Munchkin Gas-fired Hot Water Boiler Manual
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Munchkin Gas-fired Hot Water Boiler Manual

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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 • Installation Boiler • Startup Manual • Maintenance • Parts WARNING 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

    Boiler Manual GAS-FIRED BOILER CONTENTS Part 1 – Product and Safety Information ........4-6 Part 2 –...
  • Page 3 Boiler Manual GAS-FIRED BOILER CONTENTS (CONT’D) Fill and Purge Heating System Zoning with Zone Valves K. Zoning with Circulators Multiple Boilers M. Boiler Piping Details Part 6 – Boiler Piping with Vision 1 System ........27 –...
  • Page 4 Part 14 – Trouble Shooting ..........61-63 A. Munchkin Error Code B.

  • Page 5: Part 1: Product And Safety Information

    Boiler Manual 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 DANGER CAUTION...
  • Page 6 (CONT’D) Before Installing WARNING WHEN SERVICING BOILER Installer — Read all instructions in this manual, and Munchkin Venting section, before installing. • To avoid electric shock, disconnect electrical Perform steps in the order given. supply before performing maintenance. User — This manual is for use only by a •...

  • Page 7: Part 2 - How The Boiler Operates

    The slope of the heating curve can be changed return and supply water and regulates the fan by the installer of the Munchkin in the sense speed to regulate the unit’s BTU output. This that both turning points of the curve can be allows the unit to only deliver the amount of moved.
  • Page 8 Condensate is nothing more than modulating Munchkin and make it even more water vapor, derived from the combustion efficient by controlling the temperature products, similar to an automobile when it is delivered to the central heating circuits based initially started.

  • Page 9: 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 10 Boiler Manual GAS-FIRED BOILER MUNCHKIN RESIDENTIAL BOILER Model Input Modulation DOE Heating Net I=B=R Boiler Water Vent Fan Speeds Ship. Number BTU / hr BTU / hr Ratings BTU / hr AFUE% Water Connections Connections Size High Low T50M 18,000–50,000...
  • Page 11 Boiler Manual GAS-FIRED BOILER DIMENSIONS Figure 2-2 140M/199M Figure 2-3...

  • Page 12: Installations Must Comply With

    NOTICE flammable liquids and vapors can result in severe personal injury, death or substantial The Munchkin Boiler gas manifold and controls property damage. met safe lighting and other performance criteria when boiler underwent tests specified in ANSI 3.

  • Page 13: Clearances For Service Access

    PART 3: PREPARE BOILER LOCATION (CONTINUED) or rain during operation or service. WARNING 4. If the Munchkin Boiler is to replace an The space must be provided with combus- existing boiler, check for and correct any tion/ventilation air openings correctly sized for...

  • Page 14: Prevent Combustion Air Contamination

    DANGER and limits given in the Venting section. Do not install the Munchkin Boiler into a G. PREVENT COMBUSTION AIR CONTAMINATION common vent with any other appliance. This will cause flue gas spillage or appliance...

  • Page 15: Part 4: Prepare Boiler

    Boiler Manual GAS-FIRED BOILER PART 3: PREPARE BOILER LOCATION (CONTINUED) minutes of main burner operation. Use the g. Any improper operation of common venting flame of a match or candle, or smoke from a system should be corrected so the cigarette, cigar, or pipe.
  • Page 16 Always install Munchkin Boiler. It is also required that a low the system fill connection at the same point water cutoff be used if the boiler is installed as the expansion tank connection to the above the piping level.
  • Page 17 32 F to 180 F , while water expands 3% with the same temperature rise. The Munchkin Boiler is designed to function in a closed loop 15 PSI System. A factory installed Basic steps are listed below, with Illustration,...
  • Page 18 Pipe the discharge of the safety relief valve to prevent injury in the event of pressure The Munchkin Boiler Heat Exchanger does have relief. Pipe the discharge 6” above the drain to pressure drop which must be considered in a drain.
  • Page 19 Boiler Manual GAS-FIRED BOILER PART 5: BOILER PIPING (CONTINUED) The chart below represents the various system temperatures, their respective flows and friction loss through the Munchkin which will aid in circulator selection. SYSTEM TEMPERATURE RISE CHART 20°∆t 25°∆t 30°∆t 35°∆t 40°∆t...
  • Page 20 Boiler Manual GAS-FIRED BOILER PART 5: BOILER PIPING (CONTINUED) K. ZONING WITH CIRCULATORS CAUTION 1. Connect boiler to system when circulator It is highly recommended that you carefully zoning as shown in 2C and 2D in Piping follow the glycol manufacturer’s recommended Details when zoning with circulators.

