OERTLI PK 550 User manual

PK 550
Fuel oil/gas boilers
300020196-02
en
Assembly
Instructions
D000913

2PK 550 18/03/2016 - 300020196-02
1. Package list
1 Package list
Before starting to assemble the boiler, refer to the table below to check if you have received all the packages required.
•Boiler body +Accessories
- Boilers supplied with an assembled body
- Boilers supplied with an unassembled body
(1)The distributing tube fitting for PK 550 boilers with 15 to 19 sections is included in the accessory package.
(2)The diaphragm for PK 550 , 13 and 14 section boilers is delivered in the additional accessory kit package.
Boiler PK 550- Number of sections 910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Assembled boiler body (contents depend upon model) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Cleaning tool kit (contents depend upon model) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Boiler PK 550- Number of sections packag
e910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Base frame (dimensions depend upon model) 1 1 111111111111111
Rearsection 11111111111111111
Normalintermediatesection 4567891011121314141516171819
Specialintermediatesection 33333333333444444
Frontsection 11111111111111111
Set of assembly rods + Cleaning tools (contents
depend upon model) 11111111111111111
Standard accessory kit
(contents depend upon model) 1
FA 44 FA 45 FA 46 FA 47 FA 48 FA 49
FA50(1)
FA51(1) FA52(1) FA53(1) FA54(1)
FA55 FA56 FA57 FA58 FA59 FA60
Additional accessory kit (contents depend upon
model) (2) 1
FA63 FA64 FA65 FA66
FA67(2)
FA68(2)
FA69 FA70 FA71 FA72 FA73 FA74 FA75 FA76 FA77 FA78 FA79
Plainfurnaceplate 11111111111111111
Flue gas connection plate with opening
Ø 300
Ø 350
Ø 400
1
1 1 1 1
1111111
Plain flue gas connection plate 11111
Fluegasbox 11111111111111111
Distributing tube fitting (1) (1) (1) (1) (1) (1) 111111

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18/03/2016 - 300020196-02 PK 550
1. Package list
• Baffles
• Casing fittings
• Casing, variable parts
• Insulating material for body
Boiler PK 550 - Number of sections package 910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Baffles CM22 1 11111
CM23 1111111111222222
Boiler PK 550 - Number of sections package 910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Casingfittings MS1 111111111
MS2 11111111
MR3 1
MR4 1 1 1 1 1 1 1 1
MR5111 11 111
FA10 1 22 221 2211
FA11 11 222112332233
Boiler PK 550 - Number of sections package 910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Casing,variableparts FA16 11111111
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 - Number of sections package 910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Insulation FA31 1
FA32 1
FA33 1 1
FA34 1 1
FA35 1
FA36 1 1
FA37 1 1
FA38 1
FA39 1 1
FA40 11
FA41 1

4PK 550 18/03/2016 - 300020196-02
1. Package list
• Control panel
All models can be equiped with one of the following control panels:
• Accessories - Available as an option*
* Refer to the applicable price list for the other optional features (control units etc.) which may be used with these boilers.
Boiler PK 550 - Number of sections 910 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 910 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 11111111111111111
Connecting plate with opening or plain connecting
plate - Ø 300
or Plain connection plate
11111111111111111
Set of anti-vibration studs 8208-7757 1
8208-7758 1111111
8208-7759 1111
8208-7760 11111

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18/03/2016 - 300020196-02 PK 550
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.
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 assembly from figure 34

6PK 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 1431
PK 550-10 1531
PK 550-11 1 6 3 1
PK 550-12 1731
PK 550-13 1831
PK 550-14 1931
PK 550-15 11031
PK 550-16 11131
PK 550-17 11231
PK 550-18 11331
PK 550-19 11431
PK 550-20 11441
PK 550-21 11541
PK 550-22 11641
PK 550-23 11741
PK 550-24 11841
PK 550-25 11941
104
8228-0004 8228-0001
111
2
8228-0002
151
3
8228-0003
104
4

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2. Mounting PK 550
2.2 Mounting PK 550
1
`to : 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 12x40 - 19 spanner)
DESSUS
NOBE
TOP
NAVA T
VORN
FRONT
DESSUS
OBEN
TOP
ANTAV
VORN
FOR NT
3
3
M000309
3
1
2
3
23
E
DSSUS - O BEN - TOP
DESSUS - OBEN - TOP
DESSUS - O BEN - T OP
DESS US - OBEN - TO P
48555N0 2A
F
R
ONT
VORN
A
V
ANT
FRO
N
T
VO
RN
A
V
ANT
F
R
O
NT
VO
RN
A
V
A
N
T
F
R
O
N
T
V
OR
N
A
V
A
N
T
19
A
B
ABoilers: 10, 12, 14, 16, 18, 20, 22, 24 sections
BBoilers: 9, 11, 13, 15, 17, 19, 21, 23, 25 sections

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2. Mounting PK 550
2
`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.
`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, 20, 22, 24 sections
Boilers: 9, 11, 13, 15, 17, 19, 21, 23, 25 sections
00 8
M00 5

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2. Mounting PK 550
4
`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).
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
001
100
a
M000060

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2. Mounting PK 550
6
(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.
7
`Gently push in the 2 nipples.
ARRIÈREDESSUS -OBEN-TOPVA ANT
ARRIR
ÈEDE SSUS-OEB N-TOP AVANT
M000062

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2. Mounting PK 550
8
`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.
9
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 with
the bores.
100 100
010
010
M000063
a
M000064
1
2

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2. Mounting PK 550
10
`Put the assembly tool in position.
`Tighten gradually so 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

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2. Mounting PK 550
12
`Trim off any projecting ends of the thermocords the sweeping covers.
13
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).
`Stop tightening as soon as the gap between the spring spires is equal to about 2 mm.
M000067
M06000 8
2

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2. Mounting PK 550
14
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.
00069M0
2
2
21

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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).
`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 1mm
Rear
Front
Dimensions are given in millimeters.
D000915A
12
PK550-9

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2. Mounting PK 550
Rear
Front
Dimensions are given in millimeters.
PK550-10
PK550-11
PK550-12
D000916A
12
12
12

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2. Mounting PK 550
Rear
Front
Dimensions are given in millimeters.
PK550-13
PK550-14
PK550-15
D000917A
12
12
12

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2. Mounting PK 550
Rear
Front
Dimensions are given in millimeters.
PK550-16
PK550-17
PK550-18
D000918A
12
12
12

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2. Mounting PK 550
Rear
Front
Dimensions are given in millimeters.
PK550-19
PK550-20
PK550-21
D000919A
21
21
21

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2. Mounting PK 550
Rear
Front
Dimensions are given in millimeters.
PK550-22
PK550-23
D000920A
21
21