Viessmann MatriX radiant burner Operating instructions

Service instructions
for heating engineers
MatriX radiant burner
Pressure jet gas burner (typeVMIII)
for Vitocrossal300 (typeCT3)
Rated output 170 (187)kW
See notes on applicability, page2.
MatriX radiant burner
5692541 GB11/2003 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start−up, inspection,
maintenance and repairs must only
be carried out by a competent
person (heating engineer/installation
contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
Close the main gas shut−off valve
and safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Observe all commissioning work
specified for gas installations to TRGI
or TRF and all local regulations.
Repair work
It is not permitted to carry out
repairs on parts that fulfil a safety
function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start−up
The initial start−up must be carried
out by the system installer or a
designated commissioning engineer.
All actual values should be recorded
in a commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
¨Safety instructions
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
Applicability
from serial no.
7175475300001kkk
Operating and service documents
1. Complete and detach the
customer registration card:
HGive the system user this part
for safe−keeping.
HRetain the heating engineer part.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
The installation instructions will
not be required after the
installation is completed, and may
therefore be discarded.
5692541 GB

3
Contents
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documents 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner control unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnostics 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas burner control unitflow chart 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas burner control unitconnection diagram 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component summary35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Specification 40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692541 GB

4
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C I M 1. System start−up 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C2. Checking gas type 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C3. Conversion to natural gasLL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 4. Checking static and supply pressure 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 5. Checking venturi vacuum pressure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 6. Checking CO2content 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 7. Measuring CO content
C I M 8. Measuring flue gas temperature
I M 9. Checking ionisation current 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 10. System shutdown 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 11. Checking burner gauze assembly 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 12. Checking ignition and ionisation electrodes 15. . . . . . . . . . . . . . . . .
M13. Cleaning burner 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14. Burner installation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 15. Checking both valves of gas combination valve
for leaks 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 16. Checking and replacing filter element
in gas supply line (if installed)
C I M 17. Checking all gas unions for leaks 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M18. Implementing final tests 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692541 GB

5
Initial start−up, inspection and maintenance
Further details regarding the individual steps
¨Safety instructions
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure perfect system condition.
Checking the burner adjustment with the boiler at operating temperature
(min. 40ºC) is essential.
Also carry out measurements at base load.
System start−up
Boiler control unit
service instructions
1. Check the heating system
pressure.
2. Open the gas shut−off valve.
3. Switch ON the mains electrical
isolator (outside the installation
room).
4. Switch ON system ON/OFF
switchBon the control unit.
If fault indicatorAon the control
unit illuminates, and burner
control unit displayCflashes,
initially implement a reset by
pressing reset buttonDon the
gas burner control unit.
Please note:
During the initial start−up, the
equipment can enter a fault state if
it has insufficient gas in the supply
line (fault lamp on the control unit
illuminates).
Ventilate the gas supply line again
and reset the gas burner control
unit.
5692541 GB
D
A B
C

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking gas type
1. Enquire the gas type and Wobbe
index(Wo) from your gas supplier.
HWith natural gas settingE, the
boiler can be operated in the
Wobbe index range
12.0 to 16.1kWh/m3
(43.2 to 58.0MJ/m3).
HWith natural gas settingLL, the
boiler can be operated in the
Wobbe index range
10.0 to 13.1kWh/m3
(36.0 to 47.2MJ/m3).
2. The burner is set up in the factory
for natural gas E. If necessary,
convert the burner to a different
gas type in accordance with
details provided by your gas
supplier (see page7).
3. Record the gas type in the service
report (from page42).
5692541 GB

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Conversion to natural gasLL
1. Close the gas shut−off valve.
2. Switch OFF the system ON/OFF
switch on the control unit.
3. Switch OFF the mains electrical
isolator (outside the installation
room) or the mains power supply
and prevent unauthorised
reconnection.
4. Release fixing A.
5. Remove flangeEfrom the gas
combination valve.
6. Remove restrictorCtogether
with rubber−cork gasketD.
7. Secure the gas combination
valve (without restrictorC, but
with OringBand rubber cork
gasketD) on flangeE; for this,
replace the factory−fitted screws
M5×16 for M5×12 (see kit
supplied).
8. Release fixing A.
9. Affix the enclosed Adjusted to ...
labelFabove the existing label.
10. Start up the burner (see page5).
Safety instructions
Check all compression fittings for
gas leaks.
5692541 GB
A
C
E
F
B
D

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking static and supply pressure
Static pressure
1. Close the gas shut−off valve.
2. Release the screw inside test
nippleA, but do not fully remove.
3. Connect the U−shaped pressure
gauge.
4. Open the gas shut−off valve.
5. Measure the static pressure
(max. 60mbar).
6. Record the actual values in the
service report (from page42).
5692541 GB
A

