Munchkin MUNCHKIN HIGH EFFICIENCY HEATER with the 925 Controller User Manual

Installing, Operating & Maintaining  
MUNCHKIN™ HIGH EFFICIENCY HEATER  
with the “925” Controller  
WARNING  
If the information in this manual is not followed exactly, a fire or explosion may  
result causing property damage, personal injury or loss of life.  
Do not store or use gasoline or other flammable vapors and  
liquids in the vicinity of this or any other appliance.  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not touch any electrical switch: do not use any phone in  
your 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  
MH27745  
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 OF CONTENTS  
TABLE OF CONTENTS  
PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8  
GENERAL INFORMATION  
PART 6 . . . . . . . . . . . . . . . . . . . .34 thru 37  
START UP PROCEDURES  
A How It Operates . . . . . . . . . . . . . . . . . .4 A Sequence of operation . . . . . . . . . . . .34  
B
Munchkin Ratings and Dimensions . . .4  
B
Items to be checked before  
lighting the Munchkin . . . . . . . . . . . . .34  
C Pre-installation Requirements . . . . . . .8  
D Pressure Relief Valve . . . . . . . . . . . . . .9  
C Lighting Instructions . . . . . . . . . . . . . .35  
D Operating Instructions . . . . . . . . . . . .35  
PART 2 . . . . . . . . . . . . . . . . . . . . .9 thru 11  
ELECTRICAL  
E
Adjusting the Temperature  
on the Munchkin Display . . . . . . . . . .36  
Status Menu . . . . . . . . . . . . . . . . . . . .36  
F
A Electrical Connection . . . . . . . . . . . . . .9  
G Test Mode . . . . . . . . . . . . . . . . . . . . . .37  
H To Turn Off Gas to Appliance . . . . . . .37  
PART 3 . . . . . . . . . . . . . . . . . . . .12 thru 13  
GAS CONNECTION  
PART 7 . . . . . . . . . . . . . . . . . . . .38 thru 40  
TROUBLESHOOTING  
A Gas Connection . . . . . . . . . . . . . . . . . .12  
B
Gas Piping . . . . . . . . . . . . . . . . . . . . . .12  
C Gas Table . . . . . . . . . . . . . . . . . . . . . . .12  
C Boiler Fault . . . . . . . . . . . . . . . . . . . . .38  
PART 4 . . . . . . . . . . . . . . . . . . . .14 thru 21  
VENTING  
PART 8 . . . . . . . . . . . . . . . . . . . .40 thru 44  
MAINTENANCE  
A Approved Venting Materials . . . . . . . .14  
B
Venting the Munchkin . . . . . . . . . . . . .15  
A Maintenance Procedures . . . . . . . . . .41  
C Longer Vent Runs . . . . . . . . . . . . . . . .17  
D Heater Removal from a  
B
Before Each Heating Season . . . . . . .41  
C Condensate Cleaning Instructions . . .41  
D Combustion Chamber  
Common Vent System . . . . . . . . . . . .18  
Condensate Removal . . . . . . . . . . . . .18  
E
Coil Cleaning Instructions . . . . . . . . . .42  
E
F
Munchkin Controller . . . . . . . . . . . . . .43  
Components Diagrams . . . . . . . . .44–45  
PART 5 . . . . . . . . . . . . . . . . . . . .22 thru 33  
PIPING  
A Hydronic piping with  
Circulators or Zone Valves . . . . . . . . .22  
B
Circulator Sizing . . . . . . . . . . . . . . . . .23  
C Fill and Purge Heating System . . . . . .24  
D Piping Illustrations . . . . . . . . . . . . . . .25  
3
GENERAL INFORMATION  
PART 1. GENERAL INFORMATION  
A. HOW IT OPERATES  
When the room thermostat calls for heat, the Munchkin control board will start the circulator and start  
to monitor the return temperature of the system before the heater will begin to heat the water. Once  
the controller has sensed a drop in the return water temperature below the temperature set point  
minus the differential set point, the heater will start to heat the water. This eliminates the Munchkin  
starting every time the 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 return 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 fan has a direct drive current low-voltage 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 Munchkin will then go through a 4 second post-purge cycle before  
shutting off. Every Munchkin heater is equipped with a display which will read the outlet temperature of  
the heater and then will illuminate a green light showing flame on. If a problem occurs, the front indicator  
light will turn red and the display will read a fault code; see Part 7, Section B/C.  
B. MUNCHKIN RATINGS AND DIMENSIONS  
B. MUNCHKIN RATINGS AND DIMENSIONS  
PERFORMANCE RATINGS  
Model  
T50M  
T80M  
80M  
140M  
Input Modulation  
18,000 to 50,000  
19,000 to 80,000  
27,000 to 80,000  
46,000 to 140,000  
66,000 to 199,000  
DOE Heating  
16,000 to 46,000  
17,000 to 74,000  
25,000 to 74,000  
43,000 to 129,000  
61,000 to 183,000  
AFUE  
92%  
92%  
92%  
92%  
92%  
Shipping Weight  
58 lbs.  
*IBR  
40,000  
64,000  
64,000  
112,000  
159,000  
58 lbs.  
75 lbs.  
101 lbs.  
111 lbs.  
199M  
*Net water  
CONNECTION SIZES  
Supply/Return  
Model  
T50M  
T80M  
80M  
140M  
199M  
Connection  
1 1/4" NPT  
1 1/4" NPT  
1 1/4" NPT  
1 1/4" NPT  
1 1/4" NPT  
Gas Connection Size  
Vent Dia.  
3/4"  
3/4"  
3/4"  
3/4"  
3/4"  
2"  
2"  
3"  
3"  
3"  
4
GENERAL INFORMATION  
RECOMMENDED SERVICE CLEARANCES  
(NOTE: The Munchkin is rated at  
zero clearance to combustibles.)  
80M/140M/199M  
T50M/T80M  
Figure 1-1  
Figure 1-2  
5
GENERAL INFORMATION  
DIMENSIONS  
T50M/T80M  
Figure 1-3  
6
GENERAL INFORMATION  
DIMENSIONS  
80M  
Figure 1-4  
140M/199M  
Figure 1-5  
7
GENERAL INFORMATION  
C. PRE-INSTALLATION REQUIREMENT  
GENERAL  
combustible construction. In addition, it  
is design certified for use on combustible  
floors.  
1. Munchkin Boilers are supplied complete-  
ly assembled as packaged boilers. The  
package should be inspected for damage  
upon receipt and any damage to the unit  
should be reported to the shipping com-  
pany and wholesaler. This boiler should  
be stored in a clean, dry area.  
