Munchkin MUNCHKIN HIGH EFFICIENCY HEATER with the 925 Controller User Manual

Installing, Operating & Maintaining

MUNCHKIN™ HIGH EFFICIENCY HEATER

with the “925” Controller

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.

• 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.

CONTROLS

MH27745

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.

HEAT TRANSFER PRODUCTS, INC.

120 BRALEY RD., E. FREETOWN, MA

02717

TABLE OF CONTENTS

PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8

GENERAL INFORMATION

PART 6 . . . . . . . . . . . . . . . . . . . .34 thru 37

START UP PROCEDURES

A How It Operates . . . . . . . . . . . . . . . . . .4 A Sequence of operation . . . . . . . . . . . .34

Munchkin Ratings and Dimensions . . .4

Items to be checked before

lighting the Munchkin . . . . . . . . . . . . .34

C Pre-installation Requirements . . . . . . .8

D Pressure Relief Valve . . . . . . . . . . . . . .9

C Lighting Instructions . . . . . . . . . . . . . .35

D Operating Instructions . . . . . . . . . . . .35

PART 2 . . . . . . . . . . . . . . . . . . . . .9 thru 11

ELECTRICAL

Adjusting the Temperature

on the Munchkin Display . . . . . . . . . .36

Status Menu . . . . . . . . . . . . . . . . . . . .36

A Electrical Connection . . . . . . . . . . . . . .9

G Test Mode . . . . . . . . . . . . . . . . . . . . . .37

H To Turn Off Gas to Appliance . . . . . . .37

PART 3 . . . . . . . . . . . . . . . . . . . .12 thru 13

GAS CONNECTION

PART 7 . . . . . . . . . . . . . . . . . . . .38 thru 40

TROUBLESHOOTING

A Gas Connection . . . . . . . . . . . . . . . . . .12

Gas Piping . . . . . . . . . . . . . . . . . . . . . .12

C Gas Table . . . . . . . . . . . . . . . . . . . . . . .12

C Boiler Fault . . . . . . . . . . . . . . . . . . . . .38

PART 4 . . . . . . . . . . . . . . . . . . . .14 thru 21

VENTING

PART 8 . . . . . . . . . . . . . . . . . . . .40 thru 44

MAINTENANCE

A Approved Venting Materials . . . . . . . .14

Venting the Munchkin . . . . . . . . . . . . .15

A Maintenance Procedures . . . . . . . . . .41

C Longer Vent Runs . . . . . . . . . . . . . . . .17

D Heater Removal from a

Before Each Heating Season . . . . . . .41

C Condensate Cleaning Instructions . . .41

D Combustion Chamber

Common Vent System . . . . . . . . . . . .18

Condensate Removal . . . . . . . . . . . . .18

Coil Cleaning Instructions . . . . . . . . . .42

Munchkin Controller . . . . . . . . . . . . . .43

Components Diagrams . . . . . . . . .44–45

PART 5 . . . . . . . . . . . . . . . . . . . .22 thru 33

PIPING

A Hydronic piping with

Circulators or Zone Valves . . . . . . . . .22

Circulator Sizing . . . . . . . . . . . . . . . . .23

C Fill and Purge Heating System . . . . . .24

D Piping Illustrations . . . . . . . . . . . . . . .25

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. This eliminates the Munchkin

starting every time the thermostat calls for heat. This feature keeps the system from short cycling.

Once the system has sensed the temperature difference, the Munchkin will activate the blower motor

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

burner fan has a direct drive current low-voltage motor with a pulse relay counting. This system allows

precise control over the fan speed and combustion air volumes. Coupled with the Honeywell gas valve

and the Venturi 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 keeps the Munchkin running at the

highest efficiency.

When the thermostat is satisfied, the Munchkin will then go through a 4 second post-purge cycle before

shutting off. Every Munchkin heater is equipped with a display which will read the outlet temperature of

the heater and then will illuminate a green light showing flame on. If a problem occurs, the front indicator

light will turn red and the display will read a fault code; see Part 7, Section B/C.

B. MUNCHKIN RATINGS AND DIMENSIONS

PERFORMANCE RATINGS

Model

T50M

T80M

80M

140M

Input Modulation

18,000 to 50,000

19,000 to 80,000

27,000 to 80,000

46,000 to 140,000

66,000 to 199,000

DOE Heating

16,000 to 46,000

17,000 to 74,000

25,000 to 74,000

43,000 to 129,000

61,000 to 183,000

AFUE

92%

Shipping Weight

58 lbs.

*IBR

40,000

64,000

112,000

159,000

58 lbs.

75 lbs.

101 lbs.

111 lbs.

199M

*Net water

CONNECTION SIZES

Supply/Return

Model

T50M

T80M

80M

140M

199M

Connection

1 1/4" NPT

Gas Connection Size

Vent Dia.

3/4"

GENERAL INFORMATION

RECOMMENDED SERVICE CLEARANCES

(NOTE: The Munchkin is rated at

zero clearance to combustibles.)

80M/140M/199M

T50M/T80M

Figure 1-1

Figure 1-2

GENERAL INFORMATION

DIMENSIONS

T50M/T80M

Figure 1-3

GENERAL INFORMATION

DIMENSIONS

80M

Figure 1-4

140M/199M

Figure 1-5

GENERAL INFORMATION

C. PRE-INSTALLATION REQUIREMENT

GENERAL

combustible construction. In addition, it

is design certified for use on combustible

floors.

1. Munchkin Boilers are supplied complete-

ly assembled as packaged boilers. The

package should be inspected for damage

upon receipt and any damage to the unit

should be reported to the shipping com-

pany and wholesaler. This boiler should

be stored in a clean, dry area.

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.

2. Carefully read these instructions and be

sure to understand the function of all

connections prior to beginning installa-

tion. Contact your Munchkin Sales

Representative or the Heat Transfer

Products, Inc. Customer Service

Department for help in answering ques-

tions.

CAUTION

Do not install this boiler on carpeting.

COMBUSTION AND VENTILATION AIR

1. The Munchkin Boiler is designed only for

operation with combustion air piped

from outside (sealed combustion). PVC

pipe must be supplied between the air

inlet connection at the rear of the boiler

through an outside wall.

3. This boiler must be installed by a quali-

fied contractor. The boiler warranty may

be voided if the boiler is not installed cor-

rectly.

