User
Manual
GAS-FIRED BOILER
User Manual
PRODUCT AND SAFETY INFORMATION
SPECIAL ATTENTION BOXES
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.
DEFINITIONS
DANGER
CAUTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
CAUTION Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
CAUTION
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
WARNING
If the information in this manual is not followed exactly, a fire or explo-
sion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch: do not use any phone in
your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
NOTICE
Heat Transfer Products, Inc., reserves the right to make product changes or updates without notice
and will not be held liable for typographical errors in literature.
2
GAS-FIRED BOILER
User Manual
PRODUCT AND SAFETY INFORMATION (CONT’D)
PRIMARY WATER
WARNING
•
If you have an old system with cast iron
radiators, thoroughly flush the system
(without boiler connected) to remove
sediment. The high-efficiency heat exchanger
can be damaged by build-up or corrosion
due to sediment.
User — Have this boiler serviced/inspected by
a qualified service technician annually.
WARNING
Failure to adhere to the guidelines on this page
can result in severe personal injury, death or
substantial property damage.
•
Do not use petroleum-based cleaning or
sealing compounds in boiler system. Gaskets
and seals in the system may be damaged.
This can result in substantial property
damage.
WARNING
WHAT TO DO IF YOU SMELL GAS
•
•
Do not use “homemade cures” or “boiler
patent medicines.” Substantial property
damage, damage to boiler, and/or serious
personal injury may result.
• 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.
Continual fresh make-up water will reduce
boiler life. Mineral buildup in heat exchanger
reduces heat transfer, overheats the stainless
steel heat exchanger, and causes failure.
Addition of oxygen carried in by make-up
water can cause internal corrosion in system
components. Leaks in boiler or piping must
be repaired at once to prevent make-up
water.
BOILER OPERATION
•
•
Do not block flow of combustion or
ventilation air to boiler.
FREEZE PROTECTION FLUIDS
Should overheating occur or gas supply fail
to shut off, do not turn off or disconnect
electrical supply to circulator. Instead, shut off
the gas supply at a location external to the
appliance.
CAUTION
NEVER use automotive or standard glycol
antifreeze, even ethylene glycol made for
hydronic systems. Use only inhibited propylene
glycol solutions, which are specifically
formulated for hydronic systems. Ethylene
glycol is toxic and can attack gaskets and seals
used in hydronic systems.
•
Do not use this boiler if any part has been
under water. Immediately call a qualified
service technician to inspect the boiler and to
replace any part of the control system and
any gas control that has been under water.
3
GAS-FIRED BOILER
User Manual
SECTION I – COMBUSTION AIR – PREVENTION OF CONTAMINATION
AREAS LIKELY TO FIND THESE PRODUCTS
WARNING
Products to avoid
Spray cans containing fluorocarbons
If the Munchkin combustion air inlet is located
in any area likely to cause or contain
contamination, or if products, which would
contaminate the air cannot be removed, the
combustion air must be re-piped and
terminated to another location. Contaminated
combustion air will damage the unit and its
burner system, resulting in possible severe
personal injury, death or substantial property
damage.
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
Adhesives used to fasten building products and
other similar products
WARNING
Do not operate a Munchkin unit if its
combustion air inlet or the unit is located in or
near a laundry room or pool facility. These areas
will always contain hazardous contaminates.
Pool and laundry products and common
household and hobby products often contain
fluorine or chlorine compounds. When these
chemicals pass through the burner and vent
system, they can form strong acids. These acids
can create corrosion of the heat exchanger,
burner components and vent system, causing
serious damage and presenting a possible
threat of flue gas spillage or water leakage into
the surrounding area.
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages and workshops
SECTION II – MAINTENANCE SCHEDULE
•
Check boiler water pressure, piping and
expansion tank.
SERVICE TECHNICIAN
On an annual basis the following maintenance
should be performed by a qualified service tech-
nician:
•
•
Check control settings.
Check ignition electrode (use Scotch Brite Pad
and sand off any white oxide; clean and
reposition).
General
•
•
Attend to any reported problems.
•
•
•
Check ignition wiring and ground wiring.
Check all control wiring and connections.
Inspect the interior of the boiler jacket area;
clean and vacuum if necessary.
Check burner flame pattern (stable and
uniform) and flame.
•
•
•
Clean the condensate trap and fill with fresh
water.
