Munchkin Gas-Fired Hot Water Boiler Installation manual

Installation
Manual
•
•
•
•
Installation
Startup
Maintenance
Parts
MH18082
WARNING
This manual must only be used by a qualified heating installer/service technician. Read all instructions
in this manual before installing. Perform steps in the order given. Failure to comply could result in
severe personal injury, death or substantial property damage.
GAS-FIRED HEATER
Installation Manual
CONTENTS
Part 1 – Product and Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,4
Part 2 – How The Heater Operates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,6
Part 3 – Prepare Heater Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
A.
B.
C.
D.
E.
F.
G.
Installations Must Comply With:
Before Locating Heater
Clearances for Service Access
Residential Garage Installation
Air Intake and Exhaust Vent
Prevent Combustion Air Contamination
When Removing an Appliance from an Existing Common Vent System
Part 4 – Prepare Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
A.
B.
C.
D.
Remove Contender from Box
Placing Wall-Mounted Contender
Munchkin Contender Wall Mounting Instruction
Installation Steps
Part 5 – Contender Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
– Contender Piping Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
Relief Valve
General Piping Information
Separate Low Water Cutoff
Backflow Preventer
System Water Piping Methods
Circulators
Hydronic Piping with Circulators, Zone Valves and Multiple Heaters
Circulator Sizing
Fill and Purge Heating System
Zoning with Zone Valves
Zoning with Circulators
Multiple Contenders
Contender Piping Details
Part 6 – Contender Piping with Optional Vision 1 System . . . . . . . . . . . . . . . . . . . . . 23-33
– Contender Piping Details With Vision I System . . . . . . . . . . . . . . . . . . . . . . . . . . 24-33
A.
B.
C.
D.
Vision 1 System Piping
Zoning with Zone Valves Using Vision I
Zoning with Circulators Using Vision I
Contender Piping Details with the Vision I System
Part 7 – Venting Combustion Air And Condensate Removal. . . . . . . . . . . . . . . . . . . . 34-42
– Venting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,42
A.
B.
C.
D.
E.
1
Installing Exhaust Vent and Intake Air Vent
General
Approved Materials for Exhaust Vent and Intake Air Vent
Exhaust Vent and Intake Air Vent Pipe Location.
Exhaust Vent and Intake Air Vent Sizing
GAS-FIRED HEATER
Installation Manual
CONTENTS (CONT’D)
F.
G.
H.
I.
Exhaust Vent and Intake Air Pipe Installation.
Heater Removal from a Common Vent System
Condensate Removal System
Diagrams for Side Wall Venting
Part 8 – Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,44
A.
B.
C.
D.
Gas Connection
Gas Piping
Gas Table
Dungs Gas Valve
Part 9 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47
A.
B.
C.
D.
Installation Must Comply With
Field Wiring
Line Voltage Wiring
Thermostat
Part 10 – Field Wiring – Vision 1 Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Part 11 – Start Up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-51
A.
B.
C.
D.
E.
F.
G.
H.
Check/Control Water Chemistry
Freeze Protection (when used)
Fill and Test Water System
Purge Air from Water System
Check for Gas Leaks
Check Thermostat Circuit(s)
Condensate Removal
Final Checks Before Starting The Munchkin Contender
Part 12 – Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-53
A.
B.
C.
D.
Operating Instructions
Adjusting the Set Point
Status Menu
Test Mode
Part 13 – Start-Up Procedures With The Vision 1 Option . . . . . . . . . . . . . . . . . . . . . . 53-54
A. Programming the Vision I Option
B. Vision I Program Access
C. Vision I Program Navigation
Part 14 – Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-59
A. Munchkin Error Code
B. Heater Error
C. Heater Fault
Part 15 – Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-63
A. Maintenance Procedures
B. Combustion Chamber Coil Cleaning Instructions
Part 16 – Heater Inspection and Maintenance Start-Up Charts . . . . . . . . . . . . . . . . . 64-66
2
GAS-FIRED HEATER
Installation Manual
PART 1: PRODUCT AND SAFETY INFORMATION
SPECIAL ATTENTION BOXES
The following defined terms are used throughout this manual to bring attention to the presence of
hazards of various risk levels or to important information concerning the product.
DEFINITIONS
DANGER
CAUTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
CAUTION Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
CAUTION
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
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.
NOTICE
Heat Transfer Products, Inc., reserves the right to make product changes or updates without notice
and will not be held liable for typographical errors in literature.
3
GAS-FIRED HEATER
Installation Manual
PART 1: PRODUCT AND SAFETY INFORMATION (CONT’D)
supply to circulator. Instead, shut off the gas
supply at a location external to the appliance.
WARNING
Installer — Read all instructions in this manual,
and Munchkin Contender Venting section,
before installing. Perform steps in the order
given.
User — This manual is for use only by a
qualified heating installer/service technician.
Refer to User’s Information Manual for your
reference.
•
HEATER WATER
•
If you have an old system with cast iron
radiators, thoroughly flush the system (without
heater connected) to remove sediment. The
high-efficiency heat exchanger can be damaged
by build-up or corrosion due to sediment.
•
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Gaskets and seals
in the system may be damaged. This can result
in substantial property damage.
•
Do not use “homemade cures” or “boiler patent
medicines.” Substantial property damage,
damage to boiler, and/or serious personal injury
may result.
•
Continual fresh make-up water will reduce the
heater life. Mineral buildup in heat exchanger
reduces heat transfer, overheats the stainless
steel heat exchanger, and causes failure.
Addition of oxygen carried in by make-up water
can cause internal corrosion in system
components. Leaks in heater or piping must be
repaired at once to prevent make-up water.
User — Have this heater serviced/inspected by
a qualified service technician annually.
Failure to comply with the above could result in
severe personal injury, death or substantial
property damage.
WARNING
Failure to adhere to the guidelines on this page
can result in severe personal injury, death or
substantial property damage.
WARNING
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.
Before Installing
WHEN SERVICING THE MUNCHKIN CONTENDER
•
To avoid electric shock, disconnect electrical
supply before performing maintenance.
•
To avoid severe burns, allow heater to cool
before performing maintenance.
MUNCHKIN CONTENDER OPERATION
•
Do not block flow of combustion or
ventilation air to heater.
•
Should overheating occur or gas supply fail to
shut off, do not turn off or disconnect electrical
Do not use this heater if any part has been
under water. Immediately call a qualified
service technician to inspect the heater and
to replace any part of the control system and
any gas control that has been under water.
FREEZE PROTECTION FLUIDS
CAUTION
NEVER use automotive or standard glycol
antifreeze, even ethylene glycol made for
hydronic systems. Use only inhibited propylene
glycol solutions, which are specifically
formulated for hydronic systems. Ethylene
glycol is toxic and can attack gaskets and seals
used in hydronic systems.
CAUTION
Consider piping and installation when
determining heater location. Any claims for
damage or shortage in shipment must be filed
immediately against the transportation
company by the consignee.
4
GAS-FIRED HEATER
Installation Manual
PART 2: HOW THE MUNCKIN CONTENDER OPERATES
Munchkin Contender Condensing Technology is
an intelligent system that delivers highly efficient
hydronic heating, while maximizing efficiency by
measuring the Data Parameters of your heating
system.
1. Stainless Steel Heat Exchanger
The highly efficient durable Munchkin
Contender Stainless Steel Heat Exchanger is
designed to take the colder return water from
the system and extract the last bit of energy
before it is exhausted. The heat exchanger
design is separated by an internal baffle which
diverts the exhaust gas through the primary
heat exchanger into the secondary heat
exchanger where the colder return water
extracts the last residual heat.
2. Modulating Combustion System
Modulation during the central heating
operation is based on the supply temperature.
The set point used for the control depends
upon the programmed central heating curve.
The slope of the heating curve can be changed
by the installer of the Munchkin Contender in
the sense that both turning points of the curve
can be moved. The control monitors the
system to regulate the output of the burner
during operation to match the system
demand. This increase in efficiency allows for
substantial fuel savings.
3. Gas Valve
The gas valve senses suction from the blower,
allowing gas to flow only if the gas valve is
powered and combustion air is flowing.
4. Swirl Plate System
The Swirl Plate on the gas valve controls the
air and gas flow into the burner, which will
assure better mixing for improved
combustion.
5. Supply water temperature sensor
This sensor monitors heater output water
temperature (system supply). The control
module adjusts the heater firing rate so the
outlet temperature is correct.
6. Return water temperature sensor
This sensor monitors the return water
temperature (system return). The control
module reduces or increases heater input,
5
depending on how close the return water
temperature is to the outlet water
temperature.
7. Temperature and pressure gauge
Allows the user to monitor the systems
temperature and pressure.
8. Control
The integrated control system monitors the
return and supply water and regulates the fan
speed to regulate the unit’s BTU output. This
allows the unit to only deliver the amount of
heated energy required and nothing more!
9. Flue pipe adapter
The flue pipe adapter may be positioned so
that the installer is able to find a position that
will best facilitate the exhaust and combustion
air pipe connections with the least number of
elbows even in the most challenging
applications.
10. Burner
Made with metal fiber and stainless steel
construction, the burner uses pre-mixed air
and gas and provides a wide range of firing
rates.
11. Electrical field connections with terminal
strips
The electrical cover plate allows access the
line voltage terminal strip and the low voltage
terminal strip. Attach line voltage conduits to
the three holes at the right of the line voltage
terminal strip for power, CH pump and DHW
pump. Route low voltage wires through the
opening to the left of the low voltage terminal
strip. (See Field Wiring Instructions Part 9.)
12. Condensate drain connection
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 the
heater and down to a suitable inside drain, if
the condensate outlet on the Munchkin
Contender is lower than the drain, you must
use a condensate removal pump (kit p/n
554200 available from Heat Transfer Products,
Installation Manual
GAS-FIRED HEATER
PART 2: HOW THE MUNCHKIN CONTENDER OPERATES (CONT’D)
14. The Vision 1 Optional System
Inc.) A condensate filter, if required by local
authorities can be made up of lime crystals,
marble or phosphate chips and will neutralize
the condensate. This can be done in the field
by the installer or you may purchase one from
Heat Transfer Products, Inc. (P/N N1100). 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.
The Vision I System will allow the installing
contractor to take the highly efficient
modulating Munchkin Contender and make it
even more efficient by controlling the
temperature delivered to the central heating
circuits based on the outside temperature. The
Vision I system is also a two temperature
system, one temperature for central heating
and the other temperature to the Super Stor
Ultra Indirect water heater. This allows the user
to increase the temperature supplied to the
Super Stor Ultra Indirect Water Heater to get a
fast recovery by prioritizing the flow at a higher
temperature than may be needed for the
central heating circuits (this will require two
separate circulators). You must follow the
piping, wiring and programming instructions
located in the Vision One section of this
manual. Optional kit consists of the following
• Outdoor sensor – 7250P-319
• Indirect tank sensor – 7250P-325
13. Spark ignition
The burner flame is ignited by applying a high
voltage to the system spark electrode. This
causes a spark from electrode to ground.
1
SYSTEM RETURN
4
COMBUSTION AIR INLET CONNECTION
7
ELECTRICAL BOX/CONTROL PANEL
2
SYSTEM SUPPLY
5
EXHAUST VENT CONNECTION
8
GAS LINE CONNECTION
3
SYSTEM RELIEF
6
CONDENSATE CUP/DRAIN ASSEMBLY
A
G
H
M
N
J
B
C
O
7
1
D
E
S
Q
K
L
3
8
P
R
2
F
LEFT SIDE
VIEW
BACK VIEW
RIGHT SIDE
VIEW
FRONT VIEW
MUNCHKIN CONTENDER HEATER DIMENSIONS AND SPECIFICATIONS
BTU/HR BUT/HR
MODEL INPUT
INPUT
NUMBER LOW
HIGH
FIRE
FIRE
1.
2.
3.
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
COMBUSTION AIR
INLET/EXHAUST
SYSTEM
VENT
RELIEF
CONNECTION PIPE SIZE
SIZE
SYSTEM SUPPLY/
SYSTEM RETURN/
PIPE SIZE
LOW
GAS
HEATER ENERGY DOE WATER
LINE
WATER FACTOR EFF.
EFF.
AFUE 1 LTAAE
CONN. VOLUME
EF 3
2
APPROX.
SHIPPING
WEIGHT
MC50
18,000
50,000
12.50
27.50
7.00
2.75
5.25
9.00
17.25
7.75
5.50
2.75
5.25
5.00
9.00
2.75
4.00
6.50
10.25
4.00
2.00
.75
1.25
.75
.58
.91
92%
98%
71 LBS
MC80
19,000
80,000
12.50
27.50
7.00
2.75
5.25
9.00
17.25
7.75
5.50
2.75
5.25
5.00
9.00
2.75
5.25
6.50
10.25
4.00
2.00
.75
1.25
.75
.67
.93
92%
98%
74 LBS
MC99
44,000
99,000
13.50
27.50
7.00
2.75
6.50
10.25
17.25
7.75
5.50
2.75
5.25
6.00
9.00
2.75
7.75
6.50
11.25
4.00
2.00
.75
1.25
.75
.96
.95
93%
98%
84 LBS
MC120
44,000 120,000 13.50
27.50
7.00
2.75
6.50
10.25
17.25
7.75
5.50
2.75
5.25
6.00
9.00
2.75
7.75
6.50
11.25
4.00
2.00
.75
1.25
.75
.96
.95
92%
98%
84 LBS
Tested by Heat Transfer Products to the ANSI/ASHRAE 103
Tested by Heat Transfer Products to the ANSI/ASHRAE Standard 103 with 90° return and 110° supply water
Tested by Heat Transfer Products to the 10 CFR 430.23 2005
6
Installation Manual
GAS-FIRED HEATER
PART 3: PREPARE MUNCHKIN CONTENDER LOCATION
•
Local, state, provincial, and national codes,
laws, regulations and ordinances.
