User Manual (2)
Contents
1. w STAINLESS ST Gas fired Hot Water Boiler User Manual Heat Exchanger Bears the ASME Stamp MUNCHKIN GAS FIRED BOILER User Manual TABLE OF CONTENTS Product and Safety Information 2 3 Service and Maintenance Munchkin Operation Primary Water Section Combustion Air Prevention of Contamination 4 Potential Contaminating Products Areas likely to find these Products Section II Maintenance Schedule 4 5 Service Technician Owner Maintenance Section lll Maintenance Procedures 5 7 Daily Maintenance Monthly Maintenance 6 Month Maintenance Section IV Start Up Procedure 8 Heplacement Parts criar AR ANA ee sees ed 9 12 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 and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire departm2. General e Attend to any reported problems e Inspect the interior of the boiler jacket area clean and vacuum if necessary e Clean the condensate trap and fill with fresh water e Check for leaks water gas flue and condensate e Verify flue vent piping and air inlet piping are in good condition and sealed tight e Check boiler water pressure piping and expansion tank e Check control settings e Check ignition electrode use Scotch Brite Pad and sand off any white oxide clean and reposition e Check ignition wiring and ground wiring e Check all control wiring and connections e Check burner flame pattern stable and uniform and flame Additional items if combustion or performance is poor e Clean heat exchanger and flue ways e Remove burner assembly and clean burner 4 MUNCHKIN GAS FIRED BOILER SECTION II MAINTENANCE SCHEDULE cour head using compressed air only User Manual Check the pressure relief valve Once the maintenance items are completed review the service with the owner Check the condensate drain system Every 6 months OWNER MAINTENANCE Periodically Check boiler piping and gas supply piping for corrosion or potential signs of leakage e Check the area around the unit A WARNING Follow the maintenance procedures given throughout this manual Failure to perform the service and maintenance or follow the directions in this manual could result in dama
3. WHAT 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 the fire department BOILER OPERATION Do not block flow of combustion or ventilation air to boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water User Manual PRIMARY WATER If you have an old system with cast iron radiators thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Do not use petroleum based cleaning or sealing compounds in boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage Do not use homemade cures or boiler patent medicines Substantial property damage damage to boiler and or serious personal injury may result Continual fresh make up water will reduce boiler life Mineral buil
4. is detected immediately shut down the unit following procedures on page 8 Call a qualified service technician Visually inspect for leaks around the internal boiler water connections and around the heat exchanger Visually inspect the external system piping circulators and system components and fittings Immediately call a qualified service technician to repair any leaks WARNING Have leaks fixed at once by a qualified service technician Failure to comply could result in severe personal injury death or substantial property damage Operate Pressure Relief Valve 1 Before proceeding verify that the relief valve outlet has been piped to a safe place of discharge avoiding any possibility of scalding from hot water WARNING To avoid water damage or scalding due to valve operation a discharge line must be connected to the relief valve outlet and directed to a safe place of disposal This discharge line must be installed by a qualified service technician or heating plumbing installer in accordance with the Munchkin installation manual The discharge line must be terminated so as to eliminate possibility of severe burns or property damage should the valve discharges 2 Read the temperature and pressure gauge to ensure the system is pressurized Min is 10 PSI and Max is 25 PSI Lift the relief valve top lever slightly allowing water to relieve through the valve and discharge piping If water flows freely
5. and will settle on Force or attempted repair may result in a fire or the floor explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under water Immediately call a qualified service technician e Do not try to light any appliance to inspect the appliance and to replace any part of the control system and any gas control which has been Do not touch any electric switch under water do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions OPERATING INSTRUCTIONS ME STOP Read the safety information above 5 Remove front cover Set the thermostat to lowest setting 6 Turn gas shutoff valve to off Handle will be across the piping do not force Turn off all electric power to the appliance Wait five 5 minutes to clear out any gas If you then This appliance is equipped with an ignition device smell gas STOP Follow B in the safety which automatically lights the burner Do not try to information above on this label If you don t smell light the burner by hand gas go to next step Turn gas shutoff valve to on Handle will be GAS VALVE GAS VALVE in line with piping ON OFF Install Front Cover Turn on all electric power to appliance an ay Set thermostat to desired setting SZ If the appliance will no
