Potterton NXR5i User manual

NXR5i
Fuel oil/gas boilers
Assembly
Instructions
C003966-A
300029104-001-02
EN

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

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25/09/2012 - 300029104-001-02 NXR5i
1 Package list
Before starting to assemble the boiler, refer to the table below to check if you have received all the packages required.
Boiler body + Accessories
`Boilers supplied with an assembled body
`Boilers supplied with an unassembled body
(1)The distributing tube fitting for NXR5i boilers with 15 to 19 sections is included in the accessory package.
(2)The diaphragm for NXR5i , 14 section boilers is delivered in the additional accessory kit package.
Boiler NXR5i - Number of sections 14 15 16 17 18 19 20 21 22 23 24 25
Assembled boiler body (contents depend upon model) 1 11111111111
Cleaning tool kit (contents depend upon model) 1 11111111111
Boiler NXR5i - Number of sections packag
e14 15 16 17 18 19 20 21 22 23 24 25
Base frame (dimensions depend upon model) 111111111111
Rearsection 111111111111
Normal intermediate section 9 10 11 12 13 14 14 15 16 17 18 19
Specialintermediatesection 333333444444
Frontsection 111111111111
Set of assembly rods + Cleaning tools
(contents depend upon model) 111111111111
Standard accessory kit
(contents depend upon model) 1
FA 49
FA50(1)
FA51(1) FA52(1) FA53(1) FA54(1)
FA55 FA56 FA57 FA58 FA59 FA60
Additional accessory kit
(contents depend upon model) (2) 1
FA68(2)
FA69 FA70 FA71 FA72 FA73 FA74 FA75 FA76 FA77 FA78 FA79
Plainfurnaceplate 111111111111
Flue gas connection plate with opening Ø 400 1111111-----
Plainfluegasconnectionplate -------11111
Fluegasbox 111111111111
Distributing tube fitting (1) -(1) (1) (1) (1) (1) 111111

4NXR5i 25/09/2012 - 300029104-001-02
Baffles
Casing fittings
Variable casing parts
Insulating material for body
Boiler NXR5i - Number of sections package 14 15 16 17 18 19 20 21 22 23 24 25
Baffles CM22 -11111------
CM23 111111222222
Boiler NXR5i - Number of sections package 14 15 16 17 18 19 20 21 22 23 24 25
Casingfittings MR338 1111--------
MR339 - - - -11111111
MR3 1-----------
MR4 -1-1-11-1-1-
MR5 --1-1--1-1-1
FA10 - - -221- -2211
FA11 222112332233
Boiler NXR5i - Number of sections package 14 15 16 17 18 19 20 21 22 23 24 25
Variablecasingparts FA16 - - - -11111111
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 20 21 22 23 24 25
Insulatingmaterialforbody FA34 1-----------
FA35 -1----------
FA36 --11--------
FA37 ----11------
FA38 ------1-----
FA39 -------11---
FA40 ---------11-
FA41 -----------1

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25/09/2012 - 300029104-001-02 NXR5i
Control panel
All models can be equiped with one of the following control panels: KSF-CE or KSF-ISR control panel.
Accessories - Available as an option*
* Refer to the applicable price list for 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 111111111111
Connecting plate with opening or plain
connecting plate - Ø 300
or Plain connection plate
111111111111
Set of anti-vibration studs 8208-7758 1 1 1 - --------
8208-7759 - - - 1 1 1 1 - - - - -
8208-7760 -------11111

6NXR5i 25/09/2012 - 300029104-001-02
2 Mounting NXR5i
Warning: Assemble the boiler in the order given by the numbers of each figure, in compliance with all the instructions.
Tools required
- 1 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

