Munchkin Gas-Fired Hot Water Circulating Heater, Contender Installation Manual

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.

• Installation

• Startup

• Maintenance

• Parts

Installation

Manual

MH18082

GAS-FIRED HEATER Installation Manual

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.

• Installation and service must performed by a qualified installer, service agency or the gas supplier.

GAS-FIRED HEATER Installation Manual

CONTENTS

Part 1 – Product and Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5

Part 2 – How The Heater Operates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Part 3 – Prepare Heater Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

A. Installations Must Comply With: B. Before Locating Heater C. Clearances for Service Access D. Residential Garage Installation E. Air Intake and Exhaust Vent F. Prevent Combustion Air Contamination G. When Removing an Appliance from an Existing Common Vent System

Part 4 – Prepare Munchkin Contender Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

A. Remove Munchkin Contender Heater from Box B. Placing Wall-Mounted Munchkin Contender C. Munchkin Contender Wall Mounting Instruction D. Installation Steps

Part 5 – Munchkin Contender Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24

– Contender Piping Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-24

A. Relief Valve B. General Piping Information C. Separate Low Water Cutoff D. Backflow Preventer E. System Water Piping Methods F. Circulators G. Hydronic Piping with Circulators, Zone Valves and Multiple Heaters H. Circulator Sizing I. Fill and Purge Heating System J. Zoning with Zone Valves K. Zoning with Circulators L. Multiple Heaters M. Contender Piping Details

Part 6 – Contender Piping with Optional Vision 1 System . . . . . . . . . . . . . . . . . . . . . 25-35

– Contender Piping Details With Vision I System . . . . . . . . . . . . . . . . . . . . . . . . . . 26-35

A. Vision 1 System Piping B. Zoning with Zone Valves Using Vision I C. Zoning with Circulators Using Vision I D. Contender Piping Details with the Vision I System

Part 7 – Venting Combustion Air And Condensate Removal. . . . . . . . . . . . . . . . . . . . 36-44

– Venting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,44

A. Installing Exhaust Vent and Intake Air Vent B. General C. Approved Materials for Exhaust Vent and Intake Air Vent D. Exhaust Vent and Intake Air Vent Pipe Location. E. Exhaust Vent and Intake Air Vent Sizing

GAS-FIRED HEATER Installation Manual

CONTENTS

(CONT’D)

F. Exhaust Vent and Intake Air Pipe Installation. G. Heater Removal from a Common Vent System H. Condensate Removal System I. Diagrams for Side Wall Venting

Part 8 – Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,46

A. Gas Connection B. Gas Piping C. Gas Table D. Dungs Gas Valve

Part 9 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-49

A. Installation Must Comply With B. Field Wiring C. Line Voltage Wiring D. Thermostat

Part 10 – Field Wiring – Vision 1 Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Part 11 – Start Up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-53

A. Check/Control Water Chemistry B. Freeze Protection (when used) C. Fill and Test Water System D. Purge Air from Water System E. Check for Gas Leaks F. Check Thermostat Circuit(s) G. Condensate Removal H. Final Checks Before Starting The Munchkin Contender

Part 12 – Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-55

A. Operating Instructions B. Adjusting the Set Point C. Status Menu D. Test Mode

Part 13 – Start-Up Procedures With The Vision 1 Option . . . . . . . . . . . . . . . . . . . . . . 55-56

A. Programming the Vision I Option B. Vision I Program Access C. Vision I Program Navigation

Part 14 – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-61

A. Munchkin Error Code B. Heater Error C. Heater Fault

Part 15 – Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-65

A. Maintenance Procedures B. Combustion Chamber Coil Cleaning Instructions

Part 16 – Heater Inspection and Maintenance Start-Up Charts . . . . . . . . . . . . . . . . . 66-68

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.

DANGER

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

WARNING

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

CAUTION

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

CAUTION

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

DEFINITIONS

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.

GAS-FIRED HEATER Installation Manual

PART 1: PRODUCT AND SAFETY INFORMATION

(CONT’D)

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

supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

• 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.

HEATER WATER

The piping and components connected to the Munchkin Contender for space the heating application shall be suitable for use with potable water. Toxic chemicals, such a used for boiler treatment, shall not be introduced into the potable water when the Munckin Contender is used for space heating.

When the Munchkin Contender is used to supply potable water, it shall not be connected to any heating system or component(s) previously used with a non-potable water heating appliance.

• 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 heater 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 heater, 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

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.

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

NEVER use any toxic chemical, including automotive or standard glycol antifreeze or ethylene glycol made for hydronic (non-potable) systems. These chemicals are poisonous if consumed and can cause injury or death. These chemicals can also attack gaskets and seals in water heaters.

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.

GAS-FIRED HEATER Installation Manual

can cause internal corrosion in system components. Leaks in heater or piping must be repaired at once to prevent make-up water.

