FarmTek Growers Supply HydroCycle User manual

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Revision date: 03.21.18
*Actual system may differ from example shown.
115295 AQUAPONIC SYSTEM I
©2018 Growers Supply
All Rights Reserved. Reproduction
is prohibited without permission.
HydroCycle Aquaponic
Systems

2115295 Revision date: 03.21.18
Important Information
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.
Each section shows one procedure or multiple related procedures. For
best results, before assembly begins, read through this entire guide to
better understand the different assembly procedures.
Overall assembly process depends on available space and assistants.
Construction of raft bed can occur at any time. Since it requires
the most space during assembly, it may be best to store frame
components outside of the assembly area and first set tank stands
and tanks in place.
When it is time to assemble raft bed frame, identify the raft bed frame part
numbers and separate the tubes. Doing this helps prevent confusion and
mistakes during assembly.
Use the recommended layout diagrams on the following pages to get
started. If you are constructing a greenhouse or other building to house
the aquaponic system, ensure there is a sufficient opening for the large
tank (or tanks) to pass through.
Here are steps to prepare for assembly and to help get you started:
1. Read through this manual to better understand the different assembly
procedures. Review Table of Contents (left column).
2. Determine basic system layout and placement in building.
3. Locate raft bed liner and move it to a safe location until installation.
4. Set stands and tanks in place.
5. Take inventory of all plumbing parts and PVC tubing.
6. Separate and inventory the raft bed parts.
7. Begin assembly.
CAUTION: Tanks are heavy when filled. Building floor must be
capable of supporting all tanks when filled. Finished concrete is
recommended to prevent settling. Take the necessary steps to
construct a solid surface before setting tanks. Once filled, tanks
should not be moved.
Contents
Important Information ................................................................................. 2
General Information & Maintenance ......................................................... 5
Aquaponic System Site Plan — Sample...................................................... 6
Recommended Setbacks & System Layout ................................................ 7
Ra Bed Assembly......................................................................................... 8
Water Temperature: Heating Ra Beds...................................................... 14
Ra Bed Liner Installation ........................................................................... 15
Assemble & Set Tank Stands ....................................................................... 19
Prepare Tanks & Install Fittings .................................................................. 23
Install System Plumbing............................................................................... 28
Radial Flow Clarier & Mineralization Tanks........................................... 33
Assemble Ra Bed Pump Station................................................................ 35
Install Supply Plumbing................................................................................ 36
Aeration System............................................................................................. 37
Prepare Plant Ras ........................................................................................ 42
Install Bird Netting........................................................................................ 43
System Start-Up............................................................................................. 44
Adjust Flow Rates.......................................................................................... 45
Fish Stocking.................................................................................................. 46
Aquaponic Filter Maintenance .................................................................... 47
Customer Notes and Records ...................................................................... 49
DIAGRAM NOTE: TANK STANDS
Actual tank stands may differ from those shown in diagrams. Assembly of
system remains the same.

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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. If you have any questions during assembly, contact customer service.
ASSEMBLY PROCEDURE
Following instructions as presented will help
ensure proper assembly of your aquaponic
system. Steps outlining assembly are as follows:
1. Verify that all parts are included in the
shipment. Notify customer service for
questions or concerns. See below.
2. Read and understand these instructions and
the information included with the shipment
before you begin.
3. Gather tools and recruit assistants.
4. Assemble aquaponic system.
5. Read additional information as presented.
Important Information
SAFETY PRECAUTIONS
• Wear eye protection.
• Wear gloves when handling metal pipes.
• Use a portable GFCI (Ground Fault Circuit
Interrupter) when working with power tools and
cords.
UNPACK AND IDENTIFY PARTS
The following steps will ensure that you have all
the necessary parts before you begin assembly.
1. Unpack contents of shipment and place where
you can easily inventory parts. Refer to Bill of
Materials/Spec Sheets.
2. Verify that all parts listed on Bill of Materials/
Spec Sheets are present. If anything is
missing or you have questions, consult all
diagrams and photos for clarification, or
contact Customer Service.
NOTE: At this time, you do not need to open
the plastic bags containing smaller parts
such as fasteners or washers (if equipped).
WARNING: Enlist the services of an
experienced electrician when connecting
power to the pump and other electrical
devices.
All wiring to be completed according to
established codes and practices.
DROWNING HAZARD: Never allow
children or others within the boundary of
the tanks, raft bed, and pump stations at
any time.
Always have an assistant present during
harvest, tank cleaning, and system
maintenance to prevent accidents.
FLOOR DRAIN: A floor drain is recommended to
allow easier cleaning and draining of tanks. Keep
area around tanks and plumbing clean.
REQUIRED TOOLS
The following list identifies the main tools needed to
assemble the aquaponic system. Additional tools
may be needed.
• Tape measure and marker.
• Variable speed drill (cordless with extra
batteries works best).
• Small hammer and gloves.
• Level (4' or longer– recommended) and line
level.
• Utility knife or scissors.
• Tool to cut PVC tubing.
• Assorted hand tools common to construction,
plumbing, and electrical work.
• Drill bit set with assorted bits.
• Hole saw bits: 2-1/4", 2-1/2", & 3".
• Large adjustable pliers (3"-4" jaw).
• 7/32" hex (Allen) wrench or bits — preferably
bits to attach to power driver or drill. Used to
install 115303B screws.
WINDOW KITS FOR FISH TANKS
If a window kit was purchased for any fish-
holding tank, install the window kit before tank
preparation and setting tank in place on tank
stand. Consult instructions with kit or online.
CUSTOMER-SUPPLIED MATERIALS
This system includes all parts needed for
assembly except weights for the aeration
system. See Section 10 for details.
Additionally, mounting air pumps in a location
that best serves your needs requires a
customer-supplied mounting surface and
fasteners to secure pumps to that surface.
Changes to recommended layout may require
purchase of additional plumbing fittings and
related PVC pipe.

