WTE VORTEX User manual

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VORTEX Installation Manual
The information contained within this Installation Guidance Manual is provided for general
information purposes only and does not take into account any specific requirements resulting from
your particular location and/or site, of which Water Technology Engineering Limited (WTE) has no
knowledge.
Whilst we endeavour to keep the information up to date and correct, we make no representations or
warranties of any kind, express or implied, about the completeness, accuracy or reliability of the
information contained within the Installation Guidance Manual.
Special attention should be paid to the siting of the tank as damage may be caused to the exterior as
a result of inappropriate siting. We would advise that due to the wide variety of possible ground
conditions, specialist installation advice should be sought from a suitably qualified professional as to
the appropriate installation method for your particular location/site.
This manual gives details on the minimum requirements to install VORTEX tanks. It is the responsibility
of whoever is instructed to install the tank, to ensure that the installation method and materials used
are suitable for the Tank and specific location/site conditions at all times of the year.
Water Technology Engineering Ltd do not accept liability for any loss or damage caused as a result of
the customer’s failure to ensure appropriate siting of the tank or of an unsuitable, inappropriate or
incorrect installation.
When installing tanks on sites with unusual ground conditions such as high water tables, sloping
ground etc. a civil engineer or suitable qualified person must be consulted to ensure that the
guidance given below is suitable for the site.
Where the guidance below is not suitable for a specific site then a civil engineer or suitably qualified
individual must be consulted to design a suitable installation procedure.
WTE recommends that its products are installed, or the installation works supervised, by WTE
Approved Contractors.
The guidance given below is correct at time of publication but may vary due to continued product
development.

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Installation Record Sheet
Once completed, a copy of this sheet must be returned to WTE either by post (WTE Ltd, Unit 2, Bolton
Lane, York, YO41 5QX) or email ([e-mail]).
All boxes must be filled in (pump serial number only applies to tanks with an effluent pumping station)
in order to validate the warranties.
Installation refers to the tank’s physical placement, backfilling and electrical connection.
Commissioning refers to the setting up of the system –air blower(s), sludge returns, aeration, etc.
Please contact our sales office on 01759 369 915 to book a tank commission.
WTE Reference
This can be found at the top right hand side of
the Delivery Note
SITE
Contact Name
Address
Post Code
Contact Phone Number
Contact Email
INSTALLATION
Date
Company
Name of Installer
Company / Installer Address
Phone Number
COMMISSIONING
Date
Company
Name of Engineer
Company / Engineer Address
Phone Number
COMPONENTS
Air Blower Serial Number
Larger systems may have two air blowers.
Air Blower Backpressure
A reading, and photo of the reading, must be
recorded for every air blower to validate
blower warranty. A copy of the photo must
accompany this form.
Discharge Pump Serial Number (if fitted)
Larger systems may have two pumps.

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Introduction
VORTEX is a sewage treatment plant designed to process wastewater from buildings that do not
have access to municipal wastewater infrastructure.
The VORTEX system provides an ideal solution for domestic homes, offices, and other small sites that
require on site wastewater treatment.
VORTEX is made from HDPE and is divided into three chambers with each chamber performing a
different step in the treatment process.
1. Wastewater enters the Vibro Screen where any solids are physically broken down by coarse
air bubbles.
2. The wastewater then flows into the aeration chamber where it is aerated by a fine bubble
diffuser. The fine air bubbles provide excellent oxygen transfer into the wastewater slurry
and enable a bacterial culture to develop. These aerabic bacteria then digest pollutants in
the wastewater and clean it.
3. The cleaned wastewater then enters the Final Settlement Tank where settleable and floating
solids are allowed to form a sludge at the bottom and top of the chamber. The clean
effluent in the middle of the chamber is separated off and allowed to leave the tank. The
sludge management system continually recycles the settled and floating sludge for further
digestion.
VORTEX is designed to treat wastewater that is domestic in nature. The influent must not contain
trade waste. If you require advice, please contact our office.
VORTEX is designed to receive wastewater only, no rainwater, surface water or groundwater may
enter the tank.
VORTEX is designed to treat wastewater only. The influent must not contain any roof water, surface
water or groundwater.
WTE Ltd strongly recommends that VORTEX tanks are installed by contractors who have been
trained on the system’s installation and operation.
Please contact our sales office for details of your nearest installer.
Health & Safety
Sewage poses a serious risk to health.
Pathogens in sewage and wastewater can lead to many diseases such as:
Campylobacteriosis
Cryptosporidiosis
Escherichia coli Diarrhoea
Encephalitis
Gastroenteritis
Giardiasis
Hepatitis A
HIV
Leptospirosis
Methaemoglobinaemia
Poliomyelitis
Salmonellosis
Shigellosis
Paratyphoid Fever
Typhoid Fever
Yersiniosis
Every precaution should be taken to ensure a safe working environment.