2. No additional combustion or ventilation

air is required for this appliance.

CODES & REGULATIONS

Installation and repairs are to be performed in

strict accordance with the requirements of state

and local regulating agencies and codes dealing

with boiler and gas appliance installation.

3. Refer to Section 4 of this manual,

Venting, for specific instructions for pip-

ing combustion air.

PLANNING THE LAYOUT

WARNING

1. Prepare sketches and notes showing the

layout of the boiler installation to mini-

mize the possibility of interferences with

new or existing equipment, piping, vent-

ing and wiring.

Liquefied Petroleum (LP) Gas or

Propane is heavier than air and, in the

event of a leak, may collect in low

areas such as basements or floor

drains. The gas may then ignite

resulting in a fire or explosion.

2. The following sections of this manual

should be reviewed for consideration of

limitations with respect to:

a. Electrical Wiring: Part 2

b. Gas Connection: Part 3

c. Venting: Part 4

ACCESSIBILITY CLEARANCES

1. The Munchkin Boiler is certified for clos-

et installations with zero clearance to

f. Piping: Part 5

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: See Section 1, Figures 1-1 and 1-2.

If the Munchkin is set up for liquefied petroleum (LP) gas, some geographic areas follow the Uniform

Mechanical Code, section 304.6, “Liquefied petroleum gas burning appliances shall not be installed in

a pit, basement or similar location where heavier-than-air gas might collect. Appliances so fueled, shall

not be installed in a below grade under-floor space or basement unless such location is provided with

an approved means for removal of unburned gas.”

CAUTION

Condensation removal: This is a condensing high efficiency appliance, therefore

condensation removal must be addressed to avoid damage to surrounding area or

appliance. See Part (4) Section E for Condensate Requirements.

WARNING

D. PRESSURE RELIEF VALVE

A pressure relief valve is installed into the front right side manifold. We recommend a WATTS ¾"

M 335 MI valve or equivalent and meets the requirements of ANSI/ASME Heater and Pressure

Vessel Code, Section IV or CSA B51; Heater, Pressure Vessel and Piping Code as applicable for

heating heaters. A ¾" pipe must be directed to a floor drain or suitable location within 6" of a drain

or floor. Protect from freezing, do not plug or cap pressure relief valve. Serious explosion causing

property damage and or loss of life could result. Under no circumstances should the relief valve

be eliminated, capped or plugged.

PART 2. ELECTRICAL

A. ELECTRICAL CONNECTION

The electrical connection for the Munchkin is on the left hand side of the unit. There is a ½” knockout

location for an electrical connection for both the incoming power and the central heating circulator

connection. All electrical wiring must be performed by a qualified licensed electrician in accordance

with National Electrical Code ANSI Z223.1//NFPA 54 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.

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

Figures 2-1, 2-2 and 2-3 (this section).

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 than 15 Amps.

DANGER

IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED!

DANGER

IT IS VERY IMPORTANT THAT THE BUILDING GROUND IS INSPECTED BY A

QUALIFIED ELECTRICIAN PRIOR TO MAKING THIS CONNECTION!

There are two ground points in the electrical compartment that must be connected to the building

ground system. Connect the building ground to the green ground screw and the green ground wire

inside electrical box provided.

The Incoming Power Supply is connected to the Black (Hot) and the White (Neutral).The Munchkin

Control board is polarity sensitive. If the polarity 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.

DANGER

The Orange wire for the Central Heating Circulator is Switched Hot and must have a

wire nut if not connected to the Central Heating Circulator. Failure to follow this

instruction will result in a short, and the Control Board will have to be replaced.

Connect the gray wires to your heating thermostat (TT) connection. Your thermostat heat anticipator

setting is .056 amp.

CAUTION

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.

It is important that the electrical power is not turned on at this time. Double check all connections and then

turn the power on. The display that is provided with the Munchkin 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.

ELECTRICAL

DIAGRAM "A"

DIAGRAM "B"

WIRING DIAGRAM CONNECTING TO CIRCULATOR

WIRING DIAGRAM WITHOUT CONNECTION TO CIRCULATOR

GREEN (GROUND)

WHITE (NEUTRAL)

IMPORTANT NOTE:

BE CERTAIN THAT THE ORANGE

WIRE IS SECURELY CAPED.

FAILURE TO DO SO COULD

RESULT IN INJURY OR FIRE

AND COULD DAMAGE THE CONTROL.

BLACK

NORMALLY OPEN

THERMOSTAT

CONNECTION

THERMOSTAT

CONNECTION

GRAY

WHITE

(NEUTRAL)

WHITE

(NEUTRAL)

GRAY

BLACK

(HOT)

BLACK

(HOT)

GRAY

GREEN

(GROUND)

GREEN

(GROUND)

GROUND

BUS

ELECTRICAL

SWITCH JUNCTION BOX

120V 60 HZ

ELECTRICAL

SWITCH JUNCTION BOX

120V 60 HZ

Figure 2-1: Connection Wiring Directly to 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 for the central heating pump only.

ZONE

THERMOSTAT

R845A

SWITCHING

RELAY ZONE

BOILER

"TT"

GRAY

1K1

1K2

BOILER

"TT"

GRAY

ZONE

CIRCULATOR

L1 HOT (BLACK)

120 VOLT

L2 NEUTRAL

(WHITE)

Figure 2-3: For circulator amp loads greater

than 4 amps (3 amps for “HA” models) use the

wiring diagram shown at left. The brown and

orange wires will not be used in this

application.

GAS CONNECTION

PART 3. GAS CONNECTION

WARNING

Failure to follow all precautions could result in fire, explosion or death!

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 3.5" 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. "LP" for liquefied petroleum, propane gas or, "Nat"

natural or city gas. All gas connections must be approved by the local gas supplier, or utility in addition

to the governing authority, prior to turning the gas supply on. The nipple provided is ½" and it is

mandatory that a ¾" to ½" reducing coupling (provided) is used, threaded into the branch of a ¾" tee,

and a drip leg fabricated, as per the National Fuel Gas code. You must ensure that the entire gas line

to the connection at the Munchkin is no smaller than ¾". Once all the inspections have been

performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than

the maximum inlet pressure, you must isolate the Munchkin 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 ½ PSI, 14" water column, the gas valve must

be replaced. Never use an open flame (match, lighter, etc.) to check gas connections.

