System 2500/5000 Filtration Unit (Marine) Installation, Operation and Maintenance Instructions

Transcription

1 System 2500/5000 Filtration Unit (Marine) Installation, Operation and Maintenance Instructions

2 A. Installation of the SYSTEM 2500/5000 Filtration Unit (Marine) 1. Unpack the components carefully, paying particular attention to the handling of all components made of acrylic. No specialist tools are needed to erect the filtration unit. 2. Facing one of the shortest sides of the reservoir, place the bag filter box in the front with its long side parallel to the shortest side of the reservoir and pushed to the front and right hand side of the reservoir. Ensure the rubber flange is inserted in the hole in the short side of the filter box. This should be positioned to the right, and the bottom outflows must be facing outwards into the tank (see "General Layout of Main Components" diagram, particularly front and right side views). 3. Ensure that the bio media in the bio-tower does not interfere with the spray bar operation/rotation. 4. Place the support grate/platform on the reservoir, spanning the shortest dimension with the large opening towards the back. Ensure that the platform is fully supported on three sides by the reservoir rim. Place the plastic support stanchion inside the tank so that it is located flat on the base of the tank with its spigot inserted up through the grid. This stanchion should be positioned so it is approximately under the final position of the fluidised sand bed. The plastic washers are provided to go over the spigot to compensate for any eventual sag in the support grate once the components are filled and in place. This operation can be carried out even with the whole unit filled, but requires two people to slightly lift the grate to remove and reposition the stanchion after adding an adequate number of plastic washers onto the spigot end. 5. Place the remaining main components on the platform, positioned approximately as shown in the "General Layout of Main Components diagram. Use the lowest large pipe boss on each unit to orientate it correctly. The venturi pump should be mounted on the white PVC foot plate provided. 6. You are now ready to begin connecting the units together with the pre-assembled pipe work provided as per the Schematic of Pipework diagram attached. Begin assembly with the connection of the intake strainer assembly to the filtration system pump intake port. Proceed with other connections following alphabetical labelling i.e A-A, B-B etc. Please ensure all O rings are in place before making each connection, first removing any retaining tape used for packing. All unions should be tightened by hand, only once all the pipework is fully assembled and in place. IMPORTANT: Do not grease or wet any of the O rings in the connection bosses of the components. 7. Ensure that the flow meter (if included) is correctly assembled with the float, complete with the stabilising vane, inserted in the correct orientation. 8. When connecting components please ensure that joints are not under stress, suggesting incorrect alignment. This filtration unit was assembled and disassembled before dispatch to ensure correct fitting.

3 9. The following fittings, connections and components are not included, although they can be ordered separately. a) Supply to the protein skimmer freshwater wash kit, situated on top of the skimmer. This should be connected via a valve or tap to a suitable freshwater supply (see Schematic of Pipework diagram). b) Pipework from protein skimmer foam cup drain should be connected via a flexible hose to a drain or suitably sized collection vessel. c) Return drains from aquaria to bag filter box. d) Water intake pipe from the reservoir in addition to distribution pump and subsequent plumbing to aquaria (see Schematic of Pipework diagram). e) Automatic wash kits available for both freshwater and saltwater applications. 10. Suitable power cords should be wired to the pumps and UV steriliser supplied with the unit. Unless otherwise requested, all electrical equipment is wired for single phase supply only. CONNECTION TO ELECTRICAL SUPPLY If in doubt consult a qualified electrician. Caution: Use in the area of your system only if the installation complies with the relevant wiring regulations. Please consult a qualified electrician. Caution: Always disconnect the UV unit from the mains electricity supply before putting your hands into the water. Caution: Power must be supplied through a Residual Current Device (RCD) with a rated residual operating current not exceeding 30mA. All electrical installations and wiring must be adequately protected to prevent any damage. This unit is fitted with 5 metres of cable. For safety, this unit must be connected to permanent wiring. To prevent the unit inadvertently falling into the system we strongly recommend that it be securely positioned at least 2 metres from the edge of the body of water. Any flexible cabling used between the unit and the permanent wiring should also be kept to a minimum length. We recommend a maximum length of 1.5 metres. A switch with 3mm contact separation must be provided in the fixed wiring to provide disconnection from the electricity supply. INTERNAL FUSE REPLACEMENT Always isolate from mains supply before undertaking any maintenance. Use only a 3 amp fuse. 11. The filtration unit, once assembled according to the schematic, is ready to be filled with water. To test the filtration pump and system, no further connections are necessary. The unit does not need any other connection to be made to allow its full operation to be tested. We recommend that the unit is initially filled and tested with freshwater only. Follow carefully the operating instructions below. IMPORTANT: Do not add the sand media to the fluidised sand filter until you are satisfied that the unit is operating without any visible leaks from the components or joints.

