Viessmann Vitolig 300 Technical Manual

Brand: Viessmann

Model: Vitolig 300

Type: Technical Manual

File in:

Vitotec technical guide folder, register4

VITOLIG

Solid fuel boiler

5 to 40 kW

Vitolig300

Steel boiler for burning wood pellets

Vitolig200

Steel boiler for burning wood briquettes and

logs up to 50cm long

Vitolig100

Steel boiler with natural draught and water−cooled grate

for burning logs up to 33 cm long

Technical guide

Vitolig200 Vitolig300

58222411 GB 2/2002

Contents

Contents Page

1 Principles of burning wood for heat

1.1 Principles of burning logs for heat generation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

generation 1.2 Principles of burning wood pellets for heat generation 4

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

2 Product information 2.1 Product description

HVitolig 300 5

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

HVitolig 200 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HVitolig 100 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Construction and function

HVitolig 300 6

HVitolig 200 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HVitolig 100 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Vitolig 300 3.1 Specification 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Positioning 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Fuel storage

HGeneral 12

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

HSizing the storage area 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HStorage area design and essential system components 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HSystem component details 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Flue gas connection

HChimney 19

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

HFlue pipe 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Water connection

HSafety equipment acc. to DIN 47512 20

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

HGeneral design notes 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Application examples

HApplication example 1 21

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

HApplication example 2 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HApplication example 3 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Vitolig 200 4.1 Specification 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Positioning 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Fuel

HLogs 32

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

HWood briquettes 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HChipped product 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Flue gas connection

HChimney 33

HFlue pipe 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Water connection

HSafety equipment acc. to DIN 47512 34

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

HGeneral design notes 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HThermostatic drain valve 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HHeating water buffer storage unit 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Application examples

HApplication example 1 36

HApplication example 2 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HApplication example 3 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Vitolig 100 5.1 Specification 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Positioning 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Fuel 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Flue gas connection

HChimney 57

HFlue pipe 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Water connection

HSafety equipment acc. to DIN 47512 58

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

HGeneral design notes 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEmergency battery 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HMinimum thermostat 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Application examples

HApplication example 1 61

Explanation of specific

Vitolig 100 connections and functions 64

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

5822241 GB

1 Principles of burning wood for heat generation

1.1Principles of burning logs for heat generation

Units of measurements for wood

as fuel

The units of measurement commonly

used in forestry and the timber industry for

wood as fuel are solid measure of timber

(smt) and stacked cubic metre (stcm).

The solid measure of timber (smt)

describes 1m3 of solid timber mass in the

form of assorted round timbers.

The stacked cubic metre of timber (stcm)

is a measure for stacked or tipped wood,

measuring a total volume of 1m3,

including air gaps.

On average, 1 solid measure of timber

equals 0.7stacked cubic metres.

Energy content and emission

values

Timber is a renewable fuel. In

combustion, on average approx.

4.0kWh/kg energy is released.

The table shows the calorific value of

various types of firewood with a water

content of 20%.

Type of

timber

Density Calorific value

(approx. with 20%

water content)

kg/m3kWh/

smt*1

kWh/

stcm*2

kWh/

Pine

Common

spruce

Norwe−

gian

spruce

Scots

pine

Larch

430

420

510

545

2100

2200

2600

2700

1500

1550

1800

1900

4.0

4.2

4.1

4.0

Deciduous

Birch

Elm

Beech

Ash

Oak

Common

beech

580

620

650

630

720

2900

3000

3100

3300

2000

2100

2200

2300

4.1

3.9

3.8

4.0

3.7

*1Solid measure of timber

*2Stacked cubic metre

1litre fuel oil can be replaced by 3kg

firewood, given the usual efficiencies.

A stacked cubic metre (stcm) of beech

firewood corresponds to the energy of

approx. 200litres fuel oil or 200m3

natural gas. Therefore, burning wood

contributes to the preservation of finite

reserves of oil and gas.

Firewood has a generally neutral

CO2balance, as the CO2 created during

combustion is immediately reabsorbed

into the photosynthetic circle and

therefore, contributes to the formation of

new biomass.

Another aspect relevant to environmental

considerations is the fact that firewood

contains hardly any sulphur and therefore

almost no sulphur dioxide is created

during combustion.

Influence of moisture on the

calorific value

The water content of firewood

substantially influences its calorific value.

The more water firewood contains, the

lower its calorific value, since the water

evaporates during combustion and

consumes energy in the process.

Two measures are used to state the water

content.

HWater content

The water content of firewood is its

water mass as a percentage of the total

firewood mass.

