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

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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