DOMUSA TEKNIK BIOCLASS iC 150 User manual

BIOCLASS iC 150
Biomass boiler
EN | INSTALLATION AND OPERATING INSTRUCTIONS

Thank you for choosing a DOMUSA TEKNIK heating boiler. You have
chosen the BIOCLASS iC 150 model from the DOMUSA TEKNIK product
line. With a suitable hydraulic installation and with wood pellets for fuel, this
boiler will provide the ideal level of comfort for your facilities.
This document constitutes an essential part of the product and must be
delivered to the end user. It is advisable to carefully read the warnings and
advice contained in this manual, as they provide important information
regarding the safety of the installation, as well as use and maintenance.
These boilers must be installed by qualified personnel only, in accordance
with the legislation in force and following the manufacturer's instructions.
Start-up of these boilers and any maintenance operations must only be
carried out by DOMUSA TEKNIK’s Authorised Technical Assistance
Services..
Incorrect installation of these boilers could result in damage to people,
animals or property, and the manufacturer will hold no liability in such cases.
DOMUSA TEKNIK, in compliance with item 1 of the first additional provision
of Act 11/1997, hereby informs that the person in charge of delivering the
container waste or used container, for its correct environmental
management, will be the final holder of the product (Article 18.1 of Royal
Decree 782/1998). At the end of its useful life, the product must be taken to
a selected collection point for electrical and electronic equipment or must be
returned to the distributor at the time of purchasing a new equivalent
appliance. For more detailed information on the collection diagrams
available, please contact either the collection facilities of the local authority
or the distributor where the purchase was made.

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BIOCLASS iC 150
CONTENTS
1 LIST OF COMPONENTS ............................................................................................................... 6
2 INSTALLATION INSTRUCTIONS .................................................................................................. 9
2.1 LOCATION .............................................................................................................................................. 9
2.2 HYDRAULIC INSTALLATION ........................................................................................................................ 10
2.3 FUEL .................................................................................................................................................. 10
3 MOUNTING THE BOILER .......................................................................................................... 11
3.1 MOUNTING THE BURNER .......................................................................................................................... 11
3.2 MOUNTING THE RESERVE TANK AND SUCTION SYSTEM ...................................................................................... 13
3.3 MOUNTING THE ASH DRAWER .................................................................................................................... 18
3.4 ELECTRICAL CONNECTION ........................................................................................................................ 18
3.5 COMBUSTION PRODUCT REMOVAL ............................................................................................................... 19
4 STARTING UP THE BOILER ....................................................................................................... 20
4.1 PRIOR WARNINGS .................................................................................................................................. 20
4.2 ELECTRICAL CONNECTION ......................................................................................................................... 20
4.3 FILLING THE INSTALLATION ....................................................................................................................... 20
4.4 INITIAL CALIBRATION OF THE FUEL FEEDER .................................................................................................... 20
4.5 START-UP ............................................................................................................................................ 21
4.6 INSTALLATION HAND-OVER ....................................................................................................................... 21
5 DIGITAL DISPLAY: ................................................................................................................... 22
6 OPERATION ............................................................................................................................. 24
6.1 SELECTING THE BUFFER TANK OR WATER SETPOINT TEMPERATURE. ...................................................................... 24
7 OPERATION WITH BUFFER TANK .............................................................................................. 25
7.1 OPERATION WITH ONE TEMPERATURE PROBE ................................................................................................. 25
7.2 OPERATION WITH TWO TEMPERATURE PROBES ............................................................................................... 26
7.3 OPERATION WITH THREE OR FOUR TEMPERATURE PROBES.................................................................................. 26
7.4 WINTER/SUMMER MODE .......................................................................................................................... 27
8 OPERATION WITH HYDRAULIC NEEDLE .................................................................................... 28
9 USER MENU ............................................................................................................................. 29
9.1 ASH DEPOSIT STATUS .............................................................................................................................. 3 0
10 SETTINGS MENU .................................................................................................................... 31
10.1 PROGRAMMING PROCESS ........................................................................................................................ 32
10.2 TIMER PROGRAMMING OF THE BOILER ........................................................................................................ 32
10.3 ADJUSTING THE TIME ............................................................................................................................ 33
10.4 EMPTY ASH BOX NOTICE ......................................................................................................................... 33
10.5 MANUAL ADJUSTMENT OF THE CALIBRATION ................................................................................................. 34
10.6 ADJUSTING THE CONTRAST OF THE DISPLAY ................................................................................................. 34
11 CALIBRATION MENU .............................................................................................................. 35
11.1 DRAINING THE FEEDER .......................................................................................................................... 36
11.2 CALIBRATION OF THE FEEDER .................................................................................................................. 37
11.3 MANUAL ADJUSTMENT OF THE FEED AUGER CALIBRATION ................................................................................. 38
11.4 MANUAL ASH CLEANING ......................................................................................................................... 38
11.5 MANUAL OPERATION OF THE CIRCULATION PUMP ........................................................................................... 38
11.6 CALIBRATION OF THE LAMBDA PROBE ......................................................................................................... 38
12 TECHNICAL MENU .................................................................................................................. 39
13 CONFIGURING THE BOILER .................................................................................................... 4 3
13.1 BOILER MODEL (P.01) .......................................................................................................................... 43
13.2 SET THE BOILER POWER (P.02, P.03) ....................................................................................................... 43
13.3 GENERAL FAN FACTOR (P.04) .................................................................................................................. 43
13.4 FUEL FOR IGNITION (P.05) ..................................................................................................................... 43
13.5 FUEL (P.06) ....................................................................................................................................... 43
13.6 AUXILIARY PARAMETER FOR CLEANING INTERVAL SETTING OF THE BURNER (P.26) .................................................. 43
13.7 TEMPERATURE MAINTENANCE OF THE BOILER (P.13, P.14) ............................................................................. 44
13.8 SELECTION OF THE OXYGEN CONCENTRATION (P.36) ..................................................................................... 44
14 HYDRAULIC CIRCUIT ADJUSTMENTS ...................................................................................... 45
14.1 POST-CIRCULATION OF THE BUFFER TANK OR NEEDLE FEED PUMP (P.42) ............................................................. 45
14.2 MINIMUM FILLING PRESSURE OF THE INSTALLATION (P.19) .............................................................................. 45

