Chappee NXR3 Manuel utilisateur

1 Ref. : CH - 1249 - A - 2

1 . Standards-Regulations

2 . General

3 . Assemblyandinstallation

4 . Installingtheoptions

5 . Commissioning

6 . Maintenance

HIGH-EFFICIENCY, PRESSURIZED,

CAST IRON, OIL OR GAS BOILERS

70 / 290 kW

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

INSTALLATION MANUAL

NXR3

2Ref. : CH - 1249 - A - 2

1.STANDARD-REGULATIONS

BAXIdoesnotacceptanyliabilityfordamagecausedby

workthat doesnot complywith theseinstructions and/

or which has not been carried out by a qualified

installer.

This boiler design complies with the following European

directives:

Directive Mainsvoltage 73 / 23 / CEE

Directive Electromagnetic 89 / 336 / CEE

compatibility

Directive Efficiency 92 / 42 / CEE

Thisboiler complieswiththefollowingstandards:

EN303.1 • Boilers with forced air burner: Terminology,

generalspecifications,tests and marking

EN303.2 • Boilers with forced air burner: Special

specifications for boilers with sprayed oil

burner

EN304 • Test regulations for boilers with sprayed oil

burner

DIN4791 • Boilerandburnerconnections

Theboilercanbefittedwithachoiceoffueloilorgasburner

inaccordancewiththebuilder’srecommendations,theburner

complyingwiththefollowingstandards:

EN267 • Onepiecesprayedoilburner

EN676 • Automaticblown airburnerforgasfuels

EN226 • Burnerto heatgenerator connectionsizes

The heating system installation must comply with current

regulations.

Inparticular:

DTU65 • Central heating systems in buildings

DTU65.4 • Gasandliquidhydrocarbonboilers

DTU65.11 • Safety systems for central heating systems

inbuildings

Installers’Associationagreement of2July 1969.

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

manualcomplythesamerequirementsascorresponding

examined types, for which the right to use CE marking

has been granted according to "Gas appliance" and

"Boiler efficiency" European directives.

3 Ref. : CH - 1249 - A - 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

designedtoreachhighefficiency.Theexchangerisinsulated

byaglass wool layer linedbylacquered steel casingpanel,

itself insulated to reduce heat losses to a minimum.

Thesepressurizedboilersmustbefittedwithjet-oilorblown-

gasburners,providedoperatingcharacteristicsarecompati-

ble with the combustion chamber size and pressure condi-

tions.

Theyheatpremises,and,for DomesticHotWater (D.H.W.)

production,canbecoupledwith aD.H.W. tanklocatednext

to it.

2 . 2 Standard supplies

• Fire chamber cast-iron sections not assembled,

• Accessories: smoke box, optimizing baffles, flue ways

hingeddoor,openingchamberdoorwithburnerplate,

welding flanges for tubes Ø 76,

• Insulatedcasingandcleaningbrush,

• Depending on the order, this boiler is fitted with a control

panel(accordingtoversion).

2 . 3 Supplied on request

•Heatingbodydeliveredassembled,

•Twoextrapowereconomizers,

•Startersleevewithfingerbuttonforremotecontrolsensor

and¾”∅tappedopeningwithplug(notassembled),

•Returnsleevewithfingerbutton forremotecontrolsensor

and¾”∅ drainagevalve(notassembled),

•Adjustablefeetforlevellingbody,

•Controlpaneloptions,

• OILorGASburner,dependingonmatchingprescriptions,

• DomesticHotWatercalorifer(250-350-500-800)

2 . 4 Shipping, Packaging

Packaging is as follows :

