munchkin install manual pre 925
Contents
1. 16 AN WARNINGS CAUTIONS 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 7223 1 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 BOILERS ANSI ASME BOILER AND PRESSURE VESSEL CODE Section IV THE HEATER GAS PIPING WATER PIPING VENTING AND ELECTRICAL MUST BE INSTALLED BY TRAINED amp QUALIFIED PERSONNEL FAMILIAR WITH INSTALLATION PRACTICES AND LOCAL CODE AND 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 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 neighbors phone Follow the gas suppliers 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 PART 1 GENERAL INFORMATION 12. 2 PART 3 3 5 areae ERES 3 3 E E ie 3 3 GAS TABLE 3 4 VENTING 4 A ALL MODELS 3 4 4 FOR LONGER 65 2 22222 5 4 VENTING 5 6 4 D 6 CONDENSATE 2 6 VENTING 22 7 5 5 A HYDRONIC HEAT 220000 8 5 B FILL AND PURGE HEATING 5 5 222222 8 PART 6 BOILER START UP 6 A COMMON VENT TEST 9 6 B ITEMS TO BE CHECKED BEFORE LIGHTING THE 10 6 LIGHTING 5 11 PART 7 SERVICING 7 A SEQUENCE OF OPERATION 2 240242222 12 12 7 B ADJUSTMENT SET POINTS AND DIFFERENTIAL 5 58 2 2 12 7 MUNCHKIN BOILER FAULT LED 13 7 D FAULT 8 2220 13 14 PART 8 8 A MAINTENANCE PROCEDURES 15 8 B BEFORE EACH HEATING SEASON 15 8 COMPONENT
3. 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 Heat Exchanger in the unlikely event boiler flue passage is becoming blocked service must be performed only by an authorized Heat Transfer Products Representative or Certified Installing Contractor Burner check burner for deterioration If deterioration is observed change burner System Water Pressure check pressure regulator and system pressure Check system for air which will create noise Open air vents to bleed air than 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 15 670 4042 4141123 0 4042 W661 0 40 2 1 270 4052 W08 1 850 4042 100412313 JYYdS 680 40524 3384930 OIZ 610 4042 11 5 dW3L SIQOWYIHL 510 40 2 W661 10 4052 WOT 600 4052 w08 220 4052 1 7 780 4042 W661 980 d0SZZ WOT 580 4052 W08 3 018 mal l 610 d0SZZ 1 0237 080 d0SZZ JAIWAd 81 Lv1 d0SZZ 11 5 34055384 XIV 180 4042 HOLIMS 380553844 YILYM 7 650 40 42 YOLSIWYSHL HOLIMS 1 21 12313 7 8 0 d0SZZ 3 5
4. marble crystals which will neutralize the condensate The outlet of the filter is sized for 5 8 ID Inside diameter plastic tubing 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 A condensate filter and a condensate pump kit are available from HTP 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 and deterioration A second vent may be necessary to prevent condensate line vacuum lock if a long horizontal run is used Also an increase to 1 tubing may be necessary VENTING DIAGRAMS 4 EXTERIOR WALL MUNCHKIN BOILER e 8 8 g snari 5 COUPLING b MUNCHKIN BOILER INTAKE L COUPUNG FRONT ELEVATION VENTS 12 GROUND LEVEL STRAIGHT aa Pe i 3 SIDEWALL VENT WITH TEE INTAKE amp COUPLING EXHAUST doto FIGURE 2 vev LEVEL wIMPORTANT NOTE ALL VENT PIPES MUST BE GLUED PROPERLY 3 SIDEWALL VENT WITH TEE INTAKE amp COUPLING EXHAUST SUPPORTED AND THE EXHAUST MUST BE PITCHED A MINIMUM OF 1 4 PER FOOT BACK TO THE BOILER TO ALLOW DRAI
5. HOW IT OPERATES When the room thermostat calls for heat the Munchkin control board will start the pump 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 boiler will start to heat the water This eliminates the Munchkin starting every time the thermostat calls for heat This feature keeps the system from short cycling Once the system has sensed the temperature difference the Munchkin will activate the blower motor for 5 seconds to pre purge the system before starting the Munchkin The Munchkin controller will now start to modulate the pre mix burner based on analyzing the turn temperature supply water temperature and the set point temperature 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 fans have a low voltage direct current drive motor with a pulse relay counting This system allows precise control over the fan speed and combustion air volumes Coupled with the Honeywell gas valve and the Venturi 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 running at the highest efficiency When the thermostat is satisfied the
