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Installing, Operating & Maintaining
MUNCHKIN™ HIGH EFFICIENCY
399M COMMERCIAL 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 building.
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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 6 PART 6 . . . . . . . . . . . . . . . . . . . .29 thru 32 GENERAL INFORMATION START UP PROCEDURES A How It Operates . . . . . . . . . . . . . . . . . .4 A Items to be checked before B Munchkin Ratings and Dimensions .4–5 lighting the Munchkin . . . . . . . . . . . . .29 C Pre-installation Requirements . . . . . . .5 B Lighting Instructions . . . . . . . . . . . . . .29 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 DIMENSIONS Figure 1-2 C. PRE-INSTALLATION REQUIREMENTS The Munchkin is designed for installation on non-rated flooring, in alcoves, basements, utility rooms, and closet but never a bedroom closet. Choose a location for your Munchkin, centralized to the piping system, along with consideration for Electrical (Part 2, Page 6), Gas Connection (Part 3, Page 8) and Venting (Part 4, Page 11). 5
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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 1. The front of the appliance needs 24" of clearance for service minimum. It may have a non-rated or combustible door or ac
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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 Page 8, Figures 2-1, 2-2 and 2-3. The electrical requiremen
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ELECTRICAL / GAS CONNECTION 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 GRAY WHITE WHITE GRAY T T (NEUTRAL) (NEUTRAL) GRAY GRAY BLACK BLACK T T (HOT) (HOT) GREEN GREEN (GROUND)
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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 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. It is very important that you are connected to the type of gas as noted on the rating plate. "LP" for liquef
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GAS CONNECTION removing the cap and installing the manometer. The gas pressure must remain between 7" and 14" during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Munchkin. It is very important that the gas line is prop- erly purged by the gas supplier or utility. Failure to properly purge the lines or improper line siz- ing, will result in ignition failure. This problem is especially noticeable in NEW LP i
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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 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 12454-B, Formerly designate
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VENTING 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 of the Munchkin. The inlet pipe on the back of the cabinet should be 4" PVC schedule 40. It is very important that you plan the location properly to eliminate long pipe runs and excessive fitti
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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 Direct vent terminal clearance HEAT TRANSFER Minimum clearance, C PRODUCTS RECOMMENDS A Input (Btu/hr) Clearance (in.) MINIMUM 10,000 or less 6 CLEARANCE OF 4 10,001 to 50,000 9 FEET WHERE THE Over 50,000 12 PLUME CAUSED BY (see 10.8.3)* THE UNIT MAY For SI units: 1 ft = 0.305 m; 1 in. = 25.4 mm; OBSTRUCT VIEWS 1 Btu/hr = 0.293 W OR AFFECT THE COSMETIC LOOK OF THE BUIL
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VENTING Required: 4 Pcs. 4" 90 degree elbow (4 x 5 = 20 Equivalent Feet) = 20 Equivalent Feet Required: 20' of 6" Plastic PVC Pipe (20 x 1 = 20 Equivalent Feet) = 20 Equivalent Feet Total Friction Loss in Equivalent Feet (20 + 20 = 40 Equivalent Feet) = 40 Equivalent Feet C. LONGER VENT RUNS USING A COMBINATION 4" TO 6" PIPE CAUTION Do not exceed the 85 foot maximum requirement for 4" PVC and the 125 foot maximum requirement for 6" PVC (intake plus exhaust piping added together) including fitt
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VENTING 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 appliances remaining connected to common venting system are not operating. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, c
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VENTING DIAGRAMS FOR SIDEWALL VENTING (cont’d) **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: 4" Sidewall Vent with V2000 kit DIAGRAM FOR VERTICAL 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 4-4: 4" Roof
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VENTING / PIPING E. CONDENSATE REQUIREMENTS This is a condensing high efficiency appliance, therefore this unit has a condensate removal system. Condensate is nothing more than water vapor, derived from the combustion products, similar to an automobile when it is initially started. It is very important that the condensate line is sloped away from and down to a suitable inside drain, if the condensate outlet on the Munchkin is lower than the drain, you must use a condensate removal pump (kit ava
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PIPING pound. Threaded connections are 2” NPT Brass nipples located on the left hand side of unit. 2. Connect the system supply marked “Heater Out”, make sure to install with pipe sealant com- pound. Threaded connections are 2” NPT Brass nipples located on the left hand side of the unit. 3. Install Purge and Balance Valve or shut off valve and drain on system return to purge air out of each zone. 4. Install a Back Flow preventor on the Cold Feed Make-Up Water line. 5. Install a Pressure Reduc
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PIPING C. 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 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, open the valves one at a time manually. (Note: please check valve manu- facturer’s instruction prior to opening valves manually, so as not to damage the va
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PIPING D. PIPING ILLUSTRATIONS Piping Symbol Legend circulator pressure reducing valve (w/ isolation flanges) circulator w/ integral flow check) diff. pressure bypass gate valve globe valve anti-scald rated mixing valve ball valve pressure gauge swing-check valve 4-way motorized flow-check valve mixing valve spring-loaded check valve 3-way motorized Munchkin heater mixing valve hose bib / boiler drain pressure relief valve thermostatic radiator valve TRV (straight) backflow preventer thermos
