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Part number 550-110-260/0200
13
Boiler Manual
Prepare boiler — pressure test
Pressure test boiler before attaching water or gas piping (except as noted below) or electrical
supply.
Prepare boiler for test
1. Remove the shipping nipple (from CGs 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 and
Figure 29, page 56. 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 on page 3 and Figure 29, page 56. (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.
4. Close shutoff valves.
5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge
reaches no more than:
• 45 psig for boilers with 30 psig relief valve.
• 75 psig
for boilers with 50 psig relief valve.
6. Test for no more than 10 minutes at:
• 45 psig
for boilers with 30 psig relief valve.
• 75 psig
for boilers with 50 psig relief valve.
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 maintained throughout test. Check for 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 boiler will occur, resulting in substantial property
damage.
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 3a to replace relief valve.
2b
Perform hydrostatic pressure test