Skov Farm AirClean BIO Flex 2-0 Technical User Guide

2023.08.23 • 611151

Software version 6.3

• 2015.05.08

Farm AirClean • BIO Flex

Technical User Guide

English: For other language variants of this document we refer to:

Español: Para otras variantes del idioma de este documento, visite:

Français: Pour les versions dans d'autres langues de ce document veuillez consulter:

http://docs.skov.com/1144

2 Technical User Guide

Farm AirClean • BIO Flex

Program Version

This manual corresponds to:

• DOL 356 software version 6.3.

• Air cleaner version 2.0

It was released in 2017.

Product and Documentation Revision

SKOV A/S reserve the right to change this document and the product herein described without further notice. In

case of doubt, please contact SKOV A/S.

Date of change appears from the back of this manual.

In case of operating error or improper use, the air cleaner may cause loss or create a risk of

discharging uncleaned air.

All stated safety directions as well as local regulations and legislation must be complied with in

connection with installation plus the working and operation of the air cleaner.

SKOV A/S recommend that the air cleaner is only installed, operated and serviced by

professionals.

NOTE

without the express written permission from SKOV A/S.

• SKOV A/S have made all reasonable efforts to ensure the accuracy of the information contained in this

manual. Should any mistakes or imprecise information occur in spite of this, SKOV A/S would

appreciate being notified thereof.

• Irrespective of the above, SKOV A/S shall not accept any liability with regard to loss or damage caused

or alleged to be caused by reliance on any information contained herein.

Technical User Guide  3 
 
Farm AirClean • BIO Flex 
Introduction  6 
1 Personal Safety Measures .......................................................................... 6 
2 Environmental Safety Measures ................................................................. 6 
2.1 Signage .................................................................................................................................... 7 
Product Description  7 
1 2-Filter ........................................................................................................... 8 
2 Air Cleaning Computer .............................................................................. 10 
2.1 Selection of Language .......................................................................................................... 10 
2.2 Survey ................................................................................................................................... 11 
2.3 Menu Survey ........................................................................................................................ 12 
2.3.1 Service Info ............................................................................................................................ 12 
2.3.2 Operation ............................................................................................................................... 12 
2.3.3 Alarm ..................................................................................................................................... 13 
2.4 Technical ............................................................................................................................... 17 
3 Data Logging in FarmOnline WebLink ..................................................... 18 
Maintenance Instructions  19 
1 Maintenance overview for air cleaning .................................................... 19 
2 Weekly Inspection and Maintenance ........................................................ 20 
2.1 Trickling of Filter 1 and 2 ................................................................................................... 20 
2.1.1 Check of trickling .................................................................................................................. 21 
2.1.2 If trickling is insufficient ....................................................................................................... 21 
2.2 Pressure loss and biofilm on the filters .............................................................................. 22 
2.2.1 Evaluation of biofilm in relation to pressure loss .................................................................. 22 
2.2.2 Supplementary visual evaluation of the amount of biofilm ................................................... 23 
2.2.3 If the bio film and pressure loss is unsatisfactory .................................................................. 24 
2.3 Logbook ................................................................................................................................ 24 
3 Periodic Inspection and Maintenance, at Least Every Month ................ 25 
3.1 Filter Washer ........................................................................................................................ 25 
3.2 Vessel and process water ..................................................................................................... 26 
3.2.1 Changing water and cleaning vessel ...................................................................................... 26 
3.3 Regulation components ....................................................................................................... 27 
3.3.1 Hydrostat ................................................................................................................................ 27 
3.3.2 Conductivity Sensor, Temperature Sensor and pH Sensor .................................................... 27 
3.3.3 Differential pressure sensor ................................................................................................... 27 
3.3.4 Water supply and water meter ............................................................................................... 28 
3.3.5 Drainage and the water meter ................................................................................................ 28 
3.4 Pumps in general .................................................................................................................. 28 

