Viessmann MatriX Service Instructions Manual
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Viessmann MatriX Service Instructions Manual

Viessmann MatriX Service Instructions Manual

Pressure−jet gas burner, for vitocrossal300, typect3 rated output 187 to 314kw
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Service instructions
for heating engineers
MatriX radiant burner
Pressure−jet gas burner, type VM III
for Vitocrossal 300, type CT3
Rated output 187 to 314 kW
For validity, see final page.
MatriX radiant burner
Please keep safe
5692 611 GB
6/2005

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  • Page 1 Service instructions for heating engineers MatriX radiant burner Pressure−jet gas burner, type VM III for Vitocrossal 300, type CT3 Rated output 187 to 314 kW For validity, see final page. MatriX radiant burner Please keep safe 5692 611 GB 6/2005...

  • Page 2: General Information

    General information Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. H regulations issued by professional Safety instructions explained bodies, ¨ H all current safety regulations as Danger This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.

  • Page 3: Table Of Contents

    Capacity Index Page General information Safety instructions ........................Initial start−up, inspection and maintenance Steps Initial start−up, inspection and maintenance .

  • Page 4: Steps Initial Start−Up, Inspection And Maintenance

    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 1. Starting the system ..............2.

  • Page 5: Further Details Regarding The Individual Steps

    Initial start−up, inspection and maintenance Further details regarding the individual steps ¨ Danger Increased CO emissions can lead to life−threatening poisoning. Check the CO value before and after any work on gas appliances, to prevent any health hazards and to ensure the perfect operational condition of the system.

  • Page 6: Checking The Gas Type

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Starting the system (cont.) Boiler control unit Note service instructions During the initial start−up the system can enter a fault state, if it 1. Check the system pressure. has insufficient gas in the supply line (fault indicator on the control 2.

  • Page 7: Conversion To Natural Gas Ll

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Conversion to natural gas LL 5. Remove the compensation hose G from the gas combination valve. 6. Release the flange E from the gas combination valve. 7. Remove the restrictor C with the rubber cork seal D.

  • Page 8: Checking The Static And The Supply Pressure

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the static and the supply pressure Static pressure 1. Close the gas shut−off valve. 2. Release the screw in the test nipple A, but do not remove. 3.
  • Page 9 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Supply pressure 7. Start the burner. Note Initial start−up, see page 5. Switch the burner to max. output; for this, activate the emissions test switch on the control unit. 8.

  • Page 10: Checking The Venturi Suction Pressure

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the venturi suction pressure Burner with 187 kW rated output...
  • Page 11 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) 1. Release the screw in the test 7. Check the venturi suction nipple A, but do not remove. pressure. 2. Connect the pressure gauge to the Set negative pressure at the test nipple A (vacuum).
  • Page 12 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Burner with 248 and 314 kW...
  • Page 13 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) H Service: Modulation level in % 1. Release the screw in the test nipple A, but do not remove. ("00." = 100 % higher output "00" = 0 % lower output) 2.

  • Page 14: Checking The Co Content

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the CO content 3. Simultaneously press "S" (E) and " " (D). Note The display C shows H Status: "d" (= control stop) and H Service: Modulation level in % ("00."...
  • Page 15 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Lower output 7. Press " " (D), until the service display shows "00" (lower output). 8. Check the CO content at the flue pipe. For permissible CO content, see the table on page 14.

  • Page 16: Checking The Ionisation Current

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the ionisation current 6. Plug the socket A of the test 1. Switch OFF the mains isolator. cable onto the ionisation 2. Pull the ionisation cable plug C electrode.

  • Page 17: Shutting Down The System

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Shutting down the system 2. Pull the plug connectors fA and 1. Switch OFF the power supply or lÖ off the burner. mains isolator and safeguard against unauthorised reconnection.

  • Page 18: Checking The Ignition And Ionisation Electrodes

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the ignition and ionisation electrodes Ignition electrodes 1. Check the ignition electrodes and the ionisation electrode for correct gap towards the burner gauze and for damage (replace, if necessary). 2.

