Potterton NXR4 Installation, Operation & Maintenance Manual Download Page 1

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NOVEMBER 2003

heating specialists

Summary of Contents for NXR4

Page 1: ...NOVEMBER 2003 heating specialists ...

Page 2: ...th X mm 1120 1260 1400 1540 1680 1820 1960 2100 2240 Volume m3 0 24 0 27 0 30 0 33 0 36 0 39 0 42 0 45 0 48 Surface Area m2 2 06 2 28 2 51 2 74 2 97 3 20 3 43 3 66 3 89 Resistance Pressure mbar 1 5 2 1 2 2 2 8 3 3 3 3 4 5 5 6 Flue Gas Temperature Gross C 180 Efficiency All Fuels Nett 92 Gross 83 Percentage CO2 Oil 12 Gas 9 450 1295 1511 1070 700 X ØD 400 35 PN 16 125mm Mating Flange 732 497 A B PN...

Page 3: ...95 2318 2641 2965 3288 3611 3935 4258 4581 6 Mechanical Ventilation m3 sec 0 425 0 504 0 583 0 662 0 743 0 822 0 901 0 981 1 06 7 Water Connection Size BSP 5 125mm 8 Water Flow at 11 C t lit sec 6 93 8 23 9 52 10 82 12 12 13 42 14 72 16 02 17 32 8 Hydraulic Resistance at 11 C t kPa 1 56 2 16 2 84 3 61 4 46 5 39 6 42 7 51 8 68 9 Cold Feed Size to BS 6644 Min Bore mm 38 50 9 Open Vent Size to BS 664...

Page 4: ...erature 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 flanged with 5 PN16 welded counter flanges provided 8 WATER FLOW R...

Page 5: ...0 1580 1733 1555 1725 1807 1810 411 1580 1733 1600 1725 1807 1810 412 1580 1733 1600 1785 1807 1810 413 1542 1885 1610 1785 2086 2296 414 1542 1885 1610 1785 2086 2296 415 1542 2183 1610 2000 2086 2296 416 1686 2183 1950 2000 2086 2296 417 1686 2183 1950 2100 2086 2296 Fig 3 Boiler Footprint Base Details No special plinth is required for this boiler a simple dry base is sufficient Boiler footprint...

Page 6: ...e220 cast iron heat exchanger constructed in accordance with EN303 1 The boiler package meets Gas and Oil requirements of M E3 and the burners EN767 The waterway sections are joined by cast taper nipples and secured with tie rods The combustion chamber is sealed by boiler cement and silicone The powder coated mild steel casings have a 50mm fibre insulation in the casing plus a 50mm fibre wrap arou...

Page 7: ...t 44kW and above CP342 2 Centralised Hot Water Supply Gas Safety Installation Use Regulations 1998 IM 11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters IGE UP 1 Soundness Testing Purging Procedure for Non domestic Installations IGE UP 2 Gas Installation Pipework Boosters Compressors for Industrial Commercial Premises Manufacturer s notes must not be taken in any way as overr...

Page 8: ...s Horizontal Flue Runs Horizontal flue runs are not recommended particularly over 3m in length where these are unavoidable advice should be sought from a flue system specialist Common Flue Systems Where multiple boilers are installed on a common flue system the flue system should be designed to ensure the correct operation of the flue on varying load conditions For the safe and reliable operation ...

Page 9: ...osion and lime scale inhibitor added Lime scale descalers if incorrectly used could cause any remaining system debris to continue to breakdown and contaminate the new boiler causing boiler failure Advice on system cleaning and suitable products should be sought from specialist suppliers of system cleaners such as Fernox or Sentinel It is important to note that corrosion inhibitor can only be used ...

Page 10: ...r work undertaken on site 2 The work undertaken does not effect 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 this is impractical then suitable precautions must be ...

Page 11: ...persists seek medical advice Potterton Commercial Customer Erection Assembly Check List The items listed below have been put together as a guide to the actions that should be completed before the erection assembly of a boiler takes place 1 Site access available for persons carrying out the proposed work 2 Site managers personnel aware that work will be taking place 3 Risk assessments carried out o...

