Munchkin VWH User Manual

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Page 1

HEAT TRANSFER PRODUCTS, INC.

120 BRALEY RD., E. FREETOWN, MA 02717

Installing, Operating & Maintaining

MUNCHKIN™ VWH HIGH EFFICIENCY

HOT WATER SUPPLY BOILER

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

Page 2

USING THIS MANUAL

SPECIAL ATTENTION BOXES

Throughout this manual you will see these special attention boxes similar to this one, which are intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgement of Heat Transfer Products, Inc.:

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION Indicates a potentially hazardous situtation which, if not avoided, may result in minor or moderate injury.

CAUTION

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

WARNINGS

• THIS UNIT IS FOR CATEGORY IV VENTING - 2 PIPE ONLY. THIS IS A SEALED COMBUSTION APPLIANCE.

• THIS HEATER INSTALLATION MUST CONFORM TO THE LATEST EDITION OF THE “NATIONAL FUEL GAS CODE” ANSI Z223.1 NEPA 54 AND OR CAN/CGA B149 INSTALLATION CODES. STATE AND LOCAL CODES MIGHT ALSO APPLY TO INSTALLATION.

• WHERE REQUIRED BY THE AUTHORITY HAVING JURISDICTION, THE INSTALLATION MUST CONFORM TO THE STANDARDS FOR CONTROLS AND SAFETY DEVICES FOR AUTOMATICALLY FIRED HEATERS, ANSI/ASME HEATER AND PRESSURE VESSEL CODE, Section IV, ALONG WITH CSD1.

• THE HEATER, GAS PIPING, WATER PIPING, VENTING AND ELECTRICAL MUST BE INSTALLED BY TRAINED & QUALIFIED PERSONNEL FAMILIAR WITH INSTALLATION PRACTICES, LOCAL CODE, LICENSING REQUIREMENTS.

• IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT; CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

• DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE;

• THE USE OF A LOW WATER CUT-OFF DEVICE MAY BE REQUIRED BY STATE OR LOCAL CODES IF THE MUNCHKIN IS INSTALLED ABOVE RADIATION LEVELS.

Page 3

TABLE OF CONTENTS

PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8

GENERAL INFORMATION

A How It Operates . . . . . . . . . . . . . . . . . .4

B Munchkin Ratings and Dimensions . .5–7

C Pre-installation Requirements . . . . . . .7

D Pressure Relief Valve . . . . . . . . . . . . . .8

PART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

ELECTRICAL

A Electrical Connection . . . . . . . . . . . . . .9

PART 3 . . . . . . . . . . . . . . . . . . . .10 thru 11

GAS CONNECTION

A Gas Connection . . . . . . . . . . . . . . . . . .10

B Gas Piping . . . . . . . . . . . . . . . . . . . . . .10

C Gas Table . . . . . . . . . . . . . . . . . . . . . . .10

PART 4 . . . . . . . . . . . . . . . . . . . .12 thru 18

VENTING

A Approved Venting Materials . . . . . . . .12

B Venting the Munchkin in

3”, 4” or 6” Plastic Pipe . . . . . . . . . . .12

C Longer Vent Runs . . . . . . . . . . . . . . .14

D Heater Removal from a

Common Vent System . . . . . . . . . . . .15

E Condensate Removal . . . . . . . . . . . . .16

PART 5 . . . . . . . . . . . . . . . . . . . .19 thru 29

PIPING

A Expansion Tank . . . . . . . . . . . . . . . . . .19

B High Velocity Circulator Pump . . . . . .19

PART 6 . . . . . . . . . . . . . . . . . . . .30 thru 34

START UP PROCEDURES

A Sequence of Operation . . . . . . . . . . .30

B Items to be checked before

lighting the Munchkin . . . . . . . . . . . . .30

C Lighting Instructions . . . . . . . . . . . . . .31

D Operating Instructions . . . . . . . . . . . .31

E Adjusting the Operating Set Points

of the Munchkin VWH Display . . . . . .31

F Status Menu . . . . . . . . . . . . . . . . . . . .32

G Test Mode . . . . . . . . . . . . . . . . . . . . . .32

H To Turn Off Gas to Appliance . . . . . . .33

PART 7 . . . . . . . . . . . . . . . . . . . .35 thru 37

TROUBLESHOOTING

A Munchkin Error Code . . . . . . . . . . . . .35

B Boiler Error . . . . . . . . . . . . . . . . . . . . .35

C Boiler Fault . . . . . . . . . . . . . . . . . . . . .35

PART 8 . . . . . . . . . . . . . . . . . . . .38 thru 43

MAINTENANCE

A Maintenance Procedures . . . . . . . . . .38

B Annual Maintenance . . . . . . . . . . . . . .38

C Condensate Cleaning Instructions . . .38 D Combustion Chamber

Coil Cleaning Instructions . . . . . . . . . .39

E Munchkin Controllers . . . . . . . . . . . . .40

Page 4

GENERAL INFORMATION

RECOMMENDED SERVICE CLEARANCES

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 supply temperature that controls the output range of the Munchkin

When the system has sensed a temperature drop below the set point and minus the differential set point, The Munchkin VWH will activate the blower motor for a pre-purge of 5 seconds before going into operation. Once in operation, the Munchkin controller will now start to modulate the pre-mix burner based on analyzing the return, supply, differential and operating set point temperatures. By compiling this information, the controller utilizes an algorithm to fully adjust the firing rate while maintaining the desired output temperature. The pre-mix burner fan has direct drive current, lowvoltage motor with pulse relay counting. This system allows precise control over the fan speed and combustion air volumes. Coupled with the fuel and air mixing system which are set to provide a one to one ratio of precisely measured volumes of fuel to air, an accurate and instant burner output is achieved. This keeps the Munchkin VWH running at the highest efficiency.

