Viessmann MatriX Operating instructions

Service instructions
for contractors
VIESMANN
MatriX cylinder burner
Type Proflame VM IV, 400 to 630 kW
MatriX cylinder burner for natural gas E and LL
MatriX cylinder burner
5834375 GB 8/2020 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
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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.)
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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.)
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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.)
5834375

6
1. Information Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■Spare parts lists .................................................................................. 8
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 9
3. Burner control unit ................................................................................................................ 29
4. Flow diagram for burner
control unit
................................................................................................................ 33
5. Troubleshooting Fault indicator ........................................................................................ 35
■Fault display ....................................................................................... 35
■Fault memory ...................................................................................... 35
Fault codes ............................................................................................ 35
■General process errors ....................................................................... 35
■Internal system faults .......................................................................... 38
Faults without fault display ..................................................................... 40
6. Component overview ................................................................................................................ 41
7. Functions Air pressure switch ................................................................................ 42
■Fan pressure monitoring (LDW1) ....................................................... 42
■Combustion chamber pressure monitoring function (LDW2) .............. 43
8. Connection and wiring dia-
gram
Burner control unit connection diagrams ............................................... 44
■Mains filter unit connection diagram ................................................... 46
9. Reports Settings and measurement values ........................................................ 47
10. Specification ................................................................................................................ 48
11. Final decommissioning
and disposal
................................................................................................................ 49
12. Certificates Declaration of conformity ....................................................................... 50
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 50
13. Keyword index ................................................................................................................ 51
Index
Index
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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 boiler. "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.
The burner must be installed in compliance with the
applicable regulations. The burner must be operated
only in well ventilated areas. Observe instructions for
installation and operation of the burner.
Information
Symbols
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Information

8
MatriX cylinder burner, type Proflame VM IV-1/2/3 for
Vitocrossal 300, type CT3U
■For natural gas E and LL
■Output 400 to 630 kW
■Modulation range from 33 to 100 %
■For open flue and room sealed operation. Accesso-
ries are required for room sealed operation.
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
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Information

