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POTTERTON COMMERCIAL PRODUCTS DIVISION 

SECTION 4 

INSTALLATION, OPERATION & MAINTENANCE MANUAL 

 

 

 

NXR3 

PAGE 11 

 

BOILER ERECTION 

SECTION ASSEMBLY 

The  boiler  sections  are  not  self-supporting  until  the 

boiler  block  is  fully  assembled.  The  sections  are 

connected using a nipple system. To ensure a sound 

water  tight  fit  the  nipple  sealing  paste  provided  must 

be used. Assembly tools are provided for assembling 

the sections. 

 

IMPORTANT:  Ensure  the  boiler  is  adequately 

supported  especially  when  pulling  up  sections. 

The  Manual  Handling  Regulations  should  be 

followed. 

 

Erect the Boilers as follows:- 

 

1.  Open the boiler fittings box. 

 

2.  Clean  the  nipples  using  a  solvent  cleaner 

removing  all  traces  of  protective  coating  (not 

supplied), ensuring all guidelines are followed. 

 

3.  Clean both the top and bottom nipple ports of 

all 

sections

  with  a  solvent  cleaner  and  ensure  that 

they  are  rust  free,  dirt-free  and  burr  free,  if 

necessary clean with emery cloth. 

4.  Stand  the  rear  section  up  and  ensure  that  it  is 

supported  securely.  Ensure  correct  manual 

handling techniques are used. 

 

5.  Position  the  wooden  block  provided  under  the 

centre of the bottom nipple port of the rear section 

(see Fig. 4). 

 

6.  Clean  the  sealing  cord  groove  on  the  upright 

section  with  a  solvent  cleaner  and  a  wire  brush, 

ensuring any rust or burrs are removed. 

 

7.  Starting  from  the  centre  of  the  top  nipple  port, 

position  the  sealing  cord  without  stretching  it  in 

the groove around the rear section. Cut to length 

using due care and attention. 

 

8.  Coat a nipple with the sealing paste provided and 

position  in  the  top  nipple  port.  Repeat  for  the 

bottom  nipple  port.  Tap  both  nipples  slightly  into 

the  nipple  ports  using  a  mallet  to  ensure  nipples 

are not damaged.

 

 

Ensure  that  the  nipples  are  correctly  aligned 

as an out of line nipple can cause the section 

to crack when it is pulled up. 

 

 

 

Fig. 4 – Section Assembly Showing Installation of Sealing Cord, Nipples & Final Sealing Cord Tightness 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sealing Cord 

Meeting Point 

Place the Cord in the 

Sealing Cord Groove 

Tightening of the 

Sealing Cord 

Section Orientation 

Marking 

Wooden Block (provided) 

Section Orientation 

Marking 

Outside 

Separation Lug 

Summary of Contents for NXR3

Page 1: ...Working towards a cleaner future NXR3 Installation Operation and Maintenance Manual To be kept by the user October 2010 heating specialists ...

Page 2: ...Panel Assembly 16 Fig 12 Front Casing Assembly 16 Fig 13 Casing Assembly 17 Fig 14 Control Panel Configuration 18 Fig 15 Control Panel Operation 18 Fig 16 Cable Capillary Tube Routing 20 Page Fig 17 Fitting Thermometer into Flue 20 Fitting the Burner 20 Connections 21 Single Phase Installation 21 Fig 18 Boiler Burner Power Supply 21 Fig 18A Boiler Burner Single Phase Supply 21 Three Phase Installa...

Page 3: ... 38 39 Mean Diameter mm 474 Cross Sectional Area m 2 0 176 Length X mm 625 795 965 1135 1305 1475 Volume m 3 0 11 0 14 0 17 0 2 0 23 0 26 Surface Area m 2 1 11 1 36 1 61 1 87 2 12 2 37 Resistance mbar 0 25 0 54 0 95 1 32 2 2 52 Flue Gas Temperature Gross C 170 160 Percentage CO2 OIL 13 GAS 9 5 Flow 1010 Drain 1 1 2 BSP Return 110 815 450 402 X DØ B A 145 75 520 606 1180 1396 800 Clean out Hole 2 B...

