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GAS-FIRED BOILER User Manual

WARNING If the information in this manual is not followed exactly, a fire or explo-sion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors andliquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electrical switch: do not use any phone in

your building.• Immediately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions.• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualifiedinstaller, service agency or the gas supplier.

TABLE OF CONTENTSProduct and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3

Service and MaintenanceMunchkin OperationPrimary Water

Section I – Combustion Air – Prevention of Contamination. . . . . . . . . . . . . . . . . . . . . . . . 4Potential Contaminating ProductsAreas likely to find these Products

Section II – Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5Service TechnicianOwner Maintenance

Section III – Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Daily MaintenanceMonthly Maintenance6 Month Maintenance

Section IV – Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

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GAS-FIRED BOILER User Manual

PRODUCT AND SAFETY INFORMATION

DANGERDANGER indicates an imminently hazardoussituation which, if not avoided, will result indeath or serious injury.

WARNINGWARNING indicates a potentially hazardoussituation which, if not avoided, could result indeath or serious injury.

CAUTIONCAUTION Indicates a potentially hazardoussituation which, if not avoided, may result inminor or moderate injury.

CAUTIONCAUTION used without the safety alert symbolindicates a potentially hazardous situation which,if not avoided, may result in property damage.

DEFINITIONS

NOTICE

Heat Transfer Products, Inc., reserves the right to make product changes or updates without noticeand will not be held liable for typographical errors in literature.

SPECIAL ATTENTION BOXESThe following defined terms are used throughout this manual to bring attention to the presence ofhazards of various risk levels or to important information concerning the product.

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GAS-FIRED BOILER User Manual

WARNINGUser — Have this boiler serviced/inspected bya qualified service technician annually.

WARNINGFailure to adhere to the guidelines on this pagecan result in severe personal injury, death orsubstantial property damage.

WARNINGWHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electric switch; do not use

any phone in your building.• Immediately call your gas supplier from a

neighbor's phone. Follow the gas suppliers'instructions.

• If you cannot reach your gas supplier, call thefire department.

BOILER OPERATION

• Do not block flow of combustion orventilation air to boiler.

• Should overheating occur or gas supply failto shut off, do not turn off or disconnectelectrical supply to circulator. Instead, shut offthe gas supply at a location external to theappliance.

• Do not use this boiler if any part has beenunder water. Immediately call a qualifiedservice technician to inspect the boiler and toreplace any part of the control system andany gas control that has been under water.

PRODUCT AND SAFETY INFORMATION (CONT’D)

PRIMARY WATER

• If you have an old system with cast ironradiators, thoroughly flush the system(without boiler connected) to removesediment. The high-efficiency heat exchangercan be damaged by build-up or corrosiondue to sediment.

• Do not use petroleum-based cleaning orsealing compounds in boiler system. Gasketsand seals in the system may be damaged.This can result in substantial propertydamage.

• Do not use “homemade cures” or “boilerpatent medicines.” Substantial propertydamage, damage to boiler, and/or seriouspersonal injury may result.

• Continual fresh make-up water will reduceboiler life. Mineral buildup in heat exchangerreduces heat transfer, overheats the stainlesssteel heat exchanger, and causes failure.Addition of oxygen carried in by make-upwater can cause internal corrosion in systemcomponents. Leaks in boiler or piping mustbe repaired at once to prevent make-upwater.

FREEZE PROTECTION FLUIDS

CAUTIONNEVER use automotive or standard glycolantifreeze, even ethylene glycol made forhydronic systems. Use only inhibited propyleneglycol solutions, which are specificallyformulated for hydronic systems. Ethyleneglycol is toxic and can attack gaskets and sealsused in hydronic systems.

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GAS-FIRED BOILER User Manual

SECTION I – COMBUSTION AIR – PREVENTION OF CONTAMINATIONAREAS LIKELY TO FIND THESE PRODUCTSWARNING

If the Munchkin combustion air inlet is locatedin any area likely to cause or containcontamination, or if products, which wouldcontaminate the air cannot be removed, thecombustion air must be re-piped andterminated to another location. Contaminatedcombustion air will damage the unit and itsburner system, resulting in possible severepersonal injury, death or substantial propertydamage.

