Lochinvar Chronic Condensation / Leak-Induced Corrosion

Visible corrosion or rust streaks on or inside the boiler cabinet

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Condensate leaks, flue gas condensation on cold surfaces, piping leaks above boiler, improper venting

How to Fix / Troubleshooting

Safety first: Turn off power before removing panels. Wear gloves when handling rusty metal.

  • Identify moisture source: Look for active drips from piping, condensate lines, or vent joints. Repair or tighten as needed.
  • Check condensate routing: Ensure condensate drains away from sensitive components and that tubing is intact.
  • Dry affected areas: Wipe down and dry corroded areas. Light surface rust can be cleaned and treated with rust-inhibiting paint.

Professional help: If structural components or the heat exchanger show significant corrosion, a technician should assess safety and remaining life.

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Repair Difficulty

Medium 3/5

Required Part

Condensate Drain Assembly
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