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- Page 1 HydroCycle Aquaponic Systems ©2018 Growers Supply All Rights Reserved. Reproduction is prohibited without permission. 115295 AQUAPONIC SYSTEM I *Actual system may differ from example shown. Revision date: 03.21.18...
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Page 2: Table Of Contents
Important Information Contents USING THIS MANUAL This aquaponic system is designed for easy assembly. To help guide you through the assembly, we have divided this manual into different sections. Important Information ................. 2 Each section shows one procedure or multiple related procedures. For General Information &... - Page 3 Important Information READ THIS DOCUMENT BEFORE YOU BEGIN Thank you for purchasing the 115295 Aquaponic System. When properly assembled and maintained, this system will provide years of reliable service. These instructions include helpful hints and important information needed to safely assemble and properly maintain the system. Please read and understand these instructions before you begin.
- Page 4 Important Information ABOUT THIS MANUAL This manual describes how to set up your aquaponic system and check for proper operation. Additional information is presented regarding basic system maintenance. This manual does not however describe how to grow various types of fish and plants. Since the specifics of such an undertaking have filled many books, it is best to determine beforehand exactly how you want to use this system.
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Page 5: General Information & Maintenance
General Information & Maintenance 125 GALLON TANK STAND DESIGN SITE This system includes a metal tank stand for the 125 gallon tank. Stand The system layout allows for even flow of water throughout the system. Any design requires minor assembly before setting tank and installing plumbing. layout that varies from this suggested model may require additional purchase Due to weight, it is recommended to assemble stand in the area where the of PVC pipe and fittings and could affect overall operation. -
Page 6: Aquaponic System Site Plan - Sample
Aquaponic System Site Plan — Sample Diagram below shows the basic layout of the 115295 aquaponic system. Use this diagram when planning where to position your system inside the building. Review all diagrams and photos in this guide before you begin. ATTENTION: Diagram below shows recommended system layout. -
Page 7: Recommended Setbacks & System Layout
Recommended Setbacks & System Layout Diagram below shows recommended setbacks from building walls. Needs specific to your operation may require a different layout with alternative setbacks. Quantity of pipe and fittings included with this system is based on recommendations found throughout this guide. Altering dimensions shown may require the purchase of additional PVC and related fittings. -
Page 8: Raft Bed Assembly
Raft Bed Assembly Diagrams below show layout of assembled 8' x 8' raft bed. Use these diagrams and ATTENTION: Measure all long tubes dimensions as guides during raft bed frame assembly. The inside-to-inside dimensions allow to confirm length before assembly. room for liner and plant rafts. - Page 9 Raft Bed Assembly ASSEMBLY STEPS Follow these general steps when constructing raft bed: 1. To minimize possible damage to liner, install all fans, heaters, and lighting (including wiring) that will be positioned above raft bed before assembling bed. 2. Frame cannot be moved once assembled. Take the necessary steps to keep frame square during assembly. 3.
- Page 10 Raft Bed Assembly Required parts: • 110611 3-Way Corner Insert (8) ASSEMBLY STEPS – MAIN FRAME Use photos below and diagrams on previous pages to assemble • S15P016 Square Tube @ 16" (4) one (1) 8' x 8' raft bed frame. •...
- Page 11 Raft Bed Assembly ATTENTION: Actual frame may differ from what is shown. Procedure to square frame is the same. SQUARE ASSEMBLED RAFT BED FRAME After assembly, check all connections to verify that Tek screws are properly installed. Next, measure corner-to-corner diagonally as shown. When dimensions are the same, frame is square.
- Page 12 Raft Bed Assembly INSULATE RAFT BED FRAME Complete these steps: 1. Once frame is level, insulate frame bottom. (Frame shown below may differ from actual frame.) 2. Cut insulation board as needed to fit side and end walls. 3. Continue with the installation of bulkhead plate used to connect main water pump.
- Page 13 Raft Bed Assembly Required parts: • AQ139 Raft Bed Bulkhead Plate ASSEMBLY STEPS – INSTALL BULKHEAD PLATE • 108553 Wafer Head Screw (4) Use parts identified at right to install bulkhead plate. Review Section 1 diagrams for location. • 112375 Square Tube @ 15-3/4"...
