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Zombies Ultra Automated 65g

Discussion in 'Tank Builds' started by zombie, Mar 24, 2018.

  1. zombie

    zombie Tuna M.A.S.C Club Member

    Rock is done with bleaching and I made a few outcrops with some fiberglass rods and cement to create a base that my biocube rocks can surround and add to. Will cure 24 hours, then soak in RO until I am ready to cycle it in the tank this weekend.
     

    Attached Files:

    SkyShark likes this.
  2. zombie

    zombie Tuna M.A.S.C Club Member

    Tried to make the optical sensor harness and measured the sensor wrong. Ended up giving the IR LED inside the optical sensor reverse polarity and blew two $25 sensors. I will update the thread with the correct way to actually make that when new parts come in.

    Facepalm.
     
    SynDen likes this.
  3. SynDen

    SynDen Shark Staff Member M.A.S.C Club Member M.A.S.C. B.O.D. M.A.S.C President M.A.S.C Webmaster

    Doh! I've done that before, usually results in the wife giving me dirty looks, and eye rolls because I have to buy more parts
     
  4. zombie

    zombie Tuna M.A.S.C Club Member

    That's what I get for blindly following an internet pinout rather than reverse engineering myself. The thread I found had swapped +5V and signal in the pinout, so the second I plugged them in, the IR diode shorted reverse bias and burnt up.
     
    Last edited: Apr 6, 2018
  5. zombie

    zombie Tuna M.A.S.C Club Member

    Got all my floats wired up, uniseals attached to my reservoirs, and heaters placed where I want them.

    One float in overflow that will open for high water.

    Low sump float closes for low water

    High high sump float opens for very high water level (for shutting off skimmer and warning that return may have failed)

    Low water level float in New saltwater reservoir

    Low water level in RODI

    I have a conductivity probe in NSW container to alert if salinity goes out of whack and stop auto water change, and a temp probe just cause I had an extra.

    I have one 200W heater in the overflow chamber set to 80 degrees (apex will keep temp at 78). This will take over if the return is OFF or if comms are lost to the energy bar. It has its own remote temp probe attached in the tank itself.

    I have two 150W heaters in the sump set to 80 degrees. They will alternate when the return is ON and one will run on its own if comms are lost or the temp probe fails. When the return is off, one will oscillate 5 to 15 minutes every 30 (I need to do some testing to find sweet spot) to keep sump from getting too hot or cold (temp probe is in overflow so when return is OFF temp probe is unreliable)
     

    Attached Files:

  6. zombie

    zombie Tuna M.A.S.C Club Member

    Rock is soaking in RODI and water conditioner with a spare powerhead keeping movement to remove the fines from mortaring and settle some of the pH rising effect from the mortar. After a day of soaking, it will be ready to set in the tank and begin the cycling process with 60lbs of sand (40lb sugar sand white crushed coral, 20lb sugar sand aragonite).
     
  7. zombie

    zombie Tuna M.A.S.C Club Member

    Got the aquascape started. There will be another 2 large rocks and 5 or 6 small rocks from the biocube to fill out some of the unused space.

    I also picked up an AFS from RJ to help keep my future flame from snacking from hunger. Made the mistake of setting it at 2 instead of 1 and dumped like a tablespoon of food in there. Might help speed up the cycle though.
     

    Attached Files:

  8. zombie

    zombie Tuna M.A.S.C Club Member

    Door switches showed up today so I mounted those. I wired them NC in series so I could use a single input and the fuge light will turn on if either door is opened.

    I also added some toggle switches for misc use. I haven't programmed them into anything yet, but I will probably use the red one as an oh $h!t emergency stop and the green one to trigger a maintenance mode of some kind such as skimmer cleaning.

    Skimmer, Neptune WAV, and replacement opticals should arrive tomorrow. I also need to find a tablet to Velcro on the side as a display since my neptune one is staying on the biocube.
     

    Attached Files:

    SynDen likes this.
  9. zombie

    zombie Tuna M.A.S.C Club Member

    New optical sensors cam in and the DIY is a success. This is how to properly do it.