9
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Note on commissioning, inspection and maintenance.................................................. 10
•2. Checking the gas type....................................................................................................... 10
•3. Converting to natural gas LL............................................................................................ 11
••• 4. Commissioning the burner................................................................................................ 12
•5. Reducing the maximum heating output (if necessary)................................................... 12
• • • 6. Checking static pressure and supply pressure.............................................................. 13
••• 7. Checking the rotary damper setting................................................................................. 14
••• 8. Checking the CO2 content................................................................................................. 18
••• 9. Checking the CO content.................................................................................................. 19
••• 10. Checking the flue gas temperature.................................................................................. 20
• • 11. Checking the ionisation current....................................................................................... 20
• • 12. Shutting down the system................................................................................................. 20
• • 13. Opening the boiler door..................................................................................................... 20
• • 14. Checking the gaskets and thermal insulation sections................................................. 22
• • 15. Checking the burner gauze assembly.............................................................................. 22
• • 16. Checking the ignition electrodes and ionisation electrode........................................... 24
• • 17. Closing the boiler door...................................................................................................... 24
• • 18. Cleaning the burner........................................................................................................... 25
•19. Fitting the fan...................................................................................................................... 25
• • 20. Burner electrical connection............................................................................................. 26
• • 21. Automatic tightness test on the two gas train valves.................................................... 26
• • 22. Checking the gas train filter element............................................................................... 26
• • 23. Checking the filter element in the gas line (if installed) and replacing if necessary
••• 24. Checking all gas connections for tightness.................................................................... 27
•25. Performing final checks..................................................................................................... 27
••• 26. Mounting the burner hood................................................................................................. 27
•27. Instructing the system user.............................................................................................. 28
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Product contains ceramic fibres
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
Boiler inspection and maintenance
Steps that relate to the boiler are described in separate
instructions.
Vitocrossal 300, type CT3U installation and
service instructions
Removing the burner hood
Remove the burner hood to perform any work or
make any adjustments.
OPN CLOSE
1.
2.
Fig. 1
Checking the gas type
1. Check with your gas supply utility regarding the
gas type and Wobbe index (Wo).
The boiler can be operated in the following Wobbe
index ranges:
■With natural gas E:
12.0 to 16.1 kWh/m3 (43.2 to 58.0 MJ/m3)
■With natural gas LL: 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 details provi-
ded by the gas supply utility. See the following
chapter.
3. Record the gas type in the report in the appendix.
Commissioning, inspection, maintenance
Note on commissioning, inspection and maintenance
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(Not in a or c)
For conversion to natural gas LL, remove the E gas
restrictor and rubber cork gasket from the flange on
the gas train.
1. Close the gas shut-off valve.
2. Switch OFF the system ON/OFF switch on the
control unit.
3. Switch OFF the mains isolator (outside the installa-
tion room) or isolate the mains power and secure
against unintentional reconnection.
6.
5.
4.
7.
8.
D
C
E
B
A
Fig. 2
AControl cable
BSeal ring
CGas restrictor
DRubber cork gasket
ELabel
9. Assemble the burner in reverse order.
Affix supplied label "Set to..." E over the existing
label.
Note
Check control cables for:
■Connection and kink-free routing
■Application and seating of retaining clips
Danger
Escaping gas leads to a risk of explosion.
Check the fitting for gas tightness.
!Please note
The use of leak detection spray can result in
faulty operation.
Leak detection spray must not come into contact
with electrical contacts.
Commissioning, inspection, maintenance
Converting to natural gas LL
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12
■Boiler control unit operating instructions and
service instructions
■Vitocrossal 300, type CT3U service instruc-
tions
■Neutralising system operating instructions
Danger
CO formation as a result of incorrect burner
adjustment can have serious health implications.
Always carry out a CO test before and after
work on gas appliances.
Tightness test
Gaskets on the boiler door and components that route
flue gas can be checked during operation with an
inspection mirror. If necessary, remove the thermal
insulation components. Traces of condensate on the
outside of the flue gas collector or on sections of ther-
mal insulation also indicate leaks.
Note
It is essential to check the burner setting with the boiler
heated to operating temperature (min. 40 °C). Also
check in the partial load range.
1. Check the heating system pressure.
2. For open flue operation: Check that the ventilation
facility in the installation room is open.
3. Check the gas supply pressure.
4. Open the gas line shut-off valves.
5. Switch ON the mains isolator (outside the installa-
tion room).
6.
Status Service
S
R
Fig. 3 Programming unit on the burner control
unit
Switch ON the system ON/OFF switch at the con-
trol unit. If the fault indicator on the control unit illu-
minates and the display on the burner control unit
flashes, first reset the system. To do so, press
reset button R on the burner control unit.
Note
During commissioning, the appliance can enter a
fault state if there are still airlocks in the gas line.
The fault indicator on the control unit illuminates.
Purge the gas line again and reset the burner con-
trol unit.
If the fault persists, the inlet strainer of the gas train
may have become blocked by work carried out on
the gas line.
Danger
Escaping gas leads to a risk of explosion.
First close the shut-off valves in the gas line
again.
Unscrew the flange on the gas train and clean the
strainer. A blocked strainer is not recognised by the
gas pressure test at the flange.
7. Check all gaskets and plugs, and retighten if nec-
essary.
8. Check the boiler door a few days after commis-
sioning. Tighten the screws.
Reducing the maximum heating output (if necessary)
The maximum heating output of the burner can be
reduced if required.
Programming unit on the burner control unit
Status Service
S
R
Fig. 4
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".
Commissioning, inspection, maintenance
Commissioning the burner
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13
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.
Checking static pressure and supply pressure
Static pressure
A
Fig. 5
1. Close the gas shut-off valve.
2. Undo the screw in test connector A, but do not
remove.
3. Connect the pressure tester at test connector A.
4. Open the gas shut-off valve.
5. Check the static pressure: Max. 60 mbar (6 kPa).
6. Record the actual value in the report (on
page 47).
Supply pressure
1. Start the burner.
Note
For commissioning, see page 12. Switch the
burner to maximum heating output by activating
the emissions test switch at the control unit.
Boiler control unit service instructions
2. Check the supply pressure (flow pressure); see the
following table.
Note
The supply pressure (flow pressure) for natural gas
should be between 18 and 50 mbar (1.8 and
5 kPa). Nominal supply pressure for natural gas
20 mbar (2 kPa).
The boiler is factory-fitted with 2 gas pressure
switches. The gas pressure switches are set to 10
mbar (1 kPa).
3. Record the actual value in the report on page 47.
4. Close the gas shut-off valve.
5. Remove pressure gauge. Close test connector A.
Commissioning, inspection, maintenance
Reducing the maximum heating output (if… (cont.)
5834375

