I N S T A L L A T I O N

M A N U A L

NXR4
260 - 800 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 - 1250 - A - 1 - EN

11/05

Ref. : CH - 1250 - A - 1

1. STANDARDS - 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 directives: Directive Directive Directive Mains voltage Electromagnetic compatibility Efficiency 73 / 23 / CEE 89 / 336 / CEE 92 / 42 / CEE

The boiler can be fitted with a choice of fuel oil or gas burner in accordance with the builders recommendations, the burner complying with the following standards: EN 267 EN 676 EN 226 One piece sprayed oil burner Automatic blown air burner for gas fuels Burner to heat generator connection sizes

This boiler complies with the following standards: EN 303.1 EN 303.2 Boilers with forced air burner: Terminology, general specifications, tests and marking Boilers with forced air burner: Special specifications for boilers with sprayed oil burner Test regulations for boilers with sprayed oil burner Boiler and burner connections

The heating system installation must comply with current regulations.

EN 304 DIN 4791

BAXI attests that all boilers referred to in this manual comply the same requirements as corresponding examined types, for which the right to use EC marking has been granted according to "Gas appliance" and "Boiler efficiency" European directives.

Ref. : CH - 1250 - A - 1

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 designed to reach high efficiency. The exchanger is insulated by a glass wool layer lined by lacquered steel casing panel, 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 adapted to the combustion chamber size and pressure conditions. They heat premises, and, for Domestic Hot Water (D.H.W.) production, can be coupled with a D.H.W. tank located next to it.

2 . 3 Options
Heating body delivered assembled Control panel options FUEL OIL or GAS burner in accordance with specifications table recommendations Domestic hot water heater (PIM 250 - 350 - 500 - 800). Optimizers: HR models (440kW) can be fitted with 4 optimizers for Label award in accordance with the European Output Directive 92/42/EEC. Models over 440 kW are not subject to this Directive. However, they can be fitted with 4 or 8 optimizers for a 1% gain in output (see general specifications on page 5).

2 . 2 Standard supply
Exchanger cast-iron loose sections, Accessories : smoke-box, hinged burner door with burner plate, welding-neck flanges for tubes 1.25 A threaded flange 50 X 60 Flow manifold with pocket for remote control sensor (not fitted) Return manifold with pocket for remote control and drain cock 3/4 (not fitted) Insulated casing and cleaning brush Depending on the order, this boiler must be fitted with a CS, CE100, ECO5E, ECO7E or ECO8E control panel

2 . 4 Shipping - Packaging (Excluding options)

Packaging is as follows :

Packages
Unassembled exchanger Smoke hood Casing 1 Casing 2 Wired control panel Extra accessories Tie rods Door

Not assembled boiler X X X X X X X X

409 Unassembled exchanger Nb of packages 8

410 411

412

413

414

415

416

417

Ref. : CH - 1250 - A - 1

2 . 5 Technical data

Flow DN 125

Rp 2" orifice for sludge flushing

Drain Rp 3/4" orifice

Return DN 125

Fig. 1 415
620-680 15 2480 2280 2160 1963 350 2445 467 876 494 34,5 6 30-90 110 676-747 3,6-4,5

Boiler reference
Power range Number of parts Sizes: Dimension A Dimension B Dimension C Furnace depth P Smoke pipe D Weight Furnace volume Smoke circuit volume (with furnace) Water circuit volume Water circuit strength t = 15 K Maximum operating pressure Thermostat setting range Safety cut-off temperature

: N
: kW

409
9

410
10 1780 1580 1460 1263 300 1745 300 590 334 11,6 6 30-90 110

411
11 1920 1720 1600 1403 300 1883 334 642 366 15,3 6 30-90 110

412
12 2060 1860 1740 1543 350 2028 367 700 398 19,4 6 30-90 110

413
13 2200 2000 1880 1683 350 2166 400 759 430 24,0 6 30-90 110

414
560-620 14 2340 2140 2020 1823 350 2315 434 817 462 29,0 6 30-90 110 611-681 2,6-3,6 873-974

416
680-740 16 2620 2420 2300 2103 350 2585 501 934 526 35,5 6 30-90 110 741-813 4,0-5,0

