PP30 Operation Manual
PP30 Cogeneration System
Table of Contents
Technology Foundations 3
Power Pallet Crate Contents 6
Safety Procedures 7
Required Tools 9
Power Pallet Set Up 11
Facility Requirements 11
Connecting to Loads 12
Connecting to the Grid 13
Fuel Requirements 13
Operating Procedures 16
7.1 Pre-operation Procedure (15 minutes) 16
7.2 Start-Up Procedure (15 minutes) 17
7.3 Shut Down Procedure (20 minutes) 19
Maintenance Procedures 22
Spare Parts 25
Troubleshooting 26
Service Record Form 27
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1. Technology Foundations
Gasifier Supersystem (gasifier Module)
- The gasifier system
Power Generation Supersystem
- Power generation system
Combined Supersystem
- Power generation supersystem
- The gasifier supersystem
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2. Power Pallet Crate Contents
1. Power Pallet Gasifier System
2. Power Pallet Generator System
3. Charcoal for first start of reactor
4. Various supplies for maintenance operations.
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4. Required Tools
The following tools are required to perform regular Power Pallet O&M activities.
O&M Tool List (Required)
● Gas line wire brush
● 7mm wrenches
● 8mm wrenches
● ½” sockets and wrenches
● 9/16” sockets and wrenches
● 7/16” long sockets
● ¾” wrenches
● ⅞” wrenches
● Crescent wrenches various sizes
● Phillips screwdriver various sizes
● Flathead screwdriver various sizes
● Scissors
● Sharpies or sharpie equivalent ( Milwaukee Inkzall)
● Blue tape
● Electrical tape
● Propane Torch (camping size)
● Teflon tape
● Denatured alcohol
● Paper towels
● Graphite paste
● ⅛” graphite rope
● ⅜” graphite rope
● PC Computer
● Scale for measuring weight of fuel
● 1’ pipe tee for lighting
● 12’ ladder
● 6x ~30 gal trash cans or equivalent for fuel loading
● 2x - 3x Carbon Monoxide Sensor
● ABC Fire extinguisher
● Water Hose
● Fork lift
● Big Wipes Heavy Duty Textured Scrubbing Wipes
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Technician Tool List (Nice to Have)
● Pliers
● Needle nose pliers
● Wire strippers
● Crimpers (ABCDE kind)
● Wire cutters
● Timing Light
● Voltmeter
● Cables/dongles for connecting computer to PP to load firmware
● Firmware
● Configuration tools
● DSE Software
● Tunerstudio Software for MS3 Pro
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5. Power Pallet Set Up
5.1. Facility Requirements
The facility to house the power pallet must have the following characteristics:
● Level flooring made of non-flammable material capable of supporting the weight of the
machine (listed in the Specifications section).
● Facility must have a covered location to protect the power pallet from direct rain or water,
as some aspects of the system are not water/weather resistant.
● The system is to be installed with a 92 cm clearance around the footprint of the machine
and at least a 173 cm clearance above the machine. See illustration on the next page.
● Sufficient ventilation through an exhaust hood with air flow capacity adhering to local
regulations.
● Install the CO meter provided with the power pallet and verify that it functions properly.
Have a CO meter near the operating floor at all times even when the machine is not in
operation and especially when performing maintenance.
● Operate the power pallet in locations having a max temperature of 40 °C and at an
altitude of 1000m or less. The power pallet’s power output will be derated at higher
altitudes. In case of different conditions, please consult ALL Power Labs.
● Install the PP30 out of direct sunlight. UV from sunlight will damage parts over time.
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5.2. Connecting to Loads
5.2.1. Hook up the cam lock connections to an off load system you want to send
power to that is within the power pallet electricity load range. (5-25 kW)
5.2.2. Press Close generator button to close the contactor and start sending
power to a system.
5.3. Connecting to the Grid
5.3.1. Connect cam locks to interconnection point with grid.
5.3.2. Press close generator button to close the contactor and start generator
synchronization process with the grid. If generator does not synchronize,
please look at technician manual for troubleshooting steps.
