operating and maintenance manual biolectric pocket biogas

Operating and maintenance manual

Biolectric pocket biogas digester

Date of publication: October 2020

Version 4.0

Initial user manual

www.biolectric.be

[email protected]

Tel.: +32 (0) 3 689 2928

mailto:[email protected]


Operating and maintenance manual for Biolectric pocket biogas digesters v4.0

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Foreword

Biolectric thanks you for your investment in a Biolectric biogas installation. In this manual you will find

all the information you need to control and maintain the Biolectric biogas installation correctly. It is

therefore recommended that you read this manual carefully before putting the Biolectric biogas

installation into operation and carefully follow all recommendations and warnings. Always keep this

manual ready for future reference within the Biolectric biogas plant's container. Biolectric NV reserves

the right to make changes and/or additions to the contents of this manual without prior notice, should

changes or improvements to installations already delivered be necessary. It is forbidden to translate

and/or copy (parts of) this manual without prior permission.

A Biolectric pocket biogas digester has been developed for use on companies where a certain volume

of good quality liquid organic residual fraction is available on a daily basis. This organic residual fraction

consists of, for example, but is not limited to: cattle manure; pig manure.

This manual describes the operating principle and the operating and maintenance procedures applicable

to Biolectric pocket biogas digesters of the following types: 10 kW - 11 kW - 16.5 kW - 22-1 kW - 33 kW

- 40 kW - 44 kW - 60 kW - 74 kW. These installations are also referred to as Biolectric biogas installations

or biogas plants for short.

Contact information in case of questions and remarks:

Biolectric NV

+32 36 89 29 28


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Content

Foreword ............................................................................................................................................................3

1 Introduction and safety ......................................................................................................................8

1.1 Introduction ........................................................................................................................................8

1.2 Safety terms and symbols ............................................................................................................... 10

1.3 The user ........................................................................................................................................... 11

2 Product description ......................................................................................................................... 12

3 Working principle of the biogas plant ............................................................................................. 22

3.1 Organic material .............................................................................................................................. 22

3.1.1 The feeding cycle ..................................................................................................................... 24

3.1.2 Options .................................................................................................................................... 25

3.2 The coolant circuit ........................................................................................................................... 26

3.2.1 Cooling of the engine .............................................................................................................. 27

3.2.2 Heating of the reactor ............................................................................................................. 27

3.2.3 External consumption of hot water ........................................................................................ 27

3.2.4 Options .................................................................................................................................... 28

3.3 The biogas circuit ............................................................................................................................. 30

3.3.1 Biogas ...................................................................................................................................... 30

3.3.2 Main components ................................................................................................................... 30

3.3.3 Options .................................................................................................................................... 31

4 Security ............................................................................................................................................ 34

4.1 Emergencies .................................................................................................................................... 38

5 Operation ........................................................................................................................................ 40

5.1 Manual operation ............................................................................................................................ 40

5.1.1 The combustion engine ........................................................................................................... 40

5.1.2 The basement pump................................................................................................................ 41

5.2 Digital control - MyBiolectric ........................................................................................................... 41

5.2.1 Efficiency ................................................................................................................................. 43

5.2.2 Gas ........................................................................................................................................... 45

5.2.3 Engine ...................................................................................................................................... 48

5.2.4 Feeding .................................................................................................................................... 51

5.2.5 Grid .......................................................................................................................................... 55

5.2.6 Reactor .................................................................................................................................... 56

5.2.7 Errors & Warnings ................................................................................................................... 60

5.2.8 Address .................................................................................................................................... 60


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6 Preventive maintenance ................................................................................................................. 61

6.1 Daily maintenance ........................................................................................................................... 61

6.1.1 Checking for warnings and error messages ............................................................................ 61

6.1.2 Combustion engine oil level .................................................................................................... 62

6.1.3 Air cap reactor ......................................................................................................................... 66

6.1.4 Level in reactor ........................................................................................................................ 66

6.1.5 Container doors ....................................................................................................................... 66

6.2 Weekly maintenance ....................................................................................................................... 66

6.2.1 Ventilation of the container .................................................................................................... 66

6.2.2 Pressure in the cooling system ................................................................................................ 67

6.2.3 Leaks ........................................................................................................................................ 67

6.2.4 Water lock ............................................................................................................................... 67

6.2.5 Basement pump ...................................................................................................................... 67

6.2.6 Digestate pump ....................................................................................................................... 67

6.2.7 Foam breaker .......................................................................................................................... 68

6.3 Monthly maintenance ..................................................................................................................... 68

6.3.1 Warning systems ..................................................................................................................... 68

6.3.2 Cleaning magnetic filter........................................................................................................... 68

6.4 Engine maintenance ........................................................................................................................ 68

7 Actions in the event of warnings ..................................................................................................... 70

8 Error messages ................................................................................................................................ 75

8.1 Solutions for engine errors .............................................................................................................. 74

8.1.1 Engine error 1: Engine overheated.......................................................................................... 74

8.1.2 Engine error 2: No oil pressure................................................................................................ 75

8.1.3 Motor error 3: Battery voltage too low ................................................................................... 76

8.1.4 Engine error 4: Power fluctuates ............................................................................................. 78

8.1.5 Engine error 5: H2S concentration too high ............................................................................ 80

8.1.6 Engine error 6: Mains error ..................................................................................................... 82

8.1.7 Motor error 7: Monitoring relay ............................................................................................. 82

8.1.8 Engine error 8: RPM too high .................................................................................................. 82

8.1.9 Engine error 9: Insufficient power ........................................................................................... 82

8.1.10 Engine error 10: Easy startup failed ........................................................................................ 84

8.1.11 Engine error 11: Exhaust gas temperature too high ............................................................... 84

8.1.12 Engine error 12: Gas buffer low .............................................................................................. 84

8.1.13 Engine error 13: DEIF module alarm ....................................................................................... 85

8.1.14 Engine error 14: Maintenance interval ................................................................................... 85

8.1.15 Engine error 15: Difference between H2S measurements too large ...................................... 85


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8.1.16 Motor error 16: No voltage on 3rd phase ................................................................................. 85

8.1.17 Engine error 18: RPM too low ................................................................................................. 85

8.1.18 Motor error 19: Bio ID ............................................................................................................. 86

8.1.19 Engine error 21: Pressure in coolant circuit too low ............................................................... 86

8.1.20 Engine error 22: Oil tank empty .............................................................................................. 86

8.1.21 Motor error 25: Aeration is set to 0 sec/min; H2S measurement is defective ....................... 87

8.1.22 Engine error 31: Flow rate in the coolant circuit is too low .................................................... 87

8.2 Solutions for reactor errors ............................................................................................................. 89

8.2.1 Reactor error 1: Reactor level too high ................................................................................... 89

8.2.2 Reactor error 2: No flow rate when pumping in ..................................................................... 89

8.2.3 Reactor error 3: Valve digestate does not open ..................................................................... 90

8.2.4 Reactor error 4: Valve digestate does not accept ................................................................... 90

8.2.5 Reactor error 5: Gas buffer +20 cm above maximum ............................................................. 90

8.2.6 Reactor error 6: Manure level in the reactor >35cm too low ................................................. 91

8.2.7 Reactor error 7: Gas buffer 20 cm below minimum level ....................................................... 91

8.2.8 Reactor error 8: Mixer does not work, please reset thermal protection ................................ 91

8.2.9 Reactor error 9: Reactor emptying failed, power supply discontinued .................................. 91

8.2.10 Reactor error 4096: Digest state pump overheated ............................................................... 92

8.3 Maintenance of the digestate pump ............................................................................................... 92

8.3.1 The bellows pump ................................................................................................................... 92

8.3.2 The lob pump ........................................................................................................................... 94

8.3.3 The centrifugal pump .............................................................................................................. 97

9 Warranty.......................................................................................................................................... 98

Annex 1: Glossary ............................................................................................................................................ 99

Annex 2: List of figures .................................................................................................................................. 102

Annex 3: List of tables ................................................................................................................................... 105

Appendix 4: Supplied parts and service kit ................................................................................................... 106

Annex 5: CE declaration ................................................................................................................................ 107

Annex 6: Start-up of the biogas plant ........................................................................................................... 108

Annex 7: Directive to close the magnetic pressure relief valve .................................................................... 110

Security ...................................................................................................................................................... 110

Material ..................................................................................................................................................... 111

Procedure .................................................................................................................................................. 111

Annex 8: Excessive foam production ............................................................................................................ 112

Annex 9: Manual of the automatic call system (optional) ............................................................................ 113


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1 Introduction and safety

1.1 Introduction

Purpose of this manual

The purpose of this manual is to provide all the necessary information for the operation and preventive

maintenance of a Biolectric biogas plant.

ATTENTION Before operating and using the installation, it is important to read the manual carefully. Improper handling may cause personal injury and material damage and may void the warranty.

NOTE Always keep this manual ready for future reference within the installation's container.

Table 1 gives an overview of the technical characteristics of the different types of biogas plants and an

overview of the different types of reactors with technical characteristics.


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Table 1: Technical data sheet of the various Biolectric biogas plants


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Table 2: Technical data sheet of the different types of reactors.

1.2 Safety terms and symbols

Hazard levels

Hazard level Indication

NOTE Important information is printed in bold or is mentioned at NOTE.

• A potential situation which, if not noticed, could lead to undesirable conditions.

• An act that does not result in personal injury.

ATTENTION A situation which, if not noticed, can lead to slight damage to the installation or the environment.

WARNING A situation which, if it cannot be avoided, could cause serious damage to the installation or the environment and/or bodily injury.

DANGER A serious situation which, if it cannot be avoided, is life-threatening or likely to result in serious bodily injury.

In addition, additional security measures apply in the container. These are indicated by danger symbols

on the front of the container and on the electrical cabinet. If these symbols are difficult or no longer

legible, they must be cleaned or, if necessary, replaced.


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Warning: explosive atmosphere.

Warning: dangerous voltage.

No open flame: fire, open ignition and

smoking prohibited.

No smoking.

Prohibited access for unauthorised persons.

1.3 The user

DANGER This installation may only be operated by qualified persons.

DANGER Maintenance on this installation may only be carried out by qualified persons.

Please note the following precaution:

• It is not recommended to let children play around or near the components of the biogas plant.

Please supervise them at all times.


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2 Product description

The main components of a Biolectric biogas plant are: the reactor with a heating system and mixer; the

container with the combustion engine, the digestate pump; the associated auxiliary components and the

basement pump with the manure and digestate supply and discharge pipes. Each Biolectric biogas plant

is supplied with a toolbox and spare parts that can be used during the preventive maintenance of the

plant.

An overview of components in a Biolectric biogas plant is given in the figures below. The most important

components are discussed in detail in the following chapters:

Figure 1: Container with S4-H reactor

Table 2: Component designation in Figure1

N° Figure 1 Title Material type

a Magnetic overpressure valve PVC

b Drain line magnetic pressure relief valve PVC

c Viewing window Plastic

d Foam beater (optional) Various

e Supply air to reactor roof PVC + UV protection

f Pressure relief valve blower reactor roof PVC

g Fresh manure supply pipe (here: high reactor, H- type)

PVC

h Power cable(s) submersible mixer(s) Plastic

i Torch (optional) Stainless steel

j External connection digestate PVC


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Figure 2: Components organic matter circulation.

Table 3: Components organic matter circulation.

N° Figure 2 Component Material type

a Inlet pipe organic material PVC

b Flow meter N/A

c Timer automatic water lock refill and condensation drain

N/A

d Water pipe connection Brass

e Water take-off point Plastic

f Feed tap cheese whey (optional) Brass

g Automatic sliding valve Brass

h Drip tray STAINLESS STEEL

i Digest state pump (bellows pump) a.o. PVC, stainless steel, rubber

j Reactor level sensor STAINLESS STEEL

k Drainage pipe digestate PVC

l Manual sliding valve PVC

m Throughput for reactor temperature sensor PVC

n Sampling tap digestate Brass

o Sounding tube Transparent plastic

Figure 3: Coolant circuit components 10-44 kW installation

Table 4: Coolant circuit components 10-44 kW installation.


a Non-return valve Brass, plastic

b Flow sensor STAINLESS STEEL

c Circulation pump motor Cast iron

d Automatic air separator Brass

e Automatic dirt separator (+ magnetic filter) Brass

f Fan + housing (option; winter mode) Copper, galvanised steel, stainless steel

g Connection box thermostat (Frost protection option)

Plastic

h Pressure gauge Plastic

i Pressure relief valve expansion vessel Brass, plastic

j Engine flow meter Brass, glass

l 3-way valve + actuator motor circuit Brass, plastic

m Fan + housing (option; summer mode) Copper, galvanised steel, stainless steel

n Air pump H2S control in reactor a.o. plastic, steel

o Pressure sensor measurement gas buffer level STAINLESS STEEL

p Valve refill gas buffer level measurement Brass

q 3-way valve+ actuator reactor/plate heat exchanger

Brass, plastic

r Plate heat exchanger Copper

s Automatic air vent Brass, plastic

t Fan airhood Sample

u Electric instantaneous water heater Stainless steel, electronics

v Reactor temperature sensor in Electronics

w Circulation pump reactor circuit Cast iron

x Flow meter reactor circuit Brass, glass

y Reactor temperature sensor off Electronics

NOTE Not all Biolectric biogas plants contain all components as shown in figure 3.

Figure 4: Coolant cypress parts 60-74 kW installation

Biolectric nv

J. Avenue de

Malsche 2 B-9140

Temse Belgium

www.biolectric.be

[email protected]

Tel.: +32 (0) 3 689 2928

Table 5: Coolant circuit components 60-74 kW installation

Ref. Figure 4

Title Material type

a Hand wing pump Cast iron

b Pressure relief valve Brass, plastic

c Pressure gauge Plastic

d Fan Copper, steel

e Fan M1 return line STAINLESS STEEL

f Fan M1 + M2 inlet pipe STAINLESS STEEL

g Fan M2 return line STAINLESS STEEL

h Non-return valve Brass, plastic

i Circulation pump Cast iron

j Engine flow meter Brass, glass

k Automatic air separator Brass

l Automatic dirt separator (+ magnetic filter) Brass

m Manual shut-off valve fans Brass

n 3-way valve + actuator motor circuit Brass, plastic

o 3-way valve + actuator reactor/plate heat exchanger

Brass, plastic

p Plate heat exchanger Copper

q Pressure sensor gas buffer measurement Stainless steel, electronics

r Valve refill gas buffer level measurement Brass

s Expansion vessel Sample

t Air pump H2S control in reactor a.o. plastic, steel

u External air inlet fan airhood PVC

v Fan airhood Sample

w Automatic air vent Brass, plastic

x Circulation pump reactor circuit Cast iron

y Flow meter reactor circuit Brass, glass

z Manual shut-off valve reactor circuit 1 Brass

aa Reactor temperature sensor off Electronics

ab Reactor temperature sensor in Electronics

ac Electric instantaneous water heater 2 x 6 kW Stainless steel, electronics

ad Manual shut-off valve reactor circuit 2 Brass

ae Manual valve heating circuit water lock Brass




Biolectric nv

J. Avenue de

Malsche 2 B-9140

Temse Belgium

www.biolectric.be

[email protected]

Tel.: +32 (0) 3 689 2928

Figure 5: Coolant circuit components, connection to engines (here: 60-74 kW installation)

Ref. Figure 5

Title Material type

a Manual valve Brass

b Temperature sensor M2 Electronics

c Pressure sensor coolant circuit Stainless steel, electronics

d Temperature sensor M1 Electronics

e Manual valve Brass




Figure 6: Biogas circuit components - installation with 2 engines

Table 6: Biogas circuit components - installation with 2 engines.

