MEIKO-GREEN BioMaster 4 PLUS Food Waste Treatment System Instruction Manual

MEIKO-GREEN BioMaster 4 PLUS Food Waste Treatment System

Product Information:

The PLUS Food Waste Treatment System is a machine designed to efficiently and safely treat food waste. It comes with operating instructions that the user must read carefully before use. The instructions contain information on installation, commissioning, and usage of the machine.

Delivery Contents:

• PLUS Food Waste Treatment System
• Operating Instructions

Liability and Warranty:

The manufacturer is liable for any defects or damages that may arise from the machine’s design, materials, or workmanship. The manufacturer provides a warranty period for the machine from the date of purchase, subject to the terms and conditions stated in the operating instructions.

Product Usage:

Notes to the User:

The user must read and follow the operating instructions before using the PLUS Food Waste Treatment System.

Transport:

When unpacking the machine, ensure that all components are present and undamaged.

Installation:

Follow the instructions to unpack and set up the machine. Connect the electrical supply, cold water, and biomass transport pipe as directed in the operating instructions.

Commissioning:

Before commissioning the machine, ensure that all safety information is followed. Vent the water supply, run pump tests, and check for leaks. Carry out a test run with pure water before handing over the machine.

Note: Only use the PLUS Food Waste Treatment System for its intended purpose, as described in the operating instructions. Use of the machine for any other purpose may result in damage to the machine or injury to the user.

Notes to the user

The purpose of these operating instructions

These operating instructions

• Are included in the delivery of every BioMaster®.
• Describe how to operate the machine, remedy minor faults, maintain and clean the BioMaster®.
• Provide important information on how to operate the BioMaster® safely, properly and economically. Observe the notes included to avoid hazards, repair costs and downtime, and to increase the reliability and service life of the BioMaster®.

ATTENTION
Please read the operating instructions before commissioning the BioMaster®. It is imperative that you observe the safety instructions.

ATTENTION
Always keep these operating instructions where the BioMaster® is being used. The operating instructions must be freely accessible to the operating and maintenance personnel.

Ways we present the information

Action steps
The steps to be performed by the operating personnel are shown as a numbered list. The sequence of steps must be observed. The system’s response to each action by the operator is marked with an arrow.
Example:

1. Operator action step 1
   →System response to operator action

Lists
There is no fixed sequence for lists. They are displayed as a list of points to check off.

Example:

• Point 1
• Point 2

Liability and warranty

Delivery contents

Upon receipt of the delivery, please check immediately whether the contents of the delivery correspond with the shipping documents. MEIKO GREEN Waste Solutions GmbH does not assume any liability for defects and will not pay compensation for defects claimed later on. Complaints: Upon receipt of the delivery, please check immediately whether the contents of the delivery correspond with the shipping documents. MEIKO GREEN Waste Solutions GmbH does not assume any liability for defects and will not pay compensation for defects claimed later on. Complaints:

• Any noticeable damage caused in transit must be reported in writing immediately and within eight days, as per our terms and conditions.
• Any hidden defects must be reported immediately when they are discovered.

Liability
The information, data and notes specified in the operating instructions correspond to the latest version at the time of printing. No claims for BioMaster® systems which have already been delivered may be asserted based on these statements, illustrations or descriptions.
We accept no liability for damage or operational malfunctions caused by improper use. Please observe the notes in chapter 3.2 ‘Intended uses’.

Warranty
The warranty conditions can be found in the general terms and conditions and the warranty provisions of MEIKO GREEN Waste Solutions GmbH.
Please notify MEIKO GREEN Waste Solutions GmbH in writing of any warranty claims immediately after the defect or fault has been detected.

Copyright
No texts and images in this publication may be reproduced, stored in a data system or transmitted in any way. This includes extracts. Any duplication, distribution, storage, transmission, broadcast, reproduction or passing on of contents without the written permission of MEIKO GREEN Waste Solutions GmbH is expressly prohibited.

The copyright and all associated rights lie with MEIKO GREEN Waste Solutions GmbH.
© 2021 MEIKO GREEN Waste Solutions GmbH, Englerstr. 3, 77652 Offenburg.

Safety information

Presentation of safety information

• DANGER
  Indicates a hazard with a high degree of risk which, if not avoided, will result in death or serious injury.

•   WARNING
  Indicates a hazard with a moderate degree of risk which, if not avoided, will result in death or serious injury.

• CAUTION
  Indicates a hazard with a low degree of risk which, if not avoided, will result in minor or moderate injury.

• ATTENTION
  This describes a requirement to act in a certain way or carry out a specific activity to ensure the BioMaster® is handled safely and damage to property is avoided.

• NOTE
  Information on operating the BioMaster® consisting of an info pictogram and a worded note.

Intended uses

ATTENTION
Only use the BioMaster® as intended and when the machine’s condition does not present any safety-related issues.
This is the only way to ensure the operational safety of the BioMaster®.
The BioMaster® is only to be used commercially for filling with and grinding raw or-ganic and food waste of the kind that is usually generated in commercial kitchens, canteens, hotels, food service and communal catering. The ground waste is mixed with water and pumped out of the BioMaster® into a storage tank using a closed sys-tem. It is then ready to be collected and taken to a biogas plant where it can be recy-cled and used to generate energy.
The parameters and environmental conditions defined in chapter 13 must be strictly adhered to.
Kitchen waste (cleaning/raw organic waste) and food waste must always be inserted mixed.

What may be disposed of in the system?

• • Food waste
• Fully liquid deep-frying oil (which is also liquid when cold)

Allowed in small quantities

NOTE
For the best possible processing, use the pre-grinding unit available as an optional accessory.