Page 4: ... BS 6644 cm 2 388 560 732 908 1084 1260 6 Mechanical Inlet to BS 6644 m 3 sec 0 075 0 108 0 142 0 176 0 210 0 245 7 Water Connection Size Flow Return 2 BSP Screwed Flanges ALL MODELS 8 Water Flow at 11 C t lit sec 1 95 2 81 3 68 4 55 5 41 6 28 Min water flow at 20 C t lit sec 1 07 1 55 2 02 2 5 2 98 3 45 8 Hydraulic resistance at 11 C t kPa 0 9 1 7 2 8 3 9 5 8 9 3 9 Cold feed size to BS 6644 Minim...

Page 5: ...re given at STP standard temperature and pressure 15 C and 1013 25 mbar Typical flue gas temperatures are given in Table 2 5 NATURAL VENTILATION The sizes indicated are free grille areas and are based on a single boiler installation 6 MECHANICAL VENTILATION The volume given is for a single boiler installation 7 CONNECTION SIZES The boiler water connections are 2 BSP screwed flange PN6 Also supplie...

Page 6: ...t burner card Fig 2 Boiler Clearances Minimum Clearance Front Nu Way Oil Nu Way Gas Riello Oil Riello gas EOGB Oil EOGB Gas Model A mm A mm A mm A mm A mm A mm 34 900 900 900 900 900 972 35 1070 1070 1070 1070 1070 1070 36 1240 1240 1240 1240 1240 1240 37 1410 1410 1410 1410 1410 1410 38 1580 1580 1580 1580 1580 1580 39 1750 1750 1750 1750 1750 1750 Fig 3 Boiler Footprint Base Details Flat Plate 6...

Page 7: ...ets gas and oil requirements of M E36 and the burners EN676 The waterway sections are joined by cast taper nipples and secured with tie rods The combustion chamber joints are sealed by heat resistant cord The powder coated mild steel casings have a 50mm fibre insulation in the casing plus a 50mm fibre wrap around the castings thus reducing fuel consumption and emissions The NXR3 is supplied unasse...

Page 8: ...ce for Low Temperature Hot water Systems BS 779 1989 Cast Iron Boilers for Central Heating Indirect Hot Water Supply Rated Output 44kW and Above CP342 2 Centralised Hot Water Supply Gas Safety Installation Use Regulations 2002 IM 11 Flues for Commercial Industrial Gas Fired Boilers Air Heaters IGE UP 1 Soundness Testing Purging Procedure for Non domestic Installations IGE UP 2 Gas Installation Pip...

Page 9: ...roducts of combustion IMPORTANT 90 square bends must not be used on the flue system including the boiler flue spigot a straight length followed by an easy sweep or lobster back bend should be used FLUE SIZE CONSIDERATIONS Nominal flue connection sizes are given in Table 3 these sizes refer to the boiler flue connection spigot The actual size of the flue system will depend on individual site applic...

Page 10: ...make up due to water loss Evidence of magnetite black sludge in the system and the formation of gas in radiators causing air locking is a positive indicator of corrosion Where an old system shows evidence of contamination then system cleaning should be carried out before installation of new boilers The heating system should be chemically flushed to remove any lime scale or corrosion and a corrosio...

Page 11: ...work are adapted for all boiler maintenance and repair work undertaken on site 2 The work undertaken does not affect the electrical safety of the appliance In particular the earth connected to the buildings fixed electrical installation In the case of 1 above electrical work should only be undertaken once the boiler has been isolated from the electricity supply and confirmed electrically dead If t...

Page 12: ...e affected area with water and wash gently In the case of eye contact flush abundantly with water If irritation persists seek medical advice Potterton Commercial Customer Erection Assembly Check List The items listed below have been put together as a guide to what actions should be completed before the erection assembly of a boiler takes place I Site access available for persons carrying out the p...

Page 13: ... and ensure that it is supported securely Ensure correct manual handling techniques are used 5 Position the wooden block provided under the centre of the bottom nipple port of the rear section see Fig 4 6 Clean the sealing cord groove on the upright section with a solvent cleaner and a wire brush ensuring any rust or burrs are removed 7 Starting from the centre of the top nipple port position the ...