•
•
•
•
National Fuel Gas Code, ANSI Z223.1 – latest
edition.
•
A. INSTALLATIONS MUST COMPLY WITH:
•
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME
CSD-1, when required.
•
National Electrical Code.
•
For Canada only: B149.1 or B149.2
Installation Code, CSA C22.1 Canadian
Electrical Code Part 1 and any local codes.
System leaks.
Incorrectly-sized expansion tank.
Lack of freeze protection in heating water
causing system and heater to freeze and
leak.
Excessive glycol which will affect the
heater system operation.
C. CLEARANCES FOR SERVICE ACCESS
1. See Figure 3-1 for recommended service
clearances. If you do not provide minimum
clearances shown, it might not be possible to
service the heater without removing it from
the space.
NOTICE
The Munchkin Contender Heater gas manifold
and controls met safe lighting and other
performance criteria when heater underwent
tests specified in ANSI Z21.10.3 — latest edition.
BEFORE LOCATING THE MUNCHKIN
CONTENDER
24"
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
FRONT CLEARANCE
2. Check area around boiler. Remove any
combustible materials, gasoline and other
flammable liquids.
WARNING
Failure to keep heater area clear and free of
combustible materials, gasoline and other
flammable liquids and vapors can result in
severe personal injury, death or substantial
property damage.
3. The Munchkin Contender must be installed
so that gas control system components are
protected from dripping or spraying water or
rain during operation or service.
4. If the new Munchkin Contender is to replace
an existing boiler, check for and correct any
existing system problems such as:
7
6"
SIDE
CLEARANCE
Figure 3-1: Clearances required
6"
SIDE
CLEARANCE
GAS-FIRED HEATER
Installation Manual
PART 3: PREPARE MUNCHKIN CONTENDER LOCATION (CONTINUED)
WARNING
The space must be provided with combustion/ventilation air openings correctly sized for
all other appliances located in the same space as
the Munchkin Contender heater. The heater
cover must be securely fastened to the heater to
prevent heater from drawing air from inside the
boiler room. This is particularly important if the
heater is located in the same room as other appliances. Failure to comply with the above warnings could result in severe personal injury, death
or substantial property damage.
D. RESIDENTIAL GARAGE INSTALLATION
Precautions
Take the following special precautions when
installing the Munchkin Contender in a residential garage. If the heater is located in a residential garage, per ANSI Z223.1, paragraph 5.1.9:
•
•
Mount the heater with a minimum of 18
inches above the floor of the garage to the
bottom of the heater to ensure the burner
and ignition devices will be no less than 18
inches above the floor.
Locate or protect the heater so it cannot be
damaged by a moving vehicle.
E. EXHAUST VENT AND INTAKE AIR VENT
The Munchkin Contender requires a special vent
system, designed for pressurized venting.
Munchkin Contenders are rated ANSI Z21.10.3
Category IV (pressurized vent, likely to condense in the vent).
You must also install air intake piping from outside
to the heater flue adaptor. The resultant installation is categorized as direct vent (sealed combustion). Note: To prevent combustion air contamination see Table 3-2 in this section
when considering exhaust vent and intake
air vent termination.
Intake and exhaust must terminate near each
other and may be vented vertically through the
roof or out a side wall. The intake and exhuast
venting methods are detailed in the Venting
Section. Do not attempt to install the Munchkin
Contender Heater using any other means. Be
sure to locate the heater such that the air intake
and exhaust vent piping can be routed through
the building and properly terminated. The air
intake and exhaust vent piping lengths, routing
and termination method must all comply with the
methods and limits given in the Venting section.
F. PREVENT COMBUSTION AIR CONTAMINATION
Install intake air piping for the Munchkin
Contender as described in the Venting section.
Do not terminate exhaust in locations that can
allow contamination of intake air.
WARNING
You must pipe outside air to the heater air
intake. Ensure that the intake air will not
contain any of the contaminants below.
Contaminated air will damage the heater,
resulting in possible severe personal injury,
death or substantial property damage. For
example, do not pipe intake air vent near a
swimming pool. Also avoid areas subject to
exhaust fumes from laundry facilities. These
areas will always contain contaminants.
Table 3-2: Corrosive contaminants and sources
Products to avoid
Spray cans containing fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms
Adhesives used to fasten building products and
other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages and workshops
8
GAS-FIRED HEATER
Installation Manual
PART 3: PREPARE MUNCHKIN CONTENDER LOCATION (CONTINUED)
in which the appliances remaining connected
to the common venting system are located
and other spaces of the building. Turn on
clothes dryers and any appliance not
connected to the common venting system.
Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
G. WHEN REMOVING AN EXISTING BOILER
FROM AN EXISTING COMMON VENT SYSTEM
DANGER
Do not install the Munchkin Contender heater
into a common vent with any other appliance.
This will cause flue gas spillage or appliance
malfunction, resulting in possible severe
personal injury, death or substantial property
damage.
WARNING
Failure to follow all instructions can result in flue
gas spillage and carbon monoxide emissions,
causing severe personal injury or death.
At the time of removal of an existing boiler or
heater, the following steps shall be followed with
each appliance remaining connected to the common venting system placed in operation, while the
other appliances remaining connected to the common venting system are not in operation.
a. Seal any unused openings in the common
venting system.
b. Visually inspect the venting system for
proper size and horizontal pitch and
determine there is non blockage or
restriction, leakage, corrosion and other
deficiencies which could cause an unsafe
condition.
c. Insofar as is practical, close all building doors
and windows and all doors between the space
d. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
e. Test for spillage at draft hood opening after 5
minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar, or pipe.
f.
After it has been determined that each
appliance remaining connected to the
common venting system properly vents
when tested as outlined herein, return doors,
windows, exhaust fans, fireplace dampers,
and any other gas-burning appliance to their
previous conditions of use.
g. Any improper operation of the common
venting system should be corrected so the
installation conforms with the National Fuel
Gas Code, ANSI Z223.1 — latest edition.
Correct by resizing to approach the minimum
size as determined using the appropriate
tables in Table 13 of NFPA54 ANSI Z223.1
2006 of that code. Canadian installations
must comply with B149.1 or B149.2
Installation Code.
PART 4: PREPARE MUNCHKIN CONTENDER HEATER
CAUTION
Cold weather handling — If heater has been
stored in a very cold location (below 0°F) before
installation, handle with care until the plastic
components come to room temperature.
A. REMOVE MUNCHKIN CONTENDER
HEATER FROM BOX
1. The Munchkin Contender is easy to handle.
9
Care must be taken to place it in a safe location
prior to installation on the wall to prevent damage to the bottom mechanical connections.
B. PLACING THE WALL-MOUNTED
MUNCHKIN CONTENDER HEATER
Munchkin Contender Heaters are wall mounted.
Use only the Munchkin Contender Heater wall
mounting instructions included in installation
envelope.
GAS-FIRED HEATER
Installation Manual
PART 4: PREPARE MUNCHKIN CONTENDER (CONTINUED)
WARNING
The wall must be capable of carrying the weight
of the heater and its related components. The
weights of the heater are approximately:
MC-50- 71 lbs.
MC-80- 74 lbs.
MC-9984 lbs.
MC-120Failure to comply with above could result in
severe personal injury, death or substantial
property damage.
]
C. MUNCHKIN CONTENDER
WALL MOUNTING INSTRUCTIONS
WARNING
This heater is heavy and awkward to lift. It is
recommended and safer to install the heater
with two people. Use caution as to not drop the
heater which could cause personal injury. Verify
that the heater is securely mounted before
leaving the heater unsupervised.
D. INSTALLATION STEPS
1) Prior to lifting the Munchkin Contender
Heater onto the wall, use the enclosed
template to level and locate the 2 primary
screws (#12 x 3" (3/16" x 3") round head
tapping screw leaving about 1/4" under the
screw head to the wall surface to allow for
access to the keyway slot which is located in
the back of the heater panel. It is extremely
important that the line on the template is level
when locating the first 2 screws. Failure to do
so will result in an uneven or out of level
installation.
2) Remove the Munchkin Contender cover and
locate the 2 keyway slots over the screws,
then lower the heater onto the smallest part
of the keyway slot.
3) Once the heater is mounted on the first 2
screws, finish tightening the first two screws to
the back panel, then install the 6 additional
screws of the same size to the back panel
holes. This will provide additional strength and
support to the Munchkin Contender Heater.
The wall must be vertically plumb and capable of
carrying the weight of the Munchkin Contender and
its related components.
The building frame (studs) must be 16" on center. If not, you must use 1/2" minimum plywood
24" x 48", fastened with at least (14) #12 x 3"
(3/16" x 3") round head tapping screws to the
frame of the building to provide proper support
for the boiler. Alternate methods of mounting
must not be used. (ex. toggle bolts, hollow wall
anchors) or any other fastener other than #12 x
3" (3/16" x 3") round head tapping screws.
CAUTION
If the Munckin Contender is not vertically
plumb, improper and unsatisfactory operation
m a y o c c u r. T h i s w i l l c a u s e exc e s s i v e
condensation build-up causing unnecessary
maintenance and nuisance fault codes.
10
GAS-FIRED HEATER
Installation Manual
PART 5: MUNCHKIN CONTENDER PIPING
A. RELIEF VALVE
Connect discharge piping to safe disposal location, following guidelines in the WARNING below.
WARNING
To avoid water damage or scalding due to relief
valve operation:
• Discharge line must be connected to relief valve
outlet and run to a safe place of disposal.
Terminate the discharge line in a manner that
will prevent possibility of severe burns or
property damage should the valve discharge.
• Discharge line must be as short as possible and
be the same size as the valve discharge
connection throughout its entire length.
• Discharge line must pitch downward from the
valve and terminate at least 6” above the floor
drain where any discharge will be clearly visible.
• The discharge line shall terminate plain, not
threaded, with a material serviceable for
temperatures of 375 °F or greater.
• Do not pipe the discharge to any place where
freezing could occur.
• No shutoff valve shall be installed between the
relief valve and heater, or in the discharge line.
Do not plug or place any obstruction in the
discharge line.
• Test the operation of the valve after filling and
pressurizing system by lifting the lever. Make
sure the valve discharges freely. If the valve fails
to operate correctly, replace it with a new relief
valve.
• Failure to comply with the above guidelines
could result in failure of the relief valve to
operate, resulting in possibility of severe
personal injury, death or substantial property
damage.
B. GENERAL PIPING INFORMATION
CAUTION
Use two wrenches when tightening water
piping at heater, using one wrench to prevent
the heater return line or supply line from
turning. Failure to support the heater piping
connections to prevent them from turning could
cause damage to heater components.
11
NOTICE
The Munchkin Contender Heater control module
uses temperature sensors to provide both high
limit protection and modulating temperature
control. The control module also provides low
water protection by sensing the water pressure
of the heat exchanger. Some codes/jurisdictions
may require additional external controls for high
limit and/or low water cutoff protection.
C. SEPARATE LOW WATER CUTOFF
A low water cutoff may be required by state
local code or some insurance companies. Check
code requirements before installation of the
Munchkin Contender Heater. It is also required
that a low water cutoff be used if the heater is
installed above the piping level.
If required:
• Use a low water cutoff designed for
hydronic installations that is an electrode
probe type
• Install in a tee on the supply piping above
the heater
• Follow low water cutoff manufacturer’s
instructions
D. BACKFLOW PREVENTER
Use a backflow preventer specifically designed
for hydronic boiler installations. This valve
should be installed on the cold water fill supply
line per local codes. (See piping details at the
end of this section.)
CAUTION
All piping methods shown in this manual use
primary/secondary connection to the heater loop.
This is to avoid the possibility of noise or actuator
problems in zone valves because of the high-head
heater circulator. For other piping methods,
consult your local Heat Transfer Products
representative or refer to separate Munchkin
Contender piping details in this manual (Part 5).
E. SYSTEM WATER PIPING METHODS
Expansion tank and make-up water
1. Ensure expansion tank size will handle heater
and system water volume and temperature.
Allow 3 gallons for the heater and its piping.
GAS-FIRED HEATER
Installation Manual
PART 5: MUNCHKIN CONTENDER PIPING (CONTINUED)
CAUTION
Undersized expansion tanks cause system
water to be lost from relief valve and makeup
water to be added through fill valve. Eventual
failure can result due to excessive make-up
water addition.
2. Expansion tank must be located as shown in
Piping Part 5, or following recognized design
methods. See tank manufacturer ’s
instructions for details.
3. Connect the expansion tank to the air
separator only if the separator is on the
suction side of the circulator. Always install
the system fill connection at the same point
as the expansion tank connection to the
system.
4. Most chilled water systems are piped using a
closed type expansion tank.
Diaphragm (or bladder) expansion tank
1. Always install an automatic air vent on top of
the air separator to remove residual air from
the system.
F. CIRCULATORS
CAUTION
DO NOT install automatic air vents on closedtype expansion tank systems. Air must remain
in the system and return to the tank to provide
its air cushion. An automatic air vent would
cause air to leave system, resulting in waterlogging the expansion tank.
CAUTION
DO NOT use the heater circulator in any location
other than the ones shown in this manual. The
heater circulator is selected to ensure adequate
flow through the Munchkin Contender. Failure
to comply could result in unreliable
performance and nuisance shut downs from
insufficient flow.
Sizing space heat system piping
1. See Piping Details in this manual Part 5. In all
diagrams, the space heating system is
isolated from the heating loop by the
primary/secondary connection.
2. Size the piping and components in the space
heating system using recognized design
methods.