RECOMMENDED SERVICE CLEARANCES

Figure 1-1

Page 5

GENERAL INFORMATION

B. MUNCHKIN RATINGS AND DIMENSIONS

MODEL INLET OUTLET RECOVERY RATE

FIRST HOUR RATING

W/ 80 GAL. STORAGE TANK

FIRST HOUR RATING

W/ 119 GAL. STORAGE TANK

199 VWH 40° 80° 573 GAL 626 GAL 652 GAL

199 VWH 40° 90° 458 GAL 511 GAL 537 GAL

199 VWH 40° 100° 382 GAL 435 GAL 461 GAL

199 VWH 40° 110° 327 GAL 380 GAL 406 GAL

199 VWH 40° 120° 287 GAL 340 GAL 366 GAL

199 VWH 40° 130° 255 GAL 308 GAL 334 GAL

199 VWH 40° 140° 229 GAL 282 GAL 308 GAL

199 VWH 40° 150° 208 GAL 261 GAL 287 GAL

199 VWH 40° 160° 191 GAL 244 GAL 270 GAL

199 VWH 40° 170° 176 GAL 229 GAL 255 GAL

199 VWH 40° 180° 163 GAL 216 GAL 242 GAL

399 VWH 40° 80° 1149 GPH 1202 GAL 1228 GAL

399 VWH 40° 90° 919 GPH 972 GAL 998 GAL

399 VWH 40° 100° 766 GPH 819 GAL 845 GAL

399 VWH 40° 110° 657 GPH 710 GAL 736 GAL

399 VWH 40° 120° 575 GPH 628 GAL 654 GAL

399 VWH 40° 130° 510 GPH 563 GAL 589 GAL

399 VWH 40° 140° 460 GPH 513 GAL 539 GAL

399 VWH 40° 150° 418 GPH 471 GAL 497 GAL

399 VWH 40° 160° 383 GPH 436 GAL 462 GAL

399 VWH 40° 170° 354 GPH 407 GAL 433 GAL

399 VWH 40° 180° 328 GPH 381 GAL 407 GAL

Model

Input

Modulation

Output

Modulation

Supply/Return

Connection

Gas Connection

Size

Intake/Exhaust

Dia.

Shipping

Weight

L W H

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 96,000–383,040 2” NPT 1¼” 4” PVC Sch. 40 267 lbs. 44.25 18.25 25.88

199 VWH at 20GPM

Pressure Drop for Tube Length of 1¼” Copper

(10) 90° Elbows ad (2) Tees (Side Outlet)

with Munchkin 199 VWH

1¼” Tube Length 20’ 30’ 40’ 50’ 60’

20 GPM 21.65 22.62 23.6 24.56 25.53

399 VWH at 40GPM

Pressure Drop for Tube Length of 2” Copper

(10) 90° Elbows and (2) Tees (Side Outlet)

with Munchkin 399 VWH

2” Tube Length 20’ 30’ 40’ 50’ 60’

40 GPM 24 24.37 24.74 25.11 25.48

*Example recovery rate for 199VWH @ 90° rise: 400 gal. tank ÷ 255 GPH @ 90° rise = 1.56 x 60 min. = 93.6 min.

*Example recovery rate for 399VWH @ 90° rise: 400 gal. tank ÷ 510 GPH @ 90° rise = .78 x 60 min. = 46.8 min.

Page 6

GENERAL INFORMATION

DIMENSIONS

Figure 1-2

Page 7

GENERAL INFORMATION

GENERAL

1. Munchkin VWH is supplied completely assembled 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 understand the function of all connections prior to beginning installation. Contact your Heat Transfer Products, Inc. Representative or the Heat Transfer Products, Inc. Customer Service Department for help in answering questions.

3. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly.

CODES & REGULATIONS

Installation and repairs are to be performed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler and gas appliance installation.

ACCESSIBILITY CLEARANCES

1. The Munchkin VWH is certified for closet installations with zero clearance to com-

bustible construction. In addition, it is design certified for use on combustible floors.

2. Refer to Figure 1.1 for the recommended clearance to allow for reasonable access to the boiler. Local codes or special conditions may require greater clearances.

COMBUSTION AND VENTILATION AIR

1. The Munchkin VWH is designed only for operation with combustion air piped from outside (sealed combustion). PVC pipe must be supplied between the air inlet connection at the rear of the boiler through an outside wall.

2. No additional combustion or ventilation air is required for this appliance.

3. Refer to Section 4 of this manual, Venting, for specific instructions for piping combustion air.

PLANNING THE LAYOUT

1. Prepare sketches and notes showing the layout of the boiler installation to minimize the possibility of interferences with new or existing equipment, piping, venting and wiring.

2. The following sections of this manual should be reviewed for consideration of limitations with respect to:

a. Electrical Wiring: Part 2 b. Gas Connection: Part 3 c. Venting: Part 4 f. Piping the Munchkin VWH to the

Storage Tank: Part 5

WARNING

Liquefied Petroleum (LP) Gas or Propane is heavier than air and, in the event of a leak, may collect in low areas such as basements or floor drains. The gas may then ignite resulting in a fire or explosion.

CAUTION

Do not install this boiler on carpeting.

Figure 1-3

C. PRE-INSTALLATION REQUIREMENTS

Page 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 under-floor space or basement unless such location is provided with an approved means for removal of unburned gas.”

D. PRESSURE RELIEF VALVE

A pressure relief valve is installed into the right front side of the manifold. It is required that it meets the requirements of ANSI/ASME Boiler and Pressure Vessel Code, Section IV or CSA B51: Boiler Pressure Vessel and Piping Code as applicable for heating boilers. A ¾” pipe connected to the pressure relief valve must be directed to a floor drain or suitable location within 6” of a drain or floor. To protect the valve from freezing, do not plug or cap the pressure relief valve.

GENERAL INFORMATION

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 and must have a minimum of 24" clearance.

2. The left side of the heater is 12" clearance

3. The right side of the heater is 12" clearance

4. The top of the heater is 15" clearance.

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

Condensation removal: This is a condensing, high efficiency appliance, therefore

condensation removal must be addressed to avoid damage to surrounding area or appliance. See Part (4) for Condensate Requirements.

DANGER

Serious explosion causing property damage and/or loss of life could result. Under no circumstances should the relief valve be eliminated, capped or plugged.