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25/09/2012 - 300029104-001-02 NXR5i
Assemble the boiler body from the rear to the front:
1. assemble the rear section,
2. assemble all the normal intermediate sections,
3. assemble all the special intermediate sections,
4. assemble the front section.
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 1931
NXR5i-15 1103 1
NXR5i-16 1113 1
NXR5i-17 1123 1
NXR5i-18 1133 1
NXR5i-19 1143 1
NXR5i-20 1144 1
NXR5i-21 1154 1
NXR5i-22 1164 1
NXR5i-23 1174 1
NXR5i-24 1184 1
NXR5i-25 1194 1
104
8228-0004 8228-0001
111
2
8228-0002
151
3
8228-0003
104
4

8NXR5i 25/09/2012 - 300029104-001-02
1
`to : Assembly of the base frame, delivered unassembled.
`Place the frame on the floor, taking care to note the TOP and FRONT positions.
`Fit the fastening brackets as shown, depending on the type of boiler (1 Screw Ø 12x40 - 19 spanner).
DESSUS
NOBE
TOP
NAVA T
VORN
FRONT
DESSUS
OBEN
TOP
ANTAV
VORN
FOR NT
3
3
M000309
3
1
2
3
23
E
DSSUS - O BEN - TOP
DESSUS - OBEN - TOP
DESSUS - O BEN - T OP
DESSUS - OBEN - TO P
48555N0 2A
F
R
ONT
VORN
A
V
ANT
FRO
N
T
VO
RN
A
V
ANT
F
R
O
NT
VO
RN
A
V
A
N
T
F
R
O
N
T
V
OR
N
A
V
A
N
T
19
A
B
ABoilers: 14, 16, 18, 20, 22, 24 sections
BBoilers: 15, 17, 19, 21, 23, 25 sections

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2
`Establish the location of the frame on the basis of the opening direction of the furnace door and the length of the burner.
Leave enough clearance at the rear of the boiler for water connections and the distributing tube.
Refer to the installation and maintenance instructions 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 the bottom of the section.
Boilers: 14, 16, 18, 20, 22, 24 sections
Boilers: 15, 17, 19, 21, 23, 25 sections
00 8
M00 5

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4
`Fill the bottom of the U groove (located on the periphery of the section) with a continuous bead of DOW CORNING silicon, diameter
approximately 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
001
100
a
M000060

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6
(1) Sandpaper
Handle the nipples with gloves, there might 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.
ARRIÈREDESSUS -OBEN-TOPVA ANT
ARRIR
ÈEDE SSUS-OEB N-TOP AVANT
M000062

12 NXR5i 25/09/2012 - 300029104-001-02
8
`Fill the bottom of the W groove opposite the U groove for the intermediary parts (located on the periphery of the section) with a continuous
bead of DOW CORNING silicon, diameter approximately Ø 5 mm.
9
Rear section
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 bores.
100 100
010
010
M000063
a
M000064
1
2

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10
`Put the assembly tool in position.
`Tighten gradually so as to bring 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

14 NXR5i 25/09/2012 - 300029104-001-02
12
`Trim off any projecting ends of the thermocords the sweeping covers.
13
Fitting the upper and lower assembly rods
`On the lower 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
M06000 8
2

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14
Rear
Front
`Put in place the upper assembly rods in the two front and rear lugs.
`Mount the 2 crosspieces (supplied in package MR338/MR339) with their bends turned backwards and fasten them to the rods with an
expansion spring, 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 between the spires of the springs is about 1mm.
00069M0
2
2
21

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Rear
Front
Dimensions are given in millimeters.
NXR5-14
NXR5-15
NXR5-16
C003936-A

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Rear
Front
Dimensions are given in millimeters.
C003937-A
NXR5-19
NXR5-18
NXR5-17

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Rear
Front
Dimensions are given in millimeters.
C003938-A
NXR5-20
NXR5-21
NXR5-22

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Rear
Front
Dimensions are given in millimeters.
.
NXR5-23
NXR5-24
NXR5-25
C003939-A

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15
Assembling the pocket and the plugs
(1) Front
`Assemble the pocket for the thermostats and thermometer in:
- the third 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