Kingspan BioFicient 4 User manual

BioFicient 4-6
Klargester –Sewage Treatment Plant
INSTALLATION MANUAL
Part Code
Issue
Description
Date
017904
04
CC1463
Jan 2019

017904-04 BioFicient 4-6 Installation Manual
2
HEALTH AND SAFETY
You must read these warnings carefully before installing or using the equipment. Always ensure that all relevant documents are
supplied with the equipment transferred to a new owner. Observe all hazard labels and take appropriate action to avoid exposure
to the risks indicated. Take care to maintain correct posture, particularly when lifting. Use appropriate lifting equipment when
necessary.
• Only experienced contractors should carry out installation, following the guidelines.
• The unit should have a Pre-Service Agreement Inspection by an approved engineer.
• A qualified electrician should carry out electrical work.
• Covers must be kept locked.
• Observe all hazard labels and take appropriate action to avoid exposure to the risks indicated.
CLOTHING
• We recommend the use of a dust mask and gloves when cutting GRP components.
• Any person carrying out maintenance on the equipment should wear suitable protective
clothing, including gloves.
MAINTENANCE AND INSPECTION PROCEDURES
• If you wish to inspect the operation of the equipment, please observe all necessary precautions, including those listed below,
which apply to maintenance procedures.
• The power supply to the equipment must be isolated at the control panel(s) before lifting the covers.
• If the equipment should run with the covers off, all care must be taken to avoid contact with moving parts and electrical
components or conductors.
• Once power has been isolated, the control panel must be kept locked shut to avoid accidental re-connection whilst work or
inspection is being carried out.
WORKING AREA
• Ensure that the working area is adequately lit.
• Ensure that you are familiar with the safe working areas and accesses.
• Use only the designated access walkways. Do not walk on the cover or deep well safety mesh.
• Always keep proper footing and balance to avoid any sharp edges.

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DESLUDGING
Desludging should be carried out by a licensed waste disposal contractor holding the relevant permits to transport
and dispose of sewage sludge.
Desludge Volumes
Model
BFG 4
BFG 5
BFG 6
Primary
4700 Litres
6400 Litres
12300 Litres
Settlement Tank
(1040 gal)
(1420 gal)
(2730 gal)
Final
135 Litres
180 Litres
270 Litres
Settlement Tank
(30 gal)
(40 gal)
(60 gal)
Desludge Period
9 Months
9 Months
9 Months
Maximum
Maximum
Maximum
PRIMARY SETTLEMENT TANK
DESLUDGE POINT
BIOZONE 1 DO NOT DESLUDGE
FINAL SETTLEMENT TANK
DESLUDGE POINT –IF REQUIRED
BIOZONE 2 DO NOT DESLUDGE

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Contents
HEALTH AND SAFETY....................................................................................................................... 2
SYSTEM OVERVIEW......................................................................................................................... 5
BioFicient® CHECKLIST .................................................................................................................... 6
SELF HELP ....................................................................................................................................... 7
INSTALLATION ................................................................................................................................ 8
BioFicient® IPS HLA Installation......................................................................................................12
CONTROL PANEL INSTALLATION.....................................................................................................13
MAINTENANCE ..............................................................................................................................17
WARRANTY ...................................................................................................................................18
FAULT FINDING..............................................................................................................................19
NOTICE..........................................................................................................................................20
START UP ......................................................................................................................................21

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SYSTEM OVERVIEW
Pictorial representation below indicates basic requirements for a standard system, please note that not all the items
required are supplied by Kingspan.
VENT PIPE & ABOVE GROUND STACK
(BY OTHERS)
*BLOWER HOUSING Bioficient 6 ONLY
AIR DUCT
(BY OTHERS)
CONCERTE PLINTH
(BY OTHERS)
OUTLET PIPEWORK
BIOZONE 1 & BIOZONE 2
AIR DIFFUSER
INCOMING MAINS
POWER DUCT (BY OTHERS)
FINAL SETTLEMENT CHAMBER & SLUDGE RETURN
SYSTEM
PRIMARY SETTLEMENT CHAMBER
INLET PIPEWORK
ACCESS COVER
BLOWER HOUSING
(Bioficient 4-5 Design Variety,
Bioficient 6 on the picture
above*)

