HTP Munchkin T50M Installation Manual
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HTP Munchkin T50M Installation Manual

Gas-fired boiler
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Munchkin
Gas-Fired Boiler
INSTALLATION
START-UP
MAINTENANCE
PARTS
Models
T50M / T80M
80M / 140M / 199M / 399M
Heat Exchanger Bears the "ASME" Stamp
When installing models manufactured after July 7, 2008, you will notice additional selections on the control installer menu that will not
apply to this unit. DO NOT CHANGE THESE FACTORY SETTINGS. Refer to the Control Program Reference Chart within this manual
for selections that apply to this model.
This manual must be used by a qualified installer/service technician. Read all instructions in this manual before installing. Perform steps
in the given order. Failure to comply could result in substantial property damage, severe personal injury, or death.
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
120 Braley Rd. P.O. Box 429
East Freetown, MA 02717-0429
www.htproducts.com
LP-185 Rev. 9.9.14

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Summary of Contents for HTP Munchkin T50M

  • Page 1 Failure to comply could result in substantial property damage, severe personal injury, or death. NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
  • Page 2 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 GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER BOILER. WHAT TO DO IF YOU SMELL GAS ...

  • Page 3: For The Installer

    In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding officer or departmental official may be the AHJ. NOTE: HTP, Inc. reserves the right to modify product technical specifications and components without prior notice. FOR THE INSTALLER This manual must only be used by a qualified heating installer/service technician.

  • Page 4: Table Of Contents

    COVERED BY WARRANTY. IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, HTP, Inc. has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases.
  • Page 5 PART 3 – PREPARE BOILER LOCATION ..........................10 A. BEFORE LOCATING THE BOILER ............................10 B. LEVELING ....................................14 C. CLEARANCES FOR SERVICE ACCESS ..........................15 D. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS ..................15 E. EXHAUST VENT AND INTAKE PIPE ............................15 F.
  • Page 6 I. DIAGRAMS FOR SIDEWALL VENTING ............................ 48 J. DIAGRAMS FOR VERTICAL VENTING ............................ 50 PART 8 – GAS PIPING ................................51 A. GAS CONNECTION ................................. 51 B. GAS PIPING ..................................... 52 C. CHECK INLET GAS PRESSURE ............................. 52 D. GAS VALVE ....................................53 PART 9 –...

  • Page 7: Part 1 - General Safety Information

    Due to the low water content of the boiler, improper sizing of the boiler with regard to heating system load will result in excessive cycling and accelerated component failure. HTP DOES NOT warrant failures caused by improperly sized boiler applications. DO NOT oversize the boiler to the system.

  • Page 8: Boiler System

    If you have an old system with cast iron radiators, thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Damages resulting from incorrect installation or from use of products not approved by HTP, Inc. ARE NOT covered by warranty. F. WATER CHEMISTRY* ...

  • Page 9: How The Boiler Operates

    If the condensate outlet on the boiler is lower than the drain, you must use a condensate removal pump (kit p/n 554200 available from HTP.) In addition, local authorities may require a condensate neutralizer to neutralize the condensate. Condensate neutralizers are made up of lime crystals, marble or phosphate chips.

  • Page 10: Optional Equipment

    (this requires two separate circulators). You must follow the piping, wiring, and programming instructions located in the Vision One section of this manual. C. OPTIONAL EQUIPMENT Below is a list of optional equipment available from HTP:  Indirect Tank Sensor (Part # 7250P-325) ...
  • Page 11 2. Check for nearby connections to:  System water piping  Venting connections  Gas supply piping  Electrical power  Condensate drain 3. Check area around boiler. Remove any combustible materials, gasoline, and other flammable liquids. Failure to keep boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.
  • Page 12 Figure 1 – Dimensions – T-50M / T-80M / 80M LP-185 Rev. 9.9.14...
  • Page 13 Figure 2 – Dimensions - 140M / 199M / 399M LP-185 Rev. 9.9.14...

  • Page 14: Leveling

    Table 1 – Specifications Before considering location, many factors need to be addressed. Piping, Venting, and Condensation Removal are just a few of the issues that need attention prior to the installation of the boiler. Please read the entire manual, as it could save time and money. B.

  • Page 15: Clearances For Service Access

    C. CLEARANCES FOR SERVICE ACCESS See Figure 4 for recommended service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space. Space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the boiler.

  • Page 16: Prevent Combustion Air Contamination

    The boiler is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting. You must also install intake piping from outdoors to the boiler flue adaptor. The resultant installation is categorized as direct vent (sealed combustion).