Page 12: ...he compound supplied 7 Insert the nipples into the nipple ports by hand and using a piece of wood and a hammer mallet gently drive the nipples into place Do not drive them in too far as tightening should be achieved when bringing the sections together Ensure that the nipples fit square and check depth of penetration by using the template supplied see Fig 5 Ensure that the nipples are correctly ali...

Page 13: ...re Intermediate Section Rear Intermediate Section AR AV M REAR REAR INTER MIDDLE INTER FRONT INTER FRONT Apply Jointmastic Silicone to the surfaces in bold AR AV M or or SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 12 NXR4 ...

Page 14: ...r Section 409 412 411 410 417 413 414 416 415 No of Sections SIZE Front Front Inter Middle Rear Inter Rear 409 1 2 3 2 1 410 1 2 4 2 1 411 1 3 4 2 1 412 1 3 5 2 1 413 1 3 5 3 1 414 1 4 5 3 1 415 1 4 6 3 1 416 1 5 6 3 1 417 1 5 6 4 1 POTTERTON COMMERCIAL PRODUCTS DIVISION SECTION 4 INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 13 NXR4 ...

Page 15: ...led three or four sections fit the rear Stainless Steel Furnace Protective Plate in position against the rear section see Fig 10 Complete the assembly with the front section proceeding as before 3 Keep the assembly tight and seal the joints externally as follows i Clean the V groove between each pair of sections and allow to dry ii Apply the silicone seal with the gun provided see Fig 7 iii Smooth...

Page 16: ... on the Welded Flange Connect the PN16 DN 125 flanges onto the pipework then fasten them to the manifolds inserting the seals eight HM16 x 75 bolts eight nuts and eight washers for each flange Hydraulic Test After checking the connections proceed slowly with filling the system ensuring that all air is purged After filling carry out the hydraulic test 1 5 x working pressure Flue Hood see Fig 10 Scr...

Page 17: ...arkings Marking to be Towards Front Flue Access Doors Top Flange Sensor Pockets Tie Rods Top Outlet Manifold Flue Spigot Rear Section Rear Flue Hood Slip On Weld Flange Flow Distributor 409 411 Not Fitted 412 416 630mm 417 1000mm in two pieces Drain Cock Bottom Inlet Manifold SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 16 NXR4 ...

Page 18: ...s steel lugs 30 and 31 using the Rapid fastening system on Ø8 rods Place the mineral wool insulation brown against the door then the ceramic fibre white on the combustion chamber side see Fig 9 Fold the four stainless steel lugs over the ceramic fibre Cut the insulation material using the burner draught tube as a template This can be easily cut using a sharp knife or hacksaw blade Close the door a...

Page 19: ... Left Side Panel 49 Side Fastening Bracket 50 Side Fastening Lug 51 Side Panel 52 Upper Rear Metal Plate 53 Lower Rear Panel 54 Rear Side Panel 55 Lower Front Panel 56 Right Front Panel 57 Left Front Panel 58 Upper Front Panel 59 Bag of Casing Screws SECTION 4 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 18 NXR4 44 51 43 46 54 52 54 41 44 43A 42 48 57 45 42...

Page 20: ...nt panel onto the top front panel using the two locking pegs The side panel locking pegs are located on the front Side Fastening Bracket 49 Insert the side panel fastening bracket pin into the lower fold of the side panel Secure to the upright with one M5 x 10 screw Fastening Pin 50 Clip the bottom bracket onto the boiler tie rod Insert the pin into the side panel Slide the pin along the tie rod t...

Page 21: ...ssed The overheat thermostat will operate at 110 C 6 Mains Indicator indicates that the power has been turned on to the boiler 7 Fuse the boiler control panel is fused at 6 3 Amps 8 Flue Gas Thermometer indicates the primary flue temperature of the boiler supplied loose 9 Pump Switch switches the pump on and off Pump must be connected through a suitable contactor and pump overrun must be fitted 10...