Page 14: ...lling up bars 12 Assemble the other sections one by one in the same way while moving the wooden blocks alternately as you go towards the front Ensure all manual handling techniques are adhered too Note If it was necessary to dismantle one of the boiler sections and to avoid damaging the sealing groove It is imperative when dismantling the sections to place a chisel on the separating lugs as shown ...

Page 15: ...8 Burner Plate 5 Sealing Cord Ø7 17 Sensor Pocket 100mm length 29 Burner Plate Gasket 6 Tie Rod 18 Upper Baffle 30 Cleaning Door 7 Reducer 19 Flue Hood 180mm outlet 31 Internal Insulation 8 Sensor Pocket 200mm length 19a Flue Hood 200mm outlet 32 External Insulation 9 Door Hinge 20 Flueway Hatch left 33 Section Insulation Blanket 9a Door Hinge 20a Flueway Hatch right 39 Cleaning Brush 10 Door Guid...

Page 16: ...esting Blank off all connections then fill the boiler slowly ensuring that all the air is vented and the boiler is completely full of water Proceed to 9 bar to prove soundness This facility is available through our Service Offices 11 Flue Box Fig 6 items 19 to 19a Screw the short thread of the four off M8 x 40mm studs into tappings in the upper part of the rear section Check the sealing braid is i...

Page 17: ... item 51 Fit the lower rear casing over the three spacers and tighten the three screws 3 Bottom Insulation Fig 9 Place the bottom insulation blanket underneath the boiler and fold around the bottom tie rods to secure Ensure that all personal protective equipment is worn Fig 9 Insulation Position 4 Body Insulation Blanket Fig 9 Wrap the body insulation blanket around the boiler Push the ends of the...

Page 18: ...g frame support rails and the lower rear panel locating the panel onto the pin on the front middle side panel Screw into place the casing support frame rails and lower rear panel 4 Upper Rear Panel Fig 13 item 63 Slide upper rear panel into position and locate lugs in holes in rear of side panels Push down to secure 5 Front Top Instrument Panel SEE CONTROL PANEL FOR CONTROL PANEL ASSEMBLY Secure i...

Page 19: ...Strip 53 Cross Member 65 Top Casing Front Panel 54 Right Hand Side Support Rail 66 Top Casing Rear Panel 55 Left Hand Side Support Rail 67 Top casing Middle Panel 37 38 39 only 56 Lower Mask 68 Front Casing Top Panel 57 Side Casing Right Hand Front 69 Front Casing Lower Right 58 Side Casing Left Hand Front 70 Front casing Lower Left 59 Side Restraint 71 Bag of Casing Screws Fixings 60 Side Casing ...

Page 20: ...eration Pump Switch Not Used Pump Indicator Light Boiler Temperature Control Thermostat Green Indicator Light Showing 1st Stage Run If light flashes indication of overheat fault 2 nd Stage Thermostat 2 nd Stage Indicator Light CE 100 1 2 3 4 6 5 7 8 9 10 11 12 13 14 15 16 1 Control thermostat 9 2nd stage time delay 2 1st Stage indication light 10 1st stage hours run meter 3 Boiler thermometer 11 2...

Page 21: ...t flame or it goes out during operation then the burner will go to lockout and the light will be illuminated 5 Mains supply indicator indicates that the power has been turned on to the boiler 6 On Off switch turns the burner On or Off This is not a boiler isolator switch components are still live even when the switch if off mains inlet to the boiler still requires a suitable 3 pole isolator 7 Over...

Page 22: ...d provided 2 Fit the burner adaptor plates and boiler gasket to the boiler using the fixing screws provided 3 Place the burner gasket over the burner fixing studs 4 Insert the burner draught tube into the firing door aperture with the gasket in position on the mounting flange Secure in position with the nuts and washers provided 5 Connect the fuel supply to the burner The fuel supply pipes should ...