N° Figure 6

Title Material type

a Drain condensation carbon filter PVC

b Condensation drain to water trap PVC

c Carbon filter STAINLESS STEEL

d Exhaust condensate gas cooler PP

e Gas connection reactor STAINLESS STEEL

f Gas cooler STAINLESS STEEL

g Inspection cover Alu + plexiglass

h Manual valve gas pipe STAINLESS STEEL

i Exhaust silencer STAINLESS STEEL

j Electromagnetic throttle valve M2 Alu + KTL coating

k H2S sensor N/A

l Flue gas heat exchanger STAINLESS STEEL

m Air filter with throttle valve Plastic, electronics

n Gas detector (option) N/A

o Electromagnetic throttle valve M1 Alu + KTL coating

p Smoke detector (option) N/A

q Electromagnetic throttle flare (option) Alu + KTL coating

r Torch STAINLESS STEEL



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Figure 7: Connection between reactor and container - water lock

Table 7: Components connection between reactor and container - water lock


a Drainage biogas water trap PVC

b Manual valve for biogas supply to container STAINLESS STEEL

c Biogas pipeline connection to reactor STAINLESS STEEL

d Water trap insulation jacket (option)

e Water lock STAINLESS STEEL

f Condensation drain water trap PVC

g Connection condensation drain pipe container to water lock

PVC

h Frost protection water lock connection STAINLESS STEEL

Green arrow Direction of biogas flow normal operation STAINLESS STEEL

Orange arrow

Direction of flow of biogas in the event of excessive overpressure or underpressure in the reactor

STAINLESS STEEL


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3 Working principle of the biogas plant

A Biolectric biogas plant consists of three parts: a basement pump in the basement of the farm, a reactor

(also called silo) containing the digestate and a container containing all components to convert the

biogas into energy in the form of electricity and heat. Organic material is pumped to the reactor by the

cellar pump, after which the fermentation process starts. This bacterial fermentation process leads to

the formation of biogas in the reactor. The biogas is then purified and burned in an internal combustion

engine linked to a generator. The green energy generated can be used on the farm in the form of

electricity and heat. The excess electrical energy is injected into the electricity grid.

There are 3 product streams involved in this process: organic matter (after anaerobic digestion this

stream is also referred to as digestate), biogas and coolant. The corresponding circuits are discussed

in more detail in the following paragraphs.

3.1 Organic material

In the reactor of a Biolectric biogas plant, biogas is formed by the bacterial, anaerobic fermentation of

organic material. This organic material can consist of, but is not limited to, pig and cattle manure. In

general, fresh manure is pumped from the manure cellar to the reactor by means of a cellar pump, where

the fermentation takes place. After digestion, the digestate is pumped from the reactor to a storage tank

or cellar using a digestate pump (Figure 8). The most important components regarding the organic

matter are shown in figure2 and are discussed in detail here.

• The basement pump

The basement pump (Figure 9) is equipped with two levers. One lever controls whether the

manure is pumped towards the reactor or mixed internally in the manure cellar. The other lever

controls the height of the nozzle used during internal mixing. The functions of the levers are

indicated by a sticker on the basement pump. If the user mixes the manure internally, he/she

can also adjust the direction of the nozzle by means of the turning wheel mounted on the

basement pump.

• The manual sliding valve

The manual sliding valve (Figure 2) is located between the reactor and the digestate pump. This

valve can be operated manually to prevent digestate from flowing out of the reactor during

maintenance work on the digestate pump. As the digestate is pumped out of the reactor

automatically, this manual sliding valve is open as standard.

• The automatic sliding valve

The digestate discharge pipe is equipped with an automatic slide valve (Figure 2) just after the

digestate pump. This valve only opens during the pumping out of digestate to prevent the reactor

from draining through the digestate pump under the influence of gravity.

• The monitoring well

In installations with a low reactor, the level of digestate in the reactor can always be checked

using the monitoring well (Figure2). When the tap at the top of the monitoring well is briefly

opened, the monitoring well will be filled with digestate according to the principle of

communicating vessels to a level equal to the level inside the reactor. If the monitoring well on

the inside is covered with digestate, this can be cleaned by letting water flow into the monitoring

well at the top by means of the water hose in the container. Because the maximum level of

digestate in the reactor is higher than the container in H-type installations, these installations

are not equipped with a monitoring well. The level in the reactor can also be verified through the

window in the reactor (Figure 1). The user can clean the window by turning the wiper.


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• The exterior slide gate valve

The digestate discharge tube is equipped with an outlet for the digestate pump (Figure 47, figure

48) to manually release digestate from the reactor, if necessary. This connection can also be

used to supply manure during the start-up process of the plant as described in Annex 6: Start-

up of the biogas plant.

• The digestate pump

After fermentation, the digestate is removed from the reactor using a digestate pump or by

gravity run-off. A Biolectric biogas installation can be equipped with one of three types of

digestate pumps:

Table 8: Overview of the different types of digestate pumps. *: indicative numerical values based on a

theoretical approach. These values may vary in practice. The different maxima can never occur

together

Pump type Max*. length of drainpipe [m]

Max*. head [m] Max*. flow rate [m³/h]

Bellows pump 100 4 3

Lobe pump 150 7 12

Centrifugal pump - 11 50

Before the digestate pump is pumped out, the automatic sliding valve (Figure 2) will open. The

different types of digestate pumps are described in the following sections. The maintenance of

the digestate pump is discussed in chapter 8.2.9.

The bellows pump

The bellows pump is a volumetric pump, where the pump operation is based on a changing

volume of the pump chambers. At the bellows pump, this is done by pressing and stretching a

rubber band. The non-return valves (Figure2, Figure47) ensure that pressure is built up in the

discharge pipe and prevent the digestate from flowing back to the reactor.

The lob pump

The lob pump is also a volumetric pump. The digestate is pumped by means of lobes into the

pump housing. The lobe pump is equipped with a temperature sensor that detects overheating

of the pump in time (Figure 48). Overheating only occurs when the lob pump is clogged.

The centrifugal pump

Unlike the bellows pump and the lob pump, the centrifugal pump is not a volumetric pump. The

pumping action of the centrifugal pump is based on the centrifugal force. The digestate is sucked

in at the centre of the pump housing, after which it is carried by the impeller inside the pump

and pushed outwards. The centrifugal force is converted into a pressure build-up in the

discharge pipe.

WARNING When organic material is added or digestate is removed from the reactor, the maximum flow rate of 50 m³/h must not be exceeded. Exceeding this limit can lead to high overpressure or underpressure in the reactor resulting in material damage and/or personal injury.

ATTENTION Never more than 1 shut-off valve closed at the same time on (part of) the digestate pipe. The fermentation process in the digestate in the pipework continues unabated, as a result of which the pressure in a closed section of the pipework can increase considerably. Gas production in a closed off part of the pipework can lead to bursting open. or rupture this pipe.


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3.1.1 The feeding cycle

If the biogas plant is automatically fed with fresh manure, at least one feeding cycle shall be carried out

daily. A feeding cycle consists of the following steps:

• Level measurement of the digestate in the reactor

• Pumping out a pre-determined quantity of digestate from the reactor

• Pumping a pre-determined amount of fresh manure into the reactor

In the default settings, this feeding cycle is performed daily at 10:00 a.m. Both the time at which digestate

is pumped out of the reactor and the daily number of feeding cycles can be adjusted by the user via the

'Nutrition' tab on MyBiolectric. (Chapter 5.2).

The level measurement of the digestate in the reactor is done via a pressure sensor, which is installed

just after the manual sliding valve (Figure 2). The pressure sensor measures the hydrostatic pressure

of the digestate at the bottom of the reactor. This pressure, expressed in height column, is a good

approximation of the real height of the digestate in the reactor.

Figure 8: Schematic representation of manure circuit in 2 different barn installations. A) Digestate storage in an above-

ground tank, B) Digestate storage in a 2nd manure cellar.

If the measured digestate level in the reactor is higher than the desired level, a fraction of the digestate will be pumped out of the reactor. The amount of digestate to be pumped out is almost the same as the amount of fresh manure that will be pumped in. The daily amount of fresh manure can be set by the user via the 'Nutrition' tab on MyBiolectric (Chapter 5.2). The digestate must remain in the reactor for at least 30 days for the plant to function properly.

During the pumping out process, the digestate level in the reactor is again determined by the control chart of the installation. If sufficient digestate has been pumped out of the reactor, the pumping out process stops. Subsequently, pumping starts: the cellar pump pumps fresh manure from the manure cellar to the reactor (Figure 9). During pumping in, the fresh manure passes through a flow meter in the container, so that

A

B


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the supplied volume of manure can be measured. The recommended daily quantity of fresh manure depends on the type of biogas plant and on the quality of the manure supplied. An overview of the maximum feed per day is given in table13.

3.1.2 Options

Feed tap cheese whey

In installations equipped with a cheese whey supply valve, the manure supply line is equipped with a

cheese whey supply valve just in front of the flow meter. The biogas potential of cheese whey is about

twice as high as that of manure. Cheese whey boosts biogas production but may only be added in small

doses. The addition of cheese whey must be done after consultation with a Biolectric employee.

Foam sensor

In Biolectric installations equipped with a foam sensor, the formation of foam in the reactor is detected.

If the foam in the reactor exceeds a certain height, the user will be informed by SMS and the digestate

level in the reactor will be reduced by the control of the installation.

Foam control

Foam formation in the reactor can be controlled by means of a foam beater (Figure 10). This foam beater

is mounted through the reactor wall at the maximum level of the reactor. Via the user interface on

MyBiolectric, the automatic control of the foam beater can be set (Chapter 5.2).

Levers on the basement pump:

1) Internal mixing or pumping out

2) Choice of spraying height for internal mixing.

Figure 9: Installed basement pump.


Page | 26

Figure 10: The foam beater

3.2 The coolant circuit

A Biolectric biogas installation contains both components to which heat must be supplied and

components where heat is produced, and which therefore need to be cooled. In order to efficiently

exchange the heat between the different components of the system, the different parts of the digester

are connected to each other by a closed refrigerant circuit at pressure (1.5 to 2 bar). In this circuit,

coolant (30 vol% ethylene glycol) is circulated by a circulation pump.

Between the reactor and the container, the coolant circuit is exposed to the ambient temperature. In

order to keep the coolant circuit ice-free even during periods of frost, ethylene glycol is added to the

coolant upon delivery of the biogas plant. If coolant has to be added to the system during operation, the

user is expected to use only a mixture of pure water (no rain, well or tap water) and a maximum of 30%

ethylene glycol in order to avoid corrosion of the pipes and damage to the circulation pumps and other

components.

Each Biolectric biogas installation is equipped with a height measurement of the available gas buffer.

This measurement is based on a pressure measurement in a small pipe that moves up and down

together with the gas dome of the reactor. During normal operation of the system, this pipe is filled with

coolant. To top up this pipe with coolant if necessary, the user can open the ball valve at the connection

to the coolant circuit for a few seconds (Figure 3, Figure4).

ATTENTION The coolant circuit must always be filled with a water-glycol mixture to protect the installation against frost damage. The maximum percentage of ethylene glycol in the coolant circuit is 30%, this composition provides protection down to -15°C. A higher concentration of ethylene glycol may damage the circulation pumps and other components and void the warranty.

WARNING The container contains frost-sensitive components. The user must take the necessary measures to ensure that the temperature in the container does not drop below zero, e.g. by installing an electric heater during periods of severe frost. The user must ensure that the water in the water trap can never freeze.

The flow rate (or flow rate) and pressure of the coolant circuit can be read on the flow meter(s) and the

pressure gauge(s) in the container, respectively. The diagram of the coolant circuit is for the


Page | 27

Various Biolectric installations are shown in figure 12. The main functions of this circuit are:

• Cooling of the engine

• Heating of the reactor

• Supply of energy for external consumption of hot water.

3.2.1 Cooling of the engine

A Biolectric biogas plant is equipped with one or two combustion engine(s). In these engine(s) the biogas

is burned to drive an electric generator. In addition to the electrical energy generated in this way, a large

amount of heat is released during this process. Coolant is used to recover this energy and to protect the

engine(s) against overheating. Heat exchange at the engine level takes place through circulation in the

engine block itself and in the exhaust collector. In order to recover the residual energy in the hot flue

gases as much as possible, the installation is equipped with a flue gas heat exchanger (Figure6).

3.2.2 Heating of the reactor

The operating principle of the Biolectric biogas plants is based on mesophilic1 digestion of the digestate

in the reactor. This process runs optimally at a temperature of 42°C. To ensure stable fermentation

throughout the year, the reactor is heated. The reactor contains a pipe system that is immersed in the

digestate. When the coolant passes through these tubes, heat can be exchanged with the digestate in

the reactor. In normal operation, the residual heat from the combustion engine(s) is used for this

purpose. When the engines are at a standstill, the reactor can, if desired, also be heated electrically.

At standstill of the combustion engine(s), the temperature in the coolant circuit will drop. Over time, this

will cause the temperature in the reactor to drop below the minimum temperature for the fermentation

process. This has a negative impact on the efficiency of the biogas plant. To avoid this problem situation

the Biolectric biogas installations are equipped with electric heating elements. Since these heating

elements have a high electrical capacity (6kW/piece), it is always the user of the installation who decides

whether or not to switch them on in order to keep the reactor on temperature. This setting can be

adjusted via the 'Reactor' tab of the MyBiolectric user interface (Chapter 5.2). Once the user decides to

allow the electric heating elements to be switched on, they will only be used if the combustion engine(s)

in the installation are not operational.

3.2.3 External consumption of hot water

The Biolectric biogas plant is equipped with a plate heat exchanger for capturing energy in the form of

hot water. For this purpose, part of the combustion heat of the engine(s) is exchanged with an external

water circuit near the plate heat exchanger (Figure 3, figure 4). The user can connect the circulation

pump of the external circuit to the wall socket in the container labelled "heat dissipation". This socket

only receives voltage when residual heat is available at the plate heat exchanger.

1 In mesophilic digestion processes, the reactor is kept at a temperature between 32 and 42°C, in contrast to thermophilic digestion processes, where the temperature is significantly higher.


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3.2.4 Options

Heat meter

If the user of the Biolectric biogas installation wishes to measure the amount of heat absorbed in the

coolant circuit, the installation can be equipped with a heat meter. This meter contains a temperature

sensor on the coldest part of the circuit, a temperature sensor on the hottest part of the circuit, a flow

sensor and a heat calculator with display (Figure 11). Installations with two motors also have two heat

meters.

Figure 11: Heat meter consisting of A) temperature sensor on the coldest part in the water circuit; B) temperature sensor

on the warmest part in the water circuit; C) a flow sensor and D) a heat calculator with display.

A B C D

A


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B

C

Figure 12: Closed water circulation in different types of installations. A) 10kW and 11kW; B) 20kW and 22 kW;

C) 33kW, 40kW, 44kW, 60kW and 74kW installation.


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3.3 The biogas circuit

3.3.1 Biogas

In a Biolectric biogas plant, biogas is formed in the reactor by the fermentation of manure. Good quality

biogas contains about 60% methane (CH4), 39% carbon dioxide (CO2) and 1% residual traces including

hydrogen sulphide (H2S). Combustion of the methane gas by the combustion engine in the container

generates energy in the form of electricity and heat.

Both methane (CH4) and carbon dioxide (CO2) are greenhouse gases. Combustion with oxygen (O2)

converts methane gas (CH4) to carbon dioxide and water (H2O). After all chemical reactions, the

exhaust gas of the combustion engine is 9 times less harmful to the environment than the exemption of

biogas in the atmosphere.

DANGER Biogas can form an explosive mixture in the presence of oxygen. The user must at all times respect the precautionary measures as described in this manual.

WARNING When working on the gas circuit, the gas supply should be shut off with the gas valve just in front of the water trap (Figure 7).

3.3.2 Main components

The most important components in the biogas circuit are shown in figure 6 and figure 7:

• The water lock

Between the reactor and the container, the biogas is led over a water trap. If the gas pressure

exceeds 3.5 mbar, the gas is diverted to the surrounding area near the water trap to protect the

reactor.

The water lock consists of 3 compartments: in the upper half there are 2 compartments, one at each

viewing window. The lower half also forms 1 compartment. In case of overpressure of biogas in the

reactor, the water level at the right sight glass will be lower than in the left one (the water flows from the

right to the left compartment) (Figure 13B). If the pressure is too high, the water level in the right

compartment will be so low that biogas flows from the right to the left compartment. In this case the

biogas escapes to the outside air via the chimney. The water in the water trap is automatically

replenished by the condensation water - from the gas cooler (option) and the activated carbon filter -

and is also replenished at regular intervals by a timer (Figure 2). If the water in the upper compartments

is too high, it flows to the lower compartment. The lower compartment can then also overflow to the

outside. This is normal when the biogas installation is operational.

NOTE The water trap must always be filled with water. If the water level in the water trap is too low, biogas can escape into the environment and ambient air is sucked in by the engine (Chapter 6.2.4).

• The throttle solenoid valve

Inside the container, the biogas is passed over an electromagnetic valve. This throttle valve

closes automatically when the combustion engine is not operational, so that no biogas can

escape to the outside air.

• The activated carbon filter

Biogas may contain a certain volume of hydrogen sulphide (H2S). If this harmful gas is burned

into the engine(s), the service life of the engine(s) is reduced. That is why


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The biogas for the engine is filtered in the activated carbon filter, which is filled with Biolectric

Activated Carbon granules. The concentration of hydrogen sulphide (H2S) in the biogas and the

saturation of the activated carbon filter are monitored by an H2S sensor and can be consulted

via the 'Gas' tab on MyBiolectric.

