A.O. Smith 1700, 3400 Condensate Removal System, Venting Maintenance, Heat Exchanger Maintenance

CONDENSATE REMOVAL SYSTEM

Due to the highly efficient operation of this unit, condensate is formed during operation and must be removed by the condensate­ drain systems. Inspect the condensate drains and tubes at least once a month and insure they will allow the free flow of condensate at all times. The system must be inspected more frequently in cold weather if the drain system is located in an area, such as along the floor, where freezing tempera­tures are likely to occur. The condensate­ drain system must be protected against freezing. Contact a qualified service agent to inspect and correct the condition if freezing of the condensate­ lines is a problem.

The transparent drain lines and condensate drain on the bottom of the vent collector should be visually inspected at one month intervals for blockage, particularly in the areas of the loops in the lines which trap a small amount of conden­sate, and the exit point of the vent collector drain. Condensate­ in portions of the line other than the loop area indicates a blockage in the drain line. Flush the lines with air or water and clear or replace the blocked portions of the line as necessary. Note that areas of the drain line which include a sag or low spot in the line will also form a condensate trap which can be removed by levelling the tube and does not indicate a blocked system.

Inspect the metal vent drain and vent collector drain connectors at six month inter­vals. Remove the hoses from the connections, then check with a small wooden dowel or plastic rod passed up through the metal connection­ to insure the passage is clear, using caution to not bend or damage the connector. Call a qualified service agent to inspect and correct the problem if any obstructions are found in the connectors. Replace all hoses and clamps immediately after inspec­tion and before starting the boiler in accordance with the Lighting and Operating Instructions. Do not operate the boiler unless all condensate drain lines are properly connected and working. When a means to neutralize condensate has been installed you must also follow operating, inspection and maintenance procedures specified by the manufacturer of the product. Inspect the installed device to insure that it does not cause condensate to remain in the boiler or vent for any reason.

VENTING MAINTENANCE

It is recommended that the intake and exhaust piping of the boiler be checked every 6 months for dust, condensate leakage, deterioration and carbon deposits.

Qualified service agent should follow this procedure when the boiler’s intake and exhaust piping need cleaning:

1.Turn off the electrical power, and manual gas shut-off.

•Allow boiler parts to cool before disassembly.

2.Remove the vent pipe.

•Check parts and chimney for obstructions and clean as necessary.

3.Remove burner from boiler and other metal parts as required to clean as necessary.

•Refer to parts list for disassembly aid.

4.Clean and reinstall the parts removed in steps 2 and 3.

•Be sure the vent pipe has a minimum upward pitch of 1/4" per foot (2 cm/m) of length and is sealed as necessary.

5.Restore electrical power and gas supply to boiler.

•Check for gas leaks and proper boiler and vent operation.

HEAT EXCHANGER MAINTENANCE

1.Shut down the boiler:

•Turn Off gas to the boiler.

•Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2.Ensure the boiler cools down to room temperature.

3.Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside.

4.Remove the heat exchanger access cover, burner, and gas train assembly.

Note: The boiler contains ceramic fiber materials. Failure to comply could result in severe personal injury.

5.Remove the condensate hose from the heat exchanger end. Connect a field supplied 3/4" diameter hose to a drain pan.

6.Use a vacuum cleaner to remove any deposits/ debris on the boiler heating surfaces. Do not use any solvent.

7.Brush the heat exchanger while dry using a nylon bristle brush. Re-vacuum the heat exchanger.

8.Finish cleaning using a clean cloth dampened with warm water. Rinse out debris with a low pressure water supply.

9.Allow the heat exchanger to dry completely.

10.Remove the rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble.

11.Close isolation valves on piping to isolate the boiler from system. Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make-up line to the boiler.

12.Replace the access cover and restore the boiler for operation.

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