Boiler

assembled

Boiler

not assembled

Package

Heatingexchanger notassembled

Heatingexchangerassembled

Optimizingbaffles

Heatingexchangeraccessories

Controlpanelwired

Casing

Extraaccessories

Tie-rods

612

730

849

848

963

950

1082

1068

1198

1184

exchangernot

assembled Nbofparcels

Totalweightkg

exchanger

assembled Nbofparcels

Totalweightkg

4Ref. : CH - 1249 - A - 2

2 . 5 Technical data

Flow DN 65

Fig. 1

Return DN 65

Drain Rp 1 1/2" orifice

Rp 2" orifice for

sludge flushing

130-170

1335

1240

1090

292

935

180

170

270

160

30-90

110

0,11

0,40

140-185

0,5-0,8

201-265

232-306

161-180

92,7 - 93 6

139 - 183

0,5 - 1,0

199 - 262

229 - 303

147 - 166

93,4 - 94,2

250-290

1845

1750

1600

292

1445

200

260

390

232

30-90

110

0,07

0,25

271-317

1,5-2,3

388-454

448-524

170-188

92,4 - 93,2

270 - 315

1,7 - 2,5

385 - 451

445 - 520

156 - 174

93,0 - 93,8

170-210

1505

1410

1260

292

1105

180

200

320

184

30-90

110

0,09

0,33

184-229

0,7-1,2

263-328

303-378

164-182

92,6 - 93,4

182 - 227

0,8 - 1,3

261 - 325

301 - 375

150 - 168

93,2 - 94,1

210-250

1675

1580

1430

292

1275

200

230

350

208

30-90

110

0,08

0,28

228-273

1,3-1,8

325-391

375-451

167-185

92,5 - 93,3

226 - 271

1,5 - 2,0

323 - 388

372 - 447

153 - 171

93,1 - 93,9

90-130

1165

1070

920

292

765

180

140

230

136

30-90

110

0,13

0,52

97-142

0,2-0,5

139-202

160-234

158-177

92,8 - 93,7

96 - 140

0,2 - 0,5

137 - 200

158 - 231

144 - 163

93,5 - 94,4

Réf. chaudière : N°

Output : kW

Number sections

Dimensions : Cote A : mm

Cote B : mm

CoteC : mm

Cote Y : mm

Combust. chamber depth P : mm

Smoke hood Ø D : mm

Chambervolume : l

Flue path volume incl-chamber : l

Water system vulume : l

Working pressure : bar

Waterside pressure loss at (∆t = 15 K ) : mbar

Thermostat range adjustement : °C

Limit stat max setting. (temperature) : °C

Standing losses (NFD 30 002) : %

Heating maintenance needs : %

Flame output (P nom) : kW

Chamber pressure : mbar

Massic-flow oil flues : Kg/h

Massic-flow gas flues : Kg/h

Flue gas temperature : °C

Combustion efficiency (2) : %

Flame output (P nom) : kW

Chamber pressure : mbar

Massic-flow oil flues : Kg/h

Massic-flow gas flues : Kg/h

Flue gas temperature : °C

Combustion efficiency (2) : %

70 - 90

995

900

750

292

595

180

110

190

112

30 - 90

110

0,14

0,74

75 - 98

0,1 - 0,2

108 - 140

124 - 161

155 - 174

93,0 - 93,9

74 - 97

0,1 - 0,3

106 - 138

123 - 160

141 - 160

93,6 - 94,5

*Dimensions with water

connection sleeve

(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)

2 Savers(3)

4 Savers (3)

N04153.DSF

5 Ref. : CH - 1249 - A - 2

3.ASSEMBLYANDINSTALLATION

Connectionsto water supply

Connectiontotheheatingsystemneedstobedoneaccording

to statutory regulations and trade practice.

Fuel supply

For oil and gas, comply with statutory rules and

recommendations,inparticularwithrespecttosafety rules.

Power supply

comply with regulatory prescriptions, in particular with res-

pect to earthing and its connection to the boiler (main

switch...)

Fluestack

A0daPadepressionshouldbe observedatexitofsmokebox.

Complywithstatutoryregulations and tradepractice.

Please note that the efficiency of these boilers results in

relativelylowfluegastemperatures.

