Potterton NXR5i, Assembly Instructions Manual

Page 1: ...NXR5i Fuel oil gas boilers Assembly Instructions C003966 A 300029104 001 02 EN ...

Page 2: ...2 NXR5i 25 09 2012 300029104 001 02 Contents 1 Package list 3 2 Mounting NXR5i 6 3 Data plate 56 ...

Page 3: ... 1 Boiler NXR5i Number of sections packag e 14 15 16 17 18 19 20 21 22 23 24 25 Base frame dimensions depend upon model 1 1 1 1 1 1 1 1 1 1 1 1 Rear section 1 1 1 1 1 1 1 1 1 1 1 1 Normal intermediate section 9 10 11 12 13 14 14 15 16 17 18 19 Special intermediate section 3 3 3 3 3 3 4 4 4 4 4 4 Front section 1 1 1 1 1 1 1 1 1 1 1 1 Set of assembly rods Cleaning tools contents depend upon model 1 ...

Page 4: ...3 24 25 Casing fittings MR338 1 1 1 1 MR339 1 1 1 1 1 1 1 1 MR3 1 MR4 1 1 1 1 1 1 MR5 1 1 1 1 1 FA10 2 2 1 2 2 1 1 FA11 2 2 2 1 1 2 3 3 2 2 3 3 Boiler NXR5i Number of sections package 14 15 16 17 18 19 20 21 22 23 24 25 Variable casing parts FA16 1 1 1 1 1 1 1 1 FA17 1 FA18 1 FA19 1 FA20 1 FA21 1 FA22 1 FA23 1 FA24 1 1 FA25 1 FA26 1 FA27 1 Boiler NXR5i Number of sections package 14 15 16 17 18 19 ...

Page 5: ...or the other optional features control units etc which may be used with these boilers Boiler NXR5i Number of sections 14 15 16 17 18 19 20 21 22 23 24 25 Furnace plate with hole Ø 165 186 210 240 or Ø 295 1 1 1 1 1 1 1 1 1 1 1 1 Connecting plate with opening or plain connecting plate Ø 300 or Plain connection plate 1 1 1 1 1 1 1 1 1 1 1 1 Set of anti vibration studs 8208 7758 1 1 1 8208 7759 1 1 1...

Page 6: ... JD TE or JD TE Plus assembly tool 1 Flat screwdriver 1 n 2 posidrive screwdriver 1 10 13 16 17 spanners 18 19 1 22 tubular box spanner 1 27 tubular box spanner 1 electric screwdriver 1 n 2 Philipps screwdriver bit 1 Stanley knife Silicone filler Supplied Boilers supplied with an assembled body By special arrangement only Hydraulic test See fig 17 Mounting start assembly from figure 34 ...

Page 7: ...n The number of sections of each type is provided in the table below Rear section Normal intermediate section Special intermediate section Front section Section type NXR5i 14 1 9 3 1 NXR5i 15 1 10 3 1 NXR5i 16 1 11 3 1 NXR5i 17 1 12 3 1 NXR5i 18 1 13 3 1 NXR5i 19 1 14 3 1 NXR5i 20 1 14 4 1 NXR5i 21 1 15 4 1 NXR5i 22 1 16 4 1 NXR5i 23 1 17 4 1 NXR5i 24 1 18 4 1 NXR5i 25 1 19 4 1 104 8228 0004 8228 ...

Page 8: ...the type of boiler 1 Screw Ø 12x40 19 spanner DESSUS N OBE TOP N AVA T VORN FRONT DE SS US OB EN TO P AN T AVVO RN F O R NT 3 3 M000309 3 1 2 3 2 3 E D S S U S O B E N T O P D E S S U S O B E N T O P D E S S U S O B E N T O P D E S S U S O B E N T O P 4 8 5 5 5 N 0 2 A FRONT VORN AVANT FRONT VORN AVANT FRONT VORN AVANT FRONT VORN AVANT 19 A B A Boilers 14 16 18 20 22 24 sections B Boilers 15 17 19...

Page 9: ...tructions of the boiler Chapter Boiler location Fit the rear section on the frame behind the fastening brackets see detailed drawing and prop it up Insert the lower assembly rods in the holes of the rear section and the fastening brackets of the frame in order to position the rear section correctly according to the frame 3 Clean all the openings in the section with a brush Remove any deposit on th...