Page 22: ...ing position guiding the wires and capillaries into the rectangular cut out while tilting the panel 18 Remove the top control panel three screws see Fig 15 Engage the fastening screw heads into the punched holes on the control panel rear 19 Connect the earth wire one off M5 x 10 screw paint cutting washers onto the clamp nut A Fig 16 20 Gather the capillary bulbs and insert fully into the front se...

Page 23: ...ter into the clip 6 Close the control panel and refit the top Burner Cables The NXR4 is supplied as standard fitted with a 7 pin and a 4 pin Weiland plug for connection to the burner High Low Burner The 7 pin and 4 pin Weiland plugs should be connected to the respective plugs provided on the burner FITTING THE BURNER 1 Check that the burner which has been supplied is the correct burner for the boi...

Page 24: ...ered from the instrument panel lead provided FIG 18 Fig 18 Boiler Burner Power Supply Note the following single phase burners must have a separate mains supply for the burner motor as Fig 18A Nu Way NGN15 NGN25 NOL20 EOGB BG500 B50 B55 B45 BG450 Fig 18A Boiler Burner Single phase Supply Three Phase Installation CAUTION If the burner motor is supplied with three phase power control panel single pha...

Page 25: ...prevent the fuel waxing under sustained cold and exposed conditions Class D grade fuel oil should be stored and supplied to the burner at a minimum temperature of 5 C in line with the fuel supplier s recommendations 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 bei...

Page 26: ...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 only be carried out by personnel approved and competent to do so This facility is available from Potterton ...

Page 27: ...e 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 categories these being listed below Pre Commissioning Dry Run This will enable the checks on the safety cont...

Page 28: ...d 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 an integral safety system to allow the safe and reliable operation of the burner Failure of the burner to ...

Page 29: ...eat 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 twice a year of the combustion chamber and flueways and the removal of the rear clean out covers to c...

Page 30: ...F Q3 Q1 F1 E1 N L F4 K4 F5 K5 SEQUENCE CONTROL X4 X1 X2 X3 2 ND STAGE 1 ST STAGE BURNER CABLES X5 MAINS FOR EXTERNAL CONTROLS i e PUMPS X6 BURNER SAFETY OVERHEAT KA2 KA1 CONTROL PANEL OUTER CASING HINGED FRONT ZP ZT ZB F1 6 3 AMP MST VSC STB VMB2 TR2 VSB VMB1 TR1 VOLT FREE REMOTE INDICATION CH1 CH2 HOURS RUN KIT Fig 19 Boiler Wiring Diagram Q3 Q1 F1 E1 N L F4 K4 F5 K5 Power Supply ...

Page 31: ...MST Mains Indicator Light ZB Burner Switch ZT Test Switch ZP Pump Switch KA1 Relay for Remote Indication Overheat KA2 relay for Remote Indication Burner Flame Failure External Interlocks X1 On off Control external interlock boiler only X2 Water Low Pressure Switch X3 Safety Interlock eg Flow switch pressure switch X4 Power Supply 230V 50Hz 1Ph maximum 5A X5 Boiler Pump X6 DHW Pump Fig 20 Pump Over...

Page 32: ...IAL PRODUCTS DIVISION SECTION 6 INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 31 NXR4 VOLT FREE CONTACTS R4 1ST STAGE RUN INDICATION R3 2ND STAGE RUN INDICATION N NEUTRAL CONNECTIONS NO NC 11 14 11 12 N0 NORM OPEN NC NORM CLOSED N VM1 VM2 R4 N 240 V AC NO 14 NC 12 COM 11 R3 N 240 V AC NO 14 NC 12 COM 11 2 Way Volt Free Connector Box Note Two volt free contacts already fitted ...

Page 33: ...ION INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 32 NXR4 16 15 20 12 22 23 6 9 21 23 REAR SECTION 5 SECTION MA 10 24 REFRACTORY SEALANT SILICONE SEALANT 9 6 12 14 24 25 2 9A 1 3 4 14A 13 32 12 33 27 31 28 29 25 23 25 24 30 13 12 34 35 37 38 25 40A 40 41 41A 44 42 43 42 ...

