Viessmann MatriX Istruzioni operative

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

5692611GB6/2005 Please keep safe

General information

Safety instructions

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 exclusively

designed for qualified personnel.

HWork on gas equipment must

only be carried out by a

registered gas fitter.

HElectrical work must only be

carried out by a qualified

electrician.

HThe system must be

commissioned by the system

installer or a qualified person

authorised by the installer.

Regulations

Observe the following when working

on this system

Hall legal instructions regarding the

prevention of accidents,

Hall legal instructions regarding

environmental protection,

Hregulations issued by professional

bodies,

Hall current safety regulations as

defined by DIN, EN, DVGW, TRGI,

TRF, VDE and all locally applicable

standards.

If you smell gas

¨Danger

Escaping gas can lead to

explosions which may lead to

serious injury.

HDo not smoke! Prevent

naked flames and sparks.

Never switch on electrical

lights or equipment.

HOpen windows and doors.

HClose the gas shut−off valve.

HShut down the system.

HRemove all people from the

danger zone.

HObserve the safety regulations

of your local gas supplier,

found on the gas meter.

5692611GB

Capacity

Index

Page

General information

Safety instructions 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial start−up, inspection and maintenance

StepsInitial start−up, inspection and maintenance 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further details regarding the individual steps 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating and service documents 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas burner control unit 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Diagnostics 33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas burner control unit flow chart38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas burner control unit connection diagram40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of components42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts list44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix

Coding 47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning/service report 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Validity 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keyword index 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692611GB

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

C I M 1. Starting the system 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C2. Checking the gas type 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C3. Conversion to natural gasLL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 4. Checking the static and the supply pressure 8. . . . . . . . . . . . . . . . .

C I M 5. Checking the venturi suction pressure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 6. Checking the CO2content 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 7. Checking the CO content

C I M 8. Checking the flue gas temperature

I M 9. Checking the ionisation current 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 10. Shutting down the system 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 11. Checking the burner gauze 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 12. Checking the ignition and ionisation electrodes 18. . . . . . . . .

M13. Cleaning the burner 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M14. Fitting the burner 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 15. Checking both valves of the

gas combination valve for soundness 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 16. Checking and replacing (if necessary)

the filter elements

E I M 17. Checking the gas connections for soundness 22. . . . . . . . . . . . . . .

M18. Implementing final tests 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E19. Operating and service documents 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692611GB

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.

Note

An examination of the burner with the boiler heated to operating temperature

(min. 40ºC) is essential.

Also carry out measurements at the lower rated output.

Starting the system

5692611GB

A B

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Starting the system (cont.)

Boiler control unit

service instructions

1. Check the system pressure.

2. Open the gas shut−off valve.

3. Switch ON the mains isolator

(outside of the boiler room).

4. Switch the system ON/OFF

switchBon the control unit ON.

If the fault indicator lampAon

the control unit illuminates and

the gas burner control unit

displayCflashes, initially press

the reset buttonDon the gas

burner control unit.

Note

During the initial start−up the

system can enter a fault state, if it

has insufficient gas in the supply

line (fault indicator on the control

unit illuminates).

Ventilate the gas supply line again

and reset the gas burner control

unit.

5. Match the coding on the boiler

control unit according to the table

on page47.

Control unit installation

and service instructions

Checking the gas type

1. Determine the gas type and

Wobbe index (Wo) from your gas

supplier.

HWith natural gas settingE,

the boiler can be operated

in the Wobbe index range

12.0 to 16.1kWh/m3

(43.2 to 58.0MJ/m3).

HWith natural gas settingLL,

the boiler can be operated

in the Wobbe index range

10.0 to 13.1kWh/m3

(36.0 to 47.2MJ/m3).

2. The burner is set up in the factory

for natural gas E. If necessary,

convert the burner in accordance

with details provided by your gas

supplier to a different gas type

(see page7).

3. Record the gas type in the service

report (on page49).

5692611GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Conversion to natural gas LL

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 installation room) or

the power supply and prevent

unauthorised reconnection.

4. Release the fittingA.

5. Remove the compensation

hoseGfrom the gas

combination valve.

6. Release the flangeEfrom the

gas combination valve.

7. Remove the restrictorCwith the

rubber cork sealD.

8. Secure the gas combination

valve (without the restrictorC

and without the rubber cork

sealD, but with the OringB)

to the flangeE; in doing so,

replace the factory−fitted screws

M5×16 with M5×12 (see pack).

9. Secure the fittingA.

10. Secure the compensation

hoseGto the gas combination

valve.

11. Affix the enclosed label

"Adjusted to ..."Fabove the

existing label.

12. Start the burner (see page5).

¨Danger

Escaping gas leads to a risk of

explosions.

Check all fittings for

soundness.

5692611GB

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. Release the pressure gauge in the

test nippleA, but do not remove.

4. Open the gas shut−off valve.

5. Check the static pressure

(max. 60mbar).

6. Record the test value in the

service report (on page49).

5692611GB

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. Check the supply pressure (flow

pressure), see the table below.

Note

The supply pressure (flow

pressure) should be between

20 and 50mbar.

The gas governor is factory−set

to 10mbar.

Do not adjust this setting.

9. Record the test value in the

service report (on page49).

10. Close the gas shut−off valve.

11. Release the pressure gauge;

close the test nippleA.

Supply pressure

(flow pressure)

Measures

below 15mbar Do not change the settings  notify your gas supply

company

15 to 20mbar Please note: The boiler may only be operated temporarily

with these settings (emergency mode).

Notify your gas supply company.

20 to 50mbar Start the boiler

via 50mbar Install a separate gas governor with zero off upstream of

the boiler and regulate the pressure to 20mbar.

Notify your gas supply company.

5692611GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking the venturi suction pressure

Burner with 187kW rated output

5692611GB

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