4115295 Revision date: 03.21.18
Important Information
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. Water quality, location, growing environment, available resources, personal knowledge
and experience among other things all must be considered before populating system with plants and fish.
Consult with your sales representative for additional resources and information to ensure a successful start.
ABOUT THIS MANUAL

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Revision date: 03.21.18 115295
General Information & Maintenance
SITE
The system layout allows for even flow of water throughout the system. Any
layout that varies from this suggested model may require additional purchase
of PVC pipe and fittings and could affect overall operation.
Routine maintenance of the system requires flushing valves and lines. If
possible, position drain line outlets near (or pipe directly into) a floor drain if
allowed by local codes. Clean solids off floor to prevent pathogen growth.
If entire system is located in a greenhouse, installing 100% shade material
above the aquaculture section is strongly recommended. Shade helps
prevent algae issues in tanks and raft bed.
125 GALLON TANK STAND DESIGN
This system includes a metal tank stand for the 125 gallon tank. Stand
design requires minor assembly before setting tank and installing plumbing.
Due to weight, it is recommended to assemble stand in the area where the
system will operate. Stand is not easily moved once assembled.
When setting tank stands, orient stand so support legs allow easy installation
and routing of plumbing as shown in diagrams and photos.
IMPORTANT: WINDOW KITS FOR FISH TANKS
If window kits were purchased for the 125 gallon fish tank, install those
before tank preparation and setting tank in place on tank stand.
RAPID DRAIN-TO-
WASTE VALVES
Ball valve at the end
of each drainage line
is designed to rapidly
drain water from
tanks. To prevent
accumulation of
heterotrophic bacteria
(biofouling) in pipes,
open and close these
valves once a day
when in production.
NOTE: Use ball valves
to fully drain tanks for
cleaning or harvesting.
Circled ball valves
remain closed when
system is in operation.
ATTENTION: Add water as needed to the system
to maintain proper levels in tanks and raft beds.
DIAGRAM NOTE: TANK STANDS
Actual tank stands may differ from those shown in diagrams. Assembly of
system remains the same.

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1
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. Increasing distance
between tanks or between tanks and raft bed will require the purchase of additional
PVC tubing and fittings.
Top View
*Actual pump may differ.
Pump Station
&
Bulkhead Plate

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1
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. Actual dimensions may vary slightly from those shown.
ID# AQUAPONIC SYSTEM I: MAIN COMPONENTS
A125 GALLON TANK (115318); STAND: See Section 4a to assemble.
BRADIAL FLOW CLARIFIER — 15 GALLON TANK (112732), LID (115304), & TANK STAND (116062)
CMINERALIZATION TANK — 15 GALLON TANK (112732) & TANK STAND (116062)
DRAFT BED (See diagram for inside-to-inside dimensions.)
EMAIN WATER PUMP (113536) AND BULKHEAD PLATE (AQ139) LOCATION
SYSTEM FOOTPRINT APPROXIMATELY 12' X 20'.
SEE DASHED LINE.
12"
15" 15"
4' 3'
6" - 12"
20'
12'
96-1/2" to 97" inside-to-inside
Work Area
E
Minimum 2'-3' from
side of building.
Minimum 2'-3' from
end of building.
BA C D
Building Outline (solid line)
System Footprint (dashed line)
96-1/2" to 97" inside-to-inside

