User Manual - Munchkin Boilers

1 UserManual1 GAS-FIRED BOILER user ManualTABLE OF CONTENTSP roduct and Safety Information .. 2,3 Service and MaintenanceMunchkin OperationPrimary WaterSection I Combustion Air Prevention of Contamination.. 4 Potential Contaminating ProductsAreas likely to find these ProductsSection II Maintenance Schedule .. 4,5 Service TechnicianOwner MaintenanceSection III Maintenance Procedures .. 5-7 Daily MaintenanceMonthly Maintenance6 Month MaintenanceSection IV Start-Up Procedure .. 8 Replacement Parts .. 9-122 GAS-FIRED BOILER user ManualPRODUCT AND SAFETY INFORMATIONDANGERDANGER indicates an imminently hazardoussituation which, if not avoided, will result indeath or serious indicates a potentially hazardoussituation which, if not avoided, could result indeath or serious Indicates a potentially hazardoussituation which, if not avoided, may result inminor or moderate used without the safety alert symbolindicates a potentially hazardous situation which,if not avoided, may result in property Transfer Products, Inc.

2 , reserves the right to make product changes or updates without noticeand will not be held liable for typographical errors in 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 not store or use gasoline or other flammable vapors andliquids in the vicinity of this or any other TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch: do not use any phone inyour building. Immediately call your gas supplier from a neighbor's the gas supplier's instructions. If you cannot reach your gas supplier, call the fire and service must be performed by a qualifiedinstaller, service agency or the gas 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 BOILER user ManualWARNINGUser Have this boiler serviced/inspected bya qualified service technician to adhere to the guidelines on this pagecan result in severe personal injury, death orsubstantial property TO DO IF YOU SMELL GAS Do not try to light any appliance.

3 Do not touch any electric switch; do not useany phone in your building. Immediately call your gas supplier from aneighbor's phone. Follow the gas suppliers'instructions. If you cannot reach your gas supplier, call thefire 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 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.

4 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 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 of oxygen carried in by make-upwater can cause internal corrosion in systemcomponents. Leaks in boiler or piping mustbe repaired at once to prevent PROTECTION FLUIDSCAUTIONNEVER use automotive or standard glycolantifreeze, even ethylene glycol made forhydronic systems. Use only inhibited propyleneglycol solutions, which are specificallyformulated for hydronic systems.

5 Ethyleneglycol is toxic and can attack gaskets and sealsused in hydronic BOILER user ManualSECTION I COMBUSTION AIR PREVENTION OF CONTAMINATIONAREAS LIKELY TO FIND THESE PRODUCTSWARNINGIf 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 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.

6 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 fluorocarbonsPermanent wave solutionsChlorinated waxes/cleanersChlorine-based swimming pool chemicalsCalcium chloride used for thawingSodium chloride used for water softeningRefrigerant leaksPaint or varnish removersHydrochloric acid/muriatic acidCements and gluesAntistatic fabric softeners used in clothes dryersChlorine-type bleaches, detergents, and cleaningsolvents found in household laundry roomsAdhesives used to fasten building products andother similar productsAreas likely to have contaminantsDry cleaning/laundry areas and establishmentsSwimming poolsMetal fabrication plantsBeauty shopsRefrigeration repair shopsPhoto processing plantsAuto body shopsPlastic manufacturing plantsFurniture refinishing areas and establishmentsNew building constructionRemodeling areasGarages and workshopsSECTION II MAINTENANCE SCHEDULESERVICE TECHNICIANOn an annual basis the following maintenanceshould be performed by a qualified service tech-nician:General Attend to any reported problems.

7 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 burner5 GAS-FIRED BOILER user ManualSECTION II MAINTENANCE SCHEDULE(CONT D)head using compressed air the maintenance items are completed,review the service with the MAINTENANCEP eriodically: Check the area around the unit.

8 Check and remove any blockage from thecombustion air inlet and ventilation openings. Check the temperature/pressure gaugeMonthly: Check vent piping. Check combustion air inlet piping. Check the pressure relief valve. Check the condensate drain 6 months: Check boiler piping and gas supply piping forcorrosion or potential signs of 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 III MAINTENANCE PROCEDURES1. Combustible / flammable materials - Do notstore combustible materials, gasoline orother flammable vapors or liquids near theunit. Remove immediately if Air contaminates - Products containingchlorine or fluorine, if allowed to contaminatethe combustion air, will cause acidiccondensate within the unit.

9 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 mustWARNINGThe 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 to service and maintain the Munchkinand the system components could result inequipment failure , causing possible severepersonal injury, death or substantial 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 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.

10 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 products cannot be removed, immediately calla qualified service technician to re-pipe thecombustion air inlet piping and locate thecombustion air intake away from thecontaminated MAINTENANCEC heck the surrounding area6 GAS-FIRED BOILER user ManualSECTION III MAINTENANCE PROCEDURES(CONT D)be removed immediately or the combustionair intake must be relocated to another 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 Temperature display and PressureGauge1.