  • Page 21: Boiler Piping Details

    4-way motorized flow-check valve mixing valve spring-loaded check valve 3-way motorized Munchkin heater mixing valve hose bib / boiler drain pressure relief valve thermostatic radiator valve TRV (straight) backflow preventer thermostatic radiator valve TRV (angle)

  • Page 22: 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 23 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 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 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 27 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 28 Follow the piping diagrams 3A through 4H when C. ZONING WITH CIRCULATORS USING VISION I piping your Munchkin Boiler with Vision I. All general piping practices should still be main- 1. Connect the boiler to the system as shown in tained.
  • 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: Zoning With Circulators

    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 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 38 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 39: Part 7 - Venting Combustion Air And Condensate Removal

    GAS-FIRED BOILER PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL Table 7.1 DANGER APPROVED VENTING MATERIAL Munchkin Boiler must be vented as detailed in Venting section Part 7. Ensure the exhaust and Standards for Installation in: Item Material intake piping comply with these instructions...
  • Page 40 Boiler Manual GAS-FIRED BOILER PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) d. Provide a minimum of 1 foot distance Provide 4 feet clearance from the inside from any door, operable window, or corner of vertical walls, chimneys, etc., as gravity intake into any building.
  • Page 41 Boiler Manual GAS-FIRED BOILER Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Fig. 7-2 Fig. 7-3 Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot Figure 7-5 Multiple Boiler Installations Fig.

  • Page 42: Exhaust Vent And Intake Air Vent Sizing

    Boiler Manual GAS-FIRED BOILER PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) d. Effort should be made to keep a E. EXHAUST VENT AND INTAKE AIR VENT minimum difference in equivalent length SIZING between the intake air vent pipe and the exhaust vent.

  • Page 43: Heater Removal From A Common Vent System

    Boiler Manual GAS-FIRED BOILER PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED) 2. All joints must be properly cleaned, primed, venting system placed in operation, while the and cemented. Use only cement and primer other appliances remaining connected to com- approved for use with the pipe material.
  • Page 44 Use materials approved by the authority having the Munchkin Boiler is lower than the drain, you jurisdiction. In the absence of other authority, must use a condensate removal pump (kit P/N PVC and CPVC pipe must comply with ASTM.

  • Page 45: Diagrams For Sidewall Venting

    Boiler Manual GAS-FIRED BOILER J. DIAGRAMS FOR SIDEWALL VENTING SIDEWALL VENTING WITH TEE (INTAKE) SIDEWALL VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST) AND COUPLING (EXHAUST) INTAKE AIR VENT INTAKE AIR 1" MIN. VENT STRAIGHT COUPLING 12" MIN. TOP VIEW EXTERIOR WALL EXHAUST VENT STRAIGHT...
  • Page 46 Boiler Manual GAS-FIRED BOILER SIDWALL VENTING WITH KIT SIDEWALL VENTING WITH CONCENTRIC VENT KIT INTAKE AIR VENT VENT KIT SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL NOTE: INTAKE LEG AND VERTICAL PIPING MUST BE FACING UP 1" MIN. TOP VIEW EXHAUST VENT VENT KIT...

  • Page 47: Diagrams For Vertical Venting

    Boiler Manual GAS-FIRED BOILER K. DIAGRAMS FOR VERTICAL VENTING ROOF VENT WITH TEE (INTAKE) ROOF VENT WITH AND COUPLING (EXHAUST) CONCENTRIC VENT KIT 10'-0" MIN. STRAIGHT COUPLING 24" MIN. 10'-0" MIN. 12" OVER MAXIMUM SNOW LEVEL OR 24" WHICHER IS GREATER 12"...

  • Page 48: Gas Connection

    Fuel Gas Code. You must ensure that the entire sized for the proper flow and length of pipe, to gas line to the connection at the Munchkin is no smaller than ¾". Once all the inspections have avoid pressure drop. Both the gas meter and the been performed, the piping must be leak tested.

