Munchkin VWH High Efficiency Hot Water Supply Boiler manual

HEA T TRANSFER PRODUCTS, INC. 120 BRALEY RD ., E . FREET OWN , MA 02717 Installing , Operating & Maintaining MUNCHKIN VWH HIGH EFFICIENCY HO T W A TER SUPPL Y 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 applia[...]

USING THIS MANUAL 2 USING THIS MANUAL 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.: D ANGER DANGER indicates an[...]

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 . .5–7 C Pre-installation Requirements . . . . . . .7 D Pressure Relief V alve . . . . . . . . . . . . . .8 P ART 2 . . . . . . . . . . . [...]

GENERAL INFORMA TION 4 RECOMMENDED SERVICE CLEARANCES P ART 1. GENERAL INFORMA TION A. HOW IT OPERA TES The Munchkin VWH is a hot water supply boiler designed to operate in conjuction with a hot water storage tank. Each Munchkin VWH is equipped with a high velocity pump to keep the unit running efficiently for many years of service. A flow switch m[...]

GENERAL INFORMA TION 5 B. MUNCHKIN RA TINGS AND DIMENSIONS MODEL INLET OUTLET RECO VERY RA TE FIRST HOUR RA TING W/ 80 GAL. STORA GE T ANK FIRST HOUR RA TING W/ 119 GAL. STORA GE T ANK 199 VWH 40° 80° 561 GAL 614 GAL 640 GAL 199 VWH 40° 90° 450 GAL 503 GAL 529 GAL 199 VWH 40° 100° 374 GAL 427 GAL 453 GAL 199 VWH 40° 110° 320 GAL 373 GAL 399[...]

6 GENERAL INFORMA TION DIMENSIONS Figure 1-2[...]

GENERAL INFORMA TION 7 GENERAL 1. Munchkin VWH is supplied completely assem- bled as a packaged boiler . The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesaler . This boiler should be stored in a clean, dry area. 2. Carefully read these instructions and be sure to[...]

8 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 un[...]

9 ELECTRICAL P ART 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 circulator connection. All electrical wiring must be performed by a qualified licensed electrician in accordanc[...]

10 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 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 [...]

11 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 pre[...]

12 VENTING P ART 4. VENTING A. APPRO VED VENTING MA TERIALS EXHAUST VENT Use Plastic 3” and 4” and 6” 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 -1784 Class 12454-B, F ormerly desig- [...]

13 VENTING The inlet pipe on the back of the cabinet is 3" for the 199 VWH and 4" for the 399 VWH. 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 simi[...]

14 VENTING 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 [...]

15 The connection of air inlet and exhaust vent at the heater must remain 3” for 199VWH and 4” for 399VWH and each vent must extend from the heater a minimum of 15 equivalent feet before transi- tioning to a 4” vent for the 199VWH and 6” vent for the 399VWH. The overall extended maximum length of pipe on the inlet and exhaust combined, must[...]

16 VENTING 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. T urn on clothes dryers and any appliances not connected to the common venting system. T urn on any exhaust fans, such as range hoods and bathro[...]

17 VENTING Figure 4- 1: Si dewall V ent with T ee (Intake) & Coupling (Exhaust) for standard floor units 3” piping for 199VWH 4” piping for 399VWH **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 back to the boiler (to allow drainage of condensate). Al[...]

18 VENTING DIA GRAMS FOR VERTICAL VENTING Figure 4- 5: Roof V ent with tee (intake) & coupling (exhaust) for standard floor units 3” piping for 199VWH 4” piping for 399VWH **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 back to the boiler (to allow dr[...]

19 PIPING P ART 5. PIPING THE MUNCHKIN VWH T O THE ST ORAGE T ANK The Munchkin is designed to be connected to a storage tank to supply domestic hot water . Heat T ransfer Products has available storage tanks that are 80/119 gallon size storage tanks constructed in either Stainless Steel or Glass lined construction. These storage tanks will be direc[...]

