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Potterton NXR5i Assembly Instructions Manual
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Potterton NXR5i Assembly Instructions Manual

Potterton NXR5i Assembly Instructions Manual

Fuel oil/gas boilers
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Download this manual See also: Installation and Servicing Manual
Fuel oil/gas boilers
NXR5i
300029104-001-02
Assembly
Instructions
EN

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Summary of Contents for Potterton NXR5i

  • Page 1 Fuel oil/gas boilers NXR5i Assembly Instructions 300029104-001-02...
  • Page 2 Mounting NXR5i........

  • Page 3: Package List

    Flue gas box Distributing tube fitting The distributing tube fitting for NXR5i boilers with 15 to 19 sections is included in the accessory package. The diaphragm for NXR5i , 14 section boilers is delivered in the additional accessory kit package.
  • Page 4 Baffles Boiler NXR5i - Number of sections package Baffles CM 22 CM 23 Casing fittings Boiler NXR5i - Number of sections package Casing fittings MR338 MR339 FA10 FA11 Variable casing parts Boiler NXR5i - Number of sections package Variable casing parts...
  • Page 5 All models can be equiped with one of the following control panels: KSF-CE or KSF-ISR control panel. Accessories - Available as an option* Boiler NXR5i - Number of sections Furnace plate with hole Ø 165 / 186 / 210 / 240 or Ø 295 Connecting plate with opening or plain connecting plate - Ø...

  • Page 6: Mounting Nxr5I

    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...
  • Page 7 4. assemble the front section. The number of sections of each type is provided in the table below: Rear section Normal intermediate Special intermediate Front section section section Section type NXR5i-14 NXR5i-15 NXR5i-16 NXR5i-17 NXR5i-18 NXR5i-19 NXR5i-20 NXR5i-21 NXR5i-22 NXR5i-23...
  • Page 8 : 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). NXR5i 25/09/2012 - 300029104-001-02...
  • Page 9 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 Clean all the openings in the section with a brush. Remove any deposit on the bottom of the section. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 10 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. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 11 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. Gently push in the 2 nipples. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 12 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. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 13 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. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 14 Stop tightening as soon as the gap between the spring spires is equal to about 2 mm. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 15 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 1 mm. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 16 NXR5-14 NXR5-15 NXR5-16 C003936-A Rear Front Dimensions are given in millimeters. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 17 NXR5-17 NXR5-18 NXR5-19 C003937-A Rear Front Dimensions are given in millimeters. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 18 NXR5-20 NXR5-21 NXR5-22 C003938-A Rear Front Dimensions are given in millimeters. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 19 NXR5-23 NXR5-24 NXR5-25 C003939-A Rear Front Dimensions are given in millimeters. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 20 - 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.
  • Page 21 (that is 7.8 bar mini) for 10 minutes at least. The test must be done at room temperature. Fit a square flange with hole facing upwards onto the upper flange with outlet piece. Fit a blind square flange onto the lower flange with return piece. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 22 Any drop in pressure indicates a leakage in the boiler body. After the hydraulic test, drain the boiler. Remove all of the specific parts fitted to the rear section (parts used to carry out the hydraulic test). NXR5i 25/09/2012 - 300029104-001-02...
  • Page 23 Assembling the baffle plates Boiler NXR5i-14 NXR5i-15 to NXR5i-19 NXR5i-20 to NXR5i-25 Total number of baffle Pack no. CM 23 CM 22 + CM 23 2 x CM 23 Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them.
  • Page 24 Fasten the two brass nuts of each cover Cover model No. 1 No. 2 No. 3 No. 4 Number of sweeping covers per type Boiler type Front <--------------------------------------------------------> Rear NXR5i-14 NXR5i-15 NXR5i-16 NXR5i-17 NXR5i-18 NXR5i-19 NXR5i-20 NXR5i-21 NXR5i-22 NXR5i-23 NXR5i-24...
  • Page 25 Insert the thermocord in the sealing groove of the 2 lower flue ways, on the rear and front of the boiler. Put the 4 trap doors on the lower flue ways and fasten with the wing nuts. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 26 Place the furnace door on the floor and fasten the articulation onto the door with 3 screws HM 12. Installing the hinge of the furnace door Fix the furnace door hinge on the right or left-hand side of the front section by means of 3 screws HM 12x25. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 27 Fit the door onto the hinge by inserting the pin. Close the furnace door on the 8 studs and fasten with 8 washers and nuts. Fit the 2 doors of the upper flue ways (wing nuts). 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 28 Flame inspection window The flame inspection window is fitted with a 1/4" tapped hole for ventilation (optional). if a ventilation system is used, connect the hole to the one provided for that purpose before the burner combustion head. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 29 Assembling the return flange on boilers NXR5i-14 to NXR5i-25 C003941-A • NXR5i-14: NXR5i-14 Package FA 49 Package FA68 Fit the boiler return flange, intercalating a seal Ø 170x222 previously soaked in tepid water. Fit the heating return flange with a Ø 170x222 gasket in between and fix it with 4 nuts H 18.
  • Page 30 Assembling the outlet flange on boilers NXR5i-14 to NXR5i-25 • NXR5i-14 to NXR5i-15: = Package FA42 to FA 50 = Package FA61 to FA69 Place the nozzle turned outside from the boiler with a Ø 170x222 gasket in between (first soak the seal in warm water).
  • Page 31 Before assembling the flue gas box, grease all bolts, studs and screws with high-temperature grease (not supplied). Put in place the thermocord . Put the sweeping cover in place and fasten with 2 nuts H 10 and Ø 10 washers. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 32 The flue gas outlet is fastened to the rear by means of 6 studs, washers and Ø 12 nuts. First adapt the steel connecting plate to the chimney connection flue, then fasten that plate or the plate with a connecting piece with 10 nuts H10 and Ø10 washers. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 33 Fasten the flow switch on the sleeve tube. The direction of the arrow head on the collet must be the same as the flowing out of the water in the tube. Flow switch Boiler Code no. NXR5i-14 8802-4745 NXR5i-15 8802-4746 NXR5i-16...
  • Page 34 Fitting the baffle plates Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them. Boiler NXR5i-14 NXR5i-15 to NXR5i-19 NXR5i-20 to NXR5i-25 Total number of baffle Pack no.

