Bosch UNI 7000 F User guide

Installation and servicing instructions
High efficiency cast iron
UNI 7000 F
6 720 648 662-00.1T
6 720 803 940 (2010/03) AU/GB

2| Contents
UNI 7000 F6 720 803 940 (2010/03)
Contents
1 Key to symbols and safety instructions 3
1.1 Explanation of symbols 3
1.2 Safety instructions 3
2 Product information 5
2.1 Product overview 5
2.2 Correct use 5
2.3 EU Declaration of Conformity 5
2.4 Operating conditions for Uni 7000 F
cast iron boilers 6
2.4.1 Operating conditions Uni 7000 F 6
2.5 Specification 7
2.6 Accessories 9
3Regulations 10
3.1 Installation location 10
3.2 Quality of heating water 10
3.3 Disposal and recycling 10
4 Installation 10
4.1 Checking the delivery for completeness 10
4.1.1 Delivery as a pre-assembled block 10
4.1.2 Delivery in loose sections 10
4.2 Tools and accessories 11
4.3 Recommended wall clearances 11
4.3.1 Base and boiler plinth 12
4.4 Assembling the boiler block 12
4.4.1 Arrangement of boiler sections 12
4.4.2 Joining the boiler block assembly 13
4.5 Setting up the boiler block
(when supplied as a pre-assembled block) 18
4.6 Inserting the feed pipe (parts case) 18
4.7 Sealing the sensor well (fittings case) 19
4.8 Inserting the outer steam tube (fittings case) 19
4.9 Boiler block pressure test
(only when supplied in loose sections) 20
4.9.1 Preparing for pressure test 20
4.9.2 Perform pressure test 20
4.9.3 Leaking hub joint 20
4.10 Boiler water connections 21
4.11 Installing fittings and burner door
(delivery in loose sections) 22
4.11.1 Positioning the flue gas header 22
4.11.2 Fitting clean-out cover onto rear section 22
4.11.3 Installing the burner door 23
4.11.4 Inserting the hot gas baffle plates 23
4.12 Filling the heating system and checking
for leaks 25
4.13 Installing the burner 26
4.14 Boiler flue connection 27
4.14.1 Fitting the flue pipe sealing collar
(accessory) 27
4.14.2 Fitting the flue gas temperature sensor
(accessory) 27
4.15 Installing the boiler casing 27
4.15.1 Fitting the thermal insulation 27
4.15.2 Fitting the connection plates 28
4.15.3 Fitting side panels and hoods 31
4.16 Making the electrical connection 33
4.16.1 Installing the control unit 33
4.16.2 Installing the temperature sensor set 35
5 Commissioning the heating system 36
5.1 Preparing the heating system for operation 36
5.1.1 Creating operating pressure
(sealed heating systems) 37
5.1.2 Setting the capacity (open heating systems) 37
5.2 Start up the control unit 37
5.3 Starting the burner 37
5.4 Start-up report 38
6 Shutting down the heating system 39
6.1 Standard shutdown 39
6.2 In an emergency 39
7 Heating system inspection and maintenance 40
7.1 Why is regular maintenance important? 40
7.2 Preparing the boiler for cleaning 40
7.3 Cleaning the boiler 40
7.3.1 Clean the boiler with cleaning brushes 40
7.3.2 Wet cleaning (chemical cleaning) 43
7.4 Checking the operating pressure 44
7.4.1 Checking the operating pressure
(sealed systems) 45
7.4.2 Checking the fill level (open systems) 45
7.5 Inspection and maintenance reports 46
8Faults 49

