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Boiler
Manual
NOTICE
When installing Models
manufactured after July
7th, 2008, you will
n o t i c e
a d d i t i o n a l
s e l e c t i o n s o n t h e
Installer Menu of the
Control that will not
apply to this unit. DO
NOT CHANGE THESE
FACTORY SETTINGS.
Refer to the Control
Program Reference
C h a r t w i t h i n t h i s
manual for selections
that apply to this model.
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.
n
WARNING
• Installation
• Operation
• Maintenance
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Table of Contents
Related Manuals for Heat Transfer Munchkin VWH
Summary of Contents for Heat Transfer Munchkin VWH
- Page 1 • Installation Boiler • Operation Manual • Maintenance NOTICE When installing Models manufactured after July 7th, 2008, you will n o t i c e a d d i t i o n a l s e l e c t i o n s o n t h e Installer Menu of the Control that will not apply to this unit.
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Page 2: Safety Warnings
SAFETY INFORMATION SAFETY WARNINGS... -
Page 3: Using This Manual
USING THIS MANUAL USING THIS MANUAL WARNING If the information in this manual is not followed exactly, a fire or explo- sion 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 4: Table Of Contents
Gas Connection ....10 of the Munchkin VWH Display ..32 Gas Piping ..... .11 Status Menu . -
Page 5: 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 6: Munchkin Ratings And Dimensions
GENERAL INFORMATION B. MUNCHKIN RATINGS AND DIMENSIONS MUNCHKIN VWH RESIDENTIAL BOILER Fan Speeds Ship. Model Input Modulation DOE Heating Net I=B=R Boiler Water Vent Number BTU / hr BTU / hr Ratings BTU / hr AFUE % Water Connections Connections... - Page 7 GENERAL INFORMATION DIMENSIONS 399VWH 199VWH Figure 1-2...
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Page 8: Pre-Installation Requirements
3. The right side of the heater is 12" clearance COMBUSTION AND VENTILATION AIR 4. The top of the heater is 15" 1. The Munchkin VWH is designed only for oper- clearance. ation with combustion air piped from outside (sealed combustion). PVC pipe must be sup-... -
Page 9: Pressure Relief Valve
GENERAL INFORMATION 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. Appliances so fueled, shall not be installed in a below grade under-floor space or basement unless such location is provided with an approved means for removal of unburned gas.”... -
Page 10: Gas Connection
ELECTRICAL 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: Part 3
CONVERSION ON THIS UNIT. UNDER NO CIRCUMSTANCES SHOULD ANYONE OTHER THAN A LICENCED CONTRACTOR PERFORM THIS GAS VALVE CONVERSION. FAILURE TO HEED THIS PRECAUTION WILL RESULT IN SERIOUS INJURY OR DEATH! Gas conversion kits may be ordered through your local Heat Transfer Products Inc. Distributor. -
Page 12: Part 4
Provide a minimum of 1 foot clearance from Condensate from the Munchkin VWH Boiler will be the bottom of the exit terminal above the slightly acidic (typically with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes. - Page 13 VENTING walkways where condensate could drip snow accumulation. Snow removal may be and/or freeze and create a nuisance or hazard. necessary to maintain clearances. h. When adjacent to a public walkway, locate b. Do not locate air intake pipe in a parking area exit terminal at least 7 feet above grade.
- Page 14 VENTING Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Fig. 4-1 Fig. 4-2 Multiple Vent Spacing* *Note: Exhaust must extend out 1 foot. There should be no more than 2 vents and 2 intakes then a space of 36” to the next set of vents.
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Page 15: Sizing
VENTING b. Use a 6” x 4” reducing coupling to transition D. EXHAUST VENT AND INTAKE AIR PIPE from the 399VWH boiler connections to 6” SIZING vent. 1. For the 399VWH the exhaust vent and air c. The maximum equivalent length for the intake pipes should be 4"... -
Page 16: Heater Removal From A Common Vent System
This can be done in the field by the installer or you may purchase one from Heat Transfer Products, Inc. It is also very important that the condensate line is not exposed to freezing temperatures, or any other type of blockage. Plastic tubing should be the only material used for the condensate line. - Page 17 VENTING DIAGRAMS FOR SIDEWALL VENTING SIDEWALL VENTING WITH TEE (INTAKE) ROOF VENT WITH TEE (INTAKE) AND COUPLING (EXHAUST) AND COUPLING (EXHAUST) INTAKE AIR VENT STRAIGHT STRAIGHT COUPLING COUPLING TOP VIEW EXTERIOR WALL 24" MIN. EXHAUST VENT 10'-0" MIN. 1" MIN. 12"...
- Page 18 VENTING DIAGRAMS FOR SIDEWALL VENTING ROOF VENT WITH SIDEWALL VENTING WITH KIT CONCENTRIC VENT KIT 10'-0" MIN. VENT KIT INTAKE AIR VENT EXHAUST VENT 12" OVER MAXIMUM SNOW LEVEL OR 24" SUPPORT BRACKETS WHICHER IS GREATER MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING SUPPORT BRACKETS...