• The air filter and the throttle valve

Just in front of the engine, the biogas is mixed with air in the correct ratio. The air is sucked in

over the air filter and the throttle valve (Figure6). This throttle valve is built into the air filter

housing and is used to regulate the ratio of biogas to air. Downstream from the mixing point, the

gas line contains a combustible mixture of biogas and air.

• The flue gas heat exchanger

In order to recover energy from the hot flue gases in the exhaust of the combustion engine, the

biogas plant is equipped with a flue gas heat exchanger. Here, energy from the hot flue gases

is transferred to the coolant circuit. This energy is used to maintain the temperature of the

reactor or is transported to the plate heat exchanger for the external absorption of heat energy.

• The air injection pump

In order to keep the concentration of the harmful H2S in the biogas produced low, the reactor

is equipped with a network just below the gas cap where micro-organisms that can convert

hydrogen sulphide (H2S) into elemental sulphur (S) are living. As a result, the biogas is

chemically cleaned before it is led to the container. This conversion can only take place in the

presence of oxygen.

As mentioned earlier, the production of the biogas itself is an anaerobic process (i.e. in the

absence of oxygen). In order to monitor the balance between gas production and chemical

cleaning, the oxygen level in the reactor is regulated by means of an air injection pump. This

pump is located in the reactor and is connected to the gas cap.

3.3.3 Options

• Gas flow meter

If the user wishes to measure the gas flow rate, the installation can be equipped with a gas flow

meter. This sensor is built into the flexible gas line just in front of the engine.

• Gas detector and smoke detector

A gas detector and smoke detector (Figure 6) interrupt the electrical supply in the control box

when methane and smoke are detected, respectively. Both detectors have the same effect as

pressing the emergency stop. The gas detector has a battery power supply with a lifespan of

about 10 years. If the battery needs to be replaced, the smoke detector will give two short signal

tones every 60 seconds.

• Torch

As an additional safety measure, the biogas plant can be equipped with a flare. If the maximum

gas buffer is exceeded (chapter 5.2.) and no engine in the installation is operational, a flare can be

used to ignite an excess of biogas. In this way, the reactor can be protected against overpressure.

When the flare is not operational, the gas supply to the flare is shut off by means of an

electromagnetic gas valve.

• Gas cooler

Biolectric biogas plants with a rated output of 60 and 74kW are equipped with a gas cooler as

standard. For smaller installations a gas cooler is offered as an option. A gas cooler is used to

cool the biogas between the reactor and the engine. By cooling the biogas, an important volume

of water vapour can be removed from the biogas in the form of condensation water. As a result,

biogas of a higher quality is fed to the engine, which increases the efficiency of the installation.


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Figure 14 schematically shows the gas circuit of the different types of installations.

Figure 13: Water level in water lock. A) no gas pressure in reactor; B) gas pressure in reactor; C) insufficient water

in water trap.

A B C


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A

B

Figure 14: Gas circulation in different types of installations. A) 1 engine installation; B) 2 engines installation.


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Figure 15: A) View through the window of the net, saturated with sulphur (yellow-white). B) A close-up of the net.

4 Security

The Biolectric biogas plant includes adequate facilities and measures to ensure safe operation of the

plant.

• In order to protect the reactor against overpressure, the installation is equipped with: 1) a water

trap through which gas can escape to the surrounding area; 2) a magnetic pressure relief valve

through which manure, foam and gas can escape from the reactor; 3) (optional) a flare to ignite

an excess gas.

The magnetic overpressure valve will open at an overpressure of 8 mbar in the reactor, reducing

the pressure in the reactor and preventing damage. As the operation of this pressure relief valve

is based on magnetic force, correct operation is guaranteed at all times, independently of any

power cuts on the farm.

• All rotating parts are protected by fixed protective caps.

• The correct functioning of the various components of the biogas plant is continuously monitored

by the control system. If there is a risk of damage to the installation, the installation will be

switched off automatically. The user is informed of this on the


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by means of an error message (Chapter 8). The biogas plant can only be restarted if the cause

of this error message is remedied.

• The biogas plant can be switched off immediately by the user via one of the available emergency

stops. These are located on the outside door, on the door of the electrical cabinet and at the

level of the combustion engine(s). On activation of one of the emergency stops, all components

of the electrical current are interrupted, with the exception of the fan that keeps the air cover on

the reactor inflated.

• If the installation is equipped with a smoke and/or gas detector, the installation is switched off

on activation of one of these detectors. Activation of these detectors has the same result as

pressing one of the emergency stops.

• If the plant is equipped with an automatic call system to warn the user in the event of a fire

(optional), the user will be automatically called on the telephone numbers preset by the user

upon activation of the fire detection system in the biogas plant.

DANGER DANGER OF EXPLOSION! The user must respect a safety zone of 1.20m around the reactor and the water trap at all times. The following must be observed in the safety zone:

• Do not make an open fire

• No smoking

• Do not carry out any welding or grinding work

• Do not place hot objects

• Do not place and/or operate agricultural vehicles. The

safety zone is shown in Figure 16 and Figure17.

DANGER This manual describes procedures for maintenance and repairs. For safety and warranty reasons, it is not permitted to carry out repairs on parts of the Biolectric biogas plant. the procedure of which is not described in this manual.

NOTE If work has to be carried out that does not comply with these regulations, authorisation must be requested from Biolectric's service department. An employee will describe which extra precautions must be taken.

NOTE In the case of a Biolectric biogas plant equipped with an automatic call system (optional), the user must store the necessary telephone numbers in the automatic call system before the Biolectric biogas plant is put into operation (see Annex 9).

ATTENTION Check the various parts of the ventilation system in the container (Chapter 6.2.1) weekly for faults or problems.

WARNING The user must at all times guard against any gas leaks.


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Figure 16: Top view of the hazard area classification plan. Hazard zone shown in shaded area.

Figure 17: Side view of the hazard area subdivision plan S1-S2-S3-S4 silo. Hazard zone shown in shaded area.


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Figure 18: Side view of the hazard area classification plan S1H-S2H-S3H-S4H-S6H-S8H silo. Hazard zone

shown in shaded area.

DANGER Biogas should never be inhaled. The gas may contain a high concentration of H2S. Inhaling air with high concentrations of H2S has an intoxicating effect and can be fatal. Provide adequate ventilation in the

container at all times. Respect the zoning.

WARNING - Biogas is a flammable mixture if it is mixed with the correct ratio of air. After the water lock, all pipes and components of the gas circuit are airtightly connected to each other so that biogas cannot escape into the container. Small quantities of gas can always escape during maintenance work on pipes. To prevent the supply of biogas during maintenance work, the gas valve at the water lock must be closed (Figure7).

- Despite the strong ventilation in the container, caution is recommended. When working on the gas circuit by the user, a cleaning procedure is described in the relevant chapters.

- All motors, pumps, valves, etc. in the biogas plant are controlled manually or automatically or remotely via MyBiolectric by the user or a Biolectric service technician. In the latter case, they can be operated at any time if the biogas plant has a connection to the internet. For each operation it is therefore necessary to have the control unit button on electrical cabinet in 'off' position te


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places (Figure 20). This switches off the control electronics so that

pumps, motor, valves and mixer cannot be operated automatically.

- Various parts in the container, such as the engine, are at a high temperature. Caution is therefore required with regard to the burning and fire hazard of garments. Turn off the components, such as the combustion engine and gas exhaust, and allow them to cool down before starting work.

- During repair maintenance on the manure or water circuit, the electrical cabinet must be closed so that no manure or water can get into the cabinet. The wetting of electrical components can cause a short circuit.

- Switch off the engine when working on the engine and/or generator. To do so, place the control unit button on the electrical cabinet in the 'off' position. Rotating parts may pinch body parts or clothing.

- The fan of the air hood must always be on. There must be no weight on the reactor cover so that the air cover is always stretched. In case of heavy rain, snow or hail, the air cover must be kept clear.

- Switch off the cellar pump in time for manual operation to pump fresh manure into the reactor. The magnetic overpressure valve will open when the reactor is overfilled.

- The water in the water trap must never be frozen! If the water is frozen, excess biogas in the reactor cannot escape through the water trap.

- Due to the presence of engine oil it is not allowed to eat or drink in the container.

ATTENTION - Use the emergency stop only for emergency situations (Figure 20). The use of the emergency stop to shut down the engine during maintenance operations may lead to explosions in the exhaust (backfire). During maintenance operations, the engine must first be turned off and then the control unit button must be placed in the 'off' position.

- Use goggles with side covers and gloves when handling engine oil.

4.1 Emergencies

In the event of an emergency, all components of the biogas plant can be switched off immediately

by means of one of the emergency stop switches. Only use the emergency stop during emergency

situations such as fire. Installations with 1 and 2 motors are equipped with 2 and 3 emergency stop

switches respectively. The buttons are located on the door of the container, on the door of the electrical

cabinet and in the vicinity of motor 2 (Figure 19).

ATTENTION Use the emergency stop only for emergency situations (Figure 20). The use of the emergency stop to shut down the engine during maintenance operations may lead to explosions in the exhaust (backfire). During maintenance operations, the engine must first to be switched off, after which the control unit button should be placed in the 'off' position.


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Figure 19: Emergency stop switches. A) Inside the container (installation with 2 motors) ; B) On the outside of

the container.

Emergency stop on outside door


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5 Operation

5.1 Manual operation

At the biogas plant, the combustion engine(s), basement pump, control of all components and general

power supply for the biogas plant can be operated manually. The buttons can be found on the door of

the electrical cabinet (Figure20).

5.1.1 The combustion engine

The start/stop switch on the internal combustion engine(s) allows the engine to be started when it is

switched off and stopped when it is in operation. To do this, turn the knob to the desired side (engine 1/

engine 2) and keep the knob 2 s. in this position. The engine will go through several stages to start and

stop safely. After (manual) stopping the engine or restarting the installation, i.e. placing the control unit

button in the 'on' position or disabling emergency stop, the engine can be started manually or via

MyBiolectric, Motor tab (Chapter 5.2). Only if the engine has been switched off automatically after the

minimum throttle buffer has been reached, the engine will be restarted automatically after the system

registers that sufficient throttle is available (Table 10).

During maintenance work, if applicable, the engine must first be stopped with the start/stop button

and then the control unit button must always be set to the 'off' position. All moving components of

the biogas installation will be interrupted from power by setting the control unit button to the 'off' position,

with the exception of the fan of the airhood, lighting and voltage at sockets. Because components are

interrupted, they cannot suddenly be switched on. If a component is not working and the control unit

button is set to 'on', it could happen that these components are suddenly controlled automatically, for

example by a command on the MyBiolectric interface.

Figure 20: Electrical cabinet with manual control buttons (picture of installation with 1 motor).


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5.1.2 The basement pump

The basement pump can be manually activated by placing the switch of the basement pump on the

door of the electrical cabinet in position '1'. On the basement pump, the left-hand control lever can be

used to pump the manure into the reactor, as well as internal pumps to homogenise the manure in the

basement around the basement pump. If the basement pump pumps internally, the right control lever

can be used to adjust the height of the nozzle. As a safety precaution, the safety button should be pulled

out before changing the position of the control lever (Figure 21). To carry out maintenance work on the

basement pump, the control unit button must always be placed in the 'off' position.

5.2 Digital control - MyBiolectric

MyBiolectric is an interface with which the user can monitor the Biolectric biogas installation. Via this

shielded website the biogas installation can be controlled, and warnings (Chapter 7) and error messages

(Chapter 8) are communicated to the user. The digital operation of the biogas installation via MyBiolectric

requires a connection to the internet. If a fault occurs in the system, the user is also informed of this via

an SMS message if required.

The operation of a biogas digester involves various variable parameters, such as the volume of fresh

manure pumped to the reactor every day. The variable parameters partly determine the efficiency of an

installation. In order to keep the efficiency and life span of the engine(s) as high as possible in operating

mode, it is important to monitor and control these various parameters via MyBiolectric. These

parameters can also be monitored and adjusted remotely by Biolectric employees.

The user can log on to MyBiolectric via the Biolectric website: http://www.biolectric.be (Figure 22). First

click on the 3 horizontal stripes at the top right of the screen (1). The black column appears. Then click

on "MyBiolectric login" (2) in the black column on the right side of the screen. Log in with the username

and password you received from Biolectric at the delivery of the biogas installation.

NOTE Changes to the various variables can affect engine efficiency.

NOTE If after logging in on your screen in yellow text "No connection to the machine is possible". the Internet connection may have been interrupted. Examples are a power cut due to an active emergency stop or activation of the fire detection. During the (re)start-up of the control card, no connection to the machine is possible for a short period of time.

Operating lever

Safety button

Figure 21: Basement pump operation.

http://www.biolectric.be/


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There are 9 different tabs on MyBiolectric with information about the installation:

1. Efficiency;

2. Gas;

3. Engine;

4. Feeding;

5. Grid;

6. Reactor;

7. Errors & warnings;

8. Address;

9. Smart.

Figure 22: Login to MyBiolectric.

1 2


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5.2.1 Efficiency

Figure 23: Image of the Efficiency tab on MyBiolectric.

Table 9: Parameters on Efficiency tab on MyBiolectric.

Parameter Statement

Energy production last month All green energy produced in the last 4 weeks.

Own energy consumption last month The energy consumed by the electrical auxiliary components of the biogas plant over the past 4 weeks. This includes: the digestate and basement pump and the mixer(s) in the reactor, but not the 24V power supply of the circuit board and water circulation pumps. The latter is included in the emergency services. The energy consumed by the emergency services is not included in the green energy produced.

Net energy production The difference between the two parameters above. The net available green energy produced by the biogas plant.

Average return last month The average efficiency of the biogas plant during the last 4 weeks.

NOTE The efficiency graph shows the technical availability of the biogas plant (ochre) on the one hand and the efficiency of the biogas plant (green) on the other hand.

The technical availability is determined on the basis of the registered error messages. If the installation is automatically switched off after an error occurs, the installation is technically unavailable for energy production. When the installation is (automatically) switched off due to a lack of gas or at the end of the maintenance interval, the installation technically available for energy production. This downtime is factored into the realised efficiency.

The efficiency [%] achieved is determined by the ratio between the actual energy produced and the theoretical maximum energy that can be generated.


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The difference between the ochre graph and the green graph is a measure of the loss of yield due to reduced gas production, standstill during maintenance or manual shutdown of the installation.


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5.2.2 Gas

Figure 24: Image of Gas tab on MyBiolectric.

Table 10: Parameters on Gas tab on MyBiolectric.

Parameter Statement

Gas buffer min The minimum gas buffer level is used as a safety setting to stop the engine(s) of the biogas plant when the available volume of biogas falls below a predetermined level. The operation of this setting is different for plants with 1 or 2 engines.

1 Engine: If the measured gas buffer level is less than 'Min. gas buffer level', the engine will stop (Engine error 2048, Chapter 8.1.12).

2 engines: If the measured gas buffer level is less than "Min. gas buffer level + 10cm", the engine comes to a standstill with the most operating hours (engine error 2048; chapter 8.1.12). The 2nd engine will continue to run. If the measured gas buffer level drops further below the minimum gas buffer level, the 2nd

engine will also continue to run. Shut down (engine error 2048 , chapter 8.1.12).

Gas buffer max If the engine was switched off due to engine error 2048 (Chapter 8.1.12), this engine will automatically restart if


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the gas buffer level is again high enough. The operation is

different for installations with 1 or 2 engines.

1 Engine: If the measured gas buffer level rises to Max. gas buffer level, the engine will automatically restart.

2 engines: If the measured gas buffer level rises to "Max. gas buffer level -10cm" then the engine will automatically start again with the least running hours. The 2nd engine will start automatically when the measured gas buffer level rises to "Max. gas buffer level".

If the engine(s) is (are) stationary and the measured gas buffer level is higher or equal to "Max. gas buffer level + 10cm" then the flare (Optional, figure 1) will be activated. The flare burns the excess biogas in the reactor to protect it from overpressure and will be deactivated. are when the measured gas buffer level drops again to "Max. gas buffer level - 10cm".

Gas buffer actual The variable measured gas buffer level is a measure of the volume of biogas present in the reactor. This is measured through a pressure sensor at the end of a water pipe, which is attached to the gas cap of the reactor. If gas is produced in the reactor, the gas cap will rise, causing the hydrostatic pressure in this water pipe to rise as well. In this way the volume of biogas in the reactor can be monitored.

This parameter is also used to generate warnings 6 and 7 (Chapter 7).

Aeration Aeration indicates how many seconds per minute air is blown into the reactor by the air injection pumps (Chapter 2). This

setting is automatically adjusted by the control software to keep the H2S concentration in the produced biogas as low as possible. If desired, the user can also set the aeration time himself.