HFirewood moisture

The firewood moisture (in the following

referred to as moisture) is the water

mass expressed as percentage of the

total firewood mass excluding water.

The diagram shows the relationship

between the water content and moisture.

Freshly cut firewood has a moisture

content of 100%. During storage over

one summer, this moisture level reduces

to approx. 40%. During storage over

several years, this moisture level reduces

to approx. 25%.

The following diagram shows the

dependency of the calorific value on the

water content using common spruce as

an example.

With a water content of 20% (moisture

25%), the calorific value is 4.0kWh/kg.

The calorific value of firewood stored

over several years is approximately twice

that of freshly cut firewood.

Storage

Not only is the burning of wet firewood

uneconomical, but it also leads to low

combustion temperatures and high

emissions plus tar deposits inside the

chimney stack.

Tips on storing firewood

HSplit round timbers from a diameter of

10cm upwards.

HStack the split firewood in a ventilated

and preferably sunny spot underneath a

rain canopy.

HStack the split firewood with generous

air gaps to enable the air flow to carry

off the dissipating moisture.

HA hollow should be created underneath

the woodpile, e.g. in the form of storage

beams, to allow moist air to escape

downwards.

HNever store freshly cut firewood in a

cellar, since air and sunshine are

required to dry out firewood. However,

dried firewood can be stored in a

well−ventilated cellar.

5822241 GB

Water content in %

Moisture in %

Water content in %

Moisture in %

Calorific value in kWh/kg

1 Principles of burning wood for heat generation

1.2 Principles of burning wood pellets for heat generation

What are pellets?

Wood pellets are made from 100 percent

natural wood residues. This raw material

is waste matter created by the timber

processing industry in large volumes

through planing or sawing.

Without binders, these fine−grained wood

residues are compressed and pelletised

under high pressure, i.e. they are pressed

into small cylindrical shapes.

The raw material is stored and

transported in absolutely dry conditions.

Absolutely dry conditions are equally

necessary for the storage by the system

user. Only these precautions can ensure

perfect and efficient combustion.

Fuel requirements

The wood pellets used for combustion in

Vitolig 300 must correspond to the

requirements of DIN 51731 or

ÖNORM 7135.

Requirements Limits set by DIN 51731

Raw density (analogue to DIN 52182) kg/dm31.0 to 1.4

Water proportion % 12

Ash (acc. to DIN 51718) % 1.5

Calorific value (waf = free of water) kJ/kg 17,500 to 19,500

Sulphur % 0.08

Chlorine % 0.03

Nitrogen % 0.3

Arsenic mg/kg 0.8

Cadmium mg/kg 0.5

Chromium mg/kg 8

Copper mg/kg 5

Mercury mg/kg 0.05

Lead mg/kg 10

Zinc mg/kg 100

Extractable organically bound halogen

(EOX)

mg/kg 3

For the combustion in Vitolig 300, use

pellets with a diameter of 6 mm, a length

from 5 to 30 mm (20 % up to 45 mm) with

a residual moisture content of 7 to 12 %.

Delivered forms

Currently, wood pellets are offered in

15 and 30 kg sacks, in bulk up to 1000 kg

on pallets and loose.

In their loose form, pellets are

transported by tanker and pumped into

the storage room via a hose system.

Careful handling of pellets ensures a low

dust proportion, a perfect fuel supply to

the boiler and a constant boiler output.

5822241 GB

2 Product information

2.1 Product descriptions

Vitolig 300

Steel boiler for burning wood pellets

Boiler for wood pellets

Permissible flow temperature up to 95ºC

Maximum operating pressure 3 bar

HThe Vitolig300 for burning wood pellets

hardly differs at all in terms of

convenience and control from oil or

gas−fired heating systemslargely due

to a modulating output and digital

control unit.

HIdeal energy utilisation through

self−regulating output, therefore low

flue gas temperatures and high

combustion efficiency of up to95%.

HLow space requirement through

compact design (floor area: 0.6m2).

HFully automatic pellet feed and vacuum

system (accessories). The integral pellet

hopper (150litres capacity) will provide

fuel for up to two days heating

operation, subject to the prevailing

outside temperature.

HHot air fan for fully automatic, quiet

ignition.

HA pulsating pellet worm−drive, a

variable speed vacuum draught fan and

precisely metered volumes of fuel and

air for modulating operation ensure

optimum matching to the prevailing heat

demand.

HDigital control unit with automatic

function monitoring with fault

diagnostic system, heating circuit

control for one heating circuit with

mixer and DHW cylinder thermostat.

HWith self−cleaning heating surfaces and

ash removal from the burner tray for

long cleaning intervals.

