Operating instructions

7
Part Number 550-142-784/0812
GWA Series 2 Gas-Fired Water Boilers – Boiler Manual
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GWA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 21, item 3, page 42.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 21, item 2, page 42.(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ll.(Valveandnipplearenotincludedwithboiler.)
6. Connectanippleandshutoffvalvetosystemreturnconnection
(atcirculatorangeifcirculatorinstalledonreturn).Thisvalve
willbeusedtobleedairduringthell.(Valveandnippleare
not included with boiler.)
7. Temporarilyplugthe aireliminationtapping(nextto supply
tapping).
Pressure test
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ll
boiler with water.
3. Whenwaterows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ll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ll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.
2 Prepare boiler continued