Special care must be given to flue stack which must be air-

tight,heat-insulatedandprotectedagainstdegradation.One

of the actions to take is to line the duct. Tubing grade must

be compatible with the selected fuel.

It is advised :

• tokeepthesamecross-sectionasthatoftheboilersmoke

hoodoutlet,

• toavoidshortradius,

• to keep the number of bends to a minimum

• wherepossible,toslopeconnecting partsupwards,

towardschimney

• to provide a purging vessel as close to the boiler as

possible.

Water flow rate

Thesystemmustbedesignedtoensureawaterflowrate,in

each boiler, comprised between 1/3 and 3 times the QN

nominalflowrate. QN =

Water flow rate allowed in each boiler must be comprised

between :

3 . 1 Boiler room layout

Plinth (see fig. 2)

Nospecialplinthisrequiredforthistypeofboiler.Asimpledry

basesuffices.Forinformation,weprovidethedimensionsof

this dry base (figure 2). For certain special installations, a

sound-proof plinth may be necessary. We recommend a

metalplinthrestingonreachableantivibrationpads.

Fig. 3

Clearance (see fig.3)

Thedimensionsshownareminimalvalueswhichallowproper

accessforassemblyandmaintenanceoperations.

Noneedtoleaveclearanceaboveforcleaningpurposes.

Boiler

size C L

34 750 900

35 920 1070

36 1090 1240

37 1260 1410

38 1430 1580

39 1600 1750

Flat bars

width 150

Optional

sealing

Fig. 2

Caution : assembly and installation must be carried out by a qualified engineer.

PN kW x 0,86

15K

PN kW x 0,86

45K and

N0225100.PLT

N0218601.PLT

Choice of burner

Theburnershouldbechosenaccordingtotheboilerpower

andfurnace.

Ventilation

Complywithstatutoryregulationsforlowandhighventilation

6Ref. : CH - 1249 - A - 2

Boiler Numberofsections

ref. Front Middle Rear

34 1 2 1 None

35 1 3 1 None

36 1 4 1 Short

37 1 5 1 Short

38 1 6 1 Long

39 1 7 1 Long

Distributors

Cord

Fig. 5

Sludge flush

Non return valve

Fig. 4

DIAGRAMOFTHEELEMENTS S : tightening markings

E : spacing pads

Front Middle Rear

Assembly marking

Cord junction point

SSS

Minimum flow rate must be provided at all times,

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.

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

boiler, and to avoid parasitic flows in the other boilers,

position non return valves upstream from the return

connection.

The burner must be controlled by the recycling or

loadingpump.Itcanonlybeputinoperationifthepump

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

pump.

To vents

00306N0225200.PLT

N0226701.PLT

7 Ref. : CH - 1249 - A - 2

3 . 2 Assembling the sections

The sections are assembled using nipples. For a good

tightnessoftheassemblies,itiscompulsorytouseaspecial

productwhich ensuresaperfectseal(thiscoatingisalways

providedwiththeboiler).

Proceed in the following way:

1) Open the "Extra accessories" box,

2) Clean thenippleswith asolvent,

3) Put the rear section in vertical position and secure it

against tilting by propping it up,

4) Position thewoodenblock providedinthe "extra

accessories" box, 40 mm thick, in front of the rear

section’s legs,

5) On thevertical section,clean thegrooveawaitingthe

cord with a metal brush, then position the cord

without stretching it, with the junction point at the top

(see figure 6) on the axis of the nipples line.

Cutthecordcarefully.

6) Cleancarefullywithsolventthereceivingsurfaces.If

need be, use extra fine emery paper in case of rust

stains or small barbs.

Fig. 6

Assembly marking

Leaktightness cord

junction point

Place the cord in the

vertical element's

ream

BECAREFULTOASSEMBLETHEMIDDLESECTIONSCORRECTLY

Tighteningofthe

leaktightness cord

7) NEVER USE OLD NIPPLES.

Coatnipplesandreamswiththeproductprovided,

using a clean brush.

