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Low-temperature oil and gas-fired boiler
Bosch Uni 5000F US/CA
171/207/256
Installation and Service Instructions
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.
C
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Table of Contents
Related Manuals for Bosch Uni 5000F US
Summary of Contents for Bosch Uni 5000F US
- Page 1 If the boiler will be installed in Massuchussetts, it must be installed by an installer or dealer who is registered there. Low-temperature oil and gas-fired boiler Bosch Uni 5000F US/CA 171/207/256 Installation and Service Instructions...
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Page 2: Table Of Contents
Installing the boiler Pack contents Flue pipe installation Dimensions Specifications 6.1.1 Chimney venting 2.7.1 Bosch Uni 5000F dimensions Fitting the water connections Conditions for operation 6.2.1 Fitting the B-kit 2.8.1 General operating conditions 6.2.2 Installation of boiler drain (included in B-Kit) 31 2.8.2 Conditions for the boiler room and the... - Page 3 Contents | 3 Heating system servicing Why is regular maintenance important? Preparing the boiler for servicing Cleaning the boiler 9.3.1 Cleaning the boiler with brushes 9.3.2 Wet cleaning (chemical cleaning) Checking heating system operating pressure Testing relief valve Servicing and maintenance logs Troubleshooting Installation examples Parts lists...
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Page 4: Safety Considerations And Symbol Descriptions
The high tech Uni 5000F boiler is designated as a hot NOTICE water heating boiler. Use only original spare parts. Bosch can not The Installation and Maintenance Instructions are be held liable for damage caused by non- directed to the installing contractor who has Bosch parts. -
Page 5: Installation Guidelines
Safety Considerations and Symbol Descriptions | 5 1.3.1 Installation Guidelines CAUTION: DANGER TO LIFE CAUTION: DANGER TO LIFE from electric shock. from flue gas poisoning. Insufficient combustion air can result in B Do not work on electrical components dangerous operation if combustion air is unless you have the required taken from indoors. -
Page 6: Disposal
6 | Safety Considerations and Symbol Descriptions • 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 •... -
Page 7: Product Description
The boiler can alternatively be fitted with a simple aquastat control. The Bosch Uni 5000F is designed for central heating and domestic hot water (DHW) systems, for instance in The boiler jacket prevents heat loss and acts as a noise residential homes or apartment buildings, or small insulator. -
Page 8: Pack Contents
8 | Product description Pack contents Upon delivery, check that the packaging is complete and Boiler in parts undamaged. Component Packaging Boiler as assembled block Front, center and back 1 pallet sections Component Packaging Control panel or aquastat 1 box Boiler block 1 pallet Jacket Package:... -
Page 9: Dimensions Specifications
Product description | 9 Dimensions Specifications 2.7.1 Bosch Uni 5000F dimensions (600 mm) (781 mm) (881 mm) (744 mm) (744 mm) (107 mm) (686 mm) (538 mm) (83 mm) (150 mm) (302 mm) (72 mm) 6 720 648 032-02.1T (15 - 25 mm) Fig. -
Page 10: Conditions For Operation
10 | Product description 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. -
Page 11: General Operating Conditions
Product description | 11 2.8.1 General operating conditions Operating conditions Min. boiler water Operating interruption heating circuit with temperature (complete boiler shutdown) heating circuit mixing valve Min. return temperature In combination with control for variable low-temperature operating modes. If heating zones or a boiler Possible if, after interruption of the not required but recommended with not required, except for operation... -
Page 12: Combustion Air Supply Conditions
12 | Product description Operating conditions Notes – Requirement in greater detail Fans that extract air from the − During burner operation, no mechanical air handling equipment may be operated that could boiler room. extract combustion air from the boiler room, e.g.: Exhaust hood •... -
Page 13: Burner Selection
Product description | 13 2.8.5 burner selection Oil burner boiler size burner manufacturer burner model nozzle pump pressure Uni 171 Riello 40F5 1.25 x 80 B 145 Psi (10 bar) Uni 207 40F10 1.50 x 80 W 145 Psi (10 bar) Uni 256 40F10 1.75 x 45 B... -
Page 14: Conditions For Hydraulic System And Water Quality
