Chappee NXR3 User manual

1 Ref. : CH - 1249 - A - 2
1 . Standards-Regulations
2 . General
3 . Assemblyandinstallation
4 . Installingtheoptions
5 . Commissioning
6 . Maintenance
HIGH-EFFICIENCY, PRESSURIZED,
CAST IRON, OIL OR GAS BOILERS
70 / 290 kW
Ref. : CH - 1249 - A - 2 - EN 07/01
INSTALLATION MANUAL
NXR3

2Ref. : CH - 1249 - A - 2
1.STANDARD-REGULATIONS
BAXIdoesnotacceptanyliabilityfordamagecausedby
workthat doesnot complywith theseinstructions and/
or which has not been carried out by a qualified
installer.
This boiler design complies with the following European
directives:
Directive Mainsvoltage 73 / 23 / CEE
Directive Electromagnetic 89 / 336 / CEE
compatibility
Directive Efficiency 92 / 42 / CEE
Thisboiler complieswiththefollowingstandards:
EN303.1 • Boilers with forced air burner: Terminology,
generalspecifications,tests and marking
EN303.2 • Boilers with forced air burner: Special
specifications for boilers with sprayed oil
burner
EN304 • Test regulations for boilers with sprayed oil
burner
DIN4791 • Boilerandburnerconnections
Theboilercanbefittedwithachoiceoffueloilorgasburner
inaccordancewiththebuilder’srecommendations,theburner
complyingwiththefollowingstandards:
EN267 • Onepiecesprayedoilburner
EN676 • Automaticblown airburnerforgasfuels
EN226 • Burnerto heatgenerator connectionsizes
The heating system installation must comply with current
regulations.
Inparticular:
DTU65 • Central heating systems in buildings
DTU65.4 • Gasandliquidhydrocarbonboilers
DTU65.11 • Safety systems for central heating systems
inbuildings
Installers’Associationagreement of2July 1969.
BAXI S.A. attests that all boilers referred to in this
manualcomplythesamerequirementsascorresponding
examined types, for which the right to use CE marking
has been granted according to "Gas appliance" and
"Boiler efficiency" European directives.

3 Ref. : CH - 1249 - A - 2
2.GENERAL
2 . 1 Description
Boilers of this type are composed of a cast-iron
exchanger, consisting in sections assembled by means of
nipples. Their heat transfer surfaces have been specially
designedtoreachhighefficiency.Theexchangerisinsulated
byaglass wool layer linedbylacquered steel casingpanel,
itself insulated to reduce heat losses to a minimum.
Thesepressurizedboilersmustbefittedwithjet-oilorblown-
gasburners,providedoperatingcharacteristicsarecompati-
ble with the combustion chamber size and pressure condi-
tions.
Theyheatpremises,and,for DomesticHotWater (D.H.W.)
production,canbecoupledwith aD.H.W. tanklocatednext
to it.
2 . 2 Standard supplies
• Fire chamber cast-iron sections not assembled,
• Accessories: smoke box, optimizing baffles, flue ways
hingeddoor,openingchamberdoorwithburnerplate,
welding flanges for tubes Ø 76,
• Insulatedcasingandcleaningbrush,
• Depending on the order, this boiler is fitted with a control
panel(accordingtoversion).
2 . 3 Supplied on request
•Heatingbodydeliveredassembled,
•Twoextrapowereconomizers,
•Startersleevewithfingerbuttonforremotecontrolsensor
and¾”∅tappedopeningwithplug(notassembled),
•Returnsleevewithfingerbutton forremotecontrolsensor
and¾”∅ drainagevalve(notassembled),
•Adjustablefeetforlevellingbody,
•Controlpaneloptions,
• OILorGASburner,dependingonmatchingprescriptions,
• DomesticHotWatercalorifer(250-350-500-800)
2 . 4 Shipping, Packaging
Packaging is as follows :
Boiler
assembled
X
X
X
X
X
Boiler
not assembled
X
X
X
X
X
X
X
Package
Heatingexchanger notassembled
Heatingexchangerassembled
Optimizingbaffles
Heatingexchangeraccessories
Controlpanelwired
Casing
Extraaccessories
Tie-rods
34
7
612
5
612
35
7
730
5
730
36
7
849
5
848
37
7
963
5
950
38
7
1082
5
1068
39
7
1198
5
1184
exchangernot
assembled Nbofparcels Totalweightkg
exchanger
assembled Nbofparcels Totalweightkg

