Bosch Uni 5000F US 207 Guide rapide

Caution!

Observe the safety instructions of this installation

and maintenance manual before placing the boiler

in operation.

Danger!

If installation, adjustment, modification, operation or

maintenance of the heating system is carried out by

an unqualified person, this may result in danger to

life and limb or property damage.

The directions of this installation and maintenance

manual must be followed precisely.

Contact a qualified service company or service pro-

vider if support or additional information is required.

Caution!

The operating manual is a component of the techni-

cal documentation and must be handed over to the

operator of the heating system.

Discuss the content of this manual with the owner

or operator of the heating system to ensure that

they are familiar with all information required for

operation of the heating system. If the boiler will be

installed in Massuchussetts, it must be installed by

an installer or dealer who is registered there.

Installation and Service Instructions

Low-temperature oil and gas-fired boiler

Bosch Uni 5000F US/CA

171/207/256

6 720 648 032-00.1T

6 720 648 162- 2011/08 US/CA

2| Contents

6 720 648 162 (2011/08)

Contents

1 Safety Considerations and Symbol

Descriptions 4

1.1 Regarding this Manual 4

1.2 Explanation of symbols 4

1.3 Observe the following Symbols 4

1.3.1 Installation Guidelines 5

1.3.2 Boiler Room Guidelines 5

1.4 Tools, Materials and Accessories 5

1.5 Disposal 6

2 Product description 7

2.1 Intended use 7

2.2 Certification and testing mark 7

2.3 Notes on installation and operation 7

2.4 Heating system water quality 7

2.5 Product description 7

2.6 Pack contents 8

2.7 Dimensions Specifications 9

2.7.1 Bosch Uni 5000F dimensions 9

2.8 Conditions for operation 10

2.8.1 General operating conditions 11

2.8.2 Conditions for the boiler room and the

environment 11

2.8.3 Combustion air supply conditions 12

2.8.4 Conditions, Fuel 12

2.8.5 burner selection 13

2.8.6 Conditions power supply 13

2.8.7 Conditions for hydraulic system and water

quality 14

3 Moving the boiler 15

4 Installing the boiler 16

4.1 Wall clearances 16

5 Boiler block assembly 17

5.1 Assembly when delivered in sections 17

5.1.1 Preparing boiler sections 17

5.1.2 Preparing push nippples and nipple ports 18

5.1.3 Preparing the intermediate section 18

5.1.4 Inserting the section sealing 19

5.1.5 Knock intermediate section into place 19

5.1.6 Boiler section alignment 19

5.1.7 Join boiler sections by the nipples at the top

and bottom boiler hub 20

5.1.8 Fitting the anchor rods 21

5.1.9 Fitting distribution tube and supply/return

header 22

5.1.10 Sealing the sensor well 23

5.1.11 Positioning the flue outlet 23

5.1.12 Sealing boiler hubs 23

5.2 Check for leaks 24

5.2.1 Preparing for a leak test). 24

5.2.2 Leak test 24

5.3 Installation when the boiler is supplied

assembled 24

5.4 Installation steps for disassembled and

assembled delivery 25

5.4.1 Fitting adjustable feet 25

5.4.2 Insert the flue gas baffle plates 25

5.4.3 Installing the burner door 26

5.4.4 Fitting the boiler jacket 26

5.5 Positioning and leveling the boiler 29

6 Installing the boiler 30

6.1 Flue pipe installation 30

6.1.1 Chimney venting 30

6.2 Fitting the water connections 31

6.2.1 Fitting the B-kit 31

6.2.2 Installation of boiler drain (included in B-Kit) 31

6.2.3 Installing system components 32

6.3 Filling the heating system and checking for

leaks 32

6.4 Mounting the burner 33

6.5 Connecting the fuel supply 34

6.6 Installing aquastat 34

6.7 Blocked vent switch (required in Canada) 34

6.8 Electrical connections 34

6.9 Jacket panel installation 35

7 Commissioning the heating system 36

7.1 Bringing the system up to operating pressure 36

7.2 Checking the safety valve 36

7.3 Preparing the heating system for operation 36

7.4 Starting up the burner 36

7.5 Notes on commissioning the burner 36

7.6 Raising flue gas temperature 37

7.6.1 Removing flue gas baffle plates 37

7.6.2 Removing the blocking plate 38

7.7 Manual reset high limit (STB) 38

7.8 Installing jacket panels 38

7.9 Commissioning log 39

8 Shutting down the heating system 40

8.1 Shutting down normally 40

8.2 Shutting down the heating system in an

emergency 40

Contents | 3

6 720 648 162 (2011/08)