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BIOCLASS iC 150
14.3 SELECTION OF THE MINIMUM RETURN TEMPERATURE (P.37) ............................................................................ 45
15 OPERATION OF THE PELLET ASPIRATION SYSTEM .................................................................. 46
15.1 OPERATION WITH CANVAS SILO OR SUCTION NOZZLE ..................................................................................... 47
16 ADDITIONAL FUNCTIONS ....................................................................................................... 48
16.1 CONNECTION OF THE REMOTE CONTROL INPUT OF THE BOILER ......................................................................... 48
16.2 CYCLE TIME OF THE FUEL SUCTION SYSTEM (P.22) ........................................................................................ 48
16.3 RESET DEFAULT FACTORY VALUES (P.24) .................................................................................................... 48
16.4 ANTI-BLOCK PUMP FUNCTION ................................................................................................................... 48
16.5 ANTI-FROST FUNCTION .......................................................................................................................... 48
16.6 BOILER PRESSURE SENSOR FUNCTION ......................................................................................................... 48
16.7 EXTERNAL ALARM INPUT (P.38) ............................................................................................................... 49
16.8 OPERATION OF ALARM OUTPUT ................................................................................................................ 49
16.9 COMMUNICATION MODBUS TCP/IP ........................................................................................................ 49
17 FUNCTIONS OF THE “MULTIFUNCTION RELAY” (P.20) ............................................................. 50
17.1 AUTOMATIC FILLING FUNCTION (P.20 = 1) ................................................................................................ 50
17.2 ACTIVATION OF AUXILIARY SOURCE WITH BOILER LOCK-OUT (P.20 = 2) ............................................................. 50
17.3 ACTIVATION OF AUXILIARY SOURCE DURING PEAKS IN DEMAND (P.20 = 3) .......................................................... 50
17.4 ACTIVATION OF AUXILIARY SOURCE WITH BOILER LOCK-OUT AND PEAKS IN DEMAND (P.20 = 4) ................................ 50
18 SAFETY INTERLOCKS ............................................................................................................. 51
18.1 TEMPERATURE SAFETY INTERLOCK............................................................................................................. 51
18.2 SAFETY INTERLOCK DUE TO TEMPERATURE IN THE FUEL INLET PIPE ..................................................................... 51
18.3 LOW PRESSURE INTERLOCK ..................................................................................................................... 52
19 SHUTTING DOWN THE BOILER ............................................................................................... 52
20 DRAINING THE BOILER .......................................................................................................... 52
21 BOILER MAINTENANCE ........................................................................................................... 53
21.1 BOILER AND FLUE MAINTENANCE FREQUENCIES ............................................................................................. 53
21.2 CLEANING THE ASH DRAWER .................................................................................................................... 54
21.3 CLEANING THE BURNER COMBUSTION CHAMBER ............................................................................................ 55
21.4 GENERAL CLEANING OF THE BURNER .......................................................................................................... 57
21.5 CLEANING OF THE SMOKE BOX AND LAMBDA PROBE ........................................................................................ 59
21.6 GENERAL CLEANING OF THE VENT CLEANING CIRCUIT ...................................................................................... 60
21.7 CLEANING OF THE PROTECTION GRILLE AND INSPECTION OF THE SUCTION UNIT ..................................................... 61
21.8 DRAINING THE CONDENSATION WATER ....................................................................................................... 62
21.9 BOILER WATER CHARACTERISTICS ............................................................................................................. 62
22 DIAGRAMS AND MEASUREMENTS ........................................................................................... 63
23 CONNECTIONS DIAGRAM ....................................................................................................... 64
23.1 BOILER ............................................................................................................................................. 64
23.2 BURNER ............................................................................................................................................ 66
24 ELECTRICAL DIAGRAM ........................................................................................................... 67
25 ALARM CODES ....................................................................................................................... 72

