Viessmann KOB Pyromat ECO Operating instructions

Service instructions
for contractors
Pyromat ECO
Wood gasification boiler
for 50 cm or 100 cm logs
PYROMAT ECO
5604 447 GB 10/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5604 447 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5604 447 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 7
Codes
Code 1.................................................................................................................. 14
Code 2.................................................................................................................. 18
Service scans
Service functions.................................................................................................. 21
Diagnosis.............................................................................................................. 21
Scanning operating conditions and sensors ........................................................ 24
Troubleshooting
Fault display......................................................................................................... 25
Repair................................................................................................................... 29
Mixer circuit extension kit
Overview of connections...................................................................................... 33
Required settings................................................................................................. 34
Mixer circuit extension kit..................................................................................... 35
Specification......................................................................................................... 37
Function description
Display and control elements............................................................................... 38
Control functions.................................................................................................. 38
Designs
Overview of PCB.................................................................................................. 40
Connection and wiring diagram............................................................................ 42
230 V plug............................................................................................................ 44
Plug, LV................................................................................................................ 49
Parts lists............................................................................................................ 56
Commissioning/service reports........................................................................ 60
Specification....................................................................................................... 61
Certificates
Declaration of conformity...................................................................................... 62
Index
Index
5604 447 GB

5
Appendix
Wiring of plug, Pyromat Eco................................................................................. 63
Installation schemes............................................................................................. 71
Keyword index.................................................................................................... 74
Index
Index (cont.)
5604 447 GB

6
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 7
••• 2. Checking all connections on the heating water side
for leaks
•3. Switching the power ON................................................ 7
•4. Matching the control unit to the heating system ........ 7
•5. Checking outputs and actuators................................... 8
•6. Adjusting the heating curves........................................ 9
• • 7. Shutting down the system............................................. 12
• • 8. Cleaning the combustion chamber............................... 12
•9. Cleaning the flue gas fan and Lambda probe.............. 13
• • 10. Emptying the ash pans (if required)............................. 13
••• 11. Checking the function of safety valves
•12. Instructing the system user........................................... 13
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5604 447 GB

7
Filling the heating system
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the static system pressure, top
up with nitrogen until the pre-charge
pressure is 0.1 to 0.2 bar higher.
Adjust the pre-charge pressure
accordingly if it is too high.
2. Top up your heating system with
water and vent until the fill pressure
is 0.1 to 0.2 bar higher than the pre-
charge pressure of the diaphragm
expansion vessel.
Permiss. operating pressure: 3 bar
Test pressure: 4 bar
3. Mark the fill pressure at the pressure
gauge.
Switching the power ON
Matching the control unit to the heating system
Subject to the equipment level, the control unit must be matched to the system.
Boiler temperature
DHW
Solar energy
Information
Select with
48 °C
Heating
(
START
STOP
Check and possibly adjust all addresses
in Code 1 (see chapter "Code 1").
Note
The chapters "Coding 1" (from page
14) and "Coding 2" (from page 18)
contain additional setting options.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5604 447 GB

8
Checking outputs and actuators
Carrying out an actuator test
Note
An actuator test is only possible when the boiler is cold.
If the actuator test is carried out for one mixer, all other connected mixers remain in
standard operation. Following the actuator test, the tested mixer reverts to standard
operation after 3 minutes.
With respect to their application, the actuators are split into several categories:
■ Boiler actuators
■ Actuators for the corresponding mixer modules
Press the following keys:
1. d + MENU simultaneously for
approx. 4 s.
The "Service" menu is
displayed.
2. |/~for "Actuator test".
3. dto confirm.
4. |/~for the required actua-
tor category.
5. dto confirm.
6. |/~for the required actua-
tor or relay output.
Note
The actuator test is ter-
minated automatically
if no input is made for
5 min.
7. dto confirm.
8. dto terminate.
9. Press g until the default display is
shown.
The actuator test has been termina-
ted.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5604 447 GB