G. HYDRONIC PIPING WITH CIRCULATORS,
ZONE VALVES AND MULTIPLE HEATERS
The Munchkin Contender is designed to function
in a closed loop 15 PSI System. A factory installed
water pressure switch will ensure that you have
adequate pressure in the system. The Munchkin
Contender will not operate without a minimum of
10 PSI water pressure. This assures you that if the
system does have leak, the Munchkin Contender
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 allows the user to monitor the
system pressure and outlet temperature from the
Munchkin Contender. It is important to note that
the Munchkin Contender has a minimal amount
of pressure drop and must be calculated when
sizing the circulators. Each Munchkin Contender
installation must have an Air Elimination device
that will remove air from the system. Install the
Munchkin Contender so the gas ignition system
components are protected from water (dripping,
spraying, etc.) allowing clearance 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 noncombustible materials. On a Munchkin Contender
installed above radiation level, some states and
local codes require a low water cut off device at
the time of installation (See Part C this section). If
the Munchkin Contender 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 specifically formulated for
this purpose. It will include inhibitors that will
prevent the glycol from attacking the metallic
system components. Make certain that the
system fluid is checked for the correct glycol
12
GAS-FIRED HEATER
Installation Manual
PART 5: MUNCHKIN CONTENDER PIPING (CONTINUED)
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.
6. Install a circulator as shown in piping details
(this section). Make sure the circulator is
properly sized for the system and friction loss.
Basic steps are listed below, with Illustration,
which will guide you through the installation of
the Munchkin.
8. Install an Air Elimination Device on the system
supply.
CAUTION
The Munchkin Contender should not be
operated as a potable Hot Water Heater.
1. Connect the system return marked “Heater In”.
2. Connect the system supply marked “Heater Out”.
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.
7. Install an Expansion Tank on the system
supply. Consult the tank manufacturer’s
instruction for specific information relating to
expansion tank installation. Size the expansion
tank for the required system volume and
capacity.
9. Install a drain valve at the lowest point of the
system. Note: The Munchkin Contender 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. Pipe the discharge of the safety relief
valve to prevent injury in the event of pressure
relief. Pipe the discharge 6” above the drain to
a drain. Provide piping that is the same size as
the safety relief valve outlet. Never block the
outlet of safety relief valve.
H. CIRCULATOR SIZING
The Munchkin Contender Heat Exchanger does
have pressure drop which must be considered
in your system design. Refer to the graph in Fig.
5-1 below for pressure drop through the
Munchkin Contender Heat Exchanger for recommended pump selection at a 20∆t design.
Figure 5-1
* NOTE: The recommended circulators are based on 1 gpm per 10,000 btu/hr with 20°∆t.
13
GAS-FIRED HEATER
Installation Manual
PART 5: MUNCHKIN CONTENDER PIPING (CONTINUED)
The chart below represents the various system temperatures and their respective flows and friction loss
through the Munchkin Contender which will aid circulator selection.
SYSTEM TEMPERATURE RISE CHART
Model
MC-50
MC-80
MC-99
MC-120
20˚ǻt
Friction
Flow
Feet
GPM
6.5'
5
7.8'
8
9'
10
10'
12
25˚ǻt
Friction
Flow
Feet
GPM
4.5'
4
4.7'
6.4
6'
9
7'
9.6
30˚ǻt
Friction
Flow
Feet
GPM
3'
3.3
2.9'
5.3
5'
7.8
5'
8
35˚ǻt
Friction
Flow
Feet
GPM
2'
2.5
2'
4.6
4'
6.3
4'
6.8
40˚ǻt
Friction
Flow
Feet
GPM
N/R
N/R
1.5'
4
3.5'
5.6
3.5'
6
45˚ǻt
Friction
Flow
Feet
GPM
N/R
N/R
1'
3.5
2'
4.8
2'
5.3
N/R = Not recommended
I. FILL AND PURGE HEATING SYSTEM
•
Attach the hose to balance and purge hose
connector or drain valve and run hose to
nearest 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: You should check valve
manufacturer’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
connected to the balance and purge valve or
drain you will see a steady stream of water
(without 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).
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.
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.
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.
Glycol mixtures should not exceed 50%.
1. Glycol in hydronic applications which is
specially formulated for this purpose includes
inhibitors that 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 system 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.
14
GAS-FIRED HEATER
Installation Manual
MUNCHKIN CONTENDER PIPING (CONTINUED)
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.
J. ZONING WITH ZONE VALVES
K. ZONING WITH CIRCULATORS
1. Connect heater to system when circulator
zoning as shown in 1C and 1D in Piping
Details when zoning with circulators. The
heater circulator cannot be used for a zone. It
must supply only the heater loop.
2. Install a separate circulator for each zone.
3. Connect DHW (domestic hot water) piping to
indirect storage water heater as shown.
L. MULTIPLE HEATERS
1. Connect heater to system as shown in 1A
and 1B in Piping Details when zoning with
zone valves. The primary/secondary piping
shown ensures the heater loop will have
sufficient flow. It also avoids applying the
high head of the heater circulator to the zone
valves.
1. Connect multiple heaters as shown in 1E and
1F in Piping Details.
2. Connect DHW (domestic hot water) piping to
indirect storage water heater as shown.
4. Connect DHW (domestic hot water) piping to
indirect storage water heater as shown.
15
2. All piping shown is reverse return to assure
balanced flow through the connected boilers.
3. Each connected heater must have its own
circulator pump to assure adequate flow.
Installation Manual
GAS-FIRED HEATER
M. CONTENDER PIPING DETAILS
Piping symbol legend
circulator
(w/ integral check valve)
circulator
(w/ isolation ßanges)
gate valve
pressure reducing valve
globe valve
diff. pressure bypass
ball valve
anti-scald mixing valve
swing-check valve
flow-check valve
spring-loaded check valve
T/P
temperature /pressure
gauge
hose bib / boiler drain
3-way motorized
mixing valve
TRV (straight)
4-way motorized
mixing valve
Munchkin Contender Heater
TRV angle
circuit setter
purging valve
pressure relief valve
backflow preventer
manual 3-way valve
float -type
air vent
zone valve
union
DHW temperature sensor
air separator
aquastat
Outdoor temperature
sensor
Super Stor Ultra
Indirect DHW Tank
heat exchanger
diaphragm-type
expansion tank
radiant manifold
with valve actuators
radiant manifold
16
Installation Manual
GAS-FIRED HEATER
Standard Munchkin Contender
!
Heater
(zoning with valves)
Space heating mode
Drawing 1A
zone valves
see note 6
make-up water
P2
closely
spaced
tees
differential
pressure
bypass
valve
purge
purging
valves
OFF
anti-scald
mixing valve
Munchkin
Contender
Heater
T/P
Super Stor Ultra
indirect DHW Tank
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used
with the circulator flanges as an alternative.
7.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
8.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
!
17
Installation Manual
GAS-FIRED HEATER
Standard Munchkin Contender Heater
(zoning with valves)
Domestic water heating mode
Drawing 1B
OFF
OFF
make-up water
OFF
OFF
zone valves
see note 6
P2
closely
spaced
tees
differential
pressure
bypass
valve
purging
valves
anti-scald
mixing valve
Munchkin
Contender
Heater
T/P
Super Stor Ultra
indirect DHW Tank
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges. The alternative is standard ßanges with full port ball valves. Purge valves can be used with
the circulator ßanges as an alternative.
7.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
8.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.!
18
Installation Manual
GAS-FIRED HEATER
Standard Munchkin Contender Heater
Preferred piping (zoning with circulators)
Space heating mode
Drawing 1C
space heating zone circuit
see note 6
zone
circulators
make-up water
closely
spaced
tees
purging
valves
anti-scald
mixing valve
Munchkin
Contender
Heater
T/P
Super Stor Ultra
indirect DHW Tank
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
8.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
19
Installation Manual
GAS-FIRED HEATER
Standard Munchkin Contender Heater
(zoning with circulators)
Domestic water heating mode
Drawing 1D
space heating zone circuit
see note 6
zone
circulators
make-up water
closely
spaced
tees
see note 6
purging
valves
anti-scald
mixing valve
Munchkin
Contender
Heater
T/P
Super Stor Ultra
indirect DHW Tank
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation ßanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
8.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
20
Installation Manual
GAS-FIRED HEATER
Multiple Munchkin Contender Heaters
Preferred piping
(zoning with circulators)
Space heating mode
Drawing 1E
space heating zone circuit
see note 6
zone
circulators
make-up water
purging
valves
closely
spaced
tees
purging
valves
anti-scald
mixing valve
cold
water
Munchkin
Contender
Heaters
T/P
T/P
P2
outdoor
temperature
sensor
Super Stor Ultra
indirect DHW Tank
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a separate
flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
8.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
21
GAS-FIRED HEATER
Installation Manual
Multiple Munchkin Contender Heaters
Preferred piping
(zoning with circulators)
Domestic water heating mode
Drawing 1F
space heating zone circuit
zone
circulators
make-up water
purging
valves
closely
spaced
tees
purging
valves
anti-scald
mixing valve
see note 6
cold
water
Munchkin
Contender
Heaters
T/P
T/P
Super Stor Ultra
indirect DHW Tank
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a separate
flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
8.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
22
GAS-FIRED HEATER
Installation Manual
PART 6. MUNCHKIN CONTENDER PIPING WITH OPTIONAL VISION I SYSTEM (DHW PRIORITY WITH OUTDOOR RESET)
A. VISION I SYSTEM PIPING
It is important that the system piping is done
correctly when using the Vision 1 System.
Follow the piping diagrams 2A through 3G when
piping your Munchkin Contender with Vision I.
All general piping practices should still be maintained.
B. ZONING WITH ZONE VALVES USING VISION I
1. Connect the heater to the system as shown
in piping details 2A through 2C.
23
2. Connect the DHW circulator (P2) directly to
the heater as shown as shown in the piping
details. The heater circulator (P1) will shut
down when there is a DHW demand.
C. ZONING WITH CIRCULATORS USING VISION I
1. Connect the heater to the system as shown
in piping details 3A through 3G.
2. Connect the DHW circulator (P2) directly to
the heater as shown in the piping details. The
heater circulator (P1) will shut down when
there is a DHW demand.
Installation Manual
GAS-FIRED HEATER
D. BOILER PIPING DETAILS WITH THE VISION I SYSTEM
Munchkin Contender Heater with optional VISION 1 system
(zoning with valves)
Space heating mode
Drawing 2A
optional high limit safety
see note 6
make-up water
purge
zone
valves
purge
Munchkin
Contender
Heater
differential
pressure
bypass
valve
anti-scald mixing valve
P1
DHW
temperature
sensor
(Vision 1 system)
OFF
T/P
P2
outdoor
temperature
sensor
(Vision 1 system)
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with the
circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
24
Installation Manual
optional high limit safety
see note 6
OFF
OFF
Munchkin Contender Heater with optional VISION 1 system
(zoning with valves)
Domestic water heating mode
Drawing 2B
OFF
GAS-FIRED HEATER
zone
valves
make-up water
purge
purge
OFF
see note 6
Munchkin
Contender
Heater
differential
pressure
bypass
valve
anti-scald mixing valve
P1
DHW
temperature
sensor
(Vision 1 system)
OFF
T/P
P2
outdoor
temperature
sensor
(Vision 1 system)
purge
Super Stor Ultra!
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with
the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
25
Installation Manual
GAS-FIRED HEATER
Munchkin Contender Heater with optional VISION 1 system
(zoning with valves)
Space heating mode (w/ submixing)
Drawing 2C
3-way
(manually-set)
mixing valve
vent
low temperature
manifold station
air handler
optional high limit safety
see note 6
purge
purge
make-up water
balancing
valve
see note 6
anti-scald
mixing valve
differential
pressure!
bypass
valve
Munchkin
Contender
Heater
cold
water
DHW
temperature
sensor
(Vision 1 system)
P1
OFF
T/P
outdoor
temperature
sensor
(Vision 1 system)
P2
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges. The alternative is standard flanges with full port ball valves. Purge valves can be used with the
circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
26
Installation Manual
GAS-FIRED HEATER
Munchkin Contender Heater with optional VISION 1 system
(zoning with circulators)
Space heating mode
Drawing 3A
make-up water
zone
circulators
high limit safety
purge
closely spaced tees
purge
see note 6
anti-scald mixing valve
Munchkin
Contender
Heater
DHW
temperature
sensor
(Vision 1 system)
P1
OFF
T/P
outdoor
temperature
sensor
(Vision 1 system)
P2
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
27
Installation Manual
GAS-FIRED HEATER
Munchkin Contender Heater with optional VISION 1 system
(zoning with circulators)
Domestic water heating mode
Drawing 3B
make-up water
zone
circulators
high limit safety
purge
purge
closely spaced tees
Munchkin
Contender
Heater
anti-scald mixing valve
OFF
DHW
temperature
sensor
(Vision 1 system)
P1
T/P
outdoor
temperature
sensor
(Vision 1 system)
P2
see note 6
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
28
Installation Manual
GAS-FIRED HEATER
Munchkin Contender Heater with optional VISION 1 system
(zoning with circulators)
Space heating mode (w/ submixing)
Drawing 3C
3-way
(manually-set)
mixing valve
vent
air handler
low temperature
manifold station
optional high limit safety
make-up water
purge
balancing
valve
purge
see note 6
anti-scald mixing valve
Munchkin
Contender
Heater
DHW
temperature
sensor
(Vision 1 system)
P1
OFF
T/P
outdoor
temperature
sensor
(Vision 1 system)
P2
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
29
GAS-FIRED HEATER
Installation Manual
Munchkin Contender Heater with optional VISION 1 system
(zoning with circulators)
Space heating mode (3 fully reset supply temperatures)
Drawing 3D
medium temperature
manifold station
vent
air handler
(higher temp.)
vent
optional high limit safety
low temperature
manifold station
balancing
valves
purge
make-up
water
purge
see note 6
3-way (manually-set) mixing valve
anti-scald mixing valve
Munchkin
Contender
Heater
DHW
temp.
sensor
P1
(Vision 1 system)
OFF
T/P
outdoor
temperature
sensor
(Vision 1 system)
P2
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
30
Installation Manual
GAS-FIRED HEATER
Drawing 3E
Munchkin Contender Heater with optional VISION 1 system
(zoning with circulators)
Space heating mode (3 different supply temperatures)
3-way manually-set
mixing valve
vent
air handler!