Page 23: ... motor Install a three phase supply direct to the burner via a fused isolator sized to the burner manufacturers specification see Fig 18 Install a separate 220 240V 50Hz single phase electrical supply derived from the three phase supply to the boiler instrument panel This is fused 6 3A in the instrument panel Volt Free Contacts Volt free remote status contacts should be taken from the control pane...

Page 24: ...endations to suit site conditions The supply pipe and where fitted the return line should consist of copper tube galvanised steel must not be used the final connection to the pump inlet port being made with the length of flexible pipe supplied with the burner Joints should be made with compression fittings not by soldering When gravity feed is used the most common system the maximum head should no...

Page 25: ...commissioning is carried out by the Potterton service department Please refer to our standard terms and conditions for further details IMPORTANT The boiler must be commissioned following completion of the installation Operation of an uncommissioned appliance may cause injury to personnel and damage to the boiler burner unit and could invalidate the manufacturers warranties Commissioning should onl...

Page 26: ...ition should occur during commissioning or subsequent use of this product be it a fault of the burner the boiler or of any instrument machine or service in the proximity of the burner then the GAS and ELECTRICITY supply to the burner should be IMMEDIATELY ISOLATED until such time that the fault has been investigated and rectified The commissioning of the appliance can be split into three main cate...

Page 27: ...ay to allow for removal of residual heat from the boiler e The boiler is operating at the correct rate and is not overfired 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 a...

Page 28: ...nner not to cause inconvenience to any persons A layer of deposits 1 5mm thick will reduce the heat transfer through the tube wall by up to 10 Not only does this waste fuel but the higher flue gas temperatures that result will increase the thermal stress within the boiler and may lead to joint leakage or in extreme cases section failure Natural Gas LPG Fired Boilers We recommend brushing out of th...

Page 29: ...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: ...ner test switch F1 Fuse VSC Overheat indicator light MST Mains indicator light TR Safety mode thermostat TR1 1 st stage regulation thermostat TR2 2 nd stage regulation thermostat ZP Pump switch not used L Live N Neutral ZG On Off switch BRU Burner connections H Hours run counters External Interlocks DG External interlock UV Safety interlock XY Safety interlock Relays Overheat Fault Fig 20 Pump Ove...

Page 31: ...221828 COM17221829 J Control Panel COM17204280 COM17401550 COM17405437 CONTENTS OF INDIVIDUAL PACKAGES PALLETS A SECTIONS PALLET Front Section x1 Inter Sections Rear Section x1 B BOILER FITTINGS Nipples Jointing Paste Sensor Pocket Reducer Bush Sealing Rope Wooden Block C BOILER ACCESSORIES Plate Paste Weld Flanges Burner Adaptor Plate Adaptor Plate Gasket Distributor Door Guide Door Hinges Flue B...

Page 32: ...9 5 INTERMEDIATE SECTION MODEL 38 COM17800469 6 INTERMEDIATE SECTION MODEL 39 COM17800469 7 3 REAR SECTION COM17800486 1 4 NIPPLE Ø89 MODEL 34 COM17809407 6 NIPPLE Ø89 MODEL 35 COM17809407 8 NIPPLE Ø89 MODEL 36 COM17809407 10 NIPPLE Ø89 MODEL 37 COM17809407 12 NIPPLE Ø89 MODEL 38 COM17809407 14 NIPPLE Ø89 MODEL 39 COM17809407 16 4A NIPPLE SEALING PASTE NOT SHOWN COM17002081 1 5 SEALING ROPE Ø7 3 m...

Page 33: ...0434 2 UPPER BAFFLE MODEL 35 COM17300435 2 UPPER BAFFLE MODEL 36 37 COM17300437 2 UPPER BAFFLE MODEL 38 39 COM17300439 2 19 FLUE BOX MODELS 34 35 36 37 Ø180mm COM17864255 2 19A FLUE BOX MODELS 38 39 Ø200mm COM17864265 1 20 FLUEWAY CLEANING DOOR LEFT HAND SIDE COM17845665 1 20A FLUEWAY CLEANING DOOR RIGHT HAND SIDE COM17845675 1 21 SEALING BRAID COM17000167 1 22 COMBUSTION CHAMBER DOOR COM17864279 ...

