Installing, Operating & Maintaining MUNCHKIN™ HIGH EFFICIENCY 399M COMMERCIAL BOILER 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. 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.
USING THIS MANUAL USING THIS MANUAL SPECIAL ATTENTION BOXES Throughout this manual you will see these special attention boxes similar to this one, which are intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgement of Heat Transfer Products, Inc.: DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
TABLE OF CONTENTS TABLE OF CONTENTS PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 6 PART 6 . . . . . . . . . . . . . . . . . . . .29 thru 32 GENERAL INFORMATION START UP PROCEDURES A B C D How It Operates . . . . . . . . . . . . . . . . . .4 Munchkin Ratings and Dimensions .4–5 Pre-installation Requirements . . . . . . .5 Pressure Relief Valve . . . . . . . . . . . . . .6 A B C D PART 2 . . . . . . . . . . . . . . . . . . . . . .6 thru 8 ELECTRICAL A Electrical Connection . . . . . . .
GENERAL INFORMATION PART 1. GENERAL INFORMATION A. HOW IT OPERATES When the room thermostat calls for heat, the Munchkin control board will start the circulator 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 heater will start to heat the water.
GENERAL INFORMATION DIMENSIONS Figure 1-2 C. PRE-INSTALLATION REQUIREMENTS The Munchkin is designed for installation on non-rated flooring, in alcoves, basements, utility rooms, and closet but never a bedroom closet. Choose a location for your Munchkin, centralized to the piping system, along with consideration for Electrical (Part 2), Gas Connection (Part 3) and Venting (Part 4). This boiler needs to be installed on a level floor.
GENERAL INFORMATION / ELECTRICAL NOTE: It is important to refer to the site installation checklist in the back of the manual to assure proper and effective installation 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.
ELECTRICAL 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. 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.
ELECTRICAL / GAS CONNECTION DIAGRAM "A" DIAGRAM "B" WIRING DIAGRAM CONNECTING TO CIRCULATOR WIRING DIAGRAM WITHOUT CONNECTION TO CIRCULATOR T BLACK (HOT) GRAY T GRAY GRAY GREEN (GROUND) GREEN (GROUND) WHITE (NEUTRAL) BROWN (NEUTRAL) OR T GRAY NORMALLY OPEN THERMOSTAT CONNECTION ORANGE (HOT) T GREEN (GROUND) NORMALLY OPEN THERMOSTAT CONNECTION BROWN (NEUTRAL) ORANGE (HOT) BLACK BR AN GE OW GR N EE N GREEN (GROUND) WHITE (NEUTRAL) IMPORTANT NOTE: BE CERTAIN THAT THE ORANGE WIRE IS SEC
GAS CONNECTION A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pressure (3.5 kPa), and a minimum of 7" water column. The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.5" as stated in the National Fuel Gas Code. This information is listed on the rating plate. It is very important that you are connected to the type of gas as noted on the rating plate.
GAS CONNECTION removing the cap and installing the manometer. The gas pressure must remain between 7" and 14" during stand-by (static) mode and while in operating (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.
VENTING PART 4. VENTING A. GENERAL 1. Install the boiler venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes. 2. This boiler is a direct vent appliance and is listed as a Category IV appliance with Underwriters Laboratories, Inc. VENT AND INTAKE AIR PIPE WARNING This vent system will operate with a positive pressure in the pipe.
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 – Front View Fig.
VENTING D. EXHAUST VENT AND INTAKE AIR PIPE SIZING 1. For the 399M the exhaust vent and air intake pipes should be 4" Schedule 40 or 80. 2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet. a. The equivalent length of elbows, tees, and other fittings are listed in the Friction Loss Table 4.1. Table 4.1 FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS FITTINGS OR PIPING EQUIVALENT FEET a.
VENTING WARNING All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space. 5. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼" per foot to allow condensate to drain from the vent pipe. If the vent pipe must be piped around an obstacle that causes a low point in the pipe, a drain pipe must be connected to allow condensate to drain. 6. All piping must be fully supported.
