DOMUSA TEKNIK BIOCLASS iC 150 Installation And Operating Instructions Manual Download Page 1

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BIOCLASS iC 150

Biomass boiler

| INSTALLATION AND OPERATING INSTRUCTIONS

Summary of Contents for BIOCLASS iC 150

Page 1: ...BIOCLASS iC 150 Biomass boiler EN INSTALLATION AND OPERATING INSTRUCTIONS ...

Page 2: ......

Page 3: ...ance 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 ...

Page 4: ...8 9 USER MENU 29 9 1 ASH DEPOSIT STATUS 30 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 AU...

Page 5: ...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 FLU...

Page 6: ...EN 6 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 ...

Page 7: ...7 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 7 8 9 15 14 12 12 13 11 10 ...

Page 8: ... 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 b...

Page 9: ...ge 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 Lo...

Page 10: ...s 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 opt...

Page 11: ...nk 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 ...

Page 12: ...EN 12 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 ...

Page 13: ...t 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 ...

Page 14: ...EN 14 BIOCLASS iC 150 For the correct assembly of the reserve tank on the left side carefully follow the assembly sequence described below ...

Page 15: ...15 BIOCLASS iC 150 ...

Page 16: ...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 ...

Page 17: ...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 construction site A B Bucket A B Run a pipe from the main storage silo intake A to the...

Page 18: ...oiler 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 Conn...

Page 19: ...d 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 ...

Page 20: ...l 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 se...

Page 21: ...The feed auger must be calibrated for correct boiler functioning See Calibrating the feed auger Check that the type of fuel is suitable for wooden pellets it must be ENplus A1 DIN PLUS or equivalent If the installation has flow and return valves check they are open 4 6 Installation hand over After the initial start up the Technical Assistance Service will explain to the user how the boiler functio...

Page 22: ...splayed when the real time is in the OFF programme period Symbol indicating that the timer programming is active or that the meaning of the numerical display is related to the real time programming display etc D Numerical calibration Depending on what is being displayed the numerical calibration on the top part of the screen will have the following meanings Time calibration This calibration is use...

Page 23: ...Sbt2 Lower temperature probe of the buffer tank Sdown J Operating mode icons Display of any value or parameter related to operation according to the pending load of the buffer tank Display of any value or parameter related to the boiler and or burner Display of any value or parameter related to the functioning of the boiler fan Display of any value or parameter related to the weighing of fuel fuel...

Page 24: ... new heating cycle 6 1 Selecting the buffer tank or water setpoint temperature The desired buffer tank temperature is selected using the touch button as shown in the figure To select the desired temperature touch the or symbols to increase or decrease the temperature value respectively When the temperature has been selected the display will return to standby mode after a few seconds The permitted ...

Page 25: ...temperature probe Scol supplied with the boiler The burner will start working to heat the water in the boiler When the boiler temperature exceeds 60ºC the feed pump for the buffer tank Bbt will start up to heat the buffer tank The modulating burner of the BioClass iC 150 boiler will keep the water in the buffer tank at the selected temperature To heat the buffer tank to the selected temperature th...

Page 26: ...lled in the upper area of the tank and the remaining probes distributed at different heights in the tank The burner will start working to heat the water in the boiler When the boiler temperature exceeds 60ºC the feed pump for the buffer tank Bbt will start up to heat the buffer tank To heat the buffer tank to the selected temperature the boiler should have a higher set temperature to compensate fo...

Page 27: ...service mode by selecting the DHW setpoint value equal to ON In the summer service mode control is performed by the temperature probe Scol The operation is the same as that described in the section Operation with one temperature In the winter service mode the operation is performed according to the number of probes connected in the boiler ...

Page 28: ...0ºC the feed pump for the buffer tank Bbt will start up to heat the buffer tank The modulating burner of the BioClass iC 150 boiler will keep the hydraulic needle at the selected temperature To heat the hydraulic needle to the selected temperature the boiler will have to have a higher setpoint temperature to compensate for the loss of temperature from the installation between the boiler and the ne...