2. Refer to Figure 1.1 and Figure 1.2 for the  
recommended clearance to allow for rea-  
sonable access to the boiler. Local codes  
or special conditions may require greater  
clearances.  
2. Carefully read these instructions and be  
sure to understand the function of all  
connections prior to beginning installa-  
tion. Contact your Munchkin Sales  
Representative or the Heat Transfer  
Products, Inc. Customer Service  
Department for help in answering ques-  
tions.  
CAUTION  
Do not install this boiler on carpeting.  
COMBUSTION AND VENTILATION AIR  
1. The Munchkin Boiler 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.  
3. This boiler must be installed by a quali-  
fied contractor. The boiler warranty may  
be voided if the boiler is not installed cor-  
rectly.  
2. No additional combustion or ventilation  
air is required for this appliance.  
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.  
3. Refer to Section 4 of this manual,  
Venting, for specific instructions for pip-  
ing combustion air.  
PLANNING THE LAYOUT  
WARNING  
1. Prepare sketches and notes showing the  
layout of the boiler installation to mini-  
mize the possibility of interferences with  
new or existing equipment, piping, vent-  
ing and wiring.  
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.  
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  
ACCESSIBILITY CLEARANCES  
1. The Munchkin Boiler is certified for clos-  
et installations with zero clearance to  
f. Piping: Part 5  
8
GENERAL INFORMATION / ELECTRICAL  
CAUTION  
The Munchkin is certified as an indoor appliance. Do not install the Munchkin  
outdoors or locate where it will be exposed to freezing temperature. This includes all  
related piping and components. If the Munchkin is subjected to flood water or  
submersed in water, the Munchkin must be replaced.  
Note: Service clearance of the Munchkin: See Section 1, Figures 1-1 and 1-2.  
If the Munchkin is set up for liquefied petroleum (LP) gas, some geographic areas 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.”  
CAUTION  
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) Section E for Condensate Requirements.  
WARNING  
D. PRESSURE RELIEF VALVE  
A pressure relief valve is installed into the front right side manifold. We recommend a WATTS ¾"  
M 335 MI valve or equivalent and meets the requirements of ANSI/ASME Heater and Pressure  
Vessel Code, Section IV or CSA B51; Heater, Pressure Vessel and Piping Code as applicable for  
heating heaters. A ¾" pipe must be directed to a floor drain or suitable location within 6" of a 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. 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 central heating circulator  
connection. All electrical wiring must be performed by a qualified licensed electrician in accordance  
with National Electrical Code ANSI Z223.1//NFPA 54 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.  
9
ELECTRICAL  
CAUTION  
Electrical wiring on the Incoming Power and Central Heating Circulator shall be  
connected directly to the intended connection source and not be connected together  
inside the electric box provided. An Electrical Short will result and the Control board  
will have to be replaced! If Electrical Requirements of the Central Heating Circulator  
exceeds 4 amps (or 3 amps on HA models only) please follow the wiring diagrams on  
Figures 2-1, 2-2 and 2-3 (this section).  
The electrical 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.  
DANGER  
IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED!  
DANGER  
IT IS VERY IMPORTANT THAT THE BUILDING GROUND IS INSPECTED BY A  
QUALIFIED ELECTRICIAN PRIOR TO MAKING THIS CONNECTION!  
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. The Orange and Brown wire are provided to the supply of 120 volts to  
the Central Heating Circulator. Connect the Orange (Hot) and the Brown (Neutral) directly to the Central  
Heating Circulator.  
DANGER  
The Orange wire for the Central Heating Circulator is Switched Hot and must have a  
wire nut if not connected to the Central Heating Circulator. Failure to follow this  
instruction will result in a short, and the Control Board will have to be replaced.  
Connect the gray wires to your heating thermostat (TT) connection. Your thermostat heat anticipator  
setting is .056 amp.  
CAUTION  
Do not power zone valves directly from the heater transformer. Doing so will greatly  
reduce the life of the transformer. Use a separate transformer sized to handle the total  
electric load of all zone valves.  
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.  
10  
ELECTRICAL  
DIAGRAM "A"  
DIAGRAM "B"  
WIRING DIAGRAM CONNECTING TO CIRCULATOR  
WIRING DIAGRAM WITHOUT CONNECTION TO CIRCULATOR  
GREEN (GROUND)  
WHITE (NEUTRAL)  
IMPORTANT NOTE:  
BE CERTAIN THAT THE ORANGE  
WIRE IS SECURELY CAPED.  
FAILURE TO DO SO COULD  
RESULT IN INJURY OR FIRE  
AND COULD DAMAGE THE CONTROL.  
BLACK  
NORMALLY OPEN  
NORMALLY OPEN  
THERMOSTAT  
CONNECTION  
THERMOSTAT  
CONNECTION  
GRAY  
GRAY  
WHITE  
(NEUTRAL)  
WHITE  
(NEUTRAL)  
GRAY  
T
T
T
T
BLACK  
(HOT)  
BLACK  
(HOT)  
GRAY  
GREEN  
(GROUND)  
GREEN  
(GROUND)  
GROUND  
BUS  
ELECTRICAL  
SWITCH JUNCTION BOX  
120V 60 HZ  
ELECTRICAL  
SWITCH JUNCTION BOX  
120V 60 HZ  
Figure 2-1: Connection Wiring Directly to Figure 2-2: Connection Wiring without Wiring  
Central Heating Circulator  
Central Heating Circulator  
Note to Electrical Contractor: The orange  
wire is 120 Volt/4 Amp maximum for central  
heating circulator only. Loads greater than 4  
amps or 3 amps for HA models only will blow the  
fuse on the board. The brown wire is the neu-  
tral wire for the central heating pump only.  
ZONE  
THERMOSTAT  
R845A  
SWITCHING  
RELAY ZONE  
BOILER  
"TT"  
GRAY  
1K1  
5
3
T
T
1K1  
1K2  
BOILER  
"TT"  
GRAY  
2
1
4
6
ZONE  
CIRCULATOR  
L1 HOT (BLACK)  
120 VOLT  
L2 NEUTRAL  
(WHITE)  
Figure 2-3: For circulator amp loads greater  
than 4 amps (3 amps for “HA” models) use the  
wiring diagram shown at left. The brown and  
orange wires will not be used in this  
application.  
11  
GAS CONNECTION  
PART 3. GAS CONNECTION  
WARNING  
Failure to follow all precautions could result in fire, explosion or death!  
