OERTLI PK 550 Manual

PK 550
Fuel oil/gas boilers
300020192-02
en
Installation and
Service Manual
D000913

2PK 550 18/03/2016 - 300020192-02
.
Declaration of conformity CE
The appliance complies with the standard model described in
declaration of compliance 1. It is manufactured and distributed
pursuant to the requirements of european directives. The original
declaration of conformity is available from the manufacturer.
D000911

3
18/03/2016 - 300020192-02 PK 550
.
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Symbols and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2.1 Manufacturer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2.2 Installer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2.3 User's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Safety instructions and recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.3 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.4 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4.1 Boilers for following countries: France - Belgium - Spain - Luxemburg - Portugal - Bulgaria - Greece - Romania - Tunisia -
Algeria - Cyprus - Czech Republic7
3.4.2 Boilers for following countries: Germany - Austria - Poland - Slovenia - Serbia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.5 Main dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1 Choice of the location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1.1 Positioning of the appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.3 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.3.1 Dimensional information required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.3.2 Important recommendations for connecting the boiler to the heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.3.3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.3.4 Sludge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.4 Chimney connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.4.1 Flue size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.4.2 Chimney connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.5 Fuel-oil or gas connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.6 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6 Switching off the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.1 Precautions required in the case of long boiler stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.2 Precautions required if the heating is stopped when there is a risk of freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7 Checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1 Maintenance of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1.1 Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1.2 Chemical sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.1.3 Cleaning the casing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
7.2 Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
7.3 System maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
7.3.1 Water level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
7.3.2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
7.3.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
8 Spare parts - PK 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

4PK 550 18/03/2016 - 300020192-02
1. Introduction
1Introduction
1.1 Symbols and abbreviations
In these instructions, various markings and pictograms are used to
draw your attention to particular information. In so doing, OERTLI
THERMIQUE S.A.S. wishes to safeguard the user's safety, obviate
hazards and guarantee correct operation of the boiler.
Danger
Risk of a dangerous situation causing serious physical
injury.
Warning
Risk of a dangerous situation causing slight physical
injury.
Caution
Risk of material damage.
Specific information.
ZReference
Refer to another manual or other pages in this instruction
manual.
`DHW: Domestic hot water.
1.2 General
1.2.1 Manufacturer's liability
OERTLI THERMIQUE S.A.S. manufactures products in compliance
with the standard 1. Products are delivered with 1marking and
all documents required.
In the interest of customers, OERTLI THERMIQUE S.A.S. are
continuously endeavouring to make improvements in product quality.
All the specifications stated in this document are therefore subject to
change without notice.
The liability of OERTLI THERMIQUE S.A.S. as the manufacturer
may not be invoked in the following cases:
`Failure to abide by the instructions on using the appliance.
`Faulty or insufficient maintenance of the appliance.
`Failure to abide by the instructions on installing the appliance.
1.2.2 Installer's liability
The installer is responsible for the installation and commissioning of
the appliance. The installer must respect the following instructions:
`Read and follow the instructions given in the manuals provided
with the appliance.
`Carry out installation in compliance with the prevailing
legislation and standards.
`Perform the initial start up and carry out any checks necessary.
`Explain the installation to the user.
`If a maintenance is necessary, warn the user of the obligation
to check the appliance and maintain it in good working order.
`Give all the instruction manuals to the user.
1.2.3 User's liability
To guarantee optimum operation of the appliance, the user must
respect the following instructions:
`Read and abide by the instructions given in the user manual.
`Call on qualified professionals to carry out installation and initial
start up.
`Get your installer to explain your installation to you.
`Ensure the Appliance is serviced in accordance with the
manufacturer's instructions by a suitable qualified person.
`Keep the instruction manuals in good condition close to the
appliance.