Page 9

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 convenience, we have labeled all the wires that need to be connected to operate the Munchkin.

The 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 Amps.

There are two ground points in the electrical compartment that must be connected to the building ground system. Connect the building ground to the green ground screw and the green ground wire inside electrical box provided.

The Incoming power supply is connected to the Black (Hot) and the White (Neutral).The Munchkin Control board is polarity sensitive. If the polarity is reversed, the Munchkin control will not sense a flame and lock out the system.

It is important that the electrical power is not turned on at this time. Double check all connections and then turn the power on. The display that is provided with the Munchkin should now be reading the outlet temperature. Note: see Part 6/Startup Procedure section in the manual to change the temperature setting or run the heater.

DANGER

IT IS VERY IMPORTANT THAT THE BUILDING GROUND IS INSPECTED BY A QUALIFIED ELECTRICIAN PRIOR TO MAKING THIS CONNECTION!

DANGER

IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED!

Page 10

GAS CONNECTION

PART 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 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 plate. It is very important that you are connected to the type of gas as noted on the rating plate. “LP” for liquefied petroleum, propane gas or, “Nat” natural or city gas. All gas connections must be approved by the local gas supplier, or utility in addition to the governing authority, prior to turning the gas supply on. The nipple provided for the 399VWH is 1

4” with a mandatory 1 x 1

4 reducing coupling (provided). Threaded into the branch of

a 1

/4” tee and a drip leg fabricated as per the national fuel gas code. The 199VWH has a 3/4” gas supply

nipple with a

/2 x 3/4 reducing coupling (provided) which is to be threaded into the branch of a 3/4” tee.

You must ensure that the entire gas line to the connection at the Munchkin is no smaller than 1

4”

for the 399VWH and

4” for the 199VWH. Once all the inspections have been performed, the piping

must be leak tested. If the leak test requirement is a higher test pressure than the maximum inlet pressure, you must isolate the Munchkin from the gas line. In order to do this, you must shut the gas off using factory and field-installed gas cocks (following the lighting instructions in Part 6 Section B.) This will prevent high pressure. Failure to do so may damage the gas valve. In the event the gas valve is exposed to a pressure greater than

/2 PSI, 14” water column, the gas valve must be replaced. Never

use an open flame (match, lighter, etc.) to check gas connections.

B. GAS PIPING

1. Run the gas supply line in accordance with all applicable codes.

2. Locate and install manual shutoff valves in accordance with state and local requirements.

C. GAS TABLE

Refer to Table (1) to size the supply piping to minimize pressure drop between meter or regulator and unit.

Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0.5 psi or Less and a Pressure Drop of 0.3 Inch water Column

(TABLE 1) (Based on a 0.60 Specific Gravity Gas)

WARNING

Failure to follow all precautions could result in fire, explosion or death!

Nominal Iron Pipe Internal Length of Pipe (Feet) Size Diameter (inches) (inches) 10 20 30 40 50 60 70 80 90 100 125 150 175 200. 3/4 .824 278 190 152 130 115 105 96 90 84 79 72 64 59 55} BTU'S

1 1.049 520 350 285 245 215 195 180 170 160 150 130 120 110 100} PER 1 1/4 1.380 1,050 730 590 500 440 400 370 350 320 305 275 250 225 210} HOUR 1 1/2 1.610 1,600 1,100 890 760 670 610 560 530 490 460 410 380 350 320} X 1,000

Page 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 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 leg, by removing the cap and installing the manometer. The gas pressure must remain between 3.5" 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 properly purged by the gas supplier or utility. Failure to properly purge the lines or improper line sizing, will result in ignition failure. This problem is especially noticeable in NEW LP installations and

also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines. This gas valve must not be replaced with a conventional gas valve under any circumstances. As an additional safety feature, this gas valve has a flanged connection to the Venturi and blower.

WARNING

Failure to follow all precautions could result in fire, explosion or death!

Page 12

VENTING

PART 4. VENTING

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 designated Type 1, Grade 1.

2. CPVC (Chlorinated Polyvinyl Chloride) Class 23447-B, Formerly designated Type IV, Grade 1 conforming to ASTM D-1784.

3. ABS (Acrylonitrile-Butadiene-Styrene) Class 3-2-2-2-2 conforming to ASTM D3965.

The Munchkin is a direct vent appliance. The Munchkin is listed as a Category IV Condensing Appliance. (The Munchkin Venting is rated at Zero Clearance to combustibles.)

Note: For Concrete construction or to meet certain fire codes, exhaust and inlet piping at the wall penetration to the Munchkin must be CPVC Schedule 40 or 80 to meet local fire codes. The balance from the penetrated wall to the outside, may be PVC Schedule 40 or 80.

INTAKE VENT

Use the same material as used for exhaust. Plastic Pipe or Cellular Foam Core Pipe may be used for the inlet only, NEVER ON EXHAUST PIPING!

B. VENTING THE MUNCHKIN VWH IN 3”, 4” OR 6” PLASTIC PIPE

DANGER

Foam Core Pipe is not to be used in connecting the exhaust pipe.

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.

WARNING

This vent system will operate with a positive pressure in the vent pipe. Do not connect vent connectors serving appliances by natural draft into any portion of mechanical draft systems.

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.

Page 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 similar appliance. The joints must be properly cleaned, primed and cemented. The piping must also be properly supported as per Local and National Standard Plumbing Codes. It is important that the piping must be clean and free from burrs, debris, ragged ends and particles of PVC.

Exhaust piping should be sloped back to the connection on the Munchkin, at least ¼" per foot to remove additional condensate that forms within the pipe. The total combined length of pipe (intake piping plus exhaust piping added together) including elbow allowances for intake and exhaust (each elbow = 5' of pipe) should not exceed 85'. The combined vent length should not be less than a combined length of 6' plus two 90 degree elbows. Choose your vent termination locations carefully. You must also make certain that exhaust gas does not re-circulate back into the intake pipe. You must place them in an open area and follow the guidelines below.

1) Never vent into a walkway, patio area, alley or otherwise public area less than 7' from the ground. (See detail below references Fig. A.10.8 in the National Fuel Gas Code 2002 “Exit Terminals of Mechanical Draft and Direct-Venting Systems”.)