417
740-800 17 2760 2560 2440 2243 350 2725 534 992 558 36,5 6 30-90 110 807-879 4,6-6,0

260-320 320-380 380-440 440-500 500-560

:m m :m m :m m :m m :m m : kg : litres : litres : litres : mbar : bar : C : C

1640 1440 1320 1123 300 1589 268 525 302 8,4 6 30-90 110

Flame power (nominal P) : kW Furnace pressure

Without optimizer

284-352 349-417 414-483 480-549 545-615 1,0-1,5 1,4-2,1 1,5-2,2 2,1-2,8 2,8-3,3

: mbar

Fuel oil smoke mass flow: Kg/h Gas smoke mass flow Smoke temperature Combustion efficiency Number of optimizers : Kg/h : C :%

405-503 499-597 593-691 686-785 780-880

967-1068 1060-1163 1154-1257

468-580 576-689 684-798 792-906 900-1015 1008-1124 1115-1233 1223-1341 1331-1450 180-195 180-195 180-195 180-195 180-195 180-195 180-195 180-195 180-195

92,7-92,0 92,7-92,0 92,7-92,0 92,7-92,0 92,7-92,0 92,7-92,0 92,7-92,0 92,7-92,0 92,7-92,0 4 4 4 4 4 4 605-674 2,9-4,0 870-965 8 670-740 3,9-4,8 8 735-805 4,4-5,4 8 800-870 5,0-6,6

High Strength versions with optimizers

Flame power (nominal P) : kW Furnace pressure : mbar

278-345 342-410 407-474 472-543 540-609 1,2-1,7 1,6-2,3 1,7-2,4 2,3-3,0 3,1-3,6

Fuel oil smoke mass flow: Kg/h Gas smoke mass flow Smoke temperature Combustion efficiency : Kg/h : C :%

397-495 490-588 585-685 681-777 773-872

960-1060 1050-1150 1140-1245

458-571 567-678 674-786 784-900 895-1005 1000-1115 1110-1220 1215-1330 1320-1435 148-166 155-170 162-175 162-176 162-176 94,4-93,5 93,9-93,4 93,7-93,2 93,7-93 93,7-93 162-176 93,7-93 162-176 93,7-93 162-176 93,7-93 162-176 93,7-93

Values given for rated power, 20 C ambient temperature, boiler water temperature start 80 C, return 60 C Indicative values for: CO2 13% for fuel oil - CO2 10% for gas

Ref. : CH - 1250 - A - 1

N04164.DSF

3. ASSEMBLY AND INSTALLATION

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

3 . 1 Boiler room layout

Plinth (see fig. 2) No special plinth is required for this type of boiler. A simple dry base suffices. For information, we provide the dimensions of this dry base (figure 2). For certain special installations, a sound-proof plinth may be necessary. We recommend a metal plinth resting on reachable antivibration pads.
1070 440

Connections to water supply Connection to the heating system needs to be done according to statutory regulations and trade practice. Fuel supply For oil and gas, comply with statutory rules and recommendations, in particular with respect to safety rules. Power supply
A 1320 1460 1600 1740 1880 2020 2160 2300 2440 L 1540 1680 1820 1960 2100 2240 2380 2520 2660

Boiler size 409 410 411 412 413 414 415 416 417

00973-2

Flat bars width 150 Optional sealing

comply with regulatory prescriptions, in particular with respect to earthing and its connection to the boiler (main switch...) Flue stack
A 0 daPa depression should be observed at exit of smoke box.

Fig. 2

Clearance (see fig.3) The dimensions shown are minimal values which allow proper access for assembly and maintenance operations. no need to leave clearance above for cleaning purposes.

Comply with statutory regulations and trade practice. Please note that the efficiency of these boilers results in relatively low flue gas temperatures. Special care must be given to flue stack which must be airtight, 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. It is advised : to keep the same cross-section as that of the boiler smoke hood outlet, to avoid short radius, 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

N0218601.PLT

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 Water flow rate allowed in each boiler must be comprised between : PN kW x 0,86 and PN kW x 0,86 45K 5K

Choice of burner

Fig. 3

The burner should be chosen according to the boiler power and furnace.