4Ref. : CH - 1249 - A - 2
2 . 5 Technical data
Flow DN 65
Fig. 1
Return DN 65
Drain Rp 1 1/2" orifice
Rp 2" orifice for
sludge flushing
36
130-170
6
1335
1240
1090
292
935
180
170
270
160
6
15
30-90
110
0,11
0,40
140-185
0,5-0,8
201-265
232-306
161-180
92,7 - 93 6
139 - 183
0,5 - 1,0
199 - 262
229 - 303
147 - 166
93,4 - 94,2
39
250-290
9
1845
1750
1600
292
1445
200
260
390
232
6
50
30-90
110
0,07
0,25
271-317
1,5-2,3
388-454
448-524
170-188
92,4 - 93,2
270 - 315
1,7 - 2,5
385 - 451
445 - 520
156 - 174
93,0 - 93,8
37
170-210
7
1505
1410
1260
292
1105
180
200
320
184
6
21
30-90
110
0,09
0,33
184-229
0,7-1,2
263-328
303-378
164-182
92,6 - 93,4
182 - 227
0,8 - 1,3
261 - 325
301 - 375
150 - 168
93,2 - 94,1
38
210-250
8
1675
1580
1430
292
1275
200
230
350
208
6
31
30-90
110
0,08
0,28
228-273
1,3-1,8
325-391
375-451
167-185
92,5 - 93,3
226 - 271
1,5 - 2,0
323 - 388
372 - 447
153 - 171
93,1 - 93,9
35
90-130
5
1165
1070
920
292
765
180
140
230
136
6
9
30-90
110
0,13
0,52
97-142
0,2-0,5
139-202
160-234
158-177
92,8 - 93,7
96 - 140
0,2 - 0,5
137 - 200
158 - 231
144 - 163
93,5 - 94,4
Réf. chaudière : N°
Output : kW
Number sections
Dimensions : Cote A : mm
Cote B : mm
CoteC : mm
Cote Y : mm
Combust. chamber depth P : mm
Smoke hood Ø D : mm
Chambervolume : l
Flue path volume incl-chamber : l
Water system vulume : l
Working pressure : bar
Waterside pressure loss at (∆t = 15 K ) : mbar
Thermostat range adjustement : °C
Limit stat max setting. (temperature) : °C
Standing losses (NFD 30 002) : %
Heating maintenance needs : %
Flame output (P nom) : kW
Chamber pressure : mbar
Massic-flow oil flues : Kg/h
Massic-flow gas flues : Kg/h
Flue gas temperature : °C
Combustion efficiency (2) : %
Flame output (P nom) : kW
Chamber pressure : mbar
Massic-flow oil flues : Kg/h
Massic-flow gas flues : Kg/h
Flue gas temperature : °C
Combustion efficiency (2) : %
34
70 - 90
4
995
900
750
292
595
180
110
190
112
6
5
30 - 90
110
0,14
0,74
75 - 98
0,1 - 0,2
108 - 140
124 - 161
155 - 174
93,0 - 93,9
74 - 97
0,1 - 0,3
106 - 138
123 - 160
141 - 160
93,6 - 94,5
*Dimensions with water
connection sleeve
(1) The maintenance coefficient is for an average boiler temperature of 70 °C .
(2) Values given for rated output, 20 °C room temperature, boiler temperature 80 °C, return 60 °C.
(3) CO2(indicative) - 13 % (oil) - 10 % (gas)
2 Savers(3)
4 Savers (3)
N04153.DSF

5 Ref. : CH - 1249 - A - 2
3.ASSEMBLYANDINSTALLATION
Connectionsto water supply
Connectiontotheheatingsystemneedstobedoneaccording
to statutory regulations and trade practice.
Fuel supply
For oil and gas, comply with statutory rules and
recommendations,inparticularwithrespecttosafety rules.
Power supply
comply with regulatory prescriptions, in particular with res-
pect to earthing and its connection to the boiler (main
switch...)
Fluestack
A0daPadepressionshouldbe observedatexitofsmokebox.
Complywithstatutoryregulations and tradepractice.
Please note that the efficiency of these boilers results in
relativelylowfluegastemperatures.
Special care must be given to flue stack which must be air-
tight,heat-insulatedandprotectedagainstdegradation.One
of the actions to take is to line the duct. Tubing grade must
be compatible with the selected fuel.
It is advised :
• tokeepthesamecross-sectionasthatoftheboilersmoke
hoodoutlet,
• toavoidshortradius,
• to keep the number of bends to a minimum
• wherepossible,toslopeconnecting partsupwards,
towardschimney
• to provide a purging vessel as close to the boiler as
possible.
Water flow rate
Thesystemmustbedesignedtoensureawaterflowrate,in
each boiler, comprised between 1/3 and 3 times the QN
nominalflowrate. QN =
Water flow rate allowed in each boiler must be comprised
between :
3 . 1 Boiler room layout
Plinth (see fig. 2)
Nospecialplinthisrequiredforthistypeofboiler.Asimpledry
basesuffices.Forinformation,weprovidethedimensionsof
this dry base (figure 2). For certain special installations, a
sound-proof plinth may be necessary. We recommend a
metalplinthrestingonreachableantivibrationpads.
Fig. 3
Clearance (see fig.3)
Thedimensionsshownareminimalvalueswhichallowproper
accessforassemblyandmaintenanceoperations.
Noneedtoleaveclearanceaboveforcleaningpurposes.
Boiler
size C L
34 750 900
35 920 1070
36 1090 1240
37 1260 1410
38 1430 1580
39 1600 1750
Flat bars
width 150
Optional
sealing
Fig. 2
Caution : assembly and installation must be carried out by a qualified engineer.
PN kW x 0,86
15K
PN kW x 0,86
5K
PN kW x 0,86
45K and
N0225100.PLT
N0218601.PLT
Choice of burner
Theburnershouldbechosenaccordingtotheboilerpower
andfurnace.
Ventilation
Complywithstatutoryregulationsforlowandhighventilation

6Ref. : CH - 1249 - A - 2
Boiler Numberofsections
ref. Front Middle Rear
34 1 2 1 None
35 1 3 1 None
36 1 4 1 Short
37 1 5 1 Short
38 1 6 1 Long
39 1 7 1 Long
Distributors
Cord
SS
E
Fig. 5
Sludge flush
Non return valve
Fig. 4
DIAGRAMOFTHEELEMENTS S : tightening markings
E : spacing pads
S
Front Middle Rear
Assembly marking
Cord junction point
SSS
Minimum flow rate must be provided at all times,
whatever the rate of operation, either :
- by means of the main flow pump, provided that the
system has no mixing valve between each boiler and
the pump, and that the pump operates continuously,
- by means of a recycling pump or a loading pump
operating permanently.
In the case of a recycling pump or a loading pump per
boiler, and to avoid parasitic flows in the other boilers,
position non return valves upstream from the return
connection.
The burner must be controlled by the recycling or
loadingpump.Itcanonlybeputinoperationifthepump
operates. Secondarily, a flow control device, combined
with the TH thermostat, can be mounted on the return
of the boiler, downstream from the recycling or loading
pump.
To vents
00306N0225200.PLT
N0226701.PLT

7 Ref. : CH - 1249 - A - 2
3 . 2 Assembling the sections
The sections are assembled using nipples. For a good
tightnessoftheassemblies,itiscompulsorytouseaspecial
productwhich ensuresaperfectseal(thiscoatingisalways
providedwiththeboiler).
Proceed in the following way:
1) Open the "Extra accessories" box,
2) Clean thenippleswith asolvent,
3) Put the rear section in vertical position and secure it
against tilting by propping it up,
4) Position thewoodenblock providedinthe "extra
accessories" box, 40 mm thick, in front of the rear
section’s legs,
5) On thevertical section,clean thegrooveawaitingthe
cord with a metal brush, then position the cord
without stretching it, with the junction point at the top
(see figure 6) on the axis of the nipples line.
Cutthecordcarefully.
6) Cleancarefullywithsolventthereceivingsurfaces.If
need be, use extra fine emery paper in case of rust
stains or small barbs.
Fig. 6
Assembly marking
Leaktightness cord
junction point
Place the cord in the
vertical element's
ream
BECAREFULTOASSEMBLETHEMIDDLESECTIONSCORRECTLY
Tighteningofthe
leaktightness cord
7) NEVER USE OLD NIPPLES.
Coatnipplesandreamswiththeproductprovided,
using a clean brush.
8) Place the nipples in the vertical section’s orifices and
drivetheminslightly using apieceofwood onwhich
to hit with a hammer or a mallet so as to maintain the
nipplesin thereams. Donotdrivethemintoomuch,so
thatthefinaltighteningshallbeobtainedbybringingthe
sectionstogether.
Take care that the nipples be perfectly vertical, as a
deviationduringtighteningcanbreakthesection,
9) Afterhavingcleanedthemiddlesectionandappliedthe
coating, bring it on the block to place it facing the
verticalrearsectionandrespectingtheorientationof
theassemblymarkingwhichmustbealwaysoriented
towardsfront(seefigure6).
Driveit ontothetwonipplesusingamalletora pieceof
hardwood,hittingalternately,attopandbottom,facing
the nipples to ensure temporary assembly of the two
sections,
10) Ensure thattheyareperfectly vertical, and tightenitas
explainedinthefollowingchapter.
Assembly marking
Inside Outsise
Wooden block (provided)
02244-01
N0224600.PLT