6. Schedule 40 pipe plus 90 degree or two 45 degree elbows and for the exhaust 10 of PVC Schedule 40 pipe NOT FOAM CORE or CPVC plus one 90 degree or two 45 degree elbows Use a 4 x 3 PVC reducing coupling Then proceed with PVC 4 NOT FOAM CORE pipe and fittings for both the intake and exhaust piping On 4 piping you may go an additional 125 equivalent feet of pipe and fittings for a combined total length The 4 fittings have a friction loss allowance as follows 4 90 degree 3 and a 4 45 degree The total maximum venting length can be 125 plus the first 10 of each 3 and a maximum fitting allowance of the 3 total two 90 degree or four 45 degree before increasing to 4 Total equivalent would be 30 of 3 plus 125 of 4 Never use different pipe sizes for intake and exhaust The vent system must be balanced by a friction loss equivalent NOTE THE METHODS DESCRIBED ARE SUGGESTED GENERIC METHODS ONLY SPECIFIC JOB SITE OBSERVATIONS AND SIZING MAY REQUIRE ALTERNATE INSTALLATION METHODS CONSULT THE FACTORY WITH SPECIFIC JOB REQUIREMENTS FOR ADDITIONAL RECOMMENDATIONS 4 VENTING TABLE Note Do not exceed the total combined length of pipe intake piping plus exhaust piping added together including fitting allowances shown below should not exceed 85 The table shows the friction loss for plastic pipe and fitting in 3 and 4 sizes FRICTION LOSS EQUIVALENCE TABLE JOB EXAMPLE Note this example totals
7. for ambient temperature to rise or apply heat to the unit If the temperature probe is in an environment of more than 230 F then wait for the temperature to lower below 200 F Air Pressure Switch Fault Stuck Closed 7 PULSES e Ifthe control senses the blower pressure switch is closed when it is expected to be open the control will wait approximately 90 seconds for the fault condition to clear If after approximately 90 seconds the control still senses the blower pressure switch is closed the control will go into the lockout state Verify that the blower motor is operational and that the 120 VAC power cable is connected to the blower Check that the wires are connected to the blower air pressure switch and that the are pressure switch is functional This may require turning the screw in the center of the air pressure switch 1 turn clockwise to correct Initial set up only After any air pressure switch adjustment you must cycle the appliance several times to insure proper operation Air Pressure Switch Fault Stuck Open 8 PULSES Ifthe control senses the blower pressure switch is not closed during the pre purge cycle the control will attempt two additional pre purge trials If after three pre purge trials the control is still sensing the blower pressure switch is not closing the control will enter the lockout state Check that the blower motor is off and verify that the blower air pressure switch is functional This may require turning th
8. with a floor drain or installed in a suitable drain pan Proper clearance must be provided around the Munchkin as follows Sides bottom top and back are 0 zero clearance Venting is also zero clearance The front of the appliance needs 24 of clearance for service minimum It must have a non rated or combustible door or access panel and should have a minumum clearance of 24 front 15 top 6 right side and 10 to the left side Under no circumstances shall Heat Transfer Products Inc be held liable for any such water damage whatsoever This heater must not be located near flammable liquids such as gasoline adhesives solvents paint thinners butane liquefied propane etc the controls of this appliance could ignite those vapors causing an explosion 1 PRESSURE RELIEF VALVE A pressure relief valve is installed into the front right side manifold we recommend a WATTS 335 MI valve or equivalent and meets the requirements of ANSI ASME Section IV for heating boilers A pipe must be directed to a floor drain or suitable location within 6 of drain or floor Protect from freezing do not plug or cap pressure relief valve Serious explosion causing property damage and or loss of life could result Under no circumstances should the relief valve be eliminated capped or plugged PART 2 SERVICING WARNING CAUTION Before servicing let the munchkin cool down Shut off electrical and gas supply Failure to follow warning could res
9. 97 KN SLNANOdWOD LP 61 Rev 5 01 02
10. ATING 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 C Turn on gas shutoff valve located on the top of the Boiler 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 D 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 OPERATING INSTRUCTIONS 1 STOP Read the safety information above 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Remove front cover 6 Turn gas shutoff valve clockwise to off Handle will be vertical do not force 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow Section B in 6 C Li