Ventilation Comply with statutory regulations for low and high ventilation

Ref. : CH - 1250 - A - 1

Non return valve

00306

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 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 pump.

To vents

Sludge flush

Fig. 4

FLUEGAS PASSES
Rear intermediate section

Centre intermediate section

Front intermediate section

Fig. 5

Ref. : CH - 1250 - A - 1

01424

3 . 2 Assembly of sections
Proceed as follows : 1) Open the "Accessories - complement" package 2) Clean the nipples with methylated spirit solvent 3) Put the rear section into vertical position and secure it to prevent fall 4) On the vertical section, clean the groove, prior to application of the heat-resisting compound, with a metal brush. Paste the machined edges and the external groove (see fig. 6). 5) Clean carefully the bores with solvent. If rust stains or small burrs are present, remove them with very fine emery cloth. Caution : to ensure perfect leak-free assembly : never use old nipples apply the special compound supplied with the boiler, exclusively. 6) Coat the nipples and bores with the supplied compound, using a clean brush. 7) Insert the nipples into the bores by hand and drive them in slightly using a piece of wood on which to hit with a hammer or a mallet so as to maintain the in position. Do not drive them in too far, so that the tightening shall be done by bringing the sections together. Take care that the nipples fit squarely, check depth of penetration using the supplied template (see fig.6) 8) After having cleaned a rear intermediate section and applied the compound, position it vertically facing the rear section (the letters AR facing forward) 9) Slide the section using pliers, so that it slightly engages the corresponding nipples. Using a mallet or a piece of hard wood, hit alernatively at the top and at the bottom, facing the nipples, to achieve temporary assembly of both sections. Ensure that they fit perfectly squarely and proceed with tightening as explained in the following chapter. Apply the heat resisting compound destined to receive the following section.

REAR section

Rear intermediate section

Centre intermediate section

front intermediate section

FRONT section

Black heat resisting compound (on machined edges)

00329

External silicone sealing between sections

AR

or

or

AV

Fig. 6

Ref. : CH - 1250 - A - 1

N0230700

3 . 3 Tightening the sections

To tighten the sections, it is necessary to use a set of assembly tools. It comprises : For the 9-section boiler : - 2 assembly bars, variable length = 1.60 m (A), - 2 plain flanges with assembly nut (B), - 2 ratchet flanges with ball nut (C), - 1 ratchet spanner. This set is not part of normal supplies. It appears under BOX N1 reference. For 10-to 16- section boilers : - Same as above, - 2 end bars, length = 950 mm I.e. PARCEL N 1 + 2 PARCELS N 2 For 17-section boiler : - same as above, - 4 end bars, length = 950 mm I.e. PARCEL N 1 + 4 PARCELS N 2
L
l maxi 121 Nut Movement = 245 Ratchet flange C 160 Basic division = 190 End bar D
N0219800

1) Place the flange alignment screws on the 140 (see figure 7) 2) Place an assembly bar (A) in each row of nipples 3) Mount, on each bar, at the rear, a flange with assembly nut (B) 4) Mount at the front the plain flanges (C) with tightening nut, after having lubricated the threading 5) Check that the plain flanges rest squarely on the sec tions, 6) Tighten nuts alternatively 1/2 turn at a time, taking care not to skew assembly. out the compound between the sections. To ease assembly, tap at the same time with a mallet on the periphery of the sections but never hit the flat parts.

54 70

Assembly bar A

FRONT

REAR

Number sections 9 10 to 16 17

Bar without end bar 1 end bar 2 end bars

L Dimension I Dimension 1600 2550 3500 1355 2305 3255

Assembly nut Plain flange B

Alignment screws position according to bore diameters

8 holes M10

Ratchet spanner

Fig. 7

Ref. : CH - 1250 - A - 1

01639-1

BOILER CONSTRUCTION
Centre intermediate section M Front intermediate section (AV) Front section Rear intermediate section (AR) Rear section

Markings should be directed towards front

Boiler size 409 410 411 412 413 414 415 416 417

Front

Number of sections Front Centre Rear inter. inter. inter. 2 2 3 3 3 4 4 5 5 3 4 4 5 5 5 6 6 6 2 2 2 2 3 3 3 3 4

Rear

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

Fig. 8

Ref. : CH - 1250 - A - 1

02296-01

7) Tighten fully and when tightening is observed, remove the flanges.

