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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.