A. GAS CONNECTION  
The gas supply shall have a maximum inlet pressure of less  
than 14" water column (350 mm), ½ pound pressure (3.5 kPa),  
and a minimum of 3.5" water column. The entire piping  
system, gas meter and regulator must be sized properly to  
prevent pressure drop greater than 0.5" as stated in the National  
Fuel Gas Code. This information is listed on the rating 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 is ½" and it is  
mandatory that a ¾" to ½" reducing coupling (provided) is used, threaded into the branch of a ¾" 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 ¾". 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 ½ 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.  
2.  
Run the gas supply line in accordance with all applicable codes.  
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)  
Nominal  
Iron Pipe Internal  
Length of Pipe (Feet)  
Size  
Diameter  
(inches) (inches) 10  
20  
30  
40  
50  
60 70  
80  
90  
90 100  
84 79  
125 150  
72 64  
130 120  
275 250  
410 380  
175 200.  
59 55}  
110 100}  
225 210} HOUR  
350 320} X 1,000  
3/4  
1
.824  
1.049  
278  
520  
190 152 130 115 105 96  
350 285 245 215 195 180 170 160 150  
730 590 500 440 400 370 350 320 305  
BTU'S  
PER  
1 1/4  
1 1/2  
1.380 1,050  
1.610 1,600 1,100 890 760 670 610 560 530 490 460  
12  
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.  
DUNGS GAS VALVE  
THROTTLE ADJUSTER  
(NOTE: IF FOR ANY  
REASON THE THROTTLE  
NEEDS TO BE  
ADJUSTED  
VERY IMPORTANT THAT  
A "COMBUSTION  
,
IT IS  
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. 3-1  
WARNING  
Failure to follow all precautions could result in fire, explosion or death!  
13  
VENTING  
PART 4. VENTING  
DANGER  
It is extremely important to follow these venting instructions carefully. Failure to do  
so can cause severe personal injury, death or substantial property damage.  
A. APPROVED VENTING MATERIALS  
Exhaust Vent and Extensions in Plastic 2", 3" and 4" Pipe Schedule 40 or 80.  
1. Non Foam Core PVC Pipe  
2. Non Foam Core CPVC Pipe  
3. Non Foam Core ABS Pipe  
Vent Piping must conform to following  
1. PVC Non Foam Core Pipe (Polyvinyl Chloride) to ASTM D-1785 or D-1784 Class 12454-B,  
Formerly designated Type 1, Grade 1.  
2. CPVC (Chlorinated Polyvinyl Chloride) Class 23447-B, Formerly designated Type IV, Grade 1 con-  
forming to ASTM D-1784.  
3. ABS (Acrylonitrile-Butadiene-Styrene) Class 3-2-2-2-2 conforming to ASTM D3965.  
DANGER  
Foam Core Pipe is not to be used in connecting the exhaust pipe.  
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.  
Inlet Air Vent  
Use the same material as used for exhaust in either 2", 3" or 4" Plastic Pipe. Cellular Foam Core Pipe  
may be used for the inlet only, NEVER ON EXHAUST PIPING!  
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 operating under positive pressure.  
14  
VENTING  
B. VENTING THE MUNCHKIN  
DANGER  
It is extremely important to follow these venting instructions exactly. Failure to do so  
can cause severe personal injury, death or substantial property damage.  
CAUTION  
The following are code restrictions for the location of the flue gas vent terminal.  
Compliance to these requirements doesn’t insure a satisfactory installation; good  
common sense must also be applied. It is important to make sure that exhaust gases  
are not recirculated into the inlet air of the Munchkin.  
The inlet pipe on the back of the cabinet should be 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 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 intake and exhaust (each  
elbow = 5' of pipe) should not exceed 85'. The combined vent length should not be less than a com-  
bined 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 following guidelines.  
1) Never vent into a walkway, patio area, alley or otherwise public area less than 7' from the  
ground. (See the following detail 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 conden-  
sation 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.  
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  
15  
VENTING  
may require venting modifications (consult factory). The air inlet must be a minimum of 1'  
vertically above the maximum snow level. It is very important that there are no other vents,  
chimneys or air inlets in any direction for at least 4'.  
Mechanical  
draft vent  
terminal  
(see 10.8.1)*  
Mechanical draft  
vent terminal  
(see 10.8.2)*  
C
4 ft.minimum  
Less  
than 10 ft.  
12 in.minimum  
3 ft.minimum  
Direct vent terminal clearance  
Minimum clearance, C  
Input (Btu/hr)  
10,000 or less  
10,001 to 50,000  
Over 50,000  
Clearance (in.)  
Forced air  
inlet  
6
9
12  
(see 10.8.3)*  
For SI units: 1 ft = 0.305 m; 1 in. = 25.4 mm;  
1 Btu/hr = 0.293 W  
EXIT TERMINALS OF MECHANICAL DRAFT  
AND DIRECT-VENT VENTING SYSTEM  
* REFERENCE: THE NATIONAL FUEL GAS CODE  
2002 EDITION  
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.  
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 installa-  
tions, available from Heat Transfer Products, Inc. (KGAVT0601CVT [3 in.], KGAVT0501CVT [2 in.] or  
V500 for the T50M/T80M or V1000 for the 80M/140M/199M). NOTE: When using the KGAVT601CVT  
KIT, REMOVE THE 2 SCREENS FROM THE PROVIDED INLET TEE AND INSTALL THEM IN THE INLET  
SOCKET AND OUTLET SOCKET (Y TEE CONNECTION) OF THE KIT PRIOR TO INSTALLING THE  
SCHEDULE 40 PIPE AND GLUING.  
16  
VENTING  
Friction Loss Equivalent in Piping and Fittings  
Fittings or Piping  
Equivalent Feet  
90 degree elbow  
45 degree elbow  
Coupling  
air inlet tee  
Plastic Pipe  
=
=
=
=
=
=
=
5
3
0
0
1
3
0
concentric vent kit  
V500 or V1000 vent kit  
CAUTION  
Do not exceed the 85 foot maximum requirement (intake plus exhaust piping added  
together) including fitting allowance.  
Example: Installation requires the following material for both inlet and exhaust piping for the  
Munchkin  
Required: 4 Pcs. (2" or 3") 90 degree elbow (4 x 5 = 20 Equivalent Feet) = 20 Equivalent Feet  
Required: 20' of (2" or 3") 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  
The connection of the air inlet and exhaust vent at the heater must remain at the standard vent size  
from the unit (2" for the T50/T80) (3" for the 80M/140M/199M). If a transition is required, it must occur  
at a minimum of 15 equivalent feet for both intake and exhaust. Then transition to the next size pipe.  
