Installation - Aeration Industries

Transcription

Aeration Industries International, Inc.
AIRE-O2®
TRITON
DUAL MODE
PROCESS
AERATOR
5 - 75 HP
INSTALLATION
OPERATION
AND
MAINTENANCE
MANUAL
© Copyright 2002.
All rights reserved.
No part of these materials may be reproduced by any means, nor
translated into a machine language, without the written permission of
the publisher.
AIRE-O2® Aeration systems, specifications, and instructions in this
manual are subject to revision without prior notice or incurring obligation.
Published by Aeration Industries International, Inc.
4100 Peavey Road, Chaska, Minnesota 55318 USA
Telephone: 952.448.6789 (outside the USA)
Facsimile: 952.448.7293
Toll-Free: 800.328.8287 (inside the USA)
Printed in the United States of America
Part Number: 224 - 107 Revsion 1- July 20, 2005
TABLE OF CONTENTS
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
Table Of Contents
1.0
INTRODUCTION ......................................................................................................... 2
1.1 THE COMPANY ................................................................................................. 2
1.2 HOW THE AIRE-O2® TRITON® SYSTEM WORKS ........................................... 2
SAFETY ....................................................................................................................... 3
2.1 NOTATION CONVENTIONS ............................................................................. 3
2.2 YOUR ORGANIZATION’S RESPONSIBILITY .................................................. 3
2.3 SAFETY PRECAUTIONS .................................................................................. 4
2.4 CAUTION INDICATORS .................................................................................... 5
ASSEMBLY- NEW INSTALLATION ............................................................................ 6
3.1 ASSEMBLY OVERVIEW .................................................................................... 6
3.2 FLOAT ASSEMBLY ............................................................................................ 7
3.2.1 FLOAT DIMENSIONAL DRAWINGS ....................................................... 8
3.2.2 FLOAT AND FRAME ASSEMBLY DRAWINGS ..................................... 12
3.3 BLOWER ASSEMBLY ...................................................................................... 20
3.3.1 BLOWER ASSEMBLY DRAWINGS ................................................................ 21
3.4 ATOMIZER ASSEMBLY ................................................................................... 23
3.5 AIRE-O2® TRITON® ASSEMBLY ...................................................................... 23
3.5.1 AIRE-O2® TRITON® ASSEMBLY DRAWINGS ....................................... 24
3.6 VORTEX SHIELD ASSEMBLY ........................................................................ 33
3.7 AIRE-O2® TRITON® ASSEMBLY PLACEMENT .............................................. 34
4.0 MOORING OPTIONS ...................................................................................... 35
4.1 FLOTATION CABLE ATTACHMENT .............................................................. 36
4.2 CABLE SAG ALLOWANCE ............................................................................. 36
4.3 SPAN DIRECT MOORING .............................................................................. 37
4.4 IN-LINE SPAN MOORING ............................................................................... 38
4.5 SPAN BRIDLE MOORING ............................................................................... 41
4.6 WALL MOUNTING ........................................................................................... 43
4.7 BRIDGE MOUNTING ....................................................................................... 47
4.8 BRIDGE/WALL MOUNT CRANE ..................................................................... 51
4.9 FLOAT SUPPORT ASSEMBLY ....................................................................... 52
STARTUP .................................................................................................................. 55
5.1 ELECTRICAL CHECK ...................................................................................... 55
5.2 MOTOR INTERNAL CONNECTIONS ............................................................. 56
5.3 START-UP PROCEDURE ............................................................................... 56
5.4 ROTATION CHECK ......................................................................................... 56
5.5 FUNCTIONAL ELECTRICAL CHECK ............................................................. 57
5.6 OPERATIONAL CHECK .................................................................................. 57
5.7 START-UP NOTES .......................................................................................... 58
5.8 MOTOR WARRANTY VALIDATION ............................................................... 60
MAINTENANCE......................................................................................................... 61
6.1 PREVENTIVE MAINTENANCE ....................................................................... 61
6.2 MAINTENANCE AND SERVICE RECORD .................................................... 62
6.3 MAINTENANCE AND SERVICE NOTES ........................................................ 63
AIRE-O2® TRITON® SERVICE PROCEDURES ...................................................... 64
7.1 AIRE-O2® TRITON® SERVICE ......................................................................... 64
7.2 INSPECT THE AIRE-O2® TRITON® ................................................................. 64
7.3 LUBRICATION .................................................................................................. 66
PROBLEM ANALYSIS .............................................................................................. 67
8.1 PROBLEM ANALYSIS OVERVIEW ............................................................... 67
8.2 PROBLEM ANALYSIS CHARTS ..................................................................... 68
ELECTRICAL ASSEMBLY ........................................................................................ 72
9.1 THREE PHASE MOTOR CONNECTIONS ..................................................... 73
POWER CABLE SELECTION .................................................................................. 77
10.1 POWER CABLE SIZE/LENGTH SELECTION OVERVIEW ........................... 77
10.2 CABLE SELECTION BY VOLTAGE CHARTS .................................................. 78
PARTS ORDERING .................................................................................................. 84
11.1 PARTS NOTES ................................................................................................ 84
11.2 PARTS ORDER FORM ..................................................................................... 85
STORAGE PROCEDURES ...................................................................................... 86
WARRANTY ............................................................................................................. 89
13.1 WARRANTY COVERAGE ............................................................................... 89
13.2 RETURN-AUTHORIZATION ........................................................................... 89
13.3 CREDITING / DEBITING YOUR ACCOUNT .................................................. 89
SERVICE ADDENDUM ............................................................................................ 90
14.1 TRITON DISASSEMBLY AND REASSEMBLY ............................................... 90
5 - 75 Hp AIRE-O2® Triton®
1
Introduction
1.0
INTRODUCTION
IMPORTANT: Read all notations in bold print that appear throughout this manual. They
are critical to the operation and maintenance of your AIRE-O2® TRITON® System.
This manual is prepared to support the installation of an AIRE-O2® TRITON® system. The
installation will provide improved performance through:
• Enhanced horizontal mixing
• High oxygen transfer
• Ease of installation
• Ease of maintenance
• Energy efficiency
• Winter treatment performance
Manual contents will help ensure obtaining these benefits. Please review the manual before
proceeding. It will provide help for any problem that might arise.
NOTE: If further assistance is required, contact our Corporate Headquarters in
Minneapolis, Minnesota U.S.A. Use our customer service Hot-Line number 1-800-328-8287.
1.1
THE COMPANY
Aeration Industries International, Inc., is recognized worldwide for treating domestic and
industrial wastewater, for restoration of lakes, rivers, and harbors, in aquaculture, as well as in
decorative ponds and golf courses. The company was established in 1974.
Customer service, combined with an aggressive program of research and development, has
positioned the company as an innovator, concerned constantly with improving its product to
contribute to cleaning the world's scarcest natural resource .... water.
The Research and Development Center, the heart of the company's 80,000 square foot world
headquarters in Minneapolis, Minnesota, gives Aeration Industries International a world class
facility to carry out its commitment to research and development in meeting the needs of its
customers.
Aeration Industries International is the acknowledged worldwide leader in the resourceful
application of innovative technology and expertise for the improvement of water quality.
Aeration Industries International, Inc., has assumed a leadership position in solving diverse
water quality problems worldwide. The company, working hand in hand with its customers, will
ensure a brighter future by improving the environment around us.
1.2
HOW THE AIRE-O2® TRITON® SYSTEM WORKS
The AIRE-O2® TRITON® system design allows the option of mixing or mixing with the addition
of oxygen. The unique design provides a high oxygen transfer rate, mixing rate four times
greater than conventional technology, dual function nitrification / de-nitrification and no aerosol
production.
2
SAFETY
2.1
NOTATION CONVENTIONS
Safety
2.0
Throughout this manual important information will be emphasized for your protection or to
protect the integrity of the AIRE-O2® TRITON®.
“DANGER:” Indicates an imminently hazardous situation which, if not avoided, could
result in death or serious injury.
“WARNING:” Indicates an imminently hazardous situation which, if not avoided, could
result in death or serious injury.
“CAUTION:” indicates a potentially hazardous situation which, if not avoided, may
result in injury. It may also be used to alert against unsafe practices.
“NOTE:” Is used to emphasize information crucial to protecting the machine. Personal
safety is not the primary concern when a note is used to focus attention on a point.
2.2
YOUR ORGANIZATION’S RESPONSIBILITIES
Your organization has the responsibility for maintaining a safe work environment and must take
responsibility for unique environmental situations where the AIRE-O2® TRITON® will be installed
including, electrical, mechanical, biological, all in accordance with OSHA, Local, State and
Federal Regulations.
3
Safety
2.3
SAFETY PRECAUTIONS
Review the safety practices listed below. Questions should be resolved before proceeding.
1. Allow only qualified and authorized people to work on electrical equipment. A safety
hazard of great concern is the possible activation of the AIRE-O2® TRITON® during
servicing. Disconnect power at the main power control panel. Be sure to use a lock out
tag.
2. Unless a wire is positively known to be dead, treat it as a live wire.
3. Portable electrical tools should be grounded with a three conductor cord.
4. Do not lift objects too heavy for specific capabilities. Get help or use a hoist or crane.
5. Do not exceed the lifting capacity of a crane or hoist.
6. Designate one person to direct the crane operator.
7. Wear a hard hat when using lifting equipment.
8. Do not stand under any lifting object.
9. To prevent falls, recognize that flotation surfaces may be slippery when wet.
10. Clean up any spills in the work area.
11. Wear a life preserver in area's such as the edges of tanks or when working over water.
12. Never place hands or tools in the air intake holes or near the propeller when the unit is
running or not locked “out of service.”
13. As the treated liquid may be a source of infection, the best defense against infection is
the practice of good personal hygiene and prompt medical attention for any injury that
breaks the skin.
14. Workers should keep their fingers out of the eyes, nose, and mouth.
15. Never smoke or eat while working around waste water.
16. Wear gloves when handling the AIRE-O2® TRITON® propeller to protect yourself from
sharp edges.
4
2.4
CAUTION INDICATORS
Safety
When one is working near an AIRE-O2® TRITON®, you will notice bright yellow decals to remind
you of safe practices. Samples are shown below;
CAUTION
1.
WEAR
OVER
APPROVED
WATER
FLOATATION
DEVICES
WHEN
WORKING
SURFACE.
2. DISCONNECT ALL ELECTRICAL POWER BEFORE SERVICING
AERATORS ON FLOATATION EQUIPMENT
3 . PONTOON AND FRAME SURFACES ARE SLIPPERY WHEN WET
4. NO PERSONNEL ALLOWED ON FLOATATION EQUIPMENT
WHEN THE AERATORS ARE OPERATING.
5.
READ AND FOLLOW SAFETY PRECAUTlONS
LISTED IN
TROUBLESHOOTING SECTION OF OPERATING AND
MAINTENANCE MANUAL.
- SAFETY IS YOUR RESPONSIBILITY -
IMPORTANT
TWO BOLTS PER SIDE MUST BE INSTALLED TO
SECURE THE AERATOR PROPERLY. SET AERATOR AT
45˚ AND USE TWO HOLES AT THREE AND NINE OR
SIX O’CLOCK POSITION.
AERATION INDUSTRIES, INC.
CHASKA, MINNESOTA. USA
2.5
LOCKOUT TAGS
A safety hazard of great concern is the possible activation of the AIRE-O2® TRITON® when
you are servicing it. A minimum precaution is to use “lockout” cards on switching equipment
controlling the AIRE-O2® TRITON® . The best precaution is to lockout the equipment with
some form of key lock.
An example of a “lockout” card is shown. They may be purchased from sign supply houses.
When an AIRE-O2® TRITON® is shut off for service, the card is hung or fastened on the switch
or controller to inform others not to operate the switch. In addition, locking the switch off should
be done if possible.
LWT-20
®
LEM
PRODUCTS INC.
Doylestown, Pa
DANGER
EQUIPMENT
LOCKED
OUT
SIGNED BY
DANGER
DO NOT REMOVE
THIS TAG
TO DO SO WITHOUT
AUTHORITY WILL MEAN
IMMEDIATE DISCHARGE
IT IS HERE FOR A PURPOSE
SEE OTHER SIDE
DATE
5
Installation
3.0
ASSEMBLY - NEW INSTALLATION
3.1
ASSEMBLY OVERVIEW
New Installation
This section will guide initial assembly of components as received from the factory. After
removing them from their shipping container, examine components for any shipping damage.
Assembly Overview
First, assemble the flotation assembly (see pages 8 - 19). Next, mount the blower to the flotation
assembly (see pages 12 - 19). Very important: Mount the atomizer on the end of the aerator
shaft. Next, mount the AIRE-O2® TRITON®, with atomizer attached to the flotation assembly
(see pages 20 - 26). Flotation assemblies must then be positioned in the water and the motor
electrical cable attached.
Important: Do not fail to install the atomizer (and spindle extenxion 50 - 75HP), which is
shipped unattached to the Triton aerator.
AIR INTAKE
SET SCREWS (2)
HOLES FOR DRILLING NEW BEARING (3)
FLAT FOR
WRENCH
PROPELLER
(ATOMIZER)
NOTE: Electric wiring cable, clamps, ties, control boxes, and related electrical supplies
are to be provided by the customer unless specifically ordered with the AIRE-O2®
TRITON®.
6
3.2
FLOAT ASSEMBLY
Installation
Note: Important!!! Select a level work area. Do not tighten any fasteners until unit is
completely assembled and lined up.
1. Place each float on the ground, spacing them approximately as shown in the dimensional
drawings (pages 8-11).
2. Using assembly drawings (pages 12-19), assemble the cross-arches, cross rails, and
main frame on the pontoons as shown.
3. Place the U-bolts in position on each pontoon. See assembly drawings for location
(pages 12-19).
4. Attach cross rails & arches loosely to main frame. It may be necessary to enlist the
assistance of additional personnel with the five float system.
5. The mount bracket should be positioned on main frame using the lower two sets of
holes. See assembly drawings (pages 12-19) for reference.
6. As indicated in the assembly drawings (pages 12-19), remove and replace the bolt from
each front pontoon with the eyebolts provided. Eye is toward the inside of the pontoon.
Note: Reuse washers and nut from bolt. These eyebolts will be used to attach vortex
shield at final assembly.
Note: Be sure to square the frame before tightening the fasteners. This can be
verified by measuring corner to corner at identical reference points on the frame.
7. After unit is completely assembled and squared, tighten all fasteners.
7
Installation
3.2.1 FLOAT DIMENSIONAL DRAWINGS
TRI-Float Dimensional Drawings
1.0"/2.0"
96.0" 2.44M
16.5"
96.0
"
2.44M
18.25"/.46M
2.0" x 2.0" x 1/4"
316 S.S. ANGLE
2.0" x 3.0" x 3/16" GALV.
STEEL ANGLE
22.37 TYP.
15.25"
60.0"
1.5M
22.84"
.58M
141.88" ±10"
3.6M
20.0"
.5M
25.0"
.6M
*Used with 5 - 7.5 HP NEMA & I.E.C.
SK00-016
8
Installation
Four Float Dimensional Drawings
96.0" [243.8]
16.5" [41.9]
26.50"
[67.31]
96.0"
[243.8]
9.19
[23.3]
22.19"
[563.6]
TYP.
15.62"
[39.69]
15.62"
[39.69]
60.0" [152.4]
131.00" [332] MIN
148.38" [377] MAX
*Used with 10 - 25 HP (60 Hertz) NEMA & I.E.C.
SK97-014
9
Installation
Five Float Galvanized and Stainless Steel Dimensional Drawings
196.50
151.50
1.0/2.0
22.50
TYP.
15.00
15.00
16.50
96.00
15.00
32.00
60.00
84.00
55.00
73.00
22.29
93.00
25.00
*Used with 25 HP (50 Hertz) NEMA & I.E.C.
*Used with 30 HP (50/60 Hertz) NEMA & I.E.C.
