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• Installation
Boiler
Startup
Maintenance
Manual
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.
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GAS-FIRED BOILER Boiler Manual CONTENTS Part 1 – Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 4 Part 2 – How The Boiler Operates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Part 3 – Prepare Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 A. Boiler Location Should Be Level B. Installations Must Comply With: C. Before Locating Boi
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GAS-FIRED BOILER Boiler Manual CONTENTS (CONT’D) Part 8 – Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47 A. Gas Connection B. Gas Piping C. Gas Table D. Dungs Gas Valve Part 9 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-49 A. Installation Must Comply With B. Field Wiring C. Line Voltage Wiring D. Thermostat Part 10 – Field Wiring – Vision 1 .
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GAS-FIRED BOILER Boiler Manual 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 DANGER indicates an imminently hazardous CAUTION Indicates a potentially hazardous situation which, if not avoided, will result in situation which, if not avoided, may result in death or serious inj
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GAS-FIRED BOILER Boiler Manual PART 1: PRODUCT AND SAFETY INFORMATION (CONT’D) supply at a location external to the appliance. WARNING Do not use this boiler if any part has been Installer — Read all instructions in this manual, under water. Immediately call a qualified and Munchkin Venting section, before installing. service technician to inspect the boiler and to Perform steps in the order given. replace any part of the control system and any gas control that has been under water. User — Thi
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GAS-FIRED BOILER Boiler Manual PART 2: HOW BOILER OPERATES Munchkin Condensing Technology is an intelli- temperature and pressure. gent system that delivers highly efficient hydron- 7. Control ic heating, while maximizing efficiency by meas- uring the Data Parameters of your heating sys- The integrated control system monitors the tem. return and supply water and regulates the fan speed to regulate the unit’s BTU output. This 1. Stainless Steel Heat Exchanger allows the unit to only deliver the a
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GAS-FIRED BOILER Boiler Manual PART 2: HOW BOILER OPERATES (CONT’D) Also, an increase in pipe size may be temperature for central heating and the other necessary to drain properly. Support of the temperature to the Super Stor Ultra Indirect condensation line may be necessary to avoid water heater. This allows the user to increase blockage of the condensate flow. the temperature supplied to the Super Stor Ultra indirect water heater to get a fast 11. Spark ignition recovery by prioritizing the fl
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GAS-FIRED BOILER Boiler Manual PERFORMANCE RATINGS CONNECTION SIZES FAN SPEEDS Supply/ Gas Shipping Vent Model Input Modulation DOE Heating AFUE *IBR Return Connection High Low Weight Dia. Connection Size T50M 18,000 to 50,000 16,000 to 46,000 92% 58 lbs. 40,000 1 1/4" NPT 3/4" 2" 3000 1250 T80M 19,000 to 80,000 17,000 to 74,000 92% 58 lbs. 64,000 1 1/4" NPT 3/4" 2" 4250 1200 80M 27,000 to 80,000 25,000 to 74,000 92% 75 lbs. 64,000 1 1/4" NPT 3/4" 3" 3700 1600 140M 46,000 to 140,000 43,000 to 12
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GAS-FIRED BOILER Boiler Manual DIMENSIONS 80M Figure 2-2 140M/199M Figure 2-3 8
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GAS-FIRED BOILER Boiler Manual DIMENSIONS 399M Figure 2-4 PART 3: PREPARE BOILER LOCATION (CONTINUED) B. INSTALLATIONS MUST COMPLY WITH: C. BEFORE LOCATING THE BOILER Local, state, provincial, and national codes, 1. Check for nearby connection to: laws, regulations and ordinances. System water piping National Fuel Gas Code, ANSI Z223.1 – latest Venting connections edition. Gas supply piping Standard for Controls and Safety Devices for Electrical power Automatically Fired Boilers, A
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GAS-FIRED BOILER Boiler Manual 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 existing system problems such as: all other appliances located in the same space as System leaks. the Munchkin boiler. The boiler cover must be se- Incorrectly-sized expansion tank. curely fastened t
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GAS GAS-FIRED BOILER -FIRED BOILER Boiler Manual Boiler Manual PART 3: PREPARE BOILER LOCATION (CONTINUED) vent piping can be routed through the building H. WHEN REMOVING A BOILER FROM AN and properly terminated. The air intake and EXISTING COMMON VENT SYSTEM exhaust vent piping lengths, routing and termi- nation method must all comply with the methods DANGER and limits given in the Venting section. Do not install the Munchkin Boiler into a G. PREVENT COMBUSTION AIR CONTAMINATION common vent wi
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GAS-FIRED BOILER Boiler Manual 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. installation conforms with the National Fuel Gas Code, ANSI Z223.1 — latest edition. f. After it has been determined that each Correct by resizing to approach the minimum appliance remaining connected to the size as determined using
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GAS-FIRED BOILER Boiler Manual PART 5: BOILER PIPING (CONTINUED) and system water volume and temperature. B. GENERAL PIPING INFORMATION Allow 3 gallons for boiler and its piping and 4 gallons for the 399. NOTICE The Munchkin Boiler control module uses CAUTION temperature sensors to provide both high limit Undersized expansion tanks cause system protection and modulating temperature control. water to be lost from relief valve and makeup The control module also provides low water water to be adde
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GAS-FIRED BOILER Boiler Manual PART 5: BOILER PIPING (CONTINUED) diagrams, the space heating system is certain that the system fluid is checked for the isolated from the boiler loop by the correct glycol concentration and inhibitor level. primary/secondary connection. The system should be tested at least once a year and as recommend by the producer of the glycol 2. Size the piping and components in the space solution. Allowance should be made for the heating system using recognized design expan
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GAS-FIRED BOILER Boiler Manual PART 5: BOILER PIPING (CONTINUED) 10. The Safety Relief Valve is installed at the H. CIRCULATOR SIZING factory. 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. Provide piping that is the same size as your system design. Refer to the graph in Fig. 5- the safety relief valve outlet.
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GAS-FIRED BOILER Boiler Manual 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 45°∆ t Friction Friction Friction Friction Friction Friction Model Flow Flow Flow Flow Flow Flow Feet Feet Feet Feet Feet Feet G P M G P M G P M G P M G P M G P M T-50 6.5’ 5 4.5’ 4 3’ 3.3 2’ 2.5 N/A N/R N/A
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GAS-FIRED BOILER Boiler Manual PART 5: BOILER PIPING (CONTINUED) K. ZONING WITH CIRCULATORS CAUTION It is highly recommended that you carefully 1. Connect boiler to system when circulator zoning as shown in 1C and 1D in Piping follow the glycol manufacturer’s recommended Details when zoning with circulators. The concentrations, expansion requirements and boiler circulator cannot be used for a zone. It maintenance recommendations (pH additive must supply only the boiler loop. breakdown, inhibito
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GAS-FIRED BOILER Boiler Manual M. BOILER PIPING DETAILS Piping Symbol Legend circulator pressure reducing valve (w/ isolation flanges) circulator w/ integral flow check) diff. pressure bypass gate valve globe valve anti-scald rated mixing valve ball valve pressure gauge swing-check valve 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) b
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GAS-FIRED BOILER Boiler Manual Standard Munchkin boiler Drawing 2A Preferred piping (zoning with valves) Space heating mode zone valves make-up water P2 closely differential spaced pressure tees bypass valve purging V1 valves OFF anti-scald mixing valve cold water P1 T/P Super Stor Munchkin boiler indirect DHW tank NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Adjust differential pressure