  • Page 35: Fa17

    36 NXR5i-14 to NXR5i-17: Package FA30 to FA36 Assembling the top insulating material Front Put in place the 600 mm wide (packages FA30 to FA36) top insulating material on the body of the boiler. Number of sections 15 or 16...
  • Page 36 38 NXR5i-18 to NXR5i-25: Package FA37 to FA41 Assembling the top insulating material Put in place the 2 pieces of insulating material (width 600 mm, packages FA37 to FA41) on the body of the boiler. Push the insulating material under the front and rear crosspieces.

  • Page 37: Fa24

    40 NXR5i-18 to NXR5i-25: Package FA16 to FA24 Assembling the cable channels Package FA16 Package FA16 to FA24 Number of sections Length (mm) - A 2510 2600 2800 2910 3000 3110 3200 3310 Place the cable channels so that their bevelled end is to the front.
  • Page 38 42 package MR338 or MR339 Assembling the lower rail support brackets • Example for a NXR5i-14 Fasten the lower rail support brackets using H8 x 16 screws + Serrated washer. for the assembly direction, see the drawings below. Assembly direction of lower rail support brackets...
  • Page 39 NXR5-15 NXR5-17 NXR5-14 NXR5-16 NXR5-18 NXR5-20 NXR5-19 NXR5-21 NXR5-22 NXR5-24 NXR5-23 NXR5-25 C003942-A 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 40 Fit the bracket onto the stub Fasten with 1 screw H10 x 50 and serrated washers and H10 nuts Assemble 1 "Rapid" nut on the top of the bracket with the tapped shaft on the inside. NXR5i 25/09/2012 - 300029104-001-02...

