Viessmann MatriX Operating instructions

Service instructions
for contractors
VIESMANN
MatriX radiant burner
Type VMIII
Pressure-jet gas burner
for the Vitocrossal 300, type CM3
Rated heating output 87 to 142 kW
For applicability, see the last page
MatriX radiant burner
5692 921 GB 11/2015 Please keep safe.

2
Please follow these safety instructions 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are intended exclusively for quali-
fied contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
■This appliance has not been designed to be oper-
ated by individuals (including children) with limited
physical, sensory or mental capacities or who are
lacking in the appropriate experience and/or knowl-
edge, unless they are supervised by a person with
responsibility for their safety or were instructed by
that person in the operation of this appliance.
!Please note
Children should be supervised.
Ensure that children never play with the appli-
ance.
Regulations
Observe the following when working on this system:
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■Codes of practice of the relevant trade associations.
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards.
aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and
ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS Directive 1942: LPG, part 2
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Do not press any switches for lights or
electrical appliances.
■Close the gas shut-off valve.
■Open windows and doors.
■Remove all people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Shut off the electricity supply to the building
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 boiler room.
■Close all doors in the living space.
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply (e.g. at the
separate fuse or a main switch) and check that it is
de-energised.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharges.
Before beginning work, touch earthed objects,
such as heating or water pipes, to discharge
static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Replace faulty components only with original
Viessmann spare parts.
Safety instructions
Safety instructions
5692 921 GB

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 921 GB

4
1. Information Symbols ................................................................................................. 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Control unit Adjusting codes at the control unit ......................................................... 19
4. Air pressure switch ................................................................................................................ 20
5. Burner control unit Burner control unit VUC 310 .................................................................. 21
■Display and programming unit ............................................................ 21
■Operating display ................................................................................ 21
■Information display / configuration display .......................................... 22
■Reset all operating parameters to the factory setting ......................... 23
■Manual mode and service display ...................................................... 24
6. Troubleshooting Fault display ........................................................................................... 25
■Fault display ....................................................................................... 25
■Fault memory ...................................................................................... 25
Fault codes ............................................................................................ 25
■Commonly occurring process errors ................................................... 25
■Internal system faults .......................................................................... 28
Faults without fault display ..................................................................... 28
7. Flow diagram Burner control unit flow diagram ............................................................ 29
■Description of state: ............................................................................ 29
8. Parts lists Ordering parts ........................................................................................ 31
Parts lists ............................................................................................... 32
9. Component overview ................................................................................................................ 36
10. Connection diagrams Burner control unit connection diagram ................................................. 37
11. Report ................................................................................................................ 39
12. Specification ................................................................................................................ 40
13. Final decommissioning Final decommissioning and disposal ..................................................... 41
14. Keyword index ................................................................................................................ 42
Index
Index
5692 921 GB

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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
Information
Symbols
5692 921 GB
Information

