Viessmann MatriX Service Instructions For Contractors
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Viessmann MatriX Service Instructions For Contractors

Viessmann MatriX Service Instructions For Contractors

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

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  • Page 1 VIESMANN Service instructions for contractors MatriX cylinder burner Type Proflame VM IV, 400 to 630 kW MatriX cylinder burner for natural gas E and LL MatriX cylinder burner Please keep safe. 5834375 GB 8/2020...
  • Page 2 Safety instructions Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.
  • Page 3 Viessmann. 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.
  • Page 4 Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Condensate Danger Danger Escaping gas can lead to explo- Contact with condensate can be sions which may result in serious harmful to health. injury. Never let condensate touch your Do not smoke.
  • Page 5 Safety instructions Safety instructions (cont.) 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.

  • Page 6: Table Of Contents

    Index Index 1. Information Symbols ....................Intended use ..................Product information ................Spare parts lists .................. ■ 2. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......tion, maintenance 3. Burner control unit ........................ 29 4. Flow diagram for burner ........................

  • Page 7: Information Symbols

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...

  • Page 8: Product Information

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

  • Page 9: Commissioning, Inspec-Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance 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 •...

  • Page 10: Note On Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Note on commissioning, inspection and maintenance 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.

  • Page 11: Converting To Natural Gas Ll

    Commissioning, inspection, maintenance Converting to natural gas LL (Not in 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. 3. Switch OFF the mains isolator (outside the installa- tion room) or isolate the mains power and secure 2.

  • Page 12: Commissioning The Burner

    Commissioning, inspection, maintenance Commissioning the burner Boiler control unit operating instructions and ■ Status Service service instructions ■ Vitocrossal 300, type CT3U service instruc- tions ■ Neutralising system operating instructions Danger CO formation as a result of incorrect burner Fig. 3 Programming unit on the burner control adjustment can have serious health implications.

  • Page 13: Checking Static Pressure And Supply Pressure

    Commissioning, inspection, maintenance Reducing the maximum heating output (if… (cont.) 5. Use to select the required maximum heating 7. S to change to the operating display. output. 8. R, the system will be restarted. 6. S to confirm. If adopted successfully, "1" is shown under "Service";...

  • Page 14: Checking The Rotary Damper Setting

    Commissioning, inspection, maintenance Checking static pressure and supply pressure (cont.) Supply pressure Measure (flow pressure) < 15 mbar (1.5 kPa) Do not make any adjustments. Notify the gas supply utility. 15 to 18 mbar Please note: The boiler may only be operated temporarily with this setting (emergen- (1.5 to 1.8 kPa) cy mode).
  • Page 15 Commissioning, inspection, maintenance Checking the rotary damper setting (cont.) 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.
  • Page 16 Commissioning, inspection, maintenance Checking the rotary damper setting (cont.) LDW1 LDW2 Fig. 8 Control cable between LDW2 Plus and combustion Control cable between LDW1 Plus and Venturi chamber ( 4 mm, L 185 mm) inlet ( 4 mm, L 630 mm) Control cable between LDW1 Minus and Venturi Control cable between gas solenoid valve and 4 mm, L 450 mm)
  • Page 17 Commissioning, inspection, maintenance Checking the rotary damper setting (cont.) LDW1 LDW2 Fig. 10 500 kW Control cable between LDW2 Plus and combustion Control cable between LDW1 Plus and Venturi chamber ( 4 mm, L 185 mm) inlet ( 4 mm, L 410 mm) Control cable between LDW1 Minus and Venturi Control cable between gas solenoid valve and 4 mm, L 600 mm)

  • Page 18: Checking The Co2 Content

    Commissioning, inspection, maintenance Checking the CO2 content Preparing the test 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"...

  • Page 19: Checking The Co Content

    Commissioning, inspection, maintenance Checking the CO content (cont.) Gas type content Rated heating output in kW Actual value at upper heating output minus Lower heating out- 0.5 to 0.8 % 0.5 to 0.8 % 0.5 to 0.8 % put (0 %) test at the upper heating output 1.

  • Page 20: Checking The Flue Gas Temperature

    Commissioning, inspection, maintenance Checking the flue gas temperature Enter actual value into the report in the appendix. Checking the ionisation current Note 07. Read the ionisation current. The ionisation current must be called up via the burner control unit. It is not possible to check the ionisation 08.
  • Page 21 Commissioning, inspection, maintenance Opening the boiler door (cont.) Disconnecting cables/pipes lÖ aB] / fÖ fÖ aBH Fig. 16 Burner cables with plugs Control unit connecting cable with plug lÖ fÖ Power cable with plug Flue gas temperature sensors fÖ 1. Disconnect burner cables from the burner con- 3.

