SOLIDpower BlueGEN BG-15 Generic User manual

GA N° 671473 1
D2SERVICE
Design of 2 Technologies & Applications to Service
Work package
WP4: Design changes required for an easier and more competitive
service of SP’s μCHP appliance
Deliverable
D4.4: Service manual (prescriptions and instructions to installer)
Period covered:
15.02.2017 –31.01.2019
Dissemination status:
PU
Name, title and organization of the scientific representative of the project's
coordinator:
Dr. Andreas Linhart
DLR-Institut für Vernetzte Energiesysteme e. V.
Carl-von-Ossietzky-Str. 15
26129 Oldenburg / Germany
Tel: + 49 441 999 06 371
Fax: + 49 441 999 06 109
E-mail: [e-mail]
www.d2service-project.eu
This project has received funding from the Fuel Cells and
Hydrogen 2 Joint Undertaking under grant agreement No
671473. This Joint Undertaking receives support from the
European Union’s Horizon 2020 research and innovation
programme, Hydrogen Europe and Hydrogen Europe
research.

D4.4: Service manual (prescriptions and instructions to installer)
GA N° 671473 2
Document history
Version
Date
Description
1
31.01.2019
First version

BlueGEN BG-15 Generic Installation Manual
- Europe
Manual

Manual - BlueGEN BG-15 Generic Installation Manual - Europe
© SOLIDpower GmbH 2019 i
Document properties
Document Name: BlueGEN BG-15 Generic Installation Manual - Europe
Document Type: Manual
Document ID: 002-MC 999246
Revision Number: 4
Created: December 2018
Copyright & confidentiality
Copyright © SOLIDpower Spa 2018.
SOLIDpower Spa [SP] has prepared this document for use by staff or authorised contractors of SP. The information, logos,
ios ad iages i this douet ae popietay to SP ad its affiliated opaies ad ae poided upo the eipiets
promise to keep such information confidential and to use it for the sole purpose of installing or using SP`s products. The
information in this document must not be supplied to third parties without SP`s written consent. This notice must be
reproduced on any copies.
Disclaimer
SP has prepared this document in good faith and has endeavoured to ensure that the information in this document is
oet. Hoee, ay fatos outside SPs uet koledge o otol ay affet the eipiet's use o opeatio of
SPs poduts. SP does ot aat o epeset that the douet is fee fo eo o oissions.
To the fullest extent possible SP expressly excludes any express or implied warranty as to condition, fitness,
ehataility o suitaility of this douet ad liits its liaility fo diet o oseuetial loss at SPs optio to e-
supplying the document or the cost of correcting the document.
Like all eletial o gas poduts, SPs poduts ust e istalled ad opeated oetly. You ust esue that you ead,
udestad ad follo SPs istutios — and any local laws or safety standards —and use reasonable care when
istallig o usig SPs poduts.
If you do not understand the instructions or information provided in this document, contact SP at the address below for
assistance.
Feedback
For any comments or questions about this document, please contact SOLIDpower:
SOLIDpower SpA
viale Trento 115/117 –c/o BIC –Mod C/D
38017, Mezzolombardo (TN) - Italy
t: +39 0461.17.55.068
f: +39 0461.17.55.050
C.F./P.I./VAT nr. IT 02000340220
www.solidpower.com
This project has received funding from the Fuel Cells
and Hydrogen 2 Joint Undertaking under grant
agreement No 671473. This Joint Undertaking
receives support fro the Europea Uio’s Horizo
2020 research and innovation programme, Hydrogen
Europe and Hydrogen Europe research.