14
Supply pressure
(flow pressure)
Measure
< 15 mbar (1.5 kPa) Do not make any adjustments. Notify the gas supply utility.
15 to 18 mbar
(1.5 to 1.8 kPa)
Please note: The boiler may only be operated temporarily with this setting (emergen-
cy mode).
Notify the gas supply utility.
18 to 50 mbar
(1.8 to 5 kPa)
Start the boiler.
> 50 mbar (5 kPa) Install a separate gas pressure governor with zero off upstream of the boiler system,
and set the pressure to 20 mbar (2 kPa).
Notify the gas supply utility.
Checking the rotary damper setting
0
0
A B C
Fig. 6
1. Open the gas shut-off valve.
2. Check the position of the rotary damper with the
burner in idle mode. Rotary damper windows A
must be fully opened. Scale ring C on the air
damper servomotor must be set to "0", relative to
marking B.
3. Check the control cable; see page 15:
■Connection and kink-free routing
■Application and seating of retaining clips
4. Start the burner.
5. Check the position of the rotary damper during the
start-up phase. Rotary damper windows A must
be almost closed for approx. 5 s. During this time,
scale ring C must be set as follows:
Rated heating
output
Rated heat in-
put
Rotary damper
setting
Pmax
(50/30 °C)
Qmax (Hi) [net
cv]
in kW in kW in °
400 381 30
500 474 20
630 593 30
Commissioning, inspection, maintenance
Checking static pressure and supply pressure (cont.)
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15
Control cables – delivered condition
Note
The control cables must be routed without kinks and
plugged in correctly. The hose ends of the control
cables must be secured with wire clamps to prevent
them from being pulled off/falling off.
Burner 400 kW
A
B
C
D
Fig. 7
AControl cable between LDW2 Plus and combustion
chamber
BControl cable between LDW1 Minus and Venturi
CControl cable between LDW1 Plus and Venturi
inlet
DControl cable between gas solenoid valve and
Venturi
Commissioning, inspection, maintenance
Checking the rotary damper setting (cont.)
5834375

16
A
B
C
D
LDW2
LDW1
+
-
+
-
Fig. 8
AControl cable between LDW2 Plus and combustion
chamber (7 4 mm, L 185 mm)
BControl cable between LDW1 Minus and Venturi
(7 4 mm, L 450 mm)
CControl cable between LDW1 Plus and Venturi
inlet (7 4 mm, L 630 mm)
DControl cable between gas solenoid valve and
Venturi (7 6 mm)
Burners 500 and 630 kW
A
B
C
Fig. 9
AControl cable between LDW2 Plus and combustion
chamber
BControl cable between LDW1 Minus and Venturi
CControl cable between LDW1 Plus, gas solenoid
valve and rotary damper mounting plate
Commissioning, inspection, maintenance
Checking the rotary damper setting (cont.)
5834375

