Heat Transfer Munchkin VWH User Manual Download Page 45

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199VWH

BOILER

OUTLET

SWITCH

CONDENSATE

REPLACEMENT PARTS

Item

Description

Part #

Item

Description

Part #

Blocked Vent Pressure Switch

7250P-150

Cabinet Latch and Gasket Kit (w/Screws)

7250P-671

Screws # 8 x 1/2" (Blocked Vent Pressure Switch)

7250P-133

Leveling Foot

7250P-673

Low Voltage Wiring Harness (location)

7250P-720

Condensate Hose Assy

7250P-724

9 Pin Wiring Harness (location)

7250P-602

PVC Nipple Sch. 80 3/4 NPT (Condensate Assy)

7250P-648

5 Pin Wiring Harness (location)

7250P-721

Hose Clamp (Condensate Assy)

7250P-210

Control Board Mounting Panel (w/Screws)

7250P-651

PVC Tee Sch. 40 3/4 NPT (Condensate Assy)

7250P-646

Screw 1/4-20 x 1/2" (Control Board Mounting Panel)

7250P-184

Cable Clamp (Condensate Assy)

7250P-649

Control Board Hold Down Clips

7250P-352

Screw # 8 x 1/2 Self Tapping (Condensate Assy)

7250P-133

Control Board (w/Fuse)

7250P-317

Poly Plug 3/4 NPT (Condensate Assy)

7250P-647

Fuse (Control Board)

7250P-378

Band Clamp (Exhaust Assy)

CA2000

Control Board Display (w/Ribbon Cable)

7250P-332

PVC Pipe Sch. 40 3" (Exhaust Assy)

7250P-242

Electrical Box (w/Screws)

7250P-707

S.S. Hex Nut 10-32 (Blocked Vent Pressure Switch)

7250P-153

Screws # 8 x 1/2" Self Tapping (Electrical Box)

7250P-133

O-Ring 007 (Blocked Vent Pressure Switch)

7250P-152

Flow Switch (w/Paddle)

7250P-612

Hose Barb 1/4 x 10-32 (Blocked Vent Pressure Switch) 7250P-154

Flow Switch Paddle

7250P-593

Plastic Tubing 3/16" ID (Blocked Vent Pressure Switch

7000P-805

Brass Tee 1-1/4" x 1-1/4" x 1" (Flow Switch)

7250P-589

Circulator Pump - 1-1-4"

7250P-591

Brass Nipple 1 x 1-1/4 x 3-3/4"

7250P-221

Mounting Flanges - 1-1/4" (set of 2)

7250P-594

Cabinet Cover

7250P-231

LP-147-J-2

REV. 3/10/08

Summary of Contents for Munchkin VWH

Page 1: ... to keep these Instructions with the appliance Installation Operation Maintenance Boiler Manual NOTICE When installing Models manufactured after July 7th 2008 you will notice additional selections on the Installer Menu of the Control 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 thi...

Page 2: ...2 SAFETY INFORMATION SAFETY WARNINGS ...

Page 3: ...ING PROPERTY DAMAGE PERSONAL INJURY OR DEATH 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 n WARNING If the information in this manual is not followed exactly a fire or explo sion may result causing pro...

Page 4: ...Installation 15 F Heater Removal from a Common Vent System 16 G Condensate Removal 16 PART 5 19 thru 29 PIPING A Expansion Tank 19 B High Velocity Circulator Pump 19 C Circulator Sizing 20 PART 6 30 thru 34 START UP PROCEDURES A Sequence of Operation 30 B Items to be Checked Before Lighting the Munchkin 31 C Lighting Instructions 31 D Operating Instructions 31 E Adjusting the Operating Set Points ...

Page 5: ...aining the desired output temperature The pre mix burner fan has direct drive current low voltage motor with pulse relay counting This system allows precise control over the fan speed and combustion air volumes Coupled with the fuel and air mixing 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 k...

Page 6: ... 40 180 328 GPH 381 GAL 407 GAL 199 VWH at 20GPM Pressure Drop for Tube Length of 1 Copper 10 90 Elbows ad 2 Tees Side Outlet with Munchkin 199 VWH 1 Tube Length 20 30 40 50 60 20 GPM 21 65 22 62 23 6 24 56 25 53 399 VWH at 40GPM Pressure Drop for Tube Length of 2 Copper 10 90 Elbows and 2 Tees Side Outlet with Munchkin 399 VWH 2 Tube Length 20 30 40 50 60 40 GPM 24 24 37 24 74 25 11 25 48 Example...