  • Page 17: Part 4 - Prepare Boiler

    B. WALL MOUNTING CONSIDERATIONS T50M and T80M boilers may be wall mounted. Use only the wall mounting instructions included in installation envelope. The wall must be capable of carrying the weight of the boiler and its related components. The weights of the boilers are approximately: T50M –...

  • Page 18: Part 5 - Boiler Piping

    Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The boiler may be connected to a storage tank to supply domestic hot water. HTP offers 60/80/119/175 gallon size storage tanks in either stainless steel or glass-lined construction.

  • Page 19: Relief Valve

    B. RELIEF VALVE The relief valve must comply with the standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems (ANSI Z21.22) and/or the standard Temperature, Pressure, Temperature and Pressure Relief Valves and Vacuum Relief Valves, CAN1-4.4, as well as all local codes.

  • Page 20: Backflow Preventer

    All piping methods shown in this manual use primary/secondary connection to the boiler loop. This is to avoid the possibility of noise or actuator problems in zone valves because of the high-head boiler circulator. For other piping methods, consult your local HTP representative or refer to separate piping details in this manual.

  • Page 21: Circulator Sizing

    Install the boiler so the gas ignition components are protected from water (dripping, spraying, etc.), and allow clearance for basic service of the circulator, valves, and other components. Observe minimum 1” clearance around all un-insulated hot water pipes when openings around pipes are not protected by noncombustible materials. On a boiler installed above radiation level, some states and local codes require a low water cut off device (See Part C this section).
  • Page 22 Figure 6 – Pressure Drop Graph and Temperature Rise Chart – LP-171-F NOTE: The recommended circulators are based on 1 gpm per 10,000 btu/hr with 20∆t. The chart below represents various system temperatures, respective flows and friction loss through the boiler to aid in circulator selection.

  • Page 23: Zoning With Zone Valves

    I. ZONING WITH ZONE VALVES 1. Connect boiler to system as shown in 2A and 2B in Piping Details when zoning with zone valves. The primary/secondary piping shown ensures the boiler loop will have sufficient flow. It also avoids applying the high head of the boiler circulator to the zone valves. 2.

  • Page 24: Piping Details

    It is highly recommended that you carefully follow the glycol manufacturer’s concentrations, expansion requirements, and maintenance recommendations (pH additive breakdown, inhibitor reduction, etc.) You must carefully figure the additional system friction loss, as well as the reduction in heat transfer coefficients. M.
  • Page 25 Figure 8 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 26 Figure 9 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 27 Figure 10 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 28 Figure 11 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 29 Figure 12 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 30 Figure 13 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.

  • Page 31: Part 6 - Piping With Optional Vision 1 System

    PART 6 – PIPING WITH OPTIONAL VISION 1 SYSTEM (DHW PRIORITY WITH OUTDOOR RESET) A. VISION 1 SYSTEM PIPING It is important that the system piping is done correctly when using the Vision 1 System. Follow the piping diagrams 3A through 4H when piping your boiler.

  • Page 32: Piping Details With The Vision 1 System

    D. PIPING DETAILS WITH THE VISION 1 SYSTEM Figure 14 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 33 Figure 15 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 34 Figure 16 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 35 Figure 17 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 36 Figure 18 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 37 Figure 19 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 38 Figure 20 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 39 Figure 21 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 40 Figure 22 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.
  • Page 41 Figure 23 NOTES: 1. This drawing is meant to demonstrate system piping concept only. Installer is responsible for all equipment and detailing required by local codes. 2. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. 3.

  • Page 42: Part 7 - Venting, Combustion Air, And Condensate Removal

    PART 7 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL The boiler must be vented as detailed in this Venting Section. Ensure exhaust vent and intake piping complies with these instructions regarding vent system. Inspect finished exhaust vent and intake piping thoroughly to ensure all joints are well secured, airtight, and comply with all applicable code requirements, as well as with the instructions provided in this manual.

  • Page 43: Requirements For Installation In Canada

    When installing AL29-4C vent piping, install a PVC-to-stainless adapter at the boiler vent connection, and at the termination when using an HTP PVC termination kit. DO NOT mix AL-29-4C piping from different manufacturers unless using adapters specifically designed for the purpose by the manufacturer.

  • Page 44: Determine Intake Pipe Location

    Condensate from the boiler is slightly acidic with a pH of 3.2 - 4.5. To avoid long term damage to the drainage system and to meet local code requirements, HTP recommends neutralizing the condensate with a Condensate Neutralizer Kit (p/n 7450P-218). The neutralizer kit connects to the drain system and contains limestone chips that neutralize the pH level of the water vapor.