SK00-004
10
Installation
Seven Float Galvanized and Stainless Steel Dimensional Drawings
360-189
11
Installation
3.2.2 FLOAT ASSEMBLY DRAWINGS
Tri-Float Galvanized and Stainless Steel Assembly Drawings
TRI-FLOAT HARDWARE (GALV. & SS)
ITEM #
1
2
*3
4
*5
6
*7
8
9
10
11
12
13
14
360-052-1
12
15
PART #
224-112
224-113
336-001
336-005
224-019
215-209
215-207
410-614
221-019
221-022
215-092
215-093
214-843
214-863
215-184
215-022
215-052
215-027
215-206
215-133
224-017
DESCRIPTION
QTY.
LABEL, PHONE# DOMESTIC .......................... 2
LABEL, PHONE# INTERNATIONAL ................. 2
PONTOON ASS'Y GALV ................................... 3
PONTOON ASS'Y S.S. ...................................... 3
LABEL, FLOATATION SAFTEY ......................... 1
EYEBOLT 3/8" x 4 1/2" PLATED ........................ 4
EYEBOLT 3/8" x 4 1/2" S.S. ............................... 4
VORTEX SHIELD ASS'Y ................................... 1
WIRE ROPE CLAMP ASS'Y 3/8" GALV ............. 4
WIRE ROPE CLAMP ASS'Y 3/8" S.S. ............... 4
CAPSCREW 1/2-13 x 2" S.S. ............................. 6
LOCKNUT 1/2-13 S.S. ...................................... 6
MOUNT PLATE, BLOWER, S.S. ....................... 1
MOUNT PLATE, BLOWER, GALV. .................... 1
U-BOLT S.S. ..................................................... 12
U-BOLT -WITH NUTS GALV ............................ 12
HEX NUT 5/16-18 S.S. ONLY ........................... 32
5/16 LOCKWASHER ......................................... 32
EYEBOLT 3/8 x 1 1/4" S.S. ................................ 2
EYEBOLT 3/8 x 1 1/4" GALV ............................. 2
LABEL, MOUNT BRACKET ............................... 1
3.2.2 FRAME ASSEMBLY DRAWING
Installation
Tri-Float Galvanized and Stainless Steel Frame Assembly Drawings
TRI-FLOAT FRAME HARDWARE (GALV. & SS)
ITEM #
*15
16
17
18
*19
*20
*21
22
*23
PART #
214-393
214-059
215-032
215-081
215-104
214-062
214-844
214-965
214-966
214-061
214-014
214-064
214-874
214-873
DESCRIPTION
QTY.
CROSS ARCH S.S. ............................................ 2
CROSS ARCH GALV ......................................... 2
CAPSCREW 3/8-16 ........................................... 30
LOCKNUT. ........................................................ 30
FLATWASHER 3/8 (S.S. ASSY. ONLY) ......... 16
MAINFRAME S.S. ............................................ 2
MAINFRAME GALV ........................................... 2
REAR CROSSRAIL S.S. ................................... 2
REAR CROSSRAIL GALV. ................................ 2
MOUNT BRACKET S.S. ................................... 2
MOUNT BRACKET GALV. ................................ 2
BRACKET SUPPORT (S.S. ASSY ONLY) ........ 2
GUSSET S.S. ................................................... 2
GUSSET GALV. ................................................ 2
360-052-2
13
Installation
3.2.2 FLOAT ASSEMBLY DRAWING
Four Float Galvanized and Stainless Steel Assembly Drawings
FOUR FLOAT HARDWARE (GALV. & SS)
ITEM #
1
2
*3
4
*5
6
*7
8
9
*10
*11
*12
13
*14
360-160-1
14
15
16
PART #
224-112
224-113
336-001
336-005
224-019
215-209
215-207
410-591
221-019
221-022
215-092
215-093
214-863
214-843
215-197
215-099
215-198
215-093
215-027
215-022
215-184
215-052
224-017
DESCRIPTION
QTY.
PONTOON ASS'Y S.S. ...................................... 4
EYEBOLT 3/8" x 4 1/2" PLATED ........................ 4
EYEBOLT 3/8" x 4 1/2" S.S. ............................... 4
CAPSCREW 1/2-13 x 2" S.S. ............................. 6
LOCKNUT 1/2-13 S.S. ...................................... 6
MOUNT PLATE, BLOWER, GALV. .................... 1
MOUNT PLATE, BLOWER, S.S. ....................... 1
CAPSCREW 3/4-10 x 2 1/2" S.S. 20/25 HP ....... 4
CAPSCREW 1/2-13 x 1 1/2" S.S. 5/15 HP ......... 4
LOCKNUT 3/4-10 S.S. 20-25 HP ....................... 4
LOCKNUT 1/2-13 S.S. 10-15 HP ...................... 4
5/16 LOCKWASHER ......................................... 32
U-BOLT W/NUTS 5/16-18 GALV. .................... 16
U-BOLT W/NUTS 5/16-18 S.S ......................... 16
HEX NUT 5/16-18 S.S ..................................... 32
3.2.2 FRAME ASSEMBLY DRAWINGS
Installation
Four Float Galvanized and Stainless Steel Frame Assembly Drawing
FOUR FLOAT FRAME HARDWARE (GALV. & SS)
ITEM #
*17
*18
*19
*20
*21
22
23
24
25
PART #
214-385
214-393
214-844
214-845
214-440
214-421
214-812
214-014
214-807
214-061
214-873
214-874
215-032
215-081
215-099
215-032
215-093
215-081
DESCRIPTION
QTY.
CROSS ARCH GALV. ........................................ 2
CROSS ARCH S.S ............................................ 2
MAINFRAME GALV. ......................................... 2
MAINFRAME S.S. .............................................. 2
REAR CROSSRAIL GALV.. ............................... 2
REAR CROSSRAIL S.S. ................................... 2
MOUNT BRACKET GALV 20-25 HP.................. 2
MOUNT BRACKET GALV 10-15HP .................. 2
MOUNT BRACKET S.S. 20-25 HP .................... 2
MOUNT BRACKET S.S. 10-15 HP .................... 2
GUSSET GALV. ................................................ 2
GUSSET S.S. .................................................... 2
CAPSCREW .375-16UNC x 1.25 S.S ............... 20
LOCKNUT .375-16UNC S.S ............................ 20
CAPSCREW .50-13UNC x 1.50 S.S. 20-25HP .. 8
CAPSCREW .375-16UNCx1.25 S.S. 10-15HP .. 8
LOCKNUT .50-13UNC S.S. 20-25HP ................ 8
LOCKNUT .375-16UNC S.S. 10-15HP. ............. 8
360-160-2
15
Installation
Five Float Galvanized and Stainless Steel Assembly Drawing
FIVE FLOAT HARDWARE (GALV. & SS)
ITEM #
*1
*2
3
4
*5
6
7
8
9
10
*11
12
13
PART #
336-005
336-001
221-020
221-044
224-113
224-112
215-184
215-022
215-052
215-027
215-197
215-198
224-017
215-207
215-209
410-591
224-019
DESCRIPTION
QTY.
PONTOON ASS'Y S.S. ...................................... 5
U-BOLT 5/16" S.S. ........................................... 20
U-BOLT 5/16" W/NUTS GALV.. ....................... 20
HEX NUT 5/16-18 S.S. (SEE NOTE). ............... 40
LOCKWASHER 5/16 S.S. ................................. 40
CAPSCREW, 3/4-10x2" S.S. .............................. 4
LOCKNUT 3/4" S.S. ........................................... 4
EYEBOLT 3/8-16 x 4 1/2" S.S. ........................... 4
EYEBOLT 3/8-16 x 4 1/2" GALV. ....................... 4
360-114-1
16
Installation
Five Float Galvanized and Stainless Steel Assembly Drawing
FIVE FLOAT FRAME HARDWARE (GALV. & SS)
ITEM #
*1
2
*3
4
*5
*6
7
*8
*9
10
*11
PART #
214-923
214-922
215-099
214-935
214-934
215-032
214-939
214-938
214-941
214-940
215-081
214-937
215-936
214-948
215-947
215-908
215-909
215-093
214-943
214-942
DESCRIPTION
QTY.
CROSSARCH, TOP - S.S.. ................................ 2
CROSSARCH, TOP - GALV .............................. 2
CAPSCREW 1/2-13 x 1 1/2". ............................ 12
CROSSARCH, BOTTOM - S.S.. ........................ 2
CROSSARCH, BOTTOM - GALV.. ................... 2
CAPSCREW 3/8-16 z 1 1/4". ............................ 36
MAINFRAME, RIGHT - S.S................................ 1
MAINFRAME, RIGHT - GALV ............................ 1
CROSSRAIL, REAR - S.S. ................................. 2
CROSSRAIL, REAR - GALV .............................. 2
LOCKNUT 3/8-16 .............................................. 36
MAINFRAME, LEFT - S.S. ................................. 1
MAINFRAME, LEFT - GALV .............................. 1
MOUNT BRACKET - S.S. .................................. 2
MOUNT BRACKET - GALV ............................... 2
MOUNT BRACKET - S.S. .................................. 2
LOCKNUT 1/2-13. ............................................. 12
CROSS BRACE - S.S. ....................................... 2
CROSS BRACE - GALV .................................... 2
360-114-2
17
Installation
Seven Float Galvanized and Stainless Steel Assembly Drawing
SEVEN FLOAT HARDWARE (GALV. & SS)
ITEM #
*1
*2
3
4
*5
6
7
8
9
10
*11
12
13
PART #
336-005
336-001
221-053
221-052
224-113
224-112
215-184
215-022
215-052
215-027
215-197
215-198
224-017
215-207
215-209
410-591
224-019
DESCRIPTION
QTY.
PONTOON ASS'Y S.S. ...................................... 7
U-BOLT 5/16" S.S. ........................................... 28
U-BOLT 5/16" W/NUTS GALV.. ....................... 28
HEX NUT 5/16-18 S.S. (SEE NOTE). ............... 56
LOCKWASHER 5/16 S.S. ................................. 56
CAPSCREW, 3/4-10x2" S.S. .............................. 4
LOCKNUT 3/4" S.S. ........................................... 4
EYEBOLT 3/8-16 x 4 1/2" S.S. ........................... 4
EYEBOLT 3/8-16 x 4 1/2" GALV. ....................... 4
360-180-1
18
Installation
Seven Float Galvanized and Stainless Steel Assembly Drawing
SEVEN FLOAT FRAME HARDWARE (GALV. & SS)
ITEM #
*1
2
*3
4
*5
*6
7
*8
*9
10
*11
12
PART #
214-1015
214-1012
215-099
214-935
214-934
215-032
214-939
214-938
214-941
214-940
215-081
214-937
215-936
214-948
215-947
215-908
215-909
215-093
214-943
214-942
215-092
DESCRIPTION
QTY.
CROSSARCH, TOP - S.S.. ................................ 2
CROSSARCH, TOP - GALV .............................. 2
CAPSCREW 1/2-13 x 1 1/2". ............................. 8
CROSSARCH, BOTTOM - S.S.. ........................ 2
CROSSARCH, BOTTOM - GALV.. ................... 2
CAPSCREW 3/8-16 z 1 1/4". ............................ 36
MAINFRAME, RIGHT - S.S................................ 1
MAINFRAME, RIGHT - GALV ............................ 1
CROSSRAIL, REAR - S.S. ................................. 2
CROSSRAIL, REAR - GALV .............................. 2
LOCKNUT 3/8-16 .............................................. 36
MAINFRAME, LEFT - S.S. ................................. 1
MAINFRAME, LEFT - GALV .............................. 1
MOUNT BRACKET - S.S. .................................. 2
MOUNT BRACKET - S.S. .................................. 2
LOCKNUT 1/2-13. ............................................. 12
CROSS BRACE - S.S. ....................................... 2
CROSS BRACE - GALV .................................... 2
CAPSCREW 1/2-13 x 2 ..................................... 4
360-180-2
19
Installation
3.3
BLOWER ASSEMBLY
Blower Voltage Options
AIRE-O2® TRITON® blower motors are designed to handle a broad range of world voltages and
power supply variations. Our dual voltage 3 phase motors are factory tested and certified to
operate on both: 200 / 230 / 460 VAC 3 Phase 220 / 380 / 440 VAC 3 Phase 50 Hz. Our dual
voltage 1 phase motors are factory tested and certified to operate on both 104-115 / 208-230
VAC 1 Phase 60 Hz and 100-110 / 200-220 VAC 1 phase 50 Hz. All voltages above can handle
a ±10% voltage fluctuation.
NOTE: For further information regarding AIRE-O2® TRITON® blowers, please contact
Aeration Industries International at the Customer Service Hot-Line ( 1-800-328-8287 ).
Installation Instructions
(Blowers)
THE AIRE-O2® TRITON® blowers HP's are sized depending on the specific AIRE-O2® TRITON®
motor horsepower of the AIRE-O2® TRITON® system.
Bolt It Down
Mount the blower onto the frame assembly. Any blower must be secured against movement
prior to starting or testing to prevent injury or damage. The blower does not vibrate much more
than a standard electric motor.
Air Filter
All blowers should be filtered prior to starting. Care must be taken so that no foreign material
enters the blower. If foreign material does enter the blower, it could cause internal damage or
may exit at extremely high velocity.
Support the Piping
The blower flanges and nozzles are designed as connection points only and are not designed
to be support members.
Wiring
Blowers must be wired and protected/fused, all in accordance with Osha, Local, State and
Federal Regulations. . All blowers must be grounded to prevent electrical shock. Slo-Blo or
time delay fuses should be used to bypass the first second of start-up amperage. (See electrical
assembly pages 58 - 62)
Rotational check
The blower rotation is easiest to verify when the unit has been assembled and has yet
to be put in the lagoon. To verify rotation, disconnect the flexible tube at the housing and
apply power to the blower motor to verify you have air flow.
Warning: If the rotation is incorrect, the pump will pull wastewater up the housing shaft
and into the pump.
Motor Internal Connections
Your first source of wiring information should be the motor nameplate. Some motors will display
wiring information inside the junction box cover. Others may have sheets accompanying the
motor.
20
3.3.1 BLOWER ASSEMBLY DRAWINGS
SHOWN FOR REPLACEMENT
PURPOSES ONLY
10
1
3
9
2
8
8
Installation
1.5, 2 & 3 Hp 50/60 Hz (DR 454, DR 505, & DR 555 Models)
Blower Assembly Drawing
7
4
4
6
5
BLOWER HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
PART #
230-003
230-001
230-004
230-011
215-515
230-002
215-514
215-513
215-510
215-511
215-512
221-050
108-021
230-008
DESCRIPTION
QTY.
BLOWER, 3HP 50/60HZ DR-555 ....................... 1
BLOWER, 2HP 50/60HZ DR-505 ....................... 1
BLOWER, 2HP 50/60HZ 575V DR-505. ........... 1
BLOWER, 1.5HP/60HZ 1.0HP/50HZ DR-454 ... 1
PIPE COUPLING 1 1/2" GALV. .......................... 1
INLET FILTER, BLOWER. ................................. 1
PIPE NIPPLE 1 1/2 x 6" GALV ........................... 2
ELBOW, 90° 1 1/2 X 1 1/2 GALV ....................... 1
PIPE NIPPLE 1 1/2 x 3" GALV ........................... 1
ELBOW,90° REDUCING 1 1/2 X 2 1/2 ............... 1
COMBINATION NIPPLE 2 1/2" PLATED ........... 1
HOSE CLAMP S.S. 2.5" ..................................... 4
FLEXIBLE AIR DUCT, 2.5" ............................... 3'
FILTER ELEMENT ............................................. 1
360-036
21
Installation
3.3.1 BLOWER ASSEMBLY DRAWINGS
3 Hp 50/60 Hz (DR 606 & DR 656 Models) Blower Assembly Drawing
BLOWER HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
PART #
230-007
230-006
230-014
215-534
230-010
230-009
215-533
215-532
215-531
215-530
215-512
221-050
108-021
DESCRIPTION
QTY.