See the friction loss equivalent table to apply longer vent runs. The overall extended combined  
length of pipe on the inlet and exhaust must not exceed 125 equivalent feet total.  
CAUTION  
Transitioning from 2" to 3" or 3" to 4" 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.  
Example: Installation requires the following material for both the inlet and exhaust piping when  
extending the vent run for the Munchkin.  
3" Vented Appliance  
2 Pcs. – 3" 90 degree elbow  
20' of 3" Plastic PVC Pipe  
(2 x 5 = 10 Equivalent Feet)  
(20 x 1 = 20 Equivalent Feet)  
=
=
10 Equivalent Feet  
20 Equivalent Feet  
Total of 3" Equivalent Piping with Fittings  
= 30 Equivalent Feet  
Transitioning to 4" Venting  
6 Pcs. – 4" 90 degree elbows  
4 Pcs. – 4" 45 degree elbows  
40' of 4" Plastic PVC Pipe  
(6 x 3 = 18 Equivalent Feet)  
(4 x 1 = 4 Equivalent Feet)  
(40 x 1 = 40 Equivalent Feet)  
=
=
=
18 Equivalent Feet  
4 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  
17  
VENTING  
DANGER  
The Munchkin is not intended to be common vented with any other  
existing appliance!  
D. HEATER REMOVAL FROM A COMMON VENT SYSTEM  
At the time of removal of an existing heater, the following steps shall be followed with each appli-  
ance remaining connected to the common venting system placed in operation, while the other appli-  
ances remaining connected to common venting system are not operating.  
1. Seal any unused openings in the common venting system.  
2. Visually inspect the 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.  
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, fire-  
place 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 installa-  
tion 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. Also, an increase in pipe size may be necessary to drain properly. Support of  
the condensation line may be necessary to avoid blockage of the condensate flow.  
18  
VENTING  
DIAGRAMS FOR SIDEWALL VENTING  
**IMPORTANT NOTE: All vent pipes must be **IMPORTANT NOTE: All vent pipes must be glued, prop-  
glued, properly supported and the exhaust must erly supported and the exhaust must be pitched a mini-  
be pitched a minimum of a ¼" per foot back to mum of a ¼" per foot back to the heater (to allow drainage  
the heater (to allow drainage of condensate).  
of condensate).  
Figure 4-1  
Figure 4-2  
19  
VENTING  
**IMPORTANT NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a  
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).  
Figure 4-3  
**IMPORTANT NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a  
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).  
Figure 4-4  
20  
VENTING  
DIAGRAMS FOR VERTICAL VENTING  
**IMPORTANT NOTE: All vent pipes must be glued,  
properly supported, and the exhaust must be pitched  
a minimum of a ¼" per foot back to the heater (to  
allow drainage of condensate).  
**IMPORTANT NOTE: All vent pipes must be glued,  
properly supported, and the exhaust must be pitched  
a minimum of a ¼" per foot back to the heater (to  
allow drainage of condensate).  
Figure 4-5  
Figure 4-6  
21  
PIPING  
PART 5. PIPING  
A. HYDRONIC PIPING WITH CIRCULATORS OR ZONE VALVES  
The Munchkin is designed to function in a closed loop 15 PSI System. To assure you that you have  
adequate pressure in the system, we have installed in the outlet manifold, a pressure switch that will  
not let the Munchkin operate without a minimum of 10 PSI water pressure. This assures you that if the  
system does have leak, the Munchkin will lock out (PRO on the display) before it damages the Stainless  
Steel Heat Exchanger. We have also included a Temperature and Pressure gauge which should be  
located on the Munchkin outlet to monitor the system pressure and outlet temperature from the  
Munchkin. It is important to note that the Munchkin has a minimal amount of pressure drop and must  
be figured in when sizing the circulators. Each Munchkin installation must have an Air Elimination  
device which will remove air from the system. Install the Munchkin so the gas ignition system  
components are protected from water (dripping, spraying, etc.) during appliance operation for basic  
service of circulator replacement, valves and other. Observe minimum 1” clearance around all un-  
insulated hot water pipes 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. If the Munchkin supplies hot water to heating coils in air  
handler units, flow control valves or other devices must be installed to prevent gravity circulation of  
heater water in the coils during the cooling cycle. Chilled Water Medium must be piped in parallel with  
the heater. Freeze Protection for new or existing systems must use glycol that is specially formulated  
for this purpose. It includes inhibitors, which prevent the glycol from attacking the metallic system  
components. Make certain that the system fluid is checked for the correct glycol concentration and  
inhibitor level. The system should be tested at least once a year and as recommend by the producer  
of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system  
piping. Example 50% by volume solution expands 4.8% in volume for the temperature increase from  
32 F to 180 F, while water expands 3% with the same temperature rise.  
CAUTION  
The Munchkin should not be operated as a potable Hot Water Heater. It should not be  
used as a direct Hot Water Heating Device.  
Basic steps are listed below, with Illustration, which will guide you through the installation of the  
Munchkin.  
1. Connect the system return marked “Heater In”, make sure to install with pipe sealant com-  
pound. Threaded connections are 1 ¼” NPT Brass nipples located on the left hand side of  
unit.  
2. Connect the system supply marked “Heater Out”, make sure to install with pipe sealant com-  
pound. Threaded connections are 1 ¼” NPT Brass nipples located on the left hand side of the  
unit.  
3. Install Purge and Balance Valve or shut off valve and drain on system return to purge air out  
of each zone.  
4. Install a Back Flow preventor on the Cold Feed Make-Up Water line.  
5. Install a Pressure Reducing Valve on the Cold Feed Make-Up Water line, (15 PSI nominal on  
the system return). Check Temperature and Pressure Gauge which should read minimum  
pressure of 12 PSI.  
6. Install a circulator on system supply. Make sure the circulator is properly sized for the system  
and friction loss.  
7. Install an Expansion Tank on the system supply. Consult the tank manufacturer’s instruction  
for specific information relating to tank installation. Size the expansion tank for the required  
system volume and capacity.  
22  
PIPING  
8. Install an Air Elimination Device on the system supply.  
9. Install a drain valve at the lowest point of the system. Note: The Munchkin can not be drained  
completely of water without purging the unit with an air pressure 15 PSI.  
10. The Safety Relief Valve is installed at the factory located on the right hand side of Munchkin.  
Pipe the discharge of safety relief valve to prevent injury in the event of pressure relief. Pipe  
the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet.  