11. E please check manufacturers instructions prior to opening valves manually so not to damage valve Manually operate fill valve regulator When the water runs out of the hose while it s connected to the balance and purge valve you will see a steady stream with no air bubbles Close balance and purge valve to stop the water from flowing Disconnect hose and connect to next zone to be purged Repeat procedure for additional zones one at a time Upon completion make sure that the fill valve is in automatic position and each zone balance purge valve is in the open position and zone valves are positioned for automatic operation Were NOTE For installation that incorporates Standing Iron Radiation and systems manual vents high points Follow the Section 5 B procedure then starting with the nearest manual air vent open vent until water flows out then close vent Repeat procedure working your way toward furthest air vent It may be necessary to install basket strainer in an older hydronic system where larger amounts of sediment may be present Annual cleaning of the strainer may be necessary SUGGESTED HYDRONIC PIPING FOR MUNCHKIN BOILER FIGURE 7A SYSTEM O PURGE amp BALANCE VALVE SUPPLY PUMP Rice cee Basics SUPPLY BACK FLOW PREVENTER t ie RETURN L EMERG
12. ENCY LOW PRESSURE FEED 15 LB NOMINAL f T EES EXPANSION TANK COLD IN MUNCHKIN BOILER VENT Mirco bubbler Air QF KERT SIDE VIEW Eliminator Recommended AMAL ST FLOW CHECK SUPPORT DRAIN VALVE Ona apie z TEMPERATURE 8 PRESSURE GAGE 17 4 UNION BACK FRONT SUPPLIED BY CONTRACTOR CONNECT BOILER SUPPLY HOT CONNECT TQ BOILER RETURN COLD ALL PIPES MUST BE PROPERLY SUPPORTED NOTE BOILER CONNECTIONS ALL PIPES MUST BE PROPERLY SUPPORTED ARE 1 1 4 NPT FIGURE 7B 21 20 F 19 R 18 17 16 15 N 44 13 N 12 F 11 10 9 8 7 6 5 3 2 1 123 45 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 FLOW IN GALLONS PER MINUTE TACO P N GRUNOFOS P N MUNCHKIN 80M 0074 15 42 F SPD 2 MUNCHKIN 140M O O O 00104 26 64 MUNCHKIN 199 lt lt 00110 26 96 F 1 THE RECOMMENDED CIRCULATORS ARE BASED ON 1 GPM PER 10 000 BTU HR W 20 At PART 6 BOILER START UP 6 A COMMON VENT TEST At the time of removal of an existing boiler 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 the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and hori
13. IAGRAM WIRING DIAGRAM CONNECTING TO INTERNAL PUMP RELAY WIRING DIAGRAM WITHOUT CONNECTION TO INTERNAL PUMP RELAY GREEN GROUND RED NOT USED CONNECTION GRAY GRAY GRAY n W NEUTRAL W R GROUND GROUND SCREW MUNCHKIN PLECTRICAL ELECTRICAL SWITCH IUN CTION BOX TCH N BOX SWITC Junco 120V 60 H PART 3 3 A GAS CONNECTION J EE SHUT OFF VALVE The gas supply shall have a maximum inlet pressure of less than 14 water 6 D column 350 mm pound pressure 3 4 kPa and a minimum of 7 water oe 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 Lt you are connected to the type of gas as noted on the rating plate LP for liquefied petroleum or propane gas or Nat natural or city gas 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 is o and it is mandatory that a to o reducing bushing provided is used threaded into the branch of tee and a drip leg fabricated as per the National Fuel Gas code You must ensure that the entire gas line to the connection at the Munchkin is no smaller than Once all the inspections have been performed the
14. Installing Operating amp Maintaining MUNCHKIN HIGH EFFICIENCY HEATER 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 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 CONTROLS 27745 UL Dus usten SP nary US N 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 HEAT TRANSFER PRODUCTS INC 120 BRALEY RD E FREETOWN MA 02717 TABLE CONTENTS PART 1 GENERAL INFORMATION 1 HOW IT OPERATES Wid cote 1 EB LOCATION wi 2 1 PRESSURE RELIEF 2 2240222 2 PART 2 2 A ELECTRICAL CONNECTION
15. Munchkin will then go through a 4 second post purge cycle before shutting off Every Munchkin heater is equipped with an indicator light which will pulse constantly in normal operation When a problem occurs the indicator light will blink slowly to indicate the heater fault 1 B LOCATION NWARNING THE MUNCHKIN MUST BE SET ON A LEVEL SURFACE SO CONDENSATION DOES NOT BACK UP INSIDE BOILER The Munchkin is designed for Installation on combustible flooring in alcoves basements closets utility rooms The Munchkin shall be installed so that the gas ignition system components are protected from water This includes all related piping and components Choose a location for your Munchkin centralized to the piping system along with consideration to vent pipe length The length of vent pipe increases the firing rate of the Munchkin decreases You must also locate the Munchkin where it will not be exposed to freezing temperatures Additionally you will need to place the heater so that the controls inlet outlet and gas valve are easily accessed This Munchkin must not be installed outdoors for it is certified as an indoor appliance only and must be kept vertical and on a level surface Also care must be exercised when choosing the location of this appliance where leakage from the relief valve and from related piping will not result in damage to the surrounding areas or to the lower floors of the building A heater should always be located in an area