Additional items if combustion or
performance is poor:
Check for leaks: water, gas, flue and
condensate.
•
•
Clean heat exchanger and flue ways.
Verify flue vent piping and air inlet piping are
in good condition and sealed tight.
Remove burner assembly and clean burner
4
GAS-FIRED BOILER
User Manual
SECTION II – MAINTENANCE SCHEDULE (CONT’D)
head using compressed air only.
•
Check the pressure relief valve.
Once the maintenance items are completed,
review the service with the owner.
•
Check the condensate drain system.
Every 6 months:
OWNER MAINTENANCE
Periodically:
•
Check boiler piping and gas supply piping for
corrosion or potential signs of leakage.
•
•
Check the area around the unit.
WARNING
Check and remove any blockage from the
combustion air inlet and ventilation openings.
Follow the maintenance procedures given
throughout this manual. Failure to perform the
service and maintenance or follow the
directions in this manual could result in damage
to the Munchkin or in system components,
resulting in severe personal injury, death or
substantial property damage.
•
Check the temperature/pressure gauge
Monthly:
•
•
Check vent piping.
Check combustion air inlet piping.
SECTION III – MAINTENANCE PROCEDURES
WARNING
WARNING
The Munchkin must be inspected and serviced
annually, preferably at the start of the heating
season, by a qualified service technician. In
addition, the maintenance and care of the boiler
as outlined on page 3 and further explained on
pages 4 through 6 must be performed to assure
maximum efficiency and reliability of the unit.
Failure to service and maintain the Munchkin
and the system components could result in
equipment failure, causing possible severe
personal injury, death or substantial property
damage.
To prevent potential of severe personal injury,
death or substantial property damage, eliminate
all the materials listed in Section I from the area
surrounding the unit and from the vicinity of the
combustion air inlet. If contaminates are found:
Remove products immediately from the area. If
they have been there for an extended period,
call a qualified service technician to inspect the
unit for possible damage from acid corrosion.
If products cannot be removed, immediately call
a qualified service technician to re-pipe the
combustion air inlet piping and locate the
combustion air intake away from the
contaminated areas.
NOTICE
1. Combustible / flammable materials - Do not
store combustible materials, gasoline or
other flammable vapors or liquids near the
unit. Remove immediately if found.
The following information provides detailed
instruction for completing the maintenance
items outlined in the maintenance schedule in
Section II. In addition to this maintenance, the
Munchkin should be serviced at the beginning
of the heating season by a qualified service
technician.
2. Air contaminates - Products containing
chlorine or fluorine, if allowed to contaminate
the combustion air, will cause acidic
condensate within the unit. This will cause
significant damage to the unit. Read the list of
potential materials listed in Section I of this
manual. If any of these products are in the
room where the boiler is located, they must
DAILY MAINTENANCE
Check the surrounding area
5
GAS-FIRED BOILER
User Manual
SECTION III – MAINTENANCE PROCEDURES (CONT’D)
be removed immediately or the combustion
air intake must be relocated to another area.
Check Pressure Relief Valve
1. Visually inspect the primary pressure relief
valve and the relief valve discharge pipe for
signs of weeping or leakage.
Check Combustion Air Inlets
Verify that the unit’s vent termination and
combustion air intake are clean and free of
obstructions. Remove any debris on the air
intake or flue exhaust openings. If removing
the debris does not allow the unit to operate
correctly, contact your qualified service
technician to inspect the unit and the vent /
combustion air system.
2. If the pressure relief valve often weeps, the
expansion tank may not be operating
properly. Immediately contact a qualified
service technician to inspect the unit and
system.
Check Vent Condensate Drain System
1. While the unit is running, check the discharge
end of the condensate drain tubing. Ensure
no flue gas is leaking from the condensate
drain tubing or tee connection by holding
your fingers near the opening.
Check Temperature display and Pressure
Gauge
1. Ensure the pressure reading on the pressure
gauge does not exceed 25 psig. Higher
pressure readings may indicate a problem
with the expansion tank.
2. If you notice flue gas leaking from the
opening, this indicates a dry condensate
drain trap. Fill the condensate trap assembly.
Contact a qualified service technician to
inspect the unit and condensate line and refill
the condensate trap if problem persists
regularly.
2. Ensure the temperature on the LED display
panel does not exceed 180ºF. Higher
temperature readings may indicate a
problem with the operating thermostat
controls.