WINTERIZING THE MUNCHKIN CONTENDER

To winterize the Munchkin Contender, drain the entire system, then apply air pressure to the drain valve and allow air and water to escape from the purge valve (see piping instructions). Once you have evacuated all of the water that is possible, you will then need to pump in the non toxic propylene glycol food grade NSF® listed antifreeze (SAFE-T-THERM www.houghton.com or PARATHERM www.paratherm.com). Try to calculate the entire volume of the piping system to insure the entire system will be adequately protected. Consult the glycol manufacturer for mixture % recommendations to adequately protect the system for the local climate of the installation.

With a pump, fill the system with the non-toxic propylene glycol food grade NSF® listed antifreeze, allowing the air and remaining water to escape from the purge valve. Once the stream coming out of the purge valve matches the color of the non toxic propylene glycol food grade NSF® listed antifreeze, the system should be adequately filled. It is rcommended at this point to start any circulation pump and allow the

system to circulate for at least 30 minutes to completely blend any trapped water that might be in the system with the NSF® listed solution. At this point it is suggested that you check the concentration of NSF® antifreeze to be sure that protection is adequate. Consult the glycol manufacturer for specific instructions on the concentration % as well as the freeze and burst protection methods.

FREEZE PROTECTION FLUIDS

PART 1: PRODUCT AND SAFETY INFORMATION

(CONT’D

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.

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.

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

GAS-FIRED HEATER Installation Manual

PART 2: HOW THE MUNCHKIN CONTENDER OPERATES

(CONT’D)

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, 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, 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.

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.

14. The Vision 1 Optional System

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

GAS-FIRED HEATER Installation Manual

located in the Vision One section of this manual. Optional kit consists of the following

• Outdoor sensor – 7250P-319

• Indirect tank sensor – 7250P-325

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

PART 2: HOW THE MUNCHKIN CONTENDER OPERATES

(CONT’D)

D E

BACK VIEW

FRONT VIEW

RIGHT SIDE

VIEW

LEFT SIDE

EXHAUST VENT CONNECTION

SYSTEM RETURN

CONDENSATE CUP/DRAIN ASSEMBLY

SYSTEM RELIEF

GAS LINE CONNECTION

COMBUSTION AIR INLET CONNECTION

SYSTEM SUPPLY

ELECTRICAL BOX/CONTROL PANEL

MUNCHKIN CONTENDER HEATER DIMENSIONS AND SPECIFICATIONS

MODEL

NUMBER

BTU/HR

INPUT

LOW

FIRE

BUT/HR

INPUT HIGH

FIRE

ABCDEF GHJKLMNOPQRS

COMBUSTION AIR

INLET/EXHAUST

VENT

CONNECTION

SIZE

SYSTEM

RELIEF

PIPE SIZE

SYSTEM SUPPLY/ SYSTEM RETURN/

PIPE SIZE

GAS LINE

CONN.

HEATER WATER

VOLUME

ENERGY FACTOR

DOE

EFF.

AFUE

LOW

WATER

EFF.

LTAAE

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

1. Tested by Heat Transfer Products to the ANSI/ASHRAE 103

2. Tested by Heat Transfer Products to the ANSI/ASHRAE Standard 103 with 90° return and 110° supply water

3. Tested by Heat Transfer Products to the 10 CFR 430.23 2005

PART 3: PREPARE MUNCHKIN CONTENDER LOCATION

A. INSTALLATIONS MUST COMPLY WITH:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• 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.

GAS-FIRED HEATER Installation Manual

PART 3: PREPARE MUNCHKIN CONTENDER LOCATION

(CONTINUED)

BEFORE LOCATING THE MUNCHKIN CONTENDER

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Check area around heater. Remove any combustible materials, gasoline and other flammable liquids.

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 heater, check for and correct any existing system problems such as:

• 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.

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.

24"

FRONT CLEARANCE

24"

Figure 3-1: Clearances required

6" 6"

SIDE

CLEARANCE

SIDE

CLEARANCE

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.

GAS-FIRED HEATER Installation Manual

PART 3: PREPARE MUNCHKIN CONTENDER LOCATION

(CONTINUED)

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 con-

tamination 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

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 heater 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.

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.

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

Table 3-2: Corrosive contaminants and sources

GAS-FIRED HEATER Installation Manual

G. WHEN REMOVING AN EXISTING HEATER

FROM AN EXISTING 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 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

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.

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 3: PREPARE MUNCHKIN CONTENDER LOCATION

(CONTINUED)

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.

PART 4: PREPARE MUNCHKIN CONTENDER HEATER

A. REMOVE MUNCHKIN CONTENDER

HEATER FROM BOX

1. The Munchkin Contender is easy to handle.

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.

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.

GAS-FIRED HEATER Installation Manual

PART 4: PREPARE MUNCHKIN CONTENDER

(CONTINUED)

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.

C. MUNCHKIN CONTENDER

WALL MOUNTING INSTRUCTIONS

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 heater. 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.

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-99MC-120-

]]

84 lbs.

Failure to comply with above could result in severe personal injury, death or substantial property damage.

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.

CAUTION

If the Munchkin Contender is not vertically plumb, improper and unsatisfactory operation may occur. This will cause excessive condensation build-up causing unnecessary maintenance and nuisance fault codes.