B. GAS PIPING

Run the gas supply line in accordance with all applicable codes.

Locate and install manual shutoff valves in accordance with state and local requirements.

C. GAS TABLE

Refer to Table (1) to size the supply piping to minimize pressure drop between meter or regulator

and unit.

Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0.5 psi or Less and a

Pressure Drop of 0.3 Inch water Column

(TABLE 1)

(Based on a 0.60 Specific Gravity Gas)

Nominal

Iron Pipe Internal

Length of Pipe (Feet)

Size

Diameter

(inches) (inches) 10

60 70

90 100

84 79

125 150

72 64

130 120

275 250

410 380

175 200.

59 55}

110 100}

225 210} HOUR

350 320} X 1,000

3/4

.824

1.049

278

520

190 152 130 115 105 96

350 285 245 215 195 180 170 160 150

730 590 500 440 400 370 350 320 305

BTU'S

PER

1 1/4

1 1/2

1.380 1,050

1.610 1,600 1,100 890 760 670 610 560 530 490 460

GAS CONNECTION

It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to

indicate a leak is present. The gas piping must be sized for the proper flow and length of pipe, to avoid

pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1" WC, the meter, regulator or gas line is undersized or

in need of service. You can attach a manometer to the incoming gas drip leg, by removing the cap and

installing the manometer. The gas pressure must remain between 3.5" 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. 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 safety feature, this gas valve has a flanged connection to the Venturi and blower.

DUNGS GAS VALVE

THROTTLE ADJUSTER

(NOTE: IF FOR ANY

REASON THE THROTTLE

NEEDS TO BE

ADJUSTED

VERY IMPORTANT THAT

A "COMBUSTION

IT IS

ANAYLYZER" 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 IN COMBUSTION

SETTINGS.)

Fig. 3-1

WARNING

Failure to follow all precautions could result in fire, explosion or death!

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 and Extensions in Plastic 2", 3" and 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. PVC Non Foam Core Pipe (Polyvinyl Chloride) to ASTM D-1785 or D-1784 Class 12454-B,

Formerly designated Type 1, Grade 1.

2. CPVC (Chlorinated Polyvinyl Chloride) Class 23447-B, Formerly designated Type IV, Grade 1 con-

forming to ASTM D-1784.

3. ABS (Acrylonitrile-Butadiene-Styrene) Class 3-2-2-2-2 conforming to ASTM D3965.

DANGER

Foam Core Pipe is not to be used in connecting the exhaust pipe.

The Munchkin is a direct vent appliance. The Munchkin is listed as a Category

IV Condensing Appliance. (The Munchkin Venting is rated at Zero Clearance

to combustibles.)

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 the inlet only, NEVER ON EXHAUST PIPING!

WARNING

This vent system will operate with a positive pressure in the vent pipe. Do not

connect vent connectors serving appliances by natural draft into any portion of

mechanical draft systems operating under positive pressure.

VENTING

B. VENTING THE MUNCHKIN

DANGER

It is extremely important to follow these venting instructions exactly. Failure to do so

can cause severe personal injury, death or substantial property damage.

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 3" PVC schedule 40. It is very important that you

plan the location properly to eliminate long pipe runs and excessive fittings. Inlet pipe size must not

be reduced. Do not combine the inlet air with any other inlet pipe including an inlet to an additional

similar appliance. The joints must be properly cleaned, primed and cemented. The piping must also

be properly supported as per Local and National Standard Plumbing Codes. It is important that the

piping must be clean and free from burrs, debris, ragged ends and particles of PVC.

Exhaust piping should be sloped back to the connection on the Munchkin, at least ¼" per foot to

remove additional condensate that forms within the pipe. The total combined length of pipe (intake

piping plus exhaust piping added together) including elbow allowances intake and exhaust (each

elbow = 5' of pipe) should not exceed 85'. The combined vent length should not be less than a com-

bined length of 6' plus two 90 degree elbows. Choose your vent termination locations carefully. You

must also make certain that exhaust gas does not re-circulate back into the intake pipe. You must

place them in an open area and follow the following guidelines.

1) Never vent into a walkway, patio area, alley or otherwise public area less than 7' from the

ground. (See the following detail references Fig. A.10.8 in the National Fuel Gas Code 2002

“Exit Terminals of Mechanical Draft and Direct-Venting Systems”.)

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 and bushes.

6) Follow local gas codes in your region or refer to National Fuel Gas Code, Can B149.

7) Always have at least 3' from an inside corner of outside walls.

8) Maintain at least 4' clearance to electric, gas meters, windows, exhaust fans, chimneys, inlets

or mechanical vents.

9) Very Important! The inlet air connection must be connected to outside air and should be

located no closer than 8" to the exhaust and no further than 36".

10) Always place screens in all openings in intake and exhaust to prevent foreign matter from

entering the Munchkin.

11) The vent intake and exhaust must be properly cleaned and glued for a pressure tight joint.

Several methods for venting the Munchkin can be found in Figures 4-1 thru 4-6 in this section.

Use these layouts as guidelines: certain site conditions such as multiple roof lines/pitches

VENTING

may require venting modifications (consult factory). The air inlet must be a minimum of 1'

vertically above the maximum snow level. It is very important that there are no other vents,

chimneys or air inlets in any direction for at least 4'.

Mechanical

draft vent

terminal

(see 10.8.1)*

Mechanical draft

vent terminal

(see 10.8.2)*

4 ft.minimum

Less

than 10 ft.

12 in.minimum

3 ft.minimum

Direct vent terminal clearance

Minimum clearance, C

Input (Btu/hr)

10,000 or less

10,001 to 50,000

Over 50,000

Clearance (in.)

Forced air

inlet

(see 10.8.3)*

For SI units: 1 ft = 0.305 m; 1 in. = 25.4 mm;

1 Btu/hr = 0.293 W

EXIT TERMINALS OF MECHANICAL DRAFT

AND DIRECT-VENT VENTING SYSTEM

* REFERENCE: THE NATIONAL FUEL GAS CODE

2002 EDITION

CAUTION

Flue Gas will condense as it exits the vent termination. This condensate can freeze on

exterior building surfaces which may cause discoloration of these surfaces.