This parameter is also used to generate warnings 11, 12 and 15 (Chapter 7).

Max aeration This parameter can be used to set the maximum aeration time, expressed in seconds per minute.

H2S Reactor The concentration of the trace gas H2S in the biogas in the reactor. The gas sample is taken just before the activated carbon filter.

This parameter is also used to generate warnings 10, 14 and 16 (Chapter 7).

H2S Engine The concentration of the trace gas H2S in the chemically cleaned biogas, which is fed to the engine. The gas sample is taken just after the activated carbon filter.

Filter loading Filter loading is a statistical prediction of the saturation level of the carbon particles (Biolectric Activated Carbon) in the activated carbon filter. If filter loading reaches 100%, warning 4 or 5 (Chapter 7) will be generated.

NOTE: If the H2S measurement of both H2S-Reactor and H2S Engine is faulty, filter loading will remain unchanged, resulting in the actual saturation level of the activated carbon filter. is underestimated.


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NOTE: After replacing the carbon particles, the following should be done the user can reset the filter load to 0% by pressing the "RESET" button.

Sample With the Sample button an H2S measurement of the biogas can be started manually. During the automatic control of the biogas installation, a sample of the biogas is taken periodically. offered to the H2S sensor to check the concentration of hydrogen sulphide in the biogas.

Anti-foaming injection (optional) The amount of anti-foam pumped into the reactor every day. This value can be adjusted by the user on MyBiolectric and is a multiple of 3dl per day.

‒ 1 stroke of the actuator is 3dl (1 stroke = up and down movement of the actuator).

‒ The anti-foam injection is divided into 2 doses per day, unless only 3dl/day is administered, in which case there is only 1 administration of 1 stroke.

‒ The first administration is 1 hour before the set time of automatic feeding (the anti-foaming injection is independent of whether the automatic feeding is on or off).

‒ The second administration is 12 hours later than the first.

Example:

For example, the parameters set on MyBiolectric are as follows:

‒ Automatic power supply = 10h00;

‒ Anti-foam injection = 18 dl/day;

The anti-foam injection will take place the first time at 9h00 and 9dl injection (i.e. 3 strokes of the actuator immediately after each other). The 2nd administration of 9dl will take place at 21h00.

In case of an odd number of actuator strokes, the first administration will include 1 more stroke.

Foam breaker (option) This option is visible when the biogas plant is equipped with a foam breaker to combat excessive foaming in the reactor. These parameters allow both the frequency (break foam every xx minutes) and the period (break foam for xx seconds) with which the foam breaker is controlled, set.


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5.2.3 Engine

Figure 25: Image of the Engine tab on MyBiolectric.

Table 11: Parameters on the Engine tab on MyBiolectric.

Parameter Statement

Power Displays the current power generated by the engine.

Set power Here the user can set the desired maximum power. The value entered should always be less than the maximum power of the installation. Reducing the maximum capacity may be advisable when (re)starting up the biogas installation if the quality of the biogas is still insufficient. As a result, the engine will not be able to run at full power.

With a 9.7 and 11kW engine, the minimum power to be set is 8000 W and a maximum of 9700 W and 11000 W respectively.

In the case of a 20 and 22 kW engine, the minimum power to be set is 16 000 W and the maximum power to be set is 20 000 W and 22 000 W respectively.


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In the case of a 30 and 37 kW engine, the minimum power to be adjusted is 22 500 W and 30 000 W respectively, and the maximum power to be set, 30 000 W and 37 000 W respectively.

Max. power The maximum power of the engine.

Throttling valve position The combustion of the biogas requires oxygen from the air. The amount of air added to the biogas for combustion in the engine is regulated by the position of the throttle valve.

The score is at least 20%. There is a maximum supply of air. At a setting of 75-80%, the throttle valve is in a position where the supply of air to the biogas is minimal. At a position of 100%, the throttle valve is in a position where the shut-off of the air supply pipe is beyond the maximum.

The position of the throttle valve depends on the quality of the biogas and the resistance of the biogas in the gas pipes from the reactor to the engine.

If the position of the throttle valve is controlled up to 100%, the throttle automatically returns to 20% opening. When the throttle valve is controlled twice up to 100%, the system generates motor error 256 (Chapter 8.1.9).

Engine status Displays the status of the engine: 'engine running' or 'engine off'.

Last error Tracks the last motor error since the last automatic motor shutdown (See chapter 8).

If the engine restarts or the engine is stopped manually, the number '0' is displayed.

Produced green energy The total amount of green energy produced by the biogas plant to date.

Engine hours run The number of hours the engine has been running.

Engine total hours run The sum of the number of running hours of all engines (already installed) at this location in the container (engine 1 or engine 2).

Gas consumption The total amount of gas consumed by the engine(s) of the biogas plant.

Service Service is used to keep track of the preventive maintenance interval for the engines. Preventive maintenance must be carried out every 800 operating hours. With a new engine, the first preventive maintenance must be carried out after 50 hours of operation.

If desired, the user can receive an SMS with warning 3 (Chapter 7) when there are only 48 operating hours left for (one of) the engines. At the time of the warning, there are always between 24 and 48 operating hours left over for the engine.

If there are no more running hours, engine error 8192 is generated (Chapter 8.1.14).

Reset maintenance interval After a preventive maintenance of the motors is carried out, the number of hours for preventive maintenance can be reset to 800 hours using the Reset button.

Battery voltage The voltage of the battery, which supplies the starter motor(s) and the ignition mechanism of the engine(s).


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If the voltage is lower than 8V, motor error 4 is generated (Chapter 8.1.3).


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5.2.4 Feeding

Figure 26: Image of Feeding tab on MyBiolectric.

Table 12: Parameters on the Feeding tab on MyBiolectric.

Parameter Statement

Intake amount per cycle The volume of fresh manure from a feeding cycle. This volume can be set by the user. A feeding cycle consists of four consecutive events:

1. Level measurement of the digestate in the reactor

2. Pumping out a quantity of digestate from the reactor

3. Level measurement of the digestate in the reactor

4. Pumping fresh manure into the reactor


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If too much fresh manure is added to the reactor in one go, the temperature in the reactor can drop sharply. This can adversely affect the efficiency of the installation (see also 'reactor temperature' on the Reactor tab on MyBiolectric).

The maximum daily power supply for the different types of installations is shown in table 13.

Feeding cycles per day Here the user can set how many feeding cycles are performed daily. The number of possible feedings per day is: 1, 2, 3, 4, 6 or 8.

NOTE: Environmental changes in the reactor may disrupt the microbiology in the reactor resulting in foaming. In the case of foaming, it may be advisable to carry out several small feeds per day instead of one large feed.

NOTE: For large installations, it may be appropriate to to carry out several small feedings every day so that the reactor temperature does not drop too much after a feed.

Level setting Here the user can set the level to which the reactor will be filled with digestate. The reactor level is directly related to the average dwell time of the manure/digestate in the reactor. The higher the level in the reactor, the longer the average dwell time in the reactor at constant feed. The longer the residence time in the reactor, the more organic material is digested.

If the actual level in the reactor deviates too much from the level setting, reactor error 1 (Chapter 8.2.1) is generated. This parameter can also be adjusted via the Reactor tab.

Auto feeding Here the user can set the time of the power supply. If the daily number of feeding cycles is greater than 1, the different cycles are spread evenly over 24 hours. In the example shown in Figure 26, a feeding cycle starts at 6.00 am. In total there are 3 cycles so the other cycles therefore start 8 hours and 16 hours later (24/3=8), i.e. at 14.00 and 22.00.

Feeding: time-out fresh food When the basement pump is active during a feed cycle, and the signal from the flow meter to the control board is interrupted for xx seconds, the pumping of manure into the reactor is stopped. The user can set the number of seconds after which the pumping should stop. The maximum value is 999 seconds.

If desired, the user can adjust this setting, e.g. in the event of an uneven flow of manure in the supply line due to a large distance between the basement pump and the reactor, or because the manure is too thick.

This parameter is also used to generate reactor error 2 (Chapter 8.2.2).

Feeding cycle With the buttons 'Start', 'Pump in only' and 'Pump out only' the supply and discharge of manure/digestate can be controlled manually.

With the 'Start' button a feeding cycle is started, including level measurement.


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The 'Only pump in' button is used to pump fresh manure into the reactor without prior level measurement of the digestate in the reactor.

Start' and 'Only pump in' can be used e.g. when starting up the installation or at warning 8 or after the cause of the error has been remedied in reactor error 2 (Chapter 8.2.2).

With the button 'Only pump out', digestate is pumped out of the reactor. This function can be used after the cause of the error has been corrected in the case of reactor error 2048. 8.2.9) or if there is too much foam in the reactor and the user wishes to reduce the level in the reactor.

Feeding balance The amount of manure to be added to the reactor in the course of the current 24 hours.

Auto feed The user can use the 'on' button to adjust whether or not the feeding cycle is automatic.

Switching off the automatic power supply is recommended if the motor has not been in operation for more than 1 day. Warning 13 reminds the user to deactivate 'Automatic feeding'.

Start/stop manual exit

The 'start' button allows the user to pump digestate out of the reactor to the desired level (level setting). Before pumping out, the actual level of digestate in the reactor is measured.

Started on This is the time when the last 5 feeding cycles were started.

Temperature The temperature of the digestate in the reactor during the last 5 feeding cycles.

Level The level of digestate in the reactor after pumping out digestate and before pumping in fresh manure.

Exit time The time required for pumping out digestate from the reactor during the feed cycle.

Intake amount The amount of manure added to the reactor during the feeding cycle.

Intake time The time needed to pump fresh manure into the reactor.

Error A reactor fault message generated in a feeding cycle. Details of reactor error messages are described in Chapter. If no error occurs during power supply, the number '0' is displayed.


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Table 13: Maximum daily feeding amount.

Type of installation Maximum daily nutrition

10 8 000 litres

11 8 000 litres

16,5 12 000 litres

22-1 16 000 litres

33 24 000 litres

44 24 000 litres

60 32 000 litres

74 32 000 litres


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5.2.5 Grid

Figure 27: Image of Grid tab in MyBiolectric

Table 14: Parameters on the Grid tab on MyBiolectric.

Parameter Statement

Voltage per phase 1/2/3 Displays voltage of the 3 phases of the grid.

If motor error 64 (Chapter 8.1.6) is generated, then the monitoring relay is activated by means of a high or too low phase voltage.

Frequency per phase The frequency of the different phases of the grid.

Angle between phase 1 and 2 The angle between phase 1 and phase 2. In normal operation, this phase angle is equal to 120°.

Equity consumption All of electrical components of the biogas plant, such as the mixer and the digestate pump.

Own energy consumption Displays the energy consumed since the biogas plant was started up.

If your own consumption is too high, Warning 1 (See chapter 7) will be generated.


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5.2.6 Reactor

Figure 28: Image of the Reactor tab on MyBiolectric.

Table 15: Parameters on the Reactor tab on MyBiolectric.

Parameter Statement

Reactor temperature Displays the temperature of the digestate in the reactor.

The optimum temperature for mesophilic fermentation is 42°C. If the temperature drops too much, the amount of methane produced is reduced, which affects the production speed and the quality of the biogas.

Warning 2 (Chapter 7) informs the user if the temperature of the reactor drops too much.

Reactor temperature target Here the user can set the desired temperature of the digestate in the reactor.

Water temperature reactor in Temperature of the coolant at the beginning of the heating tubes in the reactor.


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The heating of the digestate in the reactor is highly dependent the temperature of the coolant flowing through the heating tubes in the reactor.

Water temperature reactor off Temperature of the coolant at the end of the heating tubes in the reactor.

The temperature difference between the beginning and the end of the heating pipes are a measure of the heating of the manure in the reactor.

Water temperature motor off (M1/M2)

Temperature of the coolant just after the engine(s). NOTE: This is the hottest point in the coolant circuit.

Antifreeze index With the anti-freeze index setting, the cellar and digestate pump are operated several times a day for a short period of time to prevent manure or digestate from freezing in the pipes. This pumping in and out is independent of the settings relating to the feeding cycle.

Antifreeze index 0: disabled

Antifreeze index 1: 4 times/day



Pumping in takes 3 to 4 seconds and pumping out 120 seconds. Note the different flow rates for the type of digestate pump: bellows pump: ±3m³/h, lobe pump: ±12m³/h and centrifugal pump max. 50m³/h.

Additional heating Here the user can set whether the electric heater can be used to keep the reactor at a temperature when all the motors in the installation are switched off. The flow-thruster has the capacity to keep the digestate at temperature but not the capacity to heat the reactor.

When all engines are switched off, there will no longer be any heat production in the installation, which will cool down the reactor. If the digestate in the reactor cools down too much, warning 2 will be generated (Chapter 7). The optimum temperature for the fermentation of manure is 42°C.

Level setting Here the user can set the level to which the reactor will be filled with digestate. The reactor level is directly related to the average dwell time of the manure/digestate in the reactor. The higher the level in the reactor, the longer the average dwell time in the reactor at constant feed. The longer the residence time in the reactor, the more organic material is digested.

If the actual level in the reactor deviates too much from the level setting, reactor error 1 (Chapter 8.2.1) is generated. This parameter can also be adjusted via the Nutrition tab.


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Reactor level current The actual level in the reactor is measured by means of a pressure sensor at the bottom of the reactor. If the actual level in the reactor deviates too much from the desired value at level setting, reactor error 1 (Chapter 8.2.1) is generated.


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Reactor status Current status of reactor . The different possibilities are: pumping in, pumping out, mixing, level measurement and 'idle'. If the reactor is in idle state, there is no activity in the reactor.

Mixer The user can use these buttons to switch the mixer on continuously or for 1 hour. The digestate can be mixed to reduce the foam layer in the reactor.

Mix every xx minutes Here the user can set the desired time interval to mix the digestate in the reactor. In order to promote the heat transfer between the coolant and the digestate, it is important to use the digestate frequently. mixes.

Mix xx seconds Here the user can set the desired time for a 'mix activity'.

Do not mix from xxx to xxx Here the user can specify a time period that will not be mixed. This function can be used e.g. to prevent a negative influence of the start-up flow of the mixer on other equipment on the farm. avoid.


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5.2.7 Errors & Warnings

On the errors & warnings tab an overview of all engine and reactor error messages and warnings is

kept. For a detailed discussion of these error messages and warnings, the reader is referred to chapter

7 and chapter 8.

5.2.8 Address

The address tab stores the installation and billing address of the biogas plant. The user can change this

address.

In addition, additional general information about the biogas plant is shown on this tab:

Table 16: General information on the Address tab on MyBiolectric

Parameter Statement

Hostname Name of the biogas plant in the general Biolectric system.

Ownership (yes/no) Here it is indicated whether or not this installation is a Biolectric property.

Compile date The software version on the control card in the biogas plant.

Hadrware version The version number of the control card in the biogas plant.

Delivery Date of delivery to the customer

Production Date on which the biogas plant was installed has successfully completed internal quality control by Biolectric.

Maintenance contract up to If a maintenance contract has been concluded for the biogas plant, the duration of this maintenance contract is shown here. contract is still ongoing.

Silo type Silo type with which the biogas plant is equipped.


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6 Preventive maintenance

In order to enable the proper functioning of the biogas plant, it is necessary to periodically carry out a

number of checks and preventive maintenance tasks. If warnings and error messages from the system

are not properly followed up, and preventive maintenance tasks are not properly carried out, the proper

functioning of the biogas plant will be compromised. If the user fails to carry out this maintenance or to

follow up the installation adequately, the right to a guarantee as discussed in chapter 9 will lapse. During

preventive maintenance, always follow the general safety regulations (chapter Fout!

Verwijzingsbron niet gevonden.).

WARNING - Close the electrical cabinet during maintenance work so that no manure or water can get into the cabinet. This may cause a short circuit.

- Biogas is a flammable mixture if it is mixed with air in the correct proportions. After the water lock, all pipes and components of the gas circuit are airtightly connected to each other so that biogas cannot escape into the container. Small quantities of gas can always escape during maintenance work on pipes. To prevent the supply of biogas during maintenance work, the gas valve at the water lock must be closed (Figure 7). Despite the strong ventilation in the container, caution with regard to fire and explosion hazards is always recommended.

- During maintenance work, if applicable, the engine must first be stopped with the start/stop push button and then the control unit button must always be set to the 'off' position. The moving components of the biogas installation, such as the basement pump, cannot be controlled automatically when the control unit button is set to the 'off' position. However, the voltage to the fan of the airhood, the lighting and the sockets in the container are not switched on. interrupted.

6.1 Daily maintenance

A Biolectric biogas installation has been designed with the highest possible ease of use for the owner.