Page 34: ...ht Front Rear COM17843429 2 24 Flue Cover Plate Curved Left Right Rear COM17843439 2 25 Stud 8mm x 45mm long COM15243514 26 Sealing Tape 15 x 6 for Flue Covers COM17000190 Sealing Tape 15 x 6 for Flue Covers per metre COM17000191 27 Flue Box 412 417 COM17850457 1 Flue Box 409 411 COM17850469 1 28 Sealing Rope 9mm x 9mm per metre COM17000171 29 Flue Adaptor Ø300mm 409 411 COM17001115 1 Flue Adaptor...

Page 35: ...7940464 Longitudinal Support Rail Rear 414 COM17940474 Longitudinal Support Rail Rear 415 COM17940484 Longitudinal Support Rail Rear 416 COM17940494 Longitudinal Support Rail Rear 417 COM17940504 45 Top Panel Front COM17940519 46 Top Panel 560mm COM17940529 Top Panel 700mm COM17940539 Top Panel 840mm COM17940549 Top Panel 980mm COM17940559 47 Front Side Panel Right COM17940569 48 Front Side Panel ...

Page 36: ...Cover COM17003854 6 Lockout Indicator COM15838247 7 Red Neon Overheat Indication COM15838260 8 Green Neon 1st Stage 2nd Stage High low COM15838262 9 Orange Neon Mains Indicator COM15838261 10 Control High low Thermostat COM17006994 11 Control High low Thermostat Knob COM17004739 12 Limit Thermostat COM17006940 13 Blanking Panel N A 14 Blanking Panels COM17000983 15 Single Switch Pump COM15804020 1...

Page 37: ...4 section not shown COM17077144 c Cleaning Handle 15 to 17 section not shown COM17077148 d Brush Head not shown COM17000824 SECTION 7 POTTERTON COMMERCIAL PRODUCTS DIVISION INSTALLATION OPERATION MAINTENANCE MANUAL PAGE 36 NXR4 ...

Page 38: ...NOTES ...

Page 39: ... filled and pumps operational any isolation valves open 5 5 Check gas available at burner 5 6 Check oil available at burner 5 7 Check gas meter fitted sized adequately 5 8 Check that gas pipe has been purged 5 9 Has an optional kit been fitted 6 0 COMBUSTION Pilot Low High Unit 6 1 Inlet Gas Supply Pressure Boilers running on High fire mbar 6 2 Burner Pressure mmwg 6 3 Gas Rate m3 hr 6 4 Ionisatio...

Page 40: ...vice Cock Installed If So Is It Accessible 8 22 Is Oil Filter Fitted 8 23 Is Fire Valve Fitted Single Pipe Two Pipe 8 24 Oil Supply Ring Main 9 0 REPAIRS CARRIED OUT COMMISSIONING REPORT Continued Baxi Heating uk Ltd Registered Office Sir Frank Whittle Road Derby DE21 4XA Registered in England No 3879156 PCF No 208 03 NOTE It is the installer s responsibility to ensure that the boiler is correctly...

Page 41: ... 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 42: ...0276 Our service offices offer a wide range of specialised services including Boiler Site Assembly Burner Commissioning for all Fuels Boiler Maintenance Maintenance Contracts Breakdown Repair Services Boiler Dismantling Re Jointing Burner Boiler Replacement Oil Gas Conversions System Conditioning Water Treatment Descaling Packaged Units Potterton Commercial spares are available nationwide through ...

Page 43: ...ig 13 Casing Exploded View 18 Fitting the Casing 19 Fig 14 Control Panel Configuration 20 Assembly of Instrument Panel 21 Fig 15 Instrument Panel Assembly 21 Fig 16 Cable Routing 22 Fig 17 Fitting Thermometer into Flue 22 Flue Gas Thermometer 22 Burner Cables 22 Fitting the Burner 22 Connections 23 Single Phase Installation 23 Fig 18 Boiler Burner Power Supply 23 Fig 18 A Boiler Burner Single Phas...

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