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Summary of Contents for Potterton NXR3
- Page 1 To be kept by the user October 2010 NXR3 Installation, Operation and Maintenance Manual Working towards a cleaner future heating specialists...
- Page 2 Pump Overrun Pipe Thermostat Fig. 5 Section Orientation Section 7 Pulling Up Bars Fig. 6 Boiler Fittings Assembly Fittings Assembly NXR3 Boiler Parts List Fig. 7 Baffles Assembly Fig. 21 Boiler Components Fig. 8 Door Hinge Guide Assembly Fig. 22 Casing Components Insulation &...
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Page 3: Table 1 - Boiler Dimensions
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 1 NXR3 Fig. 1 – General Data and Dimensions Flow Flow DØ DØ Drain 1 1/2" BSP Drain 1 1/2" BSP Return Return Clean Clean out Hole out Hole... -
Page 4: Table 3 - Technical Data
SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 2 NXR3 Table 3 – Technical Data Model Number of Sections CE Number 0085AQ0751 Output Fuel Consumption 10.04 14.5 18.95 23.51 28.06 32.62 Lit/hr 9.97 14.39 18.8 23.33 27.84... -
Page 5: Natural Ventilation
COLD FEED/ OPEN VENT/ SAFETY VALVE SIZES Sizes indicated are minimum sizes for single boiler installations. MINIMUM RETURN TEMPERATURE If system return temperatures below 55°C are required the contact the Potterton Commercial Technical Department. WEIGHT The dry weight is exclusive of the burner and gas train. Each section measures approximately 1100mm (high) ×... -
Page 6: Fig. 2 - Boiler Clearances
SECTION 1 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 4 NXR3 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 7: Standard Supply
Natural Gas, LPG, 35 Second & 28 OPTIONAL EXTRAS Second Oil. Dual Fuel options are also available. • 3 phase burners The NXR3 is suitable for use on fully pumped open • Additional volt free contacts vented systems or a sealed system with a maximum •... -
Page 8: Installation
SECTION 2 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 6 NXR3 INSTALLATION • IGE/UP/2 – Gas Installation Pipework, Boosters & Compressors Industrial & Commercial Before starting work a risk assessment should be Premises carried out in the boiler house and its access to •... -
Page 9: Ventilation
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 3 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 7 NXR3 VENTILATION FLUE SIZE CONSIDERATIONS Safe, efficient trouble free operation Nominal flue connection sizes are given in Table 3, conventionally flued boilers is vitally dependent on the these sizes refer to the boiler flue connection spigot. -
Page 10: Boiler Protection
General Existing Systems Potterton Commercial boilers are suitable for use on On existing systems where boilers are being replaced sealed systems designed in accordance with BS due to failure then the cause should be investigated 6644: 2005 and BS 6880 Part 2. -
Page 11: Boiler Erection
A lifetime guarantee is available on this boiler when main systems of work. erection and commissioning is carried out by the Potterton Commercial service department and the 1) Safe systems of work are adapted for all boiler system meets with our recommendations. Please maintenance and repair work undertaken on site. -
Page 12: C.o.s.h.h
SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 10 NXR3 C.O.S.H.H boiler house prior to persons carrying out the proposed work attending site. If this is unable During the erection procedure there are a number of... - Page 13 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 11 NXR3 BOILER ERECTION 4. Stand the rear section up and ensure that it is supported securely. Ensure correct manual SECTION ASSEMBLY handling techniques are used. The boiler sections are not self-supporting until the 5.
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Page 14: Fig. 5 - Section Orientation
SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 12 NXR3 9. Ensure that the intermediate section is correctly Note: Orientation arrow top right hand side of aligned (see Fig. 4). Offer up the first intermediate section (looking from front). The arrow must point... -
Page 15: Fig. 6 - Boiler Fittings Assembly
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 13 NXR3 Fig. 6 – Boiler Fittings Assembly Front Section Distributor (6&7 section) Sight Glass Flange Intermediate Section Distributor (8&9 section) Sight Glass & Seal Rear Section Flow and Return Manifold Door Seal (Ø16) -
Page 16: Fittings Assembly
SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 14 NXR3 Fittings Assembly 12. Flue – Connect the flue to the boiler, ensuring that the requirements of BS 6644: 1991 – Installation 1. Position Boiler – Position the boiler block in its... -
Page 17: Fig. 9 - Insulation Position
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 15 NXR3 Top Insulation 16. Combustion Chamber Door – (Fig. 6 – items 27, Blanket 30, 31 and 32). Fit the door sealing braid in place then mount the combustion chamber door. (Fig. 6 –... -
Page 18: Casing Assembly
SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 16 NXR3 7. Top Front Casing Support Bracket – (Fig. 13 – 8. Lower Mask – (Fig. 13 – item 56). Hook the lower item 64). Fit the top front casing support bracket mask over the casing brackets. -
Page 19: Fig. 13 - Casing Assembly
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 17 NXR3 Fig. 13 – Casing Assembly 71 - Bag of Screws Rear Spacer Side Casing – Middle (37/38/39 only) Lower Rear Panel Rear casing – Top panel... -
Page 20: Instrument Panel
SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 18 NXR3 INSTRUMENT PANEL Fig. 14 - Control Panel Configuration NXR3/4 Control Panel Control thermostat stage time delay Stage indication light stage hours run meter Boiler thermometer stage indication... - Page 21 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION, OPERATION & MAINTENANCE MANUAL NXR3 PAGE 19 CB 120 The CB 120 module provides the following functions: 1. Reset button – if during normal operation the flame is lost then the boiler will proceed to go to a lockout condition to reset the lockout press this button.