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Solenoid Valve
BioFicient® CHECKLIST
The delivery paperwork will have 2 no. items listed; check that the Tank Code (Item 1) & Blower Assembly Code (Item 2) are the
same as the codes on the units delivered.
Example;
Top Level Product Code –BFGAG050K
Item 1 –BFPTANK4GO50K (Tank Code)
Item 2 - BHBF4GOK (Blower Assembly Code)
Sewage Treatment Tank
Item 1
NB: Storage tanks vary in design and volume (15PE to 30PE). Please check your
order and cross reference with relevant sales drawing.
Blower Housing Assembly
Item 2 The Blower Assembly consists of the Blower Unit, Control Panel or
Isolator, and associated pipework and fittings.
13 mm Hose Coil –15 Meters
13 mm Hose required to connect from 1/2” Hose Connector in Blower Housing to
Sludge-return Pipework located with the Tank (Supplied inside Blower Housing
Packaging).
19 mm Hose Coil - 15 Meters
19 mm Hose required to connect from 3/4” Hose Connector in Blower Housing to Air
Diffuser Manifold located with the Tank (Supplied inside Blower Housing Packaging).
or

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SELF HELP
To minimize the need for dealing with emergency situations we recommend that Sewage Treatment Plants have a Pre- service.
Agreement Inspection, and then is regularly serviced by us or an approved Service Engineers. Provided that your plant is
installed, operated correctly and serviced, you should not need to get into much –if any –self-help. However, some of the most
likely question and answer situations are listed below.
Blower Failure
Blower Stopped:
• Check the unit is switched on, the incoming power supply circuit and fuse.
Blower works but no water distribution inside the plant:
• Check hose connections.
• Check distributor heads.
• If the air lift pipes are suspected to be blocked, call for service which number and
other details you can find on the back page of this manual.
• Check regulating valve is not closed.
Plant flooding
Bioficient 4-5 External Blower
• Check for blocked outlet system.
• If pumped outlet is all right, check for pump operation, check floats and pump power supply.
Plant odour
• Check blower working. If blower working, plant probably needs desludging.
• Check vent circuit is clear.
• Check that the air duct entering the blower housing has been sealed with foam.
Do take out a service agreement and let the experts look after your plant.
Do contact us for advice if you have any cause for concern. All contact
details are at the end of this manual.
Bioficient 6 External Blower
Don’t pump feed the plant without seeking advice from Kingspan or installer.
Don’t use a waste disposal unit as you will be adding to the biological load, and your system may not be large enough to cope
with the waste. If you are unsure please refer to our sales team for guidance.
Don’t throw any medicines down the toilet.
Don’t empty large quantities of bleach or similar cleaning reagents into the system.
Don’t empty cooking oil or similar down the sink.
Don’t cover the plant with soil material or prevent access for service and desludging.
Don’t apply a hose or jet wash to the biological filter unless specifically advised to do so.
Don’t try to enter the plant.
Don’t put sanitary towels, incontinence pads, nappies, tampons or other non-biodegradable items’ down the toilet.
DON’TS
DO’s

