I N S T A L L A T I O N M A N U A L

NXR3

70 / 290 kW
HIGH-EFFICIENCY, PRESSURIZED,
CAST IRON, OIL OR GAS BOILERS

1 . Standards - Regulations

2 . General

3 . Assembly and installation

4 . Installing the options

5 . Commissioning

6 . Maintenance

Ref. : CH - 1249 - A - 2 - EN 07/01 1 Ref. : CH - 1249 - A - 2

1. STANDARD - REGULATIONS

BAXI does not accept any liability for damage caused by

work that does not comply with these instructions and/
or which has not been carried out by a qualified
installer.

This boiler design complies with the following European The boiler can be fitted with a choice of fuel oil or gas burner
directives: in accordance with the builder’s recommendations, the burner
complying with the following standards:
Directive Mains voltage 73 / 23 / CEE
Directive Electromagnetic 89 / 336 / CEE EN 267 • One piece sprayed oil burner
compatibility EN 676 • Automatic blown air burner for gas fuels
Directive Efficiency 92 / 42 / CEE EN 226 • Burner to heat generator connection sizes

This boiler complies with the following standards: The heating system installation must comply with current
regulations.
EN 303.1 • Boilers with forced air burner: Terminology, In particular:
general specifications, tests and marking
EN 303.2 • Boilers with forced air burner: Special DTU 65 • Central heating systems in buildings
specifications for boilers with sprayed oil DTU 65.4 • Gas and liquid hydrocarbon boilers
burner DTU 65.11 • Safety systems for central heating systems
EN 304 • Test regulations for boilers with sprayed oil in buildings
burner Installers’ Association agreement of 2 July 1969.
DIN 4791 • Boiler and burner connections

BAXI S.A. attests that all boilers referred to in this

manual comply the same requirements as corresponding
examined types, for which the right to use CE marking
has been granted according to "Gas appliance" and
"Boiler efficiency" European directives.

Ref. : CH - 1249 - A - 2 2
2. GENERAL

2 . 1 Description

Boilers of this type are composed of a cast-iron

exchanger, consisting in sections assembled by means of
nipples. Their heat transfer surfaces have been specially 2 . 4 Shipping, Packaging
designed to reach high efficiency. The exchanger is insulated
by a glass wool layer lined by lacquered steel casing panel, Packaging is as follows :
itself insulated to reduce heat losses to a minimum.

These pressurized boilers must be fitted with jet-oil or blown-

gas burners, provided operating characteristics are compati-
ble with the combustion chamber size and pressure condi- Boiler Boiler
Package assembled not assembled
tions.
Heating exchanger not assembled X
They heat premises, and, for Domestic Hot Water (D.H.W.) Heating exchanger assembled X
production, can be coupled with a D.H.W. tank located next Optimizing baffles X X
to it. Heating exchanger accessories X X
Control panel wired X X
Casing X X
Extra accessories X
2 . 2 Standard supplies Tie-rods X

• Fire chamber cast-iron sections not assembled,

• Accessories: smoke box, optimizing baffles, flue ways
hinged door, opening chamber door with burner plate,
welding flanges for tubes Ø 76,
• Insulated casing and cleaning brush,
• Depending on the order, this boiler is fitted with a control 34 35 36 37 38 39
panel (according to version). exchanger not Nb of parcels 7 7 7 7 7 7
assembled Total weight kg 612 730 849 963 1082 1198
2 . 3 Supplied on request exchanger Nb of parcels 5 5 5 5 5 5
assembled Total weight kg 612 730 848 950 1068 1184
• Heating body delivered assembled,
• Two extra power economizers,
• Starter sleeve with finger button for remote control sensor
and ¾” ∅ tapped opening with plug (not assembled),
• Return sleeve with finger button for remote control sensor
and ¾” ∅ drainage valve (not assembled),
• Adjustable feet for levelling body,
• Control panel options,
• OIL or GAS burner, depending on matching prescriptions,
• Domestic Hot Water calorifer (250-350-500-800)

3 Ref. : CH - 1249 - A - 2
2 . 5 Technical data

Flow DN 65

Fig. 1

N04153.DSF
Return DN 65
Rp 2" orifice for * Dimensions with water
sludge flushing connection sleeve Drain Rp 1 1/2" orifice