Vitolig 200

Steel boiler for burning wood briquettes and logs up to 50 cm long

High performance wood gasification

boiler for split logs up to 50 cm long,

wood briquettes and chippings

Permissible flow temperature up to

100ºC

Maximum operating pressure 3 bar

HHigh−grade wood gasification boiler:

50cmlong split logs, chippings and

wood briquettes are easily managed by

the stainless steel hopper and

combustion chamber made from

special ceramic material.

HAutomatic heat−up process for useable

heat in minutes.

HHigh performance, variable speed,

vacuum draught fan.

Modulating operation in every output

range, therefore optimum matching to

any prevailing heat demand.

HThe process−optimised combustion and

automatic output control achieves a

combustion efficiency of up to 92%, and

with low emissions.

HNo odour nuisance in the boiler room

because of our patented carbonisation

gas extract system.

HSimple, easy to operate digital boiler

control unit with self−diagnostic system

and fault display.

HLarge stainless steel hopper for long

combustion periods of up to 12hours,

without re−filling.

HSimple, mechanical cleaning of the

heating surfaces and long cleaning

intervals, e.g. ash needs to be removed

only every other week.

Vitolig 100

Steel boiler with natural draught with water−cooled grate for burning logs up to 33 cm long

Boiler for burning logs up to 33 cm long

Permissible flow temperature up to 90ºC

Maximum operating pressure 3 bar

HSolid fuel boiler for logs up to 33cm

long at a particularly attractive price.

HRated output up to 14.8kW: no

monitoring obligation acc. to the

1stBlmSchV.

HThe water−cooled grate and controllable

pre−heated secondary air flow ensure

good fuel utilisation.

HSolid fuel boiler with natural draught

and low draught requirement, enabling

the operation with almost all types of

chimney.

HQuick installation and simple operation

from the front.

HLong combustion periods through large

hopper.

HSimple filling from the front through a

large feed door.

HControllable, pre−heated secondary air

flow for clean, environmentally friendly

combustion.

5822241 GB

2 Product information

2.2 Construction and function

Vitolig 300

Construction

Essentially, the Vitolig 300 comprises a

pellet feeder (l.h. side of the boiler) and a

combustion part (r.h. side of the boiler).

The pellet feeder on the l.h. side of the

boiler comprises the pellet hopper A

with cleaning aperture, the hot air fan for

automatically igniting the pellets B, the

feed worm (pellet worm−drive) C with

drive motor, the drive motor for removing

ash from the burner tray, the motor for

the heating surface cleaning facility and

the motor for the automatic ash removal.

The r.h. side of the boiler (combustion

part) comprises an operating part D with

boiler control unit and heating circuit

controller HKR for one heating circuit

with mixer and DHW cylinder thermostat,

the pellet feed channel E, the burner

tray F with automatic ash removal and

the automatic ash removal system G. On

the r.h. side of the boiler is the ash trolley

for the automatic ash removal system.

Function

Prior to the initial start−up check, whether

the system contains water and has been

vented.

The Vitolig 300 starts automatically, as

soon as a heat demand is reported to the

control unit.

After the pre−purge (safety function, only

for combustion chamber temperatures

above 190ºC), the ignition starts (hot air

fan), and the pellet worm−drive is

activated. The burner tray is filled with

pellets, the hot air fan ignites the pellets

and the boiler starts its heat−up phase.

A flame has been built, if the temperature

in the combustion chamber rises by 70 K,

after the heat−up phase commences. The

hot air fan is switched off and runs on for

a further minute without heat.

Vitolig 300 begins to modulate when the

temperature inside the combustion

chamber rises above 240ºC. In

modulating operation, the pellet

worm−drive feeds the required volume of

pellets into the burner tray, and the

vacuum draught fan will run at a speed of

between 800 and 2400 rpm.

The fuel will be completely burnt if the set

boiler water temperature is exceeded by

15 K for 15 minutes or if the boiler water

temperature rises above 82 ºC.

Subject to the output and combustion

state, the pellet worm−drive will either be

stopped immediately or runs on for a

further 3 minutes with the smallest

volume of fuel. During the complete

combustion mode, the fan will run at

1500 rpm. Below a combustion chamber

temperature of 250ºC the fan will run on

for two minutes.

The combustion process is completed

with the removal of the ashes from the

burner tray.

5822241 GB

2 Product information

Vitolig 200

Construction

The r.h. side of Vitolig 200 comprises the

variable speed vacuum draught fan for a

modulating matching of the system to the

output A, the large stainless steel feed

hopper for 50 cm logs with a large feed

door B, the de−gassing zone with fire

clay lining C and the large ash box with

door D.