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BIOCLASS iC 150
1 LIST OF COMPONENTS
1. Pellets suction pot.
2. BioClass iC 150 Bioler.
3. Compressor ash deposit.
4. Pellet suction turbine.
5. Removable cover.
6. Pellet reserve tank.
1
2
3
4
6
5

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BIOCLASS iC 150
7. Exterior ash drawer.
8. Interior ash drawer.
9. Burner.
10. Fuel feeder.
11. Bulb sheath.
12. Vent cleaning device.
13. Fan.
14. Water pressure sensor.
15. Boiler body.
789
15
14
12
12
13
11
10

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BIOCLASS iC 150
control components
19 20 22
18
21
1716
16. MENU touch button:
This button is used to access and browse the
"User Menu".
17. Digital display:
This is the main boiler functioning display, on
which all the operating information, settings and
values appear. This display is also used to access
the appliance's user and service settings. In
standard operating mode (default display), the
actual boiler temperature is shown. If
malfunction occurs, an alarm code will appear on
the digital display instead of the temperature.
18. RESET touch button:
When the boiler is in lock-out mode, the RESET
button is pressed to reset the lock-out and
restore "Standard" functioning. If you are
modifying any of the settings or browsing the
menus, you may press the RESET button to exit
the menu WITHOUT SAVING and return to the
previous menu level.
19. ON touch button:
This button switches the boiler on and off.
20. Touch button for selecting buffer tank
or hydraulic needle temperature:
With this button we can select the buffer tank or
hydraulic needle temperature we require.
21. Touch button for selecting the boiler
operating mode (winter/summer):
With this button we can select the boiler's
operating mode.
22. SETTINGS touch button.
This button is used to access and browse the
"Settings Menu". By pressing this button we can
access the various modifiable parameters for
adjustment.

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BIOCLASS iC 150
2 INSTALLATION INSTRUCTIONS
The boiler must be installed by personnel authorised by the Ministry of Industry, in compliance with the
applicable laws and regulations.
This boiler is suitable for heating water to a temperature below boiling point at atmospheric pressure. It
must be connected to a heating installation and/or a domestic hot water distribution network, which must
always be compatible with its performance and power.
This appliance should only be used for the purpose for which it has been expressly designed. Any other
use should be considered improper and, therefore, hazardous. The manufacturer shall not be considered
liable under any circumstances for damage caused by unsuitable, erroneous or improper use.
Remove all the packaging and check that the contents are complete. In case of doubt, do not use the
boiler. Contact your supplier. The packaging components must be kept out of the reach of children, as
they constitute potential sources of danger.
When you no longer wish to use the boiler, disable the parts that could be a potential source of hazard.
2.1 Location
The boiler must be installed in a sufficiently ventilated site, away from humidity. The boiler must be
positioned in such a way that does not obstruct the grilles on the site. All the boiler parts should be
easily accessible in such a way that they all maintenance operations can be carried out properly and
safely.
It is necessary to respect the minimum distances to the surrounding components.
a= min. 1000 mm.
b= min. 700 mm.
c= min. 700 mm.
d= min. 1200 mm.
e= min. 2500 mm.
a
b
c
d
e
a
b
c
d
e