Réf. chaudière : N° 34 35 36 37 38 39
Output : kW 70 - 90 90-130 130-170 170-210 210-250 250-290
Number sections 4 5 6 7 8 9
Dimensions : Cote A : mm 995 1165 1335 1505 1675 1845
Cote B : mm 900 1070 1240 1410 1580 1750
Cote C : mm 750 920 1090 1260 1430 1600
Cote Y : mm 292 292 292 292 292 292
Combust. chamber depth P : mm 595 765 935 1105 1275 1445
Smoke hood Ø D : mm 180 180 180 180 200 200
Chamber volume : l 110 140 170 200 230 260
Flue path volume incl-chamber : l 190 230 270 320 350 390
Water system vulume : l 112 136 160 184 208 232
Working pressure : bar 6 6 6 6 6 6
Waterside pressure loss at (∆t = 15 K ) : mbar 5 9 15 21 31 50
Thermostat range adjustement : °C 30 - 90 30-90 30-90 30-90 30-90 30-90
Limit stat max setting. (temperature) : °C 110 110 110 110 110 110
Standing losses (NFD 30 002) :% 0,14 0,13 0,11 0,09 0,08 0,07
Heating maintenance needs : % 0,74 0,52 0,40 0,33 0,28 0,25
Flame output (P nom) : kW 75 - 98 97-142 140-185 184-229 228-273 271-317
Chamber pressure : mbar 0,1 - 0,2 0,2-0,5 0,5-0,8 0,7-1,2 1,3-1,8 1,5-2,3
Massic-flow oil flues : Kg/h 108 - 140 139-202 201-265 263-328 325-391 388-454
2 Savers(3)

Massic-flow gas flues : Kg/h 124 - 161 160-234 232-306 303-378 375-451 448-524
Flue gas temperature : °C 155 - 174 158-177 161-180 164-182 167-185 170-188
Combustion efficiency (2) : % 93,0 - 93,9 92,8 - 93,7 92,7 - 93 6 92,6 - 93,4 92,5 - 93,3 92,4 - 93,2
Flame output (P nom) : kW 74 - 97 96 - 140 139 - 183 182 - 227 226 - 271 270 - 315
Chamber pressure : mbar 0,1 - 0,3 0,2 - 0,5 0,5 - 1,0 0,8 - 1,3 1,5 - 2,0 1,7 - 2,5
4 Savers (3)

Massic-flow oil flues : Kg/h 106 - 138 137 - 200 199 - 262 261 - 325 323 - 388 385 - 451
Massic-flow gas flues : Kg/h 123 - 160 158 - 231 229 - 303 301 - 375 372 - 447 445 - 520
Flue gas temperature : °C 141 - 160 144 - 163 147 - 166 150 - 168 153 - 171 156 - 174
Combustion efficiency (2) : % 93,6 - 94,5 93,5 - 94,4 93,4 - 94,2 93,2 - 94,1 93,1 - 93,9 93,0 - 93,8

(1) The maintenance coefficient is for an average boiler temperature of 70 °C .

(2) Values given for rated output, 20 °C room temperature, boiler temperature 80 °C, return 60 °C.
(3) CO2 (indicative) - 13 % (oil) - 10 % (gas)

Ref. : CH - 1249 - A - 2 4
3. ASSEMBLY AND INSTALLATION
Caution : assembly and installation must be carried out by a qualified engineer.

Connections to water supply

3 . 1 Boiler room layout
Connection to the heating system needs to be done according
Plinth (see fig. 2) to statutory regulations and trade practice.
No special plinth is required for this type of boiler. A simple dry Fuel supply
base suffices. For information, we provide the dimensions of
this dry base (figure 2). For certain special installations, a For oil and gas, comply with statutory rules and
sound-proof plinth may be necessary. We recommend a recommendations, in particular with respect to safety rules.
metal plinth resting on reachable antivibration pads. Power supply
comply with regulatory prescriptions, in particular with res-
Fig. 2 pect to earthing and its connection to the boiler (main
N0225100.PLT

switch...)
Boiler
size C L Flue stack

34 750 900 A 0 daPa depression should be observed at exit of smoke box.