  • Page 19: Cleaning The Burner

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Cleaning the burner 1. Release the fitting C on the gas supply pipe D. 2. Remove the venturi mixer pipe E from the fan A. 3. Remove the venturi mixer pipe E with the gas combination valve B and the gas supply pipe D.

  • Page 20: Fitting The Burner

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Fitting the burner 1. Fit the fan A. Note Ensure correct positioning of the gasket between the fan housing and the boiler door. 2. Reposition the connecting cables "100" and "100a" onto the fan.

  • Page 21: Checking Both Valves Of The Gas Combination Valve For Soundness

    In that case, return the gas combination valve to 4. Connect the pressure gauge on the Viessmann Werke for tests. test nipple A with a manual pump. 7. After the test, close both screws in 5. Gently activate the manual pump to the test nipples.

  • Page 22: Operating And Service Documents

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking all gas connections for soundness ¨ Danger 1. Insert new gaskets in all fittings Escaping gas leads to a risk of which have been opened and explosions. tighten fittings.
  • Page 23 Initial start−up, inspection and maintenance Air pressure limiter H if, in the pre−purge phase, the Function minimum flow rate has not been The air pressure limiter A will produced (fault shutdown via the anti−cycling function) signal in the following operating H if, in the control mode, the air conditions: H prior to the fan start (idle state...

  • Page 24: Gas Burner Control Unit

    Initial start−up, inspection and maintenance Gas burner control unit Display and programming unit Function A display and programming unit is The display comprises three, integrated into the gas burner seven−segment elements; four keys control unit. The display indicates enable settings to be adjusted at the respective operating conditions, different operating levels.
  • Page 25 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Display Status Service (single digit) (two digit) Operating display in For the actual operating Display "FL" if a Page 26 standard mode condition, see the flame signal is following table present Operating display for Fault code "A"...
  • Page 26 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Operating display See also table on page 25. Press the reset button Status Service Status Service Heat demand System tests Standby Status Service Idle state check Fan ramp up Status Service Pre−purge Status Service Status Service...
  • Page 27 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Manual mode and service display A heat demand is required through the control unit to call up the service display and to operate in manual mode. The actual level of modulation in % is shown in the service display; whereby: "d 00"...
  • Page 28 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Adjusting the DIP switches or parameter set The DIP switches are factory−set to the rated output of the burner. A change to this factory setting is only required for reduced mode. Note If another parameter set is selected, this must be acknowledged (see page 30).
  • Page 29 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Display of the selected parameter set This display will be terminated if no key is pressed within 20 s. Operating display Simultaneously press S and a Status Service Press S Status Service Under "Service", the selected parameter set will be displayed...
  • Page 30 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Cancelling a parameter set H a parameter set has been modified via the DIP switches or H if the gas burner control unit has been replaced, a "P" flashes under Status. The figures under Service show the selected parameter set (see page 31).
  • Page 31 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Fault display The fault display will be activated automatically if the gas burner control unit changes into a fault state. The most recent fault will then be displayed. The light segments of the display will flash. Operating display Automatic activation...
  • Page 32 Initial start−up, inspection and maintenance Gas burner control unit (cont.) Fault memory The most recent six faults are saved and may be scanned. The order of scans ranges from the most recent to the previous fault codes. This display will be terminated if no key is pressed within 20 s. Operating display Simultaneously press the reset button and a Status Service...

  • Page 33: Diagnostics

    Troubleshooting Diagnostics Faults indicated at the display and programming unit General process fault Fault System Cause Remedy code characteristics Fan pressure Wind influence on Check flue gas draught produced during air (chimney) pressure limiter idle state check Air pressure limiter Air pressure limiter Replace air pressure not functioning...
  • Page 34 Troubleshooting Diagnostics (cont.) Fault System Cause Remedy code characteristics Ignition cables Remedy short circuit Ionisation flame short−circuited monitor signals external light during l li ht d i Ionisation cables or Remedy short circuit start−up or after the electrode post−purge period short−circuited Gas combination Replace gas...
  • Page 35 Troubleshooting Diagnostics (cont.) Fault System Cause Remedy code characteristics Fault on gas burner Fault in feedback from Replace gas burner control unit gas safety valves, control unit output relay does not activate Fault in feedback from auxiliary start−up valve, output relay does not activate Fault in feedback from ignition, output relay...
  • Page 36 Troubleshooting Diagnostics (cont.) Fault System Cause Remedy code characteristics Scrolling Constant start Cores "L 1" and "N" Check power supply display: attempt exchanged on the and exchange cores 1 2 3 power supply of the 4 5 7 control unit Fan faulty Check cables or Fault on gas burner...
  • Page 37 Troubleshooting Diagnostics (cont.) Faults without fault display Fault Cause Remedy Combustion faults Gas throughput too high Adjust the gas through pulsation throughput in accordance with the accordance with the Too little or too much air rated boiler output Condensate backup in Check condensate drain the flue gas system Inadequate flue gas...

  • Page 38: Gas Burner Control Unit Flow Chart

    Gas burner control unit flow chart Gas burner control unit flow chart...
  • Page 39 Gas burner control unit flow chart Gas burner control unit flow chart (cont.) After the controller issues a heat demand, the following program sequence will be run: Phase Duration 01 Test for heat demand 02 Idle state check of the air pressure limiter 1 to 30 s and the fan 03 Fan ramp up...

  • Page 40: Gas Burner Control Unit Connection Diagram

    Gas burner control unit connection diagram Gas burner control unit connection diagram Ignition (−) F4 P Spd. F6 P 6.3 A (slow)
  • Page 41 Gas burner control unit connection diagram Gas burner control unit connection diagram (cont.) Legend A 1 Gas burner control unit MPA 51 A 2 Display unit with reset function B 1 Flame monitoring through ionisation current B 2 Safety chain jumper F 1 Main fuse F 2 High limit safety cut−out F 4 Gas governor minimum pressure...

  • Page 42: Overview Of Components

    Overview of components Overview of components...
  • Page 43 Overview of components Overview of components (cont.) A Boiler door B Fan C Display and programming unit D Air pressure limiter E Gas supply pipe F Gas combination valve G Venturi mixing pipe H Rotary damper with servomotor (only for 248 and 314 kW) K Burner gauze L Ignition electrodes M Ionisation electrode...

  • Page 44: Parts List

    Parts list Parts list When ordering spare parts: 005 Small parts comprising: Quote the type and serial no. (see 5a Threaded nipple type plate) and the item no. of the 5b Dowel pin required part (as per parts list). 5c Quick−release fitting Obtain standard parts from your 5d Strain relief local supplier.
  • Page 45 Parts list Parts list (cont.)
  • Page 46 Parts list Parts list (cont.)

  • Page 47: Appendix

    Appendix Coding For MatriX radiant burner 187 to 314 kW in conjunction with H Vitotronic 100, type GC1 H Vitotronic 200, type GW1 H Vitotronic 300, type GW2 Rated output of the Coding address Coding card MatriX radiant burner in kW...

  • Page 48: Specification

    Appendix Specification Rated output at a heating water temperature of 50/30 ºC Product ID CE 0085 AT 0403 Burner type VM III 4 VM III 5 VM III 6 Voltage Frequency Power consumption Motor speed 1344 5216 1504 5952 1824 5984 Modulation range 25 100 33 100...

  • Page 49: Commissioning/Service Report

    Appendix Commissioning/service report Setting and test values Initial start−up Maintenance/ service Static pressure mbar Supply pressure (flow pressure) j for natural gas E mbar j for natural gas LL mbar Tick gas type Natural gas E mbar Check the venturi suction pressure at suction pressure at higher rated output Natural gas LL mbar...
  • Page 50 Appendix...

  • Page 51: Validity

    Appendix Keyword index Adjustment of the DIP switches or Ignition and ionisation electrodes, the parameter set, 28 checking, 18 Air pressure limiter, 23 Internal system faults, 36 Ionisation current, checking, 16 Ionisation electrode, 18 Burner cleaning, 19 Burner gauze, checking, 17 Burner installation, 20 Nozzle pressure, 10 Cancelling a parameter set, 30...
  • Page 52 Validity from serial no. 7175475 3 00001 kkk 7189117 5 00001 kkk 7189118 5 00001 kkk Viessmann Werke GmbH & Co KG D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de Viessmann Limited Hortonwood 30, Telford...

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