Key to symbols and safety instructions | 3
6 720 803 940 (2010/03)UNI 7000 F
1 Key to symbols and safety instructions
1.1 Explanation of symbols
Warnings
Keywords indicate the seriousness of the hazard in terms
of the consequences of not following the safety
instructions.
•NOTICE indicates that material damage may occur.
•CAUTION indicates that minor to medium injury may
occur.
•WARNING indicates that serious injury may occur.
•DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety instructions
These installation and maintenance instructions contain
important information for the safe and appropriate
installation, commissioning and servicing of this
Uni 7000 F forced draft boiler.
These installation and maintenance instructions are
designed for specialists who – through their vocational
training and experience – are knowledgeable in handling
heating systems and gas installations.
Observe all standards and guidelines applicable to the
installation and operation of this system in your country.
Only use original Bosch spare parts. Losses caused by
the use of parts not supplied by Bosch are excluded
from the Bosch warranty.
Risk to life from gas explosion
There is a risk of explosion if you can smell gas!
BNo open fire. Do not smoke. Do not use lighters.
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 of the building, but do not ring
doorbells.
BDo call your gas supplier from outside the building.
BIf you hear gas escaping, immediately leave the
building, prevent others from entering and notify the
police and fire brigade from outside the building.
Customer information:
BOnly qualified personnel may carry out the
installation, the main fuel and flue gas connections,
the initial start-up, electrical connections and any
maintenance or repair work.
BOnly registered gas fitters may carry out work on gas
components.
Risk to life from poisoning
Insufficient ventilation can lead to dangerous flue gas
leaks!
BNever block ventilation and extract air apertures or
reduce their size.
BThe boiler must not be operated, unless you
immediately remedy the fault.
BInform the system user in writing of the fault and its
associated risks.
Warnings in this document are framed and
identified by a warning triangle which is
printed on a grey background.
Electrical hazards are identified by a lightning
symbol surrounded by a warning triangle.
Important information in cases where there is
no risk of injury or material losses is identified
by the symbol shown on the left. It is
bordered by horizontal lines above and below
the text.
Symbol Meaning
Ba step in an action sequence
Æa reference to a related part in the
document or to other related documents
•alistentry
– a list entry (second level)
Tab. 1

4| Key to symbols and safety instructions
UNI 7000 F6 720 803 940 (2010/03)
Risk to life from electric shock when the appliance is
open
BIsolate the heating system from the mains electricity
supply before starting work. Use either an emergency
isolation switch or the relevant circuit breaker.
A contact separation of at least 3mm must be
achieved across EACH pole.
BSafeguard the heating system against unintentional
reconnection.
Risk of fire through flammable materials or liquids
BNever store flammable materials or liquids in the
immediate vicinity of the heat source.
Risk of system damage through incorrect installation
BThe appliance must be installed in accordance with
and comply to, the current: Statutory Instrument
Laws, Gas Safety Regulations, IEE Regulations,
Building Regulations, Local Water By-Laws, Health &
Safety document 635 (The Electricity at Work
Regulations) and any other local requirements.
Observe all European and local installation standards,
building regulations and the latest edition of the
wiring regulations. Chemically aggressive substances,
can corrode the appliance and invalidate any
warranty.
System damage through unsatisfactory cleaning and
maintenance
BCarry out cleaning and maintenance procedures
annually. In the course of this work, check the entire
heating system including the neutralising system for
correct function.
BImmediately remedy all faults to prevent system
damage.
System damage through frost
The heating system may freeze in cold weather if the
control unit is switched off.
BIf there is a risk of frost, protect your heating system
against frost damage. With the control unit switched
OFF, drain the water from the boiler, DHW cylinder
and all heating system pipework.
System damage and personal injury through operating
faults
Operator errors can lead to injuries and/or material
losses.
BEnsure that children never operate this appliance
unsupervised or play with it.
BEnsure that only individuals who can operate this
appliance correctly have access to it.
Instructing the customer
BHand these installation and maintenance instructions
to the customer.
BExplain to the customer the function and operation of
the appliance.

Product information | 5
6 720 803 940 (2010/03)UNI 7000 F
2 Product information
2.1 Product overview
This boiler is a low temperature boiler that complies
with BS EN 303 for oil or gas combustion with
modulating boiler water temperature control and no
minimum return temperature.
The main components of the Uni 7000 F forced draught
are:
•The boiler block transfers the heat generated by the
burner to the heating water.
•The boiler shell and lagging prevent energy loss.
•The control unit serves to monitor and control all
electrical boiler components.
Fig. 1 Uni 7000 F fan-assisted boiler
1Control unit
2boiler block
3Thermal insulation
4Boiler shell (casing)
2.2 Correct use
The Uni 7000 F forced draught boiler is intended for
generating heating water. You may use any type-tested
oil or gas fired burners to EN 267 or EN 676 provided
their operating range meets the boiler specification.
Any other use is deemed to be inappropriate. Any
resulting damage is excluded from the manufacturer's
warranty.
2.3 EU Declaration of Conformity
This product conforms in design and operation to the
European Directives and the supplementary national
requirements. Its conformity is confirmed by the CE
designation.
You can call up the Declaration of Conformity for this
product on the internet or request a copy from your local
Bosch sales office.
1
4
2
3
4
6 720 648 663-04.1T