5
18/03/2016 - 300020192-02 PK 550
2. Safety instructions and recommendations
2 Safety instructions and recommendations
2.1 Safety instructions
For a proper operating of the boiler, follow carefully the
instructions.
Only qualified professionals are authorised to work on the
appliance and the installation.
Incorrect use or unauthorised modifications to the
installation or the equipment itself invalidate any right to
claim.
Before any work, switch off the mains supply to the
appliance.
Keep to the polarity shown on the terminals: phase (L),
neutral (N) and earth 4.
Keep children away from the boiler.
Fire hazard
It is forbidden to store inflammable products and materials
in the boiler room or close to the boiler, even temporarily.
Risk of intoxication
Do not obstruct the air inlets in the room (even partially).
If you smell flue gases
1.Switch the appliance off
2.Open the windows
3.Evacuate the premises
4.Contact a qualified professional
Risk of being burnt
Depending on the settings of the appliance:
- The temperature of the flue gas conduits may exceed 180°C
- The temperature of the radiators may reach 95°C
- The temperature of the domestic hot water may reach 65°C
Risk of damage
Do not stock chloride or fluoride compounds close to the
appliance.
Install the appliance in premises sheltered from rain, snow
and frost.
Do not neglect to service the appliance: Contact a qualified
professional or take out a maintenance contract for the
annual servicing of the appliance.
2.2 Recommendations
• Check regularly that the installation contains water and is
pressurised.
• Keep the appliance accessible at all times.
• Avoid draining the installation.
• Use only original spare parts.
• Never remove or cover labels and rating plates affixed to the
appliance.

6PK 550 18/03/2016 - 300020192-02
3. Technical description
3 Technical description
3.1 General description
PK 550 boilers are intended for central heating using radiators or
underfloor heating. These boilers have the following characteristics:
- Hot-water boiler
- Heating body in cast iron,
- Pressurised boiler,
- Boiler to be fitted with a gas or oil pressure jet burner
-Xor Rcontrol panel (See below)
- Production of domestic hot water can be ensured by a separate hot
water calorifier.
- Connecting to a chimney
3.2 Control panels
PKX 550: Boiler with standard X control panel
Panel comprising the settings, control and safety devices allowing
the boiler to operate autonomously, without regulation.
The standard panel is used to connect the boiler to the boiler room
control cabinet.
This cabinet can be fitted with control units.
PKR 550: Boiler with R control panel.
The control panel enables the operation of a boiler fitted with a 1
stage, 2 stage or modulating burner.
Control system based on outside temperature if a regulator has been
installed (see options).
3.3 Operating principle
Boiler with X control panel:
The operation is controlled by the boiler thermostat or by the
control system located in a cabinet, according to the heating
request.
Boiler with R control panel:
If the boiler is fitted with a REA control unit, the boiler
temperature is modulated by the regulator, which controls the
burner and the motorised mixing valves depending upon the
outside temperature.
For boilers which are not equipped with a REA regulator, either a
room thermostat: The operation is controlled by the boiler
thermostat, according to the heating request.
M000483
l
0
30
10A
TEST
STB
6A
l
0
2
M000553
1
1 2
30