Page 7: ...7 GENERAL INFORMATION DIMENSIONS Figure 1 2 399VWH 199VWH ...

Page 8: ...ustion air piped from outside sealed combustion PVC pipe must be sup plied between the air inlet connection at the rear of the boiler through an outside wall 2 No additional combustion or ventilation air is required for this appliance 3 Refer to Section 4 of this manual Venting for specific instructions for piping combustion air PLANNING THE LAYOUT 1 Prepare sketches and notes showing the lay out ...

Page 9: ...sed electrician in accordance with National Electrical Code ANSI NEPA to and or the Canadian Electrical Code Part 1 CSA C22 1 or to the applicable codes and standards For your convenience we have labeled all the wires that need to be connected to operate the Munchkin The electrical requirements are for standard 120 volts 60 Hz 15 Amp service This unit is wired with 18 awg and fused for no more tha...

Page 10: ... 11 4 with a mandatory 1 x 11 4 reducing coupling provided Threaded into the branch of a 11 4 tee and a drip leg fabricated as per the national fuel gas code The 199VWH has a 3 4 gas supply nipple with a 1 2 x 3 4 reducing coupling provided which is to be threaded into the branch of a 3 4 tee You must ensure that the entire gas line to the connection at the Munchkin is no smaller than 11 4 for the...

Page 11: ... gas line is prop erly purged by the gas supplier or utility Failure to properly purge the lines or improper line siz ing will result in ignition failure This problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines This gas valve must not be replaced with...

Page 12: ...NTAKE AIR PIPE B APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE AIR PIPE 1 Use only Non Foam Core venting material The following materials are approved for use as vent pipe for this boiler 12 VENTING n WARNING Follow these venting instructions carefully Failure to do so may result in severe personal injury death or substantial property damage n WARNING Do not use Foam Core Pipe in any portion of t...

Page 13: ...pe location a Provide 1 foot clearance from the bottom of the air inlet pipe and the level of maximum snow accumulation Snow removal may be necessary to maintain clearances b Do not locate air intake pipe in a parking area where machinery may damage the pipe c When venting with a two pipe system max imum distance between air intake and exhaust vent is 6 feet 1 8 m Minimum dis tance between exhaust...

Page 14: ... 1 NFPA 54 2002 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 Note There must be a minimum of 36 spacing between every 2 kit grouping Fig 4 3 Multiple Stainless Steel Horizontal Vent Kit Installation Front View Fig 4 1 ...

Page 15: ...er than 15 equivalent feet from the boiler the maximum equivalent length will be reduced See Table 4 2 Standard Vent Pipe is 4 and Oversized Vent Pipe is 6 for the 399VWH E EXHAUST VENT AND AIR INTAKE PIPE INSTALLATION 1 On the 399VWH Boiler the 4 exhaust vent connection is located at the rear of the boiler and the air intake is higher and toward the left side when the boiler is viewed from the fr...

Page 16: ...o the installa tion conforms with the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z 223 1 G CONDENSATE REMOVAL This is a condensing high efficiency appliance therefore this unit has a conde...

Page 17: ... VERTICAL PIPING ALL HORIZONTAL COUPLING TEE STRAIGHT SUPPORT BRACKETS MUST BE USED ON INTAKE AIR VENT 24 MIN RIGHT SIDE VIEW EXTERIOR WALL AND VERTICAL PIPING ALL HORIZONTAL COUPLING TEE INTAKE AIR VENT TOP VIEW STRAIGHT SUPPORT BRACKETS MUST BE USED ON EXHAUST VENT EXTERIOR WALL 12 MIN 1 MIN TEE STRAIGHT VENT SIDEWALL VENTING WITH TEE INTAKE AND COUPLING EXHAUST COUPLING EXHAUST INTAKE AIR VENT ...

Page 18: ...D ON EXHAUST VENT EXTERIOR WALL INTAKE AIR VENT SIDEWALL VENTING WITH KIT RIGHT SIDE VIEW AND VERTICAL PIPING VENT KIT ALL HORIZONTAL SUPPORT BRACKETS MUST BE USED ON EXHAUST VENT SIDEWALL VENTING WITH CONCENTRIC VENT KIT AND VERTICAL PIPING ALL HORIZONTAL EXTERIOR WALL VENT EXHAUST RIGHT SIDE VIEW MUST BE FACING UP NOTE INTAKE LEG SUPPORT BRACKETS MUST BE USED ON INTAKE AIR VENT 1 MIN DIAGRAMS FO...