BLOWER, 3HP 50/60HZ DR-606 575V ............. 1
BLOWER, 3HP 50/60HZ DR-606 200-440V ...... 1
BLOWER, 3HP 50/60HZ DR-656 200-440V. .... 1
PIPE COUPLING 2" GALV. .............................. 1
INLET FILTER, BLOWER. ................................. 1
FILTER ELEMENT, REPLACEMENT ................ 1
PIPE NIPPLE 2 x 6" GALV ................................. 2
ELBOW, 90° 2" X 2" GALV ................................ 1
PIPE NIPPLE 2" x 3" GALV ............................... 1
ELBOW, 90° REDUCING 2" X 2 1/2 .................. 1
COMBINATION NIPPLE 2 1/2" PLATED ........... 1
HOSE CLAMP S.S. 2.5" ..................................... 4
FLEXIBLE AIR DUCT, 2.5" ............................... 3'
360-016
22
3.4
ATOMIZER ASSEMBLY
Installation
Important: Do not fail to install the atomizer, which is shipped unattached to the Triton
aerator.
1. With the propeller attached, insert a large screwdriver through the air intake hole in the
housing as shown in the diagram below. Turn the propeller clockwise by hand until
firmly seated.
2. Apply anti-seize compound to the protruding threads
3. Thread the atomizer (and spindle extension 50 -75 HP series only) on to the shaft and
rotate clockwise until firmly seated against the propeller.
4. Tighten the set screws firmly.
AIR INTAKE
SET SCREWS (2)
FLAT FOR
WRENCH
PROPELLER
(ATOMIZER)
3.5
AIRE-O2® TRITON® ASSEMBLY
WARNING: At this point do not install the Air Duct.
1. Lift the AIRE-O2® TRITON® assembly using a hoist and sling. Maneuver the AIRE-O2®
TRITON® housing between the main frames of the float assembly with the propeller
toward the front and under the crossrail weldments. Position the motor mounting pins
above the slots in the mount brackets. Gently lower the unit to rest in the bottom of the
slots.
2. Lower the hoist to allow the sling to become loose. Pivot the AIRE-O2® TRITON® to a
horizontal position. Secure with bolts through the mount bracket and motor mounting
flange. Now, remove the sling entirely once the motor is bolted in place.
3. UPON THE COMPLETION OF STEP 2: Install the Air Duct between the blower and
housing assembly using the hose clamps provided.
23
Installation
3.5.1 AIRE-O2® TRITON® ASSEMBLY DRAWINGS
5 - 15 Hp 60 Hz Models
18
5
16
15
17
1
2
3
4
5
6
7
8
9
10
11
10
12
13
14
* WHEN ORDERING REPLACEMENT PARTS SPECIFY THE HP
AERATOR HARDWARE
ITEM #
1
2
*3
4
5
6
7
8
9
10
11
*12
13
14
15
16
17
18
PART #
----------224-013
245-030
330-028
239-194
215-100
215-088
224-021
330-099
213-053
215-123
247-034
234-245
234-249
234-220
234-221
215-190
223-048
215-127
215-147
410-609
410-588
224-117
DESCRIPTION
QTY.
MOTOR 60HZ NEMA ........................................ 1
DECAL, SERIAL NO. ......................................... 1
FLANGE, MOUNTING 10/15HP ........................ 1
FLANGE, MOUNTING 5/7.5HP ......................... 1
SHAFT ASSEMBLY ........................................... 1
LOCKWASHER, 1/2 S.S.. .................................. 8
SCREW, HH CAP 1/2-13x1" S.S. ...................... 4
DECAL, CAUTION ............................................. 1
HOUSING ASSEMBLY ...................................... 1
ARB 5-30 HP/60HZ ............................................ 1
WASHER, NYLON 2.5 O.D.X2.0 I.D. ................. 2
SDS 5-30 HP/60HZ ............................................ 1
PROP, 5HP/60HZ BRONZE. ............................. 1
PROP, 7.5HP/60HZ BRONZE ........................... 1
PROP, 10HP/60HZ BRONZE ............................ 1
PROP,15 HP/60HZ BRONZE ............................ 1
SET SCREW 5/16-18 x 5/16 .............................. 2
ATOMIZER ASSY, TRITON ............................... 1
SET SCREW, 3/8-16 x 5/16 ............................... 2
SCREW, HH CAP 1/2-13x1 1/4" S.S.................. 4
BLOWER SUB-ASSY, 5-7.5HP 230/460V ......... 1
BLOWER SUB-ASSY, 10-15HP 230/460V ........ 1
DECAL, TRITON ATOMIZER ............................ 1
360-004
24
Installation
5 - 15 Hp 50 Hz NEMA Models
18
5
16
15
17
1
2
3
4
5
6
7
8
9
10
11
10
12
13
14
AERATOR HARDWARE
ITEM #
1
2
*3
4
5
6
7
8
9
10
11
*12
13
14
15
16
*17
18
PART #
----------224-013
245-030
330-028
239-194
215-100
215-088
224-021
330-099
213-053
215-123
247-034
234-252
234-271
234-221
234-232
215-190
223-048
215-127
215-147
410-589
410-609
224-117
DESCRIPTION
QTY.
MOTOR 50HZ NEMA ........................................ 1
DECAL, SERIAL NO. ......................................... 1
FLANGE, MOUNTING 10/15HP ........................ 1
FLANGE, MOUNTING 5HP ............................... 1
SHAFT ASSEMBLY ........................................... 1
LOCKWASHER, 1/2 S.S.. .................................. 8
SCREW, HH CAP 1/2-13x1" S.S. ...................... 4
DECAL, CAUTION ............................................. 1
ARB 5-30 HP/60HZ ............................................ 1
SDS 5-30 HP/60HZ ............................................ 1
PROP, 5HP/50HZ BRONZE. ............................. 1
PROP, 7.5HP/50HZ BRONZE ........................... 1
PROP, 10HP/50HZ BRONZE ............................ 1
PROP,15 HP/50HZ BRONZE ............................ 1
SET SCREW 5/16-18 x 5/16 .............................. 2
SET SCREW, 3/8-16 x 5/16 ............................... 2
SCREW, HH CAP 1/2-13x1 1/4" S.S.................. 4
BLOWER SUB-ASSY, 10/15HP 50HZ ............... 1
BLOWER SUB-ASSY, 5/7.5HP 50HZ ............... 1
360-005
25
Installation
20 Hp, 25 Hp, & 30 Hp 50 & 60 Hz NEMA Models
AERATOR HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
360-007
26
20
PART #
----------224-013
245-117
245-032
245-090
245-118
239-194
215-100
215-147
224-021
330-099
213-053
215-123
247-034
234-224
234-224
234-222
234-232
234-276
234-278
215-190
223-048
215-127
215-151
215-150
410-589
410-623
224-117
DESCRIPTION
QTY.
MOTOR 50/60HZ NEMA ................................... 1
DECAL, SERIAL NO. ......................................... 1
FLANGE, MOUNTING 30HP .............................. 1
FLANGE, MOUNTING 20-25HP ......................... 1
RING, MOUNTING 20-25HP ............................... 1
RING, MOUNTING 30HP .................................... 1
SHAFT ASSEMBLY ........................................... 1
LOCKWASHER, 1/2 S.S.. .................................. 4
CAPSCREW, HH CAP 1/2-13x1 1/4" S.S. .......... 4
DECAL, CAUTION.............................................. 1
ARB 5-30 HP/60HZ ............................................ 1
SDS 5-30 HP/60HZ ............................................ 1
PROP, 30HP/60HZ BRONZE. ............................ 1
PROP, 20HP/50HZ BRONZE ............................. 1
PROP, 20HP / 60Hz BRONZE ........................... 1
PROP, 25HP/ 60Hz BRONZE ............................ 1
PROP, 25HP50HZ BRONZE .............................. 1
PROP, 30HP/50HZ BRONZE ............................. 1
SET SCREW 5/16-18 x 5/16............................... 2
SET SCREW, 3/8-16 x 5/16 ............................... 2
LOCKWASHER, 5/8 SPLIT S.S.. ....................... 4
SCREW, HH CAP 1/2-13x1 1/4" S.S. ................. 4
BLOWER SUB-ASSY, 3HP 60Hz DR555 .......... 1
BLOWER SUB-ASSY, 50/60HZ DR656 ............. 1
DECAL, TRITON ATOMIZER ............................. 1
Installation
5 - 15 Hp 50 Hz IEC Models
23
17
18
19
22
21
20
7
1
2
3
4
5
6
7
8
9
10
11
12
13
12
14
15
16
AERATOR HARDWARE
ITEM #
1
2
*3
4
5
*6
7
8
9
10
11
12
13
*14
15
16
17
18
19
20
*21
*22
360-006
23
PART #
----------224-013
215-340
215-356
245-113
245-030
239-195
239204
215-100
215-088
224-021
330-099
213-053
215-123
247-034
234-252
234-271
234-221
234-232
215-190
223-048
215-155
215-203
215-154
215-147
215-127
215-156
410-589
410609
224-117
DESCRIPTION
QTY.
MOTOR 60HZ IEC ............................................ 1
DECAL, SERIAL NO. ......................................... 1
MOTOR SPACER, 5-10HP ................................ 1
MOTOR SPACER, 15HP ................................... 1
ADAPTER FLANGE (IEC) ................................. 1
FLANGE, MOUNTING ....................................... 1
SHAFT ASSEMBLY 5-10HP .............................. 1
SHAFT ASSEMBLY 15HP ................................. 1
LOCKWASHER, 1/2 S.S.. .................................. 8
CAPSCREW, HH CAP 1/2-13x1 1/4" S.S. ......... 4
DECAL, CAUTION ............................................. 1
ARB 5-30 HP/60HZ ............................................ 1
SDS 5-30 HP/60HZ ............................................ 1
PROP, 5HP/50Hz BRONZE. .............................. 1
PROP, 7.5HP/50Hz BRONZE ............................ 1
PROP, 10HP/50Hz BRONZE ............................. 1
PROP, 15HP/50Hz BRONZE ............................. 1
SET SCREW 5/16-18 x 5/16 .............................. 2
LOCKNUT 5/8 SS .............................................. 4
WASHER, FLAT 5/8 S.S.. .................................. 4
SCREW, HH CAP 5/8-11x2.0S.S. ...................... 4
SCREW, HH CAP 1/2-13X1 1/4" SS .................. 4
SET SCREW, 3/8-16 x 5/16 SS 10HP ............... 2
SET SCREW, 1/2-13 x 1/2 SS 15HP ................. 2
BLOWER SUB-ASSY, 50/60HZ 10-15HP ......... 1
BLOWER SUB-ASSY, 50/60HZ 5-7.5HP ........... 1
27
Installation
3.5.1 AIRE-O2® TRITON® ASSEMBLY DRAWING
20 Hp, 25 Hp, & 30 Hp 50 Hz IEC Model
AERATOR HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
360-040
28
22
23
PART #
----------224-013
215-360
215-543
245-114
245-115
245-032
245-096
245-090
245-097
239-196
239-198
215-100
215-147
215-553
224-021
330-099
213-053
215-123
247-034
234-224
234-276
234-278
215-190
223-048
215-155
215-203
215-170
215-150
215-156
410-606
410-623
410-632
215-151
224-117
DESCRIPTION
QTY.
MOTOR 50HZ IEC .................................................... 1
DECAL, SERIAL NO. ................................................. 1
MOTOR SPACER 20HP ............................................ 1
MOTOR SPACER 25/30HP ....................................... 1
ADAPTER FLANGE 20HP ......................................... 1
ADAPTER FLANGE 25/30HP .................................... 1
FLANGE, MOUNTING 20HP ...................................... 1
FLANGE, MOUNTING 25/30HP ................................ 1
MOUNTING RING 20HP ............................................ 1
MOUNTING RING 25/30HP ....................................... 1
SHAFT ASSEMBLY 20HP ......................................... 1
SHAFT ASSEMBLY 25/30HP .................................... 1
LOCKWASHER, 1/2 S.S.. .......................................... 4
CAPSCREW, HH 1/2-13x1.25 S.S. 20HP ................ 4
CAPSCREW, HH 1/2-13x1.75 S.S. 25/30HP ........... 4
DECAL, CAUTION ..................................................... 1
HOUSING ASSEMBLY .............................................. 1
ARB 5-30 HP/60HZ .................................................... 1
WASHER, NYLON 2.5 O.D.X2.0 I.D. ......................... 2
SDS 5-30 HP/60HZ .................................................... 1
PROP, 20HP BRONZE. ............................................. 1
PROP, 25HP BRONZE .............................................. 1
PROP, 30HP BRONZE .............................................. 1
SET SCREW 5/16-18 x 5/16 ...................................... 2
ATOMIZER ASSY, TRITON ....................................... 1
LOCKNUT 5/8-11 ....................................................... 8
WASHER, FLAT 5/8 ................................................... 8
SCREW, HH CAP 5/8 x 2.5 S.S. ................................ 8
SCREW, HH CAP 5/8-11 x 1 1/2" S.S. ...................... 4
SER SCREW 1/2-13 x 1/2 S.S ................................... 2
BLOWER ASSY, DR606 ............................................ 1
BLOWER ASSY, DR656 ............................................ 1
BLOWER ASSY, DR656 500V 50HZ ......................... 1
WASHER, LOCK 5/8 .................................................. 4
DECAL, TRITON ATOMIZER ..................................... 1
Installation
50HP (37KW) 50HZ & 60HZ, 8 Pole
AERATOR HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
PART #
----------224-013
224-117
245-116
215-170
215-203
215-155
245-120
215-150
215-151
239-215
215-156
330-107
224-021
213-054
215-149
247-033
215-201
234-295
234-288
223-056
215-127
223-054
410-634
DESCRIPTION
QTY.
MOTOR, 37KW .................................................. 1
DECAL, SERIAL NO. ......................................... 1
ADAPTER FLANGE ........................................... 1
CAPSCREW .625-11UNC x 2.50 ...................... 12
FLATWASHER, .625. ......................................... 8
LOCKNUT .625-11UNC ..................................... 8
MOUNTING FLANGE ........................................ 1
CAPSCREW .625-11UNC x 1.50LG .................. 4
LOCKWASHER .625 .......................................... 8
SHAFT ............................................................... 1
SETSCREW .50-13UNC .................................... 2
DECAL, CAUTION ............................................. 1
ARB BEARING .................................................. 1
NYLON WASHER 3.25 I.D. ................................ 1
SLEEVE ............................................................. 1
NYLON WASHER 2.88 I.D. ................................ 1
PROPELLER BRONZE, 60HZ ........................... 1
ATOMIZER PROPELLER .................................. 1
SET SCREW 3/8-16UNC x 5/16LG.................... 1
SPINDLE EXTENSION ...................................... 1
BLOWER ASSEMBLY ....................................... 1
360-155
29
Installation
60HP (45KW) 50HZ & 60HZ, 8 Pole
AERATOR HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
PART #
----------224-013
224-117
245-116
215-170
215-203
215-155
245-120
215-150
215-151
239-215
215-156
330-107
224-021
213-054
215-149
247-033
215-201
234-297
234-296
223-056
215-127
223-054
410-634
DESCRIPTION
QTY.
MOTOR 50/60HZ NEMA ................................... 1
DECAL, SERIAL NO. ......................................... 1
ADAPTER FLANGE ........................................... 1
CAPSCREW .625-11UNC x 2.50 ...................... 12
FLATWASHER, .625. ......................................... 8
LOCKNUT .625-11UNC ..................................... 8
MOUNTING FLANGE ........................................ 1
CAPSCREW .625-11UNC x 1.50LG .................. 4
LOCKWASHER .625 .......................................... 8
SHAFT ............................................................... 1
SETSCREW .50-13UNC .................................... 2
DECAL, CAUTION ............................................. 1
ARB BEARING .................................................. 1
NYLON WASHER 3.25 I.D. ................................ 1
SLEEVE ............................................................. 1
NYLON WASHER 2.88 I.D. ................................ 1
SET SCREW 3/8-16UNC x 5/16LG.................... 1
BLOWER ASSEMBLY ....................................... 1
360-201
30
Installation
75HP (55KW) 60HZ, 8 Pole (IEC)
AERATOR HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
PART #
----------224-013
224-117
245-116
215-170
215-203
215-155
245-120
215-150
215-151
239-215
215-156
330-107
224-021
213-054
215-149
247-033
215-201
234-291
223-056
215-127
223-054
410-634
DESCRIPTION
QTY.
MOTOR 75HP 230/460V 60HZ IEC .................. 1
DECAL, SERIAL NO. ......................................... 1
ADAPTER FLANGE ........................................... 1
CAPSCREW .625-11UNC x 2.50 ...................... 12
FLATWASHER, .625. ......................................... 8
LOCKNUT .625-11UNC ..................................... 8
MOUNTING FLANGE ........................................ 1
CAPSCREW .625-11UNC x 1.50LG .................. 4
LOCKWASHER .625 .......................................... 8
SHAFT ............................................................... 1
SETSCREW .50-13UNC .................................... 2
DECAL, CAUTION ............................................. 1
ARB BEARING .................................................. 1
NYLON WASHER 3.25 I.D. ................................ 1
SLEEVE ............................................................. 1
NYLON WASHER 2.88 I.D. ................................ 1
PROPELLER BRONZE ...................................... 1
SET SCREW 3/8-16UNC x 5/16LG.................... 1
BLOWER ASSEMBLY ....................................... 1
360-187
31
Installation
3.5.2 INSTALLATION NOTES
32
3.6
VORTEX SHIELD ASSEMBLY
Installation
Install the four vortex shield eye bolts to the frame assembly. (Ref. pages 13, 15, 17 and 19 for
eyebolt locations.) Install the four vortex shield cable snap hooks to the eye bolts and install
the vortex shield.
NOTE: Proper mounting will suspend the vortex shield plane surface parallel with the
water surface.
3.6.1 VORTEX SHIELD ASSEMBLY DRAWING
410614 - Tri-Float Vortex Shield
5 - 7.5HP
HARDWARE
ITEM #
1
2
3
4
5
6
PART #
301-044
301-047
250-105
215-104
240-035
215-081
DESCRIPTION
QTY.
CABLE ASSEMBLY. .............................................................. 2
CABLE ASSEMBLY ............................................................... 2
CABLE ATTACHMENT .......................................................... 8
WASHER, FLAT 3/8" ............................................................. 8
VORTEX SHIELD GRATE ..................................................... 1
LOCK NUT, 3/8-16 ................................................................. 4
410591 - Four, Five and Seven
Float Vortex Shield
10 - 75 HP
ITEM #
1
2
3
4
5
PART #
301-044
250-105
215-104
240-035
215-081
HARDWARE
DESCRIPTION
QTY.
CABLE ASSEMBLY. .............................................................. 4
CABLE ATTACHMENT .......................................................... 8
WASHER, FLAT 3/8" ............................................................. 8
VORTEX SHIELD GRATE ..................................................... 1
LOCK NUT, 3/8-16 ................................................................. 4
33
Installation
3.7
AIRE-O2® TRITON® ASSEMBLY PLACEMENT
1. Slide or hoist the AIRE-O2® TRITON® and flotation assembly into the water. To hoist the
assembly, fasten a sling or chain to each main frame rail just to the front of the motor
mount brackets. This is near the balance point for the entire assembly. Lift slowly and
check the balance of the assembly before moving.
2. Once the unit has been placed in the water. Position the AIRE-O2® TRITON® at a 45
degree angle below horizontal. Secure it with four 1/2" x 1 1/2" bolts through each
mount bracket and mounting flange. These bolts will be in the 3 and 9 o'clock positions.
(Horizontal)
3. Move the AIRE-O2® TRITON® to its location on the lagoon.
34
4.0
MOORING AND MOUNTING OPTIONS
Mooring Options
1. Fasten the AIRE-O2® TRITON® to the Mooring cable using the clamps provided. Leave
the clamps loose until the AIRE-O2® TRITON® system is located in its operating position
in the pond. (Ref. floatation cable attachment drawings pages 37 - 40)
2. Wire the motors using the wiring instructions on the motors and secure the power cables
to the frame and cables with tie wraps. See Electrical Section pages 58 - 62 and
Power Cable Selection pages 64 - 67.
Note: If the span from shore to shore is too great and more then one unit is attached to
span cable, care must be taken in routing electrical cable. The weight of the electrical
cable if attached to the span cable might be too great for the aerator to support. If this
is the case, other means of routing the electrical cable must be used.
The installation of cable float supports, or overhead support cable are options. Routing of the
electrical cable on the bottom of the lagoon can be done if UL approved submersible cable is
used.
35
Mooring Options
4.1
FLOTATION CABLE ATTACHMENT
There are two methods of anchoring AIRE-O2® TRITON® flotation assemblies. The variables
listed below are considered to determine the most practical anchoring method for a given
installation. (See 1-13 below.) They are also used to select wire rope cable size, cable anchors,
power cable size, AIRE-O2® TRITON® positioning, anchor weight, anchor shape, and anchor
position.
VARIABLES:
1. AIRE-O2® TRITON® horsepower
2. Number of AIRE-O2® TRITON® (s)
3. Water depth
4. Water level fluctuation
5. Dimensions of body of water
6. Shape of body of water
7. Wind and wave action
8. Snow and ice loading
9. Embankment or wall height above water surface
10. Continuous or seasonal use
11. Navigation requirements
12. Maintenance considerations
13. AIRE-O2® TRITON® orientation in body of water
Aeration Industries International, lnc., provides technical assistance on sizing and placement
of the AIRE-O2® TRITON® (s). Cabling or anchoring method should be determined before
installation.
4.2
CABLE SAG ALLOWANCE
Cable sag is measured at the midpoint of the longest span length between anchor cable
supports. Supports include cable anchor posts, aeration flotation, and auxiliary flotation. When
installing new anchor cable, sag allowance must be decreased to compensate for in-service
stretch.
The following chart lists sag allowances for span-direct anchor cabling configurations. This is
the minimum sag allowed. Allowing more sag will place less strain or tension on the cable and
its anchors. Under no circumstances should the anchor or power cable allowed to be in the
water.
Sag Allowance
Aerator
Nominal
Power
Sag Allowance
at Maximum Span
New
Cable
10 - 30 HP
36
Stretched
Cable
1' - 6"
2' -
0"
Mooring Options
4.3
SPAN DIRECT MOORING
4.3.1 3,4, 5 AND 7 FLOAT
The span direct cabling system will accommodate water level fluctuations up to three feet. To
insure proper slack (cable sag), the span direct cables should be installed with the water at its
lowest level. If this is impractical, then close observation must be maintained as water levels
change to prevent either excessive cable tension or slack.
The standard span-direct cabling attaches the AIRE-O2® TRITON® perpendicular to the cable.
Position the cable along the front cross member and attach it with cable clamps.
Once the AIRE-O2® TRITON® unit has been attached to the span cable, run the appropriate
electrical cable to the AIRE-O2® TRITON®. Attach it to the cable with plastic ties, leaving slack
between each tie.
Note: All four flotation assemblies use the following assembly for Span Direct Mooring
HARDWARE
ITEM #
1
2
PART #
221-022
221-019
221-020
221-044
DESCRIPTION
QTY.
WIRE ROPE CLAMP 3/8", S.S. ......................... 4
WIRE ROPE CLAMP 3/8", GALV ....................... 4
WIRE ROPE CLAMP 1/2", S.S. ......................... 4
WIRE ROPE CLAMP 1/2", GALV ....................... 4
Note: When ordering replacement parts specify either stainless steel or galvanized
360-121
37
Mooring Options
4.4
IN-LINE SPAN MOORING
Cable clamps attach the cable to each end of the in-line channel. In certain applications, a
channel iron is fabricated to be used in mounting the cable. The channel iron is bolted to the
flotation frame. The cable is then fastened to the channel using cable clamps. The specific
method used is determined from site factors and is engineered with these factors or requirements
in mind.
4.4.1 TRI-FLOAT IN-LINE SPAN MOORING
8
4
6
5
7
5
7
7
1
2
3
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
PART #
214-341
214-336
215-032
215-081
214-607
214-606
215-184
215-022
215-027
221-022
221-019
215-052
DESCRIPTION
QTY.
INLINE CHANNEL, S.S. ..................................... 1
INLINE CHANNEL, GALV .................................. 1
CAPSCREW, 3/8" x 1 1/4" ................................. 4
LOCK NUT, 3/8" ................................................. 4
INLINE MT., REAR, S.S. .................................... 1
INLINE MT., REAR, GALV ................................. 1
U-BOLT, 5/16", S.S. ........................................... 2
U-BOLT, 5/16", GALV ........................................ 2
LOCKWASHER, 5/16" ....................................... 4
WIRE ROPE CLAMP, 3/8", S.S. ........................ 3
WIRE ROPE CLAMP, 3/8", GALV ...................... 3
HEX NUT, 5/16" ................................................. 4
360-161
38
4.4.2 FOUR FLOAT IN-LINE SPAN MOORING
Mooring Options
2
4
4
1
2
3
4
1
2
3
HARDWARE
ITEM #
1
2
3
4
PART #
214-341
214-336
215-032
215-081
221-020
221-044
DESCRIPTION
QTY.
INLINE CHANNEL, S.S. ..................................... 1
INLINE CHANNEL, GALV .................................. 1
CAPSCREW, 3/8" x 1 1/4" ................................. 8
LOCK NUT, 3/8" ................................................. 8
360-060
39
Mooring Options
4.4.3 FIVE & SEVEN FLOAT IN-LINE SPAN MOORING
HARDWARE
ITEM #
1
2
3
4
*5
6
7
8
9
PART #
221-044
221-020
215-032
215-081
214-944
214-510
215-184
215-022
215-027
215-052
214-945
214-946
214-982
214-981
DESCRIPTION
QTY.
CAPSCREW, 3/8" x 1 1/4" ................................. 8
LOCK NUT, 3/8" ................................................. 8
INLINE MT., CHANNEL, S.S. ............................. 2
INLINE MT., CHANNEL, GALV .......................... 2
U-BOLT, 5/16", S.S. ........................................... 2
U-BOLT, 5/16", GALV ........................................ 2
LOCKWASHER, 5/16" S.S. ................................ 4
HEX NUT, 5/16" S.S. ......................................... 4
INLINE MOUNT - REAR, GALV. ........................ 1
INLINE MOUNT - REAR, S.S. ............................ 1
INLINE MOUNT - REAR, CHANNEL, GALV. ..... 1
INLINE MOUNT - REAR, CHANNEL, S.S. ......... 1
360-115
40
Accessory Mooring Options
4.5
ACCESSORY MOORING OPTIONS
4.5.1 SPAN BRIDLE ANGLED MOORING
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
PART #
———
238-098
215-066
215-081
———
215-026
215-095
215-160
238-110
214-830
DESCRIPTION
QTY.
BRIDLE .............................................................. 1
SWING ARM PIVOT .......................................... 2
CAPSCREW .375 x 1.00 ................................... 6
LOCKNUT .375.................................................. 6
WIRE ROPE CLAMP ......................................... 5
LOCKWASHER .375 ......................................... 2
HEX NUT .375 ................................................... 4
U-BOLT .375 ..................................................... 1
SWING ARM ...................................................... 1
BRACKET, CABLE SUPPORT .......................... 1
360-147
41
4.5.2 SPAN BRIDLE MOUNTING 3 & 4 FLOAT
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
PART #
————
221-025
221-008
————
215-066
215-081
————
215-095
215-160
105-003
221-026
221-004
————
215-026
DESCRIPTION
QTY.
BRIDLE .............................................................. 2
THIMBLE .25 SS ............................................ 4
THIMBLE .25 GALV. ....................................... 4
SWING ARM PIVOT .......................................... 4
CAPSCREW .375 X 1.00................................... 8
LOCKNUT .375.................................................. 8
WIRE ROPE CLAMP ........................................ 8
HEX NUT .375 ................................................... 8
U-BOLT .375 ..................................................... 2
CABLE .25 ...................................................... A/R
WIRE ROPE CLAMP S.S. ................................ 8
WIRE ROPE CLAMP GALV. .............................. 8
SWING ARM ...................................................... 2
LOCKWASHER .375 ......................................... 4
360-186
42
4.5.3 FLOAT SUPPORT ASSEMBLY 3 & 4 FLOAT
HARDWARE
ITEM #
1
2
3
PART #
214-999
214-998
215-032
215-081
DESCRIPTION
QTY.
FLOAT SUPPORT GALV ................................... 1
FLOAT SUPPORT S.S. .................................... 1
CAPSCREW .375-16UNC X 1.25 ...................... 8
LOCKNUT .375-16UNC ..................................... 8
360-192
43
4.5.4 FLOAT SUPPORT ASSEMBLY 5 & 7 FLOAT
HARDWARE
ITEM #
1
2
3
PART #
214-902
214-901
215-081
215-032
DESCRIPTION
QTY.
FLOAT SUPPORT, STAINLESS STEEL ........... 2
FLOAT SUPPORT, GALVANIZED ..................... 2
LOCKNUT 3/8-16UNC ...................................... 16
CAPSCREW 3/8-16 X 1 ¼ SS ......................... 16
360-209
44
Accessory Mounting Options
4.6
WALL AND BRIDGE MOUNT ASSEMBLIES
4.6.1 WALL MOUNT ASSEMBLY 5 - 15 HP
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
12
360-034
13
PART #
214-218
214-049
214-223
214-357
214-054
214-369
214-225
214-055
214-224
214-056
215-145
214-061
214-014
215-032
215-081
215-093
215-099
215-165
215-125
214-226
214-075
215-088
DESCRIPTION
QTY.
WALL MOUNT, SS ............................................ 1
WALL MOUNT, GALV. ....................................... 1
FORK, S.S. 18.00 (45.72)................................... 1
FORK, S.S. 22.75 (57.79) ................................. 1
FORK, GALV. 18.00 (45.72) ............................... 1
FORK, GALV. 22.75 (57.79) ............................... 1
COLLAR, SS ...................................................... 1
COLLAR, GALV. ................................................ 1
PIVOT TUBE, SS ............................................... 1
PIVOT TUBE, GALV. ......................................... 1
CAPSCREW .50-13UNC X 3.50 ...................... 3
MOUNT BRACKET, SS ..................................... 2
MOUNT BRACKET, GALV. ................................ 2
CAPSCREW .375-16UNC X 1.25 ...................... 8
LOCKNUT .375-16UNC ..................................... 8
LOCKNUT .50-13UNC ....................................... 5
CAPSCREW .50-13UNC X 1.50 ......................... 2
PARA-BOLT ANCHOR, SS ................................ 8
PARA-BOLT ANCHOR, GALV. .......................... 8
ANCHOR BRACE, SS ........................................ 2
ANCHOR BRACE, GALV. .................................. 2
CAPSCREW .50-13UNC X 1.00 ......................... 2
45
4.6.2 VORTEX SHIELD, WALL MOUNT 5 - 15 HP
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
PART #
214-181
214-179
214-182
214-180
301-051
250-105
215-104
240-037
215-206
215-133
215-032
215-081
DESCRIPTION
QTY.
SUPPORT-RIGHT S.S. ...................................... 1
SUPPORT-RIGHT GALV. ................................... 1
SUPPORT-LEFT S.S. ........................................ 1
SUPPORT-LEFT GALV. ..................................... 1
CABLE ASSEMBLY ........................................... 4
CABLE ATTACH. BLOCK .................................. 8
FLATWASHER, .375 ......................................... 8
VORTEX SHIELD ............................................... 1
EYEBOLT S.S. .................................................. 4
EYEBOLT GALV. ............................................... 4
CAPSCREW .375-16UNC .................................. 4
LOCKNUT .375-16UNC ..................................... 8
360-204
46
4.6.3 WALL MOUNT, GALV. & SS. 20 - 75 HP
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
360-178
11
PART #
214-218
214-049
214-988
214-989
214-225
214-055
214-224
214-056
215-145
214-948
214-947
214-908
214-909
215-093
215-099
215-165
215-125
214-991
214-990
215-088
DESCRIPTION
QTY.
