Perform Hydrostatic Pressure Test - Weil-McLain Ultra Commercial Installation And Start-Up Manual

COMMERCIAL GAS
Prepare boiler
valve setting for the Ultra boiler. The boiler is shipped
with a 30 PSIG relief valve. See Replacement parts in the
back of this manual for alternate pressure setting relief
valves.

Perform hydrostatic pressure test

Pressure test boiler before permanently attaching water or gas piping
or electrical supply.
Prepare boiler for test
1. See Figure 5 for reference in following steps. Use pipe dope spar-
ingly.
2. Remove 2" supply line tee, 2x¾" bushing and ¾" nipple from ac-
cessory bag.
3. Pipe 2" tee, bushing and ¾" nipple to boiler supply connection
as shown.
4. Temporarily plug the end of the 2" supply tee.
5. Attach a ¾" shut-off valve (by others) to the ¾" nipple.
6. Attach a 2-inch tee (by others) to the boiler return pipe.
7. Install a bushing and a ¾-inch boiler drain valve off of the tee as
shown. Temporarily plug the end of the tee. (All fittings by oth-
ers.)
8. Connect a hose to the boiler drain valve, with the other end con-
nected to a fresh water supply. Make sure the hose can also be used
to drain the boiler after test.
9. To avoid getting water on the boiler, you may want to pipe street el-
bows on top of shutoff valves and attach catch-buckets beneath.
10. If convenient, install any other piping compatible with
that would still allow bleeding air from shutoff valves.
Fill and pressure test
1. Open the shutoff valves you installed on supply and return con-
nections.
2. Slowly open boiler drain valve and fresh water supply to fill boiler
with water. The boiler will fill quickly because of its low water
content.
3. When water reaches the shutoff valve on top, allow water to flow
long enough to ensure all air is out of the heat exchanger. Then
close the boiler drain valve.
4. Close shutoff valve on top.
5. Increase test pressure until the pressure/temperature gauge reaches
120 psig, but no higher. DO NOT exceed 120 psig.
6. 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.
7. Make sure constant gauge pressure has been maintained through-
out test. Check for leaks. Repair if found.
12
-
FIRED WATER BOILER
(continued)
. This is the maximum allowable relief
— Boiler Manual
Hydrostatic test piping connections
Figure 5
to do so can damage boiler, resulting in
substantial property damage.
Do not use petroleum-based cleaning or seal-
ing compounds in boiler system. Gaskets and
seals in the system may be damaged. 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. Remove hose after
draining.
3. Remove pipe fittings unless they will remain for use in
the system piping.
4. Remove the ¾" shut-off valve from the ¾" relief valve
nipple.
5. See page 13 to install relief valve on the ¾" nipple.
Failure
Part number 550-100-086/0809