• Raw organic waste – mix and process a max. 50 % proportion with nor-mal, wet food waste.
• Expanding food (mix and process with normal, wet food waste. Percent-age of expanding substances: max. 50 %).
  • Cereals, such as wheat, barley, rice
  • Semolina
  • Pasta, dough
  • Sugar
  • Flour
  • Thick fruit peels (e.g. from citrus fruits, bananas)
• Skin from marine fish, mussels, shellfish and crustaceans:
• Mix and process with normal, wet food waste. Percentage skins from ma-rine fish, etc.: max. 20 %.
• Used coffee grounds – mix and process max. 20% with normal, wet food waste.

What may not be disposed of in the system?

• Inputs with a temperature above 40 °C
• Stone fruits and tropical fruits with large stones/seeds. The stones cannot be processed. Remove after cycle.
• Bones of all kinds, including raw or cooked marrowbones
• Pineapple scoops (= pineapple stalks/leaves) and corn husks (leaves covering the corn cob)
• Wooden objects, such as wooden skewers, toothpicks or the like
• Metal or plastic objects such as dishes, cutlery, tools
• Textiles, such as serviettes, towels or the like
• Film, plastic, packaging
• Detergents
• Inorganic substances in general

Misuse

• Connecting to an on-site water pipe with contaminated water
• Improper work on the installation
• Inputting unauthorized waste
• Operator error
• Irregular or poor cleaning
• Excessive demands
• Exceeding the permissible operating parameters
• Operation at temperatures < 5°C and > 40°C
• Changing the operating parameters
• Unacceptable environmental conditions, such as strong magnetic fields, electric currents, radiation or strong vibrations
• Use of spare and wear parts or auxiliary materials not approved by the manufacturer
• Interference by third parties
• In-house extensions, conversions or modifications to the installation
• Irregular or inadequate cleaning (mold, bacteria, odors, corrosion, pipe blockage, damage to installation components).

Risks in dealing with the BioMaster®

The BioMaster® has been manufactured in line with the current state of the art and the established safety-related regulations. Nevertheless, its use may give rise to risks and restrictions:

• To life and limb of the operator or third parties
• To the BioMaster® itself
• To other tangible assets

In order to operate the BioMaster® safely and without errors, the operator must possess a complete knowledge of the safety instructions and the safety regulations.

DANGER
If you open the control cabinet, the terminal box or the casing of the Bio- Master®, live parts may become accessible. Touching them can lead to serious injury or death!
Work on the electrical equipment may only be carried out by qualified electricians.
Check the electrical equipment in the installation regularly. Remove loose connections and fried cables immediately.
Always keep the control cabinet closed. Access is only permitted to authorized personnel with keys or tools.

DANGER
The BioMaster® has been built to comply with degree of protection IPX5 and is protected against splash water and water jets.
The interior can be cleaned with a shower head or normal jet water. Do not use strong water jets or a pressure washer.

DANGER
WARNING magnetic fields!
The BioMaster® contains strong magnets.
Persons with cardiac pacemakers or implanted defibrillators must not be in the vicinity of the BioMaster®.

WARNING
If irregularities in the work sequence, unusual noises or malfunctions occur, immediately trigger an emergency stop and inform the responsible specialist personnel. No unauthorized manipulation by the operating personnel!

  WARNING
If you open the casing of the BioMaster®, pressurized lines may become accessible. Removing pressurised piping can cause serious injury.
Maintenance and repair work may only be carried out by qualified and authorised specialist personnel.

WARNING
When the lid is closing, the force switches from pressure to tension for the final section. There is a danger of crushing under the lid.
When closing the lid, hold onto the railing area, do not reach between the lid and the casing.

WARNING
The sharp edges of the grinder and the optional raw organic waste driver/pre- shredder present a risk of cutting.
Work carefully, only touch sharp-edged parts while wearing protective gloves.

WARNING
There is a risk of slipping on wet or dirty floors.
If you slip, you may accidentally come into contact with the sharp edges of the stationary grinder and the optional raw organic waste driver.
Keep your work area clean. Close the lid of the BioMaster® when it is out of use for a longer period.

WARNING
There is a risk of scalding when hot food is poured in.
Allow hot liquids to cool to below 40 °C before pouring, wear protective clothing when filling.

CAUTION
The BioMaster®’s A-scaled sound pressure level is under 70 dB(A). Depending on local conditions, a higher sound pressure level may be produced, causing noise-induced hearing loss. For these areas, the op-erating company must protect the operating personnel with appropriate protective equipment and protective measures in accordance with Noise Protection Directive 2003/10/EC.

Operator’s responsibilities

The operator undertakes to only allow those persons to work on the BioMaster® who:

• Are familiar with the foundational local regulations on safety in the work-place and accident prevention.
• Have been instructed in how to work with the BioMaster®.
• Have read and understood these operating instructions.

The operator also undertakes to:

• Comply with the requirements of EC Directive 2009/104/EC on the use of work equipment.
• Provide the prescribed personal protective equipment.
• Inform and train personnel on the location of the fire alarm system and the firefighting options.

Personnel responsibilities
All persons entrusted with work on BioMaster® undertake to:

• Observe the foundational local regulations on safety in the workplace and accident prevention.
• Read and observe the operating instructions before starting work.

Personnel qualifications

Only qualified, authorised and inducted personnel may work on the BioMaster®.
Qualified personnel who, because of their training, experience, instruction and knowledge of the relevant standards, regulations, accident prevention instructions and operating conditions, have been authorized by the person responsible for the safety of the BioMaster® dishwashing machine to carry out the necessary activities. Qualified personnel are also aware of the possible dangers and how to avoid them.

