Munchkin 399M Installing, Operating & Maintaining

High efficiency commercial boiler

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Manual (80 pages)

Installing, operating & maintaining (48 pages)

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Page 1 Installing, Operating & Maintaining MUNCHKIN™ HIGH EFFICIENCY 399M COMMERCIAL BOILER If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Page 2: Using This Manual
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE; • THE USE OF A LOW WATER CUT-OFF DEVICE MAY BE REQUIRED BY STATE OR LOCAL CODES IF THE MUNCHKIN IS INSTALLED ABOVE RADIATION LEVELS. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Page 3: Table Of Contents
START UP PROCEDURES Items to be checked before lighting the Munchkin ... . .29 Lighting Instructions ....29 Operating Instructions .
Page 4: General Information
Coupled with the Honeywell gas valve and the Venturi system which are set to provide a one-to-one ratio of precisely measured volumes of fuel to air, an accurate and instant burner output is achieved. This keeps the Munchkin running at the highest efficiency.
Page 5: C Pre-Installation Requirements
The Munchkin is designed for installation on non-rated flooring, in alcoves, basements, utility rooms, and closet but never a bedroom closet. Choose a location for your Munchkin, centralized to the piping system, along with consideration for Electrical (Part 2, Page 6), Gas Connection (Part 3, Page 8) and Venting (Part 4, Page 11).
Page 6: Pressure Relief Valve
PART 2. ELECTRICAL A. ELECTRICAL CONNECTION The electrical connection for the Munchkin is on the left hand side of the unit. There is a ½” knockout location for an electrical connection for both the incoming power and the central heating circulator connection.
Page 7 It is important that the electrical power is not turned on at this time. Double check all connections and then turn the power on. The display that is provided with the Munchkin should now be reading the outlet temperature. Note: see Part 6/Startup Procedure section in the manual to change the temperature setting or run the heater.
Page 8: Gas Connection
Note to Electrical Contractor: The orange wire is 120 Volt/4 Amp maximum for central heating circulator only. Loads greater than 4 amps or 3 amps for HA models only will blow the BOILER fuse on the board. The brown wire is the neu- "TT" GRAY tral wire for the central heating pump only.
Page 9: Gas Piping
If the leak test requirement is a higher test pressure than the maximum inlet pressure, you must isolate the Munchkin from the gas line. In order to do this, you must shut the gas off using factory and field-installed gas cocks (following the lighting instructions in Part 6 Section B.) This will prevent high pressure.
Page 10 (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Munchkin. It is very important that the gas line is prop- erly purged by the gas supplier or utility. Failure to properly purge the lines or improper line siz- ing, will result in ignition failure.
Page 11: Part 4
Note: For Concrete construction or to meet certain fire codes, exhaust and inlet piping at the wall penetration to the Munchkin must be CPVC Schedule 40 or 80 to meet local fire codes. The balance from the penetrated wall to the outside, may be PVC Schedule 40 or 80.
Page 12: Thru
PVC. Exhaust piping should be sloped back to the connection on the Munchkin, at least ¼" per foot to remove additional condensate that forms within the pipe. The total combined length of pipe (intake piping plus exhaust piping added together) including elbow allowances intake and exhaust (each elbow = 5' of pipe) should not exceed 85'.
Page 13 Consideration should be given to the plume of condensation that exits the exhaust which may affect the cosmetic appearance of the building. All venting must be properly supported. The Munchkin is not intended to support any venting whatsoever. All piping, glue, solvents, cleaners, fittings and components, must conform to ASTM (American Society for Testing and Materials), and ANSI (American National Standards Institute).
Page 14: C Longer Vent Runs Using A Combination Of 4" To 6" Pipe
Total of 6" Equivalent Piping with Fittings Total Friction Loss in Equivalent Feet for both 4" and 6" (30 + 82 = 112 Equivalent Feet) = 112 Equivalent Feet The Munchkin is not intended to be common vented with any other CAUTION CAUTION...
Page 15: Heater Removal From A Common Vent System
D. HEATER REMOVAL FROM A COMMON VENT SYSTEM At the time of removal of an existing heater, the following steps shall be followed with each appli- ance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to common venting system are not operating.
