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OERTLI PK 550, Assembly Instructions Manual

The OERTLI PK 550 is a versatile heating system renowned for its efficiency and performance. To ensure easy installation and maintenance, we provide an extensive Installation and Service Manual that can be downloaded for free from our website. Discover all the necessary instructions and guidelines to optimize the usage of this exceptional product.

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6

PK 550

18/03/2016 - 300020196-02

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

Rear section

Normal intermediate section

Special intermediate section

Front section

Section type

PK 550-9

1

4

3

1

PK 550-10

1

5

3

1

PK 550-11

1 6

3

1

PK 550-12

1

7

3

1

PK 550-13

1

8

3

1

PK 550-14

1

9

3

1

PK 550-15

1

10

3

1

PK 550-16

1

11

3

1

PK 550-17

1

12

3

1

PK 550-18

1

13

3

1

PK 550-19

1

14

3

1

PK 550-20

1

14

4

1

PK 550-21

1

15

4

1

PK 550-22

1

16

4

1

PK 550-23

1

17

4

1

PK 550-24

1

18

4

1

PK 550-25

1

19

4

1

104

8228-0004

8228-0001

111

2

8228-0002

151

3

8228-0003

104

4

Summary of Contents for PK 550

Page 1: ...PK 550 Fuel oil gas boilers 300020196 02 en Assembly Instructions D000913 ...

Page 2: ...14 15 16 17 18 19 20 21 22 23 24 25 Base frame dimensions depend upon model 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Rear section 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Normal intermediate section 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 Special intermediate section 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 Front section 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Set of assembly rods Cleaning tools contents depend upon mo...

Page 3: ...sing fittings MS1 1 1 1 1 1 1 1 1 1 MS2 1 1 1 1 1 1 1 1 MR3 1 MR4 1 1 1 1 1 1 1 1 MR5 1 1 1 1 1 1 1 1 FA10 1 2 2 2 2 1 2 2 1 1 FA11 1 1 2 2 2 1 1 2 3 3 2 2 3 3 Boiler PK 550 Number of sections package 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Casing variable parts FA16 1 1 1 1 1 1 1 1 FA17 1 FA18 1 FA19 1 1 FA20 1 1 FA21 1 1 FA22 1 1 FA23 1 1 FA24 1 1 FA25 1 FA26 1 FA27 1 Boiler PK 550 Num...

Page 4: ...s 9 10 11 12 13 14 Standard control panel X 1 Package MG1 MG1 MG1 MG1 MG1 MG1 R control panel 1 Package MG2 MG2 MG2 MG2 MG2 MG2 Boiler PK 550 Number of sections 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Furnace plate with hole Ø 165 186 210 240 or Ø 295 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Connecting plate with opening or plain connecting plate Ø 300 or Plain connection plate 1 1 1 1 1 1 1 1 ...

Page 5: ...able price list for any optional features used Tools required 1 JD TE or JD TE Plus assembly tool 1 Flat screwdriver 1 n 2 posidrive screwdriver 1 10 13 16 17 spanners 18 19 1 22 tubular box spanner 1 27 tubular box spanner 1 electric screwdriver 1 n 2 Philipps screwdriver bit 1 Stanley knife Silicone filler Supplied Boilers supplied with an assembled body Hydraulic test See fig 17 Mounting start ...

Page 6: ...ed in the table below Rear section Normal intermediate section Special intermediate section Front section Section type PK 550 9 1 4 3 1 PK 550 10 1 5 3 1 PK 550 11 1 6 3 1 PK 550 12 1 7 3 1 PK 550 13 1 8 3 1 PK 550 14 1 9 3 1 PK 550 15 1 10 3 1 PK 550 16 1 11 3 1 PK 550 17 1 12 3 1 PK 550 18 1 13 3 1 PK 550 19 1 14 3 1 PK 550 20 1 14 4 1 PK 550 21 1 15 4 1 PK 550 22 1 16 4 1 PK 550 23 1 17 4 1 PK ...