Never block the outlet of safety relief valve.  
11. In compliance with ASME CSD-1, a low water cut-off device should be properly connected in  
the field, both electrically and mechanically.  
See the piping illustrations included in this section, Figs. 5-3 to 5-11 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. CIRCULATOR SIZING  
The Munchkin Heat Exchanger does have pressure drop which must be considered in your system  
design. Refer to the graph below for pressure drop through the Munchkin Heat Exchanger.  
20  
19  
18  
17  
16  
15  
14  
13  
12  
11  
10  
9
8
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21  
Flow in Gallons per Minute  
MUNCHKIN T50M  
MUNCHKIN 140M  
MUNCHKIN T80M/80M  
MUNCHKIN 199M  
Figure 5-1  
BOILER  
TACO P/N GRUNDFOS P/N  
T50M/T80M/80M  
140M  
007 *  
0010 *  
0011 *  
UPS15-58 FC SPD 2  
26-64 F  
199M  
26-96 F  
* THE RECOMMENDED CIRCULATORS ARE BASED ON 1 GPM PER 10,000 BTU/HR W/20  
23  
PIPING  
C. FILL AND PURGE HEATING SYSTEM  
• Attach the hose to balance and purge hose connector or drain valve and run hose to near-  
est drain  
• Close the other side of the balance and purge valve or the shut off valve after the drain.  
• Open first zone balance and purge or drain valve to let water flow out the hose. If zone  
valves are used, open the valves one at a time manually. (Note: please check valve manu-  
facturer’s instruction prior to opening valves manually, so as not to damage the valve.)  
• Manually operate fill valve regulator. When water runs out of the hose, while it’s connect-  
ed to the balance and purge valve or drain you will see a steady stream or water (with no  
bubbles). Close balance and purge valve or drain to stop the water from flowing.  
Disconnect the hose and connect it to next zone to be purged.  
• Repeat this procedure for additional zones (one at time).  
Upon completion, make sure that the fill valve is in automatic position and each zone balance and  
purge or shut off is in an open position and zone valves are positioned for automatic operation.  
CAUTION  
For installation that incorporates standing Iron Radiation and systems with manual  
vents at the high points. Follow above section and 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 a basket strainer in  
an older system where larger amounts of sediment may be present. Annual cleaning  
of the strainer may be necessary.  
WARNING  
Use only inhibited propylene glycol solutions which are specially formulated for  
hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in  
hydronic systems.  
1. Glycol in hydronic applications which is specially formulated for this purpose includes  
inhibitors which prevent the glycol from attacking metallic system components. Make certain  
that the system fluid is checked for the correct glycol concentration and inhibitor level.  
2. The glycol solution should be tested at least once a year and as recommended by the glycol  
manufacturer.  
3. Anti-freeze solutions expand more than water. For example a 50% by volume solution  
expands 4.8% in volume for a temperature increase from 32° F to 180° F, while water expands  
3% with the same temperature rise. Allowances must be made for this expansion in the sys-  
tem design.  
4. A 30% mixture of glycol will result in a BTU output loss of 15% with a 5% increase in head  
against system circulator.  
5. A 50% mixture of glycol will result in a BTU output loss of 30% with a 50% increase in head  
against system circulator.  
CAUTION  
It is highly recommended that you carefully follow the glycol manufacturer’s  
recommended concentrations, expansion requirements and maintenance  
recommendations (pH additive breakdown, inhibitor reduction, etc.). You must  
carefully figure the additional friction loss in the system as well as the reduction in  
heat transfer co-efficients.  
24  
PIPING  
D. PIPING ILLUSTRATIONS  
Piping Symbol Legend  
circulator  
pressure reducing valve  
diff. pressure bypass  
(w/ isolation flanges)  
circulator w/  
integral flow check)  
gate valve  
globe valve  
ball valve  
anti-scald rated  
mixing valve  
pressure gauge  
swing-check valve  
4-way motorized  
mixing valve  
flow-check valve  
spring-loaded check valve  
3-way motorized  
mixing valve  
Munchkin heater  
hose bib / boiler drain  
pressure relief valve  
backflow preventer  
thermostatic radiator valve  
TRV (straight)  
thermostatic radiator valve  
TRV (angle)  
float -type  
air vent  
circuit setter  
union  
manual 3-way valve  
heat exchanger  
zone valve  
air separator  
vacuum breaker  
Super Stor  
indirect DHW tank  
diaphragm-type  
expansion tank  
radiant manifold  
Fig. 5-2  
25  
PIPING  
Standard Munchkin boiler  
Retrofit piping (zoning with valves)  
Space heating mode  
Drawing 1A  
zone valves  
make-up water  
P1  
flow  
bypass  
valve  
purging  
valves  
V1  
OFF  
anti-scald  
mixing valve  
cold  
water  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
NOTES:  
This drawing is meant to show system piping concept only.  
Installer is responsible for all equipment & detailing required by local codes.  
1.  
2.  
Adjust flow bypass valve for the following minimum boiler flow rates in any operating mode:  
Munchkin model T50M: 3 gpm  
Munchkin model T80M: 3 gpm  
Munchkin model 80M: 3 gpm  
Munchkin model 140M: 5 gpm  
Munchkin model 199M: 7 gpm  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
3.  
4.  
5.  
6.  
7.  
8.  
A purging valve may be used .in lieu of the ball valve / hose bib combination shown  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-3  
26  
PIPING  
Standard Munchkin boiler  
Retrofit piping (zoning with valves)  
Domestic water heating mode  
Drawing 1B  
zone valves  
make-up water  
P1  
flow  
bypass  
valve  
purging  
valves  
V1  
anti-scald  
mixing valve  
cold  
water  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
NOTES:  
1.  
This drawing is meant to show system piping concept only.  
Installer is responsible for all equipment & detailing required by local codes.  
2.  
Adjust flow bypass valve for the following minimum boiler flow rates in any operating mode:  
Munchkin model T50M: 3 gpm  
Munchkin model T80M: 3 gpm  
Munchkin model 80M: 3 gpm  
Munchkin model 140M: 5 gpm  
Munchkin model 199M: 7 gpm  
3.  
4.  
5.  
6.  
7.  
8.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown  
.
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-4  
27  
PIPING  
Standard Munchkin boiler  
Preferred piping (zoning with valves)  
Space heating mode  
Drawing 2A  
zone valves  
make-up water  
P2  
closely  
spaced  
tees  
differential  
pressure  
bypass  
valve  
purging  
valves  
V1  
OFF  
anti-scald  
mixing valve  
cold  
water  
P1  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
NOTES:  
1.  