Page 10: ...ately Ø 5 mm silicon must not be applied 100 to either side of the connection nipple assembly area Dimensions are given in millimeters 5 Fit the Ø 10 5 mm diameter thermocord into this U groove and into the groove which circles the furnace Note Do not pull on the seal while inserting it Otherwise you may stretch it and reduce its thickness M000059 100 100 00 1 100 a M000060 ...

Page 11: ...ight be sharp edges Remove any traces of rustprotective paint so that the surface is perfectly smooth Coat with the lubricant supplied with the sections 7 Gently push in the 2 nipples A R R IÈ R E D E S S U S O B E N T O P V A A N T A R R I R È E D E S S U S O E B N T O P A V A N T M000062 ...

Page 12: ...tion Intermediate section Place the first normal intermediate section making sure that it is turned in the right direction i e with the flattening groove against the thermocord For safety insert a lateral assembly rod supplied in the holes of the 2 sections Push the section gently and simultaneously on the 2 nipples of the rear section with a hammer and a piece of wood positioned in line with the ...

Page 13: ...ing together the upper and lower connections evenly and simultaneously 11 Assemble the remaining intermediate sections one by one to the procedure stated in figures 3 4 5 6 7 8 9 and 10 First assemble the normal intermediate sections then the special ones Leave the assembly tool in place M000065 M000066 ...

Page 14: ... assembly rods fit the following at each end in the given order an expansion spring a washer and a nut the holes of the front lugs must be aligned with the holes of the frame brackets as the assembly rods are used to make the boiler body integral with the frame Stop tightening as soon as the gap between the spring spires is equal to about 2 mm M000067 M 06 000 8 2 ...

Page 15: ... 1 nut and 1 washer Remove the assembly tool Assembling the side assembly rods The side assembly rods must be assembled from the rear to the front The rods must be inserted in the holes stated in the diagrams the lugs of the sections in which the assembly rods are to be inserted have 2 holes Place the expansion spring and washer on the rear of each rod Stop tightening the nuts as soon as the gap b...

Page 16: ...16 NXR5i 25 09 2012 300029104 001 02 Rear Front Dimensions are given in millimeters NXR5 14 NXR5 15 NXR5 16 C003936 A ...

Page 17: ...17 25 09 2012 300029104 001 02 NXR5i Rear Front Dimensions are given in millimeters C003937 A NXR5 19 NXR5 18 NXR5 17 ...

Page 18: ...18 NXR5i 25 09 2012 300029104 001 02 Rear Front Dimensions are given in millimeters C003938 A NXR5 20 NXR5 21 NXR5 22 ...

Page 19: ...19 25 09 2012 300029104 001 02 NXR5i Rear Front Dimensions are given in millimeters NXR5 23 NXR5 24 NXR5 25 C003939 A ...

Page 20: ...special intermediate section 150 mm wide 1 2 hole for NXR5i 14 to NXR5i 19 or the fourth special intermediate section 150 mm wide 1 2 hole for NXR5i 20 to NXR5i 25 Plug the 2 free 1 2 holes for NXR5i 14 to NXR5i 19 or the 3 free 1 2 holes for NXR5i 20 to NXR5i 25 in the special intermediate sections Front Front NXR5i 20 to NXR5i 25 NXR5i 14 to NXR5i 19 ...

Page 21: ...ion hole in the lower part of the flange using 4 H 18 nuts with the gasket in between soak in warm water first 17 Hydraulic test After assembling the boiler body the installer must carry out a water tightness test at a pressure equal to 1 3 times the operating pressure that is 7 8 bar mini for 10 minutes at least The test must be done at room temperature 1 Fit a square flange with hole facing upwa...

Page 22: ...any bursting of the body 3 Maintain pressure for at least 10 minutes 7 8 bar Any drop in pressure indicates a leakage in the boiler body After the hydraulic test drain the boiler Remove all of the specific parts fitted to the rear section parts used to carry out the hydraulic test 2 4 3 0 077 M0 0 ...