Personnel are classified using a qualification matrix. Each employee may only carry out activities using the BioMaster® that correspond to his or her level of training according to the qualification matrix. Any personnel undergoing training are only allowed to work on the BioMaster® under the supervision of an experienced person.
Specialist personnel must be trained in accordance with their area of responsibility. Completed inductions are documented in training lists and records. These show who has been trained in what area and when.

| Inducted personnel| Specialist personnel with technical training| Electricians| Supervisor with correspond ing expertise
---|---|---|---|---
Transport| X| X| —| X
Installation| | X| X| X
Commissioning| —| X| X| X
Operation| X| X| X| X
Fault finding| X| X| X| X
Troubleshoot ing, mechanical|

—

|

X

|

—

|

X

Troubleshoot ing, electrical|

—

|

—

|

X

|

—

Maintenance| X| X| X| —
Corrective maintenance|

—

|

X

|

X

|

—

Decommission ing, storage|

X

|

X

|

X

|

X

Key: X = allowed, — = not allowed

Safety devices

DANGER
Operate the BioMaster® only if all safety and protective devices are fully present and functional.

In the event of faulty safety and protective devices:

• Switch off the BioMaster® immediately.
• Secure it against switching back on.
• If necessary, disconnect the power supply from the electrical current.

Before each time you start the BioMaster® every time, all protective devices must be properly installed and functional.
Protective devices may only be removed once all parts have stopped moving and the BioMaster® has been secured against restarting.
The emergency stop button and protective devices must be tested regularly to en-sure they work reliably.

The BioMaster® has the following safety and protective devices:

• Emergency stop button on the operating panel
• Allpole disconnecting main switch on the operating panel
• Fault indication lights on the operating panel
• Lockable service hatch
• Protective cladding on all sides
• Protected against water jets according to IPX5
• Overheating protection
• Two safety contact switches connected in parallel in the lid guide shaft. The BioMaster® works only with the lid closed.
  When the lid is opened, the grinder in the BioMaster® is stopped immediately.

Safety marking
ATTENTION
Please note all warning and safety instructions on the BioMaster®, as well as other markings.
Maintain the legibility of all safety and danger notices on the BioMaster® and replace them if necessary.

The following pictograms and warning notices are on the BioMaster®:

WARNING magnetic fields!
The BioMaster® contains strong magnets.
Persons with cardiac pacemakers or implanted defibrillators must not be in the vicinity of the BioMaster®.
DANGER
When closing the lid, there is a risk of crushing between the lid and the casing of the BioMaster®.

WARNING dangerous electric voltage.

The BioMaster® has been built to comply with degree of protection IPX5 and is protected against splash water and water jets.
The interior can be cleaned with a shower head or normal jet water. Do not use strong water jets or a pressure washer.

The rating plate is located inside the casing, on the inner panel behind the door.

Transport

WARNING
There is a danger of the BioMaster® tipping over during transport! This could cause severe personal injury and damage to property. Secure the BioMaster® against tipping during transport.

Perform transport with care. Observe transport instructions on the packaging.
In order to avoid damage to the device and life-threatening injuries to those involved when moving the system, observe the following requirements:

• Only have transport work performed by qualified persons observing the safety instructions.

• Only transport the device in its original packaging, otherwise it will not be stable during transport. Square timber frame (pallet) has additional cross struts at the bottom for stabilization on lifting forks during transport. Only transport with lift truck!

When transporting the BioMaster®, make sure that you:

• Please note the environmental conditions defined in chapter 13, ‘Technical data.’
• Avoid strong mechanical impacts (shocks, vibrations, etc.)
• Switch off the BioMaster® at the main switch before transport, even if it is only a minor change of location.
• Protect the BioMaster® from direct sunlight, frost and other extreme cli-matic conditions.
• Avoid extreme climatic changes (e.g. transport from a lorry to a heated room at high humidity in winter).
• Close all hatches and lids before transport. Secure them against unintentional opening.
• When transporting the BioMaster®, follow the general safety rules for transporting loads.
• When considering the permissible floor loading for transport, take into ac-count both the weight of the BioMaster® and the self weight of the means of transport.
• Do not lift and transport the BioMaster® manually, instead only using a pal-let truck or forklift. The load capacity must be > 170 kg, the fork length > 600 mm. Drive both forks completely under the BioMaster®, paying attention to components protruding from the floor.
• When setting down, load all four feet evenly, do not tip the BioMaster® from the truck transport.

Unpacking

• First remove the tapes and the plastic film using suitable tools.

• Unscrew the two stoppers from the pallet.

• Have two people lift the device from the pallet.

Removing the protective films
After unpacking the product, remove the protective films from the housing parts and clean the stainless steel surfaces with a suitable detergent.

Structure and function

Function

The BioMaster® serves as the infeed station in the system. The system offers an economically and ecologically sensible, hygienic solution for recycling kitchen waste and food waste. The system is used in commercial kitchens, canteens, hotels, food service and communal catering. The BioMaster® converts the waste produced into a homogenous biomass.

Kitchen waste and food waste are fed into the loading chute of the BioMaster® and homogenised in the BioMaster® using the water contained in the waste and adding process water.

Additional water can be fed in via a cleaning nozzle to cleaning the loading chute and to process extremely dry or very light waste.

The resulting biomass is pumped out of the BioMaster® and transported via a closed pipe system to the storage tank.
When using the BioMaster® as an infeed station of a vacuum plant, the biomass is conveyed through the pipe system by means of vacuum.

Main group BioMaster®

1. Lid rail
2. Lid with closing magnet
3. Lid seal
4. Safety contact switch
5. Loading chute
6. Operating panel
7. Lockable service hatch with control cabinet
8. Adjustable feet with anti-slip/vibration plate and 15 cm ground clearance

Control elements

No. Operating element / Function

10. Main switch
    Switch on, position ON; switch off, position OFF.

11. EMERGENCY STOP, emergency stop button
    Immediate shutdown of the BioMaster® in dangerous situations.

12. STANDBY function
    Lights up when the lid is closed and the main switch is in the ON position.

13. Tank level 80%, confirm key for level indicator at 80 %
    Button flashes when the level sensor in the tank detects a fill level of 80%. Button lights up after confirmation. Contact disposal firm to empty tank!