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INSTALLATION
1. EXCAVATE A HOLE & LAY CONCRETE BED
Approximate dimensions
For DRY CONDITIONS excavate a hole to appropriate depth allowing minimum clearance on all sides and
base of the unit of 200mm and level the base.
For WET CONDITIONS excavate a hole at least 300mm deeper than the tank, for lean mix concrete and hard-
core base. Allow for tank width plus at least 400mm with additional allowance for any necessary shuttering.
De-water the excavation using suitable pumping equipment. Ensure that the pump discharge does not
saturate the ground in the immediate vicinity. The installer should ensure that the base is adequate to
support the weight of the tank and its contents. Place a sheet of polythene over the hard-core and up the
sides of the excavation before putting in the concrete cradle.
For UNSTABLE BASE of the excavation, i.e. running sand or similar, excavate an additional 250-300mm below
concrete levels and fill up with compacted hard-core.
A base of at least 150 - 200mm of lean mix concrete should be provided. (FOR CONCRETE SPEC. SEEBELOW).
It is recommended to back fill with C25 SEMI-DRY MIX
GENERAL CONCRETE SPECIFICATION
IN ACCORDANCE WITH BS EN 206-1 (BS 8500-1)
TYPE OF MIX
(DC) DESIGN
PERMITTED TYPE OF CEMENT
BS 12 (OPC): BS 12 (RHPC): BS 4027 (SRPC)
PERMITTED TYPE OF AGGREGATE
(coarse & fine)
BS 882
NOMINAL MAXIMUM SIZE OF AGGREGATE
20 mm
GRADES: C25 /30
C25 /30
C16 /20
REINFORCED & ABOVE GROUND WITH HOLDING
DOWN BOLTS
REINFORCED (EG. FOR HIGH WATER TABLE)
UNREINFORCED (NORMAL CONDITIONS)
MINIMUM CEMENT
CONTENT
C30
C20
270 - 280 Kg/M3
220 - 230 Kg/M3
SLUMP CLASS
S1 (25mm)
RATE OF SAMPLING
READY MIX CONCRETE SHOULD BE SUPPLIED
COMPLETE WITH APPROPRIATE DELIVERY TICKET IN
ACCORDANCE WITH BS EN 12350-1
NOTE: STANDARD MIXES SHOULD NOT BE USED WHERE SULPHATES OR OTHER AGGRESSIVE CHEMICALS
EXIST IN GROUND WATER
MODEL
DIAMETER/
WIDTH
(mm)
LENGTH
(mm)
INLET
INVERT*
(mm)
OUTLET
INVERT**
(mm)
INSTALLATION
DEPTH**
(mm)
Bioficient 4
1920
3230
500
630
2300
Bioficient 5
1920
4390
500
630
2300
Bioficient 6
1920
6220
500
630
2300
* based on 500 mm invert

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4. BACKFILL THE TANK UNIT
The backfill should be free from organic material, large stones, brick
or sharp objects.
Backfilling should be carried out in layers, making sure that voids are
not left under and around the sides of the tank and that there are no
localised stress concentrations.
It is most important that the installer progressively fills the tank via a
hose while keeping the water level 300 mm above the backfill to
stabilise pressures on the tank.
It is also important that the water level is always above or equal to
the backfill level while backfilling the main body of the tank to avoid
cracking of the tank.
Lower the tank in the hole using a sling through the lifting points
provided on the tank.
Under no circumstances should the sling be attached to the inlet
pipe or the outlet pipe.
Tank should not be lifted with any water inside.
Check that the Inlet and Outlet pipe orientation is correct.
Check if the unit is levelled.
It is required to haunch the concrete under the tank to provide full
support to the GRP case.
ONLY TO BE USED IN DRY SITE CONDITIONS.
When using Pea gravel or similar as a backfill material ONLY.
Permanent ratchet strap should be at least 50mm wide, rated to
500kg.
Pea Shingle –6 mm to 10 mm rounded pea shingle, offering low
point loading characteristics is the most suitable material for back
filling in dry ground installation.
Make sure that voids are not left under and around the sides of the
tank and that there are no localised stress concentrations.
3. STRAP TANK TO CONCRETE BASE WHEN USING PEA GRAVEL
300 mm
FIRST STAGE

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Make sure tank is ballasted with water in all chambers as you backfill.
5. SECOND BACKFILL STAGE
Ballast the tank with another 300mm of water in all chambers.
Add same level of the backfill around the tank.
It is most important that the installer progressively fills the
tank with water to a level above the backfill to stabilise pressure
on the tank.
Backfill evenly all-round the tank, consolidating in layers. The
backfilling should start before the base has hardened and be a
single continuous operation so that the tank has a full concrete
jacket without joins.
600 mm
SECOND STAGE
Note: The feet on the tank are for transport purposes only and are not load bearing. Make
sure the concrete backfill is spread underneath the tank to take pressure off the feet.