8Ref. : CH - 1249 - A - 2
3 . 3 Tightening the sections
Totightenthesections,asetofassemblybarsisnecessary.
It comprises:
For 4- to 7- section boiler:
- 2 assembly bars, length = 1.60 m (A),
- 2 fixed plates with stop-ring (B),
- 2 mobile plates with ball nut (C),
- 1ratchetwrench.
This set is not part of normal supplies.
For 8- and 9- section boilers:
- Sameasabove,
- 2 bar extensions, length = 950 mm.
Or PARCEL N° 1 + PARCEL N° 2
1) Withdraw the plates’ alignment screws,
2) Place an (A) installation bar in each row of nipples,
3) Mount, on each bar, at the rear, a plate with (B) stop-
ring,
4) Mount at the front the (C) plates with tightening nut,
afterhavinglubricatedthethread,
5) Align the plates,
6) tighten the screw alternately by 1/2 a turn each, taking
careto avoidfanassembly.
Proceed with tightening until the sections touch, and
check it by looking in the firebox and the upper
"flue-ways".
Fixed plate B
Nbr. of elements
4 to 7
8 to 9
Bar
A
A + D
L dimension
1600
2550
ldimension
1355
2305
l max.
L
121 Run = 245 160 Step = 190
assembly bar A Extension D
Nut Mobile plate C
54 70
Take alignment screws off Stop-
ring
Fig. 7
Fig. 8
Wrench
MID
section Nut CAssembly
marking
Assembly
marking
A
B
Stop-ring
REAR
section
7) Assemble the other sections (1 by 1) in the same way,
whilemovingthe wooden blocksalternatelyas yougo
towardsthefront,
8) Do not loosen the assembly bars and position the 4
assemblylinkages.Tightenthemproperly,leavingan
equal length at each end to secure the casing’s cross
members, and if necessary the adjustable legs,
9) Loosen and taketheinstallationbars off,
10) proceedwiththeboiler assembly.
NOTE: If it were necessary to dismantle one of the
boiler’s sections, and to avoid damaging the
leaktightnessgorges,itisimperative,whendismantling
the sections, to place the chisel at the level of the
spacing pads (E) provided in the upper part (see
figure 5).
FRONT BACK
Positioningaid
N0219800.PLT
N0219700.PLT

9 Ref. : CH - 1249 - A - 2
EXCHANGER
5 Sealing cord Ø 7
40 Screws bag
Fig. 9
14 Disriburor, Length 180
14a Distributor, Length 530
15 Flow and return manifold
16 Drain valve
17 Sensor pocket, Length 100 mm
18 Upper baffle
18a Lowe baffle
19 Smoke box Ø 180
19a Smoke box Ø 200
20 Flue-way hatch (L)
20a Flue-way hatch (R)
21 Leaktightness braid Ø 8
22 Chamber door
23 Internal insulation
24 External insulation
25 Sight flange
26 Sight glass and seal
27 Door seal Ø 16
28 Burner plate
29 Burner plate gasket
30 Cleaning access. door
31 Internal insulation
32 External insulation
33 Insulation body blanket
39 Cleaning brush
40 Screws bag
41 Complete adjustable leg
1 Front section
2 Middle section
3 Rear section
4 Nipple Ø 89
5 Sealing cord Ø 7
6 Tie-rod
7 Reducer
8 Sensor pocket, Length 200 mm
9 Door hinge
9a Door hinge
10 door guide
11 Door pin
12 Welding flange
13 flange gasket
02236-00

