Weil-McLain SVF 1500 Manual page 13

SVF
™
Series 1
Commercial Condensing Gas-Fired Water Boiler — Boiler Manual
Prepare boiler
Prepare boiler for pressure test
1. Do Not install the relief valve until pressure testing is fi nished.
2. See Figure 7, page 13 for reference in following steps. Use pipe
dope sparingly.
3. At the boiler supply and return connections, temporarily att ach
blind fl anges, with tapping for a nipple and valve as shown (fl anges,
valves, gaskets nipples supplied by installer).
4. Att ach a water supply and hand pump to the lower valves.
5. Att ach a drain line to the upper valve.
6. Remove the pressure and temperature gauge from the trim box
shipped with the boiler or alternate pressure rating kit.
7. Remove the factory-installed plug from the ¼-inch tapping on
the side of the boiler supply pipe.
8. Apply pipe dope to the P/T gauge and install in the ¼-inch tap-
ping as shown.
9. Install plug on the relief valve nipple, SVF 1500/2000 – 1 ¼"
FNPT and SVF 2500/3000 – 2" FNPT.
10. If pressure test will be conducted with a pressure over 160 psig
the automatic air vent must be removed and a 1/2" NPT plug
installed in its place.
Fill boiler and pressure test
1. Open the shutoff valves installed on the supply and return con-
nections.
2. Allow water to fl ow into the bott om connection and air to fl ow
out the top connection.
3. When water reaches the shutoff valve on top, allow water to fl ow
long enough to ensure all air is out of the heat exchanger. Th en
close the upper shutoff valve.
Ensure all air is purged out of heat exchanger before
performing hydrostatic pressure test.
4. Close off the water supply and use hand pump to raise water
pressure for testing.
5. Th e test pressure should be 1½ times the pressure sett ing 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; or 150 psig for a 100-psig
relief valve; or 240 psig for a 160-psig relief valve).
Th e test pressure MUST NOT exceed the maximum
pressure on the P/T gauge. If test pressure will be
higher than the maximum range of the P/T gauge, use
a diff erent gauge for the test or remove gauge and plug
tapping.
6. Gradually apply pressure until test pressure is reached. Th en close
off the shutoff valve.
7. Hold at test pressure for 10 minutes.
Do not leave boiler unatt ended. A cold water fi ll could
expand and cause excessive pressure, resulting in severe
personal injury, death or substantial property damage.
8. Make sure that constant gauge pressure has been maintained
throughout test.
9. Check for leaks. Repair any leaks from threaded joints. If leaks
are found in Heat Exchanger, please consult your Weil-McLain
representative.
10. Slowly release pressure and drain.
Th e release of high pressure water should be done in
a safe matt er. Failure to do so could resulting in severe
personal injury, death or substantial property damage.
11. Re-install Automatic air vent and P/T gauge, if removed.
Part number 550-100-250/0819
(continued)
Figure 7
Hydrostatic test piping connections — fl anges,
valves and gaskets provided by installer
(SVF 1500 shown)
Boiler drain valve
1. If not installing a drain valve off of the return piping, there are
two (2) 1-½ FNPT connections for a boiler drain valve. (See
Figure 8 ). One is lower front of the heat exchanger and second
is on the piping end on the left side.
Leaks must be repaired at once.
so can damage boiler, resulting in substantial property
damage.
Do not use petroleum-based
compounds in boiler system. Gaskets and seals in the
system may be damaged. Th is can result in substantial
property damage.
Figure 8
Boiler drain location
Drain plug
Remove
relief valve
for test
(provided by installer)
Failure to do
cleaning or sealing
13