Consideration should be given to the plume of condensation that exits the exhaust

which may affect the cosmetic appearance of the building.

All venting must be properly supported. The Munchkin is not intended to support any venting

whatsoever. All piping, glue, solvents, cleaners, fittings and components, must conform to ASTM

(American Society for Testing and Materials), and ANSI (American National Standards Institute). It is

recommended that you use one of the optional vent kits specifically designed for Munchkin installa-

tions, available from Heat Transfer Products, Inc. (KGAVT0601CVT [3 in.], KGAVT0501CVT [2 in.] or

V500 for the T50M/T80M or V1000 for the 80M/140M/199M). NOTE: When using the KGAVT601CVT

KIT, REMOVE THE 2 SCREENS FROM THE PROVIDED INLET TEE AND INSTALL THEM IN THE INLET

SOCKET AND OUTLET SOCKET (Y TEE CONNECTION) OF THE KIT PRIOR TO INSTALLING THE

SCHEDULE 40 PIPE AND GLUING.

VENTING

Friction Loss Equivalent in Piping and Fittings

Fittings or Piping

Equivalent Feet

90 degree elbow

45 degree elbow

Coupling

air inlet tee

Plastic Pipe

concentric vent kit

V500 or V1000 vent kit

CAUTION

Do not exceed the 85 foot maximum requirement (intake plus exhaust piping added

together) including fitting allowance.

Example: Installation requires the following material for both inlet and exhaust piping for the

Munchkin

Required: 4 Pcs. (2" or 3") 90 degree elbow (4 x 5 = 20 Equivalent Feet) = 20 Equivalent Feet

Required: 20' of (2" or 3") 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. LONGER VENT RUNS

The connection of the air inlet and exhaust vent at the heater must remain at the standard vent size

from the unit (2" for the T50/T80) (3" for the 80M/140M/199M). If a transition is required, it must occur

at a minimum of 15 equivalent feet for both intake and exhaust. Then transition to the next size pipe.

See the friction loss equivalent table to apply longer vent runs. The overall extended combined

length of pipe on the inlet and exhaust must not exceed 125 equivalent feet total.

CAUTION

Transitioning from 2" to 3" or 3" to 4" should be done in the Vertical position to avoid

condensation blockage. If done in the horizontal position check to make sure

condensation blockage will not occur.

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

20' of 3" Plastic PVC Pipe

(2 x 5 = 10 Equivalent Feet)

(20 x 1 = 20 Equivalent Feet)

10 Equivalent Feet

20 Equivalent Feet

Total of 3" Equivalent Piping with Fittings

= 30 Equivalent Feet

Transitioning to 4" Venting

6 Pcs. – 4" 90 degree elbows

4 Pcs. – 4" 45 degree elbows

40' of 4" Plastic PVC Pipe

(6 x 3 = 18 Equivalent Feet)

(4 x 1 = 4 Equivalent Feet)

(40 x 1 = 40 Equivalent Feet)

18 Equivalent Feet

4 Equivalent Feet

40 Equivalent Feet

Total of 4" Equivalent Piping with Fittings

= 62 Equivalent Feet

Total Friction Loss in Equivalent Feet for both 3" and 4"

(30 + 62 = 92 Equivalent Feet)

= 92 Equivalent Feet

VENTING

DANGER

The Munchkin is not intended to be common vented with any other

existing appliance!

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 appli-

ance remaining connected to the common venting system placed in operation, while the other appli-

ances remaining connected to common venting system are not operating.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch to determine if there

is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.

3. If practical, close all building doors, windows and all doors between the space in which the

appliance remains connected to the common venting system located and other spaces in the

building. Turn on clothes dryers and any appliances not connected to the common venting

system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum

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 determined that each appliance remaining connected to common venting

system properly vents when tested as outlined, return doors, windows, exhaust fans, fire-

place dampers and any other gas burning appliance to their previous condition of use.

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

E. CONDENSATE REMOVAL

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. 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 (kit available from Heat Transfer Products, Inc.) A

condensate filter, if required by local authorities can be made up of lime crystals, marble or

phosphate chips will neutralize the condensate. This can be done in the field by the installer or you

may purchase one from Heat Transfer Products, Inc. It is also very important that the condensate line

is not exposed to freezing temperatures, or any other type of blockage. Plastic tubing should be the

only material used for the condensate line. Steel, brass, copper or others will be subject to corrosion

or deterioration. A second vent may be necessary to prevent condensate line vacuum lock if a long

horizontal run is used. Also, an increase in pipe size may be necessary to drain properly. Support of

the condensation line may be necessary to avoid blockage of the condensate flow.

VENTING

DIAGRAMS FOR SIDEWALL VENTING

**IMPORTANT NOTE: All vent pipes must be **IMPORTANT NOTE: All vent pipes must be glued, prop-

glued, properly supported and the exhaust must erly supported and the exhaust must be pitched a mini-

be pitched a minimum of a ¼" per foot back to mum of a ¼" per foot back to the heater (to allow drainage

the heater (to allow drainage of condensate).

of condensate).

Figure 4-1

Figure 4-2

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).

Figure 4-3

**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 4-4

VENTING

DIAGRAMS 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).

**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 4-5

Figure 4-6

PIPING

PART 5. PIPING

A. HYDRONIC PIPING WITH CIRCULATORS OR ZONE VALVES

The Munchkin is designed to function in a closed loop 15 PSI System. To assure you that you have

adequate pressure in the system, we have installed in the outlet manifold, a pressure switch that will

not let the Munchkin operate without a minimum of 10 PSI water pressure. This assures you that if the

system does have leak, the Munchkin will lock out (PRO on the display) before it damages the Stainless

Steel Heat Exchanger. We have also included a Temperature and Pressure gauge which should be

located on the Munchkin outlet to monitor the system pressure and outlet temperature from the

Munchkin. It is important to note that the Munchkin has a minimal amount of pressure drop and must

be figured in when sizing the circulators. Each Munchkin installation must have an Air Elimination

device which will remove air from the system. Install the Munchkin so the gas ignition system

components are protected from water (dripping, spraying, etc.) during appliance operation for basic

service of circulator replacement, valves and other. Observe minimum 1” clearance around all un-

insulated hot water pipes when openings around pipes are not protected by non-combustible

materials. On a Munchkin installed above radiation level, some states and local codes require a low

water cut off device at the time of installation. If the Munchkin supplies hot water to heating coils in air

handler units, flow control valves or other devices must be installed to prevent gravity circulation of

heater water in the coils during the cooling cycle. Chilled Water Medium must be piped in parallel with

the heater. Freeze Protection for new or existing systems must 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 expansion of the glycol solution in the system

piping. Example 50% by volume solution expands 4.8% in volume for the temperature increase from

32 F to 180 F, while water expands 3% with the same temperature rise.

CAUTION

The Munchkin should not be operated as a potable Hot Water Heater. It should not be

used as a direct Hot Water Heating Device.

