Munchkin Gas-Fired Hot Water Boiler manual For GAS Leaks, Sure Exhaust Vent is no Longer Blocked

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GAS-FIRED BOILER

Boiler Manual

PART 15: MAINTENANCE (CONTINUED)

WARNING

The combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications . The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group1).”:

ƒAvoid breathing dust and contact with skin and eyes.

•Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

•Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

ƒApply enough water to the combustion chamber lining to prevent dust

ƒWash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

ƒEye: Irrigate immediately

ƒBreathing: Fresh air.

B.COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS

*Before beginning this procedure, you must have on hand the following items:

–a nylon, stainless or brass brush (not steel)

–“Rydlyme” (recommended for best

r e s u l t s ) ( a v a i l a b l e o n l i n e www.rydlyme.com) or “CLR” (available at most hardware stores)

–Gloves, eye protection

1.Shut down the Munchkin Boiler by using the fol- lowing steps:

a.Close the gas valve, shut down the unit and wait for the unit to be cool to the touch

b.Disconnect the condensate hose from the outside connection, (not from the

Munchkin Boiler side), so the flow can be observed.

c. Disconnect connections from the gas valve, spark electrode and flame rectifi- cation probe and combustion blower.

d.Remove the (4) screws on the aluminum ½” NPT connector on the gas valve.

e.Disconnect the wiring connected to the combustion blower motor.

f.Remove the (6) 10MM nuts from the burner plate assembly to access the coils.

g.Pull the entire burner plate assembly with blower still attached towards you, while removing or pushing aside any wiring to allow the removal of the assembly.

2.Using a spray bottle filled with the recommeded product “RYDLYME” or “CLR”, spray liberally on the coils, making sure the solution penetrates and funnels down through the condensate hose. If the condensate hose is blocked, let the chem- ical penetrate for at least 15 minutes or until it drains.

3.Use the nylon, stainless or brass brush (do not use steel) and scrub coils to remove any buildup, then vacuum the debris from the coils. WARN- ING: Follow precautions above

4.Spray the coils with clear water, making sure to confine the spray to the area being cleaned (Try to avoid getting the back ceramic wall of the unit wet). Flush the combustion chamber with fresh water. At this point, the Munchkin should be ready to power back up.

Before powering up the Munchkin Boiler follow the steps below

a.Re-install the burner assembly

b.Tighten the (6) 10MM nuts to the burner plate

c.Re-connect all wiring connections

e.Replace the (4) screws on the aluminum ½” NPT connector on the gas valve. Turn the gas back on. (IMPORTANT: CHECK

FOR GAS LEAKS)

f.Re-set thermostats (IMPORTANT: MAKE

SURE EXHAUST VENT IS NO LONGER BLOCKED!)

g.Turn the Munchkin Boiler back on and observe condensate flow.

h.Re-connect the condensate hose to the outside connection.