35 920 1070 Comply with statutory regulations and trade practice.
36 1090 1240 Please note that the efficiency of these boilers results in
Flat bars
37 1260 1410
width 150 relatively low flue gas temperatures.
38 1430 1580
Optional 39 1600 1750 Special care must be given to flue stack which must be air-
sealing tight, heat-insulated and protected against degradation. One
of the actions to take is to line the duct. Tubing grade must
be compatible with the selected fuel.
Clearance (see fig.3) It is advised :
• to keep the same cross-section as that of the boiler smoke
The dimensions shown are minimal values which allow proper hood outlet,
access for assembly and maintenance operations. • to avoid short radius,
No need to leave clearance above for cleaning purposes. • to keep the number of bends to a minimum
• where possible, to slope connecting parts upwards,
towards chimney
• to provide a purging vessel as close to the boiler as
possible.
Water flow rate
The system must be designed to ensure a water flow rate, in
each boiler, comprised between 1/3 and 3 times the QN
nominal flow rate.
PN kW x 0,86
QN =
15K
N0218601.PLT

Water flow rate allowed in each boiler must be comprised

between :
PN kW x 0,86 and PN kW x 0,86
45K 5K

Fig. 3

Ventilation Choice of burner

The burner should be chosen according to the boiler power
Comply with statutory regulations for low and high ventilation and furnace.

5 Ref. : CH - 1249 - A - 2
 Minimum flow rate must be provided at all times,
Non return valve whatever the rate of operation, either :
- by means of the main flow pump, provided that the
system has no mixing valve between each boiler and
the pump, and that the pump operates continuously,
- by means of a recycling pump or a loading pump
operating permanently.
00306

In the case of a recycling pump or a loading pump per

boiler, and to avoid parasitic flows in the other boilers,
To vents position non return valves upstream from the return
connection.

The burner must be controlled by the recycling or

loading pump. It can only be put in operation if the pump
operates. Secondarily, a flow control device, combined
with the TH thermostat, can be mounted on the return
of the boiler, downstream from the recycling or loading
Sludge flush pump.

Fig. 4

DIAGRAM OF THE ELEMENTS S : tightening markings

Assembly marking
E : spacing pads

Cord junction point

S E S
N0225200.PLT

S S S S

Cord

Fig. 5 Front Middle Rear

Boiler Number of sections Distributors

ref. Front Middle Rear

34 1 2 1 None
35 1 3 1 None
N0226701.PLT

36 1 4 1 Short
37 1 5 1 Short
38 1 6 1 Long
39 1 7 1 Long

Ref. : CH - 1249 - A - 2 6
3 . 2 Assembling the sections 7) NEVER USE OLD NIPPLES.
Coat nipples and reams with the product provided,
using a clean brush.
The sections are assembled using nipples. For a good
tightness of the assemblies, it is compulsory to use a special 8) Place the nipples in the vertical section’s orifices and
product which ensures a perfect seal (this coating is always drive them in slightly using a piece of wood on which
provided with the boiler). to hit with a hammer or a mallet so as to maintain the
nipples in the reams. Do not drive them in too much, so
Proceed in the following way: that the final tightening shall be obtained by bringing the
sections together.
1) Open the "Extra accessories" box,
Take care that the nipples be perfectly vertical, as a
deviation during tightening can break the section,
2) Clean the nipples with a solvent,
9) After having cleaned the middle section and applied the
3) Put the rear section in vertical position and secure it
coating, bring it on the block to place it facing the
against tilting by propping it up,
vertical rear section and respecting the orientation of
the assembly marking which must be always oriented
4) Position the wooden block provided in the "extra
towards front (see figure 6).
accessories" box, 40 mm thick, in front of the rear
Drive it onto the two nipples using a mallet or a piece of
section’s legs,
hard wood, hitting alternately, at top and bottom, facing
the nipples to ensure temporary assembly of the two
5) On the vertical section, clean the groove awaiting the
sections,
cord with a metal brush, then position the cord
without stretching it, with the junction point at the top
10) Ensure that they are perfectly vertical, and tighten it as
(see figure 6) on the axis of the nipples line.
explained in the following chapter.
Cut the cord carefully.

6) Clean carefully with solvent the receiving surfaces. If

need be, use extra fine emery paper in case of rust
stains or small barbs.