Manual - BlueGEN BG-15 Generic Installation Manual - Europe
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CONTENT
1. INTRODUCTION ....................................................................................................................3
1.1. Purpose................................................................................................................................... 3
1.2. Legend .................................................................................................................................... 3
1.3. Background ............................................................................................................................ 4
2. HEALTH AND SAFETY ............................................................................................................6
2.1. OH&S requirements............................................................................................................... 6
2.2. Emergency procedures......................................................................................................... 6
2.2.1. Gas leak ..................................................................................................................................................... 6
3. SITE SELECTION.....................................................................................................................7
3.1. Appliance dimensions........................................................................................................... 7
3.2. Installation location ............................................................................................................... 8
3.3. Installation configuration...................................................................................................... 8
3.4. Installation clearance ............................................................................................................ 8
3.5. Installation positions........................................................................................................... 11
4. MAINTENANCE ...................................................................................................................12
4.1. Instructions for BG Evo 1 yearly maintenance................................................................. 13
4.1.1. Air filter replacement ............................................................................................................................. 13
4.1.2. Desulphurizing cartridge replacement ..................................................................................................18
4.1.3. Water Treatment System (WTS) replacement...................................................................................... 23
APPENDIX A SPECIFICATIONS.............................................................................................29
APPENDIX B ABBREVIATIONS.............................................................................................32

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1. INT‘ODUCTION
1.1. Pupose
This manual explains how to install a BlueGEN appliance, the latest Solid Oxide Fuel Cell (SOFC) technology
manufactured by SOLIDpower Spa.
The BlueGEN appliance can be installed in two configurations:
1. Electrical generator system (with no heat recovery).
2. Co-Generation system (with heat recovery).
Depending on the installation configuration additional space may be required for hot water tanks or other
equipment.
If the installer has any concerns relating to the installation of the BlueGEN appliance, the installer should
contact SP for further advice. Contact details are shown in the Feedback section of this document.
NOTE: This installation manual does not include instructions for the installation of the fuel cell stack onto the
Fuel Cell Module. This activity is to be performed only by appropriately qualified service personnel.
1.2. Leged
The symbols used in this document are:
Symbol
Description
Caution
Ignoring these warnings may result in damage to the BlueGEN appliance or cause
death or serious injury.
Fire danger
Indicates fire danger or safety precautions required in the event of a fire.
Hot surface
Warning that the surface may be hot.
Refer to additional information
Details any steps required before undertaking, or helpful information to assist with,
the installation or maintenance tasks described.
European Declaration of Conformity
Certifies that this product has met European Union consumer safety, health and
environmental requirements. The appliance has been designed and built so as to
operate safely and present no danger to persons, domestic animals or property
when normally use, as defined in Article 1 of the Gas Appliance Regulation (EU)
2016/426.

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1.3. Bakgoud
Fuel cells are increasingly recognised for their environmental benefits and their potential in energy efficient
distributed power generation systems. Energy utilities worldwide are facing serious problems including
demand growth, limitations of traditional power plants, fuel shortages and greenhouse emission constraints.
SP has developed a residential scale fuel cell system, the BlueGEN appliance, designed to provide a secure,
reliable and highly efficient supply of base load power.
BlueGEN is the latest in SOFC technology and operates as a grid-connected electrical generator and can vary
the output power level to suit a number of differing electricity production requirements.
The BlueGEN appliance operates on natural gas from the mains gas supply and water from the mains water
supply. Through an electrochemical reaction, the BlueGEN appliance provides both electricity for export to
the grid and heat that can be used for heating water.
Key features of the BlueGEN appliance are:
•0.5 to 1.5 kW net output of AC electrical power operating on natural gas.
•High electrical efficiency up to 55 per cent net electrical efficiency.
•Conversion of input fuel into electrical energy with negligible noise, vibration and emissions.
•Power output modulation from 33 to 100 per cent allowing flexible operation for different conditions
and installations.
•Fuel Cell Module, consisting of balance-of-plant and fuel cell stack integration, resulting in a compact
and thermally efficient design.
•Integrated heat exchanger (waste heat recovery unit) to recover the heat from the fuel cell module
allows the BlueGEN appliance to either be installed as an electric generator system or as a co-generation
system.
•Remote data access via ethernet for monitoring and control.
The main parts of the BlueGEN appliance can be seen in Figure 1 below.
SP has developed the BlueGEN appliance to operate in a safe and reliable manner. In order to do so, proper
installation is essential.