7
18/03/2016 - 300020192-02 PK 550
3. Technical description
3.4 Technical specifications
3.4.1 Boilers for following countries: France - Belgium - Spain - Luxemburg - Portugal - Bulgaria - Greece -
Romania - Tunisia - Algeria - Cyprus - Czech Republic
Maximum operating pressure: 6 bar
Maximum operating temperature: 100 °C
Boiler thermostat setting: 30 to 90°C
Safety thermostat setting: 110 °C
*Maintenance consumption: total heat emission when the burner is
off as a percentage of the nominal input power when the difference
between the mean boiler temperature and the room temperature is
30 K - in accordance with DIN 4702 - EN 303.
(1)Nominal operation (top boiler power)
(2)CO2= 13.1 to 13.5% with fuel oil and 9.5% with natural gas.
(3)Boiler temperature: 80 °C
Ambient temperature: 20 °C
(4) In order for the boiler to operate correctly, it is
imperative to respect the draught at the nozzle.
Boiler PK
550-9
PK
550-
10
PK
550-
11
PK
550-
12
PK
550-
13
PK
550-
14
PK
550-
15
PK
550-
16
PK
550-
17
PK
550-
18
PK
550-
19
PK
550-
20
PK
550-
21
PK
550-
22
PK
550-
23
PK
550-
24
PK
550-
25
Useful output kW
464
to
522
522
to
580
580
to
638
638
to
696
696
to
754
754
to
812
812
to
870
870
to
928
928
to
986
986
to
1044
1044
to
1102
1102
to
1160
1160
to
1218
1218
to
1276
1276
to
1334
1334
to
1400
1400
to
1450
Power input kW
505
to
571
566
to
632
635
to
703
701
to
769
763
to
831
821
to
890
897
to
967
954
to
1024
1022
to
1093
1077to
1147
1146
to
1216
1198
to
1268
1265
to
1336
1333
to
1404
1393
to
1464
1463to
1544
1532
to
1595
Numberofsections 9 10111213141516171819202122232425
Water content l 465 503 541 579 617 655 693 731 769 807 845 905 943 981 1019 1057 1095
Water
resistance (1)
∆T = 10K mbar 28.4 34.8 42 50 57.6 67.2 77.6 26.2 30.2 35.8 41.4 48.0 53.6 59.2 64.8 71.6 78.4
∆T = 15K mbar 12.6 15.5 18.7 22.4 25.8 30 34.7 11.7 13.5 14.0 18.5 21.5 24 26.5 29 32 35
∆T = 20K mbar 7.1 8.7 10.5 12.5 14.4 16.8 19.4 6.5 7.6 9.0 10.4 12.0 13.4 14.8 16.2 17.9 19.6
Pressure in the furnace for
nozzle pressure = 0 (4) mbar 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.85 3 3.1 3.2 3.3 3.4 3.5
Flue gas temperature -
Ambient temperature (1) (3) K <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190
Mass flue gas
flow rate (1) (2)
Fuel oil Kg/h 790 980 1080 1180 1380 1380 1480 1580 1670 1770 1870 1970 2070 2170 2260 2360 2460
Gas 930 1030 1140 1240 1340 1450 1550 1650 1760 1860 1960 2070 2170 2270 2380 2480 2580
Combustion
chamber
Inscribed
diameter mm 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614
Equivalent
diameter mm 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694
Depth mm 928 1039 1150 1261 1372 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
Volume m30.36 0.40 0.45 0.49 0.53 0.57 0.61 0.65 0.70 0.74 0.78 0.84 0.88 0.92 0.96 1.00 1.05
Maintenance
consumption* ∆T = 30K % 0.09 0.08 0.08 0.08 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.06 0.06 0.06 0.06 0.06 0.06
Weight (empty) kg 2237 2412 2601 2810 3000 3171 3364 3561 3756 3955 4124 4343 4538 4734 4930 5107 5297

