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GAS-FIRED BOILER Boiler Manual
PART 11. START-UP PREPARATION
(CONTINUED)
G. CHECK CONDENSATE REMOVAL
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 started. The
condensation is slightly acidic (typically with
pH of 3 to 5) and must be piped with the
correct materials. Never pipe the condensate
using steel, copper, brass or other materials
that will be subject to corrosion. Plastic PVC
or CPVC pipe are the only approved
materials. A condensate filter, if required by
local authorities, can be made up of lime
crystal,s marble or phosphate chips that will
neutralize the condensate. This may be done
by the installer or you may purchase a
condensate neutralizer from Heat Transfer
Products, Inc. (P/N N1100)
2. The Munchkin Boiler is equipped with a ¾
pipe connection that runs the condensation
line to a local drain. It is very important that
the condensate line is sloped away from the
heater and down to a suitable inside drain. If
the condensate outlet is lower than the drain,
you must use a condensate removal pump,
available at Heat Transfer Products (#554200).
This pump is equipped with two leads that
can be connected to an alarm or another type
of warning device to alert residents of a
condensate overflow, which, if not corrected,
could cause property damage.
3. The Munchkin Boiler is equipped with an
internal vent on the top plug connection to
assure adequate flow of condensate. This
vent should never be blocked.
4. If a long horizontal run is used, it may be
necessary to create a second vent to prevent
a vacuum lock in the condensate line. Do not
expose the condensate to freezing
temperatures.
5. Do not expose the condensate to freezing
temperatures.
6. It is very important you support the
condensation line to assure proper drainage.
H. FINAL CHECKS BEFORE STARTING BOILER
1. Read Startup Procedures within this manual
for proper steps to start boiler. (See Startup
Report to record steps for future reference.)
2. Verify the boiler and system are full of water
and all system components are correctly set
for operation.
3. Fill condensate trap with water.
4. Verify electrical connections are correct and
securely attached.
5. Inspect intake piping and exhaust piping for
signs of deterioration from corrosion, physical
damage or sagging. Verify intake piping and
exhaust piping are intact and correctly
installed per Venting section and local code.
PART 12. START-UP PROCEDURE
FOR YOUR OWN SAFETY READ BEFORE OPERATING
1. This appliance does not have pilot. It is equipped with an ignition
device which automatically lights the burner. Do not try to light the
burner by hand.
2. BEFORE OPERATING smell all around the appliance area for gas. Be
sure to smell next to the floor because some gas is heavier than air
and will settle on the floor.
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.
3. Turn on gas shutoff valve (located inside of the Boiler) so that the
handle is aligned with the gas pipe. If the handle will not turn by
hand, don't try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
4. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and any gas
control which has been under water.
5. The Munchkin Boiler shall be installed so the gas ignition system
components are protected from water (dripping, spraying, rain, etc.)
during appliance operation and service (circulator replacement,
condensate trap, control replacement, etc.)