Page 7: ...ending on the type of boiler 1 Screw Ø 12x40 19 spanner DESSUS N OBE TOP N AVA T VORN FRONT DE SS US OB EN TO P AN T AVVO RN F O R NT 3 3 M000309 3 1 2 3 2 3 E D S S U S O B E N T O P D E S S U S O B E N T O P D E S S U S O B E N T O P D E S S U S O B E N T O P 4 8 5 5 5 N 0 2 A FRONT VORN AVANT FRONT VORN AVANT FRONT VORN AVANT FRONT VORN AVANT 19 A B A Boilers 10 12 14 16 18 20 22 24 sections B ...

Page 8: ...e Fit the rear section on the frame behind the fastening brackets see detailed drawing and prop it up Insert the lower assembly rods in the holes of the rear section and the fastening brackets of the frame in order to position the rear section correctly according to the frame 3 Clean all the openings in the section with a brush Remove any deposit on the bottom of the section Boilers 10 12 14 16 18...

Page 9: ...pproximately Ø 5 mm silicon must not be applied 100 to either side of the connection nipple assembly area Dimensions are given in millimeters 5 Fit the Ø 10 5 mm diameter thermocord into this U groove and into the groove which circles the furnace Note Do not pull on the seal while inserting it Otherwise you may stretch it and reduce its thickness M000059 100 100 00 1 100 a M000060 ...

Page 10: ...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 7 Gently push in the 2 nipples A R R IÈ R E D E S S U S O B E N T O P V A A N T A R R I R È E D E S S U S O E B N T O P A V A N T M000062 ...

Page 11: ...Rear section Intermediate section Place the first normal intermediate section making sure that it is turned in the right direction i e with the flattening groove against the thermocord For safety insert a lateral assembly rod supplied in the holes of the 2 sections Push the section gently and simultaneously on the 2 nipples of the rear section with a hammer and a piece of wood positioned in line w...

Page 12: ...as to bring together the upper and lower connections evenly and simultaneously 11 Assemble the remaining intermediate sections one by one to the procedure stated in figures 3 4 5 6 7 8 9 and 10 First assemble the normal intermediate sections then the special ones Leave the assembly tool in place M000065 M000066 ...

Page 13: ...he 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 Stop tightening as soon as the gap between the spring spires is equal to about 2 mm M000067 M 06 000 8 2 ...

Page 14: ...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 00069 M0 2 2 2 1 ...

Page 15: ...ds 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 Place the expansion spring and washer on the rear of each rod Stop tightening the nuts as soon as the gap between the spires of the springs is about 1 mm Rear Front Dimensions are given in millimeters D000915A 1 2 PK550 9 ...

Page 16: ...16 PK 550 18 03 2016 300020196 02 2 Mounting PK 550 Rear Front Dimensions are given in millimeters PK550 10 PK550 11 PK550 12 D000916A 1 2 1 2 1 2 ...

Page 17: ...17 18 03 2016 300020196 02 PK 550 2 Mounting PK 550 Rear Front Dimensions are given in millimeters PK550 13 PK550 14 PK550 15 D000917A 1 2 1 2 1 2 ...

Page 18: ...18 PK 550 18 03 2016 300020196 02 2 Mounting PK 550 Rear Front Dimensions are given in millimeters PK550 16 PK550 17 PK550 18 D000918A 1 2 1 2 1 2 ...

Page 19: ...19 18 03 2016 300020196 02 PK 550 2 Mounting PK 550 Rear Front Dimensions are given in millimeters PK550 19 PK550 20 PK550 21 D000919A 2 1 2 1 2 1 ...

Page 20: ...20 PK 550 18 03 2016 300020196 02 2 Mounting PK 550 Rear Front Dimensions are given in millimeters PK550 22 PK550 23 D000920A 2 1 2 1 ...

Page 21: ...21 18 03 2016 300020196 02 PK 550 2 Mounting PK 550 Rear Front Dimensions are given in millimeters PK550 24 PK550 25 D000921A 2 1 2 1 ...