8PK 550 18/03/2016 - 300020192-02
3. Technical description
3.4.2 Boilers for following countries: Germany - Austria - Poland - Slovenia - Serbia
Maximum operating pressure: 6 bar
Maximum operating temperature: 100 °C
Maximum operating temperature: 120 °C
(in accordance with TRD 702)
Boiler thermostat setting: 30 to 90°C
Safety thermostat setting: 110 °C
*Maintenance consumption: total heat emission when the burner is
off as a percentage of the nominal input power when the difference
between the mean boiler temperature and the room temperature is
30 K - in accordance with DIN 4702 - EN303.
(1)Nominal operation (top boiler power)
(2)CO2= 13.1 to 13.5% with fuel oil and 9.5% with natural gas.
(3)Boiler temperature: 80 °C
Ambient temperature: 20 °C
(4) In order for the boiler to operate correctly, it is
imperative to respect the draught at the nozzle.
Boiler
PK
550-
9
PK
550-
10
PK
550-
11
PK
550-
12
PK
550-
13
PK
550-
14
PK
550-
15
PK
550-
16
PK
550-
17
PK
550-
18
PK
550-
19
PK
550-
20
PK
550-
21
PK
550-
22
PK
550-
23
PK
550-
24
PK
550-
25
Useful output kW
415
to
460
460
to
505
505
to
550
550
to
595
595
to
640
640
to
685
685
to
730
730
to
775
730
to
820
820
to
865
865
to
910
910
to
955
955
to
1000
1000
to
1045
1045
to
1090
1090
to
1135
1135
to
1180
Power input kW
448
to
500
494
to
546
547
to
599
597
to
649
643
to
696
689
to
741
743
to
797
790
to
842
790
to
892
886
to
938
935
to
987
982
to
1034
1034
to
1085
1082
to
1133
1131
to
1182
1180t
o
1231
1227
to
1278
Numberofsections 9 10111213141516171819202122232425
Water content l 465 503 541 579 617 655 693 731 769 807 845 905 943 981 1019 1057 1095
Water
resistance (1)
∆T = 10K
mbar
22 25.9 30.5 37 43.5 50 55.8 21.8 24.2 26.8 30 33 35.6 38.9 42.9 45.6 48.9
∆T = 15K 9.8 11.5 13.6 16.4 19.3 22.2 24.8 9.7 10.8 11.9 13.3 14.7 15.8 17.3 19.1 20.3 21.9
∆T = 20K 5.5 6.9 8.1 9.2 10.6 12 13.9 4.5 5.8 6.5 7.2 7.9 8.6 9.4 1.6 11.8 12.4
Pressure in the furnace for
nozzle pressure = 0 (4) mbar 1.4 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.95 2.05 2.1 2.15 2.2 2.25 2.3
Flue gas temperature -
Ambient temperature (1) (3) K <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190
Mass flue gas
flow rate (1) (2)
Fuel oil Kg/h 770 850 920 1000 1070 1150 1220 1300 1370 1450 1520 1600 1670 1750 1820 1900 1970
Gas 810 890 970 1040 1120 1200 1280 1360 1440 1520 1590 1670 1750 1830 1910 1990 2070
Combustion
chamber
Inscribed
diameter mm 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614
Equivalent
diameter mm 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694
Depth mm 928 1039 1150 1261 1372 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
Volume m30.36 0.40 0.45 0.49 0.53 0.57 0.61 0.65 0.70 0.74 0.78 0.84 0.88 0.92 0.96 1.00 1.05
Maintenance
consumption* ∆T = 30K % 0.16 0.15 0.14 0.13 0.13 0.12 0.12 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.10 0.10
Weight (empty) kg 2205 2391 2567 2771 2945 3120 3314 3494 3684 3872 4040 4266 4444 4639 4817 4994 5168

9
18/03/2016 - 300020192-02 PK 550
3. Technical description
3.5 Main dimensions
(1) Burner centre line.
(2) The lateral control panel can be mounted to the right or left of the
boiler. Exact height positioning defined by the fitter during assembly.
(3) max.
Heating flow - Ø E (weld)
Heating return - Ø E (weld)
Draining - Mk3/4
Flow sensor.
Minimum height for sweeping = 850.
1566
543
496 Ø F
815
1080
200
R
791 565
17,5
S
=Q
=
240
500
maxi
700
maxi
610
U
B
MH
K
Ø E
LG
P
D
T
Ø E
C
741
1172
370
420
(1)
A
2
1
4
5
3
D000922
616