Technical User Guide 
 
Farm AirClean • BIO Flex 
4 Manual Wash Down of Filters ................................................................... 29 
5 Cleaning Air Distribution Plate ................................................................. 34 
5.1 Air Distribution Plate .......................................................................................................... 34 
6 Frost Protection ......................................................................................... 35 
6.1 Start-up after Frost Protection ........................................................................................... 35 
7 Cleaning the Livestock House .................................................................. 35 
7.1 Empty House ........................................................................................................................ 35 
Functional Description 36 
1 Main switch ................................................................................................ 36 
2 Emergency Stop - Filter Washer ............................................................... 36 
3 Exhaustion ................................................................................................. 36 
4 Filter Startup............................................................................................... 36 
5 Water ........................................................................................................... 37 
5.1 Pumps .................................................................................................................................... 37 
5.2 Water Meters ........................................................................................................................ 37 
6 Water Supply .............................................................................................. 38 
7 Drainage ..................................................................................................... 38 
8 Trickling ...................................................................................................... 39 
9 Filter Washer .............................................................................................. 39 
9.1 Filter Wash Settings ............................................................................................................. 40 
10 Air Distribution Plate ................................................................................. 40 
11 Sensors ....................................................................................................... 41 
11.1 Hydrostat .............................................................................................................................. 41 
11.2 Conductivity Sensor ............................................................................................................. 41 
11.3 Temperature Sensors ........................................................................................................... 41 
11.4 Differential Pressure Sensor ............................................................................................... 42 
11.5 pH Sensor .............................................................................................................................. 42 
11.6 pH Value ............................................................................................................................... 42 
11.6.1 BIO Flex with pH- measurement ........................................................................................... 44 
Service Guide  45 
1 Error Tracing in the Environmental Impact ............................................. 45 
2 Setting of Air Cleaning Computer ............................................................ 45 
2.1 Compact Flash Card ............................................................................................................ 47 
2.1.1 Save Logs ............................................................................................................................... 47 

Technical User Guide  5 
 
Farm AirClean • BIO Flex 
2.1.2 Software Update .................................................................................................................... 47 
2.2 Setting Technical Parameters ............................................................................................. 48 
3 Start-up Test ............................................................................................... 50 
4 Service Check - every four Months .......................................................... 51 
5 Calibration .................................................................................................. 53 
5.1 Conductivity Sensor ............................................................................................................. 53 
5.1.1 Factory settings of the conductivity transmitter HC303 ........................................................ 54 
5.2 Differential Pressure Sensor ............................................................................................... 55 
5.3 pH Sensor .............................................................................................................................. 56 
5.3.1 Factory settings on the pH transmitter HC301 ....................................................................... 59 
5.4 Filter Washer ........................................................................................................................ 59 
Technical Data  60 
Enclosures  62 
1 Starting up a BIO Flex Installation ............................................................ 62 
2 Starting up a BIO Flex Installation (copy) ................................................ 63 
 

6 Technical User Guide

Farm AirClean • BIO Flex

1 Introduction

This user manual describes the operation and maintenance of the SKOV biological air cleaning system

BIO Flex. The manual provides the user with basic knowledge about the functions of the air cleaner

and the air cleaning computer. The sections Weekly Inspection and Maintenance Instructions are

aimed at the daily user whereas the section Service Guide is intended for professional service

engineers.

SKOV A/S would like to congratulate you on your choice of your new biological air cleaning system

1.1 Personal Safety Measures

In order to avoid damage to person and material, it is important that all operators are instructed in

correct use of the installation. With regard to safety, the operators should also be instructed in the risks

connected with using the air cleaning system.

The air cleaner includes electrical components and movable parts which require the

user to exercise caution.

General terms

There are environmental conditions in the biological air cleaner requiring special measures for those

who work inside the air cleaner. Concentrations of e.g. humidity, dust and ammonia may be increased

as well as exceptionally high amounts of hydrogen sulphide fumes, for example in connection with

slurry sluicing, and it is therefore important that the following safety precautions are observed.

In the air cleaner, you should be aware that:

• there may be sharp edges on metal components and vessels.

• the floor may be slippery.

• there should be adequate lighting in order to avoid falls in the vessels and pump wells.