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Page 14: Water Temperature: Heating Raft Beds
Water Temperature: Heating Raft Beds ATTENTION: Regardless of raft bed size, follow these general guidelines: • Maximum length of any tube loop should not exceed 300'; HEATING RAFT BEDS • Loops must be of equal length. In-bed heat systems are typically installed to help maintain a constant water temperature to optimize fish and plant growth. -
Page 15: Raft Bed Liner Installation
Raft Bed Liner Installation ATTENTION: During liner installation, do not drop any tools INSTALL RAFT BED LINER or sharp objects into liner bed. Doing so can puncture liner! Exercise caution! Once raft bed is prepared, continue with installation of liner. Assistants are required to complete this installation. - Page 16 Raft Bed Liner Installation ASSEMBLY NOTE: Install Tek screws using a clutched drill driver running approximately 750 RPM while applying approximately 50 lbs of force. INSTALL RAFT BED LINER — continued Do not use an impact driver! 6. Cut material as needed to allow it to fit more 7.
- Page 17 Raft Bed Liner Installation ATTENTION: There are enough Tek screws to install one 112770 in each hole of the aluminum stock. However, to reduce SECURE LINER TO FRAME assembly time and labor, installing one in every other hole Attach 110155 aluminum flat stock to frame using will serve to secure liner.
- Page 18 Raft Bed Liner Installation Gather these parts and tools: ATTENTION: Photos show installing a larger bulkhead in a different raft bed. Installation • 112965 Bulkhead Fitting INSTALL 1-1/2" BULKHEAD FITTING steps are the same for the 1-1/2" fitting used in •...
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Page 19: Assemble & Set Tank Stands
Assemble & Set Tank Stands TANK STANDS — General Information To best judge raft bed position and to ensure economic use of available space and PVC pipe, assemble (if needed) and set all stands in place to get started. Section 1: Review diagrams on previous pages, assemble and set 15 and 125 gallon tank stands according to layout dimensions shown. Review overall layout and position stands so system plumbing can be connected as shown in diagrams. - Page 20 Assemble & Set Tank Stands Use these parts to construct stand for 125 gallon tank: ASSEMBLY TANK STAND: 125 GALLON TANK • AQ138 One-Piece Top Plate & Frame • AQ129 Support Leg The 125 gallon tank stand consists of a single top plate and frame, four (4) leg supports, and eight •...
- Page 21 Assemble & Set Tank Stands ASSEMBLY TANK STANDS: 125 GALLON TANK — continued 5. Attach two (2) struts to each leg and secure to underside of top plate. See diagram and chart below for fastener part numbers. Add two (2) flat washers to each bolt –...
- Page 22 Assemble & Set Tank Stands SET TANK STANDS: 15 GALLON TANKS Using the layout diagram, set and level tank stands for the radial flow clarifier tank and mineralization tank. DIAGRAM NOTE: TANK STANDS Actual tank stands may differ from those shown in diagrams.
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Page 23: Prepare Tanks & Install Fittings
Prepare Tanks & Install Fittings Required tools & materials: PREPARE TANKS FOR BULKHEAD FITTINGS • 2-1/4", 2-1/2", & 3" Hole Saw Bits; Locate the tanks and drill holes for bulkhead fittings in locations shown. • Battery-Powered Drill (recommended) Complete these steps to prepare tanks: •... - Page 24 Prepare Tanks & Install Fittings INSTALL TANK BOTTOM BULKHEAD FITTINGS Review diagrams below and install bulkhead fittings. NOTE: Tanks have a specific bulkhead assembly. Confirm that correct fittings are used when installing these fittings. See diagrams. In most instances, an adapter can be installed before bulkhead is attached to tank. Verify that bulkhead locknut fits over adapter before final assembly.
- Page 25 Prepare Tanks & Install Fittings INSTALL SIDE UNISEAL — LARGE TANK ® Complete these steps for the 125 gallon tank: 1. Verify that tank stand is level and in the correct position for system assembly. Set and center the 125 Steps 4 &...
