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Part number 550-100-260/0520
12
ECO
®
Tec
GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL
. This is the maximum
allowable relief valve setting for the boiler. Failure
to comply could prevent the relief valve from
operating as needed, resulting in possibility of
severe personal injury, death or substantial property
damage.
. 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.
Hydrostatic pressure test
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 reducer bushings (150/199), reducing tees, and
close nipples, shipped loose with the boiler, located and
oriented as shown in Figure 8, page 13.
Boilers installed in locations with less than the
RECOMMENDED service clearances will need to
adjust piping layout to meet space requirements.
2. Apply pipe dope to all fittings sparingly.
. Temporarily install a ¾"
pipe cap in the boiler top outlet pipe location as
directed in these instructions. The cap must be
removed after the test.
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.
3. Install the pressure/temperature gauge to the reducing tee as
shown in Figure 8, page 13.
Install fittings and valves required for
hydrostatic testing
1. The following piping components (supplied by installer) are
required for the test configuration:
a. Two shut-off valves (1" NPT on 80/110,
1¼" NPT on 150/199).
b. Two close nipples (1" NPT on 80/110,
1¼" NPT on 150/199).
c. ¾" NPT pipe cap.
2.
install a ¾" NPT pipe cap on the
boiler
top outlet pipe. After the hydrostatic test, this cap must be
removed and the relief valve, tee and elbow must be installed.
Fill and pressure test
1. See Figure 9, page 13 for use with the following instructions.
2. CLOSE the boiler drain valve (Item 11). Connect a hose to
fresh water supply and to the drain valve.
3. Place a bucket under the ends of the isolation valves (Item 9
and 10) to catch water drippings.
4. CLOSE isolation valve Item 10, then crack open the 3/4" cap
(Item 3a) slightly. Leave isolation valve Item 9 open.
5. Slowly open the boiler drain valve (Item 11) 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 seep from 3/4" cap (Item 3a), tighten
the cap.
7. Continue filling until water flows from supply isolation valve
(Item 9), then close the valve.
8. The test pressure should be 1-1/2 times the pressure setting
of the relief valve to be installed on the boiler (45 psig for a
30-psig relief valve; 75 psig for a 50-psig relief valve). Open
boiler drain valve until desired pressure is achieved.
9. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water fill
could expand and cause excessive pressure, resulting
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 11).
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 cap and install relief valve, tee and elbow as specified
in the following WARNING.
6. If any internal leaks occurred, make sure all water has been
cleaned up and electronic components, including the boiler
control, is completely dry.
Remove cap from Air Elimination/Relief Valve
Connection Water Pipe (1a). Install the relief valve
in the ¾" elbow. See page 48 or page 51 to install
relief valve discharge piping. Failure to install the
boiler relief valve could result in severe personal
injury, death or substantial property damage.
Boiler hydrostatic test
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