Burnham ES2 manual Appendix E Filling the System and Checking for Leaks

APPENDIX E – Filling the System and Checking for Leaks

Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling.

1.Close full port ball valve located between vertical hose bib and air scoop in boiler supply piping (see Appendix D – System Piping.

2.Isolate all zones by closing zone valves or shut-off valves in supply and return of each zone(s).

3.Attach a hose to the vertical hose bib located prior to the full port ball valve in the system supply piping.

i	Terminate hose in five-gallon bucket at
	a suitable floor drain or outdoor area.

4.Starting with one circuit at a time, open zone valve or shut-off valve in system supply and return piping.

5.Open hose bib.

6.Open fill valve (Make-up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank).

7.Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds.

8.Close hose bib, continue filling the system until the pressure gauge reads 12 psi. Close fill valve.

9.Starting with the first convector in the loop, open air vent to purge air until a steady stream of water flows into container for approximately 5 seconds. Proceed to next convector and repeat procedure until all convectors in the loop are purged of air

10.Close the opened zone valve or shut- off valve for the zone being purged of air.

11.Open the zone valve or shut-off valve for the next zone to be purged. Repeat the previous steps until all zones have been purged. At completion, open all zone valves or shut-off valves.

12.Close hose bib, continue filling the system until the pressure gauge reads 12 psi.

Close fill valve.

If make-up water line is equipped

i with pressure reducing valve, system will automatically fill to 12 psi. Follow fill valve manufacturer’s instructions.

13.Open isolation valve in boiler supply piping.

14.Remove hose from hose bib.

Confirm that the boiler and system have no water leaks.

1.Check Rating Label for maximum operating pressure of this boiler. Never exceed this pressure during leak test. Do not plug or change pressure relief valve. Perform visual inspection for leaks or weeping joints after initial fill and during boiler warm-up period. Repair all leaks before placing boiler into permanent operation.

2.If it is required to perform a long-term pressure leak test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler.

3.To perform a long-term pressure test including the boiler, all trapped air must be removed from the boiler and system as prescribed above. A loss of pressure during such a test, with no visible leakage, is an indication that the boiler or system contained trapped air.

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