WALL MOUNT, SS, 20-75HP ............................. 1
WALL MOUNT, GALV. 20-75HP ........................ 1
FORK, S.S. 20-75HP ....................................... 1
FORK, GALV. 20-75HP .................................... 1
COLLAR, SS ..................................................... 1
COLLAR, GALV. ................................................ 1
PIVOT TUBE, SS.............................................. 1
PIVOT TUBE, GALV. ......................................... 1
CAPSCREW .50-13UNC X 3.50 ........................ 3
MOUNT BRCKET, 20-25HP SS ....................... 2
MOUNT BRACKET, 20-25HP GALV. ............... 2
MOUNT BRACKET, 30-75HP SS ..................... 2
MOUNT BRACKET, 30-75HP GALV. ............... 2
LOCKNUT .50-13UNC ...................................... 15
CAPSCREW .50-13UNC X 1.50 ....................... 12
PARA-BOLT ANCHOR, SS ............................... 10
PARA-BOLT ANCHOR, GALV. ......................... 10
ANCHOR BRACE, SS ....................................... 2
ANCHOR BRACE, GALV. .................................. 2
CAPSCREW .50-13UNC X 1.00 ........................ 2
47
4.6.4 VORTEX SHIELD ASSEMBLY 20 - 75 HP WALL MOUNT
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
PART #
214-1009
214-1008
214-1007
214-1006
215-206
215-133
215-102
410-640
215-099
215-093
360-178
DESCRIPTION
QTY.
SUPPORT-RIGHT S.S. ..................................... 1
SUPPORT-RIGHT GALV. ................................. 1
SUPPORT-LEFT SS. ........................................ 1
SUPPORT-LEFT GALV. .................................... 1
EYEBOLT S.S. ................................................. 4
EYEBOLT GALV. .............................................. 4
LOCKNUT .31-18UNC ....................................... 4
VORTEX SHIELD ............................................... 1
HHCS ½-13UNC X 1-1/2 .................................... 4
LOCKNUT ½-13UNC ......................................... 4
TRITON WALL MOUNT ................................... REF.
360-179
48
4.6.5 BRIDGE MOUNT GALV. & SS. 5 - 15 HP
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
PART #
214-014
214-061
215-032
215-081
215-175
215-155
215-411
215-373
214-585
214-583
214-586
214-584
215-372
215-374
215-157
215-093
215-099
DESCRIPTION
QTY.
MOUNT BRACKET GALV. ................................. 2
MOUNT PRACKET S.S. .................................... 2
CAPSCREW .375-16UNC X 1.25 ...................... 8
LOCKNUT .375-16UNC ..................................... 8
LOCKNUT .625-11UNC GALV. .......................... 5
LOCKNUT .625-11UNC S.S. ............................ 5
SNUBBING WASHER GALV. ............................. 5
SNUBBING WASHER S.S. ............................... 5
BRIDGE MNT. GALV. 22.75’’ (57.79) ................ 1
BRIDGE MNT GALV. 18.00’’ (45.72) ................ 1
BRIDGE MOUNT S.S. 22.75’’ (57.79)................ 1
BRIDGE MOUNT S.S. 18.00’’ (45.72)................ 1
VIBRATION ISOLATOR ..................................... 5
CAPSCREW .625-11UNC X 4.00 ...................... 5
LOCKNUT .50-13UNC GALV. ............................ 4
LOCKNUT .50-13UNC S.S. ............................... 4
CAPSCREW .50-13UNC X 1.50 ........................ 4
360-097
49
4.6.6 VORTEX SHIELD ASSEMBLY, BRIDGE MOUNT 5 - 15 HP
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
PART #
214-181
214-179
214-182
214-180
301-040
215-104
250-105
240-037
215-206
215-133
215-032
215-081
DESCRIPTION
QTY.
SUPPORT-RIGHT S.S. ...................................... 1
SUPPORT-RIGHT GALV.................................... 1
SUPPORT-LEFT S.S. ........................................ 1
SUPPORT-LEFT GALV. ..................................... 1
CABLE ASSEMBLY ........................................... 4
FLATWASHER 3/8’’ ........................................... 8
CABLE ATTACH. BLOCK .................................. 4
VORTEX SHIELD ............................................... 1
EYEBOLT S.S. .................................................. 4
EYEBOLT GALV. ............................................... 4
CAPSCREW .375-16UNC .................................. 4
LOCKNUT .375-16UNC .................................... 12
360-203
50
4.6.7 BRIDGE MOUNT GALV. & SS. 20 - 75 HP 50 - 60 HZ
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
PART #
214-812
214-807
214-1018
214-1019
215-099
215-093
215-155
215-373
214-978
214-979
215-372
215-374
215-093
215-099
DESCRIPTION
QTY.
MOUNT BRACKET GALV. ................................. 2
MOUNT BRACKET S.S. ................................... 2
MOUNT BRACKET GALV. ................................ 2
MOUNT BRACKET S.S. ................................... 2
CAPSCREW ½-13UNC X 1.25 ........................... 8
LOCKNUT ½-13UNC .......................................... 8
LOCKNUT .625-11UNC S.S. ............................ 6
SNUBBING WASHER S.S. ............................... 6
BRIDGE MOUNT 30-50HP GALV. .................. 1
BRIDGE MOUNT 30-50HP S.S. ...................... 1
VIBRATION ISOLATOR ..................................... 6
CAPSCREW .625-11UNC X 4.00 ...................... 6
LOCKNUT .50-13UNC S.S. .............................. 4
CAPSCREW .50-13UNC X 1.50 ........................ 4
360-169
51
4.6.8 VORTEX SHIELD ASSEMBLY 20 - 75 HP BRIDGE MOUNT
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
PART #
214-1022
214-1020
214-1023
214-1021
215-206
215-133
215-081
410-640
215-099
215-093
360-169
DESCRIPTION
QTY.
SUPPORT-RIGHT S.S. ..................................... 1
SUPPORT-RIGHT GALV. ................................. 1
SUPPORT-LEFT S.S. ....................................... 1
SUPPORT-LEFT GALV. .................................... 1
EYEBOLT S.S. ................................................. 4
EYEBOLT GALV. .............................................. 4
LOCKNUT .375-16UNC ..................................... 4
VORTEX SHIELD ............................................... 1
HHCS ½-13UNC X 1-1/2 .................................... 4
LOCKNUT ½-13UNC ......................................... 4
TRITON BRIDGE MOUNT ............................... REF
360-184
52
4.6.9 BRIDGE/WALL MOUNT CRANE
HARDWARE
ITEM #
1
2
3
4
5
6
7
8
9
10
11
PART #
215-032
215-081
251-003
251-008
215-092
215-093
251-005
005-001
221-009
221-008
251-007
DESCRIPTION
QTY.
.375-16UNC X 1.25’’ HHCS ................................ 3
.375-16UNC LOCKNUT ....................................... 3
WINCH ............................................................... 1
BOOM ................................................................ 1
.50-13UNC X 2.00’’HHCS ................................... 1
.50-13UNC LOCKNUT ........................................ 1
CABLE BLOCK .................................................. 1
CABLE 3/16’’ S.S. .......................................... 15’
CABLE CLAMP .................................................. 2
THIMBLE ........................................................... 1
SNAP HOOK ...................................................... 1
360-188
53
Notes
54
START-UP
5.1
ELECTRICAL CHECK
Startup
5.0
WARNING: The main power supply control panel must be a "Power Out Manual Reset"
configuration.
After stoppage of the aerator due to a power outage, voltage spike or any other situation, single
or multiple units must not be allowed to automatically restart, or damage may occur. The
aerators must be either manually bumped and restarted as specified under the start-up section
of the O&M manual or a control panel must be supplied using technology similar to a soft start.
Failure to follow this procedure will void the factory warranty.
WARNING: Do not splice power cable or use quick disconnects between the motor and
the power supply cable at the motor or any other place.
WARNING: Always wear an approved life vest when working on the aerator near or over
water.
1. Install electrical cable onto the span-direct or in-line mount using plastic wire-ties. Space
the wire-ties to limit electrical cable sag between attachments to 2 inches maximum.
Excessive sag may allow the cable to oscillate continuously in strong winds leading to
wear damage.
WARNING: Keep cables off of walkways if provided.
2. Install the electric cable between the span-cable and the motor junction box along a
convenient frame component using wire ties for span-direct or in-line mounts.
3. Electrical cable connection to motor must be completed by a certified electrician using
the wiring diagram provided by the motor manufacturer. Failures due to improper
electrical connection are not covered by the warranty.
4. Electrical cable should not be placed over the sharp edges of the metal frame. Machine
vibration and movement due to wind or wave action will cause abrasion to the cable
insulation.
5. Mounting of the power cable should prevent any tension on any component. This applies
at all points from motor controller to motor junction box.
Use of flexible electrical cable permits easy installation. It allows the AIRE-O2® TRITON® to be
tilted-up for maintenance. Properly installed power cable should not be subjected to constant
flexing due to wind or wave action. This will assure its long life.
A qualified electrician is to check and record voltage supplied to the operating motor upon startup. (See Start-Up Procedure in this manual.)
55
Startup
5.2
MOTOR INTERNAL CONNECTIONS
Your first source of wiring information should be the motor nameplate. Some motors will display
wiring information inside the junction box cover. Others may have sheets accompanying the
motor. Another source of wiring diagrams are found in the motor wiring diagrams in this manual.
Remove the cover of the motor junction box. The numbered wire lead ends will be identified.
5.3
START-UP PROCEDURE
Prior to start-up, electrical power connections should be completed. The AIRE-O2® TRITON®
should be positioned in the water secured by cabling or other means. The propeller should be
free and clear of any obstruction. Keep in mind that once the AIRE-O2® TRITON® is started,
thrust generated will move the AIRE-O2® TRITON® in the water. The distance it will move
depends on cable tension and sag allowance.
WARNING: The AIRE-O2® TRITON® will move or surge when first turned on. No one
should be near the unit or in the water when the machine is turned on or while it is
running.
CAUTION: The AIRE-O2® TRITON® will move when first turned on. This surge or motion
is the result of the thrust created by the unit. All anchoring hardware and/or cabling
should be firmly fastened. Personnel should be clear of the AIRE-O2® TRITON® and its
propeller.
NOTE: Never run the AIRE-O2® TRITON® out of the water. The lower bearing is water
lubricated and will overheat without water lubrication. This may cause severe damage
to the bearing and sleeve. This kind of damage is not covered by the warranty.
5.4
ROTATION CHECK
Once the AIRE-O2® TRITON® (s) is anchored securely in position and all the electrical
connections are checked for correctness, the AIRE-O2® TRITON® (s) are ready for a rotation
test. Check each AIRE-O2® TRITON® individually.
1. Use two people. One operates the ON/OFF switches. Turn on for less than one
second ). The other person observes the AIRE-O2® TRITON® water flow.
CAUTION: Do not operate the AIRE-O2® TRITON® motor in reverse rotation.
2. When visually checking the water flow of the AIRE-O2® TRITON®. The water flow is
the same as a boat with a motor. With correct operation the water/air mixture flows
smoothly away from the unit. Water should not splash up toward the motor end of the
unit.
3. If the rotation is wrong, switch or reverse any two of the three power leads in the motor
starter or at the motor junction box (three-phase). Single phase motors are reversed by
reversing connection of the starter winding leads inside the motor junction box. Most
motors have a wiring diagram for reference printed inside the motor junction box cover.
56
5.5
FUNCTIONAL ELECTRICAL CHECK
Startup
Verify the amperage and voltage for each AIRE-O2® TRITON® at the motor control box. The
motor should be running at this time. This check should be made only by qualified people.
I.
The amperage and voltage readings should be equal to or less than the rating on the
motor nameplate.
2. The voltage supply should read approximately the same on all three leads (three phase).
Keep a record of both current and voltage readings. (Use sheets provided in the
Appendix of this manual.)
These initial readings will provide a reference for comparing with future readings. Any
significant change would signal a problem with the motor, propeller or bearing assembly.
5.6
OPERATIONAL CHECK
1. The AIRE-O2® TRITON® should run smoothly and quietly. Consult the troubleshooting
guide if noise is excessive.
2. Check for vortexes above the propeller. The vortex shield may need repositioning to
eliminate all vortexing. Allowing vortexing to continue may damage the propeller from
cavitation.
After the unit runs several minutes, note the operating position of the AIRE-O2® TRITON® unit.
The AIRE-O2® TRITON® may have to be repositioned on the cables to point it in the optimum
direction. Refer to the AIRE-O2® TRITON® placement drawings provided by Aeration Industries
international or the consulting engineer to reference the installation drawing or arrangement.
IMPORTANT: Because of the various environments that the aerator can be subjected to,
adjustments in the frequency of inspections will vary. Aeration Industries international
Inc. recommends that each aerator is disassembled for thorough inspection of parts at
least once a year.
Required Maintenance Summary
• Grease motor bearings.
• Grease the drive shaft U-joint once a year when disassembling for inspection.
• Inspect and clean debris out of the housing and water lubrication holes.
• Inspect the sleeve, lower bearing, propeller, and drive shaft for wear and debris.
Replace if required.
• Confirm the propeller and atomizer assembly are tightly seated.
• Confirm all fasteners to the aerator, motor and pontoons assembly are secured.
• Inspect electrical and mooring cables for improper sag and wear. Correct as required.
• Confirm all fasteners to all electrical cables are properly secured.
• Monitor and compare voltage and current readings to start-up readings.
• Clear any debris from the motor breather drain / weep hole.
• Inspect for damaged or missing parts.
• Check for proper tension on the motor cord-grip.
57
START-UP NOTES
Startup Notes
5.7
58
Cut along this line
Startup
55459-0144
CUSTOMER SERVICE
P.O. BOX 59144
Minneapolis, MN USA
Affix
proper
postage
and mail
Cut along this line
Fold
Fold
Cut along this line
COMPLETE WARRANTY ON OTHER SIDE CUT OUT PAGE ALONG VERTICAL
DOTTED LINE. ENCLOSE ADDITIONAL PHOTO COPIES IF NEEDED. FOLD PANELS
SO WARRANTY VALIDATION IS NOT EXPOSED. EXPOSE TOP ADDRESS PANEL
TAPE CLOSED, DO NOT STAPLE. AFFIX PROPER POSTAGE AND MAIL.
59
Maintenance
5.8
MOTOR WARRANTY VALIDATION
IMPORTANT: Complete this entire form and return to: Aeration Industries International, Inc. to initiate
motor warranty protection. See other side for mailing instructions.
CONTRACTOR:________________________________________________________________________
ADDRESS:_______________________CITY:_____________STATE/COUNTRY:____________ZIP: _______
TEL: _________________FAX:_________________DATE TURNED OVER TO OWNER:______________
ELECTRICIAN NAME:________________________________CO. NAME:__________________________
TEL:_______________________________________FAX:______________________________________
SIGNATURE: _______________________________ DATE:_____________________________________
EQUIPMENT OWNER/CUSTOMER: ________________________________________________________
CONTACT PERSON:________________________________________TEL:________________________
INSTALLATION/SITE ADDRESS:___________________________________________________________
EQUIPMENT OWNER/CUSTOMER MAIL ADDRESS:___________________________________________
CITY:__________________________STATE / COUNTRY:__________________________ ZIP:_________
TEL:______________________________________FAX:_________________________________________
Nameplate specifications on your aerator motor(s)
MOTOR:
HP/Kw
amps
volts
Hz
phase
RPM
S.F.
