Munchkin HeatTransfer 399M Installing, Operating & Maintaining Download

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HEAT TRANSFER PRODUCTS, INC.

120 BRALEY RD., E. FREETOWN, MA 02717

Installing, Operating & Maintaining

MUNCHKIN HIGH EFFICIENCY HEATER

with the “925” Controller

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.

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 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.

MH27745

CONTROLS

Summary of Contents for HeatTransfer 399M

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: ...D LOCAL CODES MIGHT ALSO APPLY TO INSTALLATION WHERE REQUIRED BY THE AUTHORITY HAVING JURISDICTION THE INSTALLATION MUST CONFORM TO THE STANDARDS FOR CONTROLS AND SAFETY DEVICES FOR AUTOMATICALLY FIRED HEATERS ANSI ASME 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 ...

Page 3: ... 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 35 thru 37 START UP PROCEDURES A Items to be checked before lighting the Munchkin 35 B Lighting Instructions 35 C Operating Instructions 36 D Adjusting the Temperature on the Munchkin Display 36 E Status Menu 37 F To Turn Off Gas to Appliance 37 PART 7 38 t...

Page 4: ...tor for 5 seconds 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 bu...

Page 5: ...GENERAL INFORMATION 5 Figure 1 1 NOTE The Munchkin is rated at zero clearance to combustibles Figure 1 3 T50M T80M 80M 140M 199M T50M T80M DIMENSIONS RECOMMENDED SERVICE CLEARANCES Figure 1 2 ...

Page 6: ...GENERAL INFORMATION 6 DIMENSIONS 80M 140M 199M Figure 1 4 Figure 1 5 ...

Page 7: ...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 NOTICE Service clearance of the Munchkin See Section 1 Figures 1 1 and 1 2 NOTICE Condensation removal This is a condensing high efficiency appliance therefore condensation removal must be addressed to avoid...

Page 8: ...olarity is reversed the Munchkin control will not sense a flame and lock out the system The Orange and Brown wire are provided to the supply of 120 volts to the Central Heating Circulator Connect the Orange Hot and the Brown Neutral directly to the Central Heating Circulator Connect the gray wires to your heating thermostat TT connection Your thermostat heat anticipator setting is 056 amp CAUTION ...

Page 9: ...IS SECURELY CAPED FAILURE TO DO SO COULD RESULT IN INJURY OR FIRE AND COULD DAMAGE THE CONTROL O R A N G E B R O W N G R E E N NOTICE Do not power zone valves directly from the heater transformer Doing so will greatly reduce the life of the transformer Use a separate transformer sized to handle the total electric load of all zone valves Figure 2 1 Connection Wiring Directly to Central Heating Circ...

Page 10: ...rom 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 ch...

Page 11: ... 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 maintenance to their lines This gas valve must not be replaced with a conventional gas valve under any circumstances As an additional sa...

Page 12: ... or death Fig 3 3 Fig 3 2 low high Carbon CO 2 9 1 2 10 1 2 9 1 2 10 1 2 high Dioxide 80 ppm 135 ppm 8 1 2 9 1 2 0 20 ppm 8 1 2 9 1 2 COMBUSTION SETTINGS HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS low 0 20 ppm 80 150 ppm Carbon CO ppm Monoxide Natural Gas Propane LP T50M T80M GAS VALVE ...

Page 13: ...stibles Note For Concrete construction or to meet certain fire codes exhaust and inlet piping at the wall penetration to the Munchkin must be CPVC Schedule 40 or 80 to meet local fire codes The balance from the penetrated wall to the outside may be PVC Schedule 40 or 80 Inlet Air Vent Use the same material as used for exhaust in either 2 3 or 4 Plastic Pipe Cellular Foam Core Pipe may be used for ...

Page 14: ...ms 2 Never vent over or under a window or over a doorway where the exhaust plume or conden sation liquid will cause obtrusive or dangerous conditions Or refer to National Fuel Gas Code CAN B149 3 Never install a heat saver or similar product to capture waste heat from exhaust 4 Always have a vent location at least 1 above maximum snow level 5 Always have vent 1 above ground level away from shrubs ...

Page 15: ...E INLET SOCKET AND OUTLET SOCKET Y TEE CON NECTION OF THE KIT PRIOR TO INSTALLING THE SCHEDULE 40 PIPE AND GLUING Note The V1000 when used for the T50 or T80 will require a transition piece from 2 to 3 VENTING 12 in minimum Forced air inlet Grade 3 ft minimum Less than 10 ft terminal see 10 8 1 draft vent Mechanical C 12 in minimum Direct vent terminal clearance Minimum clearance C Input Btu hr 4 ...

Page 16: ...verall extended combined length of pipe on the inlet and exhaust must not exceed 125 equivalent feet total Example Installation requires the following material for both the inlet and exhaust piping when extending the vent run for the Munchkin 3 Vented Appliance 2 Pcs 3 90 degree elbow 2 x 5 10 Equivalent Feet 10 Equivalent Feet 20 of 3 Plastic PVC Pipe 20 x 1 20 Equivalent Feet 20 Equivalent Feet ...

Page 17: ...imum speed Do not operate a summer exhaust fan Close all fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust the thermostat so the appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette 6 After it has been d...