- Page 26 Prepare Tanks & Install Fittings ATTENTION: Review diagrams on next page to better understand hole positions DRILL HOLES FOR BULKHEAD INSTALLATION (SMALL TANKS) and overall plumbing layout. Complete these steps: 1. Verify that tank stands are level and in the correct positions for system assembly. Top of top ring of each stand must be approximately 25" above floor. Do not elevate stands above floor level.
- Page 27 Prepare Tanks & Install Fittings INSTALL BULKHEAD AND ADAPTER FITTINGS (SMALL TANKS) Complete these steps: 1. Install a 1-1/2" bulkhead (112965) in each tank hole as previously described in Section 5a. 2. Install two (2) adapters (WF2198) in each radial flow clarifier tank bulkhead. Coat threads with thread sealant.
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Page 28: Install System Plumbing
Install System Plumbing TOP VIEW INSTALL SYSTEM PLUMBING Use the diagram below and on the following pages to install Raft Bed system plumbing. See list for parts and materials. 6"- 12" 3' - 4' 12" Recommended Spacing Return Flow to Raft Bed Flow Flow... - Page 29 Install System Plumbing Plumbing Fittings and Materials: • WF1982 SxS Coupling to connect 1-1/2" PVC pipe (not shown). INSTALL SYSTEM PLUMBING — LARGE TANK • WF3511 SxS Ball Valves (1-1/2") • PVC Primer and PVC Cement • 112285 SxS Union (1-1/2") General Assembly Notes: •...
- Page 30 Install System Plumbing — Large Tank Parts to secure supply tube to tank: INSTALL SYSTEM PLUMBING — LARGE TANK • (1) FAG104B (1/4" x 1") Hex Bolt • (2) FAME16B (1/4") Flat Washer After constructing the vertical supply tube, secure it to the tank as shown.
- Page 31 Install Plumbing — Small Tanks Plumbing Fittings and Materials: INSTALL PLUMBING (SMALL TANKS) • WF3511 SxS Ball Valves (1-1/2") • 112285 SxS Union (1-1/2") PHOTO: Swing drain General Assembly Notes: tube up or down as • WF1384 SxSxS Tee Fitting (1-1/2") (C) •...
- Page 32 Install Plumbing — Small Tanks Plumbing Fittings and Materials: INSTALL INSIDE PLUMBING (SMALL TANKS) • WF1574 SxS 90° Elbow (1-1/2") • WF6684 Sp x Slip 90° (1-1/2") General Assembly Notes: Elbow • Double-check all dimensions before cutting PVC pipe. • Use WF4140 (1-1/2"...
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Page 33: Radial Flow Clarifier & Mineralization Tanks
Radial Flow Clarifier & Mineralization Tanks Plumbing Fittings and Materials: ASSEMBLE AND INSTALL STILLING WELL • WF4171Z014 (4" x 14") PVC Stilling Well • WF0013 (4") PVC End Cap Assemble radial flow clarifier lid. • 115304 Radial Flow Clarifier Lid 1. - Page 34 Radial Flow Clarifier & Mineralization Tanks Parts and Materials: PREPARE MINERALIZATION TANK • 115289 PolyMax Panel (White) (1/4" X 16" X 14") Complete these steps: • 103761 Sunblocker Shade Material 1. Take tank separator panel and place inside mineralization tank as shown below. Cut-Away Side View 2.
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Page 35: Assemble Raft Bed Pump Station
Assemble Raft Bed Pump Station Plumbing Fittings and Materials: PUMP STATION ASSEMBLY • 111155 Strainer • WF3511 SxS Ball Valves (1-1/2") Main pump for this system is located opposite the mineralization tank at end of raft bed. Depending on Take the 111155 strainer parts and assemble •... -
Page 36: Install Supply Plumbing
Install Supply Plumbing Plumbing Fittings and Materials: INSTALL SUPPLY PLUMBING • WF1982 Coupling 1-1/2" (not shown) • WF1574 SxS 90° Elbow (1-1/2") Dashed line shows supply plumbing from pump station to large tank vertical supply tube. Using parts shown at right, connect pump station to vertical supply tube. •... -
Page 37: Aeration System
Aeration System WARNING: Enlist the services of an experienced electrician when connecting AERATION SYSTEM power to pumps and other electrical devices. This aquaponic system includes basic components for aeration. Air pumps provide air for fish holding All wiring to be completed according to tank (or tanks) and raft bed. - Page 38 Aeration System Example below shows one way to install air system. Desired pump locations may result in a different layout. Limited hose is included. AERATION SYSTEM ATTENTION: Air pumps to run continuously when system is in operation. Do not connect air pumps to a timer or circuit controlled by a switch.
