service center. The manufacturer reserves the right to ask the
operator to return the damaged product to the factory for inspection.
1.8.6. Exclusion from liability
No liability will be assumed for product damage if any of the following items apply:
• The manufacturer deems that information provided by the operator or customer is
insufcient or incorrect
• Failure to observe the safety instructions, the regulations and requirements of German
law or the applicable local laws, or of this operating and maintenance manual
• Improper use
• Incorrect storage and transport
• Improper assembly or dismantling
• Insufcient maintenance
• Improper repairs
• Inadequate construction site or construction work
• Chemical, electrochemical and electrical inuences
• Wear
This means the manufacturer’s liability excludes all liability for personal, material or
nancial injury.
2. Safety
This section lists all the generally applicable safety instructions and technical informa-
tion.
All instructions and information must be observed and followed during the various
phases of the product’s life cycle (installation, operation, maintenance, transport, etc.)!
The operator is responsible for ensuring that personnel follow these instructions and
guidelines.

Installation and operating instructions Wilo-Sevio AIR 47
SAFETY English
2.1. Instructions and safety information
This manual uses instructions and safety information to prevent injury and damage to
property. To clearly identify them for personnel, the instructions and safety information
are distinguished as follows:
2.1.1. Instructions
Instructions are displayed in bold type. Instructions contain text that refers to the previ-
ous text or particular sections, or highlights short instructions.
Example:
Note that products stored with drinking water must be protected from frost.
2.1.2. Safety information
Safety information is slightly indented and displayed in bold type. It always commences
with a signal word.
Information that only refers to material damage is printed in gray, without safety sym-
bols.
Information that refers to personal injury is printed in black and is always accompa-
nied by a safety symbol. Danger, prohibition or instruction symbols are used as safety
symbols.
Example:
DANGER symbol: General hazard
DANGER symbol, for example, electrical current
PROHIBITION symbol, for example, Keep out!
INSTRUCTION symbol, for example, wear protective equipment
The safety symbols used conform to the generally valid directives and regulations, such
as DIN and ANSI.
Each safety instruction begins with one of the following signal words:
• Danger
Serious or fatal injuries can occur!

48 WILO SE 11/2012 Ed.03 DIN A5
English SAFETY
• Warning
Serious injuries can occur!
• Caution
Injuries can occur!
• Caution (instruction without symbol)
Substantial material damage can occur. Irreparable damage is possible!
Safety instructions begin with a signal word and description of the hazard, followed by
its cause and potential consequences, and end with advice on prevention.
Example:
Beware of rotating parts!
The moving impeller can crush and sever limbs. Switch off the device and let the
impeller come to a halt.
2.2. General safety information
• When installing or removing the product, never work alone in rooms and shafts. A sec-
ond person must always be present.
• Sufcient ventilation must be provided in enclosed rooms.
• When welding or working with electrical devices, make sure there is no risk of explosion.
• During work in environments hazardous to health (liquid containing fecal matter, acti-
vated sludge with bacteria, etc.), special caution is required:
• Open wounds must be immediately cleaned and treated.
• Eating and drinking are strictly prohibited.
• Proper protective equipment must be worn!
• Upon leaving the system, disinfect persons and tools.
• The product must always be switched off before any work is performed on it (assembly,
dismantling, maintenance, installation). The product must be secured against being
switched back on.
• The person operating the product must notify his or her supervisor immediately should
any defects or irregularities occur.
• Tools and other objects should be kept in a place reserved for them so that they can be
found quickly.
• Only use lashing equipment which is legally dened as such and ofcially approved.
• The lashing equipment must be kept safely and must be suitable for the conditions of
use (weather, hooking device, load, etc).
• Mobile equipment for lifting loads should be used in such a way that it always remains
stable during operation.
• When using mobile equipment for lifting non-guided loads, take action to prevent
tipping, sliding, etc.
• Measures should be taken to ensure that no person is ever directly beneath a suspended
load. Furthermore, it is also prohibited to move suspended loads over workplaces where
people are present.

