Potterton NXR4 Installation, Operation & Maintenance Manual
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Potterton NXR4 Installation, Operation & Maintenance Manual

Potterton NXR4 Installation, Operation & Maintenance Manual

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NOVEMBER 2003
heating specialists

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Summary of Contents for Potterton NXR4

  • Page 1 NOVEMBER 2003 heating specialists...
  • Page 2 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 1 NXR4 Fig. 1 – General Data & Dimensions (all dimensions in mm) 1070 PN16 125mm Mating Flanges ØD 3/4" Drain PN 16 125mm Valve Mating Flange. Front...
  • Page 3 SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 2 NXR4 Table 3 Model CE Number 0085AQ0752 Output Fuel 42.7 49.4 56.1 62.9 69.7 76.4 83.2 89.9 Consumption lit/hr 35.7 42.4 55.7 62.5 69.1 75.8 82.5 89.2 Input (Net) 347.6...
  • Page 4 If system return temperatures below 55°C are required then contact the Potterton Commercial Fuel oil consumption is based on Class D (35 Technical Department. second) gas oil with a calorific value of 58.24 MJ/lit and a density of 0.855 kg/lit, Kerosene (Class C2)
  • Page 5 SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 4 NXR4 CLEARANCES The minimum boiler room clearances for access, erection and maintenance are given in Fig.2 and Fig.3, the dimensions are minimum values. There is no minimum clearance above the boiler, however, it is recommended that clearance is left above the top of the instrument panel to facilitate its removal.
  • Page 6 Sequence Controls at the erection stage. Shipping – Packaging The NXR4 is suitable for use on fully pumped open vented systems or a sealed system with a maximum The boiler package is delivered unassembled on two design pressure of 8-bar (116 p.s.i.).
  • Page 7 • BS 7671: 1992 – Requirements of Electrical Installations, IEE Wiring Regulations 16 Edition For further advice on installations, refer to Potterton • BS 6644: 1991 – Installation of Gas Fired Hot Technical Bulletins 1-4 Water Boilers for Inputs between 60kW and 2MW •...
  • Page 8 For further information regarding ventilation and flueing see Potterton Technical Bulletin No.4, current Further guidance on ventilation for gas appliances is issue or see relevant British Standard publication provided by BS 6644 - 1991.

  • Page 9: Boiler Protection

    Additionally the water system should be free of leaks to prevent raw water make up which will General dilute any inhibitors, promote corrosion and form lime scale. Potterton Commercial boilers are suitable for use on sealed systems designed accordance...

  • Page 10: Boiler Erection

    Working on appliances can be broken down into two erection and commissioning is carried out by the main systems of work. Potterton Commercial service department and the system meets with our recommendations. Please Safe systems of work are adapted for all boiler refer to our standard terms and conditions for further maintenance and repair work undertaken on site.
  • Page 11 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 10 NXR4 COSHH During the erection procedure there are a number of attending site. If this is unable to be done notice items which are subject to the Control Of Substances prior to attending site be given.
  • Page 12 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 11 NXR4 BOILER ERECTION Slide sections together that SECTION ASSEMBLY intermediate section nipple ports slightly engage with the corresponding nipples on the rear The boiler sections are not self-supporting until the section.
  • Page 13 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 12 NXR4 Fig. 4 – Fluegas Passes Centre Intermediate Section Front Intermediate Section Rear Intermediate Section Fig. 5 – Section Build FRONT REAR MIDDLE REAR FRONT INTER INTER...
  • Page 14 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 13 NXR4 Front Inter Fig. 6 – Section Layout Section AV Markings Face Middle Inter Rear Inter Front Section Towards Front Section M Section AR Rear Section No of Sections...
  • Page 15 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 14 NXR4 PULLING UP THE SECTIONS Fig. 7 – Sealing In order to erect the boiler it is necessary to use a set Assembly Tools of assembly tools, please find options available:...
  • Page 16 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 15 NXR4 Top Flange Slip on the Welded Flange Fit the four M16 x 66 studs on the upper part of the Connect the PN16 – DN 125 flanges onto the front section.
  • Page 17 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 16 NXR4 Fig. 10 – Exchanger (Exploded View) Top Flange Flue Access Doors Tie Rods Sensor Pockets Section Markings Flame Viewing Port Marking to be Towards Front Stainless Steel...
  • Page 18 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 17 NXR4 Burner Support Plate (see Fig. 9) Fig. 11 – Insulation Blanket Position Bond the ceramic fibre cord in the front section groove (the cord should be joined on the opposite side to the hinges).
  • Page 19 SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 18 NXR4 Fig. 13 – Casing (Exploded View) Front Right / Rear Left Upright Front Left / Rear Right Upright Cross Member Common ½ Cross Member Splice Plate ½...

  • Page 20: Fitting The Casing

    POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 19 NXR4 FITTING THE CASING Side Fastening Bracket (49) Open both casing packages. Insert the side panel fastening bracket pin into the lower fold of the side panel. Secure to the upright with Exchanger Lagging Materials (see Fig.

  • Page 21: Instrument Panel

    SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 20 NXR4 INSTRUMENT PANEL Fig.14 - Control Panel Configuration Kit 1 Water Flow Thermometer - indicates Fuse – the boiler control panel is fused at the water flow temperature of the boiler 6.3 Amps.
  • Page 22 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 21 NXR4 ASSEMBLY OF INSTRUMENT PANEL – MUST BE CARRIED OUT BY A COMPETENT PERSON 17 Position the control panel on the front top, lining up with its fastening position guiding the wires Open the control panel carton.