8) Place the nipples in the vertical section’s orifices and

drivetheminslightly using apieceofwood onwhich

to hit with a hammer or a mallet so as to maintain the

nipplesin thereams. Donotdrivethemintoomuch,so

thatthefinaltighteningshallbeobtainedbybringingthe

sectionstogether.

Take care that the nipples be perfectly vertical, as a

deviationduringtighteningcanbreakthesection,

9) Afterhavingcleanedthemiddlesectionandappliedthe

coating, bring it on the block to place it facing the

verticalrearsectionandrespectingtheorientationof

theassemblymarkingwhichmustbealwaysoriented

towardsfront(seefigure6).

Driveit ontothetwonipplesusingamalletora pieceof

hardwood,hittingalternately,attopandbottom,facing

the nipples to ensure temporary assembly of the two

sections,

10) Ensure thattheyareperfectly vertical, and tightenitas

explainedinthefollowingchapter.

Assembly marking

Inside Outsise

Wooden block (provided)

02244-01

N0224600.PLT

8Ref. : CH - 1249 - A - 2

3 . 3 Tightening the sections

Totightenthesections,asetofassemblybarsisnecessary.

It comprises:

For 4- to 7- section boiler:

- 2 assembly bars, length = 1.60 m (A),

- 2 fixed plates with stop-ring (B),

- 2 mobile plates with ball nut (C),

- 1ratchetwrench.

This set is not part of normal supplies.

For 8- and 9- section boilers:

- Sameasabove,

- 2 bar extensions, length = 950 mm.

Or PARCEL N° 1 + PARCEL N° 2

1) Withdraw the plates’ alignment screws,

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

3) Mount, on each bar, at the rear, a plate with (B) stop-

ring,

4) Mount at the front the (C) plates with tightening nut,

afterhavinglubricatedthethread,

5) Align the plates,

6) tighten the screw alternately by 1/2 a turn each, taking

careto avoidfanassembly.

Proceed with tightening until the sections touch, and

check it by looking in the firebox and the upper

"flue-ways".

Fixed plate B

Nbr. of elements

4 to 7

8 to 9

Bar

A + D

L dimension

1600

2550

ldimension

1355

2305

l max.

121 Run = 245 160 Step = 190

assembly bar A Extension D

Nut Mobile plate C

54 70

Take alignment screws off Stop-

ring

Fig. 7

Fig. 8

Wrench

MID

section Nut CAssembly

marking

Assembly

marking

Stop-ring

REAR

section

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

whilemovingthe wooden blocksalternatelyas yougo

towardsthefront,

8) Do not loosen the assembly bars and position the 4

assemblylinkages.Tightenthemproperly,leavingan

equal length at each end to secure the casing’s cross

members, and if necessary the adjustable legs,

9) Loosen and taketheinstallationbars off,

10) proceedwiththeboiler assembly.

NOTE: If it were necessary to dismantle one of the

boiler’s sections, and to avoid damaging the

leaktightnessgorges,itisimperative,whendismantling

the sections, to place the chisel at the level of the

spacing pads (E) provided in the upper part (see

figure 5).

FRONT BACK

Positioningaid

N0219800.PLT

N0219700.PLT

9 Ref. : CH - 1249 - A - 2

EXCHANGER

5 Sealing cord Ø 7

40 Screws bag

Fig. 9

14 Disriburor, Length 180

14a Distributor, Length 530

15 Flow and return manifold

16 Drain valve

17 Sensor pocket, Length 100 mm

18 Upper baffle

18a Lowe baffle

19 Smoke box Ø 180

19a Smoke box Ø 200

20 Flue-way hatch (L)

20a Flue-way hatch (R)

21 Leaktightness braid Ø 8

22 Chamber door

23 Internal insulation

24 External insulation

25 Sight flange

26 Sight glass and seal

27 Door seal Ø 16

28 Burner plate

29 Burner plate gasket

30 Cleaning access. door

31 Internal insulation

32 External insulation

33 Insulation body blanket

39 Cleaning brush

40 Screws bag

41 Complete adjustable leg

1 Front section

2 Middle section

3 Rear section

4 Nipple Ø 89

5 Sealing cord Ø 7

6 Tie-rod

7 Reducer

8 Sensor pocket, Length 200 mm

9 Door hinge

9a Door hinge

10 door guide

11 Door pin

12 Welding flange

13 flange gasket

02236-00

10Ref. : CH - 1249 - A - 2

Method

•Assemblethe8 studs 12 x 65around the rear section’sstart and returnorifices.