Basic steps are listed below, with Illustration, which will guide you through the installation of the

Munchkin.

1. Connect the system return marked “Heater In”, make sure to install with pipe sealant com-

pound. Threaded connections are 1 ¼” 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 com-

pound. Threaded connections are 1 ¼” 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. Install a Pressure Reducing Valve on the Cold Feed Make-Up Water line, (15 PSI nominal on

the system return). Check Temperature and Pressure Gauge which should read minimum

pressure of 12 PSI.

6. Install a circulator on system supply. Make sure the circulator is properly sized for the system

and friction loss.

7. Install an Expansion Tank on the system supply. Consult the tank manufacturer’s instruction

for specific information relating to tank installation. Size the expansion tank for the required

system volume and capacity.

PIPING

8. Install an Air Elimination Device on the system supply.

9. Install a drain valve at the lowest point of the system. Note: The Munchkin can not be drained

completely of water without purging the unit with an air pressure 15 PSI.

10. The Safety Relief Valve is installed at the factory located on the right hand side of Munchkin.

Pipe the discharge of safety relief valve to prevent injury in the event of pressure relief. Pipe

the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet.

Never block the outlet of safety relief valve.

11. In compliance with ASME CSD-1, a low water cut-off device should be properly connected in

the field, both electrically and mechanically.

See the piping 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 which must be considered in your system

design. Refer to the graph below for pressure drop through the Munchkin Heat Exchanger.

10 11 12 13 14 15 16 17 18 19 20 21

Flow in Gallons per Minute

MUNCHKIN T50M

MUNCHKIN 140M

MUNCHKIN T80M/80M

MUNCHKIN 199M

Figure 5-1

BOILER

TACO P/N GRUNDFOS P/N

T50M/T80M/80M

140M

007 *

0010 *

0011 *

UPS15-58 FC SPD 2

26-64 F

199M

26-96 F

* THE RECOMMENDED CIRCULATORS ARE BASED ON 1 GPM PER 10,000 BTU/HR W/20

PIPING

C. FILL AND PURGE HEATING SYSTEM

• Attach the hose to balance and purge hose connector or drain valve and run hose to near-

est 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 manu-

facturer’s instruction prior to opening valves manually, so as not to damage the valve.)

• Manually operate fill valve regulator. When water runs out of the hose, while it’s connect-

ed to the balance and purge valve or drain you will see a steady stream or water (with no

bubbles). Close balance and purge valve or drain to stop the water from flowing.

Disconnect the hose and connect it to next zone to be purged.

• Repeat this procedure for additional zones (one at time).

Upon completion, make sure that the fill valve is in automatic position and each zone balance and

purge or shut off is in an open position and zone valves are positioned for automatic operation.

CAUTION

For installation that incorporates standing Iron Radiation and systems with manual

vents at the high points. Follow above section and starting with the nearest manual

air vent, open vent until water flows out, then close vent. Repeat procedure, working

your way toward furthest air vent. It may be necessary to install a basket strainer in

an older system where larger amounts of sediment may be present. Annual cleaning

of the strainer may be necessary.

WARNING

Use only inhibited propylene glycol solutions which are specially formulated for

hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in

hydronic systems.

1. Glycol in hydronic applications which is specially formulated for this purpose includes

inhibitors which prevent the glycol from attacking 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 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 of 15% with a 5% increase in head

against system circulator.

5. A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head

against system circulator.

CAUTION

It is highly recommended that you carefully follow the glycol manufacturer’s

recommended concentrations, expansion requirements and maintenance

recommendations (pH additive breakdown, inhibitor reduction, etc.). You must

carefully figure the additional friction loss in the system as well as the reduction in

heat transfer co-efficients.

PIPING

D. PIPING ILLUSTRATIONS

Piping Symbol Legend

circulator

pressure reducing valve

diff. pressure bypass

(w/ isolation flanges)

circulator w/

integral flow check)

gate valve

globe valve

ball valve

anti-scald rated

mixing valve

pressure gauge

swing-check valve

4-way motorized

mixing valve

flow-check valve

spring-loaded check valve

3-way motorized

mixing valve

Munchkin heater

hose bib / boiler drain

pressure relief valve

backflow preventer

thermostatic radiator valve

TRV (straight)

thermostatic radiator valve

TRV (angle)

float -type

air vent

circuit setter

union

manual 3-way valve

heat exchanger

zone valve

air separator

vacuum breaker

Super Stor

indirect DHW tank

diaphragm-type

expansion tank

radiant manifold

Fig. 5-2

PIPING

Standard Munchkin boiler

Retrofit piping (zoning with valves)

Space heating mode

Drawing 1A

zone valves

make-up water

flow

bypass

valve

purging

valves

OFF

anti-scald

mixing valve

cold

water

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

Adjust flow bypass valve for the following minimum boiler flow rates in any operating mode:

Munchkin model T50M: 3 gpm

Munchkin model T80M: 3 gpm

Munchkin model 80M: 3 gpm

Munchkin model 140M: 5 gpm

Munchkin model 199M: 7 gpm

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used .in lieu of the ball valve / hose bib combination shown

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-3

PIPING

Standard Munchkin boiler

Retrofit piping (zoning with valves)

Domestic water heating mode

Drawing 1B

zone valves

make-up water

flow

bypass

valve

purging

valves

anti-scald

mixing valve

cold

water

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

Adjust flow bypass valve for the following minimum boiler flow rates in any operating mode:

Munchkin model T50M: 3 gpm

Munchkin model T80M: 3 gpm

Munchkin model 80M: 3 gpm

Munchkin model 140M: 5 gpm

Munchkin model 199M: 7 gpm

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-4

PIPING

Standard Munchkin boiler

Preferred piping (zoning with valves)

Space heating mode

Drawing 2A

zone valves

make-up water

closely

spaced

tees

differential

pressure

bypass

valve

purging

valves

OFF

anti-scald

mixing valve

cold

water

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure

drop operates by itself.

