Instruction/ maintenance manual of the product Gas-Fired Hot Water Circulating Heater Munchkin
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W ARNING This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. P erform steps in the order given. Failure to comply could result in severe personal injury , death or substantial property damage.
1 GAS -FIRED HEA TER Installation Manual W ARNING If the information in this manual is not followed e xactly , a fire or explo- sion 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.
2 GAS -FIRED HEA TER Installation Manual CONTENTS P art 1 – P roduct and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 P art 2 – How The Heater Operates . . . . . . . . . . . . . . . . . . . . .
3 GAS -FIRED HEA TER Installation Manual CONTENTS (CONT ’D) F . Exhaust V ent and Intak e Air Pipe Installation. G . Heater Removal from a Common V ent System H. Condensate Removal System I. Diagrams for Side W all V enting P art 8 – Gas Piping . .
4 GAS -FIRED HEA TER Installation Manual P ART 1: PRODUCT AND SAFETY INFORMA TION SPECIAL A TTENTION BO XES 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.
5 GAS -FIRED HEA TER Installation Manual P ART 1: PRODUCT AND SAFETY INFORMA TION (CONT ’D) Before Installing WHEN SERVICING THE MUNCHKIN CONTENDER • T o avoid electric shock, disconnect electrical supply before performing maintenance. • T o avoid severe burns, allow heater to cool before performing maintenance.
6 GAS -FIRED HEA TER Installation Manual can cause internal corrosion in system components. Leaks in heater or piping must be repaired at once to prevent make-up water .
7 GAS -FIRED HEA TER Installation Manual P ART 2: HOW THE MUNCHKIN CONTENDER OPERA TES (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.
8 GAS -FIRED HEA TER 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 -.
9 GAS -FIRED HEA TER Installation Manual P ART 3: PREP ARE MUNCHKIN CONTENDER LOCA TION (CONTINUED) BEFORE LOCA TING THE MUNCHKIN CONTENDER 1. Check for nearby connection to: • System water piping • V enting connections • Gas supply piping • Electrical power 2.
10 GAS -FIRED HEA TER Installation Manual P ART 3: PREP ARE MUNCHKIN CONTENDER LOCA TION (CONTINUED) D . RESIDENTIAL GARAGE INST ALLA TION P recautions T ake the following special precautions when installing the Munchkin Contender in a residen- tial garage.
11 GAS -FIRED HEA TER Installation Manual G . WHEN REMOVING AN EXISTING HEA TER FROM AN EXISTING COMMON VENT SYSTEM At the time of removal of an existing heater , the fol- lowing steps shall be follow.
12 GAS -FIRED HEA TER Installation Manual P ART 4: PREP ARE MUNCHKIN CONTENDER (CONTINUED) D . INST ALLA TION STEPS 1) Prior to lifting the Munchkin Contender Heater onto the wall, use the enclosed te.
13 GAS -FIRED HEA TER Installation Manual A. RELIEF V AL VE Connect discharge piping to safe disposal loca- tion, following guidelines in the W ARNING below . B. GENERAL PIPING INFORMA TION C. SEP ARA TE L OW WA TER CUTOFF A low water cutoff may be required by state local code or some insurance companies.
14 GAS -FIRED HEA TER Installation Manual P ART 5: MUNCHKIN CONTENDER PIPING (CONTINUED) 2. Expansion tank must be located as shown in Piping P art 5, or following recognized design methods.
15 GAS -FIRED HEA TER Installation Manual P ART 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.
16 GAS -FIRED HEA TER Installation Manual I. FILL AND PURGE HEA TING 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.
17 GAS -FIRED HEA TER Installation Manual MUNCHKIN CONTENDER PIPING (CONTINUED) J . ZONING WITH ZONE V AL VES 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 .
18 GAS -FIRED HEA TER 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 (.
19 GAS -FIRED HEA TER 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 P2 Munchkin Contender Heater T/P purge NOTES: 1.
20 GAS -FIRED HEA TER 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 OFF OFF OFF zone valves anti-scald mixing valve purging valves closely spaced tees differential pressure bypass valve P2 Munchkin Contender Heater T/P NOTES: 1.
21 GAS -FIRED HEA TER Installation Manual Standard Munchkin Contender Heater Preferred piping (zoning with circulators) Space heating mode Drawing 1C NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
22 GAS -FIRED HEA TER Installation Manual Standard Munchkin Contender Heater (zoning with circulators) Domestic water heating mode Drawing 1D NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
23 GAS -FIRED HEA TER Installation Manual Multiple Munchkin Contender Heaters Preferred piping (zoning with circulators) Space heating mode Drawing 1E NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
24 GAS -FIRED HEA TER Installation Manual Multiple Munchkin Contender Heaters Preferred piping (zoning with circulators) Domestic water heating mode Drawing 1F NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
25 GAS -FIRED HEA TER Installation Manual P ART 6. MUNCHKIN CONTENDER PIPING WITH OPTIONAL VISION I SYSTEM (DHW PRIORI TY WITH OUTDOOR RESET) A. VISION I SYSTEM PIPING It is important that the system piping is done correctly when using the Vision 1 System.
26 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with valves) Space heating mode Drawing 2A NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
27 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with valves) Domestic water heating mode Drawing 2B NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
28 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with valves) Space heating mode (w/ submixing) Drawing 2C NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
29 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with circulators) Space heating mode Drawing 3A NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
30 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with circulators) Domestic water heating mode Drawing 3B NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
31 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with circulators) Space heating mode (w/ submixing) Drawing 3C NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
32 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with circulators) Space heating mode (3 fully reset supply temperatures) Drawing 3D NOTES: 1. This drawing is meant to show system piping concept only.
