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OERTLI PK 550 Assembly Instructions Manual
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OERTLI PK 550 Assembly Instructions Manual

OERTLI PK 550 Assembly Instructions Manual

Fuel oil/gas boilers
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Download this manual See also: Installation and Servicing Manual, User Manual
Fuel oil/gas boilers
PK 550
300020196-02
Assembly
Instructions
en

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Summary of Contents for OERTLI PK 550

  • Page 1 Fuel oil/gas boilers PK 550 Assembly Instructions 300020196-02...

  • Page 2: Package List

    Distributing tube fitting The distributing tube fitting for PK 550 boilers with 15 to 19 sections is included in the accessory package. The diaphragm for PK 550 , 13 and 14 section boilers is delivered in the additional accessory kit package.
  • Page 3 1. Package list • Baffles Boiler PK 550 - Number of sections package Baffles CM 22 CM 23 • Casing fittings Boiler PK 550 - Number of sections package Casing fittings FA10 FA11 • Casing, variable parts Boiler PK 550 - Number of sections...
  • Page 4 1. Package list • Control panel All models can be equiped with one of the following control panels: Boiler PK 550 - Number of sections Standard control panel - X 1 Package R control panel 1 Package • Accessories - Available as an option*...

  • Page 5: Tools Required

    2. Mounting PK 550 2 Mounting PK 550 2.1 Introduction Warning: Assemble the boiler in the order given by the numbers of each figure, in compliance with all the instructions. Refer to the applicable price list for any optional features used.
  • Page 6 2. Mounting PK 550 Assemble the boiler body from the rear to the front: - assemble the rear section, - assemble all the normal intermediate sections, - assemble all the special intermediate sections, - assemble the front section. The number of sections of each type is provided in the table below...
  • Page 7 2. Mounting PK 550 2.2 Mounting PK 550 Boilers: 10, 12, 14, 16, 18, 20, 22, 24 sections Boilers: 9, 11, 13, 15, 17, 19, 21, 23, 25 sections : Assembly of the base frame, delivered unassembled. Place the frame on the floor, taking care to note the TOP and FRONT positions Fit the fastening brackets as shown, depending on the type of boiler (1 Screw Ø...
  • Page 8 2. Mounting PK 550 Boilers: 10, 12, 14, 16, 18, 20, 22, 24 sections Boilers: 9, 11, 13, 15, 17, 19, 21, 23, 25 sections Establish the location of the frame on the basis of the opening direction of the furnace door and the length of the burner. Leave enough clearance at the rear of the boiler for water connections and the distributing tube.
  • Page 9 2. Mounting PK 550 Fill the bottom of the U groove (located on the periphery of the section) with a continuous bead of DOW CORNING silicon, diameter approximately Ø 5 mm. silicon must not be applied 100 to either side of the connection (nipple assembly area).
  • Page 10 2. Mounting PK 550 (1) Sandpaper Handle the nipples with gloves, there might be sharp edges. Remove any traces of rustprotective paint so that the surface is perfectly smooth. Smear the nipples with the greasing product provided. Gently push in the 2 nipples.
  • Page 11 2. Mounting PK 550 Fill the bottom of the W groove opposite the U groove for the intermediary parts (located on the periphery of the section) with a continuous bead of DOW CORNING silicon, diameter approximately Ø 5 mm. Rear section Intermediate section Place the first normal intermediate section, making sure that it is turned in the right direction, i.e.
  • Page 12 2. Mounting PK 550 Put the assembly tool in position. Tighten gradually so as to bring together the upper and lower connections evenly and simultaneously. Assemble the remaining intermediate sections one by one, to the procedure stated in figures 3, 4, 5, 6, 7, 8, 9,, and 10.
  • Page 13 2. Mounting PK 550 Trim off any projecting ends of the thermocords the sweeping covers. Fitting the upper and lower assembly rods On the lower assembly rods, fit the following at each end in the given order : an expansion spring, a washer and a nut (the holes of the front lugs must be aligned with the holes of the frame brackets as the assembly rods are used to make the boiler body integral with the frame).
  • Page 14 2. Mounting PK 550 Rear Front Put in place the upper assembly rods in the two front and rear lugs. Mount the 2 crosspieces (supplied in package MS1/MS2) with their bends turned backwards and fasten them to the rods with an expansion spring, 1 nut and 1 washer Remove the assembly tool.
  • Page 15 2. Mounting PK 550 Assembling the side assembly rods The side assembly rods must be assembled from the rear to the front. The rods must be inserted in the holes stated in the diagrams (the lugs of the sections in which the assembly rods are to be inserted have 2 holes).
  • Page 16 2. Mounting PK 550 PK550-10 PK550-11 PK550-12 D000916A Rear Front Dimensions are given in millimeters. PK 550 18/03/2016 - 300020196-02...
  • Page 17 2. Mounting PK 550 PK550-13 PK550-14 PK550-15 D000917A Rear Front Dimensions are given in millimeters. 18/03/2016 - 300020196-02 PK 550...
  • Page 18 2. Mounting PK 550 PK550-16 PK550-17 PK550-18 D000918A Rear Front Dimensions are given in millimeters. PK 550 18/03/2016 - 300020196-02...
  • Page 19 2. Mounting PK 550 PK550-19 PK550-20 PK550-21 D000919A Rear Front Dimensions are given in millimeters. 18/03/2016 - 300020196-02 PK 550...
  • Page 20 2. Mounting PK 550 PK550-22 PK550-23 D000920A Rear Front Dimensions are given in millimeters. PK 550 18/03/2016 - 300020196-02...
  • Page 21 2. Mounting PK 550 PK550-24 PK550-25 D000921A Rear Front Dimensions are given in millimeters. 18/03/2016 - 300020196-02 PK 550...
  • Page 22 - 150 mm wide, 1/2’’ hole for PK 550-20 to PK 550-25. Plug the 2 free 1/2’’ holes for PK 550-9 to PK 550-19 or the 3 free 1/2’’ holes for PK 550-20 to PK 550-25 in the special intermediate sections.