9 Heating system servicing 41

9.1 Why is regular maintenance important? 41

9.2 Preparing the boiler for servicing 41

9.3 Cleaning the boiler 41

9.3.1 Cleaning the boiler with brushes 41

9.3.2 Wet cleaning (chemical cleaning) 42

9.4 Checking heating system operating pressure 42

9.5 Testing relief valve 43

9.6 Servicing and maintenance logs 44

10 Troubleshooting 47

11 Installation examples 48

12 Parts lists 51

13 Circuit diagrams 57

Index 66

4| Safety Considerations and Symbol Descriptions

6 720 648 162 (2011/08)

1 Safety Considerations and Symbol Descriptions

1.1 Regarding this Manual

This document contains important information

regarding safe and proper installation, operation and

maintenance of the boiler.

The high tech Uni 5000F boiler is designated as a hot

water heating boiler.

The Installation and Maintenance Instructions are

directed to the installing contractor who has

professional knowledge regarding boiler installation and

maintenance.

1.2 Explanation of symbols

Signal words are used to indicate the seriousness of the

ensuing risk if measures for minimising damage are not

taken.

•Caution indicates that minor damage to property may

occur.

•Warning indicates that minor personal injury or severe

damage to property may occur.

•Danger means that severe personal injury may occur.

Very serious cases may result in death.

Notes contain important additional information.

Notes do not contain any warnings or information about

hazards or risks.

1.3 Observe the following Symbols

All applicable local, state, and national codes and

regulations must be observed for the installation of the

boiler:

•The local building code requirements regarding

placement, combustion air and venting and chimney

system must be followed.

•Follow applicable electrical code requirements.

•Follow the local code and standards regarding safe

boiler operation.

•The technical rules of the gas suppply company

regarding the connection of a gas burner to the gas

system.

Warnings are indicated by a warning

triangle and a grey background.

Notes are identified in the text by this

symbol. They are bounded by horizontal

lines above and below the text.

NOTICE

Use only original spare parts. Bosch can not

be held liable for damage caused by non-

Bosch parts.

NOTICE

Oil boilers: The boiler installation must be

performed by a qualified installer in

accordance with regulations put forth in

NFPA-31 Installation of Oil-Burning

Equipment. The installation must comply

with all local and national codes, regulations

and authorities having jurisdiction regarding

the installation of oil fired boilers.

For Canada refer to the guidelines of CSA/

CGA-B139 Installation Codes.

Gas boilers: The boiler installation must be

performed by a qualified installer in

accordance with regulations put forth in

ANSI Z223.1/NFPA-54, National Fuel Gas

Code. In Canada the requirements of CAN/

CSA B149, Installation Code for Gas Burning

Appliances and Equipment have be

observed.

Safety Considerations and Symbol Descriptions | 5

6 720 648 162 (2011/08)

1.3.1 Installation Guidelines

1.3.2 Boiler Room Guidelines

1.4 Tools, Materials and Accessories

For the installation and maintenance of the boiler you

will need typical tools used in this industry.

In addition, the following components are useful:

•Hand truck with strap or boiler cart.

•Wood blocking.

•Cleaning brushes and/or chemical cleaning agents for

wet cleaning.

If the boiler is delivered in sections, you will also require

the following:

•Compression tool 1.2 if the boiler is supplied in

sections (Æcompression tool documentation).

•Flat board.

•Cleaning agent.

•Installation kit (accessory)

•Steel hammer and wooden or rubber mallet

CAUTION: DANGER TO LIFE

from electric shock.

BDo not work on electrical components

unless you have the required

qualification.

BDo not work on electrical components

unless you have the required

qualification.

BPrior to opening the control: shut down

the power supply by turning off the

emergency shut-off switch or

disengaging the heating system circuit

breaker, and prevent from accidental

reactivation.

BObserve all applicable installation

guidelines.

CAUTION: DANGER TO LIFE

from explosion of volatile gases.

BWork on gas components must be carried

out by qualified and authorized

personnel only.

CAUTION: DANGER TO LIFE

from explosion of volatile gases.

If you notic a smell of gas there is a risk of

explosion.

BExtinguish all open flames.

BDo not smoke.

BDo not use lighting.

BPrevent sparks. Do not operate electrical

switches , including telephones, plugs or

doorbells.

BClose the main gas shut-off valve.

BOpen windows and doors.

BWarn all occupants, but do not use

doorbells.

BCall gas company from outside the

building.

BIf you hear gas escaping, immediately

leave the building, prevent others from

entering and notify police and fire

brigade from outside the building.