10Ref. : CH - 1249 - A - 2
Method
•Assemblethe8 studs 12 x 65around the rear section’sstart and returnorifices.
• Ifnecessary,insertthedistributor(seefigure22)inthereturnorificebyinterpolatingtheseal
(13).
• Placetheboilerinitsfinalpositionandlevelit,whichwouldbemadeeasierbythe"Adjustable
legs"option(chapter 3.1)
• Screwthepocketandthereducer(7)inaleaktightmannerinthefrontsection’supperorifice.
• Athreadedorifice Ø 2" isprovidedatthebottomof the front section,formountingavalve
enablingrinsingandflushingoftheinstallation’ssludge(werecommendmountingcoil,a90°
bend and the valve). A pre-cut space allows for passing the tubing in the casing’s lower
panel.
• Mountadrainvalvetightly(notprovided) ontheinstallationorinthelowerpart oftherear
sectionusingareducer(notprovided).
• Adrain valveØ3/4"is deliveredwiththe "Connectionsleeves"option(see chapter4.2).
• Connecttheflangesontheinstallation’stubing,thanfastenthemontheboiler,interpolating
the seal (13), with 4 HM 12 nuts and 4 washers for each.
• Afterhavingcheckedtheconnections,proceedslowlywithfillingtheinstallation,ensuringall
theairisvented,thenproceedtothehydraulictest((1.3xP.operation)tocheckallleaktight
areas.
• Screwtheshortestthreadedpartofthe4studsM8x40intherearsectionintheupperpart.
• Checkthattheleaktightnessbraid(21)isinplace.
• Engagethesmokebox onthestudsandfasten it(4HMnutsand 4washers)bytightening
thenutsmoderatelyandsimultaneously.
• Connecttheboilertothestackinthemostdirectpossiblemannerandwithoutreductionof
thesizeofthesmokeduct.Ensurethatthelatterisleaktight.
• Inserttheassembledbaffles(18)intheupper"flue-ways"and,ifneedbe,thesimplebaffles
(18a) in the lower "flue-ways" (see chapter 4 . 3).
• Screw the small threaded part of the 8 studs M 8 x 40 in the front section following the
indicationsoffigure10.
• Definetheopeningsideforthedoors.
• Mountthe hinges(1screwHM 10x30+ 1nutHM10 +2washersL 10foreach guide).The
doorguideislocatedoppositethehinges,intheupperpart.
• Dependingonthechosenopeningside,securethehinge(9a)oneachdoorusing2screws
HM12 x 35 +2 washersM12.
Caution:Forreasonsofpracticality,itisrecommendedtomountthefireboxdoorfirst.
• Mountthedoorsonthehingesusingtheaxes(11).
• Engagethedoors onthestudsandfasten them (4nutsHM10and 4 washersL10for each
door),tighteningthenutslightlyandsimultaneously.
• Dependingonthesizeofitsfixation,theburnerismounteddirectlyon thedoor,orviaa
perforated plate (see figure 11). Mount the burner plate (4 screws HM 12 x 35 + 2 washers
M12)onthechamberdoor,interpolatingtheleaktightnessseal(29).
- Aplainplatemaybeprovidedonrequest.
3 . 4 Operational assembly diagram
Operation
Open the "chamber accessories" parcel
Distributor (14 - 14a)
Installing the boiler
Sensor pocket (8)
Sludge flushing
Drainvalve (16)
Welding- flange (12)
Filling and hydraulic test
Smoke box (19 - 19a)
Stack
Optimizing baffles (18 and 18a)
Door hinges (9)
Door guide (10)
Door hinge (9a)
Chamber (22) and
Cleaning door (30)
Burner plate (28)

11 Ref. : CH - 1249 - A - 2
Top insulation blanket
Bottom insulation blanket
Insulationpositioning
Fig. 10
Stud M 10 x 90
Hinge
Stud M 10 x 90
Stud M 10 x 90
Stud M 10 x 90
Screw TH M 10 x 30
Screw TH M 10 x 30
Screw TH M 10 x 30
Screw TH M 10 x 30
Hinge
Hinge
Hinge
Guide
Guide
Door hinge and door guide
assembly
Pre-drilled
burner door
Fig. 11
Fig. 12
Screw TH M 10 x 30
Stud M 10 x 90
Stud M 10 x 90
Screw TH M 10 x 30
Stud M 10 x 90
Stud M 10 x 90
4 holes M 8 equidistant on a perforation Ø of 170
4 holes M 10 equidistant on a perforation Ø of 200
4 holes M 14 equidistant on a perforation Ø of 254
Side insulation
blanket
Rear insulation
blanket
N0226400.PLT
N0225600.PLT
N02187-01.DSF
Front insulation blanket
Front

12Ref. : CH - 1249 - A - 2
Method
•Screw the hexagonal spacers on the rear section’s 3 spacer pads, and place on each
spacer a TH M 5 x 10 screw.
• Place the lower heat-insulator (cross-shaped, 50 mm thick on black veil) under the
heat chamber taking care to jam the ends between the assembly linkages and the
chamber.
• Casing the whole of the chamber by the side insulation (50 mm thick) and tuck
its ends under the chamber (see figure 12).
• On the rear section, insert insulation (100 mm thick) on the spacers.
•NOTE : for exchangers with 8 or 9 sections, the side insulation is supplied in 2 parts
to be positioned side-by-side, the large part towards the front.
• Engage the lower rear on the three spacers and secure it by tightening the 3 screws.
• Mount both lower feet on the front section (2 screws HM 8 x 16).
• Mount the cross sections on the assembly linkages, fasten them using the counter-
nuts HM 12. The front cross-member is provided with a protection clip (110 mm long)
with a plastic collar and a NUT nut.
• Laterally secure the side rails on the cross-members using bolts HM 8 x 16 (square
hole to the front).
Front
Middle
Rear
Nb. of elements 7
300
510
514
8
300
510
684
9
300
510
854
A
C
B
6
300
854
5
300
684
4
300
514
Operation
Open the "casing" parcel
Rear spacer (50)
(see figure 15)
Bodyinsulationblanket(33)
(see figure 12)
Lower rear (51)
Lower foot (52)
Cross-member (53)
Right side-rail (54)
Left side rail (55)
3 . 4 Operational assembly diagram (continued)
Fig. 13
Fig. 14
Rear
Front RearMiddle Front
ABACB
Casingsidesassembly Frontcasingsassembly
N0220900.PLT
N0221000.PLT