6
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system............................................................................................... 7
•2. Checking the gas type....................................................................................................... 7
•3. Converting to natural gas LL............................................................................................ 8
•4. Reducing the operational output (if required)................................................................. 8
••• 5. Checking the static pressure and supply pressure........................................................ 9
••• 6. Checking the nozzle pressure........................................................................................... 11
••• 7. Checking the CO2 content................................................................................................. 12
••• 8. Checking the CO content
••• 9. Checking the flue gas temperature
• • 10. Displaying the ionisation current..................................................................................... 14
• • 11. Shutting down the system................................................................................................. 14
• • 12. Checking the burner gauze assembly.............................................................................. 15
• • 13. Checking the ignition electrodes and ionisation electrode........................................... 15
• • 14. Cleaning the burner........................................................................................................... 16
•15. Fitting the burner................................................................................................................ 16
• • 16. Checking both gas train valves for tightness.................................................................. 17
• • 17. Checking the filter element in the gas line (if installed) and replacing if required
••• 18. Checking all gas connections for tightness.................................................................... 17
• • 19. Checking the flue gas routing
•20. Performing final checks..................................................................................................... 17
•21. Operating and service documents................................................................................... 18
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Danger
CO build-up 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.
Note
Checking the burner setting with the boiler heated to
operating temperature (min. 40 °C) is essential.
Also carry out tests at base load.
Boiler control unit service instructions
C
B
A
D
Fig. 1
1. Check the heating system pressure.
2. Open the gas shut-off valve.
3. Switch ON the mains isolator (outside the installa-
tion room).
4. Switch ON system ON/OFF switch B at the control
unit.
If fault indicator A on the control unit illuminates
and display C on the burner control unit flashes,
first reset the system. To do this, press reset button
D on the burner control unit.
Note
The appliance can enter a fault state during com-
missioning if there is insufficient gas in the gas line:
The fault indicator on the control unit illuminates.
Purge the gas line again and reset the burner con-
trol unit.
5. Adjust the codes on the boiler control unit in
accordance with the table on page 19.
Control unit installation and service instruc-
tions
Checking the gas type
1. Check the gas type and Wobbe index (Wo) with
your gas supply utility.
■With the natural gas E setting, the boiler can be
operated in the Wobbe index range 12.0 to
16.1 kWh/m3 (43.2 to 58.0 MJ/m3).
■With the natural gas LL setting, boilers can be
operated in the Wobbe index range 10.0 to
13.1 kWh/m3 (36.0 to 47.2 MJ/m3) (not in a or
c).
2. In the delivered condition, the burner is set up for
natural gas E. If required, convert the burner to a
different gas type (see page 8) in accordance
with the details provided by your gas supply utility.
3. Record the gas type in the report (on page 39).
Commissioning, inspection, maintenance
Commissioning the system
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(Not in a and c)
C
B
A
Fig. 2
01. Close the gas shut-off valve.
02. Switch OFF the system ON/OFF switch on the
control unit.
03. Switch OFF the mains isolator (outside the instal-
lation room) or isolate the mains power and
secure against unintentional reconnection.
04. Release the cable fixings on the gas pipe and
remove the connecting cables from the gas train.
05. Release fittings A and C and remove the gas
pipe.
06. Undo restrictor B.
07. Insert restrictor B for natural gas LL (included in
delivery) (for diameter, see table on page 40).
08. Refit the gas pipe. Insert gaskets into fittings A
and C .
09. Secure the gas train cables to the gas pipe.
10. Affix the enclosed label "Set to ..." over the exist-
ing label.
11. Start the burner (see page 7).
Danger
Escaping gas leads to a risk of explosion.
Check all fittings 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.
Reducing the operational output (if required)
The maximum heating output of the burner can be set
to between 70 and 100 % of the rated heating output if
necessary.
Commissioning, inspection, maintenance
Converting to natural gas LL
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C
D
E
F
Fig. 3
Status Service
S
R
D
C
EF
G
Fig. 4
1. Press S E for longer than 2 s.
flashes.
2. Press F until "6" is shown on display C under
Service.
3. Press S E. "6" is shown on display C under Sta-
tus.
4. Press S E. "1" is shown on display C under Sta-
tus and the current value for the maximum heating
output in % is shown under Service.
5. Press F or D for the required maximum heat-
ing output.
6. Press S E to confirm. If applied successfully, "1"
will be shown on display C under Service; if not,
"0" will appear.
7. Press S E to switch to the operating display.
8. Press R G.
A system restart is initiated.
Checking the 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. 50 mbar).
6. Record the actual value in the report (on
page 39).
Commissioning, inspection, maintenance
Reducing the operational output (if required) (cont.)
5692 921 GB