  • Page 23: Hydraulic Test

    2. Mounting PK 550 Fitting the upper and lower front flanges Fit the plain flange onto the upper connection of the front section (using 4 H 18 nuts), with the Ø 170x222 gasket in between (first soak the gasket in warm water).
  • Page 24 2. Mounting PK 550 Ensure that all the air in the boiler is vented to avoid any bursting of the body Maintain pressure for at least 10 minutes: 7,8 bar (MPa). Any drop in pressure indicates a leakage in the boiler body.
  • Page 25 2. Mounting PK 550 Assembling the baffle plates Boiler PK 550-9 PK 550-10 to PK 550-14 PK 550-15 to GPK 550-19 PK 550-20 to PK 550-25 Total number of baffle Package no. CM 22 CM 23 CM 22 + CM 23 2 x CM 23 Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them.
  • Page 26 2. Mounting PK 550 Assembling the sweeping covers Type Thermocord length 1335 mm 1110 mm 890 mm 665 mm Rear Front The covers are numbered from 1 to 4, and must be fitted with a thermocord . The length of the thermocord depends upon the cover and is given below.
  • Page 27 2. Mounting PK 550 Insert the thermocord in the sealing groove on each side and hold it in place with a few drops of silicone filler. Putting in place the lower trap doors Insert the thermocord in the sealing groove of the 2 lower flue ways, on the rear and front of the boiler.
  • Page 28 2. Mounting PK 550 2 screws SIM 3.94x25.4 Refractory felt Rigid refractory plate - Put the furnace door insulating material in place and retain it with the 4 screws SIM 3.94x25.4. - Place the furnace door on the floor and fasten the articulation onto the door with 3 screws HM 12.
  • Page 29 2. Mounting PK 550 Fit the door onto the hinge by inserting the pin. Close the furnace door on the 8 studs and fasten with 8 washers and nuts. - Fit the 2 doors of the upper flue ways (wing nuts).