Page 16 VENTING DIAGRAMS FOR SIDEWALL VENTING (cont’d) **IMPORTANT NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per foot back to the heater (to allow drainage of condensate). Figure 4-3: 4" Sidewall Vent with V2000 kit DIAGRAM FOR VERTICAL VENTING **IMPORTANT NOTE: All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a ¼"...
Page 17: Condensate Requirements
On a Munchkin installed above radiation level, some states and local codes require a low water cut off device at the time of installation. If the Munchkin supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle.
Page 18: Circulator Sizing
8. Install an Air Elimination Device on the system supply. 9. Install a drain valve at the lowest point of the system. Note: The Munchkin can not be drained completely of water without purging the unit with an air pressure 15 PSI.
Page 19: Fill And Purge Heating System
C. FILL AND PURGE HEATING SYSTEM • Attach the hose to balance and purge hose connector or drain valve and run hose to near- est drain • Close the other side of the balance and purge valve or the shut off valve after the drain. •...
Page 20: Piping Illustrations
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 PIPING Munchkin heater Super Stor indirect DHW tank...
Page 21: 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. 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 is 1.25 inches. 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. 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 is 1.25 inches. 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. 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. 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. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball 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. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
Page 29: Part 6
Air Switch. 4. Make sure that the Gas is turned on inside the cabinet and outside of the Munchkin. 5. Double check the temperature setting (Note: The Munchkin is factory set at 180 degrees) 6.
Page 30: Operating Instructions
Munchkin, minus the differ- ential EX: The Munchkin is set to heat at 180° F degrees and the differential is set at 20° F. The burn- er will not start until the outlet temperature of the system falls below 159° F degrees (180° – 20° F = 160°...
Page 31: Status Menu
Connections). Automatic modulation does not take place when the controller is in Test mode, only temperature limitation based on the Munchkin Central Heating set point. The user will be allowed to increase or decrease the fan speed by pressing in either the...
Page 32: Part 7
B. MUNCHKIN TEMPORARY FAULT CONDITION A Temporary Fault Condition 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 button.
Page 33: Munchkin Fault Requiring Manual Reset
To reset the lockout condition, simply push the bring the control out of its lockout state. If the problem is not corrected, the Munchkin will repeat the fault until the condition is corrected. Once corrected, the display will resume its supply temperature setting.
Page 34 Supply Temperature is to High – This code appears if the Supply temperature sensor goes above 230 degrees. Remedy – Let the Munchkin cool down, then manually push the reset button and see if the temperature increases to above 230 degrees. Determine if you have water flow or if the thermostat is continuously energized and correct the problem.
Page 35 Watchdog. Call Factory for further assistance. Remedy – Call Factory for further assistance Parameter Memory. External Parameter memory corrupted Remedy – Call Factory for further assistance Parameter memory write error. External Parameter memory fault Remedy – Call Factory for further assistance Programming Error.
Page 36 Boiler & Indirect Temperature (˚F) RESISTANCE TABLES Resistance (ohms) 32550 25340 19870 15700 12490 10000 SERVICING 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070...
Page 37: Part 8
• Gas Piping – check for and repair any leaks. C. CONDENSATE CLEANING INSTRUCTIONS 1. Turn down the thermostat so the Munchkin will not cycle and then follow the steps below. a. Close gas valve b. Disconnect the condensate hose from the outside connection (not from the Munchkin) so flow can be observed.
Page 38: Combustion Chamber Coil Cleaning Instructions
Close the gas valve, shut down the unit and wait for the unit to be cool to the touch b. Disconnect the condensate hose from the outside connection, (not from the Munchkin side), so the flow can be observed.
Page 39: Munchkin Controller
E. MUNCHKIN CONTROLLER Fig. 8-1 There is a spare 6.3 amp “slow blow” fuse included on the control cover. HTP p/n 7250-378 or you may purchase it from Radio Shack p/n: 270-1068 Caution: Do not replace with any amperage other than 6.3A...
Page 40 MAINTENANCE...
Page 41 MAINTENANCE...
Page 42 NOTES...
Page 43 NOTES...
Page 44 SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc. © 2004 Heat Transfer Products, Inc. LP-121 REV. 10/20/04...

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