GOLD CGs 
2b Prepare boiler — pressure test
Hydrostatic pressure test
Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply.
Prepare boiler for test
1.Remove the shipping nipple (from CGs supply tap- ping) 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 circulator hardware and pressure/temperature gauge carton. Install in boiler return connection as shown on page 3 and Figure 29, page 58. Install circulator on either the return or supply.
3.Remove 1¼” nipple, 1¼” x 1¼” x ½” tee and pres- sure/temperature gauge from circulator hardware and pressure/temperature gauge carton. Pipe to boiler supply connection as shown on page 3 and Figure 29, page 58. (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 re- turn 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.)
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 sup- ply 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 on the pressure/temperature gauge reaches no more than:
•45 psig for boilers with 30 psig relief valve.
•75 psig for boilers with 50 psig relief valve.
6.Test for no more than 10 minutes at:
•45 psig for boilers with 30 psig relief valve.
•75 psig for boilers with 50 psig relief valve.
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 main- tained 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
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 and valves unless they will remain for use in the system piping.
4.Remove plug from relief valve tapping. See page 14 to replace relief valve.
Part number
13