Page 23: ...lates Put the baffle plates into place in the upper front flue ways taking care to interlock them with each other before fitting them M000079 Boiler NXR5i 14 NXR5i 15 to NXR5i 19 NXR5i 20 to NXR5i 25 Total number of baffle 4 6 8 Pack no CM 23 CM 22 CM 23 2 x CM 23 ...

Page 24: ...with a system whereby it can only be mounted with the handles turned outward Fit the two locks of each cover between the sections Push the cover towards the outside of the boiler to the closed position Fasten the two brass nuts of each cover Type Thermocord length 1 1335 mm 2 1110 mm 3 890 mm 4 665 mm Rear Front M000080 1 2 3 4 1 2 3 Cover model No 1 No 2 No 3 No 4 Boiler type Number of sweeping c...

Page 25: ...de and hold it in place with a few drops of silicone filler 21 Putting in place the lower trap doors Insert the thermocord in the sealing groove of the 2 lower flue ways on the rear and front of the boiler Put the 4 trap doors on the lower flue ways and fasten with the wing nuts M000081 M000082 ...

Page 26: ...in place and retain it with the 4 screws SIM 3 94x25 4 Place the furnace door on the floor and fasten the articulation onto the door with 3 screws HM 12 23 Installing the hinge of the furnace door Fix the furnace door hinge on the right or left hand side of the front section by means of 3 screws HM 12x25 M000083 1 1 3 2 7 mm M 0 0 0084 M000085 ...

Page 27: ...104 001 02 NXR5i 24 Fit the door onto the hinge by inserting the pin Close the furnace door on the 8 studs and fasten with 8 washers and nuts 25 Fit the 2 doors of the upper flue ways wing nuts 1 M000086 M000087 2 M000088 ...

Page 28: ...6 Flame inspection window The flame inspection window is fitted with a 1 4 tapped hole for ventilation optional if a ventilation system is used connect the hole to the one provided for that purpose before the burner combustion head M000089 ...

Page 29: ...uts H 18 NXR5i 15 to NXR5i 25 Package FA50 to FA60 Package FA69 to FA79 Fit the water balancing tube onto the boiler return with a Ø 170x222 gasket in between first soak the gasket in warm water Fit the heating return flange with a Ø 170x222 gasket in between first soak the gasket in warm water and fix it with 4 nuts H 18 NXR5i 14 Package FA 49 Package FA68 C003941 A Boiler type Length mm NXR5i 15...

Page 30: ...irst soak the seal in warm water Assemble the flange with angled piece so that the angle is turned upward with a Ø 170x222 gasket in between first soak the gasket in warm water and fasten with 4 nuts H 18 NXR5i 16 to NXR5i 25 Package FA51 to FA60 Package FA70 to FA79 Assemble the flange with angled piece so that the angle is turned upward with a Ø 170x222 gasket in between first soak the gasket in...

Page 31: ...the groove of the rear section and hold it in place with a few drops of silicone 30 Before assembling the flue gas box grease all bolts studs and screws with high temperature grease not supplied Put in place the thermocord Put the sweeping cover in place and fasten with 2 nuts H 10 and Ø 10 washers 0 0 M 00 92 ...

Page 32: ...gas outlet is fastened to the rear by means of 6 studs washers and Ø 12 nuts 32 First adapt the steel connecting plate to the chimney connection flue then fasten that plate or the plate with a connecting piece with 10 nuts H10 and Ø10 washers M000095 ...

Page 33: ... on the collet must be the same as the flowing out of the water in the tube 0 9 M0 00 6 Boiler Flow switch Code no NXR5i 14 8802 4745 NXR5i 15 8802 4746 NXR5i 16 8802 4736 NXR5i 17 8802 4738 NXR5i 18 8802 4752 NXR5i 19 8802 4753 NXR5i 20 8802 4754 NXR5i 21 8802 4755 NXR5i 22 8802 4757 NXR5i 23 8802 4757 NXR5i 24 8802 4759 NXR5i 25 8802 4759 ...

Page 34: ... before fitting them 35 Boilers supplied with an assembled body By special arrangement only Assembling the upper crosspieces package MR338 or MR339 Rear Front Dimensions are given in millimeters Mount the 2 crosspieces and fasten them onto the rods with an expansion spring 2 nut and 2 washer M000097 Boiler NXR5i 14 NXR5i 15 to NXR5i 19 NXR5i 20 to NXR5i 25 Total number of baffle 4 6 8 Pack no CM 2...