4 B. Operation of the SYSTEM 2500/5000 (Marine). 1. Before starting any pumps, fill pump strainer basket chamber, ensure that the reservoir is full of water and that all connections are sound. IMPORTANT: Read the following operating instructions carefully before switching on any pumps. Do not switch on the UV steriliser. 2. Close all valves (see Schematic of Pipe work diagram) EXCEPT the following which should be fully open:- Ball valve no.1 - Valve on system bypass to the reservoir. Ball valve no.3 - Valve on protein skimmer bypass. Gate valve no.8 - Valve on protein skimmer outlet to bag filter box. 3. Start filtration system pump and allow it to prime and clear air from line, purging only through fully open ball valve no.1 and returning directly to the reservoir. 4. Slowly adjust ball valve no.1 to allow the rest of the system to fill. 5. Check all joints and unions for leaks, and remove any plastic swarf floating in the reservoir. Place the four filter bags supplied in the location rings in the bag filter box. 6. We advise that at least 100kg of PVD salt is added to the system and that it is left to run for 24 hours. This will help to cure all plastic surfaces and remove all traces of oils used in the manufacture of the plastic components, filter media and pipework. It is also beneficial to increase the temperature of the water to approximately 25 o C to aid the dissolving and efficiency of the salt. 7. Drain the water from the system and system elements, flush again with freshwater and run the system until all components are fully rinsed to remove any remaining salt. Empty again, and refill with clean, freshwater, adding Tropic Marin Salt to the correct density. (Allow approx. 25kg of Tropic Marin for the volume of water in the reservoir). 8. Thoroughly rinse/wash the sand for the bio-sand filter before use. 9. With the system turned off you must siphon off 50% of the water in the fluid sand filter before adding the sand media. Remove the clear push-fit vent pipe on top of the fluidised sand filter. Using a funnel (not supplied with the filtration system) carefully add the sand media. When all the sand media has been added, ensure that the push-fit joint is completely clear of sand and grit before replacing and securing the push-fit clear vent pipe. IMPORTANT: Repeat steps 1-3 but then proceed as follows:- 10. Very slowly adjust ball valve no.1 until the sand media in the fluid sand filter is fluidised to the correct level. In the white polypropylene models this is the level at which the fluidised sand is just visible in the side sight glass. In the clear acrylic models the level should be a minimum of 500mm from the lower flange of the lid section. Any trapped air should pass through the unit. IMPORTANT: Do not adjust any valves completely or too quickly otherwise sand media may be fluidised to the point of overflowing through the clear vent pipe or overflowing into the other filtration elements. Large amounts of rising trapped air may also cause the sand to overflow if this start up procedure is not carried out carefully. 11. Once the water flow through the fluidised sand bed filter is stabilised and the protein skimmer has filled to the point of overflowing into the bag filter box, open ball valve no.2 to the spray bar of the bio-tower. Allow the spray bar to pick up momentum before further adjustment. If there is insufficient pressure to divert flow to the spray bar then slowly close ball valve no.3 on the protein skimmer by-pass to achieve the desired flow or rotation rate.