14. START
    The button lights up during the working cycle.

15. ERROR, fault indication light
    Lights up in the event of malfunction, evaluation in chapter 0.

16. TANK LEVEL 100%, level indicator 100%
    Button lights up when the storage tank is 100% full. The BioMaster® can no longer be started. Empty storage tank immediately.

17. PUMP, Switch on pump
    Manual pumping out of loading chute content. Button lights up when pump is in operation.

Loading chute

• 31 Grinder
• 32 Pre-grinding unit mount
• 33 Process water nozzle
  Optional cutlery catcher magnet on outside of loading chute

Technical equipment

• 40 Drinking water module with pressurized water pump
• 41 Pump motor
• 42 BioPump®
• 43 Water distribution
• 44 Process water nozzle dosing valve
• 45 Grinder motor
• 46 Transport pipe connection, PE D 63 – screw connection
• 47 Overload circuit breaker
• 48 Control cabinet

Product Installation

Unpacking and setting up

• Carefully remove the transport packaging.
• Check the delivery includes everything it should.
• Report obvious transport damage immediately.
• Observe the permissible floor load when selecting a location.
• Set the BioMaster® on a solid, vibration-free surface.
• Please note the environmental conditions defined in chapter 13, ‘Technical data.’
• Adjust the working height using the BioMaster®’s adjustable feet.
• Set up the BioMaster® using a spirit level.
• Ensure that all machine feet and adjustable feet are resting firmly on the floor.

Connections
Electrical connection

DANGER
Only use cables standardized for the correct power rating and only connect the BioMaster® to a fused power supply as per the applicable standards. Use a socket (CEE 16 amp) with IP67 degree of protection. In case of doubt, con-tact the authority responsible for the power supply in your company.

WARNING
The BioMaster® may only be connected by a qualified electrician.

ATTENTION
The machine wiring is aligned for a clockwise rotation field. Before turning on the power to the BioMaster®, check whether the power supply runs a clock- wise rotation field.
Note the color of the wires.

ATTENTION
Please note the information on electrical connections provided in chapter 13, ‘Technical data.’

Cold water connection

• WARNING
  The BioMaster® may only be connected by qualified specialist personnel.

• ATTENTION
  Wash the on-site water pipe before connecting until clear, clean water flows out permanently.
  Dirt, turbidities and foreign particles such as sand and small pebbles must be flushed out as they can damage the valves of the BioMaster®.
  Damage caused by dirty water will void the manufacturer’s warranty.

• ATTENTION
  Risk of corrosion!
  Do not use osmosis or demineralized water.
  The hardness of the added water shall not exceed 8 dH or 1.43 mold/l CaCo3.

• ATTENTION
  Connect the BioMaster® to the water supply in accordance with local regulations.
  Observe the relevant country-specific water regulations.
  For USA/Canada only:
  This equipment is to be installed with adequate backflow protection that com- plies with federal, state, or local codes having jurisdiction.

• ATTENTION
  Observe the connection information provided in chapter 13, ‘Technical data.’

Connecting the biomass transport pipe

• Use the screw connection to connect the BioMaster® to the transport pipe installed on site. The union nut is on the BioMaster®.
• Screw connection: PE DN56 PN5
• Electrofusion socket: DN56 (max. 45° arc)

Commissioning

Safety information
DANGER
Only commission the BioMaster® when all safety and protective devices have been fully installed.

Cancel commissioning if:

• A pipe or other parts are damaged.
• The BioMaster® is not working properly even though you have been operating it according to the operating instructions.
• You hear unusual noises from the loading chute.
• Water escapes.

DANGER
WARNING magnetic fields!
The BioMaster® contains strong magnets.
Persons with cardiac pacemakers or implanted defibrillators must not be in the vicinity of the BioMaster®.

WARNING
The BioMaster® may only be commissioned by qualified and authorized personnel.

WARNING
When the lid is closing, the force switches from pressure to tension for the final section. There is a danger of crushing under the lid.
When closing the lid, hold onto the railing area, do not reach between the lid and the casing.

CAUTION
The BioPump® on the BioMaster® must never run when dry. This may cause ir- reparable deformations and damage in and to the BioPump®. MEIKO GREEN Waste Solutions GmbH accepts no liability whatsoever for such damage.

Process water quantity

ATTENTION
Do not close or adjust the process water nozzle!
It has been optimally adjusted to your individual operating conditions.
If the water supply is too low, there is an increased risk of clogging in the Bio-Master® and in the system.

The homogenization technology enables the efficient conversion of food waste into pulpy biomass with simultaneous volume reduction.

By using the waste’s own water, the addition of process water can be kept as low as possible.
The required amount of water to add depends largely on the type of food waste and the length of the transport and extraction pipe. MEIKO GREEN Waste Solutions GmbH adjusts the settings to the individual customer requirements during commis-sioning. Settings can be readjusted during maintenance if necessary.

Venting the water supply, pump test run, leak check

1. Switch on the BioMaster® at the main switch – position ON.
2. The STANDBY button lights up green when the lid is closed.
3. Make sure that the emergency stop button is unlocked.
4. Make sure that the on-site ¾” water valve is fully open and that water is making it to the BioMaster®.
5. Open the mini ball valve at the water distribution system in the interior of the BioMaster®.
6. Open the lid of the BioMaster®. Check that no objects (e.g. tools, packaging material, etc.) have been left in the loading chute.
7. Fill the loading chute with 10 liters of fresh water.
8. Press the white PUMP button. Keep it pressed until the loading chute is completely empty.
9. Then check the water distribution and the connection on the transport pipe for leaks.