3. Contact a qualified service technician if
problem persists.
3. The Service Technician must ensure the
condensate drain line is not blocked by
pouring water through the plug T fitting on
the condensate drain assembly. The water
should flow out of the end of the drain line. If
water does not appear at the end of the drain
line, the qualified service technician must
clean the condensate line.
MONTHLY MAINTENANCE
Check Vent Piping
1. Visually inspect the flue gas vent piping for
any signs of blockage, leakage or
deterioration of the piping. Notify a qualified
service technician immediately if any
problems are found.
4. To fill the condensate drain assembly. Slowly
pour water into the T fitting on the assembly
until water appears at the end of the drain
line.
WARNING
Failure to inspect the venting system as noted
and have it repaired by a qualified service
technician can result in the vent system failure,
causing severe personal injury or death.
WARNING
You must make sure the condensate hose is
securely fastened before restarting boiler. Do a
final check to assure proper flow.
Check Intake Air Vent Piping
1. Visually inspect the intake air vent piping for
any signs of blockage. Inspect the entire
length of the intake air vent piping to ensure
piping is intact and all joints are properly
sealed.
2. Notify a qualified service technician if any
problems are found.
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GAS-FIRED BOILER
User Manual
SECTION III – MAINTENANCE PROCEDURES (CONT’D)
valve does not weep after the line has had
time to drain. If the valve weeps, lift the lever
again to attempt to clean the valve seat. If the
valve does not properly seat and continues to
weep afterwards, contact a qualified service
technician to inspect the valve and system.
6-MONTH MAINTENANCE
Check primary and gas piping
1. Remove the boiler cover and perform a gas
leak inspection following Operating
Instructions in Section IV. If gas odor or leak
is detected, immediately shut down the unit
following procedures on page 8. Call a
qualified service technician.
4. If the water does not flow from the valve
when you lift the lever completely, the valve
or discharge line may be blocked.
Immediately shut the unit down per
instructions on page 8 and call a qualified
service technician to inspect the valve and
system.
2. Visually inspect for leaks around the internal
boiler water connections and around the heat
exchanger. Visually inspect the external
system piping, circulators, and system
components and fittings. Immediately call a
qualified service technician to repair any
leaks.
WARNING
Have leaks fixed at once by a qualified service
technician. Failure to comply could result in
severe personal injury, death or substantial
property damage.
Operate Pressure Relief Valve
1. Before proceeding, verify that the relief valve
outlet has been piped to a safe place of
discharge, avoiding any possibility of
scalding from hot water.
WARNING
To avoid water damage or scalding due to valve
operation, a discharge line must be connected
to the relief valve outlet and directed to a safe
place of disposal. This discharge line must be
installed by a qualified service technician or
heating/plumbing installer in accordance with
the Munchkin installation manual. The
discharge line must be terminated so as to
eliminate possibility of severe burns or property
damage should the valve discharges.
2. Read the temperature and pressure gauge to
ensure the system is pressurized. Min. is 10
PSI and Max is 25 PSI. Lift the relief valve top
lever slightly, allowing water to relieve
through the valve and discharge piping.
3. If water flows freely, release the lever and
allow the valve to seat. Watch the end of the
relief valve discharge pipe to ensure that the
7
GAS-FIRED BOILER
User Manual
SECTION IV – OPERATIONS INSTRUCTIONS
.FOR YOUR SAFETY READ BEFORE OPERATING.
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result, causing property damage, personal injury or loss of life.
A. This appliance does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do not try to
light the burner by hand.
B. 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.
suppliers’ instructions.
If you cannot reach your gas supplier, call
the fire department.
•
C. Use only your hand to turn the gas control
knob. Never use tools. 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.
WHAT TO DO IF YOU SMELL GAS
D. 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.
•
•
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
•
.OPERATING INSTRUCTIONS.
GAS SHUT OFF VALVE
1. STOP! Read the safety
information above.
2. Set the thermostat to
lowest setting.
Follow “B” in the safety
information above on this
label. If you don’t smell
gas, go to next step.
8. Turn gas shutoff valve
counterclockwise to “on”.
Handle will be horizontal.
9. Install Front Cover.
10.Turn on all electric power
to appliance.
3. Turn off all electric power
to the appliance.