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Receipt of Goods
Upon delivery all goods must be inspected for damage and to ensure that all components are
present.
If the VORTEX tank is damaged or any of the components are damaged or missing then this must be
recorded on the P.O.D. (proof of delivery document) and WTE Ltd must be notified immediately.
If goods are damaged or items are missing but the P.O.D. has been signed for as either undamaged
or unchecked, WTE Ltd will be unable to exchange the goods in question or supply additional items
free of charge.
If the tank is not going to be used immediately, all electrical components must be removed from the
tank and stored in a dry place.
Handling & Storing
The tank should only be lifted if it is empty.
When lifting the tank both parts of the lid should be in place to prevent the tank distorting.
The tank should be lifted via a rated strap placed through the lifting eyes as shown below. If the
straps press against the turret of the tank then a spreader bar must be used.
The tanks should be stored vertically on a smooth and level surface. Wherever possible the tanks
should not be stored on pallets.
In warm weather (>15°C) the tanks should be stored in a cool, shaded location if possible.

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Installation - Below Ground
The method of installation is dependant of the site’s ground conditions.
Sites are divided into four categories:
Dry Site Where ground water or the water table does not rise above the base of the
excavation at any time of the year.
Wet Site Where ground water or the water table rises, or is suspected to rise, to 1,400mm or
less above the base of the tank.
Saturated Site Where ground water or the water table rises, or it suspected to rise, above the tank
outlet.
VORTEX S (Standard Duty) tanks are suitable for Dry and Wet sites where groundwater does not rise
above the base of the outlet (1.4m above the base of the tank).
VORTEX S tanks are white.
VORTEX H (Heavy Duty) tanks are suitable for Saturated sites where groundwater rises above the
base of the outlet (1.4m above the base of the tank).
VORTEX H tanks are black.
Do not undertake any concrete work if the temperature is likely to drop below freezing within the
following 24 hours.
Ensure the area is secure before undertaking any works.
It is essential that the VORTEX tank does not flood. The tank must be installed so that surface
water does not pool around the tank as this can cause the tank and Blower Tray to fill with water
(please note that the Blower Tray does have drainage holes). If there is any doubt, install the tank
so that the top of the turret is 25mm above ground level.
If required, a separate Blower Housing can be supplied.
Dry Site Installation
Excavate a hole that is 200mm greater than the diameter of the tank.
The excavation should be sufficiently deep so that the tank inlet is at the same depth as the
incoming drain from the building.
The tank must be placed a smooth, level and stable base. This base must be suitable for the site
specific ground conditions and soil structure. It must also be suitable for the operating weight of the
VORTEX tank. The tank must be able to distribute its weight evenly across the whole base.
The base must be free of any sharp objects or other objects that may puncture the tank.
A 150mm reinforced C28/35 concrete base is often the preferred option for many sites
If the ground contains high levels of contaminants, including for example sulphate or chloride, this
concrete mix will not be suitable. In these circumstances the advice of a qualified civil or structural
engineer should be sought.

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The tank should be safely lowered into the excavation using suitable rated straps.
Once the tank is in position the inlet and outlet pipes should be connected to the respective
drainage pipes.
Inlet = black socket
The void around the tank should be backfilled with soft sand. The sand should be free of stones and
sharp objects. The backfilling should be done in 200mm layers and tamped by hand so ensure that
there are no voids.
Do not pour backfill material directly onto the tank.
During backfilling the lid should be closed to prevent the backfill material from being poured in to
the VORTEX plant. This is also required to ensure that the tank retains its shape.
During backfilling the tank should be filled with clean water. The water level inside the tank should
lead the backfill by 200mm.
Prior to filling the tank with water, the diffuser assembly (rigid vertical air pipe) in the Biozone that
supplies air to the fine bubble diffuser, must be pushed down to ensure it is correctly seated in the
bracket at the base of the tank. This is to ensure that the diffuser is captive and cannot move post
installation. To ensure that the diffuser assembly cannot rise, the top elbow must be cable tied to
the bracket at the top of the baffle as shown below.
The last 200-300mm of backfilling should be done with top soil. The top soil must be loose and free
from stones, clay and sharp objects. The top soil should be laid and tamped in the same way as the
sand.

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Wet and Saturated Site Installation
If required the site should be dewatered prior to, during and after the installation of the VORTEX
tank via the use of a side sump or other appropriate dewatering method. During dewatering it is
essential that cement and other constituents are not drawn out of the concrete by the action of the
dewatering pumps.
Depending on site conditions the excavation may require shuttering to prevent it from collapsing.
Independent engineering advice should be sought if there is any doubt regarding these issues.

