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Munchkin Gas-Fired Hot Water Boiler manual

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Table of contents for the manual

  • Page 1

    W ARNING This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. P erform steps in the order given. Failure to comply could result in severe personal injury , death or substantial property damage. • Installation • Startup • Maintenance • Parts Boiler Manual[...]

  • Page 2

    GAS -FIRED BOILER Boiler Manual 1 CONTENTS P art 1 – P roduct and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 4 P art 2 – How The Boiler Operates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 P art 3 – Prepare Boiler Location . . . . . . . . . . . [...]

  • Page 3

    2 GAS -FIRED BOILER Boiler Manual CONTENTS (CONT ’D) P art 8 – Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47 A. Gas Connection B. Gas Piping C. Gas T able D . Dungs Gas V alve P art 9 – Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    3 GAS -FIRED BOILER Boiler Manual P ART 1: PRODUCT AND SAFETY INFORMA TION SPECIAL A TTENTION BO XES 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. D ANGER DANGER indicates an imminently hazardous situation which, if[...]

  • Page 5

    4 GAS -FIRED BOILER Boiler Manual P ART 1: PRODUCT AND SAFETY INFORMA TION (CONT ’D) Before Installing WHEN SERVICING BOILER • T o avoid electric shock, disconnect electrical supply before performing maintenance. • T o avoid severe burns, allow boiler to cool before performing maintenance. BOILER OPERA TION • Do not block flow of combustion[...]

  • Page 6

    5 GAS -FIRED BOILER Boiler Manual P ART 2: HOW BOILER OPERA TES Munchkin Condensing T echnology is an intelli- gent system that delivers highly efficient hydron- ic heating, while maximizing efficiency by meas- uring the Data P arameters of your heating sys- tem. 1. Stainless Steel Heat Exchanger The highly efficient durable Munchkin Stainless Stee[...]

  • Page 7

    6 GAS -FIRED BOILER Boiler Manual P ART 2: HOW BOILER OPERA TES (CONT ’D) Also, an increase in pipe size may be necessary to drain properly . Support of the condensation line may be necessary to avoid blockage of the condensate flow . 11. Spark ignition The burner flame is ignited by applying a high voltage to the system spark electrode. This cau[...]

  • Page 8

    7 GAS -FIRED BOILER Boiler Manual Figure 2-1 T50M/T80M DIMENSIONS PERFORMANCE RA TINGS Input Modulation DOE Heating AFUE Shipping W eight *IBR 18,000 to 50,000 16,000 to 46,000 92% 58 lbs. 40,000 19,000 to 80,000 17,000 to 74,000 92% 58 lbs. 64,000 27,000 to 80,000 25,000 to 74,000 92% 75 lbs. 64,000 46,000 to 140,000 43,000 to 129,000 92% 101 lbs.[...]

  • Page 9

    8 GAS -FIRED BOILER Boiler Manual DIMENSIONS 80M 140M/199M Figure 2-2 Figure 2-3[...]

  • Page 10

    9 GAS -FIRED BOILER Boiler Manual P ART 3: PREP ARE BOILER LOCA TION (CONTINUED) C. BEFORE LOCA TING THE BOILER 1. Check for nearby connection to: • System water piping • V enting connections • Gas supply piping • Electrical power 2 . Check area around boiler . Remove any combustible materials, gasoline and other flammable liquids. 3. The M[...]

  • Page 11

    10 GAS -FIRED BOILER Boiler Manual or rain during operation or service. 4. If the Munchkin Boiler is to replace an existing boiler , check for and correct any existing system problems such as: • System leaks. • Incorrectly-sized expansion tank. • Lack of freeze protection in boiler water causing system and boiler to freeze and leak. • Exces[...]

  • Page 12

    GAS -FIRED BOILER Boiler Manual 11 GAS -FIRED BOILER Boiler Manual vent piping can be routed through the building and properly terminated. The air intake and exhaust vent piping lengths, routing and termi- nation method must all comply with the methods and limits given in the V enting section. G . PREVENT COMBUSTION AIR CONT AMINA TION Install inta[...]

  • Page 13

    12 GAS -FIRED BOILER Boiler Manual W ARNING T o avoid water damage or scalding due to relief valve operation: • Discharge line must be connected to relief valve outlet and run to a safe place of disposal. T erminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge. • Disc[...]