Page 22: ...al intermediate section 150 mm wide 1 2 hole for PK 550 9 to PK 550 19 or the fourth special intermediate section 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 1 Front Front Front PK 550 20 to PK 550 25 PK 550 9 to PK 550 19 ...

Page 23: ...ont section hole in the lower part of the flange using 4 H 18 nuts with the gasket in between soak in warm water first 17 Hydraulic test 1 After assembling the boiler body the installer must carry out a water tightness test at a pressure equal to 1 3 times the operating pressure that is 7 8 bar mini for 10 minutes at least The test must be done at room temperature Fit a square flange with hole fac...

Page 24: ...r in the boiler is vented to avoid any bursting of the body 3 Maintain pressure for at least 10 minutes 7 8 bar MPa Any drop in pressure indicates a leakage in the boiler body After the tightness test drain the boiler and remove all the parts used for the test 2 4 3 0 077 M0 0 ...

Page 25: ...e baffle plates into place in the upper front flue ways taking care to interlock them with each other before fitting them M000079 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 2 4 6 8 Package no CM 22 CM 23 CM 22 CM 23 2 x CM 23 ...

Page 26: ... mounted with the handles turned outward Fit the two locks of each cover between the sections Push the cover towards the outside of the boiler to the closed position Fasten the two brass nuts of each cover Type Thermocord length 1 1335 mm 2 1110 mm 3 890 mm 4 665 mm Rear Front 1 2 3 4 1 2 3 Cover model No 1 No 2 No 3 No 4 Boiler type Number of sweeping covers per type Front Rear PK 550 9 2 2 PK 55...

Page 27: ... each side and hold it in place with a few drops of silicone filler 21 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 Put the 4 trap doors on the lower flue ways and fasten with the wing nuts M000081 M000082 ...

Page 28: ...terial 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 23 Installing the hinge of the furnace door Fix the furnace door hinge on the right or left hand side of the front section by means of 3 screws HM 12x25 M000083 1 1 3 2 7 mm M 0 0 0084 M000085 ...

Page 29: ...PK 550 2 Mounting PK 550 24 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 25 Fit the 2 doors of the upper flue ways wing nuts 1 M000086 M000087 2 M000088 ...

Page 30: ...PK 550 26 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 M000089 ...

Page 31: ...er Secure with 4 H 18 nuts PK 550 13 PK 550 14 Fit the boiler return flange intercalating a seal Ø 170x222 previously soaked in tepid water Fit the heating return flange with a Ø 170x222 gasket in between and fix it with 4 nuts H 18 PK 550 15 to PK 550 25 Fit the water balancing tube onto the boiler return with a Ø 170x222 gasket in between first soak the gasket in warm water Fit the heating retur...

Page 32: ...angled piece so that the angle is turned upward with a Ø 170x222 gasket in between first soak the gasket in warm water and fasten with 4 nuts H 18 PK 550 16 to PK 550 25 Assemble the flange with angled piece so that the angle is turned upward with a Ø 170x222 gasket in between first soak the gasket in warm water and fasten with 4 nuts H 18 4 M000091 B PK 550 9 to PK 550 15 Package FA42 to FA50 Pac...

Page 33: ...ket in the groove of the rear section and hold it in place with a few drops of silicone 30 Before assembling the flue gas box grease all bolts studs and screws with high temperature grease not supplied Put in place the thermocord Put the sweeping cover in place and fasten with 2 nuts H 10 and Ø 10 washers 0 0 M 00 92 ...

Page 34: ...he flue gas outlet is fastened to the rear by means of 6 studs washers and Ø 12 nuts 32 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 M000095 ...

Page 35: ...K 550 9 8802 4736 8802 4735 PK 550 10 8802 4738 8802 4737 PK 550 11 8802 4740 8802 4739 PK 550 12 8802 4742 8802 4740 PK 550 13 8802 4743 8802 4742 PK 550 14 8802 4745 8802 4743 PK 550 15 8802 4746 8802 4744 PK 550 16 8802 4736 8802 4735 PK 550 17 8802 4738 8802 4736 PK 550 18 8802 4752 8802 4750 PK 550 19 8802 4753 8802 4751 PK 550 20 8802 4754 8802 4752 PK 550 21 8802 4755 8802 4753 PK 550 22 88...