Page 19: ...k flow device built into the system to prevent a back flow of water back into city mains Some states require back flow pre venters on all incoming water supplies Under these circumstances you will need a hot water expan sion tank listed for potable water use The expansion tank should be located on the cold inlet piping close to the water heater It is important that you follow the expansion tank ma...

Page 20: ...20 25 30 35 37 5 40 Flow in Gallons per Minute Friction in Feet of Head MUNCHKIN 399VWH MUNCHKIN 199 VWH 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 The recommended circulators are based on 1 gpm per 10 000 BTU hr w 20 ...

Page 21: ...ve spring loaded check valve hose bib boiler drain diaphragm type expansion tank for potable water anti scald rated mixing valve pressure gauge pressure relief valve or P T relief valve union Munchkin heater vacuum breaker T P temperature pressure gauge flow switch Superstor Ultra Storage Tank PIPING ILLUSTRATIONS Fig 5 1 ...

Page 22: ... connecting to a water storage tank is 1 25 inch for 199 VWH and 2 inches for 399 VWH 5 The minimum pipe size for connecting a Munchkin boiler is 1 25 inches for 199 VWH and 2 inches for 399 VWH 6 All pumps are shown with isolation flanges or full port ball valves for isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 ...

Page 23: ...m pipe size for connecting to a water storage tank is 1 25 inch for 199 VWH and 2 inches for 399 VWH 5 The minimum pipe size for connecting a Munchkin boiler is 1 25 inches for 199 VWH and 2 inches for 399 VWH 6 All pumps are shown with isolation flanges or full port ball valves for isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a...

Page 24: ... port ball valves for isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks shall be installed with reverse return piping as sho...

Page 25: ...ball valves for isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown 10 ...

Page 26: ...r isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown 10 Anti scald rat...

Page 27: ...r isolation The alternative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown 10 Anti scald rat...

Page 28: ...ative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown 10 Anti scald rated mixing valve is rec...

Page 29: ...ative is standard flanges with full port ball valves and a separate flow check valve 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves 8 Install vacuum relief valve in accordance with local code requirements 9 All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown 10 Anti scald rated mixing valve is rec...

Page 30: ... 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 4 When the pre purge period is complete power is applied to the spark ignitor for approxi mately 6 seconds Approximately 2 seconds later we verify flame If a flame is not verified during the trial for ignition the gas valve is immediately c...

Page 31: ...around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas suppli...

Page 32: ...nto the control Listed below are the set points that can be programmed into the control Note When using a mechanical control on the storage tank it is recommend that the temperature set point on the Munchkin VWH boiler is set 5 F above the setting of the mechanical control located on the storage tank The Munchkin VWH will modulate its firing rated based on the supply temper ature sensor until the ...

Page 33: ...mended limits on each 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 S1 or S2 keys To activate the test mode press and hold the S2 and the S3 Program Key simulta...

Page 34: ... SEE PART 12 SECTION D FOR COMBUSTION SETTING TABLE PRESSURE TAP OUTLET THROTTLE ADJUSTER NOTE IF FOR ANY REASON THE THROTTLE NEEDS TO BE ADJUSTED IT IS VERY IMPORTANT THAT A COMBUSTION ANALYZER BE USED TO ENSURE SAFE AND PROPER OPERATION TURN THE ADJUSTER TO THE TO INCREASE GAS OR THE TO DECREASE THE GAS SUPPLY THIS ADJUSTMENT COULD AFFECT CO CO LEVELS MAKE SURE THE LEVELS CORRESPOND TO THE CHART...

Page 35: ... servicing n CAUTION If overheating occurs or the gas supply fails to shut off do not turn off electrical power to the circulating pump This may aggravate the problem and increase the likelihood of boiler damage Instead shut off the gas supply to the boiler at the gas service valve Table 7 1 925 Control Board Error Codes n WARNING When servicing or replacing any components of this boiler be certai...