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1. Concentric flue adapter (60/100 mm)
2. Fuel Cell Module
3. Waste heat recovery unit
4. Gas safety double block valves (hidden from view)
5. Condensate tank (hidden from view)
6. Air delivery system
7. Water treatment system
8. Power system
9. Gas desulphuriser
Figure 1: BlueGEN appliance main components

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2. HEALTH AND SAFETY
2.1. OH&S euieets
The BlueGEN appliance must be operated in accordance with applicable local occupational health and safety
requirements, and the following SP recommendations:
•Ensure site is clean and tidy and there are no access restrictions.
•Use the following personal protection equipment:
osafety goggles or glasses when working on the unit.
oprotective clothing (e.g. labcoat or overalls).
osafety footwear.
ogloves and safety masks for handling chemicals or insulation.
•Hot surface gloves should be within easy access.
•Observe all warning and prohibition signs posted on the BlueGEN appliance and on the plant room (if
applicable).
•It is the installers responsibility to instruct the user in the operation and the safety devices and to give
him the user manual
Caution
Only appropriately qualified service personnel may install this appliance. Improper
installation will void the warranty.
2.2. Eegey poedues
The BlueGEN appliance is fitted with a CE approved gas safety control system. In the event of the BlueGEN
appliance operating outside its normal parameters, the safety system is designed to isolate the internal gas
supply and safely shut the system down.
2.2.1. Gas leak
The BlueGEN appliance generates deodorised natural gas internally via the desulphuriser assembly. If an
internal leak occurred, downstream of the desulphuriser, it would not be detectable by smell. It is important
that the appliance be commissioned and maintained by authorised personnel only, following approved
safety procedures.
In an emergency situation natural gas, electricity and water supply to the BlueGEN appliance are to be
isolated, only if safe to do so.

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3. SITE SELECTION
This section outlines the basic site requirements for installing the BlueGEN appliance.
3.1. Appliae diesios
Figure 2 shows the BlueGEN appliance as it will be supplied to the customer. The connection interfaces are
provided with the appliance.
A. Top view
B. Front view
C. Side view
D. Rear view (service connections)
Figure 2: Appliance dimensions (mm)

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3.2. Istallatio loatio
The BlueGEN appliance is only suitable for indoor installation. The appliance must be suitably protected from
temperature extremes, intense sunlight, excessive humidity and dust. Please be aware that BlueGENs heat
loss into the direct environment is about 250W. Installation with multiple BlueGENs might need a ventilation
concept. The BlueGEN appliance is designed to operate in ambient temperatures between 1 and 45 °C.
Physical requirements
The following physical requirements apply to the installation of the BlueGEN appliance:
•The appliance is only suitable for floor mounting.
•The installation location should provide suitable protection from extreme temperature and humidity
levels.
•The area should not have excessive dust levels. The appliance contains sophisticated electronics that
must be protected from excessive dust and moisture. In a dusty environment the frequency of
maintenance inspections for the blower filter may have to be increased.
•The appliance is to be installed on a flat and level surface capable of withstanding a point load of 60kg
at the support feet of the appliance. The installer must ensure that the floor can support the BlueGEN
appliance and all associated hot water equipment.
•The installation of the flue system must satisfy all appropriate installation codes of the respective
country, ensuring that the appliance does not pose a hazard to people or animals.
•The BlueGEN dissipates approximately 250W heat to the installation space. The installation space should
be designed such that temperatures remain in the recommended operating range.
•Consultation with SP is required if the appliance is to be installed in an earthquake zone.
•Children or infirm persons should not have access to the BlueGEN appliance and the installation (piping,
flue and supply isolators).
If there is any uncertainty about the appropriate installation location, please contact SP.
3.3. Istallatio ofiguatio
The BlueGEN appliance can be installed in two configurations:
1. Electrical generator system (no heat recovery).
2. Co-generation system (with heat recovery).
Depending on the installation configuration, additional space may be required for hot water tanks or other
equipment.
3.4. Istallatio leaae
When installing the BlueGEN appliance, it is necessary to allow sufficient space for access and maintenance
activities. Figure 3 shows the minimum clearance requirements for the appliance. The BlueGEN appliance
has been designed for maintenance access from two sides. There must be sufficient space on these sides to
allow the doors to be opened for maintenance purposes.