4. This appliance is
equipped with an ignition
device which
GAS
VALVE
automatically lights the
burner. Do not try to light
the burner by hand.
GAS VALVE SHUT OFF
11.Set thermostat to desired
setting.
5. Remove front cover.
6. Turn gas shutoff valve to
“off”. Handle will be
12.If the appliance will not
operate, follow the
instructions “To Turn Off
Gas To Appliance” and
call your service
vertical, do not force.
7. Wait five (5) minutes to
clear out any gas. If you
then smell gas, STOP!
technician or gas
supplier.
MAIN GAS VALVE
.TO TURN OFF GAS TO APPLIANCE.
1. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance if
service is to be performed.
4. Turn gas shutoff valve clockwise to “off”.
Handle will be vertical. Do not force
5. Install Front Cover.
3. Remove front cover.
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GAS-FIRED BOILER
User Manual
REPLACEMENT PARTS
5
2
3
6
1
5
13
12
17
16
14
15
4
7
11
19
18
8
21
22
9
20
10
23
43
24
42
25
35
40
41
36
37
34
39
38
33
T50M/T80M
32
29
27
31
30
28
23
25
26
REPLACEMENT PARTS
Item
#
Item
Description
Thermodisc Flue ECO 210 F
Steel Push Retainer (Thermodisc Flue ECO)
Part #
#
Description
Part #
1
2
3
4
5
6
7
7250P-089
7250P-151
7250P-311
7250P-080
7250P-059
7250P-081
7250P-019
22 Nut M5 (Aluminum Elbow to Air Channel)
23 Gasket (Flame Rec./Spark Electrode)
24 Spark Electrode (w/Gasket)
7250P-063
7250P-005
PVC Black Tubing 1/8 ID (Thermodisc Flue ECO)
Relief Valve
7250P-421 (T50M)
7250P-058 (T80M)
7250P-005
Thermistor
25 Screws M4 x 8MM (Probe/Electrode)
26 Flame Rectification Probe (w/Gasket)
27 Screws Torx M5 X 22MM
Water Pressure Switch
ECO High Limit Sensor
7250P-049
7250P-206
8
9
Aluminum Elbow
7250P-445
7250P-061
7250P-003
7250P-144
7250P-084
7250P-644
28 Air Channel
7250P-692
7250P-170
7500P-067
7250P-691
7250P-702
7250P-070
Screws M5 X 25MM (Aluminum Elbow to Air Channel)
29 Gasket (Burner Door to Air Channel)
30 Nuts M6 (Burner Door)
31 Burner Door
10 Gasket (Aluminum Elbow to Air Channel)
11 Gasket (Aluminum Elbow to Combustion Blower)
12 Combustion Blower
32 Burner Door Ceramic Refractory
33 Gasket (Burner)
13 Gas Valve Adapter Plate (w/Screws)
14 Screws M5 x 12MM (Gas Valve Adapter Plate)
15 Swirl Plate
7250P-484
34 Burner
7250P-216 (T50M)
7500P-091 (T50M)
7250P-248 (T80M)
7250P-204
7250P-704
7500P-109
7250P-160
7250P-212
SN1018
7250P-092 (T80M) 35 Screws (Burner)
16 Dungs Gas Valve
7250P-448 (T50M) 36 Screw M4 x 8MM (Ceramic Target Wall)
7250P-449 (T80M) 37 Washer M4 (Ceramic Target Wall)
17 Gas Piping Assembly (w/Shut-off Valve, Screws)
18 Screws M4 x 12MM (Gas Valve Piping Assy)
19 O-Ring (Gas Valve Piping Assy)
N/A
38 Ceramic Target Wall
7500P-099
7500P-094
39 Brass 90 Street Elbow 3/4 NPT
40 Brass Nipple 3/4 NPT x 3"
20 Screws M4 x 12MM (Gas Valve)
7500P-099
7250P-060
41 Brass 90 Elbow 3/4 NPT
42 Gasket (Top Flue Exhaust to Module)
43 Top Flue Exhaust
7250P-313