ID #
CABLE:
Length
size
No.1
____
____
____
____
____
____
____
____
No. 2
____
____
____
____
____
____
____
____
No. 3
____
____
____
____
____
____
____
____
No. 4
____
____
____
____
____
____
____
____
No. 5
____
____
____
____
____
____
____
____
No. 6
____
____
____
____
____
____
____
____
____
____
____
____
____
____
____
____
____
____
____
____
Motor #
____
Leg 1-Leg 2
____ volts
Leg 1-Leg 3
____ volts
Leg 3-Leg 2
____volts
____
____
____ volts
____ volts
____ volts
____ volts
____volts
____volts
____
____
____ volts
____volts
____ volts
____ volts
____volts
____volts
Leg 1
Leg 2
Leg 3
Leg 1-GND
Leg 2-GND
Leg 3-GND
___amps
___amps
___amps
___amps
___amps
___amps
____volts
____volts
____volts
____volts
____volts
____volts
___amps
___amps
___amps
___amps
___amps
___amps
____volts
____volts
____volts
____volts
____volts
____volts
___amps
___amps
___amps
____volts
____volts
____volts
Power ON Frequency ________
Type of over-current protection used? Thermal, Magnetic, other __________________________________
What is the rating and setting of your over-current protection _____________________________________
For three phase power, is there phase loss protection? (Circle )
yes
no
What is the date(s) of aerator(s) start up? ___________________________________________________
Who performed the initial start-up?___________________________________________________
PHOTOCOPY FORM AS REQUIRED TO INCLUDE ALL AERATORS
REQUIRING WARRANTY VALIDATION
60
MAINTENANCE
6.1
PREVENTIVE MAINTENANCE
Maintenance
6.0
Maintenance And Service Schedule
The maintenance record sheet follows on page 42. Make copies and use them to insure
documentation and performance of maintenance procedures. File for a maintenance record.
Honoring any warranty claim will require these signed, dated, and completed sheets as
evidence of proper maintenance.
Daily Observations
Aeration Industries International, Inc., recommends when possible that each unit be observed
daily. The AIRE-O2® TRITON® should run quietly without excessive vibration. Also note the flow
of water and air from the AIRE-O2® TRITON®. Noise, vibration, and disrupted air or water flow
are indicators of operational problems. Daily observation will ensure that problems will be
corrected before damage can occur to the AIRE-O2® TRITON®.
Quarterly Inspection
The record sheets on page 48 should be copied for use during scheduled maintenance of the
AIRE-O2® TRITON® throughout each year of service. Keep the completed sheets on file as a
record of maintenance performed. Copy or reproduce one sheet for each AIRE-O2® TRITON®
for each year of service.
Perform inspection and maintenance at 3, 6, 9, and 12 month intervals. The date of service and
the name of the servicing person should be recorded.
Assign a number to each AIRE-O2® TRITON® and note its location in the lagoon or basin. This
number is used to specify each individual AIRE-O2® TRITON®. Record any changes in location
if needed.
Yearly Inspection
Aeration Industries International Inc. recommends disassembly of the AIRE-O2® TRITON® at
least once a year for universal U-joint lubrication and to visually inspect bearings, sleeve and
shaft for wear or damage.
NOTE: Disassembly and Assembly instructions are covered in the "Service Addendum"
starting on page 74.
Blower Preventive Maintenance
Inspect he Blower filter and replace if dirty (Maximum filter life is 6 months.) Prompt
replacement of filters is the only required blower maintenance. During the yearly tear
down maintenance, it is advisable to check the electrical connections.
61
Maintenance
6.2
MAINTENANCE AND SERVICE RECORD
Service Interval
3 Month
6 Month
9 Month
12 Month
Maintenance Person, Initials
and Actual Date of Service
_______
_______
_______
_______
Grease motor bearings 3 month
interval -see section in manual on
lubrication procedure. Use lithiumbased grease. (Ref Page 42)
_______
_______
_______
_______
Grease universal joint, one a year
when disassembled for inspection.
_______
_______
_______
_______
Check all bolts on the AIRE-O2®
TRITON® and flotation for tightness.
_______
_______
_______
_______
If span bridle cabling is used, check
the cable bridle attachment for wear.
_______
_______
_______
_______
Check electrical connections, power
cable condition, and power cable
fastenings.
_______
_______
_______
_______
Lower unit inspection of propeller and
bearing. Keep record of service
performed
_______
_______
_______
_______
Inspect the Blower filter every 3
months and replace if dirty. (Maximum
filter life is 6 months)
_______
_______
_______
_______
Measure and record voltage at each
leg.
Leg1 - Leg2
Leg2 - Leg3
Leg3 - Leg2
Measure and record amp draw at
each leg.
Leg1
Leg2
Leg3
Estimated cumulative hours in
operation.
______ Volts _____ Volts _____ Volts _____ Volts
_____ Amps _____ Amps _____ Amps _____ Amps
_____ Hrs ______ Hrs ______ Hrs ______ Hrs
Record below any observations or additional repairs performed. Identify the specific unit by
number and indicate date.
DANGER: Voltage and current readings should be measured in the control box or panel,
not at the motor. Readings should be taken by qualified personnel familiar with using
volt and amp meters.
62
6.3
MAINTENANCE AND SERVICE NOTES
Maintenance
63
Maintenance
7.0
AIRE-O2® TRITON® SERVICE PROCEDURES
7.1
AIRE-O2® TRITON® SERVICE
The AIRE-O2® TRITON® shaft-housing assembly may be removed for servicing without the
need for removing the heavy motor. This permits leaving the AIRE-O2® TRITON® installation in
place, simplifying routine maintenance. AIRE-O2® TRITON® (s) may be pivoted raising the
propeller out of the water so that inspection, lubrication, and repairs can be made. If motor repair
or replacement is to be performed, then a hoist will be needed. A boat will be needed to service
AIRE-O2® TRITON® (s) mounted on floats.
NOTE: Disassembly and Assembly instructions are covered in the "Service Addendum"
starting on page 74.
DANGER: Turn off electrical power and lock the AIRE-O2® TRITON® “out of service”
before servicing . Use lock-Out Cards.
1. Turn the motor off and lock the unit out of service.
2. Approach the AIRE-O2® TRITON® (using the boat) to reach the motor mounting
brackets. Disconnect the vortex shield to take it out of the way.
3. Loosen the four mounting bolts, permitting the AIRE-O2® TRITON® to tip to a nearly
horizontal position. This lifts the propeller and housing assembly out of the water. Lock
the motor assembly in the nearly horizontal position by replacing a bolt and nut through
the mount bracket slot and a hole in the mounting flange.
4. Move the boat around the AIRE-O2® TRITON® flotation to approach the propeller end
with the rear of the boat. Position the boat between the pontoons and under the AIREO2® TRITON®, Inspect the AIRE-O2® TRITON®. The points listed may be followed in any
order. The specific items checked will prevent problems and extend service life.
7.2
INSPECT THE AIRE-O2® TRITON®
1. Check the bolts on the housing and motor mounting flange and retighten.
2. Look for any signs of corrosion.
3. Check the flotation unit for any loose bolts, parts, or damage. Correct as necessary.
4. The propeller and atomizer should be free of debris.
5. Closely examine the propeller and diffuser for indication of wear Slight propeller wear
grooves are acceptable if the profile or shape of the propeller blade is not affected.
Should wear be extensive, replace the worn item.
6. Remove any debris obstructing the bearing water lubrication holes. These holes are
locatedin the lower end of the housing just above the propeller.
7. Visually inspect the bearing for wear. Wear groves should be visible and even. Replace
the bearing and sleeve if the wear groves are gone or uneven wear is evident replace
the bearing.
64
Note: Replace the sleeve if it is showing any wear.
Maintenance
8. Manually turn the shaft. The sleeve should rotate with the shaft. Keeping the propeller
tight will hold the sleeve to the shaft. If the sleeve slips on the shaft it must be replaced
to prevent further damage to the shaft.
9. To properly inspect the sleeve both the atomizer and power mix propellers must be
removed. Remove the nylon washer and slide the sleeve off the shaft. The sleeve must
be replaced to prevent additional damage if there are groves, ships or signs of cracking.
Note: The sleeve must rotate with the drive shaft
10. The hollow shaft should be open and free of debris.
11. Attach a rat tail (bottle) brush to a rod. Use it to clean the interior of the shaft. Be sure
the brush reaches to the air intake holes.
12. Manually turn the shaft. It should turn freely. If it does not, check the motor bearings and
elastomeric bearings (surrounding the sleeve) for binding. (See "Problem Analysis"
pages 54-57.)
13. Lubricate the grease zerk fitting at the universal joint. Access to the zerk fitting is attained
by removing the atomizer, power mix propeller and the four bolts that hold the housing
to the mounting flange. Slide the housing away from the motor to expose the universal
joint. Grease and reassemble.
NOTE: See lubrication instructions on Page 52)
14. Examine electrical cable, cable mounting, and connections. If insulation is damaged,
repair the damage or replace the cable, All fastenings should be secure.
( Do not under any circumstances splice the power cable.)
15. The positioning or securing of the wire rope cable should be in satisfactory condition with
clamps or mounting devices properly tightened.
Once the above checks have been completed, the AIRE-O2® TRITON® motor should be
positioned as it was before Steps 3 and 4. Tighten bolts securely.
65
Maintenance
7.3
LUBRICATION
An adequate procedure and schedule of bearing lubrication is necessary to prolong bearing life
yet prevent motor damage from over greasing.
The motor manufacturer's standard recommendation are that all motors should be greased
every 3 months
The motor should be warm and should have been operating at least 20 minutes immediately
prior to lubrication.
Examine the motor to determine the procedure to be used. Where Alemite or zerk fittings are
provided, clean the fittings. Insert the lubrication fitting on the motors provided with plugs.
Remove both upper and lower grease relief plugs before greasing. Check for hardened grease
by inserting a wire into the grease relief tube to clean it. Evidence of hardening or waxy grease
would require through cleaning of the tube.
Grease both the upper and lower bearings of the motor. Use a limited amount of lithium based
grease.
WARNINGS:
-
Do not pump grease through the bearing to "Flush" it out. Excessive greasing is
detrimental to motor life.
The motor should be "Off" when greasing or performing other maintenance.
After greasing, run the motor one hour before replacing the relief plugs. This allows excess
grease to be purged or any pressure build-up to be relieved.
U- Joint Lubrication
Lubricate the grease zerk fitting once a year when the unit is disassembled for inspection.
LUBRICATION VOLUME
FRAME SIZE
VOLUME
182 Thru 215
254 Thru 286
324 Thru 365
404 Thru 449
0.5 Cu. In.
1.0 Cu. In.
1.5 Cu. In.
2.5 Cu. In.
Recommended lithium based greases are:
General Electric D6-A2C5
Shell Oil Company’s Dolium R
Chevron Oil’s SRI No. 2
Texaco Premium RB. Use lithium based grease.
66
PROBLEM ANALYSIS
8.1
PROBLEM ANALYSIS OVERVIEW
Problem Analysis
8.0
The purpose of the troubleshooting guide is to help you recognize problems, make the
corrections, and thus avoid costly down time for the AIRE-O2® TRITON®. Various “Symptoms,”
“Possible Causes,” and “Corrections” are provided to help guide you.
The AIRE-O2 ® TRITON® is thoughtfully engineered to permit servicing by two people. Problems
are simple to diagnose and to correct.
Experience indicates that most problems fall into one of three areas:
Motor / Electrical
Mechanical
Operational
Have qualified personnel performing troubleshooting and maintenance work. Read and follow
safety precautions in this manual.
The unit may be pivoted in the mounting bracket for servicing, minimizing the need for a hoist.
67
Problem Analysis
8.2
PROBLEM ANALYSIS CHARTS
SYMPTOMS
POSSIBLE CAUSES
CORRECTlONS
Excessive current
Inaccurate ammeter
Re-calibrate amp meter
Excessive current, running no
load
High line voltage of 5 - 10%
over rating
Consult power company, or
consider changing
transformer taps
Excessive current
Motor overloaded
Propeller fouled
Replace motor with one of
correct voltage rating
Motor voltage rating does not
match power system supply
Consult power company,
or consider changing
transformer taps
Bearing drag
Replace or lubricate
Motor runs wrong direction
Incorrect motor wiring
Switch two of three power
leads (3 phase, only)
Motor runs hot
Overloaded
Clean fouled propeller
Replace seized motor
bearings or seized lower
bearing
Reduce load or number of
starts per hour, or increase
motor size
68
Blocked ventilation
Clean external ventilation
system and check fan
High ambient temperature
Eliminate external
interference to motor
ventilation
Unbalanced input current
Balance supply voltagecheck motor leads for
tightness (3 phase, only)
8.2
POSSIBLE CAUSES
CORRECTIONS
Motor will not start
Rotor or bearing locked
Shut off power check shaft for
free rotation
Problem Analysis
SYMPTOMS
Be sure proper sized overload
relays are in each of the three
phases of the starter
Refer to National Electrical
Code
Voltage drop exceeds 2% of
supply voltage
Overload relays trip at startup (See also slow starting)
Motor wired wrong
Check wiring diagram
Phase wrong
Consult power company
Excessive start load
Clean fouled propeller.
Replace seized motor bearings
or seized lower bearing.
Inadequate power supply
Undersized supply lines
Increase line size or shorten
length
Each phase lead run in
separate conduits
All three phase leads shall be
in a single conduit, per
National Electrical Code. (This
applies only to metal conduit
with magnetic properties).
Slow starting ( 10 to 15
seconds or more) due to high
inertia load
Clean fouled propeller.
Replace seized motor bearings
or seized lower bearing
Low voltage at motor
terminals
Improve power supply or
increase line size
Overload
Check for mechanical
problems
Unbalanced input current
Balance supply voltage
Single phasing
Too frequent starting or
intermittent overloading
Reduce frequency of starts
and overloading or increase
motor size
High ambient starter
temperature
Reduce ambient temperature
or provide outside source of
cool air
69
Problem Analysis
8.2
SYMPTOMS
POSSIBLE CAUSES
CORRECTlONS
Overload relays trip at
start-up (Continued)
Wrong size relays
Correct size per nameplate
current of motor - relays have
built-in allowance for service
factor current. Confirm line
drop is included.
RPM below specification
Excessively low voltage
Check power Source,
consult power company
Inaccurate method of
measuring RPM
Re-calibrate RPM meter
Single phased
Shut off power-if it cannot
be restarted, it may be
single phased
Mismatched controller
Check for properly sized
overload relays
Note: A reasonable load or
voltage drop will reduce
speed only I - 2%. Reported
RPM drop of greater amount
would be questionable.
Excessive electrical noise
or chatter under load
Refer to National Electric
Code
Slow starting
( 10 - 15 seconds or more)
Excessive voltage
Consult with power
company or check with
certified electrician
Noisy motor bearing
(listen to bearings)
Internal fit of bearing too
tight
Replace bearing-check fit
Internal fit of bearing too
loose
Replace bearing-check fit
Bearing destroyed
Replace bearing
Loose mounting
Check motor and housing
mounting bolts
AIRE-O2® TRITON® or
motor out of balance
Disconnect the AIRE-O2®
TRITON® from the motor
and restart motor.
a. Motor imbalance
Have motor serviced at a
certified motor repair shop
b. Shaft or propeller
imbalance
Check for worn bearing.
Clean the shaft and propeller,
or return propeller / shaft
assembly
to Aeration
Industries international for
balance check.
Mechanical noise and
excessive vibration
Note: If you can observe the
housing shaking, vibration
is excessive. An increase in
noise is the best indicator of
a problem.
70
8.2
POSSIBLE CAUSES
CORRECTIONS
Intermittent or no air coming
out
Fouled propeller
Clean propeller
Plugged shaft
Clean shaft
Worn bearing or sleeve
Replace bearing or sleeve
Detached prop or shaft
Reassemble propeller and
shaft assembly or replace
(Check for damage)
Propeller on backward or
loose
Check propeller illustration in
the assembly section
Blower Inoperative
Check blower for proper
operation
Propeller vortexing
Add vortex shield
Propeller vortexing
Add vortex shield
Loose mounting cable
Tighten cable
Float assembly moving on
pond
insufficient anchoring
Too much slack in mooring
cable
Re-anchor to shore
Tighten mooring cable
Water splashing back
Motor running in reverse
Reverse two of the power
leads at the electrical control
box (3 phase, only )
Float assembly bucking and
vortexing
Problem Analysis
SYMPTOMS
71
Electrical Connections
9.0
ELECTRICAL ASSEMBLY
9.1
THREE PHASE MOTOR CONNECTIONS
Wound coil ends terminating in the motor junction box are identified as T1, T2, T3, T4, etc. You
will find 3, 6, 9, or 12 of these leads.
