Munchkin Gas-Fired Hot Water Boiler Stainless Steel Heat Exchanger, Modulating Combustion System

GAS-FIRED BOILER Boiler Manual

PART 2: HOW BOILER OPERATES

Munchkin Condensing Technology is 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 the system and extract the last bit of energy before it is exhausted. The heat exchanger design is separated by an internal baffle which diverts the exhaust gas through the primary heat exchanger into the secondary heat exchanger where the colder return water extracts the last residual heat.

2.Modulating Combustion System

Modulation during the central heating operation is based on the supply temperature. The set point used for the control depends upon the programmed central heating curve. 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. This increase in efficiency allows for substantial fuel savings.

3.Gas Valve

The gas valve senses suction from the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.

4.Supply water temperature sensor

This sensor monitors boiler output water temperature (system supply). The control module adjusts the boiler firing rate so the outlet temperature is correct.

5.Return water temperature sensor

This sensor monitors the return water temperature (system return). The control module reduces or increases boiler input, depending on how close the return water temperature is to the outlet water temperature.

6.Temperature and pressure gauge

Allows the user to monitor the systems

temperature and pressure.

7.Control

The integrated control system monitors the return and supply water and regulates the fan speed to regulate the unit’s BTU output. This allows the unit to only deliver the amount of heated energy required and nothing more!

8.Burner

Constructed of high grade stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

9.Electrical field connections with terminal strips

The electrical cover plate allows access the line voltage terminal strip and the low voltage terminal strip. Attach line voltage conduits to the three holes at the right of the line voltage terminal strip for power, CH pump and DHW pump. Route low voltage wires through the opening to the left of the low voltage terminal strip. (See Field Wiring Instructions Part 9.)

10.Condensate drain connection

This is a condensing high efficiency appliance, therefore this unit has a condensate removal system. Condensate is nothing more than water vapor, derived from the combustion products, similar to an automobile when it is initially started. It is very important that the condensate line is sloped away from the boiler and down to a suitable inside drain, if the condensate outlet on the Munchkin 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 authorities can be made up of lime crystals, marble or phosphate chips and will neutralize the condensate. This can be done in the field by the installer or you may purchase one from Heat Transfer Products, Inc. (P/N N1100). It is also very important that the condensate line is not exposed to freezing temperatures or any other type of blockage. Plastic tubing must be the only material used for the condensate line. Steel, brass, copper or others will be subject to corrosion or deterioration. A second vent may be necessary to prevent condensate line vacuum lock if a long horizontal run is used.

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