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Supply pressure
7. Start up the burner.
Please note:
Initial start−up, see page5.
Switch the burner to max. output;
to do this, activate the emissions
test switch on the control unit.
8. Check the supply pressure (flow
pressure), see the table below.
Please note:
The supply pressure (flow
pressure) should be between
20 and 50mbar.
The gas governor is factory−set to
12mbar.
Do not change this setting.
9. Record the actual values in the
service report (from page42).
10. Close the gas shut−off valve.
11. Remove the U−shaped pressure
gauge and close test nippleA.
Supply pressure
(flow pressure)
Remedy
below 15mbar Do not change settings  contact gas supply company
15 to 20mbar Warning: The boiler may only be temporarily operated with
these settings (emergency mode).
Notify your gas supply company.
20 to 50mbar Boiler start−up
above 50mbar Install a separate gas governor with zero off upstream of the
boiler, and regulate the pressure to 20mbar.
Notify your gas supply company.
5692541 GB
A

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking venturi vacuum pressure
1. Release the screw inside test
nippleA, but do not fully remove.
2. Connect the U−shaped pressure
gauge to test nippleA(vacuum).
3. Open the gas shut−off valve.
4. Start up the burner (see page5).
5. Simultaneously press keysSD
and C.
Please note:
DisplayBshows:
HStatus: d (=regular stop) and
HService: Level of modulation in
% (00.=100%=full load,
00=0%=partial load)
6. Press key+E, until 00. shows in
the display.
Burner is now at max. output.
7. Check the venturi vacuum
pressure.
Please note:
At full load, the vacuum pressure
should be
H5.9mbar for natural gasE,
H6.7mbar for natural gasLL.
During the adjustment, also
check the gas throughput by
means of a volumetric test.
8. Record the actual values in the
service report (from page42).
9. Press keysSDand C
simultaneously.
Burner is now in operating mode.
10. Close the gas shut−off valve.
11. Remove the U−shaped pressure
gauge and close test nippleA.
¨Safety instructions
Check the test nipple and fittings for
gas leaks.
5692541 GB
A
B
C
D
E

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking CO2content
1. Open the gas shut−off valve.
2. Start up the burner.
3. Press keysSEand D
simultaneously.
Please note:
DisplayCshows:
HStatus: d (=regular stop) and
HService: Level of modulation in
% (00.=100%=full load,
00=0%=partial load)
Full load
4. Press+Funtil the service display
has incremented to 00. (=100%).
5. Measure the CO2content at the
flue pipe.
The CO2should be 8.8 to 9.3%.
6.If the CO2content must be
changed,
Hremove capBand
Hturn adjusting screwA(Allen
key 2.5mm) until the CO2
content is within the stated
range:
 Turning clockwise
³CO2content drops,
 Turning anti−clockwise
³CO2content rises.
5692541 GB
C
D
E
F
A
B

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Partial load
7. Press keyD, until the service
display has decremented to 00
(partial load).
8. Measure the CO2content at the
flue pipe.
The CO2should be 8.8 to 9.3%.
9. If the CO2content must be
changed,
HUnscrew coverBand
Hturn adjusting screwAin
small steps (Torx40) until the
CO2content is within the stated
range.
10. Record the actual values in the
service report (from page42).
11. Press+Funtil the
service display shows 00.
(=100%).
12. Measure the CO2content.
Repeat step6, if the value is not
8.8 to 9.3%.
13. Record the actual values in the
service report (from page42).
14. Press keysSEand D
simultaneously.
Burner is now in operating mode.
5692541 GB
C
D
E
F
B
A

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking ionisation current
1. Switch OFF the mains electrical
isolator.
2. Pull ionisation cable plugCoff.
3. Switch ON the mains electrical
isolator.
There must be a fault shutdown
after a burner start has been
attempted. DisplayBflashes fault
codeF25.
4. Switch OFF the mains electrical
isolator.
Please note:
Test cable no.1 is required when
checking with Testomatik−Gas
equipment.
You can also carry out this check with
a multimeter.
5. Push plugCof the ionisation
current lead into adaptorD.
6. Plug socketAof the test lead
onto the ionisation electrode.
7. Switch the mains electrical
isolator ON and check the
ionisation current.
Please note:
Ionisation current
Hmin. 10mA approx. 2 to 3s after
opening the gas valve,
Hmin. 30mA at full load,
Hmin. 5mA at partial load.
8. Record the actual values in the
service report (from page42).
9. Switch the mains electrical
isolator OFF, remove the test
equipment and reconnect the
plug connector of the ionisation
cable.
10. Switch ON the mains electrical
isolator.
5692541 GB
A
B
CD