For example, important settings and parameters of the installation can be remotely monitored and

adjusted by Biolectric employees. Nevertheless, the user needs to monitor the biogas installation on a

daily basis in order to quickly detect any problems or damage. In this way, a maximum efficiency of the

installation is pursued.

6.1.1 Checking for warnings and error messages

In the event of possible problems in the biogas plant, the user is notified via a warning or an error

message on MyBiolectric. In order to enable optimal operation of the biogas installation, it is important

to follow up these warnings and error messages on a daily basis.

The warnings and error messages are divided into two categories: engine errors and reactor errors.

Warnings and error messages of both categories can be consulted on MyBiolectric. The different motor

errors are also shown on the display of the control card in the container.

Follow the procedures described in Chapters 7 and 8 to correct the cause of the messages so that the

installation can function optimally.


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6.1.2 Combustion engine oil level

In order to ensure a long engine life, the oil level of the engine should be checked daily. The level of oil

in the engine must always be filled to the maximum level.

NOTE - Always top up the engine oil with small quantities and allow sufficient time for the oil level to be measured correctly using the oil dipstick.

WARNING - Switch off the internal combustion engine when working on the engine and/or generator. To do so, place the control unit button on the electrical box in the 'off' position. Rotating parts may pinch body parts or loose clothing.

- When topping up, no oil must be allowed to get onto hot engine parts. Danger of fire!

Follow the procedure below to check the oil level of the internal combustion engine and top it up if

necessary:

a) Switch off the engine (Figure 20) by placing the control unit button in the 'off' position.

b) To check the oil level, pull the oil dipstick out of the guide pipe (Figure 29, Figure 30). Wipe the

oil dipstick with a clean cloth and push it back into the guide pipe until it stops. Pull the oil dipstick

out of the guide pipe and read the oil level.

c) If the oil level is below the maximum level, refill with Biolectric Engine Oil:

- Unscrew the filler cap from the motor oil filler neck (Figure 29, Figure30).

- Top up to the maximum level.

- Check oil level again after 2 min. Refill with oil if necessary.

- Close the oil filler cap again and push the oil dipstick back as far as it will go.

d) Return the control unit button to the 'on' position.

Engines with a high number of running hours can consume more oil. Contact Biolectric's customer

service to order Biolectric Engine Oil.


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Spark plug caps

Bobbins

Oil dipstick

Engine oil exhaust

Oil filler cap

Oil pressure contact

Oil filter

Figure 29: 10/11kW engine.


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Engine oil exhaust

Penbines

Oil filler cap

Oil dipstick

Oil pressure contact

Oil filter

Figure 30: 20/22kW engine.


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Figure 31: 30/37 kW engine


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6.1.3 Air cap reactor

Verify that the reactor cover is properly tensioned and does not move in wind, hail, snow or rain. If

necessary, tighten the tarpaulin firmly or contact Biolectric's service department. Always observe the

general safety regulations.

WARNING In the case of snow, the reactor roof must be cleared of snow.

6.1.4 Level in reactor

Check the level in the reactor through the window. Use the ATEX approved torch supplied. If the level

is too high, this may be due to excessive foam production in the reactor, or to excess manure. If the

level in the reactor becomes too high, the magnetic overpressure valve will automatically open, allowing

the excess foam or manure to flow out of the reactor. To avoid damage to the reactor, the automatic

pressure relief valve will also open at pressures higher than 8 mbar. If the magnetic pressure relief valve

is open, follow the instructions in annex 7 to close the pressure relief valve again.

WARNING The magnetic overpressure valve is a safety mechanism that protects the reactor against excessive overpressure. To ensure correct operation of the magnetic pressure relief valve, this opening must never be blocked in any way.

6.1.5 Container doors

Check that the container doors are closed. To ensure proper cooling of the various components in the

container, the container doors must be closed. When the doors are closed, the fan (Figure32) will create

a slight underpressure in the container, creating a flow of air in the container through the holes and

grilles in the container wall and floor.

6.2 Weekly maintenance

6.2.1 Ventilation of the container

Check that the ventilation openings in the outer wall of the container at the level of the fan(s) and the

generator(s) and in the floor at the level of the external water supply and at the door opening are free. If

necessary, remove obstructions such as fallen leaves. If the temperature inside the container is too high

due to poor ventilation, this can cause damage.

The fan hood (optional) can be placed in 2 positions. In summer, the plate should be placed on the

container floor so that warm air is blown into the container (Figure32 B). In winter, the plate should be

in an upright position (Figure 32 A) to draw in air from underneath the container. With this arrangement,

warm air remains in the container to avoid frost.

Figure 32: Ventilation cap for fan (optional). A) Ventilation hood position during winter; B) Ventilation

hood position during summer.

A B


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6.2.2 Pressure in the cooling system

The pressure in the coolant circuit must be between 1.0 and 2.0 bar. This can be read on the pressure

gauge, just above the expansion tank as well as on MyBiolectric. If the pressure is too low, additional

Biolectric coolant must be added to the circuit. To do this, open the tap above the hand pump and pump

coolant into the system with the hand pump until the pressure is equal to 1.5 bar (cold engine) or 2.0

bar (warm engine).

ATTENTION Use only Biolectric coolant to increase the pressure in the coolant circuit. The concentration of ethylene glycol in the coolant must never exceed 30% in order to avoid damage to components such as the circulation pumps.

6.2.3 Leaks

Check the container weekly for leaks in the various liquid flows. Repair damaged pipes as soon as

possible or contact Biolectric's service department. If water or oil needs to be added weekly, this may

indicate a leak.

6.2.4 Water lock

The water level on the left-hand viewing window of the water trap should always be half full of water. If

the level is too low, biogas could flow from the left to the right compartment, escaping the outside air

and draining the gas buffer in the reactor.

If the water level is too low, press 'test' on the timer until water flows out of the water trap drain.

ATTENTION The water in the water trap must never be frozen! If the water is frozen, an excess of biogas in the reactor cannot escape. In this case, an excess of biogas will escape from the reactor via the magnetic overpressure valve.

6.2.5 Basement pump

The basement pump is used to pump fresh manure into the reactor, as well as to homogenise the

manure in the manure cellar, around the basement pump.

Visually check for proper installation and operation of the basement pump. This includes:

- Electricity lines and socket,

- Stable mounting of the basement pump.

6.2.6 Digestate pump

The digestate pump is used to pump digestate from the reactor to the post-storage. Plants without a

digestate pump use the hydrostatic pressure in the reactor to transfer the digestate from the reactor to

the post-storage.

Visually check for proper installation and operation of the digestate pump. This includes:

- Electrical connection and socket

- Digest state pipes and seals before and after the digestate pump

- Silent operation of the pump


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6.2.7 Foam breaker

In installations fitted with a foam breaker, the user must check the oil level of the foam breaker on a

weekly basis. A low oil level can shorten the life of the foam breaker and cause a gas leak to the

surrounding area.

6.3 Monthly maintenance

6.3.1 Warning systems

Check the various warning systems in the container on a monthly basis to ensure that they are working

correctly. This can be done e.g. by pressing the test button. Check the pressure and expiry date of the

fire extinguisher. A Biolectric biogas installation is equipped with one or more of the following warning

systems:

- Emergency stop switch

- Fire detector

- Fire extinguisher

- Gas detector

- Automatic call system in the event of fire

6.3.2 Cleaning magnetic filter

The magnetic filter under the circulation pump can be cleaned as follows:

1. Switch off the circulation pump by switching off the corresponding motor. After 2 - 3 minutes,

the circulation pump switches off automatically. The pump can also be switched off by

disconnecting the pump's electrical connector.

2. Remove the magnet from the filter.

3. Open the drain at the bottom of the filter for 2 to 3 seconds. Open the drain at once and collect

the coolant in a bucket.

4. Use the hand wing pump to re-pressurise the coolant circuit if necessary (1.5 to 2 bar).

NOTE The coolant circuit is under pressure. This will cause the coolant to spray out of the filter. This is normal.

ATTENTION During the cleaning of the magnetic filter, make sure that no coolant on the electrical components near the filter. Protect e.g. the electrical control of the three-way valve.

WARNING Only clean the magnetic filter if the coolant has cooled down sufficiently. Risk of burns and serious personal injury. The temperature of the coolant can be consulted via the MyBiolectric interface.

6.4 Engine maintenance

Engine maintenance includes changing engine oil, spark plugs and oil filter. The parts can be ordered

from Biolectric's customer service department.

Engine maintenance should be carried out every 800 hours. The maintenance of a new engine must be

carried out after 50 hours of operation. The user can consult the number of hours left per engine on the

Motor tab on MyBiolectric (Chapter 5.2).


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If there are 48 operating hours left, an SMS will be sent at 2 p.m. the same day or the day after with

warning 3 (Chapter 7). The number of hours left, as stated in the SMS, is therefore between 48 and 24

hours each time. SMSs are only sent if this function has been activated by a Biolectric employee at the

user's request. When there are no operating hours left, motor error 8192 is generated (Chapter 8.1.14).

ATTENTION Use goggles with side covers and gloves when handling engine oil.

Follow the procedure below to perform engine maintenance:

a) Turn off the engine (Figure 20).

b) Place the control unit button in the 'off' position (Figure20).

c) Drain old engine oil through the oil drain. (Figure29, figure30). Take the old engine oil to a

collection point near you.

d) Replace the oil filter using the chain spanner from the toolbox supplied. Take the old filter to a

collection point near you.

e) Replace the spark plugs with the spark plug spanner from the toolbox. When disconnecting the

spark plug heads, be careful not to pull on the cable, but only on the heads so that the cables

are not damaged.

f) Close the oil drain. If the oil was drained through a cap in the crankcase, a new copper washer

must be fitted.

g) Fill the engine with Biolectric Engine Oil along the oil filler cap (Figure29, Figure30). 10/11kW:

6 l; 20/22 kW: 7 l; 30/37 kW: 12.2 l. Use the oil dipstick to check the oil level. This is described

in more detail in Chapter 6.1.2.

WARNING There must be no oil on hot engine parts. Danger of fire! In case of fire, extinguish with the fire extinguisher, not with water.

NOTE Make sure that no oil is spilled near the spark plugs. This can cause ignition problems. If water or oil is spilled on the spark plug caps of a 10/11kW engine, they must be replaced. Old spark plug caps can be removed by pulling them off the cable. Before fitting new ones, 2mm of the end of the spark plug cap must be removed. be cut off from the cable. The new spark plug caps must be screwed onto the cable.

h) Return the control unit button to the 'on' position.

i) Start the engine and let it run for a short time. This allows the new oil filter to fill up with oil.

j) Measure the oil level after switching off the engine/installation. If the oil level is below the

maximum, repeat instructions (g), (h) and (i). If the oil level is too high, drain the engine oil.

After maintenance has been carried out, press the reset button on MyBiolectric, tab Motor at

reset maintenance interval (Chapter 5.2). This resets the number of hours until a new engine

maintenance is carried out to 800 hours.

Keep the oil receptacle under the engine clean so that oil and water leaks can be easily detected.


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7 Actions in the event of warnings

The user of a Biolectric biogas installation is automatically warned of possible problems. These warnings

and error messages must be followed up on a daily basis via MyBiolectric. Table 17 gives an overview

of all possible warnings. Table 18 gives an overview of the instructions to solve the cause of the different

warnings. If the instructions are not followed after receiving a warning, this can lead to an error (Chapter

8) which will automatically switch off the installation.

Table 17: Overview of warnings.

Warning-

number Warning

1 Own consumption greater than 72 kWh in the last 24 hours

2 Reactor temperature has fallen sharply

3 Maintenance within 48 hours

4 Carbon filter engine 1 to be replaced

5 Carbon filter engine 2 to be replaced

6 Gas buffer metering frozen

7 Gas buffer metering defective

8 Not fed yesterday

9 Pumping speed of last feed was 50% faster than average for last month

10 H2S value too high (>1500ppm)

11 Aeration is 60 sec./min.

12 Aeration is less than or equal to 3 sec./min.

13 Yesterday's efficiency was 0% and automatic power supply is on

14 H2S reactor measurement - deviation exceeds 400ppm

15 Air injection very high - watch out for gas quality

16 H2S measurement fails for 24 hours

17 /

18 /

19 /

20 Pressure in cooling water circuit is low


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Table 18: Overview of cause and solutions for the different warnings.

Number Warning Possible cause Solution

1 Own consumption in the last 24 hours was higher than 72 kWh

One or more electrical components with a high energy consumption, such as pumps, are in operation for too long.

- Check the settings of the mixing regime, the electric heating... via MyBiolectric. Adjust if necessary. E.g. If mixer mixes longer and more frequently

to reduce the H2S concentration, check

whether the H2S concentration is indeed decreasing.

- Remove external devices that are connected are plugged into a socket in the container.

2 Reactor temperature has dropped sharply

Another error message was left unresolved for an extended period of time, preventing the coolant from heating up and thus cooling down the digestate in the reactor.

If the reactor temperature drops to 25°C, the user can consider activating the electric heating via MyBiolectric. If the electric heating has already been activated, check the correct operation of the heating system. If necessary, contact Biolectric's service department.

3 Maintenance within 48 hours Preventive engine maintenance must be carried out every 800 hours of operation. It is possible that no maintenance has been carried out yet.

a) Carry out preventive engine maintenance as soon as possible (Chapter 6.4), b) Only after carrying out preventive engine maintenance: reset the maintenance interval of the engine in question on MyBiolectric.

4 Replace carbon filter motor 1 Loading of the activated carbon filter of engine 1 has reached 100%, the carbon particles have to be replaced. become.

Replace Biolectric Activated Carbon in the activated carbon filter of engine 1. Reset the filter loading of engine 1 to MyBiolectric.

5 Replace carbon filter engine 2 Loading of the activated carbon filter of engine 2 has reached 100%, the carbon particles need to be replaced.

Replace Biolectric Activated Carbon in the activated carbon filter of engine 2. Reset the filter loading of engine 2 on MyBiolectric.


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6 Gas buffer metering frozen Excessive pressure on the pressure sensor in the gas buffer meter due to frozen coolant in the water pipe connected to the gas cap of the reactor.

-Check that the coolant contains 30% ethylene glycol. (30% = -15°C). If necessary, contact Biolectric's service department to add coolant.


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-Add additional coolant with the correct composition to the coolant circuit. with the hand pump.

7 Gas buffer metering defective Too little water in line of gas buffer measurement or pressure sensor defective.

- Open the tap on the water pipe of the gas buffer meter for 2 seconds.

- Check whether the gas meter buffer is working correctly. Repeat if necessary.

8 Installation was not powered yesterday

Automatic feeding cycle switched off on MyBiolectric.

Switch on automatic power on MyBiolectric.

9 Pumping speed of last feed was 50% faster than average for last month

Manure has become more fluid. - Check whether water gets into the manure. - Check that the manure in the cellar is

sufficiently mixed. - If necessary, pump old manure from the

cellar directly to the digestate storage.

10 H2S concentration too high (>1500ppm)

H2S concentration in reactor too high. Contact Biolectric's service department: - Establish a better mix regime;

- Take measures to remove foam in the reactor.

11 Aeration is 60 sec./min. H2S concentration in reactor too high. - Check that the air pump is working correctly: - Makes noise

- Air comes out of the exhaust (to do this, remove the plastic casing on the exhaust)

- Contact the service department to set up a better mixing regime.

12 Aeration is less than or equal at 3 sec./min.

H2S sensor defective. Contact Biolectric's service department.

13 Yesterday's yield was 0% and automatic power supply is switched on.

The installation has been halted by another error and the automatic power supply was not switched off.

Switch off automatic power on MyBiolectric.

14 H2S reactor measurement - deviation exceeds 400ppm

H2S sensor defective. Contact Biolectric's service department.


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15 Air injection very high - watch out for gas quality.

The setting for aeration of the reactor is high for the current efficiency of the installation. This can be due to a high sulphur content

-Decrease the setting for aeration of the reactor. A high sulphur content in the reactor may be due to a foam layer in the


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in the reactor. This situation may lead to lower gas quality.

reactor preventing the degradation of H2S

on the grid. -Alternatively, the institution for the

Maximum aeration can be set on the Gas tab on MyBiolectric.

16 H2S measurement fails for 24 hours H2S sensor defective. Contact Biolectric's service department.

17 /

18 Engine oil too low The oil level in the internal combustion engine is

too low.

Top up the engine with Biolectric Engine Oil until the

maximum level of the oil dipstick.

19 /

20 Low pressure in the coolant circuit. Water leak in the coolant circuit. - Detect if there is a leak.

- Seal the leak.

- Increase the pressure in the coolant circuit by

adding coolant using the hand pump as

described in chapter

6.2.2.

