Munchkin GAS-FIRED BOILER User Manual
User
Manual
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GAS-FIRED BOILER User Manual
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.
WARNING
If the information in this manual is not followed exactly, a fire or explosion 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.
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 technician:
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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