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must be approved for
use with stainless steel
and FDA approved for
use in a potable water
system.
3. Thoroughly flush the
heat exchanger before
commissioning the unit
back in service.
D. Maintaining the
Condensate System
1. Ensure the boiler is
powered off and has had
time to cool.
2. Remove the hose
clamp
attaching
the
condensate trap to the
condensate hose from
the
heat
exchanger.
Remove the clear plastic
hose from the hose barb. Remove the condensate hose clamp
to detach the condensate trap from the drain tube. Remove
the condensate trap from the boiler.
3. Remove the bottom cap from the condensate trap.
The condensate trap assembly MUST BE PROPERLY
INSTALLED according to these instructions when operating
the boiler. Operating the boiler without the condensate trap
assembly will cause flue gases to leak and result in serious
personal injury or death.
When servicing is complete, make sure the condensate
collector cap is replaced securely. Failure to do so will cause
venting issues that will result in serious injury or death.
4. Flush trap with fresh water to remove debris from the trap.
NOTE: Ensure the float moves freely within the trap. If the
float does not move, DO NOT reinstall the trap.
5. When the condensate trap is sufficiently clean, reinstall the
bottom cap on the trap.
NOTE: Ensure all parts shown in Figure 29, Condensate Detail,
are installed with the condensate trap. If any parts are missing,
DO NOT reinstall the trap. Replace the entire assembly.
Do not install the condensate assembly if a component is lost
or missing. Replace the entire assembly. Failure to follow this
warning could result in property damage, serious personal
injury, or death.
6. Fill the condensate trap with fresh water prior to reassembly
on the boiler.
7. Install the condensate trap on the condensate hose from
the heat exchanger. Use the hose clamp to secure the trap.
Attach the clear plastic hose onto the hose barb. Reinstall the
condensate hose clamp to detach the condensate trap from
the drain tube.
8. If a condensate neutralizer kit is installed with the boiler,
check the assembly when cleaning the condensate trap, and
replenish the limestone chips if necessary. When replacing
limestone chips, take care to ensure chips are no smaller than
½" to avoid blockage in condensate piping (for piping details,
Figure 29 - Condensate Detail
refer to condensate neutralizer installation instruction.)
9. Check condensate piping for sagging and/or leakage. Repair
any sags or leaks before restoring power to the boiler.
Do not operate the boiler without the clear hose attached
from the hose barb to the pressure switch. Failure to follow
this warning could result in property damage, serious personal
injury, or death.
It is very important that the condensate piping be no smaller
than ¾". To prevent sagging and maintain pitch, condensate
piping should be supported with pipe supports, and pitched
¼" per foot to allow for proper drainage. Failure to maintain
proper pipe size and pitch could result in condensate leakage
and potential water damage to property.
The condensate line must remain unobstructed, allowing free
flow of condensate. If condensate freezes in the line, or if line is
obstructed in any other manner, condensate can exit from the
tee, resulting in potential water damage to property.
10. If the boiler has a condensate pump, ensure the pump
operates properly before considering maintenance complete.
61
WHL-052 Rev. 4.28.16
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