Potterton NXR5i Manual

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

2NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
Declaration of conformity 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.

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

4NXR5i 17/04/2012 - 300029103-001-01
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

PROVISOIRE
5
17/04/2012 - 300029103-001-01 NXR5i
1Introduction
1.1 Symbols and abbreviations
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.
DHW: Domestic hot water
1.2 General
We congratulate you for having chosen a quality product. We
advise you warmly to read the instructions below in oder to
ensure the optimal operation of your burner. We are convinced
that it will give you complete satisfaction and meet all your
expectations.
`Keep these instructions in a safe place close to the appliance.
`In the interest of customers, Chappée are continuously
endeavouring to make improvements in product quality. All the
specifications stated in this document are therefore subject to
change without notice.
1.2.1 Manufacturer's liability
The liability of Chappée as the manufacturer may not be invoked in
the following cases:
- Failure to abide by the instructions on using the appliance.
- Faulty 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 compliance with the prevailing
legislation and standards.
`Perform the initial start up and carry out any checks necessary.
When handing over the installation to the user, the installer will draw
the user's particular attention to the following points:
- The safety of the installation.
- The functioning of the installation and the boiler.
- Periodic maintenance to be done.
1.2.3 User's liability
To ensure the optimum operation of your appliance, we strongly
recommend that you abide by the following instructions:
`Read and follow the instructions given in the manuals provided
with the appliance.
`Call on qualified professionals to:
- Carry out installation in compliance with the prevailing legislation
and standards.
- Perform the initial start up.
- Carry out work on the appliance and the installation.
- To carry out inspections and maintenance required by a qualified
professional.
`Get your installer to explain your installation to you.

6NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
1.3 Homologations
1.3.1 Certifications
CE identification no: 1312 AQ 954.
1.3.2 Directive 97/23/EC
Gas and oil boilers with a maximum operating temperature of 110°C
and hot water tanks 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/EC, 2006/95/EC and 2004/108/EC.

PROVISOIRE
7
17/04/2012 - 300029103-001-01 NXR5i
2 Safety instructions and recommendations
2.1 Safety instructions
For a proper operating of the boiler, follow carefully the
instructions.
Only qualified professionals are authorised to work on the
appliance and the installation.
Incorrect use or unauthorised modifications to the
installation or the equipment itself invalidate any right to
claim.
Before any work, switch off the mains supply to the
appliance.
Keep to the polarity shown on the terminals: phase (L),
neutral (N) and earth 4.
Keep children away from the boiler.
2.1.1 Fire hazard
It is forbidden to store inflammable products and materials
in the boiler room or close to the boiler, even temporarily.
If you smell gas, do not use a naked flame, do not smoke,
do not operate electrical contacts or switches (doorbell,
lights, motor, lift, etc.).
1. Shut off the gas supply.
2. Open the windows.
3. Extinguish all flames.
4. Evacuate the premises.
5. Contact a qualified professional.
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 may reach 95°C.
- The temperature of the domestic hot water may reach 65°C.
2.1.4 Risk of damage
Do not stock chloride or fluoride compounds close to the
appliance.
Install the appliance in frost-free premises.
Do not neglect to service the appliance: Contact a qualified
professional or take out a maintenance contract for the
annual servicing of the appliance.
2.2 Recommendations
`Check regularly that the installation contains water and is
pressurised.
`Keep the appliance accessible at all times.
`Avoid draining the installation.
`The appliance should be on Summer or Antrifreeze mode rather
than switched off to guarantee the following functions:
- Anti blocking of pumps
- Frost protection
- Protection against corrosion on domestic hot water tanks fitted
with a titanium anode

8NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
3 Technical description
3.1 General 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

