REMEHA P 520 User manual

P 520
Fuel oil/gas boilers
Remeha
Assembly
Instructions
300016864-001-C
EN
63118

2P 520 25/01/2012 - 300016864-001-C
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
*The distributing tube fitting for P 520 boilers with 15 to 19 sections is included in the accessory package.
**The diaphragm for P 520 , 13 and 14 section boilers is delivered in the additional accessory kit package.
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
Assembled boiler body (contents depend upon model) 1 111111
Cleaning tool kit (contents depend upon model) 1 111111
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
Base frame (dimensions depend upon model) 1 111111
Rearsection 1111111
Normal intermediate section 8 10 12 14 15 17 19
Specialintermediatesection 3333444
Frontsection 1111111
Set of assembly rods + Cleaning tools (contents
depend upon model) 1111111
Standard accessory kit
(contents depend upon model) 1 package FA 48 FA 50* FA 52* FA 54* FA 56 FA 58 FA 60
Additional accessory kit (contents depend upon
model)** 1 package FA 67** FA 69 FA 71 FA 73 FA 75 FA 77 FA 79
Plainfurnaceplate 1111111
Flue gas connection plate with opening
Ø 300
Ø 350
Ø 400 1 1 1 1
Plain flue gas connection plate 111
Fluegasbox 1111111
Distributing tube fitting* * * * 1 1 1

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25/01/2012 - 300016864-001-C P 520
Baffle plates
Casing fittings
Casing, variable parts
Insulating material for body
Control panel
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
Baffle plates
package CM 22 1 1 1
package CM 23 1 111222
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
Casing fittings
package RC 2 1 1 1
package RC 3 1 1 1 1
package MR 4 1 1 1
package MR 5 1 1 1 1
package FA 10 2 2 1 2 1
packageFA11 212323
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
package FA 16 1 1 1 1
package FA 18 1
package FA 20 1
package FA 22 1
package FA 23 1
package FA 24 1
package FA 25 1
package FA 27 1
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
Insulation
package FA 34 1
package FA 35 1
package FA 36 1
package FA 37 1
package FA 39 1
package FA 40 1
package FA 41 1
Boiler P 520 - Number of sections 13 15 17 19 21 23 25
Control panel package RC 6 1 111111

4P 520 25/01/2012 - 300016864-001-C
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 P 520 - Number of sections 13 15 17 19 21 23 25
Furnace plate with hole
Ø 165/ 186/ 210/ 240 or Ø 295 1111111
Connecting plate with Ø 300 opening or plain
connecting plate or Plain connection plate 1111111
Set of anti-vibration studs 8208-7758 1 1
8208-7759 1 1
8208-7760 1 1 1

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25/01/2012 - 300016864-001-C P 520
2 Mounting
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, 17, 19 spanners
- 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. 18
- Mounting: start assembly from figure 35
Mounting the boiler body:
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
P 520-13 1831
P 520-15 11031
P 520-17 11231
P 520-19 11431
P 520-21 11541
P 520-23 11741
P 520-25 11941
104
8228-0004 8228-0001
111
2
8228-0002
151
3
8228-0003
104
4

6P 520 25/01/2012 - 300016864-001-C
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
M000056
F
R
ONT
VORN
A
V
ANT
F
R
O
NT
VO
RN
A
V
A
N
T
19

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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.
M000057
00 8M00 5

8P 520 25/01/2012 - 300016864-001-C
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.
Caution: silicon must not be applied 100 to either side of the connection (nipple assembly area).
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

9
25/01/2012 - 300016864-001-C P 520
6
Handle the nipples with gloves, there might be sharp
edges.
Clean the bores and nipples with diluent.
Remove any traces of rustprotective paint so that the surface is perfectly smooth.
Coat with the lubricant supplied with the sections.
7
`Gently push in the 2 nipples.
ARRIÈREDESSUS -OBEN-TOPVA ANT
ARRIR
ÈEDE SSUS-OEB N-TOP AVANT
M000062

10 P 520 25/01/2012 - 300016864-001-C
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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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, and 8.
`First assemble the normal intermediate sections, then the special ones.
Leave the assembly tool in place.
M000065
M000066

12 P 520 25/01/2012 - 300016864-001-C
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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25/01/2012 - 300016864-001-C P 520
14
Rear
Front
`Put in place the upper assembly rods in the two front and rear lugs.
`Mount the 2 crosspieces (supplied in package FA 5/6) 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

