Boiler Connections For Pressure Testing; Perform Hydrostatic Pressure Test - Weil-McLain 4 Series Manual

insTallaTion
Boiler Assembly, continued
1

Boiler Connections for Pressure Testing

Install the boiler connections per the appropriate
instructions below according to the boiler model
Models 1494-2094:
2
1 Secure supply elbows and outlet gaskets to front
and back sections
a Use 5/8" x 3" studs, nuts, and washers
b Thread the flat end of the studs into the
sections
2 Secure 6" NPT return opening counter flange and
3
gasket to back section Use 3/4" x 2" cap screws
and washers
Models 2194-2594:
1 Secure outlet cover plates and gaskets to front
and back sections
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a The 3/4" tappings in plates should be at top
b Use 5/8" x 1-3/4" bolts
2 Secure 10" supply outlets and gaskets on top of
"SI" sections, when used
a Supply outlet installed close to boiler front
should have 1-1/4" tapping facing front
b Use 5/8" x 3" studs, nuts, and washers
5
3 Secure 6" NPT return opening counter flange and
gasket to back section using 3/4" x 2" hex head
cap screws and washers

Perform Hydrostatic Pressure Test

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1 See Figure 7, page 17 for tapping locations
2 Install a water pressure gauge for testing only
a The pressure gauge must be able to handle
the required test pressure stated in this
section Gauge maximum should be at least
1 5 times the test pressure
b Install the pressure test gauge in the tapping
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specified in Figure 7, page 17
3 Install an air vent in an upper tapping
4 Install 3" close nipples and caps in washout
tappings on the front section
5 Prepare the rear section
a Install a drain valve (furnished by installer) in
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one of the washout tappings on the rear section
b Verify drain valve size per Figure 7, page 17
c Install a 2" x 2-1/2" nipple and cap in the other
washout tapping
16
sTeam series
94
6 Plug or use blind flanges on remaining tappings.
NOTICE
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 the boiler for at least 10 minutes at
a pressure between 45 and 55 psig
NOTICE
Do not exceed above test pressures by more than 10
psig.
WARNING
!
Do not leave boiler unattended. Cold water fill
could expand and cause excessive pressure,
which can result in severe personal injury, death
or substantial property damage.
9 Check for maintained gauge pressure and leaks
Repair any leaks immediately
NOTICE
Leaks must be repaired at once. Failure to do so
can damage boiler, resulting in substantial property
damage.
NOTICE
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Using these compounds
can cause severe damage to system components,
resulting in substantial property damage.
10 Drain the boiler Remove the air vent, boiler drain,
and pressure gauge
11 Remove plugs from tappings that will be used for
controls and accessories
boiler manual
4
550-100-157/0523