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GENERAL INFORMATION

7

DIMENSIONS

80M

140M/199M

Figure 1-4

Figure 1-5

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Summary of Contents for MUNCHKIN

Page 1: ...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 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 WARNING This manual must ...

Page 2: ...E HEATER AND PRESSURE VESSEL CODE Section IV ALONG WITH CSD1 THE HEATER GAS PIPING WATER PIPING VENTING AND ELECTRICAL MUST BE INSTALLED BY TRAINED QUALIFIED PERSONNEL FAMILIAR WITH INSTALLATION PRACTICES LOCAL CODE LICENSING REQUIREMENTS IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT STORE OR...

Page 3: ... 18 G Condensate Removal 18 PART 5 22 thru 33 PIPING A Hydronic piping with Circulators or Zone Valves 22 B Circulator Sizing 23 C Fill and Purge Heating System 24 D Piping Illustrations 25 PART 6 34 thru 37 START UP PROCEDURES A Sequence of operation 34 B Items to be checked before lighting the Munchkin 34 C Lighting Instructions 35 D Operating Instructions 35 E Adjusting the Temperature on the M...

Page 4: ...econds to pre purge the system before starting the Munchkin The Munchkin controller will now start to modulate the pre mix burner based on analyzing the return temperature supply water temperature and the set point temperature By compiling this information the controller utilizes an algorithm to fully adjust the firing rate while maintaining the desired output temperature The pre mix burner fan ha...

Page 5: ...GENERAL INFORMATION 5 Figure 1 1 NOTE The Munchkin is rated at zero clearance to combustibles 80M 140M 199M T50M T80M RECOMMENDED SERVICE CLEARANCES Figure 1 2 ...

Page 6: ...GENERAL INFORMATION 6 Figure 1 3 T50M T80M DIMENSIONS ...

Page 7: ...GENERAL INFORMATION 7 DIMENSIONS 80M 140M 199M Figure 1 4 Figure 1 5 ...

Page 8: ...o combustible construction In addition it is design certified for use on combustible floors 2 Refer to Figure 1 1 and Figure 1 2 for the recommended clearance to allow for rea sonable access to the boiler Local codes or special conditions may require greater clearances COMBUSTION AND VENTILATION AIR 1 The Munchkin Boiler is designed only for operation with combustion air piped from outside sealed ...

Page 9: ...or your convenience we have labeled all the wires that need to be connected to operate the Munchkin CAUTION The Munchkin is certified as an indoor appliance Do not install the Munchkin outdoors or locate where it will be exposed to freezing temperature This includes all related piping and components If the Munchkin is subjected to flood water or submersed in water the Munchkin must be replaced CAU...

Page 10: ...in 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 CAUTION Electrical wiring on the Incoming Power and Central Heating Circulator shall be connected directly to the intended connection source and not be connected together inside the electric box provided An Electrical Short will result and the ...

Page 11: ...A N G E B R O W N G R E E N Figure 2 1 Connection Wiring Directly to Central Heating Circulator Figure 2 2 Connection Wiring without Wiring Central Heating Circulator Note to Electrical Contractor The orange wire is 120 Volt 4 Amp maximum for central heating circulator only Loads greater than 4 amps or 3 amps for HA models only will blow the fuse on the board The brown wire is the neu tral wire fo...

Page 12: ...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 Failure to do so may damage the gas valve In the event the gas valve is exposed to a pressure greater than PSI 14 water column the gas valve must be replaced Never use an open flame match lighter etc to c...

Page 13: ...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 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 mai...

Page 14: ...expected snow accumulation level Snow removal may be necessary to maintain clearance f Provide 4 feet horizontal clearance from electrical meters gas meters gas regulators and relief equipment In no case shall the exit terminal be above or below the afore mentioned equipment unless the 4 foot hor izontal distance is maintained g Do not locate the exit terminal over public walkways where condensate...