6. Fuel Requirements
For your gasifier to operate properly, you must use the correct biomass fuels which have been
properly prepared and sifted. Certain material shapes and sizes flow better in feedstock
systems. For example, long stringy pieces, such as toothpicks, do not flow well, as they get
stuck in feeds. Materials in circular shapes such as walnut shells or macadamia nut shells flow
well.
Feedstock fuel must be dry, of the correct shape and size to flow through the reactor, and free
of dust, sand and contaminants:
● Particle size: 1 cm – 4 cm (0.5 in. – 1.5 in.)
● Moisture content (% by dry weight): 5% – 30%
● Ash content <5%
The following Table of Feedstocks shows the most common ones that have been tested and are
known to work, which ones are known to be unusable, and which ones need more testing. For
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more information on fuel preparation, contact APL For more information on fuel preparation,
contact APL.
LEGEND
Green
Known to work with standard operations and maintenance
effort
Yellow
Known to work with increased operations and maintenance
effort
Grey
Not enough testing to approve at this time. Use voids
warranty
Red
Known to not work. Use voids warranty.
Feedstock
Notes
Wood Chips (e.g: Oak,
Rubber, Pine)
Use only chips; chunks or long shards can bind auger or
bridge in the reactor
Nut Shells (e.g: Coconut,
Walnut, Hazelnut)
Not all shells will work, please contact us to discuss your
particular feedstock
Corn Cobs
Must be broken to size and must not include husks.
Increased chance of slagging
Palm Kernel Shells
Risk of high temperatures. May need to be blended or other
steps taken to lower temperatures
Macadamia Nut Shells
Excellent shape, not enough testing
Cashew Nut Shells
Known toxicity, not enough testing
Wood Pellets
May work depending on size & makeup, pellets prone to
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decompose
Coffee Grounds
Too fine, not physically compatible, pelletization may allow
use
Saw Dust
Too fine, not physically compatible, pelletization may allow
use
Corn stover
High ash content; silica content leads to slag
Rice Husk
High silica content leads to slagging
Bamboo
Difficult to prepare to correct size and shape
Grasses: Switchgrass,
Miscanthus, etc.
High silica and low bulk density.
Paper, Sugarcane Bagasse,
Coconut Husk
Shapes not physically compatible
Municipal Solid Waste /
Trash
Slag risk; heavy metals; plastic content not suitable
Coal
Burns too hot, releases sulfur and heavy metals
Plastics
Melts and fouls auger/reactor
Manure - Cow, Pig, Chicken,
etc
High slag, low energy density
Tires
Not chemically compatible
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7. Operating Procedures
The following procedures assume that the Power Pallet has been assembled and installed
correctly. Training by a certified APL trainer is recommended before operating the PP30 for the
first time.
7.1 Pre-operation Procedure (15 minutes)
1. SD card: transfer existing and wipe card before start-up
Power Generation Supersystem
2. Check radiator coolant level and refill if necessary
3. Check expansion tank fluid and refill if necessary
4. Check engine oil level and refill if necessary
5. Check governo and clean if valve is stuck only.
6. Check that the throttle plate in governor opens by pressing with finger
Gas Making Supersystem
7. Empty ash collection vessel (ACV)
8. Empty cyclone particulate ash can (CCC)
9. Inspect filter bags and empty base pan: check for ash and carbon build up on the base
pan
10. Fill hopper with feedstock (refer to Chapter 6 for feedstock specifications)
a. Important: when starting the Power Pallet for the first time, fill the reactor with
charcoal until it reaches the tip of the fuel switch. If there is not enough charcoal
provided, use locally sourced charcoal. The correct size of the charcoal to use to
fill the reactor is roughly that of the charcoal produced from the ACV. APL
provides an initial bag of the correct size for starting the power pallet the first
time.
11. Check functionality of ash auger, blower and grate shaker from PCU control
a. manually turn on ash auger and check, turn off
b. manually turn on blower and check, turn off
c. manually turn on grate shaker and check, turn off
12. Fill out service record form/ online data
13. Record SD card number
14. Perform Leak Down test
a. Turn on the automation assembly
b. Open the valve to the flare and close the valve to the engine
c. Seal off the air intake check valve with a 1.5” metal pipe plug
d. Turn the gas blower up to 11 (the maximum setting) to apply vacuum pressure to
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the entire gas circuit
e. Shut the valve to the flare, then turn off the blower. The valve should lock in the
vacuum pressure.