2) Never vent over or under a window or over a doorway where the exhaust plume or condensation liquid will cause obtrusive or dangerous conditions. (Or refer to National Fuel Gas Code, CAN B149)

3) Never install a heat saver or similar product to capture waste heat from exhaust.

4) Always have a vent location at least 1' above maximum snow level.

5) Always have vent 1' above ground level, away from shrubs and bushes.

6) Follow local gas codes in your region or refer to National Fuel Gas Code, Can B149.

7) Always have at least 3' from an inside corner of outside walls, including roof overhang.

8) Maintain at least 4’ clearance to electric, gas meters, windows, exhaust fans, chimneys, inlets or mechanical vents.

9) Very Important! The inlet air connection must be connected to outside air and should be located no closer than 8” to the exhaust and no further than 36”.

10) Always place screens in all openings in intake and exhaust to prevent foreign matter from entering the Munchkin.

11) The vent intake and exhaust must be properly cleaned and glued for a pressure tight joint. Several methods for venting the Munchkin can be found in Figures 4-1 thru 4-6 in this section. Use these layouts as guidelines: certain site conditions such as multiple roof lines/pitches 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’.

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.

Page 14

VENTING

RECOMMENDED VENTING CLEARANCES PER THE NATIONAL 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 Testing and Materials), and ANSI (American National Standards Institute). It is recommended that you use one of the optional vent kits specifically designed for Munchkin installations, available from Heat Transfer Products, Inc.

Example: Installation requires the following material for both inlet and exhaust piping for the Munchkin 199VWH and the 399VWH.

Required: 4 Pcs. 90 degree elbow (4 x 5 = 20 Equivalent Feet) = 20 Equivalent Feet

Required: 20' of 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

CAUTION

Flue Gas will condense as it exits the vent termination. This condensate can freeze on exterior building surfaces which may cause discoloration of these surfaces. Consideration should be given to the plume of condensation that exits the exhaust which may affect the cosmetic appearance of the building.

EXIT TERMINALS OF MECHANICAL DRAFT AND DIRECT-VENT VENTING SYSTEM

* REFERENCE: THE NATIONAL FUEL GAS CODE 2002 EDITION

*IMPORTANT NOTE

HEAT TRANSFER

PRODUCTS

RECOMMENDS A

MINIMUM CLEARANCE OF 4 FEET WHERE THE

PLUME CAUSED BY

THE UNIT MAY

OBSTRUCT VIEWS

OR AFFECT THE

COSMETIC LOOK OF

THE BUILDING.

NOTICE

Do not exceed the 125 foot maximum requirement for (intake plus exhaust piping added together). Consider fitting allowance shown in friction loss equivalent table on the following page.

echan

raft vent

d term (se

ical draft

echan

inal

inim

12 in.minimum

Direct vent terminal clearance Minimum clearance, C

Input (Btu/hr) 10,000 or less 10,001 to 50,000

Over 50,000 (see 10.8.3)*

For SI units: 1 ft = 0.305 m; 1 in. = 25.4 mm; 1 Btu/hr = 0.293 W

Clearance (in.)

4 ft.m

4 ft.

minimum

12 in.minimum

6 9

12 in.m

vent term (see 10.8

inim

.2)*

than 10 ft.

3 ft.minim

Fo inlet

rad

rced air

e 10

ica

.8.1)*

Page 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 transitioning 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 not exceed 125 equivalent feet. Listed below are the 3”, 4” and 6” size equivalent table.

Example: Installation requires the following material for both the inlet and exhaust piping when extending the vent run for the Munchkin 199VWH.

3" Vented Appliance

2 Pcs. – 3" 90 degree elbow (2 x 5 = 10 Equivalent Feet) = 10 Equivalent Feet 20' of 3" Plastic PVC Pipe (20 x 1 = 20 Equivalent Feet) = 20 Equivalent Feet

Total of 3" Equivalent Piping with Fittings = 30 Equivalent Feet

Requirements for 4" Venting

6 Pcs. – 4" 90 degree elbows (6 x 3 = 18 Equivalent Feet) = 18 Equivalent Feet 4 Pcs. – 4" 45 degree elbows (4 x 1 = 4 Equivalent Feet) = 4 Equivalent Feet 40' of 4" Plastic PVC Pipe (40 x 1 = 40 Equivalent Feet) = 40 Equivalent Feet

Total of 4" Equivalent Piping with Fittings = 62 Equivalent Feet

Total Friction Loss in Equivalent Feet for both 3" and 4" (30 + 62 = 92 Equivalent Feet) = 92 Equivalent Feet

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 appliance 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, corrosion or other deficiencies that could cause an unsafe condition.

DANGER

The Munchkin is not intended to be common vented with any other

existing appliance!

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 vent kit = 0

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.

Page 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. 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. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette.

6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code , ANSI Z 223.1

E. CONDENSATE REMOVAL

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 available from Heat Transfer Products, Inc.) A condensate filter, if required by local authorities, can be made up of lime crystals, marble or phosphate chips will neutralize the condensate. This can be done in the field by the installer or you may purchase one from Heat Transfer Products, Inc. It is also very important that the condensate line is not exposed to freezing temperatures, or any other type of blockage. Plastic tubing should be the only material used for the condensate line. Steel, brass, copper or others will be subject to corrosion or deterioration. A second vent may be necessary to prevent condensate line vacuum lock if a long horizontal run is used. An increase to 1” tubing may be necessary.

Page 17

VENTING

Figure 4-1: Sidewall Vent with Tee (Intake) &

Coupling (Exhaust) for standard floor units

3” piping for 199VWH 4” piping for 399VWH

**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 boiler (to allow drainage of condensate). Always increase pipe in vertical position. Never increase pipe size in horizontal position.