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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: Circulator Sizing
PIPING C. CIRCULATOR SIZING The Munchkin VWH Heat Exchanger has a pressure drop which must be considered in your system design. Refer to the graph below for pressure drop through the Munchkin VWH Heat Exchanger. 37.5 Flow in Gallons per Minute... - Page 21 PIPING PIPING ILLUSTRATIONS Piping Symbol Legend circulator (open loop) anti-scald rated (w/ isolation flanges) mixing valve flow switch pressure gauge gate valve pressure relief valve (or P&T relief valve) globe valve ball valve temperature / pressure gauge swing-check valve union spring-loaded check valve vacuum breaker hose bib / boiler drain...
- Page 22 PIPING Drawing VWH 1/1 Volume Water Heating using Munchkin boiler (1 boiler supplying one storage tank) ASEE 1017 rated anti-scald valve (recommended) vacuum breaker (where required by code) constant circulation flow switch expansion Superstor Ultra tank Storage Tank condensate drainage NOTES: This drawing is meant to show system piping concept only.
- Page 23 PIPING Drawing VWH 1/2 Volume Water Heating using Munchkin boiler (1 boiler supplying two storage tanks) ASEE 1017 rated anti-scald valve (recommended) vacuum breaker (where required by code) constant circulation expansion tank flow switch Superstor Ultra Superstor Ultra Storage Tank Storage Tank condensate drainage...
- Page 24 PIPING Drawing VWH 2/1 H Volume Water Heating using Munchkin boiler (2 boilers supplying one storage tank) ASEE 1017 rated anti-scald valve (recommended) vacuum breaker (where required by code) constant constant circulation circulation flow switch Munchkin 1 Munchkin 2 Superstor Ultra expansion Storage Tank tank...
- Page 25 PIPING Drawing VWH 2/1 V Volume Water Heating using Munchkin boiler (2 boilers supplying one storage tank) ASEE 1017 rated anti-scald valve (recommended) constant vacuum breaker (where required by code) circulation flow switch Munchkin 1 constant circulation flow switch Munchkin 2 Superstor Ultra Storage Tank expansion...
- Page 26 PIPING Drawing VWH2/2 H Volume Water Heating using Munchkin boilers (2 boilers supplying two storage tanks) ASEE 1017 rated anti-scald valve (recommended) vacuum breaker (where required by code) constant constant circulation circulation expansion tank flow flow switch switch Superstor Ultra Superstor Ultra Munchkin 1 Munchkin 2...
- Page 27 PIPING Drawing VWH2/2 V Volume Water Heating using Munchkin boilers (2 boilers supplying two storage tanks) ASEE 1017 rated anti-scald valve (recommended) constant vacuum breaker circulation (where required by code) flow switch Munchkin 1 constant circulation expansion tank flow switch Superstor Ultra Superstor Ultra Munchkin 2...
- Page 28 PIPING Drawing VWH 3/2 H Volume Water Heating using Munchkin boiler (3 boilers supplying two storage tanks) ASEE 1017 rated anti-scald valve (recommended) vacuum breaker (where required by code) constant constant constant circulation circulation circulation expansion tank flow flow flow switch switch switch...
- Page 29 PIPING Drawing VWH 3/2 V Volume Water Heating using Munchkin boiler (3 boilers supplying two storage tanks) constant circulation flow switch ASEE 1017 rated anti-scald valve Munchkin 1 (recommended) constant vacuum breaker circulation (where required by code) flow switch Munchkin 2 constant circulation expansion...
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Page 30: Part 6
This will activate the burner and modulate the heater off the programmed set-point value on your Munchkin VWH unit. It is recommended that the VWH control set-point is 5° higher than the set-point on the mechanical control. -
Page 31: Items To Be Checked Before Lighting The Munchkin
START-UP PROCEDURES B. ITEMS TO BE CHECKED BEFORE LIGHTING THE MUNCHKIN It is recommended that you read the General Information Section (Part 1) to get a better under- standing how the Munchkin operates before you start the unit. 1. Make sure that you follow the Lighting instruction before running the Munchkin. 2. -
Page 32: Adjusting The Operating Set Points Of The Munchkin Vwh Display
E. ADJUSTING THE OPERATING SET POINTS OF THE MUNCHKIN VWH DISPLAY To adjust the temperature set point value of the Munchkin VWH Boiler, press the { | S 3/Program} key for three seconds until you see Sh then an alternating value of 7°F. This is the default setting for the unit differential setting which operates off of the supply sensor. -
Page 33: Test Mode
START-UP PROCEDURES Function Value Actual Temperature from outlet sensor Actual Temperature from inlet sensor If using a standard mechanical control, the control will display |0| for closed and | 1 | for open. If the tank sensor is connected to the SuperStor storage tank, it will measure the actual temperature 307 (Not used) NC (Not used) -
Page 34: To Turn Off Gas To Appliance
START-UP PROCEDURES MUNCHKIN VWH FAN SPEEDS BOILER HIGH IGNITION 199M 4800 1550 2765 399M 7700 1900 3000 Fig. 6-2 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. -
Page 35: Part 7
An error code may occur in the installation of the When servicing or replacing any components of this boiler be certain that: Munchkin VWH. This condition may lead to a lock out • The gas is off. condition of the controller, which will need to be •... - Page 36 TROUBLESHOOTING Table 7-2: 925 Control Board FAULT Codes F ° t s i t s i c t i . y t c t i c t i . y t i r t t s i t s i i r t t s i l n i...