Page 36: ...r e l i o b e h T l a n g i S e m a l F f o s s o L e h t e r o f e b s e m i t 4 t h g i l e r l l i w t u o k c o l s i h t o t n i s e o g l o r t n o c n o i t i d n o c 1 2 3 4 5 6 n o i t a r e p o n i e l i h w t i n u e h t o t e r u s s e r p s a g e h t r o t i n o M t i l n e h w e l b a t s s i e m a l f e h t t a h t e r u s s A e h t e l i h w t u o s i e l u d o m y a l p s i d e h ...

Page 37: ...iler Resistance ohms 32 32550 41 25340 50 19870 59 15700 68 12490 77 10000 86 8059 95 6535 104 5330 113 4372 122 3605 131 2989 140 2490 149 2084 158 1753 167 1481 176 1256 185 1070 194 915 203 786 212 667 RESISTANCE TABLES ...

Page 38: ...ized Heat Transfer Products Representative or Certified Installing Contractor See coil cleaning instructions Section D Burner check burner for deterioration If deterioration is observed replace burner System Water Pressure check pressure regulator and system pressure Check system for air which will create noise Open air vents or purge system to bleed air then close once air is fully purged from th...

Page 39: ...s WARNING Follow precautions above 4 Spray the coils with clear water making sure to confine the spray to the area being cleaned Try to avoid getting the back cermic wall of the unit wet Flush the combustion chamber with fresh water At this point the Munchkin should be ready to power back up Before powering up the Munchkin follow the steps below a Re install the burner assembly b Replace the 6 10M...

Page 40: ...NOTE When firing up the boiler for the first few times you may experience some flut tering of the gas burner that may result in a flame lockout This is normal and will require you to re cycle the unit until this clears up This is caused by water still present in the combustion chamber n DANGER IT IS EXTREMELY IMPORTANT THAT YOU CHECK FOR LEAKS WHEN RECONNECTING THE GAS VALVE AND MAKING SURE THE EX...

Page 41: ...41 MAINTENANCE Fig 8 1 E MUNCHKIN CONTROLLERS ...

Page 42: ...P 019 24 Spark Electrode w Gasket 7350P 020 8 Screws M4 x 30MM Allen Head N A 25 Screws M4 x 8MM Probe Electrode 7250P 069 9 Right Angle Connector 7250P 723 26 Flame Rectification Probe w Gasket 7250P 049 10 Screws M4 x 12MM Allen Head N A 27 Screws Torx M5 x 22MM Air Gas Channel to Burner Door 7250P 206 11 Dungs Gas Valve Assembly 7250P 710 28 Gasket Air Gas Channel to Burner 7500P 074 12 Screws ...

Page 43: ...ard Display w Ribbon Cable 7250P 332 27 PVC Pipe Sch 40 4 Exhaust Assembly 7250P 524 10 Electrical Box w Screws 7250P 707 28 S S Hex Nut 10 32 Blocked Vent Pressure Switch 7250P 153 11 Screws 8 x 1 2 Self Tapping Electrical Box 7250P 133 29 O Ring 007 Blocked Vent Pressure Switch 7250P 152 12 Cabinet Cover 7250P 501 30 S S Hose Barb 1 4 x 10 32 Blocked Vent Pressure Switch 7250P 154 13 Flow Switch...

Page 44: ... Air Gas Channel to Burner 7500P 074 8 Screws M4 x 25MM Gas Valve 7250P 718 25 NIT Burner 7250P 117 9 Swirl Plate 7500P 093 26 Nut M6 Burner Door 7500P 067 10 Gas Valve Adapter Plate w Screws 7250P 644 27 Burner Door 7250P 684 11 Screws M5 x 12MM Gas Valve Adapter Plate 7250P 484 28 Burner Door Ceramic Refractory 7250P 702 12 Relief Valve 7250P 080 29 Screw M4 x 8MM Ceramic Target Wall 7250P 704 1...

Page 45: ... Cable Clamp Condensate Assy 7250P 649 8 Control Board Hold Down Clips 7250P 352 26 Screw 8 x 1 2 Self Tapping Condensate Assy 7250P 133 9 Control Board w Fuse 7250P 317 27 Poly Plug 3 4 NPT Condensate Assy 7250P 647 10 Fuse Control Board 7250P 378 28 Band Clamp Exhaust Assy CA2000 11 Control Board Display w Ribbon Cable 7250P 332 29 PVC Pipe Sch 40 3 Exhaust Assy 7250P 242 12 Electrical Box w Scr...

Page 46: ...of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector w...

Page 47: ...e manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete...

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