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Contents Boiler Manual Contents Contents CONT’D Definitions Part 1 Product and Safety InformationBoiler Water Before InstallingWhen Servicing Boiler Boiler OperationStainless Steel Heat Exchanger Supply water temperature sensorReturn water temperature sensor Temperature and pressure gaugeBoiler Location should be Level Part 3 Prepare Boiler LocationSpark ignition Vision 1 SystemPerformance Ratings Connection Sizes FAN Speeds Dimensions80M 140M/199M Before Locating the Boiler Installations Must Comply withExhaust Vent and Intake AIR Vent PrecautionsClearances for Service Access Residential Garage InstallationCorrosive contaminants and sources When Removing a Boiler from AN Existing Common Vent SystemPart 5 Boiler Piping Remove Boiler from BOXRelief Valve Diaphragm or bladder expansion tank Part 5 Boiler Piping Circulator Sizing Circulator Sizing ChartFill and Purge Heating System System Temperature Rise ChartZoning with Zone Valves Zoning with CirculatorsMultiple Boilers Boiler Piping Details Piping Symbol LegendOFF Zone valves Make-up water Boiler Manual Space heating zone circuit Zone Circulators Make-up water PB1 PB2 PB1 PB2 Vision I System Piping Zoning with Circulators Using VisionBoiler Piping Details with the Vision I System Space heating modeOFF DHW Space heating mode w/ submixing Water OFF Munchkin Vision 1 system zoning with circulators Space heating mode 3 fully reset supply temperatures Space heating mode 3 different supply temperatures OFF Thermal trap Drain plug Installing Exhaust Vent and Intake AIR Vent GeneralExhaust Vent and Intake AIR Vent Pipe Location Part 7 VENTING, Combustion AIR & Condensate Removal Reference National Fuel Gas Code Ansi Z223.1/NFPA 54 Exhaust Vent and Intake AIR Pipe Installation Exhaust Vent and Intake AIR Vent SizingLonger Vent Runs Vent Termination Kits Description Stock Code Heater Removal from a Common Vent SystemCondensate Removal System Sidewall Venting with TEE Intake Coupling Exhaust Diagrams for Sidewall VentingSidwall Venting with KIT Roof Vent with TEE Intake Coupling Exhaust Diagrams for Vertical VentingGAS Table Part 8 GAS PipingGAS Connection GAS PipingDungs GAS Valve for T50/T80/80M/140M/199M OFF SET AdjustmentKrom Schroder Valve for 399M Installation Must Comply withField Wiring Line Voltage WiringPart 9 Field Wiring Part 9 Field Wiring Indirect Circulator P2 Program Part 10 Field Wiring VisionPart 11. START-UP Preparation Check for GAS Leaks Purge AIR from Water SystemCheck Thermostat Circuits Final Checks Before Starting Boiler Check Condensate RemovalStatus Menu Part 12. START-UP ProcedureAdjusting the Setpoint Operating InstructionsTest Mode Vision 1 Program AccessProgramming the Vision I Option Vision 1 Program Navigation Boiler cannot be programmed while there is a call for heatDefault Function Function Value Description FunctionCentral Heating Curve Function Function Default Setting Programmed Setting Control Program Reference ChartMunchkin Error Code Boiler ErrorBoiler Fault 925 Control Board Fault Codes Description Remedy Part 14 TroubleshootingOutdoor Sensor 7250P-319 Maintenance ProceduresSure Exhaust Vent is no Longer Blocked For GAS LeaksT50M/T80M Part 15 MaintenanceT50M/T80M 80M/140M/199M Boiler Replacement Parts Boiler Boiler Boiler Start UP ReportManual Boiler Inspection and Maintenance ScheduleBoiler Inspection and Maintenance Schedule Maintenance Notes Maintenance Notes Maintenance Notes Heat Transfer Products, Inc LP-185 REV /20/07

Gas-Fired Hot Water Boiler specifications

The Munchkin Gas-Fired Hot Water Boiler is a highly efficient heating system that has garnered attention in residential and commercial applications for its innovative design and advanced technology. This boiler is compact yet powerful, providing exceptional heating performance while maximizing energy efficiency.

One of the standout features of the Munchkin boiler is its modulating condensing technology. This system allows the boiler to adjust its output based on demand, which optimizes energy use and reduces unnecessary fuel consumption. By modulating the flame, the Munchkin boiler can maintain a steady heating output even during variable load conditions, ensuring that users enjoy consistent hot water without waste.

The Munchkin boiler offers an impressive AFUE (Annual Fuel Utilization Efficiency) rating, typically exceeding 95%. This high efficiency translates to significant savings on energy bills and a reduced carbon footprint. By capturing and reusing flue gases that would otherwise be lost, the condensing feature enhances the overall efficiency, making it a sustainable choice for modern heating needs.

In terms of installation, the Munchkin boiler is designed for versatility. Its compact size allows for easy placement in tight spaces, whether in residential basements or utility closets. The unit is compatible with a variety of piping systems and can be integrated with multiple heating sources including radiators, baseboards, and even in-floor heating setups.

Another notable characteristic of the Munchkin boiler is its advanced control system. The boiler is equipped with a user-friendly digital display that allows for easy programming, monitoring, and adjustments. This enhanced control capability ensures that users can fine-tune their heating schedules according to their lifestyle, optimizing comfort while maintaining peak efficiency.

Reliability is a hallmark of the Munchkin brand. Built with high-quality materials, these boilers are engineered to withstand the rigors of daily operation, offering durable performance for years. Furthermore, Munchkin provides robust customer support and service options to assist homeowners and professionals alike.

In summary, the Munchkin Gas-Fired Hot Water Boiler stands out due to its modulating condensing technology, high efficiency, compact design, and advanced control system. These characteristics make it an excellent choice for those seeking a reliable, efficient, and versatile heating solution. Whether for residential or commercial use, the Munchkin boiler provides consistent, effective heating that meets the demands of today's energy-conscious consumers.
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