Remeha P520 Assembly Instructions

Remeha

Fuel oil/gas boilers

P 520

EN

Assembly Instructions

300016864-001-C

63118

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

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

• Boilers supplied with an unassembled body

Boiler P 520 - Number of sections 13 15 17 19 21 23 25

Base frame (dimensions depend upon model) 1 111111

Rear section 1111111

Normal intermediate section 8 10 12 14 15 17 19

Special intermediate section 3333444

Front section 1111111

Set of assembly rods + Cleaning tools (contents depend upon model)

Standard accessory kit (contents depend upon model)

Additional accessory kit (contents depend upon model)**

Plain furnace plate 1111111

Flue gas connection plate with opening

Plain flue gas connection plate 111

Flue gas box 1111111

Distributing tube fitting* * * * 1 1 1

1 package FA 48 FA 50* FA 52* FA 54* FA 56 FA 58 FA 60

1 package FA 67** FA 69 FA 71 FA 73 FA 75 FA 77 FA 79

Ø 300

Ø 350

Ø 400 1 1 1 1

1111111

*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.

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P 520 25/01/2012 - 300016864-001-C

 Baffle plates

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

 Casing fittings

Boiler P 520 - Number of sections 13 15 17 19 21 23 25

package RC 2 1 1 1

package RC 3 1 1 1 1

Casing fittings

package MR 4 1 1 1

package MR 5 1 1 1 1

package FA 10 2 2 1 2 1

package FA 11 212323

 Casing, variable parts

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

 Insulating material for body

Boiler P 520 - Number of sections 13 15 17 19 21 23 25

package FA 34 1

package FA 35 1

package FA 36 1

Insulation

package FA 37 1

package FA 39 1

package FA 40 1

package FA 41 1

 Control panel

Boiler P 520 - Number of sections 13 15 17 19 21 23 25

Control panel package RC 6 1 111111

25/01/2012 - 300016864-001-C P 520

3

 Accessories - Available as an option

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

Connecting plate with Ø 300 opening or plain connecting plate or Plain connection plate

Set of anti-vibration studs 8208-7758 1 1

8208-7759 1 1

8208-7760 1 1 1

Refer to the applicable price list for the other optional features (control units etc.) which may be used with these boilers.



1111111

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P 520 25/01/2012 - 300016864-001-C

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



104

Section type

8228-0004

P 520-13 1831

P 520-15 11031

P 520-17 11231

P 520-19 11431

111

2

8228-0001

151

3

8228-0002

104

4

8228-0003

P 520-21 11541

P 520-23 11741

P 520-25 11941

Rear section Normal intermediate section Special intermediate section Front section

25/01/2012 - 300016864-001-C P 520

5

1

E

D

S

U

S

O

B

E

N

TO

P

D

E

S

US

OBEN

TOP

M000056

F

R

ONT

V

ORN

A

V

A

NT

F

R

O

NT

V

O

R

N

A

V

A

N

T

19

1

2

3

DE

SSU O BE

S

TOP

N

ANTA

3

V

NT

VORN

OR

F

2

3

`

to : Assembly of the base frame, delivered unassembled.



DESS

US

TOP

NOBE

NAVA T

VORN

FRONT

M000309

` 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).

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P 520 25/01/2012 - 300016864-001-C

2

M000057

` 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

00 8M00 5

` Clean all the openings in the section with a brush. Remove any deposit on the bottom of the section.

25/01/2012 - 300016864-001-C P 520

7

4

100

a

100

001

M000059

100

` 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

M000060

` 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.



8

P 520 25/01/2012 - 300016864-001-C

6

Remove any traces of rustprotective paint so that the surface is perfectly smooth.



Coat with the lubricant supplied with the sections.



Handle the nipples with gloves, there might be sharp



edges. Clean the bores and nipples with diluent.

7

A R

R

I ÈR

E

D

ES

S

US

O

B

E

N

T

O

` Gently push in the 2 nipples.

M000062

A

R

R I

È

R

E

DE

S

U

S

O

EB

N

T

OP

A

V

A

P

VA

A

N T

NT

25/01/2012 - 300016864-001-C P 520

9

8

a

010

100

` 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.

010

100

M000063

9

 Rear section

1

 Intermediate section

2

M000064

` 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.

10

P 520 25/01/2012 - 300016864-001-C

10

M000065

` Put the assembly tool in position.

Tighten gradually so as to bring together the upper and lower connections evenly and simultaneously.

11

M000066

` 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.

25/01/2012 - 300016864-001-C P 520

11

12

M000067

` Trim off any projecting ends of the thermocords the sweeping covers.

13 Fitting the upper and lower assembly rods

M06000 8

2

` 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.

12

P 520 25/01/2012 - 300016864-001-C

14

21

2

00069M0

` Put in place the upper assembly rods in the two front and rear lugs.

Rear Front

` 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.

25/01/2012 - 300016864-001-C P 520

13

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).

1 mm

A

B

1

C

A

300 mm

520 mm

D

C

1 mm

P520-13

C

A

300 mm

520 mm

D

- 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.

D

420 mm

D

1 mm

520 mm

C

520 mm

C

1 mm

B

E

A

2

1

C

A

D

420 mm520 mm

520 mm520 mm

C

2

B

P520-15

A

1

E

420 mm

D

C

420 mm

D

420 mm520 mm

C

520 mm

D

C

420 mm

520 mm520 mm

C

520 mm

B

2

B

P520-17

E

420 mm

D

C

520 mm

D

C

420 mm420 mm

520 mm

B

M000072

Rear Front

14

P 520 25/01/2012 - 300016864-001-C

A

B

C

1 mm

D

1 mm

E

A

1 mm

E

C

420 mm

C

420 mm

520 mm

1 mm

21

C

520 mm

D

520 mm

D

420 mm

C

520 mm

B

P520-19

C

520 mm

D

520 mm

C

D

520 mm

D

520 mm

420 mm

D

385 mm

C

520 mm

B

21

C

520 mm

B

P520-21

D

520 mm

C

520 mm

D

385 mm

C

520 mm

B

E

Rear Front

E

420 mm

D

420 mm

D

420 mm

D

420 mm

D

520 mm

420 mm

520 mm

21

420 mm

C

D

C

520 mm

D

C

385 mm

520 mm

B

P520-23

420 mm

C

D

C

520 mm

D

C

520 mm

C

520 mm

C

D

385 mm

C

D

385 mm

520 mm

B

21

B

P520-25

C

520 mm

D

C

520 mm

D

C

385 mm

520 mm

B

M000073

25/01/2012 - 300016864-001-C P 520

15

16 Assembling the pocket and the plugs

P520-13/15/17/19

P520-21/23/25

1

M000074

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.

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P 520 25/01/2012 - 300016864-001-C