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Potterton NXR5i, Installation And Service Manual

The Potterton NXR5i is an exceptional heating system designed to meet your installation and service needs. With its compact design and powerful features, it is perfect for both residential and commercial settings. To ensure smooth operation, don't forget to download the Installation and Service Manual for free from our website.

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PROVISOIRE

3

17/04/2012 - 300029103-001-01

NXR5i

Contents

1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Symbols and abbreviations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2.1

Manufacturer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2.2

Installer's liability  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2.3

User's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.3 Homologations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.3.1

Certifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.3.2

Directive 97/23/EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2

Safety instructions and recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1 Safety instructions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.1

Fire hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.2

Risk of intoxication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.3

Risk of being burnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1.4

Risk of damage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.1 General description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.2 Composition of the range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.2.1

KSF-CE control panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.2.2

KSF-ISR control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.1 Regulations governing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.1.1

In general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.1.2

In particular for France . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.2 Package list  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.3.1

Main dimensions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.3.2

Data plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.3.3

Boiler location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.3.4

Ventilation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.4 Hydraulic connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.4.1

Dimensional information required  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.4.2

Hydraulic connection of the water circuit for domestic use  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

4.4.3

Hydraulic connection of the heating circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.5 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.6 Sludge removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.7 Chimney connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.7.1

Flue size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.7.2

Connection to the flue gas pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.8 Fuel-oil or gas connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.9 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

6

Switching off the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

6.1 Precautions required in the case of long boiler stops (one or more years)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.2 Precautions required if the heating is stopped when there is a risk of freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7

Checking and maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

7.1 System maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Summary of Contents for NXR5i

Page 1: ...Working towards a cleaner future NXR5i Installation and service manual To be kept by the user August 2013 heating specialists Fuel Oil Gas boilers 810 to 1460kW ...

Page 2: ...formity CE The appliance complies with the standard model described in declaration of compliance 1 It is manufactured and distributed pursuant to the requirements of european directives The original of the declaration of compliance is available from the manufacturer ...

Page 3: ...ions governing installation 10 4 1 1 In general 10 4 1 2 In particular for France 10 4 2 Package list 11 4 3 Mounting 11 4 3 1 Main dimensions 11 4 3 2 Data plate 12 4 3 3 Boiler location 13 4 3 4 Ventilation 14 4 4 Hydraulic connections 15 4 4 1 Dimensional information required 15 4 4 2 Hydraulic connection of the water circuit for domestic use 15 4 4 3 Hydraulic connection of the heating circuit...

Page 4: ...0029103 001 01 PROVISOIRE 7 1 1 Water level 20 7 1 2 Draining 20 7 2 Maintenance 20 7 2 1 Sweeping 20 7 2 2 Chemical sweeping 23 7 2 3 Maintenance of the burner 24 7 3 Cleaning the casing material 24 8 Spare parts NXR5i 25 ...

Page 5: ...lty or insufficient maintenance of the appliance Failure to abide by the instructions on installing the appliance 1 2 2 Installer s liability The installer is responsible for the installation and inital start up of the appliance The installer must respect the following instructions Read and follow the instructions given in the manuals provided with the appliance Carry out installation in complianc...

Page 6: ... with a maximum operating pressure of 10 bar pertain to article 3 3 of the directive and therefore cannot be CE marked to certify compliance with the directive 97 23 EC The boilers and hot water tanks are designed and manufactured in accordance with the sound engineering practice as requested in article 3 3 of the directive 97 23 EC it is certified by compliance with the directives 90 396 EC 92 42...

Page 7: ...6 Inform the gas supplier 2 1 2 Risk of intoxication Do not obstruct the air inlets in the room even partially If you smell flue gases 1 Switch the appliance off 2 Open the windows 3 Evacuate the premises 4 Contact a qualified professional 2 1 3 Risk of being burnt Depending on the settings of the appliance The temperature of the flue gas conduits may exceed 60 C The temperature of the radiators m...

Page 8: ...neral description The boilers of the NXR5i range are pressurised hot water boilers designed for connecting to a flue pipe which require a separate automatic fuel oil or gas burner 3 2 Composition of the range 3 2 1 KSF CE control panel 3 2 2 KSF ISR control panel L000067 L000054 ...

Page 9: ...K mbar 67 2 77 6 26 2 30 2 35 8 41 4 48 0 53 6 59 2 64 8 71 6 78 4 T 15K 30 34 7 11 7 13 5 14 0 18 5 21 5 24 26 5 29 32 35 T 20K 16 8 19 4 6 5 7 6 9 0 10 4 12 0 13 4 14 8 16 2 17 9 19 6 Pressure in the furnace for nozzle pressure 0 4 mbar 2 3 2 4 2 5 2 6 2 7 2 85 3 3 1 3 2 3 3 3 4 3 5 Flue gas temperature Ambient temperature 1 3 K 190 190 190 190 190 190 190 190 190 190 190 190 Mass flue gas flow ...