    Assuming numbering like this on the Molex connector

    4 5 6
    1 2 3

    Switch1
    Tip - 3
    Upper ring - 5
    Lower ring - 6
    Sleeve - 4

    Switch2
    Tip - 3
    Upper ring - 1
    Lower ring - 2
    Sleeve - 4

    I used some 1/8" TRRS extension cables, cut the end off and wired to the Molex connector as shown above. The Molex part numbers are Molex 43025-0600 for the receptacle, and 46235-0001 for the crimp pins.
     

    Attached Files:

  10. zombie

    zombie Tuna M.A.S.C Club Member

    I seeded the tank with 6 cups of sand from the biocube and all the loose rocks I could gather that didn't have corals on them and weren't part of the base structure.

    My Neptune WAV showed up and it is rediculously powerful for this tank. I have to keep it under 25% or the tank turns into a sandstorm.

    I also picked up a Fire HD 8 and HD 10 tablet off Craigslist for $40 for both and will velcro the 8 (which has hands free alexa built in that I will use when they release the beta) to the side of the tank as a display I can see from the couch.

    Skimmer should be in tomorrow and the only thing left in the build is to find a redundancy powerhead, do the cable management, and put the final touches on the code. Once I am happy with the code I will post it up in sections so everybody can see how a real control freak programs an apex.
     
  11. zombie

    zombie Tuna M.A.S.C Club Member

    My bigger skimmer showed up that should be good for the life of the tank. Bubble Magus Curve 5. Fits the skimmer section perfect with plenty of room to spare and is already breaking in quite nicely. The store I bought it from accidentally shipped it to the wrong guy and shipped me his HOB, but he lived like 10 minutes away (really nice coincidence) and we just met up and swapped each other for the right one.
     

    Attached Files:

  12. zombie

    zombie Tuna M.A.S.C Club Member

    I wasn't able to reach my target flowrate of 2000-4000 gph (varying depending on time of day and simulating tidal swells) with the sugar sand, so I scooped and siphoned out about 2 gallons worth, placed half of it in the refugium section and added a 20lb bag of 1-2 MM grain size. It's not as pretty but I was able to increase the WAV from a 25% max intensity up to about 50% and the sand is actually staying in place now. I can get it up to 70, but I will wait to see how corals like 50 before pushing it.

    The initial ammonia spike is just finishing up and has almost settled to 0. The nitrite spike is still sitting at 1ppm so it will probably be another week or so before adding a couple snails to clean up diatoms. It does appear I may be able to finish this cycle in 2-3 weeks instead of 4-6 since I already have a healthy bacteria population in the biocube, so all I need to do is make sure ammonia and nitrite hit 0.
     

    Attached Files:

    Last edited: Apr 14, 2018
    Haddonisreef likes this.
  13. zombie

    zombie Tuna M.A.S.C Club Member

    Now for the fun part. I have a preliminary code that I am happy enough with to start posting. Anything dependent on livestock is either set to a temporary starting point (like the WAV and feeder timings) or hasn't been done yet (like ORP based code) First off here is the cheat sheet of devices so you can tell what everything is.

    Device List

    - Tmp: tank temperature probe placed in overflow.
    - Tmpx6: temp probe placed in NSW container. Only used for temp compensation.
    - Salt: conductivity probe in sump.
    - NSWsal: conductivity probe in NSW container.
    - pH: pH probe in sump.
    - ORP: ORP probe in sump. Currently only used for display until I know typical ranges.

    - ATOlow: normal water level optical sensor.
    - ATOhig: high water level optical sensor placed 1/4" above ATOlow.
    - Smplow: low water level float set to close just below where the return starts bubbling.
    - Smphigh: high sump water level float. Set to open if water level in skimmer chamber rises more than 1/4".
    - OvFlow: float placed in overflow chamber. will open if water level rises 1" above normal siphon point.
    - DoorSw: Magnetic reed door switches in series. Will open if either door is opened.
    - RedSw: Toggle switch with red cover in sump door. Used as an Emergency stop or for manual water changes.
    - GrnSw: Toggle switch with green cover in sump door. used currently for skimmer maintenance.
    - LowROD: Low level float in RODI reservoir. closes when water level is 6" above uniseal bulkhead 10 of 50 gallons remaining.
    - LowNSW: Low level float in NSW reservoir. closes when water level is 3" above uniseal bulkhead 5 of 30 gallons remaining.