14 | Product description 2.8.7 Conditions for hydraulic system and water quality Operating conditions Notes – Requirement in greater detail Operating pressure 15 – 58 psi Maximum 30 psi (2 bar) with the supplied safety valve. (overpressure) (1,0 - 4,0 bar) Permissible site test pressure 45 –... -
Page 15: Moving The Boiler
CAUTION: Risk of injury if load is inadequately secured during transportation. B Use suitable means of transportation, e.g. the Bosch boiler hand truck with strap. B Secure the load against falling. Protect boiler connections from damage and dirt if the boiler is not installed immediately. -
Page 16: Installing The Boiler
16 | Installing the boiler Installing the boiler This chapter describes how to install and place the boiler in the boiler room. CAUTION: Risk of system damage from freezing. B Install the heating system in a frost-free room. Wall clearances Position the boiler with the recommended wall clearances. -
Page 17: Boiler Block Assembly
Boiler block assembly | 17 Boiler block assembly CAUTION: Risk of injury by not securing the Assembly when delivered in sections boiler adequately during transport. B Assembly all boiler sections in accordance with the B Use only suitable means for following instructions and diagrams. -
Page 18: Preparing Push Nippples And Nipple Ports
18 | Boiler block assembly B Evenly coat the boiler hub sealing faces with red lead B Remove any burrs with a file. putty. B Coat the packing spring or packing groove with adhesive (adhesive base). 6 720 648 032-07.1T Fig. -
Page 19: Inserting The Section Sealing
Boiler block assembly | 19 5.1.4 Inserting the section sealing CAUTION: System damage from leaking boiler sections. B Never stretch the sealing rope during application to ensure that the faces between the boiler sections are sealed correctly. B Carefully insert the sealing rope into the boiler section packing grooves. -
Page 20: Join Boiler Sections By The Nipples At The Top And Bottom Boiler Hub
20 | Boiler block assembly 5.1.7 Join boiler sections by the nipples at the top B Push the mating flange onto the pull rod of the lower and bottom boiler hub and upper boiler hubs, and secure with the respective wedges. -
Page 21: Fitting The Anchor Rods
Boiler block assembly | 21 B Set both ratchet wrenches on the clamping nuts of the compression units and press the boiler sections together by evenly tightening the nuts. 6 720 648 032-16.1T Fig. 16 Fit the compression tool to the front section 5.1.8 Fitting the anchor rods CAUTION: System damage due to incorrect... -
Page 22: Fitting Distribution Tube And Supply/Return Header
22 | Boiler block assembly B Tighten the nuts on the anchor rod threads by hand. B Tighten the nuts 1 to 1 ½ turns on the anchor rods. B Release and remove the compression tool. 5.1.9 Fitting distribution tube and supply/return header The distribution tube, the supply/return header and the sensor well are already assembled if the boiler block is... -
Page 23: 5.1.10 Sealing The Sensor Well
Boiler block assembly | 23 5.1.11 Positioning the flue outlet The flue come with sealing rope already fitted. B Remove the washers and nuts from the threaded studs. B Position the flue outlet on both threaded studs on the back saction and secure with nuts. 6 720 648 032-21.1T Fig. -
Page 24: Check For Leaks
24 | Boiler block assembly B Remove the distribution tube. B Release and remove the anchor rods. B Separate the leaking boiler by driving flat wedges or chisels into the leaking part. 6 720 648 032-25.1T 6 720 648 032-26.1T Fig. -
Page 25: Installation Steps For Disassembled And Assembled Delivery
Boiler block assembly | 25 5.4.2 Insert the flue gas baffle plates B Remove the corrugated cardboad packaging when the block is supplied ready assembled. -or- B Remove the flue gas baffles plates from the carton containing the small iron fillings when the boiler is supplied in sections. -
Page 26: Installing The Burner Door
26 | Boiler block assembly B Hook the burner door with the hinge lobes onto the Boiler section hinge pins. 2nd flue gas pass center bottom 3rd flue gas pass Table 14 Arrangement of the flue gas baffle plates The flue gas temperature can be increased by removing the flue gas baffle plates Chapter 7.6.1, page 37). - Page 27 Boiler block assembly | 27 B Secure the boiler back panel with nuts to the Fitting the bottom tie-bar threaded and spacer pins. B Screw the bottom cross bar with hexagon bolts to the front section. 6 720 648 032-36.1T Fig.