The l.h. side of the boiler is the actual

combustion part of Vitolig 200. Primary

and secondary air apertures with variable

control E and the combustion chamber

constructed from special ceramics F

with temperature sensor provide

excellent combustion results. The large

clean−out door provides easy access to

the heating surfaces G to enable

thorough cleaning from the front. A

100mm thick thermal insulation H

reduces cool−down losses.

The ready−to−connect control unit K is

easily accessible for maintenance

purposes.

Function

Prior to the initial start−up, check whether

the system contains water and has been

vented.

The wood gasification (pyrolysis) takes

place inside the stainless steel hopper

through the incandescent bed. The

combustible wood gases created by this

process are sucked into the ceramic

combustion chamber and there, transfer

their heat via the heating surfaces. This

quickly raises the combustion chamber

temperature to a high level, resulting in

clean combustion both in partial and in

full load operation.

Before heating up or re−filling with fuel,

operate the heating surface cleaning lever

L 3 5times.

For heating up, the feed flap is pulled out

after opening the feed door, and the

exposed grate is covered with crumpled

paper balls up to the top edge of the lined

de−gassing zone (approx. 5 cm). The

paper is then covered with a layer of

dried chippings, thin kindling or course

cuttings. Several layers of split logs with

a height (edge) of 4 to 6 cm and

preferably without air gaps should then

be inserted. Then, the feed hopper can be

filled with split logs up to 45 to 55 cm in

length and a max. height (edge) of 15cm.

A complete filling of Vitolig 200 can only

be recommended if the heating water

buffer storage unit is cold and/or the

outside temperature is low (ensure

sufficient heat consumption).

Fill with less wood for summer operation.

After pressing the system On/Off switch

at the control unit, the unit tests itself and

all connected sensors; at the end the

boiler water temperature is displayed.

To fire Vitolig 200, the ash door and the

upright grate behind the door are opened.

Ignite the paper and press the heat−up

button on the boiler control panel. Close

the upright grate and the ash door, when

the paper is thoroughly burned through

(approx. 20 to 30 seconds).

Depending on the fill level of the hopper,

the fuel quality and the heat

consumption, combustion may last from

4 to 13.5 hours. Do not open the feed

door for at least three hours after heat−up.

Open the feed door up to the lock

position when re−filling and leave in that

position for at least 15 seconds. The

carbonisation gases inside the hopper

will then be withdrawn by the vacuum

draught fan, and the feed door can be

fully opened. If sufficient incandescence

is present, distribute this evenly over the

grate and pile up split logs horizontally as

for the heating−up process. If insufficient

incandescence is present (the grate is

visible), proceed as for heating up.

At the end of combustion, the fan runs on

for 20 minutes at maximum speed and is

then switched off. This make best use of

remaining incandescence.

5822241 GB

2 Product information

Vitolig 100

Construction

As a boiler with natural draught and

combustion from below, Vitolig 100

comprises only a few, simple operating

elements.

Behind the large feed door A is the

hopper B for split logs up to a length of

33 cm. A water−cooled and therefore

low−wearing grate C utilises the high

temperatures of the incandescent bed.

The secondary ventilation control D

assures Vitolig 100 of excellent

combustion results  from heat−up to

complete combustion.

The secondary air is channelled into the

feed door through a rotary valve. The

heat−up flap E is easy to operate from

the front and is only opened during

heating−up and re−filling.

The combustion controller F regulates

the required boiler water temperature via

the primary air volume. To achieve this,

close the ash door G.

The integral heat exchanger H in

conjunction with a thermostatic drain

valve (accessory) acts as excess

temperature protection. The 60 mm thick

thermal insulation K ensures low losses

during the heating operation.

Function

Prior to the initial start−up, check whether

the system contains water and has been

vented. The required boiler water

temperature is regulated via the

combustion controller using the following

table (ash door must be closed).

The highest flow temperature is usually

allocated to the lowest outside

temperature (in this example 20ºC).

A three−way mixer with heating circuit

control (accessory) regulates the heating

flow temperature in weather−compensated

mode.

Outside temperature 20ºC10ºC0ºC+10ºC

For system temperature 90ºC

Heating flow temperature 90 80 65 45

Boiler water temperature 90 80 75 75

For system temperature 75ºC

Heating flow temperature 75 65 55 40

Boiler water temperature 75 75 75 75

For underfloor heating and low−temperature

heating systems

Heating flow temperature 45 40 38 28

Boiler water temperature 75 75 75 75

5822241 GB

During the heat−up phase, and if the

boiler water temperature falls below

60ºC, the standard minimum

temperature controller switches the

heating pump and possibly the DHW

circulation pump off.

