Viessmann MatriX-Disk burner Operating instructions

Service instructions
for contractors
VIESMANN
MatriX-Disk burner
Type MDI, 800 and 1000 kW
MatriX-Disk burner for natural gas E and LL
MatriX-Disk burner
6151060 GB 1/2020 Please keep safe.

2
Please follow these safety instruc-
tions closely to prevent accidents
and material 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on gas installations may only be
carried out by a registered gas fitter.
■Work on electrical equipment may only
be carried out by a qualified electrician.
■The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, e.g. by removing the separate fuse
or by means of a mains isolator, and
check that it is no longer live.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
6151060

3
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
6151060

4
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not smoke. Prevent naked
flames and sparks. Never switch
lights or electrical appliances on
or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the
danger zone.
■Notify your gas or electricity sup-
ply utility from outside the building.
■Have the power supply to the
building shut off from a safe place
(outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening
poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be
harmful to health.
Never let condensate touch your
skin or eyes and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion air can cause life threatening
poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good
working order. Vents for supplying
combustion air must be non-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
6151060

5
Danger
The simultaneous operation of the
boiler and appliances that exhausts
air to the outside can result in life
threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
6151060

6
1. Information Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■System examples ............................................................................... 8
■Spare parts lists .................................................................................. 8
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 9
3. Burner control unit Burner control unit VUC 310 .................................................................. 30
■Display and programming unit ............................................................ 30
■Operating display ................................................................................ 30
■Selecting the menu ............................................................................. 31
■Calling up information and resetting meters ....................................... 31
■Changing the configuration ................................................................. 32
■Resetting operating parameters to their delivered condition .............. 34
■Setting the modulation level for manual operation ............................. 34
Flow diagram for burner start ................................................................. 35
■Description of state ............................................................................. 36
4. Troubleshooting Fault display ........................................................................................... 37
■Calling up the fault history (fault memory) .......................................... 37
Fault codes with display on burner control unit ...................................... 38
■General process errors: Displayed fault codes ................................... 38
■Internal system faults: Displayed fault codes and detailed fault
codes .................................................................................................. 41
Faults without fault display ..................................................................... 42
5. Component overview Overview of burner components ............................................................ 44
6. Function description Air pressure switch ................................................................................ 45
■Fan pressure monitoring function (LDW1) .......................................... 45
■Combustion chamber pressure monitoring function (LDW2) .............. 45
Gas pressure switch .............................................................................. 45
■Monitoring gas inlet pressure GDW1 .................................................. 45
■Monitoring gas intermediate pressure GDW2 .................................... 45
Boiler water temperature sensors and flue gas temperature sensors ... 45
7. Connection diagrams Burner control unit connection diagram ................................................. 47
8. Reports ................................................................................................................ 48
9. Specification Specification – MatriX-Disk burner ........................................................ 49
10. Final decommissioning Final decommissioning and disposal ..................................................... 50
11. Certificates Declaration of conformity ....................................................................... 51
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 51
12. Keyword index ................................................................................................................ 52
Index
Index
6151060

7
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The burner must only be operated when installed in
the Vitocrossal boiler, type CRU. "Appliance" here
refers to the boiler with burner fitted.
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Information
Symbols
6151060
Information

8
MatriX-Disk burner, type MDI
■Gas burner for Vitocrossal gas condensing boilers,
type CRU 800 and 1000 kW
■Modulation 1:6
■For natural gas E and natural gas LL
Information about installation, commission-
ing, inspection and maintenance of the entire
boiler
■"Vitocrossal, type CRU" installation instruc-
tions
■"Vitocrossal, type CRU" service instructions
System examples
Available system examples: See www.viessmann-
schemes.com.
Spare parts lists
Information about spare parts can be found at
www.viessmann.com/etapp or in the Viessmann
spare part app.
Information
Product information
6151060
Information