10 PK 550 18/03/2016 - 300020192-02
3. Technical description
* Plain plate, requires cutting. Maximum cut-out 500 x 700.
**G = Length required for clearing the water distributing tube.
*** Dimension representing the end of the 100 mm long chimney connection.
with models PK 550-21, PK 550-22, PK 550-23,, PK 550-24
and PK 550-25, a plain plate which must be cut out is supplied
without the 100 mm chimney connection.
Boiler PK
550-9
PK
550-
10
PK
550-
11
PK
550-
12
PK
550-
13
PK
550-
14
PK
550-
15
PK
550-
16
PK
550-
17
PK
550-
18
PK
550-
19
PK
550-
20
PK
550-
21
PK
550-
22
PK
550-
23
PK
550-
24
PK
550-
25
A (mm) 1119 1230 1341 1452 1563 1674 1785 1896 2007 2118 2229 2380 2491 2602 2713 2824 2935
B (mm) 1078 1300 1300 1522 1522 1744 1744 1966 1966 2188 2188 2450 2450 2672 2672 2894 2894
C (mm) 1488 1488 1488 1488 1488 1488 1488 1488 1488 1504 1504 1504 1504 1504 1504 1504 1504
D (mm) 212 233 234 255 256 217 188 189 210 236 257 208 209 230 231 252 253
Ø E (weld) (mm) 139.7 139.7 139.7 139.7 139.7 139.7 139.7 139.7 139.7 159 159 159 159 159 159 159 159
Ø F
(mm) 300 350 350 350 350 400 400 400 400 400 400 400 * * * * *
G**
(mm) ------150150370370370650650650980980980
H (mm) -7 14 15 36 37 -2 -31 -30 -9 -8 13 -36 -35 -14 -13 8 9
K***
(mm) 5 2627484910-19-183 4 25-24-23-2 -12021
L (mm) 1555 1645 1755 1845 1955 2105 2245 2355 2445 2555 2645 2845 2955 3045 3155 3245 3355
M (mm) 319 243 297 221 275 259 324 269 321 265 299 269 324 269 324 249 303
P (mm) R355 355 355 355 355 355 355 355 355 355 355 355 355 355 355 355 355
Standard - X 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130 130
R (mm) R175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175 175
Standard - X 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
S (mm) R1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760 1760
Standard - X 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670 1670
T (mm) 928 1039 1150 1261 1372 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744
U (mm) 1577.5 1688.5 1799.5 1910.5 2021.5 2132.5 2243.5 2354.5 2465.5 2576.5 2687.5 2838.5 2949.5 3060.5 3171.5 3282.5 3393.5
V (mm) R755 755 755 755 755 755 755 755 755 755 755 755 755 755 755 755 755
Standard - X 738 738 738 738 738 738 738 738 738 738 738 738 738 738 738 738 738

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4. Installation
4 Installation
4.1 Choice of the location
4.1.1 Positioning of the appliance
For the assembly and because of their design, PK 550 boilers require
no special base. Their closed furnace system means that the floor
need not have refractory properties. All you have to ensure is that the
floor can support the weight of the boiler when it is fitted for operation.
If the boiler location is not determined precisely, leave enough space
around the boiler to facilitate monitoring and maintenance
operations.
Boiler body *
Straight connection (not supplied) *
* 1) In order to facilitate subsequent work on the boiler(replacing the
water distributing tube etc.) use a flanged connection from the boiler
to the system, making sure you comply with minimum clearance
dimension D.
Angled connection (not supplied)
Air inlet
Air outlet
If A = 1.2 m(door opening side), A’ = 0.5 m
If A = 0.5 m, A’ = 1.2 m (door opening side): adapt the dimensions
on the basis of the dimensions of the burner when the door is open.
B = 1.5 m: adapt the dimensions on the basis of the dimensions of
the burner.
D000923
Boiler PK
550-9
PK
550-10
PK
550-11
PK
550-12
PK
550-13
PK
550-14
PK
550-15
PK
550-16
PK
550-17
PK
550-18
PK
550-19
PK
550-20
PK
550-21
PK
550-22
PK
550-23
PK
550-24
PK
550-25
L 1555 1645 1755 1845 1955 2105 2245 2355 2445 2555 2645 2845 2955 3045 3155 3245 3355
M 319 243 297 221 275 259 324 269 321 265 299 269 324 269 324 249 303
C min. 300 300 300 300 300 300 436 436 656 656 656 936 936 936 1266 1266 1266
Dmin.------136136356356356636636636966966966