(higher temp.)
vent
low temperature
manifold station
optional high limit safety
variable
speed
injection
mixing
make-up
water
purge
medium
temperature
manifold station
purge
balancing
valves
see note 6
anti-scald mixing valve
purge
Munchkin
Contender
Heater
cold
water
DHW
temp.
sensor
P1
(Vision 1 system)
OFF
T/P
outdoor
temperature
sensor
(Vision 1 system)
P2
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves and a
separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
31
Installation Manual
GAS-FIRED HEATER
Munchkin Contender Heater with optional VISION 1 system
Drawing 3F
Multiple high temperature priority loads controlled with zone valves
high temperature loads
low temperature loads
OFF
make-up water
OFF
OFF
air handler
zone
circulators
optional high limit safety
air handler
purge
closely spaced tees
purge
multi-zone
relay center
Munchkin
Contender
Heater
anti-scald
mixing valve
DHW
tank
aquastat
OFF
P1
P2
T/P
outdoor
temperature
sensor
(Vision 1 system)
see note 6
purge
Super Stor Ultra
Indirect DHW Tank
thermal trap
(w/ drain plug)
differential pressure bypass valve
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves
and a separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
32
Installation Manual
GAS-FIRED HEATER
Munchkin Contender Heater with optional VISION 1 system
Multiple high temperature priority loads
controlled with zone circulators
Multiple low temperature load controls with zone circulators
high temperature loads
Drawing 3G
low temperature loads
OFF
make-up water
OFF
OFF
air handler
zone
circulators
optional high limit safety
air handler
multi-zone
relay center
purge
closely spaced tees
purge
Munchkin
Contender
Heater
anti-scald
mixing valve
DHW
tank
aquastat
OFF
P1
P2
T/P
outdoor
temperature
sensor
(Vision 1 system)
purge
see note 6
Super Stor Ultra
indirect DHW Tank
thermal trap
(w/ drain plug)
NOTES:
1.
This drawing is meant to show system piping concept only.
Installer is responsible for all equipment & detailing required by local codes.
2.
All closely spaced tees shall be within 4 pipe diameters center to center spacing.
3.
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.
4.
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.
5.
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch
6.
Circulators are shown with isolation flanges and integral check valves. The alternative is standard flanges with full port ball valves
and a separate flow check valve. Purge valves can be used with the circulator flanges as an alternative.
7.
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.
8.
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.
9.
Install a minimum of 12 diameters of straight pipe upstream of all circulators.
33
GAS-FIRED HEATER
Installation Manual
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL
DANGER
Munchkin Contender Heater must be vented as
detailed in Venting section Part 7. Ensure the
exhaust and intake piping comply with these
instructions regarding vent system.
Inspect finished combustion air intake and
exhaust piping thoroughly to ensure all joints
are well secured and airtight and comply with
all applicable code requirements, as well as
with the instructions provided in this manual.
Failure to provide a properly installed vent
system will cause severe personal injury or
death.
A. INSTALLING EXHAUST VENT AND
INTAKE AIR VENT
WARNING
This vent system will operate with a positive
pressure in the pipe. Do not connect vent
connectors serving appliances vented by natural
draft into any portion of mechanical draft
systems operating under positive pressure.
Follow the venting instructions below carefully.
Failure to do so may result in severe personal
injury, death, or substantial property damage.
b. Non Foam Core CPVC (Chlorinated
Polyvinyl Chloride) Pipe conforming to
ASTM D-1784 Class 23447-B (formerly
designated Type IV, Grade 1).
c. Non Foam Core ABS (AcrylonitrileButadiene- Styrene) Pipe conforming to
ASTM D3965 Class 3-2-2-2-2.
WARNING
Do not use Foam Core Pipe in any portion of the
exhaust piping from this heater. Use of Foam
Core Pipe may result in severe personal injury,
death, or substantial property damage.
2. Cellular foam core piping may be used on air
inlet piping only. Never use cellular foam core
material for exhaust vent piping.
D. EXHAUST VENT AND INTAKE AIR VENT
PIPE LOCATION
WARNING
Both exhaust and intake air vents must exit
from the same side of the building to assure
correct appliance operation.
1. Determine exhaust vent location:
B. GENERAL
1. Install the Munchkin Contender venting
system in accordance with these instructions
and with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, CAN/CGA B149, and/or
applicable provisions of local building codes.
2. This heater is a direct vent appliance and is
listed as a Category IV appliance with
Underwriters Laboratories, Inc. VENT AND
INTAKE AIR PIPE
C. APPROVED MATERIALS FOR EXHAUST
VENT AND INTAKE AIR VENT
1. Use only Non Foam Core venting material.
The following materials are approved for use
as vent pipe for this heater:
a. Non Foam Core PVC (Polyvinyl Chloride)
Pipe conforming to ASTM D-1784 Class
12454-B (formerly designated Type 1,
Grade 1).
a. The vent piping for this heater is
approved for zero clearance to
combustible construction.
b. See illustration within this section of
clearances for location of exit terminals of
direct-vent venting systems.
c. This heater vent system shall terminate at
least 3 feet (0.9 m) above any forced air
intake located within 10 ft (3 m). Note:
this does not apply to the combustion air
intake of a direct-vent appliance.
d. Provide a minimum of 1 foot distance
from any door, operable window, or
gravity intake into any building.
e. Provide a minimum of 1 foot clearance
from the bottom of the exhaust above the
expected snow accumulation level. Snow
removal may be necessary to maintain
clearance.
34
Installation Manual
GAS-FIRED HEATER
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
f.
Provide 4 feet horizontal clearance from
electrical meters, gas meters, gas
regulators and relief equipment. In no
case shall the exit terminal be above or
below the aforementioned equipment
unless the 4 foot horizontal distance is
maintained.
g. Do not locate the exhaust over public
walkways where condensate could drip
and/or freeze and create a nuisance or
hazard.
h. When adjacent to a public walkway,
locate exit terminal at least 7 feet above
grade.
i.
Do not locate the exhaust directly under
roof overhangs to prevent icicles from
forming.
j.
Provide 4 feet clearance from the inside
corner of vertical walls, chimneys, etc., as
well as horizontal corners created by roof
overhangs.
2. Determine air intake vent location.
a. Provide 1 foot clearance from the bottom
of the intake air vent and the level of
maximum snow accumulation. Snow
removal may be necessary to maintain
clearances.
b. Do not locate intake air vent in a parking
area where machinery may damage the
pipe.
c. When venting with a two pipe system,
maximum distance between intake air
vent and exhaust vent is 6 feet (1.8 m).
Minimum distance between exhaust vent
and intake air vent on single heater is 8”
(0.2 m) center-to-center. Minimum
distance between exhaust vents and
intake air vents on multiple heaters is 8”
(0.2 m) center-to-center.
CONDENSATE PIPING
CONDENSATE PIPING W/PUMP
SUGGESTED SETUP FOR
CONDENSATE REMOVAL TO
FLOOR DRAIN
3/4" PIPE
HANGER
ASSEMBLIES
3/4" PVC PIPE
(LENGTH DETERMINED BY
DISTANCE TO FLOOR)
3/4" PVC PIPE
(LENGTH DETERMINED
BY DISTANCE TO FLOOR)
3/4" PVC
90 ELBOW
3/4" PVC
90 ELBOW
3/4" PIPE
HANGER
ASSEMBLIES
(2 SHOWN)
(2 SHOWN)
3/4" SOCKET X
1/2" NPT THREAD
PVC ADAPTER
3/4" SOCKET X
1/2" THREAD
PVC ADAPTER
(2 SHOWN)
(2 SHOWN)
N1100 CONDENSATE
NEUTRALIZER
HORIZONTAL LINES MUST
BE INSTALLED WITH A
PITCH OF 1/4" PER FOOT
N1100 CONDENSATE
NEUTRALIZER
HORIZONATAL LINES MUST
BE INSTALLED WITH A
PITCH OF 1/4" PER FOOT
FLOOR DRAIN
CONDENSATE
CUP ASSEMBLY
DETAILS
CONDENSATE
SWITCH
CONDENSATE
CUP ASSEMBLY
35
SUGGESTED SETUP FOR
CONDENSATE REMOVAL
TO OUTSIDE SOURCE
3/4" NPT PVC NIPPLE
3/4" NPT FEMALE
PVC UNION
3/4" SOCKET
PVC TEE
3/4" THREAD X
SOCKET PVC
ADAPTER
3/4" SOCKET X
1/2" THREAD
PVC ADAPTER
3/8" TUBE X
3/4" NPT
HOSE BARB
3/8" ID TUBING
CONDENSATE
PUMP
GAS-FIRED HEATER
Installation Manual
EXHAUST PIPING
AROUND OBSTRUCTIONS
(SUGGESTED SETUP FOR PIPING
AROUND BEAMS IN ORDER
TO ELIMINATE CONDENSATION)
BUILDING
STRUCTURE
THE INTAKE VENT
CAN BE ROTATED
INTO ANY POSITION
PIPING LENGTH
DETERMINED BY
DISTANCE NEEDED
TO CLEAR BEAM
1/4" NPT X 1/2"
HOSE BARB
TUBING MUST
FORM A LOOP
6" IN DIAMETER
TOP VIEW
1/2" ID CLEAR
FLEXIBLE TUBING
(LENGTH DETERMINED
BY DISTANCE TO
CONDENSATE LINE)
1/4" NPT X 1/2"
HOSE BARB
TO DRAIN
36
GAS-FIRED HEATER
Installation Manual
Location of exit terminals of mechanical draft and direct-vent venting systems.
(Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002).
Fig. 7-1
Fig. 7-2 Multiple Vent Spacing*
*Note: Exhaust must extend out 1 foot
Figure 7-4: Multiple Heater Installations
Fig. 7-3 Multiple Stainless Steel Horizontal Vent Kit Installation – Front View
37
GAS-FIRED HEATER
Installation Manual
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
minimum difference in equivalent length
between the intake air vent pipe and the
exhaust vent.
E. EXHAUST VENT AND INTAKE AIR VENT
SIZING
1. The exhaust vent and intake air vent pipes
should be 2" or greater, Schedule 40 or 80.
3. The minimum combined equivalent length is
16 equivalent feet.
2. The total combined equivalent length of
exhaust vent and intake air pipe should not
exceed 85 feet for 2" and 125' for 3".
4. The maximum combined equivalent length
can be extended by increasing the diameter
of both exhaust vent and intake air vent pipe
equally. However, the transitions should
begin a minimum of 15 equivalent feet from
the boiler.
a. The equivalent length of elbows, tees,
and other fittings are listed in the Friction
Loss Table 7.6.
Table 7.6
FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS
FITTINGS OR PIPING
EQUIVALENT FEET
2"
3"
90 DEGREE ELBOW*
5'
5'
45 DEGREE ELBOW
3'
3'
COUPLING
0'
0'
AIR INLET TEE
0'
0'
STRAIGHT PIPE
1'
1'
CONCENTRIC VENT KIT
3'
3'
V500 2" VENT KIT
1'
N/A
V1000 3" VENT KIT
N/A
1'
*Friction loss for long radius elbow is 1 foot less.
b. For example: If the exhaust vent has two
90° elbows and 10 feet of PVC pipe we
will calculate:
Exhaust Vent Pipe Equivalent Length = (2x5)+10=20 feet
Further, if the intake air vent pipe has two
90° elbows, one 45° elbow and 10 feet of
PVC pipe, the following calculation
applies:
Intake Air Vent Pipe Equivalent Length = (2x5)+3+10=23 feet
Finally, if a concentric vent kit is used we
find:
a. Transitions should always be made in
vertical sections of pipe to prevent the
condensate from pooling in the vent
pipe.
b. Use a 3” x 2” reducing coupling to
transition from the 2” connections to a 3”
vent.
c. The maximum equivalent length for the
increased diameter vent pipes is 125 feet.
d. If the transition occurs at a distance
greater than 15 equivalent feet from the
boiler, the maximum equivalent length
will be reduced. See Table 7.7. The
standard Vent Pipe for Munchkin
Contender is 2".
Table 7.7: Vent Termination Kits
Transition
Point
(ft from
boiler)
TEL of
Standard
2" Vent
Pipe (ft)
TEL of
Maximum
Oversized
TEL of all
2" or 3" Vent Vent
Pipe (ft)
Pipe (ft)
15
30
95
125
20
40
77-1/2
117-1/2
25
50
60-1/2
110-1/2
30
60
43
103
35
70
26
96
40
80
8-1/2
88-1/2
None
85
0
85
TEL = Total Equivalent Length
Total Combined Equivalent Length = 20+23+3=46 feet
Therefore, the total combined equivalent
length is 46 feet which is well below the
maximum of 85 feet.
c. The intake air vent pipe and the exhaust
vent are intended to penetrate the same
wall or roof of the building.
d. Effort should be made to keep a
F. EXHAUST VENT AND INTAKE AIR PIPE
INSTALLATION
1. On the Munchkin Contender the 2" exhaust
vent connection is located on the top, right
side of the boiler and the air intake is on the
top, left side. The air intake connection is
intended for a slip fit. No sealant or adhesive
is required.
38
GAS-FIRED HEATER
Installation Manual
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
2. Use only solid PVC, CPVC, or ABS schedule
40 or 80 pipe. FOAM CORE PIPING IS NOT
APPROVED.
3. Remove all burrs and debris from joints and
fittings.
4. All joints must be properly cleaned, primed,
and cemented. Use only cement and primer
approved for use with the pipe material.
