 Design guideline

Manual

BioKube Venus 2800

Instruction Manual

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BioKube Venus 2800
Instruction manual

Indhold
1 Introduction ................................................................................................................................... 3
Precautions when Working with Wastewater .................................................................................. 4
Installation ............................................................................................................................................. 5
Foundation........................................................................................................................................ 5
Confirmation of Packing List ........................................................................................................... 5
Inspection of Vital Components .................................................................................................... 5
Unloading and relocating the Venus 2800 unit ........................................................................... 6
Installation of Venus 2800................................................................................................................ 7
2 Installation of settling tank........................................................................................................... 8
Step 1 – Placement ...................................................................................................................... 9
Step 2 – Inlet ................................................................................................................................ 10
Step 3 – Outlet ............................................................................................................................ 11
Step 4 – Phosphorous Removal (Optional) ............................................................................. 11
Step 5 – Power to the control box............................................................................................ 12
Step 6 – External alarm .............................................................................................................. 13
Step 7 – Control Box ................................................................................................................... 15
Control Scheme – Installation....................................................................................................... 16

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Instruction manual

1 Introduction
This manual includes the procedures and guidelines for the installation,
commissioning, operation, maintenance and troubleshooting of the BioKube Venus
2800 treatment plant.

The Venus 2800 system is designed to treat ordinary domestic sewage wastewater.
Unless specifically approved by BioKube, no other forms of wastewater, such as
industrial wastewater, can be fed through the treatment system.
The BioKube Venus 2800 system is designed for treating wastewater capacities
specified by BioKube. The plant allows for fluctuations in both concentrations and
volume of the incoming water. However, if the average daily load exceeds the
capacity of the designed system, a larger system or additional units will be required
to be installed.

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Instruction manual

Precautions when Working with Wastewater

Protecting Workers from Infection

Along with “good” micro-organisms that break down sewage, wastewater contains
disease-causing bacteria, viruses, fungi and parasites. When operators can’t avoid
contact with sewage, management should provide them with the following
protective equipment and services:
• Elbow-length rubber gloves
• Rubber pants and jackets
• Goggles
• Disposable mask to be worn in dusty sludge areas or areas with heavy
aerosols
• Commercial high temperature washing machines for work clothing
Operators should also take the following precautions:
• Wash gloves before removing them.
• Wash hands before smoking or eating.
• Keep protective clothing and equipment out of eating areas.
• Keep work clothes and street clothes in separate lockers.
• Shower and change into street clothes before going home.
• Consider all cuts or abrasions to be infected. Flush them with large amounts of
clean, running water and soap, and bandage them with a sterile dressing.
• Workers should have a tetanus booster every 10 years and workers, who have
never been vaccinated for polio, should consult a physician about getting a
vaccination.
• Workers should receive the hepatitis A vaccination. Workers working in sewers
that may contain fresh blood or come into regular contact with used syringes
or body parts should receive the hepatitis B vaccination.
• Trucks that carry materials contaminated with sewage should be washed
frequently.
• Records should be kept of workers’ major and minor illnesses and complaints
of irritation and discomfort.
Seek medical attention when you have diarrhea or are ill. Since doctors are often
unaware of the connections between occupation and disease, be sure to inform
your personal physician of job exposure to sewage.

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BioKube Venus 2800
Instruction manual

Installation

Foundation
A levelized foundation should be completed prior to arrival of the Venus 2800
system, which will make the installation faster when the equipment is delivered.

Confirmation of Packing List

Always confirm that the components and parts received are in accordance with
the purchase order and packing list. Also, confirm that the goods show no signs of
visible damage or faults. All pipe diameter dimensions in this manual are external
diameters.