16. NAGE OF CONDENSATE ax gt FIGURE 1 NOTE ALL VENT PIPES MUST BE GLUED PROPERLY SUPPORTED AND THE EXHAUST MUST BE PITCHED A MINIMUM OF 1 4 PER FOOT BACK TO THE BOILER TO ALLOW DRAINAGE OF CONDENSATE EXTERIOR WALL MUNCHKIN BOILER 1000 VENT KIT GROUND 3 SIDEWALL VENT WITH V1000 KIT FIGURE 3 NOTE ALL VENT PIPES MUST BE GLUED PROPERLY SUPPORTED AND THE EXHAUST MUST PITCHED MINIMUM OF 37 ROOF VENT WITH TEE INTAKE amp COUPLING SEXHAUST A 1 4 PER FOOT BACK TO THE BOILER TO ALLOW DRAINAGE OF CONDENSATE FIGURE 4 NOTE ALL VENT PIPES MUST BE GLUED PROPERLY SUPPORTED AND THE EXHAUST MUST BE PITCHED A MINIMUM OF 1 4 PER FOOT BACK THE BOILER TO ALLOW DRAINAGE OF CONDENSATE gt ax EXTERIOR WALL MUNCHKIN BOILER MUNCHKIN BORER GROUND LEVEL 3 SIDEWALL VENT WITH 3 CONCENTRIC VENT KGAVTO6OICVT gt FIGURE 5 n NOTE ALL VENT PIPES MUST BE GLUED PROPERLY ROOF VENT VITH 3 CONCENTRIC VENT KIT SUPPORTED AND THE EXHAUST MUST BE PITCHED A MINIMUM OF 1 44 PER FOOT BACK TO THE BOILER TO ALLOW DRAINAGE OF CONDENSATE FIGURE 6 NOTE ALL VENT PIPES MUST BE GLUED PROPERLY SUPPORTED AND PITCHED A MINIMUM OF A QUARTER INCH PER FOOT BACK TO THE BOILER TO ALLOW DRAINAGE OF CONDENSATE 5 5 HYDRONIC HEAT PIPING
17. The Munchkin is designed to function in a closed loop 15 PSI System To assure that there is adequate pressure in the system we have installed in the Outlet Manifold a pressure switch which will not let the Munchkin operate without a minimum of 10 PSI water pressure This assures that the system does not have a leak which could cause damage to the Munchkin System It is Important to note that the Munchkin Boiler does have minimal amount of pressure drop and must be figured in when sizing the circulator to the System See Figure 7B Each Munchkin System must have an Air Eliminator which is designed to be installed in the Boiler Return Pipe boiler in which will remove air from the Hydronic System Always follow good piping practices Observe minimum 1 clearance to combustibles around all uninsulated hot water pipes or when openings around pipes are not protected by non combustible materials On a Munchkin installed above radiation level some states and local codes require a low water cut off device at the time of installation by the installer If the Munchkin supplies hot water to heating coils in air handlers units flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle CAUTION THE MUNCHKIN SHOULD NOT BE OPERATED AS A PORTABLE HOT WATER HEATER IT IS NOT TO BE USED AS A DIRECT DOMESTIC HOT WATER APPLIANCE Basic steps are listed below with an Illustration
18. both intake and exhaust piping 4 pes 3 90 20 20 3 PVCSCH 40 PIPE 20 40 Total combined length is under max allowable vent run of 85 This job is okay 3 VENTED MODELS EQUIVALENT AFTER THE FIRST 10 OF 3 ONLY TABLE 4 VENTED MODELS EQUIVALENT TABLE EQUIVALENT FEET OF PIPE EQUIVALENT FITTING FEET OF DESC PIPE 4 90 4 45 4 COUPLING 4 PIPE 4 TEE 3 COUPLING 3 TEE 27 V1000 VENT VENTING EXAMPLES EQUIVALENT GRAND TOTAL FRICTION TOTAL VENT LENGTH LOSS FRICTION FEET FEET LOSS WITH FITTING FOR EACH FOR FRICTION ELBOW ELBOWS LOSS ADDED 2 2 3 4 5 6 7 8 9 1 3 4 5 6 7 8 3 4 5 6 3 4 4 D CLEANER CEMENT Cement for Exhaust and Intake piping must conform to ASTM D 2564 for joining PVC joints Make sure to check all joints to assure that they are properly sealed against leaks It is important to pay special attention to the exhaust piping which is pressurized with harmful gases 4 E CONDENSATE 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 This condensate does have a low PH and should be treated with a condensate filter This filter contains either lime crystals or