6. release the lever and allow the valve to seat Watch the end of the relief valve discharge pipe to ensure that the User Manual valve does not weep after the line has had time to drain If the valve weeps lift the lever again to attempt to clean the valve seat If the valve does not properly seat and continues to weep afterwards contact a qualified service technician to inspect the valve and system If the water does not flow from the valve when you lift the lever completely the valve or discharge line may be blocked Immediately shut the unit down per instructions on page 8 and call a qualified service technician to inspect the valve and system MUNCHK N GAS FIRED BOILER User Manual SECTION IV OPERATIONS INSTRUCTIONS MO FOR YOUR SAFETY READ BEFORE OPERATING DE WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped e If you cannot reach your gas supplier call the fire with an ignition device which automatically lights the department burner Do not try to light the burner by hand Use only your hand to turn the gas control knob BEFORE OPERATING smell all around the appliance Never use tools If the handle will not turn by hand area for gas Be sure to smell next to the floor don t try to repair it call a qualified service technician because some gas is heavier than air
7. ass through the burner and vent system they can form strong acids These acids can create corrosion of the heat exchanger burner components and vent system causing serious damage and presenting a possible threat of flue gas spillage or water leakage into the surrounding area AREAS LIKELY TO FIND THESE PRODUCTS Products to avoid Spray 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 dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry 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 SCHEDULE SERVICE TECHNICIAN On an annual basis the following maintenance should be performed by a qualified service tech nician
8. dup in heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by make up water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent make up water FREEZE PROTECTION FLUIDS A CAUTION NEVER use automotive or standard glycol antifreeze even ethylene glycol made for hydronic systems Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems MUNCHK N GAS FIRED BOILER User Manual SECTION COMBUSTION AIR PREVENTION OF CONTAMINATION A WARNING If the Munchkin combustion air inlet is located in any area likely to cause or contain contamination or if products which would contaminate the air cannot be removed the combustion air must be re piped and terminated to another location Contaminated combustion air will damage the unit and its burner system resulting in possible severe personal injury death or substantial property damage A WARNING Do not operate a Munchkin unit if its combustion air inlet or the unit is located in or near a laundry room or pool facility These areas will always contain hazardous contaminates Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds When these chemicals p
9. ent Installation and service must be performed by a qualified installer service agency or the gas supplier MUNCHK N GAS FIRED BOILER PRODUCT AND SAFETY INFORMATION SPECIAL ATTENTION BOXES User Manual The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the product DEFINITIONS DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury NOTICE A CAUTION CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage Heat Transfer Products Inc reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature MUNCHKIN GAS FIRED BOILER PRODUCT AND SAFETY INFORMATION conro A WARNING User Have this boiler serviced inspected by a qualified service technician annually A WARNING Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage A WARNING
10. ge to the Munchkin or in system components resulting in severe personal injury death or substantial property damage e Check and remove any blockage from the combustion air inlet and ventilation openings e Check the temperature pressure gauge Monthly e Check vent piping e Check combustion air inlet piping SECTION 111 MAINTENANCE PROCEDURES A WARNING The Munchkin must be inspected and serviced annually preferably at the start of the heating season by a qualified service technician In addition the maintenance and care of the boiler as outlined on page 3 and further explained on pages 4 through 6 must be performed to assure maximum efficiency and reliability of the unit Failure to service and maintain the Munchkin and the system components could result in equipment failure causing possible severe personal injury death or substantial property damage A WARNING To prevent potential of severe personal injury death or substantial property damage eliminate all the materials listed in Section from the area surrounding the unit and from the vicinity of the combustion air inlet If contaminates are found Remove products immediately from the area If they have been there for an extended period call a qualified service technician to inspect the unit for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to re pipe the combustion air inlet piping and l