The pumps are automatically switched

on again, if the minimum temperature of

60ºC is exceeded. A fall below the dew

point (condensation) is thereby safely

prevented.

The installation of a three−way mixer is

essential to improve the controllability

of Vitolig 100.

Do not add too much fuel when heat is

only drawn off in modest quantities

(mild outside temperature). Always

ensure that heat is drawn off.

3 Vitolig 300

3.1 Specification

Rated output range kW 5 to 15 8 to 26

Permissible flow temperature ºC 95 95

Minimum return temperature ºC 20 20

Max. operating pressure

Boiler

Heat exchanger

bar

CE designation

In accordance with the

Machinery Guideline

CE CE

Boiler class acc. to EN3035 3 3

Overall dimensions

Overall length

Overall width

Overall height

 boiler

 with fully automatic

pellet feed

656

1285

1142

1805

721

1285

1142

1805

Total weight kg

Boiler shell with thermal insulation

250 297

Max. elec. power consumption

 during ignition

 during heating operation

1377

Contents

Boiler water

Fuel hopper

litres

150

Boiler connections

Boiler flow and return plus G(female thread) 1" 1"

safety connection

(safety valve)

Safety return and R(male thread) ½" ½"

drain

Heat exchanger connections

Cold water, hot water R(male thread) ½" ½"

Primary side

Flow resistance

DT=20K

DT=10K

mbar

1.2

5.9

19.3

Flue gas*1

Average temperature (gross*2)

 at upper heat output

 at partial load (33% of the

upper heat output)

Mass flow rate

 at upper heat output

 at partial load (33% of the

upper heat output)

CO2 content in the flue gas

ºC

kg/h

145

38.9

14.8

12.0

144

23.4

12.0

Flue outlet External ∅mm 130 130

Required draught Pa

mbar

0.05

*1Values for calculating the size of the flue system, according to DIN4705 based on 12.0% CO2.

*2Flue gas temperature measured as gross value as per EN304 at 20ºC combustion air temperature.

5822241 GB

3 Vitolig 300

Rear view − boiler

144

Overall length

Overall boiler height

Overall height with fully automatic pellet feed

Overall width

930

382

452

192

736

816

922

322

AGA

KV/SA

279

TAS

Legends

AGA Flue pipe

E Drain and diaphragm

expansion vessel

KR Boiler return

KV Boiler flow

KW Cold water entry of the

safety heat exchanger

SA Safety connection

(safety valve)

TAS Coupling R½" for sensor for

thermostatic drain valve

WW Hot water outlet of the safety heat

exchanger (no DHW connection)

APellet feed connection

BReturn air connection

CFully automatic pellet feed

DBoiler

EAsh trolley for fully automatic ash

removal

5822241 GB

3 Vitolig 300

approx. 3000

min. 100

approx. 2000

3.2 Positioning

HNo air contamination through

halogenated hydrocarbons (e.g. as

contained in sprays, paints, solvents

and cleaning agents).

HAvoid very dusty conditions.

HAvoid high levels of humidity.

HAvoid danger of freezing and ensure

good ventilation.

Otherwise the system may suffer faults

and damage.

The boiler may only be installed in

rooms, where air contamination through

halogenated hydrocarbons may occur,

such as through hairdressing salons,

printing shops, chemical cleaners,

laboratories etc., if adequate measures

can be taken to provide uncontaminated

combustion air.

If in doubt, please contact us.

If these instructions are not observed, any

consequential damage to the boiler

directly related to any of these causes,

are excluded from our warranty.

Installation example − system with fully automatic pellet feed

*1Example, dimensions not binding

AFully automatic pellet feed

BChangeover unit

CFill and return air adaptor

(Storz couplings)

DTimber planks

ESuction wands

FDeflector

5822241 GB

*1Required for cleaning and manual venting

*2Required for the removal of the worm−drive

*3With fully automatic pellet feed

*4Without fully automatic pellet feed

*5Required for the removal of the ash container

200

650

1285

930500

120

400

721 (8−26 kW)

656 (5−15 kW)

*6For the installation of the fully automatic pellet feed

Boiler with fully automatic pellet feed

2010

400*6

3 Vitolig 300

3.3 Fuel storage and feed

General

Pellets are delivered in a tanker when

bought loose and in bulk. The size of the

delivery vehicle must be taken into

consideration when planning the access.

These vehicles are mostly over 15tonnes

in weight and can be between 3.7to

3.9 m high. Therefore, check whether the

access could be affected by weight

restrictions, subways, narrow or steep

access routes, tight bends or a lack of

turning space.