Page 36: ...fitting them 35 Boilers supplied with an assembled body Assembling the upper crosspieces package MS1 or MS2 Mount the 2 crosspieces and fasten them onto the rods with an expansion spring 2 nut and 2 washer Rear Front Dimensions are given in millimeters 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 2 4 6 8 Pack no CM 22 CM 23 CM 22 CM 23...

Page 37: ... PK 550 17 Package FA17 to FA27 Assembling the cable channels Rear Place the cable channels so that their bevelled end is to the front Fasten with 2 screws H8 x 16 L8 washers in the third hole starting from the front and opposite the special nut Fasten at the rear with 2 screws H8 x 16 L8 washers opposite the oblong holes and special nut M000099 80 90 1 Number of sections 9 10 11 12 13 14 15 16 17...

Page 38: ...of the boiler Push the insulating material under the front and rear crosspieces 39 PK 550 18 to PK 550 25 Package FA6 Assembling the intermediate piece Assemble the intermediate piece on the assembly rods by fitting one slotted side onto one rod and using the flexibility of the other rod M000101 80 90 Number of sections 18 19 20 21 22 23 24 25 Length mm 2 x 1200 2 x 1200 2 x 1300 2 x 1400 2 x 1400...

Page 39: ...ce and the rear crosspieces with 2 screws H8 x 16 and L8 washers Align the 2 additional cable channels with the two others Fasten them to the intermediate piece and the rear crosspieces with 4 screws H8 x 16 and L8 washers 41 package MS1 or MS2 Assembling the casing positioning brackets Fasten the positioning brackets package MS1 or MS2 onto the right and left hand upper bosses of the front sectio...

Page 40: ...ting PK 550 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 1 M000105 ...

Page 41: ... 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 Left hand side Rail support brackets Base frame 2 lower rail support brackets and 2 upper rail brackets are left unused with 9 and 10 sections ...

Page 42: ...16 300020196 02 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: ...sections see fig 46 44 package MS1 or MS2 Assembling the fastening brackets of the upper and lower rails Imperative alignment Fix the fastening bracket of the upper rails package MS1 or MS2 on the upper lug these brackets must be vertically aligned with the lower rail support brackets Fit the bracket onto the stub Fasten with 1 screw H10 x 50 and serrated washers and H10 nuts Assemble 1 Rapid nut ...

Page 44: ...ing material evenly so that you have the same side insulating material on either side of the boiler Cut the insulation similary along the fastening brackets Boiler type Side insulating material mm Front Rear PK 550 9 1200 PK 550 10 600 400 400 PK 550 11 1200 400 PK 550 12 1200 600 PK 550 13 1200 600 PK 550 14 1200 600 PK 550 15 1200 400 400 PK 550 16 1200 400 600 PK 550 17 1200 400 600 PK 550 18 1...

Page 45: ...he rail must be opposite the first fastening bracket and similarly with the other brackets Fix the additional upper and lower rails making sure you comply with dimension A see table below Push the insulating material behind the lower rail and underneath the boiler Join the pieces of insulating material to each other with the clips PK 550 9 FA19 PK 550 10 FA20 PK 550 11 FA21 PK 550 12 FA22 PK 550 1...

Page 46: ...ide panels to each other with the clips 0 1 M0 0 1 1 1 2 3 2 4 5 Boiler type Side panels mm Front Rear PK 550 9 1050 400 Collectors 400 mm long panel in package FA10 600 mm long panel in package FA11 800 mm long panel in package MR3 940 mm long panel in package MR4 1050 mm long panel in package MR5 PK 550 10 940 600 PK 550 11 1050 600 PK 550 12 940 400 400 PK 550 13 1050 400 400 PK 550 14 800 600 ...