Page 18: ...ched a minimum of a per foot back to the heater to allow drainage of condensate Figure 4 1 IMPORTANT NOTE All vent pipes must be glued prop erly supported and the exhaust must be pitched a mini mum of a per foot back to the heater to allow drainage of condensate Figure 4 2 DIAGRAMS FOR SIDEWALL VENTING ...

Page 19: ...aust must be pitched a minimum of a per foot back to the heater to allow drainage of condensate Figure 4 3 IMPORTANT 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 Figure 4 4 ...

Page 20: ...tched a minimum of a per foot back to the heater to allow drainage of condensate Figure 4 5 IMPORTANT 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 Figure 4 6 DIAGRAMS FOR VERTICAL VENTING ...

Page 21: ...tubing 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 Heat Transfer Products Inc It is also very important that the condensate line is not exposed to freezing temperatures or a...

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: ...ping illustrations included in this section pages 25 34 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 pre...

Page 24: ...acking metallic system components Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level 2 The glycol solution should be 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 ...

Page 25: ...ackflow preventer diaphragm type expansion tank pressure reducing valve diff pressure bypass 3 way thermostatic 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 T P Super Stor indirect DHW tank temperature pressure gauge circulator w integral flow check Piping Symbol Legend P T r...

Page 26: ...50M 3 gpm Munchkin model T80M 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 heater 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 t...

Page 27: ...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 heater 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 fact...

Page 28: ...e for connecting a Super Stor water heater is 1 inch 5 The minimum pipe size for connecting a Munchkin heater shall be 1 25 inches 6 All pumps are shown with isolation flanges The alternative is standard flanges with full port ball valves for isolation 7 The anti scald mixing valve shown on the domestic water heater is optional 8 Install a minimum of 12 diameters of straight pipe upstream of all c...

Page 29: ...g 3 A minimum of 6 pipe diameters of straight pipe shall be installed 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 heater 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 m...

Page 30: ...tor water heater is 1 inch 4 The minimum pipe size for connecting a Munchkin heater 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 ...

Page 31: ...ne with highest pressure drop operates by itself 3 The minimum pipe size for connecting a Super Stor water heater is 1 inch 4 The minimum pipe size for connecting a Munchkin heater 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 set...

Page 32: ...uper Stor water heater is 1 inch 5 The minimum pipe size for connecting a Munchkin heater 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 ci...

Page 33: ... of 6 pipe diameters of straight pipe shall be installed 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 heater 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 i...

Page 34: ...hes 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 the ball valve hose bib combination shown make up water ...

Page 35: ...rical section Part 2 Page 8 7 Turn on the power to the Munchkin The Temperature of the Munchkin Outlet will appear in the display provided If a fault code appears correct the fault before operating Make sure that the room thermostat is connected and turn the room thermostat up above room temperature to start the combustion blower fan to run the Munchkin The Munchkin will now run its pre purge cycl...

Page 36: ...n a heating cycle To adjust the temperature to the Munchkin simply press in the S3 Program key for three seconds until you see a flashing C then an alternate value of 180 This number is the factory set point of the unit which is 180 degrees To change the temperature simply push either the S1 or S2 on the display The S1 button will decrease the tempera ture while the S2 will increase the temperatur...

Page 37: ...sensor Vision only d6 Actual Fan speed multiplied by 10 Example If fan speed displayed is 410 RPM x 10 4100 actual fan speed d7 Actual Ionization current read from Flame Rectification probe d8 Actual Status of the Central Heating Circulator Off 0 On 1 Vision only d9 Actual Status of the Indirect Fired Circulator Off 0 On 1 Vision only d10 Actual Status bus communication co connected no not connect...

Page 38: ...evices 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 control will illuminate an error code will appear in the display B MUNCHKIN TEMPORARY FAULT CONDITION ...

Page 39: ...tion simply push the S4 Reset to bring the control out of its lockout state If the problem is not corrected the Munchkin will repeat the fault until the condition is corrected Once corrected the display will resume its supply temperature setting Listed below are the Fault Codes and the remedies to correct the fault F00 Safety Limit ECO This code appears if the Safety Limit ECO opens The ECO will n...

Page 40: ...ent If it s less than 1 micro amp change or clean the flame rod Also check the Gas pressure while the unit is running to determine if pressure is adequate See Part 3 Gas Connection If the gas pressure is too low correct the problem Manually reset by pushing the S4 reset button F11 The flame detector circuit is seeing a flame signal while no flame is present Remedy Check the wiring to the Gas Valve...

Page 41: ...ther assistance Remedy Call Factory for further assistance F31 Parameter Memory External Parameter memory corrupted Remedy Call Factory for further assistance F32 Parameter memory write error External Parameter memory fault Remedy Call Factory for further assistance F33 Programming Error Programming with PC not successful Remedy Call Factory for further assistance SERVICING Boiler Indirect Tempera...

Page 42: ...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 the system Water Piping check for and repair any leaks Gas Piping check for and repair any leaks C CONDENSATE C...

Page 43: ... any buildup then vacuum the debris from the coils 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 R...

Page 44: ...AYOUT Fig 8 1 There is a spare 6 3 amp slow blow fuse included on the control cover HTP p n 7250 378 or you may purchase it from Radio Shack p n 270 1068 Caution Do not replace with any amperage other than 6 3A E MUNCHKIN CONTROLLER ...

Page 45: ...MAINTENANCE 45 ...

Page 46: ...MAINTENANCE 46 ...

Page 47: ...NOTES 47 ...

Page 48: ...48 LP 61 REV 9 01 03 ...

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