Munchkin 399M manual

HEA T TRANSFER PRODUCTS, INC. 120 BRALEY RD ., E . FREET OWN , MA 02717 Installing , Operating & Maintaining MUNCHKIN™ HIGH EFFICIENCY 399M COMMERCIAL BOILER Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHA T T O DO IF Y OU SMELL GAS • Do not try to light any appliance. ?[...]

USING THIS MANUAL 2 SPECIAL A TTENTION BO XES Throughout this manual you will see these special attention box es similar to this one, which are intended to supplement the instructions and mak e special notice of potential hazards. These categories mean, in the judgement of Heat T ransfer Products, Inc.: W ARNINGS • THIS UNIT IS FOR CA TEGOR Y IV [...]

T ABLE OF CONTENTS 3 T ABLE OF CONTENTS P ART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 6 GENERAL INFORMA TION A How It Operates . . . . . . . . . . . . . . . . . .4 B Munchkin Ratings and Dimensions .4–5 C Pre-installation Requirements . . . . . . .5 D Pressure Relief V alve . . . . . . . . . . . . . .6 P ART 2 . . . . . . . . . . . . [...]

GENERAL INFORMA TION 4 B. MUNCHKIN RA TINGS AND DIMENSIONS PERFORMANCE RA TING CONNECTION SIZES RECOMMENDED SERVICE CLEARANCES l e d o Mn o i t a l u d o M t u p n Ig n i t a e H E O Dy c n e i c i f f E n o i t s u b m o Cy c n e i c i f f E l a m r e h T* E U F At h g i e W g n i p p i h S M 9 9 30 0 0 , 9 9 3 o t 0 0 0 , 0 0 10 0 0 , 9 7 2 o t 0[...]

5 GENERAL INFORMA TION DIMENSIONS C. PRE-INST ALLA TION 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 (P art 2, P age 6), Gas Conn[...]

6 GENERAL INFORMA TION / ELECTRICAL NOTE: Service clearance of the Munchkin 1. The front of the appliance needs 24" of clearance for service minimum. It may have a non-rated or combustible door or access panel and must have a minimum of 24" clearance. 2. The left side of the heater is 12" clearance 3. The right side of the heater is [...]

7 ELECTRICAL 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. 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[...]

P ART 3. GAS CONNECTION 8 W ARNING F ailure to follow all precautions could result in fire, explosion or death! ELECTRICAL / GAS CONNECTION 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. NORMALLY OPEN T T GR[...]

9 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 kP a), 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 F u[...]

10 W ARNING F ailure to follow all precautions could result in fire, explosion or death! 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 t[...]

11 VENTING P ART 4. VENTING A. APPRO VED VENTING MA TERIALS Exhaust V ent Use Plastic 4" Pipe Schedule 40 or 80. 1. Non-F oam Core PVC Pipe 2. Non-F oam Core CPVC Pipe 3. Non-F oam Core ABS Pipe V ent Piping must conform to following 1. PVC Non F oam Core Pipe (P olyvinyl Chloride) to ASTM D -1785 or D -1784 Class 12454-B, F ormerly designated[...]

12 VENTING 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. 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 jo[...]

13 RECOMMENDED VENTING CLEARANCES PER THE NA TIONAL FUEL GAS CODE* 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 T esting and Materials), and ANSI (American National Standards Institut[...]

14 VENTING Required: 4 Pcs. 4" 90 degree elbow (4 x 5 = 20 Equivalent F eet) = 20 Equivalent Feet Required: 20' of 6" Plastic PVC Pipe (20 x 1 = 20 Equivalent F eet) = 20 Equivalent F eet T otal F riction Loss in Equivalent Feet (20 + 20 = 40 Equivalent Feet) = 40 Equivalent F eet C. LONGER VENT RUNS USING A COMBINA TION 4" T O [...]

VENTING 15 D . HEA TER REMOV AL 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 appliances remaining connected to common venting system are not operating. 1. Seal any unused openi[...]

16 **IMPORT ANT NO TE : 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: 4" Roof V ent with T ee (Intake) & Coupling (Exhaust) DIA GRAM FOR VERTICAL VENTING VENTING **IMPORT ANT NO TE : All vent pipes must be [...]

17 VENTING / PIPING E. CONDENSA TE 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. It is very important that the condensate line is sloped away f[...]