6| Product information
UNI 7000 F6 720 803 940 (2010/03)
2.4 Operating conditions for Uni 7000 F
cast iron boilers
2.4.1 Operating conditions Uni 7000 F
Operating conditions Uni 7000 F
Thermostream technology is a unique feature of Bosch
cast iron boilers. Return water is preheated and mixed
within the boiler before it comes in contact with the
heated surface of the combustion chamber. The
Thermostream technology ensures there is an even
temperature distribution in the boiler and avoids
condensate forming within the combustion chamber.
This reduces thermal stress, the main cause of failure of
normal cast iron boilers. The benefit of this technology
is that if the minimum boiler operating temperature of
the boiler is maintained (see table below), there is no
need for a conventional shunt pump to be installed,
saving the cost of a pump, the electricity it consumes
and the breakdown it can cause. The minimum boiler
operating temperature as shown in the table below must
be reached within 10 minutes and then be maintained
while the burner is running.
1) This temperature has to be reached within ten minutes of the burner starting and has to be maintained whilst the
burner is firing.
This operating condition can be easily achieved by the
controls monitoring the boiler temperature and reducing
the flow rate through the boiler until the required temper-
ature is reached. This is then maintained by continuing to
control flow based on the boiler temperature. The controls
can reduce the flow rate by closing the valves on the
mixed heating circuits or by modulating the boiler primary
pumps or by closing the motorised butterfly valves or 3
port mixing valves on a cascade system or by having a 3
port motorised valve in the boiler return on a single boiler
installation. The Bosch CFB series controls can manage
this process or it can be done by the BMS.
Failure to ensure that the operating condition is
maintained may lead to thermal stress in the boiler and
eventual failure of the sections which would be outside
the scope of the warranty.
Please contact your local Bosch sales office for further
advice.
Boiler controls Minimum
flow rate
through the
boiler
Minimum
return water
temperature
Minimum
boiler
operating
temperature
for oil
Minimum
boiler
operating
temperature
for gas
Other
conditions
Bosch CFB with control over all
heating circuits
none none 50 degrees1) 50 degrees1) none
Where the Bosch control is not
controlling the heating circuits ie
External control (BMS) or
Constant temperature control
with Bosch CFB810
none none 50 degrees1) 50 degrees1) none
Tab. 2

Product information | 7
6 720 803 940 (2010/03)UNI 7000 F
2.5 Specification
Fig. 2 Connections and dimensions
1365
Specification and dimensions
Boiler size kW 570 660 740 820 920 1020 1110 1200
Boiler sections Quantity 910 11 12 13 14 15 16
Rated output kW 511 –
570
571 –
660
661 –
740
741 –
820
821 –
920
921 –
1020
1021
–
1110
1111
–
1200
Combustion output kW 546.6
–
616.2
610.7
–
713.5
707.0
–
800.0
792.5
–
886.5
878.1
–
994.6
985.0
–
1102.0
1092.0
–
1200.0
1188.0
–
1297.0
Overall boiler length
(LG)
mm 1926 2096 2266 2436 2606 2776 2946 3116
Length of boiler
block (LK)
mm 1804 1974 2144 2314 2484 2654 2824 2994
Loose boiler section
transport unit
mm Width 1096/height 1640/depth 170
Boiler block
transport unit
mm Width 1096/height 1640/length LK
Combustion chamber
length (LF)
mm 1525 1695 1865 2035 2205 2375 2545 2715
Combustion
chamber diameter
mm 680
Burner door depth mm 145
Net weight1) kg 2505 2747 2990 3232 3475 3710 3953 4147
Tab. 3 Specifications and dimensions
1) Weight excluding packaging 4 – 5 % lower.

