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Boiler ManualGAS-FIRED BOILERPART 2: HOW BOILER OPERATESMunchkin Condensing Technology is an intelligent system that delivers highly efficient hydronic heating, while maximizing efficiency by measuring the Data Parameters of your heating system.1. Stainless Steel Heat ExchangerThe highly efficient durable MunchkinStainless Steel Heat Exchanger is designed totake the colder return water from the systemand extract the last bit of energy before it isexhausted. The heat exchanger design isseparated by an internal baffle which divertsthe exhaust gas through the primary heatexchanger into the secondary heat exchangerwhere the colder return water extracts the lastresidual heat.2. Modulating Combustion SystemModulation during the central heatingoperation is based on the supply temperature.The set point used for the control dependsupon the programmed central heating curve.The slope of the heating curve can be changedby the installer of the Munchkin in the sensethat both turning points of the curve can bemoved. The control monitors the system toregulate the output of the burner duringoperation to match the system demand. Thisincrease in efficiency allows for substantial fuelsavings.3. Gas ValveThe gas valve senses suction from the blower,allowing gas to flow only if the gas valve ispowered and combustion air is flowing.4. Supply water temperature sensorThis sensor monitors boiler output watertemperature (system supply). The controlmodule adjusts the boiler firing rate so theoutlet temperature is correct.5. Return water temperature sensorThis sensor monitors the return watertemperature (system return). The controlmodule reduces or increases boiler input,depending on how close the return watertemperature is to the outlet watertemperature.6. Temperature and pressure gaugeAllows the user to monitor the systems5temperature and pressure.7. ControlThe integrated control system monitors thereturn and supply water and regulates the fanspeed to regulate the unit’s BTU output. Thisallows the unit to only deliver the amount ofheated energy required and nothing more!8. BurnerConstructed of high grade stainless steelconstruction, the burner uses pre-mixed airand gas and provides a wide range of firingrates.9. Electrical field connections with terminalstripsThe electrical cover plate allows access theline voltage terminal strip and the low voltageterminal strip. Attach line voltage conduits tothe three holes at the right of the line voltageterminal strip for power, CH pump and DHWpump. Route low voltage wires through theopening to the left of the low voltage terminalstrip. (See Field Wiring Instructions Part 9.)10. Condensate drain connectionThis is a condensing high efficiency appliance,therefore this unit has a condensate removalsystem. Condensate is nothing more thanwater vapor, derived from the combustionproducts, similar to an automobile when it isinitially started. It is very important that thecondensate line is sloped away from the boilerand down to a suitable inside drain, if thecondensate outlet on the Munchkin is lowerthan the drain, you must use a condensateremoval pump (kit p/n 554200 available fromHeat Transfer Products, Inc.) A condensatefilter, if required by local authorities can bemade up of lime crystals, marble or phosphatechips and will neutralize the condensate. Thiscan be done in the field by the installer or youmay purchase one from Heat TransferProducts, Inc. (P/N N1100). It is also veryimportant that the condensate line is notexposed to freezing temperatures or any othertype of blockage. Plastic tubing must be theonly material used for the condensate line.Steel, brass, copper or others will be subjectto corrosion or deterioration. A second ventmay be necessary to prevent condensate linevacuum lock if a long horizontal run is used.

Boiler ManualGAS-FIRED BOILERPART 2: HOW BOILER OPERATES (CONT’D)Also, an increase in pipe size may benecessary to drain properly. Support of thecondensation line may be necessary to avoidblockage of the condensate flow.11. Spark ignitionThe burner flame is ignited by applying a highvoltage to the system spark electrode. Thiscauses a spark from electrode to ground.12. The Vision 1 SystemThe Vision I System will allow the installingcontractor to take the highly efficientmodulating Munchkin and make it even moreefficient by controlling the temperaturedelivered to the central heating circuits basedon the outside temperature. The Vision Isystem is also a two temperature system, onetemperature for central heating and the othertemperature to the Super Stor Ultra Indirectwater heater. This allows the user to increasethe temperature supplied to the Super StorUltra indirect water heater to get a fastrecovery by prioritizing the flow at a highertemperature than may be needed for thecentral heating circuits (this will require twoseparate circulators). You must follow thepiping, wiring and programming instructionslocated in the Vision One section of thismanual. The Vision 1 kit consists of thefollowing, which is included with yourequipment Outdoor sensor – 7250P-319 Indirect tank sensor – 7250P-325PART 3: PREPARE BOILER LOCATIONA. BOILER LOCATION SHOULD BE LEVELCAUTIONWhen preparing the boiler location, make sure the area where you are placing the boiler is level. In orderfor the condensate to flow to the location of the condensate hose, the boiler must be slightly pitchedback to assure proper flow direction. The Munchkin Boiler comes equipped with leveling feet. Shouldyou find the floor beneath the boiler is uneven, with a wrench, adjust the leveling feet so the boiler ispitched back at 1/8” per footINCORRECTCORRECT6