13 Ref. : CH - 1249 - A - 2
CASINGASSEMBLY
50 Rear spacer
51 Lower rear
52 Lower foot
53 Cross-member
54 Right side-rail
55 Left side-rail
56 Lower mask
57 Right side
58 Left side
59 Side restraint
60 Rear right side
61 Rear left side
62 Middleside
63 Upper rear
65 Front top
66 Rear top
67 Middletop
68 Upper front
69 Lower right front
70 Lower left front
71 Casing screw bag
71 Casing screw bag
Fig. 15
02237-01.TIF

14Ref. : CH - 1249 - A - 2
Operation
Lower mask (56)
Front sides (57 - 58)
Side restraint (59)
Middle sides (62)
Rear sides (60 - 61)
Upper rear (63)
Upper heat-insulator (33)
Fronttop (65)
Middle top (67)
Rear top (66)
Controlpanel
Lower left and right façades
(69 - 70)
Upper façade (68)
(see figure 14)
Method
•Place the lower mask on both lower feet at the front of the boiler (this part is pre-cut
to allow passing of sludge tubing, or can also be taken out)).
• Hook the front sides onto the side-rails and fasten them using the axis screws (Ø 8)
in the upper part and at the bottom using a TH M 5 screw on the lower foot.
• Extract the restraint from the side panel by tilting it, insert it in the side heat-insulator’s
slit, and hook it on the assembly linkage; Tighten the axis screw.
• (only for boilers with 7, 8 or 9 sections)
• Put the middle side on the side-rails. Slide it so that the axis of the restraint enters the
orifice provided.
• Extract the side restraint in the same way as for the front side.
• Put the rear side on the side-rails, and slide so that the side’s return fold casings the
lower rear (51) “s fold and the axis of the restraint enters the orifice provided.
• Secure the rear sides on the lower rear using 4 HM 5 x 10 screws.
• Pin the upper rear on the sides and click it in downwards in the keyhole slots provided
for this purpose.
• Place the upper heat-insulator on the side-rails (slit at the front).
• Place the front top on the side axes and push it forwards to bumper.
• (only for boilers with 7, 8 or 9 sections)
• Place it on its axes and push it forwards until it joins up with the front top.
• Place it on its axes and push forwards until it joins up with the front or middle side in
the case of a boiler 7, 8 or 9 sections.
• Secure it on the upper rear (2 HM x 10 screws).
• Assemble the control board as indicated on this page.
• Click the faþades in laterally and downwards on the buttons fastened on the sides’
folds.
Locking is done by the central feet.
• Engage both axes in the lower faþades’ holes.
• Press the façade on the sides.
-fitthecontrolpanelonthefronttopwhileroutingthe
probecablesthrough theopeningincluded tothis
effect
- engage the pins under the panel into the slots, and
pull thecontrolpanel towards you.
-Lockitusingthe2placticpins(A) andtheM5 screw
(B) onthetop front
CONTROLPANELASSEMBLY
N04214DSF
Fig.16
plastic pins
A
Probe cables
B