Carry out test run with pure water

1. Close the lid of the BioMaster®.

2. Press the green START button.

   • →  The START button lights up.

   • →  The automatic homogenization cycle starts. The pressurized water pump, BioPump® and grinder start automatically with the preset sequence and duration.

   • →  The white PUMP button lights up when the BioPump® is in operation.

   • →  During the cycle, the preset amount of process water is introduced into the homogenization.
     ATTENTION
     If you hear unusual noises from the loading chute, switch off the Bio-Master® immediately by pressing the EMERGENCY STOP button. Then check the contents of the loading chute for foreign substances.

   • → When the homogenization cycle finishes, the START and PUMP buttons go out. The BioMaster® switches off automatically.

3. Then check the water distribution and the connection on the transport pipe for leaks again.

4. When all cycles have been completed without any problems, the Bio-Master® is ready for regular use.

Handover and commissioning report

• → Fill in the ‘Handover and commissioning report’ printed in chapter 14.

Operation

Safety information

DANGER
WARNING magnetic fields!
The BioMaster® contains strong magnets.
Persons with cardiac pacemakers or implanted defibrillators must not be in the vicinity of the BioMaster®.

Switching on

CAUTION
Only switch on the BioMaster® if the service hatch at the front is locked.

1. Fully open the stop valve on the water supply.
2. Switch on the main switch – ON position.

When the lid is closed, the STANDBY indicator lights up green. After a few seconds, the BioMaster® is ready for operation.

If the red ERROR fault indication light lights up, the BioMaster® is not ready for operation.
Possible causes can be found in chapter 0.

Opening and closing the lid

ATTENTION
Observe the following safety instructions whenever opening and closing the lid!

WARNING
When opening, there is a risk of crushing under the lid.
If you release the lid in the lower quarter when opening it, it closes automatically again.
Guide the lid by hand until it is fully open; do not reach between the lid and the casing.

ATTENTION
The half-opened lid is raised with a jerky movement by the internal gas pressure spring.
The lid could be damaged in the process.
Guide the lid by hand until it is fully open.

WARNING
When closing, there is a danger of crushing under the lid.
The lid closes automatically in the lower quarter.
When closing the lid, hold onto the railing area, do not reach between the lid and the casing.

Filling

1. Lift the lid by the lid rail and open it as far as it will go.
   WARNING
   There is a danger of crushing when opening the lid!

2. Fill the loading chute to no more than the -MAX- level marking.
   The marking indicates the maximum permissible filling level.
   NOTE
   For larger quantities of liquid, pour into the empty loading chute.
   ATTENTION
   Please note the information in chapter 3.2 ‘Intended uses’.
   WARNING
   There is a risk of scalding when hot food is poured in.
   Allow hot liquids to cool to below 40 °C before pouring, work carefully, wear protective clothing when filling.
   WARNING
   If you would like to insert food waste only infrequently or just a little food, close the lid between occasions if possible.
   If you slip, you may accidentally come into contact with the sharp edges of the grinder and the optional raw organic waste driver.

3. When the loading chute is full, close the lid.

WARNING
There is a danger of crushing when closing the lid!

Starting the automatic homogenization cycle

Note
Start the BioMaster® only when the loading chute is sufficiently filled. Orientate yourself at the level marking -MAX- in order to save consumption costs.
Observe the information in chapter ‘Filling’.

1. Press the green START button.

   • → The START button lights up.
   • → The automatic homogenization cycle starts. The pressurized water pump, BioPump® and grinder start automatically with the pre-set sequence and duration.
   • → The white PUMP button lights up when the BioPump® is in opera- tion.
   • → When the homogenization cycle finishes, the START and PUMP buttons go out. The BioMaster® switches off automatically.
   • → The STANDBY indicator lights up green.
     ATTENTION
     If you hear unusual noises from the loading chute during the homogenization cycle, switch off the BioMaster® immediately by pressing the EMER-GENCY STOP button. Check the contents of the loading chute for foreign substances and remove them.

2. When the STANDBY indicator lights up, open the lid.

3. If the loading chute is extremely dirty, you can perform the cleaning procedure described in the chapter 8.7.

Pumping out contents of loading chute

Note
Pour larger quantities of liquid, e.g. soup or cleaning water, into the empty loading chute. Pump them out without a homogenization process.

1. Press the white PUMP button. Keep it pressed until the loading chute is completely empty.
2. When the button is released, the pump stops and the PUMP button goes out.

Daily cleaning

ATTENTION
Clean the BioMaster® thoroughly at the end of the shift every day. Irregu-lar or improper cleaning can lead to the formation of mold and bacteria, unpleasant odors, corrosion, pipe blockages and damage to the pump impeller. Only use suitable, biodegradable agents in the dosage recommended by the manufacturer.

1. Rinse or spray the loading chute (if a cleaning hose is provided by the customer). Make sure your water consumption is sparing.

2. Switch of the BioMaster® at the main switch – position OFF.

3. Open the lid.
   WARNING
   There is a danger of crushing when opening the lid!

4. Thoroughly clean the loading chute, the area around the grinder, the lid, the seal on the lid and the casing surface on BioMaster® using hot water, sufficient biodegradable detergent (fat solvents) and sponge cloth.

5. Make sure that all critical points, such as the lid seal and loading chute, are thoroughly cleaned of grease and residues.

6. Wipe all cleaned areas dry.
   WARNING
   The sharp edges of the stationary grinder and the optional raw organic waste driver/pre-shredder present a risk of cutting.
   Work carefully, only touch sharp-edged parts while wearing protective gloves.

7. Close the lid.
   WARNING
   There is a danger of crushing when closing the lid!

Weekly cleaning

ATTENTION
Clean the interior of the BioMaster® once a week.