Before entering the air cleaner, you must:

• activate the emergency stop for the filter washer.

• if possible, stop the ventilation through the air cleaner.

• open and secure doors, so they cannot slam shut.

• wear practical work clothes, e.g. rain gear, rubber boots, protective goggles, gloves and

breathing mask (P2).

1.2 Environmental Safety Measures

If the biofilm on the filters dries out, the environmental efficiency of the air cleaning may

subsequently be reduced for days or weeks.

In order to prevent the biofilm from drying out, it is important that:

• the trickling is not switched off.

• the ventilation is switched off through the air cleaner, if trickling is switched off.

Technical User Guide 7

Farm AirClean • BIO Flex

1.2.1 Signage

The following signs are used:

Warning: Slippery floor.

This sign is positioned on the doors in the technical room opening into the air

cleaner unit.

Warning: Be careful.

Place this sign on the door to room B where the filter washer is in operation.

2 Product Description

BIO Flex air cleaning system from SKOV A/S cleans the outgoing air from the livestock house of

ammonia, odour and dust. BIO Flex is well suited for large air cleaning systems in connection with

central channel and wall exhaustion.

BIO Flex with two filters is a biological air cleaning system - a two-step biotrickling filter. Air

cleaning is a biological process that works by exhaust air being removed from the house through

cleaning filters sprinkled with recirculating water. The unwanted substances in the air are absorbed by

the water or decompose when they come into contact with the water and the layer of bacteria on the

cleaning filters.

The biological process is controlled by an air cleaning computer, which monitors the chemical

composition of the water. The latter is adjusted by draining and supplying fresh water. The drained

water is either collected or directed to the slurry tank and is an applicable manure product due to its

high content of nitrogen.

As a standard, BIO Flex is supplied with a filter washer on the first filter. One can opt for the filter

washer for filter 2. The filter washer regularly washes the dust and redundant biomass off the filter.

This way, the filter washer ensures a high level of air cleaning efficiency, a low back pressure level

through the filters and reduces greenhouse gas emissions. Optimum air cleaning with minimum

resource consumption is handled by a DOL 356 air cleaning computer. Operating data is collected by

the FarmOnline WebLink network unit.

Ammonia

Smell of pig

Dust

Ammonia. Nitrite/nitrate. Organic material.

Residual products can be spread together with the

slurry.

Cleaned air

8 Technical User Guide

Farm AirClean • BIO Flex

2.1 2-Filter

Figure 1: Simplified sketch

Technical Room

Room A

Room B

Room D

Vessel 1

Vessel 2

Technical User Guide 9

Farm AirClean • BIO Flex

• 0: Air distribution plate

• 1: Filter 1

• 2: Filter 2

• 4: Exhaustion

• N1: Filter washer

• N1/N2: Filtervasker

• N1.1/N2.1:Water trap

• Q1: Main stopcock

• Q4/Q5: Rinse valves

• V1: Filter water supply

Technical Room

• K1: DOL 356

• K2: DOL 356 Extension

• B2: Differential pressure sensor

• M40: Horizontal filter washer 1

• P1: Water meter drainage

• P10: Water meter water supply

• Q15: Rep.switch filter washer 1

• Q10: Solenoid valve water supply

• S1: Main switch

• S2: Emergency stop filter washer

Horizontal/vertical

• S3: Socket outlet

Room A

• B1: Hydrostat

• B3: Temperature sensor before

• M10/M15: Trickling filter 1

• M32: Draining to slurry tank

Room B

• B9: Limit stop sensor back 1

• B10: Limit stop sensor forward 2

• M1/M2: Filter washer 1

• M17/M22: Trickling filter 2

• M46: Vertical filter washer 1

Room D

• B4: Conductivity sensor

• B5: pH sensor

• B7: Temperature sensor after

• B8: Temperature sensor water

Option

• M41: Horizontal filter washer 2

• M47: Vertical filter washer 2

• B11: Limit stop sensor back 2

• B12: Limit stop sensor forward 2

• Q16: Rep.switch filter washer 2

• M3/M4: Filter washer 2

In order to create an active biological environment, the filters must be kept wet at all times. The pumps

M10-M15 and M17-M22 suck water from the respective vessels and sprinkle the filters in their full

length. The pumps start and stop according to a time-dependent cycle which ensures minimum energy

consumption.