BE CAREFUL TO ASSEMBLE THE MIDDLE SECTIONS CORRECTLY

Leaktightness cord
junction point

Assembly marking

Inside Outsise

N0224600.PLT

Tightening of the
leaktightness cord

Assembly marking
02244-01

Place the cord in the

vertical element's
ream

Fig. 6 Wooden block (provided)

7 Ref. : CH - 1249 - A - 2
3 . 3 Tightening the sections 1) Withdraw the plates’ alignment screws,

2) Place an (A) installation bar in each row of nipples,

To tighten the sections, a set of assembly bars is necessary.
It comprises:
3) Mount, on each bar, at the rear, a plate with (B) stop-
ring,
For 4- to 7- section boiler:
4) Mount at the front the (C) plates with tightening nut,
- 2 assembly bars, length = 1.60 m (A),
after having lubricated the thread,
- 2 fixed plates with stop-ring (B),
- 2 mobile plates with ball nut (C),
5) Align the plates,
- 1 ratchet wrench.
6) tighten the screw alternately by 1/2 a turn each, taking
This set is not part of normal supplies.
care to avoid fan assembly.
For 8- and 9- section boilers:
Proceed with tightening until the sections touch, and
check it by looking in the firebox and the upper
- Same as above,
"flue-ways".
- 2 bar extensions, length = 950 mm.

Or PARCEL N° 1 + PARCEL N° 2

L
l max. 54 70

N0219800.PLT
121 Run = 245 160 Step = 190

Nut Mobile plate C assembly bar A Extension D

FRONT BACK

Take alignment screws off Stop-

Nbr. of elements Bar L dimension l dimension ring
Fixed plate B
4 to 7 A 1600 1355
8 to 9 A+D 2550 2305
Fig. 7

7) Assemble the other sections (1 by 1) in the same way,

Stop-ring A
Assembly while moving the wooden blocks alternately as you go
B marking towards the front,
REAR
section 8) Do not loosen the assembly bars and position the 4
assembly linkages. Tighten them properly, leaving an
equal length at each end to secure the casing’s cross
N0219700.PLT

members, and if necessary the adjustable legs,

Positioning aid

9) Loosen and take the installation bars off,

10) proceed with the boiler assembly.

MID NOTE: If it were necessary to dismantle one of the
Nut Assembly
section C
marking boiler’s sections, and to avoid damaging the
leaktightness gorges, it is imperative, when dismantling
the sections, to place the chisel at the level of the
Wrench spacing pads (E) provided in the upper part (see
Fig. 8 figure 5).

Ref. : CH - 1249 - A - 2 8
EXCHANGER

02236-00
5 Sealing cord Ø 7
40 Screws bag

Fig. 9

1 Front section 14 Disriburor, Length 180 24 External insulation

2 Middle section 14a Distributor, Length 530 25 Sight flange
3 Rear section 15 Flow and return manifold 26 Sight glass and seal
4 Nipple Ø 89 16 Drain valve 27 Door seal Ø 16
5 Sealing cord Ø 7 17 Sensor pocket, Length 100 mm 28 Burner plate
6 Tie-rod 18 Upper baffle 29 Burner plate gasket
7 Reducer 18a Lowe baffle 30 Cleaning access. door
8 Sensor pocket, Length 200 mm 19 Smoke box Ø 180 31 Internal insulation
9 Door hinge 19a Smoke box Ø 200 32 External insulation
9a Door hinge 20 Flue-way hatch (L) 33 Insulation body blanket
10 door guide 20a Flue-way hatch (R) 39 Cleaning brush
11 Door pin 21 Leaktightness braid Ø 8 40 Screws bag
12 Welding flange 22 Chamber door 41 Complete adjustable leg
13 flange gasket 23 Internal insulation

9 Ref. : CH - 1249 - A - 2
3 . 4 Operational assembly diagram

Operation Method

Open the "chamber accessories" parcel

• Assemble the 8 studs 12 x 65 around the rear section’s start and return orifices.
Distributor (14 - 14a) • If necessary, insert the distributor (see figure 22) in the return orifice by interpolating the seal
(13).

Installing the boiler • Place the boiler in its final position and level it, which would be made easier by the "Adjustable
legs" option (chapter 3 . 1)

Sensor pocket (8) • Screw the pocket and the reducer (7) in a leaktight manner in the front section’s upper orifice.

Sludge flushing • A threaded orifice Ø 2" is provided at the bottom of the front section, for mounting a valve
enabling rinsing and flushing of the installation’s sludge (we recommend mounting coil, a 90°
bend and the valve). A pre-cut space allows for passing the tubing in the casing’s lower
panel.

Drain valve (16) • Mount a drain valve tightly (not provided) on the installation or in the lower part of the rear
section using a reducer (not provided).
• A drain valve Ø 3/4" is delivered with the "Connection sleeves" option (see chapter4 . 2).