  • Page 14

    13 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) B. GENERAL PIPING INFORMA TION C. SEP ARA TE LOW W A TER CUTOFF A low water cutoff may be required by state local code or some insurance companies. Check code requirements before installation of the Munchkin Boiler . It is also required that a low water cutoff be used if the boil[...]

  • Page 15

    14 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) diagrams, the space heating system is isolated from the boiler loop by the primary/secondary connection. 2. Size the piping and components in the space heating system using recognized design methods. G . HYDRONIC PIPING WITH CIRCULA TORS , ZONE V AL VES AND MUL TIPLE BOILERS The [...]

  • Page 16

    15 GAS -FIRED BOILER Boiler Manual 10. The Safety Relief V alve is installed at the factory . Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief . Pipe the discharge 6” above the drain to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of safety r[...]

  • Page 17

    16 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) I. FILL AND PURGE HEA TING SYSTEM • Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain • Close the other side of the balance and purge valve or the shut off valve after the drain. • Open first zone balance and purge or drain val[...]

  • Page 18

    17 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) J . ZONING WITH ZONE V AL VES 1. Connect boiler to system as shown in 2A and 2B in Piping Details when zoning with zone valves. The primary/secondary piping shown ensures the boiler loop will have sufficient flow . It also avoids applying the high head of the boiler circulator to[...]

  • Page 19

    18 GAS -FIRED BOILER Boiler Manual Piping Symbol Legend circulator (w/ isolation flanges) gate valve globe valve ball valve swing-check valve flow-check valve spring-loaded check valve hose bib / boiler drain thermostatic radiator valve TRV (straight) circuit setter manual 3-way valve zone valve air separator backflow preventer diaphragm-type expan[...]

  • Page 20

    19 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with valves) Space heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 2A make-up water zone valves NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local[...]

  • Page 21

    20 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with valves) Domestic water heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 2B make-up water V1 zone valves anti-scald mixing valve purging valves closely spaced tees differential pressure bypass valve P2 NOTES: 1. This drawing is meant to [...]

  • Page 22

    21 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center [...]

  • Page 23

    22 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with circulators) Domestic water heating mode Munchkin boiler make-up water Super Stor indirect DHW tank closely spaced tees P2 zone circulators T/P space heating zone circuit Drawing 2D purging valves NOTES: 1. This drawing is meant to show system piping concept o[...]

  • Page 24

    23 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diamete[...]

  • Page 25

    24 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pip[...]

  • Page 26

    25 GAS -FIRED BOILER Boiler Manual P ART 6. BOILER PIPING WITH VISION I SYSTEM (DHW PRIORITY WITH OUTDOOR RESET) A. VISION I SYSTEM PIPING It is important that the system piping is done correctly when using the Vision 1 System. F ollow the piping diagrams 2A through 3G when piping your Munchkin Boiler with Vision I. All general piping practices sho[...]

  • Page 27

    26 GAS -FIRED BOILER Boiler Manual D . BOILER PIPING DET AILS WITH THE VISION I SYSTEM Munchkin VISION 1 system (zoning with valves) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 p[...]

  • Page 28

    27 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with valves) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center spacing. 3. A[...]

  • Page 29

    28 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with valves) Space heating mode (w/ submixing) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center spacing[...]

  • Page 30

    29 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center spacing. 3. A min[...]

  • Page 31

    30 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.[...]

  • Page 32

    31 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode (w/ submixing) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center sp[...]

  • Page 33

    32 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode (3 fully reset supply temperatures) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diamete[...]

  • Page 34

    33 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode (3 different supply temperatures) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter [...]

  • Page 35

    34 GAS -FIRED BOILER Boiler Manual anti-scald mixing valve Munchkin heater closely spaced tees purge purge make-up water high limit safety zone circulators outdoor temperature sensor thermal trap (w/ drain plug) T/P P1 P2 Super Stor indirect DHW tank air handler air handler multi-zone relay center differential pressure bypass valve Munchkin VISION [...]

  • Page 36

    35 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system Multiple high temperature priority loads controlled with zone circulators Multiple low temperature load controls with zone circulators NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. [...]