19. e screw in the center of the air pressure switch in 1 4 tum counter clockwise to correct initial set up only After any air pressure switch adjustment you must cycle the appliance several times to insure proper operation Redundant Gas Valve Gas Valve Relay Stuck ON 9 PULSES 1 If the controller senses the redundant gas valve or the gas valve relay is stuck ON it will go into the lockout state Check for short circuit s from the 24VAC and no continuity between CN4 pins 3 amp 4 If the problem persists replace the control board Redundant Gas Valve Gas Valve Relay Stuck OFF 10 PULSES 1 Ifthe controller senses the redundant gas valve or if the gas valve relay is stuck OFF it will go into a lockout state Replace the control board Gas Valve NOT Connected 11 PULSES 1 If the controller detects that the gas valve is not connected it will go into the lockout state Check the connection of the gas valve ROM Checksum Failure 12 PULSES 1 If the controller detects that the ROM check has failed then it will go into a lockout state Cycle the power from the ON to OFF state If the problem persists you may need to replace the control board RAM Test Failure 13 PULSES 1 If the controller detects that the RAM test failed it will go into a lockout state Cycle the power from the ON to OFF state If the problem persists you may need to replace the control board 60Hz Failure 14 PULSES 1 Ifthe generator inverter or other p
20. ghting Instructions in the safety information above on this label If you don t smell gas go to next step 8 Turn gas shutoff valve counter clockwise to on Handle will be horizontal 9 Install Front Cover 10 Turn on all electric power to appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier Combination Gas Control Gas Shutoff Valve TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove front cover Turn gas shutoff valve clockwise to off Handle will be vertical Do not force Install front cover 11 7 SERVICING 7 A SEQUENCE OF OPERATION 1 2 When power is first applied to the control 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 the idle state If the thermostat is calling for heat the control will apply power to the circulator pump If the control determines the appliance water temperature is below the programmed set point value less the switching differential the control will initiate a heating cycle The control then performs selected system diagnostic checks If all checks are successfully passed a pre purge cycle is initiated bl
21. hoose your vent termination locations carefully You must additionally 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 following guidelines 1 Never vent into a walkway patio area alley or otherwise public area less than 7 from the ground 2 Never vent over or under a window or over a doorway 3 Never install a heat saver or similar product to capture waste heat from exhaust 4 Always have vent location at least 17 above maximum snow level 5 Always have vent 17 above ground level away from shrubs and bushes 6 Follow local gas codes in your region or refer to National Fuel Gas Code Can 149 7 Always have vent at least 3 from an inside corner of outside walls 8 Maintain at least 4 clearance to electric gas meters and exhaust fans or inlets 9 Very Important Inlet air must be taken from outside of building next to exhaust outlet no closer than 8 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 1 thru 6 Use the following layout as a guideline 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 abo
22. itch Fault Stuck Open 8 Redundant Gas Valve Relay Stuck ON 9 Gas Valve Relay Stuck ON 9 Redundant Gas Valve Relay Stuck OFF 10 Gas Valve Relay Stuck OFF 10 Gas Valve wire disconnected 11 ROM Checksum Failure 12 RAM Test Failure 13 60 Hz Failure 14 NOTE Toread LED flashes 1 flash per second within sets of flashes with 2 second wait periods between sets of flashes During normal operation the LED will pulse continuously 7 D FAULT CONDITIONS Limit String Open High Limit Failure 2 PULSES Ifthe limit string opens the control will immediately remove power to the gas valve complete a post purge cycle and enter a lockout state To restart the control make sure that there is at least 10 PSI in the water system then remove and re apply 120 VAC line power The bi metallic high limit device must physically close before the control board will function properly If a user recycles power to restart the control and the high limit device is still open the control will revert back to the lockout state 2 LED PULSES e Ifthe control senses a fault in the limit string the control will immediately remove power to the gas valve After completing a post purge cycle the control will go into the lockout state Flame Stuck ON 3 PULSES The current state of the flame may be determined by looking through the view port on the combustion chamber If the flame is stuck ON OFF then the flame rod insulator or the connector CN6 may no