Welding- flange (12) • Connect the flanges on the installation’s tubing, than fasten them on the boiler, interpolating
the seal (13), with 4 HM 12 nuts and 4 washers for each.

Filling and hydraulic test • After having checked the connections, proceed slowly with filling the installation, ensuring all
the air is vented, then proceed to the hydraulic test ((1.3 x P. operation) to check all leaktight
areas.

• Screw the shortest threaded part of the 4 studs M 8 x 40 in the rear section in the upper part.
Smoke box (19 - 19a) • Check that the leaktightness braid (21) is in place.
• Engage the smoke box on the studs and fasten it (4 HM nuts and 4 washers) by tightening
the nuts moderately and simultaneously.

Stack • Connect the boiler to the stack in the most direct possible manner and without reduction of
the size of the smoke duct. Ensure that the latter is leaktight.

Optimizing baffles (18 and 18a) • Insert the assembled baffles (18) in the upper "flue-ways" and, if need be, the simple baffles
(18a) in the lower "flue-ways" (see chapter 4 . 3).

• Screw the small threaded part of the 8 studs M 8 x 40 in the front section following the
indications of figure 10.
Door hinges (9) • Define the opening side for the doors.
Door guide (10) • Mount the hinges (1 screw HM 10 x 30 + 1 nut HM 10 + 2 washers L 10 for each guide). The
door guide is located opposite the hinges, in the upper part.

Door hinge (9a) • Depending on the chosen opening side, secure the hinge (9a) on each door using 2 screws
HM 12 x 35 + 2 washers M 12.

Caution: For reasons of practicality, it is recommended to mount the firebox door first.
• Mount the doors on the hinges using the axes (11).
Chamber (22) and • Engage the doors on the studs and fasten them (4 nuts HM 10 and 4 washers L 10 for each
Cleaning door (30) door), tightening the nuts lightly and simultaneously.

Burner plate (28) • Depending on the size of its fixation, the burner is mounted directly on the door, or via a
perforated plate (see figure 11). Mount the burner plate (4 screws HM 12 x 35 + 2 washers
M 12) on the chamber door, interpolating the leaktightness seal (29).
- A plain plate may be provided on request.

Ref. : CH - 1249 - A - 2 10
 Stud M 10 x 90 Stud M 10 x 90

Guide Hinge
Door hinge and door guide
assembly
Screw TH M 10 x 30 Screw TH M 10 x 30

Screw TH M 10 x 30

Hinge
Stud M 10 x 90
N0226400.PLT

Stud M 10 x 90
Stud M 10 x 90 Stud M 10 x 90

Guide Hinge

Screw TH M 10 x 30 Screw TH M 10 x 30
Screw TH M 10 x 30

Stud M 10 x 90 Hinge

Stud M 10 x 90

Fig. 10
Pre-drilled
burner door

N0225600.PLT
Fig. 11

4 holes M 8 equidistant on a perforation Ø of 170

4 holes M 10 equidistant on a perforation Ø of 200

Front 4 holes M 14 equidistant on a perforation Ø of 254

Insulation positioning

Front insulation blanket

Top insulation blanket

Side insulation
blanket
N02187-01.DSF

Rear insulation
blanket

Bottom insulation blanket

Fig. 12

11 Ref. : CH - 1249 - A - 2
3 . 4 Operational assembly diagram (continued)

Operation Method

Open the "casing" parcel

Rear spacer (50) • Screw the hexagonal spacers on the rear section’s 3 spacer pads, and place on each
(see figure 15) spacer a TH M 5 x 10 screw.

Body insulation blanket (33) • Place the lower heat-insulator (cross-shaped, 50 mm thick on black veil) under the
(see figure 12) heat chamber taking care to jam the ends between the assembly linkages and the
chamber.

• Casing the whole of the chamber by the side insulation (50 mm thick) and tuck
its ends under the chamber (see figure 12).

• On the rear section, insert insulation (100 mm thick) on the spacers.

• NOTE : for exchangers with 8 or 9 sections, the side insulation is supplied in 2 parts
to be positioned side-by-side, the large part towards the front.

Lower rear (51) • Engage the lower rear on the three spacers and secure it by tightening the 3 screws.

Lower foot (52) • Mount both lower feet on the front section (2 screws HM 8 x 16).