8 Error messages

If a problem occurs with one or more components of the Biolectric biogas plant, the user will be informed

with an error message or error. In order to avoid damage to the installation, all internal combustion

engines of the biogas installation are automatically switched off. In order to be able to detect and remedy

problems in the biogas plant more quickly, the various error messages are indicated with a numerical

code as shown in table 19. Once the cause of the error message has been remedied, the user can

restart the engines.

The different error messages are divided into two categories depending on the part of the biogas plant

to which they belong: motor error or reactor error. In the case of plants with two engines, the error code

indicates whether it is engine 1 (a) or engine 2 (b). The user is informed of engine problems via the

display on the control card and via the Engine and Errors & Warnings tabs on MyBiolectric. Problems

near the reactor are only communicated via MyBiolectric (Chapter 5.2). If desired by the user, an SMS

can also be sent automatically as soon as the fault occurs.

Table 19: Overview of all error messages.

Error code Old error code Engine error

1 err 1 Engine overheated

2 err 2 No oil pressure

3 err 4 Battery voltage too low

4 err 8 Power fluctuates

5 err 16 H2S concentration too high

6 err 32 Net error

7 err 64 Monitoring relays

8 err 128 Speed too high

9 err 256 Insufficient power

10 err 512 Easy startup failed

11 err 1024 Exhaust gas temperature too high

12 err 2048 Gas buffer low

13 err 4096 Alarm DEIF module

14 err 8192 Maintenance interval

15 err 16384 Difference between H2S measurements too large

16

No voltage on 3rd phase

18

Speed too low

19

Bio ID

21

Pressure in coolant circuit too low

22

Oil tank empty

25

Aeration is set to 0 sec/min; H2S

measurement is defective

31

Flow rate in the coolant circuit too low

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Error code Old error code Reactor error

1 1 Reactor level too high

2 2 No flow rate when pumping in

3 16 Valve digestate does not open

4 32 Valve digestate does not allow

5 256 Gas buffer > maximum + 20 cm

6 512 Gas buffer < minimum - 20 cm

7 1024 Mixer does not work. Reset the

thermal protection.

8 2048 Pumping out digestate failed.

Nutrition is discontinued.

9 4096 Digest state pump overheated

10 8192 Anti-foaming agent is on or the

Injection pump is defective.

11 16384 The foam sensor is defective

NOTE An insufficient gas buffer is not considered an error in the strict sense of the word, and therefore no SMS is sent to the user when the engine(s) is (are) switched off. as a result of too low a gas buffer level.

8.1 Solutions for engine errors

8.1.1 Engine error 1: Engine overheated

Engine error 1 occurs when the thermal protection of the internal combustion engine is activated. This

may indicate that the temperature in the coolant circuit is too high to cool the engine sufficiently. The

temperature in the coolant circuit may be too high if, for example, the fins of the blow-off valve are too

dirty or if the coolant is not pumped around in the correct sub-circuit, for example due to a defective

three-way valve. The temperature at the engine will also rise too high if the flow rate or pressure in the

coolant circuit is too low. In these cases error 1 may occur together with or linked to error 21 and/or 31.

Error 1 can also be caused by a defective thermal contact. The decision tree in figure 33 can be used

to come to a solution.

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Figure 33: Engine error 1 decision tree.

Table 20: Explanation of engine error 1 decision tree.

Letter in Figure 33

Additional information

a The pressure in the coolant circuit can be read on the pressure gauge at the level of the expansion tank. The flow rate in the coolant circuit can be visually checked by the flow meter(s) under the circulation pump(s). This is only possible when the circulation pump(s) are in operation. If necessary, restart the engine(s) to start the circulator(s).

b In order to be able to clean the fins of the fan, the cabinet and fan must first be dismantled. To do this, use the tools provided.

8.1.2 Engine error 2: No oil pressure

Engine error 2 occurs if the control board does not receive a signal from the oil pressure contact on the

engine. This problem can be caused by an insufficient oil level in the crankcase or by a problem with

the oil pressure contact itself. The decision tree in figure34 can be used to come to a solution.

NOTE Engine error 2 can also be caused by engine errors 16 and 18.

In this case, the solutions for these engine errors must be followed.

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Figure 34: Decision tree engine error 2.


Letter in Figure 34


a Follow the procedure described in section 6.1.2 to top up the oil.

8.1.3 Motor error 3: Battery voltage too low

Motor error 3 occurs if the battery voltage is less than 8V. The decision tree in figure 35 can be used

to come to a solution.

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Table 22: Explanation engine error 3 decision tree

Letter in Figure 35


a The location of the 5A-230V fuse on the control board is shown in Figure 36. There are 3 fuses at the bottom left of the control board. The 5A fuse is located on the far right.

Spare fuses are included with the toolbox.

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Figure 36: Location of fuses on the control board (v4.0).

8.1.4 Engine error 4: Power fluctuates

Engine error 4 occurs when the power of an engine fluctuates too much and too often for 3 minutes.

This can be a result of failures in the gas supply or the electrical circuit. The decision tree in figure 37

can be used to come to a solution.

15A-12V

5A-230V

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Letter in Figure 37


a If there is insufficient water in the water trap, biogas flows from the right to the left compartment. This is shown in Figure 13C.

b At gas pressure in the reactor, the water level in the water trap is higher in the left compartment compared to the right compartment. This is shown in figure 13B.

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c Close the manually operated tap on the biogas supply line before carry out maintenance work on the electromagnetic valves. Always place the control button on the electrical cabinet in the 'off' position.

8.1.5 Engine error 5: H2S concentration too high

Engine error 5 occurs if the H2S concentration in the biogas at the input of the engine is too high.

This problem can occur when the carbon particles in the activated carbon filter are saturated.

Carry out the 3 steps below:

1. Replace the Biolectric Activated Carbon particles in the activated carbon filter.

NOTE No personal protective equipment is required when trading Biolectric Activated Carbon. However, Biolectric advises the user to open the container doors to ensure good ventilation of the space. The saturated carbon particles may be disposed of with the residual waste.

a) Close the manual gas valve between the reactor and the container.

b) Let the engine run for 2 minutes and in the meantime open the viewing window on the

gas line with the screwdriver supplied. This ensures that all remaining biogas from the

pipes and activated carbon filter is sucked in by the engine.

c) Stop the engine with the start/stop button on the outside of the electrical box (Figure 20).

d) Place the control unit button on the outside of the electrical cabinet in the 'off' position

(Figure20).

e) Close the viewing window.

Activated carbon filter small type (Figure 38)

1. Open the hatch of the activated carbon filter (Figure38).

2. Remove all carbon particles. Use the plastic sump provided for this purpose.

3. Open the lid of the activated carbon filter (Figure 38) and clean the activated carbon

filter from the inside as well as the grid on which the carbon particles are lying. If there

is a deposit on the grille, this can lead to engine error 9 (Chapter 8.1.9).

4. Close the hatch of the activated carbon filter.

5. Fill the activated carbon filter with 1 bag of 25 kg Biolectric Activated Carbon particles.

6. Reattach the lid to the activated carbon filter.

Large activated carbon filter type (Figure 38)

1. Open largest hatch at the bottom of the activated carbon filter (Figure38).

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2. Remove all carbon particles. Use the plastic sump provided for this purpose. Close

the hatch.

3. Open the smallest hatch at the bottom of the activated carbon filter. Catch these

granules with the plastic collection tray supplied but keep it. Close the hatch.

4. Open the lid of the activated carbon filter (Figure 38) and clean the inside as well as

the grilles containing the carbon particles. If there is a deposit on the grille, this can

lead to engine error 9 (Chapter 8.1.9).

5. Pour the carbon particles from the smallest compartment into the largest

compartment. Add 1 bag of 25 kg Biolectric Activated Carbon particles.

6. Fill the smallest compartment with 1 bag of 25 kg Biolectric Activated Carbon

particles.

7. Reattach the lid to the activated carbon filter.

f) Open the manual gas valve.

g) Place the control unit button on the outside of the electrical cabinet in the 'on' position.

h) Start the engine.

A B

Figure 38: Activated carbon filter A) small type B) large type

2. Press the 'reset' button on the Gas tab on MyBiolectric at filter load (Chapter 5.2).

3. Replace the engine oil. This procedure is described in Chapter 6.4.

WARNING Ignoring engine error 5 by restarting the engine before replacing the carbon particles and engine oil will result in irreparable damage to the combustion engine, flue gas heat exchanger and will void the warranty as described in chapter 9. The service life of the internal combustion engine is shorter if high concentration gases are used. H2S is burned. The flue gas heat exchanger will have to be replaced prematurely by sulphur deposits inside.

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8.1.6 Engine error 6: Mains error

Motor error 6 occurs if the control board detects mains failures. The control board can detect under-

and overvoltage, a different mains frequency and different phase angles. This problem is often not due

to the Biolectric biogas installation but to the electricity grid to which the biogas installation is connected.

Motor error 6 can occur together with motor error 7. Contact Biolectric's service department.

8.1.7 Motor error 7: Monitoring relay

Motor error 7 occurs if the monitoring relay detects mains failures. The monitoring relay can detect

undervoltage, an abnormal mains frequency and abnormal phase angles. This problem is often not due

to the Biolectric biogas installation but to the electricity grid to which the biogas installation is connected.

Please contact Biolectric's service department.

8.1.8 Engine error 8: RPM too high

Engine error 8 occurs if the engine speed is too high. This problem may be due to a faulty transmission

belt or an incorrect belt tension. Contact Biolectric's service department and state whether a distribution

belt is broken.

8.1.9 Engine error 9: Insufficient power

Engine error 9 occurs if the engine cannot deliver the required power after the throttle valve is controlled

twice over the full range. This problem can have various causes, for example a failure in the gas or

electrical circuit. The decision tree in figure 39 can be used to find a solution.

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Letter in Figure 39


a The coils on an 11kW motor are shown in Figure 29.

b Check the following gas taps:

- At water lock between reactor and container,

- Near the viewing window in the gas pipeline.

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c If there is insufficient water in the water trap, biogas flows from the right to the left compartment. This is shown in Figure 13C.

8.1.10 Engine error 10: Easy startup failed

This error only occurs in Biolectric biogas plants equipped with the Easy Start System (optional). Check

whether there is enough petrol in the petrol tank and top it up if necessary. If this does not solve the

problem, contact Biolectric's service department.

8.1.11 Engine error 11: Exhaust gas temperature too high

Engine error 11 occurs in older installations if the flue gases become too hot. This error can be caused

by problems with the coolant circuit, a blockage in the flue gas heat exchanger or a malfunction of the

temperature sensor or the control board. Contact Biolectric's service department.

8.1.12 Engine error 12: Gas buffer low

Engine error 12 occurs if insufficient biogas is available in the reactor. If the gas buffer level falls

below the minimum level, all internal combustion engines are automatically switched off until sufficient

biogas is available again. The engines are also restarted automatically.


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Letter in Figure 40


a The procedure for closing the magnetic pressure relief valve is described in Annex 7.

b If there is insufficient water in the water trap, biogas flows from the right to the left compartment. This is shown in Figure 13C.

c If the cochlea of the basement pump is not submerged in manure, biogas may escape to the outside air via the manure pipe.

8.1.13 Engine error 13: DEIF module alarm

In Biolectric biogas plants equipped with a synchronous generator, the plant can only be connected to

the grid after start-up if the generator runs synchronously with the grid. Switching on the grid is monitored

by a DEIF module. Contact Biolectric's service department.

8.1.14 Engine error 14: Maintenance interval

Depending on the type of crankcase, engine maintenance should be carried out every 400 or 800 hours

of engine operation (See section 6.4). The very first maintenance of a new engine must be carried out

after 50 hours of operation. The number of operating hours remaining can be consulted on MyBiolectric,

Engine tab (Chapter 5.2). When the maintenance interval is reached, motor error 14 is displayed.

When maintenance is carried out, the user can reset the number of operating hours to the initial value

by pressing the reset button on MyBiolectric. This error can only be solved by pressing the reset

button at 'reset maintenance interval' on MyBiolectric, Motor tab. Only do this after the maintenance

has been carried out!

WARNING Ignoring engine error 14 by restarting the engine before performing engine maintenance will reduce engine life. The warranty will be invalidated if prescribed maintenance intervals are not observed.

8.1.15 Engine error 15: Difference between H2S measurements too large

Motor error 15 can occur in installations with two motors. In these installations the correct functioning

of the H2S sensors is checked by comparing both measurements. A large deviation between the

measurement results of both sensors indicates an incorrect functioning of (one of) the sensor(s). Contact

the service department of Biolectric.

8.1.16 Motor error 16: No voltage on 3rd phase

Motor error 16 occurs when the circuit with electrical devices, controlled directly from the control board,

is switched off. This circuit contains, for example, the air injection pumps or the control signals for the

contactors. Check that the 5A 230V pipe fuse on the control board (see figure 36) is burnt out and

replace if necessary. Additional fuses are supplied in the toolbox. Contact the Biolectric service

department if the problem persists.

8.1.17 Engine error 18: RPM too low

Engine error 18 occurs if the generator speed is too low when the control board tries to connect the

installation to the mains. This error can also be caused by automatic fuses in the farm's own electrical

installation being deactivated. If this is not the case, or if the problem persists, contact Biolectric's service

department.

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8.1.18 Motor error 19: Bio ID

Contact Biolectric's service department.

8.1.19 Engine error 21: Pressure in coolant circuit too low

Engine error 21 occurs if the pressure sensor on the coolant circuit does not register pressure. The decision

tree in Figure 41 can be used to come to a solution.

Figure 41: Decision tree engine error 21

Table 26: Explanation of decision tree engine error 21.

Letter in Figure 40


a Visually check the pressure in the coolant circuit through the pressure gauge at the pressure relief valve. The pressure in the coolant circuit must be between 1 and 2 bar.

b Pressurise the system by adding additional coolant to the system using the hand pump.

8.1.20 Engine error 22: Oil tank empty

Engine error 22 occurs when the oil level in the engine crankcase becomes too low. The decision tree

in figure 42 can be used to come to a solution.

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Letter in Figure 42


a Follow the procedure described in section 6.1.2 to top up the oil.

8.1.21 Motor error 25: Aeration is set to 0 sec/min; H2S measurement is defective

Engine error 25 is activated if the H2S sensor does not work correctly after an automatic test. To protect

the engine from excessive H2S concentration in the biogas, the installation is automatically switched off.

Contact Biolectric's service department.

8.1.22 Engine error 31: Flow rate in the coolant circuit is too low

Engine error 31 occurs if the flow sensor in the coolant circuit registers a too low flow rate. No or

insufficient flow rate in the coolant circuit can cause the temperature at certain places in the installation

to rise too much, which can cause damage. To protect the installation, the engines are automatically

switched off.

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Letter in Figure 43


a Visually check the flow rate in the coolant circuit by means of the flow meter under the circulation pump.

b The circulating pump may become jammed if impurities get into the coolant or the impeller of the pump runs in an air bubble for an extended period of time. The coolant circuit contains filters and automatic de-aeration systems to counteract this. If the pump is jammed, the pump's safety device is activated and a warning light will flash.

c Switch off the circulation pump by placing the control button on the electrical cabinet in the off position. Remove the magnet from the filter. Open the filter outlet for 3 seconds and collect the coolant in a bucket.

NOTE: The coolant circuit is pressurised, causing this fluid to flow out of the filter under pressure. Make sure that electrical components under the filter (e.g. the three-way valve control) do not get wet.

DANGER: Do not clean the magnetic filter until the coolant has cooled down sufficiently! Danger of burns and serious personal injury.

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8.2 Solutions for reactor errors

8.2.1 Reactor error 1: Reactor level too high

Reactor error 1 can have two different causes:

- Before starting a feeding cycle, the level in the reactor is already more than 20 cm higher

than the set desired level on the MyBiolectric feeding tab. (Chapter 5.2).

- During the feeding cycle, the level in the reactor rises faster than expected. At the beginning of

a feeding cycle, the expected course of the digestate level is determined from the digestate level

at the beginning of the cycle and the declared amount of fresh feed per cycle. If the measured

digestate level during the feeding cycle deviates from this expected course by more than 5 cm,

reactor error 1 shall occur.

Check that the button of the basement pump on the door of the electrical cabinet is in the 'auto' position.

It is possible that too much manure was pumped in or too little digestate was pumped out at a previous

feed. If pumping out the digestate is difficult, the user can clean the digestate pump according to the

procedure described in Chapter 8.2.9.

8.2.2 Reactor error 2: No flow rate when pumping in

Reactor error 2 occurs if no flow rate in the supply line is measured during the pumping process of

fresh manure into the reactor for a predetermined period of time. This time interval can be set at timeout

fresh feed on the feeding tab on MyBiolectric (Chapter 5.2). The flow rate in the supply line is measured

by the manure flow meter (Figure 2). The decision tree in Figure 44 can be used to come to a solution.