- Page 28 28 | Boiler block assembly Fitting the side panels B Hook the rear part of the side panel to the extended hook. The side panels are fitted identically on each side (r.h. side panel shown here). B Push the snap nut onto the angled sheet steel of the side panel until it locks the hole provided.
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Page 29: Positioning And Leveling The Boiler
Boiler block assembly | 29 Installing the top front boiler cover Positioning and leveling the boiler Installation of the boiler cover B Positioning the boiler in its final location. Chapter 5.4.4, page 26). B Level the boiler horizontally by turning the adjustable feet and using a spirit level. -
Page 30: Installing The Boiler
30 | Installing the boiler Installing the boiler This chapter details how to install your boiler correctly. Minimum clearances to combustible material The individual steps involved are: Flue pipe Type Minimum clearance • Connecting the flue Double-wall 6" (150 mm) •... -
Page 31: Fitting The Water Connections
Installing the boiler | 31 B Seal conversion nipple on boiler inlet VK. B Seal pressure/temperature gauge to conversion nipple. Do not fit the safety valve until the leak test Chapter 6.3, page 32) has been completed. The relief valve must be installed in a vertical position. -
Page 32: Installing System Components
32 | Installing the boiler 6.2.3 Installing system components Filling the heating system and See the installation diagram for installation of the checking for leaks heating system components. When the boiler is delivered assembled it is checked for For more installation examples refer to Chapter 11, leaks at the factory. -
Page 33: Mounting The Burner
B Fit the burner to the hole circle of the burner door. Approved burners with accessories (such as aquastat and circulator) are also available as a package from Bosch. 7 747 010 720-24.2RS B Install burner with the correct nozzle and settings Fig. -
Page 34: Connecting The Fuel Supply
34 | Installing the boiler Connecting the fuel supply Blocked vent switch (required in Canada) Make the fuel connection in accordance with all applicable local and national codes and regulations. We For Canadian installations fit a blocked vent switch per recommend fitting a fuel filter and de-aerator for oil the vent switch manufacturer’s instructions and as close boilers. -
Page 35: Jacket Panel Installation
Installing the boiler | 35 Jacket panel installation B Fit the rear boiler cover. B Secure by reinstalling cover screws. 6 720 648 162-01.1T Fig. 54 Removing/Installing the back boiler cover Back boiler cover 6 720 648 162 (2011/08) -
Page 36: Commissioning The Heating System
36 | Commissioning the heating system Commissioning the heating system This chapter describes the initial start-up procedure regardless of the installed control device. B Complete the start-up protocol during this process Chapter 7.9, page 39). Further information on boiler room layout and clearances, combustion air requirements and venting systems and boiler operational requirements can be found in... -
Page 37: Raising Flue Gas Temperature
Commissioning the heating system | 37 Incorrect burner adjustment can cause CAUTION: Risk of explosion due to contamination of the boiler (e.g. soot), escaping gas. leading to low efficiency, high emissions, B Shut off the main shut-off valve if the gas and a greater risk of service calls. -
Page 38: Removing The Blocking Plate
B Only operate the boiler with the burner hood/door panel fitted. CAUTION: Risk of system damage from use of incorrect fuel. B Only use burners which meet the technical requirements of the Bosch Uni 5000F ( Chapter 2.7, page 9). 6 720 648 162-03.1T Fig. 58... -
Page 39: Commissioning Log
Commissioning the heating system | 39 Commissioning log B Initial and date the commissioning steps carried out. Commissioning operations Page Readings taken Comments Fill heating system and check for leaks ___________ psi (bar) • Heating system pressure Bringing the system up to operating pressure B bleeding heating system ___________ psi (bar) B Testing relief valve... -
Page 40: Shutting Down The Heating System
40 | Shutting down the heating system Shutting down the heating system CAUTION: Risk of system damage from Shutting down the heating system in freezing. an emergency If the heating system has been switched off, Use the heating system emergency shut-off it may freeze up in cold weather conditions. -