Page 29: ...standby after 20 seconds have elapsed The following table shows the different display options Standby The actual boiler temperature is shown Ash deposit filling status see Ash deposit status Current time HH MM Boiler or buffer tank setpoint temperature selected using the corresponding touch button 20 Actual temperature of the buffer tank or needle Scol Actual average temperature of the buffer tank...

Page 30: ...warns us when the ashtray drawer is full and needs to be emptied In the Ash deposit status parameter you can see its condition and the upper part of the screen will display a bar indicating the fill level of the ash deposit When it is full a notice to empty the ashtray is activated Every time the ashtray is emptied the screen value for Ash deposit status should be set to zero to do this press the ...

Page 31: ...he desired parameter has been adjusted press again to save and return to the Settings Menu From the Settings menu or any of its settings press Reset to return to the previous display level without saving These settings are listed in the table below No Parameter Display 1 Timer programming of the boiler 2 Adjusting the time 3 Ash deposit empty notice 4 Manual adjustment of the calibration 5 Contras...

Page 32: ...process Using the symbols or for Heating 20 you can browse through the timer programming in increments of 30 minutes Once the desired scheduling period has been selected using the symbols or of DHW 21 the programming status will change from off displaying the symbol to on displaying the symbol and vice versa Once all the desired time periods are adjusted pressing the symbol for the last time will ...

Page 33: ...ed with its emptying In the parameter Ash box status of the User Menu we can see its status When it is full an empty the ash box notice is activated By default the ash box reminder function is supplied activated and is set to indicative fuel consumption values which depending on the quality and type of fuel will have to be adjusted for each system Shown below are the default number of pellet tonne...

Page 34: ... flashing and using the symbols or of DHW 21 we can set the desired value The range of setpoint calibration is OFF 5 000 9 900 kg 10 6 Adjusting the contrast of the display Once the display Contrast adjustment from the Settings Menu is selected by pressing the symbol we can access it SET will begin flashing and using the symbols or of DHW 21 we can set the desired value The range of selected value...

Page 35: ...g 20 you can browse through the menu settings Once the desired parameter is selected press again to access it and it can be adjusted or modified using symbols or of DHW 21 Once the desired parameter has been adjusted press again to save and return to the Calibration Menu From the Calibration menu or any of its settings press RESET to return to the previous display level without saving These settin...

Page 36: ...essing the symbol we can access it SET will begin flashing Pressing symbol again will start the drainage process activating the fuel feeder for a maximum of 15 minutes While the drainage operation is running the display will show the time elapsed Pressing will stop the feeder at any time and by pressing RESET we can exit the drainage process at any time To ensure the fuel feeder is properly draine...

Page 37: ...ring start up On selecting the Calibration of the fuel feeder display from the Calibration Menu by pressing the symbol we can access it and SET will begin flashing Pressing symbol again will start the calibration process activating the countdown from 200 doses in the fuel feeder When the countdown finishes the current calibration value will be displayed and its value may be adjusted using the or o...

Page 38: ...SET you can go back to the Calibration menu at any time 11 5 Manual operation of the circulation pump In this display we can manually operate the feed pump of the buffer tank or needle On selecting the Manual operation of pump Bbt from the Calibration Menu by pressing the symbol we can access it and SET will begin flashing Pressing the symbol again the pumps will start up and run for a maximum of ...

Page 39: ...ing the symbols or for Heating 20 will browse through the menu parameters P 01 P 28 Once the desired parameter is selected by pressing the symbol we can access it and adjust or modify it Once the desired parameter has been adjusted press again to save and return to the Technical Menu In the Technical Menu or within any parameter of it press RESET to return to the previous display level without sav...

Page 40: ...er pressure adjustment P 20 Multifunction relay P 21 Automatic water filling pressure adjustment Only when P 20 3 P 22 Cycle time of the fuel suction system P 24 Reset default values P 25 Set access code P 26 Auxiliary adjustment setting of the burner cleaning interval P 29 Cascade sequence type Only active with the cascade module connected ...

Page 41: ...setpoint and temperature setpoint of tank or needle P 36 Selection of the oxygen concentration at rated ower P 37 Return temperature selection P 38 External Alarm Input P 39 Lower temperature selection of the buffer tank P 40 Load status of the buffer tank for activating heat demand P 41 Load status of the buffer tank for disabling heat demand P 42 Post circulation time of the buffer tank or needl...