9
The following boiler actuators can be controlled subject to system equipment
level (not required during commissioning):
Display Explanation
"Boiler pump ON"
"Open boiler valve"
"Close boiler valve"
"Open valve accumulator [Open buffer
valve]"
"Close valve accumulator [Close buf-
fer valve]"
"Open primary air valve [Open primary
air damper]"
"Close primary air valve [Close pri-
mary air damper]"
"Open secondary air valve [Open sec-
ondary air damper]"
"Close secondary air valve [Close sec-
ondary air damper]"
"Open central fault" Test of fault alarm system connected on-
site (if installed).
The following mixer module actuators can be controlled separately depending
on the module (recommended during commissioning):
Display Explanation
"Pump on"
"Open valve"
"Close valve"
Adjusting the heating curves
The heating curves illustrate the relationship between the outside temperature and
the boiler water or flow temperature.
To put it simply: The lower the outside temperature, the higher the boiler water or flow
temperature.
The room temperature, again, depends on the boiler water or flow temperature.
Settings in the delivered condition:
■ Slope = 1.4
■ Level = 0
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5604 447 GB

10
0.2
Outside temperature in °C
Boiler water or Flow temperature in °C
Slope
2.4 2.6 2.8 3.0 3.2 3.4
90
80
70
60
50
40
30
0 -10 -2010
A
B
2.0 2.2
Set room temperature in °C
35 30 25 20 15 10 5
0.4
0.6
0.8
1.0
1.2
1.4
-30
1.8
1.6
C
-14
Example for outside temperature
−14 °C:
AUnderfloor heating system, slope
0.2 to 0.8
BLow temperature heating system,
slope 0.8 to 1.6
CHeating system with a boiler water
temperature in excess of 75 °C,
slope 1.6 to 2.0
Adjusting the set room temperature
Individually adjustable for each heating
circuit.
The heating curve is offset along the axis
of the set room temperature. When the
heating circuit pump logic function has
been enabled, it modifies the starting
and stopping characteristics of the heat-
ing circuit pump.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5604 447 GB

11
Standard room temperature
DE
B
C
A
110
20°C
26°C
-20°C
26 20
Adjustment of the standard room tem-
perature from 20 to 26 °C
AFlow temperature in °C
BOutside temperature in °C
CSet room temperature in °C
DHeating circuit pump OFF
EHeating circuit pump ON
Press the following keys in the standard
menu:
1. |/~for "Heating".
2. dto confirm.
3. Ù / Úfor selecting the heating cir-
cuit.
4. |/~for "Set room temperature"
5. dto confirm.
6. |/~for the required temperature.
7. dto confirm.
Reduced room temperature
3
14
20
C
110
3°C
A
D E
B-20°C
14°C
Adjustment of the reduced room temper-
ature from 3 to 14 °C
AFlow temperature in °C
BOutside temperature in °C
CSet room temperature in °C
DHeating circuit pump OFF
EHeating circuit pump ON
Press the following keys in the standard
menu:
1. åfor "Advanced menu".
2. |/~for "Heating".
3. dto confirm.
4. Ù / Úfor selecting the heating cir-
cuit.
5. |/~for "Set red. room temp.".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5604 447 GB

12
6. dto confirm.
7. |/~for the required temperature.
8. dto confirm.
Changing slope and level
Individually adjustable for each heating
circuit.
A
B
Boiler water or flow temperature in °C
110
+20 -20
Outside temperature in °C
3.5
1.4
0.2
AChanging the slope
BChanging the level (vertical parallel
offset of the heating curve)
Press the following keys in the standard
menu:
1. åfor Advanced menu.
2. Ù / Úfor selecting the heating cir-
cuit.
3. |/~for "Heating curve".
4. dto confirm.
5. |/~for "Slope" or "Level".
6. dto confirm.
7. |/~for the required value.
8. dto confirm.
9. With g back to the default display.
Shutting down the system
Operating instructions - Pyromat
ECO
Cleaning the combustion chamber
Cleaning work to be carried out:
■ Clean the top combustion chamber
■ Clean the tubular heat exchanger
■ Clean the bottom combustion cham-
ber
■ Clean the hopper
Operating instructions - Pyromat
ECO
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5604 447 GB

13
Cleaning the flue gas fan and Lambda probe
1. Undo wing nuts on flue gas fan and
pull out motor with impeller.
2. Clean impeller with spatula and ash
vacuum cleaner.
3. Check impeller for visible damage
and replace if required.
4. Clean Lambda probe with cleaning
brush and ash vacuum cleaner and
check for damage.
5. Reassemble in reverse order.
Emptying the ash pans (if required)
Empty the ash box regularly.
The following must be emptied:
■ Ash pan, hopper
■ Ash pan, tubular heat exchanger
Operating instructions - Pyromat
ECO
Instructing the system user
Operating and service instructions
File all parts lists, operating and service
instructions in the folder and hand this
over to the system user.
Instructing the system user
The installer should instruct the user in
the operation of the system and hand
over the cleaning equipment.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5604 447 GB