8| Product information
UNI 7000 F6 720 803 940 (2010/03)
Specification and dimensions
Water content l561 621 681 741 801 861 921 981
Gas content l922 1027 1132 1237 1342 1447 1552 1657
Flue gas
temperature1)
partial load 60 %
°C 140
Flue gas
temperature1)
full load
°C 170 – 180
Flue gas mass flow
rate, oil,
partial load 60 %
kg/s 0.1537 0.1778 0.1995 0.2207 0.2479 0.2750 0.2992 0.3234
Flue gas mass flow
rate, oil,
full load2)
kg/s 0.2320
–
0.2615
0.2592
–
0.3028
0.3001
–
0.3396
0.3364
–
0.3763
0.3727
–
0.4222
0.4181
–
0.4678
0.4635
–
0.5093
0.5043
–
0.5505
Flue gas mass flow
rate, gas, partial load
60 %
kg/s 0.1542 0.1785 0.2002 0.2215 0.2488 0.2760 0.3003 0.3246
Flue gas mass flow
rate, gas,
full load2)
kg/s 0.2328
–
0.2625
0.2602
–
0.3039
0.3012
–
0.3408
0.3376
–
0.3776
0.3741
–
0.4237
0.4196
–
0.4694
0.4652
–
0.5112
0.5061
–
0.5525
CO2content, oil %13
CO2content, gas %10
Required draught Pa 0
Pressure drop on the
hot gas side
mbar 2.4 3.4 4.2 4.2 4.1 4.5 5.4 5.8
Permissible flow
temperature3)
°C 100 – 1204)
Permissible operating
pressure
bar 6
Maximum time
constant T on
thermostat
s40
Maximum time
constant T on
monitor/limiter
s40
Tab. 4 Specifications and dimensions
1) According to BS EN 303. The minimum flue gas temperature for the chimney calculation acc. to DIN 4704 is
approx. 12 K lower.
2) The information for full load refers to the upper and lower rated heat output range.
3) Safety limit (high limit safety cut-out). Maximum possible flow temperature = safety limit (STB) – 18 K.
Example: Safety limit (STB) = 100 °C, max. possible flow temperature = 100 – 18 = 82 °C.
4) According to country-specific standards and regulations (for all countries)

Product information | 9
6 720 803 940 (2010/03)UNI 7000 F
2.6 Accessories
Please see the current sales information for details of
accessories.
Use only original parts.
Country: All countries
Fuels Oil Fuel Class D Gasoil
and Class C Kerosene
LPG Natural gas Biogas (special
conditions of use)
Consult your local
Bosch sales office for
advice
Remarks The boiler can only be operated with the specified fuels.
Carry out maintenance and cleaning procedures annually. Check that the entire system is functioning
correctly. Immediately remedy all defects found.
Tab. 5 Fuels

10 | Regulations
UNI 7000 F6 720 803 940 (2010/03)
3 Regulations
3.1 Installation location
3.2 Quality of heating water
BThe operator’s log enclosed with the specifications
MUST be observed when using and treating fill and
top-up water.
BRecord the filling water quantity and composition in
the operator’s log.
3.3 Disposal and recycling
BIf any heating system components need to be
replaced, they should be disposed of in an
environmentally responsible manner, via an approved
disposal site.
BDispose of packaging in an environmentally
responsible manner.
4 Installation
4.1 Checking the delivery for
completeness
The boiler can be delivered either as a pre-assembled
block or in loose sections.
BAfter delivery, check all packaging is in perfect
condition.
BCheck all components have been delivered.
4.1.1 Delivery as a pre-assembled block
4.1.2 Delivery in loose sections
Observe all standards and directives
applicable to the installation and operation
of this heating system in the country in
which it is used.
The information on the type plate is binding
and must be observed.
NOTICE: System damage due to frost!
BSite the heating system in a room safe
from the risk of frost. Component Pce Packaging
Boiler block 1 Pallet
Furniture 1 Case
Fixing elements 1 Case
Casing Pack A 1 Case
Casing Pack B 1 Case
Thermal insulation 1 Foil bag
Tab. 6 Scope of supply (block delivery)
Component Pce Packaging
Front, rear, central sections
with upper flow connection
and burner door
1Pallet
Central sections
(depending on boiler size)
2 – 5 Pallet
Base unit fittings,
9 – 16 sections
1Case
Supplementary fittings
(contents depend
on the size of the boiler)
1Case
Fixing elements 1 Case
Casing Pack A 1 Case
Casing Pack B 1 Case
Thermal insulation 1 Foil bag
Set of anchor rods
with spring packages
Tab. 7 Scope of supply (loose sections)

