48
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 Figures in Appendix D. 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.
i
If make-up water line is equipped
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.
4.
At completion of any leak test, open the
hose bib until pressure is reduced to 12 PSI
(cold).