PROVISOIRE
9
17/04/2012 - 300029103-001-01 NXR5i
3.3 Technical specifications
Conditions of use:
Maximum operating pressure: 6 bar
Maximum operating temperature: 100 °C
Boiler thermostat setting: 30 to 90°C
Safety thermostat setting: 110 °C
*Maintenance consumption: total heat emission when the burner is
off as a percentage of the nominal input power when the difference
between the mean boiler temperature and the room temperature is
30 K - in accordance with DIN 4702 - EN 303.
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
Useful output kW 754
to
812
812
to
870
870
to
928
928
to
986
986
to
1044
1044
to
1102
1102
to
1160
1160
to
1218
1218
to
1276
1276
to
1334
1334
to
1400
1400
to
1450
Power input kW 821
to
890
897
to
967
954
to
1024
1022
to
1093
1077
to
1147
1146
to
1216
1198
to
1268
1265
to
1336
1333
to
1404
1393
to
1464
1463
to
1544
1532
to
1595
Number of sections 14 15 16 17 18 19 20 21 22 23 24 25
Water content l 655 693 731 769 807 845 905 943 981 1019 1057 1095
Water resistance
(1)
∆T = 10K 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 2.32.42.52.62.72.853 3.13.23.33.43.5
Flue gas temperature - Ambient
temperature (1) (3)
K<190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190
Mass flue gas
flow rate (1) (2)
Fuel oil Kg/h 1380 1480 1580 1670 1770 1870 1970 2070 2170 2260 2360 2460
Gas 1450 1550 1650 1760 1860 1960 2070 2170 2270 2380 2480 2580
Combustion
chamber
Inscribed
diameter
mm 614 614 614 614 614 614 614 614 614 614 614 614
Equivalent
diameter
mm 694 694 694 694 694 694 694 694 694 694 694 694
Depth mm 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
Volume m30.57 0.61 0.65 0.70 0.74 0.78 0.84 0.88 0.92 0.96 1.00 1.05
Maintenance
consumption* ∆T = 30K %0.07 0.07 0.07 0.07 0.07 0.07 0.06 0.06 0.06 0.06 0.06 0.06
Weight (empty) kg 3171 3364 3561 3756 3955 4124 4343 4538 4734 4930 5107 5297
(1) Nominal operation (top boiler power)
(2) CO2= 13.1 to 13.5% with fuel oil and 9.5% with natural gas.
(3) Boiler temperature: 80 °C
Ambient temperature: 20 °C
(4) In order for the boiler to operate correctly, it is
imperative to respect the draught at the nozzle.

10 NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
4 Installation
4.1 Regulations governing installation
4.1.1 In general
Installation must be carried out in accordance with the
prevailing regulations, the codes of practice and the
recommendations in these instructions.
4.1.2 In particular for France
Heating installations must be designed and constructed in such a
way as to prevent the return of water from the heating circuit and
products put into it into the drinking water network located upstream.
The installation must not be in direct relation with the drinking water
network (Article 16-7 of the departmental health Directive).
When these installations are fitted with a filling system connected to
the drinking water network, they comprise a CB disconnector
(disconnector for zones with non-controllable pressure differences)
which satisfy the functional requirements of the NF P 43-011
standard.
Residential buildings
Statutory terms and conditions of installation and maintenance:
The installation and maintenance of the appliance must be carried
out by a qualified professional in compliance with the statutory texts
of the codes of conduct in force, particularly:
- Order of 27 April 2009 amending the Order of 2 August 1977
Technical and safety rules applicable to combustible gas and
liquefied hydrocarbon 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 of installation:
The installation and maintenance of the appliance must be carried
out in compliance with the statutory texts and rules of the codes of
conduct in force, particularly:
- Safety regulations against fire and panic in establishments open to
the public:
a. General regulations
For all appliances:
- Articles GZ - Installations operating on combustible gases and
liquefied hydrocarbons.
Then, depending on use:
- Articles CH-Heating, ventilation, refrigeration, air conditioning and
production of steam and domestic hot water.
b. Instructions specific to each type of establishment open to the
public (hospitals, stores, etc.).
Certificate of compliance (only concerns NXR5i
boilers fitted with a gas burner)
In application of Article 25 of the Order of 27 April 2009 amending the
Order of 2 August 1977 amended and Article 1 of the amended Order
of 05/02/1999, the installer is required to draw up certificates of
conformity approved by the Ministers responsible for construction
and gas safety:
- Different forms (forms 1, 2 or 3) for a new gas installation
- Model 4 in particular after replacing a furnace with a new one.

PROVISOIRE
11
17/04/2012 - 300029103-001-01 NXR5i
4.2 Package list
ZSee assembly instructions
4.3 Mounting
ZPHRASE NON TRADUITE : 55086.
4.3.1 Main dimensions
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

12 NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
with models NXR5i-21, NXR5i-22, NXR5i-23,, NXR5i-24 and
NXR5i-25, a plain plate which must be cut out is supplied
without the 100 mm chimney connection.
4.3.2 Data plate
The rating plate fixed on the side of the boiler during installation is
used to identify the boiler correctly and also provides the main
specifications of the boiler.
Boiler type
Manufacturing date
Year of manufacture
Week of manufacture
Serial no. of the appliance
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
A (mm) 2538 2649 2760 2871 3017 3128 3279 3390 3501 3612 3723 3834
B (mm) 1744 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
ØF(mm) 400400400400400400400*****
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
L (mm) 2105 2245 2355 2445 2555 2645 2845 2955 3045 3155 3245 3355
M (mm) 259 324 269 321 265 299 269 324 269 324 249 303
T (mm) 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
U (mm) 2132.5 2243.5 2354.5 2465.5 2576.5 2687.5 2838.5 2949.5 3060.5 3171.5 3282.5 3393.5
* Plain plate, requires cutting. Maximum cut-out 500 x 700.
** G = Length required for clearing the water distributing tube.
*** Dimension representing the end of the 100 mm long chimney
connection.
C003929-B