Pellet storage areas should, where

possible, be located alongside an outside

wall to leave the supply hoses as short as

possible. Because of fluctuating air

volumes, handling with supply hoses

between 20 and 40 m becomes difficult.

Supply tankers are equipped with a pump

fan, i.e. pellets are blown into the storage

area at a working pressure of 0.5 to

0.9 bar. The overpressure is then

withdrawn from the storage area by a

vacuum fan and filter installation. A

power supply with 230 V and at least 10 A

capacity is required.

Sizing the storage area

The storage area should be more

rectangular than square and should be of

a size, which allows an annual quantity of

fuel to be stored. The size of the storage

room depends on the heat demand of the

building.

The storage volume in m3 (incl. empty

space) is calculated by multiplying the

required heat output (in kW) by a factor of

0.9 (m3/kW).

Example:

A detached house with a heat demand of

15 kW requires a storage volume of

approx. 13.5 m3 incl. empty space (this

corresponds to a room of 2 x 3 m floor

area and a useable height of 2.25 m).

Storage room characteristics and fuel feed with all necessary system components

HThe pellet storage area must be dry, as

pellets will substantially swell up if

subjected to moisture. This leads to

great difficulties (e.g. blockages at the

suction wand).

HThe pellet storage area must be

constructed as a solid, leak−proof

structure, since blowing pellets into this

room will create dust and blowing

pellets against the walls creates high

pressure.

HSurrounding walls and ceiling must

correspond to fire resistance class F 90,

e. g. house bricks 12 cm, rendered on

both sides; hollow breeze block 17 cm,

rendered on both sides; concrete 10 cm,

plaster slab 12 cm.

HDoors or access hatches into the pellet

storage area must open outwards and

must be sealed. Ensure the doors or

hatches are constructed as fire doors

T 30 or, if necessary, T 90.

HFit protective boards A on the inside of

the door opening, so that pellets do not

push against the door (see page 13).

HThe pellet storage area should not

contain any electrical installations.

Essential electrical installations must be

of the explosion−proof type  in

accordance with current regulations.

HAvoid the installation of water pipes

inside the storage area because of

condensation and the risk of burst

pipes.

HPellet storage areas should be equipped

with a filling F and a return air adaptor

G with Storz system type A Ğ100 mm

coupling (fire hose adaptor) with

extension hose leading into the storage

area. Pipes should be metal (not

plastic), and should be connected to the

brickwork and must be earthed.

HA deflector B should be fitted opposite

the filling adaptor to protect the pellets

and the brickwork.

HThe pellet storage area must be free

from debris (small stones, wood

particles, etc.).

HDistribute the suction wands H so that

the storage area is efficiently emptied.

HThe maximum length of the feed and

return hoses E and the maximum

height of the suction wand, which is the

furthest removed from the feed unit

should not be greater than 15 m in

length or 2.8 m in height. Hoses should

be earthed, may not be installed on the

outside and should be protected

against temperatures above 60ºC.

HClose the wall opening for the

automatic changeover unit D from the

storage room side in a fireproof manner

(e.g. rendering).

5822241 GB

3 Vitolig 300

Top view onto the pellet storage and the boiler room (installation example)

Section through the pellet storage area (installation example)

*1Example, dimensions not binding

AProtective boards

BDeflector

CVitolig 300

DChangeover unit

EPellet feed and return air hose

FFill adaptor

GReturn air adaptor

HSuction wand

KAir gap

LEmpty space

MLateral slope for improved

emptying

5822241 GB

approx. 3000 mm

>100 mm

A B

500 −

1000 mm

= =

300 mm

approx. 2000 mm

Useable volume

approx. ¾ of the

room volume

>200 mm

Height of room 2500 mm

3 Vitolig 300

System component details

Protective boards with Z profiles

Z profiles are available as accessories for

the installation of the protective boards.

Do not install Z profiles up to the ceiling

to permit the removal or addition of the

protective boards.

AZ profile (length 2000 mm)

BProtective board (30 mm thick 

on−site provision)

CFire door T 30 or T 90

Deflector

The deflector should be installed at a

distance of at least 100 mm from the wall

opposite the filling adaptor (see adjacent

diagram). This deflector protects the

pellets as well as the brickwork or the

rendering/plaster.

Plaster/rendering or pieces of brick that

have been dislodged can block the

suction wands and the pellet worm−drive

or the burner tray ash removal of

Vitolig 300.