5 One rotation per second should be adequate and can be further reduced to give a suitable dry/wet exposure of the random fill media, depending on application and filtration requirements. IMPORTANT: The arms of the spray bar are not glued to allow the customer to adjust the angle of the spray to further control the speed of rotation for a given flow of water. 12. Ball valves no.4 and no.7 on the inlet and outlet to the venturi pump can now be opened prior to starting the venturi pump. If the venturi is to be used with an ozonizer this connection should now be made via an air line to the small hose tail spigot located above ball valve no.6. Ball valve no.6 should be used to adjust the volume of air, should additional air be required by the ozone generator. Typically the air flow requirement of the venturi is litres/hour. This line should not be pressurised by connection to a compressed air supply as this will disrupt the performance of the venturi. The venturi, when operating correctly, should infuse the whole body of the protein skimmer with a relatively dense and even cloud of very fine bubbles. It may take several hours before the whole system is cleared of air trapped during the start up and this will initially disrupt the correct operation of the venturi. This is normal. If the internal saltwater foam column wash is connected to the venturi pump via an auto timer kit, then ball valve no.5 should be left open. If this is not the case then ball valve no.5 should be closed and only used to manually wash the foam column as required. 13. Finally it is necessary to set the correct operating level of the protein skimmer. This is achieved by slowly and gradually closing outlet gate valve no.8 until the water level in the protein skimmer (not the foam level) is within a few centimetres of the top flange of the main body, where the main body meets the tapering cone.the water level should not rise significantly within the tapering foam cone or the final vertical column. This level can be adjusted more precisely by using protein skimmer bypass ball valve no.3, to achieve the desired consistency of foam emanating from the foam cup and draining to waste. If the foam is too dry it may settle at the top of the foam tower and risk refluxing its contents back into the main body of water. If the foam is too wet there could be unacceptable losses of water from the system which is costly if artificial seawater is being used. 14. Further adjustments may be necessary to fine tune the flow of water to the main filter elements and this should be done using valves 1, 2, 3, and 8. Once satisfied with the operation and running of the filtration system, the distribution pump may now be switched on for supply to the aquaria via the UV unit. The UV unit must only be switched on when it has water flowing through it. IMPORTANT: SYSTEM 2500/5000, like any other biological filtration unit, will require a maturation period (to allow colonisation of the appropriate levels of nitrifying bacteria) before it can be used on a fully stocked system. The length of this maturation period will vary from 4-12 weeks depending on the initial stocking levels, water temperatures, feed rates and other criteria. Throughout this period, ammonia and nitrite should be monitored daily to assess the progress of the maturation process. Further stocking should only be considered once the system is fully matured. ABIL AQUA Nitrifying Package (TMC Product Code 1650) has been developed to inoculate marine and freshwater recirculation system bio filters in order to get them up and running in a shorter time period, and it can mature new systems within 10 days (depending on water conditions). It basically consists of the bacterial strains that have been identified and isolated to perform the biological conversion of toxic ammonia to less toxic nitrate. ABIL AQUA Nitrifying Package contains:- ABIL Culture P: 1000 ml per 2500 litre system volume ABIL Nutrient M: 2 x 30 ml per 2500 litre volume

6 15. When reservoir levels are low due to maintenance or high sales, ensure that all pumps do not draw air. It is strongly recommended that systems be fitted with water level switches to ensure that water pumps cannot draw air. Do not allow airstones or bubbles from returning water to introduce air to the pump inlet. BEWARE ALL OF THESE WILL CAUSE EMBOLISM THAT WILL KILL LIVESTOCK. All items supplied with this system are covered by warranties under Tropical Marine Centre's standard terms and conditions. However, Tropical Marine Centre Limited cannot be held responsible for any subsequent damage or the loss of livestock caused by the failure of any system component.