Figure 44: Decision tree reactor error 2.

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Table 29: Explanation of reactor decision tree error 2.

Letter in Figure 44


a Location of the thermal protection in the electrical cabinet see Figure 45.

b If manure is diluted with water, the flow rate increases. Use chlorine-free (rinsing) water to dilute the manure.

Contactor

Thermal protection

Figure 45: Components in electrical cabinet with close-up of contactor with thermal protection.

8.2.3 Reactor error 3: Valve digestate does not open

Reactor error 3 occurs if the automatic sliding valve cannot open (Figure2). Contact Biolectric's

service department to solve this error.

8.2.4 Reactor error 4: Valve digestate does not accept

Reactor error 4 occurs if the automatic sliding valve cannot close (Figure 2).

Try to close the automatic sliding valve manually while it is electronically driven: to do this, restart the

biogas installation by placing the control unit knob in the 'off' position and then in the 'on' position. This

will close the automatic sliding valve.

Contact Biolectric's service department to solve this error.

8.2.5 Reactor error 5: Gas buffer +20 cm above maximum

Reactor error 5 occurs if the gas buffer level is more than 20cm above the maximum level. This problem

can be caused by a faulty flare (optional) or an excess of fresh manure fed to the installation. The

decision tree in Figure 46 can be used to come to a solution.

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Figure 46: Reactor decision tree error 5.

8.2.6 Reactor error 6: Manure level in the reactor >35cm too low

Reactor error 256 occurs if the manure level in the reactor is > 35cm too low compared to a

predefined reference point. This reference point is 'Level setting' on MyBiolectric, tab Food (Chapter

5.2).

In the case of silos equipped with a transparent monitoring well (low silos), a level measurement of the

digestate in the reactor can be carried out. Compare this value with the measurement of the digestate

level of the reactor on MyBiolectric. If both values deviate strongly from each other, it is necessary to

check whether the automatic slide valve (Figure 2) and slide valve outflow (Figure 47) are properly

closed. If both values are similar, pump fresh manure into the reactor.

If this feed error occurs during the start-up of an installation, wait until the digestate level in the reactor

has risen sufficiently.

8.2.7 Reactor error 7: Gas buffer 20 cm below minimum level

Reactor error 7 occurs if the measured gas buffer level falls more than 20cm below the minimum. Check

that the magnetic overpressure valve (Figure1) is still closed. If the pressure relief valve is open, contact

Biolectric's service department.

8.2.8 Reactor error 8: Mixer does not work, please reset thermal protection

Reactor error 8 occurs when the power consumed by the mixer (in operation) is much lower than the

theoretical consumption of the mixer. It is possible that the mixer's thermal protection has been switched

on. Check the mixer's thermal protection in the electrical cabinet (Figure 45) and reset if necessary. If

this does not solve the problem, contact Biolectric's service department.

8.2.9 Reactor error 9: Reactor emptying failed, power supply discontinued

Reactor error 9 occurs if emptying the reactor to the set level fails. When this error occurs, the feed

cycle is stopped. Manure cannot be pumped into the reactor until the problem is solved and the level in

the reactor drops back to a normal level.

Check that the manual sliding gate valve is open (Figure 2). If the sliding valve was already open, there

may be a blockage in the digestate pipes or digestate pump. The procedure to solve such blockages is

described in chapter 8.3. If this error occurs, contact Biolectric's service department.

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ATTENTION In case of an emergency, the reactor can be emptied manually by means of the connection outside the container. The maximum allowable flow rate is 50m³/h. Open the magnetic overpressure valve before pumping out if there is a chance that the maximum flow rate is exceeded and pump out very slowly to avoid damage to the reactor.

8.2.10 Reactor error 4096: Digest state pump overheated

Reactor error 4096 is generated if the digestate pump overheats. This error can only occur with a

lobe pump and a centrifugal pump and not with a bellows pump. Only the lobe pump and the centrifugal

pump have a temperature sensor. An over-temperature of the pump can occur if an obstruction or air

enters the digestate pump during pumping out, e.g. due to a block of wood or a lost eartag. Remove the

obstruction. Instructions are given in previous section 8.3.

8.3 Maintenance of the digestate pump

A Biolectric biogas plant can be equipped with one of three different types of digestate pumps. During

the lifespan of the biogas plant, blockages may occur in the digestate pipe or in the digestate pump.

This can be caused for example by impurities in the digestate, such as a cattle ear tag, a block of wood

or other contaminants. Follow the procedures below to clear blockages in and around the digestate

pump.

8.3.1 The bellows pump

In case the Biolectric biogas plant is equipped with a bellows pump, problems may occur in the area of

non-return valve 1 between the manual sliding valve and the rubber band of the pump (green area in

Figure 47), and in the area of non-return valve 2 (blue area in Figure 47). If the obstruction is in the

vicinity of non-return valve 1, i.e. in front of the pump chamber, the pump will slowly vacuum the pump

chamber. In this case, the thermal protection of the bellows pump will not be activated. If the obstruction

is in the vicinity of non-return valve 2, i.e. after the pump chamber, the thermal protection of the pump

will be activated automatically.

DANGER Keep the doors of the electrical cabinet closed at all times during maintenance work so that water or digestate cannot splash into the cabinet. Risk of short-circuiting and electrocution!

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Non-return valve 2

Water supply tap

Tap for sampling

digestate

Non-return valve 1

Sliding valve external spout

Manual sliding valve

Figure 47: Bellows pump with non-return valves and inlet and outlet pipes for digestate where potential

problems may occur. A) Blockage at check valve 2: blue; B) Blockage between manual slide valve -

bellows pump - check valve 1: green.

1. An obstruction in the pump chamber - thermal protection not activated

a. Switch off the internal combustion engine (Figure20).

b. Place the control unit button in the 'off' position (Figure20).

c. Close the manual sliding valve.

d. Visually check that the automatic sliding valve is closed. If it is open, set the control unit

button on the electrical cabinet to the 'on' position and then back to the 'off' position. As

a result, this flap will close automatically. Placing the button back on 'off' prevents the

bellows pump from suddenly becoming active. Do not switch off the installation via the

emergency stop switch.

e. Open the manual slide valve outlet (Figure47) to release any accumulated pressure.

f. Open the sampling tap (Figure 47) to release any accumulated pressure.

g. Open the water inlet valve at the manure outlet (Figure47) until all the contamination

that caused the blockage between the bellows pump and manual sliding valve is pushed

out of the pipes.

h. Dismantle non-return valve 1 using the supplied chain spanner.

i. Clean non-return valve 1. If necessary, use the water hose in the container.

j. Visually check that both the piping and the non-return valve are free of digestate,

organic matter and sediment.

k. Reconnect the non-return valve to the pipe. The valve cannot be mounted incorrectly.

Pay attention to the correct assembly of the rubber sealing rings.

NOTE Screw on the PVC couplings by hand and not with the chain spanner.

l. Close the manual slide valve external spout and the sampling valve.

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m. Open the manual sliding gate valve.

n. Switch on the installation by setting the control unit button to the 'on' position.

2. An obstruction after the pump chamber - thermal protection activated

a. Switch off the internal combustion engine (Figure20).

b. Place the control unit button in the 'off' position (Figure20).

c. Close the manual sliding valve.

d. Remove non-return valve 2 on the digestate pipe with the supplied chain spanner.

e. Rinse the non-return valve with water, possibly with the water hose in the container. If

necessary, manually remove residues of the contamination that caused the blockage.

NOTE Screw on the PVC couplings by hand and not with the chain spanner.

f. Open the manual sliding gate valve.

g. Press the blue reset button on the thermal protection of the bellows pump in the

electrical cabinet (Figure 45). Note that the position of the contactor and thermal

protection of the bellows pump in the electrical cabinet may differ from the one shown

in the figure. All contactors in the cabinet have a label.

h. Place the control unit button in the 'on' position (Figure20).

8.3.2 The lob pump

If the performance of the lob pump decreases, this may be due to wear of the lobes, housing, wear

plates or seals. The procedure to replace components is described below:

DANGER Keep the doors of the electrical cabinet closed at all times during maintenance work so that water or digestate cannot splash into the cabinet. Risk of short-circuiting and electrocution!

a) Switch off the internal combustion engine (Figure20).

b) Place the control unit button in the 'off' position (Figure20).

c) Close the manual sliding gate (Figure48).

d) Open the slide valve external spout (Figure 48) so that the remaining digestate in the pipes can

flow out.

e) Remove the PVC outlet flange from the lob pump.

a) Remove the outlet with flange from the pump housing (41.m).

b) Clean the pump housing.

c) Remove the screws (41.e; 41.f) from the front flap.

d) Loosen the bolt of the lobes (41.d) with a 30mm spanner after unscrewing the pin (41.b).

e) Remove the lobes (41.k) and check the lobes for wear by comparing the dimensions with those

of a new lob. Replace if necessary. If the lobes need to be replaced, also replace the O-rings

and gaskets.

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f) Check the pump housing (41.m) for wear and tear. In case of wear, replace both parts of the

pump housing.

g) Check the keyed connections (41.a). They should be replaced if there is any indication of

damage or angular play between the shaft and the lobes.

h) Unscrew the screws and remove the wear plates (41.h and 41.n). Replace them in the event of

visible damage or wear and tear. Do not overturn the wear plates in case of wear and tear.

They cannot be reused and must therefore be replaced.

i) Assemble the pump in reverse order.

j) The O-rings should be greased so that they fit perfectly into the groove of the metal part.

Lubricate the lobes with grease if they are replaced. Gently turn the shaft. The rotation should

be smooth, with little resistance.

In case of other problems, please contact Biolectric's service department.

NOTE - The bolts of the lobes only need to be tightened slightly.

- Replace the brass washer (41.c) and use Loctite 243 under this washer and on the thread of the pin (41.b).

k) Place the control unit button in the 'on' position (Figure20).

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Figure 48: Lobe pump. A) Lob pump installed; B) Lob pump components.

Table 30: Designation of components in Figure 48.

N° Figure 48 Title

41.a Key 8x7x28

41.b Pen M8x8mm

41.c Brass sealing ring

41.d Bolt of lobes

41.e Screw M8x30mm

41.f Screw 8.8 M8x40mm

41.g Front cover

41.h Cover wear plate

41.i Pump housing gasket

41.f

41.j

41.i

41.h 41.g

41.k

41.e

41.l 41.m

41.n

41.b 41.c

41.d

41.a

B

Sliding valve external spout

Exhaust with flange

PVC outlet flange

Manual sliding valve

A

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41.j Screw 10.9 M6x16

41.k Lobben

41.l Screw 8.8 M8x100mm

41.m Pump house

41.n Sealing flange wear plate

8.3.3 The centrifugal pump

If the thermal protection of the centrifugal pump is activated, this may indicate a blockage in the digestate

pipe near the centrifugal pump or in the pump itself. The internal components of the centrifugal pump

can be rinsed by means of the water connection on the digestate pipe just in front of the centrifugal

pump. In the event of problems with the centrifugal pump, the user should contact Biolectric's service

department.

Figure 49: The centrifugal pump

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9 Warranty

A general warranty period of one (1) year applies from the delivery of the Biolectric biogas installation

on the buyer's site. In case of a defect during this period, the warranty includes the costs linked to the

replacement of parts if the defect was caused by production faults, incorrect settings or errors of

employees or subcontractors of the producer. Assembly costs shall be borne by the seller. Neither the

seller nor the manufacturer can be held liable for any consequential damage.

This guarantee is only valid for new Biolectric products that show material and/or production defects. All

other parts are not part of this warranty.

The following components/parts and circumstances are not part of this warranty or may void it:

• Making technical modifications to the installation without the consent of the seller or the

manufacturer;

• The use of non-original or unsuitable parts;

• Parts subject to wear and tear;

• Non-Biolectric parts and consumables;

• Any adjustment to the installation compared to the situation on delivery without the consent of

the seller or the manufacturer;

• Maintenance work carried out by persons other than specialised Biolectric technicians;

• Improper use and/or control of the installation (other than as described in this user manual);

• Failure to observe the prescribed maintenance intervals for the various components;

• Consequential damage caused by failure to replace, remove or incorrectly adjust worn parts;

• Damage due to climatic conditions or normal wear and tear;

• Damage caused by the use of unsuitable cleaning agents or tools such as high-pressure

cleaners or applied additives.

The buyer is responsible for carrying out the daily and weekly maintenance as described in this user

manual. The purchaser must check the error messages and warnings that can be consulted on the

online MyBiolectric interface and that are sent by SMS. The purchaser is expected to follow up these

messages and take the necessary action. Damage resulting from failure to follow these error messages

and warnings does not form part of the guarantee as described above.

NOTE Only use original spare parts to replace any worn or defective parts. The use of non-original spare and third party parts can lead to malfunctions, damage, and injury, as well as the lapse of the warranty.

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Annex 1: Glossary

Biogas Biogas is gas produced from the anaerobic fermentation of manure. It consists

of about 50-60% methane (CH4), 35-40% carbon dioxide (CO2) and trace

concentrations of other gases including hydrogen sulphide (H2S).

Digestate After the manure in the reactor has gone through the anaerobic fermentation

process, the manure is also called digestate. During the digestion process, all

nutrients are retained. A Biolectric biogas installation treats the manure, but

does not process any manure.

Error An error message. In the event of possible problems with the Biolectric biogas

installation, the user will be notified by an error message or 'error'. These errors

have a number to quickly indicate where the problem occurs.

MyBiolectric The online user interface of Biolectric. The user can log in via

https://app.biolectric.be. Via MyBiolectric, the biogas installation can be

monitored and controlled remotely by the user and/or by a Biolectric employee.

ppm Parts per million or particles per million particles. Unit of measurement to

express a very low concentration. E.g. the concentration of hydrogen sulphide

(H2S) in biogas.

Warning A message to the user of the Biolectric biogas plant. A warning is used to

communicate information about abnormal operation or decreasing efficiency of

the biogas plant to the user. The user can consult an overview of all warnings

on MyBiolectric.

https://app.biolectric.be/

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Annex 2: List of figures

Figure 1: Container with S4-H reactor ................................................................................................... 12

Figure 2: Organic material circulation components .............................................................................. 13

Figure 3: Coolant circuit components 10-44 kW installation ................................................................ 14

Figure 4: Coolant cypress parts 60-74 kW installation .......................................................................... 16

Figure 5: Coolant circuit components, connection to engines (here: 60-74 kW installation) .............. 18

Figure 6: Biogas circuit components - installation with 2 engines ........................................................ 19

Figure 7: Connection between reactor and container - water lock ...................................................... 21

Figure 8: Schematic representation of manure circuit in 2 different barn installations. A) Digestate

storage in an above-ground tank, B) Digestate storage in a 2nd manure cellar. .................................... 24

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Figure 9: Installed basement pump ....................................................................................................... 25

Figure 10: The foam beater ................................................................................................................... 26

Figure 11: Heat meter consisting of A) temperature sensor on the coldest part in the water circuit; B)

temperature sensor on the warmest part in the water circuit; C) a flow sensor and D) a heat

calculator with display. .......................................................................................................................... 28

Figure 12: Closed water circulation in different types of installations. A) 10kW and 11kW; B) 20kW

and 22 kW; C) 33kW, 40kW, 44kW, 60kW and 74kW installation. ....................................................... 29

Figure 13: Water level in water lock. A) no gas pressure in reactor; B) gas pressure in reactor; C)

insufficient water in water trap. ............................................................................................................ 32

Figure 14: Gas circulation in different types of installations. A) 1 engine installation; B) 2 engines

installation. ............................................................................................................................................ 33

Figure 15: A) View through the window of the net, saturated with sulphur (yellow-white). B) A close-

up of the net. ......................................................................................................................................... 34

Figure 16: Top view of the hazard area classification plan. Hazard zone shown in shaded area. ........ 36

Figure 17: Side view of the hazard area subdivision plan S1-S2-S3-S4 silo. Hazard zone shown in

shadedarea ............................................................................................................................................ 36

Figure 18: Side view of the hazard area classification plan S1H-S2H-S3H-S4H-S6H-S8H silo. Hazard

zone shown inshadedarea. .................................................................................................................... 37

Figure 19: Emergency stop switches. A) Inside the container (installation with 2 motors) B) On the

outside of the container. ....................................................................................................................... 39

Figure 20: Electrical cabinet with manual control buttons (picture of installation with 1 motor). ..... 40

Figure 21: Basement pump operation41

Figure 22: Login to MyBiolectric. .......................................................................................................... 42

Figure 23: Image of the Yield tab on MyBiolectric. .............................................................................. 43