20 PIPING Piping Symbol Legend circulator (open loop) (w/ isolation flanges) gate valve globe valve ball valve swing-check valve spring-loaded check valve hose bib / boiler drain diaphragm-type expansion tank (for potable water) anti-scald rated mixing valve pressure gauge pressure relief valve (or P&T relief valve) union Munchkin heater vacuum[...]

21 PIPING Volume Water Heating using Munchkin boiler (1 boiler supplying one storage tank) Drawing VWH 1/1 flow switch expansion tank ASEE 1017 rated anti-scald valve (recommended) condensate drainage constant circulation vacuum breaker (where required by code) Superstor Ultra Storage Tank hot water supply recirculation line cold water NOTES: 1. Th[...]

22 PIPING Volume Water Heating using Munchkin boiler (1 boiler supplying two storage tanks) flow switch expansion tank ASEE 1017 rated anti-scald valve (recommended) condensate drainage constant circulation vacuum breaker (where required by code) Superstor Ultra Storage Tank Superstor Ultra Storage Tank Drawing VWH 1/2 hot water supply recirculatio[...]

23 PIPING Drawing VWH 2/1 H Volume Water Heating using Munchkin boiler (2 boilers supplying one storage tank) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Boiler circulator must be rated for open loop application. Do not use cast-iron circu[...]

24 PIPING Volume Water Heating using Munchkin boiler (2 boilers supplying one storage tank) Drawing VWH 2/1 V NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Boiler circulator must be rated for open loop application. Do not use cast-iron circu[...]

25 PIPING Drawing VWH2/2 H Volume Water Heating using Munchkin boilers (2 boilers supplying two storage tanks) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Boiler circulator must be rated for open loop application. Do not use cast-iron circ[...]

26 PIPING Drawing VWH2/2 V Volume Water Heating using Munchkin boilers (2 boilers supplying two storage tanks) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Boiler circulator must be rated for open loop application. Do not use cast-iron circ[...]

27 PIPING Drawing VWH 3/2 H Volume Water Heating using Munchkin boiler (3 boilers supplying two storage tanks) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Boiler circulator must be rated for open loop application. Do not use cast-iron circ[...]

28 PIPING Drawing VWH 3/2 V Volume Water Heating using Munchkin boiler (3 boilers supplying two storage tanks) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes. 2. Boiler circulator must be rated for open loop application. Do not use cast-iron circ[...]

29 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[...]

30 C. LIGHTING INSTRUCTIONS FOR Y OUR OWN SAFETY READ BEFORE OPERA TING 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 OPERA TING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas [...]

31 F . 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 [...]

32 ST ART -UP PROCEDURES H. T O TURN OFF GAS TO APPLIANCE 1. Set the thermostat to lowest setting. 2. T urn off all electric power to the appliance if service is to be performed. 3. Remove the front cover . 4. T urn gas shutoff valve to "off". 5. Install front cover . Fig . 6-1 S G N I T T E S N O I T S U B M O CH W V 9 9 3 / H W V 9 9 1 [...]

MUNCHKIN 199VWH GAS V AL VE MUNCHKIN 399VWH GAS V AL VE ST ART -UP PROCEDURES 33 Fig . 6-3 THROTTLE ADJUSTER (NOTE: IF FOR ANY REASON THE THROTTLE NEEDS TO BE ADJUSTED , IT IS VERY IMPORTANT THAT A "COMBUSTION ANAYLYZER" BE USED TO ENSURE SAFE AND PROPER OPERATION. TURN THE ADJUSTER TO THE (+) TO INCREASE GAS OR THE (-) TO DECREASE THE GA[...]

34 TROUBLESHOOTING 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 t[...]

35 TROUBLESHOOTING T able 7-2: 925 Control Board F AUL T 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[...]

36 TROUBLESHOOTING Boiler 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 ST AND ARD 925 CONTROL WIRING LA Y OUT FOR 199VWH Fig . 8-1 925 CONTROL WIRING LA Y OUT FOR 399VWH Fig . 8-2 E. MUNCHKIN CONTROLLERS[...]

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LP -147 REV . 7/7/04[...]