Figure 4-2: Sidewall Vent with Tee (Intake) &

Coupling (Exhaust) for standard floor units

3” piping for 199VWH 4” piping for 399VWH

Figure 4-3: Sidewall Vent with V1000 or V2000 kit

for standard floor units

3” piping for 199VWH 4” piping for 399VWH

DIAGRAMS FOR SIDEWALL VENTING

Figure 4-4: Sidewall Vent with 3” concentric vent

kit (KGAVT0601CVT) for standard floor units

3” piping for 199VWH

Page 18

VENTING

DIAGRAMS FOR VERTICAL VENTING

Figure 4-5: Roof Vent with tee (intake) & coupling

(exhaust) for standard floor units

3” piping for 199VWH 4” piping for 399VWH

Figure 4-6: Roof Vent with 3” concentric vent kit

(KGAVT0601CVT) for standard floor units

3” piping for 199VWH

Page 19

PIPING

PART 5. PIPING THE MUNCHKIN VWH TO THE STORAGE TANK

The Munchkin is designed to be connected to a storage tank to supply domestic hot water. Heat Transfer 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 directly connected to the Munchkin VWH supply and return connection. Connect the cold water supply to both the storage bottom port and the supply side of the Munchkin VWH (shown in Piping details, this section) It is important that you install a flow check on the supply line of Munchkin VWH before you connect feed line to the storage. This will allow the cold feed to flow through the storage tank first and not the Munchkin VWH. It is recommended that you install shut off valves on the cold feed line for ease of future service. If there is a back flow preventer, or any type of no return valve in the system, then you must install an additional tee for a suitable potable hot water expansion tank. Connect the Storage tank return line to the return connection located on the Munchkin VWH (shown in Piping details, this section). Then connect your hot water outlet located on the storage tank to your hot water plumbing lines.

A. EXPANSION TANK

A potable hot water expansion tank my be required to offset the water expansion as the water is heated. In most city plumbing systems, the water meter has a no return or back flow device built into the system to prevent a back flow of water back into city mains. Some states require back flow preventers on all incoming water supplies. Under these circumstances, you will need a hot water expansion tank listed for potable water use. The expansion tank should be located on the cold inlet piping close to the water heater. It is important that you follow the expansion tank manufacturer’s installation guidelines when installing any expansion tank.

See the piping illustrations included in this section, Figs. 5-2 to 5-9 for suggested guidelines in piping the Munchkin heater with either zone valves or circulator pumps. *Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

B. HIGH VELOCITY CIRCULATOR PUMP

Every Munchkin VWH is shipped with a high velocity circulating pump to assure the correct amount of continuous flow through the all stainless steel heat exchanger at all times. If a replacement of the high velocity circulator pump is needed, it must match the performance of the pump provided with the Munchkin VWH package. NOTE: The circulator must be designed for potable water systems.

WARNING

Plumbing of this product should only be done by a qualified, licensed plumber in accordance with all local plumbing codes.

WARNING

NEVER USE DIELECTRIC UNIONS OR GALVANIZED STEEL FITTINGS WHEN CONNECTING TO A STAINLESS STEEL 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.

Page 20

PIPING

C. CIRCULATOR SIZING

The Munchkin VWH Heat Exchanger has a pressure drop which must be considered in your system design. Refer to the graph below for pressure drop through the Munchkin VWH Heat Exchanger.

*The recommended circulators are based on 1 gpm per 10,000 BTU/hr w/20

Friction in Feet of Head

5 10152025303537.540

Flow in Gallons per Minute

MUNCHKIN 399VWH MUNCHKIN 199 VWH

Circulator Sizing Chart

BOILER TACO P/N GRUNDFOS P/N Bell & Gosset t

199M 0011 26-96 PL-36 399M 1400-60 UPS 32-160 PL-55

Page 21

PIPING

PIPING ILLUSTRATIONS

Fig. 5-1

Piping Symbol Legend

circulator (open loop) (w/ isolation flanges)

flow switch

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)

temperature / pressure gauge

T/P

union

vacuum breaker

Superstor Ultra

Storage Tank

Munchkin heater

Page 22

PIPING

Fig. 5-2

Volume Water Heating using Munchkin boiler (1 boiler supplying one storage tank)

ASEE 1017 rated anti-scald valve

(recommended)

vacuum breaker

(where required by code)

hot water supply

cold water

recirculation line

Drawing VWH 1/1

constant

circulation

flow switch

Superstor Ultra

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 circulators

3. Boiler circulator(s) operate continuously

4. The minimum pipe size for connecting to a water storage tank is 1 inch.

5. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

6. All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.

7. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves.

8. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

expansion

tank

condensate

drainage

Page 23

PIPING

Fig. 5-3

Volume Water Heating using Munchkin boiler (1 boiler supplying two storage tanks)

ASEE 1017 rated anti-scald valve

(where required by code)

(recommended)

vacuum breaker

hot water supply

recirculation line

Drawing VWH 1/2

cold water

constant

circulation

expansion

tank

Superstor Ultra

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. Boiler circulator must be rated for open loop application. Do not use cast-iron circulators

2. Boiler circulator(s) operate continuously

4. The minimum pipe size for connecting to a water storage tank is 1 inch.

5. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

6. All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves.

7. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

Superstor Ultra

Storage Tank

flow switch

condensate

drainage

Page 24

PIPING

Fig. 5-4

Volume Water Heating using Munchkin boiler (2 boilers supplying one storage tank)

ASEE 1017 rated anti-scald valve

(recommended)

vacuum breaker

(where required by code)

hot water supply

cold water

recirculation line

constant

circulation

Drawing VWH 2/1 H

constant

circulation

flow switch

Superstor Ultra

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 circulators

3. Boiler circulator(s) operate continuously The minimum pipe size for connecting to a water storage tank is 1 inch.

4. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

5. All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges

6. with full port ball valves and a separate flow check valve. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves.

8. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

expansion

tank

Munchkin 1

Munchkin 2

condensate

drainage

Page 25

PIPING

Fig. 5-5

Volume Water Heating using Munchkin boiler (2 boilers supplying one storage tank)

ASEE 1017 rated anti-scald valve

(recommended)

vacuum breaker

(where required by code)

hot water supply

cold water

recirculation line

constant

circulation

flow switch

Drawing VWH 2/1 V

Munchkin 1

constant

circulation

flow switch

Superstor Ultra

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 circulators

3. Boiler circulator(s) operate continuously

4. The minimum pipe size for connecting to a water storage tank is 1 inch.

5. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

6. All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.

7. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves.

8. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

expansion

tank

Munchkin 2

condensate

drainage

Page 26

PIPING

Fig. 5-6

Volume Water Heating using Munchkin boilers (2 boilers supplying two storage tanks)

ASEE 1017 rated anti-scald valve

(where required by code)

(recommended)

vacuum breaker

hot water supply

cold water

recirculation line

Drawing VWH2/2 H

constant

circulation

constant

circulation

expansion

tank

Superstor Ultra

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 circulators Boiler circulator(s) operate continuously

3. The minimum pipe size for connecting to a water storage tank is 1 inch.

4. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

7. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

Superstor Ultra

StorageTank

flow

switch

Munchkin 1

flow

switch

Munchkin 2

condensate

drainage

Page 27

PIPING

Fig. 5-7

Volume Water Heating using Munchkin boilers (2 boilers supplying two storage tanks)

ASEE 1017 rated anti-scald valve

(recommended)

vacuum breaker

(where required by code)

hot water supply

cold water

recirculation line

Drawing VWH2/2 V

constant

circulation

flow switch

Munchkin 1

constant

circulation

expansion

tank

Superstor Ultra

Storage Tank

NOTES:

This drawing is meant to show system piping concept only.

1. 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 circulators

3. Boiler circulator(s) operate continuously The minimum pipe size for connecting to a water storage tank is 1 inch.

4. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

6. All pumps are shown with isolation flanges or full port ball valves for isolation. The alternative is standard flanges with full port ball valves and a separate flow check valve.

7. Install a minimum of 12 diameters of straight pipe upstream of all circulators and check valves. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

Superstor Ultra

Storage Tank

flow switch

Munchkin 2

condensate

drainage

Page 28

PIPING

Fig. 5-8

Volume Water Heating

Drawing VWH 3/2 H

using Munchkin boiler (3 boilers supplying two storage tanks)

ASEE 1017 rated anti-scald valve

(where required by code)

(recommended)

vacuum breaker

hot water supply

cold water

recirculation line

constant

circulation

constant

circulation

expansion

Superstor Ultra

Storage Tank

Superstor Ultra

Storage Tank

tank

flow

switch

Munchkin 1

flow

switch

Munchkin 2

switch

NOTES:

This drawing is meant to show system piping concept only.

1. 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 circulators

3. Boiler circulator(s) operate continuously The minimum pipe size for connecting to a water storage tank is 1 inch.

4. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

7. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

flow

Munchkin 3

condensate

drainage

Page 29

2929

PIPING

Fig. 5-9

Volume Water Heating using Munchkin boiler (3 boilers supplying two storage tanks)

ASEE 1017 rated anti-scald valve

(recommended)

vacuum breaker

(where required by code)

hot water supply

cold water

recirculation line

Drawing VWH 3/2 V

constant

circulation

flow switch

Munchkin 1

constant

circulation

flow switch

Munchkin 2

constant

circulation

expansion

tank

Superstor Ultra

Storage Tank

NOTES:

This drawing is meant to show system piping concept only.

1. Installer is responsible for all equipment & detailing required by local codes. Boiler circulator must be rated for open loop application. Do not use cast-iron circulators

3. Boiler circulator(s) operate continuously

4. The minimum pipe size for connecting to a water storage tank is 1 inch.

5. The minimum pipe size for connecting a Munchkin boiler is 1.25 inches for 199 VWH, and 2-inches for 399 VWH

7. Install vacuum relief valve in accordance with local code requirements

9. All multiple boilers and multiple storage tanks shall be installed with reverse return piping as shown

10. Anti-scald rated mixing valve is recommended on all tanks if the leaving hot water temperature from tank is above 119 ˚F.

11. Expansion tank must be rated for use with potable water

Superstor Ultra

Storage Tank

flow switch

Munchkin 3

condensate

drainage

Page 30

START-UP PROCEDURES

PART 6. START-UP PROCEDURES

A. SEQUENCE OF OPERATION

1. When power is first applied to the control, the control display will read the outlet temperature. The control will initially run through a self-diagnostic routine and then go into its operating mode. If there is no call for heat, the System will go into an idle state. The circulator must be wired to incoming power to operate continuously. If there is a code FL in the display window, then either the circulator is not operating or there is a restriction in the piping system, rendering an inadequate flow.

2. The control then performs selected system diagnostic checks. If all checks are successfully passed, a pre-purge cycle is initiated (the blower will be on maximum speed).

3. When the actual temperature is below a set-point, minus the switching differential, the burner will operate and modulate to heat the system.

4. When the pre-purge period is complete, power is applied to the spark ignitor for approximately 6 seconds. Approximately 2 seconds later, we verify flame. If a flame is not verified during the trial-for-ignition, the gas valve is immediately closed and the control will return to step 2. After three trials, if a flame is not verified, the control will go into a lockout mode. If a flame is confirmed, the control enters the heating mode. The fire rate will be based on the proprietary algorithm.

5. When water temperature reaches the temperature set point, the gas valve is closed and the control enters a post-purge state (the blower will be on maximum speed).

6. When the post-purge is complete, the control enters an idle state while continuing to monitor temperature and the state of other system devices. If a call-for-heat is received, the control will automatically return to step 2 in sequence and repeat the entire operating cycle.

B. ITEMS TO BE CHECKED BEFORE LIGHTING THE MUNCHKIN

It is recommended that you read the General Information Section (Part 1) to get a better understanding how the Munchkin operates before you start the unit.

1. Make sure that you follow the Lighting instruction before running the Munchkin.

2. Check to see if all the electrical connections are on securely.

3. Make sure that the Gas is turned on inside the cabinet and outside of the Munchkin.

4. Double check the temperature setting (Note: The Munchkin is factory set at 119 degrees)

5. Make sure the unit is properly grounded and the electrical wiring meets the requirements of the electrical section (Part 2).

