Summary of Contents for Munchkin Gas-Fired Hot Water Boiler
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Boiler Manual This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
GAS-FIRED BOILER PART 1: 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...
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PART 1: PRODUCT AND SAFETY INFORMATION WARNING Installer — Read all instructions in this manual, and Munchkin Venting section, before installing. Perform steps in the order given. User — This manual is for use only by a qualified heating installer/service technician.
The slope of the heating curve can be changed by the installer of the Munchkin in the sense that both turning points of the curve can be moved. The control monitors the system to regulate the output of the burner during operation to match the system demand.
The Munchkin Boiler comes equipped with leveling feet. Should you find the floor beneath the boiler is uneven, with a wrench, adjust the leveling feet so the boiler is pitched back at 1/8”...
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GAS-FIRED BOILER PERFORMANCE RATINGS Model Input Modulation DOE Heating T50M 18,000 to 50,000 16,000 to 46,000 T80M 19,000 to 80,000 17,000 to 74,000 27,000 to 80,000 25,000 to 74,000 140M 46,000 to 140,000 43,000 to 129,000 92% 101 lbs. 112,000 199M 66,000 to 199,000 61,000 to 183,000 92% 111 lbs.
For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes. NOTICE The Munchkin Boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13 — latest edition.
GAS-FIRED BOILER PART 3: PREPARE BOILER LOCATION or rain during operation or service. 4. If the Munchkin Boiler is to replace an existing boiler, check for and correct any existing system problems such as: • System leaks. • Incorrectly-sized expansion tank.
Venting section. G. PREVENT COMBUSTION AIR CONTAMINATION Install intake air piping for the Munchkin Boiler as described in the Venting section. Do not ter- minate exhaust in locations that can allow con- tamination of intake air.
• Do not pipe the discharge to any place where freezing could occur. • No shutoff valve shall be installed between the relief valve and boiler, or in the discharge line. Do not plug or place any obstruction in the discharge line.
A low water cutoff may be required by state local code or some insurance companies. Check code requirements before installation of the Munchkin Boiler. It is also required that a low water cutoff be used if the boiler is installed above the piping level.
G. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES AND MULTIPLE BOILERS The Munchkin Boiler is designed to function in a closed loop 15 PSI System. A factory installed water pressure switch will ensure that you have adequate pressure in the system. The Munchkin Boiler will not operate without a minimum of 10 PSI water pressure.
*See drawings on the following pages (CONTINUED) H. CIRCULATOR SIZING The Munchkin Boiler Heat Exchanger does have pressure drop which must be considered in your system design. Refer to the graph in Fig. 5- 1 below for pressure drop through the Munchkin Boiler Heat Exchanger for recom- mended pump selection at a 20∆t design.
GAS-FIRED BOILER PART 5: BOILER PIPING The chart below represents the various system temperatures, their respective flows and friction loss through the Munchkin which will aid in circulator selection. 20°∆t Friction Friction Model Flow Feet Feet G P M T-50 6.5’...
J. ZONING WITH ZONE VALVES 1. Connect boiler to system as shown in 2A and 2B in Piping Details when zoning with zone valves. The primary/secondary piping shown ensures the boiler loop will have sufficient flow.
The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M . All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M . All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
It is important that the system piping is done correctly when using the Vision 1 System. Follow the piping diagrams 2A through 3G when piping your Munchkin Boiler with Vision I. All general piping practices should still be main- tained.
The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M . All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
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The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches and 2 inches for the 399M. All pumps are shown with isolation flanges and integral flow check valves.
GAS-FIRED BOILER PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL DANGER Munchkin Boiler must be vented as detailed in Venting section Part 7. Ensure the exhaust and intake piping comply with these instructions regarding vent system. Inspect finished combustion air intake and...
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6 feet (1.8 m). Minimum distance between exhaust vent and intake air vent on single boiler is 8” (0.2 m) center-to-center. Minimum distance between exhaust vents and intake air vents on multiple boilers is 8”...
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(Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Fig. 7-1 Fig. 7-2 Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot Fig. 7-3 Multiple Stainless Steel Horizontal Vent Kit Installation – Front View Boiler Manual Figure 7-4 Multiple Boiler Installations...
Connection 2" 3" 4" c. If the transition occurs at a distance greater than 15 equivalent feet from the boiler, the maximum equivalent length will be reduced. See Table 7.7. Table 7.7: Vent Termination Kits Transition Point (ft from boiler)
4 foot intervals to prevent sagging of the pipe where condensate may form. 6. Do not use the boiler to support any piping. 7. A screened straight coupling is provided with the boiler for use as an outside exhaust termination.
Munchkin Boiler is lower than the drain, you must use a condensate removal pump (kit P/N 554200 available from Heat Transfer Products, Inc.) A condensate filter, if required by local...
NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the appliance and the balance at 4 foot invervals on the vent pipe. The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
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NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the appliance and the balance at 4 foot invervals on the vent pipe. The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the appliance and the balance at 4 foot invervals on the vent pipe. The boiler venting must be readily accessible for visual inspection for the first three feet from the boiler.
National Fuel Gas Code. You must ensure that the entire gas line to the connection at the Munchkin is no smaller than ¾". Once all the inspections have been performed, the piping must be leak tested.