7250P-428
7250P-394
21 Screw M4 x 20MM (Combustion Blower)
9
GAS-FIRED BOILER
User Manual
REPLACEMENT PARTS (CONTINUED)
1
2
4
3
15
11
7
6
5
14
13
9
12
8
BOILER
SWITCH
16
CONDENSATE
OUTLET
17
18
19
20
21
10
22
26
23
24
28
27
T50M/T80M
25
REPLACEMENT PARTS
Item
#
Item
Description
Part #
#
Description
Part #
7250P-133
1
2
3
4
5
6
7
8
Exhaust Vent Pipe - 2" PVC
Pipe Coupling
N/A
15 Screws # 8 x 1/2" (Electrical Box)
F3001
16 Hose Barb 1/4 x 10-32 (Blocked Vent Pressure Switch) 7250P-154
Exhaust Manifold Tube
Air Inlet Baffle
7250P-444
7250P-145
17 O-Ring 007 (Blocked Vent Pressure Switch)
18 S.S. Hex Nut 10-32 (Blocked Vent Pressure Switch)
19 Fuse (Control Board)
7250P-152
7250P-153
7250P-378
7250P-559
7250P-427
7250P-647
7250P-133
7250P-648
7250P-649
7250P-646
7250P-482
7250P-302
Plastic Tubing 3/16" ID (Blocked Vent Pressure Switch) 7250P-378
Control Board Display (w/Ribbon Cable)
Blocked Vent Pressure Switch
Screws # 8 x 1/2" (Blocked Vent Pressure Switch)
Cover
7250P-332
7250P-150
7250P-133
N/A
20 S.S. Hex Nuts
21 Gasket (Top Flue Exhaust Pipe)
22 Poly Plug 3/4 NPT (Condensate Assy)
23 Screw # 8 x 1/2" (Condensate Assy)
24 PVC Nipple Sch. 80 3/4 NPT (Condensate Assy)
25 Cable Clamp (Condensate Assy)
26 PVC Tee Sch. 40 3/4 NPT (Condensate Assy)
27 Condensate Hose Assy
9
10 Brass Nipple 1 x 1-1/4 x 3-3/4"
11 Control Board (w/Fuse)
7250P-221
7250P-317
7250P-352
7250P-651
7250P-114
12 Control Board Hold Down Clips
13 Control Board Mounting Panel (w/Screws)
14 Electrical Box (w/Screws, Covers)
28 Spring Clamp (Condensate Assy)
10
GAS-FIRED BOILER
User Manual
REPLACEMENT PARTS (CONTINUED)
12
13
14
3
2
7
1
5
6
8
4
1
9
10
15
11
16
17
18
35
19
34
20
33
32
30
31
29
28
21
27
25
24
23
26
80M/140M/199M
19
22
REPLACEMENT PARTS
Item #
Description
Part #
Item #
Description
Part #
7250P-685 (80M)
1
2
3
4
Thermistor
Thermodisc Flue ECO 210 F
Steel Push Retainer (Thermodisc Flue ECO)
7250P-667
7250P-089
7250P-151
18
Air/Gas Channel
7250P-687 (140M/199M)
7250P-005
19
20
Gasket (Flame Rec./Spark Electrode)
Spark Electrode (w/Gasket)
PVC Black Tubing 1/8 ID (Thermodisc Flue ECO) 7250P-311
7500P-040
5
6
7
Water Pressure Switch
Eco/High Limit Sensor
Dungs Gas Valve
7250P-096
21
22
23
Screws M4 x 8MM (Probe/Electrode)
Flame Rectification Probe (w/Gasket)
7250P-069
7500P-039
7250P-019
7250P-450 (80M)
Screws Torx M5 x 22M (Air/Gas Channel to Burner Door) 7250P-206
7250P-451 (140M)
7250P-452 (199M)
7500P-099
24
25
Gasket (Air/Gas Channel to Burner)
NIT Burner
7500P-074
7500P-016 (80M)
7250P-102 (140M)
7250P-117 (199M)
7500P-067
8
9
Screws M4 x 12MM (Gas Valve)
Swirl Plate
7500P-092 (80M)
7500P-093 (140M/199M)
7250P-644
26
27
Nut M6 (Burner Door)
Burner Door
10 Gas Valve Adapter Plate (w/Screws)
11 Screws M5 x 12MM (Gas Valve Adapter Plate)
12 Relief Valve
7250P-684
7250P-484
28
29
30
31
32
33
34
35
Burner Door Ceramic Refractory
7250P-702
7250P-704