14 P 520 25/01/2012 - 300016864-001-C
15 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 1 mm.
Rear
Front
B
B
B
B
A
A
A
A
520 mm
520 mm
420 mm
300 mm
520 mm
520 mm
420 mm
300 mm
520 mm520 mm
420 mm520 mm
520 mm520 mm
420 mm520 mm
C
C
C
C
C
C
C
C
D
D
D
D
B
B
E
E
520 mm
520 mm
420 mm
420 mm
520 mm
520 mm
420 mm
420 mm420 mm
420 mm
C
C
C
C
D
D
D
D
P520-17
1 mm 1 mm
1 mm
B
ACD
B
ACD
1 mm
A
E
P520-15
P520-13
M000072
1
1
1
2
2
2

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25/01/2012 - 300016864-001-C P 520
Rear
Front
B
B
B
B
E
A
A
E
520 mm
520 mm
520 mm
420 mm
520 mm
520 mm
520 mm
520 mm
420 mm
520 mm
520 mm
520 mm
520 mm
385 mm
520 mm
420 mm
520 mm
520 mm
520 mm
385 mm
520 mm
420 mm
C
C
C
C
C
C
C
C
C
C
D
D
D
D
D
D
D
D
1 mm 1 mm
1 mm
B
ACD
B
ACD
1 mm
A
E
M000073
P520-21
P520-19
E
E
B
B
520 mm
520 mm
420 mm
420 mm
385 mm
520 mm
420 mm
520 mm
520 mm
420 mm
420 mm
385 mm
520 mm
420 mm
CCC
C
C
C
D
D
DDD
D
E
E
B
B
520 mm
520 mm
420 mm
385 mm
520 mm
520 mm
520 mm
520 mm
520 mm
420 mm
385 mm
520 mm
520 mm
520 mm
D
D
DD
D
D
C
C
CC
C
C
21
21
21
21
P520-23
P520-25

16 P 520 25/01/2012 - 300016864-001-C
16 Assembling the pocket and the plugs
Safety pressure sensitive switch
Assembling the safety pressure sensitive switch only valid for the Netherlands !
`Assemble the pocket for the thermostats and thermometer in:
• the third special intermediate section - 150 mm wide, 1/2’’ hole for P 520-13 to P 520-19
or
• the fourth special intermediate section - 150 mm wide, 1/2’’ hole for P 520-21 to P 520-25.
`Plug the 2 free 1/2’’ holes for P 520-13 to P 520-19 or the 3 free 1/2’’ holes for P 520-21 to P 520-25 in the special intermediate sections.
M000074
P520-13/15/17/19
P520-21/23/25
1

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25/01/2012 - 300016864-001-C P 520
17 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).
`Fit the flange with the sludge removal hole onto the lower connection of the front section (hole in the lower part of the flange) using 4 H
18 nuts, with the gasket in between (soak in warm water first).
18 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 9.75 bar mini) for 10 minutes at least.
Fit a square flange with hole facing upwards onto the upper flange with outlet piece.
Fit a blind square flange onto the lower flange with return piece.
M000075
1
2
M000076

18 P 520 25/01/2012 - 300016864-001-C
2.
Ensure that all the air in the boiler is vented to avoid any bursting of the body.
3.
`Maintain pressure for at least 10 minutes. 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
0077
M0 0
7
7,8
bar
0
7
5
8
11
9
10
6
6
078M0 00

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25/01/2012 - 300016864-001-C P 520
19 Assembling the baffle plates
`Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them.
M000079
Boiler P 520 - Number of sections P 520-13 P 520-15 to 19 P 520-21 to 25
Total number of baffle 4 6 8
Package no. CM 23 CM 22 + CM 23 2 x CM 23

20 P 520 25/01/2012 - 300016864-001-C
20 Assembling the sweeping covers
Rear
Front
- Clean off the protective varnish on the ground surfaces with
diluent.
- 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.
Place the 2 no. 1 sweeping covers (with the handles turned outward
) on either side of the boiler starting from the front. Distribute the
other covers evenly.
Each cover is fitted with a system whereby it can only be
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 .
M000080
1
2
34
1
2
3
Type Thermocord length
11335 mm
21110 mm
3890 mm
4665 mm
Cover model No. 1 No. 2 No. 3 No. 4
Boiler type
Number of sweeping covers per type
Front Rear
P 520-13 24
P 520-15 24 2
P 520-17 26
P 520-19 26 2
P 520-21 28
P 520-23 264
P 520-25 210