VALVE Fig. 8-2 For gas conversions for a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under “Startup” section of this manual. See separate natural to propane conversion instructions for conversion of an existing boiler available from Heat Transfer Products.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes. B. FIELD WIRING The Munchkin Boiler box has a 24 volt terminal GAS VALVE SHUT OFF INLET SOLENOID THROTTLE SCREW OUTLET SOLENOID...
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GAS-FIRED BOILER PART 9: FIELD WIRING Fig. 9-1 Fig. 9-2 (CONTINUED) Fig. 9-3 Fig. 9-4 Boiler Manual...
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Boiler Manual GAS-FIRED BOILER PART 9: FIELD WIRING (CONTINUED) Fig. 9-5...
150 feet. Length of wire run cannot exceed 150 feet. Outdoor Sensor is connected in the junction box on the Munchkin Boiler. Route wires from the Munchkin Boiler terminal strip to your out- door sensor, which will allow the user to change the temperature going to the Central Heating loop automatically.
Water pH between 6.0 and 8.0 1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water treatment company.
Connect a hose to the purge valve and route hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and fill connection to the system. c. Close zone isolation valves.
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.)
In addition to changing the tem- perature you are also allowed to change three more settings in this model (1. Munchkin differ- ential – 2. Indirect setting (with Vision System) (CONTINUED) –...
( ( C C O O 2 2 % % ) ) A. PROGRAMMING THE VISION I OPTION The Vision I allows the installer to set system limits and the heat curve for the Munchkin Boiler. These system limits should not be changed by the user. It is important to document...
Maximum Outside Design Temperature. Range: 32ºF to 180ºF 68º F Allows the installer to set the low- est temperature on the Munchkin for Central Heating. Range: 32ºF to 180ºF 0 Min. Allows the installer to change the...
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— cascade slave) (Not currently used.) Interface Board Activation 0 = not active 1 = active WARNING: Never change the de- fault setting without the Munchkin Interface Board installed.** Interface Board Function 0 = Building Management 1 = Enables Tekmar Modulating control.
GAS-FIRED BOILER PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION CENTRAL HEATING CURVE Factory Default 201˚ FUNCTION 9 FUNCTION 11 5˚ OUTSIDE TEMPERATURE (F) Fig. 13-1 CONTROL PROGRAM REFERENCE CHART Function Fig. 13-3 DEFAULT RESET CURVE 68˚ Fig. 13-2...
PART 14: TROUBLESHOOTING A. MUNCHKIN ERROR CODE An error code may occur in the installation of the Munchkin. This condition may lead to a lock out condition of the controller, which will need to be manually reset through the S4/Reset but- ton.
Description 1. Check circulation pump operation 2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the return thermister to the supply thermister. 3. Check thermister reading on supply thermister. Replace switch if faulty.
6652 5522 BEFORE EACH HEATING SEASON A trained and qualified service technician should perform the inspections as per the boiler inspection and maintenance schedule in the back of manual. Failure to do so could result in death or serious injury.
“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.
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GAS-FIRED BOILER PART 15: MAINTENANCE T50M/T80M T50M/T80M Item Description Thermodisc Flue ECO 210 F Steel Push Retainer (Thermodisc Flue ECO) PVC Black Tubing 1/8 ID (Thermodisc Flue ECO) Relief Valve Thermistor Water Pressure Switch ECO High Limit Sensor Aluminum Elbow...
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GAS-FIRED BOILER PART 15: MAINTENANCE T50M/T80M T50M/T80M Item Description Exhaust Vent Pipe - 2" PVC Pipe Coupling Exhaust Manifold Tube Air Inlet Baffle Plastic Tubing 3/16" ID (Blocked Vent Pressure Switch) 7000P-805 Control Board Display (w/Ribbon Cable) Blocked Vent Pressure Switch Screws # 8 x 1/2"...
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GAS-FIRED BOILER PART 15: MAINTENANCE 80M/140M/199M Item # Description Thermistor Thermodisc Flue ECO 210 F Steel Push Retainer (Thermodisc Flue ECO) PVC Black Tubing 1/8 ID (Thermodisc Flue ECO) Water Pressure Switch Eco/High Limit Sensor Dungs Gas Valve Screws M4 x 12MM (Gas Valve)
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GAS-FIRED BOILER PART 15: MAINTENANCE 80M/140M/199M Item Description Blocked Vent Pressure Switch Screws # 8 x 1/2" (Blocked Vent Pressure Switch) Low Voltage Wiring Harness (location) 9 Pin Wiring Harness (location) 5 Pin Wiring Harness (location) Control Board Mounting Panel (w/Screws) Screw 1/4-20 x 1/2"...
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GAS-FIRED BOILER PART 15: MAINTENANCE 399M Item Description Thermodisc Flue ECO 210 F Steel Push Retainer (Thermodisc Flue ECO) PVC Black Tubing 1/8 ID (Thermodisc Flue ECO) 7250P-311 Thermistor Water Pressure Switch Krom Schroder Gas Valve Assembly Gas Valve Solenoid Kit...
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GAS-FIRED BOILER PART 15: MAINTENANCE 399M Item Description Blocked Vent Pressure Switch Screws # 8 x 1/2" Self Tapping (Blocked Vent Pressure Switch) Relay Board Control Board Mounting Panel (w/Screws) Screw 1/4-20 x 1/2" (Control Board Mounting Panel) Control Board Hold Down Clips...
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