9
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Information about commissioning, inspection and maintenance................................. 10
••• 2. Opening the boiler.............................................................................................................. 10
• • 3. Checking the electrical connections................................................................................ 10
• • 4. Checking the gas control cables...................................................................................... 11
•5. Checking the gas type....................................................................................................... 11
•6. Setting the gas type........................................................................................................... 12
••• 7. Commissioning the burner................................................................................................ 13
•8. Reducing the maximum heating output (if required)...................................................... 14
••• 9. Checking the static pressure and supply pressure........................................................ 15
••• 10. Measuring the CO2 content............................................................................................... 16
• • 11. Measuring the CO content................................................................................................. 18
• • 12. Measuring the flue gas temperature................................................................................. 18
• • 13. Checking the ionisation current....................................................................................... 18
• • 14. Checking the fan pressure and AIC pressure................................................................. 19
• • 15. Shutting down the system................................................................................................. 20
• • 16. Opening the combustion chamber................................................................................... 21
• • 17. Cleaning the burner........................................................................................................... 22
•18. Cleaning the air filter.......................................................................................................... 22
• • 19. Checking the burner door................................................................................................. 23
• • 20. Checking and cleaning the burner gauze assembly....................................................... 24
• • 21. Checking the ignition electrodes and ionisation electrode........................................... 24
•22. Fitting the burner................................................................................................................ 25
• • 23. Closing the combustion chamber.................................................................................... 25
• • 24. Checking the gas train valves for tightness.................................................................... 26
• • 25. Checking the gas train filter element............................................................................... 27
• • 26. Checking the filter element in the gas line...................................................................... 28
••• 27. Checking the gas connections for tightness................................................................... 28
• • 28. Performing final checks..................................................................................................... 28
• • 29. Closing the boiler casing................................................................................................... 28
••• 30. Checking the installation room ventilation air apertures............................................... 29
•31. Instructing the system user.............................................................................................. 29
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Steps that relate to the boiler are described in a sepa-
rate manual.
"Vitocrossal, type CRU" service instructions
Ensure the quality of the combustion air drawn in.
■Combustion air must be free from flammable, explo-
sive gases and vapours.
■Dust free according to directive 89/427/EEC, daily
average < 150 µg/m3 air
■Combustion air must not be contaminated with halo-
gens or other solvent vapours. In swimming pools in
particular, pay special attention to chlorine and salts
from water treatment.
Opening the boiler
1.
2.
4.
3.
2x
Fig. 1
Checking the electrical connections
Check all electrical connections for firm seating.
Commissioning, inspection, maintenance
Information about commissioning, inspection and maintenance
6151060

11
Check control cables for
■Connection and kink-free routing
■Application and seating of retaining clips
+
-
+
-
L=225
L=180
L=220 L=735
L=200
L=120
L=770
L=75
Fig. 2
Checking the gas type
1. Check with your gas supply utility regarding the
gas type and Wobbe index Ws (0 °C;
1013.25 mbar).
The boiler can be operated in the following Wobbe
index ranges:
■With natural gas E:
Wobbe index range 12.0 to 16.1 kWh/m3 (43.2 to
58.0 MJ/m3)
■With natural gas LL:
Wobbe index range 10.0 to 13.1 kWh/m3 (36.0 to
47.2 MJ/m3)
2. In the delivered condition, the burner is set up for
natural gas E. If required, convert the burner to a
different gas type in accordance with the details
provided by your gas supply utility: See chapter
"Setting the gas type", page 10. 12
3. Record the gas type in the report on page 48.
Commissioning, inspection, maintenance
Checking the gas control cables
6151060

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In the delivered condition, the boiler is preset for natu-
ral gas E and can be changed over to natural gas LL.
The setting can later be changed back to natural
gas E.
A
Fig. 3
AAdjusting screw
1. Turn the adjusting screw on the main volume but-
terfly of the gas train fully towards "–".
2. Turn the adjusting screw in direction "+" as detailed
in the table below:
3. Start the burner.
4. Measure the CO2 content in the flue gas and
adjust: See page 16.
Rated heating output Natural gas LL Natural gas E
800 kW 5 turns 4 turns
1000 kW 8 turns 6 turns
Commissioning, inspection, maintenance
Setting the gas type
6151060

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Danger
CO build-up as a result of incorrect burner
adjustment or flue gas system leakage can have
serious health implications.
Always carry out a CO test before and after
work on gas appliances.
!Please note
Dust can impair the function of the burner and
falsify burner settings.
Only operate the burner with the air filter instal-
led.
■Vitotronic control unit operating instructions
and service instructions
■Neutralising system operating instructions
■Flue system installation instructions
■"Vitocrossal, type CRU" service instructions
1. Check the heating system pressure.
"Vitocrossal, type CRU" service instructions
2. For open flue operation: Check that the ventilation
facility in the installation room complies with the
boiler room guidelines.
3. Open the gas line shut-off valves.
4. Check the static pressure. See page 15.
A
Fig. 4
5. Check the adjustment on air pressure switch 1 A
for the specified set pressure.
Rated heating output
800 kW 2 mbar (0.2 kPa) ↓
1000 kW 4 mbar (0.4 kPa) ↓
6. Switch ON the mains isolator (outside the installa-
tion room).
7. Switch on the ON/OFF switch at the programming
unit of the Vitotronic control unit.
Vitotronic control unit operating instructions
Note
During commissioning, the appliance may enter a
fault state due to remaining airlocks in the gas line:
"Burner fault" and are shown on the display
■Purge the gas line again.
■Confirming the fault on the display of the
Vitotronic control unit resets the burner.
8. Check all gaskets and plugs, and retighten if nec-
essary.
Commissioning, inspection, maintenance
Commissioning the burner
6151060