Page 10: ...ydrocarbon installations situated inside residential buildings and their annexes NF P 45 204 standards Gas installation formerly DTU 61 1 gas installations April 1982 addendum no 1 July 1984 Local Sanitary Regulations For appliances connected to the electricity network NF C 15 100 standards Low voltage electrical installation Rules Establishments open to the public Statutory terms and conditions o...

Page 11: ...sions 150 1805 540 291 150 240 1566 C003927 C 6 1 Burner centre line 2 The lateral control panel can be mounted to the right or left of the boiler Exact height positioning defined by the fitter during assembly 3 max Heating flow Ø E weld Heating return Ø E weld Draining Mk3 4 Flow switch Minimum height for sweeping 850 2 tapped sludge removal hole ...

Page 12: ...44 1744 1966 1966 2188 2188 2450 2450 2672 2672 2894 2894 C mm 1488 1488 1488 1488 1504 1504 1504 1504 1504 1504 1504 1504 D mm 217 188 189 210 236 257 208 209 230 231 252 253 Ø E weld mm 139 7 139 7 139 7 139 7 159 159 159 159 159 159 159 159 Ø F mm 400 400 400 400 400 400 400 G mm 150 150 370 370 370 650 650 650 980 980 980 H mm 2 31 30 9 8 13 36 35 14 13 8 9 K mm 10 19 18 3 4 25 24 23 2 1 20 21...

Page 13: ...replacing the water distributing tube etc use a flanged connection from the boiler to the system making sure you comply with minimum clearance dimension D Angled connection not supplied Air inlet Air outlet If A 1 2 m door opening side A 0 5 m If A 0 5 m A 1 2 m door opening side adapt the dimensions on the basis of the dimensions of the burner when the door is open B 1 5 m adapt the dimensions on...

Page 14: ...stock such products close to the boilers If the boiler and or peripheral equipment are corroded by such chloride or fluoride compounds the contractual guarantee cannot be applied France The minimum cross sections and the emplacement of the fresh air inlet and the air discharge are governed by the order of 21 03 1968 amended by the orders of 26 02 1974 and 03 03 1976 Generator installed in a buildi...

Page 15: ...ions 139 7 5 18 to 25 sections 159 6 weld Heating flow 14 to 17 sections 139 7 5 18 to 25 sections 159 6 weld dimension without connection see figure on chapter Boiler location straight or angled connection Boiler NXR5i 14 NXR5i 15 NXR5i 16 NXR5i 17 NXR5i 18 NXR5i 19 NXR5i 20 NXR5i 21 NXR5i 22 NXR5i 23 NXR5i 24 NXR5i 25 C mm 1488 1488 1488 1488 1504 1504 1504 1504 1504 1504 1504 1504 D mm 217 188 ...

Page 16: ... The water temperature in the boiler is maintained at 50 C or more The first stage must be set to a minimum of 30 of the nominal stage Operation at modulated low temperature minimum outlet temperature 40 C The first stage must be set to a minimum of 50 of the nominal stage ZRefer to the installation and service manual for the KSF CE control panel Operation with modulating burner The water temperat...

Page 17: ...lves with the capability to bleed the system by themselves when it is operating the manual bleeder valves are used to bleed all the high points of the system and to make sure that the filled system is free of air before the burner is turned on Do not add cold water suddenly into the boiler when it is hot 4 6 Sludge removal A tapped Ø 2 hole with a plug has been provided on the bottom of the front ...

Page 18: ...ecial sealing precautions have been taken for instance in order to connect a static condenser regenerator 4 7 2 Connection to the flue gas pipe The connection shall be removable and offer minimum load losses i e it must be as short as possible with no sudden change in section Its diameter shall always be at least equal to that of the boiler outlet i e Ø 400 mm Boilers with 21 to 25 sections are su...

Page 19: ...structions Cut the gas supply to the boiler if present 6 1 Precautions required in the case of long boiler stops one or more years The boiler and the chimney must be swept carefully Close all the doors of the boiler to prevent air from circulating inside the boiler We advise removing the pipe which connects the boiler to the chimney and to close off the nozzle with a cover 6 2 Precautions required...

Page 20: ...essary For example Several months absence with the risk of ice in the building 7 2 Maintenance The operations described below shall only be performed with the boiler and power supply off The boiler will only operate efficiently if the exchange surfaces are kept clean The boiler should be cleaned as soon as required and as the chimney at least once a year or more depending upon applicable regulatio...