  • Page 37

    36 GAS -FIRED BOILER Boiler Manual b . Non Foam Core CPVC (Chlorinated P olyvinyl Chloride) Pipe conforming to ASTM D -1785. c . Non F oam Core ABS (Acrylonitrile - Butadiene- Styrene) Pipe conforming to ASTM D3965 Class 3-2-2-2-2. 2. Cellular foam core piping may be used on air inlet piping only . Never use cellular foam core material for exhaust [...]

  • Page 38

    37 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) f . P rovide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators and relief equipment. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintai[...]

  • Page 39

    38 GAS -FIRED BOILER Boiler Manual Location of exit terminals of mechanical draft and direct -vent venting systems. (Reference: National F uel Gas Code ANSI Z223.1/NFP A 54 2002). Fig. 7-2 Multiple V ent Spacing* *Note: Exhaust must extend out 1 foot Figure 7-4 Multiple Boiler Installations Fig. 7-3 Multiple Stainless Steel Horizontal V ent Kit Ins[...]

  • Page 40

    39 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) E. EXHAUST VENT AND INT AKE AIR VENT SIZING 1. The exhaust vent and intake air vent pipes should be 2" for the T50/T80, 3" for the 80M/140M/199M and 4" for the 399M. 2. The total combined equivalent length of exhaust vent and int[...]

  • Page 41

    40 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) 40 or 80 pipe. FOAM CORE PIPING IS NO T APPROVED . 2. Remove all burrs and debris from joints and fittings. 3. All joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement[...]

  • Page 42

    41 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) I. CONDENSA TE REMOV AL SYSTEM This is a condensing high efficiency appliance, therefore this unit has a condensate removal system. Condensate is nothing more than water vapor , derived from the combustion products, similar to an automobile whe[...]

  • Page 43

    42 GAS -FIRED BOILER Boiler Manual J . DIA GRAMS FOR SIDEWALL VENTING GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per foot back to the heater (to allow drainage of condensate). RIGHT SIDE VIEW EXTERIOR WALL AND VERTICAL PIPING ALL HORIZONTAL COUPLING TEE INTAKE AIR VENT TOP [...]

  • Page 44

    43 GAS -FIRED BOILER Boiler Manual VIEW TOP VIEW AND VERTICAL PIPING SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL VENT KIT RIGHT SIDE EXTERIOR WALL NOTE: EXTENDED VENT RUNS WHEN TRANSITIONING TO A LARGER DIAMETER MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE. SIDWALL VENTING WITH KIT VENT KIT INTAKE AIR VENT EXHAUS[...]

  • Page 45

    44 GAS -FIRED BOILER Boiler Manual Figure 7-13 Figure 7-14 K. DIAGRAMS FOR VERTICAL VENTING 10'-0" MIN. WHICHEVER IS GREATER 12" OVER MAXIMUM SNOW LEVEL OR 24" AND COUPLING (EXHAUST) EXTERIOR WALL RIGHT SIDE VIEW ROOF VENT WITH TEE (INTAKE) EXHAUST VENT AND VERTICAL PIPING ALL HORIZONTAL COUPLING TEE STRAIGHT SUPPORT BRACKETS MU[...]

  • Page 46

    45 GAS -FIRED BOILER Boiler Manual A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pressure (3.5 kP a), and a mini- mum of 3.5" water column. The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5" as stat[...]

  • Page 47

    46 GAS -FIRED BOILER Boiler Manual P ART 8: GAS PIPING (CONTINUED) D . DUNGS GAS V AL VE FOR T50/T80/80M/140M/199M OFF SET ADJUSTMENT CAUTION: DO NOT REMOVE THIS SCREW OR ATTEMPT TO MAKE ANY ADJUSTMENT TO THIS SCREW WITHOUT A COMBUSTION ANALYZER SEE PART 12 SECTION "D" FOR COMBUSTION SETTING TABLE. PRESSURE TAP OUTLET THROTTLE ADJUSTER NO[...]

  • Page 48

    47 GAS -FIRED BOILER Boiler Manual P ART 9: FIELD WIRING A. INST ALLA TION MUST COMPL Y WITH: 1 . National Electrical Code and any other national, state, provincial or local codes or regulations. 2. In Canada, CSA C22.1 Canadian Electrical Code P art 1, and any local codes. B. FIELD WIRING The Munchkin Boiler box has a 24 volt terminal strip on the[...]