7 C. Long Term Maintenance of SYSTEM 2500/5000 (Marine) Daily Check overall system and livestock health for early signs of problems. Check bag filters for blockages and wash as necessary. Check protein skimmer cup and operate internal and external wash kits as necessary. Check rotation of bio-tower spraybar. Check sand bed fluidisation level and adjust accordingly. Check redox if applicable. Weekly Monthly Carry out regular water tests with particular reference to ph, ammonia and nitrite when the system is maturing. Perform partial water change. Check water salinity/density. Change bag filters. If new bags are used, rinse in freshwater before installation. Check and manually clean protein skimmer cup as necessary. Carry out a visual check on pump strainer baskets and intake strainers. Inspect pump, UV steriliser and filter seals to ensure there is no build up of salt due to minor seepage, especially on pumps. Check consistency of protein skimmer foam and adjust as per setting up instructions. Note - Due to the abrasive nature of the fluidised sand bed filter media, the bowl may need to be replaced periodically and should be inspected for any signs of wear. Replacement bowls are available from TMC (product code FSB/VFCA4G8). Bi-annually Change ultra violet lamps using TMC 55 Watt UV lamps (product code 6056) Clean quartz sleeves (product code 5277) on UV steriliser and replace O rings (product code 5281). Inspect bio media for mulm build up and clean/replace as necessary. Check and clean clear pump lids. The system has been designed with as much flexibility as possible. Modifications and expansions are usually very easy to achieve. Please consult Tropical Marine Centre directly with any queries.

8 Monday Tuesday Wednesday Thursday Friday Saturday Sunday CHECK DATE Temperature Salinity/Specific Gravity Dissolved Oxygen ph Ammonia Nitrite Nitrate Copper Phosphate Calcium Magnesium Strontium Alkalinty/Carbonate Hardness Redox Potential (mv) Air Flow to Ozone Generator Supply Pump Filtration Pump Venturi Pump Flow Rate in Livestock Tanks Water Level in Skimmer Water Level in Fluid Sand Tower Flow Rate through Trickle Tower Bag Filter Additional Mechanical Filter Heater Chiller UV Unit Water Change Volume Signed Comments

9 OPTIMAL VALUES FOR WATER QUALITY PARAMETERS Parameter Optimal Acceptable Caution Specific Gravity (25 o C/77 o F) > < Conductivity ms/cm ms/cm > 60 ms/cm ms/cm < 43 ms/cm Redox Potential mv mv > 450 mv mv < 150 mv ph Value > < 7.8 o o Alkalinity/Carbonate Hardness 7-16 dkh dkh > 18 dkh o o 5-6 dkh < 5 dkh Phosphate PO 4 3- <0.05 mg/l mg/l > 0.15 mg/l Ammonium/Ammonia NH 4 +/NH 3 <0.01 mg/l mg/l > 0.05 mg/l Total Concentration Nitrite NO 2-0 mg/l mg/l > 0.02 mg/l Nitrate NO mg/l mg/l > 20 mg/l 1-2 mg/l < 1 mg/l Calcium Ca mg/l mg/l <300 mg/l mg/l Magnesium Mg mg/l mg/l >1600 mg/l mg/l <1000 mg/l o For marine tanks only. These values are a general guideline. Optimal tank parameters may vary depending on specific tank conditions.

10 System 2500/5000 Marine General Layout of Main Components

11 System 2500/5000 Marine Dimensions and General Layout C A D B Dimensions A 1070mm B 1200mm C 2500mm D 750mm

12 System 2500/5000 Marine Schematic of Pipework Return to aquaria via UV steriliser UV steriliser Distribution pump (not included) Connection of external wash kit to FW supply System bypass to reservoir Non return valve Anti siphon Pipe Intake from reservoir via strainer (not included) Skimmer Venturi air/ozone intake pipe Internal foam cup wash Bio-tower Venturi System pump Venturi pump Intake from reservoir via strainer Fluid sand filter Bypass drain to reservoir Skimmer drain to reservoir Foam cup drain to waste Water from aquaria to be added by client Outlet from skimmer Bag filter box

13 Commercial Ultraviolet Water Steriliser INSTRUCTIONS FOR INSTALLATION AND USE All TMC Commercial Ultraviolet Water Sterilisers using 55 watt lamps are supplied with 2 solvent weld unions to allow easy connection to any existing pipework. We recommend that a 2 by-pass system is plumbed in with the installation of the UV unit to simplify any maintenance. For countries using imperial specification plumbing the units are supplied with 2" solvent weld sockets. All units from Model P4 upwards are supplied with 2" solvent weld unions. For countries using metric specification plumbing the units are supplied with 2" x 63mm solvent weld sockets to convert from imperial to metric. All TMC 120v 60Hz Commercial Water Sterilisers using 30 watt lamps are supplied with 1 1 / 2 solvent weld sockets for P2 units through to P6 units. P8 units through to P12 units are supplied with 2 solvent weld sockets. IMPORTANT SAFETY INFORMATION PLEASE READ CAREFULLY All units must be mounted with the lamps in a horizontal position. Under no circumstances must any unit be mounted with the lamps in a vertical position. If mounted with lamps in a vertical position there is a real risk of air being trapped allowing the unit to overheat, resulting in damage to the white plastic body. Never look directly at an illuminated UV lamp. Do not run the unit dry. Always isolate the unit from mains electricity and turn off the water supply before carrying out any maintenance. Always disconnect from mains supply before putting your hands into the water. Power must be supplied through a Residual Current Device (RCD) with a rated residual operating current not exceeding 30mA. This unit must be earthed. Never use a fuse larger than 3 amps. Rating: UK and European models v 50Hz. Class 1. IP64. Rating: USA models 120v 60Hz. Class 1 IP64. This unit must not be submerged in water. This unit must be either fully frost protected or taken inside during the winter months. To prevent this unit falling into water do not install it above or immediately alongside exposed water. CONNECTION TO ELECTRICAL SUPPLY If in doubt consult a qualified electrician. Caution: Use in the area of your system only if the installation complies with the relevant wiring regulations. Please consult a qualified electrician. Caution: Always disconnect the UV unit from the mains electricity supply before putting your hands into the water. Caution: Power must be supplied through a Residual Current Device (RCD) with a rated residual operating current not exceeding 30mA. Caution: The UV lamps in this unit are powered by electronic ballasts. This UV Steriliser should not be installed in any electrical circuit with equipment that may produce an inductive load. This equipment may include, but is not limited to, conventional fluorescent luminaires, floodlights and water pumps. Inductive loads can generate high energy surges that will permanently damage the electronic ballast. All electrical installations and wiring must be adequately protected to prevent any damage. This unit is fitted with 5 metres of cable. For safety, this unit must be connected to permanent wiring. To prevent the unit inadvertently falling into the system we strongly recommend that it be securely positioned at least 2 metres from the edge of the body of water. Any flexible cabling used between the unit and the permanent wiring should also be kept to a minimum length. We recommend a maximum length of 1.5 metres. A switch with 3mm contact separation must be provided in the fixed wiring to provide disconnection from the electricity supply. INTERNAL FUSE REPLACEMENT Always isolate from mains supply before undertaking any maintenance. Use only a 3 amp fuse.