Installation | 11
6 720 803 940 (2010/03)UNI 7000 F
4.2 Tools and accessories
The following tools and auxiliary materials are required
for the boiler assembly (the listed items are not
contained in the scope of supply).
•Boiler compression tool 2.3
•Installation kit (accessory)
•Steel hammer and wooden or rubber mallet
•Half-round bastard file
•Screwdriver (Philips and flat head)
•Flat chisel, support wedge, flat iron
•Spanners, sizes 13 mm, 19 mm, 24 mm and 36 mm,
and socket size 19 mm
•Cleaning rags and cloth
•Fine emery cloth
•Wire brush
•Lubricating oil
•Solvent (petrol or solution)
•Spirit level, ruler, chalk, straight edge
Fig. 3 Boiler compression tool 2.3 (dimensions in mm)
1Pull rod
2Extension
3Wedge (size 2.3)
4Mating flange
5Additional flange
6Compression unit
4.3 Recommended wall clearances
Observe the recommended wall clearances for easier
boiler installation, cleaning and maintenance. Adhere to
the minimum clearances (in brackets) in all cases.
Take into account the space required for opening the
burner door.
The burner door can be hung on the right or left.
The wall clearance on the hinge side must be at least the
same as the amount by which the burner projects (AB).
Recommended wall clearance AB + 100 mm.
If you do not observe the recommended minimum wall
clearances, you will not be able to use the cleaning set
(accessory) to clean the boiler. As an alternative, we
recommend using shorter (approx. 1 m in length)
mountable cleaning devices or wet cleaning.
Fig. 4 Boiler room with boiler (dimensions in mm)
Sections Compression
tool(s) per
boiler hub
Extension(s)
per
boiler hub
Length
(total)
mm
9–16 1 33080
Tab. 8 Boiler compression tool size 2.3 (complete in the
toolbox)
6 720 648 663-06.1T
21
456
3
Boiler size Clearance A (mm)
kW Sections recommended minimum
570 –
820
9–12 2300 1400
920 –
1200
13 – 16 3000 1500
Tab. 9 Recommended and minimum wall clearances

12 | Installation
UNI 7000 F6 720 803 940 (2010/03)
4.3.1 Base and boiler plinth
Place the boiler on a 50 – 100 mm high base (observe
wall clearances). The base must be flat and level. The
front edge of the boiler should be flush with the edge of
the base.
If you are not using a boiler plinth (accessory), angled
steel sections (100 x 50 x 8 mm) or flat steel sections
(100 x 5 mm) must be put in place when installing the
base.
Fig. 5 Foundation dimensions
4.4 Assembling the boiler block
A distinction is made between delivery as a pre-
assembled block and delivery in loose sections. When
delivered as a block, the boiler sections are already fully
assembled and checked for leaks prior to despatch. If,
because of physical limitations, a boiler block cannot be
installed or brought inside the building, delivery in loose
sections would facilitate assembly on site.
The following describes the assembly of the boiler block
when delivered in loose sections.
For the further installation of a pre-assembled boiler
block, Æsee Chapter 4.5, page 18.
4.4.1 Arrangement of boiler sections
Fig. 6 Assembled boiler block
1Central section with flow connection
2Flue gas collector
3Anchor rod
4Installation direction arrow
5Front section
6Burner door with burner plate
7Base/sound-absorbing boiler plinth
8Centre section
9Rear section
A sound-absorbing plinth is available as an
accessory. The boiler plinth prevents the
transmission of vibrations to the base.
Number of
sections
L1 (base) L2 (steel
section)
916701470
10 1840 1640
11 2010 1810
12 2180 1980
13 2350 2150
14 2520 2320
15 2690 2490
16 2860 2660
Tab. 10 Base dimensions for angled/flat steel sections
CAUTION: Risk of injury due to inadequately
secured boiler sections.
BUse only a suitable means of
transportation when handling the boiler
sections, e.g. a sack truck with strap or a
stair or step trolley.
BPrevent the boiler sections from sliding
off when transporting them.
BPrevent the boiler sections from falling
over using the installation aid
(accessory) First screw the rear section
firmly onto the installation aid (ÆFig. 7).
3
3
6
5
4
7
1 2
6 720 648 663-07.1T
8
9

