Bosch Uni 5000F US 207 Quick guide

C
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.
2
3
1
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
1
1
1
1
1 box on a
pallet
1 box1)
1 box1)
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
1
1
1
1
1
1 box on a
pallet
1 box1)
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)
74
(302 mm)
58
(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)
58
(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)
31
(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)
31
(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)
18
(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.