Cement must conform to ASTM D2564 for
PVC or CPVC pipe and ASTM D2235 for ABS
pipe.
WARNING
All joints of positive pressure vent systems
must be sealed completely to prevent leakage
of flue products into the living space.
5. Horizontal lengths of exhaust vent must slope
back towards the heater not less than ¼" per
foot to allow condensate to drain from the
vent pipe. If the exhaust pipe must be piped
around an obstacle that results in the creation
of a low point, condensate will collect in this
low point and form a blockage. This
condensate must be drained away using a
field-installed condensate drain assembly as
shown.
6. All piping must be fully supported. Use pipe
hangers at a minimum of 4 foot intervals to
prevent sagging of the pipe where
condensate may form.
7. Do not use the Munchkin Contender to
support any piping.
8. A screened straight coupling is provided with
the heater for use as an outside exhaust
termination.
9. A screened inlet air tee is provided with the
heater to be used as an outside intake
termination.
10. The following information on Table 7.8 are
optional intake air/exhaust vent terminations
available from Heat Transfer Products, Inc.
Table 7.8: Vent Termination Kits
Description
2" PVC Concentric Vent Termination Kit
3" PVC Concentric Vent Termination Kit
2" Stainless Steel Vent Termination Kit
3" Stainless Steel Vent Termination Kit
39
Stock Code
KGAVT0501CVT
KGAVT0601CVT
V500
V1000
G. HEATER REMOVAL FROM A COMMON
VENT SYSTEM
At the time of removal of an existing heater, the
following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
other appliances remaining connected to common venting system are not operating.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
size and horizontal pitch to determine if there
is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.
3. If practical, close all building doors, windows
and all doors between the space in which the
appliance remains connected to the common
venting system located and other spaces in
the building. Turn on clothes dryers and any
appliances not connected to the common
venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts,
at maximum speed. Do not operate a summer
exhaust fan. Close all fireplace dampers.
4. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust the thermostat so the appliance will
operate continuously.
5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use the flame of a match or candle
or smoke from a cigarette.
6. After it has been determined that each
appliance remaining connected to common
venting system properly vents when tested
as outlined, return doors, windows, exhaust
fans, fireplace dampers and any other gas
burning appliance to their previous condition
of use.
7. Any improper operation of the common
venting system should be corrected so the
installation conforms with the National Fuel
Gas Code, ANSI Z223.1. When resizing any
portion of the common venting system, the
common venting system should be resized to
approach the minimum size as determined
using the appropriate tables in Appendix G in
the National Fuel Gas Code , ANSI Z 223.1
Installation Manual
GAS-FIRED HEATER
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)
H. CONDENSATE REMOVAL SYSTEM
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 the heater and down to a
suitable inside drain, if the condensate outlet on
the Munchkin Contender is lower than the drain,
you must use a condensate removal pump (kit
P/N 554200 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. (P/N N1100) 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.
NOTICE
Use materials approved by the authority having
jurisdiction. In the absence of other authority,
PVC and CPVC pipe must comply with ASTM
D1785 or D1784, F441 or D2665. Cement and
primer must comply with ASTM D2564 or F493.
For Canada, use CSA or ULC certified PVC or
CPVC pipe, fittings and cement. (See Table 7-9)
When installing a condensate pump, select one
approved for use with condensing heaters and
furnaces. The pump should have an overflow
switch to prevent property damage from
condensate spillage.
Condensate from the Munchkin Contender
Heater will be slightly acidic (typically with a pH
from 3.2 to 4.5). Install a neutralizing filter if
required by local codes.
Table 7-9
Item
Material
United States
PVC schedule 40
ANSI/ASTM D1785
Vent or air PVC-DWV
pipe and
CPVC schedule 40
fitting
Pipe
cement/
primer
Canada
ANSI/ASTM D2665
ANSI/ASTM F441
CSA or ULC
ABS-DWV schedule 40 ANSI/ASTM D2661 certified
only
PVC
ANSI/ASTM D2564
CPVC
ANSI/ASTM F493
ABS
ANSI/ASTM D2235
CAUTION
The condensate line must remain unobstructed,
allowing free flow of condensate. If condensate
is allowed to freeze in the line or if the line is
obstructed in any other manor, condensate can
exit from the boiler tee, resulting in potential
water damage to property.
40
Installation Manual
GAS-FIRED HEATER
I. DIAGRAMS FOR SIDEWALL VENTING
VENT KIT
INTAKE
1" MIN.
INTAKE
(TEE)
12" MIN.
EXHAUST
TOP VIEW
EXTERIOR WALL
EXHAUST
(STRAIGHT
COUPLING)
TOP VIEW
VENT KIT
NOTE: EXTENDED VENT
RUNS WHEN TRANSITIONING
TO A LARGER DIAMETER
MUST ALWAYS TAKE PLACE
IN A VERTICAL POSITION
TO PREVENT CONDENSATE
BLOCKAGE.
EXTERIOR WALL
EXHAUST
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
1" MIN.
12" MIN.
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
INTAKE
(TEE)
EXHAUST
(STRAIGHT
COUPLING)
RIGHT SIDE VIEW
Fig. 7-10 2” sidewall vent with V500 kit
EXTERIOR WALL
INTAKE
IMPORTANT:
INTAKE LEG MUST
BE FACING UP
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
RIGHT SIDE VIEW
Fig. 7-9
2” sidewall vent with tee (intake) and
coupling (exhaust)
**Important Note: All vent pipes must be
glued, properly supported, and the exhaust
must be pitched a minimum of a 1/4" per
foot back to the heater (to allow for
drainage of condensate).
41
EXHAUST
Fig. 7-11 2” sidewall vent with 2” concentric vent
kit (KGAVT0501CVT)
1"
MIN.
GAS-FIRED HEATER
EXHAUST
(STRAIGHT
COUPLING)
10'-0" MIN.
Installation Manual
24" MIN.
10'-0" MIN.
12" OVER MAXIMUM
SNOW LEVEL OR 24"
WHICHEVER IS GREATER
12" OVER MAXIMUM
SNOW LEVEL OR 24"
WHICHEVER IS GREATER
INTAKE
(TEE)
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
SUPPORT BRACKETS
MUST BE USED ON
ALL HORIZONTAL
AND VERTICAL PIPING
RIGHT SIDE VIEW
RIGHT SIDE VIEW
Fig. 7-12 2" roof vent with tee (intake) & coupling
(exhaust)
Fig. 7-13 2" roof vent with 2" concentric vent kit
(KGAVT0501CVT)
NOTE: When placing support brackets on vent piping, the first bracket must be within 1 foot of the
appliance and the balance at 4 foot invervals on the vent pipe. The heater venting must be readily
accessible for visual inspection for the first three feet from the heater.
42
Installation Manual
GAS-FIRED HEATER
PART 8: GAS PIPING
WARNING
B. GAS PIPING
Failure to follow all precautions could result in
fire, explosion or death!
1. Run the gas supply line in accordance with all
applicable codes.
A. GAS CONNECTION
2. Locate and install manual shutoff valves in
accordance with state and local
requirements.
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. Fig. 8-1
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" with a factory installed. Do not
remove this ¾" x ½" bell reducer! It is mandatory that this fitting is used for connection to a field
fabricated drip leg as shown in the illustration
above per the National Fuel Gas Code. You must
ensure that the entire gas line to the connection
at the Munchkin Contender 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 Contender from the gas line.
In order to do this, you must shut the gas off
using factory and field-installed gas cocks. 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.
43
C. GAS TABLE
Refer to Table 8.2 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 8-2) (Based on a 0.60 Specific Gravity Gas)
Nominal
Iron Pipe
Size
(inches)
3/4
1
1 1/4
1 1/2
Internal
Diameter
( i n c h e s ) 10 20
.824
278 190
1.049
520 350
1.380 1,050 730
1.610 1,600 1,100
3/4
1
1 1/4
1 1/2
.824
1.049
1.380
1.610
80
90
170
350
530
90
84
160
320
490
Length of Pipe (Feet)
30
152
285
590
890
40
130
245
500
760
50
115
215
440
670
60
105
195
400
610
70
96 BTU'S
180 PER
370 HOUR
560 x1,000
100
79
150
305
460
125
72
130
275
410
150
64
120
250
380
175 200
59 55 BTU'S
110 100 PER
225 210 HOUR
350 320 x1,000
}
}
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
Installation Manual
GAS-FIRED HEATER
PART 8: GAS PIPING (CONTINUED)
Contender. 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
swirl plate and blower.
D. DUNGS GAS VALVE
PRESSURE TAP OUTLET
OFF SET ADJUSTMENT
CAUTION: DO NOT
REMOVE THIS SCREW
OR ATTEMPT TO MAKE
ANY ADJUSTMENT TO
THIS SCREW WITHOUT
A COMBUSTION
ANALYZER
SEE PART 12 SECTION
"D" FOR COMBUSTION
SETTING TABLE.
THROTTLE ADJUSTER
NOTE: IF FOR ANY REASON THE
THROTTLE NEEDS TO BE ADJUSTED,
IT IS VERY IMPORTANT THAT A
"COMBUSTION ANALYZER" 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. SEE PART 12 SECTION "D"
WARNING
PRESSURE
TAP INLET
GAS VALVE
GAS SHUT OFF
VALVE
Fig. 8-3
For a heater already installed,
you must turn off gas supply,
turn off power and allow
heater to cool before
proceeding. You must also
completely test the heater
after conversion to verify
performance as described
under “Startup” section of
this manual. See separate
natural to propane conversion
instructions for conversion of
an existing heater available
from Heat Transfer Products.
Failure to comply with the
proper gas conversion
instructions could result in
severe personal injury, death
or substantial property
damage. Failure to follow all
precautions could result in
fire, explosion or death!
44
GAS-FIRED HEATER
Installation Manual
PART 9: FIELD WIRING
WARNING
ELECTRICAL SHOCK HAZARD — For your
safety, turn off electrical power supply at service
entrance panel before making any electrical
connections to avoid possible electric shock
hazard. Failure to do so can cause severe
personal injury or death.
NOTICE
Wiring must be N.E.C. Class 1.
If original wiring as supplied with heater must
be replaced, use only TEW 105 °C wire or
equivalent.
Heater must be electrically grounded as
required by National Electrical Code ANSI/NFPA
70 — latest edition.
A. INSTALLATION MUST COMPLY WITH:
1. National Electrical Code and any other
national, state, provincial or local codes or
regulations.
2. In Canada, CSA C22.1 Canadian Electrical
Code Part 1, and any local codes.
B. FIELD WIRING
For you convenience we have located the electrical connection of the Munchkin Contender on the
45
front right hand side of the unit. The electrical junction box has a 24 volt terminal compartment and
120 volt terminal compartment. Each terminal connection is clearly marked to assure correct installation.
C. LINE VOLTAGE WIRING
1. Connect 120 VAC power wiring to the line
voltage terminal strip located inside the
electric junction box, as shown in figure 9.5.
2. Wire the Heater Primary Circulator (P1) to the
terminal strip. See wiring diagram in this
section.
D. THERMOSTAT
1. Connect room thermostat or end switch
2. Install thermostat on inside wall away from
influences of drafts, hot or cold water pipes,
lighting fixtures, television, sunrays or
fireplaces.
3. Thermostat anticipator (if applicable):
a. If connected directly to heater, set for 0.1
amps.
b. If connected to relays or other devices,
set to match total electrical power
requirements of connected devices. See
specifications of the device and
thermostat instructions for details.
GAS-FIRED HEATER
Installation Manual
PART 9: FIELD WIRING (CONTINUED)
Fig. 9-3
Fig. 9-1
Fig. 9-2
Fig. 9-4
46
GAS-FIRED HEATER
PART 9: FIELD WIRING (CONTINUED)
Fig. 9-5
47
Installation Manual
GAS-FIRED HEATER
Installation Manual
PART 10: FIELD WIRING – VISION 1 OPTION
Outdoor Sensor Function The user can program the desired supply temperature based on
the heat transmitter (Baseboard, Radiant Floor,
Air Handler) that will be used in the installation.
Once the outdoor sensor (Light Green Wires) is
connected to the control board, the water temperature of the heater will adjust to run the
heater more efficiently and provide greater comfort to the living space.
Connection Specification – Wire 22 AWG
maximum to 100 feet or 18 AWG up to
150 feet. Length of wire run cannot
exceed 150 feet.
Outdoor Sensor is connected in the junction
box on the Munchkin Contender. Route wires
from the Munchkin Contender terminal strip to
your outdoor sensor, which will allow the user to
change the temperature going to the Central
Heating loop automatically. Place the outdoor
sensor preferably to the north or northwest or to
the side which will be affected by changing
weather conditions outside. NOTE: Do not
locate the sensor in the direct sunlight.
CAUTION
The wire to outdoor sensor must not be laid
closer than 6' to line voltage wiring (120/240 V)
and must never be in the same conduit.
Indirect Sensor Function: The Maximum
run time on priority function for the Super Stor
Ultra Indirect Fired Water Heater is from 1-60
minutes. The water temperature can only be
adjusted when using a sensor (not a mechanical
control). Temperature adjustments are from 95
to 185 degrees, plus a differential 1-18 degrees
(Note: It is recommend that you do not exceed
5 minutes on the DHW pump post purge cycle
to avoid cooling down your DHW tank).
Indirect Sensor is connected to the main
control on the Munchkin Contender. Route wires
from the terminal strip to the sensor or the
mechanical control Honeywell Part # L4080b-
1395 (Not included in Vision I Package) into the
control well located in the front of the water
heater. This will allow the installer to control the
temperature of the indirect from the Munchkin
Contender and give the water heater priority
over the Central Heating Circuit. Once the Water
Heater is satisfied, the heater will then switch
back to the Central Heating Circuit only if there
is a call for heat, otherwise the Munchkin
Contender will then shut down.
