Potterton NXR4i User manual

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NXR4i
Assembly Instructions
August 2011
heating specialists

2NXR4i 12/07/2011 - 300025089-001-B
1 Package list
Refer to the applicable product list for any optional features
used.
Packagelist:Before starting to assemble the boiler, refer to the table
below to check if you have received all the packages required.
1. Boiler body + Accessories
2. Baffle plates
3. Casing
4. Cable channel
5. Technical documents
6. Control panel
All models can be equiped with one of the following control panels: KSF ISR or KSF CE control panel.
Number of sections 8 9 10 11 12 13 14
Rear section Package 8229-0003 1111111
Special intermediate section Package 8229-0005 1111111
Normal intermediate section Package 8229-0001 567891011
Front section Package 8229-0002 1111111
Accessories (contents depend upon model) 1 111111
Common accessories 1 Package CS 20 CS 20 CS 20 CS 20 CS 20 CS 20 CS 20
Lower insulation, boiler body 1 Package CS 51 CS 53 CS 53 CS 55 CS 55 CS 57 CS 57
Base frame - dimensions depend upon model 1 111111
Number of sections 8 9 10 11 12 13 14
Baffles 1 Package CS 30 CS 31 CS 31 CS 32 CS 32 CS 33 CS 33
Number of sections 8 9 10 11 12 13 14
Casing (common parts) Package MP133 1 111111
Casing, variable parts Package MP2 - - 1 - - 1 -
Package MP3 1 - - 1 - - 1
Package MP4 - 111222
Package MP5 - 1 - - 1 - -
Number of sections 8 9 10 11 12 13 14
Cable channel 1 Package CS 41 CS 42 CS 43 CS 44 CS 45 CS 46 CS 47
Number of sections 8 9 10 11 12 13 14
1 Package (Content depends upon country) 1 111111

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12/07/2011 - 300025089-001-B NXR4i
2 Mounting
Tools required
- 1 22 box spanner
- 1 Phillips screwdriver
- 1 hammer
- 1 putty gun
- 1 stanley knife
- 13 - 19 - 24 spanners
- 1 Allen key (12 mm spanner)
- Assembly tool: JDTE Plus
Warning: Assemble the boiler in the order given by the
numbers of each figure, in compliance with all the
instructions.
Symbols used
Caution danger Risk of injury and damage to equipment. Attention must be paid to the warnings on
safety of persons and equipment.
Specific information Information must be kept in mind to maintain comfort.
ZReference Refer to another manual or other pages in this instruction manual.

4NXR4i 12/07/2011 - 300025089-001-B
Boilers supplied with an assembled body
start assembly with stage 19: Hydraulic test.
For boiler supplied with the boiler body in bulk
Mounting: Assembly of the elements is carried out from back
to front, as illustrated below.
Front - Rear
(1) Special intermediate section in front of rear section. The shape of
the intermediate element is particular: the slot includes one triangle
instead of two.
ZSee step 10: Assembling the sections.
Ensure that no residue remains between the various
elements ; use if necessary a magnetic rod.
Boiler type Rear section Special intermediate
section (1) Normal intermediate section Front section
NXR4i-8 1151
NXR4i-9 1161
NXR4i-10 1171
NXR4i-11 1181
NXR4i-12 1191
NXR4i-13 11101
NXR4i-14 11111

5
12/07/2011 - 300025089-001-B NXR4i
1
2
M001233-C
C003341-A
1
2

6NXR4i 12/07/2011 - 300025089-001-B
3
Use the holes corresponding to the number of the boiler's elements, following the indication on the frame.
4
1
1-8 /-10 /-12 /-14
-9 /-11 /-13
2x
2x
M12 x 25
M12
C003342-C
2
C003345-A
M12
8229-0003

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5
(1) Sandpaper
Handle the nipples with gloves, there might be sharp
edges.
6
(2) Putty for nipple (Supplied)
Clean the nipples and coat them with the product.
(1)
2
C003346-B
(1)
1
C003347-B

8NXR4i 12/07/2011 - 300025089-001-B
7
8
(3) Silicon (supplied)
C003348-C
C003349-B
1
100

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9
(1) Thermocord (Supplied)
Donotpullon thesealwhile insertingit.Otherwise,youmay stretch itandreduceits thickness.Youmustnot makethejunction
point with the thermocord in the lower part of the section.
10
C003350-A
C003353-B
8229-0005

10 NXR4i 12/07/2011 - 300025089-001-B
11
12
Caution: Do not overtighten. Correct tightening is achievedwhen the cast iron sections come into contact.
C003354-A
C003355-A

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13
(1) Sandpaper
(2) Putty for nipple (Supplied)
Clean the nipples and coat them with the product.
Caution:Donotovertighten.Correcttighteningisachieved
when the cast iron sections come into contact.
C003358-D
8229-0005
8229-0003
8229-00018229-0001
8229-0002
100

12 NXR4i 12/07/2011 - 300025089-001-B
14
- Fit the upper assembly rods (boiler body accessories) in the order shown in the (3) diagram (See following pages: Top view). Place the
expansion spring and its washer on each rod at the rear. Stop tightening the nuts when the free space between the threads is around
2 mm.
- Fit the upper casing supports (package MP4) as per the details C-D and the upper cross-bars (package MP133-MP2-MP3-MP5) with the
assembly rods (boiler body accessories package) as per the details A-B.
- Fit the lower assembly rods in the order shown in the (4) diagram (See following pages: Bottom view).
- Remove the assembly tool.
A
C D
A B
B
C
D
C003359-A

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(1) Front - (2) Rear - (3) Top view - (4) Bottom view (See next page)
NXR4-8
NXR4-9
NXR4-10
NXR4-11
NXR4-12
NXR4-13
NXR4-14
L000084-B

14 NXR4i 12/07/2011 - 300025089-001-B
(1) Front - (2) Rear - (3) Top view - (4) Bottom view
NXR4-8
NXR4-9
NXR4-10
NXR4-11
NXR4-12
NXR4-13
NXR4-14
C003455-A
(4)

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15
16
M12 x 61/ 57
2x
M12 x 33/ 26
4x
C003361-B
A
A
A
C003360-B
4x
4x
M12 x 40
M12

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17
18
10x
C003362-B
M12
8x
C003363-B

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19 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.
Ensure that all the air in the boiler is vented to avoid any bursting of the body.
8x
C003364-B
1
2
C003366-B
4
3

18 NXR4i 12/07/2011 - 300025089-001-B
Maintain pressure for at least 10 minutes. Any drop in pressure indicates a leakage in the boiler body.
20
A: For NXR4i 8 to 10.
B: For NXR4i 11 to 14, the return collector is replaced by a
collector with water distributor (marked "INJ").
C003367-B
7
8
611
9
10
5
8x
C003454-A
INJ
INJ
INJ
A
B

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21
22
Fit the hinge on the door of the combustion chamber (boiler
body accessories package) to the left or right depending on
which way you wish to open it.
8x
M12 x 50
C003414-B
C
B
A
D
2x
2x
4x
3x
M12 x 30
M12 x 25
M12 x 85
M12
C003415-A
C
C
C
B
B
A
C
A
D
D
D

20 NXR4i 12/07/2011 - 300025089-001-B
23
Leave the 3 screws HM12x30 and the 3 washers L12 in
place on the combustion chamber door on the side
opposite to the added hinge.
24
3x
M12 x 30
C003416-B
0 18
M12
4x
C003417-B