Freestyle 2 Series - Page 8

Part number 550-142-950/0122
8
FreeStyle
®
series 2 wall mount gas-fired water boiler – boiler manual
Hydrostatic pressure test
DO NOT install a relief valve with a pressure
higher than 30 PSIG. This is the maximum
allowable relief valve setting for the boiler.
Failure to comply could prevent the relief
valve from operating as needed, resulting in
possibility of severe personal injury, death
or substantial property damage.
Use two wrenches when tightening any pipe
connection to the boiler
. Failure to prevent the
boiler pipes from turning could damage pipes or
heat exchanger, resulting in possible severe personal
injury, death or substantial property damage.
Pressure test the boiler before permanently attaching water or
gas piping or electrical supply.
Install pipe ttings for relief valve and
P/T gauge
1. Install the reducing tees, and close nipples, eld supplied,
located and oriented as shown in Figure5,page9. Apply pipe
dope to all ttings sparingly.
DO NOT install the relief valve until after the
hydrostatic test
. Temporarily install a ¾” pipe
plug in the relief valve location as directed in these
instructions. e plug must be removed aer the
test.
Connect the relief valve ONLY on the BOILER
SUPPLY OUTLET, NOT
the boiler return. Con-
nect the relief valve only as shown in this manual.
Ensure relief valve is located above heat exchanger.
Failure to comply with the above could prevent the
relief valve from operating as needed, resulting in
possibility of severe personal injury, death or sub-
stantial property damage.
2. Install the test pressure/temperature gauge (eld supplied)
to the reducing tee as shown in Figure6,page9.
Install ttings and valves required for
hydrostatic testing
(supplied by installer)
1. e following piping components (supplied by installer) are
required for the test conguration:
a. Two shut-o valves (1” NPT on FS-80/120, 1
-1/4”NPT
on FS-155).
b. Two close nipples (1”NPT on FS-80/120, 1
-1/4”NPT on
FS-155).
c. ¾” NPT pipe plug.
d. Pressure/temperature gauge.
e. ¾” NPT boiler drain valve.
2.
TEMPORARILY insert a ¾” NPT pipe plug in the relief valve
tapping. Aer the hydrostatic test, this plug must be removed
and the relief valve must be installed.
Fill and pressure test
1. See Figure5,page9, for use with the following instructions.
2. CLOSE the boiler drain valve (item 10). Connect a hose to
fresh water supply and to the drain valve.
3. Place a bucket under the ends of the isolation valves
(item 8 and 9) to catch water drippings.
4. CLOSE isolation valve item 9, then crack open the valve
slightly. Leave top isolation valve item 8 open.
5. Slowly open the boiler drain valve (item 10) and fresh water
supply to ll boiler with water. e boiler and piping will ll
quickly because of the low water content.
6. When water begins to ow from bottom isolation valve
(item 9), close the valve.
7. Continue lling until water ows from top isolation valve
(item 8), then close the valve.
8. When pressure on the pressure/temperature gauge (item
4) reaches at least 45 PSIG, but no higher than 55 PSIG,
CLOSE the boiler drain valve (item 10).
9. Hold at test pressure for 10 minutes.
Do not leave boiler unattended. A cold water ll
could expand and cause excessive pressure, result-
ing in severe personal injury, death or substantial
property damage.
10. 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. Gaskets and seals
in the system may be damaged. is can result in
substantial property damage.
Drain and remove ttings
1. Disconnect ll water hose from water source.
2. Drain boiler through drain valve (item 10).
Use caution when releasing pressure from the boiler.
Rapid water ow could cause injury.
3. Remove hose aer draining.
4. Remove nipples and valves unless they will remain for use
in the system piping.
5. Remove plug and install relief valve as specied in the fol-
lowing WARNING.
Remove plug from relief valve street elbow. Install
the relief valve in the ¾” street. See page42 to install
relief valve discharge piping. Failure to install the
boiler relief valve could result in severe personal
injury, death or substantial property damage.
3 Prepare boiler continued