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Raft Bed Assembly
2
96-1/2" to 97"
Inside-to-Inside
96-1/2" to 97"
Inside-to-Inside
Sidewall
End
Wall
Evenly
Spaced
Evenly
Spaced
ATTENTION: Measure all long tubes
to confirm length before assembly.
104779 Tube (96")
104779 Tube (96")
Sidewall
End Wall
104779 Tube (96")
104779 Tube (96")
112375 Tube (15-3/4")
Vertical Supports
S15P016 Tube (16")
All Corners
(Install flush to top of
3-way fittings.)
110611
3-Way Insert
All Corners
S15P016 Tube (16")
All Corners
(Install flush to top of
3-way fittings.)
Sample End Wall
104779 Tube
Install vertical tube
tight against the
3-way corner insert.
16
”
Diagrams below show layout of assembled 8' x 8' raft bed. Use these diagrams and
dimensions as guides during raft bed frame assembly. The inside-to-inside dimensions allow
room for liner and plant rafts.
ASSEMBLY NOTE: Install Tek screws using a
clutched drill driver running approximately 750 RPM
while applying approximately 50 lbs of force.
Do not use an impact driver!

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2
ASSEMBLY NOTE: During frame assembly, set inside-to-inside dimensions at 96-1/2" to 97". Do not seat tube tight to the inside of corner fittings. Doing
so will result in a dimension too narrow to accept 96" lettuce rafts once liner is installed. When setting inside dimensions always evenly divide space
between corner fittings. At least 2" of any tube must remain within a coupler, fitting, or other tube.
*Not to scale.
16
”
Sample End Wall
104779 Tube
Install vertical tube
tight against the
3-way corner insert.
Ends of upper and lower tubes are
1/2" from being fully seated in fittings.
Center in End Wall
97" Inside-to-Inside
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. Clear site of debris and obstacles that could hamper construction progress.
4. Level the surface where raft bed will be located.
5. Read all assembly steps for raft bed to better understand parts layout.
6. Separate parts and set aside (if this has not been done) to prevent confusion and mixing of parts during construction.
7. Secure all tube and fitting connections using FA4572 Tek screws.
8. Install Tek screws in positions that will not contact bed liner when it is installed.

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Required parts:
• 110611 3-Way Corner Insert (8)
• S15P016 Square Tube @ 16" (4)
• 104779 Square Tube @ 96" (8)
• 112375 Square Tube @ 15-3/4" w/ 45° Cuts (28)
• FA4572 Tek Screws
• 100442 Magnetic Nut Setter
ATTENTION: Do not install any Tek screw along top rail of raft
bed frame. Surface is reserved for installation of raft bed liner
and retaining bars.
Install all corner tubes flush with top of 3-way fitting as shown.
ASSEMBLY STEPS – MAIN FRAME
Raft Bed Assembly
Complete these steps:
1. Construct main frame using corner fittings and the upper and lower tubes.
2. After perimeter frame is assembled, install vertical supports. Secure each support to upper
and lower tubes using two (2) FA4572 Tek screws for each beveled support.
Use photos below and diagrams on previous pages to assemble
one (1) 8' x 8' raft bed frame.
16
”
Install vertical tube tight
against 3-way corner and
3-way tee fittings (if present).
Evenly space all beveled vertical supports
throughout length and width of raft bed frame.
Center
2a
ASSEMBLY NOTE: Install Tek screws using a
clutched drill driver running approximately 750 RPM
while applying approximately 50 lbs of force.
Do not use an impact driver!

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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. Be sure to measure from same points at each corner. Finally, level frame. Frame must be level so water depth is consistent
throughout frame once raft bed is filled. Prepare site inside the raft bed frame if not on a solid surface such as wood or concrete.
ATTENTION: Actual frame may differ from what is
shown. Procedure to square frame is the same.
Raft Bed Assembly
2b

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2c 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.
Raft Bed Assembly

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2d ASSEMBLY STEPS – INSTALL BULKHEAD PLATE
Raft Bed Assembly
Required parts:
• AQ139 Raft Bed Bulkhead Plate
• 108553 Wafer Head Screw (4)
• 112375 Square Tube @ 15-3/4" w/ 45° Cuts (1)
• FA4572 Tek Screws (2)
• 100442 Magnetic Nut Setter
View of installed pump plate as seen
standing outside raft bed frame.
Attach plate next to
second support.
NOTE: Insulation removed to better
show installation of pump plate.
Use parts identified at right to install bulkhead plate. Review Section 1 diagrams for location.
ATTENTION: Install bulkhead plate opposite where mineralization tank flows into raft bed.
Additional 112375 support
to secure insulation.
After attaching plate to inside of frame
using four 108553 wafer head screws,
attach another beveled support.
Use a utility knife and carefully remove
insulation to access pump plate.
Cut
insulation
to
remove.
View of installed pump plate as seen
standing inside assembled raft bed frame.
108553