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BIOCLASS iC 150
2.2 Hydraulic installation
The hydraulic installation should be carried out by qualified personnel, in compliance with the current
installation regulation (RITE) and considering the following recommendations:
• It is obligatory and essential to install a device for raising the return temperature to
prevent any water condensation in the heat exchanger. If this requirement is not complied
with, DOMUSA TEKNIK's guarantee of the appliance will automatically be null and void.
• The inside of the installation piping should be thoroughly cleaned before switching on the
boiler.
• We recommend inserting cut-off valves between the installation piping and the boiler to
simplify maintenance tasks.
• Leave a free space around the boiler for carrying out any maintenance and repair operations.
• Drain valves and suitable devices for correctly bleeding the air from the circuit during the
boiler filling stage should be fitted. The boiler has an inlet on its highest part for fitting a
drain valve.
• Install all the necessary safety elements in the installation (expansion vessel, safety valve,
etc.) to comply with the required installation standards.
2.3 Fuel
The BIOCLASS iC 150 boiler must be fuelled by ENplus-A1, DIN PLUS certified wood pellet or
equivalent. The DIN PLUS certificate assures that the fuel's humidity levels and calorific value are ideal
for optimum boiler functioning. If this requirement is not complied with, DOMUSA TEKNIK's
guarantee of the appliance will automatically be null and void.
The following aspects must be taken into account for correct fuel storage:
• The wooden pellets must be stored in a room protected from humidity and the weather. It
is important to create an air gap around the bags or big-bags of wood pellets to ensure good
ventilation. These bags or big-bag must never be stored in direct contact with the floor and/or
a wall.
• The wooden pellets must be handled with care, as any handling may damage them.
• The wooden pellets must be visually inspected before use in the boiler to ensure there are
no large amounts of dust or crushed pellets, which could cause the boiler to malfunction.

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BIOCLASS iC 150
3 MOUNTING THE BOILER
DOMUSA TEKNIK shall supply, along with the boiler, the pellet burner, the reserve tank with the fuel
suction system and the ash drawer.
3.1 Mounting the burner
The burner and reserve tank can be mounted on either the left or right side of the boiler.
IMPORTANT: It is essential to obtain a good seal in the join between the burner and the
boiler (drawing No. 5) and the maintenance door and the boiler (drawing
No. 8).

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BIOCLASS iC 150
If the burner is installed on the right side of the boiler the air inlet part from the burner must be
changed:

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BIOCLASS iC 150
3.2 Mounting the reserve tank and suction system
The reserve tank and the pellet suction system is delivered ready for mounting on the left side of
the boiler. The mounting of the reserve tank and suction system must be carried out on the same
side as the burner.
For the correct assembly of the reserve tank on the left side, carefully follow the assembly sequence
described below:

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BIOCLASS iC 150
For the correct assembly of the reserve tank on the left side, carefully follow the assembly sequence
described below:

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BIOCLASS iC 150

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BIOCLASS iC 150
The pellet feeder must be assembled by following the instructions below:
There is a ventilation slot on the rear of the reserve tank to prevent a vacuum from being created inside
it. Do not cover this slot, and keep it free from any obstacles that could block it.
NOT COVER

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BIOCLASS iC 150
The fill level detection sensor for the pellets is supplied already set by the factory, therefore there is no
need to adjust it unless it has become maladjusted during transport.
2-3 mm Filling sensor
Fill indicator
The various automatic fuel suction system components must be connected pneumatically using a hose
with an interior diameter of 50 mm, preferably a flexible plastic hose with electrostatic charge
accumulation protection.
To ensure the system is correctly connected and sealed, the boiler includes 4 coupling flanges for fixing
the hose ends to the respective pneumatic components.
The figure below shows the connection diagram of the fuel suction system:
Bucket
A
B
Canvas
Silo
B
A
Nozzle for
constructionsite
A
B
Bucket
A
B
Run a pipe from the main storage silo (intake A) to the boiler reserve tank and connect it to the cyclonic
suction intake, (intake A) located on the rear part of the same. Run a pipe from the cyclonic air pipe
(intake B) to intake B of the canvas silo or working nozzle.