Usually, filter 1 is the most exposed filter as, apart from ammonia, it catches dust from the house air.

The N1 filter washer ensures that the film is kept at a suitable level so that air passes at a minimum

drop of pressure while an active biological mass is kept on the filter surface. The filter washer should

be adjusted in accordance with the given conditions. The differential pressure sensor B2 monitors the

pressure loss over the entire air cleaner so that clogged filters can be detected.

The air distribution plate 0 distributes the air over filter 1 and thus ensures optimum distribution of air

over the entire filter surface. Furthermore, it reduces the amount of dust on the filters.

Fresh water is supplied via the Q1 solenoid valve directly to the vessel below filter 2 and continues to

the vessel below filter 1.

The water in the vessel below filter 2 is continuously checked by a conductivity sensor B4. It ensures a

suitable biologically active water quality by activating the M32 drainage pump (water conductivity

reflects the content of waste products in the water).

DOL 356 initiates automatic drainage, if the set volume of minimum drainage has not been reached.

The water level is controlled by means of hydrostat B1. The water meters P10 and P1 measure water

supply and drainage. This is registered in the air cleaning computer. If a set value is exceeded, an

alarm/stop is triggered. Operating status, e.g. alarm, is shown on the main menu of the air cleaning

computer.

The mechanically, manually operated Q4 and Q5 valves are intended for routine rinsing of the

Trickling pipes.

10 Technical User Guide

Farm AirClean • BIO Flex

2.2 Air Cleaning Computer

The DOL 356 air cleaning computer controls the air cleaning process and monitors alarm limits and

consumption. The default setting of the computer ensures an operation form based on climate and

operation under Danish conditions.

The computer is operated by means of an adjustment knob/push button. In the main menu, the water

consumption and water drainage is read.

Select main menu, press

Main menu

Turn to select a menu

Water quantity in/out Filter washer menu

Press to

select a

menu

Press to

acknowledge

an alarm

Alarm lamp

Quick flashing = alarm

Press to return to

the main menu

Slow flashing = acknowledged alarm

Constant light = non-acknowledged alarm where the error has ceased

More submenus

Adjustable entity

Information

Options

Check box

Entry of name/code

2.2.1 Selection of Language

The default setting of the DOL 356 computer is English display texts. When you want to change

language, open the menu Technical/ User setup / Language.

Select book icon and

press

Press and select

language

Technical User Guide 11

Farm AirClean • BIO Flex

2.2.2 Survey

In this menu, it is possible to start/stop the functions of the air cleaner.

Rotate to select, e.g. like illustrated here ON, and press.

If for instance filter 1 is to be washed again, mark and

Extra wash.

If elements are marked with a cross, like e.g. , it means water drainage/water supply disconnected.

An example of disconnected water supply after the alarm: Leakage.

Water inlet is marked in the main menu.

Acknowledge the alarm to reactivate the water supply.

The water supply has now again been re-established.

OFF/START/ON

of the air cleaner

There is direct access from the

main menu to the functions

and status information.

Display shows:

- Trickling not active

- Filter washer

disconnected

- Water supply

disconnected

12 Technical User Guide

Farm AirClean • BIO Flex

2.2.3 Menu Survey

2.2.3.1 Service Info

Current operational data on selected sensor.

Summary of water supply and drainage

2.2.3.2 Operation

Technical User Guide 13

Farm AirClean • BIO Flex

2.2.3.3 Alarm

Active alarm and alarm

limits depend on the

sensor according to

which regulation is

carried.

Possibility of selecting

alarm vessel and whether

the alarm is to be high

and/or low for the

installed sensor.

Possible to enable/disable

the alarm.

Max. pressure drop over

the filter at an output of

100%.

Max. air flow through the

filter at an output of

100%.

Alarm leakage, only

active if the air quantity

sensor is installed.

Possible to enable/disable

the alarm.

14 Technical User Guide

Farm AirClean • BIO Flex

2.2.3.3.1 Alarms

When the air cleaning computer is OFF, all alarms are deactivated.

Active alarms

Displays the alarms that have not been attended to and

require action.

Value:

ON: Time when the error emerged.

ACK: Time when the alarm was acknowledged.

Previous alarms

Displays errors that have been corrected or ceased.

OFF: Shows the time when the error ceased.

Alarm limits

Alarms not maintained: If this field is ticked off, it

means that an alarm ceases, if the error ceases.

The alarm limits are not to be changed without the

acceptance of SKOV service.

Alarm test

Testing the alarm function.

Technical User Guide 15

Farm AirClean • BIO Flex

2.2.3.3.2 Alarm limits

Changes of alarm limits should not be carried out without the acceptance of SKOV A/S.

Alarm type

Remarks

Water level

Alarm high water level 20-40cm

Alarm low water level 10-30cm

Depend on desired normal water level

15 - 35cm.

Conductivity

High alarm limit: 20 mS/cm

Low alarm limit: 5 mS/cm

Regulation occurs after vessel 1

Conductivity

High alarm limit: 6 mS/cm

Low alarm limit: 0 mS/cm

Regulation occurs after vessel 2

pH

High alarm limit: 8.5 pH

Low alarm limit: 2.0 pH

The alarm limits for high and low pH

value.

Beware of regional or national standards

as regards the pH value in air cleaners.

Washer

Horizontal

Vertical

The DOL 356 computer is currently

calculating an alarm limit for the filter

washer.

Pressure

Alarm high pressure

Max. pressure loss 45 Pa

Delay 2 hour

The alarm limits are adjusted at start-up

so they match the system in question.

Alarm dynamic high pressure

Max. pressure loss 45 Pa

Max. airflow

Delay 2 hour

The alarm limits are adjusted at start-up

so they match the system in question.

This function is only active if a air flow

sensor has been installed.

DOL 356 is currently calculating the

pressure limit and adapts it to the

current air output.

Leakage

Alarm leakage

Every noon, DOL 356 calculates

whether a leakage has occurred based

on data collected over 24 hours.

This function is only active if a air flow

sensor has been installed.

Water inlet

Alarm water supply missing

This function is only active if a pressure

sensor has been installed.

Drainage

Alarm drainage, no flow

16 Technical User Guide

Farm AirClean • BIO Flex

2.2.3.3.3 Alarms

Alarm

Display shows

Reason

Check…

Low water level

Too little water is supplied.

Hydrostat B1

Water supply

Solenoid valve Q10

Filter in water supply

High water level

The supplied quantity of water is too

high.

Hydrostat B1

Solenoid valve Q10

Water meter P10

Low conductivity

Too much water is supplied.

The drainage pump runs but should not.

No animals in the house.

Vessel for leakages

Drainage pump M32

Sensor B4. See page 7

High conductivity

Too little water is drained.

Defective drainage pump.

Defective conductivity sensor.

Drainage pump M32

Water meter P1

Sensor B4, film. See page 7 and 26.

Washer Horizontal

Washer Vertical

Filter washer is not working.

Motor and wire tension

Inductive sensor for end stop

Vertical actuator

Leakage

Redundant water supplied during a

given period of time.

Water meter measures too much.

Water meter measures too little.

Solenoid valve Q10

Water meter P10

Vessel for leakages

Water meter P1

Water inlet, no flow

Water meter does not measure any flow

when the solenoid valve is activated.

Water meter P10

Solenoid valve Q10

Lack of water

Drainage, no flow

Water meter does not measure any flow

when the drainage pump is activated.

Water meter P1

Drainage pump M32

High Pressure

The filters are clogged.

Coating on the filters or air distribution plate

Setting of alarm limit for high pressure.

Differential pressure sensor.

Dynamic High

Pressure

The filters are clogged.

Coating on the filters or air distribution plate

Setting of alarm limit for high pressure.

Differential pressure sensor.