Page 41: Heating System Servicing
• to ensure reliable operation and long service life. on the sides. Servicing work may only be carried out by a qualified service technician. If parts are replaced, only Bosch 9.3.1 Cleaning the boiler with brushes approved components may be used. A service must be B Note the position of the flue gas baffle plates to carried out once a year. -
Page 42: Wet Cleaning (Chemical Cleaning)
B If the pressure gauge shows less than 12 psi (1 bar), You can obtain suitable sealing rope from the pressure is too low. Top up the system with water. your local Bosch sales office. CAUTION: Risk of system damage due to frequent topping up. -
Page 43: Testing Relief Valve
Heating system servicing | 43 CAUTION: Risk of damage to system due to material stresses caused by temperature differentials. B Only fill the system when cold (the flow temperature at the temperature/ pressure gauge should be no more than 100 °F (37 °C)). B Add water through the feed valve. -
Page 44: Servicing And Maintenance Logs
44 | Heating system servicing Servicing and maintenance logs B Initial and date the servicing operations completed. The inspection and servicing logs can also be used as copy masters. Service work Page Date:______ Date:______ Date:______ Check general condition of heating system Visual inspection and function check of the heating system Checking fuel and water-carrying components of the... - Page 45 Heating system servicing | 45 Date:______ Date:______ Date:______ Date:______ Date:______ Date:______ Date:______ Company Company Company Company Company Company Company stamp/ stamp/ stamp/ stamp/ stamp/ stamp/ stamp/ signature signature signature signature signature signature signature Table 19 If any condition requiring maintenance work is identified in the course of servicing, that work must be carried out as necessary to ensure safe and proper operation.
- Page 46 46 | Heating system servicing On-demand maintenance procedures Page Date:______ Date:______ Date:______ Shutting down the heating system Removing and cleaning the flue baffles Cleaning the (heating surfaces) and combustion chamber and afterwards re-install the flue baffle plates in their original position Checking seals/cord gaskets on burner door and burner and replacing as necessary Commissioning the heating system...
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Page 47: Troubleshooting
Troubleshooting | 47 Troubleshooting Two type of fault are distinguished: • Burner faults and • Control and heating system faults. If there is a burner fault the fault indicator lamp on the burner comes on ( burner documentation). Such faults can generally be reset by pressing the reset button on the burner. -
Page 48: Installation Examples
48 | Installation examples Installation examples Key to abbreviations Check valve Mixing valve Expansion tank Adjustment for raising return temperature System pump Air scoop Hot water pump Zone valve Pressure bypass loop Table 22 G125 WS/NA Uni 5000F 7 747 019 141-40.1RS Fig. - Page 49 Installation examples | 49 Uni 5000F G125 WS/NA 7 747 019 141-41.1RS Fig. 67 Multiple circuits with circuit valves Baseboard Uni 5000F G125 WS/NA 3/4" 7 747 019 141-42.1RS Fig. 68 Multiple circuits of water diversion for systems with a high water volume Radiator Boiler bypass 6 720 648 162 (2011/08)
- Page 50 50 | Installation examples 180˚ 160˚ 120˚ 100˚ control 100˚ 180˚ Uni 5000F G125 WS/NA 6 720 648 160-12.1T Fig. 69 Multiple circuits with pumps and motor-actuated 3-way mixing valve Baseboard 6 720 648 162 (2011/08)
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Page 51: Parts Lists
Parts lists | 51 Parts lists The following parts are available from Bosch. If there are Legend for tables 23 and 24: several Bosch article numbers for one item number, the x = no spare part numbers for the various models are listed in the relevant (x) = component of a set, only available with set columns. - Page 52 52 | Parts lists Item no. Description Part number Uni 171 Uni 207 Uni 256 4 section 5 section 6 section Washer DIN 125-A1.5-A3K 7747022052 Hexagon nut ISO 4032-M10-8-A3K 7747028583 Tie-bar M10x445 compl. for 4 sections 05127966 − − Tie-bar M10x555 compl. for 5sections −...