This drawing is meant to show system piping concept only.  
Installer is responsible for all equipment & detailing required by local codes.  
Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure  
drop operates by itself.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream  
of all closely spaced tees.  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-5  
28  
PIPING  
Standard Munchkin boiler  
Preferred piping (zoning with valves)  
Domestic water heating mode  
Drawing 2B  
zone valves  
make-up water  
P2  
closely  
spaced  
tees  
differential  
pressure  
bypass  
valve  
purging  
valves  
V1  
anti-scald  
mixing valve  
cold  
water  
P1  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
NOTES:  
1.  
This drawing is meant to show system piping concept only.  
Installer is responsible for all equipment & detailing required by local codes.  
Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure  
drop operates by itself.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler is 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream  
of all closely spaced tees.  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-6  
29  
PIPING  
Standard Munchkin boiler  
Preferred piping (zoning with circulators)  
Space heating mode  
Drawing 2C  
space heating zone circuit  
zone  
circulators  
make-up water  
closely  
spaced  
tees  
purging  
valves  
anti-scald  
mixing valve  
P2  
cold  
water  
P1  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
NOTES:  
This drawing is meant to show system piping concept only.  
Installer is responsible for all equipment & detailing required by local codes.  
All closely spaced tees shall be within 4 pipe diameter center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream  
of all closely spaced tees.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown.  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-7  
30  
PIPING  
Standard Munchkin boiler  
Preferred piping (zoning with circulators)  
Domestic water heating mode  
Drawing 2D  
space heating zone circuit  
zone  
circulators  
make-up water  
closely  
spaced  
tees  
purging  
valves  
anti-scald  
mixing valve  
P2  
cold  
water  
P1  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
NOTES:  
This drawing is meant to show system piping concept only.  
Installer is responsible for all equipment & detailing required by local codes.  
All closely spaced tees shall be within 4 pipe diameter center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream  
of all closely spaced tees.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown.  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-8  
31  
PIPING  
Standard Munchkin boiler  
Preferred piping  
(multiple boilers / zoning with circulators)  
Space heating mode  
Drawing 2E  
space heating zone circuit  
zone  
circulators  
make-up water  
closely  
spaced  
tees  
purging  
valves  
anti-scald  
mixing valve  
cold  
water  
P2  
PB1  
PB2  
T/P  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
Munchkin boiler  
NOTES:  
This drawing is meant to show system piping concept only.  
1.  
Installer is responsible for all equipment & detailing required by local codes.  
All closely spaced tees shall be within 4 pipe diameter center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream  
of all closely spaced tees.  
2.  
3.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown.  
4.  
5.  
6.  
7.  
8.  
9.  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-9  
32  
PIPING  
Standard Munchkin boiler  
Preferred piping  
(multiple boilers / zoning with circulators)  
Domestic water heating mode  
Drawing 2F  
space heating zone circuit  
zone  
circulators  
make-up water  
closely  
spaced  
tees  
purging  
valves  
anti-scald  
mixing valve  
cold  
water  
P2  
PB1  
PB2  
T/P  
T/P  
Super Stor  
indirect DHW tank  
Munchkin boiler  
Munchkin boiler  
NOTES:  
This drawing is meant to show system piping concept only.  
1.  
Installer is responsible for all equipment & detailing required by local codes.  
All closely spaced tees shall be within 4 pipe diameter center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream  
of all closely spaced tees.  
2.  
3.  
The minimum pipe size for connecting a Super Stor water heater is 1 inch.  
The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.  
All pumps are shown with isolation flanges. The alternative is standard flanges with full port ball valves.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
A purging valve may be used in lieu of the ball valve / hose bib combination shown.  
4.  
5.  
6.  
7.  
8.  
9.  
NOTE: FOR VISION PIPING APPLICATIONS, REFER TO THE VISION INSTALLATION PIPING DIAGRAMS.  
Fig. 5-10  
33  
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 tempera-  
ture. The control will initially run through a self-diagnostic routine and then go into its oper-  
ating mode. If there is no call for heat, the System will go into an idle state.  
2. If the thermostat is calling for heat, the control will apply power to the circulator pump. If the  
control determines the water temperature is below the programmed set point value minus  
the switching differential, the control will initiate a heating cycle.  
3. 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).  
4. When the pre-purge period is complete, power is applied to the spark ignitor for approxi-  
mately 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. 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 value plus 10 degrees F (or if the  
thermostat call-for-heat is satisfied), the gas valve is closed and the control enters a post-  
purge state (the blower will be on maximum speed). NOTE: If the thermostat is still calling  
for heat, the circulator pump will continue to run until the thermostat call for heat is satis-  
fied.  
6. When the post-purge is complete, the control enters an idle state while continuing to moni-  
tor temperature and the state of other system devices. If a call-for-heat is received, the con-  
trol will automatically return to step 2 in sequence and repeat the entire operating cycle.  
During the idle state and heat state, if the control detects an improper operating state from external  
devices, such as the high-limit switch, the red light on the control will illuminate an error code will  
appear in the display.  
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 under-  
standing how the Munchkin operates before you start the unit.  
1. Make sure that you follow the Lighting instruction before running the Munchkin.  
2. Make sure the unit has a minimum water supply pressure of 10 PSI or a fault code of PrO will  
appear in the display. While this Fault code is on the display the unit will not operate unit until  
the water pressure is brought above 10 PSI. This Fault code is caused by the Water pressure  
switch being open for more than 5 seconds which is an indication your system pressure is  
below 10 PSI. Increase the water pressure in the system until the pressure gauge reads 10psi.  
This code will disappear once the Water Pressure switch is closed, which will allow you to  
start the Munchkin.  
3. Check to see if all the electrical connections are on securely.  
4. Make sure that the Gas is turned on inside the cabinet and outside of the Munchkin.  
5. Double check the temperature setting (Note: The Munchkin is factory set at 180 degrees)  
6. Make sure the unit is properly grounded and the electrical wiring meets the requirements of  
the electrical section (Part 2).  
7. 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  
34  
START-UP PROCEDURES  
the room thermostat is connected and turn the room thermostat up above room temperature  
to start the combustion blower fan to run the Munchkin. 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.  
DANGER  
If you do not follow these instructions exactly, a fire or explosion may  
result, causing property damage, personal injury or loss of life.  
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 automatical-  
ly 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 tech-  
nician. 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 serv-  
ice 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 Boiler 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. Set the thermostat to the 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 to “off”.  
