Munchkin pmn User Manual

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.  
6
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.  
8
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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