Inspection of Vital Components

Treatment Plant: BioKube Venus 2800
Confirm that tanks, filters and components are intact and undamaged.
Pump System
The system is delivered with an inlet pump installed in the buffer tank. The system
consists of a submersible sewage pump connected to the inlet pipe. The pump can
easily be lifted out of the buffer tank in the inlet pipe for service and maintenance.
Confirm components for pump system are undamaged and according to packing
list.
Float Switch System
The float switch system is installed on the inlet piping in the buffer tank. Confirm
components for pump system are undamaged and in accordance with the
packing list.
Air System
Diaphragm blower for air supply to the biological treatment is placed in the internal
control box. Confirm that diaphragm blowers and air-pipes are intact, undamaged
and in accordance with the system specifications.
Electrical Cabinet
Confirm that the internal control box is undamaged.
Other parts
Confirm that all remaining parts are undamaged and in accordance to the parts
list.

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Instruction manual

Unloading and relocating the Venus 2800 unit

The BioKube Venus 2800 can be installed both below or above ground, and is
therefore possible to relocate. The unit contains electrical and mechanical parts
and must therefore be handled with care. The unit must always be closed during
operation with the cover placed on top of the system. Before shutting down for
transportation the unit must be emptied of any water or sludge and the internal
components such as pumps and blowers need to be secured before loading and
transportation. Loading is done by means of forklift or crane (see Picture 1).

Tank dimensions are found in the Venus 2800 outline and load drawing sheet.
When relocating the unit, sludge must be emptied and disposed of according to
local regulation. (stabilization, landfill, etc.)

The unit is equipped with four lifting eyes used when lifting the system.

Picture 1

Notice: Do not lift the Venus 2800 units with water inside. The unit must
be transported and handled carefully to avoid damage to the
components installed inside. Assess all components for damages after
each transportation.

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BioKube Venus 2800
Instruction manual

Installation of Venus 2800

1. Water gravitates from the external septic tank to the internal buffer tank via
the low inlet.

2. The buffer tank will even out any fluctuations for the incoming water load. A
float switch placed close to the top of the buffer tank works as an emergency
switch and runs the inlet pump continuously if activated. In case there is ever
a buffer tank pump failure, an overflow ensures that the untreated
wastewater is directed to the outlet and will not run over the edge of the
system.

3. In the biological treatment zone 1 the submerged filter, with a large surface
area for the microbes, is exposed to heavy aeration. The system will never
clog and does not need any maintenance or chemicals.

4. Bio sludge settles in the settling zone. Airlift pumps in bottom keep the settling
zone clean by recirculating the bio sludge to the settling tank.

5. In the biological treatment zone 2 the submerged filter, with a large surface
area for the microbes, is exposed to heavy aeration. The system will never
clog and does not need any maintenance or chemicals.

6. Bio sludge settles in the settling zone. Airlift pumps in bottom keep the settling
zone clean by recirculating the bio sludge to the settling tank.

7. If disinfection of the treated wastewater is required, the integrated chlorine

dosing or UV-treatment system placed at the outlet ensures that no bacteria
will leave the system. This is needed if the water is to be reused.

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Instruction manual

The function of the BioKube Venus 2800 system and the flow through the system

2 Installation of settling tank

All gravitation pipes must have a decline of minimum

20‰.
Sludge return: Gravitation
in Ø110mm pipe Between
Inlet: Wastewater from BioKube Venus 2800 and
the source settling tank.

Terrain

Inlet to BioKube from Outlet: Treated water

settling tank - Ø160mm gravitates to receiver
PVC-rør

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Instruction manual

Step 1 – Placement
The unit must be placed on a flat and leveled load bearing surface with a
maximum level variation of +/- 1 cm high per 4 meters across. Surface must consist
of either (i) stable compressed gravel, (ii) at least 200mm cast concrete slab built on
stable soil, or (iii) a checker plate capable of handling the load, see Picture 2.

Picture 2

All pipe connections to the unit must have the dimension Ø160mm (External
measure) and all connections from the unit must have the dimension Ø160mm. In
Picture 3 connections, placement and dimensions are shown. For a full overview of
the unit, please see the Outline and Load drawing.

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Instruction manual

Picture 3

If the unit is placed in the ground and the water table is high, the unit must be
secured from buoyancy. This is done making an in-situ concrete cast around the
base plate of the unit, see Picture 4. Make sure that necessary pipe connections
have been made before casting the concrete.