Boiler ManualGAS-FIRED BOILERPERFORMANCE RATINGSCONNECTION SIZESModelInput ModulationDOE HeatingAFUET50MT80M80M140M199M399M18,000 to 50,00019,000 to 80,00027,000 to 80,00046,000 to 140,00066,000 to 199,000100,000 to 399,00016,000 to 46,00017,000 to 74,00025,000 to 74,00043,000 to 129,00061,000 to 183,00093,000 to 279,00092%92%92%92%92%92%DIMENSIONST50M/T80MFigure 2-17ShippingWeight*IBR58 lbs. 40,00058 lbs. 64,00075 lbs. 64,000101 lbs. 112,000111 lbs. 159,000252 lbs.N/ASupply/GasVentReturn ConnectionDia.ConnectionSize1 1/4" NPT3/4"2"1 1/4" NPT3/4"2"1 1/4" NPT3/4"3"1 1/4" NPT3/4"3"1 1/4" NPT3/4"3"2" NPT1-1/4"4"FAN 40015501675

GAS-FIRED BOILERBoiler ManualDIMENSIONS80MFigure 2-2140M/199MFigure 2-38

Boiler ManualGAS-FIRED BOILERDIMENSIONS399MFigure 2-4PART 3: PREPARE BOILER LOCATION (CONTINUED)B. INSTALLATIONS MUST COMPLY WITH: Local, state, provincial, and national codes,laws, regulations and ordinances. National Fuel Gas Code, ANSI Z223.1 – latestedition. Standard for Controls and Safety Devices forAutomatically Fired Boilers, ANSI/ASMECSD-1, when required. National Electrical Code. For Canada only: B149.1 or B149.2Installation Code, CSA C22.1 CanadianElectrical Code Part 1 and any local codes.NOTICEThe Munchkin Boiler gas manifold and controlsmet safe lighting and other performance criteriawhen boiler underwent tests specified in ANSIZ21.13 — latest edition.9C. BEFORE LOCATING THE BOILER1. Check for nearby connection to: System water piping Venting connections Gas supply piping Electrical power2. Check area around boiler. Remove anycombustible materials, gasoline and otherflammable liquids.WARNINGFailure to keep boiler area clear and free ofcombustible materials, gasoline and otherflammable liquids and vapors can result insevere personal injury, death or substantialproperty damage.3. The Munchkin gas control system componentsare protected from dripping or spraying water

Boiler ManualGAS-FIRED BOILERPART 3: PREPARE BOILER LOCATION (CONTINUED)or rain during operation or service.WARNING4. If the Munchkin Boiler is to replace anexisting boiler, check for and correct anyexisting system problems such as: System leaks. Incorrectly-sized expansion tank. Lack of freeze protection in boiler watercausing system and boiler to freeze and leak. Excessive glycol which will affect theboiler system operation.The space must be provided with combustion/ventilation air openings correctly sized forall other appliances located in the same space asthe Munchkin boiler. The boiler cover must be securely fastened to the boiler to prevent boilerfrom drawing air from inside the boiler room.This is particularly important if the boiler is located in the same room as other appliances.Failure to comply with the above warnings couldresult in severe personal injury, death or substantial property damage.D. CLEARANCES FOR SERVICE ACCESS1. See Figure 3-1 for recommended serviceclearances. If you do not provide minimumclearances shown, it might not be possible toservice the boiler without removing it fromthe space.80M/140M/199M/399ME. RESIDENTIAL GARAGE INSTALLATIONPrecautionsTake the following special precautions wheninstalling the boiler in a residential garage. If theboiler is located in a residential garage, per ANSIZ223.1, paragraph 5.1.9: Mount the boiler with a minimum of 18inches above the floor of the garage to thebottom of the boiler to ensure the burner andignition devices will be no less than 18 inchesabove the floor. Locate or protect the boiler so it cannot bedamaged by a moving vehicle.F. EXHAUST VENT AND INTAKE AIR VENTT50M/T80MThe Munchkin Boiler requires a special vent system, designed for pressurized venting.Munchkin Boilers are rated ANSI Z21.13Category IV (pressurized vent, likely to condense in the vent).You must also install air intake piping from outside to the boiler flue adaptor. The resultantinstallation is categorized as direct vent (sealedcombustion). Note: To prevent combustionair contamination see Table 3-2 in thissection when considering exhaust ventand intake air vent termination.Intake and exhaust must terminate near eachother and may be vented vertically through theroof or out a side wall. The intake and exhuastventing methods are detailed in the VentingSection. Do not attempt to install the MunchkinBoiler using any other means. Be sure to locatethe boiler such that the air intake and exhaustFigure 3-1: Clearances required10

Boiler ManualGAS-FIRED BOILERPART 3: PREPARE BOILER LOCATION (CONTINUED)vent piping can be routed through the buildingand properly terminated. The air intake andexhaust vent piping lengths, routing and termination method must all comply with the methodsand limits given in the Venting section.G. PREVENT COMBUSTION AIR CONTAMINATIONInstall intake air piping for the Munchkin Boileras described in the Venting section. Do not terminate exhaust in locations that can allow contamination of intake air.WARNINGYou must pipe outside air to the boiler airintake. Ensure that the intake air will notcontain any of th

Feb 20, 2007 · Munchkin Condensing Technologyis an intelli-gent system that delivers highly efficient hydron-ic heating, while maximizing efficiency by meas-uring the Data Parameters of your heating sys-tem. 1. Stainless Steel Heat Exchanger The highly efficient durable Munchkin Stainless Steel Heat Exchanger is designed to take the colder return water from .