10
Supply pressure
A
Fig. 6
1. Start the burner.
Note
For commissioning, see page 7. Switch the burner
to maximum heating output. For this, activate the
emissions test switch at the control unit.
2. Check the supply pressure (flow pressure); see
table on page 10.
Note
The supply pressure (flow pressure) should be
between 18 and 50 mbar (1.8 and 5 kPa). The gas
pressure switch is factory set to 10 mbar (1 kPa).
Never alter this setting.
3. Record the actual value in the report (on
page 39).
4. Close the gas shut-off valve.
5. Remove the pressure tester and close test connec-
tor A.
Supply pressure
(flow pressure)
Steps to take
Below 15 mbar (1.5 kPa) Make no adjustments and 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 your gas supply utility.
18 to 50 mbar (1.8 to 5
kPa)
Start the boiler.
Above 50 mbar (5 kPa) Install a separate gas pressure governor with zero off upstream of the boiler system,
and regulate the pressure to 20 mbar.
Notify your gas supply utility.
Commissioning, inspection, maintenance
Checking the static pressure and supply pressure (cont.)
5692 921 GB

11
Preparing the test
A
Fig. 7
B
C
D
E
Fig. 8
1. Undo the screw in test connector A, but do not
remove.
2. Connect the pressure tester at test connector A.
3. Open the gas shut-off valve.
4. Start the burner (see page 7).
5. Simultaneously hold down S D and C for longer
than 2 s.
Display B 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)
Testing the nozzle pressure at the upper heating output
1. Press E until the service display has counted up
to "100" (= 100 %).
2. Check the nozzle pressure in accordance with the
Wobbe index and the heating output in the nozzle
pressure table on page 12.
Note
During the adjustment, also check the gas through-
put by means of a volumetric test.
3. Check and, if required, adjust the nozzle pressure.
Note
The adjusted gas pressure will be present at the
burner approx. 20 s after the burner has started.
4. Record the actual value in the report (on
page 39).
5. Simultaneously hold down S D and C for longer
than 2 s. The burner is now in operating mode.
6. Close the gas shut-off valve.
7. Remove the pressure tester and close test connec-
tor A.
Danger
Escaping gas leads to a risk of explosion.
Check the test connector and fittings 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
Checking the nozzle pressure
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Nozzle pressure table for natural gas E and LL
Note
Check that the nozzle pressure table is applicable to
the burner. To do so, compare the serial number on
the type plate with the serial number on page 44.
Gas group Wobbe index Wo Supply pres-
sure
Rated heating output*1 of the boil-
er
kWh/m3MJ/m3mbar*2 87 kW 115 kW 142 kW
Natural gas
E
15.00 54.00 20.0 Nozzle pres-
sure mbar*2
10.5 10.6 10.0
Natural gas
LL*3
12.40 44.60 20.0 Nozzle pres-
sure mbar*2
10.5 10.6 10.0
Note
The nozzle pressures in the table represent a standard
factory setting for natural gas E or L. The values apply
to 15 °C, 1013 mbar and dry. These values may differ
slightly after a CO2 adjustment (see following chapter).
Checking the CO2 content
Preparing the test
A
Fig. 9
B
C
D
E
Fig. 10
1. Open the gas shut-off valve.
2. Start the burner.
3. Simultaneously hold down S D and C for longer
than 2 s.
Display B 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)
*1 Details relative to TV/TR = 50/30 °C.
*2 1 mbar corresponds approximately to 10 mmWC; e.g. 12.0 mbar ≈ 120 mmWC.
*3
a
,
c
: No natural gas LL in Austria or Switzerland.
Commissioning, inspection, maintenance
Checking the nozzle pressure (cont.)
5692 921 GB