Page 34: ...PORT RAIL MODEL 37 COM17937404 COM17937404 RIGHT HAND SIDE SUPPORT RAIL MODEL 38 COM17937414 COM17937414 RIGHT HAND SIDE SUPPORT RAIL MODEL 39 COM17937424 COM17937424 55 LEFT HAND SIDE SUPPORT RAIL MODEL 34 COM17937373 COM17937373 LEFT HAND SIDE SUPPORT RAIL MODEL 35 COM17937383 COM17937383 LEFT HAND SIDE SUPPORT RAIL MODEL 36 COM17937393 COM17937393 LEFT HAND SIDE SUPPORT RAIL MODEL 37 COM1793740...

Page 35: ...OM17937499 S506312 63 REAR CASING TOP PANEL COM17937514 S501405 64 TOP PANEL FRONT SUPPORT SRTIP COM17937524 COM17937524 65 TOP CASING FRONT PANEL COM17937536 S139165EE 66 TOP CASING REAR PANEL MODELS 34 37 COM17937546 S120860EE TOP CASING REAR PANEL MODELS 35 38 COM17937556 S120861EE TOP CASING REAR PANEL MODELS 36 39 COM17937566 S120862EE 67 TOP CASING MIDDLE MODELS 37 38 39 ONLY COM17937576 S12...

Page 36: ...el Casing 1 S504313 6 Cable Terminal Support 1 S136979 10 Thermostat TXA4C 019 1 S17007004 11 Thermostat Lever 1 S17004738 12 12a Fuse Support Fuse TFS 5 x 20 6 3A 1 1 S15803999 S15803525 13 Bag of Lights 1 S501970 14 Bag of Switches 1 S503081 15 Thermostat TG400 Cap 2m 1 S17006955 16 Thermometer 68 5 x 14 5 0 120 1 S134421 17 CB120 Module Front Panel 1 S137158 19 Relay LY2F 220AC 1 S15815049 19a ...

Page 37: ...tails of flue system showing length of runs and diameter 5 6 Approximate Overall Height m 6 0 COMBUSTION Pilot Low High Unit 6 1 Inlet Gas Supply Pressure All Boilers running mbar 6 2 Burner Pressure mbar 6 3 Gas Rate m 3 hr 6 4 o Oil Pump Pressure Bar 6 5 Ionisation Probe Current A 6 6cp Air Shutter Position 6 7 O2 6 8 CO2 6 9 CO ppm 6 10 o Smoke Number 6 11 Nett Flue Gas Temperature o C 6 12 Flu...

Page 38: ... The Installation Safe For Use If The Answer Is NO Has A Warning Label Been Raised Is Any Remedial Work Required Have Warning Labels Been Fitted Has RIDDOR Form Been Raised CUSTOMER SIGNATURE PRINT NAME DATE ENGINEER DETAILS NAME COMPANY SIGNATURE DATE PCF No 212 04 2007 Note It is the installer s responsibility to ensure that the boiler is correctly commissioned by a competent engineer and that t...

Page 39: ... g 0 0394 in w g 1 mm w g 9 8 Pa LENGTH 1m 1000mm 1 inch 25 4mm 1 ft 0 3048 m 1 yard 0 9144 m 1 mile 1 609 km 1 mm 0 03937 in 1 m 3 281 ft 1 m 1 094 yard 1 km 0 6214 mile VOLUME 1 ft3 0 02832 m3 1 ft3 28 32 litre 1 m3 35 3147 ft3 1 litre 0 03531 ft3 AREA 1 in2 645 2 mm2 1 in2 6 452 cm2 1 ft2 929 cm2 1 ft2 0 0929 m2 1 mm2 0 00155 in2 1 cm2 0 155 in2 1 m2 1550 in2 1 m2 10 76 ft2 FLOW RATE 1 kg sec 1...

Page 40: ...LL Tel 0844 871 1540 Applications Installations Our experienced technical support team are available to offer advice on any aspect of heating system design and boiler installation Please contact 0845 070 1057 Commercial service offices Our service organisation covers the whole of the UK to look after your needs for all Potterton Commercial products Our service office offers a wide range of special...

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