11. ocate the combustion air intake away from the contaminated areas NOTICE The following information provides detailed 1 Combustible flammable materials i Do not instruction for completing the maintenance are Combustible materials gasoline ses A other flammable vapors or liquids near the items outlined in the maintenance schedule in unit Remove immediately if found Section Il In addition to this maintenance the Munchkin should be serviced at the beginning 2 Air contaminates Products containing of the heating season by a gualified service technician DAILY MAINTENANCE Check the surrounding area chlorine or fluorine if allowed to contaminate the combustion air will cause acidic condensate within the unit This will cause significant damage to the unit Read the list of potential materials listed in Section of this manual If any of these products are in the room where the boiler is located they must MUNCHKIN GAS FIRED BOILER be removed immediately or the combustion air intake must be relocated to another area Check Combustion Air Inlets Verify that the unit s vent termination and combustion air intake are clean and free of obstructions Remove any debris on the air intake or flue exhaust openings If removing the debris does not allow the unit to operate correctly contact your qualified service technician to inspect the unit and the vent combustion air system Check Temperature display and Press
12. t operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier nn TO TURN OFF GAS TO APPLIANCE MERE Set the thermostat to lowest setting 4 Turn gas shutoff valve to off Handle will be Turn off all electric power to the appliance if service is across the piping Do not force to be performed mov ReontiCover 5 Install Front Cover LP 175 Rev 4 3 11 08 O 2008 Heat Transfer Products Inc www HTproducts com LP 182 Rev 9 9 14
13. ualified service technician to inspect the unit and system Check Vent Condensate Drain System 1 While the unit is running check the discharge end of the condensate drain tubing Ensure no flue gas is leaking from the condensate drain tubing or tee connection by holding your fingers near the opening If you notice flue gas leaking from the opening this indicates a dry condensate drain trap Fill the condensate trap assembly Contact a qualified service technician to inspect the unit and condensate line and refill the condensate trap if problem persists regularly The Service Technician must ensure the condensate drain line is not blocked by pouring water through the plug T fitting on the condensate drain assembly The water should flow out of the end of the drain line If water does not appear at the end of the drain line the qualified service technician must clean the condensate line To fill the condensate drain assembly Slowly pour water into the T fitting on the assembly until water appears at the end of the drain line A WARNING You must make sure the condensate hose is securely fastened before restarting boiler Do a final check to assure proper flow MUNCHK N GAS FIRED BOILER SECTION 111 MAINTENANCE PROCEDURES conro 6 MONTH MAINTENANCE Check primary and gas piping 1 Remove the boiler cover and perform a gas leak inspection following Operating Instructions in Section IV If gas odor or leak
14. ure Gauge 1 Ensure the pressure reading on the pressure gauge does not exceed 25 psig Higher pressure readings may indicate a problem with the expansion tank Ensure the temperature on the LED display panel does not exceed 180 F Higher temperature readings may indicate a problem with the operating thermostat controls Contact a qualified service technician if problem persists MONTHLY MAINTENANCE Check Vent Piping 1 Visually inspect the flue gas vent piping for any signs of blockage leakage or deterioration of the piping Notify a qualified service technician immediately if any problems are found A WARNING Failure to inspect the venting system as noted and have it repaired by a qualified service technician can result in the vent system failure causing severe personal injury or death Check Intake Air Vent Piping 1 Visually inspect the intake air vent piping for any signs of blockage Inspect the entire length of the intake air vent piping to ensure piping is intact and all joints are properly sealed 2 Notify a qualified service technician if any problems are found User Manual SECTION III MAINTENANCE PROCEDURES conto Check Pressure Relief Valve 1 Visually inspect the primary pressure relief valve and the relief valve discharge pipe for signs of weeping or leakage If the pressure relief valve often weeps the expansion tank may not be operating properly Immediately contact a q
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