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CO2 test at the upper heating output
1. Press E until the service display has counted up
to "100" (= 100 %).
2. Check the CO2 content at the flue pipe.
Burner output in
kW
Permissible CO2 content in
%
87
9.0 (+0.3/-0.1)
115
142
3. If the CO2 content has to be adjusted:
Turn setting screw "V" A (2.5 mm Allen key) until
the CO2 content is within the specified range.
4. Record the actual value in the report (on
page 39).
CO2 test at the lower heating output
A
Fig. 11
B
C
D
E
Fig. 12
1. Press C until the service display has counted
down to "0" (lower heating output).
2. Check the CO2 content at the flue pipe.
Burner output in
kW
Permissible CO2 content in
%
87
8.5 (+0.2/-0.2)
115
142
Note
The CO2 content must always be lower in partial
load than it is in full load.
3. If the CO2 content has to be adjusted:
Turn setting screw "N" A in small increments
(2.5 mm Allen key) until the CO2 content lies within
the specified range.
4. Record the actual value in the report (on
page 39).
Rechecking the values
Regulate to the upper and lower heating output
again using the programming unit in the burner con-
trol unit. If the values do not match the permissible
CO2 content in the tables, repeat the steps for the
upper and lower heating output.
5. Hold down S D and C simultaneously for longer
than 2 s. The burner will change to the operating
mode.
Checking the CO content
Commissioning, inspection, maintenance
Checking the CO2 content (cont.)
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Displaying the ionisation current
Note
The ionisation current must be called up via the burner
control unit. It is not possible to measure the ionisation
current using the Testomatik-Gas or a multimeter.
01. Press S approx. 2 s , " " flashes.
02. Press until "5" is shown under Service.
03. Press S. "5" will be displayed under Status.
04. Press until "3" is shown under Service.
05. Press S. "3" is shown under Status, and during
operation the ionisation current is shown under
Service (e.g. 30 = 3.0 µA).
06. Start the burner with the emissions test switch.
07. Read the ionisation current.
Note
The ionisation current should be at least 3 µA for
approx. 2 to 3 s after the gas train has been
opened and during operation.
08. Record the actual value in the report.
09. Press S approx. 2 s , " " flashes.
10. Press until "5" is shown under Service.
11. Press S. "5" will be displayed under Status.
12. Press until "0" is shown under Service.
13. Press S. The operating display will be shown
again.
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 burner hood.
3. Remove burner cables with plug fA and lÖ from
the burner control unit and pull out of the burner
casing.
4. Close the gas shut-off valve.
Commissioning, inspection, maintenance
Checking the flue gas temperature
5692 921 GB

15
ABB
Fig. 13
1. Remove the gas supply pipe; to do so, release the
control cables and plug from the gas train.
Danger
Escaping gas leads to a risk of explosion.
Close the gas shut-off valve.
2. Undo the screws on the boiler door and open the
door.
3. Check the wire mesh of burner gauze assembly A
and thermal protection ring B for damage and con-
tamination. Slight wavy deformations of burner
gauze assembly A are unproblematic. Remove
any contamination thoroughly using compressed
air.
4. If required, replace burner gauze assembly A and
thermal protection ring B.
!Please note
Scratches inside the combustion chamber can
lead to corrosion.
Never place tools or other objects inside the
combustion chamber.
Burner component installation instructions
For cleaning the combustion chamber and flues,
see boiler service instructions.
Checking the ignition electrodes and ionisation electrode
Ignition electrodes
70,5
+
-
51
+
-
3,5 0,5
+
-
Fig. 14
Ionisation electrode
12 2
+
-
Fig. 15
1. Check the ignition electrodes and ionisation elec-
trode for correct gap to the burner gauze assembly
and for possible damage. Replace the electrodes if
required.
2. Close the boiler door and tighten the screws on the
boiler door evenly and diagonally.
Burner component installation instructions
Commissioning, inspection, maintenance
Checking the burner gauze assembly
5692 921 GB

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B
A
Fig. 16
1. Remove the connecting cables from fan B.
2. Remove the fan.
3. Clean the fan casing and the impeller.
4. For severe fan contamination (dust, fluff), remove
the ignition, ionisation and control cables from the
boiler door, then remove air collector casing A and
clean it (using compressed air).
Note
Ensure the gasket between the fan housing and the
boiler door is correctly seated.
5. If required, vacuum the inside of the burner gauze
assembly.
Fitting the burner
B
A
Fig. 17
1. Fit air collector casing A to the boiler door.
2. Install fan B.
Note
Ensure the gasket between the fan housing and the
boiler door is correctly seated.
3. Plug connecting cables "100" and "100A" into the
fan.
4. Connect the ignition and ionisation cables.
5. Fit the control cables to the boiler door.
6. Fit the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check the fitting for gas tightness.
7. Secure the gas train cables to the gas pipe.
Commissioning, inspection, maintenance
Cleaning the burner
5692 921 GB

