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Installing, Operating & Maintaining
MUNCHKIN™ HIGH EFFICIENCY HEATER
with the "925" Controller
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.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch: do not use any phone in
your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
This manual must only be used by a qualified heating installer / service
technician. Failure to comply could result in severe personal injury, death or
substantial property damage. It is also important to keep these Instructions
with the appliance.
WARNING
CONTROLS
MH27745
WARNING
HEAT TRANSFER PRODUCTS, INC.
120 BRALEY RD., E. FREETOWN, MA
02717
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Summary of Contents for Munchkin MUNCHKIN HIGH EFFICIENCY HEATER with the "925" Controller
- Page 1 Installing, Operating & Maintaining MUNCHKIN™ HIGH EFFICIENCY HEATER with the “925” Controller 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.
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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
Munchkin Error Code ... . .38 Boiler Error .....38 Boiler Fault .....38 PART 8 . -
Page 4: Part 1
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 RECOMMENDED SERVICE CLEARANCES 80M/140M/199M Figure 1-1 GENERAL INFORMATION (NOTE: The Munchkin is rated at zero clearance to combustibles.) T50M/T80M Figure 1-2...
- Page 6 GENERAL INFORMATION DIMENSIONS T50M/T80M Figure 1-3...
- Page 7 GENERAL INFORMATION DIMENSIONS Figure 1-4 140M/199M Figure 1-5...
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Page 8: Pre-Installation Requirements
The gas may then ignite resulting in a fire or explosion. ACCESSIBILITY CLEARANCES 1. The Munchkin Boiler is certified for clos- et installations with zero clearance to GENERAL INFORMATION combustible construction. In addition, it is design certified for use on combustible floors. -
Page 9: 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 10 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 11 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.
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Page 12: Gas Connection
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 13: Part 3
(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 properly purged by the gas supplier or utility. Failure to properly purge the lines or improper line sizing, will result in ignition failure. -
Page 14: 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 15: Venting The Munchkin
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 16 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).
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Page 17: Longer Vent Runs
If done in the horizontal position check to make sure condensation blockage will not occur. Example: Installation requires the following material for both the inlet and exhaust piping when extending the vent run for the Munchkin. 3" Vented Appliance 2 Pcs. – 3" 90 degree elbow 20' of 3"... -
Page 18: Heater Removal From A Common Vent System
It is very important that the condensate line is sloped away from 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 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 will neutralize the condensate. - Page 19 DIAGRAMS FOR SIDEWALL VENTING **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 4-1 **IMPORTANT NOTE: All vent pipes must be glued, prop- erly supported and the exhaust must be pitched a mini- mum of a ¼"...
- Page 20 VENTING **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 **IMPORTANT NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼"...
- Page 21 DIAGRAMS FOR VERTICAL VENTING **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 4-5 **IMPORTANT NOTE: All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a ¼"...
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Page 22: Part 5
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 23: 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 24: 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 25: 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 26: 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 27 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 28 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 29 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 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. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball 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. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
- Page 32 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 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. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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Page 34: Part 6
3. Check to see if all the electrical connections are on securely. 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 35: Lighting Instructions
Munchkin. The Munchkin will now run its pre- purge cycle, then begin running, which will be indicated by the Green light illuminating under “Flame On”... -
Page 36: Adjusting The Temperature On The Munchkin Display
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 37: Test Mode
Munchkin Heater and the Combustion Settings. 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 38: Part 7
A. MUNCHKIN ERROR CODE An error code may occur in the installation of the Munchkin. This condition may lead to a lock out con- dition of the controller, which will need to be manu- ally reset through the S4/Reset button. These tempo-... - Page 39 Table 7-1: 925 Control Board Error Codes t s i . r e t s i . r e . F ° . F ° a l f – l i o – l l l i g i l –...
- Page 40 Boiler & Indirect Temperature (˚F) RESISTANCE TABLES Resistance (ohms) 32550 25340 19870 15700 12490 10000 TROUBLESHOOTING 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070...
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Page 41: 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 poly hose from the combustion blower motor c. -
Page 42: 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 43: 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 44: F Components Diagrams
MAINTENANCE... - Page 45 MAINTENANCE...
- Page 46 NOTES...
- Page 47 NOTES...
- Page 48 SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc. Munchkin R1 © 2004 Heat Transfer Products, Inc. LP-61 REV. 1/17/05...