Indirect
Circulator
(P2)
Program
function: The indirect water heater circulator
program function will automatically start when
the water heater sensor reads a call for heat, the
installer can also program the post purge
function on the circulator. The Post purge
circulator function ranges from 1-30 minutes.
Indirect Circulator (P2) is connected to the
terminal strip on the Munchkin Contender. Run
the wire to the Super Stor Ultra Indirect circulating pump. The purple wire will be your neutral
lead and the pink wire will be your hot. This will
supply 120 volts to the water heater circulator
directly.
Fault Code Alarm Output is connected to
the main controller on the Munchkin Contender.
Route wire from the Munchkin Contender controller to an external relay or an audible alarm.
The red wire will be your hot lead supplying 120
volts. The neutral connection will be connected
to the neutral on the incoming power to the
Munchkin Contender.
CAUTION
Do not tie neutrals or hot wire leads to any
other wires, go directly from the
Munchkin Contender controller to the circulator.
Connection Specification – Wire 18 AWG
maximum. Length of wire run cannot
exceed 100 feet.
48
GAS-FIRED HEATER
Installation Manual
PART 11. START-UP PREPARATION
A. CHECK/CONTROL WATER CHEMISTRY
WARNING
Do not use petroleum-based cleaning or sealing
compounds in heater system. Damage to
elastomer seals and gaskets in system could
occur, resulting in substantial property damage.
Water pH between 6.0 and 8.0
1. Maintain heater water pH between 6.0 and 8.0.
Check with litmus paper or have chemically
analyzed by water treatment company.
2. If pH differs from above, consult local water
treatment company for treatment needed.
Hardness less than 7 grains.
1. Consult local water treatment companies for
unusually hard water areas (above 7 grains
hardness).
Chlorine concentration less than 200 ppm
1. Filling with chlorinated fresh water should be
acceptable since drinking water chlorine
levels are typically less than 5 ppm.
2. Do not use the heater to directly heat
swimming pool or spa water.
3. Do not fill heater or operate with water
containing chlorine in excess of 200 ppm.
Clean system to remove sediment
1. You must thoroughly flush the system
(without heater connected) to remove
sediment. The high-efficiency heat exchanger
can be damaged by buildup or corrosion due
to sediment.
2. For zoned systems, flush each zone separately through a purge valve. (If purge valves
and isolation valves are not already installed,
install them to properly clean the system.)
3. Flush system until water runs clean and you
are sure piping is free of sediment.
Test/replace freeze protection fluid
1. For systems using freeze protection fluids,
follow fluid manufacturer’s instructions to
verify inhibitor level and that other fluid
characteristics are satisfactory.
2. Freeze protection fluid must be replaced period49
ically due to degradation of inhibitors over time.
Follow all fluid manufacturer’s instructions.
B. FREEZE PROTECTION (WHEN USED)
WARNING
NEVER use automotive or standard glycol
antifreeze, even ethylene glycol made for
hydronic systems. Use only freeze-prevention
fluids certified by fluid manufacturer as suitable
for use with stainless steel heaters, verified in
fluid manufacturer’s literature.
Throroughly clean and flush any system that
has has used glycol before installing the new
Contender Contender Heater.
Provide Munchkin Contender Heater owner
with a material safety data sheet (MSDS) on the
fluid used.
1. Determine freeze protection fluid quantity
using total system water content, following
fluid manufacturer’s instructions. Remember
to include expansion tank water content.
2. Local codes may require back flow preventer
or actual disconnect from city water supply.
3. When using freeze protection fluid with
automatic fill, install a water meter to monitor
water makeup. Freeze protection fluid may
leak before the water begins to leak, causing
concentration to drop, reducing the freeze
protection level.
C. FILL AND TEST WATER SYSTEM
1. Fill system only after ensuring the water
meets the requirements of this manual.
2. Close manual and automatic air vents and
heater drain valve.
3. Fill to correct system pressure. Correct
pressure will vary with each application.
a. Typical cold water fill pressure for a
residential system is 12 psi.
b. Pressure will rise when heater is turned
on and system water temperature
increases. Operating pressure must
never exceed 25 psig.
4. At initial fill and during heater startup and
testing, check system thoroughly for any leaks.
Repair all leaks before proceeding further.
GAS-FIRED HEATER
Installation Manual
PART 11. START-UP PREPARATION (CONTINUED)
WARNING
Eliminate all system leaks. Continual fresh
make-up water will reduce heater life. Minerals
can build up in the heat exchanger, reducing
heat transfer, overheating heat exchanger, and
causing heat exchanger failure.
5. The system may have residual substances
that could affect water chemistry. After the
system has been filled and leak tested, verify
water pH and chlorine concentrations are
acceptable.
CAUTION
It is important that you purge the system of air
to avoid damage to the heater.
D. PURGE AIR FROM WATER SYSTEM
1. Purge air from system:
a. Connect a hose to the purge valve and
route hose to an area where water can
drain and be seen.
b. Close the heater or system isolation valve
between the purge valve and fill
connection to the system.
c. Close zone isolation valves.
d. Open quick-fill valve on cold water makeup line.
e. Open purge valve.
f. One zone at a time, open the isolation
valves. Allow water to run through the
zone, pushing out the air. Run until no
noticeable air flow is present. Close the
zone isolation valves and proceed with
the next zone. Follow this procedure until
all zones are purged.
g. Close the quick-fill water valve and purge
valve and remove the hose. Open all
isolation valves. Watch that system
pressure rises to correct cold-fill
pressure.
h. After the system has operated for a
while, eliminate any residual air by using
the manual air vents located throughout
the system.
i. If purge valves are not installed in
system, open manual air vents in system
j.
one at a time, beginning with lowest
floor. Close vent when water squirts out.
Repeat with remaining vents.
Refill to correct pressure.
E. CHECK FOR GAS LEAKS
WARNING
Before starting the Munchkin Contender, and
during initial operation, smell near the floor and
around the heater for gas odorant or any
unusual odor. Remove heater front door and
smell interior of heater enclosure. Do not
proceed with startup if there is any indication of
a gas leak. Repair any leak at once.
WARNING
Propane heater only — Your propane supplier
mixes an odorant with the propane to make its
presence detectable. In some instances, the
odorant can fade, and the gas may no longer
have an odor. Before startup (and periodically
thereafter), have the propane supplier verify the
correct odorant level in the gas.
F. CHECK THERMOSTAT CIRCUIT(S)
1. Disconnect the two external wires connected
to the heater thermostat terminals (low
voltage terminal strip terminals 5 and 6).
2. Connect a voltmeter across these two
incoming wires. Close each thermostat, zone
valve and relay in the external circuit one at
a time and check the voltmeter reading
across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition,
check and correct the external wiring. (This is
a common problem when using 3-wire zone
valves.)
5. Once the external thermostat circuit wiring is
checked and corrected if necessary,
reconnect the external thermostat circuit
wires to heater low voltage terminal strip
Allow the heater to cycle.
50
GAS-FIRED HEATER
Installation Manual
PART 11. START-UP PREPARATION (CONTINUED)
G. CONDENSATE REMOVAL
1. The Munchkin Contender is a high efficiency
condensing heater, there, the unit has a
condensation drain. Condensate is nothing
more than water vapor, derived from
combustion products, similar to an
automobile when it is initially started. The
condensation is slightly acidic (typically with
pH of 3 to 5) and must be piped with the
correct materials. Never pipe the condensate
using steel, copper, brass or other materials
that will be subject to corrosion. Plastic PVC
or CPVC pipe are the only approved
materials. A condensate filter, if required by
local authorities, can be made up of lime
crystal,s marble or phosphate chips that will
neutralize the condensate. This may be done
by the installer or you may purchase a
condensate neutralizer from Heat Transfer
Products, Inc. (P/N N1100)
2. The Munchkin Contender is equipped with a
¾ pipe connection that runs the condensation
line to a local drain. It is very important that
the condensate line is sloped away from the
heater and down to a suitable inside drain. If
the condensate outlet is lower than the drain,
you must use a condensate removal pump,
available at Heat Transfer Products (#554200).
This pump is equipped with two leads that
can be connected to an alarm or another type
of warning device to alert residents of a
condensate overflow, which, if not corrected,
could cause property damage.
3. The Munchkin Contender is equipped with an
internal vent on the top plug connection to
assure adequate flow of condensate. This
vent should never be blocked.
4. If a long horizontal run is used, it may be
necessary to create a second vent to prevent
a vacuum lock in the condensate line. Do not
expose the condensate to freezing
temperatures.
5. Do not expose the condensate to freezing
temperatures.
6. It is very important you support the
condensation line to assure proper drainage.
H. FINAL CHECKS BEFORE STARTING
MUNCHKIN CONTENDER
1. Read Startup Procedures within this manual
for proper steps to start heater. (See Startup
Report to record steps for future reference.)
2. Verify the heater and system are full of water
and all system components are correctly set
for operation.
3. Fill condensate trap with water.
4. Verify electrical connections are correct and
securely attached.
5. Inspect intake piping and exhaust piping for
signs of deterioration from corrosion, physical
damage or sagging. Verify intake piping and
exhaust piping are intact and correctly
installed per Venting section and local code.
PART 12. START-UP PROCEDURE
FOR YOUR OWN SAFETY READ BEFORE OPERATING
1. This appliance does not have pilot. It is equipped with an ignition
device which automatically lights the burner. Do not try to light the
burner by hand.
2. BEFORE OPERATING smell all around the appliance area for gas. Be
sure to smell next to the floor because some gas is heavier than air
and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas suppliers' instructions.
51
• If you cannot reach your gas supplier, call the fire department.
3. Turn on gas shutoff valve (located inside of the Heater) so that the
handle is aligned with the gas pipe. If the handle will not turn by
hand, don't try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
4. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and any gas
control which has been under water.
5. The Munchkin Contender Heater shall be installed so the gas ignition
system components are protected from water (dripping, spraying,
rain, etc.) during appliance operation and service (circulator
replacement, condensate trap, control replacement, etc.)
GAS-FIRED HEATER
Installation Manual
PART 12. START-UP PROCEDURE (CONTINUED)
A. OPERATING INSTRUCTIONS
Remove Munchkin Contender Heater cover. If
you smell gas, STOP. Follow listed safety
instructions. If you do not smell gas, follow the
next steps.
1. Turn on all electric power to appliance.
2. Adjust the temperature setpoint of the
Munchkin Contender Heater if desired. The
factory default setting is 180°. If changes are
ncessary follow “Adjusting The Munchkin
Setpoint” in this section.
3. Set the thermostat to the desired setting.
4. If the appliance fails to start, refer to the
Troubleshooting section in the back of this
manual.
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.
Indirect setting (with Vision System option) – 3.
Celsius to Fahrenheit measurement. Simply
press in the {S3/Program} key to get to next value,
the Munchkin Contender Heater 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 Contender
Heater. The burner will not start until the outlet
water temperature reaches a temperature that is
equal to the temperature setting for the
Munchkin Contender Heater, minus the differential EX: The Heater is set to heat at 180° F
degrees and the differential is set at 30° F. The
burner will not start until the outlet temperature
of the system reaches 149° F degrees (180° – 30°
F = 150° 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 (with Vision
Systems option) To adjust, press either {S1/-}
Decrease Value) or {S2/+} (Increase Value).
The final adjustment in this mode is the Fahrenheit
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.
C. STATUS MENU
B. ADJUSTING THE SETPOINT
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 controller will not memorize a
program setting while in a heating cycle. To
adjust the temperature to the Munchkin
Contender 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 temperature
while the {S2/+} will increase the temperature of
the Munchkin. The temperature of the heater
can be set as low as 50 Degrees and as high 180
Degrees. These ranges are your maximum and
minimum ranges of the boiler. In addition to
changing the temperature you are also allowed
to change three more settings in this model (1.
Munchkin Contender Heater differential – 2.
Installers are also able to check the current status
of the Munchkin Contender Heater parameters by
pressing {S4/RESET} key for 3 seconds. Once activated, the display will show |d1| alternating value
of the actual outlet temperature. Actual values are
displayed for each function. To view the next
value simply press the {S/4} key to go to the next
displayed value. Listed below are the values
which can be displayed. These values cannot be
changed. To exit this menu, simply press
{S3/Program} key to resume normal operation.
Function
d1 —
d2 —
d3 —
Value
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 option.)
52
Installation Manual
GAS-FIRED HEATER
PART 12. START-UP PROCEDURE (CONTINUED)
Function Value
d4 — Not used
d5 — Actual Temperature from the outdoor
sensor. (Vision option.)
d6 — Actual Fan speed multiplied by 10
(Example: If fan speed displayed is
|410| RPM x 10 = 4100 actual fan
speed)
d7 — Actual Ionization current read from
Flame Rectification probe
d8 — Actual Status of the Central Heating
Circulator Off = |0|, On = |1|. (Vision
option.)
d9 — Actual Status of the Indirect Fired
Circulator Off = |0|, On = |1|. (Vision
option.)
d10 — Actual Status bus communication
|co| = connected, |no| = not connected
d11 — Central Heating Set Point
d12 — Power On Hours in units
d13 — Total Central Heat Hours
d14 — Total Indirect/dhw Hours
d15 — Passed Ignition Attempts
D. TEST MODE
This function is intended to simplify the gas valve
adjustment if needed. Listed below are the
recommended limits on each Munchkin
Contender and the Combustion Settings.
Automatic modulation does not take place when
the controller is in Test mode, only temperature
limitation based on the Munchkin Contender
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.