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(BY OTHERS)
6. FURTHER BACKFILL STAGES
Continue to fill up tank with water and backfill evenly all-
round the tank, consolidating in 300mm layers.
DO NOT use vibrating pokers to consolidate concrete.
DO NOT discharge concrete directly on to the tank.
Ensure that the concrete is not too wet and that is tamped in
around the tank.
Continue until just below inlet / outlet pipework.
Remove covers and connect inlet and outlet pipework.
Continue to backfill.
7. VENTING
Installer must ensure adequate venting is provided for treatment plant to work efficiently.
A vent connection is supplied in the tank neck and is clearly marked. This vent connection should only be
used to connect to venting pipework.
It is also important to seal off the air duct to the blower housing with expanding foam.
This prevents odour from reaching the blower housing and ensures blower is only drawing in cleanair.
VENT PIPE & ABOVE GROUND STACK
(BY OTHERS)
BLOWER HOUSING
BLOWER AIR DUCT
(BY OTHERS)
CONCERTE PLINTH
(BY OTHERS)
OUTLET PIPEWORK
BIOZONE 1 & BIOZONE 2
AIR DIFFUSERS
900 mm
THIRD STAGE
INCOMING MAINS POWER
DUCT (BY OTHERS)
ACCESS COVER
INLET
PIPEWORK

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BioFicient® IPS HLA Installation
100mm
Cable Gland
250mm
High Level Alarm
Float
1. Remove the loose float, pivot weight & cable gland
located in the blower housing.
2. Drill Ø20mm hole & fit cable gland in position
shown above the Final Settlement Tank (FST).
3. The bottom of the float to be approx. 250mm from
the top of the pivot weight.
4. Pass the float cable through the cable gland and
align the top of the pivot weight with the top of
the FST. Tight the cable gland up.
5. Ensure the operation of the float will not foul on
any pipework.
High Level Alarm
19mm Air Diffusers
Hose Connection
6. If required, float cable to be extended to control
panel.
7. On All types of plant. Connect hoses to Sludge
Recycle and Diffusers.
Final Settlement Tank
13mm Sludge recycle
Hose Connection

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CONTROL PANEL INSTALLATION
Battery pack Blower pressure sensor
Battery
Header
Dip Switch SW11 must
be ‘ON’ for PPFDS to
work. All others ‘OFF’
Fuse 5 A
Discharge
pump
Isolator
Switch
Mains
input
230V 50Hz
Fuse 3.15A
Motor Drive
TB1
Discharge Pump or
Solenoid Valve:
Phase (red)
on «1» Neutral (black)
on «2»
Ground (if applicable)
TB3
Blower
Phase (red)
on «5»
Neutral (black)
on «6»
and Ground
TB6
High water level detector.
Remove link between Pin11
and Pin12 if you fit HLA
Wire 1 (red) on « 11 »
Wire 2 (black) no
connection
Wire 3 on « 12 »
(if applicable)
TB7
Remote beacon
Phase (red)
on « 16 »
Neutral (white)
on «17 »
Ground (black)
on « 18 »
(if applicable)

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017904-04 BioFicient 4-6 Installation Manual
CONTROL PANEL ENTRY POINTS DEPENDING ON THE EQUIPMENT SUPPLY
*Pumped discharge only
** See Fig.1 below
Product
Required Gland
Feed through Gland Hole
number
Terminate to connection
Mains power supply
M20
1
Integral discharge pump power cable
M20
2
1&2
Sludge Return Solenoid Cable
*
M20
3
1&2
Blower power supply cable
**
M20
4
5&6
High level alarm cable
M12
7
11&12
Beacon
*
M12
9
16, 17&18
Fig.1 Sludge Return Solenoid
Sludge Recirculation Hose
Connection Point Ø13mm
Hose Tail
Bioficient 4 Bioficient 5 Bioficient 6
Integral discharge pump 240-volt single phase only 2.2 2.2 2.2
Solenoid Valve Low Voltage 0.08 0.08 0.08
Full Load Current (Amps)
1.4
1.0
0.7
240-volt single phase
Blower
7
9
2
4
6
8
1
3
5
Control Panel
Power Pressure Failure
Detection System Hose
Blower Unit
Solenoid Valve
c/w Timer
Mains Power
Entry Point
Diffuser & Desludge
Recirculation Hose
Entry Point
Diffuser Hose
Connection Point
Ø19mm Hose Tail