GAS-FIRED HEATER Installation Manual

A. RELIEF VALVE

Connect discharge piping to safe disposal location, following guidelines in the WARNING below.

B. GENERAL PIPING INFORMATION

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 heater 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.)

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.

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).

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.

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.

PART 5: MUNCHKIN CONTENDER PIPING

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.

• For heaters installed with only a pressure relief valve, the separate storage vessel must have a temperature and pressure relief valve installed. This relief valve shall comply with the standard for Relief

Valves for Hot Water Supply Systems, ANSI Z21.22 CSA4.4.

• 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.

GAS-FIRED HEATER Installation Manual

PART 5: MUNCHKIN CONTENDER PIPING

(CONTINUED)

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

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

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.

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.

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.

Basic steps are listed below, with Illustration, which will guide you through the installation of the Munchkin.

1. Connect the system return marked “Heater In”.

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.

6. Install a circulator as shown in piping details (this section). Make sure the circulator is properly sized for the system and friction loss.

7. Install an Expansion Tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to expansion tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an Air Elimination Device on the system supply.

9. Install a drain valve at the lowest point of the system. Note: The Munchkin 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.

CAUTION

The Munchkin Contender should not be operated as a potable Hot Water Heater.

Figure 5-1

* NOTE: The recommended circulators are based on 1 gpm per 10,000 btu/hr with 20°∆t.

GAS-FIRED HEATER Installation Manual

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).

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.

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.

PART 5: MUNCHKIN CONTENDER PIPING

(CONTINUED)

CAUTION

For installation that incorporates standing Iron Radiation and systems with manual vents at the high points. Follow above section and starting with the nearest manual air vent, open vent until water flows out, then close vent. Repeat procedure, working your way toward furthest air vent. It may be necessary to install a basket strainer in an older system where larger amounts of sediment may be present. Annual cleaning of the strainer may be necessary.

WARNING

Use only inhibited propylene glycol solutions which are specially formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. Glycol mixtures should not exceed 50%.

SYSTEM TEMPERATURE RISE CHART

Model

Friction

Feet

Flow GPM

Friction

Feet

Flow GPM

Friction

Feet

Flow GPM

Friction

Feet

Flow GPM

Friction

Feet

Flow GPM

Friction

Feet

Flow

GPM MC-50 6.5' 5 4.5' 4 3' 3.3 2' 2.5 N/R N/R N/R N/R MC-80 7.8' 8 4.7' 6.4 2.9' 5.3 2' 4.6 1.5' 4 1' 3.5 MC-99 9' 10 6' 9 5' 7.8 4' 6.3 3.5' 5.6 2' 4.8

MC-120 10' 12 7' 9.6 5' 8 4' 6.8 3.5' 6 2' 5.3

40˚ǻt45˚ǻt20˚ǻt25˚ǻt30˚ǻt35˚ǻt

The chart below represents the various system temperatures and their respective flows and friction loss through the Munchkin Contender which will aid circulator selection.

N/R = Not recommended

GAS-FIRED HEATER Installation Manual

MUNCHKIN CONTENDER PIPING

(CONTINUED)

J. ZONING WITH ZONE VALVES

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.

2. Connect DHW (domestic hot water) piping to indirect storage water heater as shown.

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 multiple heaters as shown in 1E and 1F in Piping Details.

2. All piping shown is reverse return to assure balanced flow through the connected heaters.

3. Each connected heater must have its own circulator pump to assure adequate flow.

4. Connect DHW (domestic hot water) piping to indirect storage water heater as shown.

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.

GAS-FIRED HEATER Installation Manual

circulator (w/ isolation flanges)

gate valve

globe valve

ball valve

swing-check valve

flow-check valve

spring-loaded check valve

hose bib / heater drain

TRV (straight)

TRV angle

circuit setter

manual 3-way valve

zone valve

air separator

backflow preventer

diaphragm-type expansion tank

pressure reducing valve

diff. pressure bypass

anti-scald mixing valve

temperature /pressure gauge

pressure relief valve

float-type air vent

heat exchanger

union

4-way motorized mixing valve

3-way motorized mixing valve

Munchkin Contender Heater

radiant manifold

with valve actuators

Super Stor Ultra

Indirect DHW Tank

Piping symbol legend

radiant manifold

purging valve

circulator (w/ integral check valve)

aquastat

DHW temperature sensor

Outdoor temperature sensor

T/P

M. CONTENDER PIPING DETAILS

GAS-FIRED HEATER Installation Manual

Standard Munchkin Contender Heater! (zoning with valves)

Space heating mode

Super Stor Ultra

indirect DHW Tank

Drawing 1A

make-up water

see note 6

OFF

differential pressure bypass valve

anti-scald

mixing valve

purging

valves

closely

spaced

tees

Munchkin

Contender

Heater

T/P

purge

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.

9. Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the shut-off connection.

zone valves

GAS-FIRED HEATER Installation Manual

Standard Munchkin Contender Heater (zoning with valves)

Domestic water heating mode

Super Stor Ultra

indirect DHW Tank

Drawing 1B

make-up water

OFF

zone valves

anti-scald

mixing valve

purging

valves

closely spaced