Test criteria #1: When the numbers indicated for Preac and Pcomb stop rising,
● If the reactor pressure reading is near or >90, the reactor passes the first leak
test.
● If the pressure is <90, it may be that the battery has insufficient charge, there is
a significant leak, or there is a large pressure drop in the system. This needs to
be solved before continuing.
Test criteria #2: After closing the valve, the pressure will begin to drop. Start timing the
pressure drop on the PCU right after the valve is closed.
● Takes >60s to reach 0.
This is typical for new and well sealed systems. The
reactor passes the leak test.
● If the pressure drops to zero <30 sec, the reactor fails, and should not be
operated until the leak is repaired.
Entire Power Pallet
15. Check and tighten all gas connections, bolts and sanitary clamps
PRE-OPERATION PROCEDURE COMPLETE
7.2 Start-Up Procedure (15 minutes)
Gas Making Supersystem
1. Attach pipe tee to lighting port
2. Place a pinch of ACV charcoal in pipe tee
3. Close valve to blowers and turn gas up to 11 (maximum)
4. Using a propane torch, light the ACV char in pipe tee
5. When char is glowing, slowly open the valve to the flare, letting the char embers into the
reactor
6. Flare stack will start to get smokey and the flammable gasses will ignite. When this
happens, turn the air blower down to 5. When you hear a low roaring sound, the air and
gasses are mixing and the PP30 is flaring
7. Open the air intake valve using a pipe wrench. A screwdriver can be used punch the
valve loose if stuck
8. Close the lighting port. Use pipe wrench to tighten
9. Turn gas blower to maximum. Increase air blower to maintain a strong roaring sound
10. Once Trst is greater than 750°C and Tred is greater than 300°C, start the engine (note:
while the engine can be started at lower values, the PP30 system will collect more tar
and require more operation and maintenance)
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Power Generation Supersystem
11. Close the valve to the blowers, turn both the gas and air down to 0, and open the valve
to the engine. On the generator controller, press the red Stop/Reset button, then the
Manual Mode button (hand symbol), then the green Start button to start the engine.
12. The status screen will confirm that the engine is running. Once the engine has warmed
up, the ‘Generator Available’ light will turn on. Press the close generator button (squiggly
line symbol) to close the connection to the generator and export power.
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7.3 Shut Down Procedure (20 minutes)
1. Turn off all devices/loads connected to the PP30’s electrical output
2. Disconnect generator by pressing the ‘Load’ button on the top left of the Deep Sea
controller
3. Press the red button to turn off the engine
4. Flare the PP30 by turning the gas and air blowers up to 6, and then open the flare valve
and close the engine valve. Let the PP30 flare for 15 mins
5. After 15 mins turn gas and air blowers to 0, and cap and tighten air intake using pipe
wrench
6. Close blower valve
7. Turn off the PP30
7.4 Refueling the PP30
Recommended hopper fill schedule
Fuel type
kW
Time between refills
Amount to fill each refill
Walnuts
15
2.5 hrs
100 L
20
2 hrs
100 L
25
1.5 hrs
100 L
Woodchips
15
1.5 hrs
100 L
20
1 hrs
100 L
25
.5 hrs
100 L
Refueling Procedure
1
Check to make sure the fuel to run the pallet is staged for the day and weighted into their
respective loading containers (bags, buckets, etc)
2
Make sure there is a safe means to refuel the system, either using a ladder, stairs, etc.If
using a watertainer system, use a safe means to get to the top of the container.
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3
Make sure you have a respirator, preferably 3M type with 60926 cartridges, and
earmuffs. This PPE must be worn when refueling power pallet systems.
4
Make sure the load is less than 15 kW when refueling. If it is not less than 15 kW, lower
the load while refueling and it can be turned up after.
5
Once you are ready to load the hopper, safely open the hopper to get to the top of the
unit and open the twist hopper lid. If using a watertainer system, this will be through the
top hole in the container where the hopper can be seen.
6
Top off the hopper with fuel.
7
Close the hopper lid securely.
8
Record the amount of fuel loaded. (note this can also be planned to be recorded before
fueling the unit)
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