• Ifnecessary,insertthedistributor(seefigure22)inthereturnorificebyinterpolatingtheseal

(13).

• Placetheboilerinitsfinalpositionandlevelit,whichwouldbemadeeasierbythe"Adjustable

legs"option(chapter 3.1)

• Screwthepocketandthereducer(7)inaleaktightmannerinthefrontsection’supperorifice.

• Athreadedorifice Ø 2" isprovidedatthebottomof the front section,formountingavalve

enablingrinsingandflushingoftheinstallation’ssludge(werecommendmountingcoil,a90°

bend and the valve). A pre-cut space allows for passing the tubing in the casing’s lower

panel.

• Mountadrainvalvetightly(notprovided) ontheinstallationorinthelowerpart oftherear

sectionusingareducer(notprovided).

• Adrain valveØ3/4"is deliveredwiththe "Connectionsleeves"option(see chapter4.2).

• Connecttheflangesontheinstallation’stubing,thanfastenthemontheboiler,interpolating

the seal (13), with 4 HM 12 nuts and 4 washers for each.

• Afterhavingcheckedtheconnections,proceedslowlywithfillingtheinstallation,ensuringall

theairisvented,thenproceedtothehydraulictest((1.3xP.operation)tocheckallleaktight

areas.

• Screwtheshortestthreadedpartofthe4studsM8x40intherearsectionintheupperpart.

• Checkthattheleaktightnessbraid(21)isinplace.

• Engagethesmokebox onthestudsandfasten it(4HMnutsand 4washers)bytightening

thenutsmoderatelyandsimultaneously.

• Connecttheboilertothestackinthemostdirectpossiblemannerandwithoutreductionof

thesizeofthesmokeduct.Ensurethatthelatterisleaktight.

• Inserttheassembledbaffles(18)intheupper"flue-ways"and,ifneedbe,thesimplebaffles

(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

indicationsoffigure10.

• Definetheopeningsideforthedoors.

• Mountthe hinges(1screwHM 10x30+ 1nutHM10 +2washersL 10foreach guide).The

doorguideislocatedoppositethehinges,intheupperpart.

• Dependingonthechosenopeningside,securethehinge(9a)oneachdoorusing2screws

HM12 x 35 +2 washersM12.

Caution:Forreasonsofpracticality,itisrecommendedtomountthefireboxdoorfirst.

• Mountthedoorsonthehingesusingtheaxes(11).

• Engagethedoors onthestudsandfasten them (4nutsHM10and 4 washersL10for each

door),tighteningthenutslightlyandsimultaneously.

• Dependingonthesizeofitsfixation,theburnerismounteddirectlyon thedoor,orviaa

perforated plate (see figure 11). Mount the burner plate (4 screws HM 12 x 35 + 2 washers

M12)onthechamberdoor,interpolatingtheleaktightnessseal(29).

- Aplainplatemaybeprovidedonrequest.

3 . 4 Operational assembly diagram

Operation

Open the "chamber accessories" parcel

Distributor (14 - 14a)

Installing the boiler

Sensor pocket (8)

Sludge flushing

Drainvalve (16)

Welding- flange (12)

Filling and hydraulic test

Smoke box (19 - 19a)

Stack

Optimizing baffles (18 and 18a)

Door hinges (9)

Door guide (10)

Door hinge (9a)

Chamber (22) and

Cleaning door (30)

Burner plate (28)

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