15 Ref. : CH - 1249 - A - 2
BOILERANDBURNERPOWERSUPPLY
Fig. 20 Three-phase
current
Single-phase
current Single-phase
current
CABLESFITTING
Fig. 21
Control
Control
Burner motor
power supply
CAUTION:In the case the burner motor is supplied with
three-phase power, control panel single phase supply
must imperatively be taken from one of the phases
supplying theburnermotor.
VERYIMPORTANT:Neverconnecttheburnercontrolbox
directly to one of the phases.
N0225300
ELECTRIC CONNECTION
Thefacilitymustcomplywithcurrentlyenforcednationaland
localregulations.Notably,theelectricconnectionoftheboiler
requiresasectioningdeviceoneachpolewithaminimum3
mm distance between each contact.
For the complete electric connection of the various
types of control panels, refer to the manual specific to
the panel.
Thepowersupplyconnectionterminalstripisaccessibleafter
removingthecoveratthebackofthepanel.Itislocatedinthe
lowerrightcorner seenfromthe back.
Connect the phase to the strip’s L terminal.
Thelinemustbeabletowithstandanintensityof6.3Aunder
230V 50 Hz + Ground (check whether the power of the
pump(s)iscompatible).
Apply the electric connection as per the electric diagram in
theinstructions.Planagroundingwireexceedingby50mm
in length to the neutral and phase wires for tearing safety.
The burner switch located on the control panel does not
dispensefrominstallingthe regulatory wallswitch.
Inthecaseofinsufficientionisingcurrentduetononcompliant
neutral or ground, we recommend adding a circuit isolation
transformer with a power at least equal to 600 VA.
Control panel supply connection terminal strip
Theground socketplannedontheconnecting termi-
nalstripmustbeconnectedaspercurrentlyenforced
provisions.
03935-00
Main power supply
230 Vac 50 Hz
(phase imperatively in L)
shunt "UV"
Boiler glove finger
withoud regulation probe
When fitting the capillaries, ensure they are inserted fully
in the glove finger.
1 - Overheating safety thermostat
2 - Heating outlet thermometer
3 - Regulation thermostat
4 - Tube Ø 6
5 - Heating regulation probe
3 - Regulation thermostat 2nd Stage
Boiler glove finger
with regulation probe
02078-01
00229-5
02078-05
2
CM control panel CE,ECO5E,ECO7E,ECO8E
control panel
CS control panel
6
Fittingthethermostatbulbs,thermometer(andregulation
probeinoption)intheglovefingerasshowninthediagram.
Capillaries
Burner
cables
Clamp-
nut A
Earthing
wire
Front
crosspiece
AV
Lower piece
N04156.DSF

16Ref. : CH - 1249 - A - 2
4.INSTALLINGTHEOPTIONS
4 . 1 Adjustable legs
Forlevelling theassembledheatingchamber,locatedintheboilerroom.
Assembly of the 4 heating chamber legs:
- Screw the adjusting screws up to the maximum in the supports,
- Engagethesupportinthe space provided on eachheatingchamberleg,as shown in figure 19.Fastenthesupportson
the end of each assembly linkage (nut + washer),
- Slide the pads under the adjusting screws,
- Level using the screw with a 17 flat wrench (adjusting travel = 16 mm maximum).
15 - Return manifold
16 - Drain valve
17 - Sensor pocket
12 - Flange
13 - Gasket
14 - Distributor
4 . 2 Heating system flow and return connection manifolds with drain valve and Sensor
pocket for remote control
Boiler leg Support Support fixation
nut
Pad
Wrench
Fig. 19
Fig. 20
Adjusting
screw
The manifolds move the main heating system connection
outsidethecasing.Theyareprovidedwiththreadedorifices
forfittingthefollowingaccessories:
- On Ø 1/2" start and return: pockets (17) for remote
controlsensor,
- OnØ3/4"flow:drainorsafetyaccessories(notprovided),
- OnØ3/4"return:drainvalve(16);
Mountthemanifolds (see figure20)on the boiler’sflowand
returnorifices,positioningthethreadedorificeØ1/2"towards
theexchanger,placedontopforflowandonthesideforreturn.
NOTE: For boilers fitted with a water distributor (14) on the
return,thedistributormustpenetrateasfaraspossibleinthe
exchangerreturnorifice.
Its fixation flange will be placed, between two joints (13),
betweenthereturnmanifoldandtherearsection.
Heatingsystem’sconnectingflanges(12)shouldbewelded
to the water system’s pipes before fitting on the boiler.
N0223000.PLT
02244-00

17 Ref. : CH - 1249 - A - 2
Ø 7,5
Upper baffles
Lower baffles
4 . 3 Lower savers
Thetwooptionalextraoptimizingbafflesshouldbeplacedin
thetwolower"flue-ways" as showninfigure21:
Engageeachbaffleinthe"flue-way".
Performance as shown in the characteristics table corres-
pondtotheboileroperatingwiththeupperandlowerbaffles
as shown in the position diagram opposite.
Fig. 22
Fig. 21
4. 4 Control panel options
Beforeanyoperationinsidethecontrolpanel,disconnect
powersupplyusingmainswitchlocatedonheatingsystem
general control board.
Flue gas thermometer :
Itshousing istobepositionedonthecontrolpanelfront and
the bulb on the flue stack.
- Takeoffthetop,openpanelfront
- Takeoffthefactory-mountedblankplateandengagethe
capillaryandthethermometerhousingintothefrontaper-
ture
- Guidethe capillarythrough controlpanelrearandcasing
front top, parallel to the other installed capillaries. Direct
thecapillarytowardsthe back oftheboiler,on exchanger
insulating blanket, in order to be able to bring its bulb up
intotheconnectionpipebetween flue hood andstack
- Drill, preferably vertically, the fluegas duct to + 7.5 and
drivethebulbholdingclip (seefig. 22)
- Engagethebulbinto the clip. Closethecontrolpanel and
fit top again.
Burner cables :
The1ststageburnercablewitha7-contactconnectorandthe
2nd stage burner with a 4-contact connector are to be
connected on the terminal block inside "B" control panel,
markingsbeingproperlyaligned.guidethewiresasexplained
in the ñ of page 15.
Flue
stack
Holding
clips
Bulb
N0221000.PLTN224200.PLT