- Page 39 Aeration System Use these parts for fish tank aeration system: AERATION SYSTEM – STONE PLACEMENT (FISH TANKS) • (4) AQ116 (6") Air Stone 3/8" Barb • WF1060A Braided Hose Complete these steps: • FA8006B Loop Clamps 1. Locate parts noted at the right and construct four (4) stone and hose assemblies. Cut each •...
- Page 40 Aeration System Use these parts for raft bed aeration system: AERATION FOR SYSTEM I – RAFT BED (8' x 8') • AQ113 (6") Air Stone 1/2" NPT • WF1355 (3/4" Slip x 3/4" Slip x 1/2" FPT) Tee General Assembly Notes: WF2160 •...
- Page 41 Aeration System CUSTOMER-SUPPLIED MATERIALS AERATION SYSTEM — CUSTOMER-SUPPLIED AIR MANIFOLD WEIGHTS Suggested parts to construct customer-supplied weights for raft bed air manifolds: The air supply manifolds in raft bed are buoyant, especially when air pump is operating. To • 1/2" PVC Pipe in 10' Lengths keep manifold firmly in place at bottom of raft bed during operation, construct water-tight weights (using customer-supplied materials) and attach to each manifold throughout their •...
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Page 42: Prepare Plant Rafts
Prepare Plant Rafts IMPORTANT: Read the system cycling information under the Start Up section before drilling plant sites in polystyrene panels. Solid panels can be used to cover raft beds during the cycling process. PREPARE PLANT RAFTS The templates below show one of many ways to prepare plant rafts. (There are other patterns.) Each has its advantages. Determine the best pattern for your growing needs and prepare the 4' x 8' rigid foam boards as needed. -
Page 43: Install Bird Netting
Install Bird Netting Suggested parts to cover tanks: • TC2630A Bird Netting (included) INSTALL BIRD NETTING • CC5310 3/16" Black Rope (included) – used to secure Bird netting helps prevent fish from jumping out of tanks once tanks are populated. Review bird netting. -
Page 44: System Start-Up
System Start-Up SYSTEM START-UP Aquaponic systems are functioning ecosystems that require delicacy and patience to setup and maintain. Follow these guidelines to get started: Water Quality: Water for the system must come from a trusted and controlled source. Using surface water from a creek or lake is not recommended. If •... -
Page 45: Adjust Flow Rates
Adjust Flow Rates Congratulations! Your aquaponic system is now constructed and tanks and Number of Tank Flow raft bed are filled with water. Now it is time to dial in your system to make System Fish-Holding Tanks (gallons per minute – gpm) Total Flow sure it functions properly. -
Page 46: Fish Stocking
Fish Stocking Fish Stocking Our aquaponic systems were designed specifically around raising tilapia. The following fish stocking and density information is relevant for tilapia only; however, that does not mean these are the only fish you can raise. For others, such as trout, yellow perch, or koi to name a few, please contact your local aquaculture extension, or call our customer service for more assistance. -
Page 47: Aquaponic Filter Maintenance
Aquaponic Filter Maintenance FILTER MAINTENANCE Performing the necessary routine maintenance for your aquaponic system is essential to your growing success. Maintaining clean filters and preventing excess buildup of solids will help to mitigate pathogens that could affect fish and plants. Preforming this maintenance also results in cleaner water. How System Filters Work Daily Maintenance The first tank that water flows into from the fish tanks is called the settling... - Page 48 Aquaponic Filter Maintenance With a hand brush or simple scrubby pad, remove any algae growth that may FILTER MAINTENANCE — continued have accumulated in either tank. Daily Maintenance — continued IMPORTANT! Do not use any type of detergent or sanitizer! In addition to the filter maintenance, flush the lines coming from the fish Use water only! tanks once a day to prevent buildup of microbes inside the pipes.
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Page 49: Customer Notes And Records
Customer Notes and Records Revision date: 03.21.18 115295...