Munchkin MUNCHKIN HIGH EFFICIENCY HEATER with the "925" Controller manual

HEA T TRANSFER PRODUCTS, INC. 120 BRALEY RD ., E . FREET OWN , MA 02717 Installing , Operating & Maintaining MUNCHKIN ™ HIGH EFFICIENCY HEA TER with the “925” Controller Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHA T T O DO IF Y OU SMELL GAS • Do not try to light [...]

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.: NOTICE Heat T ransfer Products manufactures b[...]

T ABLE OF CONTENTS 3 T ABLE OF CONTENTS P ART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8 GENERAL INFORMA TION A How It Operates . . . . . . . . . . . . . . . . . .4 B Munchkin Ratings and Dimensions . . .4 C Pre-installation Requirements . . . . . . .8 D Pressure Relief V alve . . . . . . . . . . . . . .9 P ART 2 . . . . . . . . . . . . [...]

GENERAL INFORMA TION 4 B. MUNCHKIN RA TINGS AND DIMENSIONS PERFORMANCE RA TINGS *Net water CONNECTION SIZES 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 DE U F At h g i e W g n i p p i h SR B I * M 0 5 T0 0 0 , 0 5 o t 0 0 0 , 8 10 0 0 , 6 4 o t 0 0 0 , 6 1% 2 9. s b l 8 50 0 0 , 0 4 M 0 8 T0 0 0 , 0 8 o t 0 0 0 , 9 10 0 0 , 4 7 o t 0 0 [...]

GENERAL INFORMA TION 5 Figure 1-1 (NOTE: The Munchkin is rated at zero clearance to combustibles.) 80M/140M/199M T50M/T80M RECOMMENDED SERVICE CLEARANCES Figure 1-2[...]

GENERAL INFORMA TION 6 Figure 1-3 T50M/T80M DIMENSIONS[...]

GENERAL INFORMA TION 7 DIMENSIONS 80M 140M/199M Figure 1-4 Figure 1-5[...]

GENERAL INFORMA TION 8 C. PRE-INST ALLA TION REQUIREMENT GENERAL 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. Carefully[...]

GENERAL INFORMA TION / ELECTRICAL 9 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 locat[...]

10 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 wir[...]

11 ELECTRICAL NORMALLY OPEN T T GROUND BUS SWITCH JUNCTION BOX 120V 60 HZ ELECTRICAL SWITCH JUNCTION BOX 120V 60 HZ ELECTRICAL NORMALLY OPEN THERMOSTAT CONNECTION WIRING DIAGRAM WITHOUT CONNECTION TO CIRCULATOR GREEN (GROUND) GRAY GRAY CONNECTION THERMOSTAT (NEUTRAL) WHITE BLACK (HOT) GRAY T T GRAY WIRING DIAGRAM CONNECTING TO CIRCULATOR BLACK WHIT[...]

12 GAS CONNECTION P ART 3. 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 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[...]

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

14 VENTING P ART 4. VENTING A. APPRO VED VENTING MA TERIALS Exhaust V ent and Extensions in Plastic 2", 3" and 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 [...]

15 VENTING B. VENTING 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 s[...]

16 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'. All venting must be properly supported. The Munchkin is not intended to support any venting what[...]

17 VENTING Friction Loss Equivalent in P iping and Fittings Fittings or P iping Equivalent Feet 90 degree elbow = 5 45 degree elbow = 3 Coupling = 0 air inlet tee = 0 Plastic Pipe = 1 concentric vent kit = 3 V500 or V1000 vent kit = 0 Example: Installation requires the following material for both inlet and exhaust piping for the Munchkin Required: [...]

VENTING 18 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 appli- ances remaining connected to common venting system are not operating. 1. Seal any unused ope[...]

19 VENTING **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- 1 **IMPORT ANT NO TE : All vent pipes must be glued, prop- erly supported and the exhaust must be pitched a mini- mum of a ¼" per foot[...]

VENTING 20 **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- 3 **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 bac[...]

VENTING 21 **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 4-5 **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 ba[...]

22 PIPING P ART 5. PIPING A. HYDRONIC PIPING WITH CIRCULA TORS OR ZONE V AL VES The Munchkin is designed to function in a closed loop 15 PSI System. T o 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 pressu[...]

23 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 V alve is installed at the factory located on the right hand side of Munchkin. Pipe th[...]

24 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[...]

25 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[...]

26 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. [...]

27 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 [...]

28 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[...]

29 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[...]

30 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 [...]

31 PIPING 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 respons[...]

32 PIPING 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 center spacin[...]

PIPING 33 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[...]

34 ST ART -UP PROCEDURES P ART 6. ST ART -UP PROCEDURES 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[...]

35 ST ART -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 . C. LIGHTING INSTR[...]

36 12. If the appliance will not operate, follow the instructions “T o T urn Off Gas T o Appliance” Section E and call your service technician or gas supplier . E. ADJUSTING THE TEMPERA TURE ON THE MUNCHKIN DISPLA Y : 1. Before you can change the temperature from the factory setting of 180 degrees. Y ou must make sure that none of the thermosta[...]

37 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 T est mode, only temperature limitation based on the Munchkin Central Heating set point. The user w[...]

38 C A UTION 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. V erify proper operation after servicing. C A UTION If overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulatin[...]

TROUBLESHOOTING 39 T able 7-1: 925 Control Board Error Codes e d o Cn o i t p i r c s e Dy d e m e R 0 0 F . d e d e e c x E t i m i L h g i H . 1 . 2 . 3 n o i t a r e p o p m u p n o i t a l u c r i c k c e h C e h t g n i s s e c c a y b r e l i o b e h t h g u o r h t w o l f e t a u q e d a s i e r e h t t a h t e r u s s A e h t m o r f e s i[...]

TROUBLESHOOTING 40 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[...]

41 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[...]

42 MAINTENANCE 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 Munch[...]

MAINTENANCE 43 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[...]

MAINTENANCE 44[...]

MAINTENANCE 45[...]

NOTES 46[...]

NOTES 47[...]

SuperStor Ultra, SuperStor , V oyager , V oyager Sanitizer , and Everlast are registered trademarks of Heat T ransfer Products, Inc. Munchkin R1 © 2004 Heat T ransfer P roducts, Inc. LP -61 REV . 1/17/05[...]