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Installing, Operating & Maintaining
MUNCHKIN VWH HIGH EFFICIENCY
HOT WATER SUPPLY 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.
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
MH27745
WARNING
HEAT TRANSFER PRODUCTS, INC.
120 BRALEY RD., E. FREETOWN, MA
CONTROLS
02717
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Summary of Contents for Munchkin VWH High Efficiency Hot Water Supply Boiler
- Page 1 Installing, Operating & Maintaining MUNCHKIN VWH HIGH EFFICIENCY HOT WATER SUPPLY 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.
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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 ... . .34 Boiler Error .....34 Boiler Fault .....34 PART 8 . -
Page 4: General Information
PART 1. GENERAL INFORMATION A. HOW IT OPERATES The Munchkin VWH is a hot water supply boiler designed to operate in conjuction with a hot water storage tank. Each Munchkin VWH is equipped with a high velocity pump to keep the unit running efficiently for many years of service. -
Page 5: Munchkin Ratings And Dimensions
B. MUNCHKIN RATINGS AND DIMENSIONS Input Output Model Modulation Modulation 199VWH 66,000–199,000 48,000–191,040 399VWH 100,000–399,000 96,000–343,040 MODEL INLET OUTLET RECOVERY RATE 199 VWH 40° 80° 561 GAL 199 VWH 40° 90° 450 GAL 199 VWH 40° 100° 374 GAL 199 VWH 40°... - Page 6 GENERAL INFORMATION DIMENSIONS Figure 1-2...
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Page 7: Pre-Installation Requirements
CAUTION Do not install this boiler on carpeting. COMBUSTION AND VENTILATION AIR 1. The Munchkin VWH is designed only for oper- ation with combustion air piped from outside (sealed combustion). PVC pipe must be sup- plied between the air inlet connection at the rear of the boiler through an outside wall. -
Page 8: Pressure Relief Valve
4. The top of the heater is 15" clearance. If the Munchkin is set up for liquefied petroleum (LP) gas, some geographic areas follow the Uniform Mechanical Code, section 304.6, “Liquefied petroleum gas burning appliances shall not be installed in a pit, basement or similar location where heavier-than-air gas might collect. -
Page 9: Part 2
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 circulator connection. All electrical wiring must be performed by a qualified licensed electrician in accordance with National Electrical Code ANSI/NEPA to and/or the Canadian Electrical Code, Part 1 CSA C22.1, or to the... -
Page 10: 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 11: Part 3
(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 12: 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 13: 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 for intake and exhaust (each elbow = 5' of pipe) should not exceed 85'. -
Page 14: Longer Vent Runs
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 15: Heater Removal From A Common Vent System
Total Friction Loss in Equivalent Feet for both 3" and 4" (30 + 62 = 92 Equivalent Feet) = 92 Equivalent Feet The Munchkin is not intended to be common vented with any other D. HEATER REMOVAL FROM A COMMON VENT SYSTEM... -
Page 16: Condensate Removal
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 phos- phate chips will neutralize the condensate. - Page 17 **IMPORTANT NOTE: All vent pipes must be glued, prop- erly supported and the exhaust must be pitched a mini- mum of a ¼" per foot back to the boiler (to allow drainage of condensate). Always increase pipe in vertical position.
- Page 18 **IMPORTANT NOTE: All vent pipes must be glued, prop- erly supported and the exhaust must be pitched a mini- mum of a ¼" per foot back to the boiler (to allow drainage of condensate). Always increase pipe in vertical position.
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Page 19: Part 5
This will allow the cold feed to flow through the storage tank first and not the Munchkin VWH. It is recommended that you install shut off valves on the cold feed line for ease of future service. If there is a back flow preventer, or any type of no return valve in the system, then you must install an additional tee for a suitable potable hot water expansion tank. - Page 20 / boiler drain diaphragm-type expansion tank (for potable water) Munchkin heater Fig. 5-1 anti-scald rated mixing valve pressure gauge pressure relief valve (or P&T relief valve) temperature / pressure gauge...
- Page 21 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 22 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 23 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 24 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 25 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 26 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 27 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
- Page 28 The minimum pipe size for connecting to a water storage tank is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.
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Page 29: Part 6
2. Check to see if all the electrical connections are on securely. 3. Make sure that the Gas is turned on inside the cabinet and outside of the Munchkin. 4. Double check the temperature setting (Note: The Munchkin is factory set at 119 degrees) 5. -
Page 30: Lighting Instructions
5. The Munchkin Heater shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.) -
Page 31: Status Menu
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 32: To Turn Off Gas To Appliance
– Fig. 6-1 H. TO TURN OFF GAS TO APPLIANCE 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Remove the front cover. 4. Turn gas shutoff valve to "off". 5. - Page 33 MUNCHKIN 199VWH GAS VALVE Fig. 6-2 MUNCHKIN 399VWH GAS VALVE Fig. 6-3 START-UP PROCEDURES THROTTLE ADJUSTER (NOTE: IF FOR ANY REASON THE THROTTLE NEEDS TO BE ADJUSTED IT IS VERY IMPORTANT THAT A "COMBUSTION ANAYLYZER" BE USED TO ENSURE SAFE AND PROPER OPERATION.
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Page 34: Part 7
A. MUNCHKIN ERROR CODE An error code may occur in the installation of the Munchkin VWH. This condition may lead to a lock out condition of the controller, which will need to be manually reset through the S4/Reset button. These... - Page 35 Table 7-2: 925 Control Board FAULT Codes . F ° . F ° a l f – – l – l a l f – l l i l l i t s i t s i c t i .
- Page 36 Boiler RESISTANCE TABLES Resistance (ohms) 32550 25340 19870 15700 12490 10000 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070 TROUBLESHOOTING...
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Page 37: Part 8
Close gas valve b. Disconnect the condensate hose from the outside connection (not from the Munchkin) so flow can be observed. c. Block the air flow in the exhaust by temporarily plugging the exhaust from the outside vent. -
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 Controllers
MAINTENANCE E. MUNCHKIN CONTROLLERS STANDARD 925 CONTROL WIRING LAYOUT FOR 199VWH Fig. 8-1 925 CONTROL WIRING LAYOUT FOR 399VWH Fig. 8-2... - Page 43 NOTES...
- Page 44 LP-147 REV. 7/7/04...