*1Blow inlet approx. 4  5 m

AFill adaptor

BDeflector (1500 x 1500 mm)

5822241 GB

A B A

>100 mm

3 Vitolig 300

Feed and return air hose

HThe maximum length in one direction

(feed or return air) should not be

greater than 15 m; the height from the

furthest suction wand to the feed unit

should not be greater than 2.8 m.

HHoses should not be kinked and radii

should not be tighter than 30 cm.

HHoses should be routed as straight and

level as possible. If hoses are routed

several times up and down, pellets will

not be perfectly transported from the

lower lying areas.

HSelect the shortest possible way from

the storage area to the feeder unit and

route hoses, positioning than so that no

one can step onto them. However,

hoses should be long enough to enable

all to be connected to any position of

the changeover unit. This is necessary

to allow the pellet feed hose to be

purged with return air, if necessary.

HHoses must be earthed to prevent static

being built up during pellet handling.

HThe pellet feed hose should be made

from one piece, whilst the return air

hose can be made from several

sections. The connection fitting should

be made from metal to ensure the earth

continuity.

HThe hoses should not be exposed to

temperatures above 60ºC (these could,

for example, be created by non−

insulated heating pipes and at the flue

pipe).

HHoses should not be routed outside

(danger of becoming brittle through UV

radiation).

HTo calculate the required length of hose,

the distance between the feeder unit

and the changeover unit as well as the

distances between the changeover unit

and all three suction wands must be

established. These dimensions are

added and multiplied by two, since

pellet feed and return air hoses are

required.

Filling adaptor and return air adaptor

HGeneral

Arrange the adaptors so that, during

the filling process, no overpressure is

created in the pellet storage area.

Therefore, keep the return air adaptor

unrestricted, even when the maximum

filling level in the storage area has been

reached (see page 13).

The adaptors should be located as high

as possible inside the storage area, to

enable the pellet storage area to be

filled to the maximum. The filling

adaptor should be at least 20 cm below

the ceiling, to prevent pellets hitting the

ceiling (fit protective boards if the

ceiling is plastered).

The adaptors should be located along

the narrow side of the storage room.

Pellets are blown approx. 4  5 m with

straight filling adaptors. Where a 90º

elbow fitting is located before the entry

into the storage room, fit a straight pipe

of at least 1 m length on the other side

to protrude into the storage room. This

enables the pellets to reach the required

velocity and therefore the necessary

blow−in distance.

HEarthing

Earth all adaptors to prevent static

building up during the filling process.

Generally, the connection of each pipe

element to the building earth is

recommended. At the very least,

connect each pipe element to the

brickwork, either by setting the pipe

into the brickwork (without insulating

material) or via pipe cleats set into the

brickwork.

5822241 GB

3 Vitolig 300

HAdaptor length and location

Adaptor clearance y 500 mm Adaptor clearance < 500 mm The length of the filling adaptor is subject

to the distance from the return air

adaptor.

Adaptor clearances of < 500 mm may

occur if both adaptors are set into a cellar

window.

AFill adaptor

BReturn air adaptor

Alternating filling

If adaptors must be located in the long

flanks of the storage room, filling should

be alternated from side to side. This

would ensure a more efficient filling. In

any event, both adaptors should be

earthed. A deflector should be installed

opposite both adaptors.

ADeflector

BFilling and return air adaptors

Internal pellet storage area

If the filling and return air adaptors must

be routed through a neighbouring room,

clad both with a material offering fire

resistance compliant with class F 90

(Rockwool, etc.). Earth each extension

piece via pipe cleats. Plastic pipes should

not be used as extension pieces.

AAdaptors

BFire resistant cladding (F 90)

CExtension piece

DPipe cleat

5822241 GB

approx. 100 mm

>500 mm

<500 mm

approx. 100 mm

>500 mm

approx. 100 mm

>100 mm

A B C D

3 Vitolig 300

HAdaptor installation options

AFill adaptor

BThrough brickwork Ğ 150 mm

Setting into brickwork

The adaptor is set into the opening

without insulation.

CScrews

DThrough brickwork Ğ 110 mm

EPipe cleat for earthing

Threaded wall installation

The adaptor is fitted to the outside wall

via threaded connections and earthed via

a pipe cleat.

Threaded window installation

A plate is set into the window opening.

The adaptor is fitted through the plate,

connected with threaded fittings and

earthed via a pipe cleat.

FWindow opening

Installation into a lighting duct

Adaptors may be installed through a wall

or through a window opening. The

reduced filling and return air adaptors are

each pushed into a 45º elbow fitting,

which in turn is located in an extension

piece pushed through the wall or the

window opening.