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Water Temperature: Heating Raft Beds
HEATING RAFT BEDS
In-bed heat systems are typically installed to help maintain a
constant water temperature to optimize fish and plant growth.
Depending on conditions and fish species raised, some
systems may benefit from (or require) heated raft beds. A raft
bed heat system is not part of this aquaponic system.
ATTENTION: Regardless of raft bed size, follow these general guidelines:
• Maximum length of any tube loop should not exceed 300';
• Loops must be of equal length.
Consult the services of a qualified contractor familiar with installing similar heating systems. If you purchased components to heat your
aquaponic system, install tubing in raft bed before liner installation. See note above.
After installing raft bed tubing for heat (if needed), return to these instructions and continue with Section 3 to install raft bed liner.
*Actual raft bed and number of lines may differ from examples shown. Some
systems may not need a heat package.

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3Once raft bed is prepared, continue with installation of liner. Assistants
are required to complete this installation.
1. With assistance, carefully spread liner over
assembled frame. Ensure that equal lengths
overhang ends and sides.
4. Take two (2) FA4572 Tek screws and two (2)
102921B neo-bonded washers and carefully
secure liner to top of frame.
2. Beginning at one corner, loosely and carefully
fold and press liner into corner and along
inside of base rails.
NOTE: Ensure liner is fully seated in corners
and on bottom before installing fasteners.
These are removed later in procedure.
3. Fold liner evenly up and over top of frame rails.
Remove as many wrinkles as possible. Do not
crease liner material.
5. Move to another corner and press liner into
place.
Required parts:
• Raft Bed Liner
• FA4572 Tek Screws, 102921B Washers, and 100442 Nut Setter
ATTENTION: During liner installation, do not drop any tools
or sharp objects into liner bed. Doing so can puncture liner!
Exercise caution!
Verify that all debris is removed from insulation surface that
could damage or puncture liner once installed.
INSTALL RAFT BED LINER
Raft Bed Liner Installation

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INSTALL RAFT BED LINER — continued
3
Raft Bed Liner Installation
10. Move to remaining corners and repeat steps
to temporarily secure them to frame.
7. Repeat steps to secure liner material.
8. Check bottom of liner for wrinkles and remove
these by working material toward free edge.
11. While adding water, remove any excess
material that touches ground. Allow a couple
inches to remain for final steps.
9. Start adding water to raft bed to allow water to
seat liner inside frame.
NOTE: Do not fill more than 1"- 2". Water level
to stay below hole in bulkhead plate.
12. Fill bed with 1"- 2" of water. Water level to
remain below hole in bulkhead plate (2d).
13. Install pre-drilled aluminum retaining strap.
6. Cut material as needed to allow it to fit more
evenly at corners.
ATTENTION: Do not drop any sharp objects
into bed liner at any time. Contact your sales
representative for products used to repair
damage to liner if needed.
ASSEMBLY NOTE: Install Tek screws using a clutched drill driver running
approximately 750 RPM while applying approximately 50 lbs of force.
Do not use an impact driver!

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Attach 110155 aluminum flat stock to frame using
FA4572 Tek screws and 100442 driver.
Remove Tek screws and
washers before installing the
aluminum retaining straps.
1. Begin at a corner and remove Tek screw and
washer to install first 110155 strap.
4. Apply slight downward force to stretch liner
material and secure strap with Tek screws.
NOTE: Do not lift liner or pull it away from
frame sides. Use slight force only!
Take the necessary steps prevent metal
shavings from dropping into raft bed.
2. Align strap with frame fitting and attach using
the FA4572 Tek screw.
5. Continue attaching aluminum straps to frame
until entire perimeter of bed liner is secure.
NOTE: Remove temporary Tek screws and
washers before installing aluminum straps.
6. Install 112770 finishing plug at each corner
when liner is secured.
3. Grip edge of bed liner with duck-bill locking
pliers or similar tool.
7. Using a utility knife or scissors, remove excess
bed liner material. Allow 1" or so to remain
beyond the edge of aluminum strap if desired.
NOTE: To prevent contamination and algae
growth, do not fill raft bed until remainder of
system is constructed. If possible, cover to
prevent damage to liner.
SECURE LINER TO FRAME
ATTENTION: There are enough Tek screws to install one
in each hole of the aluminum stock. However, to reduce
assembly time and labor, installing one in every other hole
will serve to secure liner.
3
Raft Bed Liner Installation
112770
112770