Picture 4

Step 2 – Inlet
Sewage water is led from the external septic tank to Venus 2800 Inlet. The
connection is made with an Ø110mm PCV pipe connected to the In-situ
connection at the inlet, see Picture 5.

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Instruction manual

Inlet connection
Picture 5

The top of the Venus 2800 is made for a maximum weight of 100 kg/m2

Step 3 – Outlet
The treated sewage leaves the side of the Venus 2800 through an Ø110 mm outlet.
The stub out for the pipe connections are pre-fabricated ready to connect to, see
Picture 6. Remove cover for transportation and connect the outlet pipe to the
discharge point. Outlet pipe is placed inside the Venus 2800 during transportation.

Outlet connection

Picture 6

Step 4 – Phosphorous Removal (Optional)

The chemical tank for phosphorus removal liquid is installed in the ground close to
the control box in the Venus 2800, see Picture 7.

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Instruction manual

All components for the chemical dosing are installed in the chemical tank and
inside the BioKube Mars system.

Only the suction hose and dosing pump cable from the chemical tank to the
controller inside the Mars Treatment System must be connected. The chemical tank
should be installed 200 mm above ground to prevent inflow from surface water into
the chemical tank.

Picture 7

Step 5 – Power to the control box

The control box is located in the electrical cabinet integrated into the system. All
electrical components in the system are powered through the control box, which is
connected directly to the power supply, see Picture 8.

Picture 8

Minimum requirement for the power supply cable to the plant is a 5 x 2.5 mm² core
(for 230V – 50Hz). This cable supplies both power to the plant and connects the
alarm unit. The cables are placed in the steel pipe going to the technical box, see
Picture 9.

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BioKube Venus 2800
Instruction manual

Picture 9

Standard BioKube Venus 2800 is powered with 230/110 Volt, 1 phase power supply.
The maximum current is 2-5 Ampere (5-15 for 110V areas) depending on the number
of pumps installed. The draw of maximum current occurs only while starting the inlet
pump. For the continuous use of blowers, the BioKube Mars only uses 300 - 600 watt.

It’s recommended that the Venus 2800 is connected to a separate fuse in the
electrical panel, which will ensure that issues can easily be isolated in the event
there’s a problem with the power supply to the treatment plant.

All electrical work must be done by a certified electrician. Maximum

voltage loss in cable may not exceed 10 V.

Power supply cable is not included. Length of the 5-core supply cable to be
determined on site based on distance to power source.

Step 6 – External alarm

The alarm must be placed inside a building or be protected from the weather. The
alarm will go off both visually and audibly in case there’s a problem with the inflow
to the system, see Picture 10 and Picture 11.

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Instruction manual

Picture 10

Picture 11

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Instruction manual

Step 7 – Control Box

The system is controlled by a BioKube E-V control unit installed in the electrical
cabinet, see Picture 8. The control unit starts inlet pump, valves etc. at pre-set
settings.

In the center of the control unit the test button is found, see Picture 12. When
holding down the test button the following test sequence will loop the components
in the following steps: Inlet pump, dosing pump (where installed), valve 2, valve 1,
air pump 3, buzzer/alarm. There is a 3 second pause between the steps.

When the test button is released, the plant returns to its normal functions. The test
sequence will also be started whenever power to the system is switched on.

Picture 12

The system is switched on by turning the main switch in the technical box, see
Picture 13.

Picture 13

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BioKube Venus 2800
Instruction manual

Control Scheme – Installation

ID REFERENCE
(SECTION) TASK DOCUMENTS ACCEPTANCE CRITERIA
Civil works is made according
Follow instructions in
Project specific layout to project specific layout and
3.1 section 3.1 prior to
drawings no cracks or similar
installing the equipment
deviations are observed
Follow instructions in
Supplied equipment is
section 3.2 after Project specific parts
3.2 according to Specific parts
equipment has arrived to list and packing list
list and packing list
customer
Follow instructions in
No damages or errors are
section 3.3 after Project specific parts
3.3 observed on the supplied
equipment has arrived to list and packing list
equipment
customer

Follow instructions in The system is installed

3.5 section 3.5 when installing This manual according to specifications in
the system this manual

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