Installation and operating instructions Wilo-Sevio AIR 49
SAFETY English
• If mobile equipment is used for lifting loads, a second person should be present to coor-
dinate the procedure if required (for example, if the operator’s eld of vision is blocked).
• The load to be lifted must be transported in such a manner that nobody can be injured
in the event of a power outage. Additionally, when working outdoors, such procedures
must be stopped immediately if weather conditions worsen.
These instructions must be strictly observed. Non-observance can result in injury or
substantial material damage.
2.3. CE marking
If the product is obliged to carry a CE marking,
• the marking is attached to the product and
• a copy of the EC declaration of conformity is enclosed or is part of this operating man-
ual.
2.4. Ground connection
Products with metallic and/or conductive surfaces must be grounded. If there is a pos-
sibility that people can come into contact with the product and the pumped liquid, the
connection must be additionally equipped with a residual current circuit breaker.
2.5. Safety rules during operation
When operating the product, always follow the locally applicable laws and regulations
for accident prevention and securing the worksite. To help to ensure safe working
practice, the responsibilities of employees should be clearly set out by the owner. All
personnel are responsible for ensuring that regulations are observed.
2.6. Liquids
Each liquid differs in terms of its composition, corrosiveness, abrasiveness and dry mat-
ter content, as well as in many other aspects. Generally, our products can be used for
many applications. Please note that if requirements change (density, viscosity or general
composition), this can also affect many operational parameters of the product.
When using or replacing the product in a different liquid, observe the following points:
• When used in drinking water applications, all the parts that come into contact with the
uid must be approved for use with drinking water.
Before being used in drinking water, the corresponding products must be checked to
ensure that they have been approved for such use.
• Products that have been operated in dirty waste water must be cleaned thoroughly
before being used for other liquids.
• Products that have been operated in sewage water and/or uids that are hazardous to
health must be decontaminated before being used with other liquids.
It must be claried whether the product can be used with another liquid.

50 WILO SE 11/2012 Ed.03 DIN A5
English TRANSPORT AND STORAGE
• If the product is to be used with highly ammable, explosive and/or aggressive uids,
the manufacturer must be consulted.
2.7. Sound pressure
The product itself is generally operated under water and only with air. This means that
the sound pressure cannot be measured.
However, the air is supplied using a compressor. Depending on its power and environ-
mental conditions, this compressor can have elevated sound pressure.
For this reason we recommend that the operator carry out an the additional measure-
ment in the workplace when the product is operating.
CAUTION: Wear ear protectors!
In terms of the applicable laws and regulations, ear protection must be worn if the
sound pressure is greater than 85 dB (A). The owner is responsible for ensuring
compliance with these regulations.
3. Transport and storage
3.1. Delivery
On delivery, immediately check that the product is complete and undamaged. If any
parts are damaged or missing, the transport company or the manufacturer must be no-
tied on the day of delivery. Claims made after this date cannot be recognized. Damage
to parts must be noted on the delivery or freight documentation.
3.2. Transport
Before transport, the product must be packaged in such a way that it is protected from
moisture, frost and other damage. It is important to keep the original packaging.
3.3. Storage
• The components must be stored in the original packaging.
• The store room must be dry and frost-proof. We recommend storage in a room with a
temperature between 10°C and 25°C. The temperature may not exceed +50°C.
• The product must be protected from direct sunlight, heat, dust and frost. Furthermore,
the product may not be stored in rooms where welding takes place. Heat and cold, as
well as the gas and radiation given off during welding, can damage the plastic parts.
• New disc aerators may not be stored for more than three months. If they are stored for
more than three months, there is a risk that the membranes will become porous and
leaky.

Installation and operating instructions Wilo-Sevio AIR 51
PRODUCT DESCRIPTION English
4. Product description
4.1. Proper use
The Wilo-Sevio AIR disc aerator and aerator systems are used for ne-bubble air
inclusion in liquids such as water, waste water or sludges, for the purpose of supplying
oxygen to the liquids.
The temperature of the liquid must be between +5°C and 30°C. If the products are to
be used in liquid with higher temperatures, the manufacturer must be consulted. The
surrounding liquid must also be free of objects with sharp edges. We recommend that
the liquid be pre-cleaned with a lter.
The supplied air must be free of oil, dust and solvents. Dust lters must correspond to
lter class EU4 according to DIN24185 (degree of separation >90%).
All lters and insulating materials in use may not be made of berglass, mineral bers or
other materials consisting of ne bers. Rotary slide valves with graphite ns must be
equipped with an air lter on the pressure side.
These materials can lead to clogging of or damage to the membranes.
4.2. Construction
A Wilo-Sevio AIR aerator system consists of one or more aerator groups. An aerator
group forms the base unit and consists of several components:
Fig. 1.: Aerator system component overview
1Air distributor with connecting ange for
the intake line (down pipe) 6Disc aerators
2Base support for air distributor 7 Basin bottom
3Intake line (down pipe); must be installed
by the customer. 8Pipe coupling for connecting the individ-
ual components
4Aerator pipe with pre-assembled disc
aerators 9 Drainage connection
5Base support for aerator pipe 10 Drainage line; must be installed by the
customer.
4.2.1. Piping
The pipes are pre-fabricated in components that can be easily used:
• PVC air distributors in the diameters of 90mm, 160mm and 200mm with central or
lateral DN80 to DN200 ange connection for the intake line. Larger diameters are
available in stainless steel with DN125 to DN350 ange connections.
• PVC aerator pipes with 90mm external diameter or made from stainless steel with
88.9mm external diameter with pre-assembled disc aerator

