Munchkin Gas-Fired Hot Water Boiler Manual
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Munchkin Gas-Fired Hot Water Boiler Manual

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.
• Installation
• Startup
• Maintenance
• Parts
WARNING

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Summary of Contents for Munchkin Gas-Fired Hot Water Boiler

  • Page 1 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.

  • Page 2: Table Of Contents

    Part 6 – Boiler Piping with Vision 1 System ........25 – Boiler Piping Details With Vision I System ......26-35 A.
  • Page 3 Part 15 – Maintenance........... 61-66 A. Maintenance Procedures B. Combustion Chamber Coil Cleaning Instructions Part 16 – Boiler Inspection and Maintenance Start-Up Charts ....67-69 Boiler Manual...

  • Page 4: Part 1: Product And Safety Information

    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...
  • Page 5 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.

  • Page 6: Part 2 - How The Boiler Operates

    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.

  • Page 7: Part 3: Prepare Boiler Location

    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”...
  • Page 8 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.
  • Page 9 Boiler Manual GAS-FIRED BOILER DIMENSIONS Figure 2-2 140M/199M Figure 2-3...

  • Page 10: Installations Must Comply With

    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.

  • Page 11: Clearances For Service Access

    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.

  • Page 12: Prevent Combustion Air Contamination

    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.

  • Page 13: Part 4: Prepare Boiler

    • 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.

  • Page 14: General Piping Information

    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.

  • Page 15: Hydronic Piping With Circulators, Zone Valves And Multiple Boilers

    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.

  • Page 16: Circulator Sizing

    *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.

  • Page 17: Fill And Purge Heating System

    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’...

  • Page 18: Zoning With Zone Valves

    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.

  • Page 19: Boiler Piping Details

    4-way motorized mixing valve 3-way motorized mixing valve pressure relief valve backflow preventer float -type air vent union heat exchanger vacuum breaker radiant manifold Boiler Manual Munchkin heater Super Stor indirect DHW tank...

  • Page 20: Space Heating Mode

    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.
  • Page 21 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.
  • Page 22 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.
  • Page 23 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.
  • Page 24 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.
  • Page 25 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.

  • Page 26: Part 6 - Boiler Piping With Vision 1 System

    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.

  • Page 27: Boiler Piping Details With The Vision I System

    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.
  • Page 28 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.
  • Page 29 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.
  • Page 30 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.
  • Page 31 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.
  • Page 32 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.
  • Page 33 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.
  • Page 34 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.
  • Page 35 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.
  • Page 36 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.

  • Page 37: Part 7 - Venting Combustion Air And Condensate Removal

    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...
  • Page 38 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”...
  • Page 39 (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...

  • Page 40: Exhaust Vent And Intake Air Vent Sizing

    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)

  • Page 41: Heater Removal From A Common Vent System

    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.

  • Page 42: Condensate Removal System

    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...

  • Page 43: Diagrams For Sidewall Venting

    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.
  • Page 44 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.

  • Page 45: Diagrams For Vertical Venting

    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.

  • Page 46: Part 8: Gas Piping

    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.

  • Page 47: Dungs Gas Valve

    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.

  • Page 48: Part 9: Field Wiring

    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...
  • Page 49 GAS-FIRED BOILER PART 9: FIELD WIRING Fig. 9-1 Fig. 9-2 (CONTINUED) Fig. 9-3 Fig. 9-4 Boiler Manual...
  • Page 50 Boiler Manual GAS-FIRED BOILER PART 9: FIELD WIRING (CONTINUED) Fig. 9-5...

  • Page 51: Part 10 - Field Wiring - Vision 1

    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.

  • Page 52: Part 11. Start-Up Preparation

    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.

  • Page 53: Purge Air From Water System

    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.

  • Page 54: Condensate Removal

    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.)

  • Page 55: Operating Instructions

    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) –...

  • Page 56: Test Mode

    ( ( 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...

  • Page 57: Vision I Program Navigation

    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...
  • Page 58 — 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.

  • Page 59: Part 13 – Start-Up Procedures With The Vision 1 Option

    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...

  • Page 60: Part 14: Troubleshooting

    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.

  • Page 61: 925 Control Board Fault Codes

    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.

  • Page 62: Part 15: Maintenance

    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.

  • Page 63: Combustion Chamber Coil Cleaning Instructions

    “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.
  • Page 64 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...
  • Page 65 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"...
  • Page 66 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)
  • Page 67 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"...
  • Page 68 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...
  • Page 69 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...
  • Page 70 Boiler Manual GAS-FIRED BOILER...
  • Page 71 Boiler Manual GAS-FIRED BOILER...
  • Page 72 Boiler Manual GAS-FIRED BOILER...

  • Page 73: Maintenance Notes

    MAINTENANCE NOTES...
  • Page 74 MAINTENANCE NOTES...
  • Page 75 MAINTENANCE NOTES...
  • Page 76 © 2007 Heat Transfer Products, Inc. LP-185 REV. 2/20/07...

This manual is also suitable for:

Heattransfer t-50Heattransfer t-80Heattransfer 399m

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