  • Page 41: Fa35

    Distribute the insulating material evenly so that you have the same side insulating material on either side of the boiler. Cut the insulation similary along the fastening brackets. Side insulating material (mm) Boiler type Front <---------------------------------------------------------------> Rear NXR5i-14 1200 NXR5i-15 1200 NXR5i-16 1200 NXR5i-17...
  • Page 42 Package Package Boiler fastening bracket, and similarly with the other brackets). FA24 NXR5i-14 Push the insulating material behind the lower rail and underneath the boiler. FA25 NXR5i-15 FA26...
  • Page 43 Fasten the side panels to each other with the clips. Side panels (mm) Boiler type Front <------------------------------> Rear Panels NXR5i-14 400 mm long panel in package FA10 NXR5i-15 600 mm long panel in package FA11 NXR5i-16 1050 800 mm long panel in package MR3...
  • Page 44 4 "Rapid" nuts for 7 to 17 sections. 8 "Rapid" nuts for 18 to 25 sections. Fix the control panel bracket (package MR338 or MR339) underneath the 2 cable channels by means of 2 screws (H8 x 16) and 2 serrated washers. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 45 Fit the front cross piece (2 Screw H8 x 30, 2 Self-tapping screw Ø 3,94 x 12,7 + Serrated washers). 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 46 C003955-B NXR5i 25/09/2012 - 300029104-001-02...
  • Page 47 C003956-B C003957 25/09/2012 - 300029104-001-02 NXR5i...

  • Page 48: Electrical Connections

    Fitting the cap M000120-B Mounted screw Cable channel Control panel trim Control panel bracket Serrated washer Front crosspiece "Rapid" nut Unfasten the screws (mounted in fig. 56). Slide the control panel trim along the screws Fasten the screws NXR5i 25/09/2012 - 300029104-001-02...
  • Page 49 Place the insulating material in the lower central front panel (black cloth facing outward). Fit the lower central front panel (package MR338 or MR339) onto the lower front crosspiece and fix it to the furnace door panel. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 50 59 package MR338 MR339 Fit the left and right-hand side front panels (package MR338 or MR339) onto the lower front crosspiece and fit them onto the studs of the side panels. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 51 Put in place the insulation of the flue gas box and the lower rear insulating material (package MR338 or MR339). If the side crosspieces overlap at the rear by more than 10 mm, we advise you to saw them off using a hacksaw. 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 52 Fit the upper rear panel (package MR338 or MR339) onto the studs and push it up Fasten with 2 screws (H8 x 16) and serrated washers Fit the 2 lower rear panels (package MR338 or MR339) onto the rear crosspieces NXR5i 25/09/2012 - 300029104-001-02...
  • Page 53 64 NXR5i-14 to NXR5i-17: Package FA17 to FA27 Fitting the walkway Place the central plate on the cable channels with the round holes towards the front of the boiler. Fasten with H8 x 30 screws and serrated washers. 25/09/2012 - 300029104-001-02...
  • Page 54 4 tapping screws and serrated washers. 66 Package FA30 to FA41 C003946-A Put in place the sweeping cover insulating material(packages FA30 to FA41): - NXR5i-14 to NXR5i-17: 2 pieces. - NXR5i-18 to NXR5i-25: 4 pieces. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 55 Place the side covers (package FA10 - FA11, MR3 to MR5, see table) from the front to rear. They have the same lengths as the side panels. Central and boiler side covers (mm) Boiler type Front <-----------------------------------> Rear NXR5i-14 NXR5i-15 NXR5i-16 1050 NXR5i-17 NXR5i-18 1050...

  • Page 56: Data Plate

    3 Data plate Boiler type Manufacturing date Year of manufacture Week of manufacture Serial no. of the appliance Glue the rating plate and CE marking on the casing of the boiler in an easily visible location. NXR5i 25/09/2012 - 300029104-001-02...
  • Page 57 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 58 NXR5i 25/09/2012 - 300029104-001-02...
  • Page 59 25/09/2012 - 300029104-001-02 NXR5i...
  • Page 60 © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations. 25/09/2012 300029104- 001- 02...