  • Page 23: Fitting The Burner

    Burner Cables The housing for the thermometer is positioned on the The NXR4 is supplied as standard fitted with a 7-pin control panel front and the thermometer in the flue and a 4-pin Weiland plug for connection to the burner.
  • Page 24 CONNECTIONS Boiler & Burner Power Supply The NXR4 is supplied with either single phase or Three Phase Installation three phase burners. The electrical supply to the boiler installation should be connected via a fused CAUTION: If the burner motor is supplied with three- isolator.

  • Page 25: Connecting The Gas Supply

    SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 24 NXR4 Volt Free Contacts under sustained cold and exposed conditions, Class D grade fuel oil should be stored and supplied to the Volt free connection should be taken from the control burner at a minimum temperature of 5°C, in line with...

  • Page 26: Boiler Commissioning

    The items listed below have been put together as a erection and commissioning is carried out by the guide to what actions should be completed before the Potterton service department. Please refer to our commissioning of a boiler takes place. standard terms and conditions for further details.

  • Page 27: Important Safety

    The commissioning form provided at the back of this manual MUST be completed and returned to Commissioning – Live Run Potterton Commercial at the address on the back page. This will enable the burner to be commissioned fully and should include:...

  • Page 28: Fault Finding

    The use of a primary loop system is highly recommended to provide a constant boiler flow rate under all operating conditions. For further information please refer to the Potterton Technical Bulletin series. Burner Lockout The package burners supplied with the boiler unit have an integral safety system to allow the safe and reliable operation of the burner.

  • Page 29: Boiler Maintenance

    Class D (35 second) and Class 2 (28 registration of personnel undertaking work on these second) during the heating season but more frequent appliances. This facility is available from Potterton attention may be necessary dependant on the Commercial Division service department, details are operating conditions to prevent the formation of hard available on the rear of this manual.
  • Page 30 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 29 NXR4 Fig.19 – Boiler Wiring Diagram...
  • Page 31 SECTION 6 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 30 NXR4 Wiring Diagram – Notes & Legend Important: Maximum current rating at each terminal is 2A. Loads greater than 2A require isolating relays or contactors, this particularly applies to pumps and fans.
  • Page 32 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 31 NXR4 Fig. 21 – Additional Volt Free Signals Using Potterton Volt Free Contact Kit (available through Commercial Sales Office - telephone number on the back of this manual). VOLT-FREE CONTACTS R4 – 1 STAGE RUN INDICATION R3 –...
  • Page 33 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 32 NXR4 Fig 22 – Boiler Components REAR SECTION SECTION REFRACTORY SEALANT SILICONE SEALANT 40 41...
  • Page 34 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 33 NXR4 NXR4 BOILER PARTS LIST (See Fig. 22) ITEM DESCRIPTION PART No QUANTITY Per Boiler Tube of Silicone COM17002086 Dependant Refractory Sealant COM17004778 Dependant Front Section COM17801777...
  • Page 35 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 34 NXR4 Fig. 23 – Casing NXR4 BOILER PARTS LIST (See Fig. 22) ITEM DESCRIPTION PART No Front Support Rail – Left & Right Vertical COM17940414 Rear Support Rail – Left & Right Vertical COM17940413 Longitudinal Support Rail –...
  • Page 36 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 35 NXR4 ITEM DESCRIPTION PART No Side Panel – 700mm COM17940599 Side Panel – 840mm COM17940609 Side Panel – 980mm COM17940619 Rear Panel Upper COM17940719 Rear Panel Lower COM17940688 Rear Vertical Panel –...
  • Page 37 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 36 NXR4 Cleaning Handle 13 to 14 section (not shown) COM17077144 Cleaning Handle 15 to 17 section (not shown) COM17077148 Brush Head (not shown) COM17000824...
  • Page 38 NOTES...

  • Page 39: Commissioning Report

    COMMISSIONING REPORT REPORT SENT TO INSTALLER: DATE: Brooks House, Coventry Road, Warwick, CV34 4LL. SIGNATURE: Tel: (08706) 050607 Fax: (08706) 001516 REPORT No: INSTALLER NAME & ADDRESS: SITE ADDRESS: COMMISSIONING DATE: BOILER Check oil available at burner Type: 5.7* Check gas meter fitted & sized No.
  • Page 40 NOTE: It is the installer’s responsibility to ensure that the boiler is correctly commissioned by a competent engineer and that this report is completed and kept as a record. A commissioning service available from Potterton at the address listed on the back page of this manual. When a Potterton engineer commissions, this completed report will be sent to the installer.

  • Page 41: Conversion Chart

    CONVERSION CHART IMPERIAL TO METRIC METRIC TO IMPERIAL HEAT 1 Btu/hr = 0.2931 W 1 kW = 3412 Btu/hr 1 Therm = 100,000 Btu/hr 1 Btu = 1055 J = 0.0009478 Btu 1 Btu/hr = 0.252 kcal/hr 1 kcal/hr = 3.968 Btu/hr 1 ft 3 = 28.317 dm 3 (litre) 1 m 3...
  • Page 42 Web Site: www.pottertoncommercial.co.uk COMMERCIAL SERVICE OFFICES Our service organisation covers the whole of the U.K. to look after your needs for all Potterton Commercial Products. We are also able to offer our services for other manufacturers products. SOUTHERN REGION...
  • Page 43 Fig. 8 - Tie Rod Fixing - Exchanger Assembly Fig. 22 - Boiler Components Fig. 9 - Burner Door - NXR4 Parts List Fig. 10 - Exchanger (Exploded View) Fig. 23 - Casing Components - Burner Support Plate Fig. 24...

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