  • Page 49: Dungs Gas Valve

    Boiler Manual GAS-FIRED BOILER PART 8: GAS PIPING (CONTINUED) service to an area to provide maintenance to their As an additional safety feature, this gas valve has lines. This gas valve must not be replaced with a a flanged connection to the swirl plate and blower. conventional gas valve under any circumstances.

  • Page 50: Installation Must Comply With

    2. In Canada, CSA C22.1 Canadian Electrical set to match total electrical power Code Part 1, and any local codes. requirements of connected devices. See B. FIELD WIRING specifications of the device and thermostat instructions for details. The Munchkin Boiler box has a 24 volt terminal...
  • Page 51 Boiler Manual GAS-FIRED BOILER PART 9: FIELD WIRING (CONTINUED) Fig. 9-3 Fig. 9-1 Fig. 9-2 Fig. 9-4...
  • Page 52 Boiler Manual GAS-FIRED BOILER PART 9: FIELD WIRING (CONTINUED) Fig. 9-5...

  • Page 53: Part 10 - Field Wiring - Vision 1

    Outdoor Sensor is connected on the terminal when the water heater sensor reads a call for strip in the junction box on the Munchkin Boiler. heat, the installer can program the post purge Route wires from the Munchkin Boiler terminal function on the circulator.

  • Page 54: Check/Control Water Chemistry

    Boiler Manual GAS-FIRED BOILER PART 11. START-UP PREPARATION ically due to degradation of inhibitors over time. A. CHECK/CONTROL WATER CHEMISTRY Follow all fluid manufacturer’s instructions. WARNING B. FREEZE PROTECTION (WHEN USED) Do not use petroleum-based cleaning or sealing WARNING compounds in boiler system. Damage to elastomer seals and gaskets in system could NEVER use automotive or standard glycol occur, resulting in substantial property damage.

  • Page 55: Purge Air From Water System

    Boiler Manual GAS-FIRED BOILER PART 11. START-UP PREPARATION (CONTINUED) one at a time, beginning with lowest WARNING floor. Close vent when water squirts out. Repeat with remaining vents. Eliminate all system leaks. Continual fresh make-up water will reduce boiler life. Minerals Refill to correct pressure.

  • Page 56: Condensate Removal

    • Do not try to light any appliance. 5. The Munchkin Boiler shall be installed so the gas ignition system • Do not touch any electric switch; do not use any phone in your building.

  • Page 57: Operating Instructions

    In addition to changing the tem- it will measure the actual temperature. perature you are also allowed to change three (Vision option.) more settings in this model (1. Munchkin differ- d4 — Not used ential – 2. Indirect setting (with Vision System)

  • Page 58: Test Mode

    Listed below are the rec- d6 — Actual Fan speed multiplied by 10 ommended limits on each Munchkin Boiler and (Example: If fan speed displayed is the Combustion Settings. Automatic modulation |410| RPM x 10 = 4100 actual fan...

  • Page 59: Programming The Vision I Option

    The Vision I allows the installer to set system limits and the heat curve for the Munchkin I n s t a l l e r w i l l p r o g r a m f o r Boiler.
  • Page 60 32ºF to 180ºF 0 = off 68º F Allows the installer to set the low- 185° Indirect boiler set point (flow) est temperature on the Munchkin Temperature default = 119° to for Central Heating. Range: 32ºF 180° to 180ºF Not applicable 0 Min.
  • Page 61 Boiler Manual GAS-FIRED BOILER PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED) CENTRAL HEATING CURVE CENTRAL HEATING CURVE Factory Default Plot your Curve 201˚ FUNCTION 9 DEFAULT RESET CURVE FUNCTION 11 5˚ 68˚ OUTSIDE TEMPERATURE (F) OUTSIDE TEMPERATURE (F) Fig.

  • Page 62: Munchkin Error Code

    An error code may occur in the installation of When servicing or replacing any components of this boiler be certain that: the Munchkin. This condition may lead to a lock • The gas is off. out condition of the controller, which will need •...
  • Page 63 Boiler Manual GAS-FIRED BOILER PART 14: TROUBLESHOOTING (CONTINUED) Table 14-2: 925 Control Board FAULT Codes Code Description Remedy 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.

  • Page 64: Maintenance Procedures

    Boiler Manual GAS-FIRED BOILER PART 14: TROUBLESHOOTING (CONTINUED) Resistance Tables Indirect Sensor Outdoor Sensor (7250P-319) Boiler Sensor (7250P-667) (7250P-320) Outside Temperature (°F) Resistance (ohms) Boiler and Indirect Temperature (°F) Resistance (ohms) –22 171800 32550 –13 129800 25340 –4 98930 19870 76020 15700 58880...