  • Page 30: Flame Inspection Window

    2. Mounting PK 550 Flame inspection window The flame inspection window is fitted with a 1/4" tapped hole for ventilation (optional): if a ventilation system is used, connect the hole to the one provided for that purpose before the burner combustion head.
  • Page 31 2. Mounting PK 550 Assembling the return flange on boilers PK 550-9 to PK 550-25 PK 550-9 to PK 550-12: PK 550-14: =Package FA42 to FA 47 = Package FA 49 = Package FA61 to FA66 = Package FA68 PK 550-13:...
  • Page 32 2. Mounting PK 550 Assembling the outlet flange on boilers PK 550-9 to PK 550-25 PK 550-9 to PK 550-15: Package FA42 to FA50 Package FA61 to FA69 PK 550-16 to PK 550-25: Package FA51 to FA60 Package FA70 to FA79 •...
  • Page 33 2. Mounting PK 550 Fitting the boiler outlet flange - Carefully insert the Ø 15 gasket in the groove of the rear section and hold it in place with a few drops of silicone. Before assembling the flue gas box, grease all bolts, studs and screws with high-temperature grease (not supplied).
  • Page 34 2. Mounting PK 550 - The flue gas outlet is fastened to the rear by means of 6 studs, washers and Ø 12 nuts. - First adapt the steel connecting plate to the chimney connection flue, then fasten that plate or the plate with a connecting piece with 10 nuts H10 and Ø10 washers.
  • Page 35 2. Mounting PK 550 Assembling the flow switch - Fasten the flow switch on the sleeve tube. The direction of the arrow head on the collet must be the same as the flowing out of the water in the tube.
  • Page 36 Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them. Boiler PK 550-9 PK 550-10 to PK 550-14 PK 550-15 to PK 550-19 PK 550-20 to PK 550-25 Total number of baffle Pack no.
  • Page 37 2. Mounting PK 550 36 PK 550-9 to PK 550-17: Package FA31 to FA36 Assembling the top insulating material Front Put in place the 600 mm wide (packages FA31 to FA36) top insulating material on the body of the boiler.
  • Page 38 2. Mounting PK 550 38 PK 550-18 to PK 550-25: Package FA37 to FA41 Assembling the top insulating material Put in place the 2 pieces of insulating material (width 600 mm, packages FA37 to FA41) on the body of the boiler.
  • Page 39 2. Mounting PK 550 40 PK 550-18 to PK 550-25: Package FA16 to FA24 Assembling the cable channels Package FA16 Package FA16 to FA24 Number of sections Length (mm) - A 2510 2600 2800 2910 3000 3110 3200 3310 Place the cable channels so that their bevelled end is to the front.
  • Page 40 42 package MS1 or MS2 Assembling the lower rail support brackets • Example for a PK 550-10 Fasten the lower rail support brackets using H8 x 16 screws + Serrated washer. Note: for the assembly direction, see the drawings below.
  • Page 41 2. Mounting PK 550 Assembly direction of lower rail support brackets (seen from the top of the frame) A: 8 and 10 sections B: 9 sections C: 11-13-15 and 17 sections D: 12, 14 and 16 sections Rear Front Right-hand side...
  • Page 42 2. Mounting PK 550 E: 18 and 20 sections F: 19 and 21 sections G: 22 and 24 sections H: 23 and 25 sections 2 lower rail support brackets and 2 upper rail brackets are left unused with 18, 19, 20 and 21 sections.
  • Page 43 2. Mounting PK 550 43 Package FA17 to FA27 Front Fasten the lower rail with H8 x 30 screws and L8 washers. The other rail support brackets are fastened opposite the holes provided on the lower rail. Length required while assembling the 2-piece rails (boilers with 18 to 25 sections), see fig. 46.
  • Page 44 2. Mounting PK 550 45 Package FA31 to FA41 Installing the insulating material Front Place the side insulating material against the positioning bracket and cut it so that it is flush with the upper lug on which the rail fastening bracket is fixed, along a 220 mm length Push the insulating material in behind the lug and the rail fastening bracket Distribute the insulating material evenly so that you have the same side insulating material on either side of the boiler.
  • Page 45 2. Mounting PK 550 Fitting the rails Rear Front package package Boiler A: 9 to 17 sections: FA19 PK 550-9 FA20 PK 550-10 Fix the upper rail with H8 x 30 screws and L8 washers (the first hole from the front end of the rail must be opposite the first...
  • Page 46 2. Mounting PK 550 Assembling the side casing panels First assemble the panels on the front using the assembly length table opposite and continue up to the rear section. Fix the front side panels to the positioning brackets with H8 x 16 screws and serrated washers.
  • Page 47 2. Mounting PK 550 48 package MS1 or MS2 Assembling the furnace door and lower crosspiece panels Put the furnace door panel in place (package MS1 or MS2) and fasten with 2 tapping screws (Ø 3.94 x 12.7). The furnace door panel may be cut in 2 at the micro-joints.