17
A B
Fig. 18
1. Close the gas shut-off valve.
2. Undo the screw inside test connector B for intake
pressure, but do not remove.
3. Undo the screw in test connector A, but do not
remove.
4. Connect the pressure tester with manual pump at
test connector A.
5. Steadily operate the manual pump to build a test
pressure of approx. 50 mbar (5 kPa).
6. Wait approx. 5 min for the temperature to level out
and then observe the display on the pressure
tester:
The gas train is gas-tight if the displayed pressure
does not drop by more than 1 mbar (0.1 kPa) within
5 min.
Otherwise there is a leak. In this case, return the
gas train to your local Viessmann sales office for
tests.
7. After testing, close both test connectors by tighten-
ing the respective screws.
Danger
Escaping gas leads to a risk of explosion.
Check the test connectors 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.
Checking the filter element in the gas line (if installed) and replacing if
required
Checking all gas connections for tightness
Danger
Escaping gas leads to a risk of explosion.
Always carry out the following steps.
1. Insert new gaskets in all gas fittings that have been
opened and then tighten the fittings.
2. Open the gas shut-off valve.
3. Check the inlet seals of the gas train for tightness.
4. Start the burner (see page 7).
5. Check the outlet seals of the gas train for 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.
Checking the flue gas routing
Performing final checks
1. Carry out final checks in accordance with the steps
on pages 12 to 14.
2. Record the actual values in the report (on
page 39).
Commissioning, inspection, maintenance
Checking both gas train valves for tightness
5692 921 GB

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1. Complete and detach the customer registration
card:
■Hand system users their section for safekeeping.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instructions
in the folder and hand this over to the system user.
The installation instructions are no longer required
after the installation is complete and therefore do
not need to be retained.
Commissioning, inspection, maintenance
Operating and service documents
5692 921 GB

19
Vitotronic service instructions
In conjunction with the following control units:
■Vitotronic 100, type GC1B
■Vitotronic 200, type GW1B
■Vitotronic 300, type GW2B
Coding address Rated heating output of the MatriX radiant burner in kW Coding card
87 115 142
02 2 2 2 1042
05 0 0 0
08 80 5 30
09 0 1 1
15 20 20 20
0A 33 33 33
Control unit
Adjusting codes at the control unit
5692 921 GB
Codes

20
Fan pressure monitoring (LDW1)
A B
Fig. 19
The switching threshold of air pressure switch 1
(LDW1) is monitored in all fan ramp-up phases and
checked in modulating burner operation. This ensures
a minimum pre-purge, among other things.
Air pressure switch A triggers a fault shutdown at the
burner control unit under the following circumstances:
■The static pressure check was unsuccessful after
approx. 5 minutes.
■The air pressure is outside the permissible range
during the pre-purge phase (tolerance time approx.
5 minutes).
■The air pressure switch fails in control mode or the
air pressure lies outside the permissible range.
The fault shutdown is indicated by fault codes "F F5"
and "F F7" in the burner control unit display (see
page 21). To clear the fault display, press reset but-
ton B.
Burner output in kW LDW1 setting value in mbar
87 0.5 ↓
115 1 ↓
142 1 ↓
Combustion chamber pressure monitoring (LDW2)
C B
Fig. 20
To monitor the combustion chamber pressure, the
switching threshold of air pressure switch 2 (LDW2) is
monitored in all operating phases (except during safety
and stabilising time).
Air pressure switch C triggers a fault shutdown at the
burner control unit under the following circumstances:
■The combustion chamber pressure is outside the
permissible range in the pre-purge phase, in control
mode or in the post-purge phase after 2 attempts.
The fault shutdown is indicated by fault code "F FB" in
the burner control unit display (see page 21). To
clear the fault display, press reset button B.
Burner output in kW LDW2 setting value in mbar
87
5 ↑115
142
Air pressure switch
Air pressure switch
5692 921 GB
Diagnosis