Hydro Test Guide
FermZilla Tri-Conical 27L & 55L | Hydro Test Guide
Last updated
FermZilla Tri-Conical 27L & 55L | Hydro Test Guide
Last updated
This instruction sheet contains vital information that is related to safely performing a hydro test of a FermZilla tank which is past its Hydro Test date. It is vital that you read this instruction sheet from front to back before performing this test!
THIS IS FOR YOUR OWN SAFETY
Hydrotesting is a simple process that anyone can do at home with relatively basic tools and equipment.
If you have any doubts in the process or do not have time to do the hydrotest then once the tank has expired you should not continue to use the tank under pressure. Replacement new tanks can be purchased from KegLand Distributors
All FermZillas have a Date Stamp on the tank body as below
This date is the date after which the tank needs to be Hydro Tested before using under pressure.
NOTE: If you are not using the FermZilla under pressure then it does not require hydrotesting.
The Date Stamp on the FermZilla tank is 24 months after the manufacture date. This is a good guide as to when the tank requires hydro testing.
However, if the FermZilla has been correctly stored in the original, unopened carton then it is not required to Hydro Test until 24 months from the date of purchase.
The tank will remain in 'as new' condition when stored correctly in an unopened carton as it is not exposed to UV or chemicals etc.
Please make a note of the date of purchase of the FermZilla and ensure it is Hydro Tested 24 months from the date of purchase
Do not perform the Hydro Test with an empty tank
Fill the tank with water to the brim before testing.
The reason it is important to fill the tank with water when testing is because water is incompressible. This means in the event that the tank fails the test the resulting rupture will be safe. If the tank is filled with compressible gas such as CO2 then the failure will have significantly more stored energy and the resultant failure can be much more dangerous.
Thus it is important to completely fill the tank with water prior to testing
Assemble the FermZilla (if required). Fill the tank to the brim with water
Once the FermZilla is filled with water and the lid in place, slowly apply pressure to the tank. It is important to apply pressure in a controlled manner. There are two methods to apply pressure in a controlled manner
Ensure the Inline Regulator is set to 0psi - the yellow knob should be turned all the way anticlockwise. Connect the liquid disconnect to the liquid post of the FermZilla.
Connect the gas disconnect and gauge to the gas post of the FermZIlla
Slowly turn the yellow handle of the Inline Regulator until the pressure reaches 4 bar (60psi). Confirm this pressure on the gauge attached to the gas post of the FermZilla. Note: It is normal for the FermZilla tank to swell in size and stretch during the hydro test
Once 4 bar has been reached, stop increasing pressure. Leave everything connected for 1 minute. Remove the liquid disconnect (connecting the tank to mains pressure water). Inspect the FermZilla tank. If the tank has not failed then the FermZilla has been successfully passed the Hydro Test and does not need testing for a further 24 months
If there are any visible cracks or damage, or if the tank ruptures then the Hydro Test has failed and the tank will need to be replaced
Fill a Cornelius Keg and the FermZilla to be tested completely with water
Ensure the regulator is set to 0psi - the knob should be turned all the way anticlockwise
Slowly and in a controlled manner adjust the regulator until the pressure reaches 4 bar (60psi). Confirm this pressure on the gauge attached to the gas post of the FermZilla. Ensure that water is being transferred into the FermZilla, not gas. Note: It is normal for the FermZilla tank to swell in size and stretch during the hydro test
Once 4 bar has been reached, stop increasing pressure. Leave everything connected for 1 minute. Remove the liquid disconnect connect the keg to the FermZIlla. Inspect the FermZilla tank. If the tank has not failed then the FermZilla has been successfully passed the Hydro Test and does not need testing for a further 24 months
If there are any visible cracks or damage, or if the tank ruptures then the Hydro Test has failed and the tank will need to be replaced
Remove the red 2.5bar PRV from the FermZilla lid and replace with a . NOTE: Ensure this PRV is swapped back for the red 2.5bar PRV immediately the test is complete. DO not operate the FermZilla with the incorrect PRV installed
Connect mains pressure water to a length of 6.35mm EVABarrier with an inline regulator and liquid disconnect. You can use a KL13888 to connect to a 3/4" tap outlet, or a KL17756 to connect to a standard under sink outlet
Use a short length of KL42789 , a KL26918 and a KL24235 to make a mains connected water line with inline regulation and a liquid disconnect to attach to the liquid post on the FermZilla
Connect a KL11532 to a KL20756 . This will be used on the FermZilla to accurately measure the pressure in the tank
Connect the Cornelius Keg to a regulated gas source such as a KL01489 or KL01496 and and a KL07429
Ensure the line out from the regulator is terminated with a gas disconnect such as a KL20756
Daisy chain the Cornelius Keg from the Liquid (Out) Post of the keg to the Liquid Post of the FermZilla to be tested using a length of EVABarrier and 2 x Liquid Disconnects. A length of KL06224 and 2 x KL20749 is ideal for this
Connect a KL11532 to a KL20756 . This will be used on the FermZilla to accurately measure the pressure in the tank. Connect the gas disconnect and gauge to the gas post of the FermZIlla