Cross-member (53) • Mount the cross sections on the assembly linkages, fasten them using the counter-
nuts HM 12. The front cross-member is provided with a protection clip (110 mm long)
with a plastic collar and a NUT nut.

Right side-rail (54) • Laterally secure the side rails on the cross-members using bolts HM 8 x 16 (square
Left side rail (55) hole to the front).

Casing sides assembly Front casings assembly

Front Rear Front Middle Rear

N0220900.PLT

A B A C B

Fig. 13

Nb. of elements 4 5 6 7 8 9
Front A 300 300 300 300 300 300
N0221000.PLT

Middle C 510 510 510

Rear B 514 684 854 514 684 854
Fig. 14

Ref. : CH - 1249 - A - 2 12
CASING ASSEMBLY

02237-01.TIF
71 Casing screw bag

Fig. 15

50 Rear spacer 61 Rear left side

51 Lower rear 62 Middle side
52 Lower foot 63 Upper rear
53 Cross-member 65 Front top
54 Right side-rail 66 Rear top
55 Left side-rail 67 Middle top
56 Lower mask 68 Upper front
57 Right side 69 Lower right front
58 Left side 70 Lower left front
59 Side restraint 71 Casing screw bag
60 Rear right side

13 Ref. : CH - 1249 - A - 2
 Operation Method

Lower mask (56) • Place the lower mask on both lower feet at the front of the boiler (this part is pre-cut
to allow passing of sludge tubing, or can also be taken out)).

Front sides (57 - 58) • Hook the front sides onto the side-rails and fasten them using the axis screws (Ø 8)
in the upper part and at the bottom using a TH M 5 screw on the lower foot.

Side restraint (59) • Extract the restraint from the side panel by tilting it, insert it in the side heat-insulator’s
slit, and hook it on the assembly linkage; Tighten the axis screw.

Middle sides (62) • (only for boilers with 7, 8 or 9 sections)

• Put the middle side on the side-rails. Slide it so that the axis of the restraint enters the
orifice provided.
• Extract the side restraint in the same way as for the front side.

Rear sides (60 - 61) • Put the rear side on the side-rails, and slide so that the side’s return fold casings the
lower rear (51) “s fold and the axis of the restraint enters the orifice provided.
• Secure the rear sides on the lower rear using 4 HM 5 x 10 screws.

Upper rear (63) • Pin the upper rear on the sides and click it in downwards in the keyhole slots provided
for this purpose.

Upper heat-insulator (33) • Place the upper heat-insulator on the side-rails (slit at the front).

Front top (65) • Place the front top on the side axes and push it forwards to bumper.

Middle top (67) • (only for boilers with 7, 8 or 9 sections)

• Place it on its axes and push it forwards until it joins up with the front top.

Rear top (66) • Place it on its axes and push forwards until it joins up with the front or middle side in
the case of a boiler 7, 8 or 9 sections.
• Secure it on the upper rear (2 HM x 10 screws).

Control panel • Assemble the control board as indicated on this page.

Lower left and right façades • Click the faþades in laterally and downwards on the buttons fastened on the sides’
(69 - 70) folds.
Locking is done by the central feet.

Upper façade (68) • Engage both axes in the lower faþades’ holes.
(see figure 14) • Press the façade on the sides.

CONTROL PANEL ASSEMBLY Fig. 16

- fit the control panel on the front top while routing the
probe cables through the opening included to this plastic pins
effect A
N04214DSF

- engage the pins under the panel into the slots, and
pull the control panel towards you.

- Lock it using the 2 plactic pins (A) and the M5 screw

(B) on the top front Probe cables

Ref. : CH - 1249 - A - 2 14
ELECTRIC CONNECTION CABLES FITTING

The facility must comply with currently enforced national and

local regulations.Notably, the electric connection of the boiler
requires a sectioning device on each pole with a minimum 3 Capillaries
mm distance between each contact.
For the complete electric connection of the various
Front
types of control panels, refer to the manual specific to crosspiece
the panel. AV
The power supply connection terminal strip is accessible after
removing the cover at the back of the panel. It is located in the
lower right corner seen from the back. Earthing
Connect the phase to the strip’s L terminal. Clamp- wire
nut A
The line must be able to withstand an intensity of 6.3A under
230V 50 Hz + Ground (check whether the power of the
pump(s) is compatible).
Apply the electric connection as per the electric diagram in

N04156.DSF
the instructions. Plan a grounding wire exceeding by 50 mm
in length to the neutral and phase wires for tearing safety.
The burner switch located on the control panel does not
dispense from installing the regulatory wall switch.
The ground socket planned on the connecting termi- Burner
nal strip must be connected as per currently enforced cables
provisions.
In the case of insufficient ionising current due to non compliant
neutral or ground, we recommend adding a circuit isolation Lower piece
transformer with a power at least equal to 600 VA. Fig. 21

Control panel supply connection terminal strip

Fitting the thermostat bulbs, thermometer (and regulation
probe in option) in the glove finger as shown in the diagram.