Page 15: ...al Fuel Gas Code ANSI Z223 1 NFPA 54 2002 Fig 4 2 Multiple Vent Spacing Note Exhaust must extend out 1 foot Figure 4 5 Multiple Boiler Installations Fig 4 3 Multiple Stainless Steel Vertical Vent Kit Installation Front View Fig 4 4 Multiple Stainless Steel Horizontal Vent Kit Installation Front View Fig 4 1 ...

Page 16: ...b Use a 3 x 2 reducing coupling to transition from the T50 and T80 boiler connections to a 3 vent c Use a 4 x 3 reducing coupling to transition from the 80M 140M and 199M boiler con nections to 4 vent d The maximum equivalent length for the increased diameter vent pipes is 125 feet e If the transition occurs at a distance greater than 15 equivalent feet from the boiler the maximum equivalent lengt...

Page 17: ...rs at a minimum of 4 foot intervals to prevent sagging of the pipe where conden sate may form 8 Do not use the boiler to support any piping 9 A screened straight coupling is provided with the boiler for use as an outside exhaust termi nation 10 A screened inlet air tee is provided with the boiler to be used as an outside intake termi nation 11 The following information on Table 4 3 are optional in...

Page 18: ...e 7 Any improper operation of the common venting system should be corrected so 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 T...

Page 19: ...RAL NOTE All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a per foot back to the heater to allow drainage of condensate DIAGRAMS FOR SIDEWALL VENTING Figure 4 1a Figure 4 2a ...

Page 20: ...VENTING 20 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 per foot back to the heater to allow drainage of condensate ...

Page 21: ...re 4 5a Figure 4 6a DIAGRAMS FOR VERTICAL VENTING GENERAL NOTE All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a per foot back to the heater to allow drainage of condensate ...

Page 22: ... use glycol that is specially formulated for this purpose It includes inhibitors which prevent the glycol from attacking the metallic system components Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level The system should be tested at least once a year and as recommend by the producer of the glycol solution Allowance should be made for the expansi...

Page 23: ...ng illustrations included in this section Figs 5 3 to 5 11 for suggested guidelines in piping the Munchkin heater with either zone valves or circulator pumps Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes B CIRCULATOR SIZING The Munchkin Heat Exchanger does have pressure drop whi...

Page 24: ...tested at least once a year and as recommended by the glycol manufacturer 3 Anti freeze solutions expand more than water For example a 50 by volume solution expands 4 8 in volume for a temperature increase from 32 F to 180 F while water expands 3 with the same temperature rise Allowances must be made for this expansion in the sys tem design 4 A 30 mixture of glycol will result in a BTU output loss...

Page 25: ... valve air separator backflow preventer diaphragm type expansion tank pressure reducing valve diff pressure bypass anti scald rated mixing valve pressure gauge 4 way motorized mixing valve 3 way motorized mixing valve pressure relief valve float type air vent heat exchanger union Munchkin heater radiant manifold Super Stor indirect DHW tank vacuum breaker thermostatic radiator valve TRV angle circ...

Page 26: ...l 140M 5 gpm Munchkin model 199M 7 gpm 3 The minimum pipe size for connecting a Super Stor water heater is 1 inch 4 The minimum pipe size for connecting a Munchkin boiler is 1 25 inches 5 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 11...

Page 27: ... gpm Munchkin model 80M 3 gpm Munchkin model 140M 5 gpm Munchkin model 199M 7 gpm 3 The minimum pipe size for connecting a Super Stor water heater is 1 inch 4 The minimum pipe size for connecting a Munchkin boiler is 1 25 inches 5 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 6 The anti scald mixing valve is recommended if the DHW tempera...

Page 28: ... for connecting a Munchkin boiler is 1 25 inches 5 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 7 Install a minimum of 12 diameters of straight pipe upstream of all circulators 8 A purging valve may be used in lieu of the ball va...

