Prepare Boiler; Placement And Setup; Pressure Test; Perform Hydrostatic Pressure Test - Williamson-Thermoflo GWA 3 Series Manual

2 Prepare boiler

Placement and setup

Place boiler/crate near position
1. Leave boiler in crate and on pallet until installation site is
ready.
2. Move entire crate and pallet next to selected location.
3. Remove crate. Leave boiler on pallet.
4. Remove boiler from pallet as follows:
a. Tilt left side of boiler up and place a board under left legs.
b. Tilt boiler the other way and place a board under right legs.
c. Slide boiler backwards off pallet and into position.
Do not drop boiler or bump jacket on floor or pal-
let. Damage to boiler can result.
5. Check level.
a. Shim legs, if necessary.
b. Do not alter legs.
The boiler contains ceramic fiber and fiberglass
materials. Use care when handling these materials
per instructions on page 52 of this manual. Failure
to comply could result in severe personal injury.
Inspect orifices and burners
1. Remove front jacket door. Remove base access panel
(See Figure 29, item 4, page 46).
2. Check for correctly-sized manifold orifices. See Table 3 for
sizing. (The orifice size is stamped on the orifice spud barrel.)
Correctly-sized manifold orifices must be used.
Failure to do so will result in severe personal injury,
death or substantial property damage.
3. Level and straighten burners.
Burners must be properly seated in slots in burner
rest with their openings face up. Main burner ori-
fices must inject down center of burner. Failure to
properly seat burners will result in severe personal
injury, death or substantial property damage.
4. Reinstall access panel.
Do not operate boiler without access panel se-
cured in place. Failure to comply could cause
momentary flame rollout on ignition of main flame,
resulting in possible fire or personal injury hazard.
Table 3 Manifold orifice sizing
Location
U.S.
GWA-038
GWA-067 thru 233
Location
U.S.
GWA-038
GWA-067 thru 233
Note 1: For elevations above 2,000 feet, contact your
Williamson-Thermoflo sales office for details.
Part Number 550-142-320/0720
GWA Series 3 Gas-Fired Water Boilers – Boiler Manual
Natural gas
over 2,000 ft.
0-2,000 ft.
1.90mm
(Note 1)
2.00mm
(Note 1)
Propane gas
0-2,000 ft. over 2,000 ft.
#61 (Note 1)
#56 (Note 1)

Pressure test

Perform hydrostatic pressure test

Pressure test boiler before attaching water or gas piping
or electrical supply (except as noted below).
Prepare boiler for test
1. Remove the shipping nipple (from boiler 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 in Figure 31, item 3, page 48. 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 in Figure 31, item 2, page 48. (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.)
7. Temporarily plug the air elimination tapping (next to supply
tapping).
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 of not more
than 45 psi is reached on the pressure/temperature gauge.
6. Test at no more than 45 psi for no more than 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
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, valves and plus unless they will remain for
use in the system piping.
4. Remove plug from relief valve tapping. See Section 3,
page 10, to replace relief valve.
7