A.O. Smith 405, 400, 402 Replacement Parts, Tubecleaningprocedure Mechanical Removal of Deposits

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all of the hardness (lime). For this reason it is recommended that a regular schedule for deliming be maintained.

The time between cleaning will vary from two to six months depending upon water conditions and usage. A change of approximately 5oF (3°C) in the normal temperature rise through the boiler is usually an indication that scale should be removed. For long life, copper or brass is recommended for all valves, pipe and fittings.

TUBECLEANINGPROCEDURE

MECHANICAL REMOVAL OF DEPOSITS

Establish a regular inspection schedule, the frequency depends on the local water conditions and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" (1.6 mm) thickness.

To service heat exchanger tubes, remove return header casting on the side opposite the water connections. Use a U.S. standard 5/8" deep socket ratchet to remove the nuts, exposing the tube ends. Inspect to ensure tubes are free of scale and deposits. If scaled, remove deposits with a stiff wire brush or mechanical tube cleaner to bare metal. Reinstall return header casting. Flush system.

Note: Removal of the heat exchanger is not required.

CAUTION

IF HEAT EXCHANGER MAINTENANCE REQUIRES TUBING REPLACEMENT, SPECIAL PROVISIONS SHALL BE TAKEN TO ENSURE THAT THE DAMAGED TUBES ARE CAREFULLY REMOVED.

REPLACEMENT TUBES MUST BE PROPERLY INSTALLED AND EXPANDED INTO THE ROLLED TUBE TUB.

OVER-ROLLING, MISALIGNMENT OF TUBES OR IMPROPER TIGHTENING OF THE ASSEMBLY MAY RESULT IN LEAKS OR DAMAGE TO THE HEAT EXCHANGER. CONTACT YOUR A. O. SMITH DEALER FOR DETAILED INSTRUCTIONS.

REPLACEMENT PARTS

Replacement parts may be ordered through A. O. Smith dealers, authorized servicers or distributors. Refer to the Yellow Pages for where to call or contact (in United States) the A. O. Smith

Water Products Company, 500 Tennessee Waltz Parkway, Ashland City, TN 37015, 1-800-433-2545 or (in Canada) A. O. Smith Enterprises Ltd., 768 Erie Street, Stratford, Ontario, Canada N5A 6T3, 519-271-5800. When ordering parts be sure to state the quantity, part number and description of the item including the complete model and serial number as it appears on the product. Refer to the parts lists (P/N 212513-000) for more information.

For Technical Assistance call A. O. Smith Technical Information Center at 1-800-527-1953.

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Contents Installation Operation Maintenance Limited Warranty Copper Boilers for Hydronic Heating HOT Water SupplyDimensional Data DIMENSIONS/CAPACITIES DataGAS and Electrical Requirement Dimensions Data for Outdoor Configuration Recovery Capacities ForewordFEATURES/CONTROLS Water Flow Switch Differential Pressure Switch Combustion AIR BlowerBlocked Flue Pressure Switch ON/OFF SwitchRequired Ability Installation InstructionsSafety Relief Valves LocationLevelling Installation ClearancesChemical Vapor Corrosion AIR RequirementsVenting Horizontal Vent Installation INTAKE/EXHAUST Installation Requirements System InstallationInstallation AS Boiler Replacement GeneralEquivalent Standard Vent Vertical CategoryType B or 16 40.6 cmSteel Standard Vent Horizontal CategoryIII Stainless IIIDirect Vent Vertical Exhaust Configurations Direct Vent Vertical CategoryStainless GAL. Steel Sealed Direct Vent Horizontal Exhaust ConfigurationsDirect Vent Horizontal Category Stainless GAL.STEELHydronic Installation Internal Contaminants Space Heating ApplicationsVAC System Controller Optional Hard Water Conditions Tank Probe Installation ProcedureGAS Connections Water Line Connections Tank Probe OptionalSingle boiler with horizontal tank Single boiler with vertical tank Suggested Pipe Size For Multiple Gas Appliances Propane Gas Distance from Meter BTU Input Single Unit INSTALLATION, Suggested Pipe SizeWiring Connections BTU/HRGAS Manifold Assembly Genesis GB/GW 1000-2500 Series 400 Wiring Diagram Page Genesis GB/GW 1000-2500 Series 400 Schematic Diagram Page CCB Central Control Board FCB Flame Control Board Diagram PDB Power Distribution Board Diagram Purging of GAS Line OperationFilling and Purging Water System Inlet GAS PressureFor Your Safety Read Before Operating For Your Safety Read Before Operating Setting Degree Burns on Adult Skin AdjustmentsRisk of Scalds Temperature Control SystemWater Level Sensor open condition indicates fault Air Pressure Sensors open condition indicates faultGas Pressure Sensors open condition indicates fault CCB/FCB Indicator Lamps & FusesCCB Ten Position Dipswitch Central Control Section SW1 CCB-SW2FCB Eight-Position Dipswitch Operating SequenceStages 1 and 2 will turn on in sequence from 1 to Temperature Setpoints System Control AlgorithmUIM Operating Procedures UIM ScreensMenu Screen Temperature ScreenStatus Displayed True Condition Input System Status ScreenDescription of FCB control states High Limit Differential Setpoint Adjustment Procedure Operating Setpoint Adjustment ProcedureOperating Differentialsetpoint Adjustment Procedure Fault Displayed Description Redled Lockout Hard Main Burners Tank Probe Tank Remote probe shorted or open FlashingDeliming Replacement Parts Tubecleaningprocedure Mechanical Removal of DepositsNEW Boiler Limited Warranty Conditions and ExceptionsTennessee Waltz Parkway, Ashland City, TN Phone