    - SumpHeat1_1: 150W heater in sump
    - SumpHeat2_2: 150W heater in sump
    - RTN_3: Return pump
    - ATO_4: litermeter3 100ml/min as an ATO pump
    - SPARE_5: unused outlet for future expansion
    - TankHeat_6: 200W heater placed in tank overflow with temp probe placed in tank itself
    - FugeLight_7: Combination refugium light and under-cabinet lighting
    - Skimmer_8: Bubble Magus curve 5 skimmer
    - SolBlue: Blue channel of AI SOL lights
    - SolWht: White channel of AI SOL lights
    - SolRyl: Royal blue channel of AI SOL lights
    - DOS_Add: DOS head used to add NSW for auto water change
    - DOS_Rem: DOS head used to remove tank water for auto water change
    - Feeder: AFS filled with a mix of herbivore/omnivore pellets and Neptune crossover pellets
    - WAV_1: Neptune WAV, which is currently the only powerhead in the tank. a backup will be added when I decide what I want.
     
    Last edited: Apr 14, 2018
  14. zombie

    zombie Tuna M.A.S.C Club Member

    Heater Code

    The heaters are set to maintain the seasonal temperatures within +-0.2 degrees, which vary between 77 in the winter to 80 in the summer. This is mainly for energy savings, but also has the benefit of strengthening corals and giving each coral its ideal temperature for part of the year. The sump heaters are set to take turns heating the tank when the return pump is ON. When the return pump is off, the tank heater takes over. If one heater is not sufficient to maintain tank temp and temp drops to 0.4 degrees below the setpoint, both sump heaters work in tandem to bring up temp. If temperature continues dropping to 0.6 degrees below the setpoint, the tank heater will also join in. If a heaters internal thermostat fails or a heater shorts, the other heaters take over in its place. If a heater shorts, that heater will be shut to manual OFF as well to prevent further damage. In the event the energy bar loses communications with the head unit, a single sump heater and the tank heater will be allowed to run up to their internal; thermostat setting. If the temp probe fails or a power outage causes tank temp to drop below 75 degrees, than one sump heater will be excluded from the heating cycle. If a power outage is detected or the emergency stop is pressed, all heaters will be shut off.

    SumpHeat1_1
    Fallback ON
    If Tmp < RT+-0.1 Then ON
    If Tmp > RT+0.1 Then OFF
    If Time 00:00 to 11:59 Then OFF
    If Output LowStatHeat = ON Then ON
    If Tmp < RT+-0.3 Then ON
    If Output RTN_3 = OFF Then OFF
    If Output Heat1Fail = ON Then OFF
    If Output Estop = ON Then OFF
    If Power Apex Off 000 Then OFF
    Defer 000:10 Then ON

    SumpHeat2_2
    Fallback OFF
    If Tmp < RT+-0.1 Then ON
    If Tmp > RT+0.1 Then OFF
    If Time 12:00 to 23:59 Then OFF
    If Tmp < RT+-0.3 Then ON
    If Output LowStatHeat = ON Then ON
    If Tmp < 75.0 Then OFF
    If Output RTN_3 = OFF Then OFF
    If Output Heat2Fail = ON Then OFF
    If Output Estop = ON Then OFF
    If Power Apex Off 000 Then OFF
    Defer 000:10 Then ON

    TankHeat_6
    Fallback ON
    If Tmp < RT+-0.1 Then ON
    If Tmp > RT+0.1 Then OFF
    If Output RTN_3 = ON Then OFF
    If Output LowStatHeat = ON Then ON
    If Tmp < RT+-0.5 Then ON
    If Output HeatTnkFail = ON Then OFF
    If Output Estop = ON Then OFF
    If Power Apex Off 000 Then OFF
    Defer 000:10 Then OFF

