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Part Number 550-142-300/0520
13
CGa Series 3 Gas-Fired Water Boiler — Boiler Manual
Hydrostatic pressure test
Pressure test boiler before attaching water or gas piping
or electrical supply (except as noted below).
Prepare boiler for test
1. Remove the shipping nipple (from CGa supply
tapping) and remove the boiler relief valve.
Temporarily plug the relief valve tapping with a ¾”
NPT pipe plug.
2. Remove 1¼” nipple, reducing tee and drain
valve from accessory bag. Install in boiler return
connection as shown on page 3 or in
Figure 34, item
3, page 62. Install circulator on either the return or
supply.
3. Remove 1¼” nipple, 1¼” tee, bushing and pressure/
temperature gauge from accessory bag. Pipe to
boiler supply connection as shown in
Figure 34,
page 62-. (Use pipe dope sparingly.)
4. Connect a hose to boiler drain valve, the other end
connected to a fresh water supply. Make sure hose
can also be used to drain boiler after test.
5. Connect a nipple and shutoff valve to system supply
connection on the 1¼” tee. This valve will be used
to bleed air during the fill. (Valve and nipple are
not included with boiler.)
6. Connect a nipple and shutoff valve to system
return connection (at circulator flange if circulator
installed on return). This valve will be used to
bleed air during the fill. (Valve and nipple are not
included with boiler.)
Fill and pressure test
1. Open the shutoff valves you installed on supply and
return connections.
2. Slowly open boiler drain valve and fresh water
supply to fill boiler with water.
3. When water flows from shutoff valves, close boiler
drain valve.
Drain and remove fittings
1. Disconnect fill water hose from water source.
2. Drain boiler at drain valve or out hose, whichever
provides best access to drain. Remove hose after
draining if used to drain boiler.
3. Remove nipples and valves unless they will remain
for use in the system piping.
4. Remove plug from relief valve tapping. See Section 3
to replace relief valve.
Do not use petroleum-based clean-
ing or sealing compounds in boiler
system. Severe damage to boiler
will occur, resulting in substantial
property damage.
Leaks must be repaired at once.
Failure to do so can damage boiler,
resulting in substantial property
damage.
4. Close shutoff valves.
5. Slowly reopen boiler drain valve until test pressure
of not more than 45 psi is reached on the pressure/
temperature gauge.
6. Test at no more than
45 psi for no more than 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.
7. Make sure constant gauge pressure has been main-
tained throughout test. Check for leaks. Repair if
found.
Prepare boiler — pressure test
2b
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