14
Call up code 1
Press the following keys:
1. d + åsimultaneously for
approx. 4 s.
The "Service" menu is
displayed.
2. |/~for "Code 1".
3. dto confirm.
4. |/~for the required cate-
gory.
5. dto confirm.
6. |/~for the required coding
address.
7. dto confirm.
8. |/~for the required value.
9. dto confirm.
"Adopted" appears
briefly on the display.
10. gExit service menu.
Overview
The coding addresses are displayed in
categories that are subject to the respec-
tive system configuration:
■"Hardware"
Coding addresses
See page 14
■"General"
Coding address "7F"
See page 15
■"Boiler"
Coding addresses "0A", "0B" to "0C",
"0D"
See page 15
■"Heating"
Coding addresses "A5" , "A6", "A7",
"C5", "C6", "F2", ""
See page 16.
■"DHW"
Coding addresses "0C" , "0D"
See page 18
Hardware
Coding
Coding in the delivered condition Possible change
Number of DHW circuits used
Number of
DHW:1
One DHW circuit instal-
led. Optional use of up to
2 heating circuits.
Number of
DHW:0
No DHW circuit. Enables 3
heating circuits to be
used.
Codes
Code 1
5604 447 GB

15
Coding in the delivered condition Possible change
Number of heating circuits used
Number of
HC:2
2 heating circuits instal-
led.
Number of
HC:0
to
Number of
HC:2
possible number of heating
circuits with 1 DHW circuit.
Number of
HC:0
to
Number of
HC:3
possible number of heating
circuits without addit.
DHW circuit.
General
Coding
Coding in the delivered condition Possible change
Detached house/apartment building
7F:1 Detached house, same
holiday program for all
heating circuits
7F:0 Apartment building, holi-
day program can be adjus-
ted separately
Boiler
Coding
Coding in the delivered condition Possible change
Additional heat source, burner
0A:0 No additional heat source
available
0A:1 Pyromat ECO features an
oil burner
0A:2 External additional heat
source available
Additional heat source, buffer charging operation
0B:0 No 0B:1 Yes
Additional heat source, buffer charging operation up to
0C:60 Temperature in °C at the
upper sensor up to which
the additional heat source
or mounted burner should
charge the buffer
0C:30
to
0C:100
Setting range of between
30 °C and 100 °C.
Codes
Code 1 (cont.)
5604 447 GB

16
Coding in the delivered condition Possible change
Fan speed, burner
0D:80 Flue gas fan speed when
the burner is in operation
as a percentage of the
maximum speed.
0D:0
to
0D: 100
Setting range from 0 to 100
percent.
Heating
Coding
Coding in the delivered condition Possible change
Summer eco function room temperature
A5:5 With heating circuit pump
logic function (economy
mode): Heating circuit
pump „OFF“, if outside
temperature (AT) 1 K is
greater than the room
temperature set value
(RTset ) AT > RTset + 1
K
A5:0 Without heating circuit
pump logic
A5:1
to
A5:15
With heating circuit pump
logic function: Heating cir-
cuit pump „OFF“ see fol-
lowing table
1 AT > RTset + 5 K
2 AT > RTset + 4 K
3 AT > RTset + 3 K
4 AT > RTset + 2 K
5 AT > RTset + 1 K
6 AT > RTset
7
to
AT > RTset −1 K
to
15 AT > RTset −9 K
Codes
Code 1 (cont.)
5604 447 GB

17
Coding in the delivered condition Possible change
Summer eco function absolute
A6:36 Extended economy mode
disabled
A6:5
to
A6:35
Extended economy mode
enabled, i.e. the heating
circuit pump will be
switched OFF at a variable
value, adjustable between
5 and 35 °C plus 1 °C. The
mixer is closed. This value
is based on the adjusted
outside temperature, com-
prising the actual outside
temperature and a time
constant. The time con-
stant takes the cooling
down of an average build-
ing into account.
Recommended setting:
"A6:16" to "A6:18"
Mixer economy function
A7:0 Without mixer economy
function
A7:1 With mixer economy func-
tion (extended heating cir-
cuit pump logic):
Heating circuit pump also
"OFF":
The mixer has been closed
for longer than 20 min.
Heating circuit pump
"ON":
■ Mixer changes to control
function
or
■ If there is a risk of frost
Flow temperature minimum limit
C5:20 Electronic minimum flow
temperature limit 20 °C
C5:1
to
C5:127
Electronic minimum limit
adjustable from 1 to
127 °C
Flow temperature maximum limit
C6:75 Electronic maximum flow
temperature limit of
75 °C
C6:10
to
C6:127
Electronic maximum limit
adjustable from 10 to
127 °C
Codes
Code 1 (cont.)
5604 447 GB