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INSTALL 1-1/2" BULKHEAD FITTING
3a Gather these parts and tools:
• 112965 Bulkhead Fitting
• Utility Knife
1. Place a flat board or something
similar inside bed against liner
and plate to use as backing.
2. Apply pressure against liner and
have someone cut hole in liner.
Exercise caution when cutting!
NOTE: Use bulkhead plate as a
template when cutting hole.
Do not cut through backing!
6. Ensure washer and fitting body
are tight against liner.
4. Take bulkhead fitting (112965)
and slide rubber washer over
bulkhead body.
3. Remove liner material after
cutting.
7. Add large locking nut and tighten
until snug.
5. From the inside, insert bulkhead
fitting through hole in liner and
through bulkhead plate.
ATTENTION: Photos show installing a larger
bulkhead in a different raft bed. Installation
steps are the same for the 1-1/2" fitting used in
this raft bed.
Complete these steps to install the 1-1/2" bulkhead fitting:
Raft Bed Liner Installation
NOTE: Some fittings also include
a hard plastic washer. If present,
slide that over the threaded
bulkhead body and then install
locking nut.
8. Tighten locking nut to secure
fitting to bulkhead plate.
9. Apply thread sealant and install
WF2198 adapter as described in
Section 5a. Tighten until snug.
Adapter

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TANK STANDS — General Information
Assemble & Set Tank Stands
ATTENTION: The stand for the 125 gallon tank is heavy when assembled. It should be assembled at or near the spot where it will be in use to minimize
moving and to facilitate leveling. Once assembled and leveled, stand cannot be moved without repeating the leveling steps.
Leg support assemblies require a solid surface. If stands are not positioned on concrete as recommended, take additional steps to construct a solid base on
which to mount each tank stand support. Take the necessary steps to firmly pack the soil or gravel and then bury concrete blocks, pavers, or solid wood blocks
level with finished grade for each support. Do not set on soil, sand, or gravel. Do not set tank stands on raised blocks or platforms.
IMPORTANT: To ensure proper water levels throughout the system during operation, set tank stands on the same finished grade as the float bed. Review
layout diagrams for additional details.
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.
Turn stands so support legs do not interfere with plumbing installation.
Stand for 125 Gallon Tank
Stand for 15 Gallon Tank
ATTENTION: Stands require a solid base such as reinforced concrete or concrete pavers capable of supporting full tanks for adequate support and to prevent
settling. Take the necessary steps to construct a solid surface before setting tanks.
4

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4a ASSEMBLY TANK STAND: 125 GALLON TANK
The 125 gallon tank stand consists of a single top plate and frame, four (4) leg supports, and eight
(8) struts. Complete these steps to assemble the stand for the 125 gallon tank:
1. Assemble four (4) leg supports by threading an FALB04B locking nut onto a 113030S03
adjustable footer and thread that assembly into leg tube.
IMPORTANT: Install adjustable footer at end of leg support tube that includes the strut
mounting holes. See diagram.
2. Set distance from top of adjustable foot to leg assembly at approximately 1" or so.
3. Next, take the AQ138 top plate and frame section and attach leg assemblies as shown using
the 115303 flat head bolts.
4. Tighten using a 7/32" Allen wrench. Verify that bolt holes for struts are oriented so struts align
with mounting holes. See diagrams on next page.
ATTENTION: Mounting holes on legs are in different positions. If legs are installed incorrectly,
mounting holes in struts will not align with mounting holes in frame top. Use a strut to match
hole locations during leg installation. Rotate leg as needed and tighten.
Use these parts to construct stand for 125 gallon tank:
• AQ138 One-Piece Top Plate & Frame
• AQ129 Support Leg
• AQ133 Strut
• 113030S03 Adjustable Footer
• FALB04B (NUT 3/8-16 ZINC EACH)
• 115303B (3/8"-16 X 3"L FLAT HEAD BOLT ZINC)
• FAG338B (HEX CAP 5/16 X 3" ZINC – EACH)
• FAME07B (BULK FLT WSH 5/16" ZINC – EACH)
• FALB02B (NUT BULK 5/16-18 ZINC – EACH)
1"
FALB04B
Nut 113030S03
Adjustable Footer
AQ129
Support Leg
AQ129
Support Leg
Strut
Mounting
Hole
AQ138
1-Piece Top
115303B
Flat Head Bolt
AQ129
Support Leg
Assemble & Set Tank Stands