Munchkin Gas-Fired Hot Water Boiler User manual

User
Manual

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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 and
liquids 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 qualified
installer, service agency or the gas supplier.
TABLE OF CONTENTS
Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3
Service and Maintenance
Munchkin Operation
Primary Water
Section I – 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 III – Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Daily Maintenance
Monthly Maintenance
6 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
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.
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.
DEFINITIONS
NOTICE
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.
SPECIAL ATTENTION BOXES
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.

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GAS-FIRED BOILER User Manual
WARNING
User — Have this boiler serviced/inspected by
a qualified service technician annually.
WARNING
Failure to adhere to the guidelines on this page
can result in severe personal injury, death or
substantial property damage.
WARNING
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.
PRODUCT AND SAFETY INFORMATION (CONT’D)
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 buildup 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
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.

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GAS-FIRED BOILER User Manual
SECTION I – COMBUSTION AIR – PREVENTION OF CONTAMINATION
AREAS LIKELY TO FIND THESE PRODUCTS
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.
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 pass 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.
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:
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 fresh
water.
• Check for leaks: water, gas, flue and
condensate.
• Verify flue vent piping and air inlet piping are
in good condition and sealed tight.
• Check boiler water pressure, piping and
expansion tank.
• Check control settings.
• Check ignition electrode (use Scotch Brite Pad
and sand off any white oxide; clean and
reposition).
• Check ignition wiring and ground wiring.
• Check all control wiring and connections.
• Check burner flame pattern (stable and
uniform) and flame.
Additional items if combustion or
performance 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 the
combustion 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.
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 damage
to the Munchkin or in system components,
resulting in severe personal injury, death or
substantial property damage.
SECTION III – MAINTENANCE PROCEDURES
1. Combustible / flammable materials - Do not
store combustible materials, gasoline or
other flammable vapors or liquids near the
unit. Remove immediately if found.
2. Air contaminates - Products containing
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 I of this
manual. If any of these products are in the
room where the boiler is located, they must
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.
NOTICE
The following information provides detailed
instruction for completing the maintenance
items outlined in the maintenance schedule in
Section II. In addition to this maintenance, the
Munchkin should be serviced at the beginning
of the heating season by a qualified service
technician.
WARNING
To prevent potential of severe personal injury,
death or substantial property damage, eliminate
all the materials listed in Section I 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 locate the
combustion air intake away from the
contaminated 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 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 Pressure
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.
2. Ensure the temperature on the LED display
panel does not exceed 180ºF. Higher
temperature readings may indicate a
problem with the operating thermostat
controls.
3. 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.
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.
Check Pressure Relief Valve
1. Visually inspect the primary pressure relief
valve and the relief valve discharge pipe for
signs of weeping or leakage.
2. If the pressure relief valve often weeps, the
expansion tank may not be operating
properly. Immediately contact a qualified
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.
2. 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.
3. 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.
4. 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.
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.
WARNING
You must make sure the condensate hose is
securely fastened before restarting boiler. Do a
final check to assure proper flow.

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GAS-FIRED BOILER 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.
4. 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.
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
is detected, immediately shut down the unit
following procedures on page 8. Call a
qualified service technician.
2. 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.
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.
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.
3. If water flows freely, release the lever and
allow the valve to seat. Watch the end of the
relief valve discharge pipe to ensure that the
SECTION III – MAINTENANCE PROCEDURES (CONT’D)
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.
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.

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GAS-FIRED BOILER User Manual
SECTION IV – OPERATIONS INSTRUCTIONS

© 2008 Heat Transfer Products, Inc.
www.HTproducts.com LP-182 REV. 9/10/08