L1, L2, and L3 identify 3 - phase line connecting points.
Reversing motor rotation on 3 - phase motors involves interchanging any two of the three power
leads, L1, L2, or L3.
A small triangle may be used to indicate Delta winding connections. Y connections may be
called “star-” or “wye” The following configurations apply to both 50 Hz and 60 Hz motors.
3 LEADS
Motors with 3 leads (T1, T2, T3) are connected directly to LI, L2, and L3 in any order. Reversing
any two of the three leads will reverse the rotation of the motor.
Delta or Y Connected
Single Voltage
Across The Line Starting
72
9.1
6 LEADS
Motors with 6 leads are usually special voltage or large horsepower motors and are
wired for single voltages.
The following connection configuration applies to both 50 Hz and 60 Hz motors. Motors
may be wound in Delta or Y configurations. Therefore, it is important to consult the wiring
diagram on the nameplate or inside the cover of the conduit box. If there is no wiring
diagram and you are unsure of winding configuration, call Motor manufacturer or
Delta-Connected
Single Voltage
73
9.1
9 LEADS
Motors with 9 leads are dual voltage motors manufactured as either Delta or as Y connected.
This configuration cannot be changed at the motor junction box. Therefore, it is important to
consult the wiring diagram on the nameplate or inside the cover of the conduit box.
The following connection configurations apply to both 50 Hz and 60 Hz motors. If there is no
diagram and you are unsure of winding configuration, call motor manufacturer or Aeration
Industries International, Inc.
Nine lead motors cannot be wired for Y start / Delta run.
Delta Connected
Dual Voltage
Y Connected
Dual Voltage
74
9.1
12 LEADS
Motors with 12 leads are dual voltage motors and are typically provided in Y configuration for
1 hp to 5 hp and Delta configurations for 7.5 hp and larger. They are wired with coils in series
(high voltage) or in parallel (low voltage). The following connection configurations apply to both
60 Hz and 50 Hz motors, except for 575 volt 60 Hz and 660 volt 50 Hz, which are listed
separately on the next page.
The motors can be started across the line or they may be switched for Y start/Delta run.
Part winding start may also be used to minimize starting current draw.
Delta Connected (7.5 hp)
Y Connected (1 hp to 5 hp)
75
ELECTRICAL CONNECTIONS
9.1
76
POWER CABLE SELECTION
10.1
POWER CABLE SIZE/LENGTH SELECTION OVERVIEW
Power Cable Selection
10.0
The following charts will aid in determining the power cable conductor size for a given
horsepower and installation distance.
In the interest of long motor life, it is recommended that voltage drop between the motor
controller and the motor be less than 2% of the motor nameplate voltage. This design criterion
is particularly important where motors are to operate reliably under high ambient temperature
and “brown out” voltage conditions.
The recommendations are based upon information obtained from the 2002 National Electric
Code (NEC).
Certain installations may pose unusual design problems. Consult with Aeration Industries
International, Inc. before committing to designs that may compromise motor life.
NOTE: AIRE-O2® TRITON® blower motors are designed to handle a broad range of world
voltages and power supply variations. Our dual voltage 3 phase motors are factory
tested and certified to operate on both: 200 / 230 / 460 VAC 3 Phase 220 / 380 / 440 VAC
3 Phase 50 Hz. Our dual voltage 1 phase motors are factory tested and certified to operate
on both 104-115 / 208-230 VAC 1 Phase 60 Hz and 100-110 / 200-220 VAC 1 phase 50 Hz.
All voltages above can handle a ±10% voltage fluctuation.
77
78
208 VAC 3ø
FLA2
x 125%3
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
4.6
7.5
10.6
16.7
24.2
30.8
46.2
59.4
74.8
88
114.4
143
169.9
211.2
272.8
343.2
396
Nominal cable weight
5
5.8
9.4
13.3
20.9
30.3
38.5
57.8
74
94
110
143
179
212
264
341
429
495
LB
/F
4
# 14
# 12
# 10
#8
#6
#4
#3
#2
#1
1/0
2/0
3/0
4/0
20
132
81
57
36
——
——
——
——
——
——
——
——
——
——
——
——
——
25
208
128
90
57
40
——
——
——
——
——
——
——
——
——
——
——
——
35
347
213
150
95
66
52
——
——
——
——
——
——
——
——
——
——
——
50
533
327
231
147
101
80
53
——
——
——
——
——
——
——
——
——
——
65
849
521
368
234
161
127
85
66
——
——
——
——
——
——
——
——
——
85
1342
823
582
370
255
200
134
104
83
——
——
——
——
——
——
——
——
100
1664
1021
722
458
316
249
166
129
102
87
——
——
——
——
——
——
——
115
2189
1343
950
603
416
327
218
170
135
114
88
——
——
——
——
——
——
130
150
175
200
230
255
285
310
335
1701
1204
764
527
414
276
215
171
145
112
——
——
——
——
——
——
2126
1504
955
659
518
345
268
213
181
139
112
——
——
——
——
——
2551
1805
1146
791
621
414
322
256
217
167
134
113
——
——
——
——
2345
1488
1027
807
538
418
332
282
217
174
146
——
——
——
——
1848
1275
1002
668
520
413
351
270
216
182
146
——
——
——
2204
1521
1195
797
620
492
418
322
257
217
174
——
——
——
1797
1412
941
732
581
494
380
304
256
206
159
——
——
2081
1635
1090
848
673
572
440
352
296
238
185
——
——
2396
1883
1255
976
775
659
507
406
341
275
213
——
——
0.104
0.157
0.286
0.387
0.532
0.793
0.986
1.187
1.743
2.087
2.587
3.037
4.688
n.a.
n.a.
n.a.
n.a.
ml
2
cml
30
cml
1
HP indicates rated horsepower obtained from motor nameplate.
2
FLA (full-load amperes) obtained from NEC Table 430-150. Full-Load Curent, Three Phase Alternating Current.
3
Cable length calculations are based on 125% motor full-load amperage (FLA), NEC Article 430-22 (A).
For special motors wired for Wye-Start, Delta-Run, the selection of conductors between the controller and the motor may be based on 58
percent of the motor full-load currrent [NEC 430.22 (C)]. It is recommended that the contractor/electrician contact Aeration Industries for
recommended wiring sizing.
4
Kcml indiates wire size in circular mils
5
35 cml 400
Allowable Ampacities, obtained from NEC Table 310-16, Ampacities of Insulated Conductors - Copper Conductor at 75o C, “——” indicates inadequate Ampacity.
NOTE: Length calculations are based on resistance values obtained from NEC Table 9, AC Resistance and Reactance for 600 VAC Cables, 3 Phase, 60 Hz, 75o
C (167o F). Typically the power cable is sized using the distance between the junction box on the shore and the motor, this being refered to as the "hard wire" connection.
The power cable between the junction box and the controller is then sized separately using this new distance. This is especially critical where there is a great distance
to a central control station and a heavier gage wire is required.
CABLE SELECTION BY VOLTAGE CHARTS
Allowable Ampacities
(Cable Length In Feet)
10.2
HP1
Voltage Drop ≤ 2%
HP
2
FLA
x 125%
5
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
4.2
6.8
9.6
15.2
22
28
42
54
68
80
104
130
154
192
248
312
360
5.3
8.5
12.0
19.0
27.5
35.0
52.5
68
85
100
130
163
193
240
310
390
450
LB
/FT
Voltage Drop ≤ 2% (Cable Length In Feet)
4
# 14
# 12
# 10
#8
#6
#4
#3
#2
#1
1/0
2/0
3/0
4/0
20
160
99
70
44
——
——
——
——
——
——
——
——
——
——
——
——
——
25
252
156
110
70
48
——
——
——
——
——
——
——
——
——
——
——
——
35
420
259
184
116
80
63
——
——
——
——
——
——
——
——
——
——
——
50
646
399
283
178
123
97
65
——
——
——
——
——
——
——
——
——
——
65
1028
635
450
284
196
154
103
80
——
——
——
——
——
——
——
——
——
85
1625
1004
711
449
310
244
163
126
100
85
——
——
——
——
——
——
——
100
2015
1245
882
557
385
302
202
157
124
106
——
——
——
——
——
——
——
115
130
150
175
200
230
255
285
310
335
1638
1160
733
506
398
265
206
164
139
107
——
——
——
——
——
——
2075
1469
928
641
504
336
261
207
176
136
——
——
——
——
——
——
2593
1837
1160
802
630
420
327
259
220
170
136
——
——
——
——
——
2204
1392
962
756
504
392
311
265
203
163
137
——
——
——
——
1808
1249
981
654
509
404
344
264
211
178
143
——
——
——
2245
1551
1219
813
632
502
427
328
263
222
178
——
——
——
1850
1453
969
754
598
509
391
313
264
212
164
——
——
2186
1718
1145
891
707
601
462
370
312
250
194
——
——
2531
1989
1326
1031
819
696
535
428
362
290
225
——
——
2290
1527
1187
943
802
617
493
416
334
259
206
——
0.104
0.157
0.286
0.387
0.532
0.793
0.986
1.187
1.743
2.087
2.587
3.037
4.688
n.a.
n.a.
n.a.
n.a.
ml
2
cml
30
cml
1
2
3
4
35 cml 400
5
3
10.2
230 VAC 3ø
1
79
80
Voltage Drop ≤ 2%
380 VAC 3ø
FLA2
x 125%3
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
2.3
4
5.4
8.9
12.2
16.1
23.5
32
38
45
59
71
85
100
133
158
194
5
2.9
5.0
6.8
11.1
15.3
20.1
29.4
40
48
56
74
89
106
125
166
198
243
kg
/M
# 12
# 10
#8
#6
#4
#3
#2
#1
1/0
2/0
3/0
4/0
20
148
85
63
38
28
21
——
——
——
——
——
——
——
——
——
——
——
25
232
133
99
60
44
33
23
——
——
——
——
——
——
——
——
——
——
35
386
222
164
100
73
55
38
28
——
——
——
——
——
——
——
——
——
50
594
342
253
153
112
85
58
43
36
30
——
——
——
——
——
——
——
65
946
544
403
244
178
135
93
68
57
48
37
——
——
——
——
——
——
85
1495
859
637
386
282
214
146
107
90
76
58
48
——
——
——
——
——
100
1853
1066
789
479
349
265
181
133
112
95
72
60
50
——
——
——
——
115
2438
1402
1039
630
460
348
239
175
148
125
95
79
66
56
——
——
——
130
150
175
200
230
255
285
310
335
1776
1316
798
582
441
302
222
187
158
120
100
84
71
——
——
——
2220
1644
998
728
552
378
277
234
197
151
125
104
89
67
——
——
1973
1197
873
662
453
333
280
237
181
150
125
107
80
67
——
2563
1555
1134
860
589
432
364
308
235
195
163
138
104
88
71
1931
1409
1068
731
537
452
382
291
242
202
172
129
109
89
2302
1680
1273
872
640
539
455
347
289
241
205
154
130
106
1985
1504
1031
757
637
538
410
341
285
242
182
153
125
2298
1742
1193
876
738
623
475
395
330
280
211
177
145
2006
1374
1009
850
718
547
455
380
323
243
204
166
0.155
0.234
0.426
0.576
0.792
1.180
1.467
1.766
2.593
3.105
3.849
4.519
6.975
n.a.
n.a.
n.a.
n.a.
ml
2
cml
30
cml
1
2
3
4
5
35 cml 400
4
# 14
10.2
HP1
(Cable Length In Meters)
380 VAC 3ø
FLA2
x 125%3
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
2.3
4
5.4
8.9
12.2
16.1
23.5
32
38
45
59
71
85
100
133
158
194
5
2.9
5.0
6.8
11.1
15.3
20.1
29.4
40
48
56
74
89
106
125
166
198
243
LB
/FT
# 12
# 10
#8
#6
#4
#3
#2
#1
1/0
2/0
3/0
4/0
20
484
278
206
125
91
69
——
——
——
——
——
——
——
——
——
——
——
25
760
437
324
196
143
109
74
——
——
——
——
——
——
——
——
——
——
35
1267
728
540
327
239
181
124
91
——
——
——
——
——
——
——
——
——
50
1949
1121
830
504
367
278
191
140
118
100
——
——
——
——
——
——
——
65
85
100
115
130
150
175
200
230
255
285
310
335
1784
1321
802
585
443
304
223
188
159
121
——
——
——
——
——
——
2088
1267
924
700
480
352
297
251
191
159
——
——
——
——
——
2590
1571
1146
869
595
437
368
311
237
197
165
——
——
——
——
2067
1508
1143
783
575
484
409
312
259
216
184
——
——
——
1910
1448
992
728
613
518
395
328
274
233
——
——
——
2388
1810
1240
910
767
647
494
410
343
291
219
——
——
2171
1488
1093
920
777
593
492
411
350
263
221
——
1932
1419
1195
1009
770
639
534
454
341
287
234
2399
1762
1484
1253
956
794
663
564
424
357
291
2101
1769
1494
1140
947
791
672
505
426
347
2483
2091
1766
1347
1119
935
795
597
503
410
2421
2044
1559
1296
1082
920
692
582
474
2354
1796
1492
1246
1059
797
671
546
0.104
0.157
0.286
0.387
0.532
0.793
0.986
1.187
1.743
2.087
2.587
3.037
4.688
n.a.
n.a.
n.a.
n.a.
ml
2
cml
30
cml
1
2
3
4
35 cml 400
5
4
# 14
10.2
HP1
81
82
460 VAC 3ø
FLA2
x 125%3
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
1.7
3.4
4.8
7.6
11
14
21
27
34
40
52
65
77
96
124
156
180
5
2.1
4.3
6.0
9.5
13.8
17.5
26.3
34
43
50
65
81
96
120
155
195
225
LB
/FT
# 12
# 10
#8
#6
#4
#3
#2
#1
1/0
2/0
3/0
4/0
20
793
396
281
177
123
96
——
——
——
——
——
——
——
——
——
——
——
25
1245
622
441
278
192
151
101
——
——
——
——
——
——
——
——
——
——
35
2075
1037
735
464
321
252
168
131
104
——
——
——
——
——
——
——
——
50
65
85
100
115
130
150
175
200
230
255
285
310
335
1596
1130
714
493
388
258
201
160
136
——
——
——
——
——
——
——
2540
1799
1136
785
617
411
320
254
216
166
——
——
——
——
——
——
1796
1241
975
650
506
402
341
263
210
177
——
——
——
——
2227
1539
1209
806
627
498
423
326
260
220
176
——
——
——
2025
1591
1061
825
655
557
428
343
289
232
——
——
——
2565
2015
1343
1045
830
705
543
434
366
294
228
——
——
2519
1679
1306
1037
882
678
543
458
367
284
——
——
2015
1567
1245
1058
814
651
550
441
341
271
——
2036
1617
1374
1057
846
714
573
443
352
305
2528
2008
1706
1313
1050
886
711
550
438
379
2394
2035
1565
1252
1057
848
656
522
452
2405
1850
1480
1249
1002
776
617
534
2142
1713
1446
1160
898
714
619
2466
1973
1665
1336
1034
822
712
0.104
0.157
0.286
0.387
0.532
0.793
0.986
1.187
1.743
2.087
2.587
3.037
4.688
n.a.
n.a.
n.a.
n.a.
ml
2
cml
30
cml
1
2
3
4
5
35 cml 400
4
# 14
10.2
HP1
575 VAC 3ø
FLA2
x 125%3
1.4
2.7
3.9
6.1
9
11
17
22
27
32
41
52
62
77
99
125
144
1.8
3.4
4.9
7.6
11.3
13.8
21.3
28
34
40
51
65
78
96
124
156
180
LB
/FT
# 12
# 10
#8
#6
#4
#3
#2
#1
1/0
2/0
3/0
4/0
20
1203
624
432
276
187
153
99
——
——
——
——
——
——
——
——
——
——
25
1889
980
678
434
294
240
156
120
——
——
——
——
——
——
——
——
——
35
50
65
85
100
115
130
150
175
200
230
255
285
310
335
1633
1130
723
490
401
259
200
163
138
——
——
——
——
——
——
——
2512
1739
1112
754
617
399
308
251
212
165
——
——
——
——
——
——
1770
1200
981
635
491
400
337
263
208
174
——
——
——
——
1896
1551
1004
776
632
533
416
328
275
222
——
——
——
2351
1924
1245
962
784
661
516
407
341
275
214
——
——
2531
1638
1266
1031
870
679
535
449
362
281
——
——
2075
1603
1306
1102
860
678
569
458
356
282
——
2593
2004
1633
1378
1075
848
711
573
445
353
306
2405
1959
1653
1290
1017
853
687
534
423
367
2544
2147
1676
1321
1108
892
694
550
477
2081
1641
1376
1108
862
683
593
2481
1956
1641
1321
1028
814
706
2312
1939
1561
1214
962
835
2245
1808
1406
1114
967
2586
2082
1619
1282
1113
0.104
0.157
0.286
0.387
0.532
0.793
0.986
1.187
1.743
2.087
2.587
3.037
4.688
n.a.
n.a.
n.a.
n.a.
ml
2
cml
30
cml
1
2
3
4
35 cml 400
5
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
5
4
# 14
10.2
HP1
83
Parts
84
11.0
PARTS ORDERING
11.1
PARTS ORDER NOTES
11.2
PARTS ORDER FORM
Parts
Parts Orders:
The following information is important to assure that when you order spare or emergency parts
that the correct part has been defined. Being prepared with the proper information when placing
your order will expedite your order process and assure you receive the correct part (s). Some
Part numbers will be determined at Aeration Industries international Inc., based upon
Product Information and Description Provided.
