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 output 80 to 130 (87 to 142) kW
For applicability, see the last page
MatriX radiant burner
5692 488 GB 6/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 488 GB

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Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Air pressure switch............................................................................................ 21
Burner control unit
Burner control unit MPA 51.................................................................................. 22
Troubleshooting
Diagnosis.............................................................................................................. 29
Burner control unit flow chart........................................................................... 35
Burner control unit connection diagram.......................................................... 37
Component overview......................................................................................... 39
Control unit
Adjusting codes at the control unit....................................................................... 41
Parts list.............................................................................................................. 42
Report.................................................................................................................. 45
Specification....................................................................................................... 46
Keyword index.................................................................................................... 47
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system........................................... 6
•2. Checking the gas type.................................................... 7
•3. Conversion to natural gas LL........................................ 7
••• 4. Checking the static and the supply pressure.............. 8
••• 5. Checking the nozzle pressure....................................... 10
••• 6. Checking the CO2 content............................................. 12
••• 7. Checking the CO content
••• 8. Checking the flue gas temperature
• • 9. Checking the ionisation current.................................... 14
• • 10. Shutting down the system............................................. 15
• • 11. Checking the burner gauze assembly.......................... 16
• • 12. Checking the ignition and ionisation electrodes......... 17
• • 13. Cleaning the burner........................................................ 18
•14. Fitting the burner............................................................ 18
• • 15. Checking both gas train valves for tightness.............. 19
• • 16. Checking the filter insert (if installed) in the gas
supply pipe and replacing if required
••• 17. Checking all gas connections for tightness................ 19
•18. Final testing..................................................................... 20
•19. Operating and service documents................................ 20
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
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Commissioning the system
Danger
CO formation as a result of an
incorrect burner setting can have
serious health implications.
Carry out a CO test before and
after work on gas equipment.
Note
An examination of the burner setting with
the boiler heated up (min. 40 ºC) is
essential.
Also carry out tests at base load.
Boiler control unit service instruc-
tions
C
B
A
D
1. Check the heating system pressure.
2. Open the gas shut-off valve.
3. Switch ON the main isolator (outside
the installation room).
4. Switch ON the system ON/OFF
switch B at the control unit.
If fault indicator lamp A on the con-
trol unit illuminates and display C on
the burner control unit flashes, first
press reset button D on the burner
control unit.
Note
The system may enter a fault state
during commissioning because the
gas pipe may not yet contain suffi-
cient gas (fault indicator on control
unit illuminates). Vent the gas pipe
again and reset the burner control
unit.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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7
Checking the gas type
1. Determine the gas type and Wobbe
index (Wo) from your gas supply util-
ity.
■ With the natural gas E setting, the
boilers 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,
the 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 and c).
2. In the delivered condition, the burner
is set up for natural gas E. If required,
convert the burner to the other gas
type in accordance with details provi-
ded by your gas supply utility (see
page 7).
3. Record the gas type in the report (on
page 45).
Conversion to natural gas LL
(not in a and c)
C
B
A
01. Close the gas shut-off valve.
02. Switch OFF the control unit ON/OFF
switch.
03. Switch OFF the main isolator (out-
side the installation room) or the
power supply and prevent unauthor-
ised reconnection.
04. Release the cable fixings on the gas
pipe.
05. Release compression fittings A
and C remove the gas pipe.
06. Unscrew gas restrictor B.
07. Take gas restrictor B for natural
gas LL from the pack supplied and
screw on (for diameter see table on
page 46).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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08. Refit the gas pipe. Insert gaskets
into fittings A and C.
Danger
Escaping gas leads to a risk
of explosion.
Check all fittings for gas
tightness.
09. Secure the gas train cables to the
gas pipe.
10. Affix the enclosed label "Adjusted
to ..." over the existing label.
11. Start the burner (see page 6).
Checking the static and the supply pressure
Static pressure
A
1. Close the gas shut-off valve.
2. Undo the screw inside test nipple
A, but do not remove.
3. Connect the pressure tester at test
nipple A.
4. Open the gas shut-off valve.
5. Measure the static pressure (max.
57.5 mbar).
6. Record the actual value in the report
(on page 45).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Supply pressure
A
1. Start the burner.
Note
For commissioning, see page 6.
Switch the burner to maximum out-
put. To do so, activate the emissions
test switch on the control unit.
2. Check the supply pressure (flow
pressure); see table on page 9.
Note
The supply pressure (flow pressure)
should be between 17.4 and
50 mbar. The gas pressure switch is
factory set to 10 mbar. Never alter
this setting.
3. Record the actual value in the report
(on page 45).
4. Close the gas shut-off valve.
5. Remove the pressure tester and
close test nipple A.
Supply pressure
(flow pressure)
Measures
below 15 mbar Make no adjustments and contact the gas supply utility.
15 to 17.4 mbar Caution! The boiler may only be operated temporarily with this
setting (emergency mode).
Notify the gas supply utility.
17.4 to 50 mbar Start the boiler.
above 50 mbar Install a separate gas pressure governor with zero off upstream
in the boiler system, and regulate the pressure to 20 mbar.
Notify the gas supply utility.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the nozzle pressure
Preparing the test
A
B
C
D
E
1. Undo the screw inside test nipple
A, but do not remove.
2. Connect the pressure tester at test
nipple A.
3. Open the gas shut-off valve.
4. Start the burner (see page 6).
5. Press "S" D and "-" C simultane-
ously.
Display C will then show the follow-
ing:
■ Under status: "d" (= control stop)
■ Under service: Modulation level in
% ("00" = 100 % = upper output,
"00" = 0 % = lower output)
Testing the nozzle pressure at the upper output
1. Press "+" E until the service display
has incremented to "00" (=100 %).
2. Check the nozzle pressure in accord-
ance with the Wobbe index and the
output in the nozzle pressure table on
page 11.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 488 GB

11
Note
During the adjustment, also check
the gas throughput by means of a
volumetric test.
3. Check and if required adjust the noz-
zle pressure.
Note
The adjusted gas pressure will be
available at the burner approx. 20
seconds after the burner has star-
ted.
4. Record the actual value in the report
(on page 45).
5. Press "S" D and "-" C simultane-
ously. The burner is now in operating
mode.
6. Close the gas shut-off valve.
7. Remove the pressure tester and
close test nipple A.
Danger
Escaping gas leads to a risk of
explosion.
Check the test nipple and fittings
for tightness.
Nozzle pressure table for natural gas E and LL
Note
Check that the nozzle pressure table is
applicable for the burner. To do so, com-
pare the serial number on the type plate
with the serial number on page 48.
Gas
group
Wobbe index Wo Supply
pressure
Rated output*1 of the
boiler
kWh/m3MJ/m3mbar*2 80 kW 105
kW
130 kW
Natural
gas E
15.00 54.00 20.0 Nozzle
pressure
mbar*2
10.5 10.6 10.0
Natural
gas LL*3
12.40 44.60 20.0 Nozzle
pressure
mbar*2
10.5 10.6 10.0
*1 Details relative to TV/TR = 80/60 ºC.
*2 1 mbar corresponds to approximately 10 mmWC, e.g. 12.0 mbar
≈
120 mmWC.
*3
a
,
c
: No natural gas LL in Austria or Switzerland.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Note
The nozzle pressures apply to 15 ºC,
1013 mbar, dry.
The gas pressure must not be altered
from these values because of the factory
setting to natural gas E or LL.
Checking the CO2 content
Preparing the test
A
B
C
D
E
1. Open the gas shut-off valve.
2. Start the burner.
3. Press "S" D and "-" C simultane-
ously.
Display B will then show the follow-
ing:
■ Under status: "d" (= control stop)
■ Under service: Modulation level in
% ("00" = 100 % = upper output,
"00" = 0 % = lower output)
CO2 test at the upper output
1. Press "+" E until the service display
has incremented to "00" (=100 %).
2. Check the CO2 content at the flue
pipe.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Burner output
in kW
Permissible CO2
content in %
80 9.0 to 9.5
105 to 130 8.7 to 9.2
3. If the CO2 content has to be adjus-
ted:
Turn adjusting screw "V" A
(2.5 mm Allen key) until the CO2 con-
tent is within the specified range.
4. Record the actual value in the report
(on page 45).
CO2 test at the lower output
A
B
C
D
E
1. Press "-" C until the service display
has decremented to "00" (lower out-
put).
2. Check the CO2 content at the flue
pipe.
Burner output
in kW
Permissible CO2
content in %
80 8.5 to 9.0
105 to 130 8.0 to 8.5
3. If the CO2 content has to be adjus-
ted:
Turn adjusting screw "N" A in small
increments (2.5 mm Allen key) until
the CO2 content lies within the speci-
fied range.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 488 GB

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4. Record the actual value in the report
(on page 45).
Rechecking the values
Ramp up and down to the upper and
lower outputs again using the pro-
gramming unit in the burner control
unit. If the values do not match the
permissible CO2 content according to
the table on pages 13 and 13, repeat
the steps for the upper and lower out-
put.
5. Press "S" D and "-" C simultane-
ously. The burner is now in operating
mode.
Checking the ionisation current
A
CD
B
01. Switch OFF the main isolator.
02. Pull off ionisation current cable plug
C.
03. Switch ON the main isolator.
There must be a fault shutdown
after two burner starts have been
attempted. Fault code "F 25" flashes
in display A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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04. Switch OFF the main isolator.
Note
Test cable no.1 is required when
checking with the Testomatik-Gas.
You can also carry out this test with
a multimeter.
05. Push ionisation current cable plug
C into adaptor D.
06. Push test cable socket B onto the
ionisation electrode.
07. Switch the main isolator ON and
press reset.
08. Check the ionisation current.
Note
Approx. 2 to 3 s after the gas valve
has been opened and during oper-
ation, the ionisation current should
be at least 3
μ
A.
09. Record the actual value in the report
(on page 45).
10. Switch the main isolator OFF,
remove the test equipment and
reconnect the ionisation cable plug-
in connectors.
11. Switch ON the main isolator.
Shutting down the system
1. Switch OFF the main isolator or the
power supply and safeguard against
unauthorised reconnection.
2. Pull connecting plugs fA and lÖ from
the burner.
3. Close the gas shut-off valve.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the burner gauze assembly
A
1. Remove the gas supply pipe; to do
so, release the control cables and
plug from the gas train.
2. Undo the screws on the boiler door
and open the door.
3. Check the wire mesh of burner gauze
assembly A for damage. Slight
wavy deformations of burner gauze
assembly A are OK.
4. Replace burner gauze assembly A
if required.
Installation instructions
Burner component replacement
For cleaning the combustion
chamber and hot gas flues, see
boiler service instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 488 GB

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Checking the ignition and ionisation electrodes
Ignition electrodes
70,5
+
-
51
+
-
3,5 0,5
+
-
Ionisation electrode
12 2
+
-
1. Check the ignition electrodes and the
ionisation electrode for the correct
gap to the burner gauze assembly,
and for damage (replace if
required).
2. Close the boiler door and tighten the
screws on the boiler door evenly and
diagonally.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the burner
B
A
1. Remove the connecting cables from
fan B.
2. Remove the fan.
3. Clean the fan casing and impeller.
4. For severe fan contamination (dust,
fluff), remove the ignition, ionisation
and control cables from the burner
door, then remove and clean air col-
lector casing A.
Fitting the burner
B
A
1. Fit air collector casing A to the boiler
door.
2. Install fan B.
3. Connect the ignition and ionisation
cables.
4. Fit the control cables to the boiler
door.
5. Fit the gas supply pipe.
Danger
Escaping gas leads to a risk of
explosion.
Check all fittings for gas tight-
ness.
6. Secure the gas train cables to the gas
pipe.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 488 GB

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Checking both gas train valves for tightness
A B
1. Close the gas shut-off valve.
2. Undo the screw inside test nipple
B for supply pressure, but do not
remove.
3. Undo the screw inside test nipple
A, but do not remove.
4. Connect the pressure tester with the
manual pump to test nipple A.
5. Gently activate the manual pump to
build a test pressure of approx.
50 mbar.
6. Wait approx. 5 min for the tempera-
ture to level out and then observe the
display on the pressure tester:
If the displayed pressure does not
drop by more than 1 mbar within
5 min, then the gas train is tight.
Otherwise there is a leak. If this is the
case, return the gas train to
Viessmann Werke for testing.
7. After the test, close both test nipples
by tightening the relevant screws.
Danger
Escaping gas leads to a risk of
explosion.
Check the test nipple for gas
tightness.
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 connec-
tions that have been opened and
tighten afterwards.
2. Open the gas shut-off valve.
3. Check the inlet seals of the gas train
for tightness.
4. Start the burner (see page 6).
5. Check the seals on the outlet side of
the gas train for tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Final testing
1. Carry out the final tests according to
the information on pages 12 to 14.
2. Record the actual values in the report
(on page 45).
Operating and service documents
1. Complete and detach the customer
registration card:
■ Hand the system user their part for
safekeeping.
■ Retain the heating contractor's
part.
2. File all parts lists, operating and serv-
ice instructions in the folder and hand
this over to the system user.
The installation instructions are no
longer required after installation and
therefore do not need to be
retained.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 488 GB