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The maximum heating output of the burner can be
reduced if required.
Programming unit on the burner control unit
Status Service
S
R
Fig. 5
Press the following buttons:
1. Press and hold S for longer than 2 s, flashes.
2. repeatedly, until "6" is shown under "Service".
3. S to confirm, "6" is shown under "Status" and "1" is
shown under "Service".
4. S to confirm, "1" is shown under "Status". The cur-
rent value for the maximum heating output in % is
shown under "Service".
5. Use or to select the required maximum heating
output.
6. S to confirm. If adopted successfully, "1" is shown
under "Service"; if it failed, "0" will appear.
7. S to change to the operating display.
8. R, the system will be restarted.
Note
Max. heating output can also be reduced via the
Vitotronic control unit.
Vitotronic control unit operating instructions
Commissioning, inspection, maintenance
Reducing the maximum heating output (if required)
6151060

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A
Fig. 6
ATest connector
Static pressure
1. Close the gas shut-off valve.
2. Undo the screw in test connector A. Do not
remove the screw.
3. Connect the pressure tester at test connector A.
4. Open the gas shut-off valve.
5. Measure the static pressure: Max. 60 mbar
(6 kPa).
Note
The max. static pressure corresponds to the max.
short-term gas pressure at the burner for which
safe commissioning of the appliance can be guar-
anteed.
6. Record the actual value in the report.
Supply pressure
1. Activate emissions test mode.
Vitotronic control unit operating instructions
Commissioning, inspection, maintenance
Checking the static pressure and supply pressure
6151060

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2. Measure the supply pressure (flow pressure) at
rated heating output.
Natural gas E/LL
■Set value: 17 to 25 mbar (1.7 to 2.5 kPa)
■Nominal supply pressure: 20 mbar (2 kPa)
Note
■The nominal supply pressure can differ from
these values subject to region; see type plate of
the burner.
■Gas pressure switch 1 on the gas train is set to
10 mbar (1.0 kPa).
i.e. the burner cannot be operated at a gas sup-
ply pressure below 10 mbar (1.0 kPa).
Note
Use a suitable measuring device with a resolution
of at least 0.1 mbar (0.01 kPa) to check the supply
pressure.
3. Record the actual value in the report.
4. Switch off the ON/OFF switch at the programming
unit of the Vitotronic control unit.
5. Close the gas shut-off valve.
6. Remove pressure gauge. Close test connector A
with the screw.
7. Open the gas shut-off valve. Start up the appli-
ance. Check gas tightness at test connector A.
Danger
Gas escaping from the test connector leads
to a risk of explosion.
Check for gas tightness.
Supply pressure
(flow pressure) nat-
ural gas E and LL
Measure
< 10 mbar
< 1.0 kPa
Do not make any adjustments.
Notify the gas supply utility.
10 to 17 mbar
1.0 to 1.7 kPa
Please note: The boiler may only be operated temporarily with this setting (emergency
mode). Reduce the max. heating output sufficiently to achieve a flow pressure of min.
15 mbar at the corresponding output.
Notify the gas supply utility.
17 to 25 mbar
1.7 to 2.5 kPa
Start the boiler.
> 25 mbar
> 2.5 kPa
Install a separate gas pressure governor with zero off upstream of the boiler system.
!Please note
Excessive flow pressure can damage the burner.
Only operate the boiler temporarily with a setting > 25 mbar (emergency mode).
Note
The nominal supply pressure must be set subject to regional conditions, see type plate of
the burner.
Measuring the CO2 content
Programming unit on the burner control unit
Status Service
S
R
Fig. 7
Commissioning, inspection, maintenance
Checking the static pressure and supply pressure (cont.)
6151060