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017904-04 BioFicient 4-6 Installation Manual
SLUDGE RETURN SOLENOID RUN AND PAUSE TIME SETTING (IF FITTED)
1. When power is present, press ‘’Mode’’ button
until the display reads ‘’on – off’’.
2. Press ‘’Enter’’ button to accept mode selected.
3. To set ‘’ON’’ time, press ‘’Enter’’ button to move
cursor along indicator to reach single minute’s
position.
4. Press ‘’ADD’’ button to increment minutes.
5. Press ‘’Enter’’ again to get to the end of display.
6. When display changes back to all zero’s, timer is
asking for ‘’OFF’’ time.
7. Press ‘’Enter’’ to get to single hour’s section.
8. Press ‘’ADD’’ to enter hours.
9. Press ‘’Enter’’ again to get to the end of display.
10. When times have been entered, the ‘’on – off’’
should appear for a few seconds and the timer
will start working.
11. When timer is ‘’ON’’ the indicator is illuminated.
12. Pressing ‘’Reset’’ button in operation will cause
the timer to re-start the ‘’ON-OFF’’ cycle.
13. The timer should be factory set at the correct settings. (5 minutes ‘’ON’’ and 1 hour ‘’OFF’’)
Sludge Recirculation
Hose Connection
Point Ø13mm Hose
Diffuser & Desludge
Recirculation Hose
Entry Point
Diffuser Hose
Connection Point
Ø19mm Hose Tail
Mains Power
Entry Point
Control Panel
Blower Unit
Solenoid Valve
c/w Timer
Power Pressure
Failure Detection
Display
Screen
Mode and
Time
‘’ON’’
Indicator
Solenoid
Connection
Control
Buttons

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017904-04 BioFicient 4-6 Installation Manual
SLUDGE RETURN SOLENOID RUN AND PAUSE ANALOGUE TIMER SETTING (IF FITTED)
‘’ON’’ INDICATOR
‘’OFF’’ INDICATOR
TIME ON CONTROL REGULATOR
TIME OFF CONTROL REGULATOR
SOLENOID CONNECTION
The timer should be factory set at the correct settings.
Factory settings are: 5 minutes for timer ‘’ON’’ and 1 hour for timer ‘’OFF’’.
COMPLETING THE INSTALLATION (refer to Control Panel illustration on page 13.).
1. Plug the lead from the battery into the small white socket in the top right corner of the PCB marked
“BATTERY HEADER”.
2. Power & Pressure Failure Detection System (where applicable) - Using a small screwdriver, push switch 11 to
the ON position.
3. Installation of High Level Alarm (where applicable) - Remove the link in the terminal blocks between
connections 11 & 12 (TB6) before inserting cables. Using a suitable M12 gland, feed the high-level alarm
float cable through Gland Hole 7 and terminate to connection 11 & 12 (TB6) –Red to 11 & Black to12.
CONTROL PANEL FAULT CODES AND FUSES
CODE
FAULT CONDITION
FUSE
Amp
F1
No power to the unit
Customer Fuse
box
N/A
F2
The blower pressure has failed
N/A
N/A
F3
The high-level alarm has activated (where fitted)
N/A
N/A
F4
The fuse to the blower has failed
F4
3.15
F5
The fuse to the discharge pump has failed (where fitted)
F5
5.0
F6
The fuse to the chemical dosing pump has failed (where fitted)
F6
0.25
F7
The fuse to the recirculation pump has failed (where fitted)
F7
5.0
F8
The loss of rotation alarm has been activated (not applicable)
N/A
N/A
The unit has had a fault which has now corrected itself
- -
(Flashing left and right - Battery charging
N/A
N/A
Flashing left only - Battery charged)
All fuses are Time Lag HBC 20mm type

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017904-04 BioFicient 4-6 Installation Manual
MAINTENANCE
Every sewage treatment plant needs regular maintenance as does the upkeep of drainage fields and drains.
This is the responsibility of the owner/user.
We recommend that plants are maintained by qualified service personnel, however some self help and an
awareness of normal operation is helpful in identification of a larger problem.
If the plant appears not to be operating correctly, refer to the Fault Finding section of this manual.
MAINTENANCE SCHEDULE
DAILY
Check the operation of the compressor. It should be possible to hear it running by standing close to the unit.
MONTHLY
Check the operation of the compressors (bubbles should be rising in the reactors and media should be seen slowly
rotating).
Visually check that the inlet and outlet zones are clear of debris.
Visually check the biomass growth on the filter media. The biomass colours should vary from light brown colour,
(not white or grey.) to rich brown. Odour from the plant should be 'earthy' and hydrogen sulphide odours
('rotten eggs') should not be present.
Visually check the final effluent. If cloudy or containing many suspended particles, then the humus and or
primary tank is likely to require desludging.
THREE MONTHLY
Assess the depth of the thickness of the floating sludge in the primary and final zones.
Check the blower filter, and replace if necessary. Note. The filter will collect dirt particles from the air and the
location of blower/inlet will influence the frequency of filter change.
ANNUALLY
The unit is designed to be emptied of sludge every 12 months