PROVISOIRE
13
17/04/2012 - 300029103-001-01 NXR5i
4.3.3 Boiler location
For the assembly and because of their design, NXR5i boilers require
no special base. Their closed furnace system means that the floor
need not have refractory properties. All you have to ensure is that the
floor can support the weight of the boiler when it is fitted for operation.
If the boiler location is not determined precisely, leave enough space
around the boiler to facilitate monitoring and maintenance
operations.
Boiler body *
Straight connection (not supplied) *
* 1) In order to facilitate subsequent work on the boiler(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 the basis of the dimensions of
the burner.
240
C003928-A
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
L 2105 2245 2355 2445 2555 2645 2845 2955 3045 3155 3245 3355
M 259 324 269 321 265 299 269 324 269 324 249 303
C min. 300 436 436 656 656 656 936 936 936 1266 1266 1266
D min. - 136 136 356 356 356 636 636 636 966 966 966

14 NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
4.3.4 Ventilation
The location of air inlets in relation to the high ventilation openings
shall ensure that the air is renewed in the entire volume of the boiler
room.
Position the air inlets in relation to the high ventilation vents in order
that the air is refreshed throughout the boiler room.
It is in any case imperative to conform to the local
regulations in force.
Do not obstruct the air inlets in the room (even partially).
Upper and lower air vents compulsory:
Top ventilation:
- Cross section equal to half the total cross section of the flue gas
pipes with a minimum of 2.5 dm
2
.
Bottom ventilation:
- Direct air inlet: S (dm2)
P = Installed power in kW
In order to avoid damage to the boiler, it is necessary to
prevent the contamination of combustion air by chlorine
and/or fluoride compounds, which are particularly
corrosive.
These compounds are present, for example, in aerosol sprays,
paints, solvents, cleaning products, washing products, detergents,
glues, snow clearing salts, etc.
Therefore:
• Do not pull in air evacuated from premises using such products:
hairdressing salons, dry cleaners, industrial premises (solvents),
premises containing refrigeration systems (risk of refrigerant
leakage), etc.
• Do not 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 building for collective use
(installations less than 70 kW)
`The fresh air inlet must:
- Come out in the lower section of the premises,
- Have a free minimum cross section calculated on the basis of 0.03
dm² per kilowatt installed output and at least equal to 2.5 dm².
`The air discharge must:
- Be located in the upper section of the premises,
- Rise above the roof (unless using an equivalent system which
does not cause a nuisance to neighbours),
- Have a free cross section (corresponding to 2/3 of that of the air
inlet and at least equal to 2.5 dm²).
Generator installed in a builing for individual use
`An adequate supply of fresh air must be provided as close as
possible to the appliances. Its cross section must be at least 0.5
dm².
`In the upper section of the premises, an air outlet must ensure
effective ventilation.
Establishments open to the public
`New establishment: Refer to the order of 25/06/1980
(installations of more than 20 kW and less than or equal to 70
kW).
`Existing establishment: Refer to the order of 25/06/1980
(installations less than 70 kW).
0≥86,P
20
--
----------------------

PROVISOIRE
15
17/04/2012 - 300029103-001-01 NXR5i
4.4 Hydraulic connections
4.4.1 Dimensional information required
4.4.2 Hydraulic connection of the water circuit for domestic use
ZSee: Domestic hot water calorifier instructions.
Draining outlet 3/4"
Heating return:
- 14 to 17 sections : 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) 217 188 189 210 236 257 208 209 230 231 252 253
H (mm) -2 -31 -30 -9 -8 13 -36 -35 -14 -13 8 9