    Heat1Fail (detects short or heating element failure)
    Set OFF
    If Output SumpHeat1_1 Watts > 180 Then ON
    If Output SumpHeat1_1 Amps > 1.9 Then ON
    Defer 000:10 Then ON
    Defer 000:10 Then OFF
    When On > 000:05 Then ON

    Heat2Fail (detects short or heating element failure)
    Set OFF
    If Output SumpHeat2_2 Watts > 180 Then ON
    If Output SumpHeat2_2 Amps > 1.9 Then ON
    Defer 000:10 Then ON
    Defer 000:10 Then OFF
    When On > 000:05 Then ON

    HeatTnkFail (detects short or heating element failure)
    Set OFF
    If Output TankHeat_6 Watts > 250 Then OFF
    If Output TankHeat_6 Amps > 2.5 Then ON
    Defer 000:10 Then ON
    Defer 000:10 Then OFF
    When On > 000:05 Then ON

    Smp1Stat (detects internal thermostat failure or setpoint needs to be bumped up on the dial)

    Set OFF
    If Output SumpHeat1_1 Watts < 100 Then ON
    Defer 000:30 Then ON
    Min Time 030:00 Then ON

    Smp2Stat (detects internal thermostat failure or setpoint needs to be bumped up on the dial)
    Set OFF
    If Output SumpHeat2_2 Watts < 100 Then ON
    Defer 000:30 Then ON
    Min Time 030:00 Then ON

    TankStat (detects internal thermostat failure or setpoint needs to be bumped up on the dial)
    Set OFF
    If Output TankHeat_6 Watts < 150 Then ON
    Defer 000:30 Then ON
    Min Time 030:00 Then ON

    LowStat (VO to detect heater failures)
    Set OFF
    If Output Smp1Stat = ON Then ON
    If Output Smp2Stat = ON Then ON
    If Output TankStat = ON Then ON
    If Output Heat1Fail = ON Then ON
    If Output Heat2Fail = ON Then ON
    If Output HeatTnkFail = ON Then ON

    LowStatHeat (VO to run setpoint when a heater fails)
    If Tmp < RT+-0.1 Then ON
    If Tmp > RT+0.1 Then OFF
    If Output LowStat = OFF Then OFF
     
    Last edited: Apr 15, 2018
  15. zombie

    zombie Tuna M.A.S.C Club Member

    Return and Skimmer

    The return is set to be always on unless a failure mode occurs or it is time for a feeding or maintenance. It will turn off if the water level is low and it would have run dry and stays off for 2 hours before automatically restarting to see if anything has changed. If the overflow chamber starts to overflow, it will shut off and latch off until I manually intervene. IF a stall or impeller failure is detected, the return will shut off and latch off until I manually intervene. If the Estop is pressed or a power outage is detected it will also shut off.

    The skimmer follow the state of the return pump to avoid overflowing as water level rises in the sump. It is also delayed an additional 5 minutes to allow water level to settle. It will shut off for 1 minute following a power outage to prevent overflows after the system reboots. It will shut off if high sump water level is detected. It will also shut off if the skimmer maintenance green switch is toggled on.

    RTN_3
    Fallback ON
    Set ON
    If FeedA 000 Then OFF
    If FeedD 000 Then OFF
    If Output Overflow = ON Then OFF
    If Output LowSump = ON Then OFF
    If Output vFeed = ON Then OFF
    If Output RtnFail = ON Then OFF
    If Output Estop = ON Then OFF
    If Power Apex Off 000 Then OFF

    Skimmer_8
    Fallback ON
    Set ON
    If Output RTN_3 = OFF Then OFF
    If Power Apex Off 001 Then OFF
    If SmpHig OPEN Then OFF
    If GrnSw CLOSED Then OFF
    Defer 005:00 Then ON