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Figure 24: Image of Gas tab on MyBiolectric ........................................................................................ 45

Figure 25: Image of the Motor tab on MyBiolectric. ............................................................................ 48

Figure 26: Image of Nutrition tab on MyBiolectric. .............................................................................. 51

Figure 27: Image of Net tab in MyBiolectric.......................................................................................... 55

Figure 28: Image of the Reactor tab on MyBiolectric. ......................................................................... 56

Figure 29: 10/11kW engine. ................................................................................................................. 62

Figure 30: 20/22kW engine. ................................................................................................................. 63

Figure 31: 30/37 kW engine .................................................................................................................. 64

Figure 32: Ventilation cap for fan (optional). A) Ventilation hood position during winter; B)

Ventilation hood position during summer. ........................................................................................... 65

Figure 33: Engine error decision tree 1 ................................................................................................. 75



Figure 36: Location of fuses on the control board (v4.0). .................................................................... 78


Figure 38: Activated carbon filter A) small type B) large type .............................................................. 81


Figure 40: Engine error decision tree 12 ............................................................................................... 84




Figure 44: Reactor error decision tree 2 ............................................................................................... 89

Figure 45: Components in electrical cabinet with close-up of contactor with thermal protection. .... 90

Figure 46: Reactor decision tree error 5 ............................................................................................... 91

Figure 47: Bellows pump with non-return valves and inlet and outlet pipes for digestate where

potential problems may occur. A) Blockage at check valve 2: blue; B) Blockage between manual slide

valve - bellows pump - check valve 1: green. ....................................................................................... 93

Figure 48: Lobe pump. A) Lob pump installed; B) Lob pump components ........................................... 96

Figure 49: The centrifugal pump ........................................................................................................... 97

Figure 50: Magnetic pressure relief valve mounted in the holder. .................................................... 110

Figure 51: Safety equipment. A) H2S detector; B) full face mask with gas and vapour filter. ........... 111

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Annex 3: List of tables

Table 1: Technical data sheet of the various Biolectric biogas plants..................................................... 9

Table 2: Designation of components in Figure 1 ................................................................................... 12

Table 3: Components of organic matter circulation. ............................................................................ 13

Table 4: Coolant circuit components 10-44 kW installation. ............................................................... 15

Table 5: Coolant circuit components 60-74 kW installation17

Table 6: Biogas circuit components - installation with 2 engines. ....................................................... 20

Table 7: Components connection between reactor and container - water trap .................................. 21

Table 8: Overview of the different types of digestate pumps. *: indicative numerical values based on

a theoretical approach. These values may vary in practice. The different maxima can never occur

together ................................................................................................................................................ 23

Table 9: Parameters on Yield tab on MyBiolectric. .............................................................................. 43

Table 10: Parameters on Gas tab on MyBiolectric. .............................................................................. 45

Table 11: Parameters on the Motor tab on MyBiolectric. ................................................................... 48

Table 12: Parameters on the Nutrition tab on MyBiolectric. ............................................................... 51

Table 13: Maximum daily feeding amount ........................................................................................... 54

Table 14: Parameters on the Net tab on MyBiolectric. ........................................................................ 55

Table 15: Parameters on the Reactor tab on MyBiolectric. ................................................................. 56

Table 16: General information on the Address tab on MyBiolectric .................................................... 59

Table 17: Overview of warnings. .......................................................................................................... 69

Table 18: Overview of cause and solutions for the different warnings. .............................................. 70

Table 19: Overview of all error messages. ........................................................................................... 73

Table 20: Explanation of engine error decision tree ............................................................................ 175

Table 21: Explanation of engine error decision tree 2 .......................................................................... 76

Table 22: Explanation of engine error decision tree 3 .................................................................. 77



Table 25: Explanation of engine error decision tree 12 ........................................................................ 85




Table 29: Explanation of reactor error decision tree ........................................................................... 290

Table 30: Designation of components in Figure 48 ............................................................................... 96

Table 31: Contents of material case and supplied maintenance items. ............................................ 106

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Appendix 4: Supplied parts and service kit

Upon delivery, a material case and cleaning materials are supplied. An overview per type of

installation is given below.

Table 31: Contents of material case and supplied maintenance items.

Description and number per type motor

10 and 11

20-2 and 22-2

22-1 33 40 44 60 74

Tube fuse 5A 10 10 10 10 10 10 10 10

Spark plug spanner 10kW

1 1 0 0 0 0 0 0

Spark plug spanner 20kW

0 0 1 1 1 1 1 1

Carolus screwdriver (+) PZ1

1 1 1 1 1 1 1 1

Carolus screwdriver (+) PZ2

1 1 1 1 1 1 1 1

Carolus spanner size 14-15

1 1 0 0 0 0 0 0

Chain key 1 1 1 1 1 1 1 1

Ventilation key 1 1 1 1 1 1 1 1

Lamp 1 1 1 1 1 1 1 1

Nitrile glove GR10

1 1 1 1 1 1 1 1

Safety goggles 1 1 1 1 1 1 1 1

Spark plug 12 24 16 32 32 32 32 32

Spark plug cap 3 6 0 0 0 0 0 0

Oil filter 10/11kW 4 8 0 0 0 0 0 0

Oil filter 20/22kW 0 0 4 8 8 8 0 0

Oil filter 30/37kW 0 0 0 0 0 0 8 8

Carbon particle collection tray

1 1 1 1 1 1 1 1

Oliekan 1 1 1 1 1 1 1 1

Biolectric engine oil (bottle)

1 2 2 2 2 2 2 2

Tractor 1 1 1 1 1 1 1 1

Bucket 1 1 1 1 1 1 1 1

Fire extinguisher 1 1 1 1 1 1 1 1

Ratchet spanner 13 mm (optional)

1 1 1 1 1 1 1 1

H2S detector (optional)

1 1 1 1 1 1 1 1

Gas mask (optional)

1 1 1 1 1 1 1 1

Extra for lobe pump as digestate pump: adjustable key: 1 extra for

Easy-Start motors: 15A fuses: 10 pieces.

Extra for a fan hood: adjustable key: 1 piece

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Annex 5: CE declaration

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Annex 6: Start-up of the biogas plant

After delivery of a new Biolectric biogas installation or after maintenance work on the reactor of an

existing Biolectric biogas installation, the biogas production in the reactor has to be (re)started. In order

to get the anaerobic digestion process in the reactor up and running quickly, the following step-by-step

plan must be followed:

1) Supply of grafting material

In order to initiate the fermentation process in the reactor, it is important to add quality grafting

material to the reactor. Biolectric advises the user to use hot digestate from a nearby Biolectric

biogas plant as grafting material. If there are no Biolectric installations in the vicinity of the farm,

the user can also start up the biogas installation with hot digestate from another type of reactor.

In order to pump in hot digestate, the manual slide valve and the manual slide valve - outside

drain must be opened. Afterwards, the manual sliding valve-outlet has to be closed.

The more hot digestate is available in the reactor at start-up, the faster the fermentation reaction

will start. Biolectric recommends that at least 50% of the volume of the reactor is supplied with

hot digestate at start-up.

WARNING Always respect the maximum flow rate of 50 m³/h during pumping in order to avoid damage to the reactor.

ATTENTION The user must ensure that the digestate supplied does not contain any impurities that could lead to blockages in, for example, the Biolectric digestate pump. biogas plant

2) Production of biogas in the reactor

Once the reactor is filled with hot digestate, biogas will be produced. However, when a biogas

installation is started up, the gas heaven of the reactor is still filled with a large volume of air.

The mixture of this air and the first biogas produced is not yet suitable for combustion in the

engine and has to be removed from the reactor regularly by opening the foam valve for a few

minutes. The gas buffer in the reactor can be monitored via MyBiolectric.

In order to maintain biogas production, it is important that the digestate in the reactor remains

warm and that the reactor is fed daily with fresh manure. Biolectric recommends switching on

the electric heating during the start-up process of the biogas installation in order to keep the

reactor at the right temperature. During the start-up process, the daily feed should be limited to

2 to 4 tons of fresh manure.

NOTE The composition of the gas mixture in the reactor can also be measured by a Biolectric employee. A measurement of the gas quality indicates whether the quality of the biogas is already high enough to be burned by the engines.

NOTE During the production of the first gas in the reactor, the level in the water trap between the reactor and the container must be properly monitored so that the biogas cannot escape from the reactor.

3) Starting of the engine(s)

The start-up of the engine(s) is only possible if the quality of the biogas in the reactor is high

enough. Usually, the quality of the biogas is good enough after the user has regularly opened

the foam valve for a few days after the hot grafting material has been pumped in to allow the

poor quality gas mixture to escape from the reactor.

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If the gas buffer is filled with suitable biogas, the user can try to start up the engine(s). If the

quality of the biogas is high enough, this gas can be burned in the engine(s). From this moment

on, the engine(s) can produce limited power. The residual heat from the engine(s) is used to

further heat the reactor and the electric heating can be switched off.

If the engine(s) cannot start at the current gas quality, the user must wait at least 12 hours before

attempting a new startup attempt. During these 12 hours, the gas buffer can also be regularly

ventilated.

NOTE If low quality biogas is burned, the desired power of the engine(s) must be adjusted on MyBiolectric via "set power" on the Motor tab. An installation with low quality biogas quality controlled to produce the maximum power will be switched off due to engine error 256.

4) Step up nutrition:

Once the motor(s) are running, the user can gradually increase the daily power supply to the

desired level allowing the motor(s) to run 24 hours a day. The temperature of the digestate in

the reactor must not drop. The system will not pump digestate out of the reactor until the reactor

is filled to the desired level.

Please keep the following points in mind:

1. Entry material

a) Minimum 50 % of the reactor volume.

b) Preferably from a Biolectric biogas installation. Always without contaminants.

c) Maximum flow rate of 50m³/h when pumping in to avoid damage to reactor.

d) Open the manual slide valve and manual slide valve outlet before applying grafting

material. Close the manual sliding gate outside spout after inoculation.

2. Production of biogas in the reactor

a) Switch on the heating.

b) Check level of water trap.

c) Follow the height of the gas buffer and let bad gas escape from the reactor.

d) Feed 2 to 4 tonnes per day so that the reactor does not cool down.

3. Starting of the engine(s)

a) A few days after full gas buffer.

b) In case of engine error 256, try again after 12 noon.

4. Step up nutrition

a) Systematically increase the power supply once the engine is running.

b) Make sure that the reactor temperature does not drop.

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Annex 7: Directive to close the magnetic pressure relief

valve

The purpose of this Directive is to inform the user of a Biolectric biogas plant about safe practices when

closing the magnetic pressure relief valve.

In order to protect the reactor against excessive pressure, every Biolectric biogas plant is equipped

with an automatic overpressure valve in the reactor. This magnetic overpressure valve opens when

the pressure in the reactor exceeds 8 mbar.

WARNING When the pressure relief valve is open, biogas escapes from the

reactor. Biogas may contain toxic hydrogen sulphide (H2S).

Security

Holder magnetic pressure relief valve

Magnetic overpressure valve

Figure 50: Magnetic pressure relief valve mounted in the holder.

DANGER - Biogas may contain the gas H2S. Inhalation of high concentrations of H2S can be fatal.

- Avoid breathing in biogas at all times. Always keep a sufficient distance between the face and the opening in the reactor during maintenance work.

- Always keep a fully covering face mask with adapted filter to filter H2S within reach during maintenance work.

WARNING -Always observe the general safety regulations.

NOTE -In order to inform the user of the risks of H2S, a warning sticker is affixed in the vicinity of the magnetic pressure relief valve. "Danger: Poison gas H2S".

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Material

To ensure safety, Biolectric recommends the use of the following personal protective

equipment:

- Fully covering face mask with adapted filter

- H2S detector.

These personal protection equipment are for sale at Biolectric.

Procedure

1. Turn off the fan that keeps the airhood inflated (Figure 2). This causes the pressure in the gas

buffer to drop by 2 mbar so that less biogas escapes from the opening of the magnetic

overpressure valve.

2. Disconnect the fan before inflation (Figure 2; 2.b). This will reduce the pressure on the gas cap

by 2mbar, so that less biogas flows out of the magnetic overpressure valve.

3. Attach an H2S detector (Figure 51) to your clothing, as close to the face as possible. This sensor

gives a signal if the concentration of H2S exceeds the safety limit. If the detector emits a signal,

it is necessary to wear the face mask with the appropriate filter and stop the maintenance work

until the detector no longer emits a signal. Do not continue the maintenance work until 30

minutes later. Consult the manual of the mask and filters for correct use.

A)

Figure 51: Safety equipment. A) H2S detector; B) full face mask with gas and vapour filter.

4. Clean the magnetic overpressure valve and the holder with a cloth and do not remove residues

of manure, foam or water.

5. Check that all 8 magnets are still attached in the magnetic pressure relief valve (Figure50). If

one or more magnets have disappeared from the pressure relief valve, contact Biolectric's

service department.

6. Place the magnetic pressure relief valve in the holder in the reactor wall. Both the relief valve

and the holder contain magnets to keep both parts firmly in place.

7. Check that the warning sticker 'Danger: Poison gas H2S' is clearly legible. Clean or replace if

necessary.

B)

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Annex 8: Excessive foam production

In the reactor of a biogas plant, a layer of foam can form on top of the digestate. This foam production

is often due to changing conditions in the reactor, for example after feeding fresh manure with too high

a protein content. If this layer becomes too thick, adverse effects may occur on the biogas plant. It is

therefore important to monitor the possible foam layer and take appropriate measures if the foam layer

becomes too thick. Biolectric recommends the following procedure to the user to break down the foam

layer:

1. Split the daily diet into several smaller feeds per day. The maximum number of power supplies

per day is 9. By carrying out several small power supplies per day, the reactor is less disrupted.

2. Adjust the foam breaker settings (option). Via the MyBiolectric platform, the frequency and

period of time the foam breaker is controlled can be set.

3. Adjust the mixer settings. There are 2 options that can or cannot be performed at the same time:

‒ Mix longer. This can be set on MyBiolectric.

4. Add an anti-foaming agent to the reactor in one of the following ways (option):

‒ Disconnect the flexible manure gut at the level of the cellar pump and then pour in the

antifoaming agent. Then reconnect the manure casing and manually feed it by

switching on the cellar pump for 1 minute using the button on the electrical box.

‒ Use the anti-foaming injection pump settings on MyBiolectric to inject anti-foaming

agent into the reactor.

NOTE To prevent corrosion in the anti-foaming injection pump, only oil-based anti-foaming agents may be used. Biolectric distributes two oil-based anti-foaming agents: Biolectric anti-foam agent and Biolectric anti-foam agent maxi.

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Annex 9: Manual of the automatic call system

(optional)

Foreword

This manual describes the settings for the automatic call system in the event of a fire. If the detection

systems in the container of the Biolectric biogas plant detect a fire, the user is automatically informed

via an automatic voice call. It is possible to preset different receivers for this alarm message.

1 Introduction

In case of fire detection in the Biolectric container, the automatic call system will alert the user by means

of a pre-recorded message. The user will be called on the preset GSM numbers. In order to guarantee

the correct operation of this security system, it is necessary for the user to insert an activated SIM card

with sufficient call credit into the automatic call system. Biolectric can under no circumstances be held

liable for any damage resulting from the absence of the automatic emergency call if this is due to or

related to the GSM reception, the SIM card or an insufficient call credit.

The automatic call system must be unlocked before use. This can be done by pressing the MEM button

and then entering the unlock code. This code is set to 1-2-3-4 by default.

2 Settings

a) Unlock the SIM card for use in the automatic call system. This can be done, for example, by

inserting the SIM card into a mobile phone. Unlock the SIM card with the PIN code and

deactivate PIN code protection in the settings menu.

b) Insert the unblocked SIM card into the automatic call system.

c) Set the telephone numbers to receive an automatically generated call in case of fire. A maximum

of 10 phone numbers can be set. Press the MEM key followed by the number of the telephone

number (11, first to 20, last). Then press ENTER and enter the telephone number, then press

ENTER again. e.g. MEM-11-ENTER-0032123456789-ENTER will set the phone number 0032

123 45 67 89 as the first number to be called (place 11) in case of fire.

d) If desired, a personal message can be recorded via the key combination MESSAGE-ENTER-

1-"record message here"-ENTER.

e) The recorded message can be listened to using the MESSAGE-CHECK-1 key combination.

NOTE

The user is advised to always ensure that the automatic call system is working correctly. For example, the correct functioning of the system can be tested monthly by pressing the test button of the fire alarm. After a short period of time, the user would then make an automatic call to the pre-defined must receive a telephone number.

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operating and maintenance manual biolectric pocket biogas

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