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017904-04 BioFicient 4-6 Installation Manual
WARRANTY
Taken from ‘Kingspan’s Terms & Conditions of Sale’
The company will replace or, at its option, properly repair without charge any goods which are found to be
defective and which cause failure in normal circumstances of use within a period of twelve months from the date
of delivery.
This warranty is conditional upon:
(a) the Buyer notifying the Company of any claim within seven days of the failure becoming discernible.
(b) the Company being allowed a reasonable opportunity to inspect the goods so as to confirm that they are
defective.
(c) the goods not having been modified, mishandled or misused and being used strictly in accordance with any
relevant instructions issued by the Company.
The Company’s liability under this Clause is limited to the repair or replacement of the defective goods, and
does not cover costs of transport, installation or associated site costs, if applicable.
The Company’s liability to replace or repair the goods is in lieu of and excludes all other warranties and conditions,
and in particular (but without limitation) the Company shall have no liability of any kind for consequential loss or
damage.
For any further advice, please contact us.
A Warranty Form is included in this package, to register your unit for Warranty. Please complete ALL sections of the
Form, and return it at your earliest convenience.
Also within this package is a Notice, describing the necessary maintenance of the plant in use. This should be fixed
within the building.

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017904-04 BioFicient 4-6 Installation Manual
FAULT FINDING
1. COMPRESSOR NOT RUNNING
Cause
Remedy
Power cut
Do nothing. When power is restored the system will restart
automatically
Check Mini Circuit Breaker on electrical supply board
Power supply RCD (Residual current
Device) tripped
Isolate the power supply and reset the RCD
Switch on the blower, which should start automatically
If not, switch off the power and call an electrician
2. NO EVIDENCE OF AIR BUBBLES RISING THROUGH THE MEDIA
Cause
Remedy
Blower not running
Refer to fault condition 1
Contact our Service company (Details on front cover)
3. MEDIA NOT MOVING
Cause
Remedy
Blower not running
Refer to fault condition 1
Contact Service company
4. NO BIOMASS GROWTH ON MEDIA OR WHITE GROWTH THROUGHOUT BOTHBIOLOGICAL
REACTORS
Cause
Remedy
Blower not running
Refer to fault condition 1
Contact service company
Toxic input
Consider each chemical and the amount used within the
properties
E.g. washing powders bleaches. Switch to alternative
products, consider switch from biological powders to non
biological washing liquids and use less per wash
5. SMELL
Cause
Remedy
Blower not running
Refer to fault condition 1
Contact service company
Time for a Desludge
Remove sludge from primary and final compartments

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017904-04 BioFicient 4-6 Installation Manual
NOTICE
BioFicientTreatment Plant
The foul drainage from this property discharges to a Treatment Tank and an irrigation
system / soak-away.
The tank requires monthly inspections of the outlet chamber or sample chamber to
observe that the effluent is free-flowing and clear. The soak-away should also be
inspected regularly.
The Sewage Treatment tank requires emptying at least once every 12 months by a
licensed contractor.
THE OWNER OF THE PROPERTY IS LEGALLY RESPONSIBLE FOR
ENSURING THAT THE SYSTEM DOES NOT CAUSE POLLUTION, A HEALTH
HAZARD OR A NUISANCE.
We recommend that a separate log is kept of all service visits, the log should detail the
date and any action taken, e.g. regular maintenance service and de-sludge volume
removed.
This notice should be fixed by the owner within the building alerting current and future
owners to the maintenance requirement.
Please contact Kingspan Water and Energy on [phone] to arrange a
maintenance service or to request replacement operating instructions.