23. ower on max speed 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 If after three trials a flame is not verified the control will go into lockout mode If a flame is confirmed the control enters the heating mode Fire rate based on the proprietary algorithm When water temperature reaches the temperature set point valve plus 10 degrees F or if the thermostat call for heat is satisfied the gas valve is closed and the control enters post purge blower on max speed NOTE IF THE THERMOSTAT IS STILL CALLING FOR HEAT THE CIRCULATOR PUMP WILL CONTINUE TO RUN UNTIL THE THERMOSTAT CALL FOR HEAT IS SATISFIED When post purge is complete the control enters the 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 and repeat the entire operating cycle During the idle state and heat state if the control detects an improper operating state for external devices such as the high limit switch the green LED on the control will flash an error code sequence 7 B ADJUSTMENT SET POINTS AND DIFFERENTIAL SETTINGS 1 2 Temperature Adjustment potentiometer located on the control board is used to adjust
24. ower source does not provide 60Hz then the power source must be replaced If the power source used supplies 60Hz then cycle the power from the On to OFF state If the problem persists then you may need to replace the control board 14 THERMO DISC TEMP SWITCH 210 DEGREE ECO WATER HIGH LIMIT gt OUTLET TEMP PROBE THERMISTOR 120 VAC CONBUSTION BLOWER CIRC PUMP PART 8 8 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 boiler Installer must also inform owner that the lack of proper care and maintenance of the boiler may result in a hazardous condition Installer should discuss contents of the User s Information Manual with the owner 8 B BEFORE EACH HEATING SEASON A trained and qualified service technician should perform the inspections listed below at least once a year Boiler check the boiler for dust or foreign materials which may have been drawn in from the air intake of the boiler 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
25. 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 following lighting instruction on page 11 Unscrew the threaded mounting flange which is located on the gas valve which will prevent high pressure which may damage the gas valve In the event the gas valve is exposed to a pressure greater than o PSI 14 water column the gas valve must be replaced Never use an open flame lit match lighter to check gas connections 3 B GAS PIPING DRIP 0 WARNING Failure to follow all precautions could result in fire explosion or death 1 Run gas supply line in accordance with all applicable codes 2 Locate and install manual shutoff valves in accordance with state and local requirements 3 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 Nominal Iron Pipe Internal Length of Pipe Feet Size Diameter inches 10 60 824 278 105 96 90 1 049 520 195 180 170 1 380 1 050 400 370 350 1 610 1 600 610 560 530 It is recommended that a soapy solution be used to de
26. property damage The inlet pipe on the back of the cabinet use 3 PVC schedule 40 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 burs debris ragged ends and particles of PVC Exhaust pipe on the back of the cabinet will use 3 PVC CPVC ABS Schedule 40 or 80 For concrete construction or to meet certain fire codes exhaust piping inlet air pipe must be 3 CPVC Schedule 40 or 80 only to meet local fire codes The balance of the inlet and exhaust piping may be PVC Schedule 40 or 80 or ABS solid only NOT FOAM CORE The only approved exhaust vent materials are PVC Schedule 40 NOT FOAM CORE PIPE Exhaust piping should be sloped back to the connection on the Munchkin at least 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 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 C
27. propriate tables in Appendix in the National Fuel Gas Code ANSI Z223 1 6 B ITEMS TO BE CHECKED BEFORE LIGHTING THE MUNCHKIN READ SECTION 1 A OPERATION 1 Make sure you have minimum 10 psi water pressure The water pressure switch will not allow the unit to run without 10 psi 2 Check all molex plugs making sure they properly connected into each plug 3 Check clear hose connection from pressure switch to outlet of blower 4 Make sure gas is turned on WARNING If you smell gas Shut gas off Following the instructions in Section B in 6 C Lighting Instructions in Safety Information on next page 5 Double check temperature setting and differential settings 6 Make sure that unit is properly ground and black hot white neutral lead are connected properly Note If not properly grounded or black hot white neutral lead are reversed then the unit will light for 3 4 seconds then shut off after three cycles 7 Turn power to the Munchkin 8 Check to see that the LED light indicator is illuminated 10 6 LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A 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 B BEFORE OPER