Page 47: ...casing support lower crosspiece package MS1 or MS2 by means of 2 screws H6 x 20 and 2 serrated washers 49 package MS1 or MS2 Assembling the control panel bracket all control panels Fit the 4 Rapid nuts on the front of the cable channels Fit the Rapid nuts in the slots 4 Rapid nuts for 9 to 17 sections 8 Rapid nuts for 18 to 25 sections Fix the control panel bracket package MS1 or MS2 underneath th...

Page 48: ...l 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 3 94 tapping screws x 12 7 serrated washers R control panel see stage 54 8555N146 ...

Page 49: ...and bring them out of the control panel through the opening in the bottom on the panel Cut out the top insulating material to free the boiler pocket Secure the rear cover H pacakge MS1 or MS2 to the panel support using 2 screws EC CB 4 x 40 Serrated washers Make the electrical connections See Control panel instructions Close the control panel 53 X Standard control panel Bring the burner cable behi...

Page 50: ...ge 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 1 Rear 2 Front Position the control panel on the front studs Open the control panel 2 screws on the side 000 15 M 1 2 1 1 2 ...

Page 51: ...51 18 03 2016 300020196 02 PK 550 2 Mounting PK 550 56 R control panel Reverse the trim M0 58 00 0 ...

Page 52: ...52 PK 550 18 03 2016 300020196 02 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 M000116 ...

Page 53: ... the control panel through the opening in the bottom on the panel 59 Cut out the top insulating material to free the boiler pocket Then insert the bulbs inside the pocket and maintain them with the spring 60 Electrical connections All connections are made with the terminal boxes designed for that purpose on the back of the boiler s command board ZSee the Electrical Connections section of the instr...

Page 54: ...g 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 Front crosspiece Unfasten the screws mounted in fig 56 Slide the control panel trim along the screws Fasten the screws 000119 M A A 2 1 3 4 5 6 7 2 M000120 A A ...

Page 55: ...l panel using 2 tapping screws and serrated washers 64 package MS1 or MS2 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 M000121 M000122 ...

Page 56: ...the lower front crosspiece and fit them onto the studs of the side panels 66 package MS1 or MS2 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 Fit the upper front panel package MS1 or MS2 onto the side panels via the 4 studs M000123 ...

Page 57: ...ng 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 68 package MS1 or MS2 Put in place the 2 rear crosspieces package MS1 or MS2 behind the bend of the rear side panels and fasten each crosspiece to the side panels using 2 screws Ø 3 94 x 12 7 0 1 M000125 M000126 ...

Page 58: ...tuds and push it up 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 Fasten with H8 x 30 screws and serrated washers 1 3 4 2 M0 7 0012 M000128 ...

Page 59: ...Place the front plate with the round holes towards the front of the boiler Fasten with 4 screws H8 x 30 and serrated washers Fasten the joining plate with the round holes towards the front of the boiler with 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 ...

Page 60: ...2 940 400 400 PK 550 13 1050 400 400 PK 550 14 800 600 600 PK 550 15 940 600 600 PK 550 16 1050 600 600 PK 550 17 940 600 400 400 PK 550 18 1050 600 400 400 PK 550 19 940 600 600 400 PK 550 20 940 600 600 600 PK 550 21 1050 600 600 600 PK 550 22 940 600 600 400 400 PK 550 23 1050 600 600 400 400 PK 550 24 940 600 600 600 400 PK 550 25 1050 600 600 600 400 Cover packages 400 mm long panel in packag...

Page 61: ... 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 M000581 B ...

Page 62: ...62 PK 550 18 03 2016 300020196 02 2 Mounting PK 550 ...

Page 63: ...63 18 03 2016 300020196 02 PK 550 2 Mounting PK 550 ...

Page 64: ...well as any drawings and technical descriptions supplied remain our property and shall not be multiplied without our prior consent in writing Subject to alterations 18 03 2016 300020196 001 02 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 ...

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