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BIOCLASS iC 150
3.3 Mounting the ash drawer
3.4 Electrical Connection
The boiler is prepared for connection to a 230 V~ 50 Hz (J20 connector). The socket should have
an appropriate earth connection.
The burner is electrically connected to the boiler using connectors C1, C2, C3 and C4 (see
“Connection diagram”).
The suction system is connected via the two hoses included with the boiler. The communication
hose and the supply hose must be connected to the corresponding terminal strip J18 located in the
pellet reserve tank (see “Connection diagram"”).
The terminal strip J14 includes terminals for connecting the fuel feeder, while terminal strip J12
includes terminals for connecting the feed pump for the buffer or needle tank (Bbt).
The boiler has a terminal strip CR (J6), prepared (see "Connection Diagram") for remote control
of the boiler.
IMPORTANT: When working on the electrical installation of the boiler, make sure that
it is disconnected from the electrical network.

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BIOCLASS iC 150
3.5 Combustion product removal
The BioClass boiler is a BIOCLASS iC 150 biomass boiler and it is essential for it to be connected to
a flue, i.e. a smoke duct able to create a pressure drop (which in this case should be between 0.10 and
0.20 mbar), in compliance with the applicable laws in this regard.
The combustion product exhaustion ducts must be installed by qualified personnel and must comply
with the regulations in force. For the flue to create a pressure drop, the following recommendations
should be taken into account:
• It should be suitably insulated.
• It should be independently located, with a separate flue for each boiler.
• It should be vertical, avoiding any angles greater than 45º.
• It should always have the same diameter. It is recommendable for it to be circular, and never
any narrower than the boiler outlet.
• It is obligatory to install a fume inspection plate with condensation collection, to
remove the condensation generated in the flue. Otherwise, the condensation may
reach the inside of the boiler and cause irreparable damage, which would not be covered
by DOMUSA TEKNIK's guarantee. The condensation pipe should lead to a drain outlet,
as a large amount of water may be generated. This connection must be made in compliance
with the regulations for draining off condensation water to the drain system.
• It is recommended that a draught stabiliser be installed to prevent any pressure drop
variations in the flue due to atmospheric conditions, which could affect correct boiler
combustion.

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BIOCLASS iC 150
4 STARTING UP THE BOILER
4.1 Prior warnings
Repair and maintenance of the boiler must be carried out by a qualified professional, authorised by
DOMUSA TEKNIK. For optimum functioning and conservation of the boiler, it should be serviced
annually.
Please carefully read this instruction manual and keep it in a safe, easily-accessible place. DOMUSA
TEKNIK will not be liable for any damages caused by failure to follow these instructions.
Before any servicing, disconnect the boiler from the mains.
4.2 Electrical connection
The boiler is equipped for connection at 230 V~ 50 Hz to terminals No. 1 and 2 of the J20 power
strip. The socket should have an appropriate earth connection..
4.3 Filling the installation
The hydraulic installation must include a fill valve, a safety valve, drain valves and the necessary
hydraulic components for correctly filling the installation.
To fill the installation, open the fill valve until the
"water pressure" on the "User Menu" shows a
pressure of between 1 - 1.5 bars. The installation must be filled slowly, bleeding the air from the
water circuit using the drain valves provided for this purpose. Close the fill valve after filling.
The BIOCLASS iC 150 boilers have a pressure sensor for controlling the pressure of the installation.
If the installation does not have minimum of the pressure selected in parameter P.19 of the
"Technical Menu" (default setting 0.5 bar), the low-pressure alarm ("E-19) will appear on the
display.").
IMPORTANT: Switching on the boiler with no water inside could result in serious
damage.
4.4 Initial calibration of the fuel feeder
The BioClass Ic 150 boiler is supplied from the factory with a fuel feeder, which should be
assembled inside the reserve tank, as indicated in section
“Assembly of the reserve tank” . Due to
the diversity of fuel qualities on the market, it will be essential to carry out at least an initial
calibration of the feeder for optimal operation of the boiler.
To carry out the calibration process correctly the instructions of section
"Calibration of the feeder
should be carefully followed.
" .