Assembly nut REAR section

9) Keep assembly tight and externally seal the body, proceeding as follows : Clean the V-groove between each section and allow to dry,

A B

Assembly aid

Apply the silicone seal with the pressure gun provided (see figure 10), Smooth down the bead with a damp tool (a spatula for example).
Assembly tools

N0229900

External silicone seal

Intermediate section

Nut

Assembly aid
00304

Spanner

Fig. 9 Fig. 10

8) Proceed for the other sections (1 by 1) as before. Caution : it is imperative that the intermediate sections assembly order be respected (see figure 8). Also, the markings (AR, M and AV) (see figure 6) on the sections must always be directed towards front. After having assembled three or four sections, fit the rear hearth protection plate in position against the rear section (see figure 12).

10) Fit the tie rods and tighten as follows Fit the special spring washers (see figure 11) at the rear end of rods. Tighten the nuts, leaving 1 mm gap between each turn of the spring washers. This operation should be done one rod at a time.

Flow distributor

Fig. 11
409 to 411 sans

N0229800

412 to 414

11) Loosen and take the assembly bars off. 12) Go on assembling the boiler.

N0232800

415 to 417

Caution: If the body was delivered factory assembled, you should immediately place the special washers on the connection rods (see 3.5).

Ref. : CH - 1250 - A - 1

10

00328-01

Complete assembly with the front section, proceeding as before.

EXCHANGER EXPLODED VIEW

Top flange Sensor pockets

Flue access doors

Tie rods

Section markings

Flame viewing port Marking to be directly towards front

Stainless steel furnace protective plate

Burner support door (see figure 14)

Fig. 12
Bottom front flange Nipple

Front section

Top outlet maniflod

Slip on weld flange

Rear flue hood

REAR SECTION
00325-00

Fig. 13

Flow distributor Flue spigot

Drain cock

Bottom inlet manifold

11

Ref. : CH - 1250 - A - 1

00326-02

3 . 4 Exchanger assembly

Operation
Open the parcel "accessories for exchanger" Flow distributor

Method

Assembly 8 studs M16 x 65 around the rear section flow and return orifices. Sizes 412 to 417 introduce distributor in the return pipe, inserting its gasket (see fig. 13). Sizes 415 to 417 distributor comes in 2 parts to make the fitting easier. Linkage through 3 bolts.

Boiler set-up

Set the exchanger in its final position and level it. Ensure that each section is in contact with the base. If necessary, use metal shims to ensure this. Fit the 4 studs M 16 x 66 on upper part of front section. Fit top flange, inserting its gasket and using 4 nuts and 6 washers. Screw the two sensor pockets tight on both threaded holes of top flange. Fit 4 studs M 16 x 66 on lower part of front section. A threaded hole 2" is provided on this flange, to enable a quick sludge flushing valve to be fitted. A pre-punched hole is provided to insert the pipes through casing lower front panel.

Top flange

Sensor pocket Sludge flushing Bottom flange

Outlet manifold

Fit the outlet manifold on rear section 4 upper studs, placing the 1/2" orifice on the top and inserting a gasket (see figure 13). Fit tight the 1/2" sensor pocket on above orifice.

Inlet manifold

Fit the inlet manifold on the rear section 4 lower studs, fitting the 1/2" orifice on the top and inserting a gasket. Fit tight the 1/2" sensor pocket on above orifice, the reducing adaptor 1-3/4" and the drain cock 3/4" on the side orifice provided for this purpose.

Slip on weld flange

Connect the flanges PN PN 16 - DN 125 on the pipework, then fasten them on the manifolds, inserting the seals (8 HM 16 X 75 bolts, 8 nuts, 8 wahsers for each flange). After having checked the connections, proceed sowly with filling the system, ensuring all air is purged, then carry out the hydraulic test (1.3 x working pressure) to check overall tightness. Screw the shortest threaded part of the 4 studs M 8 x 40 on upper part of rear section.