14
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
System shutdown
1. Switch OFF the mains electric
power or mains electrical isolator
and safeguard against
unauthorised reconnection.
2. Pull plug−connectorsfA and lÖ off
the burner.
3. Close the gas shut−off valve.
Checking burner gauze assembly
1. Release fixing Afrom the gas
supply pipe.
2. Loosen the screws on the boiler
door and open it.
3. Check the wire mesh of burner
gauze assemblyBfor damage.
Slight wavy deformations are
nothing to worry about.
4. Replace burner gauze
assemblyB, if required.
Installation instructions
Burner component
replacement
Cleaning the combustion
chamber and hot gas flues,
see boiler service
instructions.
5692541 GB
BA

15
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking ignition and ionisation electrodes
Ignition electrodes
Ionisation electrode
1. Check the ignition electrodes and
the ionisation electrode for correct
gap towards the burner gauze
assembly and damage (replace, if
necessary).
2. Close the boiler door and tighten
the screws on the boiler door
evenly and diagonally.
5692541 GB
70.5
+
−
3.5 0.5
+
−

16
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning burner
1. Release fixing Cfrom gas supply
pipeD.
2. Unscrew venturi mixing tubeE
from fanA.
3. Remove venturi mixing tubeE
with gas combination valveB
and gas supply pipeD.
4. Remove fanA.
5. Clean the fan housing and the
impeller.
6. Clean the inside of burner gauze
assemblyFwith a vacuum
cleaner, if required.
Burner installation
1. Install fanA.
2. Secure venturi mixing tubeE
with gas combination valveB
and gas supply pipe Dto fanA.
3. Secure fixing Con gas supply
pipeD.
5692541 GB
C
D
F
B
E
A
A
B
C
D
E

17
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking both valves of gas combination valve for leaks
1. Close the gas shut−off valve.
2. Release the screw in test
nippleBbut do not remove.
3. Release the screw in test nippleA
but do not remove.
4. Connect the U−shaped pressure
gauge with a manual pump to test
nippleA.
5. Gently activate the manual pump
to create a test pressure of approx.
50mbar.
6. Wait approx. 5 minutes for the
temperature to level out, and then
observe the display on the
U−shaped pressure gauge:
If the displayed pressure does not
fall within a further 5min by more
than 1mbar, the gas combination
valve is sound³continue with
step7).
Otherwise, the system leaks. In
this case, return the gas
combination valve to Viessmann
Werke for tests.
7. After the test, close both test
nipples by closing their respective
screws.
¨Safety instructions
Check the test nipple for gas leaks.
5692541 GB
B
A

18
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking all gas unions for leaks
1. Insert new gaskets in all fittings
which have been opened, and
tighten fittings.
2. Open the gas shut−off valve.
3. Check the inlet seals of the gas
combination valve for leaks.
4. Start up the burner (see page5).
5. Check the outlet seals of the gas
combination valve for leaks.
Implementing final tests
1. Implement a final check in
accordance with the steps on
pages11 to 13.
2. Record the actual values in the
service report (from page42).
5692541 GB

19
Initial start−up, inspection and maintenance
Gas burner control unit
Display and programming unit
Function
A display and programming unit is
integrated into the burner control
unit. The display indicates the
respective operating conditions, the
service and parameter conditions as
well as any fault and error messages.
The display comprises three,
seven−segment elements; four keys
enable settings to be adjusted at
different operating levels. A DIP
switch on the rear of the display and
programming unit enables burner
parameters to be configured (for
settings, see page23).
AReset button
BDecimal point
will be set if a display value
exceeds99
CDHW cylinder LED
will be set if a value is saved
DSelection key
5692541 GB
Status Service
A
B
C
D

20
Initial start−up, inspection and maintenance
Gas burner control unit (cont.)
Display Status
(1 digit)
Service
(two digits)
See
Operating display in
standard mode
Current operating state
see following table
DisplayFL if a
flame signal is
present
Page21
Operating display for
operation deviating
from the standard
condition
Message codeA to L
see following table
 
Service display Message coded
see following table
Current modulation
level
Page22
Fault display Message codeF
see following table
Display flashes
Fault code
display flashes
see page27 to 30
Page25
Display
Status
Operating condition
0No heat demand
Standby
1Heat demand
System tests
Start−up decision
2Idle state check
Fan run−up
3 Pre−purge
4 Pre−ignition
5Safety time
7 Mode
8 Post−purge
Display
Status
Message code
ALack of gas
dControl stop function
active
F Error
LAir pressure switch
standby position/flue gas
backup
5692541 GB