  • Page 49

    48 GAS -FIRED BOILER Boiler Manual P ART 9: FIELD WIRING (CONTINUED) Fig. 9-4 Fig. 9-3 Fig. 9-1 Fig. 9-2[...]

  • Page 50

    49 GAS -FIRED BOILER Boiler Manual P ART 9: FIELD WIRING (CONTINUED) Fig. 9-5[...]

  • Page 51

    50 GAS -FIRED BOILER Boiler Manual Outdoor Sensor Function The user can pro- gram the desired supply temperature based on the heat transmitter (Baseboard, Radiant Floor , Air Handler) that will be used in the installation. Once the outdoor sensor (Light Green Wires) is connected to the control board, the water tem- perature of the boiler will adjus[...]

  • Page 52

    51 GAS -FIRED BOILER Boiler Manual P ART 11. ST ART-UP PREP ARA TION A. CHECK/CONTROL WA TER CHEMISTRY W ater pH between 6.0 and 8.0 1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water treatment company . 2. If pH differs from above, consult local water treatment company for treatment needed[...]

  • Page 53

    52 GAS -FIRED BOILER Boiler Manual P ART 11. ST ART-UP PREP ARA TION (CONTINUED) 5. The system may have residual substances that could affect water chemistry . After the system has been filled and leak tested, verify water pH and chlorine concentrations are acceptable. D . PURGE AIR FROM W A TER SYSTEM 1. P urge air from system: a. Connect a hose t[...]

  • Page 54

    53 GAS -FIRED BOILER Boiler Manual P ART 11. ST ART-UP PREP ARA TION (CONTINUED) G . CHECK CONDENSA TE REMOV AL 1. The Munchkin Boiler is a high efficiency condensing boiler , there, the unit has a condensation drain. Condensate is nothing more than water vapor , derived from combustion products, similar to an automobile when it is initially starte[...]

  • Page 55

    54 GAS -FIRED BOILER Boiler Manual P ART 12. ST ART-UP PROCEDURE (CONTINUED) A. OPERA TING INSTRUCTIONS Remove boiler cover . If you smell gas, STOP . F ollow listed safety instructions. If you do not smell gas, follow the next steps. 1. T urn on all electric power to appliance. 2 . Adjust the temperature setpoint of the Munchkin Boiler if desired.[...]

  • Page 56

    55 GAS -FIRED BOILER Boiler Manual P ART 12. ST ART-UP PROCEDURE (CONTINUED) P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 Function V alue d5 — Actual T emperature from the outdoor sensor . (Vision option.) d6 — Actual Fan speed multiplied by 10 (Example: If fan speed displayed is |410| RPM x 10 = 4100 actual fan speed) d7 — Actual Ionizat[...]

  • Page 57

    56 GAS -FIRED BOILER Boiler Manual P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 (CONTINUED) the pass code is correct, you will need to press and hold the {S3/Program} for 1 second to confirm. If the pass code is entered incorrectly , the con- troller program function will be cancelled and the control returns to normal operation. If the code is [...]

  • Page 58

    57 GAS -FIRED BOILER Boiler Manual P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 (CONTINUED) Default Function Function Value Description 14 30 Min. Allows the installer to set the Maximum run time for the Indirect Fired W ater Heater and the Minimum run time for Central Heating. Range 0 to 60 Minutes 15 0 Bus address (0=zone master 1–8 — cas[...]

  • Page 59

    58 GAS -FIRED BOILER Boiler Manual Fig. 13-3 P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED) 50 32 41 167 158 149 131 122 113 104 77 59 68 86 95 212 203 194 185 176 201˚ SUPPLY OUTLET TEMPERATURE (F) -24 -59 -41 OUTSIDE TEMPERATURE (F) -9 9 27 63 45 81 99 FUNCTION 9 FUNCTION 11 FUNCTION 8 FUNCTION 10 0 68˚ 5˚ DEFAULT RESET CU[...]

  • Page 60

    59 GAS -FIRED BOILER Boiler Manual A. MUNCHKIN ERROR CODE An error code may occur in the installation of the Munchkin. This condition may lead to a lock out condition of the controller , which will need to be manually reset through the S4/Reset but- ton. These temporary codes will help the installer correct the problem before going into a lock out [...]

  • Page 61

    60 GAS -FIRED BOILER Boiler Manual P ART 14: TROUBLESHOOTING (CONTINUED) T able 14-2: 925 Control Board F AUL T Codes Code Description Remedy  F00 High Limit Exceeded. 1. Check circulation pump operation 2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from th[...]