Page 42: ...ccess code cod display is selected or adjusted P 25 pressing the symbol will access it and SET will begin flashing using the symbols or for heating 20 we can navigate through the code digits Using the symbols or from HCW 21 we can adjust the value of each digit independently The factory default access code is 1234 Parameter P 25 can be used to set a new desired access code ...

Page 43: ...sure the correct values for combustion Changing its value adjusts the fan percentage for the entire modulation curve The selectable range of parameter P 04 is 0 200 default value 100 if a value under 100 is set the air quantity will reduce and if a value higher than 100 is set it will increase 13 4 Fuel for ignition P 05 Parameter P 05 may be used to adjust the amount of fuel used in the burner ig...

Page 44: ...perature maintenance modes for the boiler P 13 0 Maintains the minimum boiler temperature set in P 14 only with the Remote Control signal enabled input CR closed P 13 1 Maintains the boiler setpoint temperature selected on the control panel P 13 2 Minimum boiler temperature is not maintained P 13 4 Maintains the minimum boiler temperature set in P 14 regardless of the Remote Control signal 13 8 Se...

Page 45: ...inutes 14 2 Minimum filling pressure of the installation P 19 The BioClass iC 150 boiler has a water pressure sensor through which the electronic control is able to monitor the boiler pressure at all times in such a way that if the pressure drops to a specified value the control will lock out the boiler and trigger the alarm E 19 see Safety Interlocks Parameter P 19 is used to set the minimum wate...

Page 46: ...n the control disables the operation of the fuel feeding system and waits until it starts up again During the whole time in which the suction turbine is operating the silo symbol will appear flashing on the boiler display If after 9 consecutive cycles the sensor continues without detecting the filling of the reserve tank the control will lock out the suction system and trigger alarm E 27 fuel suct...

Page 47: ... the boiler display To unlock the system we should press on the boiler control panel and 9 more consecutive cycles will rerun or until the sensor detects the tank filling The optimum cycle time is the time required for the cyclone on the reserve tank to be filled to its full capacity The amount of pellets conveyed by cycle will depend on the length and route of the installation and the type of pel...

Page 48: ...y have been out of use for a long period This system remains enabled while the boiler is plugged into the mains 16 5 Anti frost function This function protects the boiler from freezing up during cold weather If the boiler temperature drops to below 6ºC the boiler circulation pump will start up until it reaches 8ºC If the boiler temperature continues to drop and reaches 4ºC the burner will start up...

Page 49: ...closed If contact opening is detected the boiler operation will lock out and an alarm will be triggered on the display E 68 16 8 Operation of Alarm Output The BioClass iC 150 boiler includes an alarm output When the boiler triggers an operating alarm that shuts down the boiler the relay output supplied with voltage 230 V from terminal strip J12 where any external alarm signalling device can be con...

Page 50: ...um pressure set using parameter P 19 the boiler will automatically fill up again until the maximum filling pressure has been reached The selectable range of fill pressure in P 21 is 0 6 2 0 bar and the default factory setting is 1 bar 17 2 Activation of auxiliary source with boiler lock out P 20 2 The auxiliary source activation function with boiler lock out P 20 2 will activate the output of the ...

Page 51: ... stop heating the installation The interlock occurs whenever the water in the boiler exceeds a temperature of 100ºC To unlock this alarm wait until the temperature drops to below 90ºC and press the button on the safety thermostat located on the underside of the boiler electrical box 18 2 Safety interlock due to temperature in the fuel inlet pipe When this interlock occurs the alarm code E 05 will ...

Page 52: ...nd 1 5 bar 19 SHUTTING DOWN THE BOILER To switch off the boiler place your finger on the power touch button for 1 second see Hand Components In the Off mode while the boiler is plugged into the mains and connected to the fuel installation the boiler will stop operating but the anti frost protection and pump anti block functions will remain activated To shut down the boiler functioning completely u...