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown.

A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream

of all closely spaced tees.

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-5

PIPING

Standard Munchkin boiler

Preferred piping (zoning with valves)

Domestic water heating mode

Drawing 2B

zone valves

make-up water

closely

spaced

tees

differential

pressure

bypass

valve

purging

valves

anti-scald

mixing valve

cold

water

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure

drop operates by itself.

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown.

A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream

of all closely spaced tees.

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-6

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

cold

water

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

All closely spaced tees shall be within 4 pipe diameter center to center spacing.

A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream

of all closely spaced tees.

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown.

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-7

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

cold

water

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

All closely spaced tees shall be within 4 pipe diameter center to center spacing.

A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream

of all closely spaced tees.

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown.

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-8

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

PB1

PB2

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

All closely spaced tees shall be within 4 pipe diameter center to center spacing.

A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream

of all closely spaced tees.

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown.

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-9

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

PB1

PB2

T/P

Super Stor

indirect DHW tank

Munchkin boiler

NOTES:

This drawing is meant to show system piping concept only.

Installer is responsible for all equipment & detailing required by local codes.

All closely spaced tees shall be within 4 pipe diameter center to center spacing.

A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream

of all closely spaced tees.

The minimum pipe size for connecting a Super Stor water heater is 1 inch.

The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.

All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.

The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.

Install a minimum of 12 diameters of straight pipe upstream of all circulators.

A purging valve may be used in lieu of the ball valve / hose bib combination shown.

NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.

Fig. 5-10

START-UP PROCEDURES

PART 6. START-UP PROCEDURES

A. SEQUENCE OF OPERATION

1. When power is first applied to the control, the control display will read the outlet tempera-

ture. The control will initially run through a self-diagnostic routine and then go into its oper-

ating mode. If there is no call for heat, the System will go into an idle state.

2. If the thermostat is calling for heat, the control will apply power to the circulator pump. If the

control determines the water temperature is below the programmed set point value minus

the switching differential, the control will initiate a heating cycle.

3. The control then performs selected system diagnostic checks. If all checks are successfully

passed, a pre-purge cycle is initiated (the blower will be on maximum speed).

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 closed and the control will return to

step. After three trials, if a flame is not verified, the control will go into a lockout mode. If a

flame is confirmed, the control enters the heating mode. The fire rate will be based on the

proprietary algorithm.

5. When water temperature reaches the temperature set point value plus 10 degrees F (or if the

thermostat call-for-heat is satisfied), the gas valve is closed and the control enters a post-

purge state (the blower will be on maximum speed). NOTE: If the thermostat is still calling

for heat, the circulator pump will continue to run until the thermostat call for heat is satis-

fied.

6. When the post-purge is complete, the control 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 control will illuminate an error code will

appear in the display.

B. ITEMS TO BE CHECKED BEFORE LIGHTING THE MUNCHKIN

It is recommended that you read the General Information Section (Part 1) to get a better under-

standing 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. While this Fault code is on the display the unit will not operate unit until

the water pressure is brought above 10 PSI. This Fault code is caused by the Water pressure

switch being open for more than 5 seconds which is an indication your system pressure is

below 10 PSI. Increase the water pressure in the system until the pressure gauge reads 10psi.

This code will disappear once the Water Pressure switch is closed, which will allow you to

start the Munchkin.

3. Check to see if all the electrical connections are on securely.

4. Make sure that the Gas is turned on inside the cabinet and outside of the Munchkin.

5. Double check the temperature setting (Note: The Munchkin is factory set at 180 degrees)

6. Make sure the unit is properly grounded and the electrical wiring meets the requirements of

the electrical section (Part 2).

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

START-UP PROCEDURES

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 cycle, then begin running, which will be indicated by the Green light illuminating under

“Flame On” in your display.

DANGER

If you do not follow these instructions exactly, a fire or explosion may

result, causing property damage, personal injury or loss of life.

C. LIGHTING INSTRUCTIONS

FOR YOUR OWN SAFETY READ BEFORE OPERATING

1. This appliance does not have pilot. It is equipped with an ignition device which automatical-

ly lights the burner. Do not try to light the burner by hand.

2. BEFORE OPERATING smell all 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 supplier, call the fire department.

3. Turn on gas shutoff valve (located inside of the Heater) so that the handle is aligned with the

gas pipe. If the handle will not turn by hand, don't try to repair it, call a qualified service tech-

nician. 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 (dripping, spraying, rain, etc.) during appliance operation and service (circulator

replacement, condensate trap, control replacement, etc.)

D. OPERATING INSTRUCTIONS

1. STOP! Read the safety information in Part 6.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do

not try to light the burner by hand.

5. Remove front cover.

6. Turn gas shutoff valve to “off”.

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow Part 6, Section

B/Lighting Instructions in the safety information. If you don't smell gas, go to the next step.

8. Turn the gas shutoff valve counter clockwise to “on”. The handle will be horizontal.

9. Replace the Front Cover.

10. Turn on all electric power to appliance.

11. Set the thermostat to the desired setting.

START-UP PROCEDURES

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance”

Section E and call your service technician or gas supplier.

E. ADJUSTING THE TEMPERATURE ON THE MUNCHKIN DISPLAY:

1. Before you can change the temperature from the factory setting of 180 degrees. You must make

sure that none of the thermostats are calling for heat. The Munchkin controller will not memorize a

program setting while in 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 temperature of the Munchkin. The temperature of the

Munchkin can be set as low as 50 Degrees and as high 203 Degrees. These ranges are your maxi-

mum and minimum ranges of the Munchkin. In addition to changing the temperature you are also

allowed to change three more settings in this model (1. Munchkin differential – 2. Indirect setting

(Vision System Only) – 3. Celsius to Farenheit measurement. Simply press in the S3/Program key

to get to next value, the Munchkin differential setting will appear in the display ch and alternating

value of 30. This allows the installer to adjust the activation of the burner based on the differential

temperature setting of the Munchkin. The burner will not start until the outlet water temperature

reaches a temperature that is equal to the temperature setting for the Munchkin, minus the differ-

ential EX: The Munchkin is set to heat at 180° F degrees and the differential is set at 20° F. 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 in this mode is the Farenheit to Celcius measurement. Press the S3/Program

key again and you will see t and alternating value of F. To change value press the S1/– or S2/+ to

choose the correct measurement.