VENTING DIAGRAMS FOR SIDEWALL VENTING **IMPORTANT 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). Always increase pipe in vertical position. Never increase pipe size in horizontal position.
VENTING DIAGRAMS FOR SIDEWALL VENTING (cont’d) **IMPORTANT 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). Figure 4-2a: 4" Sidewall Vent with V2000 kit DIAGRAM FOR VERTICAL VENTING **IMPORTANT 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).
VENTING / PIPING G. CONDENSATE REQUIREMENTS This is a condensing high efficiency appliance, therefore this unit has a condensate removal system. Condensate is nothing more than water vapor, derived from the combustion products, similar to an automobile when it is initially started.
PIPING pound. Threaded connections are 2” NPT Brass nipples located on the left hand side of unit. 2. Connect the system supply marked “Heater Out”, make sure to install with pipe sealant compound. Threaded connections are 2” NPT Brass nipples located on the left hand side of the unit. 3. Install Purge and Balance Valve or shut off valve and drain on system return to purge air out of each zone. 4. Install a Back Flow preventor on the Cold Feed Make-Up Water line. 5.
PIPING C. FILL AND PURGE HEATING SYSTEM • • • • • Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain Close the other side of the balance and purge valve or the shut off valve after the drain. Open first zone balance and purge or drain valve to let water flow out the hose. If zone valves are used, open the valves one at a time manually. (Note: please check valve manufacturer’s instruction prior to opening valves manually, so as not to damage the valve.
PIPING D. PIPING ILLUSTRATIONS Piping Symbol Legend circulator (w/ isolation flanges) pressure reducing valve circulator w/ integral flow check) diff.
PIPING Standard Munchkin boiler Retrofit piping (zoning with valves) Space heating mode Drawing 1A zone valves make-up water P1 flow bypass valve purging valves V1 OFF anti-scald mixing valve cold water T/P Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
PIPING Standard Munchkin boiler Retrofit piping (zoning with valves) Domestic water heating mode Drawing 1B OFF OFF OFF OFF zone valves make-up water P1 flow bypass valve purging valves V1 anti-scald mixing valve cold water T/P Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
PIPING Standard Munchkin boiler Preferred piping (zoning with valves) Space heating mode Drawing 2A zone valves make-up water P2 closely spaced tees differential pressure bypass valve purging valves V1 OFF anti-scald mixing valve cold water P1 T/P Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
PIPING Standard Munchkin boiler Preferred piping (zoning with valves) Domestic water heating mode Drawing 2B OFF OFF make-up water OFF OFF zone valves P2 closely spaced tees differential pressure bypass valve V1 purging valves anti-scald mixing valve cold water P1 T/P Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
PIPING Standard Munchkin boiler Preferred piping (zoning with circulators) Space heating mode Drawing 2C space heating zone circuit zone circulators make-up water closely spaced tees purging valves anti-scald mixing valve P2 cold water P1 T/P Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
PIPING Standard Munchkin boiler Preferred piping (zoning with circulators) Domestic water heating mode Drawing 2D space heating zone circuit zone circulators make-up water closely spaced tees purging valves anti-scald mixing valve P2 cold water P1 T/P Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
PIPING Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Space heating mode Drawing 2E space heating zone circuit zone circulators make-up water closely spaced tees purging valves anti-scald mixing valve cold water P2 PB1 T/P PB2 T/P Munchkin boiler Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This drawing is meant to show system piping concept only.
PIPING Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Domestic water heating mode Drawing 2F space heating zone circuit zone circulators make-up water closely spaced tees purging valves anti-scald mixing valve cold water P2 PB1 T/P PB2 T/P Munchkin boiler Munchkin boiler Super Stor indirect DHW tank NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This drawing is meant to show system piping concept only.