52 WILO SE 11/2012 Ed.03 DIN A5
English PRODUCT DESCRIPTION
• Drainage connection as the terminating connection of all aerator pipes with a connec-
tion for the drainage line. This can be used to drain off the condensate that can form
during aeration.
• Pipe coupling with rubber ring seal as a plug connection for connecting the individual
PVC components. The pipe coupling for securing the aerator pipes on the air distributor
must also be equipped with a stainless steel clamping ring.
4.2.2. Base support
All pipes on the basin bottom are secured by the base supports. They also make it pos-
sible to level the aerator group.
There are two different base supports:
• For securing the stainless steel air distributor
• For securing the aerator pipes and the PVC drainage connection
4.2.3. Disc aerators
The disc aerators introduce the supplied air into the liquid. The air is distributed across
the entire membrane surface and released through the perforated membrane. The disc
aerator consists of several components.
Fig. 2.: Disc aerator component overview
1Threaded ring 5Non-return valve
2Separation ring 6Aerator housing
3 Membrane 7 O ring
4 Membrane support 8Slide closure
• Fiberglass-reinforced plastic threaded ring for securing the membrane to the membrane
support. The threaded ring and aerator housing are matched to each other in such a
way that the threaded ring can be easily loosened even after years of use, allowing the
membrane to be replaced.
• The polyacetal separation ring prevents the membrane from sticking to the threaded
ring. This ensures that the membrane can be easily replaced.
• The EPDM membrane with perforations across its entire surface for optimal air inclusion.
• Fiberglass-reinforced plastic membrane support, which holds the membrane in place.
• The EPDM non-return valve protects the aerator system from penetration of the liquid if
the membrane is defective.
• Fiberglass-reinforced plastic aerator housing with integrated anti-rotation lock
• NBR O ring for sealing the disc aerator against the aerator pipe
• Fiberglass-reinforced sliding closure for easy installation and removal of the disc aerator

Installation and operating instructions Wilo-Sevio AIR 53
PRODUCT DESCRIPTION English
4.3. Function
A blower or compressor is used to pump air through the intake line into the air distrib-
utor. The air is evenly distributed into the aerator pipes through the air distributor and
fed to the disc aerators. The disc aerators distribute the air across the entire membrane
surface and introduce this air into the liquid.
4.4. Technical data
• Disc aerators
• External diameter: 280mm
• Membrane diameter: 237mm
• Membrane surface: 0.044m²
• Oxygen utilization: 6.5 ... 8.5%/m
• Size of the air bubbles: 1–3mm
• Pressure loss: 22 ... 43mbar
• Connection size: 88.9 ... 90mm
• Max. air temperature in the system / disc aerator: 100°C
• Pressurization range
• Air volume range: 1–8Nm³/h*
• Min. pressurization: 1.5Nm³/h*
• Standard pressurization: 4.0Nm³/h*
• Max. pressurization: 6.0Nm³/h*
Pressurization of 7.5Nm³/h* is possible for a brief period (no more than 15 minutes).
*The values for the pressurization apply to standardized conditions: 0°C and 1013hPa.
4.5. Scope of delivery
The scope of delivery differs according to whether a complete aerator system or only
disc aerators (with the pipes provided by the customer) were ordered.
4.5.1. “Aerator system” scope of delivery
• Air distributor with ange connection for intake line
• Aerator pipes with pre-assembled disc aerator
• Drainage connection
• Pipe connections
• Base support
• Fastening material
• Drilling plan for the base supports
• Overview and position diagram of the individual components
• Special key for easy installation/removal of the threaded ring on the disc aerator
• Rubber mallet
4.5.2. “Disc aerator” scope of delivery
• Disc aerators
• Drilling plan for the connection holes on the pipes for the disc aerators

54 WILO SE 11/2012 Ed.03 DIN A5
English INSTALLATION
4.5.3. Material to be provided by the customer
• Intake line for the air supply
• Blower or compressor
• Drainage line with shut-off valve
• All pipes if only disc aerators were ordered
5. Installation
In order to prevent damage to the product or serious injury during installation, the
following points must be observed:
• Installation work – assembly and installation of the machine – may only be carried out
by qualied persons. The safety instructions must be followed at all times.
• The machine must be inspected for transport damage before carrying out any installa-
tion work.
5.1. General requirements
For planning and operation of technical waste water systems, pay attention to the per-
tinent local regulations and directives for wastewater technology (such as those of the
German Association for Water, Wastewater and Waste).
The following information must be observed when installing the product:
• This work must be carried out by qualied personnel.
• Check that the available planning documentation (installation plans, layout of the oper-
ating area, drilling plan) is complete and correct.
• Observe all regulations, rules and legal requirements for working with and underneath
heavy suspended loads.
• Wear appropriate protective equipment.
• During all work, a second person must always be present. If there is a risk of poisonous
or asphyxiating gases forming, the necessary precautions must be taken.
• Please also observe the applicable national accident prevention regulations and trade
association safety provisions.
DANGER of falling!
Work may be necessary directly at the edge of the shaft and/or basin during instal-
lation. Carelessness or wearing inappropriate clothing could result in a fall. There is
a risk of fatal injury! Take all necessary safety precautions to prevent this.