Fig. 12-1
COMBUSTION SETTINGS
HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS
Natural Gas
Propane LP
low
high
low
high
Carbon
Monoxide
(CO %)
0–20 ppm
70 ppm–135 ppm
0–20 ppm
80 ppm–150 ppm
Carbon
Dioxide
(CO 2 %)
8½% – 9½%
8½% – 9½%
9½% – 10½%
9½% – 10½%
PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION
The Vision I option allows the user to have one
temperature for central heating and another
temperature for the Super Stor Ultra Indirect
Fired Water Heater. This allows the user to
increase the temperature supplied to the Super
Stor Ultra indirect water heater to get a fast
recovery by prioritizing the flow at a higher temperature than may be needed for the Central
Heating Circuits (this will require two separate
circulators). Once the Super Stor Ultra Indirect is
satisfied, the Vision I system will switch back to
the Central Heating Circuit to continue to heat
the living space at a temperature based on outside temperature. This gives you a higher comfort level and further increases the efficiency of
the Munchkin Contender.
53
A. PROGRAMMING THE VISION I OPTION
The Vision I option allows the installer to set system limits and the heat curve for the Munchkin
Contender. These system limits should not be
changed by the user. It is important to document
your settings within this manual after you program the sytem parameters so this will be
recorded for future reference.
B. VISION 1 PROGRAM ACCESS
To start, press down and hold the {S/3} and {S/4}
simultaneously for three seconds. You will notice
that the display will change to |000|. Then, with
your {S1/-} key on the display press down until you
see |925|. This is the pass code. To confirm that
GAS-FIRED HEATER
Installation Manual
PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED)
the pass code is correct, you will need to press
and hold the {S3/Program} for 1 second to confirm.
If the pass code is entered incorrectly, the controller program function will be cancelled and the
control returns to normal operation. If the code is
entered correctly, the control will switch off the
gas valve and purge fan while showing a solid |--| in the display. The display will than show a |1|
alternating to |de|. This first function verifies that
the control will address the requirements of the
Superstor Indirect Fired Water Heater.
C. VISION 1 PROGRAM NAVIGATION
Next you will have to press the {S/3} key to move
through each function. To increase or decrease
a value, you will need to press either the {S/1-}
key or {S/2+} key to change the default values. If
there is no key action for 1 minute, the display
returns to normal operation. Changes are effective immediately but not directly stored until the
{S/4} key is pressed down for 3 seconds then the
new values are stored. Listed below are the variety of functions the installer can program into
the Vision I System.
CAUTION
The Munchkin Contender cannot be
programmed while there is a call for
heat.
NOTE: See Chart 13-1 in Part 13 to set outdoor
reset curve.
Default Function
Function Value Description
1
de
Not Applicable
2
149ºF Not Applicable
3
160ºF Maximum Domestic Delivery
Water Temperature Setpoint the
Installer will program for
SuperStor Indirect Fired Water
Heater (Note: Does not apply if
used with Mechanical Control)
Range: 95ºF to 160ºF
4
36ºF Not Applicable
5
7ºF Allows the installer to change the
differential in the Indirect Fired
Water Heater (Does not apply if
used with a Mechanical Control)
Range: 1ºF to 18ºF
Default Function
Function Value Description
6
0 Min. Allows the installer to change the
Indirect Circulator Post Purge
Time once the sensor is satisfied
(Note: it is recommend that
Circulator Post Purge Time be set
no greater than 5 minutes).
Range: 0 to 60 minutes
7
68ºF Outdoor temperature that you
wish the central heating should be
disabled—(warm weather shutoff) Range: 41ºF to 122ºF
*8
5ºF Allows the installer to change the
Minimum Outside Design
Temperature. Range: –49ºF to
32ºF (See Chart 13-1 to set outdoor reset curve)
*9
180ºF Allows the installer to change the
D e s i g n S u p p l y Wa t e r
Temperature from the Munchkin
based on the Minimum Outside
Design Temperature Range: 77ºF
to 180ºF
*10
68ºF Allows the installer to change the
Maximum Outside Design
Temperature for Central Heating.
Range: 95ºF to 32ºF
*11
95ºF Allows the installer to change the
Design Supply Water
Temperature from the Munchkin
based on the Maximum Outside
Design Temperature. Range:
32ºF to 180ºF
12
68º F Allows the installer to set the lowest temperature on the Munchkin
for Central Heating. Range: 32ºF
to 180ºF
13 0 Min. Allows the installer to change the
Central Heating Circulator Post
Purge Time once the thermostat is
satisfied. Range 0 to 10 minutes.
Default Function
Function Value Description
54
GAS-FIRED HEATER
Installation Manual
PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED)
14
15
16
17
18
19
20
30 Min. Allows the installer to set the
Maximum run time for the Indirect
Fired Water Heater and the
Minimum run time for Central
Heating. Range 0 to 60 Minutes
0
Bus address (0=zone master 1–8
— cascade slave) (Not currently
used.)
0
Interface Board Activation
0 = not active
1 = active
WARNING: Never change the default setting without the Munchkin
Interface Board installed.**
0
Interface Board Function
0 = Building Management
1 = Enables Tekmar Modulating
control.
(Consult with Tekmar to assure
the Tekmar Control is compatible)
1
Step Modulation – Regulates the
burner output in 6 steps in oneminute intervals. This reduces
short cycling.
1 = on
0 = off
180° Indirect heater set point (flow)
Temperature default = 119° to
180°
1
Not applicable
* Central Heating Curve Function
The central heating demand is detected when
the room thermostat closes. When an outside
55
sensor is also connected, the supply temperature will depend on the factory default central
heating curve.
To set your heat curve you will have to set the
following parameters
1. Minimum outside design temperature:
Function 8
2. Design Supply water temperature at the
minimum design outside temperature:
Function 9
3. Maximum outside design temperature:
Function 10
4. Design Supply water temperature at the
maximum outside temperature: Function 11
NOTICE
It is important to note that the homeowner can
adjust the heat curve down by adjusting the
central heating temperature to a lower setting.
Installation Manual
GAS-FIRED HEATER
PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED)
CENTRAL HEATING CURVE
Factory Default
201˚
CENTRAL HEATING CURVE
Plot your Curve
212
212
203
203
194
194
185
185
FUNCTION 9
176
176
DEFAULT RESET CURVE
149
131
122
113
104
95
FUNCTION 11
77
FUNCTION 10
86
68
59
50
SUPPLY OUTLET TEMPERATURE (F)
167
158
FUNCTION 8
SUPPLY OUTLET TEMPERATURE (F)
167
158
149
131
122
113
104
95
86
77
68
59
50
41
41
32
32
-59
-41
-24
-9
0
9
27
45
5˚
Fig. 13-1
81
99
-59
68˚
OUTSIDE TEMPERATURE (F)
Function
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
63
-41
-24
-9
0
9
27
45
63
81
99
OUTSIDE TEMPERATURE (F)
Fig. 13-2
CONTROL PROGRAM REFERENCE CHART
Default Setting
Programmed Setting
de
No change allowed
149 F
No change allowed
160 F
36 F
No change allowed
7F
0 minutes
68 F
5F
180 F
68 F
95 F
68 F
0 minutes
30 minutes
0
0
0
1
180°F
Fig. 13-3
56
GAS-FIRED HEATER
Installation Manual
PART 14: TROUBLESHOOTING
A. MUNCHKIN ERROR CODE
WARNING
An error code may occur in the installation of
the Munchkin Contender. This condition may
lead to a lock out condition of the controller,
which will need to be manually reset through
the S4/Reset button. These temporary codes
will help the installer correct the problem before
going into a lock out condition, which will
require a manual reset.
B. HEATER ERROR
1. When an error condition occurs the controller
will display an error code on the display
module.
2. These error codes and several suggested
corrective actions are included in Table 14-2.
3. In the case of E00, E13, and E14 this error, if
uncorrected, will go into a fault condition as
described is Paragraph C (Heater Fault).
When servicing or replacing any components of this
heater be certain that:
• The gas is off.
• All electrical power is disconnected
DANGER
When servicing or replacing that are in direct contact
with the heater water, be certain that:
• There is no pressure in the heater. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).
• The heater water is not hot
• The electrical power is off
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 heater and to repair or replace any part of
the heater which has been under water.
C. HEATER FAULT
1. When a fault condition occurs the controller
will illuminate the red “fault” indication light
and display a fault code in the format
(Example: |F00|) on the display module.
2. Note the fault code and refer to Table 14-2 for
an explanation of the fault code along with
several suggestions for corrective actions.
3. Press the reset key to clear the fault and
resume operation. Be sure to observe the
operation of the unit to prevent a recurrence
of the fault.
CAUTION
This appliance has wire function labels on all internal
wiring. Observe the position of each wire before removing it. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.
CAUTION
If overheating occurs or the gas supply fails to shut
off, do not turn off electrical power to the circulating
pump. This may aggravate the problem and increase
the likelihood of heater damage. Instead, shut off the
gas supply to the heater at the gas service valve.
Table 14-1 : 925 Control Board ERROR Codes
Code
E00
„
E13
„
E14
„
Description
High Limit Exceeded
Combustion Fan Speed Low.The
heater combustion air fan speed less
than 70% of expected.
Combustion Fan Speed High. The
heater combustion air fan speed is
more than 130% of expected.
Duration
50 Sec.
60 Sec.
60 Sec.
PR0
„
Pressure Switch Open
Until
Corrected
FLU
„
Blocked Vent Pressure Switch Open
Until
Corrected
57
Corrective Action
1. Check circulation pump operation.
2. Assure that there is adequate flow through the heater
by accessing the status menu and assuring that there
is less than a 50°F rise from the return thermister to
the supply thermister.
3. Replace switch if faulty.
1. Check the combustion air fan wiring.
2. Replace the combustion air fan.
3. Replace the control board.
1. Check the combustion air fan wiring.
2. Replace the combustion air fan.
3. Replace the control board.
1. Assure that the system pressure is above 10 psig.
2. Check for leaks in the system piping.
1. Assure that the vent is not blocked
2. Check the switch operation by applying a jumper. (If
the switch is not functioning properly, replace it.)
Installation Manual
GAS-FIRED HEATER
PART 14: TROUBLESHOOTING (CONTINUED)
Table 14-2: 925 Control Board FAULT Codes
Code
Description
F00
„
High Limit Exceeded.
F01
„
Vent Temperature Limit Exceeded.
F02
„
F03
„
Interrupted or Shorted
Supply (Outlet) Thermister.
Interrupted or Shorted
Return (Inlet) Thermister.
F05
„
Supply (Outlet)
Temperature exceeds 230°F.
F06
„
Return (Inlet) Temperature
Exceeded 230°F.
F09
„
No flame detected – The heater
will make three attempts at
ignition before the control goes
into this lockout condition. *See
spark electrode detail.
F10
„
Loss of Flame Signal – The heater
will relight 4 times before the
control goes into this lockout
condition.
F11
„
False Flame Signal – The heater
will lock out if it senses a flame
signal when there should be none
present.
F13
„
F14
„
Combustion Fan Speed Low – The
heater will lock out if it senses that
the fan speed is less than 70% of
expected rate for more than 60
seconds.
Combustion Fan Speed High – The
heater will lock out if the fan speed
is more than 130% of expected
rate for more than 60 seconds.
Remedy
1. Check circulation pump operation
2. Assure that there is adequate flow through the heater by accessing the
status menu and assuring that there is less than a 50°F rise from the
return thermister to the supply thermister.
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.
3. Replace the switch if faulty.
1. Check the electrical connection to the thermister on the outlet manifold.
2. Replace thermister if necessary.
1. Check the electrical connection to the thermister on the inlet manifold.
2. Replace thermister if necessary.
1. Check circulation pump operation.
2. Assure that there is adequate flow through the heater by accessing the
status menu and assuring that there is less than a 50°F rise from the
return thermister to the supply thermister.
1. Check circulation pump operation.
2. Assure that there is adequate flow through the heater by accessing the
status menu and assuring that there is less than a 50°F rise from the
return thermister to the supply thermister.
1. Watch the igniter through the observation window provided.
2. If there is no spark, check the spark electrode for the proper ¼” gap. Use
detail drawing of spark electrode as a gauge to hold ignitor against to
check gap distance.
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 heater.
5. If there is a flame, check the flame sensor.
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
heater 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.
1. Turn the gas off to the unit at the service valve.
2. If the flame signal is still present replace the igniter.
3. If the flame signal is not present after turning off the gas supply, check
the gas valve electrical connection.
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.
1. Check the combustion air fan wiring.
2. Replace the combustion air fan.
3. Replace the control board.
1. Check the combustion air fan wiring.
2. Replace the combustion air fan.
3. Replace the control board.
F18
„
Gas Valve Error
1.
2.
3.
4.
Make sure the connector is correctly connected to the gas valve.
Check the electrical wiring from the valve to the control board.
Replace the low voltage wiring harness assembly.
Replace control board.
F30
„
F31
„
F32
„
F33
„
Watchdog
Call factory for further assistance.
Parameter Memory
Call factory for further assistance.
Parameter Memory Write Error
Call factory for further assistance.
Programming Error
Call factory for further assistance.
58
GAS-FIRED HEATER
Installation Manual
PART 14: TROUBLESHOOTING (CONTINUED)
Resistance Tables
Outdoor Sensor (7250P-319)
Heater Sensor (7250P-059)
Outside Temperature (°F) Resistance (ohms)
Indirect Sensor
(7250P-320)
Heater and Indirect Temperature (°F) Resistance (ohms)
–22
171800
32
32550
–13
129800
41
25340
–4
98930
50
19870
5
76020
59
15700
14
58880
68
12490
23
45950
77
10000
32
36130
86
8059
41
28600
95
6535
50
22800
104
5330
59
18300
113
4372
68
14770
122
3605
77
12000
131
2989
86
9804
140
2490
95
8054
149
2084
Fig. 14-2
104
6652
158
1753
NOTE: If receiving an
F09 fault code, check
the gap spacing
between points on the
electrode by holding
two quarters together
and sliding them
through the gap. There
should be a slight
resistance.
