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Installing, Operating & Maintaining
MUNCHKIN VWH HIGH EFFICIENCY
HOT WATER SUPPLY BOILER
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 buildi
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USING THIS MANUAL USING THIS MANUAL SPECIAL ATTENTION BOXES DANGER DANGER indicates an imminently hazardous Throughout this manual you will see these special attention boxes similar to this one, situation which, if not avoided, will result in which are intended to supplement the death or serious injury. instructions and make special notice of potential hazards. These categories mean, in the judgement of Heat Transfer Products, Inc.: WARNING WARNING indicates a potentially hazardous situatio
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TABLE OF CONTENTS TABLE OF CONTENTS PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8 PART 6 . . . . . . . . . . . . . . . . . . . .29 thru 33 GENERAL INFORMATION START UP PROCEDURES A How It Operates . . . . . . . . . . . . . . . . . .4 A Sequence of Operation . . . . . . . . . . .29 B Munchkin Ratings and Dimensions . .5–7 B Items to be checked before C Pre-installation Requirements . . . . . . .7 lighting the Munchkin . . . . . . . . . . . . .29 D Pressure Relief Valve . . . . . .
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GENERAL INFORMATION PART 1. GENERAL INFORMATION A. HOW IT OPERATES 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 monitors the water flow through the heat exchanger to make sure that the unit has an adequate flow rate during operation. The Munchkin VWH Controller accurately monitors the return and s
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GENERAL INFORMATION B. MUNCHKIN RATINGS AND DIMENSIONS Input Output Supply/Return Gas Connection Intake/Exhaust Shipping Model L W H Modulation Modulation Connection Size Dia. Weight 199VWH 66,000–199,000 48,000–191,040 1¼” NPT ¾” 3” PVC Sch. 40 126 lbs. 24.50 18.25 25.88 399VWH 100,000–399,000 96,000–343,040 2” NPT 1¼” 4” PVC Sch. 40 267 lbs. 44.25 18.25 25.88 FIRST HOUR RATING FIRST HOUR RATING MODEL INLET OUTLET RECOVERY RATE W/ 80 GAL. STORAGE TANK W/ 119 GAL. STORAGE TANK 199 VWH 40° 80° 56
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GENERAL INFORMATION DIMENSIONS Figure 1-2 6
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GENERAL INFORMATION Figure 1-3 C. PRE-INSTALLATION REQUIREMENTS bustible construction. In addition, it is design GENERAL certified for use on combustible floors. 1. Munchkin VWH is supplied completely assem- 2. Refer to Figure 1.1 for the recommended clear- bled as a packaged boiler. The package should ance to allow for reasonable access to the boil- be inspected for damage upon receipt and any er. Local codes or special conditions may damage to the unit should be reported to the require great
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GENERAL INFORMATION WARNING 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. NOTICE 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
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ELECTRICAL 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 circulator connection. All electrical wiring must be performed by a qualified licensed electrician in accordance with National Electrical Code ANSI/NEPA to and/or the Canadian Electrical Code, Part 1 CSA C22.1, or to the applicable codes and standards. For your conv
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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 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 Fuel Gas Code. This information is listed on the rating plate.
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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
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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 Use Plastic 3” and 4” and 6” 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-1784 Class 12454-B, Formerly desig
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VENTING NOTICE 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 VWH. 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
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4 ft. minimum 12 in.minimum 12 in.minimum VENTING RECOMMENDED VENTING CLEARANCES PER THE NATIONAL FUEL GAS CODE* *IMPORTANT NOTE HEAT TRANSFER Direct vent terminal clearance PRODUCTS Minimum clearance, C RECOMMENDS A MINIMUM Input (Btu/hr) Clearance (in.) CLEARANCE OF 4 10,000 or less 6 FEET WHERE THE 10,001 to 50,000 9 PLUME CAUSED BY Over 50,000 12 THE UNIT MAY (see 10.8.3)* OBSTRUCT VIEWS For SI units: 1 ft = 0.305 m; 1 in. = 25.4 mm; OR AFFECT THE 1 Btu/hr = 0.293 W COSMETIC LOOK OF THE BUIL
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VENTING WARNING Transitioning into a larger diameter pipe 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. 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
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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. 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. Follo
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VENTING DIAGRAMS FOR SIDEWALL VENTING Figure 4-1: Sidewall Vent with Tee (Intake) & Figure 4-2: Sidewall Vent with Tee (Intake) & Coupling (Exhaust) for standard floor Coupling (Exhaust) for standard floor units units 3” piping for 199VWH 3” piping for 199VWH 4” piping for 399VWH 4” piping for 399VWH **IMPORTANT NOTE: All vent pipes must be glued, prop- **IMPORTANT NOTE: All vent pipes must be glued, prop- erly supported and the exhaust must be pitched a mini- erly supported and the exhaust must
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VENTING DIAGRAMS FOR VERTICAL VENTING Figure 4-6: Roof Vent with 3” concentric vent kit Figure 4-5: Roof Vent with tee (intake) & coupling (KGAVT0601CVT) for standard floor (exhaust) for standard floor units units 3” piping for 199VWH 3” piping for 199VWH 4” piping for 399VWH 4” piping for 399VWH **IMPORTANT NOTE: All vent pipes must be glued, prop- **IMPORTANT NOTE: All vent pipes must be glued, prop- erly supported and the exhaust must be pitched a mini- erly supported and the exhaust must be
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PIPING PART 5. PIPING THE MUNCHKIN VWH TO THE STORAGE TANK WARNING When raising tank temperature, you increase the risk of scalding – Please use a water tempering or mixing valve and extreme caution. Consult codes for conformance. WARNING Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes. The Munchkin is designed to be connected to a storage tank to supply domestic hot water. Heat Transfer Products has available storage
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PIPING PIPING ILLUSTRATIONS Piping Symbol Legend circulator (open loop) anti-scald rated (w/ isolation flanges) mixing valve flow switch pressure gauge gate valve pressure relief valve (or P&T relief valve) globe valve ball valve temperature / pressure gauge T/P swing-check valve union spring-loaded check valve vacuum breaker hose bib / boiler drain diaphragm-type expansion tank (for potable water) Superstor Ultra Storage Tank Munchkin heater Fig. 5-1 20