7500P-109
7250P-160
N/A
7250P-080
Screw M4 x 8MM (Ceramic Target Wall)
Washer M4 (Ceramic Target Wall)
Ceramic Target Wall
13 Brass Nipple 3/4 NPT x 3"
SN1018
14 Brass 90 Elbow - 3/4 NPT
7250P-313
15 Combustion Blower (w/Gasket)
7250P-084 (80M)
7250P-086 (140M)
7250P-087 (199M)
7250P-478
Screws M4 x 30MM Allen Head (Gas Piping Assy)
Screws M4 x 12MM Allen Head (Gas Piping Assy)
Gas Piping Assembly (w/Shut-off Valve, Screws)
Welded Module
N/A
7250P-705
7250P-298 (80M)
7250P-299 (140M)
7250P-300 (199M)
16 Screws M5 x 14MM (Combustion Blower)
17 Gasket (Air/Gas Channel to Combustion Blower) 7500P-075
11
GAS-FIRED BOILER
User Manual
REPLACEMENT PARTS (CONTINUED)
1
2
6
8
7
9
3
4
11
16
10
12
13
BOILER
SWITCH
5
CONDENSATE
OUTLET
30
29
28
27
14
26
25
15
16
24
23
22
21
17
20
19
18
80M/140M/199M
REPLACEMENT PARTS
Item
Item
Description
#
Part #
Description
Part #
#
1
Blocked Vent Pressure Switch
7250P-150
16 Cabinet Latch and Gasket Kit (w/Screws)
7250P-668 (80M)
2
3
4
Screws # 8 x 1/2" (Blocked Vent Pressure Switch)
Low Voltage Wiring Harness (location)
9 Pin Wiring Harness (location)
7250P-133
7250P-700
7250P-697
7250P-669 (140M/199M)
7250P-673
17 Leveling Foot
18 Condensate Hose Assy
7250P-082
5
6
7
8
9
5 Pin Wiring Harness (location)
7250P-696
7250P-651
19 PVC Nipple Sch. 80 3/4 NPT (Condensate Assy)
20 Spring Clamp (Condensate Assy)
21 PVC Tee Sch. 40 3/4 NPT (Condensate Assy)
22 Cable Clamp (Condensate Assy)
23 Screw # 8 x 1/2 Self Tapping (Condensate Assy)
24 Poly Plug 3/4 NPT (Condensate Assy)
25 Band Clamp (Exhaust Assy)
7250P-648
7250P-302
7250P-646
7250P-649
7250P-133
7250P-647
CA2000
Control Board Mounting Panel (w/Screws)
Screw 1/4-20 x 1/2" (Control Board Mounting Panel) 7250P-184
Control Board Hold Down Clips
Control Board (w/Fuse)
7250P-352
7250P-317
7250P-378
7250P-332
7250P-707
7250P-133
7250P-221
7250P-235 (80M)
10 Fuse (Control Board)
11 Control Board Display (w/Ribbon Cable)
12 Electrical Box (w/Screws)
26 PVC Pipe Sch. 40 3" (Exhaust Assy)
7250P-242
13 Screws # 8 x 1/2" Self Tapping (Electrical Box)
14 Brass Nipple 1 x 1-1/4 x 3-3/4"
15 Cabinet Cover
27 S.S. Hex Nut 10-32 (Blocked Vent Pressure Switch)
28 O-Ring 007 (Blocked Vent Pressure Switch)
7250P-153
7250P-152
29 Hose Barb 1/4 x 10-32 (Blocked Vent Pressure Switch) 7250P-154
7250P-231 (140M/199M) 30 Plastic Tubing 3/16" ID (Blocked Vent Pressure Switch 7000P-805
12
GAS-FIRED BOILER
User Manual
REPLACEMENT PARTS (CONTINUED)
2
3
4
1
5
4
14
7
12
13
10
8
9
11
15
16
17
18
6
19
20
31
30
29
28
21
24
23
27
25
399M
26
19
22
REPLACEMENT PARTS
Item
#
Item
Description
Part #
Description
Part #
#
1
2
3
4
5
6
Thermodisc Flue ECO 210 F
7250P-089
7250P-151
7250P-311
7250P-667
7250P-096
7250P-695
16 Screws M5 x 14MM (Combustion Blower)
7250P-478
7500P-075
7250P-687
7250P-005
7500P-040
7250P-069
Steel Push Retainer (Thermistor)
17 Gasket (Air/Gas Channel to Combustion Blower)