  • Page 65: Combustion Chamber Coil Cleaning Instructions

    Re-set thermostats (IMPORTANT: MAKE – Gloves, eye protection SURE EXHAUST VENT IS NO LONGER BLOCKED!) 1. Shut down the Munchkin Boiler by using the fol- g. Turn the Munchkin Boiler back on and lowing steps: observe condensate flow. a. Close the gas valve, shut down the unit h.
  • Page 66 Boiler Manual GAS-FIRED BOILER PART 15: MAINTENANCE (CONTINUED) T50M/T80M T50M/T80M REPLACEMENT PARTS Item Item Description Part # Description Part # Thermodisc Flue ECO 210 F 7250P-089 Nut M5 (Aluminum Elbow to Air Channel) 7250P-063 Steel Push Retainer (Thermodisc Flue ECO) 7250P-151 Gasket (Flame Rec./Spark Electrode) 7250P-005...
  • Page 67 Boiler Manual GAS-FIRED BOILER PART 15: MAINTENANCE (CONTINUED) BOILER SWITCH CONDENSATE OUTLET T50M/T80M T50M/T80M REPLACEMENT PARTS Item Item Description Part # Description Part # Exhaust Vent Pipe - 2" PVC 17 5 Pin Wiring Harness (location) 7250P-696 Pipe Coupling F3001 18 9 Pin Wiring Harness (location) 7250P-697 Exhaust Manifold Tube...
  • Page 68 Boiler Manual GAS-FIRED BOILER PART 15: MAINTENANCE (CONTINUED) 80M/140M/199M 80M/140M/199M REPLACEMENT PARTS Item # Description Part # Item # Description Part # Thermistor 7250P-667 Air/Gas Channel 7250P-685 (80M) Thermodisc Flue ECO 210 F 7250P-089 7250P-687 (140M/199M) Steel Push Retainer (Thermodisc Flue ECO) 7250P-151 Gasket (Flame Rec./Spark Electrode) 7250P-005...
  • Page 69 Boiler Manual GAS-FIRED BOILER PART 15: MAINTENANCE (CONTINUED) BOILER SWITCH CONDENSAT OUTLET 80M/140M/199M 80M/140M/199M REPLACEMENT PARTS Item Item Description Part # Description Part # Blocked Vent Pressure Switch 7250P-150 16 Cabinet Latch and Gasket Kit (w/Screws) 7250P-671 Screws # 8 x 1/2" (Blocked Vent Pressure Switch) 7250P-133 17 Leveling Foot 7250P-673...
  • Page 70 Boiler Manual GAS-FIRED BOILER PART 15: MAINTENANCE (CONTINUED) 399 MUNCHKIN REPLACEMENT PARTS Item Item Description Part # Description Part # Thermodisc Flue ECO 210 F 7250P-089 19 Brass 90 Elbow - 3/4" NPT 7250P-313 Steel Push Retainer (Thermodisc Flue ECO)
  • Page 71 Boiler Manual GAS-FIRED BOILER PART 15: MAINTENANCE (CONTINUED) BOILER SWITCH CONDENSATE OUTLET 399M 399M REPLACEMENT PARTS Item Item Description Part # Description Part # Blocked Vent Pressure Switch 7250P-150 17 PVC Nipple Sch. 80 3/4 NPT (Condensate Assembly) 7250P-648 Screws # 8 x 1/2" Self Tapping (Blocked Vent Pressure Switch) 7250P-133 18 Hose Clamp (Condensate Assembly) 7250P-210...
  • Page 72 Boiler Manual GAS-FIRED BOILER...
  • Page 73 Boiler Manual GAS-FIRED BOILER...
  • Page 74 Boiler Manual GAS-FIRED BOILER...
  • Page 75 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
  • Page 76 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
  • Page 77 MAINTENANCE NOTES...
  • Page 78 MAINTENANCE NOTES...
  • Page 79 MAINTENANCE NOTES...
  • Page 80 © 2007 Heat Transfer Products, Inc. www.HTproducts.com LP-185 REV. 12/10/07...

This manual is also suitable for:

Heattransfer t50mHeattransfer t80mHeattransfer 399m

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