Munchkin Gas-Fired Hot Water Boiler Operations Instructions

Browse online or download Operations Instructions for Water heaters & boilers Munchkin Gas-Fired Hot Water Boiler. Munchkin Gas-Fired Hot Water Boiler Operating instructions User Manual

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HEAT TRANSFER PRODUCTS, INC.
120 BRALEY RD., E. FREETOWN, MA 02717
Installing, Operating & Maintaining
MUNCHKIN™ HIGH EFFICIENCY HEATER
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.
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.
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.
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.
MH27745
CONTROLS
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Summary of Contents

Page 1 - CONTROLS

HEAT TRANSFER PRODUCTS, INC.120 BRALEY RD., E. FREETOWN, MA 02717Installing, Operating & MaintainingMUNCHKIN™ HIGH EFFICIENCY HEATERwith the

Page 2 - USING THIS MANUAL

10ELECTRICALThe 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

Page 3 - TABLE OF CONTENTS

11ELECTRICALNORMALLY OPENTTGROUNDBUSSWITCH JUNCTION BOX120V 60 HZELECTRICALSWITCH JUNCTION BOX120V 60 HZELECTRICALNORMALLY OPENTHERMOSTATCONNECTIONW

Page 4 - PART 1. GENERAL INFORMATION

12GAS CONNECTIONPART 3. GAS CONNECTIONA. GAS CONNECTIONThe gas supply shall have a maximum inlet pressure of lessthan 14" water column (350 mm),

Page 5 - T50M/T80M

13WARNING Failure to follow all precautions could result in fire, explosion or death!GAS CONNECTIONIt is recommended that a soapy solution be used to

Page 6

14VENTINGPART 4. VENTINGA. APPROVED VENTING MATERIALSExhaust Vent and Extensionsin Plastic 2", 3" and 4" Pipe Schedule 40 or 80.1. Non

Page 7 - 140M/199M

15VENTINGB. VENTING THE MUNCHKINThe inlet pipe on the back of the cabinet should be 3" PVC schedule 40. It is very important that youplan the loc

Page 8

16may require venting modifications (consult factory). The air inlet must be a minimum of 1'vertically above the maximum snow level. It is very i

Page 9 - PART 2. ELECTRICAL

17VENTINGFriction Loss Equivalent in Piping and FittingsFittings or Piping Equivalent Feet90 degree elbow = 545 degree elbow = 3Coupling = 0air inlet

Page 10 - DANGER

VENTING18D. HEATER REMOVAL FROM A COMMON VENT SYSTEMAt the time of removal of an existing heater, the following steps shall be followed with each appl

Page 11 - ELECTRICAL

19VENTING**IMPORTANT NOTE: All vent pipes must beglued, properly supported and the exhaust mustbe pitched a minimum of a ¼" per foot back tothe h

Page 12 - PART 3. GAS CONNECTION

USING THIS MANUAL2SPECIAL ATTENTION BOXES Throughout this manual you will see thesespecial attention boxes similar to this one,which are intended to

Page 13 - WARNING

VENTING20**IMPORTANT NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched aminimum of a ¼" per foot back to the

Page 14 - PART 4. VENTING

VENTING21**IMPORTANT NOTE: All vent pipes must be glued,properly supported, and the exhaust must be pitcheda minimum of a ¼" per foot back to the

Page 15

22PIPINGPART 5. PIPING A. HYDRONIC PIPING WITH CIRCULATORS OR ZONE VALVES The Munchkin is designed to function in a closed loop 15 PSI System. To as

Page 16

23PIPING8. 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 n

Page 17

24PIPINGC. 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 t

Page 18

25PIPINGPiping Symbol Legendcirculator (w/ isolation flanges)gate valveglobe valveball valveswing-check valveflow-check valvespring-loaded check valve

Page 19 - DIAGRAMS FOR SIDEWALL VENTING

26PIPINGStandard Munchkin boilerRetrofit piping (zoning with valves)Space heating modeMunchkin boilerP1Super Storindirect DHW tankT/PDrawing 1Amake-up

Page 20

27PIPINGStandard Munchkin boilerRetrofit piping (zoning with valves)Domestic water heating modeMunchkin boilerP1Super Storindirect DHW tankT/PDrawing

Page 21 - DIAGRAMS FOR VERTICAL VENTING

28PIPINGStandard Munchkin boilerPreferred piping (zoning with valves)Space heating modeMunchkin boilerP1Super Storindirect DHW tankT/PDrawing 2Amake-u

Page 22 - PART 5. PIPING

29PIPINGStandard Munchkin boilerPreferred piping (zoning with valves)Domestic water heating modeMunchkin boilerP1Super Storindirect DHW tankT/PDrawing

Page 23 - Friction in Feet of Head

TABLE OF CONTENTS3TABLE OF CONTENTS PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8GENERAL INFORMATIONA How It Operates . . . . . . . . .