WARNINGDo not operate a Munchkin unit if itscombustion air inlet or the unit is located in ornear a laundry room or pool facility. These areaswill always contain hazardous contaminates. Pool and laundry products and commonhousehold and hobby products often containfluorine or chlorine compounds. When thesechemicals pass through the burner and ventsystem, they can form strong acids. These acidscan create corrosion of the heat exchanger,burner components and vent system, causingserious damage and presenting a possiblethreat of flue gas spillage or water leakage intothe surrounding area.

Products to avoidSpray cans containing fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryersChlorine-type bleaches, detergents, and cleaningsolvents found in household laundry roomsAdhesives used to fasten building products andother similar products

Areas likely to have contaminantsDry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages and workshops

SECTION II – MAINTENANCE SCHEDULESERVICE TECHNICIAN

On an annual basis the following maintenanceshould be performed by a qualified service tech-nician:

General• Attend to any reported problems.

• Inspect the interior of the boiler jacket area;clean and vacuum if necessary.

• Clean the condensate trap and fill with freshwater.

• Check for leaks: water, gas, flue andcondensate.

• Verify flue vent piping and air inlet piping arein good condition and sealed tight.

• Check boiler water pressure, piping andexpansion tank.

• Check control settings.

• Check ignition electrode (use Scotch Brite Padand sand off any white oxide; clean andreposition).

• Check ignition wiring and ground wiring.

• Check all control wiring and connections.

• Check burner flame pattern (stable anduniform) and flame.

Additional items if combustion orperformance is poor:• Clean heat exchanger and flue ways.

• Remove burner assembly and clean burner

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GAS-FIRED BOILER User Manual

SECTION II – MAINTENANCE SCHEDULE (CONT’D)

head using compressed air only.

Once the maintenance items are completed,review the service with the owner.

OWNER MAINTENANCE

Periodically:• Check the area around the unit.

• Check and remove any blockage from thecombustion air inlet and ventilation openings.

• Check the temperature/pressure gauge

Monthly:• Check vent piping.

• Check combustion air inlet piping.

• Check the pressure relief valve.

• Check the condensate drain system.

Every 6 months:• Check boiler piping and gas supply piping for

corrosion or potential signs of leakage.

WARNINGFollow the maintenance procedures giventhroughout this manual. Failure to perform theservice and maintenance or follow thedirections in this manual could result in damageto the Munchkin or in system components,resulting in severe personal injury, death orsubstantial property damage.

SECTION III – MAINTENANCE PROCEDURES

1. Combustible / flammable materials - Do notstore combustible materials, gasoline orother flammable vapors or liquids near theunit. Remove immediately if found.

2. Air contaminates - Products containingchlorine or fluorine, if allowed to contaminatethe combustion air, will cause acidiccondensate within the unit. This will causesignificant damage to the unit. Read the list ofpotential materials listed in Section I of thismanual. If any of these products are in theroom where the boiler is located, they must

WARNINGThe Munchkin must be inspected and servicedannually, preferably at the start of the heatingseason, by a qualified service technician. Inaddition, the maintenance and care of the boileras outlined on page 3 and further explained onpages 4 through 6 must be performed to assuremaximum efficiency and reliability of the unit.Failure to service and maintain the Munchkinand the system components could result inequipment failure, causing possible severepersonal injury, death or substantial propertydamage.

NOTICEThe following information provides detailedinstruction for completing the maintenanceitems outlined in the maintenance schedule inSection II. In addition to this maintenance, theMunchkin should be serviced at the beginningof the heating season by a qualified servicetechnician.

WARNINGTo prevent potential of severe personal injury,death or substantial property damage, eliminateall the materials listed in Section I from the areasurrounding the unit and from the vicinity of thecombustion air inlet. If contaminates are found: Remove products immediately from the area. Ifthey have been there for an extended period,call a qualified service technician to inspect theunit for possible damage from acid corrosion.If products cannot be removed, immediately calla qualified service technician to re-pipe thecombustion air inlet piping and locate thecombustion air intake away from thecontaminated areas.

DAILY MAINTENANCE

Check the surrounding area

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GAS-FIRED BOILER User Manual

SECTION III – MAINTENANCE PROCEDURES (CONT’D)

be removed immediately or the combustionair intake must be relocated to another area.

Check Combustion Air InletsVerify that the unit’s vent termination andcombustion air intake are clean and free ofobstructions. Remove any debris on the airintake or flue exhaust openings. If removingthe debris does not allow the unit to operatecorrectly, contact your qualified servicetechnician to inspect the unit and the vent /combustion air system.