1. Clean the BioMaster® as described in chapter 8.6 ‘Daily cleaning’.

2. Get the key for the service hatch from the designated person.

3. Make sure that the BioMaster®’s main switch is switched off.

4. Open the service hatch.
   DANGER
   The BioMaster® has been built to comply with degree of protection IPX5 and is protected against splash water and water jets.
   The interior can be cleaned with a shower head or normal jet water. Do not use strong water jets or a pressure washer.

5. Clean the side walls and the inside of the service hatch with hot water, sufficient biodegradable detergent (fat solvents) and a sponge cloth.

6. Wipe all cleaned areas dry.

7. Lock the service hatch and give the key to the designated person.

8. Switch on the BioMaster® at the main switch – position ON.

9. Open the lid.
   WARNING
   There is a danger of crushing when opening the lid!

10. To minimize the risk of pipe blockage, clean the transport pipe by washing it with 15 liters of maximum 40°C hot water:
    Pour the hot water carefully into the loading chute.

11. Press the white PUMP button. Keep it pressed until the loading chute is completely empty.

12. Wipe and dry the loading chute, the grinder area, the lid, the lid seal, and the casing surface on the BioMaster® afterwards.
    

13. Check the vacuum ventilation gap at the rear of the lid seal. The gap must be at least 2 cm wide. If necessary, move the seal by hand on both sides until there is a 2 cm gap.

14. Close the lid.

WARNING
There is a danger of crushing when closing the lid!

Measures in case of longer installation standstill

NOTE
Before the installation is shut down for more than two days, the following additional measures must be taken:

1. To minimise the risk of pipe blockage, clean the transport pipe by washing it with maximum 40°C hot water:
2. Pour the hot water carefully into the loading chute up to the ‘Max.’ marking.
3. Press the white PUMP button. Keep it pressed until the loading chute is completely empty.
4. Repeat this procedure several times, if necessary, depending on the length of the transport pipe to the storage tank, until the pipe has been completely flushed.

Switching off **

**

NOTE
Switch off the BioMaster® for shorter downtimes, too, e.g. when changing shifts, overnight or on weekends.

5. Depending on the duration of the downtime, clean the BioMaster®.
   6. Switch of the BioMaster® at the main switch – position OFF.
   7. The STANDBY indicator goes out.
   8. Close the water supply stop valve.

Fault finding
WARNING
If irregularities in the work sequence, unusual noises or malfunctions occur, immediately trigger an emergency stop and inform the responsible specialist personnel.
No unauthorised manipulation by the operating personnel!

Any troubleshooting which goes beyond the simple inspection of the in-put loading chute and the grinder may only be carried out by qualified and authorized personnel.

• Is the machine connected to the power supply?
• Is the main switch switched on?
• Is the EMERGENCY STOP button unlocked?
• Are the necessary fuses operational?

• Is the storage tank full and is the ‘Fill level indicator 100 %’ lit up red? Have the storage tank(s) emptied immediately.
• Is the EMERGENCY stop button unlocked?
• Is the red ERROR fault indication light lit up? (See next item).
• Is the lid properly closed? The STANDBY indicator light must be lit up.

The ERROR fault indication light is continuously lit up|

• Overheating of the pump, mill motor or control unit.
  • Check the mill and pump.
  • Check the motor temperature.
• If there is no fixed connection: The BioMaster®’s electrical plug is not correctly inserted in the socket.
  • Check the machine plug.
  • Check whether the plug screw connection is tightened.
• Grinder jammed or motor overloaded.
  • Check loading cute contents for foreign matter.
  • Check that the grinder can be rotated using an unlock- ing key.
  • Remove foreign matter.
• Open the service hatch and set the overload circuit breaker to ON.

Biomass is not pumped out of the loading chute|

• BioPump® is blocked.
• With the lid open, press the PUMP button for about five seconds and observe the fill level in the loading chute. If the fill level sinks, repeat the procedure until the loading chute is emptied and the BioPump® is free again.
• If the fill level remains the same, the grinder, BioPump® or transport pipe is blocked. If this is the case, call a technician for help.
• Check whether a foreign object (plastic, bandage, cloth, etc.) is blocking the grinder.
• The biomass in the machine is too dry and therefore cannot be pumped away. Try filling it with hot water.
• Any replacement of the pump impeller should only be carried out by trained personnel.

The loading chute is emitting an unusual noise|

• Stop the BioMaster® with the EMERGENCY STOP button, check loading chute contents for foreign objects (cutlery, etc.)
• Remove foreign matter.

The grinder no longer rotates.

WARNING

|

• Switch off the main switch – OFF position. Completely clear the loading chute.
• Switch on the main switch – ON position.
• Pump out the remaining liquid by pressing the PUMP button.
• Switch off the main switch – OFF position.
• If necessary, remove jammed solid parts/foreign materials with the aid of a suitable tool.

• Turn the jammed grinder forcefully to the left and right with the unlocking key until the grinder is able to move again.
• Then rinse the BioMaster® with hot water and pump the water out again by pressing the PUMP button.

Maintenance

Safety information

DANGER
If you open the control cabinet, the terminal box or the casing of the Bio- Master®, live parts may become accessible.
Touching them can lead to serious injury or death!
Check the electrical equipment in the installation regularly. Remove loose connections and fried cables immediately.
Always keep the control cabinet closed. Access is only permitted to authorized personnel with keys.
Only operate the BioMaster® at the prescribed voltage and frequency. Only replace fuses with fuses of the same specifications.

WARNING
If you open the casing of the BioMaster®, pressurized lines may become accessible. Removing pressurized piping can cause serious injury.
Inspect all cables, hoses, hose lines and screw connections regularly for signs of damage or aging. In the event of faulty parts, take the BioMaster® out of operation immediately.
Never repair damaged hoses or hose lines. Only replace them with original spare parts.