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Excavation
Wet Site
Saturated Site
VORTEX 4
VORTEX 6 & 8
VORTEX 4
VORTEX 6 & 8
Length (A)
1,650mm
2,250mm
1,900mm
2,250mm
Width (B)
1,650mm
2,250mm
1,900mm
2,250mm
Depth (C)
Height of tank
+150mm
Height of tank
+150mm
Height of tank
+150mm
Height of tank
+150mm

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Backfill
Wet Site
Saturated Site
Base (D)
150mm
150mm
Concrete (E)
1,400mm
Tank height -200mm
Sand/Gravel (F)
To suit
None
Soil (G)
200mm
200mm
Excavate a square excavation to the dimensions above.
Ensure that the excavation sides are properly and fully supported throughout the works, with all
water being pumped away to ensure that the excavation is kept dry.
Place concrete onto a dry formation to a depth of 150mm using a semi-dry C28/35 mix to BS EN 206-
1 / BS 8500. (Max aggregate Size: 40mm, Consistence class: S1)
If the ground contains high levels of contaminants, including for example sulphate or chloride, this
concrete mix will not be suitable. In these circumstances the advice of a qualified civil or structural
engineer should be sought.
Compact and finish with a tamped and level surface.
Place the tank onto the concrete formation.
Ensure the tank is level and connect the outlet and inlet pipes.
Inlet = black socket
Fill the tank with 300mm of clean water.

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Ensure the tank is secure and surround the tank to the depth ‘C’ given in Table A with a semi-dry
C28/35 mix to BS EN 206-1 / BS 8500. (Max aggregate Size: 40mm, Consistence class: S1). Ensure
filling is brought up on each side of the tank in a uniform and even manner.
Do not pour backfill material directly onto the tank.
The concrete backfill should be poured in 200mm layers with each layer being tamped by hand to
eliminate voids. A vibrating poker must not be used.
Prior to filling the tank with water, the rigid vertical air pipe (in larger systems there is more than
one) in the Biozone that supplies air to the fine bubble diffuser, must be pushed down to ensure it is
correctly seated in the bracket at the base of the tank. This is to ensure that the diffuser is captive
and cannot move post installation.
The tank must be filled with clean water during backfilling. The water inside the tank should lead the
concrete backfill by 300mm.
Prior to filling the tank with water, the diffuser assembly (rigid vertical air pipe) in the Biozone that
supplies air to the fine bubble diffuser, must be pushed down to ensure it is correctly seated in the
bracket at the base of the tank. This is to ensure that the diffuser is captive and cannot move post
installation. To ensure that the diffuser assembly cannot rise, the top elbow must be cable tied to
the bracket at the top of the baffle as shown below.
During backfilling the lid should be closed to prevent the backfill material from being poured into the
VORTEX plant. This is also required to ensure that the tank retains its shape.
Note that the electric cable must be installed prior to backfilling over the shoulder of the tank.

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Finish with a hand tamped level surface.
Ensure excavation is kept free from water for at least 3 days (may reduce to 1 day in very warm
weather). This is to allow the concrete to set.
The water in the tank must remain in place until the concrete has fully cured.
Once the concrete has set the excavation should be backfilled with sand or gravel. Filling is to be
undertaken uniformly on each side to prevent uneven loading on the tank.
The last 200mm should be backfilled with topsoil.
Installation –Above Ground
The tank must be placed a smooth, level and stable base. This base must be suitable for the site
specific ground conditions and soil structure. It must also be suitable for the operating weight of the
VORTEX tank.
The tank must be able to distribute its weight evenly across the whole base.
The base must be free of any sharp objects or other objects that may puncture the tank.
A 200-300mm reinforced concrete base is often the preferred option on many sites
For sites where the winter temperature may drop below 0°C the VORTEX must be insulated against
the cold.
A possible method of insulating the VORTEX is to construct a solid wall, 50mm shorter than height of
the tank, around the VORTEX unit. There should be a gap of at least 200mm between the tank and
the wall and the gap can be filled with compacted sand or other insulative material.
Air Line Connections
There are four air lines (hoses) inside the tank that need to be connected. This should be done once
the tank is backfilled.
RED Vibro Screen
BLUE SSR (Settled Sludge Return)
WHITE Air Diffuser
These are connected to the corresponding colour on the Regulator.
BLACK FSR (Floating Sludge Return) –operated by the solenoid valve.
This is connected to the outlet on the Blower Tray.
Beacon Installation
VORTEX tanks are supplied with either one or two alarm beacons.
Colour
Alarm
Position on Lid

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RED (all models)
Air Blower
Left
BLUE (pumped outlet models)
Discharge Pump / High Water Level
Right
To install each beacon the following is required (see picture below):
•5mm Drill Bit (not supplied)
•Beacon
•Neoprene Gasket
•2x 20mm Washer
•2x M4 Nut