F. 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 tem-

perature. 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 val-

ues cannot be changed. To exit this menu, simply press S3/Program key to resume normal operation.

Function Value

d1/

d2/

d3/

Actual Temperature from outlet sensor

Actual Temperature from inlet sensor

If using a standard mechanical control, the control will display 1 for closed 0 for open

If the sensor is connected to the SuperStor Indirect Fired Water Heater it will measure

the actual temperature. (Vision only.)

d4/

d5/

d6/

Not used

Actual Temperature from the outdoor sensor. (Vision only.)

Actual Fan speed multiplied by 10 (Example: If fan speed displayed is

410 RPM x 10 = 4100 actual fan speed)

d7/

d8/

d9/

d10/

d11/

Actual Ionization current read from Flame Rectification probe

Actual Status of the Central Heating Circulator Off = 0 , On = 1 . (Vision only.)

Actual Status of the Indirect Fired Circulator Off = 0 , On = 1 . (Vision only.)

Actual Status bus communication co = connected, no = not connected

Central Heating Set Point

START-UP PROCEDURES / SERVICING

G. TEST MODE

This function is intended to simplify the gas valve adjustment if needed. Listed below are the

recommended 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 simply press the S2/+ and S3/Program key together for 1 second. Once

activated, you will see in the display Ser and the actual fan speed. The measurement of the

combustion levels should always be taken at the highest and lowest fan speed. After 10 minutes, the

Test mode stops automatically. To exit Test Mode press S1/- and S2/+ key together for 1 second.

COMBUSTION SETTINGS

HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS

Natural Gas

Propane LP

low

high

low

high

0–20 ppm

70 ppm–135 ppm

8-1/2% – 9-1/2%

0–20 ppm

80–150 ppm

Carbon CO ppm Monoxide

Carbon CO₂% Monoxide

8-1/2% – 9-1/2%

9-1/2% – 10-1/2%

Fig. 6-1

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.

DANGER

Water temperature over 125 degrees F. can cause severe burns

instantly, or death from scalds. Children, disabled, and elderly

are at highest risk of being scalded. See instruction manual

before setting temperature at water heater. Feel water before

bathing or showering! Temperature limiting valves are available.

Fig. 6-2

TROUBLESHOOTING

PART 7. TROUBLESHOOTING

A. MUNCHKIN ERROR CODE

WARNING

An error code may occur in the installation of the

Munchkin. This condition may lead to a lock out con-

dition of the controller, which will need to be manu-

ally reset through the S4/Reset button. These tempo-

rary codes will help the installer correct the problem

before going into a lock out condition, which will

require a manual reset.

When servicing or replacing any components of this

boiler be certain that:

• The gas is off.

• All electrical power is disconnected

DANGER

When servicing or replacing that are in direct

contact with the boiler water, be certain that:

• There is no pressure in the boiler. (Pull the release

on the relief valve. Do not depend on the pressure

gauge reading).

• The boiler water is not hot

• The electrical power is off

B. BOILER ERROR

1. When an error condition occurs the con-

troller will display an error code on the dis-

play module.

2. These error codes and several suggested

corrective actions are included in Table 7.1.

WARNING

Do not use this appliance if any part has been under

water. Improper or dangerous operation may result.

Contact a qualified service technician immediately

to inspect the boiler and to repair or replace any part

of the boiler which has been under water.

3. In the case of E00, E13, and E14 this error, if

uncorrected, will go into a fault condition as

described is Paragraph C (Boiler Fault).

C. BOILER FAULT

1. When a fault 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.

CAUTION

This appliance has wire function labels on all

internal wiring. Observe the position of each wire

before removing it. Wiring errors may cause

improper and dangerous operation. Verify proper

operation after servicing.

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.

CAUTION

3. Press the reset key to clear the fault and

resume operation. Be sure to observe the

operation of the unit to prevent a recurrence

of the fault.

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.

Code

Description

Duration

Corrective Action

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 return

thermister to the supply thermister.

E00 High Limit Exceeded

50 Sec.

3. Replace switch if faulty.

Combustion Fan Speed Low.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

E13 The boiler combustion air fan

60 Sec.

speed less than 70% of expected.

Combustion Fan Speed High. The

E14 boiler combustion air fan speed is

more than 130% of expected.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

60 Sec.

Until

1. Assure that the system pressure is above 10 psig.

PR0 Pressure Switch Open

Corrected 2. Check for leaks in the system piping.

1. Assure that the vent is not blocked

Until

Blocked Vent Pressure Switch Open

2. Check the switch operation by applying a jumper.

Corrected

FLU

(If the switch is not functioning properly, replace it.)

TROUBLESHOOTING

Table 7-1: 925 Control Board Error Codes

Code 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

return thermister to the supply thermister.

F00 High Limit Exceeded.

3. Check thermister reading on supply thermister. Replace switch if faulty.

1. Push the red reset button on the switch.

2. Check the flue temperature during operation using a combustion

analyzer.

F01 Vent Temperature Limit Exceeded.

3. Replace the switch if faulty.

Interrupted or Shorted

F02

1. Check the electrical connection to the thermister on the outlet manifold.

2. Replace thermister if necessary.

Supply (Outlet) Thermister.

Interrupted or Shorted

Return (Inlet) Thermister.

1. Check the electrical connection to the thermister on the inlet manifold.

2. Replace thermister if necessary.

F03

1. Check circulation pump operation.

Supply (Outlet)

F05

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

return thermister to the supply thermister.

Temperature exceeds 230°F.

1. Check circulation pump operation.

Return (Inlet) Temperature

Exceeded 230°F.

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

return thermister to the supply thermister.

F06

1. Watch the igniter through the observation window provided.

2. If there is no spark, check the spark electrode for the proper ¼” gap.

3. Remove any corrosion from the spark electrod and flame rectifier probe.

4. If there is a spark but no flame, check the gas supply to the boiler.

5. If there is a flame, check the flame sensor.

No flame detected – The boiler will

make three attempts at ignition

F09

before the control goes into this

lockout condition.