28. t be clean or unplugged Ignition Failure No Flame 4 PULSES Ifan ignition failure occurs during the trial for ignition the control will return to the pre purge state and attempt another ignition trial If after three trials an ignition failure is still occurring the control will go into the lockout state Check that the gas valve is operating correctly and the plug is fully connected into the valve Verify that the gas supply is turned on that there is a proper connection to the 120VAC line source that the flame rod is connected and also that the flame rod is clean Replace the Low Voltage Cable assembly 13 Open Temperature Sensor On Inlet Probe Fault 5 PULSES e The control will sense an open temperature probe If an open probe is sensed the control will go into the lockout state Verify that the Inlet probe is properly connected to the control board If the temperature probe is in an environment of less then 0 F then wait for ambient temperature to rise or apply heat to the unit If the temperature probe is in an environment of more then 230 F then wait for the temperature to lower below 200 F Open Temperature Sensor On Outlet Probe Fault 6 PULSES e control will sense an open temperature probe If an open probe is sensed the control will go into the lockout state Verify that the Outlet probe is properly connected to the control board If the temperature probe is in an environment of less than 0 then wait
29. tect leaks Bubbles will appear on pipe to indicate a leak is present 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 or regulator or gas line is undersized or in need of service You can attach a meter to the incoming gas drip leg by removing the cap and installing the meter The gas pressure must remain between 7 and 14 during stand by and unit running heat cycle 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 the failure of the Munchkin lighting off 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 valve must not be replaced with a conventional valve under any circumstances As an additional safety feature this valve has a flanged connection to the Venturi and blower PART 4 VENTING 4 A ALL MODELS 3 VENTED N WARNING It is extremely important to follow these venting instructions exactly Failure to follow the venting instructions can cause severe personal injury death or substantial
30. the set point temperature on the boiler appliance This can be set between 70 and 210 degrees Temperature Differential Adjustment A DIP switch is located on the control board Depending upon the configuration of the DIP switch the differential selection is 6 12 20 or 30 See the figure below for further detail NOTE the differential adjustment is the value below the set point when the burner will fire Example 190 degree set point 30 degrees differential burner will not fire until return water drops below 160 degrees and will modulate the flame until 190 degrees is reached then post purge and idle state will be achieved If at any point TT is satisfied the cycle will be interrupted by post purge and idle state 12 7 MUNCHKIN BOILER FAULT LED CODE When a fault condition occurs or is sensed on the WHC 1100 Munchkin Controller or in the appliance the control board goes to a LOCKOUT state When in the LOCKOUT state the green LED located on the WHC1100 Control board will flash a fault code The number of times to LED flashes ON OFF will determine the nature of the fault see the table below To reset the Control from the LOCKOUT state remove and re apply 120VAC line power to the Control board DESCRIPTION of FAULT of LED PULSES Limit String Open Water Pressure Switch ECO s 2 Flame Stuck ON 3 Ignition Fault No Flame 4 Inlet Probe Fault 5 Outlet Probe Fault 6 Air Pressure Switch Fault Stuck Closed 7 Air Pressure Sw