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To fit the beacon to the lid:
1. Drill a 5mm hole in each of the three drill starts on the tank lid.
2. Fit the gasket to the underside of the beacon.
3. Pull the wires through the centre hole.
4. Push the bolts through the outer holes.
Turn the Lid over
5. Fit the washers over the bolts and secure with the nuts. DO NOT OVER TIGHTEN.
To connect the wires of the RED beacon:
1. Insert the brown and blue wires from the beacon into the grey junction box on the
underside of the lid. (If a white wire is present it must be isolated).
2. Insert the alarm cable from the air blower into the grey junction box.
3. Connect the blue and brown wires.
To connect the wires of the BLUE beacon:
1. Insert the brown and blue wires from the beacon into the grey junction box on the
underside of the lid. (If a white wire is present it must be isolated).
2. Insert the loose cable from the black junction box into the grey junction box.
3. Connect the blue and brown wires.
Extension Turret
Extension Turrets are available for deeper inverts and are supplied as a kit.

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The Turret Extension can be cut down on each rib to give the required height.
Both the Turret and Turret Extension must be clean and dry.
Butyl tape must be laid in a triple layer on the Turret of the tank as shown below.

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The Turret Extension is then placed onto the Turret and fixed with the 12 screws and washers
provided as shown below. The screws must be evenly spaced at approximately 215mm intervals.

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Trafficked Installation
VORTEX tanks may be installed in a trafficked location.
The VORTEX tank is not designed to be load bearing so a suitable reinforced transfer slab must be
laid with a rated 900mm x 900mm clear opening cover and frame over the tank turret. Please note
that the moulded VORTEX lid is not required.
For a trafficked installation, a separate Blower Housing is required as the air blower must be sited
remotely and not in the turret of the tank.
Blower Housing can be purchased from our sales office.
The Blower Housing sits above ground adjacent to the tank.
The Blower Housing should be positioned as close to the tank as possible and no further than 5m
away.
The Blower Housing is connected to the tank via a 110mm duct (not supplied).
Every effort should be taken to ensure the duct connects the Blower Housing to the tank in a straight
line. Where bends are necessary, they must be sweeping (long radius) bends.
There are two airlines inside the tank that need to be connected to fittings inside the Blower
Housing through the 110mm duct.
As shown below, the green airline is connected to the T fitting on the solenoid vale and the white
airline is connected to the elbow.
Any excess airline must be cut off.

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Both ends of the duct must be sealed with expanding foam to prevent the air blower(s) drawing air
from inside the tank.
The Blower Housing should be orientated so that the alarm light will be seen when it activates.

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Electrical Installation
All electrical work must be carried out by qualified personnel, using suitable materials and must
comply with current regulations.
All electrical items must be sited and installed so that wherever possible a service engineer has full
access to the system without requiring entry to a building.
The electrical contractor must provide a steel wire armoured (SWA) cable from a local fused point of
isolation to the socket in the Blower Housing.
Cable protection should be provided via 6 amp miniature circuit breaker (MCB) protected by residual
current detector (RCD), rated 230V, AC and tripping current 0.03 amps.
The incoming electric cable should come through the metal compression gland provided. See
images below. The plastic within the moulded brass insert must be drilled out to allow the passage
of the cable.

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The cable must enter the Blower Tray through the compression gland (5) as shown below.

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If the tank has a pumped outlet:
6= Pump power cable.
7= High level alarm float switch. This gland has an insert to reduce the diameter.
8= Pump lifting chain.
The equipment in the Blower Housing is pre-assembled. The power supply cable should be
connected and terminated into the socket provided with a suitable gland (not provided).
It is very important that there is sufficient slack cable inside the tank to enable the Blower Tray to be
removed.
Setting the Timer
The timer that operates the solenoid valve should be delivered pre-set so that it energises the
solenoid as follows:
ON
(Valve Open)
OFF
(Valve Closed)
1 mins
30 mins
Both dials should be turned fully to the left.
The solenoid valve will then open for approximately 1 minute and then close for approximately 30
minutes where upon the cycle is repeated.
Air Blower Backpressure
Once all air line connections have been made and power supplied to the blower housing, the
backpressure in the air line must be checked.
A pressure gauge must be fitted to the air line immediately after the air blower. For tanks with more
than one air blower, a backpressure reading must be taken and recorded for every air blower.
The backpressure should be set as close to 200mbar as possible. The pressure must not be less than
180mbar and must not exceed 200mbar.
Pressure adjustment is done by opening and closing the valves on the Regulator whilst maintaining
correct aeration inside the tank.
If the backpressure exceeds 200mbar do the following:
•Open/close the valves on the Regulator whilst maintaining the correct aeration inside the
tank.
•Check for obstructions (kinks).
The final backpressure reading(s) must be noted on the Installation Record Sheet and the
completed sheet returned to our office.