6. Check any flue blockage or condensate blocks.

1. Monitor the gas pressure to the unit while in operation.

2. Assure that the flame is stable when lit.

3. Check to see if the green light on the display module is out while the

boiler is running.

4. If the green light doesn’t come on or goes off during operation check

the flame signal on the status menu.

5. If the signal reads less than 1 microampere, clean the flame rectifier

probe.

6. If the flame rectifier probe continues to read low, replace it.

Loss of Flame Signal – The boiler

will relight 4 times before the

F10

control goes into this lockout

condition.

1. Turn the gas off to the unit at the service valve.

2. If the flame signal is still present replace the igniter.

False Flame Signal – The boiler will 3. If the flame signal is not present after turning off the gas supply, check

F11 lock out if it senses a flame signal the gas valve electrical connection.

when there should be none present. 4. If there is no power to the gas valve, remove the valve and check for

obstruction in the valve seat or replace the gas valve.

5. Turn the gas on at the service valve after corrective action is taken.

Combustion Fan Speed Low – The

boiler will lock out if it senses that

F13 the fan speed is less than 70% of

expected rate for more than 60

seconds.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

Combustion Fan Speed High – The

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

boiler will lock out if the fan speed is

F14

more than 130% of expected rate

for more than 60 seconds.

1. Make sure the connector is correctly connected to the gas valve.

2. Check the electrical wiring from the valve to the control board.

3. Replace the low voltage wiring harness assembly.

4. Replace control board.

F18 Gas Valve Error

F30 Watchdog

Call factory for further assistance.

F31 Parameter Memory

F32 Parameter Memory Write Error

F33 Programming Error

TROUBLESHOOTING

RESISTANCE TABLES

Boiler & Indirect Temperature (˚F) Resistance (ohms)

104

113

122

131

140

149

158

167

176

185

194

203

212

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 con-

dition. The installer should discuss the contents of the User's Information Manual with the owner.

B. BEFORE EACH HEATING SEASON:

A trained and qualified service technician should perform the inspections listed below at least once

a year.

• Heater – check the heater for dust or foreign materials, which may have been drawn in from the

air intake of the heater. Simply blow out or wipe down with a dry rag.

• Vent Termination – check to remove any obstructions, such as leaves, bushes, or other

sources which may interfere with the units ability to draw fresh air on the air intake or exhaust

flue gas from the exhaust outlet.

• Vent Piping – make sure that all vent piping is in good condition. Check Joints for possible leaks.

• Condensate – check the Condensate trap by simply starting the unit and observing the flow of

Condensate which should not be restricted in any fashion. (See instructions below.)

• Heat Exchanger – in the unlikely event the heater flue passage is becoming blocked, service

must be performed only by an authorized 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 the system.

• Water Piping – check for and repair any leaks.

• Gas Piping – check for and repair any leaks.

C. CONDENSATE CLEANING INSTRUCTIONS

1. Turn down the thermostat so the Munchkin will not cycle and then follow the steps below.

a. Close gas valve

b. Disconnect the poly hose from the combustion blower motor

c. Disconnect the condensate hose from the outside connection (not from the Munchkin) so

flow can be observed.

d. Block the air flow in the exhaust by temporarily plugging the exhaust from the outside vent.

e. Disconnect the white, red, blue, and black connection from the Molex on the combustion

blower. (Refer to Control Wiring Layout fig. 8-1 this section.) This will cause the fan to run at

100%, which will then blow out any sediment that has accumulated in the condensate line.

(This process should only take a few minutes.)

f. The unit should now be ready to re-start.

2. Before re-starting the Munchkin follow the steps below:

a. Reconnect the Molex connection and un-block the vent (IMPORTANT: MAKE SURE

EXHAUST VENT IS NO LONGER BLOCKED!)

b. Open the gas valve and turn up the thermostats

c. Observe the boiler function to make sure you see a condensate flow.

d. If you do not observe a condensate flow, repeat the above procedure.

3. If the problem is not corrected at this point, it is possible you have a material deposit problem,

in which case, a qualified plumber will need to be contacted to follow the Combustion Chamber Coil

Cleaning Instructions (Section D) included in this section to dissolve deposit and clean condensate

line.

MAINTENANCE

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*

*Before beginning this procedure, you must have on hand the following items:

– a nylon, stainless or brass brush (not steel)

– “Rydlyme” (recommended for best results) (available on line www.rydlyme.com) or “CLR”

(available at most hardware stores)

1. Shut down the Munchkin by using the following steps:

a. Close the gas valve, shut down the unit and wait for the unit to be cool to the touch

b. Disconnect the condensate hose from the outside connection, (not from the Munchkin side),

so the flow can be observed.

c. Remove the (4) screws on the aluminum ½” NPT connector on the gas valve.

d. Disconnect the poly hose connected to the combustion blower motor. (This does not apply

to T50/T80.)

e. Remove the (6) 10MM nuts from the burner plate assembly to access the coils.

f. Pull the entire burner plate assembly towards you, while removing or pushing aside any

wiring to allow the removal of the assembly.

2. Using a spray bottle filled with the recommeded product “RYDLYME” or “CLR”, spray liberally on the

coils, making sure the solution penetrates and funnels down through the condensate hose. If the con-

densate hose is blocked, let the chemical penetrate for at least 15 minutes or until it drains.

3. Use the nylon, stainless or brass brush (do not use steel) and scrub coils to remove 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 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 T50 or

T80.)

e. Replace the (4) screws on the aluminum ½” NPT connector on the gas valve. Turn the gas

back on. (IMPORTANT: CHECK FOR GAS LEAKS)

f. Re-set thermostats (IMPORTANT: MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED!)

g. Turn the Munchkin back on** and observe condensate flow.

h. Re-connect the condensate hose to the outside connection.

DANGER

IT IS EXTREMELY IMPORTANT THAT YOU CHECK FOR LEAKS WHEN

RECONNECTING THE GAS VALVE AND MAKING SURE THE EXHAUST VENT IS NO

LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN SEVERE PERSONAL INJURY

OR DEATH.

**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.

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 6.3A

MAINTENANCE

NOTES

SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc.

Munchkin R1

LP-61 REV. 1/17/05

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