Manual Bosch Uni 3000 F (page 16 of 40) (English)

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Uni 3000 F6 720 812 900 (2014/10)

4.4 Flue gas and water connections for heating system

4.4.1 General requirements of the flue system

The following recommendations pertaining to the implementation of flue

systems should guarantee trouble-free operation of a combustion system.

Failure to observe these rules can result in substantial operating problems

during combustion and may even result in explosions. Possible problems

frequently include acoustic disturbances, compromised combustion

stability or excessive vibrations on assemblies or their components. Low

NOx combustion systems are to be viewed as being more sensitive to

operating faults on account of their combustion control. Therefore,

engineer and implement the flue system with particular care.

Commonly, the flue system comprises a connection piece between the

heat source and the vertical flue system itself (chimney).

When sizing and implementing the flue system, comply with the

following requirements:

• Size flue systems in accordance with the respective national and

local regulations and applicable standards. For instance, free-

standing chimneys, fluid mechanical calculation (for examples of

pertinent standards, see  Chapter 2.1, page 4). The

implementation of the flue system must comply with local Building

Regulations. Observe country-specific regulations.

• When selecting the material for a flue system, take the composition

and temperatures of the flue gases into account to prevent damage

and contamination of the flue parts that are in contact with flue gas.

•

Route flue gases as directly as possible to the chimney considering the

best possible flow characteristics (e.g. short and with a gradient and

the fewest possible deviations). Provide a separate chimney flue for

each boiler. Take the thermal expansion of the system into account.

• Implement deviations in the connection pieces, such as bends or

deflectors, so as to minimise flow resistance. Connection pieces with

several deviations should be avoided, as they would have a

detrimental effect on air-borne and structure-borne noise as well as

the start-up pressure hammer. Prevent sharp-edged joints between

rectangular connection flanges and the connection pipe. The joint

angle should not exceed 30°, the same as for any reducers/

expansions that may be required.

• Where possible, connection pieces should be joined to the chimney

to provide optimum flow characteristics and with an incline (at an

angle less than 45°). Any terminal pieces at the chimney outlet must

ensure the free discharge of flue gas into the open air.

•

Any condensate must be able to drain freely over the entire length of its

discharge pipework and drained off in accordance with local regulations.

• Inspection apertures should be provided in compliance with local

regulations, possibly after discussion with the responsible Local

Authority inspector.

• The chimney must be separated from the boiler system (e.g. with

compensators) to interrupt transfer of structure-borne noise.

•

Where a flue gas damper is set into a flue system, an “OPEN” safety

limit switch must be integrated into the boiler control. Combustion

must only be able to start when the feedback from the limit switch

confirms that the flue damper is fully open. A temperature drop inside

the boiler is possible on account of the time it takes the actuator to

move the damper into position. Implement the end position CLOSED

at the flue damper so that the flue damper never closes fully. This

prevents damage to the fitted burner through heat build up.

4.4.2 Fitting a sealing collar (accessory)

▶ Fit the sealing collar in accordance with the installation instructions

supplied.

4.4.3 Connecting the boiler to the pipework

Observe the following information for connecting the boiler to the

pipework. This is important to ensure trouble-free operation.

Connecting the heating return

▶ Connect the heating system return to the boiler return connection

( Fig. 14 and Fig. 15 [3]).

Fig. 14 Uni 3000 F 420 kW to 1200 kW boiler (left = rear of boiler)

[1] Boiler flow connection (VK)

[2] Safety flow line (VSL - connection for an on-site safety valve)

[3] Boiler return connection (RK)

[4] Test point (sensor well 3/4") for 190 kW to 1200 kW

DANGER: Risk to life through poisoning!

Insufficient ventilation can lead to dangerous flue gas

leaks!

▶ Never operate the boiler unless faults are rectified

immediately.

▶ Inform the operator in writing of any faults and their

associated risks.

Boiler contamination on the water side is not permitted.

To prevent contamination on the water side, we

recommend the installation of an air/dirt separator in the

return.

NOTICE: Risk of system damage from leaking

connections.

▶ Install all lines free from stress to the boiler

connections.

NOTICE: Risk of system damage from too low a return

temperature.

▶ Observe the operating conditions ( Tab. 4,

page 5). Back-end Protection must be designed into

the hydraulic arrangement.

6 720 806 032-05.1ITL

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