6. Turn on the power to the Munchkin. The Temperature of the Munchkin Outlet will appear in the display provided. If a fault code appears, correct the fault before operating. Make sure that the flow switch is connected and adjust the setpoint for the desired water temperature. The Munchkin will now run its pre-purge cycle, then begin running, which will be indicated by the Green light illuminating under “Flame On” in your display.

WARNING

If you do not follow these instructions exactly, a fire or explosion may

result, causing property damage, personal injury or loss of life.

Page 31

C. LIGHTING INSTRUCTIONS

FOR YOUR OWN SAFETY READ BEFORE OPERATING

1. This appliance does not have pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

2. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas suppliers'

instructions.

• If you cannot reach your gas supplier, call the fire department.

3. Turn on gas shutoff valve (located inside of the Heater) so that the handle is aligned with the gas pipe. If the handle will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

4. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

5. The Munchkin Heater shall be installed so the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.)

D. OPERATING INSTRUCTIONS

1. STOP! Read the safety information in Part 6.

2. Turn off all electric power to the appliance.

3. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

4. Remove front cover.

5. Turn gas shutoff valve to “off” position.

6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow Part 6, Section B/Lighting Instructions in the safety information. If you don't smell gas, go to the next step.

7. Turn the gas shutoff valve to “on” position.

8. Replace the Front Cover.

9. Turn on all electric power to appliance.

10. Set the temperature to the desired setting.

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

E. ADJUSTING THE OPERATING SET POINTS OF THE MUNCHKIN VWH DISPLAY

To adjust a set point value on the Munchkin VWH, Simply press the S3/Program key for three seconds until you see dd then an alternating value of 119° F. This will be your first function. To advance to the next function, simply press the S3/program (see set point adjustment chart on next page). Any function setting may be changed by pressing either the S1/- or the S2/+ key on the display. After advancing through the function, press the S3/Program key, this will bring you back to normal operation, displaying the output temperature of the Munchkin VWH.

START-UP PROCEDURES

Page 32

F. STATUS 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 temperature. Actual values are displayed for each function. To view the next value simply press the S/4 key to go to the next displayed value. Listed below are the values which can be displayed. These values cannot be changed. To exit this menu, simply press S3/Program key to resume normal operation.

Function Value

d1/ Actual Temperature from outlet sensor d2/ Actual Temperature from inlet sensor d3/ N/A d4/ N/A d5/ N/A d6/ Actual Fan speed multiplied by 10 (example: If fan speed displayed is

410 RPM x 10 = 4100 actual fan speed) d7/ Actual Ionization current read from Flame Rectification probe d8/ N/A d9/ N/A d10/ N/A d11/ N/A d12/ power on in 1,000 units 100 hrs = 0.1 / 1,000 hrs = 1.0

3,000 hrs = 3.0 d13/ N/A d14/ Total Running Hours in 1,000 units d15/ Total number of ignition cycles in 1,000 units.

G. TEST MODE

This function is intended to simplify the gas valve adjustment if needed. Listed below are the recommended limits on each Munchkin Heater and the Combustion Settings. Automatic modulation does not take place when the controller is in Test mode, only temperature limitation based on the Munchkin Central Heating set point. The user will be allowed to increase or decrease the fan speed by pressing in either the S1/- or S2/+ keys.

To activate the Test mode simply press the S2/+ and S3/Program key together for 1 second. Once activated, you will see in the display Ser and the actual fan speed. The measurement of the combustion levels should always be taken at the highest and lowest fan speed. After 10 minutes, the Test mode stops automatically. To exit Test Mode press S1/- and S2/+ key together for 1 second.

START-UP PROCEDURES

DANGER

Water temperature over 125 degrees F. can cause severe burns instantly, or death from scalds. Children, disabled, and elderly are at highest risk of being scalded. See instruction manual before setting temperature at water heater. Feel water before bathing or showering! Temperature limiting valves are available.

Set Point Adjustment

Function Display Default Setting Range of Adjustment

Temperature Set Point dd 119° F 95° F/185° F

Differential Set Point dh 8° F 1–18° F Temp. Measurement t Fahrenheit to Celcius F or C

Page 33

START-UP PROCEDURES

H. TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove the front cover.

4. Turn gas shutoff valve to "off".

5. Install front cover.

Fig. 6-1

DANGER

SGNITTESNOITSUBMOCHWV993/HWV991—

saGlarutaNPLenaporP

wolhgihwolhgih

mppOCnobraC

edixonoM

OCnobraC

edixoiD

mpp02–0mpp531–mpp07mpp02–0mpp051–07

%2/1-9–%2/1-8%2/1-9–%2/1-8%2/1-01–%2/1-9%2/1-01–%2/1-9

SLEDOMLLANOSETARGNIRIFWOLdnaSETARGNIRIFHGIH

Page 34

MUNCHKIN 199VWH GAS VALVE

MUNCHKIN 399VWH GAS VALVE

START-UP PROCEDURES

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 GAS SUPPLY. THIS ADJUSTMENT COULD AFFECT CO/CO% LEVELS. MAKE SURE THE LEVELS CORRESPOND TO THE CHART IN COMBUSTION SETTINGS.)

Fig. 6-2

Page 35

TROUBLESHOOTING

CAUTION

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. Verify proper operation after servicing.

CAUTION

If overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve.

Table 7-1: 925 Control Board Error Codes

WARNING

When servicing or replacing any components of this boiler be certain that:

• The gas is off.

• All electrical power is disconnected

WARNING

Do not use this appliance if any part has been under water. Improper or dangerous operation may result. Contact a qualified service technician immediately to inspect the boiler and to repair or replace any part of the boiler which has been under water.

DANGER

When servicing or replacing that are in direct contact with the boiler water, be certain that:

• There is no pressure in the boiler. (Pull the release on the relief valve. Do not depend on the pressure gauge reading).

• The boiler water is not hot

• The electrical power is off

A. MUNCHKIN ERROR CODE

An error code may occur in the installation of the Munchkin VWH. This condition may lead to a lock out condition of the controller, which will need to be manually reset through the S4/Reset button. These temporary codes will help the installer correct the problem before going into a lock out condition, which will require a manual reset.

