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Part number 550-100-325/0419
8
AquaBalance
®
Series 2 Wall Mount Gas-fired Water Boiler – Boiler Manual
Hydrostatic pressure test
-
-
mum allowable relief valve setting for the
. Failure to prevent the
boiler pipes from turning could damage pipes
or heat exchanger, resulting in possible severe
personal injury, death or substantial property
damage.
Pressure test the boiler before permanently attaching water or
gas piping or electrical supply.
Install pipe fittings for relief valve
and P/T gauge
1. Install the reducing tees, and close nipples, field supplied,
located and oriented as shown in Figure 5, page 9. Apply
pipe dope to all fittings sparingly.
. Temporarily install a ¾” pipe
plug in the relief valve location as directed in these
instructions. The plug must be removed after the
test.
the boiler supply. Con-
nect the relief valve only as shown in this manual.
Failure to comply with the above could prevent
the relief valve from operating as needed, resulting
in possibility of severe personal injury, death or
substantial property damage.
2. Install the test pressure/temperature gauge (field supplied)
to the reducing tee as shown in Figure 6, page 9.
Install fittings and valves required for
hydrostatic testing (supplied by installer)
1. The following piping components (supplied by installer)
are required for the test configuration:
a. Two shut-off valves - (1”NPT on the 80/120 boilers,
1
-1/4”NPT on the 155 boiler).
b. Two close nipples - (1”NPT on the 80/120 boilers,
1
-1/4”NPT on the 155 boiler).
c. ¾” NPT pipe plug.
d. Pressure/temperature gauge.
e. ¾” NPT boiler drain valve.
2.
insert a ¾” NPT pipe plug in the relief valve
tapping. After the hydrostatic test, this plug must be removed
and the relief valve must be installed.
Fill and pressure test
1. See Figure 5, page 9, for use with the following instructions.
2. CLOSE the boiler drain valve (item 10). Connect a hose to
fresh water supply and to the drain valve.
3. Place a bucket under the ends of the isolation valves
(item 8 and 9) to catch water drippings.
4. CLOSE isolation valve item 9, then crack open the valve
slightly. Leave top isolation valve item 8 open.
5. Slowly open the boiler drain valve (item 10) and fresh water
supply to fill boiler with water. The boiler and piping will
fill quickly because of the low water content.
6. When water begins to flow from bottom isolation valve
(item 9), close the valve.
7. Continue filling until water flows from top isolation valve
(item 8), then close the valve.
8. When pressure on the pressure/temperature gauge (item
4) reaches at least 45 PSIG, but no higher than 55 PSIG,
CLOSE the boiler drain valve (item 10).
9. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water fill
could expand and cause excessive pressure, result-
ing in severe personal injury, death or substantial
property damage.
10. Make sure constant gauge pressure has been maintained
throughout test. Check for leaks. Repair if found.
Failure to
do so can damage boiler, resulting in substantial
property damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Gaskets and seals
in the system may be damaged. This can result in
substantial property damage.
Drain and remove fittings
1. Disconnect fill water hose from water source.
2. Drain boiler through drain valve
(item 10).
Use caution when releasing pressure from the boiler.
Rapid water flow could cause injury.
3. Remove hose after draining.
4. Remove nipples and valves unless they will remain for use in
the system piping.
5. Remove plug and install relief valve as specified in the fol-
lowing WARNING.
Remove plug from relief valve street elbow. Install
the relief valve in the ¾” street. See page 42 to install
relief valve discharge piping. Failure to install the
boiler relief valve could result in severe personal
injury, death or substantial property damage.
3 Prepare boiler continued
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