Installation | 13
6 720 803 940 (2010/03)UNI 7000 F
The boiler block is always installed from the back
forwards, i.e. the rear section (ÆFig. 6, [3]) is always
installed first, and the front section (ÆFig. 6, [8])
always installed last.
When assembling, observe the installation direction
arrows (ÆFig. 6, [7]) for each boiler section.
Make sure you position the middle section with the
upper flow connection (ÆFig. 6, [4]) correctly.
Install the boiler block according to the following
instructions and illustrations.
Fig. 7 Rear section with fitted installation set
4.4.2 Joining the boiler block assembly
Preparation of boiler sections
BRemove nuts and washers from the studs on the hubs
of the boiler sections before attaching the rear
section and front section.
BPut the rear section in place and prevent from falling
over using the installation aid (Æsee Fig. 7 and
separate installation aid instructions).
BFile down any burrs on the hubs.
Fig. 8 Deburring the hub
BClean the packing grooves where required using a
wire brush and cloth.
BClean the hub sealing faces with a rag soaked in white
spirit.
BEvenly coat the hub sealing faces with sealant.
The installation aid is available on request.
WARNING: Danger of burning from
flammable cleaning agents.
BObserve the cleaning agent safety
instructions.
BWhen using cleaning agents, avoid naked
flames, incandescence and sparks.
The next step involves preparing the nipples
that will eventually seal the boiler sections.

14 | Installation
UNI 7000 F6 720 803 940 (2010/03)
Fig. 9 Coating the hub sealing faces
1Packing groove
2Upper hub sealing face
3Lower hub sealing face
BClean nipple with a rag soaked in white spirit and coat
evenly with sealant.
BInsert nipple directly into the upper (size 4, 181/70)
and lower (size 2, 119/50) hub on the rear section.
BHammer nipple home with alternate heavy blows.
BRemove any burrs with a file.
Fig. 10 Driving nipples home
BCoat the packing grooves with adhesive (adhesive
base)
Fig. 11 Coat the packing grooves with adhesive
1Packing grooves
The upper nipple must protrude
approx. 43 mm and the lower nipple
approx. 32 mm out of the corresponding
hubs.
The packing grooves must be clean and dry
to enable the packing cord to adhere
properly.
6 720 648 663-08.1T
2
1
3
CAUTION: Risk to health from vapours
released and also skin contact during the
processing of materials, such as adhesives,
adhesive bases or sealants.
BObserve processing and safety
instructions on the material packaging.
BEnsure good ventilation in the installation
area.
BWear work gloves to avoid contact with
skin.
BThe product and its container must be
treated as hazardous waste for disposal
purposes.
6 720 648 663-09.1T
1

Installation | 15
6 720 803 940 (2010/03)UNI 7000 F
BInsert the flexible packing cord on the front of the rear
section, starting around the upper hub, into the
packing grooves, and press in lightly.
BAt the butt joints, overlap the packing cord by approx.
2 cm and press firmly together.
BDo not allow the packing cord to overlap on the left-
or right-hand joints (ÆFig. 12, [3]).
Fig. 12 Inserting packing cord (KM cord)
1Packing grooves
2Packing cord
3Joints
Prepare the first central section (with the upper flow
connection):
BFile down any burrs on the hub.
BThe packing springs must be clean and dry. Clean if
necessary.
BClean the hub sealing faces with a rag soaked in white
spirit.
Fig. 13 Preparing the centre section
1Hub sealing face
2Sealing springs
BEvenly coat the hub sealing faces with sealant.
BCoat the packing springs with adhesive (adhesive
base)
BPosition the central section with the flow connection
so that the upper and lower hubs fit onto the nipples
in the rear section. The installation direction arrow
must point towards the back.
BDrive first central section onto the rear section using
a wooden or a rubber mallet.
Unroll the required length of packing cord (KM
cord) from the roll supplied. Peel the backing
paper from the packing cord when inserting
into the packing groove (do not stretch).
CAUTION: Risk to health from vapours
released during the processing of materials,
such as adhesives, adhesive bases or
sealants.
BObserve processing and safety
instructions on the material packaging.
BEnsure good ventilation in the installation
area.
BWear work gloves to avoid contact with
skin.
BThe product and its container must be
treated as hazardous waste for disposal
purposes.
1
2
3
6 720 648 663-10.1T To make installation easier, place the boiler
section to be fitted onto the nipple on the
upper hub first. The boiler section can then
be adjusted accordingly on the lower hub.
Before the nipples are inserted in the next
central section, the part-assembled boiler
block must be pulled together using the
boiler compression tool.
6 720 648 663-11.1T
12