B. BOILER ERROR

1. When an error condition occurs the controller will display an error code on the display module.

2. These error codes and several suggested corrective actions are included in Table 7.1.

3. In the case of E00, E13, and E14 this error, if uncorrected, will go into a fault condition as described is Paragraph C (Boiler Fault).

C. BOILER FAULT

1. When a fault condition occurs the controller will illuminate the red “fault” indication light and display a fault code in the format (Example: F00 ) on the display module.

2. Note the fault code and refer to Table 7.2 for an explanation of the fault code along with several suggestions for corrective actions.

3. Press the reset key to clear the fault and resume operation. Be sure to observe the operation of the unit to prevent a recurrence of the fault.

PART 7. TROUBLESHOOTING

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00E

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Page 36

TROUBLESHOOTING

Table 7-2: 925 Control Board FAULT Codes

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.1 .2

00F

10F

20F

30F

50F

60F

90F

01F

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11F

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81F

03F

13F

23F

33F

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Page 37

TROUBLESHOOTING

RESISTANCE TABLES

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

Page 38

MAINTENANCE

PART 8. MAINTENANCE

A. MAINTENANCE PROCEDURES

Periodic 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 also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition. The installer should discuss the contents of the User's Information Manual with the owner.

B. ANNUAL MAINTENANCE

A trained and qualified service technician should perform the inspections listed below at least once a year.

• Heater – check the heater for dust or foreign materials, which may have been drawn in from the air intake of the heater. Simply blow out or wipe down with a dry rag.

• Vent Termination – check to remove any obstructions, such as leaves, bushes, or other sources which may interfere with the units ability to draw fresh air on the air intake or exhaust flue gas from the exhaust outlet.

• Vent Piping – make sure that all vent piping is in good condition. Check Joints for possible leaks.

• Condensate – check the Condensate trap by simply starting the unit and observing the flow of Condensate which should not be restricted in any fashion. (See instructions below.)

• Heat Exchanger – in the unlikely event the heater flue passage is becoming blocked, service must be performed only by an authorized Heat Transfer Products Representative or Certified Installing Contractor. (See coil cleaning instructions Section D)

• Burner – check burner for deterioration. If deterioration is observed, replace burner.

• System Water / Pressure – check pressure regulator and system pressure. Check system for air which will create noise. Open air vents or purge system to bleed air then close once air is fully purged from the system.

• Water Piping – check for and repair any leaks.

• Gas Piping – check for and repair any leaks.

C. CONDENSATE CLEANING INSTRUCTIONS

1. Turn down the temperature setpoint dd so the Munchkin will not cycle and then follow the steps

below.

a. Close gas valve b. Disconnect the condensate hose from the outside connection (not from the Munchkin) so

flow can be observed. c. Block the air flow in the exhaust by temporarily plugging the exhaust from the outside vent. d. Turn up the temperature set point dd so the Munchkin VWH will begin to cycle. This will

cause the fan to run at 100% which will then blow out any sediment that has accumulated in

the condensate line. This process should only take a few minutes. e. The unit should now be ready to re-start.

2. Before re

-starting the Munchkin follow the steps below:

a. Reconnect the Molex connection and un-block the vent (IMPORTANT: MAKE SURE

EXHAUST VENT IS NO LONGER BLOCKED!)

b. Open the gas valve. c. Hit System Reset and increase the temperature to assure that the VWH will operate. d. Observe the boiler function to make sure you see a condensate flow. e. If you do not observe a condensate flow, repeat the above procedure.

3. If the problem is not corrected at this point, it is possible you have a material deposit problem,

Page 39

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, stainless or brass brush (not steel) – “Rydlyme” (recommended for best results) (available on line www.rydlyme.com) or “CLR”

(available at most hardware stores)

1. Shut down the Munchkin by using the following steps: a. Close the gas valve, shut down the unit and wait for the unit to be cool to the touch b. Disconnect the condensate hose from the outside connection, (not from the Munchkin side),

so the flow can be observed. c. Remove screws and loosen bracket holding gas valve in place. d. Pull connector to the venturi by sliding gas valve to left, remembering to disconnect both

Molex connectors. e. Remove the (6) 10MM nuts from the burner plate assembly to access the coils. f. Pull the entire burner plate assembly towards you, while removing or pushing aside any

wiring to allow the removal of the assembly.

2. Using a spray bottle filled with the recommeded product “RYDLYME” or “CLR”, spray liberally on the coils, making sure the solution penetrates and funnels down through the condensate hose. If the condensate hose is blocked, let the chemical penetrate for at least 15 minutes or until it drains.

3. Use the nylon, stainless or brass brush (do not use steel) and scrub coils to remove any buildup, then vacuum the debris from the coils.

4. Spray the coils with clear water, making sure to confine the spray to the area being cleaned (Try to avoid getting the back cermic wall of the unit wet). Flush the combustion chamber with fresh water. At this point, the Munchkin should be ready to power back up.

Before powering up the Munchkin follow the steps below

a. Re-install the burner assembly b. Replace the (6) 10MM nuts to the burner plate c. Re-connect the Molex connectors d. Re-connect gas valve, air-gas mixer and replace bracket. (IMPORTANT: CHECK FOR GAS

LEAKS)

e. Re-set thermostats (IMPORTANT: MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED!) f. Turn the Munchkin back on** and observe condensate flow. g. Re-connect the condensate hose to the outside connection.

**NOTE: When firing up the boiler for the first few times you may experience some fluttering of the gas burner that may result in a flame lockout. This is normal and will require you to re-cycle the unit until this clears up. This is caused by water still present in the combustion chamber.

DANGER

IT IS EXTREMELY IMPORTANT TO MAKE SURE THE EXHAUST VENT IS NO LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH.

DANGER

IT IS EXTREMELY IMPORTANT THAT YOU CHECK FOR LEAKS WHEN RECONNECTING THE GAS VALVE AND MAKING SURE THE EXHAUST VENT IS NO LONGER BLOCKED. FAILURE TO DO SO MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.

Page 40