14 ROUTINE MAINTENANCE PROCEDURE IMPORTANT SAFETY INFORMATION PLEASE READ CAREFULLY Never look directly at an illuminated UV lamp. Always isolate from mains electrical supply and isolate the water supply prior to carrying out any maintenance. If the quartz sleeve is accidentally cracked it must be replaced before reconnecting either the electrical supply or the water supply. If you do not have a replacement quartz sleeve then use the two blue blanking plugs supplied with the unit to close off the ends of that particular tube. Only do this once the broken quartz sleeve has been removed. HALF YEARLY MAINTENANCE All maintenance must only be undertaken by trained and competent staff. The UV lamps should be changed at six monthly (approximately 4000 hours) intervals if a higher UV efficiency is required. Should the lamps only be changed at annual intervals (approximately 8000 hours) there will be a depreciation of 15% UV efficiency over a one year period. PROCEDURE Isolate the ultraviolet steriliser from the electrical supply at the control panel. Isolate the ultraviolet steriliser from the water supply by closing any utility valves fitted. Drain the water from the unit by opening the drainage tap (orange bib tap) located on the bottom support bar of the unit. Wall mounted units are not fitted with a drainage tap. Carefully remove the numbered black lamp end cap from the lamp. Repeat this procedure at the opposite end of the same lamp assembly. Carefully slide out the used UV lamp ensuring that no pressure is applied to the quartz sleeve. Unscrew the compression fitting at either end of the lamp assembly. Remove the 'O' ring at either end of the quartz sleeve assembly. NOTE: If water pours out of the unit at this stage then the unit has either not been isolated from the system or not drained prior to commencing the maintenance procedure. Remove the 'O' rings and discard them. New 'O' rings should be used at each service interval. After removing the 'O' ring carefully slide out the quartz sleeve. Clean the quartz sleeve by washing in warm soapy water. Rinse it thoroughly in fresh water and then dry and polish it using a paper towel. NOTE: If the quartz sleeve has calcified with limescale deposits from the water it should be cleaned with a proprietary plastic kettle descaling solution, following the manufacturer s recommendations. Plastic gloves and eye protection should be worn for this process. The quartz sleeve should be rinsed in fresh water, dried and polished with a paper towel. To reassemble the unit reverse the above procedure by carefully sliding the quartz sleeve back into the plastic housing and locating it correctly. Slide the new 'O' rings over either end of the quartz sleeve and locate them into the 'O' ring recess on the main casing.

15 Ensure that the female threads on the compression fitting and the male threads on the main plastic body are clean. Wipe a little silicon grease or Vaseline (NOT silicon sealant) onto these threads. As these threads are only serviced twice a year this lubrication will help prevent them binding. Then replace and firmly hand tighten the compression fittings. NOTE: The compression fitting must be adequately tightened onto the 'O' ring and quartz sleeve or the unit will leak water when reconnected to the main system. Once all the quartz sleeves, 'O' rings and compression fittings have been reassembled the drainage tap at the base of the unit must be closed and any utility valves must be opened. At this point check each assembly and ensure there are no water leaks. If water is leaking from any of the assemblies then the unit must be drained down again following the procedure above. At the points where water is leaking the quartz sleeve must be checked to ensure it has not been damaged and the 'O' ring must be checked to ensure it is positioned correctly. Also ensure that the compression fitting has been tightened correctly. Assuming there are no water leaks, slide the new UV lamp into the quartz sleeve and replace the correct lamp end cap onto each lamp. Each end cap has a unique number that refers to each lamp. It is critical that the correct lamp end cap is fitted to the appropriate lamp. Once all the lamps have been connected the UV steriliser unit should be turned back on at the control panel. Each lamp should be checked to ensure that it is working. Only view the lamp through the plastic locknut compression fitting - NEVER look directly at an exposed UV lamp. Always ensure that water is circulating through the UV steriliser before the lamps are turned back on. IMPORTANT The plastic body of this unit has been manufactured from polymers that have been specifically stabilised to protect them from the effects of germicidal UVC emitted from the UV lamp. Despite this UV protection the unit will be eroded by a combination of the UVC and water flow. As a matter of course it should be inspected whenever a lamp change is carried out, to ensure that it is not showing excessive wear and tear. Replacement parts are available from our Chorleywood factory. Tropical Marine Centre Ltd., Solesbridge Lane, Chorleywood, Hertfordshire, WD3 5SX, UK Tel: +44 (0) Fax: +44 (0) Website: tmc@tmc-ltd.co.uk