  • Page 22: Checking The Gaskets And Thermal Insulation Sections

    Commissioning, inspection, maintenance Opening the boiler door (cont.) Fig. 17 Please note Scratches inside the combustion chamber can lead to corrosion. Never place tools or other objects inside the combustion chamber. Checking the gaskets and thermal insulation sections 1. Check the gaskets and packing cord in the boiler 3.
  • Page 23 Commissioning, inspection, maintenance Checking the burner gauze assembly (cont.) 1. Check the wire mesh and cover of burner gauze assembly for damage. Slight wavy deforma- tions in burner gauze assembly are not prob- lematic. 2. Replace burner gauze assembly if required. Fig.

  • Page 24: Checking The Ignition Electrodes And Ionisation Electrode

    Commissioning, inspection, maintenance Checking the ignition electrodes and ionisation electrode Ignition electrodes Ionisation electrode Fig. 21 Fig. 23 ± Check the ignition electrodes and ionisation electrode for the correct gap to the burner gauze assembly and for possible damage. Replace the electrodes if neces- Fig.

  • Page 25: Cleaning The Burner

    Commissioning, inspection, maintenance Cleaning the burner Removing the fan Danger Mains voltage can be life threatening. For maintenance work, isolate the gas fan from the power supply. 1. Pull off the control cables. 2. Undo the Venturi mixing pipe and remove with the gas train and gas supply pipe.

  • Page 26: Burner Electrical Connection

    Commissioning, inspection, maintenance Burner electrical connection lÖ fÖ aB] aB] fÖ aBH Fig. 26 Burner cables with plugs Control unit connecting cable with plug lÖ fÖ Power cable with plug Flue gas temperature sensor fÖ Please note Hot components can damage electrical cables. Never route cables near hot components.

  • Page 27: Checking All Gas Connections For Tightness

    Commissioning, inspection, maintenance Checking the gas train filter element (cont.) Danger Escaping gas leads to a risk of explosion. Check the gas train for gas tightness. Checking the filter element in the gas line (if installed) and replacing if necessary Checking all gas connections for tightness Danger 4.

  • Page 28: Instructing The System User

    Commissioning, inspection, maintenance Instructing the system user The system installer should hand the operating instruc- This includes all components installed as accessories, tions to the system user and instruct the user in oper- e.g. remote control units. In addition, the system instal- ating the system.

  • Page 29: Burner Control Unit

    Burner control unit Burner control unit Display and programming unit A display and programming unit is integrated into the burner control unit. The display screen shows the rele- vant operating status, the service and parameter sta- tus, as well as any fault or error messages. The display comprises four elements of 7 segments Status Service...
  • Page 30 Burner control unit Burner control unit (cont.) Status Service Status Service Reheat Forced ventilation if no Post-purge flame formation has been detected. Status Service Status Service Safety shutdown due to Dwell program, no air flame tear-off pressure Status Service Status Service Safety shutdown when the Dwell program, no gas max.
  • Page 31 Burner control unit Burner control unit (cont.) Menu point "5" is used to display the following process information: Sub-menu point Process information Unit/scale Phase Not assigned — Flue gas temperature °C Ionisation current I in 1/10 μ Set speed PWM variable Actual speed n in 10/min Gas pressure switch 1...
  • Page 32 Burner control unit Burner control unit (cont.) Resetting operating parameters to their delivered condition Resetting operating parameters to their delivered con- until "0" is shown under Service. dition: 5. S "1" is shown under Status and "dEL" under Serv- 1. S longer than 2 s, " " flashes. ice.

  • Page 33: Flow Diagram For Burner

    Flow diagram for burner control unit Flow diagram for burner control unit Fig. 29...
  • Page 34 Flow diagram for burner control unit Flow diagram for burner control unit (cont.) Description of state: Phase Dis- Description Duration play System "A" System start 10 s start Fan ramp-up, system start max. 20 s Forced ventilation, system start 20 s Relay test "P"...

  • Page 35: Control Unit

    Troubleshooting Fault indicator Fault display The fault display is activated automatically if the burner 1. Remedy the fault. For fault codes and measures, control unit switches to a fault state. The most recent see the following pages. Carry out measures in the fault is then displayed.
  • Page 36 Troubleshooting Fault codes (cont.) Displayed fault System characteristics Cause Measures code F 82 Burner control unit in a fault Short circuit, flue gas tem- Check connecting cable and sen- state; system cooling down; perature sensor (A or B), sors (A and B); replace sensor if burner control unit locked out.
  • Page 37 Troubleshooting Fault codes (cont.) Displayed fault System characteristics Cause Measures code F F1 Burner control unit in a fault Flue gas excess tempera- Wait until temperature falls below state; system cools down ture; excessive gas the permissible flue gas tempera- throughput ture.