Boiler glove finger

03935-00

withoud regulation probe

CS control panel

6
Main power supply Boiler glove finger
230 Vac 50 Hz with regulation probe
(phase imperatively in L)
shunt "UV" CE, ECO 5E, ECO7E, ECO8E
CM control panel control panel

BOILER AND BURNER POWER SUPPLY

Fig. 20 Three-phase
N0225300

2
current
Single-phase Single-phase
02078-01 02078-05
current current
power supply
Burner motor

00229-5
Control

Control

When fitting the capillaries, ensure they are inserted fully

in the glove finger.

1 - Overheating safety thermostat

CAUTION : In the case the burner motor is supplied with 2 - Heating outlet thermometer
3 - Regulation thermostat
three-phase power, control panel single phase supply 4 - Tube Ø 6
must imperatively be taken from one of the phases 5 - Heating regulation probe
supplying the burner motor. 3 - Regulation thermostat 2nd Stage
VERY IMPORTANT : Never connect the burner control box
directly to one of the phases.

15 Ref. : CH - 1249 - A - 2
4. INSTALLING THE OPTIONS
4 . 1 Adjustable legs
For levelling the assembled heating chamber, located in the boiler room.

Assembly of the 4 heating chamber legs:

- Screw the adjusting screws up to the maximum in the supports,
- Engage the support in the space provided on each heating chamber leg, as shown in figure 19. Fasten the supports on
the end of each assembly linkage (nut + washer),
- Slide the pads under the adjusting screws,
- Level using the screw with a 17 flat wrench (adjusting travel = 16 mm maximum).

Boiler leg Support Support fixation Fig. 19

nut
N0223000.PLT

Adjusting
screw
Pad

Wrench

4 . 2 Heating system flow and return connection manifolds with drain valve and Sensor
pocket for remote control

Fig. 20
The manifolds move the main heating system connection
outside the casing. They are provided with threaded orifices
for fitting the following accessories:

- On Ø 1/2" start and return: pockets (17) for remote

control sensor,

- On Ø 3/4" flow: drain or safety accessories (not provided),

- On Ø 3/4" return: drain valve (16); 02244-00

Mount the manifolds (see figure 20) on the boiler’s flow and
return orifices, positioning the threaded orifice Ø 1/2" towards
the exchanger, placed on top for flow and on the side for return.
NOTE: For boilers fitted with a water distributor (14) on the
return, the distributor must penetrate as far as possible in the
exchanger return orifice.
Its fixation flange will be placed, between two joints (13),
between the return manifold and the rear section.

Heating system’s connecting flanges (12) should be welded

to the water system’s pipes before fitting on the boiler.
12 - Flange 15 - Return manifold
13 - Gasket 16 - Drain valve
14 - Distributor 17 - Sensor pocket

Ref. : CH - 1249 - A - 2 16
4 . 3 Lower savers Upper baffles

The two optional extra optimizing baffles should be placed in

the two lower "flue-ways" as shown in figure 21:

Engage each baffle in the "flue-way".

Performance as shown in the characteristics table corres-

pond to the boiler operating with the upper and lower baffles

N0221000.PLT
as shown in the position diagram opposite.

4 . 4 Control panel options

Before any operation inside the control panel, disconnect
power supply using main switch located on heating system Fig. 21 Lower baffles
general control board.