  • Page 48: Control Panel Assembly

    2. Mounting PK 550 Control panel assembly - X Standard control panel - Package MG1 + MS1: see: stage "51". - R control panel - Package MG2 + package MS1 or MS2: see: stage "54". 51 X Standard control panel - Put the front crosspiece in place (package MS1 or MS2) and fasten with 2 screws (H8x30) and Ø...
  • Page 49 2. Mounting PK 550 52 X Standard control panel Package MG1 + MS1 or MS2 A: Rear B: Front Position the control panel in the rear bushes. Remove the 3 screws . Open the control panel (3 screws at the back).
  • Page 50 2. Mounting PK 550 54 R control panel (Package MG1 + MS1 or MS2) Fit the front cross piece (2 Screw H8 x 30, 2 Self-tapping screw Ø 3,94 x 12,7 + Serrated washers). 55 R control panel (Package MG1 + MS1 or MS2)
  • Page 51 2. Mounting PK 550 56 R control panel Reverse the trim. 18/03/2016 - 300020196-02 PK 550...
  • Page 52 2. Mounting PK 550 57 R control panel Bring the burner cable behind the casing support and down to the burner between the side panel and insulating material. PK 550 18/03/2016 - 300020196-02...

  • Page 53: Electrical Connections

    2. Mounting PK 550 58 R control panel Installing the bulbs Fix the control panel to the rear of the control panel bracket using 2 screws (H Ø 4 x 40) and serrated washers. Carefully unroll the various bulbs and bring them out of the control panel through the opening in the bottom on the panel.
  • Page 54 2. Mounting PK 550 61 Installing the insulating material Put in place the insulating material as shown above. 62 package MS1 or MS2 Fitting the cap Mounted screw Control panel trim Serrated washer "Rapid" nut Cable channel Control panel bracket...
  • Page 55 2. Mounting PK 550 63 package Fix the trim to the control panel using 2 tapping screws and serrated washers. 64 package Place the insulating material in the lower central front panel (black cloth facing outward). Fit the lower central front panel (package MS1 or MS2) onto the lower front crosspiece and fix it to the furnace door panel.
  • Page 56 2. Mounting PK 550 65 package Fit the left and right-hand side front panels (package MS1 or MS2) onto the lower front crosspiece and fit them onto the studs of the side panels. 66 package Place the retaining crosspiece (package MS1 or MS2) on the left and right-hand front panels, taking care to place the 2 central tabs behind the furnace door panel.
  • Page 57 2. Mounting PK 550 67 package MS1 or MS2 Put in place the insulation of the flue gas box and the lower rear insulating material (package MS1 or MS2). If the side crosspieces overlap at the rear by more than 10 mm, we advise you to saw them off using a hacksaw.
  • Page 58 Fasten with 2 screws (H8 x 16) and serrated washers Fit the 2 lower rear panels (package MS1 or MS2) onto the rear crosspieces 70 PK 550-9 to PK 550-17: Package FA17 to FA27 Fitting the walkway Place the central plate on the cable channels with the round holes towards the front of the boiler.
  • Page 59 4 tapping screws and serrated washers. 72 Package FA30 to FA41 Put in place the sweeping cover insulating material(packages FA30 to FA41): - PK 550-9 to PK 550-17: 2 pieces. - PK 550-18 to PK 550-25: 4 pieces. 18/03/2016 - 300020196-02...
  • Page 60 2. Mounting PK 550 Package MS1 - MS2 - MR3 - MR4 - MR5. Package FA10 - FA11. Place the side covers (package FA10 - FA11, MR3 to MR5, see table) from the front to rear. They have the same lengths as the side panels.

  • Page 61: Type Plate

    2. Mounting PK 550 74 Type plate Boiler type Manufacturing date Year of manufacture Week of manufacture Serial no. of the appliance - Glue the rating plate and CE marking on the casing of the boiler in an easily visible location.
  • Page 62 2. Mounting PK 550 PK 550 18/03/2016 - 300020196-02...
  • Page 63 2. Mounting PK 550 18/03/2016 - 300020196-02 PK 550...
  • Page 64 REMEHA NV/SA Koralenhoeve 10 B-2160 WOMMELGEM +32 (0)3 230 71 06 +32 (0)3 354 54 30 info@remeha.be www.remeha.be © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing.