Xylem Sanitaire Silver Series User manual

Installation, Operation,
and Maintenance Manual
Sanitaire, Silver Series

Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.2 Safety terminology and symbols........................................................................................3
1.3 User safety.............................................................................................................................4
1.4 Special hazards.....................................................................................................................4
1.5 Protecting the environment................................................................................................6
1.6 Spare parts............................................................................................................................6
1.7 Warranty................................................................................................................................6
2 Transportation and Storage...................................................................................................... 7
2.1 Inspect the delivery..............................................................................................................7
2.1.1 Inspect the package..................................................................................................... 7
2.1.2 Inspect the product...................................................................................................... 7
2.2 Transportation guidelines...................................................................................................7
2.2.1 Lifting..............................................................................................................................7
2.3 Storage guidelines...............................................................................................................8
2.3.1 Dry storage location..................................................................................................... 8
2.3.2 Specific storage requirements.................................................................................... 9
3 System Description.................................................................................................................. 10
3.1 Diffuser design................................................................................................................... 10
4 Installation................................................................................................................................. 11
4.1 Precautions......................................................................................................................... 11
4.1.1 Leveling guidelines.................................................................................................... 11
4.2 Support types..................................................................................................................... 11
4.3 Dropleg and manifold installation...................................................................................12
4.3.1 Lay out the manifold centerline................................................................................ 13
4.3.2 Lay out the manifold support locations................................................................... 14
4.3.3 Install the manifold anchors and supports ............................................................. 15
4.3.4 Assemble the manifold pipe sections......................................................................17
4.3.5 Install the lower dropleg............................................................................................19
4.4 Air distributor installation................................................................................................. 21
4.4.1 Lay out the air distributor support locations........................................................... 21
4.4.2 Install the air distributor anchors and supports...................................................... 22
4.4.3 Assemble an air distributor section..........................................................................23
4.5 Drainline installation..........................................................................................................28
4.6 Purge system installation.................................................................................................. 28
4.6.1 Install a manual purge system...................................................................................28
4.6.2 Install a continuous purge system............................................................................ 29
4.7 Diffuser installation............................................................................................................ 30
4.7.1 Install the diffusers......................................................................................................30
4.7.2 Plug blank holders......................................................................................................31
4.7.3 Install pre-assembled diffusers................................................................................. 32
4.8 Tank storage.......................................................................................................................33
4.8.1 Store in tank when air and water is available.......................................................... 33
4.8.2 Store in tank without air, removed diffusers............................................................34
4.8.3 Store in tank without air, with diffusers.................................................................... 34
4.8.4 Store in tank with neither air nor water.................................................................... 34
Table of Contents
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 1

5 Operation.................................................................................................................................. 35
5.1 Precautions......................................................................................................................... 35
5.2 Start the system..................................................................................................................35
6 Maintenance..............................................................................................................................38
6.1 Precautions......................................................................................................................... 38
6.2 Preventive maintenance....................................................................................................38
6.2.1 Moisture purging........................................................................................................ 38
6.2.2 Air bumping................................................................................................................ 39
6.2.3 Power failure and loss of air supply..........................................................................39
6.2.4 Visual inspection......................................................................................................... 39
6.3 Recurrent maintenance.....................................................................................................39
6.4 Diffuser cleaning................................................................................................................ 39
6.4.1 Clean the diffusers......................................................................................................39
6.5 Manifold repair...................................................................................................................40
6.5.1 Replace a saddle.........................................................................................................40
6.5.2 Repair a minor leak.....................................................................................................41
6.5.3 Replace a cracked manifold pipe section................................................................42
6.5.4 Align an air distributor connection...........................................................................43
6.6 Air distributor repair..........................................................................................................44
6.6.1 Replace an air distributor end...................................................................................44
6.6.2 Replace a spline coupling retainer ring...................................................................46
6.6.3 Replace a holder.........................................................................................................46
6.6.4 Refit a holder............................................................................................................... 47
6.6.5 Reroute an air distributor section............................................................................. 47
7 Troubleshooting....................................................................................................................... 49
7.1 Operational troubleshooting........................................................................................... 49
7.2 Diffuser fouling...................................................................................................................49
8 Technical Reference.................................................................................................................51
8.1 Operational limits.............................................................................................................. 51
8.2 Application limits............................................................................................................... 51
8.3 Maximum piping temperature......................................................................................... 51
Table of Contents
2 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide necessary information for working with the unit.
Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the
unit.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment and the
surroundings. This includes any modification to the equipment or use of parts not
provided by Xylem. If there is a question regarding the intended use of the equipment,
please contact a Xylem representative before proceeding.
Other manuals
See also the safety requirements and information in the original manufacturer's manuals
for any other equipment furnished separately for use in this system.
1.2 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
WARNING:
A hazardous situation which, if not avoided, could result
in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result
in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
1 Introduction and Safety
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 3

Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical Hazard: CAUTION:
1.3 User safety
All regulations, codes, and health and safety directives must be observed.
The site
• Observe lockout/tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by
the site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves
and shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.
1.4 Special hazards
Confined spaces
DANGER: Inhalation Hazard
The chamber or tank where the equipment is installed should be treated as a confined
space. Always follow the applicable safety laws, regulations and guidelines for confined
spaces.
Never work alone in a confined space. Before entering the space, check that the following
requirements are complied with:
• The atmosphere contains sufficient oxygen
• The atmosphere contains no explosive or toxic gases
• If there is a risk of insufficient oxygen or toxic or hazardous gases, then use an airline
respirator or self-contained breathing apparatus.
• All energy sources are locked out and tagged out
• Adequate ventilation is in place
• There is a clear path of retreat
• Monitoring is in place for hazards which can develop after entering the confined space
• The applicable safety laws, regulations, and guidelines for enclosed spaces are
understood and followed.
Drowning
Spaces that are not fully drained or dry can pose a risk of drowning. It takes relatively little
standing water or other liquid to create a drowning hazard. For example, insufficient
oxygen or the presence of a toxic material can make a worker unconscious, which makes
1 Introduction and Safety
4 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

them vulnerable to drowning if they fall face down into a small pool of water. Never work
alone where there is a risk of drowning.
Working with solvents
WARNING: Explosion/Fire Hazard
Before starting any permit-required hot work such as welding, gas cutting, grinding, or
using electrical handtools, do the following: 1. Check the explosion risk. 2. Provide
sufficient ventilation.
CAUTION: Chemical Hazard
Contact the supplier for information for proper handling and use.
Be aware of changing conditions when using solvents. Follow all health and safety rules
and local codes and ordinances.
Organic dust
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
When performing maintenance on the product inside or close to the tank or pit where the
product is used, workers may be exposed to organic dust contaminated with
microorganisms.
Employers and workers can minimize the risks of exposure to organic dust by taking the
following precautions:
• Be aware of the adverse health effects of breathing organic dust.
• Use engineering controls such as local exhaust ventilation, and wet methods of dust
suppression to minimize exposure to organic dust.
• Use appropriate respirators when exposure to organic dust cannot be avoided.
• Follow all health and safety rules and local codes and ordinances.
Biological hazards
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
• Make sure that all personnel who may come into contact with biological hazards are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in
eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1 Introduction and Safety
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 5

Condition Action
Chemicals or hazardous fluids on
skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.5 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless
Xylem has been informed and appropriate actions have been agreed upon.
1.6 Spare parts
CAUTION:
Only use the manufacturer’s original spare parts to replace any worn or faulty
components. The use of unsuitable spare parts may cause malfunctions, damage, and
injuries as well as void the warranty.
1.7 Warranty
For information about warranty, see the sales contract.
1 Introduction and Safety
6 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

2 Transportation and Storage
2.1 Inspect the delivery
2.1.1 Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.1.2 Inspect the product
1. Inspect the product to determine if any parts have been damaged or are missing.
2. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
3. Contact your sales representative if anything is out of order.
2.2 Transportation guidelines
Precautions
DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before
servicing to prevent unexpected startup. Failure to do so could result in death or serious
injury.
2.2.1 Lifting
Lifting equipment is always required when handling the shipment. The equipment
components can be lifted with either a crane or a forklift.
WARNING: Crush Hazard
1) Always lift the unit by its designated lifting points. 2) Use suitable lifting equipment and
ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4)
Stay clear of cables and suspended loads.
Lifting with crane
Cranes used to lift the equipment components must fulfill the following requirements:
• The lifting equipment must be able to hoist the equipment components straight up
and down, preferably without the need for resetting the lifting hook.
• The lifting strap must be fastened to the lifting points on top of the package.
2 Transportation and Storage
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 7

1
3
2
WS000152B
1. Lifting point
2. Minimum 2 m (6 ft 7 in.)
3. Lifting device
Figure 1: Lifting points
1. Check that the site where the equipment components will be placed has a clean and
level surface.
2. Fasten a suitable lifting strap or sling to the lifting points on top of the pallet, if used.
3. If the equipment components are secured to the flatbed or other surface, then cut the
transportation straps.
4. Lift using proper lifting equipment.
5. Place the equipment components on a clean, rigid, horizontal surface so that they
cannot fall over.
Lifting with pallet and forklift
WS003729A
1. Align the forklift prongs with the forklift hole(s), and insert the prongs.
2. If the pallet is secured to the flatbed or other surface, then cut the transportation
straps.
3. Lift the pallet and move it to its new position.
4. Place the pallet on a clean, rigid, horizontal surface so that it cannot fall over.
2.3 Storage guidelines
2.3.1 Dry storage location
The storage site must be available before equipment arrival. The equipment must be
stored in a level and dry location free from heat and dirt. It is recommended that the
equipment is stored indoors or in a covered area.
NOTICE:
Do not cover the pipe components with plastic. Excessive heat build-up can damage
plastic pipes and void the warranty.
2 Transportation and Storage
8 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

NOTICE:
Do not stack shipping units.
NOTICE:
Do not place heavy weights on the packed product.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Risk of wear. Make sure the equipment is clean before it is placed into service.
2.3.2 Specific storage requirements
Component Storage
Diffusers • Original packaging until final installation
PVC piping • Uncovered
• Maximum stack of two bundles
PVC piping with diffusers installed (pre-mounted) • Uncovered
• A sheet of wood placed on top of the piping bundles
To keep membrane diffusers shielded from the
elements
Wooden crates • Uncovered
• Maximum stack of two crates
Cardboard boxes • Uncovered
• Unstacked
• Dry location
The cardboard box pallets can loose structure
integrity and topple if they get wet
For more information on long-term storage of installed equipment, see Tank storage
(page 33).
2 Transportation and Storage
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 9

3 System Description
Diffusers included
Type Model
Fine bubble Silver Series II LP, 7 and 9 in.
Silver Series II, 7 and 9 in.
3.1 Diffuser design
Fine bubble disc diffusers are designed for an efficient and reliable aeration and mixing
process of industrial and municipal wastewater. The fine bubble diffuser is completely
compatible with other Sanitaire aeration equipment.
Intended use
The product is only for use with municipal and industrial wastewater. If there is a question
regarding the intended use of the equipment, then contact a sales representative.
Definition of system components
The main components in an aeration system are shown in the figure below.
1
2
3
4
5
6
7
WS003581A
Position
number
Description Definition
1 Blower The device that distributes the air to the air main.
2 Air main The pipe that connects the blower to the upper dropleg.
3 Dropleg The pipe that connects the air main to the manifold.
4 Manifold The pipe that connects the dropleg to the air distributor. There are no diffuser connectors mounted on this pipe.
5 Air distributor A set of pipes, couplings, and holders with diffusers from the manifold to the end cap.
6 Holder with
diffuser
The diffuser is attached to the holder. It forms part of the air distributor, and distributes the air to the liquid.
3 System Description
10 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

4 Installation
4.1 Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and
Safety (page 3) have been read and understood.
Requirements
The following requirements apply:
• Never work alone.
• Make sure to have a clear path of retreat.
• Make sure that the work area is properly ventilated.
• Provide a suitable barrier around the work area, for example a guard rail.
• Check the explosion risk before you weld or use electrical hand tools.
• Ensure that welding or construction work does not damage the aeration system
equipment.
• Use the installation drawings, containing the required part number designation, in
order to ensure proper installation.
• Remove all debris from the air main before installation.
The figures in the instructions can differ from the delivered products.
4.1.1 Leveling guidelines
To ensure an installation where maximum system efficiency is obtained, and where leaks,
adjustments, and damage to products are minimized, follow these guidelines:
• Always use the highest point of the tank floor as a reference when leveling. The height
of the grid should be as low as possible at this point.
• Use a level system which ensures installation within the given tolerance (6 mm [¼ in.]
horizontally).
• Allow for movement of the pipes when securing the clamps.
• Align pipes correctly before couplings are assembled.
4.2 Support types
There are three types of supports:
• Single anchor support that is used for 110 mm (4 in) diameter manifolds or air
distributors.
• Support with strut that is used for 160 mm (6 in) diameter or greater manifolds where
the manifold centerline elevation is less than 559 mm (22 in) from the floor.
• Support with strut that is used for 160 mm (6 in) diameter or greater where the
manifold centerline elevation is above 559 mm (22 in) from the floor.
WS002660A
Figure 2: Single anchor support
4 Installation
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 11

WS007948B
Figure 3: Support with strut, low
WS007949A
Figure 4: Support with strut, high
4.3 Dropleg and manifold installation
Prerequisites
• Always use the highest point of the tank floor as a reference when leveling.
• Ensure that the air filtration equipment is installed and operating.
• Ensure that all dirt and debris are removed from the air main.
If air blowers are used, then follow the instructions from the manufacturer. Blowers can
require a minimum back pressure when operating.
Upper dropleg connection requirement
1
2
WS000153A
1. Air main
2. Upper dropleg
Figure 5: Vertical flange connection
WS000296A
1
2
1. Air main
2. Upper dropleg
Figure 6: Horizontal flange connection
Ensure that the upper dropleg is attached to the air main, and vertical to its centerline.
Refer to the installation drawings. In order to allow easy installation of the lower dropleg,
the dropleg must be attached loosely.
• If the dropleg is connected with a vertical flange, then ensure that it can be swung to
the side.
• If the dropleg is connected with a horizontal flange, then ensure that it can be easily
removed.
Ensure that the end plugs of the upperdroplegs are removed.
4 Installation
12 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

Installation procedure overview
WS003553A
The manifold installation includes the following steps:
•Lay out the manifold centerline (page 13)
•Lay out the manifold support locations (page 14)
•Install the manifold anchors and supports (page 15)
•Assemble the manifold pipe sections (page 17)
•Install the lower dropleg (page 19)
4.3.1 Lay out the manifold centerline
The dropleg connection to the manifold is located directly under the dropleg. In some
installations, the dropleg connection is offset.
4 Installation
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 13

1
2
WS003554B
1. In-line manifold
2. Offset manifold
1. Locate the centerline of the manifold.
Use the installed upper dropleg and the installation drawings.
2. Mark clearly the position on the floor.
4.3.2 Lay out the manifold support locations
WS003555A
1. Locate and layout all manifold support locations.
4 Installation
14 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

Use the installation drawings and shippings lists.
2. Mark clearly the positions on the floor.
4.3.3 Install the manifold anchors and supports
The manifold sections must be placed according to the manifold and anchor layout
before the anchors are installed.
Always use the highest point of the tank floor as a reference when leveling.
1. Lower the manifold sections into the tank.
2. Place the sections according to the layout and double check for possible interference.
Use the reference numbers from the installation drawings to identify the pipe sections.
3. Check, and if necessary, correct the positions of the support anchors.
Consider the offset from the anchor position to the center line of the support, and
install all supports in the same direction.
Ensure that the maximum support spacing does not exceed 2400 mm or 8 ft.
WS003556D
70 mm (2 3/4 in)
4. Install the manifold support anchors according to the instructions from the
manufacturer.
The threaded projection from the floor level must correspond to the installation
drawing anchor table.
4 Installation
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 15

WS003548C
The tightening torque values are listed in the installation instructions from the anchor
bolt manufacturer.
5. On a single anchor support, install the locating plate with the two bent prongs in front,
inside the support rod, and the single prong to the back, inside the u-bend.
Install all supports in the same direction.
1
2
8
76
5
4
3
WS000180A
1. Hexagon nut
2. Flat washer
3. Locating plate
4. Back of support
5. Support rod
6. Inside of support rod
7. Anchor bolt
8. Front of support rod
WS003559A
6. Install the struts, if applicable.
7. Install the hexagon nuts and place the lower pipe support clamp on them.
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16 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual

Project-specific anchor dimensions are found in the erection drawing.
1
2
4
5
6
7
8
9
C
L
3
10
11
WS000157C
1. Hexagon nut
2. Strut
3. Anchor bolt
4. Clamp
5. Washer
6. Hexagon nut
7. Rod
8. Anchor bolt
9. Hexagon nut
10.Washer, round
11.Washer, square
8. Use the installation drawings and a level system to find the correct clamp flange
elevation.
The correct elevation is equal to the manifold center line, and the tolerance is ± 6 mm
(¼ in.).
4.3.4 Assemble the manifold pipe sections
CAUTION: Chemical Hazard
Contact the supplier for information for proper handling and use.
1. Examine the manifold sections.
If the sections are dirty and contain debris from storage, then flush with water before
installation.
2. Remove all protective dust covers from the pipe ends and connections.
3. Place the manifold sections in the lower part of the support clamp.
4 Installation
Sanitaire, Silver Series Installation, Operation, and Maintenance Manual 17

WS003557A
4. Connect the manifolds:
a) Connect flanges with bolts loosely.
b) Connect joints with glue.
c) Connect spline couplings without tightening.
5. Install the upper part of the support clamp with washers and nuts.
Tighten loosely.
6. Level the manifold sections which attach to the droplegs.
– For in-line manifolds, ensure that the air distributor connections are horizontal.
– For raised manifolds, ensure that the air distributor connections are vertical.
WS007950A
Figure 7: In-line manifold
WS007951A
Figure 8: Raised manifold
7. Secure the clamps on the sections which attach to the droplegs by tightening the
hexagon nuts.
Ensure that the manifold is horizontal.
8. Install all manifold sections according to the installation drawings.
4 Installation
18 Sanitaire, Silver Series Installation, Operation, and Maintenance Manual