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Adjusting screws on the gas train
AB
Fig. 8
Note
Check measurements and settings with a clean air fil-
ter.
01. Check the gas control cables:
■Connection and kink-free routing
■Fixing and firm seating of the connecting points
Note
See chapter "Checking the gas control cables",
Fig. 2, page 11.
02. Open the gas shut-off valve.
03. Activate emissions test mode.
Vitotronic control unit operating instructions
04. On the burner control unit, press S+ simultane-
ously for longer than 2 s.
■"P" is displayed under "Status" (controlled stop).
■The current modulation level in % is shown
under "Service".
05. To measure the CO2, set the upper and lower
heating output in turn:
■Upper heating output:
Press until "100" (≙ 100 %) is shown under
"Service".
■Lower heating output:
Press until "0" (≙ 0 %) is shown under "Serv-
ice".
06. Check the CO2 content at the flue pipe.
For permissible CO2 content, see the table.
Note
At the lower heating output, the CO2 content must
always be lower than at the upper heating output.
07. If the CO2 content lies outside the specified range:
■Upper heating output:
Turn main adjusting screw A in small incre-
ments until the CO2 content is within the speci-
fied range.
Note
Adjusting the upper heating output changes the
CO2 value of the lower heating output simultane-
ously.
■Lower heating output:
Slide the shut-off slider on the gas solenoid
valve to the left and turn offset adjusting screw
B in small increments until the CO2 content is
within the specified range.
Rotational direction of adjusting screws A
and B:
■Direction "–": CO2 content falls.
■Direction "+": CO2 content rises.
Note
Especially at the lower heating output, the system
responds sluggishly to CO2 adjustments. After
making a change, wait a few minutes until the gas
solenoid valve has adjusted to the new value.
Commissioning, inspection, maintenance
Measuring the CO2 content (cont.)
6151060

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08. Check the CO2 content at the upper and lower
heating output again.
If required, set the CO2 content for the upper and
lower heating output again.
09. Enter the actual values into the report.
10. On the burner control unit, press S and simulta-
neously for longer than 2 s. Burner switches to
operating mode.
Permissible CO2 content
Gas type Heating output CO2 content, dry
Natural gas E
Wobbe index Ws 12.0 to 16.1 kWh/m3
(0 °C; 1013.25 mbar)
Upper heating output (100 %) 8.9 ±0.1 %
Lower heating output (0 %) 7.9 ±0.1 %
Natural gas LL
Wobbe index Ws 10.0 to 13.1 kWh/m3
(0 °C; 1013.25 mbar)
Upper heating output (100 %) 8.8 ±0.1 %
Lower heating output (0 %) 7.8 ±0.1 %
Measuring the CO content
Enter the actual value in the service report.
Measuring the flue gas temperature
Enter the actual value in the service report.
Checking the ionisation current
Note
The ionisation current can only be called up via the
programming unit of the burner control unit. It is not
possible to measure it with Testomatik-Gas or a multi-
meter.
Programming unit on the burner control unit
Status Service
S
R
Fig. 9
Press the following buttons:
01. Press S for longer than 2 s; flashes.
02. repeatedly until "5" is shown under "Service".
03. S to confirm, "5" is shown under "Status".
04. repeatedly until "3" is shown under "Service".
05. S to confirm, "3" is shown under "Status". Under
"Service" the ionisation current is shown during
operation (e.g. 80 ≙ 8.0 µA).
06. Activate emissions test mode.
Vitotronic control unit operating instructions
07. Read the ionisation current at the lower and upper
heating outputs.
Enter actual value into the report in the appendix.
Required value at lower heating output
800 kW >6.5 µA
1000 kW >7 µA
If the measured value is not within the value
range, check the ionisation electrode for damage
and check the fan pressure. See chapter "Check-
ing the fan pressure".
08. Press S for longer than 2 s; flashes.
09. repeatedly until "5" is shown under "Service".
10. S to confirm, "5" is shown under "Status".
Commissioning, inspection, maintenance
Measuring the CO2 content (cont.)
6151060

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11. repeatedly until "0" is shown under "Service". 12. S to change to the operating display.
Checking the fan pressure and AIC pressure
A
Fig. 10
BB
Fig. 11
1. For the fan pressure, connect the pressure gauge
to measuring point A with a tee.
Measure the fan pressure during full load operation
at the upper heating output.
2. For the AIC pressure, connect the pressure gauge
to measuring point B, either directly or with a tee.
Measure the AIC pressure (negative pressure).
Burner type Fan pressure
max.
AIC pressure
max.
MDI 800 mbar 11 8
MDI 1000 mbar 19 10
If the fan pressure exceeds the values in the table with
a clean filter, clean the burner gauze assembly. See
page 24.
If the AIC pressure exceeds the specified value, clean
the air filter.
Commissioning, inspection, maintenance
Checking the ionisation current (cont.)
6151060

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1. Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a
mains isolator, and check that it is no longer live.
Safeguard the system against reconnection.
Danger
An electric shock can be life threatening.
Before opening the boiler, disconnect it from
the mains voltage, e.g. at the fuse or mains
isolator.
2. Close the gas shut-off valve.
Commissioning, inspection, maintenance
Shutting down the system
6151060