WARNING
Maintenance of the BioMaster® may only be carried out by specially trained personnel. Work on the electrical equipment may only be carried out by trained electricians.
Note the information in the Maintenance plan.

WARNING
Switch off the BioMaster® at the main switch before starting work. Close the water supply.
Secure all utilities against unintentional startup.

WARNING
After completion of maintenance work:

• Check all screw fittings which were unscrewed are fitted securely.
• Check all pipes and connecting elements for leaks.
• Mount and install all covers and safety devices and check that they function correctly.

ATTENTION
All maintenance work is carried out by MEIKO GREEN Waste Solutions GmbH under a maintenance contract.
If you have not concluded a maintenance contract, you are responsible for the timely performance of the prescribed maintenance and inspection work. Adjust the maintenance intervals to your operating conditions.
Damage caused as a result of neglected or improper maintenance will void the manufacturer’s warranty.

Maintenance plan
This work may only be carried out by qualified specialist personnel.
❌This work may be carried out by inducted personnel.

Work to be carried out| Commissioning| Daily| Weekly| 1000 h, minimum every 6 months| 2000 h, minimum every 12 months
---|---|---|---|---|---
Cleaning the BioMaster® Visible surfaces, loading chute, grinder area, lid, lid seal, casing surface| ❌| ❌| | |
Cleaning the interior of the Bio- Master®

Wipe the service hatch and side walls with a damp cloth

| ❌| | ❌| |
Check the pump, incl. impeller| | | | |
Check the lid seal for wear| | | | ❌|
Clean the transport pipe by washing it with 15 liters of hot water| | | ❌| |
Check all functions| ❌| | | |
Adjust and check process water quantity| | | | |
Visual check for damage| ý| | ❌| |
Cover fuse test| | | | |
Brake motor test| | | | |

Corrective maintenance

WARNING
Repair work on the BioMaster® may only be performed by specialist personnel trained by the manufacturer or by persons authorised by the manufacturer.
Take the BioMaster® out of service immediately in the event of a fault that can-not be rectified using chapter 0. Notify MEIKO GREEN Waste Solutions GmbH.

Decommissioning, storage

WARNING
Switch off the BioMaster® at the main switch before decommissioning. Close the water supply.
Secure all utilities against unintentional start-up.

  WARNING
The BioMaster® may only be decommissioned by trained specialist personnel.
Work on the electrical equipment may only be carried out by trained electricians.

ATTENTION
Store the BioMaster® according to the environmental conditions specified in chapter 13 ‘ Technical data’.

Disposal

CAUTION
The components of the BioMaster®, all packaging, operating and auxiliary materials and replacement parts must be disposed of safely and in an environmentally friendly manner in accordance with the applicable local laws and regulations.
Disposing of the BioMaster® generates only working or auxiliary materials which are customary in mechanical engineering.

ATTENTION
Observe all safety in the workplace and environmental protection regulations valid at the time of disposal.
The operator is responsible for proper disposal and compliance with all applicable local regulations.

Technical data

General

Specific designation| BioMaster® 4 PLUS
Width x depth x height [mm]| 700 x 700 x 865-935
Height adjustable via the adjustable feet
Weight [kg]| approx. 195
Chute volume [l]| 40
Filling height| Continuously variable
Capacity| > 1000 kg/hour in batch mode
Sound emission value

(operation at no load, measuring position 1 m away)

| ≤ 70 dB (A)
Electrical connection
Connected electrical load [V]| 3 x 400 V + PE
Connection| Socket (CEE 16 A)
Frequency [Hz]| 50
Power [kW]| 4.5
Fuse protection| 16 A / FI circuit breaker TYPE A with 30 mA trip current
Rotating field| Clockwise rotation field
Degree of protection| IPX5
Water connection
On-site specifications| Stop valves with ¾” screw connection, easily accessible for regular use
Cold water connection| ¾” external thread
Line pressure [kPa]| 200 – 800
Filter size for cold water connection| ≤ 100 µm
Max. water hardness| 14° dH (German hardness) 25°fH (French hardness) 2.50 mmol/l
Process water addition| yes, automatic dosing
---|---
Connection to the storage tank| Screw connection: PE DN56 PN5 Electrofusion socket: DN56 (max. 45° arc)
Safety device for drinking water| Type AB air gap (according to national and international standards)
Environmental conditions
Temperature (operating) [°C]| +5 – +40
Temperature (storage) [°C]| -25 – +55
Altitudes| up to 2000 m above sea level
Air humidity [%]| 10 to 90 (non-condensing)
Other|

• no large temperature fluctuations
• no strong magnetic fields, electric currents, radiation, vibrations or shocks

EC/EU declaration of conformity
See separate EC/EU declaration of conformity.

Handover and commissioning report – Checklist

Work carried out

1. The process water flows clear and without turbidity/foreign matter from the on-site water connection.| ◻
2.  Position of installation: level and angle| ◻
2.  Check 16 A mains connection, level sensor connection| ◻
3.  Check transport pipe connection| ◻
4.    Safety contact switch (emergency stop when lid is open)| ◻
a.  In the working cycle| ◻
b.  Installation does not work with the lid open (nothing is allowed to run.)| ◻
5.  Test function with water adjusted to __ litres| ◻
6.    Check the connections on the tank for| ◻
a.  Seals| ◻
b.  Completeness| ◻
c.   Open ball valves (except extraction)| ◻
7.    Checking the level monitoring in the storage tank| ◻
a.  80%| ◻
b.  100%| ◻
8.  Inducting employees| ◻
Max. filling of the BioMaster®| ◻
Do not put foreign bodies into machine (e.g. cutlery)| ◻
Danger of clogging if foreign substances are put in| ◻
Rice, coffee grounds, potatoes, etc. (filling)| ◻
Cleaning| ◻
Confirm/unlock 80 % and disposal notification| ◻
Work carried out