  • Page 62

    61 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE A. MAINTENANCE PROCEDURES P eriodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is in safe efficient operation. The owner can make necessary arrangements with a qualified heating contrac- tor for periodic maintenance of the he[...]

  • Page 63

    62 GAS -FIRED BOILER Boiler Manual 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 results) (available on line www .rydlyme.com) or “CLR” (available at most hardware stores) – [...]

  • Page 64

    63 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) 5 2 3 6 7 42 41 40 39 4 38 37 36 35 34 33 32 31 30 29 28 27 23 26 25 23 24 25 22 8 9 10 11 12 21 13 14 15 16 20 19 17 18 5 1 43 T50M/T80M REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Thermodisc Flue ECO 210 F 7250P-089 22 Nut M5 (Aluminum Elbow to Air Ch[...]

  • Page 65

    64 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 E xhaust Vent Pipe - 2" PVC N/A 17 5 Pin Wiring Harness (location) 7250P-696 2 Pipe Coupling F3001 18 9 Pin Wiring Harness (location) 7250P-697 3 E xhaust Manifold Tube 7250P-444 19 Low Voltag e Wiring Ha[...]

  • Page 66

    65 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Thermistor 7250P-667 18 Air/Gas Channel 7250P-685 (80M) 2 Thermodisc Flue ECO 210 F 7250P-089 7250P-687 (140M/199M) 3 Steel Push Retainer (Thermodisc Flue ECO) 7250P-151 19 Gasket (Flame Rec./Spark Electrode) [...]

  • Page 67

    66 GAS -FIRED BOILER Boiler Manual REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Blocked Vent Pressure Swi tch 7250P-150 16 Cabinet Latch and Gasket Kit (w/Screws) 7250P-668 (80M) 2 Screws # 8 x 1/2" (Blocked Vent Pressure Switch) 7250P-133 7250P-669 (140M/199M) 3 Low Voltage Wiring Harness (locati on) 7250P-700 17 Le[...]

  • Page 68

    67 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) 30 31 11 6 4 1 2 3 5 4 8 9 7 12 13 14 15 16 17 18 19 20 21 22 19 23 24 25 26 27 28 29 10 REPLACEMENT PARTS Item # Description Part # Ite m # Description Part # 1 Thermodisc Flue ECO 210 F 7250P-089 16 Screws M5 x 14MM (Co mbustion Blower) 7250P-478 2 Steel Push Retainer (Thermodis[...]

  • Page 69

    68 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) 28 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 SWITCH 29 30 31 14 8 BOILER CONDENSATE OUTLET REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Blocked Vent Pressure Switch 7250P-150 17 PVC Nipple Sch. 80 3/4 NPT (Condensate Assembly)[...]

  • Page 70

    69 GAS -FIRED BOILER Boiler Manual BOILER ST ART UP REPORT Light Off Activities 1) Fill the heating system Check all piping and gas connections, verify they are all tight Pressurize System (12-15 PSI) _____PSI What percentage of propylene glycol is installed in the system (0-50%) ____% Verify near heater piping is properly supported 2) Check Gas Pi[...]

  • Page 71

    70 GAS -FIRED BOILER Boiler Manual BOILER INSPECTION AND MAINTENANCE SCHEDULE Inspection Activities Piping 1st Year 2nd Year 3rd Year 4th Year* Near Heater Piping Check heater and system piping for any sign of leakage, verify proper support Vent Check condition of all vent pipe and joints Gas Check gas piping, test for gas leaks and signs of aging,[...]

  • Page 72

    71 GAS -FIRED BOILER Boiler Manual BOILER INSPECTION AND MAINTENANCE SCHEDULE (CONTINUED) Condensate 1st Year 2 Year 3 Year 4 Year* Condensate Neutralizer Check condensate neutralizer, replace if necessary Gas Pressure Pressure Drop Measure drop in pressure on light off (no more than 1" W.C.) Check gas pipe for leaks Check piping for leaks, an[...]

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    72 MAINTENANCE NOTES[...]

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    73 MAINTENANCE NOTES[...]

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    74 MAINTENANCE NOTES[...]

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    © 2007 Heat T ransfer P roducts, Inc. LP -185 REV . 2 / 20/07[...]