Hydraulic test

Flue hood (19 - 19a)

Fit and bond the ceramic cord. Fit the flue hood on the studs and fasten it (4 HM nuts and 4 washers) by tightening the nuts moderately and simultaneously.

To chimney

Connect the boiler to the chimney the most directly possible and without reduction in the size of the flue stack. Check proper tightness of the latter. Screw the 18 studs M8 x 45 Position the pre-assembled flue access doors (as shown in fig.13) Screw. On the hinged side, the side access door fastening wing nut must be replaced by a standard HM 8 nut in order to allow the door to open.

Flue access doors

Ref. : CH - 1250 - A - 1

12

Operation
Burner support plate (figure 14)

Method
- If necessary, drill the door according to burner size. - Bond the ceramic fibre cord in the front section groove (the cord is connected on the side opposite to the hinge). - Mount the complete flame viewing port (3) on the door(4) with the studs (5), the washers (2) and the wihg nuts (1). - Mount the truarc ring (19) on the axle (21). Slip the female shells (17 ) and the male shells (18) on the axle (21) not forgetting the washer (20). - Fit the whole assembly on the boiler with the screws (15) and the washers (10). - Fit the fastening plates (11) on the boiler with the screws (9) and the washers (10). Screw the studs (12) in the fastening plates (11). - Screw centering nuts (6) on the shells (18). Fit the door on these nuts and screw the other two centering nuts on the shells (18). - Set the 4 stainless steel lugs using the "RAPID" fastening systems on 8 rods. Arrange the isulating materials in the mineral wool door (brown) against the door, then ceramic fibre (white) on the side of the combustion chamber (see figure 15). - Fold the four stainless steel lugs over on the ceramic fibre. - Cut the lagging material (by menas of a saw blade) using the burner hole cut in the door as template. - Close the door with the nuts (7) and the washers (8). - Adjust the door leaktightness, using the nuts (6 and 7).
- Refer to paragraph 4.2.

Placing the optimizers

(option)

IMPORTANT : After a few hours operation, check the door tightness, using : 1 The 4 adjusting nuts (6) on the hinge side 2 The 2 locknuts (7) on the opening side

BURNER SUPPORT DOOR

Fig. 14

00334

00335-01

Fig. 15

13

Ref. : CH - 1250 - A - 1

3 . 5 Casing assembly

Caution :
Exchanger lagging blanket set-up If exchanger hasbeen supplied in assembled form, the special rings should, imperatively, be fixed onto the tie-rods. Proceed Rod after Rod. Loosen up back nut of rod then introduce special ring (see fig. 11). Tighten up the nut, leaving a one mm - gap between the wings of rings. You may then start to build the casing.
N0230600

Fig. 16

Assembly of casing sides and top panel

Front panel assembly

9 sections 10 sections 11 sections 12 sections 13 sections 14 sections 15 sections 16 sections 17 sections

N0231200 N0230800

Fig. 17

Fig. 18

Ref. : CH - 1250 - A - 1

14

CASING EXPLODED VIEW

59

Casing screws

Fig. 19

Designation 40 41 42 43 43a 44 45 46 47 48 49 Front-right rear left upright Front left - rear right upright Cross member Common 1/2 cross member Splice plate 1/2 cross member Front top panel Top panel Front right side panel Front left side panel Side fastening bracket 50 51 52 53 54 55 56 57 58 59 Side fastening lug Side panel Upper rear metal plate Lower rear panel Rear side panel Lower front panel Right front panel Left front panel Upper front panel Bag of screws for casing

15

Ref. : CH - 1250 - A - 1

02311-00

Operation
Open both "casing parcels" Exchanger lagging materials ( see fig. 16)