Page 53: ... pellets 5 Check the boiler visually weekly 7 Check the feed auger is correctly calibrated as required 8 General cleaning of the bu yearly 9 General cleaning of the vent cleaning system yearly 10 Check and clean the flue The flue must be free of any obstacles and have no leaks yearly 11 Calibration of the lambda probe yearly 11 Check the expansion vessel It must be full according to its reference ...

Page 54: ...e figure Open the cover of the drawer using the latches and empty out the ash Replace the ash drawer ensuring it is hermetically sealed IMPORTANT Before any maintenance operation switch off the boiler by pressing the power touch button Leave the boiler switched off and allow it to cool down for at least one hour Then turn off the main switch and ensure that it cannot be switched back on ...

Page 55: ...ustion chamber The burner must be cleaned regularly to prevent the premature build up of dirt due to the accumulation of slag solid combustion waste adhered to the burner walls The following procedure is recommended for correctly cleaning the burner ...

Page 56: ... formations Handle the refractory parts with care to avoid breaking them IMPORTANT Before any maintenance operation switch off the boiler by pressing the power touch button Leave the boiler switched off and allow it to cool down for at least one hour Then turn off the main switch and ensure that it cannot be switched back on Warning To be carried out only when the boiler is switched off and cooled...

Page 57: ...57 BIOCLASS iC 150 21 4 General cleaning of the burner The following procedure is recommended for correctly cleaning the burner ...

Page 58: ... formations Handle the refractory parts with care to avoid breaking them IMPORTANT Before any maintenance operation switch off the boiler by pressing the power touch button Leave the boiler switched off and allow it to cool down for at least one hour Then turn off the main switch and ensure that it cannot be switched back on Warning To be carried out only when the boiler is switched off and cooled...

Page 59: ...ecommended for correctly cleaning the vents IMPORTANT Before any maintenance operation switch off the boiler by pressing the power touch button Leave the boiler switched off and allow it to cool down for at least one hour Then turn off the main switch and ensure that it cannot be switched back on ...

Page 60: ...EN 60 BIOCLASS iC 150 21 6 General cleaning of the vent cleaning circuit The following procedure is recommended for correctly cleaning the vents ...

Page 61: ...lone mesh ensure that the suction system is disconnected from the mains At least once a year depending on the amount of dust in the pellets unscrew the cyclone cover and hoover the dust in the protection grille underneath the suction turbine If the pellets suction turbine generates a lot of noise or throws out sparks this may be due to dirt deposited in the fan blades You must remove the suction t...

Page 62: ... the boiler s heat conductivity causing a major drop in performance Treated water must be used in the heating circuit in the following cases Very large circuits containing a large amount of water Frequent filling of the installation If repeated partial or total draining of the installation is necessary we recommend filling it with treated water IMPORTANT NOTE Improper handling of the boiler may ca...

Page 63: ...MEASUREMENTS 1485 830 655 1800 1585 320 1050 O 200 535 1530 1730 90 415 95 80 105 115 465 345 1290 1440 1415 1545 TP IC SH RC V IC Ida Boiler 2 H RC Boiler Return 2 H SH Fume outlet V Drainage outlet H TP Boiler drain valve outlet 1 2 H ...

Page 64: ...EN 64 BIOCLASS iC 150 23 CONNECTIONS DIAGRAM 23 1 Boiler ...

Page 65: ...or Sdown Rdown Lower tank probe Scol Upper tank probe EAE External Alarm Input SR Boiler Return sensor Sbt1 Rbt1 Intermediate sensor 1 Sbt2 Rbt2 Intermediate sensor 2 J1 C2 Connector J2 Lambda probe connector J4 Communication connector J6 Remote Control Connector J7 Fume sensor connector J8 Sensor connector J9 External alarm input connector J10 Return probe connector J11 BT intermediate probe conn...

Page 66: ... Limit switch closed FC2 Limit switch open FCS Safety limit switch Qin Burner input connector FR Photocell FCp Ash cleaning device limit switch Te Pellet safety thermostat AI Internal supply line R1 Fire resistance R2 Fire resistance 2 SPA Air pressure sensor Spel Pellet level sensor C1 C2 C3 C4 ...

