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Boiler manual: • Installation • Start-Up • Maintenance • Parts
11Part No. 550-110-275/1018
Perform hydrostatic pressure test
Install boiler connections
894 – 1294 W
1. Secure supply elbow and gasket to front section and supply
outlet cover plate and gasket to back section.
• Use
5
⁄8" x 3" studs, nuts, and washers.
• Thread flat end of stud into section.
2. Secure 6" NPT return opening counter flange and gasket to
back section using ¾" x 2" cap screws and washers.
1394 – 2094 W
1. Secure supply elbow and gasket to front section.
2. Use
5
⁄8" x 3" studs, nuts, and washers.
3. Thread flat end of stud into section.
4. Secure supply outlet cover plate and gasket to back section.
5. Use
5
⁄8" x 1¾" bolts.
6. Secure 8" pipe with standard 8" flange (not furnished) and
gasket (furnished) to back section. Use ¾" x 2" cap screws
and washers (furnished).
2194 — 2594 W
1. Secure outlet cover plate with 3 holes (¾" tapping on top)
and gasket to front section.
2. Secure outlet cover plate with 2 holes and gasket to back
section.
3. Use
5
⁄8" x 1¾" bolts.
4. Secure 10" supply outlets and gaskets on top of "SI" sections.
• Supply outlet should have 1¼" tapping facing front.
• Use
5
⁄8" x 3" studs, nuts, and washers.
5. Secure 10" flanged return adapter and gasket to back section
using ¾" x 2" hex head cap screws and washers.
894 S
1. Secure supply elbow and outlet gasket to front section and
supply outlet cover plate and gasket to back section.
• Use
5
⁄8" x 1¾" bolts.
2. Secure 6" return opening counter flange and gasket to back
section. Use ¾" x 2" cap screws and washers.
994 — 2094 S
1. Secure supply elbows and outlet gaskets to front and back
sections.
• Use
5
⁄8" x 3" studs, nuts and washers.
• Thread flat end of stud into section.
2. Secure 6" NPT return opening counter flange and gasket to
back section. Use ¾" x 2" cap screws and washers.
2194 — 2594 S
1. Secure outlet cover plates and gaskets to front and back
sections.
• The ¾" tappings in plates should be at top.
• Use
5
⁄8" x 1¾" bolts.
2. Secure 10" supply outlets and gaskets on top of "SI" sections.
• Supply outlet installed close to boiler front should have
1¼" tapping facing front.
• Use
5
⁄8" x 3" studs, nuts, and washers.
3. Secure 6" NPT return opening counter flange and gasket to
back section using ¾" x 2" hex head cap screws and washers.
Prepare boiler and test:
1. See Figure 10 (water boilers) or Figure 11 (steam boilers) for
tapping locations.
2. Install water pressure gauge —
for test only. Be sure gauge
can handle test pressure — see step 8 for required test pres-
sure. Gauge range should be at least 1.5 times the test pres-
sure. Install the pressure test gauge in the tapping specified
in Figure 10 (water boilers) or Figure 11 (steam boilers).
3. Install an air vent in an upper tapping.
4. On front section: Install 3" close nipples and caps in washout
tappings.
5. On rear section: Install drain valve (furnished by installer)
in one of the washout tappings. (Verify drain valve size per
Figure 15, page 15.) Install 2" x 2
1
⁄2" nipple and cap in the
other washout tapping.
6. Plug or use blind flanges on remaining tappings.
Do not pressure test with any control installed.
Damage to control can occur due to overpressure.
7. Fill the boiler with water. Vent all air.
8. Pressure test at least 10 minutes at a pressure not less than
the following:
a.
Steam boiler: Between 45 and 55 psig.
b.
Water boiler: 1½ times maximum allowable working
pressure
(MAWP) stamped on the boiler nameplate,
located on boiler jacket front panel.
Do not exceed above test pressures by more than
10 psig.
Do not leave boiler unattended. Cold water fill
could expand and cause excessive pressure, result-
ing in severe personal injury, death or substantial
property damage.
9. Check for maintained gauge pressure and leaks. Repair if
found.
Leaks must be repaired at once. Failure to do so
can damage boiler, resulting in substantial property
damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
system components can result, causing substantial
property damage.
10. Drain boiler and remove air vent, boiler drain and gauge.
11. Remove plugs from tappings that will be used for controls
and accessories.
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