CAUTION: DANGER TO LIFE

from flue gas poisoning.

Insufficient combustion air can result in

dangerous operation if combustion air is

taken from indoors.

BPlease observe that combustion air

openings are not reduced in size or

closed.

BMake sure that no mechanical air

openings or devices remove combustion

air from the boiler room such as central

vacuum systems, dryers and air

conditioning appliances.

BMake sure that the boiler is connected to

a chimney or horizontal venting system

that is capable of handling the slight

positive breeching pressure.

BIf any of these problems have not been

corrected, the boiler must not be

operated.

BMake the end-user aware of these

guidelines and their potential danger.

CAUTION: FIRE DANGER

due to flammable or liquid materials.

BMake sure that flammable and liquid

materials are not stored in the close

vicinity of the boiler.

6| Safety Considerations and Symbol Descriptions

6 720 648 162 (2011/08)

•Half- round bastard file

•Screwdriver (Philips and slotted head)

•Flat chisel

•Wrench SW 19, 36, 13, 19, 18, 24, 27 and Allen key

SW19

•Support wedge, flat iron

•Cleaning rags and cloth

•Fine emery cloth

•Wire brush

•3-in-1 oil

•Cleaning agent, ruler, chalk, straight edge

•Blanking flange with vent facilitiy (for pressure test)

1.5 Disposal

BPlease dispose of any trash in an environmentaly

friendly fashion.

BPlease discard properly of any heating system related

components.

Product description | 7

6 720 648 162 (2011/08)

2 Product description

This installation and maintenance manual contains

important information for the safe and intended

installation, initial start-up and maintenance of this

boiler.

The special oil or gas-fired boiler is generally referred to

below as a boiler.

The installation and maintenance manual is provided for

technicians who have been trained and have experience

in working with heating systems and oil/gas fired

installations.

2.1 Intended use

The Bosch Uni 5000F is designed for central heating and

domestic hot water (DHW) systems, for instance in

residential homes or apartment buildings, or small

commercial applications.

2.2 Certification and testing mark

This appliance has been tested and certified to meet

rules and regulations in place for the US and Canadian

markets.

2.3 Notes on installation and operation

When installing and operating the heating system, it is

the installer's responsibility to meet all applicable

federal, state, and local codes.

2.4 Heating system water quality

Poor water quality can damage heating systems due to

scale formation and corrosion.

Please refer to Chapter 2.8.7, Tab. 9 for further details

of the water quality.

2.5 Product description

The boiler is a low-temperature for oil or gas combustion

appliance with automatic control panel or aquastat for

boiler water temperature.

The boiler consists of:

•Boiler block with insulation

•Boiler jacket

•Control panel or aquastat

The controls monitor and control all electrical boiler

components.

The boiler can alternatively be fitted with a simple

aquastat control.

The boiler jacket prevents heat loss and acts as a noise

insulator.

The boiler block transfers the heat generated by the

burner to the heating water. The insulation prevents

energy loss.

Suitable burners

Fig. 1 Boiler without burner

1Burner door casing

2Boiler jacket

3Boiler block with insulation

CAUTION: Risk of system damage due to

unsuitable boiler water.

BIf oxygen-permeable pipes are used, e.g.

for radiant heating systems, the systems

must be separated from the boiler by a

heat exchanger. Unsuitable heating

system water promotes sludge formation

and corrosion. This can result in heating

system malfunction and boiler damage.

CAUTION: Risk of system damage from use

of incorrect burner.

BOnly the burner provided may be

employed with this boiler.

6 720 648 032-01.1T

8| Product description

6 720 648 162 (2011/08)

2.6 Pack contents

Upon delivery, check that the packaging is complete and

undamaged.

Boiler as assembled block

Boiler in parts

Component Qty Packaging

Boiler block 1 1 pallet1)

1) 1 pallet

Control panel or aquastat 1 1 box

Jacket Package:

•Boiler jacket

•Insulation

•Burner door, burner

door cover and

assembly equipment2)

•Technical documents

B-Kit components:

•Supply manifold (11/4")

•30 psi (2 bar) relief valve

•Boiler drain (¾ ")

•Pressure/temperature

gauge

•90°-elbow (¾ ")

•Burner mounting studs

and washers

•Aquastat well (¾ ")

•Bushing 1" x ¾ "

•Plug 1"

2) The srew-in feet are in the burner door and burner door

cover package.