Page 67: ...iC 150 24 ELECTRICAL DIAGRAM N Neutral L Phase ASP Suction turbine Dp Pellet filling level sensor R Relay J4 Communication connector J16 Components connector J17 Filling level sensor connector J18 Sensor connector ...

Page 68: ...EN 68 BIOCLASS iC 150 ...

Page 69: ...put connector SPW Water pressure sensor SPA Air pressure sensor ASP Suction turbine Dp Filling level sensor J4 Communication connector J15 Connector J16 Components connector J17 Pellet filling level sensor connector J19 Feed connector J20 Feed connector J21 Fuel aspiration system feed connector S1 S2 Boiler model selector ...

Page 70: ...2 mg m3 126 OGC organic gaseous substances at minimum power 10 O2 mg m3 0 Classification as per EN 303 5 Class 5 Maximum operating pressure bar 3 Max operating temperature C 80 Maximum safety temperature C 100 Water content litres 202 Minimum flue draught mbar 0 10 Maximum flue draught mbar 0 20 Electrical supply 230 V 50 Hz 10 A Fume outlet diameter mm 200 Mass flow rate of fumes at rated minimum...

Page 71: ...l Wooden pellet Ø6 8 mm Maximum length 35 mm Seasonal performance Ƞs 83 Seasonal heating emissions Part mg m3 18 COG mg m3 0 CO mg m3 116 NOx mg m3 139 Electricity consumption at rated power the max kW 0 323 Electricity consumption at 30 of rated power the min kW 0 180 Electricity consumption in standby mode PSB kW 0 005 Energy efficiency index EEI 121 Class A It is recommended to use the boiler w...

Page 72: ...ial Technical Assistance Service E 07 Error in Ash cleaning start phase These alarms are triggered whenever a malfunction is detected in the ash cleaning system of the burner If this alarm occurs repeatedly please contact the nearest official Technical Assistance Service E 08 Error in Ash cleaning final phase E 09 Limit switch error FCp1 or FCp2 Ash cleaning E 10 Boiler overheating The water in th...

Page 73: ...The air depression in the furnace is excessive The burner will lock out until the depression is correct If this alarm occurs repeatedly please contact the nearest official Technical Assistance Service E 23 Excessive air overpressure in the furnace The air overpressure at the inlet to the burner is excessive The burner will lock out until the depression is correct If this alarm occurs repeatedly pl...

Page 74: ...s broken or disconnected Please contact your nearest official Technical Assistance Service to have it replaced E 33 Intermediate sensor No 1 of tank Sbt1 shortcircuited E 34 Intermediate sensor No 2 of tank Sbt2 open circuit The intermediate sensor of tank Sbt2 is broken or disconnected Please contact your nearest official Technical Assistance Service to have it replaced E 35 Intermediate sensor N...

Page 75: ...tem is operating properly E 51 Communication error between a boiler and the MC Cascade Control One of the boilers connected to the MC control has stopped communicating suddenly If this alarm occurs repeatedly please contact the nearest official Technical Assistance Service E 52 Error due to excessive fume temperature The temperature of the fumes from the boiler has exceeded the maximum safety temp...

Page 76: ...ill lock out until the external alarm has been reset E 80 Upper sensor Scol of the MC Cascade control open circuit The Scol probe is damaged or disconnected Please contact your nearest official Technical Assistance Service to have it replaced E 81 Upper sensor Scol of the MC Cascade controlshortcircuited E 82 Upper sensor Sdown of the MC Cascade control open circuit The Scol probe is damaged or di...

Page 77: ...77 BIOCLASS iC 150 NOTES ...

Page 78: ...EN 78 BIOCLASS iC 150 NOTES ...

Page 79: ...79 BIOCLASS iC 150 NOTES ...

Page 80: ...rior notice any change in the characteristics of its products www domusateknik com POSTAL ADDRESS FACTORY OFFICES Section 95 Bº San Esteban no number 20730 AZPEITIA 20737 ERREZIL Gipuzkoa Tel 34 943 813 899 Fax 34 943 815 666 CDOC002320 CDOC002320 03 03 21 ...

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