Meiko BioMaster 4 PLUS User manual

9764577 / Valid from: 2018-03 / Updated on: 2021-12
www.meiko-green.com
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BioMaster®4 PLUS
Food waste treatment system
Operating instructions
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Read carefully before use!
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EN

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Translation of the "original operating instructions"
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Contents
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1Notes to the user....................................................................................................................................4
1.1 The purpose of these operating instructions ......................................................................................4
1.2 Ways we present the information .......................................................................................................4
2Liability and warranty ............................................................................................................................4
2.1 Delivery contents ................................................................................................................................4
2.2 Liability................................................................................................................................................5
2.3 Warranty .............................................................................................................................................5
2.4 Copyright.............................................................................................................................................5
3Safety information..................................................................................................................................5
3.1 Presentation of safety information......................................................................................................5
3.2 Intended uses .....................................................................................................................................6
3.3 Misuse.................................................................................................................................................7
3.4 Risks in dealing with the BioMaster®..................................................................................................7
3.5 Operator's responsibilities ..................................................................................................................9
3.6 Personnel responsibilities...................................................................................................................9
3.7 Personnel qualifications......................................................................................................................9
3.8 Safety devices ..................................................................................................................................10
3.9 Safety marking..................................................................................................................................11
4Transport...............................................................................................................................................12
4.1 Unpacking.........................................................................................................................................13
5Structure and function.........................................................................................................................13
5.1 Function............................................................................................................................................13
5.2 Main group BioMaster®.....................................................................................................................14
5.3 Control elements...............................................................................................................................15
5.4 Loading chute ...................................................................................................................................16
5.5 Technical equipment.........................................................................................................................17
6Installation.............................................................................................................................................18
6.1 Unpacking and setting up.................................................................................................................18
6.2 Connections......................................................................................................................................18
6.2.1 Electrical connection.....................................................................................................................18
6.2.2 Cold water connection ..................................................................................................................19
6.2.3 Connecting the biomass transport pipe........................................................................................19
7Commissioning.....................................................................................................................................19
7.1 Safety information.............................................................................................................................19
7.2 Process water quantity .....................................................................................................................20
7.3 Venting the water supply, pump test run, leak check.......................................................................20
7.4 Carry out test run with pure water ....................................................................................................21
7.5 Handover and commissioning report................................................................................................21
8Operation...............................................................................................................................................21
8.1 Safety information.............................................................................................................................21
8.2 Switching on .....................................................................................................................................22
8.3 Opening and closing the lid ..............................................................................................................22
8.4 Filling.................................................................................................................................................23
8.5 Starting the automatic homogenisation cycle...................................................................................24

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8.6 Pumping out contents of loading chute ............................................................................................24
8.7 Daily cleaning ...................................................................................................................................25
8.8 Weekly cleaning................................................................................................................................26
8.9 Measures in case of longer installation standstill .............................................................................27
8.10 Switching off......................................................................................................................................27
8.11 Fault finding ......................................................................................................................................27
9Maintenance..........................................................................................................................................29
9.1 Safety information.............................................................................................................................29
9.2 Maintenance plan .............................................................................................................................30
10 Corrective maintenance.......................................................................................................................31
11 Decommissioning, storage .................................................................................................................31
12 Disposal.................................................................................................................................................31
13 Technical data.......................................................................................................................................32
13.1 EC/EU declaration of conformity ......................................................................................................33
14 Handover and commissioning report –Checklist ............................................................................34
15 Index ......................................................................................................................................................36
16 Notes......................................................................................................................................................37
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1 Notes to the user
1.1 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.
1.2 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 ac-
tion 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
2 Liability and warranty
2.1 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:
Any noticeable damage caused in transit must be reported in writing im-
mediately and within eight days, as per our terms and conditions.
Any hidden defects must be reported immediately when they are discov-
ered.

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2.2 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, illustra-
tions 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’.
2.3 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.
2.4 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, stor-
age, transmission, broadcast, reproduction or passing on of contents without the
written permission of MEIKO GREEN Waste Solutions GmbH is expressly prohib-
ited.
The copyright and all associated rights lie with MEIKO GREEN Waste Solutions
GmbH.
© 2021 MEIKO GREEN Waste Solutions GmbH, Englerstr. 3, 77652 Offenburg.
3 Safety information
3.1 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.

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3.2 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 %).
oCereals, such as wheat, barley, rice
oSemolina
oPasta, dough
oSugar
oFlour
oThick 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 cov-
ering the corn cob)
Wooden objects, such as wooden skewers, toothpicks or the like
Metal or plasticobjects such as dishes, cutlery, tools
Textiles, such as serviettes, towels or the like
Film, plastic, packaging
Detergents
Inorganic substances in general

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3.3 Misuse
Connecting to an on-site water pipe with contaminated water
Improper work on the installation
Inputting unauthorised 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 (mould, bacteria, odours, corrosion, pipe
blockage, damage to installation components).
3.4 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 pos-
sess 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 au-
thorised 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.

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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 oc-
cur, immediately trigger an emergency stop and inform the responsible
specialist personnel. No unauthorised manipulation by the operating per-
sonnel!
WARNING
If you open the casing of the BioMaster®, pressurised 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.

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3.5 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.
3.6 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.
3.7 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 authorised 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 ac-
cording to the qualification matrix. Any personnel undergoing training are only al-
lowed 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.

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Inducted
personnel
Specialist per-
sonnel
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
3.8 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
All-pole disconnecting main switch on the operating panel
Fault indication lights on the operating panel
Lockable service hatch
Protective cladding on all sides