113
5522
167
1481
176
1256
185
1070
194
915
203
786
212
667
Fig. 14-3
PART 15: MAINTENANCE
A. MAINTENANCE PROCEDURES
Periodic maintenance should be performed
once a year by a qualified service technician to
assure that all the equipment is in safe efficient
operation. The owner can make necessary
arrangements with a qualified heating contractor for periodic maintenance of the heater.
Installer must also inform the owner that the lack
of proper care and maintenance of the heater
may result in a hazardous condition. The
installer should discuss the contents of the
User's Information Manual with the owner.
59
WARNING
BEFORE EACH HEATING SEASON A trained
and qualified service technician should perform
the inspections as per the heater inspection and
maintenance schedule in the back of manual.
Failure to do so could result in death or serious
injury.
GAS-FIRED HEATER
Installation Manual
PART 15: MAINTENANCE (CONTINUED)
WARNING
The combustion chamber insulation in
this product contains ceramic fiber
material. Ceramic fibers can be
converted to cristobalite in very high
temperature applications. The
International Agency for Research on
Cancer (IARC) has concluded,
“Crystalline silica inhaled in the form of
quartz or cristobalite from occupational
sources is carcinogenic to humans
(Group1).”:
ƒ Avoid breathing dust and contact with skin and
eyes.
• Use NIOSH certified dust respirator (N95). This
type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of respirators
may be needed depending on the job site
conditions. Current NIOSH recommendations
can be found on the NIOSH website at
http://www.cdc.gov/niosh/homepage.html.
NIOSH approved respirators, manufacturers, and
phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing,
gloves, and eye protection.
ƒ Apply enough water to the combustion chamber
lining to prevent dust
ƒ Wash potentially contaminated clothes separately
from other clothing. Rinse clothes washer
thoroughly.
NIOSH stated First Aid.
ƒ Eye: Irrigate immediately
ƒ Breathing: Fresh air.
B. COMBUSTION CHAMBER COIL
CLEANING INSTRUCTIONS
*Before beginning this procedure, you must have on
hand the following items:
– a nylon, stainless or brass brush (not steel)
– “Rydlyme” (recommended for best
results) (available on line
www.rydlyme.com) or “CLR” (available at
most hardware stores)
– Gloves, eye protection
1. Shut down the Munchkin Contender 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 Contender side), so the flow
can be observed.
c. Disconnect connections from the gas
valve, spark electrode and flame rectification probe and combustion blower.
d. Remove the (4) screws on the aluminum
½” NPT connector on the gas valve.
e. Disconnect the wiring connected to the
combustion blower motor.
f. Remove the (4) 10MM nuts from the
burner plate assembly to access the
coils.
g. Pull the entire burner plate assembly with
blower still attached towards you, while
removing or pushing aside any wiring to
allow the removal of the assembly.
2. Using a spray bottle filled with the recommeded
product “RYDLYME” or “CLR”, spray liberally on
the coils, making sure the solution penetrates
and funnels down through the condensate hose.
If the condensate hose is blocked, let the chemical penetrate for at least 15 minutes or until it
drains.
3. Use the nylon, stainless or brass brush (do not
use steel) and scrub coils to remove any buildup,
then vacuum the debris from the coils. WARNING: Follow precautions above
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 Contender
should be ready to power back up.
Before powering up the Munchkin Contender follow
the steps below
a. Re-install the burner assembly
b. Replace the (4) 10MM nuts to the burner
plate
c. Re-connect all wiring connections
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 Contender back on
and observe condensate flow.
h. Re-connect the condensate hose to the
outside connection.
60
Installation Manual
GAS-FIRED HEATER
PART 15: MAINTENANCE (CONTINUED)
1
HEATER LIMIT
FUSE CONNECTION
2
5
4
3
6
8
7
9
11
10
16
13
12
21
10
14
18
17
15
19
22
20
23
24
REPLACEMENT PARTS
Item #
1
Description
Composite Module
Part #
7500P-010 (MC50)
Item #
13
Description
Screws M4 x 8 (Probe/Electrode)
7500P-012 (MC80)
14
Gasket (Air Channel to Combustion Blower) 7500P-075
7500P-014 (MC99/MC120)
15
Combustion Blower (w/Screws)
7500P-031
7250P-161
16
Screws M5 x 14 (Combustion Blower)
7250P-254
2
Ceramic Target Wall
3
Burner Door Ceramic Refractory 7500P-076
17
Gas Valve Adapter Plate (w/Screws)
7250P-644
4
Burner Door (w/Nuts)
7500P-078
18
Screws M4 x 16 (Gas Valve Adapter Plate)
7500P-105
5
Nuts - M6 (Burner Door)
7500P-067
19
Gas Valve Swirl Plate
6
NIT Burner
7500P-015 (MC50)
7500P-017 (MC99/MC120)
7
Gasket (Burner)
8
Air/Gas Channel (w/Torx Screws) 7500P-079
9
Torx Screws (Air/Gas Channel)
Gasket (Flame Rec./Spark
Electrode)
Flame Rectification Probe
(w/Gasket, Screws)
Spark Electrode (w/Gasket,
Screws)
10
11
12
Fig. 15-1
7500P-091(MC50)
7500P-092 (MC80)
7500P-016 (MC80)
61
Part #
7250P-069
7500P-093 (MC99/MC120)
20
Gas Valve (w/Swirl Plate, Screws)
7500P-074
7250P-448 (MC50)
7250P-449 (MC80)
7000P-862 (MC99/MC120)
7500P-068
21
Screws M4 x 12 (Gas Valve)
7500P-099
7250P-005
22
O-Ring (Gas Valve Piping Assy)
7500P-094
7500P-039
23
Gas Valve Piping Assembly (w/O-ring,
Screws)
7500P-095
7500P-040
24
Screws M4 x 12 (Gas Valve Piping Assy)
7500P-099
Installation Manual
GAS-FIRED HEATER
PART 15: MAINTENANCE (CONTINUED)
1
2
6
8
7
3
9
4
10
5
11
12
REPLACEMENT PARTS
Description
Item #
1
2
3
4
5
13
14
16
15
17
18
Concentric Flue Outlet (w/Gasket)
Gasket (Concentric Flue Outlet)
PVC Pipe (2" Sch. 40 - 12" Long)
Flue Adapter
Part #
7500P-025
7500P-008
7500P-097
7500P-007
7500P-002
6
Flue ECO
O-Ring (S.S. Barbed Fitting)
7
S.S. Barbed Fitting
7250P-154
8
9
10
Water Pressure Switch
Clear Tubing 3/16 ID x 5/16 OD
Water Pressure Switch Adapter
7000P-805
7500P-003
11
O-Ring (Water Pressure Switch)
7500P-100
12
13
Water Pressure Switch Clip
Supply/Return Manifold Clip
7500P-077
7500P-080
14
15
16
O-Ring (Supply/Return Manifold)
Thermistor
High Limit Sensor
7500P-026
7250P-059
7500P-033
17
Relief Valve
7250P-080
18
Supply Manifold Assembly (w/O-Ring, Relief
7500P-029
Valve, Temperature/Pressure Gauge)
19
20
Return Manifold Assembly (w/O-Ring)
Temperature/Pressure Gauge
7250P-152
7250P-096
7500P-030
7500P-098
19
20
Fig. 15-2
62
Installation Manual
GAS-FIRED HEATER
PART 15: MAINTENANCE (CONTINUED)
1
2
21
3
5
6
9
4
10
7
8
11
12
11
13
14
16
15
17
20
18
19
REPLACEMENT PARTS
Part #
Item # Description
Item # Description
Cover Filler Plate(w/Screws)
2
Blocked Vent Pressure Switch
3
Screws 8-32x3/8 (Blocked Vent Pressure
Switch)
7500P-047
4
Control Board (w/Screws)
5
5 Pin Wiring Harness (location)
6
9 Pin Wiring Harness (location)
7500P-054
17
Gas Inlet Plate
7500P-043
7
Low Voltage Wiring Harness (location)
7500P-053
18
Condensate Switch
7500P-041
8
Screws # 6 x 1/2 - Control Board
7250P-480
19
Condensate Cup
7500P-090
9
Clamp -Module to Bracket (w/Screws)
7500P-073
20
Control Board Display
7500P-058
10
Screws M4x6 (Clamp)
7500P-069
21
Contender Cover
7500P-027 (MC50/MC80)
11
Spring Clamp - Condensate Hose
7250P-302
Fig. 15-3
63
Part #
1
7500P-044 (MC50/MC80)
12
Condensate Hose (clear)
7500P-057
7500P-032 (MC99/MC120)
13
Screws 8-32x3/8 (Filler/Gas Inlet Plate) 7500P-047
7250P-150
14
Supply/Return Filler Plate (w/Screws)
7250P-317
15
Lip Style Grommet - 1"
7500P-050
7500P-055
16
Lip Style Grommet - 1/2"
7500P-049
7500P-022 (MC50/MC80)
7500P-023 (MC99/MC120)
7500P-028 (MC99/MC120)
Notes:
If necessary convert the heater to the proper type of gas (always use proper kit)
8) Convert the boiler
____ppm CO
Verify Combustion settings after gas conversion, Carbon Monoxide
Mail in the conversion registration
____% CO2
____de
____*8
____ µA
Verify Combustion settings after gas conversion, Carbon Dioxide
Locate the stickers in the appropriate locations on the heater
Verify safety and operation of the Super-Stor Indirect water heater, record setttings
Record heating curve (with optional Vision One kit, record steps)
6) Record System Settings
7) Indirect water heater
Check µA reading at d7 on the status menu (see start-up section)
5) Record Ionization Current
____ppm CO
Check and adjust (if necessary) carbon monoxide content
Turn up thermostat to verify wiring connections
____% CO2
____in w.c.
What is the "drop" on light off (No more than 1" W.C.)
Check and adjust (if necessary) carbon dioxide content
____in w.c.
____%
_____PSI
Static
High Fire
High Fire
____dh
____*9
High Fire
High Fire
High Fire
____ppm CO
____% CO2
____*10
____ µA
____ppm CO
____%CO2
_______________
Dynamic
Date completed
Check incoming gas pressure (3.5" to 14" W.C.)
Leak test using locally approved methods (consult jurisdictional code book)
Verify near heater piping is properly supported
What percentage of propylene glycol is installed in the system (0-50%)
Add Water to prime condensate cup
Pressurize System (12-15 PSI)
Check all piping and gas connections, verify they are all tight
4) Verify System Operation
3) Check Combustion
2) Check Gas Pipe
1) Fill the heating system
Light Off Activities
HEATER START UP REPORT
Low Fire
Low Fire
____*11
Low Fire
Low Fire
Low Fire
GAS-FIRED HEATER
Installation Manual
64
65
Check condition of all vent pipe and joints
Check gas piping, test for gas leaks and signs of aging, make sure all pipes are supported properly.
Vent
Gas
Test all functions of the system (Heat, DHW, Safeties)
Verify safe settings on Super-Stor indirect fired water heater or Anti-Scald Valve ( see part 12 for
realted safety warnings)
Verify temperature settings programmed into the heating curve ( See Part 13)
Functional
Temperatures
Temperatures
Check to see that the circuit breaker is clearly labeled, exercise circuit breaker
Verify ON/OFF switch and convenience plug are both functional
Verify devices are installed and working properly, change batteries if necessary
Circuit breakers
Switch and Plug
Smoke and CO detector
Check burner tube, and combustion chamber coils, clean according to maintenance section of
manual
Clean with scoth brite , Set gap at 1/4" (see Fig 14-2 Part 14 in Troubleshooting section)
Clean with scoth brite , Check ionization in µA (d7 on status menu in Start-up Procedures) record
high fire (3.8 to 4.2) and low fire (3.0 to 3.4)
Combustion Chamber
Spark Electrode
Flame Probe
* NOTE : CONTINUE MAINTENANCE BEYOND THE 4TH YEAR IS REQUIRED ON A YEARLY BASIS.
Vacuum Combustion Chamber if Necessary
Combustion Chamber
Chamber and Burner
Check wire connections, make sure they are tight
Connections
Electrical
Do a full visual inspection of all system components
Visual
System
Check heater and system piping for any sign of leakage, verify proper support
Near Heater Piping
Piping
Inspection Activities
HEATER INSPECTION AND MAINTENANCE SCHEDULE
1st Year
2nd Year
3rd Year
Date last completed
4th Year*
GAS-FIRED HEATER
Installation Manual
Disconnect condensate cup, clean out dirt, fill with water to level of outlet and re-install ( Note: you
must verify the flow of condensate, making sure that the cup is connected properly during final
inspection.)
Condensate Cup
Check piping for leaks, and verify they are all properly supported
Check gas pipe for leaks
Check operation , check for signs of leakage, replace if corroded
Check wiring, verify through ohms reading (see chart part 14 Fig. 14-3)
Water Pressure Switch
Thermistors
Review, with the homeowner what you have done
Homeowner
* NOTE : CONTINUE MAINTENANCE BEYOND THE 4TH YEAR IS REQUIRED ON A YEARLY BASIS.
Verify that you have completed the entire check list WARNING: FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.
Check List
Final Inspection
Check continuity on Flue and Water ECO, replace if corroded
ECO (Energy Cut Out)
Safeties
Check CO/CO2 Levels
Check levels of CO and CO2 in Exhaust (See start up section 12 fig 12-1 for ranges) record at high
and low fire
Measure drop in pressure on light off (no more than 1" W.C.)
Pressure Drop
Combustion
Measure incoming gas pressure (from 3.5" to 14" W.C.)
Pressure
Gas
Check condensate neutralizer, replace if necessary
Condensate Neutralizer
Condensate
Inspection Activities
HEATER INSPECTION AND MAINTENANCE SCHEDULE (CONTINUED)
1st Year
2 Year
3 Year
Date last completed
4 Year*
GAS-FIRED HEATER
Installation Manual
66
© 2006 Heat Transfer Products, Inc.
LP-171 REV. 10/16/06