Troubleshooting (emergency key)| ◻
Only throw in mixed food and raw organic waste| ◻
Test run with operator| ◻

Participating employees

• Name
• Signature
• Machine number:_____
• ____ Date and signature

Index

B

• BioPump …………………………………………………….. 17
• Bones …………………………………………………………… 6

C

• CAUTION ……………………………………………………… 5
• Cleaning
• daily ……………………………………………………………………… 25
• weekly …………………………………………………………………… 26
• Commissioning ……………………………………………. 19
• Commissioning protocol ……………………………….. 34
• Connections ………………………………………………… 18
• electrical ……………………………………………………………….. 18
• transport pipe ………………………………………………………… 19
• water ……………………………………………………………………. 19
• Control cabinet ……………………………………….. 14, 17
• Control elements ………………………………………….. 15
• Corrective maintenance ………………………………… 31
• Cutlery………………………………………………………….. 6

D

• DANGER ……………………………………………………… 5
• Data, technical …………………………………………….. 32
• Declaration of conformity ………………………………. 33
• Decommissioning ………………………………………… 31
• Detergent
• biodegradable …………………………………………………… 25, 26
• Dishes ………………………………………………………….. 6
• Disposal ……………………………………………………… 31
• Drinking water module ………………………………….. 17

E

• Electrical connection …………………………………….. 32
• Emergency stop …………………………………………… 15
• Emergency stop button …………………………………. 15
• Environmental conditions………………………………. 33
• ERROR ………………………………………………………. 15

F

• Fat solvent …………………………………………….. 25, 26
• Fault finding ………………………………………………… 27
• Fault indication light ………………………………… 15, 28
• Film ……………………………………………………………… 6

G

• Grinder ……………………………………………………….. 16
• Grinder motor ………………………………………………. 17
• Grinding unit mount ……………………………………… 16

H

• Handover report …………………………………………… 34
• Homogenisation technology …………………………. 20

I

• Inorganic substances ………………………………………6
• Inputs
• not allowed ……………………………………………………………… 6
• Installation ………………………………………………….. 18

L

• Lid …………………………………………………………….. 14
• closing …………………………………………………………………… 22
• opening …………………………………………………………………. 22
• Lid rail ……………………………………………………….. 14
• Lid seal ………………………………………………………. 14
• Loading chute ……………………………………….. 14, 16

M

• Main switch ………………………………………………… 15
• Maintenance ………………………………………………. 29
• Maintenance plan………………………………………… 30
• Malfunctions ……………………………………………….. 27
• Metal …………………………………………………………….6
• Misuse …………………………………………………………..7

N

• Noise …………………………………………… 8, 21, 24, 28
• NOTE ……………………………………………………………5

O

• Operating panel ………………………………………….. 14
• Overload circuit breaker ………………………….. 17, 28

P

• Packaging ……………………………………………………..6
• Personal protective equipment …………………………9
• Personnel ………………………………………………………9
• Personnel qualifications …………………………………..9
• Plastic …………………………………………………………..6
• Pressurised water pump ………………………………. 17
• Prevent a pipe blockage ………………………………. 26
• Process water nozzle …………………………………… 16
• Process water nozzle dosing valve ………………… 17
• Process water quantity ………………………………… 20
• Protective devices ……………………………………….. 10
• Pump …………………………………………………………. 15
• Pump motor ……………………………………………….. 17
• Pumping …………………………………………………….. 24
• Pumping contents of loading chute ………………… 24
• Pumping out ……………………………………………….. 24

Q

• Qualification matrix …………………………………………9
• Qualified personnel …………………………………………9

R

• Risks ……………………………………………………………. 7

S

• Safety contact switch ……………………………………. 14
• Safety devices …………………………………………….. 10
• Safety information ………………………………………….. 5
• Safety marking …………………………………………….. 11
• Service hatch ………………………………………………. 14
• Serviettes ……………………………………………………… 6
• Setting up ……………………………………………………. 18
• Specialist personnel ……………………………………….. 9
• STANDBY …………………………………………………… 15
• Start normal mode ……………………………………….. 24
• Start, normal mode ………………………………………. 15
• Starting……………………………………………………….. 24
• Stone fruit …………………………………………………….. 6
• Storage ………………………………………………………. 31
• Structure …………………………………………………….. 13
• Switching off ……………………………………………….. 27
• Switching on ……………………………………………….. 22

T

• Tank level …………………………………………………… 15
• Technical data …………………………………………….. 32
• Temporary decommissioning ………………………… 27
• Test run ……………………………………………………… 21
• Textiles ………………………………………………………….6
• Toothpicks ……………………………………………………..6
• Transport ……………………………………………………. 12
• Transport pipe connection ……………………………. 17
• Tropical fruits with large stones ………………………..6

U

• Unlocking key ……………………………………………… 28
• Unpacking ………………………………………………….. 13
• Use ……………………………………………………………….6
• as intended ……………………………………………………………… 6

V

• Ventilation ………………………………………………….. 20

W

• WARNING ……………………………………………………..5
• Water connection ………………………………………… 32
• Water distribution ………………………………………… 17
• Wooden skewers ……………………………………………6

MEIKO GREEN Waste Solutions GmbH
Englerstraße 3
77652 Offenburg
Germany
Telephone: +49 (0)781 / 9191 9000
http://www.meiko-green.com
[email protected]

Design and construction subject to change without prior notice!

9764577 / Valid from: 2018-03 / Updated on: 2021-12

References

• Fast and simple food waste treatment - MEIKO

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