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Installing, Operating & Maintaining
MUNCHKIN™ HIGH EFFICIENCY HEATER
with the "925" Controller
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
CONTROLS
MH27745
WARNING
HEAT TRANSFER PRODUCTS, INC.
120 BRALEY RD., E. FREETOWN, MA
02717
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Table of Contents
Summary of Contents for Heat Transfer MUNCHKIN
- 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.
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Page 3: Table Of Contents
PART 3 ....12 thru 13 Items to be checked before lighting the Munchkin ... . .34 GAS CONNECTION Lighting Instructions . -
Page 4: Part 1
Coupled with the Dungs gas valve and the the swirl plate 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 Munchkin is rated at 80M/140M/199M zero clearance to combustibles.) T50M/T80M Figure 1-1 Figure 1-2...
- Page 6 GENERAL INFORMATION DIMENSIONS T50M/T80M Figure 1-3...
- Page 7 GENERAL INFORMATION DIMENSIONS Figure 1-4 140M/199M Figure 1-5...
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Page 8: Pre-Installation Requirements
2. Carefully read these instructions and be sure to understand the function of all COMBUSTION AND VENTILATION AIR connections prior to beginning installa- 1. The Munchkin Boiler is designed only for tion. Contact your Munchkin Sales operation with combustion air piped Representative or the Heat Transfer from outside (sealed combustion). -
Page 9: Pressure Relief Valve
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 10 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...
- Page 11 4 amps (3 amps for “HA” models) use the wiring diagram shown above. The brown and orange wires on the Munchkin boiler will not be used in this application and should be terminated so they do not cause a short circuit.
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Page 12: 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 13: Part 3
(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 14: Part 4
VENTING PART 4. VENTING A. GENERAL C. EXHAUST/VENT / AIR INTAKE PIPE LOCATION 1. Install the boiler venting system in accor- dance with these instructions and with the 1. Determine exhaust vent location: National Fuel Gas Code, ANSI Z223.1/NFPA a. The vent piping for this boiler is approved for 54, CAN/CGA B149, and/or applicable provi- zero clearance to combustible construction. - Page 15 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 Fig. 4.3 Multiple Stainless Steel Vertical Vent Kit Installation –...
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Page 16: D Exhaust Vent And Intake Air
VENTING 4. The minimum combined equivalent length is D. EXHAUST VENT AND INTAKE AIR PIPE 16 equivalent feet. SIZING 5. The maximum combined equivalent length 1. For the T50 and T80 Boilers the exhaust vent can be extended by increasing the diameter and air intake pipes should be 2"... - Page 17 11. The following information on Table 4.3 are 6. Horizontal lengths of exhaust vent must slope optional intake air/exhaust vent terminations back towards the boiler not less than ¼" per available from Heat Transfer Products, Inc. Table 4.3: Vent Termination Kits Stock Description Code 2"...
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Page 18: Heater Removal From A Common Vent System
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 phosphate chips will neutralize the condensate. - Page 19 VENTING DIAGRAMS FOR SIDEWALL VENTING Figure 4-1a Figure 4-2a GENERAL 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).
- Page 20 VENTING Figure 4-3a Figure 4-4a GENERAL 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).
- Page 21 VENTING DIAGRAMS FOR VERTICAL VENTING Figure 4-5a Figure 4-6a GENERAL 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).
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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
4-way motorized flow-check valve mixing valve spring-loaded check valve 3-way motorized Munchkin heater mixing valve hose bib / boiler drain pressure relief valve thermostatic radiator valve TRV (straight) backflow preventer thermostatic radiator valve TRV (angle) - Page 26 The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler 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 boiler is 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
- Page 28 The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
- Page 29 The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler is 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 boiler shall be 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 boiler shall be 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 boiler 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 boiler shall be 1.25 inches. All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.
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Page 34: Part 6
3. Check to see if all the electrical connections are on securely. 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 35: Lighting Instructions
Munchkin. The Munchkin will now run its pre- purge cycle, then begin running, which will be indicated by the Green light illuminating under “Flame On”... -
Page 36: Adjusting The Temperature On The Munchkin Display
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: Test Mode
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 38: 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. This condition may lead to a lock out con- • The gas is off. dition of the controller, which will need to be manu- •... - Page 39 TROUBLESHOOTING Table 7-2: 925 Control Board FAULT Codes t a l l i o F ° t s i t s i . r e t s i t s i . r e c t i . y t c t i .
- Page 40 TROUBLESHOOTING...
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Page 41: 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 42: 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 43: Munchkin Controller
Replace the (4) screws on the aluminum ½” NPT connector on the gas valve. Turn the gas back on. (IMPORTANT: CHECK FOR GAS LEAKS) Re-set thermostats (IMPORTANT: MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED!) g. Turn the Munchkin back on** and observe condensate flow. h. Re-connect the condensate hose to the outside connection. DANGER... -
Page 44: F Components Diagrams
MAINTENANCE... - Page 45 MAINTENANCE...
- Page 47 Installation Checklist for Munchkin Boilers Questions relating to electrical Is there continuous 120 volts line voltage supplied to the unit? Is the line power properly polarized? (Black wire is “hot” lead) Is there and adequate ground supplied to the heater?
- Page 48 SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc. Munchkin R1 © 2006, 2005, 2004 Heat Transfer Products, Inc. LP-61 REV. 4/1/06...