Page 29: ... 3 The minimum pipe size for connecting a Super Stor water heater is 1 inch 4 The minimum pipe size for connecting a Munchkin boiler is 1 25 inches 5 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 6 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 7 Install a minimum of 12 diameter...

Page 30: ...ipe size for connecting a Munchkin boiler shall be 1 25 inches 6 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 A purging valve may be used in lieu ...

Page 31: ...nstalled upstream and downstream of all closely spaced tees 4 The minimum pipe size for connecting a Super Stor water heater is 1 inch 5 The minimum pipe size for connecting a Munchkin boiler shall be 1 25 inches 6 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 7 The anti scald mixing valve is recommended if the DHW temperature is set abov...

Page 32: ...size for connecting a Munchkin boiler shall be 1 25 inches 6 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 A purging valve may be used in lieu of t...

Page 33: ...ipe size for connecting a Munchkin boiler shall be 1 25 inches 6 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves 7 The anti scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119 F 8 Install a minimum of 12 diameters of straight pipe upstream of all circulators 9 A purging valve may be used in lieu ...

Page 34: ...ol enters an idle state while continuing to moni tor temperature and the state of other system devices If a call for heat is received the con trol will automatically return to step 2 in sequence and repeat the entire operating cycle During the idle state and heat state if the control detects an improper operating state from external devices such as the high limit switch the red light on the contro...

Page 35: ...cian Force or attempted repair may result in a fire or explosion 4 Do not use this appliance if any part has been under water Immediately call a qualified serv ice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water 5 The Munchkin Boiler shall be installed so the gas ignition system components are protected from water dri...

Page 36: ...The burn er will not start until the outlet temperature of the system falls below 159 F degrees 180 20 F 160 F To adjust press either S1 Decrease Value or S2 Increase Value Ranges 5 F to 30 F Press the S3 Program key again and you will see the Indirect Setting de and an alternative value of 119 Vision Systems Only To adjust press either S1 Decrease Value or S2 Increase Value The final adjustment i...

Page 37: ...t mode stops automatically To exit Test Mode press S1 and S2 key together for 1 second 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 3 Remove the front cover 4 Turn gas shutoff valve to off 5 Install front cover START UP PROCEDURES SERVICING Fig 6 2 DANGER Water temperature over 125 degrees F can c...

Page 38: ...t condition occurs the controller will illuminate the red fault indication light and display a fault code in the format Example F00 on the display module 2 Note the fault code and refer to Table 7 2 for an explanation of the fault code along with several suggestions for corrective actions 3 Press the reset key to clear the fault and resume operation Be sure to observe the operation of the unit to ...

Page 39: ...k c o l b e u l f y n a k c e h C 0 1 F 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 ...

Page 40: ...TROUBLESHOOTING 40 ...

Page 41: ... 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 the system Water Piping check for and repair any leaks Gas Piping check for and repair any leaks C CONDENSATE CLEANING INSTRUCT...

Page 42: ...y to avoid getting the back ceramic 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 10MM nuts to the burner plate c Re connect the wiring d Re connect the poly hose to the combustion blower motor Does not apply to the...

Page 43: ...CKED g Turn the Munchkin back on and observe condensate flow h Re connect the condensate hose to the outside connection 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 ch...

Page 44: ...MAINTENANCE 44 ...

Page 45: ...MAINTENANCE 45 ...

Page 46: ...46 TYPICAL MUNCHKIN BOILER INSTALLATION NOTE THIS DETAIL IS MEANT TO SHOW A TYPICAL INSTALLATION THE INSTALLER IS RESPONSIBLE FOR ALL EQUIPMENT DETAILING REQUIRED BY LOCAL CODES ...

Page 47: ...side corners building air intakes etc 5 Does exhaust stay clear of intake piping and have enough separation as not to re circu late flue gas Questions relating to condensate management 1 Would elevating the boiler off of the floor help the condensate run 2 Does the condensate line slope to the drain at a minimum of per foot 3 Is the condensate pump installed properly 4 Does the condensate line hav...

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 ...

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