31. ult in severe burn electrical shock gas leakage fire or explosion 2 A ELECTRICAL CONNECTION The electrical connection for the Munchkin is on the left side of the unit There is a o knockout location for electrical connection All electrical wiring must be performed by a qualified licensed electrician in accordance with National Electrical Code or to the applicable local codes and standards For your convenience we have labeled all the wire which needs to be connected to operate the Munchkin Caution Do not remove labels on wires prior to disconnection The electrical requirements are for standard 120 volts 60 Hz 10 amp service This unit must be wired with 14 awg and fused for no more than 15 amps It is of extreme importance that this unit be properly grounded There two ground points in the electrical compartment that must be connected to the building ground system Connect the building to the green ground screw and the green ground wire It is very important that the building system ground is inspected by a qualified electrician prior to making this connection The black wire is the hot lead and white wire is the neutral lead Once all connections have been made the electrical access may be closed It is very important that the electrical power is not turned on at this time A green LED is provided on the main control board This LED must be illuminated when the Munchkin is turned on for proper operation DIAGRAM D
32. ve the maximum snow level 24 which ever is greater The air inlet must also be a minimum of 10 horizontally from the roof and terminated with a tee The exhaust must be a minimum of 24 above the air inlet opening and terminated with a coupling It is very important that there are no other vents chimneys or air inlets in any direction for at least 4 4 venting must be properly supported as 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 Standard Institute 12 It is recommended that you use one of the optional vent kits specifically for Munchkin installations KGAVTO601CVT 3 in or V1000 NOTE WHEN USING THE HGAVTT6OICVT KIT REMOVE THE 2 SCREENS FROM THE PROVIDED INLET TEE AND INSTALL THEM IN THE INLET SOCKET AND OUTLET SOCKET OF THE KIT PRIOR TO INSTALLING THE SCHEDULE 40 PIPE AND GLUING 4 FOR LONGER VENT LENGTHS All venting must be 3 both intake and exhaust NEVER use any piping less than 3 or different size pipe on the intake and exhaust You may use 4 venting on both intake and exhaust to lower the pressure drop to provide additional venting length It is imperative when using 4 to follow these instructions very carefully For longer lengths the first 10 of both the intake and exhaust piping 3 For the intake 10 of 3 PVC
33. which will guide you through the installation of the Munchkin Pipe properly In accordance to Figure 7A Connect system return marked IN make sure to install with pipe sealant compound Threaded connection NPT brass nipples Connect system supply marked BOILER Make sure to install with pipe sealant compound Threaded connection are 1 NPT brass nipple 4 Install Purge and Balance Valve on system return 5 Install Back Flow Preventer if required by local codes on system return 6 Install Pump on system supply Make sure pump is properly sized for piping loss 7 Install on Cold Water Feed Pressure Reducing Valve 15 PSI nominal on system return Check temperature pressure gauge should read minimum of 12 PSI 8 Install Expansion Tank on system supply Use appropriate size tank for volume of water in system 9 Install Air Vent on system return 10 Install Flow Check on system supply 11 Install Drain Valve on system supply Note Munchkin can not be drained of water without purging the unit with air pressure 15 PSI minimum 12 Install Temperature pressure gauge on system supply 5 B FILL AND PURGE HEATING SYSTEM Attach hose to balance and purge hose connector and run to drain Close the other side of the balance and purge valve Open first zone balance and purge valve so as to let the water flow out of the hose If zone valves are used open zone valves one at a time manually NOT
34. zontal pitch to determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 If practical close all building doors windows and all doors between the space in which the appliances remain connected to the common venting system are located and other spaces of 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 fireplace dampers 4 Place operation the appliance being inspected Follow the lighting instructions Adjust thermostat so 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 cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above 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 ap
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