Munchkin T50M Installing, Operating & Maintaining

High efficiency heater with the 925 controller

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Manual (80 pages)

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Page 1 Installing, Operating & Maintaining MUNCHKIN HIGH EFFICIENCY HEATER with the “925” Controller WARNING 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 • DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND 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.
Page 3: Table Of Contents
Items to be checked before Munchkin Ratings and Dimensions . . .4 lighting the Munchkin ... .35 Pre-installation Requirements ..7 Lighting Instructions ... . .35 Pressure Relief Valve .
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 GENERAL INFORMATION RECOMMENDED SERVICE CLEARANCES (NOTE: The 80M/140M/199M T50M/T80M Munchkin is rated at zero clearance to combustibles.) Figure 1-2 Figure 1-1 DIMENSIONS T50M/T80M Figure 1-3...
Page 6 GENERAL INFORMATION DIMENSIONS Figure 1-4 140M/199M Figure 1-5...
Page 7: 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 8), Gas Connection (Part 3, Page 10) and Venting (Part 4, Page 13).
Page 8: 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 central heating circulator connection.
Page 9 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 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 (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 12 GENERAL INFORMATION T50M/T80M GAS VALVE Fig. 3-2 WARNING Failure to follow all precautions could result in fire, explosion or death! COMBUSTION SETTINGS HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS Natural Gas Propane LP high high Carbon CO ppm...
Page 13: 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 14: B Venting The Munchkin In
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 15 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 16: 2" Or 3" Plastic Pipe
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...
Page 17: Heater Removal From A Common Vent System
DANGER The Munchkin is not intended to be common vented with any other existing appliance! 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 appli- ances remaining connected to common venting system are not operating.
Page 18 VENTING DIAGRAMS FOR SIDEWALL VENTING **IMPORTANT NOTE: All vent pipes must be glued, prop- **IMPORTANT NOTE: All vent pipes must be erly supported and the exhaust must be pitched a mini- glued, properly supported and the exhaust must mum of a ¼" per foot back to the heater (to allow drainage be pitched a minimum of a ¼"...
Page 19 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 20 VENTING DIAGRAMS FOR VERTICAL VENTING **IMPORTANT NOTE: All vent pipes must be glued, **IMPORTANT NOTE: All vent pipes must be glued, properly supported, and the exhaust must be pitched properly supported, and the exhaust must be pitched a minimum of a ¼" per foot back to the heater (to a minimum of a ¼"...
Page 21: Condensate Requirements
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. A condensate filter and a condensate pump kit are available from Heat Transfer Products, Inc.
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
PIPING 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
(w/ isolation flanges) circulator w/ integral flow check diff. pressure bypass gate valve 3-way thermostatic globe valve Munchkin heater ball valve pressure gauge swing-check valve 4-way motorized mixing valve flow-check valve spring-loaded check valve 3-way motorized...
Page 26 The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin heater 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 heater is 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
Page 28 The ninimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin heater shall be 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves for isolation.
Page 29 The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin heater shall be 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 heater is 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 heater is 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 heater 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 heater shall be 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
Page 34 The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin heater shall be 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
Page 35: 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 36: 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 37: Status Menu
START-UP PROCEDURES E. STATUS MENU Installers are also able to check the current status of the Munchkin parameters by pressing S4/RESET key for 3 seconds. Once activated, the display will show alternating value of the actual outlet tem- perature. Actual values are displayed for each function. To view the next value simply press the key to go to the next displayed value.
Page 38: 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 39: Munchkin Fault Requiring Manual Reset
To reset the lockout condition, simply push the S4/Reset 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 40 Return temperature is too High – This code comes if the return water temperature goes above 230 degrees, Remedy – Let the Munchkin cool down then manually push the reset button and see if the temperature on the return increases to above 230 degrees. Check piping and determine the source of over heating and correct the problem.
Page 41 SERVICING Gas Valve not correctly connected/internal fault. Just before ignition, a test is per- formed on the gas connection. If there is a failure in the gas valve connection and or the valve is not connected, this fault code will appear. Remedy –...
Page 42: 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 43: 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 44: Munchkin Controller
MAINTENANCE E. MUNCHKIN CONTROLLER CONTROL WIRING LAYOUT 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 45 MAINTENANCE...
Page 46 MAINTENANCE...
Page 47 NOTES...
Page 48 LP-61 REV. 9/01/03...

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