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5773 597 - 04
Vitocrossal 200, CM2 400, 500 and 620 Installation
Boiler
Hydrostatic Test Procedure
All Vitocrossal boilers are factory tested (hydrostatic
testing) to ASME requirements. The following testing
procedure is to ensure that the boiler remained intact
during shipping and handling.
1. Isolate boiler from hydronic heating system using
isolating valves (i.e. expansion tank, feed water valve,
pressure relief valve etc.).
2. Remove 75 psig pressure relief valve from the boiler
and cap pipe outlet.
3. Fill boiler with city water and pressurize it to one and
a half (1½) times the maximum working pressure of
boiler. The pressure must be controlled such that it
will never be 10 psig higher than the testing pressure.
Max. allowable working pressure:
75 psig
Testing pressure:
112 psig (do not exceed 122 psig)
4. Monitor pressure over a period of approximately one
hour to ensure that the pressure remains constant and
steady at 112 psig.
5. Should there be a drop in pressure, ensure that all fittings
are secure and tight. Check all flanged connections
with a flashlight.
6. Flue gas collector shall be removed for boiler inspection
should the test water show up in the condensate drain.
7. Open the boiler combustion chamber door and inspect
with a flashlight the front portion of the Inox-Crossal®
heat exchanger sections for system water or fluid.
8. If test is successful, reinstall all hydronic system
components and refill the boiler with water or system
fluid.
WARNING
Never expose the boiler to any pressures higher than
122 psig during testing.
Legend
A
Boiler supply
B
Pressure gauge
C
Pressure relief valve
D
Boiler return
E
Drain valve
F
Precharged expansion tank
G
Automatic fill
H
Condensing water drain