- Page 53 Parts lists | 53 Item no. Description Part number Uni 171 Uni 207 Uni 256 4 section 5 section 6 section Sealing rope 14x1855, GP 63025436 Gasket compound brown (cartridge 310ml) for gluing dealing rope without 63014361 residue Burner door insulation compl. Uni 5000F 63002402 Available spare parts: Burner door panel insulation Uni 5000F...
- Page 54 54 | Parts lists 6 720 648 162-21.1T Fig. 70 Boiler block and burner door 6 720 648 162 (2011/08)
- Page 55 4 hexagon nuts DIN6923-M10-8.8-A3K with locking teeth 2 hexagon nuts DIN6923-M8-A3K with locking teeth Articles that are not supplied with the jacket: Front panel compl. for boiler with third-party burner 8718582396 Badge Bosch 8718582440 Boiler block insulation in plastic bag Boiler block insulation 05261065...
- Page 56 56 | Parts lists 6 720 648 162-16.2T Fig. 71 boiler jacket Uni 5000F 6 720 648 162 (2011/08)
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Page 57: Circuit Diagrams
Circuit diagrams | 57 Circuit diagrams 6 720 648 162-18.1T Fig. 72 Circuit diagram 1 6 720 648 162 (2011/08) - Page 58 58 | Circuit diagrams Riello F3 or F5 Series Oil Burner Wiring Thermostat, Aquastat or end switch Terminal strip on Riello Burner L814(A Honeywell Operating Aquastat Quick connect plug Service Switch Red wire - NOT USED IN THIS Fuse APPLICATION Hot Neutral Riello F3 or F5 Series Oil fired Burner Using a L8148A Aquastat -...
- Page 59 Circuit diagrams | 59 Beckett AFG Burner Wiring Beckett AFG Wiring Schematic - 6 720 648 162-17.1T Fig. 74 Circuit diagram 3 6 720 648 162 (2011/08)
- Page 60 60 | Circuit diagrams Honeywell L7248C with Riello F3 and F5 Burners for Bosch Uni-5000F series 6 720 648 162-04.1T Fig. 75 Circuit diagram 4 6 720 648 162 (2011/08)
- Page 61 Circuit diagrams | 61 Honeywell L7248C with Beckett AFG Burner for Bosch Uni-5000F series 6 720 648 162-05.1T Fig. 76 Circuit diagram 5 6 720 648 162 (2011/08)
- Page 62 62 | Circuit diagrams Honeywell L7248C with Beckett CF375 Burners for Bosch Uni-5000F series 6 720 648 162-06.1T Fig. 77 Circuit diagram 6 6 720 648 162 (2011/08)
- Page 63 Circuit diagrams | 63 AquaSmart with Riello F3 and F5 Burners for Bosch Uni-5000F series AquaSmart (7600A) 6 720 648 162-07.1T Fig. 78 Circuit diagram 7 6 720 648 162 (2011/08)
- Page 64 64 | Circuit diagrams AquaSmart with Beckett AFG Burner for Bosch Uni-5000F series AquaSmart (7600A) 6 720 648 162-08.1T Fig. 79 Circuit diagram 8 6 720 648 162 (2011/08)
- Page 65 Circuit diagrams | 65 AquaSmart with Beckett CF372 Burners for Bosch Uni-5000F series AquaSmart (7600A) 6 720 648 162-09.1T Fig. 80 Circuit diagram 9 6 720 648 162 (2011/08)
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Page 66: Index
66 | Index Index Aquastat..............34 Pack contents............... 8 Parts lists..............51 Permissible operating pressure........9 B-kit components............8 Power supply voltagePower supply......13 Boiler output..............9 Pressure testing nozzle ..........36 Boiler room ..............11 Pressure/temperature gauge........ 36, 42 Boiler type .............. - Page 67 | 67 Notes 6 720 648 162 (2011/08)
- Page 68 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-584-1681 www.bosch-climate.us U.S.A. Products manufactured by Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.