    Overflow (VO latches ON for high water in overflow chamber)
    Set OFF
    If OvFlow OPEN Then OFF
    Defer 000:10 Then ON
    Defer 000:10 Then OFF
    When On > 000:05 Then ON

    LowSump (detects low water level in sump. stays ON for 2 hours then retries)
    Set OFF
    If SmpLow CLOSED Then ON
    Defer 000:30 Then ON
    Defer 120:00 Then OFF

    RtnFail (Detects stall or impeller failure in pump. latches ON)
    Set OFF
    If Output RTN_3 Watts < 60 Then OFF
    If Output RTN_3 Amps > 1.5 Then ON
    Defer 000:10 Then ON
    Defer 000:10 Then OFF
    When On > 000:05 Then ON
     
  16. zombie

    zombie Tuna M.A.S.C Club Member

    Auto Top OFF

    The ATO is currently in a temporary setup until I take the time to evaluate the evaporation rates and run times. An OSC based code will be used for better redundancy when I get around to it. This allows the ATO to run up to once every 30 minutes and if it runs longer than 10 minutes in a single fill, it will set to manual OFF and alert me. its target level is the ATOlow sensor, but is backed up from overfilling by both the ATOhig sensor and the SmpHig float. It will be deactivated if the return is off and indirectly if the sump level is very low. The defer statements are there to filter the optical and float states to be "certain" that the change isn't just a wave or noise.

    ATO_4
    Fallback OFF
    Set ON
    If ATOlow CLOSED Then OFF
    If ATOhig CLOSED Then OFF
    If SmpHig OPEN Then OFF
    If LowROD CLOSED Then OFF
    If Output RTN_3 = OFF Then OFF
    Defer 000:30 Then ON
    Defer 000:30 Then OFF
    Min Time 030:00 Then OFF
    When On > 010:00 Then OFF
     
  17. zombie

    zombie Tuna M.A.S.C Club Member

    Lighting

    The AI sol lights are set to a minimal calm blue setting for anytime that I would likely be awake to view the tank. They begin ramping up at 9am and slowly transition their intensity and spectrum to hit roughly a 20k spectrum (at least according to my eyes) 4 hours later at noon. the lights will hold this intensity for 5 hours and then begin ramping down both spectrum and intensity for another 4 hours back to the calm blue setting. I will need to refine intensities and spectrums a bit when I borrow a PAR meter from somebody after the rockwork from the biocube is added.

    [​IMG]

    I also added a few things into the advanced code for each light to set the spectrum so it is optimal for picture taking when I activate a virtual outlet, create a lightning storm when I set a different virtual outlet, and shut them off when a power outage is detected.

    SolBlue advanced
    If Output Demo = ON Then 10
    If Output Photograph = ON Then 5
    If Power Apex Off 000 Then OFF

    SolWht advanced
    If Output Demo = ON Then Stormy
    If Output Photograph = ON Then 30
    If Power Apex Off 000 Then OFF

    SolRyl advanced
    If Output Demo = ON Then 10
    If Output Photograph = ON Then 10
    If Power Apex Off 000 Then OFF

    Stormy profile
    [​IMG]

    The refugium light is set inverse of tank hours for a total of 18 hours per day to maximize growth but allow some rest for the cheato. It will be turned off if a power outage is detected. If I open the cabinet doors it will turn on so I can see what I am doing and I placed that line after the power outage line so I can use the light for troubleshooting if I need to.

    FugeLight_7
    Fallback ON
    Set OFF
    If Time 19:00 to 13:00 Then ON
    If Power Apex Off 000 Then OFF
    If DoorSw OPEN Then ON
     

    Attached Files:

  18. zombie

    zombie Tuna M.A.S.C Club Member

    Tank Flow

    The flow is in a temporary configuration and I plan to add a backup pump as well. The basic idea behind the current setup is to mimic tidal swells by varying the intensity every 3 hours (I will use 6 when I have a pump running the other direction) and to have a higher average flow during the day when fish will be active than at night when fish are sleeping and polyps are mostly closed.

