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Munchkin Installing, Operating & Maintaining

Munchkin Installing, Operating & Maintaining

High efficiency heater
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Installing, Operating & Maintaining
MUNCHKIN HIGH EFFICIENCY HEATER
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.
MH27745
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
WARNING:
HEAT TRANSFER PRODUCTS, INC.
120 BRALEY RD., E. FREETOWN, MA
02717

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  • Page 1 Installing, Operating & Maintaining MUNCHKIN HIGH EFFICIENCY HEATER 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: Table Of Contents

    PART 7 SERVICING 7-A. SEQUENCE OF OPERATION ........12 7-B. ADJUSTMENT SET POINTS AND DIFFERENTIAL SETTINGS ........12 7-C. MUNCHKIN BOILER FAULT LED CODE ....13 7-D. FAULT CONDITIONS..........13-14 PART 8 8-A. MAINTENANCE PROCEDURES .........15 8-B. BEFORE EACH HEATING SEASON ......15 8-C. COMPONENT DIAGRAM..........16...

  • Page 3: General Information

    1-A. HOW IT OPERATES When the room thermostat calls for heat, the Munchkin control board will start the pump and start to monitor the return temperature of the system before the heater will begin to heat the water. Once the controller has sensed a drop in the return water temperature below the temperature set point minus the differential set point, the boiler will start to heat the water.

  • Page 4: 1-B. Location

    Choose a location for your Munchkin, centralized to the piping system, along with consideration to vent pipe length. The length of vent pipe increases the firing rate of the Munchkin decreases. You must also locate the Munchkin where it will not be exposed to freezing temperatures.

  • Page 5: 3-A. Gas Connection

    " tee, and a drip leg fabricated, as per the National Fuel Gas code. You must ensure that the entire gas line to the connection at the Munchkin is no smaller than ". Once all the inspections have been performed, the piping must be leak tested.

  • Page 6: Venting

    The gas pressure must remain between 7" and 14" during stand-by and unit running heat cycle. 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.

  • Page 7: 4-B. For Longer Vent Lengths

    All venting must be properly supported, as 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 Standard Institute).

  • Page 8: 4-D. Cleaner/Cement

    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 HTP.

  • Page 9: 4-F. Venting Tables

    VENTING DIAGRAMS 4-F.

  • Page 10: 5-A. Hydronic Heat Piping

    5-A. HYDRONIC HEAT PIPING The Munchkin is designed to function in a closed loop 15 PSI System. To assure that there is adequate pressure in the system, we have installed in the Outlet Manifold, a pressure switch which will not let the Munchkin operate without a minimum of 10 PSI water pressure.

  • Page 11: Boiler Start Up

    It may be necessary to install basket strainer in an older hydronic system where larger amounts of sediment may be present. Annual cleaning of the strainer may be necessary. SUGGESTED HYDRONIC PIPING FOR MUNCHKIN BOILER FIGURE 7A...

  • Page 12: 6-B. Items To Be Checked Before Lighting The Munchkin

    Appendix G in the National Fuel Gas Code, ANSI Z223.1 6-B. ITEMS TO BE CHECKED BEFORE LIGHTING THE MUNCHKIN READ SECTION 1-A (OPERATION) Make sure you have minimum 10 psi water pressure.

  • Page 13: 6-C. Lighting Instructions

    6-C. LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING!! If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life. This appliance 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 14: Servicing

    PART 7 SERVICING 7-A. SEQUENCE OF OPERATION When power is first applied to the control, the control will initially run through a self-diagnostic routine and then go into its operating mode. If there is no call for heat, the System will go into the idle state. If the thermostat is calling for heat, the control will apply power to the circulator pump.

  • Page 15: 7-C Munchkin Boiler Fault Led Code

    7-C MUNCHKIN BOILER FAULT LED CODE: When a fault condition occurs or is sensed on the WHC1100 Munchkin Controller or in the appliance, the control board goes to a LOCKOUTstate. When in the LOCKOUTstate, the green LED located on the WHC1100 Control board will flash a fault code. The number of times to LED flashes ON/OFF will determine the nature of the fault (see the table below).
  • Page 16 Open Temperature Sensor On Inlet (Probe Fault) — 5 PULSES ! The control will sense an open temperature probe. If an open probe is sensed, the control will go into the lockout state. Verify that the Inlet probe is properly connected to the control board. If the temperature probe is in an environment of less then 0°F then wait for ambient temperature to rise or apply heat to the unit.

  • Page 17: 8-A. Maintenance Procedures

    Heat Exchanger - in the unlikely event boiler flue passage is becoming blocked, service must be performed only by an authorized Heat Transfer Products Representative or Certified Installing Contractor. Burner - check burner for deterioration. If deterioration is observed, change burner.

  • Page 18: 8-C. Component Diagram

    LP-61 Rev 5/01/02...

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