7. 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.  
8. Turn the gas shutoff valve counter clockwise to “on”. The handle will be horizontal.  
9. Replace the Front Cover.  
10. Turn on all electric power to appliance.  
11. Set the thermostat to the desired setting.  
35  
START-UP PROCEDURES  
12. 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 TEMPERATURE ON THE MUNCHKIN DISPLAY:  
1. Before you can change the temperature from the factory setting of 180 degrees. You must make  
sure that none of the thermostats are calling for heat. The Munchkin controller will not memorize a  
program setting while in a heating cycle. To adjust the temperature to the Munchkin simply press in  
the S3/Program key for three seconds until you see a flashing (C) then an alternate value of (180).  
This number is the factory set point of the unit, which is 180 degrees. To change the temperature,  
simply push either the S1/– or S2/+ on the display. The S1/– button will decrease the tempera-  
ture while the S2/+ will increase the temperature of the Munchkin. The temperature of the  
Munchkin can be set as low as 50 Degrees and as high 203 Degrees. These ranges are your maxi-  
mum and minimum ranges of the Munchkin. In addition to changing the temperature you are also  
allowed to change three more settings in this model (1. Munchkin differential – 2. Indirect setting  
(Vision System Only) – 3. Celsius to Farenheit measurement. Simply press in the S3/Program key  
to get to next value, the Munchkin differential setting will appear in the display ch and alternating  
value of 30. This allows the installer to adjust the activation of the burner based on the differential  
temperature setting of the Munchkin. The burner will not start until the outlet water temperature  
reaches a temperature that is equal to the temperature setting for the Munchkin, minus the differ-  
ential EX: The Munchkin is set to heat at 180° F degrees and the differential is set at 20° F. The burn-  
er will not start until the outlet temperature of the system falls below 159° F degrees (180° – 20° F =  
160° F). To adjust, press either S1/– (Decrease Value) or S2/+ (Increase Value) Ranges 5° F to 30°  
F. Press the S3/Program key again and you will see the Indirect Setting de and an alternative value  
of 119 (Vision Systems Only) To adjust, press either S1/– (Decrease Value) or S2/+ (Increase Value).  
The final adjustment in this mode is the Farenheit to Celcius measurement. Press the S3/Program  
key again and you will see t and alternating value of F. To change value press the S1/– or S2/+ to  
choose the correct measurement.  
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 tem-  
perature. 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 val-  
ues cannot be changed. To exit this menu, simply press S3/Program key to resume normal operation.  
Function Value  
d1/  
d2/  
d3/  
Actual Temperature from outlet sensor  
Actual Temperature from inlet sensor  
If using a standard mechanical control, the control will display 1 for closed 0 for open  
If the sensor is connected to the SuperStor Indirect Fired Water Heater it will measure  
the actual temperature. (Vision only.)  
d4/  
d5/  
d6/  
Not used  
Actual Temperature from the outdoor sensor. (Vision only.)  
Actual Fan speed multiplied by 10 (Example: If fan speed displayed is  
410 RPM x 10 = 4100 actual fan speed)  
d7/  
d8/  
d9/  
d10/  
d11/  
Actual Ionization current read from Flame Rectification probe  
Actual Status of the Central Heating Circulator Off = 0 , On = 1 . (Vision only.)  
Actual Status of the Indirect Fired Circulator Off = 0 , On = 1 . (Vision only.)  
Actual Status bus communication co = connected, no = not connected  
Central Heating Set Point  
36  
START-UP PROCEDURES / SERVICING  
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.  
COMBUSTION SETTINGS  
HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS  
Natural Gas  
Propane LP  
low  
high  
low  
high  
0–20 ppm  
70 ppm–135 ppm  
8-1/2% – 9-1/2%  
0–20 ppm  
80–150 ppm  
Carbon CO ppm Monoxide  
Carbon CO2% Monoxide  
8-1/2% – 9-1/2%  
9-1/2% – 10-1/2%  
9-1/2% – 10-1/2%  
Fig. 6-1  
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.  
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.  
Fig. 6-2  
37  
TROUBLESHOOTING  
PART 7. TROUBLESHOOTING  
A. MUNCHKIN ERROR CODE  
WARNING  
An error code may occur in the installation of the  
Munchkin. This condition may lead to a lock out con-  
dition of the controller, which will need to be manu-  
ally reset through the S4/Reset button. These tempo-  
rary codes will help the installer correct the problem  
before going into a lock out condition, which will  
require a manual reset.  
When servicing or replacing any components of this  
boiler be certain that:  
• The gas is off.  
• All electrical power is disconnected  
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  
B. BOILER ERROR  
1. When an error condition occurs the con-  
troller will display an error code on the dis-  
play module.  
2. These error codes and several suggested  
corrective actions are included in Table 7.1.  
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.  
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.  
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.  
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.  
CAUTION  
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.  
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.  
Code  
Description  
Duration  
Corrective Action  
1. Check circulation pump operation.  
2. Assure that there is adequate flow through the  
boiler by accessing the status menu and assuring  
that there is less than a 50°F rise from the return  
thermister to the supply thermister.  
E00 High Limit Exceeded  
50 Sec.  
3. Replace switch if faulty.  
Combustion Fan Speed Low.  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
E13 The boiler combustion air fan  
60 Sec.  
speed less than 70% of expected.  
Combustion Fan Speed High. The  
E14 boiler combustion air fan speed is  
more than 130% of expected.  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
60 Sec.  
Until  
1. Assure that the system pressure is above 10 psig.  
PR0 Pressure Switch Open  
Corrected 2. Check for leaks in the system piping.  
1. Assure that the vent is not blocked  
Until  
Blocked Vent Pressure Switch Open  
2. Check the switch operation by applying a jumper.  
Corrected  
FLU  
(If the switch is not functioning properly, replace it.)  
38  
TROUBLESHOOTING  
Table 7-1: 925 Control Board Error Codes  
Code Description  
Remedy  
1. Check circulation pump operation  
2. Assure that there is adequate flow through the boiler by accessing the  
status menu and assuring that there is less than a 50°F rise from the  
return thermister to the supply thermister.  
F00 High Limit Exceeded.  
3. Check thermister reading on supply thermister. Replace switch if faulty.  
1. Push the red reset button on the switch.  
2. Check the flue temperature during operation using a combustion  
analyzer.  
F01 Vent Temperature Limit Exceeded.  