16 NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
4.4.3 Hydraulic connection of the heating circuit
Water flow in the boiler
The water flow in the boiler when the burner is operating must
correspond with the following formulae:
- Nominal water flow Qn = 0.86 Pn/20.
- Minimum flow Qmin = 0.86 Pn/45 (this flow also corresponds with
the minimum recycle flow in the boiler).
- Maximum water flow Qmax = 0.86 Pn/5.
Qn = flow in m3/h
Pn = Nominal output (full boiler output) in kW.
Connect the flow controller to the terminal blocks UV in the
control panel KSF CE.
Connect the flow switch to Qbetween terminals SK1 and SK2
on the KSF ISR control panel.
Operation in cascade
After stopping the burner:
- Timeout required before the order to close a 2 way valve: 3 min.
- Switch a possible shunt pump (located between the boiler and a
butterfly valve) off via the end of run contact of the butterfly valve.
Operation with 2-stage burner
- 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 temperature in the boiler is maintained at 50°C or more:
The burner can modulate down to 30% of the nominal stage.
- Operation at modulated low temperature (minimum outlet
temperature: 40°C); The burner can modulate down to 50% of the
nominal stage.
ZRefer to the installation and service manual for the KSF ISR
control panel.
Minimum safety valve flowrate as a function of maximum boiler nominal output
Example:
Maximum boiler nominal output is 800 kW.
Minimum safety valve flowrate must be 2600 Kg/h.
There must be no total or partial closing mechanism
between the boiler and the safety valves (France: DTU -
65.11, § 4.22 - NF P 52-203).
Minimum relieving capacity
Maximum gross boiler output
Unit (a) = kW
(b) = lb/h
(c) = MBtu/h
(d) = Kg/h

PROVISOIRE
17
17/04/2012 - 300029103-001-01 NXR5i
4.5 Filling the system
Filling shall be performed with a low flow rate from a low point in the
boiler room in order to ensure that all the air in the boiler is bled from
the high point of the system.
All the pumps must be stopped before filling (included shunt
pump(s)).
VERY IMPORTANT: Instructions for starting up the boiler
for the first time after the system is fully or partly drained:
If all the air is not bled naturally to an expansion vessel
which opens out onto the air, the system must include
manual bleeder valves, in addition to automatic bleeder
valves 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 of the boiler.. Fit a 1/4 turn valve (not supplied) on the
opening to remove the sludge.
Sludge removal leads to the draining of large quantities of water, so
remember to refill the system after the operation.
never replace a boiler in an existing system without carefully
rinsing the system first. Install a sludge decanting pot on the
return pipe, very close to the boiler.
2" tapped sludge removal hole
C003964-A

18 NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
4.7 Chimney connection
The high-performance features of modern boilers and their use in
specific conditions as a result of the advance in burner technology
(e.g. first-stage or low modulation range operation) lead to very low
flue gas temperatures (<160°C).
For this reason:
- Use flue gas pipes designed to enable the flow of condensates
which may result from such operating modes in order to prevent
damage to the chimney.
- Install a draining tee at the bottom of the chimney.
The use of a draught moderator is recommended as well.
4.7.1 Flue size
Refer to applicable regulations while determining the size of the flue. Please note that NXR5i boilers have pressurised and tight furnaces
and that the pressure at the nozzle must not exceed 0 mbar, unless
special 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 supplied with a plain plate. The
maximum cut-out dimensions are 500 x 700 mm.
Fit a measuring point (Ø 10 mm hole) on the flue, in order to adjust
the burner (combustion check).
*Dimension representing the end of the 100 mm long chimney
connection.
Nota: with models NXR5i-21, NXR5i-22, NXR5i-23,, NXR5i-24 and
NXR5i-25, a plain plate which must be cut out is supplied without the
100 mm chimney connection.
C003965-A
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
Ø F 400 400 400 400 400 400 400 Plain plate
K 10 -19 -18 3 4 25 -24 -23* -2* -1* 20* 21*

PROVISOIRE
19
17/04/2012 - 300029103-001-01 NXR5i
4.8 Fuel-oil or gas connections
ZRefer to the instructions supplied with the burner.
4.9 Electrical connections
ZRefer to the connection instructions supplied with the control panel..
5 Commissioning
ZSee:
- Control panel instructions
- Burner instructions
- Domestic hot water calorifier instructions
6 Switching off the boiler
`Set the On/Off switch to O.
ZSee: Control panel instructions
`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 if the heating is stopped when there is a risk of freezing
We recommend the use of a correctly dosed antifreeze agent to
prevent to the heating circuit from freezing.
If this cannot be done, drain the system completely.

20 NXR5i 17/04/2012 - 300029103-001-01
PROVISOIRE
7 Checking and maintenance
7.1 System maintenance
7.1.1 Water level
Regularly check the level of water in the system and top up if
required, taking care that cold water is not added suddenly into the
boiler when it is hot.
This operation should be required only a few times in each heating
season, with very low quantities of water; otherwise, look for the leak
and repair it.
7.1.2 Draining
We advise you against draining the system unless it is absolutely
necessary.
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
regulations and specific needs.
7.2.1 Sweeping
Step 1:
`Cut the power supply to the boiler.
Remove the upper front panel.
Remove the front upper holding cross-bar.
Unhook the lower left and right front panels.
Remove the lower front panel.
Step 2:
`Unfasten the wing nuts and remove the 4 sweeping doors.
C001001-B
M000039
2