Flue gas thermometer :

Its housing is to be positioned on the control panel front and

the bulb on the flue stack.
- Take off the top, open panel front
- Take off the factory-mounted blank plate and engage the
capillary and the thermometer housing into the front aper- Bulb
ture
- Guide the capillary through control panel rear and casing

N224200.PLT
front top, parallel to the other installed capillaries. Direct
Holding
the capillary towards the back of the boiler, on exchanger
clips
insulating blanket, in order to be able to bring its bulb up
into the connection pipe between flue hood and stack
- Drill, preferably vertically, the fluegas duct to + 7.5 and Flue
stack
drive the bulb holding clip (see fig. 22)
- Engage the bulb into the clip. Close the control panel and
fit top again. Ø 7,5

Fig. 22

Burner cables :

The 1st stage burner cable with a 7-contact connector and the
2nd stage burner with a 4-contact connector are to be
connected on the terminal block inside "B" control panel,
markings being properly aligned. guide the wires as explained
in the ñ of page 15.

17 Ref. : CH - 1249 - A - 2
5. COMMISSIONING 6. MAINTENANCE

5 - 1 Filling Boiler

- Water quality for the heating system Check water pressure on pressure gauge and, if necessary,
restore normal pressure. Only perform this operation when
Avoid using hard water, which may scale the boiler. If TH the system is cold. If frequent topping-up is necessary, there
or total hardness is above the French 25°, the boiler is a leak in this case, notify the installer. Never draw water
should be filled with softened water. from the heating system. In order to avoid slow but steady
sooting, harmful to proper boiler operation, it is recommended
- Filling the boiler and heating system to clean it regularly twice a year at least.

While filling, which must be done slowly, ensure that the This is always done with the boiler stopped and the power
stop valves are open and that the mixing valve can be 1/ supply cut out.
2 open.
The automatic drain cock plug, normally fitted on the Proceed as follows :
boiler outlet, must remain untightened in order to achieve
continuous draining during filling-up. Drain all high points • put ON burner switch located on the control panel as well
of heating system and close the various draining screws as the main boiler room switch
one after the other as soon as water reaches their level. • remove casing front panels
After filling the boiler for the first time, flush completely • open the cleaning door and the chamber door and take
(using the sludge flushing valve) in order to get rid of the flue-way hatches away.
foreign bodies that may come into the components or the • take the optimizing baffles down and brush them.
pipes during assembly. • clean the walls of each flueway with the brush provided
with the boiler as well as the combustion chamber walls.
- Water topping up • remove soot and combustion deposits, if possible using
a vacuum cleaner
Subsequent boiler topping-up should be practically non- • Clean the inside of the smoke hood
existent and in all cases controlled and registered by a • the lagging material of the doors may be brushed with a
water flow meter. Frequent topping-up is the a symptom soft brush. Do not use a metal brush. Be careful not to
of a leakage which should be repaired as soon as possi- damage the seal.
ble. • once the cleaning is over, put the hatches back up on
the smokebox, put the optimizing baffles back in their
5 - 2 Preliminary checks respective "flue-ways", close the chamber and cleaning
doors, ensuring that they are tight.
When commissioning the boiler for the first time in the • set casing front panels back up.
season, or after a prolonged shutdown period :
Sludge
- ensure that filling was done properly and check overall This sludge, due to corrosion in the system, travels inside the
tightness. If necessary, put more water and drain all high pipework and makes up deposits in the boilers. We
points until water flows slightly. recommend to rinse the boiler efficiently and thoroughly
- check the connection of the flue stack and the proper and check the flushed water quality.
working condition of the draught regulator if any
- check that the high and low vents are not obstructed Burner
- ensure that the doors and the flue access plates are The burner should be submitted to regular maintenance. See
closed and tight special instructions, provided with the burner. If necessary,
If necessary, act upon the tightening points. contact the retailer or manufacturer of the burner.
- ensure that the burner is properly locked
- check if it is properly supplied in fuel, that supply and
return valves are open
- for operation with gaseous fuel types, check that the
safety conditions are fulfilled.

Note : After starting up a system for the first time, it is

recommended to clean the pump filter in the case of oil firing,
or the line filter in the case of gas firing.

After a few hours of operation, check the tightness of the

doors. If necessary, tighten their fastening nuts.

Ref. : CH - 1249 - A - 2 18
19 Ref. : CH - 1249 - A - 2
157, Avenue Charles Floquet
93158 Le Blanc-Mesnil - Cedex
Téléphone : + 33 (0)1 45 91 56 00
Télécopie : + 33 (0)1 45 91 59 50
www.chappee.com

S A au capital de 43 214 640 €

RCS Bobigny B 602 041 675 A.P.E 282 D
Ref. : CH - 1249 - A - 2 20 PRINTED AT SOISSONS FACTORY - FRANCE