Perform Hydrostatic Pressure Test - Weil-McLain Ultra 3 series User Manual

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gas fired water boiler
Prepare boiler
DO NOT install a relief valve with a pressure higher
than 30 PSIG
valve setting for the Ultra boiler.

Perform hydrostatic pressure test

Pressure test boiler before permanently attaching water or gas piping
or electrical supply.
Prepare boiler for test
1. See Figure 2 for reference in following steps.
2. Remove supply line tee* and ¾" street elbow from accessory bag.
Pipe to boiler supply connection as shown. Use pipe dope spar-
ingly. (*1" x 1" x ¾" tee with Ultra-80 to -230 or 1¼" x 1¼" x ¾"
tee with Ultra-299/399)
3. Temporarily plug the ¾" relief valve tapping in the street elbow
with a ¾" NPT pipe plug.
4. Connect a hose to the boiler drain valve, the other end connected
to a fresh water supply. Make sure the hose can also be used to
drain the boiler after test.
5. Connect a nipple and shutoff valve to system supply connection
on the supply tee. This valve will be used to bleed air during the
fill. (Valve and nipple are not included with boiler.)
6. Connect a shutoff valve to system return connection. (Valve is not
included with boiler.)
7. To avoid getting water on boiler, you may want to pipe street elbows
on top of shutoff valves and attach catch-buckets beneath.
8. If convenient, install the boiler circulator and any other piping
compatible with Figure 2 that would still allow bleeding air from
shutoff valves.
9. Follow guidelines in this manual for piping components, locations
and sizing.
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 shutoff valves, close boiler drain valve.
4. Close shutoff valves.
5. Slowly reopen boiler drain valve until test pressure on the pres-
sure/temperature gauge reaches at least 45 psig, but no higher
than 55 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.
Leaks must be repaired at once.
can damage boiler, resulting in substantial property
damage.
8
— Boiler Manual
(continued)
. This is the maximum allowable relief
Failure to do so
Figure 2
Hydrostatic test piping connections
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 nipples and valves unless they will remain for
use in the system piping.
4. Remove plug from relief valve street elbow. See
to install relief valve.
page 9
Part number 550-100-090/0809