Page 35: ...14 to NXR5i 17 Package FA17 to FA27 Assembling the cable channels Rear Place the cable channels so that their bevelled end is to the front Fasten with 2 screws H8 x 16 L8 washers in the third hole starting from the front and opposite the special nut Fasten at the rear with 2 screws H8 x 16 L8 washers opposite the oblong holes and special nut M000099 80 90 1 Number of sections 14 15 or 16 17 Length...

Page 36: ...boiler Push the insulating material under the front and rear crosspieces 39 NXR5i 18 to NXR5i 25 Package FA6 Assembling the intermediate piece Assemble the intermediate piece on the assembly rods by fitting one slotted side onto one rod and using the flexibility of the other rod M000101 80 90 Number of sections 18 19 20 21 22 23 24 25 Length mm 2 x 1200 2 x 1200 2 x 1300 2 x 1400 2 x 1400 2 x 1500...

Page 37: ...ar crosspieces with 2 screws H8 x 16 and L8 washers Align the 2 additional cable channels with the two others Fasten them to the intermediate piece and the rear crosspieces with 4 screws H8 x 16 and L8 washers 41 package MR338 or MR339 Assembling the casing positioning brackets Fasten the positioning brackets package MR338 or MR339 onto the right and left hand upper bosses of the front section wit...

Page 38: ...rackets using H8 x 16 screws Serrated washer for the assembly direction see the drawings below Assembly direction of lower rail support brackets seen from the top of the frame Rear Front Right hand side Left hand side Rail support brackets Base frame 2 lower rail support brackets and 2 upper rail brackets are left unused with 18 19 20 and 21 sections 1 M000105 ...

Page 39: ...39 25 09 2012 300029104 001 02 NXR5i NXR5 15 NXR5 17 NXR5 14 NXR5 16 NXR5 18 NXR5 20 NXR5 19 NXR5 21 NXR5 22 NXR5 24 NXR5 23 NXR5 25 C003942 A ...

Page 40: ...see fig 46 44 package MR338 or MR339 Assembling the fastening brackets of the upper and lower rails Imperative alignment Fix the fastening bracket of the upper rails package FA5 or FA6 on the upper lug these brackets must be vertically aligned with the lower rail support brackets Fit the bracket onto the stub Fasten with 1 screw H10 x 50 and serrated washers and H10 nuts Assemble 1 Rapid nut on th...

Page 41: ...rail fastening bracket Distribute the insulating material evenly so that you have the same side insulating material on either side of the boiler Cut the insulation similary along the fastening brackets Boiler type Side insulating material mm Front Rear NXR5i 14 1200 600 NXR5i 15 1200 400 400 NXR5i 16 1200 400 600 NXR5i 17 1200 400 600 NXR5i 18 1200 1200 NXR5i 19 1200 1200 NXR5i 20 1200 400 400 600...

Page 42: ... opposite the first fastening bracket and similarly with the other brackets Fix the additional upper and lower rails making sure you comply with dimension A see table below Push the insulating material behind the lower rail and underneath the boiler Join the pieces of insulating material to each other with the clips A M000110 1 2 5 5 A B 5 4 5 Boiler Package Package NXR5i 14 FA24 NXR5i 15 FA25 NXR...

Page 43: ...ectric screwdriver 2 screws per panel Fasten the side panels to each other with the clips 0 1 M0 0 1 1 1 2 3 2 4 5 Boiler type Side panels mm Front Rear NXR5i 14 800 600 600 Panels 400 mm long panel in package FA10 600 mm long panel in package FA11 800 mm long panel in package MR3 940 mm long panel in package MR4 1050 mm long panel in package MR5 NXR5i 15 940 600 600 NXR5i 16 1050 600 600 NXR5i 17...