    [​IMG]

    The WAV is set to use a slow pulsing profile when I feed the tank to help keep the food suspended but moving slow enough for picky eaters to easily catch it. If a power outage is detected it will run at 1% constant to maximize UPS life but maintain some flow in the tank. If I press the Estop or perform maintenance it will be shut off completely.
     

    Attached Files:

  19. zombie

    zombie Tuna M.A.S.C Club Member

    Automatic Water Change

    My DOS pumps are set to change 1 gallon per day (equated to same nutrient reduction as 10% weekly water changes) but with a number of different failsafes to make me feel warm and safe inside. I added a prime profile that will run the DOS at maximum speed for 250ml to either prime the lines or add a little extra NSW to make up for salt creep and skimmer cup collection as needed. The triggering VOs are a neat little trick. By using a Set ON statement with the When statement, the virtual outlet will turn on for the desired maximum time and then go right back to manual OFF. This prevents you from forgetting about a virtual outlet or fusion being a POS and locking you out at just the wrong time. AWC will be suspended if the tank salinity or the NSW container is out of range (I am using wider ranges than I will later during testing). It will also turn off the water level is very low or very high in the sump (indirectly from return pump state) or when the return is off. It will also be disabled if there is a power outage to help conserve energy or if the Estop is pressed.

    DOS_Add advanced
    If Output PrimeDOS = ON Then Prime
    If Output SaltCreep = ON Then Prime
    If LowNSW CLOSED Then OFF
    If Salt < 32.0 Then OFF
    If Salt > 37.0 Then OFF
    If NSWsal < 32.0 Then OFF
    If NSWsal > 37.0 Then OFF
    If SmpHig OPEN Then OFF
    If Output RTN_3 = OFF Then OFF
    If Output Estop = ON Then OFF

    DOS_Rem advanced
    If Output PrimeDOS = ON Then Prime
    If LowNSW CLOSED Then OFF
    If Salt < 32.0 Then OFF
    If Salt > 37.0 Then OFF
    If NSWsal < 32.0 Then OFF
    If NSWsal > 37.0 Then OFF
    If SmpHig OPEN Then OFF
    If Output RTN_3 = OFF Then OFF
    If Output Estop = ON Then OFF

    PrimeDOS and SaltCreep
    Set ON
    When On > 002:00 Then OFF
     
  20. zombie

    zombie Tuna M.A.S.C Club Member

    Email Alerts

    The email is set to alert me of non-critical warnings only outside of work hours and when I am normally awake and have time to check on those. Critical alerts will bypass that limit so I can send my girlfriend home to fix it or call the retired neighbor across the street who also runs saltwater tanks.

    EmailAlm_I5
    Set OFF
    If Output HeatTnkFail = ON Then ON
    If Output ATOstuck = ON Then ON
    If Output RtnFail = ON Then ON
    If Output Heat1Fail = ON Then ON
    If Output Heat2Fail = ON Then ON
    If Output Smp1Stat = ON Then ON
    If Output Smp2Stat = ON Then ON
    If Output TankStat = ON Then ON
    If LowNSW CLOSED Then ON
    If LowROD CLOSED Then ON
    If NSWsal < 32.0 Then OFF
    If NSWsal > 37.0 Then OFF
    If Output WeekStop = ON Then OFF
    If Output wEndStop = ON Then OFF
    If Error Wav_1 Then ON
    If Error ATO_4 Then ON
    If Salt < 33.0 Then ON
    If Salt > 38.0 Then ON
    If Tmp > RT+2.0 Then ON
    If Tmp < RT+-2.0 Then ON
    If Output Overflow = ON Then ON
    If Output HIGHwater = ON Then ON
    If Power Apex Off 001 Then ON
    If Power Apex Off 000 Then ON
    Defer 000:30 Then ON

    WeekStop
    Set OFF
    If Time 23:00 to 07:00 Then ON
    If Time 08:00 to 19:00 Then ON
    If DoW S-----S Then OFF

    wEndStop
    Set OFF
    If Time 23:00 to 10:00 Then ON
    If DoW -MTWTF- Then OFF
     

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