Method

- Common and specific packages - Cover the whole exchanger with the lagging blanket (50 mm thick) supplied in several 3.2 m long strips. - Assemble the strips using pins. - Wedge the ends of the lagging blanket between the exchanger and the tie rods. Vertical uprights (40 - 41) - Place the vertical uprights on boiler front (2 screws HM8X16 with washers). - Do the same on the back of the boiler. Left and right cross - For boiler sizes 412 to 417, the cross member is delivered in wo parts with a splice plate (43a). (42 - 43 - 43a - 44) Assemble, mounting both 1/2 cross members (43 - 44) on the splice plate. - Mount the cross members with the larger stud vertically on the uprights. - Secure with 1 HM 8 X 16 screw in the front square hole. - Secure with 1 HM 8X16 screw with washer in the rear oblong hole. - Align the ends of the cross members with the vertical uprights on boiler front. - Fasten completely the uprights and the cross members. - Put the front top panel on the cross members, locking knobs directed backwards. Front top panel (45) Centering is done using a knob on the right under front top panel which goes into the square hole above the cross member. - Put 2 HM 5 screws in the oblong holes. Top panels (46) - Make up scheme as per fig.17 - Fit them on the cross members, fastening them on the knobs of preceeding component. - Put 2 HM 5 screws in oblong holes without tightening them. - Hook side front onto front top (2 securing knobs) Right - left front panel (47 - 48) - Side panel securing knobs are located on the front. - Insert side panel fastening bracket pin into lower fold of the side panel. Side fastening bracket (49) - Then, put 1 HM 5 x 10 screw on the upright. - Clip the spacer pad on boiler tie rod. Fastening lug (50) - Insert the pin into the side panel. Set up is done by sliding the lug. - Place the side panels on the fastening holes of intermediate top panels (make up scheme fig. 17) Side panel (51) - Rotate the panels to clip it in the pin of the spacer pad. - Then put another spacer pad and the following panels. - End with the two fastening lugs. Adjustment - Carry out complete casing adjustment. - Start on the right, pull the top panel forwards, secure and tighten the fastening lug screw at the bottom. - Do the same on the left then at the rear. - Check that all the side panels are properly joined. Lower back panel (53) - Engage it around the manifold, then slide it into the notches. Upper back metal plate (52) - Put it in place using two HM 5 x 10 screws Right and left side panels (54) - Hook the left and right rear metal plates on both fastening knobs. Lower front panel (55) - A pre-punched hole for the sludge flushing valve (cut the lagging blanket if necessary). - Hook onto the side panel knobs. Left and right front panels (56 - 57) - Position the left and right front panels using the pin and the fastening knobs. Control panel - Fit the control panel as shown on this page Upper front panel (58) - Engage both axles into the lower front panel holes. - Clip the front panel on the sides (see fig. 18)

CONTROL PANEL ASSEMBLY

Fig. 16

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

A
N04214DSF

Probe cables

B Ref. : CH - 1250 - A - 1 16

ELECTRIC CONNECTION
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 mm distance between each contact. For the complete electric connection of the various types of control panels, refer to the manual specific to the panel. 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. Connect the phase to the strips L terminal. 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 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 terminal strip must be connected as per currently enforced provisions. In the case of insufficient ionising current due to non compliant neutral or ground, we recommend adding a circuit isolation transformer with a power at least equal to 600 VA. Control panel supply connection terminal strip

CABLES FITTING
Earthing wire Capillaries Clampnut A

Fig. 21

Burner cables

Fitting the thermostat bulbs, thermometer (and regulation probe in option) in the glove finger as shown in the diagram.
03935-00

Boiler glove finger with regulation probe CS control panel

shunt "UV"

Main power supply 230 Vac 50 Hz (phase imperatively in L)

6
Boiler glove finger with regulation probe CM control panel
N0225300

BOILER AND BURNER POWER SUPPLY Fig. 20

Single-phase current Three-phase current Single-phase current
Burner motor power supply

CE, ECO 5E, ECO7E, ECO8E control panel

2
02078-01
02078-05

Control

Control

00229-5

When fitting the capillaries, ensure they are inserted fully in the glove finger.