1 box on a

pallet

1 box1)

1 plastic

package

1 package

Table 1 Package Contents

Component Qty Packaging

Front, center and back

sections

1 1 pallet1)

1) 1 pallet

Control panel or aquastat 1 1 box

Jacket Package:

•Fittings

•Boiler jacket

•Insulation

•Burner door, burner

door cover and

assembly equipment2)

•Technical documents

B-Kit components:

•Supply manifold (11/4")

•30 psi (2 bar) relief valve

•Boiler drain (¾ ")

•Pressure/temperature

gauge

•90°-elbow (¾ ")

•Burner mounting studs

and washers

•Aquastat well (¾ ")

•Bushing 1" x ¾ "

•Plug 1"

2) The srew-in feet are in the burner door and burner door

cover package.

1 box on a

pallet

1 box1)

1 plastic

package1)

1 box1)

1 plastic

package

1 package

Table 2 Package Contents

Product description | 9

6 720 648 162 (2011/08)

2.7 Dimensions Specifications

2.7.1 Bosch Uni 5000F dimensions

Fig. 2 Connections and dimensions (measurements in inches (mm))

VK = Boiler supply

RK = Boiler return

EL = Boiler drain (connection for drain valve)

VS = Hot water tank supply

Connections and dimensions:

6 720 648 032-02.1T

(781 mm)

(744 mm)

(686 mm)

(538 mm)

(72 mm)

(15 - 25 mm)

(150 mm)

(744 mm)

(107 mm)

(83 mm)

(302 mm)

(600 mm)

(881 mm)

Boiler model Unit Uni 171 Uni 207 Uni 256

Boiler sections Number 456

Heating capacity (gross output) Btu/hr

(kW)

171,000

(50)

207,000

(60)

256,000

(75)

Thermal output (net IBR output) Btu/hr

(kW)

149,000

(43)

180,000

(52)

223,000

(65)

Boiler water content Gal

(l) [Liter]

approx. 16.1

(61)

approx. 19.3

(73)

approx. 22.5

(85)

Gas capacity cu.ft.

(l) [Liter]

1.73

(68.8)

2.10

(85,1)

2.48

(101,4)

Oil firing rate GPH

(kg/h)

1.4

(4,5)

1.7

(5,4)

2.1

(6,7)

Maximum input rating Gas Btu/hr

(kW)

164,000

(48)

199,000

(58)

245,000

(72)

Hot gas resistance psi

(Pa)

0.0023−0.0078

(15,86 - 53,78)

Permissible max. supply temperature1) °F

(°C)

248

(120)

Allowable operating pressure psi

(bar)

(4)

Maximum time constant of thermostat and high limit

safety cut-out (STB)

s40

Table 3 Technical data for boilers without burners

10 | Product description

6 720 648 162 (2011/08)

2.8 Conditions for operation

Maintaining the specified operating conditions will

enable the boiler to provide a high level of reliability and

long service life.

1) Limit (safety temperature limiter, STB)

Maximum permitted flow temperature = Safety limit (STB) - 32 °F (18 K)

Example: Safety limit (STB) = 212 °F (100 °C), maximum permitted flow temperature = 212 ° (100 °C) - 32 ° (18 K) = 180 °F

(82 °C)

The safety limit must meet the national regulations of the country concerned.

Boiler model Unit Uni 171 Uni 207 Uni 256

Boiler overall length (L) Inch

(mm)

(787)

35 ¾

(907)

40 ½

(1027)

Boiler block length (LK) Inch

(mm)

26 ¾

(680)

31 ½

(800)

36 ¼

(920)

Boiler section insert (width; height; depth) Inch

(mm)

−18 1/8; 32 ¼ ; 5 7/8

(460 / 820 / 150)

Boiler block insert (width; height; depth) Inch

(mm)

18 1/8; 32 ¼ ; Length LK

(460 / 820)

Combustion chamber length Inch

(mm)

21 ½

(546)

26 ¼

(668)

(788)

Combustion chamber diameter Inch

(mm)

13 ¼

(337)

Burner door thickness Inch

(mm)

3 ¾

(95)

Burner pipe diameter (DB) Inch

(mm)

4 3/8

(112)

Hole circle diameter (DL) Inch

(mm)

5 7/8

(150)

Distance between boiler feet (FL)Inch

(mm)

(455)

22 ¾

(575)

27 ¼

(695)

Net weight1)– Lbs

(kg)

500

(227)

600

(272)

700

(317)

Table 4 Dimensions, weight and other data for boilers without burners

1) Incl. packaging material approx. 6-8 % more

CAUTION: Risk of system damage if

operating conditions are not maintained.

Irreversible damage to individual

components of the boiler as a whole or the

heating system may occur.

BThe information on the rating plate is

binding and must be observed.

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