16 | Installation
UNI 7000 F6 720 803 940 (2010/03)
Fig. 14 Knocking the centre section into place
1Wooden or rubber mallet
2Flow connection
3Upper hub
4Installation direction arrow
5Lower hub
BPush flange bearings with clamping nuts onto the pull
rods.
BPush a pull rod through the upper and lower hubs on
the boiler block.
BPush mating flanges onto the pull rods and secure
each with wedge.
BHold the pull rod in the middle of the hubs and slightly
draw together the compression tools using the
clamping nut.
Fig. 15 Using the boiler compression tool
1Boiler compression tool (top hub)
2Flange bearings (top)
3Flange bearings (bottom)
4Boiler compression tool (bottom hub)
BPlace ratchet wrench onto clamping nut and
compress boiler sections by tightening evenly.
BRelease and remove the boiler compression tool.
BCheck nipples are seated correctly.
Use a size 2.3 boiler compression tool
(‡ Fig. 3, page 11).
NOTICE: The boiler can be damaged by
pulling the boiler sections together
incorrectly, or due to excessive
compression.
BEnsure that the nipples are positioned
straight in the boiler sections after being
hammered in and that they have not been
damaged.
BNever compress more than one nipple
joint at a time.
BStop compressing when the boiler hubs
meet.
1
2
3
4
56 720 648 663-12.1T
WARNING: Danger of accident from
material fatigue. Improperly used or poorly
maintained compression tools may break.
BNever work directly in front of the
compression tool while it is being
tensioned.
BEnsure that no one is standing in front of
the compression tool.
NOTICE: Compression tool damage
The compression tool may be damaged or
destroyed if you compress pull rods with
loose threaded connections.
BAlways check the pull rods before each
use and tighten as necessary. The pull
rod is correctly positioned if it is fully
inserted and no thread is showing.
BAlways keep the thread clean. Dirty
threads may damage the compression
tool during compression.
BAlways lubricate the thread sufficiently.
6 720 648 663-13.1T
1
4
2
3

Installation | 17
6 720 803 940 (2010/03)UNI 7000 F
Fig. 16 Boiler compression tool 2.3
1Threaded connection on the pull rods (loosened)
2Threaded connection on the pull rods (correct position)
Fig. 17 shows the central section with flow connection.
The nipples for fitting the next central section are
inserted into the corresponding hubs. The packing cord
has already been inserted into the packing groove. As
with the rear section (ÆFig. 12, page 15), there is also
a break in the elastic packing cord here. The boiler
section has been equipped with foot wedges for ease of
installation. The boiler section foot wedges are also used
later for final levelling of the boiler block.
Fig. 17 Using the boiler section foot wedges
1Packing cord (with break)
2Boiler section foot wedge
Assemble all other boiler sections as described. The
front section is fitted last.
BInsert the anchor rods (with spring packs fitted) into
the cast lugs on the top left and right and bottom left
and right, next to the boiler block hubs.
BPut a nut onto each of the threaded anchor rods and
tighten by hand.
BNow tighten the nuts on the anchor rods 1 to
1½ turns.
BLevel the boiler block vertically and horizontally on
the base/silencing plinth (Æsee Chapter 4.3.1,
page 12). Use the boiler section foot wedges
provided for this purpose (ÆFig. 17, page 17).
BRemove boiler compression tool.
Fig. 18 Inserting the anchor rods
1Anchor rods (top)
2Anchor rod with spring pack
3Anchor rods (bottom)
The next step describes the installation of the feed pipe
(Æsee Chapter 4.6, page 18).
6 720 642 623-18.1o
1
2
1
2
6 720 648 663-14.1T
After the front section is attached, loosen
the compression tool but do not remove it.
Insert the anchor rods first.
NOTICE: Damage to system through
excessively low contact pressure.
BDo not compress the spring pack. Only
use the spring pack in its original state.
1
2
36 720 648 663-15.1T