Page 21: ...lating material Step 5 Unfasten the nuts up to the stop Push in the handles of the sweeping covers Remove the sweeping covers Step 6 Brush the vertical plates Put back the sweeping covers insulating material and casing covers by reversing the procedure above chemical sweeping is recommended for such boilers See chapter Chemical sweeping Put the baffle plates back in place Interlock them with each ...

Page 22: ...val procedure See chapter Chemical sweeping Step 9 Remove the lower rear panels Remove the lower rear crosspiece Remove the lower insulating material on the rear Step 10 Unfasten the wing nuts and remove the lower left and right hand sweeping doors Remove any soot deposit with a scraper or a vacuum cleaner Open the lower sweeping cover of the flue gas box 2 H 10 nuts Ø 10 washers Remove the soot P...

Page 23: ... 5 l spray with separate reservoir nozzle and connecting tube The nozzles enable easy application at the back of the combustion chamber Manual pressurisation of the reservoir Motor assisted pressurisation spray with reservoir nozzle and connecting tube These sprays are intended for intensive use Operational mode The operating mode mentioned corresponds to standard user situations Refer to the manu...

Page 24: ...n products brief application after cleaning has a preventive effect limiting deposits on the heating surfaces Replace the baffle plates Close the door of the combustion chamber Service the burner Replace the front panel 7 2 3 Maintenance of the burner ZRefer to the instructions supplied with the burner 7 3 Cleaning the casing material Use a soapy solution and a sponge only Rinse with clean water a...

Page 25: ...terpart Brooks House Coventry Road WARWICK CV34 4LL 08706 000454 08706 000545 8 Spare parts NXR5i To order a spare part quote the reference number next to the part required 300029104 002 01 Boiler body Miscellaneous ...

Page 26: ...26 NXR5i 17 04 2012 300029103 001 01 PROVISOIRE Insulation 71 70 M000050 ...

Page 27: ...PROVISOIRE 27 17 04 2012 300029103 001 01 NXR5i Casing C001003 B ...

Page 28: ...28 NXR5i 17 04 2012 300029103 001 01 PROVISOIRE Control panels ZRefer to the Spare Parts list in the panel instructions KSF ISR control panel KSF CE control panel L000054 L000067 ...

Page 29: ...8 mm 24 sections 18 8015 8925 Assembly rod Ø 14 2960 mm 25 sections 19 8006 8906 Plain square flange Gasket 20 8006 8907 Square flange with tapped hole Gasket 21 9501 4155 Gasket 222 x 170 x 4 22 8112 0028 Plug 2 23 8008 8904 Flange with outlet piece Gasket 14 to 17 sections 23 8008 8905 Flange with outlet piece Gasket 18 to 25 sections 24 8008 8922 Nozzle Gasket 25 8802 4731 Flow controller 25 88...

Page 30: ...al for body 23 and 24 sections 70 8555 5527 Complete insulating material for body 25 sections Insulating material for sweeping covers 71 8555 5533 Complete insulating material for sweeping covers 14 sections Ref Code no Description 71 8555 5534 Complete insulating material for sweeping covers 15 sections 71 8555 5535 Complete insulating material for sweeping covers 16 and 17 sections 71 8555 5536 ...

Page 31: ...ace door 96 8555 8519 Control panel trim 97 8555 8520 Rear cover for standard control panel 98 8555 8521 Control panel bracket 99 8259 8055 Lower rear crosspiece 100 8555 8522 Upper crosspiece 101 8555 8526 Intermediate upper crosspiece 102 8555 8082 Joining central plate 103 8555 8523 Lower tab of rail 104 8555 8022 Upper bracket 105 8555 0526 Upper front crosspiece 106 9532 0780 Clamp 107 9775 8...

Page 32: ...nstalled by a qualified engineer In particular the manufacturer shall not be held responsible for any damage loss or injury caused by installations which do not comply with the following applicable local laws and regulations specific requirements relating to the installation such as national and or local regulations the manufacturer s instructions in particular those relating to the regular mainte...

Page 33: ...PROVISOIRE 33 17 04 2012 300029103 001 01 NXR5i ...

Page 34: ...34 NXR5i 17 04 2012 300029103 001 01 PROVISOIRE ...

Page 35: ...PROVISOIRE 35 17 04 2012 300029103 001 01 NXR5i ...

Page 36: ...AUG2013 Baxi Commercial Wood Lane Erdington Birmingham B24 9QP Email potterton commercial baxicommercialdivision com www pottertoncommercial co uk heating specialists Sales 0845 070 1056 Technical 0845 070 1057 RS 33961 ...

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