  • Page 45: Exhaust Vent And Intake Pipe Sizing

    E. EXHAUST VENT AND INTAKE PIPE SIZING 1. The exhaust vent and intake pipe size is 2" for the T50/80, 3” for the 80/140/199M, and 4” for the 399M. 2. The total equivalent length of exhaust vent and intake pipe should not exceed 85’. a.

  • Page 46: Exhaust Vent And Intake Pipe Installation

    Figure 24 H. EXHAUST VENT AND INTAKE PIPE INSTALLATION 1. Use only solid PVC or CPVC pipe, AL29-4C Stainless Steel, or a Polypropylene vent system approved for use with Category IV appliances. FOAM CORE PIPING IS NOT APPROVED. All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into living space. 2.
  • Page 47 14. A screened straight coupling is provided with the boiler for use as an outside exhaust termination. 15. A screened inlet air tee is provided with the boiler to be used as an outside intake termination. The following information on Table 8 lists optional exhaust/intake terminations available from HTP. DESCRIPTION STOCK CODE 2”...

  • Page 48: Diagrams For Sidewall Venting

    I. DIAGRAMS FOR SIDEWALL VENTING Figure 25 – Venting LP-185 Rev. 9.9.14...
  • Page 49 Figure 26 – Sidewall Venting LP-185 Rev. 9.9.14...

  • Page 50: Diagrams For Vertical Venting

    J. DIAGRAMS FOR VERTICAL VENTING Figure 27 – Vertical Venting LP-185 Rev. 9.9.14...

  • Page 51: Part 8 - Gas Piping

    PART 8 – GAS PIPING Failure to follow all precautions in this section could result in fire, explosion, severe injury or death! A. GAS CONNECTION Connect the gas supply to the system following state and local plumbing codes. The gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pressure (3.5 kPa), and a minimum of 3.5"...

  • Page 52: Gas Piping

    B. GAS PIPING 1. Run the gas supply line in accordance with all applicable codes. 2. Locate and install manual shutoff valves in accordance with state and local requirements. 3. In Canada, the Manual Shutoff must be identified by the installing contractor. 4.

  • Page 53: Gas Valve

    Figure 28 – LP-171-N Do not do a gas conversion on this boiler without an officially approved conversion kit and instructions supplied by HTP. Failure to use a conversion kit when converting the boiler to fire on Natural or LP gas will result in extremely dangerous burner operation, leading to fire, explosion, severe injury or death.

  • Page 54: Part 9 - Field Wiring

    Adjustments to the throttle screw or offset may only be made by a qualified gas technician using a calibrated combustion analyzer capable of measuring CO and CO. Failure to follow this instruction could result in fire, explosion, property damage, severe personal injury, or death.
  • Page 55 Figure 29 LP-185 Rev. 9.9.14...
  • Page 56 Figure 30– NOTE: A resistor is provided between Bus Lines A and B. DO NOT REMOVE THIS RESISTOR! DOING SO WILL EFFECT HEATER OPERATION AND VOID WARRANTY! LP-185 Rev. 9.9.14...

  • Page 57: Part 10 - Field Wiring - Vision 1 Option

    PART 10 – FIELD WIRING – VISION 1 OPTION Outdoor Sensor Function The user can program the desired supply temperature based on the heat transmitter (baseboard, radiant floor, air handler) that will be used in the installation. Once the outdoor sensor (light green wires) is connected to the control board, the water temperature of the boiler will adjust to run the boiler more efficiently and provide greater comfort to the living space.

  • Page 58: Part 11 - Start-Up Preparation

    Fault Code Alarm Function Connect the fault annunciator or lights to the alarm output on the boiler terminal strip and the incoming neutral line in the junction box. NOTE: The annunciator or light must be rated for 120 volt AC. A relay may be employed to use devices with ratings other than 120 volt Do not tie neutrals or hot wire leads to any other wires.

  • Page 59: Freeze Protection (When Used)

    2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time. Follow all fluid manufacturer instructions. NOTE: Boiler failure due to improper water chemistry is not covered by warranty. B. FREEZE PROTECTION (WHEN USED) NEVER use automotive or standard glycol antifreeze, or ethylene glycol made for hydronic systems. System water, including additives, must be non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

  • Page 60: Check For Gas Leaks

    If the condensate outlet is lower than the drain, you must use a condensate removal pump, available at HTP (#554200). This pump is equipped with two leads that can be connected to an alarm or another type of warning device to alert residents of a condensate overflow, which, if not corrected, could cause property damage.