18 | Installation
UNI 7000 F6 720 803 940 (2010/03)
4.5 Setting up the boiler block (when
supplied as a pre-assembled block)
BCut through the straps.
BRemove pallet.
Fig. 19 Boiler block on pallet
1Pallet
2Securing straps
Level the boiler block vertically and horizontally on the
base/silencing plinth. Use the boiler section foot wedges
provided for this purpose.
Once the boiler block is levelled, remove the transport
stay from the upper and lower hubs.
Fig. 20 Removing transport stay
1Upper hub
2Lower hub
3Transport stay
4.6 Inserting the feed pipe (parts case)
On boilers with 9 – 11 sections the feed pipe is in 2
parts; on boilers with 12 – 16 sections, it comes in 3
parts.
BPush the flat gasket over the feed pipe.
BPush the feed pipe from the front into the upper
boiler hub.
BClose off with dummy flange.
BPlace the lug on the feed pipe connection endplate
into the recess on the upper boiler hub.
DANGER: Risk to life due to falling loads!
BObserve the transport information on the
data sheet (attached to boiler block)
when lifting the boiler block off the
pallet.
The following pages describe the
installation of the feed pipe, sensor well and
outer steam tube. The installation steps are
the same, regardless of whether delivery is
as a pre-assembled block or in loose
sections.
6 720 648 663-16.1T
12
To ensure the discharge openings of the
feed pipe are at the correct angle, the lug on
the feed pipe connection endplate must be
placed in the recess on the upper boiler
hub.
6 720 648 663-17.1T
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3
2

Installation | 19
6 720 803 940 (2010/03)UNI 7000 F
Fig. 21 Sealing in the feed pipe
1Cam
2Gasket
3Feed pipe
4Recess in upper boiler hub
5Dummy flange
4.7 Sealing the sensor well (fittings case)
Sensor well R ¾ "
BSeal sensor well R ¾ " from the front (length 110 mm)
into the upper R ¾ " tapped hole in the flow
connection.
Sensor well R ½ "
BSeal sensor well R ½ " from the front (length 110 mm)
into the lower R ½ " tapped hole in the flow
connection.
Fig. 22 Sealing the sensor wells
1Sensor well R ¾ "
2Sensor well R ½ "
4.8 Inserting the outer steam tube
(fittings case)
BFit the flange (length of edge: 130 mm) with R ¾ "
tapped hole for the drain connection onto the rear
lower boiler hub.
BFit customer-supplied boiler fill and drain valve.
Fig. 23 Fitting the flange
1Fill and drain connection
2Lower boiler hub (rear)
6 720 648 663-18.1T
1
3
2 4
5
4
1
6 720 648 663-19.1T
1
2
The customer-supplied boiler fill and drain
valve is only used as a drain valve in this
instance.
6 720 648 663-20.1T
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2

20 | Installation
UNI 7000 F6 720 803 940 (2010/03)
BPush outer steam tube element with spring (L3) first
into the lower boiler hub.
BHook the other outer steam tube elements (L2) onto
each other as shown in the detail drawing.
BHook on the outer steam tube element with the
handle (L1) last.
BClose off lower boiler hub with flat gasket and dummy
flange.
Fig. 24 Inserting the outer steam tube
1Outer steam tube element L2
2Dummy flange
3Gasket
4Outer steam tube element L1
5Outer steam tube element L3
4.9 Boiler block pressure test (only
when supplied in loose sections)
A boiler block pressure test must be carried out (only
when supplied in loose sections). If supplied as a pre-
assembled block, the pressure test has already been
carried out in the factory.
For the further installation of a pre-assembled boiler
block, (Æsee Chapter 4.11.4, page 23).
4.9.1 Preparing for pressure test
BClose off flow and return connections (flow
connection flange with air vent valve).
BSlowly fill the boiler block with water via the fill and
drain connection. Vent the boiler block via the boiler
flow connection with air vent.
4.9.2 Perform pressure test
Carry out a pressure test with a test pressure of 8.6 bar
(in accordance with the requirements of the European
Pressure Vessel Directive).
Use a pressure gauge class 1.0 to measure the pressure.
BDrain water via fill and drain valve (ÆFig. 23, [1],
page 19) upstream of the connection to the water
system, or if a hub joint is leaking.
4.9.3 Leaking hub joint
If you establish during the pressure test that hub joints
are leaking, follow the procedure described below.
The length and number of outer steam tube
elements depend on the boiler rating, and
can be worked out using the ÆTab. 11
below.
Elements 910 11 12 13 14 15 16
L1480 mm 1–– 1 – 1 – –
650 mm – 1 1–1–11
L2510 mm 11 – 2 2–– 3
680 mm – – 1–– 2 2–
L3450 mm 1
Tab. 11 Length and number of outer steam tube elements
1
2
3
4
5
6 720 648 663-21.1T
WARNING: Risk of accident as a result of
ignoring the safety regulations.
BObserve the relevant country-specific
standards, work safety legislation and
regulations for carrying out pressure
tests.
NOTICE: Risk of system damage from
excessive pressure.
BThe boiler block must not be connected
to the pipework of the heating system.