18 Air/Gas Channel
PVC Black Tubing 1/8 ID (Thermistor)
Thermistor
19 Gasket (Flame Rec./Spark Electrode)
20 Spark Electrode (w/Gasket)
Water Pressure Switch
Gas Valve Assembly
21 Screws M4 x 8MM (Probe/Electrode)
7
8
Gas Valve Solenoid Kit
Eco/High Limit Sensor
7250P-701
7250P-019
22 Flame Rectification Probe (w/Gasket)
7250P-049
23 Screws Torx M5 x 22MM (Air/Gas Channel to Burner Door) 7250P-206
9
Screws M4 x 16MM (Air/Gas Mixer)
7250P-708
7250P-622
24 Gasket (Air/Gas Channel to Burner)
7500P-074
10 Welded Module
25 NIT Burner
7250P-703
7500P-067
11 Air/Gas Mixer (w/Rings, Cork Gasket, Screws) 7250P-545
26 Nuts M6 (Burner Door)
12 Relief Valve
7250P-080
SN1018
27 Burner Door
7250P-684
7250P-702
13 Brass Nipple 3/4 NPT x 3"
28 Burner Door Ceramic Refractory
14 Brass 90 Elbow - 3/4 NPT
7250P-313
7250P-518
29 Screw M4 x 8MM (Ceramic Target Wall)
30 Washer M4 (Ceramic Target Wall)
31 Ceramic Target Wall
7250P-704
7500P-109
7250P-160
15 Combustion Blower (w/Gasket)
13
GAS-FIRED BOILER
User Manual
REPLACEMENT PARTS (CONTINUED)
1
2
4
29
30
31
6
3
7
14
5
9
10
11
8
28
27
BOILER
SWITCH
CONDENSATE
OUTLET
26
25
12
13
14
24
22
23
21
20
15
19
16
17
18
399M
REPLACEMENT PARTS
Item
#
Item
Description
Part #
#
Description
Part #
1
Blocked Vent Pressure Switch
7250P-150
7250P-133
7250P-580
7250P-651
17 PVC Nipple Sch. 80 3/4 NPT (Condensate Assembly)
18 Spring Clamp (Condensate Assembly)
7250P-648
7250P-302
7250P-646
7250P-649
2
3
4
Screws # 8 x 1/2" Self Tapping (Blocked Vent Pressure Switch)
Relay Board
19 PVC Tee Sch. 30 3/4 NPT (Condensate Assembly)
20 Cable Clamp (Condensate Assembly)
Control Board Mounting Panel (w/Screws)
5
6
7
8
9
Screw 1/4-20 x 1/2" (Control Board Mounting Panel)
Control Board Hold Down Clips
Control Board (w/Fuse)
7250P-184
7250P-352
7250P-317
7250P-378
7250P-332
7250P-707
7250P-133
7250P-514
7250P-501
7250P-671
7250P-673
7250P-082
21 Screw # 8 x 1/2" Self Tapping (Condensate Assembly)
22 Poly Plug 3/4 NPT (Condensate Assembly)
23 Band Clamp (Exhaust Assembly)
7250P-133
7250P-647
7250P-549
7250P-524
7250P-153
7250P-152
Fuse (Control Board)
24 PVC Pipe Sch. 40 4" (Exhaust Assembly)
25 S.S. Hex Nut 10-32 (Blocked Vent Pressure Switch)
26 O-Ring 007 (Blocked Vent Pressure Switch)
Control Board Display (w/Ribbon Cable)
10 Electrical Box (w/Screws)
11 Screws # 8 x 1/2" Self Tapping (Electrical Box)
12 Brass Nipple 1-1/2 x 2 x 3-3/4"
13 Cabinet Cover
27 S.S. Hose Barb 1/4 x 10-32 (Blocked Vent Pressure Switch) 7250P-154
28 Plastic Tubing 3/16" ID (Blocked Vent Pressure Switch)
29 5 Pin Wiring Harness (location)
7000P-805
7250P-696
7250P-697
7250P-699
14 Cabinet Latch and Gasket Kit (w/Screws)
15 Leveling Foot
30 9 Pin Wiring Harness (location)
31 Low Voltage Wiring Harness (location)
16 Condensate Hose Assy
14
© 2006 Heat Transfer Products, Inc.
LP-182 REV. 12/18/06
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