Unit installation

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5285 873 - 02
Vitocrossal 300, CT3 Series Installation
Boiler Connections
Hydrostatic Test Procedure
All Vitocrossal boilers are factory tested (hydrostatic
testing) to ASME requirements. The following testing
procedure is to ensure that the boiler remained intact
during shipping and handling.
1. Isolate boiler from hydronic heating system using
isolating valves (i.e. expansion tank, feed water valve,
pressure relief valve etc.).
2. Remove 30 psig pressure relief valve from the boiler
and cap pipe outlet.
3. Fill boiler with city water and pressurize it to one and
a half (1½) times the maximum working pressure of
boiler. The pressure must be controlled such that it
will never be 10 psig higher than the testing pressure.
Max. allowable working pressure = 30 psig
Testing pressure = 45 psig (do not exceed 55 psig)
4. Monitor pressure over a period of approximately one
(1) hour to ensure that the pressure remains constant
and steady at 45 psig.
5. Should there be a drop in pressure, ensure that
all fittings are secure and tight. Check all flanged
connections with a flashlight.
6. Remove the condensate collection inspection cover
and observe the condensate drum for system water
or fluid.
7. With a flashlight, observe and check the lower portion
of the Inox-Crossal® wafer heat exchanger sections
for system water or fluid.
8. Open the boiler combustion chamber door and inspect
with a flashlight the top portion of the Inox-Crossal®
wafer heat exchanger sections for system water
or fluid.
9. If test is successful, reinstall all hydronic system
components and refill the boiler with water or system
fluid.
Legend
A Boiler return 1 (BR1 - low temp.)
B Drain
C Boiler return 2 (BR2 - high temp.) / safety return
D Boiler temperature sensor/AHL/FHL
E Safety supply, alternative pressure relief valve location
and additional boiler supply
F ¾ in. coupling for additional control equipment
G Boiler supply
H Coupling for air vent / pressure gage
K Condensate drain
L Condensate inspection cover
M Flue gas damper
Vitocrossal 300, CT3-17 to -89
WARNING
Never expose the boiler to any pressures higher than
55 psig during testing.