Page 24

30PIPINGStandard Munchkin boilerPreferred piping (zoning with circulators)Space heating modeNOTES:1. This drawing is meant to show system piping conc

Page 25 - Piping Symbol Legend

31PIPINGStandard Munchkin boilerPreferred piping (zoning with circulators)Domestic water heating modeMunchkin boilermake-up waterSuper Storindirect DH

Page 26 - Drawing 1A

32PIPINGStandard Munchkin boilerPreferred piping (multiple boilers / zoning with circulators)Space heating modeNOTES:1. This drawing is meant to show

Page 27 - Drawing 1B

PIPING33Standard Munchkin boilerPreferred piping (multiple boilers / zoning with circulators)Domestic water heating modeNOTES:1. This drawing is mean

Page 28 - Drawing 2A

34START-UP PROCEDURESPART 6. START-UP PROCEDURES A. SEQUENCE OF OPERATION1. When power is first applied to the control, the control display will read

Page 29 - Drawing 2B

35START-UP PROCEDURESthe room thermostat is connected and turn the room thermostat up above room temperatureto start the combustion blower fan to run

Page 30 - Drawing 2C

3612. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance”Section E and call your service technician or gas suppl

Page 31 - Drawing 2D

37G. TEST MODEThis function is intended to simplify the gas valve adjustment if needed. Listed below are therecommended limits on each Munchkin Heater

Page 32 - Drawing 2E

38CAUTION This appliance has wire function labels on allinternal wiring. Observe the position of each wirebefore removing it. Wiring errors may cause

Page 33 - Drawing 2F

TROUBLESHOOTING39Table 7-1: 925 Control Board Error CodesedoCnoitpircseDydemeR00F.dedeecxEtimiLhgiH.1.2.3noitarepopmupnoitalucrickcehCehtgnisseccaybre

Page 34 - PART 6. START-UP PROCEDURES

GENERAL INFORMATION4B. MUNCHKIN RATINGS AND DIMENSIONSPERFORMANCE RATINGS*Net waterCONNECTION SIZESledoMnoitaludoMtupnIgnitaeHEODEUFAthgieWgnippihSRBI

Page 35

TROUBLESHOOTING40Boiler & Indirect Temperature (˚F) Resistance (ohms)32 3255041 2534050 1987059 1570068 1249077 1000086 805995 6535104 5330113 437

Page 36 - START-UP PROCEDURES

41MAINTENANCEPART 8. MAINTENANCEA. MAINTENANCE PROCEDURESPeriodic maintenance should be performed once a year by a qualified service technician to ass

Page 37 - Fig. 6-1

42MAINTENANCED. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS**Before beginning this procedure, you must have on hand the following items:– a nylon, s

Page 38 - PART 7. TROUBLESHOOTING

MAINTENANCE43CONTROL WIRING LAYOUTFig. 8-1*There is a spare 6.3 amp “slow blow” fuse included on the control cover. HTP p/n 7250-378 oryou may purchas

Page 42

NOTES47

Page 43 - MAINTENANCE

SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc.Munchkin R1© 2004 Heat T

Page 44

GENERAL INFORMATION5Figure 1-1(NOTE: The Munchkin is rated atzero clearance to combustibles.)80M/140M/199MT50M/T80MRECOMMENDED SERVICE CLEARANCESFigur

Page 45

GENERAL INFORMATION6Figure 1-3T50M/T80MDIMENSIONS

Page 46

GENERAL INFORMATION7DIMENSIONS80M140M/199MFigure 1-4Figure 1-5

Page 47

GENERAL INFORMATION8C. PRE-INSTALLATION REQUIREMENTGENERAL 1. Munchkin Boilers are supplied complete-ly assembled as packaged boilers. Thepackage shou

Page 48 - Munchkin R1

GENERAL INFORMATION / ELECTRICAL9Note: Service clearance of the Munchkin: See Section 1, Figures 1-1 and 1-2.If the Munchkin is set up for liquefied p

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