START-UP PROCEDURES PART 6. START-UP PROCEDURES A. ITEMS TO BE CHECKED BEFORE LIGHTING THE MUNCHKIN It is recommended that you read the General Information Section (Part 1) to get a better understanding how the Munchkin operates before you start the unit. 1. Make sure that you follow the Lighting instruction before running the Munchkin. 2. Make sure the unit has a minimum water supply pressure of 10 PSI or a fault code of PrO will appear in the display.
START-UP PROCEDURES 4. Do not use this appliance if any part has been under water. Immediately call a qualified service 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 Heater shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.) C.
START-UP PROCEDURES E. STATUS MENU Installers are also able to check the current status of the Munchkin parameters by pressing S4/RESET key for 3 seconds. Once activated, the display will show d1 alternating value of the actual outlet temperature. Actual values are displayed for each function. To view the next value simply press the S/4 key to go to the next displayed value. Listed below are the values which can be displayed. These values cannot be changed.
START-UP PROCEDURES / SERVICING GAS SHUT OFF VALVE OUTLET VALVE SOLENOID INLET VALVE SOLENOID MOUNTING BRACKET OUTLET PRESSURE TAP INLET PRESSURE TAP THROTTLE ADJUSTMENT Fig. 6-1 OFFSET ADJUSTMENT PART 7. SERVICING A. SEQUENCE OF OPERATION 1. When power is first applied to the control, the control display will read the outlet temperature. The control will initially run through a self-diagnostic routine and then go into its operating mode.
SERVICING closed. This could occur if the clear hose, which is connected to the outlet of the fan is disconnected. This can be corrected by re-connecting the hose. Listed below are the Temporary Fault Codes. E00 This code will appear if there is an overshoot of the high limit. The Temporary Fault Code will be displayed only 50 seconds. E13 This code will appear if the expected fan speed is lower then 70%. This will show on the display 10 seconds after the fan has started.
SERVICING Table 7-1: 925 Control Board Error Codes Code E00 E13 E14 Description High Limit Exceeded Combustion Fan Speed Low. The boiler combustion air fan speed less than 70% of expected. Combustion Fan Speed High. The boiler combustion air fan speed is more than 130% of expected. Duration 50 Sec. 60 Sec. 60 Sec. PR0 Pressure Switch Open Until Corrected FLU Blocked Vent Pressure Switch Open Until Corrected 34 Corrective Action 1. Check circulation pump operation. 2.
SERVICING Table 7-2: 925 Control Board FAULT Codes Code F00 F01 F02 F03 F05 F06 F09 F10 F11 F13 F14 F18 F30 F31 F32 F33 Description Remedy 1. Check circulation pump operation 2. Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the High Limit Exceeded. return thermister to the supply thermister. 3. Check thermister reading on supply thermister. Replace switch if faulty. 1.
SERVICING 36
MAINTENANCE PART 8. MAINTENANCE A. MAINTENANCE PROCEDURES Periodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is in safe efficient operation. The owner can make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition.
MAINTENANCE in which case, a qualified plumber will need to be contacted to follow the Coil Cleaning Instructions (Section D) included in this section to dissolve deposit and clean condensate line. DANGER IT IS EXTREMELY IMPORTANT TO MAKE SURE THE EXHAUST VENT IS NO LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH. D. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS* WARNING The combustion chamber insulation in this product contains ceramic fiber material.
MAINTENANCE d. Re-connect gas valve, air-gas mixer and replace bracket. (IMPORTANT: CHECK FOR GAS LEAKS) e. Re-set thermostats (IMPORTANT: MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED!) DANGER IT IS EXTREMELY IMPORTANT THAT YOU CHECK FOR LEAKS WHEN RECONNECTING THE GAS VALVE AND MAKING SURE THE EXHAUST VAN IS NO LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH. f. Turn the Munchkin back on** and observe condensate flow. g.
MAINTENANCE 40
MAINTENANCE 41
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.
Installation Checklist for Munchkin Boilers Questions relating to electrical 1. 2. 3. 4. 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? Are we correctly using the supplied wires to power the pumps? (No shared neutrals) Questions relating to gas 1. 2. 3. 4. 5. 6. 7. 8. 9.
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