12 PK 550 18/03/2016 - 300020192-02
4. Installation
4.1.2 Ventilation
The location of air inlets in relation to the high ventilation openings
shall ensure that the air is renewed in the entire volume of the boiler
room.
It is in any case imperative to conform to the local regulations in force.
Upper and lower air vents compulsory:
Top ventilation:
- Cross section equal to half the total cross section of the flue gas
pipes with a minimum of 2.5 dm
2
.
Bottom ventilation:
- Direct air inlet: S (dm2)
P = Installed power in kW
Caution:
In order to avoid damage to the boiler, it is necessary to prevent the
contamination of combustion air by chlorine and/or fluoride
compounds, which are particularly corrosive.
These compounds are present, for example, in aerosol sprays,
paints, solvents, cleaning products, washing products, detergents,
glues, snow clearing salts, etc.
Therefore:
• Do not pull in air evacuated from premises using such products:
hairdressing salons, dry cleaners, industrial premises (solvents),
premises containing refrigeration systems (risk of refrigerant
leakage), etc.
• Do not stock such products close to the boilers.
If the boiler and/or peripheral equipment are corroded by such
chloride or fluoride compounds, the contractual guarantee
cannot be applied.
4.2 Mounting
For mounting instructions, see installation instructions.
0≥86,P
20
--
----------------------

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18/03/2016 - 300020192-02 PK 550
4. Installation
4.3 Hydraulic connections
4.3.1 Dimensional information required
Draining outlet 3/4’’
Heating return:
- 9 to 17 sections : 139.7 - 5"
- 18 to 25 sections
: 159 - 6"
weld.
Heating flow:
- 9 to 17 sections : 139.7 - 5"
- 18 to 25 sections
: 159 - 6"
weld.
* dimension without connection (see figure on chapter Boiler location,
straight or angled connection).
4.3.2 Important recommendations for connecting the boiler to the heating circuit
Installation must be carried out in accordance with the prevailing regulations, the codes of practice and the recommendations in these
instructions.
France:
Heating installations must be designed and constructed in such a way as to prevent the return of water in the heating circuit and the products
put into it into the drinking water network located upstream; The installation must not be connected directly to the drinking water network (article
16-7 of the local health directive). When these installations are fitted with a filling system connected to the drinking water network, they comprise
a CB disconnector (disconnector for zones with non-controllable pressure differences) which satisfy the functional requirements of the NF P
43-011 standard.
`Minimum safety valve flowrate as a function of maximum boiler nominal output:
Minimum relieving capacity
Maximum gross boiler output
(a) = kW, (b) = lb/h, (c) = MBtu/h, (d) = Kg/h
Example
Maximum boiler nominal output is 800 kW.
Minimum safety valve flowrate must be 2600 Kg/h.
There must be no total or partial closing mechanism
between the boiler and the safety valves (France: DTU -
65.11, § 4.22 - NF P 52-203).
C
1080mm
H*
D
M000034
1
2
3
0m20m
Boiler PK
550-9
PK
550-
10
PK
550-
11
PK
550-
12
PK
550-
13
PK
550-
14
PK
550-
15
PK
550-
16
PK
550-
17
PK
550-
18
PK
550-
19
PK
550-
20
PK
550-
21
PK
550-
22
PK
550-
23
PK
550-
24
PK
550-
25
C (mm) 1488 1488 1488 1488 1488 1488 1488 1488 1488 1504 1504 1504 1504 1504 1504 1504 1504
D (mm) 212 233 234 255 256 217 188 189 210 236 257 208 209 230 231 252 253
H (mm) -7 14 15 36 37 -2 -31 -30 -9 -8 13 -36 -35 -14 -13 8 9