18
Coding in the delivered condition Possible change
Party mode time limit
F2:8 Party mode can be active
for up to 8 hours.
F2:0 No time limit for party mode
Party mode is deactivated
when changing the heating
program to "Heating".
F2:1
to
F2:12
Time limit for party mode
adjustable from 1 to 12
hours.
DHW
Coding
Coding in the delivered condition Possible change
DHW differential
0C:0 Differential temperature
is calculated automati-
cally.
0C:1
to
0C:20
Fixed differential tempera-
ture adjustable between
1 ° C and 20° C.
DHW return temperature
0D:10 Flow control activated.
Set return temperature
corresponds to DHW
temperature plus 10 °C
0D:0 Flow control deactivated.
Valve is always fully
opened.
0D:1
to
0D:30
Flow control activated. Set
return temperature corre-
sponds to DHW tempera-
ture plus value set in °C.
Setting range between 1° C
and 30° C.
Code 2
The coding addresses are displayed in categories that are subject to the respective
system configuration:
■"General"
Coding addresses "80" , "81", "90"
■"Heating"
Coding addresses "A3" , "A4"
Codes
Code 1 (cont.)
5604 447 GB

19
Calling up code 2
Press the following keys:
1. d + åsimultaneously for
approx. 4 s.
The "Service" menu is
displayed.
2. g + dsimultaneously for
approx. 4 s.
"Code 2" appears in the
"Service" menu.
3. |/~for "Code 2".
4. dto confirm.
5. |/~for the required coding
address.
6. dto confirm.
7. |/~for the required value.
8. dto confirm.
"Adopted" appears
briefly on the display.
9. gExit service menu.
Overview
General
Coding
Coding in the delivered condition Possible change
80:6 Minimum duration before
a fault message is
issued.
80:0
to
80:199
Adjustable between 0 s
and 995 s. One setting
increment corresponds to 5
s.
81:1 Automatic summer/win-
tertime changeover
81:0 Manual summer/winter-
time changeover
90:128 Time constant for calcu-
lating adjusted outside
temperature 21.3 h
90:0
to
90:199
Fast (low values) or slow
(high values) matching of
the flow temperature, sub-
ject to the set value accord-
ing to changes in outside
temperature; 1 setting
increment ≙ 10 min
Codes
Code 2 (cont.)
5604 447 GB

20
Heating
Coding
Coding in the delivered condition Possible change
Not allocated to any function mode
A3:+2 Outside temperature
below 1°C: Heating cir-
cuit pump „ON“ outside
temperature higher than
3 °C: Heating circuit
pump „OFF“
A3:-9
to
A3:+15
Setting range between
-9° C and +15° C. Heating
circuit pump „ON/
OFF“ (see the following
table)
!Please note
If a value below 1 °C is selected, there is a risk that pipes outside the thermal
envelope of the house could freeze up.
The standby mode, in particular, should be taken into consideration, e.g. dur-
ing holidays.
Parameter Heating circuit pump
Address A3:... "ON" "OFF"
-9 - 10 °C - 8 °C
-8 - 9 °C - 7 °C
-7 - 8 °C - 6 °C
-6 - 7 °C - 5 °C
-5 - 6 °C - 4 °C
-4 - 5 °C - 3 °C
-3 - 4 °C - 2 °C
-2 - 3 °C - 1 °C
-1 -2 °C 0 °C
0 - 1 °C 1 °C
1 0 °C 2 °C
2
to
15
1 °C
to
14 °C
3 °C
to
16 °C
Coding in the delivered condition Possible change
Not allocated to any function mode
A4:0 With frost protection func-
tion (see code A3)
A4:1 No frost protection, adjust-
ment only possible if code
"A3: -9" has been set.
Codes
Code 2 (cont.)
5604 447 GB