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 com- pound. Threaded connections are 2” NPT Brass nipples located on the left hand side of the unit. 3. Install P urge and Balance V alve or shut off valve and [...]

19 PIPING C. FILL AND PURGE HEA TING 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[...]

20 PIPING Piping Symbol Legend circulator (w/ isolation flanges) gate valve globe valve ball valve swing-check valve flow-check valve spring-loaded check valve hose bib / boiler drain thermostatic radiator valve TRV (straight) circuit setter manual 3-way valve zone valve air separator backflow preventer diaphragm-type expansion tank pressure reduci[...]

21 PIPING Standard Munchkin boiler Retrofit piping (zoning with valves) Space heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 1A make-up water zone valves purging valves NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. [...]

22 PIPING Standard Munchkin boiler Retrofit piping (zoning with valves) Domestic water heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 1B make-up water purging valves V1 zone valves flow bypass valve anti-scald mixing valve NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all [...]

23 PIPING Standard Munchkin boiler Preferred piping (zoning with valves) Space heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 2A make-up water zone valves NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Adjust differe[...]

24 PIPING Standard Munchkin boiler Preferred piping (zoning with valves) Domestic water heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 2B make-up water V1 zone valves anti-scald mixing valve purging valves closely spaced tees differential pressure bypass valve P2 NOTES: 1. This drawing is meant to show system piping concep[...]

25 PIPING Standard Munchkin boiler Preferred piping (zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to center spacing. 3. A minimum of [...]

Standard Munchkin boiler Preferred piping (zoning with circulators) Domestic water heating mode Munchkin boiler make-up water Super Stor indirect DHW tank closely spaced tees P2 zone circulators T/P space heating zone circuit Drawing 2D purging valves NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for a[...]

27 PIPING Fig. 5-9 Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to cent[...]

28 PIPING Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. All closely spaced tees shall be within 4 pipe diameter center to cent[...]

29 ST ART -UP PROCEDURES P ART 6. ST ART -UP PROCEDURES A. ITEMS T O BE CHECKED BEFORE LIGHTING THE MUNCHKIN It is recommended that you read the General Information Section (P art 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.[...]

30 ST ART -UP PROCEDURES 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 Heater shall be installed so the gas ignition system components are protect[...]

31 E. ST A TUS 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. T o view the next value simply press the S/4 key to go to the next d[...]

32 P ART 7. SERVICING A. SEQUENCE OF OPERA TION 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 ca[...]

33 SERVICING closed. This could occur if the clear hose, which is connected to the outlet of the fan is disconnect- ed. This can be corrected by re- connecting the hose. Listed below are the T emporary F ault Codes. E00 This code will appear if there is an overshoot of the high limit. The T emporary F ault Code will be displayed only 50 seconds. E1[...]

34 F05 Supply T emperature 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 pro[...]

35 F30 W atchdog. Call F actory for further assistance. Remedy – Call Factory for further assistance F31 P arameter Memory . External P arameter memory corrupted Remedy – Call Factory for further assistance F32 P arameter memory write error . External P arameter memory fault Remedy – Call Factory for further assistance F33 P rogramming Error [...]

SERVICING 36 Boiler & Indirect Temperature (˚F) Resistance (ohms) 32 32550 41 25340 50 19870 59 15700 68 12490 77 10000 86 8059 95 6535 104 5330 113 4372 122 3605 131 2989 140 2490 149 2084 158 1753 167 1481 176 1256 185 1070 194 915 203 786 212 667 RESISTANCE TABLES[...]

37 MAINTENANCE P ART 8. MAINTENANCE A. MAINTENANCE PROCEDURES P eriodic 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 a[...]

38 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. D . COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS* *Before beginning this procedure, you must have on hand the following items: – a nylon, stainles[...]

39 MAINTENANCE CONTROL WIRING LA Y OUT Fig . 8-1 * There is a spare 6.3 amp “slow blow ” fuse included on the control cover . HTP p/n 7250-378 or you may purchase it from Radio Shack p/n: 270-1068 Caution: Do not replace with any amperage other than 6.3A E. MUNCHKIN CONTROLLER[...]

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SuperStor Ultra, SuperStor , V oyager , V oyager Sanitizer , and Everlast are registered trademarks of Heat T ransfer Products, Inc. © 2004 Heat T ransfer P roducts, Inc. LP -121 REV . 10/20/04[...]