Signal from air flow sensor.

pH low

Sudden change in the livestock house

management

Error on pH Sensor

Sensor B5

Water in the vessel

pH high

Error on pH Sensor

Sensor B5

Water in the vessel

Contact Service if the value is exceeded for

more than one week.

Technical User Guide 17

Farm AirClean • BIO Flex

2.2.4 Technical

18 Technical User Guide

Farm AirClean • BIO Flex

2.3 Data Logging in FarmOnline WebLink

Operation data from DOL 356 for analysis and documentation

purposes in relation to regulatory requirements is collected by

FarmOnline WebLink.

Data is logged every two minutes and is stored for up to five

years.

To reach the data, please contact SKOV A/S.

The following data can be collected in FarmOnline WebLink:

• conductivity vessel 1 and 2

• pH in vessel 1and 2

• amount of air going through the air

cleaner

• pressure loss through the air cleaner

• inlet air temperature

• outlet air temperature

• water temperature vessel 1or 2

• supplied quantity of water - consumption

filter 1 and 2

• drained quantity of water – consumption

filter 1 and 2

• Trickling pump filter 1 and 2 - operation

time

• wash pump filter washer 1and 2 -

operation time

• horizontal motor filter washer 1 and 2-

operation time

• vertical motor filter washer 1and 2 -

operation time

• drainage pump - operation time

Technical User Guide 19

Farm AirClean • BIO Flex

3 Maintenance Instructions

In order to ensure the efficiency of the air cleaner, it is important to carry out inspection and

maintenance of basic functions. Focus must be placed on ensuring the trickling of filters, in

order to keep them saturated and to rinse nutrient salts efficiently out of the filters.

3.1 Maintenance overview for air cleaning

Maintenance overview for air cleaning

Weekly

Periodicall

y, at least

monthly

Every 4th

month

Carried out by

User

SKOV

Check that there is running water in general as well as in all the filters.

X

Rinse sprinkling and clean if necessary

X

Check pressure loss above filters and the air distribution plate – wash if

necessary

X

Assess BIO film and correct if necessary

X

Fill out the logbook

X

Check the effect of the filter washer – clean and correct wash frequency

X

Assess the contamination of the process water and replace if necessary

X

Check and clean hydrostat

X

Check and clean conductivity sensor

X

Check and clean pH sensor

X

Check temperature sensor

X

Check water supply and clean filter sieve if necessary

X

Check that water meters register water consumption and drainage

X

Check drainage and clean pump sieve if necessary

X

Check management – setting, maintenance, FO data

X

Check environmental impact – measure pH, mS/cm, pressure loss –

correct if necessary

X

Check environmental impact - Bio film, filter water – correct if necessary

X

Check process water – replace and clean if necessary

X

Check and calibrate hydrostat

X

Check and calibrate conductivity sensor

X

Check and calibrate pH sensor

X

Check temperature sensor and replace if necessary

X

Check and calibrate the differential pressure sensor

X

Check pumps – clean sieve and measure leakage current

X

Check filter washer – adjust and replace wearing parts if necessary

X

Check trickling – assess frequency and adjust if necessary

X

Check water meters – data collection in DOL 356 – clean if necessary

X

Check solenoid valve and clean if necessary

X

Documentation for authorities

X

20 Technical User Guide

Farm AirClean • BIO Flex

3.2 Weekly Inspection and Maintenance

3.2.1 Trickling of Filter 1 and 2

The purpose of trickling is to keep the filter soaked and rinse the nutrient salts out of the filter and the

biofilm. When trickling is enabled, there must be running water everywhere on and inside the filter.

The pump in the vessel pumps water up into the sprinkling pipe. The water jets are directed into the

half shell from which water is distributed and runs down into the filter.

The environmental effect of the filter is reduced if the trickling of the filter is insufficient. Dry,

inactive zones/stripes may arise on the filter and the amount of drained water may be increased.

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Skov Farm AirClean BIO Flex 2-0 Technical User Guide

Skov Farm AirClean BIO Flex 2-0 Technical User Guide

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