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It is important that no permanent or temporary obstructions are placed in front of the appliance, as this may
edue the ai iulatio that ools the appliaes eletial opoets.
The clearances on the remaining sides of the appliance are absolute minimum clearances. Care must be
taken to ensure ease of access to the BlueGEN appliance connections and, if applicable, the tank
connections.
Figure 3: Installation clearances (mm)

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If installing a domestic hot water tank adjacent to the service connection side of the BlueGEN appliance, a
minimum clearance of 500mm is required between the BlueGEN and the tank. This clearance will provide
sufficient room for all ancillary equipment.
1. Wall
2. 500mm clearance (minimum)
3. Domestic hot water tank
Figure 4: Clearance between BlueGEN and tank
As shown in Figure 5, a minimum clearance of 500 mm is required above the cabinet to any permanent
structure to allow access to the BlueGEN appliance. If BlueGEN will be installed on a plattform the height
should not exceed 150 mm for maintenance reasons.
Figure 5: Permanent structure

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3.5. Istallatio positios
The BlueGEN appliae is a odula geeato that a e istalled i a ue of diffeet positios. The
appliance must be installed on a flat and even footing designed to carry the weight of the appliance. Figure
6 illustrates possible installation positions.
A. Wall
B. Domestic hot water tank
1. Parallel installation (recommended)
2. Perpendicular installation
3. Corner installation 1
4. Corner installation 2
5. Corner installation 3
Figure 6: Installation positions

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4. MAINTENANCE
Table 1 below details the maintenance schedule necessary to ensure optimal continued operation of the
BlueGEN appliance. The appliance will detect and schedule its maintenance requirements automatically. The
information provided below indicates the average maintenance requirements for a typical installation.
The control system of the BlueGEN appliance ensures that automated alerts are sent to SP support personnel
to notify of an impending maintenance task, or if a component requires maintenance outside the normal
maintenance schedule.
There are no user-serviceable parts and so end-users should have no need to open the BlueGEN appliance
cabinet doors for inspections or replacements.
Table 1: Recommended maintenance schedule for BlueGEN appliance
Caution
Under no circumstances should the end-user open the BlueGEN appliance cabinet doors.
Serviceable
Components
Inspection
Replacement Interval
Time Required (approx.)
Desulphuriser
Canister
N/A
1-3 years1
1 hr
Air Filter
N/A
12 months1
15 min
CO/CH4 sensor
N/A
2 years
30 min
Water Treatment
System
1 hr (total)
RO filters
N/A
3 years1
Demineralisation
filter
N/A
12 months1
Demineralisation
filter (polishing)
N/A
2 years1
Carbon filter
N/A
12 months1
Sediment filter
N/A
12 months1
Condensate
Recovery System
30 min
Condensate Resin
filter
N/A
12 months1
1. Depends on site water/gas/air quality.

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4.1. Istutios fo BG Eo 1 yealy aiteae
BG Evo 1 yearly maintenance consists in the replacement used Air filter, desulphurizing cartridge and Water
Treatment system with new ones.
The system must be shut down before beginning maintenance operation.
Caution
For safety reasons, that the natural gas and the tap water manual valves at the BG inlet must
be closed before maintenance.
4.1.1. Ai filte eplaeet
Tools:
Key to open BG Evo 1
front panel
30 mm adjustable
wrench to rotate the
filter wingnut
Materials:
A spare new air filter
N.
Sequence
Image
1/7
Remove the front panel with the
dedicated key.
Key Locks

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N.
Sequence
Image
2/7
AIR FILTER

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N.
Sequence
Image
3/7
Unscrew the wingnut at the centre
of the air filter.
4/7
Remove the air filter by pulling and
keep the washers for the new filter
installation.
5/7
Install the spare new air filter, paying
attention to insert the washers.
WINGNUT
WASHERS
WASHERS

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N.
Sequence
Image
6/7
Screw the wingnut to secure the
filter.
7/7
Put on the front panel and secure it
with the key.
WINGNUT
Key Locks

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N.
Sequence
Image