14 PK 550 18/03/2016 - 300020192-02
4. Installation
`Water flow in the boiler :
The water flow in the boiler when the burner is operating must correspond with the following formulae:
- Nominal water flow Qn = 0.86 Pn/20
- Minimum flow Qmin = 0.86 Pn/45 (this flow also corresponds with the minimum recycle flow in the boiler)
- Maximum water flow Qmax = 0.86 Pn/5
Qn = flow in m3/h
Pn = Nominal output (full boiler output) in kW.
`Operation in cascade
After stopping the burner:
- Timeout required before the order to close a 2 way valve: 3 min
- Switch a possible shunt pump (located between the boiler and a butterfly valve) off via the end of run contact of the butterfly valve.
`Operation with 2-stage burner
- The water temperature in the boiler is maintained at 50°C or more; The first stage must be set to a minimum of 30% of the nominal stage
- Operation at modulated low temperature (minimum outlet temperature: 40°C); The first stage must be set to a minimum of 50% of the nominal
stage.
`Operation with modulating burner
- The water temperature in the boiler is maintained at 50°C or more: The burner can modulate down to 30% of the nominal stage
- Operation at modulated low temperature (minimum outlet temperature: 40°C); The burner can modulate down to 50% of the nominal stage

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18/03/2016 - 300020192-02 PK 550
4. Installation
4.3.3 Filling the system
Filling shall be performed with a low flow rate from a low point in the
boiler room in order to ensure that all the air in the boiler is bled from
the high point of the system.
All the pumps must be stopped before filling (included shunt
pump(s)).
VERY IMPORTANT: Instructions for starting up the boiler
for the first time after the system is fully or partly drained:
If all the air is not bled naturally to an expansion vessel
which opens out onto the air, the system must include
manual bleeder valves, in addition to automatic bleeder
valves with the capability to bleed the system by
themselves when it is operating, the manual bleeder valves
are used to bleed all the high points of the system and to
make sure that the filled system is free of air before the
burner is turned on.
Do not add cold water suddenly into the boiler when it is
hot.
4.3.4 Sludge removal
A tapped Ø 2’’ hole with a plug has been provided on the bottom of
the front of the boiler.. Fit a 1/4 turn valve (not supplied) on the
opening to remove the sludge.
Sludge removal leads to the draining of large quantities of water, so
remember to refill the system after the operation.
Note:
never replace a boiler in an existing system without carefully rinsing
the system first. Install a sludge decanting pot on the return pipe, very
close to the boiler.
2’’ tapped sludge removal hole
D000924

16 PK 550 18/03/2016 - 300020192-02
4. Installation
4.4 Chimney connection
The high-performance features of modern boilers and their use in
specific conditions as a result of the advance in burner technology
(e.g. first-stage or low modulation range operation) lead to very low
flue gas temperatures (<160°C).
For this reason:
- Use flue gas pipes designed to enable the flow of condensates
which may result from such operating modes in order to prevent
damage to the chimney.
- Install a draining tee at the bottom of the chimney.
The use of a draught moderator is recommended as well.
4.4.1 Flue size
Refer to applicable regulations while determining the size of the flue.
Please note that PK 550 boilers have pressurised and tight furnaces
and that the pressure at the connection to the chimney must not
exceed 0 mbar, unless special sealing precautions have been taken,
for instance in order to connect a static condenser/regenerator.
4.4.2 Chimney connection
The connection shall be removable, and offer minimum load losses,
i.e. it must be as short as possible with no sudden change in section.
Its diameter shall always be at least equal to that of the boiler outlet,
i.e.:
Ø 300 mm for 9 sections
Ø 350 mm for 10 to 13 sections
Ø 400 mm for 14 to 20 sections
Boilers with 21 to 25 sections are supplied with a plain plate. The
maximum cut-out dimensions are 500 x 700 mm.
Fit a measuring point (Ø 10 mm hole) on the flue, in order to adjust
the burner (combustion check).
*Dimension representing the end of the 100 mm long chimney
connection.
Note: with models PK 550-21, PK 550-22, PK 550-23,, PK 550-24
and PK 550-25, a plain plate which must be cut out is supplied
without the 100 mm chimney connection.
815mm
86mm55mm86
K
M000037
Ø F
Boiler PK
550-9
PK
550-
10
PK
550-
11
PK
550-
12
PK
550-
13
PK
550-
14
PK
550-
15
PK
550-
16
PK
550-
17
PK
550-
18
PK
550-
19
PK
550-
20
PK
550-
21
PK
550-
22
PK
550-
23
PK
550-
24
PK
550-
25
Ø F 300 350 350 350 350 400 400 400 400 400 400 400 Plain plate
K 5 26 27 48 49 10 -19 -18 3 4 25 -24 -23* -2* -1* 20* 21*