  • Page 38: Internal System Faults

    Troubleshooting Fault codes (cont.) Displayed fault System characteristics Cause Measures code F F5 Air pressure switch switches Flue gas back pressure; Remove flue gas back pressure; off during operation condensate banked up; air check if condensate banked up; re- pressure switch hose faul- set burner control unit;...
  • Page 39 Troubleshooting Fault codes (cont.) Shown on dis- System characteristics Cause Measures play F E5, F EC, Fault in burner control unit Internal system fault and Reset the burner control unit. Re- F Ed, F EE, area place the burner control unit if the F FF fault persists.

  • Page 40: Faults Without Fault Display

    Troubleshooting Fault codes (cont.) Detailed fault code Component/signal Cause of fault Measure Air pressure switch 2 High switching sequence, Check flue gas path and re- switch flutters, external volt- heating surfaces. Check air pressure switch 2 setting. Hall signal fan feedback Fan speed too high.

  • Page 41: Component Overview

    Component overview Component overview MatriX cylinder burner Fig. 30 Burner frame Air pressure switch 2 Air pressure switch 1 Burner control unit with display and programming unit Gas train Gas supply pipe Mains filter unit with contactor Gas fan Venturi mixing pipe Rotary damper with servomotor Fig.

  • Page 42: Functions Air Pressure Switch

    Functions Air pressure switch Fan pressure monitoring (LDW1) 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. The air pressure switch triggers a fault shutdown of the burner control unit under the following circumstances: If the static pressure check was unsuccessful after ■...

  • Page 43: Combustion Chamber Pressure Monitoring Function (Ldw2)

    Functions Air pressure switch (cont.) Combustion chamber pressure monitoring function (LDW2) To monitor the combustion chamber pressure, the switching threshold of air pressure switch 2 (LDW2) is monitored in all operating phases (except during the safety and stabilising time). Air pressure switch triggers a fault shutdown at the burner control unit under the following circumstances: If the combustion chamber pressure is outside the...

  • Page 44: Connection And Wiring Dia-Burner Control Unit Connection Diagrams

    Connection and wiring diagram Burner control unit connection diagrams Fig. 34 Fan motor with PWM switching and feedback Air pressure switch 2 Display and programming unit Flue gas temperature sensor 2 Gas pressure switch 2 Flue gas temperature sensor 1 Air pressure switch 1 To the mains filter unit Gas pressure switch 1...
  • Page 45 Connection and wiring diagram Burner control unit connection diagrams (cont.) Fig. 35 Burner control unit VUC 310 Fuel valve BV2 Flame monitor through ionisation current Plugs high limit safety cut-out high limit aBÖ Vitotronic control unit safety cut-out Servomotor for rotary damper or 2/2-way solenoid valve aBÖ...

  • Page 46: Gram ■ Mains Filter Unit Connection Diagram

    Connection and wiring diagram Burner control unit connection diagrams (cont.) Mains filter unit connection diagram Fig. 36 Mains filter Power supply 230 V~/50 Hz Contactor Protect the power cable, max. 16 A To the fan, plug a-Ö Air pressure switch 2 To the burner control unit Flue gas temperature sensor 1 and 2 Control unit power supply, plug...

  • Page 47: Reports Settings And Measurement Values

    Reports Settings and measurement values Commissioning Maintenance/Service Static pressure mbar Supply pressure (flow pressure) Natural gas E mbar Natural gas LL mbar Tick gas type. Carbon dioxide content CO At the upper rated heat- Actual % by vol. ■ ing output % by vol.

  • Page 48: Specification

    Specification Specification MatriX cylinder burner Rated heat input 127 to 381 158 to 474 198 to 593 Product ID CE-0085BS0400 Connection values Relative to the max. load with Natural gas E 13.4 to 40.3 16.7 to 50.2 21.0 to 62.8 ■...

  • Page 49: Final Decommissioning

    Final decommissioning and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.

  • Page 50: Certificates Declaration Of Conformity

    Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the MatriX cylinder burner meets the conditions specified by the 1st German Immissions Order (BImSchV): limits according to paragraph 6 (1).

  • Page 51: Keyword Index

    Keyword index Keyword index Air pressure switch Heating output reduction..........12 – Combustion chamber pressure monitoring (LDW2)43 – Fan pressure monitoring (LDW1)......42 Ignition electrodes, checking........24 Instructing the system user........28 Boiler door Internal system faults..........38 – Closing..............24 Ionisation current check..........20 –...
  • Page 52 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

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Proflame vm iv

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