Page 44: ...pport lower crosspiece package MR338 or MR339 by means of 2 screws H6 x 20 and 2 serrated washers 49 package MR338 or MR339 Assembling the control panel bracket all control panels Fit the 4 Rapid nuts on the front of the cable channels Fit the Rapid nuts in the slots 4 Rapid nuts for 7 to 17 sections 8 Rapid nuts for 18 to 25 sections Fix the control panel bracket package MR338 or MR339 underneath...

Page 45: ...45 25 09 2012 300029104 001 02 NXR5i 50 Fit the front cross piece 2 Screw H8 x 30 2 Self tapping screw Ø 3 94 x 12 7 Serrated washers ...

Page 46: ...46 NXR5i 25 09 2012 300029104 001 02 51 L000068 B C003955 B 3 4 2 4 4 1 ...

Page 47: ...47 25 09 2012 300029104 001 02 NXR5i 52 53 C003956 B 1 3 4 2 C003957 ...

Page 48: ...on of the instructions supplied with the control panel 55 Installing the insulating material Put in place the insulating material as shown above 56 package MR298 or MR299 Fitting the cap Mounted screw Control panel trim Serrated washer Rapid nut Cable channel Control panel bracket Front crosspiece Unfasten the screws mounted in fig 56 Slide the control panel trim along the screws Fasten the screws...

Page 49: ...g screws and serrated washers 58 package MR338 or MR339 Place the insulating material in the lower central front panel black cloth facing outward Fit the lower central front panel package MR338 or MR339 onto the lower front crosspiece and fix it to the furnace door panel C003958 B M000122 ...

Page 50: ... 25 09 2012 300029104 001 02 59 package MR338 or MR339 Fit the left and right hand side front panels package MR338 or MR339 onto the lower front crosspiece and fit them onto the studs of the side panels M000123 ...

Page 51: ...central tabs behind the furnace door panel Fit the upper front panel package MR338 or MR339 onto the side panels via the 4 studs 61 package MR338 or MR339 Put in place the insulation of the flue gas box and the lower rear insulating material package MR338 or MR339 If the side crosspieces overlap at the rear by more than 10 mm we advise you to saw them off using a hacksaw 0 1 M000125 ...

Page 52: ...n each crosspiece to the side panels using 2 screws Ø 3 94 x 12 7 63 package MR338 or MR339 Put the 2 clip on nuts in place on the side panels Fit the upper rear panel package MR338 or MR339 onto the studs and push it up Fasten with 2 screws H8 x 16 and serrated washers Fit the 2 lower rear panels package MR338 or MR339 onto the rear crosspieces M000126 1 3 4 2 M0 7 0012 ...

Page 53: ...02 NXR5i 64 NXR5i 14 to NXR5i 17 Package FA17 to FA27 Fitting the walkway Place the central plate on the cable channels with the round holes towards the front of the boiler Fasten with H8 x 30 screws and serrated washers C003943 A ...

Page 54: ...Place the front plate with the round holes towards the front of the boiler Fasten with 4 screws H8 x 30 and serrated washers Fasten the joining plate with the round holes towards the front of the boiler with 4 tapping screws and serrated washers 66 Package FA30 to FA41 Put in place the sweeping cover insulating material packages FA30 to FA41 NXR5i 14 to NXR5i 17 2 pieces NXR5i 18 to NXR5i 25 4 pie...

Page 55: ...00 600 600 NXR5i 15 940 600 600 NXR5i 16 1050 600 600 NXR5i 17 940 600 400 400 NXR5i 18 1050 600 400 400 NXR5i 19 940 600 600 400 NXR5i 20 940 600 600 600 NXR5i 21 1050 600 600 600 NXR5i 22 940 600 600 400 400 NXR5i 23 1050 600 600 400 400 NXR5i 24 940 600 600 600 400 NXR5i 25 1050 600 600 600 400 Cover packages 400 mm long panel in package FA10 600 mm long panel in package FA11 800 mm long panel ...

Page 56: ...9104 001 02 3 Data plate Boiler type Manufacturing date Year of manufacture Week of manufacture Serial no of the appliance Glue the rating plate and CE marking on the casing of the boiler in an easily visible location C003929 C ...

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Page 60: ...formation contained in these technical instructions as well as any drawings and technical descriptions supplied remain our property and shall not be multiplied without our prior consent in writing Subject to alterations 25 09 2012 300029104 001 02 ...