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Installing, Operating & Maintaining
MUNCHKIN™ HIGH EFFICIENCY HEATER
with the “925” Controller
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
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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 WARNING the judgement of Heat Transfer Products, Inc.: WARNING indicates a potentially hazardous situatio
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TABLE OF CONTENTS TABLE OF CONTENTS PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8 PART 6 . . . . . . . . . . . . . . . . . . . .34 thru 37 GENERAL INFORMATION START UP PROCEDURES A How It Operates . . . . . . . . . . . . . . . . . .4 A Sequence of operation . . . . . . . . . . . .34 B Munchkin Ratings and Dimensions . . .4 B Items to be checked before C Pre-installation Requirements . . . . . . .8 lighting the Munchkin . . . . . . . . . . . . .34 D Pressure Relief Valve . . . . .
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GENERAL INFORMATION PART 1. GENERAL INFORMATION A. HOW IT OPERATES When the room thermostat calls for heat, the Munchkin control board will start the circulator and start to monitor the return temperature of the system before the heater will begin to heat the water. Once the controller has sensed a drop in the return water temperature below the temperature set point minus the differential set point, the heater will start to heat the water. This eliminates the Munchkin starting every time the th
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GENERAL INFORMATION RECOMMENDED SERVICE CLEARANCES (NOTE: The Munchkin is rated at 80M/140M/199M zero clearance to combustibles.) T50M/T80M Figure 1-1 Figure 1-2 5
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GENERAL INFORMATION DIMENSIONS T50M/T80M Figure 1-3 6
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GENERAL INFORMATION DIMENSIONS 80M Figure 1-4 140M/199M Figure 1-5 7
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GENERAL INFORMATION C. PRE-INSTALLATION REQUIREMENT combustible construction. In addition, it GENERAL is design certified for use on combustible 1. Munchkin Boilers are supplied complete- floors. ly assembled as packaged boilers. The 2. Refer to Figure 1.1 and Figure 1.2 for the package should be inspected for damage recommended clearance to allow for rea- upon receipt and any damage to the unit sonable access to the boiler. Local codes should be reported to the shipping com- or special condit
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GENERAL INFORMATION / ELECTRICAL CAUTION 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. 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 foll
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ELECTRICAL CAUTION Electrical wiring on the Incoming Power and Central Heating Circulator shall be connected directly to the intended connection source and not be connected together inside the electric box provided. An Electrical Short will result and the Control board will have to be replaced! If Electrical Requirements of the Central Heating Circulator exceeds 4 amps (or 3 amps on HA models only) please follow the wiring diagrams on Figures 2-1, 2-2 and 2-3 (this section). The electrical req
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ELECTRICAL DIAGRAM "A" DIAGRAM "B" WIRING DIAGRAM CONNECTING TO CIRCULATOR WIRING DIAGRAM WITHOUT CONNECTION TO CIRCULATOR GREEN (GROUND) IMPORTANT NOTE: BE CERTAIN THAT THE ORANGE WHITE (NEUTRAL) WIRE IS SECURELY CAPED. FAILURE TO DO SO COULD BLACK RESULT IN INJURY OR FIRE AND COULD DAMAGE THE CONTROL. NORMALLY OPEN NORMALLY OPEN THERMOSTAT THERMOSTAT CONNECTION CONNECTION WHITE GRAY WHITE GRAY T T (NEUTRAL) (NEUTRAL) GRAY BLACK BLACK GRAY T T (HOT) (HOT) GREEN GREEN (GROUND) (GROUND) GROUND
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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 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 stated in the National Fuel Gas Code. This information is listed on the rating plat
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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 and Extensions in Plastic 2", 3" and 4" 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-1785 or D-1784 Class 12
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VENTING B. VENTING THE MUNCHKIN DANGER It is extremely important to follow these venting instructions exactly. Failure to do so can cause severe personal injury, death or substantial property damage. CAUTION 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
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4 ft. minimum 12 in.minimum 12 in.minimum VENTING 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'. Direct vent terminal clearance Minimum clearance, C Input (Btu/hr) Clearance (in.) 10,000 or less 6 10,001 to 50,000 9 Over 50,000 12 (see 10.8.3)* For SI units: 1 ft = 0.305 m; 1 in. = 25.4 mm; 1 Btu/hr = 0.2
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VENTING Friction Loss Equivalent in Piping and Fittings Fittings or Piping 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 CAUTION Do not exceed the 85 foot maximum requirement (intake plus exhaust piping added together) including fitting allowance. Example: Installation requires the following material for both inlet and exhaust piping for the Munchkin Required: 4 Pcs. (2" or 3") 90 degre
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VENTING DANGER The Munchkin is not intended to be common vented with any other existing appliance! D. HEATER REMOVAL 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 openings in the common venting system. 2. Visually inspect the ve
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VENTING DIAGRAMS FOR SIDEWALL VENTING **IMPORTANT NOTE: All vent pipes must be **IMPORTANT NOTE: All vent pipes must be glued, prop- glued, properly supported and the exhaust must erly supported and the exhaust must be pitched a mini- be pitched a minimum of a ¼" per foot back to mum of a ¼" per foot back to the heater (to allow drainage the heater (to allow drainage of condensate). of condensate). Figure 4-1 Figure 4-2 19
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VENTING **IMPORTANT NOTE: 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 **IMPORTANT NOTE: 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 20