Check Temperature display and PressureGauge1. Ensure the pressure reading on the pressure

gauge does not exceed 25 psig. Higherpressure readings may indicate a problemwith the expansion tank.

2. Ensure the temperature on the LED displaypanel does not exceed 180ºF. Highertemperature readings may indicate aproblem with the operating thermostatcontrols.

3. Contact a qualified service technician ifproblem persists.

MONTHLY MAINTENANCE

Check Vent Piping1. Visually inspect the flue gas vent piping for

any s igns of b lockage, leakage ordeterioration of the piping. Notify a qualifiedservice technician immediately if anyproblems are found.

Check Intake Air Vent Piping1. Visually inspect the intake air vent piping for

any signs of blockage. Inspect the entirelength of the intake air vent piping to ensurepiping is intact and all joints are properlysealed.

2. Notify a qualified service technician if anyproblems are found.

Check Pressure Relief Valve1. Visually inspect the primary pressure relief

valve and the relief valve discharge pipe forsigns of weeping or leakage.

2. If the pressure relief valve often weeps, theexpansion tank may not be operatingproperly. Immediately contact a qualifiedservice technician to inspect the unit andsystem.

Check Vent Condensate Drain System1. While the unit is running, check the discharge

end of the condensate drain tubing. Ensureno flue gas is leaking from the condensatedrain tubing or tee connection by holdingyour fingers near the opening.

2. If you notice flue gas leaking from theopening, this indicates a dry condensatedrain trap. Fill the condensate trap assembly.Contact a qualified service technician toinspect the unit and condensate line and refillthe condensate trap if problem persistsregularly.

3. The Service Technician must ensure thecondensate drain line is not blocked bypouring water through the plug T fitting onthe condensate drain assembly. The watershould flow out of the end of the drain line. Ifwater does not appear at the end of the drainline, the qualified service technician mustclean the condensate line.

4. To fill the condensate drain assembly. Slowlypour water into the T fitting on the assemblyuntil water appears at the end of the drainline.WARNING

Failure to inspect the venting system as notedand have it repaired by a qualified servicetechnician can result in the vent system failure,causing severe personal injury or death.

WARNINGYou must make sure the condensate hose issecurely fastened before restarting boiler. Do afinal check to assure proper flow.

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GAS-FIRED BOILER User Manual

valve does not weep after the line has hadtime to drain. If the valve weeps, lift the leveragain to attempt to clean the valve seat. If thevalve does not properly seat and continues toweep afterwards, contact a qualified servicetechnician to inspect the valve and system.

4. If the water does not flow from the valvewhen you lift the lever completely, the valveor discharge l ine may be blocked.Immediately shut the unit down perinstructions on page 8 and call a qualifiedservice technician to inspect the valve andsystem.

6-MONTH MAINTENANCE

Check primary and gas piping1. Remove the boiler cover and perform a gas

leak inspection fol lowing OperatingInstructions in Section IV. If gas odor or leakis detected, immediately shut down the unitfollowing procedures on page 8. Call aqualified service technician.

2. Visually inspect for leaks around the internalboiler water connections and around the heatexchanger. Visually inspect the externalsystem piping, circulators, and systemcomponents and fittings. Immediately call aqualified service technician to repair anyleaks.

Operate Pressure Relief Valve1. Before proceeding, verify that the relief valve

outlet has been piped to a safe place ofdischarge, avoiding any possibility ofscalding from hot water.

2. Read the temperature and pressure gauge toensure the system is pressurized. Min. is 10PSI and Max is 25 PSI. Lift the relief valve toplever slightly, allowing water to relievethrough the valve and discharge piping.

3. If water flows freely, release the lever andallow the valve to seat. Watch the end of therelief valve discharge pipe to ensure that the

SECTION III – MAINTENANCE PROCEDURES (CONT’D)

WARNINGHave leaks fixed at once by a qualified servicetechnician. Failure to comply could result insevere personal injury, death or substantialproperty damage.

WARNINGTo avoid water damage or scalding due to valveoperation, a discharge line must be connectedto the relief valve outlet and directed to a safeplace of disposal. This discharge line must beinstalled by a qualified service technician orheating/plumbing installer in accordance withthe Munchkin installation manual. Thedischarge line must be terminated so as toeliminate possibility of severe burns or propertydamage should the valve discharges.

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GAS-FIRED BOILER User Manual

SECTION IV – OPERATIONS INSTRUCTIONS