3. Replace the switch if faulty.  
Interrupted or Shorted  
F02  
1. Check the electrical connection to the thermister on the outlet manifold.  
2. Replace thermister if necessary.  
Supply (Outlet) Thermister.  
Interrupted or Shorted  
Return (Inlet) Thermister.  
1. Check the electrical connection to the thermister on the inlet manifold.  
2. Replace thermister if necessary.  
F03  
1. Check circulation pump operation.  
Supply (Outlet)  
F05  
2. Assure that there is adequate flow through the boiler by accessing the  
status menu and assuring that there is less than a 50°F rise from the  
return thermister to the supply thermister.  
Temperature exceeds 230°F.  
1. Check circulation pump operation.  
Return (Inlet) Temperature  
Exceeded 230°F.  
2. Assure that there is adequate flow through the boiler by accessing the  
status menu and assuring that there is less than a 50°F rise from the  
return thermister to the supply thermister.  
F06  
1. Watch the igniter through the observation window provided.  
2. If there is no spark, check the spark electrode for the proper ¼” gap.  
3. Remove any corrosion from the spark electrod and flame rectifier probe.  
4. If there is a spark but no flame, check the gas supply to the boiler.  
5. If there is a flame, check the flame sensor.  
No flame detected – The boiler will  
make three attempts at ignition  
F09  
before the control goes into this  
lockout condition.  
6. Check any flue blockage or condensate blocks.  
1. Monitor the gas pressure to the unit while in operation.  
2. Assure that the flame is stable when lit.  
3. Check to see if the green light on the display module is out while the  
boiler is running.  
4. If the green light doesn’t come on or goes off during operation check  
the flame signal on the status menu.  
5. If the signal reads less than 1 microampere, clean the flame rectifier  
probe.  
6. If the flame rectifier probe continues to read low, replace it.  
Loss of Flame Signal – The boiler  
will relight 4 times before the  
F10  
control goes into this lockout  
condition.  
1. Turn the gas off to the unit at the service valve.  
2. If the flame signal is still present replace the igniter.  
False Flame Signal – The boiler will 3. If the flame signal is not present after turning off the gas supply, check  
F11 lock out if it senses a flame signal the gas valve electrical connection.  
when there should be none present. 4. If there is no power to the gas valve, remove the valve and check for  
obstruction in the valve seat or replace the gas valve.  
5. Turn the gas on at the service valve after corrective action is taken.  
Combustion Fan Speed Low – The  
boiler will lock out if it senses that  
F13 the fan speed is less than 70% of  
expected rate for more than 60  
seconds.  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
Combustion Fan Speed High – The  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
boiler will lock out if the fan speed is  
F14  
more than 130% of expected rate  
for more than 60 seconds.  
1. Make sure the connector is correctly connected to the gas valve.  
2. Check the electrical wiring from the valve to the control board.  
3. Replace the low voltage wiring harness assembly.  
4. Replace control board.  
F18 Gas Valve Error  
F30 Watchdog  
Call factory for further assistance.  
Call factory for further assistance.  
Call factory for further assistance.  
Call factory for further assistance.  
F31 Parameter Memory  
F32 Parameter Memory Write Error  
F33 Programming Error  
39  
TROUBLESHOOTING  
RESISTANCE TABLES  
Boiler & Indirect Temperature (˚F) Resistance (ohms)  
32  
41  
50  
59  
68  
77  
86  
95  
104  
113  
122  
131  
140  
149  
158  
167  
176  
185  
194  
203  
212  
32550  
25340  
19870  
15700  
12490  
10000  
8059  
6535  
5330  
4372  
3605  
2989  
2490  
2084  
1753  
1481  
1256  
1070  
915  
786  
667  
40  
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 con-  
dition. The installer should discuss the contents of the User's Information Manual with the owner.  
B. BEFORE EACH HEATING SEASON:  
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 thermostat so the Munchkin will not cycle and then follow the steps below.  
a. Close gas valve  
b. Disconnect the poly hose from the combustion blower motor  
c. Disconnect the condensate hose from the outside connection (not from the Munchkin) so  
flow can be observed.  
d. Block the air flow in the exhaust by temporarily plugging the exhaust from the outside vent.  
e. Disconnect the white, red, blue, and black connection from the Molex on the combustion  
blower. (Refer to Control Wiring Layout fig. 8-1 this section.) 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.)  
f. 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 and turn up the thermostats  
c. Observe the boiler function to make sure you see a condensate flow.  
d. 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,  
in which case, a qualified plumber will need to be contacted to follow the Combustion Chamber Coil  
Cleaning Instructions (Section D) included in this section to dissolve deposit and clean condensate  
line.  
41  
MAINTENANCE  
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.  
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)  
(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 the (4) screws on the aluminum ½” NPT connector on the gas valve.  
d. Disconnect the poly hose connected to the combustion blower motor. (This does not apply  
to T50/T80.)  
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 con-  
densate 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 ceramic 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 wiring  
d. Re-connect the poly hose to the combustion blower motor. (Does not apply to the T50 or  
T80.)  
e. Replace the (4) screws on the aluminum ½” NPT connector on the gas valve. Turn the gas  
back on. (IMPORTANT: CHECK FOR GAS LEAKS)  
f. Re-set thermostats (IMPORTANT: MAKE SURE EXHAUST VENT IS NO LONGER BLOCKED!)  
g. Turn the Munchkin back on** and observe condensate flow.  
h. Re-connect the condensate hose to the outside connection.  
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.  
**NOTE: When firing up the boiler for the first few times you may experience some flut-  
tering 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.  
42  
MAINTENANCE  
E. MUNCHKIN CONTROLLER  
CONTROL WIRING LAYOUT  
Fig. 8-1  
There is a spare 6.3 amp “slow blow” fuse included on the control cover. HTP p/n 7250-378 or  
you may purchase it from Radio Shack p/n: 270-1068  
*
Caution: Do not replace with any amperage other than 6.3A  
43  
MAINTENANCE  
44  
MAINTENANCE  
45  
NOTES  
46  
NOTES  
47  
SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc.  
Munchkin R1  
LP-61 REV. 1/17/05  
© 2004 Heat Transfer Products, Inc.  

Perle Systems Cable Box S 4GPT DSFP XT User Manual
Panasonic NV RZ9ENC User Manual
Panasonic HHR380A User Manual
Optoma Technology BX AL133 User Manual
Nokia HS 26W User Manual
Nikon COOLPIXS9100RED User Manual
Nikon 7x50CF User Manual
Melissa 646 071 User Manual
Kicker DS7130 User Manual
Kenwood KDC 122 User Manual