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GAS-FIRED BOILER
PART 15: MAINTENANCE
WARNING
The combustion chamber insulation in
this product contains ceramic fiber
material. Ceramic fibers can be
converted to cristobalite in very high
t e m p e r a t u r e a p p l i c a t i o n s . T h e
International Agency for Research on
C a n c e r ( I A R C ) h a s c o n c l u d e d ,
"Crystalline silica inhaled in the form of
quartz or cristobalite from occupational
sources is carcinogenic to humans
(Group1).":
Avoid 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.
Apply enough water to the combustion chamber
lining to prevent dust
Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately
Breathing: 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
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
(CONTINUED)
2. Using a spray bottle filled with the recommeded
3. Use the nylon, stainless or brass brush (do not
4. Spray the coils with clear water, making sure to
Before powering up the Munchkin Boiler follow the
o n
l i n e
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.
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.
use steel) and scrub coils to remove any buildup,
then vacuum the debris from the coils. WARN-
ING: Follow precautions above
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.
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.
Boiler Manual
64
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