18Ref. : CH - 1249 - A - 2
5 - 1 Filling
- Water quality for the heating system
Avoidusinghardwater,which mayscale theboiler.IfTH
ortotalhardnessis above the French25°,the boiler
shouldbefilledwithsoftenedwater.
- Filling the boiler and heating system
While filling, which must be done slowly, ensure that the
stopvalvesareopenand thatthe mixingvalvecanbe1/
2open.
The automatic drain cock plug, normally fitted on the
boileroutlet,mustremainuntightenedinordertoachieve
continuousdrainingduringfilling-up.Drainallhighpoints
ofheatingsystemand close thevariousdraining screws
oneaftertheother as soon aswaterreaches their level.
After filling the boiler for the first time, flush completely
(usingthesludgeflushingvalve)inordertogetridof
foreignbodiesthatmaycomeintothecomponentsorthe
pipesduring assembly.
- Water topping up
Subsequentboilertopping-upshouldbepracticallynon-
existent and in all cases controlled and registered by a
waterflowmeter. Frequenttopping-upis the asymptom
of a leakage which should be repaired as soon as possi-
ble.
5 - 2 Preliminary checks
When commissioning the boiler for the first time in the
season,orafteraprolongedshutdownperiod:
- ensurethatfillingwasdoneproperlyandcheckoverall
tightness.Ifnecessary, putmore wateranddrain allhigh
points until water flows slightly.
- check the connection of the flue stack and the proper
workingconditionofthedraughtregulatorifany
- check that the high and low vents are not obstructed
- ensure that the doors and the flue access plates are
closed and tight
If necessary, act upon the tightening points.
- ensurethatthe burner isproperlylocked
- check if it is properly supplied in fuel, that supply and
returnvalvesareopen
- for operation with gaseous fuel types, check that the
safetyconditionsarefulfilled.
Note : After starting up a system for the first time, it is
recommendedtocleanthepumpfilterinthecaseofoilfiring,
or the line filter in the case of gas firing.
After a few hours of operation, check the tightness of the
doors.Ifnecessary,tightentheir fastening nuts.
5. COMMISSIONING 6. MAINTENANCE
Boiler
Checkwaterpressureonpressuregaugeand,ifnecessary,
restorenormalpressure.Onlyperformthisoperationwhen
thesystemiscold.Iffrequenttopping-upisnecessary,there
is a leak in this case, notify the installer. Never draw water
from the heating system. In order to avoid slow but steady
sooting,harmfultoproperboileroperation,itisrecommended
to clean it regularly twice a year at least.
This is always done with the boiler stopped and the power
supply cut out.
Proceed as follows :
• putONburnerswitchlocatedonthecontrolpanelaswell
as the main boiler room switch
• removecasingfrontpanels
• openthecleaningdoorand thechamber doorandtake
theflue-wayhatchesaway.
• taketheoptimizing baffles downandbrush them.
• cleanthe wallsof eachfluewaywiththebrushprovided
with the boiler as well as the combustion chamber walls.
• removesootand combustion deposits,ifpossible using
avacuumcleaner
• Clean the inside of the smoke hood
• the lagging material of the doors may be brushed with a
soft brush. Do not use a metal brush. Be careful not to
damagethe seal.
• once the cleaning is over, put the hatches back up on
the smokebox, put the optimizing baffles back in their
respective"flue-ways",closethechamberandcleaning
doors, ensuring that they are tight.
• set casing front panels back up.
Sludge
Thissludge,duetocorrosioninthesystem,travelsinsidethe
pipework and makes up deposits in the boilers. We
recommendtorinsetheboilerefficientlyandthoroughly
and check the flushed water quality.
Burner
Theburnershouldbesubmittedtoregularmaintenance.See
specialinstructions,providedwiththeburner.Ifnecessary,
contacttheretailerormanufactureroftheburner.

19 Ref. : CH - 1249 - A - 2

20Ref. : CH - 1249 - A - 2 PRINTEDAT SOISSONS FACTORY -FRANCE
157, Avenue Charles Floquet
93158 Le Blanc-Mesnil - Cedex
Téléphone : + 33 (0)1 45 91 56 00
Télécopie : + 33 (0)1 45 91 59 50
www.chappee.com
S A au capital de 43 214 640 €
RCS Bobigny B 602 041 675 A.P.E 282 D