- Page 37 TROUBLESHOOTING RESISTANCE TABLES Boiler Resistance (ohms) 32550 25340 19870 15700 12490 10000 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070...
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Page 38: Part 8
Condensate which should not be restricted in any fashion. (See instructions below.) • Heat Exchanger – in the unlikely event the heater flue passage is becoming blocked, service must be performed only by an authorized Heat Transfer Products Representative or Certified Installing Contractor. (See coil cleaning instructions Section D) •... -
Page 39: Combustion Chamber Coil Cleaning Instructions
MAINTENANCE in which case, a qualified plumber will need to be contacted to follow the Coil Cleaning Instructions (Section D) included in this section to dissolve deposit and clean condensate line. DANGER IT IS EXTREMELY IMPORTANT TO MAKE SURE THE EXHAUST VENT IS NO LONGER BLOCKED. - Page 40 MAINTENANCE d. Re-connect gas valve, air-gas mixer and replace bracket. (IMPORTANT: CHECK FOR GAS LEAKS) e. Re-set thermostats (IMPORTANT: MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED!) Turn the Munchkin back on** and observe condensate flow. g. Re-connect the condensate hose to the outside connection. DANGER IT IS EXTREMELY IMPORTANT THAT YOU CHECK FOR LEAKS WHEN RECONNECTING THE GAS VALVE AND MAKING SURE THE EXHAUST VENT IS NO...
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Page 41: Munchkin Controllers
MAINTENANCE E. MUNCHKIN CONTROLLERS Fig. 8-1... - Page 42 399 VWH REPLACEMENT PARTS Item Item Description Part # Description Part # Thermodisc Flue ECO 210 F 7250P-089 18 Brass 90 Elbow - 3/4" NPT 7250P-313 Steel Push Retainer (Thermodisc Flue ECO) 7250P-151 19 Combustion Blower (w/Gasket) 7250P-518 PVC Black Tubing 1/8 ID (Thermodisc Flue ECO) 7250P-311 20 Screws M5 x 12MM (Combustion Blower) 7250P-478 Thermistor...
- Page 43 399VWH REPLACEMENT PARTS Item Item Description Part # Description Part # Blocked Vent Pressure Switch 7250P-150 19 Condensate Hose Assy 7250P-724 Screws # 8 x 1/2" Self Tapping (Blocked Vent Pressure Switch) 7250P-133 20 PVC Nipple Sch. 80 3/4 NPT (Condensate Assembly) 7250P-648 Relay Board 7250P-580...
- Page 44 199VWH REPLACEMENT PARTS Item # Description Part # Item # Description Part # Thermistor 7250P-667 Air/Gas Channel 7250P-687 Thermodisc Flue ECO 210 F 7250P-089 Gasket (Flame Rec./Spark Electrode) 7250P-005 Steel Push Retainer (Thermistor) 7250P-151 Spark Electrode (w/Gasket) 7350P-020 PVC Black Tubing 1/8 ID (Thermistor) 7250P-311 Screws M4 x 8MM (Probe/Electrode) 7250P-069...
- Page 45 BOILER SWITCH CONDENSATE OUTLET 199VWH REPLACEMENT PARTS Item Item Description Part # Description Part # Blocked Vent Pressure Switch 7250P-150 19 Cabinet Latch and Gasket Kit (w/Screws) 7250P-671 Screws # 8 x 1/2" (Blocked Vent Pressure Switch) 7250P-133 20 Leveling Foot 7250P-673 Low Voltage Wiring Harness (location) 7250P-720...
- Page 46 ADDITIONAL INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS In the Commonwealth of Massachusetts, the installer or service agent shall be a plumber or gas fitter licensed by the Commonwealth. When installed in the Commonwealth of Massachusetts or where applicable state codes may apply;...
- Page 47 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
- Page 48 © Copyright 2008, 2007, 2006, 2005, 2004 Heat Transfer Products, Inc. M M u u n n c c h h k k i i n n V V W W H H R R 2 2 www.HTProducts.com LP-147 REV. 8/5/08...