17
A
B
C
D
LDW2
LDW1
+
-
+
-
Fig. 10 500 kW
AControl cable between LDW2 Plus and combustion
chamber (7 4 mm, L 185 mm)
BControl cable between LDW1 Minus and Venturi
(7 4 mm, L 600 mm)
CControl cable between LDW1 Plus and Venturi
inlet (7 4 mm, L 410 mm)
DControl cable between gas solenoid valve and
Venturi (7 6 mm)
A
B
C
D
LDW2
LDW1
+
-
+
-
Fig. 11 630 kW
AControl cable between LDW2 Plus and combustion
chamber (7 4 mm, L 185 mm)
BControl cable between LDW1 Minus and Venturi
(7 4 mm, L 600 mm)
CControl cable between LDW1 Plus and Venturi
inlet (7 4 mm, L 410 mm)
DControl cable between gas solenoid valve and
Venturi (7 6 mm)
Commissioning, inspection, maintenance
Checking the rotary damper setting (cont.)
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18
Preparing the test
AB
Fig. 12
Status Service
S
R
Fig. 13
1. Open the gas shut-off valve.
2. Start the burner via menu point "Emissions test
mode" at the control unit.
3. Simultaneously press S and for longer than 2 s.
The display will then show the following:
■Under "Status": "P" (= controlled stop)
■Under "Service": Modulation level in %
("100" = 100 % = upper heating output,
"0" = 0 % = lower heating output)
Note
400 - 630 kW
Nominal CO2 value set at the factory at the upper heat-
ing output with gas type "G20" (delivered condition):
8.8 %
Permissible CO2 content
Gas type CO2 content Rated heating output in kW
at 400 500 630
Natural gas E (G20) Upper heating out-
put (100 %)
7.0 - 9.9 % 7.0 - 9.9 % 7.0 - 9.9 %
Actual value at upper heating output minus
Lower heating out-
put (0 %)
0.5 to 0.8 % 0.5 to 0.8 % 0.5 to 0.8 %
Natural gas H (G20) Upper heating out-
put (100 %)
7.9 - 9.9 % 7.9 - 9.9 % 7.9 - 9.9 %
Actual value at upper heating output minus
Lower heating out-
put (0 %)
0.5 to 0.8 % 0.5 to 0.8 % 0.5 to 0.8 %
Natural gas LL (G25) Upper heating out-
put (100 %)
7.1 - 9.7 % 7.1 - 9.7 % 7.1 - 9.7 %
Actual value at upper heating output minus
Lower heating out-
put (0 %)
0.5 to 0.8 % 0.5 to 0.8 % 0.5 to 0.8 %
Natural gas L (G25) Upper heating out-
put (100 %)
8.1 - 9.7 % 8.1 - 9.7 % 8.1 - 9.7 %
Commissioning, inspection, maintenance
Checking the CO2 content
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Gas type CO2 content Rated heating output in kW
at 400 500 630
Actual value at upper heating output minus
Lower heating out-
put (0 %)
0.5 to 0.8 % 0.5 to 0.8 % 0.5 to 0.8 %
CO2 test at the upper heating output
1. Press until the service indicator has counted up
to "100" (= 100 %).
2. Check the CO2 content at the flue pipe. For the
permissible CO2 content, see the table above.
3. If the CO2 content needs adjusting:
Remove cap B and turn setting screw A in small
steps (Allen key 3 mm) until the CO2 content is
within the specified range:
■Turning clockwise → CO2 content drops
■Turning anti-clockwise → CO2 content rises
4. Enter actual value into the report in the appendix.
5. Checking the control cables
■Connection and kink-free routing
■Application and seating of retaining clips
CO2 test at the lower heating output
AB
Fig. 14
Status Service
S
R
Fig. 15
1. Press until the service indicator has counted
down to "0" (lower heating output).
2. Check the CO2 content at the flue pipe.
3. If the CO2 content needs adjusting:
Undo cover B. Turn adjusting screw A in small
increments (Torx 40) until the CO2 content is within
the specified range:
■Turning clockwise → CO2 content rises
■Turning anti-clockwise → CO2 content drops
4. Enter actual value into the report in the appendix.
5. Check the CO2 content at the upper and lower
heating output again. If the CO2 content is not
within the specified range: Repeat the steps for the
upper and lower heating output.
6. Hold down S and simultaneously for longer than
2 s. Burner switches to operating mode.
Note
At the lower heating output, the CO2 content must
always be lower than at the upper heating output by a
given amount. See table on page 18.
Checking the CO content
Enter actual value into the report in the appendix.
Commissioning, inspection, maintenance
Checking the CO2 content (cont.)
5834375

20
Enter actual value into the report in the appendix.
Checking the ionisation current
Note
The ionisation current must be called up via the burner
control unit. It is not possible to check the ionisation
current with a Testomatik-Gas or a multimeter.
Press the following buttons:
01. Hold down S for approx. 2 s; " " flashes.
02. until "5" is shown under "Service".
03. Press S. "5" is displayed under "Status".
04. until "3" is shown under "Service".
05. Press S. "3" is shown under "Status"; under "Serv-
ice" the ionisation current is shown during opera-
tion (e.g. 30 = 3.0 µA).
06. Start the burner via menu point Emissions test
mode in the control unit menu.
07. Read the ionisation current.
08. Record the actual value in the report.
09. Hold down S for approx. 2 s; " " flashes.
10. until "5" is shown under "Service".
11. Press S. "5" is displayed under "Status".
12. until "0" is shown under "Service".
13. Press S. The operating display will be shown
again.
Note
Approx. 2 to 3 s after the gas train has opened and
during operation, the ionisation current should be at
least 3 µA.
Shutting down the system
1. Switch OFF the mains isolator or the power supply,
and safeguard against unauthorised reconnection.
Danger
Mains voltage can be life threatening.
For maintenance work, isolate the gas fan
from the power supply.
2. Remove the connecting plug from the burner. See
Fig. 16.
3. Close the gas shut-off valve.
Opening the boiler door
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
Commissioning, inspection, maintenance
Checking the flue gas temperature
5834375