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18/03/2016 - 300020192-02 PK 550
4. Installation
4.5 Fuel-oil or gas connections
ZRefer to the instructions supplied with the burner.
4.6 Electrical connections
ZRefer to the connection instructions supplied with the control panel..

18 PK 550 18/03/2016 - 300020192-02
5. Commissioning
5 Commissioning
ZSee:
- Control panel instructions
- Burner instructions
- Domestic hot water calorifier instructions
6 Switching off the boiler
`Set the On/Off switch to O.
ZSee: Control panel instructions
`Cut the gas supply to the boiler (if present)
DIEMATIC-m3 control panel
The panel must always be supplied with 230V voltage:
- to ensure the anti-grip of the heating pump,
- to ensure Titan Active System® operation when a titanium anode
is protecting the DHW tank.
Use the mode:
- summer to shut down the heating.
- antifreeze to shut down the boiler if you are to be absent.
6.1 Precautions required in the case of long boiler stops
- The boiler and the chimney must be swept carefully.
- Close all the doors of the boiler to prevent air from circulating inside
the boiler.
- We advise removing the pipe which connects the boiler to the
chimney and to close off the nozzle with a cover.
6.2 Precautions required if the heating is stopped when there is a risk of freezing
We recommend the use of a correctly dosed antifreeze agent to
prevent to the heating circuit from freezing.
If this cannot be done, drain the system completely.

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18/03/2016 - 300020192-02 PK 550
7. Checking and maintenance
7 Checking and maintenance
7.1 Maintenance of the boiler
The operations described below shall only be performed
with the boiler and power supply off.
7.1.1 Sweeping
The boiler will only operate efficiently if the exchange surfaces
are kept clean.
The boiler should be cleaned as soon as required and as the
chimney, at least once a year or more, depending upon applicable
regulations and specific needs.
- Cut the power supply to the boiler.
- Remove the upper front panel.
- Remove the retaining upper front crosspiece and then the lower
left and right-hand front panels.
- Remove the lower front panel.
- Unfasten the wing nuts and remove the 4 sweeping doors.
M000039
2

20 PK 550 18/03/2016 - 300020192-02
7. Checking and maintenance
- Remove the baffle plates from the upper flue ways.
- Carefully sweep the flue ways with the brush supplied for that
purpose.
- Brush the baffle plates as well.
- If possible, use a vacuum cleaner.
- Remove the left and right-hand casing covers.
Remove the top insulating material.
1 Unfasten the nuts up to the stop.
2 Push in the handles of the sweeping covers.
3 Remove the sweeping covers.
- Brush the vertical plates.
- Put back the sweeping covers, insulating material and casing
covers by reversing the procedure above.
Chemical sweeping is recommended for such boilers
See chapter "Chemical sweeping" - See page 22.
- Put the baffle plates back in place. Interlock them with each other
while fitting them into the flue ways.
- Close the upper sweeping doors.
M000040
3
M000041
4
M000042
5
1
19
2
3
M000043
6