CAUTION : In the case the burner motor is supplied with three-phase power, control panel single phase supply must imperatively be taken from one of the phases supplying the burner motor. VERY IMPORTANT : Never connect the burner control box directly to one of the phases.
17

1 2 3 4 5 3

Overheating safety thermostat Heating outlet thermometer Regulation thermostat Tube 6 Heating regulation probe Regulation thermostat 2nd Stage

Ref. : CH - 1250 - A - 1

N0231000

4. INSTALLING THE OPTIONS

4 . 1 Control panel complements
Before any operation inside the control panel, disconnect power supply using main switch located on heating system 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 aperture - Guide the capillary through control panel rear and casing front top, parallel to the other installed capillaries. Direct the capillary towards the back of the boiler, on exchanger 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 drive the bulb holding clip (see fig. 23) - Engage the bulb into the clip. Close the control panel and fit top again.

Bulb
N0224200

Holding clips

Flue stack

7,5

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 control panel, markings being properly aligned. guide the wires as explained in the page 17. Fig. 23

4 . 2 Fitting optimizers
- Put the 4 optional optimizers supplied on the centre flues in accordance with the diagram in figure 24. For optimal performance, it is important to put them on the blades in accordance with the diagram in figure 24. - Insert each optimizer to the second body section. - Fitting optimizers allows Label award in accordance with the European Output Directive 92/42/EEC for the rele vant boilers (400kW). - For models 409 to 411 fix the relevant plate (attached to the package) beside the existing plate. Caution: - For models 415 to 417 insert 2 optimizers per flue, housing them one inside the other with the sleeves. Fig. 24

Upper optimizers

Lower optimizers

Ref. : CH - 1250 - A - 1

18

03036-00

5. COMMISSIONING
5 - 1 Filling
- Water quality for the heating system Avoid using hard water, which may scale the boiler. If TH or total hardness is above the French 25, the boiler should be filled with softened water. - Filling the boiler and heating system While filling, which must be done slowly, ensure that the stop valves are open and that the mixing valve can be 1/ 2 open. The automatic drain cock plug, normally fitted on the boiler outlet, must remain untightened in order to achieve continuous draining during filling-up. Drain all high points of heating system and close the various draining screws one after the other as soon as water reaches their level. After filling the boiler for the first time, flush completely (using the sludge flushing valve) in order to get rid of foreign bodies that may come into the components or the pipes during assembly. - Water topping up Subsequent boiler topping-up should be practically nonexistent and in all cases controlled and registered by a water flow meter. Frequent topping-up is the a symptom of a leakage which should be repaired as soon as possible.

6. MAINTENANCE
Boiler
Check water pressure on pressure gauge and, if necessary, restore normal pressure. Only perform this operation when the system is cold. If frequent topping-up is necessary, there is a leak in this case, notify the installer. Never draw water from the heating system. In order to avoid slow but steady sooting, harmful to proper boiler operation, it is recommended to clean it regularly twice a year at least. This is always done with the boiler stopped and the power supply cut out. Proceed as follows : put ON burner switch located on the control panel as well as the main boiler room switch remove casing front panels open the cleaning door and the chamber door and take the flue-way hatches away. take the optimizing baffles down and brush them. clean the walls of each flueway with the brush provided with the boiler as well as the combustion chamber walls. remove soot and combustion deposits, if possible using a vacuum cleaner Clean the inside of the smoke hood the lagging material of the doors may be brushed with a soft brush. Do not use a metal brush. Be careful not to damage the seal. once the cleaning is over, put the hatches back up on the smokebox, put the optimizing baffles back in their respective "flue-ways", close the chamber and cleaning doors, ensuring that they are tight. set casing front panels back up.

5 - 2 Preliminary checks
When commissioning the boiler for the first time in the season, or after a prolonged shutdown period : - ensure that filling was done properly and check overall tightness. If necessary, put more water and drain all high points until water flows slightly. - check the connection of the flue stack and the proper working condition of the draught regulator if any - check that the high and low vents are not obstructed - ensure that the doors and the flue access plates are closed and tight If necessary, act upon the tightening points. - 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.

Sludge
This sludge, due to corrosion in the system, travels inside the pipework and makes up deposits in the boilers. We recommend to rinse the boiler efficiently and thoroughly and check the flushed water quality.

Burner
The burner should be submitted to regular maintenance. See special instructions, provided with the burner. If necessary, contact the retailer or manufacturer of the burner.

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