GExtension piece

H45º elbow

5822241 GB

B or D

3 Vitolig 300

Suction wands

Distribute suction wands along the floor

of the pellet storage area, so that the

room is emptied evenly.

The distance of the wands to the walls of

the storage area should be approx. half of

the distance between wands (see

adjacent diagram).

The dimensions shown are only

examples. Select appropriate distances

for storage areas with alternative

dimensions.

AFill adaptor

BReturn air adaptor

CSuction wands

Changeover unit

Create a wall opening in the storage area

in accordance with the adjacent diagram.

Close the gap between the wall opening

and the fitted changeover unit with

fire−resistant material (e.g. rendering/

plaster).

5822241 GB

approx. 3000 mm

500 mm 1000 mm 1000 mm 500 mm

>150 mm

>200 mm

3 Vitolig 300

3.4 Flue gas connection

Chimney

A chimney corresponding to regulations

and appropriate for the rated boiler

output is a pre−requisite for an efficient

operation.

The chimney opening (clearance

diameter, smallest lateral length) should

be 130 mm, or better still 140 mm. In

borderline cases, provide verification in

accordance with DIN 4705.

Note that in its lower output range, Vitolig

300 can create flue gas temperatures

below 90ºC. Therefore, connect

Vitolig 300 to a moisture−resistant

chimney (heat throughput factor

resistance class I acc. to DIN 18160 T1).

If Vitolig 300 should not be connected to

a moisture−resistant chimney, carry out a

chimney calculation or request a chimney

assessment (values for a chimney

calculation see page 9).

Flue pipe

AClean−out cover

BThermal insulation

CFlexible flue pipe adaptor

The vacuum draught fan may induce

vibrations, which may lead to a noise

nuisance. We therefore recommend you

implement the connection to the chimney

with a flexible flue pipe adaptor.

Note the following when connecting the

flue pipe:

HInstall the flue pipe rising to the

chimney (if possible with 45º).

HDo not push the flue pipe too far into

the chimney.

HEnsure the full flue gas path (incl.

clean−out cover) is gas−tight.

HDo not insert the flue pipe into the

brickwork of the chimney; instead use a

flexible flue pipe adaptor.

HProvide the flue pipe with thermal

insulation (min. thickness 50 mm).

5822241 GB

400 mm

3 Vitolig 300

3.5 Water connection

Safety equipment acc. to DIN 47512

DIN 47512 requires the following safety

equipment to be installed:

HA sealed expansion vessel.

HA safety valve at the highest point of

the boiler or a pipe connected with the

boiler.

The pipework between the boiler and

the safety valve must not be able to be

shut off. Pumps, fittings or restrictions

must not be present in this pipework.

The blow−off line should be constructed

so as to prevent the possibility of

increases in pressure.

Any expelled heating water must be

able to be drained off safely. Arrange

the outlet of the blow−off line so that

any water expelled from the safety

valve can be safely observed and

drained off.

HA low water indicator (water limiter

available as accessory).

HA thermometer and a pressure gauge.

HAn automatic device for heat disposal,

which prevents the maximum

permissible operating temperature to

be exceeded. To affect this, connect a

thermostatic drain valve (available as

accessory) to the integral heat

exchanger.

General design notes

This boiler is only suitable for heating

systems with pumped hot water.

HThe minimum boiler water inlet

temperature is 60ºC.

Only regulated heating circuits with

mixers may be installed.

We recommend the installation of a

check valve into the heating flow, acting

as gravity brake. This prevents

uncontrolled heat entering the heating

system through gravity, when DHW

heating is given priority, or the system

is in summer mode.

For underfloor heating circuits, a high

limit thermostat should be installed.

HVitolig 300 can be operated with a

return temperature as low as 20ºC

when operated with an internal return

temperature raising facility. This makes

an external return temperature raising

facility unnecessary.

Systems with a combination or heating

water buffer storage unit loaded directly

by Vitolig 300 are an exception to this

rule. The large volume of cold water

returning from the cylinder in such

cases necessitates the installation of an

external return temperature raising

facility.

HIn many cases, the heat demand of a

building does not remain constant

(extensions or thermal insulation

measures). Therefore, the rated output

is matched to the maximum heat

demand foreseeable in the long term. A

heating water buffer storage unit

should be installed, if the heat demand

of 8 kW (for Vitolig 300, 5 to 15 kW) or

12 kW (for Vitolig 300, 8 to 26 kW) will

not be reached within a given period.

5822241 GB

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Viessmann Vitolig 300 Technical Manual

Viessmann Vitolig 300 Technical Manual

Viessmann Vitolig 300 Technical Manual

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