4100 Peavey Road
Chaska, Minnesota 55318 USA
Attention: Customer Service
Telephone: 1-952-448-6789
Facsimile: 1-952-448-7293
Customer Service Hotline: 1-800-328-8287
E-mail: http://www.aiii@aireo2.com
Your Purchase Order #: _________________
Page ______ of _______
AIII Customer # ________________________
Your Phone #__________________________Fax # _______________________________
E-Mail # ________________________________________
Original Product Purchase Information
Product Name:__________________________ HP:_______________ HZ:_______________
Assembly Part #: ______________ Serial #: ______________ Purchase Date:_____________
Original Purchase Sales Order #: __________________(From the front page of this Manual)
Shipping Address if Different from your billing address:
Company Name:
Line 1 ____________________________________________________
Line 2 ____________________________________________________
Line 3 ____________________________________________________
Company Address:
Line 1____________________________________________________
Line 2 ____________________________________________________
Line3 ____________________________________________________
City __________________State _____________Country______________Zip Code________
Ship to the Attention of: ____________________________Phone / Ext # __________________
Shipping Preference_______________________________________________________
Urgency:________________________________________________________________
Parts Needed:
ITEM #
1.
2.
3.
4.
5.
6.
7.
Part #
_______________
_______________
_______________
_______________
_______________
_______________
_______________
Description
Quantity
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
_______
_______
_______
_______
_______
_______
_______
Attach additional copies of this form if more than 7 different parts are needed.
85
Storage
12.0
STORAGE PROCEDURES
Storage
In case of outdoor storage, the motor must be covered with plastic without sealing it. Otherwise,
condensation will occur, which can cause motor damage.
If the units are left in the water, put a plastic cover securely over the motor without sealing it.
To prevent condensation on the windings when the motors are stopped for a long time, motor
space heaters are required.
Storage Conditions
Short Term
The following storage requirements must be followed:
1. Motors are to be kept in their original containers or provided with equivalent protection
and stored in a warehouse free from extremes in temperature, humidity, and corrosive
atmosphere.
2.
If unusual vibrations exist at the storage location, the motor should be protected with
isolation pads.
3. All breathers and drains are to be operable while in storage and/or the moisture drain
plugs removed. The motors must be stored so the drain is at the lowest point.
Storage Preparation
Improper storage of electric machines will result in seriously reduced reliability of that
equipment. For example, and electric motor that does not experience regular usage while being
exposed to normally humid atmospheric conditions is likely to cause the bearings to rust or rust
particles from surrounding surfaces to contaminate the bearings, The electrical insulation may
absorb and excessive amount of moisture leading to the motor winding failing to ground. The
following preparations should be followed:
1. Minimize condensation in and around the motor by use of desiccants or other humidity
control methods.
2. Motor space heaters when specified are to be energized where there is a possibility that
the storage ambient conditions will reach dew point. Space heaters are an option.
3. Coat all external machined surfaces with a material to prevent corrosion. An acceptable
product for this purpose is Exxon Rust Ban #392.
4. Measure and record the electrical resistance of the winding insulation with a megger or
an insulation resistance meter. Minimum accepted Megohm Level is the insulation kV
rating +l Megohm. If levels fall below the above, contact the nearest Reliance sales
office. The recorded data will be required when removing from storage.
5. Some motors have a shipping brace attached to the shaft to prevent damage during
transportation. The shipping brace, if provided, must be removed and stored for future
use. The brace must be reinstalled to hold shaft firmly in place against the bearing
before the motor is moved.
86
12.0
STORAGE PROCEDURES
Storage
6. Upon placing the motor into extended storage (greater than 3 months), the motors with
greaseable bearings must be greased per Table 1 on page 72, followed by the motor
shaft being rotated a minimum of 15 times after greasing. Non-greaseable motors with
“Do not Lubricate” nameplates should also be rotated 15 times to redistribute grease
within bearing.
7. Motor shafts are to be rotated manually every 6 months and additional grease added
purging some of that cavity. Grease in the bearings is to be purged at the time of
removal from storage, making sure that an ample supply of fresh grease is in each
grease cavity.
8. Remove the grease drain plug, if supplied, (opposite the grease fitting) on bottom of
each end bracket prior to lubricating the motor.) Replace the plug after greasing.
Non-greaseable motors should have their shaft rotated 15 revolutions every 3 months.
9. All breather drains should be fully operable while in storage. The motors must be stored
so the drain is at the lowest point. All breathers and automatic “T” drains must be
operable to allow breathing at points other than through the
bearing fits.
10. The space heaters when specified are to be connected and operable while in storage.
11. Windings are to be meggered at the time equipment is put in storage. At the time of
removal from storage, the insulation resistance reading must not have dropped more
than 50% from the initial reading. Any drop below this point necessitates electrical or
mechanical drying. Refer to “Motor Drying Procedure.”
12. Where motors are not stored in the original containers, but are removed and mounted
on other pieces of machinery, the mounting must be such that the drains and breathers
and space heaters are fully operable. In thisrespect, the drains must be kept at the
lowest point in the motor so that all condensation can automatically drain out.
For Storage of Extended Periods of Time
Greater than 18 months
All requirements of general preparation and short term storage apply with the following
additional requirements.
1. Motor is to be crated in a box similar to EXPORT BOXING but that the “shell” (sides &
top of box) will be LAG- BOLTED to the wooden base (not nailed as export boxes are).
This design will allow for the opening and re-closing the box many times without
destroying the “shell”.
2. The motor will be sealed in an airtight vapor barrier bag with desiccant inside. This
airtight bag will give added protection during shipment of motor to the permanent
storage area.
3. After the first “Inspection” for megger reading, turning the shaft, etc., the vapor bag
should be re-sealed by taping it closed with masking or similar tape. Also add new
desiccant inside bag before closing. The shell should then be placed over the motor and
87
Storage
12.0
STORAGE PROCEDURES
the lag bolts replaced.
4. If a “zipper-closing” type bag is used instead of the “heated-sealed” type bag, then rezipper the bag closed Instead of taping it.
5. Be sure to add new desiccant inside bag after each periodic inspection.
6. Minimize the accumulation of condensed water in and around the machine.
88
13.0
WARRANTY
Warranty
With proper use, installation, and maintenance, Aeration Industries International, Inc., warrants
that it will, at its option, replace goods found to be defective in material or workmanship for a
period of up to 36 months from date of shipment, providing the purchaser gives written notice
of such defect to the manufacturer. This warranty specifically excludes labor charges that may
be incurred. It is also stipulated in this warranty that the purchaser shall return the goods, if
requested, to the manufacturer at the point of origin, with transportation charges prepaid by the
purchaser. If an examination by the manufacturer discloses to its satisfaction the existence of
such defect, the manufacturer will honor this warranty. In no event shall the manufacturer be
liable for any incidental, special, or consequential damages resulting from said defects.
13.1
WARRANTY COVERAGE
When the AIRE-O2® TRITON® is put into service, follow the warranty validation procedure
previously sent by registered mail after start-up. These sheets request data on parties involved
with installation and motor warranty validation information. Complete and return these sheets
to Aeration Industries International, Inc. Failure to complete the warranty information will result
in Non-issuance of the factory warranty. Locate "Maintenance and Service Record" page 48.
Customer Service may request completed forms as evidence of proper AIRE-O2® TRITON®
maintenance. Complete and file Maintenance and Service Record Sheets.
CAUTION: (Exclusions to Warranty)
- The sleeve and bearing located just above the propeller are water lubricated. If the
unit is allowed to run dry, bearing damage will occur. This condition is not
covered under terms of our warranty.
- Never use an AIRE-O2® TRITON® aerator in a basin where a foam-layer covers the
motor either partly or completely. Defects resulting from such situations will not
be covered by the warranty.
13.2
RETURN-AUTHORIZATION POLICY
Prior to returning any parts, call Customer Service Hot-Line (1-800-328-8287), to discuss the
reason for return and obtain an authorization for the return. A Returned Materials Authorization
(RMA) number will be issued by the representative if returned parts will be accepted. This
number should be referenced on the shipping label(s) of the material being returned to ensure
that the Receiving Department will accept the shipment.
NOTE: A copy of the Maintenance and Service Record sheet for the applicable AIREO2® TRITON® must be returned with the part. No parts will be accepted without the RMA
number indicated on the shipping label.
13.3
CREDITING / DEBITING YOUR ACCOUNT
Warranty replacement parts will be debited to your account. Parts returned under a Returned
Materials Authorization (RMA) number will be credited to your account after receipt at our facility
addressed below.
Aeration Industries Int. Inc.
4100 Peavey Road
Chaska, Minnesota 55318
Ref: RMA Number
89
Service Addendum
14.0
SERVICE ADDENDUM
14.1
AIRE-O2® TRITON® DISASSEMBLY AND REASSEMBLY
DANGER: Turn off electrical power and Iock the aerator “Out of Service “ before working
on the aerator. A hoist will be needed if the motor will be replaced. Otherwise servicing
and repairs can be preformed after tipping the unit up raising the propeller above the
water. Lock in place using bolts.
Propeller and Diffuser Disassembly: (Ref: Drawing on page 76)
1. Slip a large screwdriver through the air intake hole in the housing and into the shaft
universal joint, to prevent the shaft from turning. Take care not to damage the grease
zerk in the universal joint.
2. Remove the two (2) set screws from the diffuser (atomizer).
3. Using a wrench, loosen the diffuser, screw the diffuser off in a counter clockwise
direction.
4. To remove the propeller tap the propeller with the rubber mallet and unscrew the
propeller in a counterclockwise direction.
CAUTION: Always wear gloves when handling the propeller. Blade edges may be sharp.
Housing Disassembly:
Remove the housing by unscrewing the four cap screws attaching the housing to the motor
mounting flange. Slide or pry the housing off the shaft.
NOTE: The sleeve may remain in the bearing and come off with the housing. Take care
not to drop the sleeve as it may shatter.
Sleeve Removal:
Slip the sleeve and the two nylon washers off the shaft. Remember, the sleeve will crack or
shatter if dropped.
Shaft Disassembly:
Loosen the two Universal joint set screws holding the aerator shaft to the motor shaft. Slide the
aerator shaft off the motor shaft. Remove the key. Aerator parts can be serviced if needed.
Bearing Removal:
The bearing can be removed from the housing by pressing’ it all the way through from the
propeller end, letting it fall out the flange end of the housing. Scrape off any bearing residue
that may stick to the housing bore.
Another method is to hammer a screwdriver along the inside diameter of the bearing. Once the
black elastomeric portion of the bearing has been split, wedge the screwdriver between the fiber
backing and the housing bore at the point of split. The bearing will crack and can be peeled out.
Scrape off any bearing residue that may stick to the housing bore.
90
14.1
Service Addendum
Bearing Assembly:
1. Stand the shaft housing vertically, with flange end down, and insert a new bearing into
the prop end of the housing. Place a fiat protective plate over the outside face of the
bearing. Press or pound on the protective plate until the bearing is installed flush with
the face of the housing.
2. Using the three existing holes located in the propeller end of the housing as guides,
match drill holes completely through the bearing. Remove any material shreds
remaining around the newly drilled holes. Use a sharp knife to do this trimming. Bevel
the internal opening. Cut away bearing burrs or shreds to smooth opening.
Mounting Flange And Shaft Assembly:
1. If the mounting flange has been removed, reattach the mounting flange to the motor
using four cap screws and washers. Viewing the motor from the shaft end, with the
electrical junction box at 12 o’clock, orient the pins on the mounting flange in the 9 and
3 o’clock positions.
2. Insert the key into the motor shaft and coat the shaft, key way, and the key liberally with
anti-seize compound.
3. Slide the aerator shaft Universal joint onto the motor shaft until it contacts the shaft
shoulder. It may require tapping with a rubber hammer.
4. Apply anti-seize compound to the two Universal joint setscrews. Tighten the setscrew
over the key first to ensure proper balance of the shaft. Tighten the remaining set screw.
Housing Assembly:
1. Slip the shaft housing, flange end first, over the aerator shaft, bolt it to the motor
mounting flange. Use four cap screws and lock washers.
NOTE: The air intake hole should be in the up position, in line with the motor electrical
box.
Sleeve Assembly:
1. Slide a nylon washer onto the aerator shaft. Apply a grease lubricant to the outer surface
of the sleeve, and slide the sleeve over the protruding shaft end. Insert the sleeve
through the housing bearing until it contacts the shaft shoulder.
2. Slide the remaining nylon washer onto the shaft into place against the sleeve.
Propeller And Diffuser Assembly:
1. Insert a large screwdriver through the air intake hole in the housing and into the shaft
Universal joint to prevent the shaft from turning. Do not damage the grease zerk in the
Universal joint.
2. Inspect the propeller inside bore and threads. Inspect the shaft area protruding from the
housing, and the threads. Remove dirt or debris.
3. Liberally apply anti-seize compound to the entire shaft area protruding from the housing
including the threads and slide the propeller onto the shaft.
91
Service Addendum
14.1
CAUTION: Always wear gloves when handling the propeller. Blade edges may be sharp.
4. Using the force of one hand only, turn the propeller in the clockwise direction until firmly
seated against the nylon washer and sleeve. DO NOT FORCE. If any resistance is
encountered, back the propeller off and inspect for dirt, debris, impurities, nick, etc. You
may wish to “bump” the propeller with a rubber mallet to give final tightening
5. Thread the diffuser onto the shaft end and rotate clockwise until firmly seated against
the propeller. Tighten the two set screw.
The aerator reassembly is now complete.
WARNING! WARNING!
Remember! Remove the screwdriver from the air intake hole.
AIR INTAKE
SET SCREWS (2)
FLAT FOR
WRENCH
PROPELLER
(ATOMIZER)
ELEV
92
4100 Peavey Road
Chaska, Minnesota 55318 USA
Telephone: 1-952-448-6789
Facsimile: 1-952-448-7293
Customer Service Hotline: 1-800-328-8287 (inside the U.S.A)
E-mail: aiii@aireo2.com
Web Site: http://www.aireo2.com

Installation - Aeration Industries

Transcription

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