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Page 22: Fitting The Burner
Casing Frame Cross Member Burner Cables 3. Place the burner gasket over the burner fixing The NXR3 is supplied as standard fitted with a 7-pin studs. and a 4-pin Weiland plug for connection to the burner. 4. Insert the burner draught tube into the firing door... -
Page 23: Connecting The Gas Supply
CAUTION: If the burner motor is supplied with three- phase power, control panel single-phase supply must The NXR3 is supplied with either single phase or be taken from one of the phases supplying the burner three phase burners. The electrical supply to the motor. -
Page 24: Connecting The Oil Supply
SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 22 NXR3 The installation should be made in accordance with pump free of air by slackening the plug in the the requirements of the Gas Safety (Installation &... -
Page 25: 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 26: 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 27: 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 28: Boiler Maintenance
CORGI Class ‘D’ Fuel Oil & Class ‘C2’ Kerosene registration of personnel undertaking work on these appliances. This facility is available from Potterton The boilers should be brushed out thoroughly at least Commercial Division service department, details are bi-monthly for Class D (35 second) and Class 2 (28 available on the rear of this manual. -
Page 29: Boiler Wiring Diagram
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 6 INSTALLATION, OPERATION & MAINTENANCE MANUAL NXR3 PAGE 27 Fig. 19 – Boiler Wiring Diagram For Further details, please refer to the Control Panel Manual... - Page 30 SECTION 6 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 28 NXR3 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.
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Page 31: Nxr3 Boiler Parts List
POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION & MAINTENANCE MANUAL NXR3 PAGE 29 NXR3 BOILER PARTS LIST (See Fig.21, Fig.22, Fig.23) “AS DELIVERED” PACKAGES / PALLETS NXR34 NXR35 NXR36 NXR37 NXR38 NXR39 Description Package Part Number Sections Pallet Front... -
Page 32: Fig. 21 - Boiler Components
SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 30 NXR3 Fig. 21 – Boiler Components NXR3 BOILER PARTS LIST (See Fig. 21) ITEM DESCRIPTION PART NO QUANTITY Per Boiler FRONT SECTION COM17800476 INTERMEDIATE SECTION – MODEL 34 COM17800469 INTERMEDIATE SECTION –... - Page 33 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 7 INSTALLATION, OPERATION & MAINTENANCE MANUAL NXR3 PAGE 31 ITEM DESCRIPTION PART NO QUANTITY Per Boiler TIE ROD – MODEL 38 – M12 x 1300mm COM17077158 TIE ROD – MODEL 39 – M12 x 1470mm COM17077159 REDUCING BUSH (2”...
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Page 34: Fig. 22 - Casing Components
SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 32 NXR3 Fig. 22 – Casing Components 71 - Packet of Screws NXR3 CASING PARTS LIST (See Fig.22) RED CASING WHITE CASING ITEM DESCRIPTION PART NO PART NO... - Page 35 FRONT CASING – TOP PANEL COM17937619 S506636 FRONT CASING – LOWER RIGHT COM17937769 S506302 FRONT CASING – LOWER LEFT COM17937768 S506303 MISC CASING FIXINGS (NOT SHOWN) COM17880141 COM17880141 INSTRUMENT PANEL COM17204280 MAGNET FASTNER COM17002395 COM17002395 POTTERTON NXR3 BADGE (NOT SHOWN) S139050...
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Page 36: Instrument Panel Components
SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION, OPERATION & MAINTENANCE MANUAL PAGE 34 NXR3 Fig. 23 – Instrument Panel Components NXR3 INSTRUMENT PANEL COMPONENTS LIST (See Fig. 23) ITEM DESCRIPTION PART NO Front Panel S137535 Front Panel Cover (Not Shown) -
Page 37: Commissioning Report
COMMISSIONING REPORT ALL BOILER TYPES REPORT SENT TO INSTALLER: SITE VISIT COMMISSIONING (Office use Only) Wood Lane, Erdington, Birmingham, B24 9QP DATE: Tel: 08702 412759 Fax: 08701 653000 SIGNATURE: REPORT No: INSTALLER NAME & ADDRESS: SITE ADDRESS: COMMISSIONING/SITE VISIT DATE: BOILER COMBUSTION Pilot... - Page 38 COMMISSIONING REPORT (Continued) 10.0 Comments On Accessibility For Maintenance PLANT ROOM Yes No 8.13 Is The Fan Interlocked With The Boiler? Are Flue Dampers Fitted? 8.14 If So Are They Interlocked? Fan Assisted Ventilation? 8.15 If So Interlocked? 8.16 Any Evidence Of Condensate Formation? 8.17 c Any Evidence Of Condensate Leakage? 8.18 Any Evidence Of Water Leakage?
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Page 39: 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 FUEL CONSUMPTION 1 ft 3 = 28.317 dm 3 (litre) - Page 40 Our service organisation covers the whole of the UK to look after Spares your needs for all Potterton Commercial products. Our service office offers a wide range of specialised services Potterton Commercial spares are available nationwide including: through the interpart network of approved stockists.
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