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Boiler hydrostatic test
$/./4INSTALLARELIEFVALVEWITHA
PRESSUREHIGHERTHAN03)'. This
is the maximum allowable relief valve
setting for the ECO 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.
5SETWOWRENCHESWHENTIGHTENING
ANYPIPE CONNECTION TO THE BOILER.
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 (155 only), reducing
tees, and close nipples, shipped loose with the boiler,
located and oriented as shown in Figure 8, page 12.
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.
$/ ./4INSTALL THE RELIEF VALVE UNTIL
AFTERTHEHYDROSTATICTEST
. Temporarily
install a ¾” pipe plug in the relief valve
location as directed in these instructions.
The plug must be removed after the test.
#ONNECTTHERELIEFVALVE/.,9ONTHE
"/),%2 3500,9 /54,%4 ./4
the
boiler return. Connect the relief valve
only as shown in this manual. Ensure re-
lief valve is located above heat exchanger.
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 reduc-
ing tee as shown in Figure 8, page 12.
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 70/110,
1¼”NPT on 155).
b. Two close nipples (1”NPT on 70/110,
1¼”NPT on 155).
c. ¾” NPT pipe plug.
2.
4%-0/2!2),9 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 9, page 12 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 valve 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 flow from bottom isolation valve (item 10),
close the valve.
7. Continue filling until water flows from top isolation valve (item 9),
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 11).
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.
,EAKSMUSTBEREPAIREDATONCE 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 dam-
aged. 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 plug and install relief valve as specified in the following
WARNING.
Remove plug from relief valve street elbow. Install the relief
valve in the ¾” street. See page 40 or page 46 to install
relief valve discharge piping. Failure to install the boiler
relief valve could result in severe personal injury, death or
substantial property damage.
Part number 550-142-122/0513
11
TM
GAS-FIRED WATER BOILER — Boiler Manual
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