  • Page 61: Part 12 - Start-Up Procedure

    4. Verify electrical connections are correct and securely attached. 5. Inspect exhaust vent and intake pipe for signs of deterioration from corrosion, physical damage or sagging. PART 12 – START-UP PROCEDURE FOR YOUR OWN SAFETY READ BEFORE OPERATING 1. This boiler does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

  • Page 62: Status Menu

    Carbon Dioxide (CO 8 ½% - 9 ½% 8 ½% - 9 ½% 9 ½% - 10 ½% 9 ½% - 10 ½% Table 10 FAN SPEEDS BOILER HIGH IGNITION T50M 3000 1250 3000 T80M 4250 1200 3000 3700 1600...

  • Page 63: Part 13 - Start-Up Procedures With Vision 1 Option

    PART 13 – START-UP PROCEDURES WITH VISION 1 OPTION The Vision I option allows the user to have one temperature for central heating and another temperature for the SuperStor Ultra Indirect Fired Water Heater. This enables the user to increase the temperature supplied to the indirect water heater by prioritizing flow at a higher temperature than may be needed for the central heating circuits (this will require two separate circulators).
  • Page 64 DEFAULT FUNCTION DESCRIPTION FUNCTION VALUE Interface Board Function 0 = Building Management, 1 = Enables Tekmar Modulating Control (Consult with Tekmar to assure the Tekmar Control is compatible.) Step Modulation – Regulates the burner output in 6 steps in one-minute intervals. This reduces short cycling. 1 = on, 0 = off Indirect boiler set point (flow) Temperature default = 119...

  • Page 65: Part 14 - Troubleshooting

    Table 14 – Central Heating Curve – Factory Default PART 14 – TROUBLESHOOTING A. ERROR CODE An error code may occur in the installation of the boiler. This condition may lead to a lock out condition of the controller, which will need to be manually reset through the {S4}.
  • Page 66 When servicing or replacing parts that are in direct contact with boiler water, be certain that:  There is no pressure in the boiler. (Pull the release on the relief valve. Do not rely on the pressure gauge reading.)  The boiler water is not hot.
  • Page 67 Code Description Remedy 1. Check the electrical connection to the thermister on the outlet manifold. Verify 5 VDC by checking in Interrupted or shorted supply Molex connector. Verify thermistor values by referencing the chart in this manual. (outlet) thermister. 2. If connection is okay, replace thermister. 1.

  • Page 68: Part 15 - Maintenance

    Resistance Tables BOILER SENSOR (7250P-059) INDIRECT SENSOR (7250P-325) OUTDOOR SENSOR BOILER AND INDIRECT RESISTANCE (ohms) (7250P-319) TEMPERATURE ( OUTSIDE TEMP. RESISTANCE 32550 (ohms) 25340 171800 19870 129800 15700 98930 12490 76020 10000 58880 8059 45950 6535 36130 5330 28600 4372 22800 3605 18300...

  • Page 69: Combustion Chamber Coil Cleaning Instructions

    General  Attend to any reported problems.  Inspect the interior of the boiler jacket area; clean and vacuum if necessary.  Clean the condensate trap and fill with fresh water.  Check for water, gas, flue and condensate leaks. ...
  • Page 70 Figure 31 LP-185 Rev. 9.9.14...
  • Page 71 Figure 32 LP-185 Rev. 9.9.14...
  • Page 72 Figure 33 LP-185 Rev. 9.9.14...
  • Page 73 Figure 34 LP-185 Rev. 9.9.14...
  • Page 74 Figure 35 LP-185 Rev. 9.9.14...
  • Page 75 Figure 36 LP-185 Rev. 9.9.14...

  • Page 76: Boiler Start-Up Report

    BOILER START-UP REPORT LIGHT OFF ACTIVITIES DATE COMPLETED ________________ 1) Fill the Check all piping and gas connections, verify all heating system are tight Pressurize system (12-15 PSI) ____ PSI Add water to prime condensate hose What percentage of propylene glycol is ____ % installed in the system (0-50%) Verify near boiler piping is properly supported...
  • Page 77 INSPECTION ACTIVITIES DATE LAST COMPLETED PIPING YEAR YEAR YEAR YEAR* Near boiler piping Check boiler and system piping for any sign of leakage, make sure they are properly supported. Vent Check condition of all vent pipes and joints. Check Gas piping, test for leaks and signs of aging. Make sure all pipes are properly supported.
  • Page 78 LP-185 Rev. 9.9.14...

  • Page 79: Lp-185 Rev. 9.9.14

    LP-185 Rev. 9.9.14...
  • Page 80 MAINTENANCE NOTES LP-185 Rev. 9.9.14...
  • Page 81 HTP CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.

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