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 A B C D PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 6 PART 6 . . . . . . . . . . . . . . . . . . . .29 thru 32 GENERAL INFORMATION START UP PROCEDURES 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 A B C 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, Page 6), Gas Connection (Part 3, Page 8) and Venting (Part 4, Page 11).
GENERAL INFORMATION / ELECTRICAL 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. NOTE: Service clearance of the Munchkin 1. The front of the appliance needs 24" of clearance for service minimum.
ELECTRICAL 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 Control board will have to be replaced! If Electrical Requirements of the Central Heating Circulator exceeds 4 amps (or 3 amps on HA models only) please follow the wiring diagrams on Page 8, Figures 2-1, 2-2 and 2-3.
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 DANGER It is extremely important to follow these venting instructions carefully. Failure to do so can cause severe personal injury, death or substantial property damage. A. APPROVED VENTING MATERIALS Exhaust Vent Use Plastic 4" Pipe Schedule 40 or 80. 1. Non-Foam Core PVC Pipe 2. Non-Foam Core CPVC Pipe 3. Non-Foam Core ABS Pipe Vent Piping must conform to following 1.
VENTING CAUTION The following are code restrictions for the location of the flue gas vent terminal. Compliance to these requirements doesn’t insure a satisfactory installation; good common sense must also be applied. It is important to make sure that exhaust gases are not recirculated into the inlet air of the Munchkin. The inlet pipe on the back of the cabinet should be 4" PVC schedule 40. It is very important that you plan the location properly to eliminate long pipe runs and excessive fittings.
VENTING RECOMMENDED VENTING CLEARANCES PER THE NATIONAL FUEL GAS CODE* Mechanical draft vent terminal (see 10.8.1)* Mechanical draft vent terminal (see 10.8.2)* C 12 in. mi nim um *IMPORTANT NOTE HEAT TRANSFER PRODUCTS RECOMMENDS A MINIMUM CLEARANCE OF 4 FEET WHERE THE PLUME CAUSED BY THE UNIT MAY OBSTRUCT VIEWS OR AFFECT THE COSMETIC LOOK OF THE BUILDING. 4 ft.minimum Direct vent terminal clearance Minimum clearance, C Less than 10 ft. mi 4 ft nim . um 12 in.minimum 12 in. mi nim um 3 ft.
VENTING Required: 4 Pcs. 4" 90 degree elbow (4 x 5 = 20 Equivalent Feet) = 20 Equivalent Feet Required: 20' of 6" Plastic PVC Pipe (20 x 1 = 20 Equivalent Feet) = 20 Equivalent Feet Total Friction Loss in Equivalent Feet (20 + 20 = 40 Equivalent Feet) = 40 Equivalent Feet C.
VENTING D. HEATER REMOVAL FROM A COMMON VENT SYSTEM At the time of removal of an existing heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to common venting system are not operating. 1. Seal any unused openings in the common venting system. 2.
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 4-3: 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 E. 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 INLET VALVE SOLENOID OUTLET 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 F05 Supply Temperature is to High – This code appears if the Supply temperature sensor goes above 230 degrees. Remedy – Let the Munchkin cool down, then manually push the reset button and see if the temperature increases to above 230 degrees. Determine if you have water flow or if the thermostat is continuously energized and correct the problem. Manually reset by pushing the S4/reset button.
SERVICING F30 Watchdog. Call Factory for further 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.
SERVICING RESISTANCE TABLES Boiler & Indirect Temperature (˚F) 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212 36 Resistance (ohms) 32550 25340 19870 15700 12490 10000 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070 915 786 667
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.
MAINTENANCE E. MUNCHKIN CONTROLLER CONTROL WIRING LAYOUT 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.
MAINTENANCE 40
MAINTENANCE 41
NOTES 42
NOTES 43
SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc. © 2004 Heat Transfer Products, Inc. LP-121 REV.