33 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system (zoning with circulators) Space heating mode (3 different supply temperatures) Drawing 3E NOTES: 1. This drawing is meant to show system piping concept only.
34 GAS -FIRED HEA TER Installation Manual Munchkin Contender Heater with optional VISION 1 system Multiple high temperature priority loads controlled with zone valves Drawing 3F NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
35 GAS -FIRED HEA TER Installation Manual 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 Drawing 3G NOTES: 1.
36 GAS -FIRED HEA TER Installation Manual a. Non F oam Core PVC (P olyvinyl Chloride) Pipe conforming to ASTM D -1785). b . Non F oam Core CPVC (Chlorinated P olyvinyl Chloride) Pipe conforming to ASTM D -1785). c . Non Foam Core ABS (Acrylonitrile- Butadiene- Styrene) Pipe conforming to ASTM D3965 Class 3-2-2-2-2.
37 GAS -FIRED HEA TER Installation Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) f . Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators and relief equipment.
38 GAS -FIRED HEA TER Installation Manual HOSE BARB DISTANCE NEEDED TO DRAIN INTO ANY POSITION TO CLEAR BEAM CONDENSATE LINE) DETERMINED BY AROUND OBSTRUCTIONS 1/4" NPT X 1/2" (SUGGESTED SET.
39 GAS -FIRED HEA TER Installation Manual Location of exit terminals of mechanical draft and direct -vent venting systems. (Reference: National F uel Gas Code ANSI Z223.1/NFP A 54 2002). Fig . 7-2 Multiple V ent Spacing* *Note: Exhaust must extend out 1 foot Figure 7-4: Multiple Heater Installations Fig .
40 GAS -FIRED HEA TER Installation Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) 1. The exhaust vent and intake air vent pipes should be 2" or greater , Schedule 40 or 80. 2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet for 2" and 125' for 3".
41 GAS -FIRED HEA TER Installation Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) 40 or 80 pipe. FOAM CORE PIPING IS NO T APPROVED . 3. Remove all burrs and debris from joints and fittings. 4. All joints must be properly cleaned, primed, and cemented.
42 GAS -FIRED HEA TER Installation Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) H. CONDENSA TE REMOV AL SYSTEM This is a condensing high efficiency appliance, therefore this unit has a condensate removal system.
43 GAS -FIRED HEA TER Installation Manual BE FACING UP SIDEWALL VENT WITH INTAKE EXHAUST IMPORTANT: INTAKE LEG MUST EXTERIOR WALL CONCENTRIC VENT KIT FRONT VIEW SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING MIN. 1" Fig. 7 - 1 1 2” sidewall vent with 2” concentric vent kit (KGA VT0501CVT) 12" MIN.
44 GAS -FIRED HEA TER Installation Manual 10'-0" MIN. WHICHEVER IS GREATER 12" OVER MAXIMUM SNOW LEVEL OR 24" RIGHT SIDE VIEW SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL AND VERTICAL PIPING 24" MIN. INTAKE (TEE) EXHAUST (STRAIGHT COUPLING) Fig.
45 GAS -FIRED HEA TER Installation Manual A. GAS CONNECTION The gas sup- ply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pres- sure (3.5 kP a), and a mini- mum of 3.5" water column. The entire pip- ing system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.
46 GAS -FIRED HEA TER Installation Manual 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.
47 GAS -FIRED HEA TER Installation Manual P ART 9: FIELD WIRING A. INST ALLA TION MUST COMPL Y 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 P art 1, and any local codes.
48 GAS -FIRED HEA TER Installation Manual P ART 9: FIELD WIRING (CONTINUED) Fig. 9-4 Fig. 9-3 Fig. 9-1 Fig. 9-2.
49 GAS -FIRED HEA TER Installation Manual P ART 9: FIELD WIRING (CONTINUED) Fig. 9-5.
50 GAS -FIRED HEA TER Installation Manual Outdoor Sensor Function The user can pro- gram the desired supply temperature based on the heat transmitter (Baseboard, Radiant Floor , Air Handler) that will be used in the installation.
51 GAS -FIRED HEA TER Installation Manual P ART 11. ST ART-UP PREP ARA TION A. CHECK/CONTROL WA TER CHEMISTRY W ater 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 .
52 GAS -FIRED HEA TER Installation Manual P ART 11. ST ART-UP PREP ARA TION (CONTINUED) 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.
53 GAS -FIRED HEA TER Installation Manual P ART 11. ST ART-UP PREP ARA TION (CONTINUED) G . CONDENSA TE REMOV AL 1. The Munchkin Contender is a high efficiency condensing heater , there, the unit has a condensation drain.
54 GAS -FIRED HEA TER Installation Manual P ART 12. ST ART-UP PROCEDURE (CONTINUED) A. OPERA TING INSTRUCTIONS Remove Munchkin Contender Heater cover . If you smell gas, STOP . F ollow listed safety instructions. If you do not smell gas, follow the next steps.
55 GAS -FIRED HEA TER Installation Manual P ART 12. ST ART-UP PROCEDURE (CONTINUED) P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 OPTION Function V alue d4 — Not used d5 — Actual T emperature from the outdoor sensor .
56 GAS -FIRED HEA TER Installation Manual P ART 13: ST ART-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 con- troller program function will be cancelled and the control returns to normal operation.
57 GAS -FIRED HEA TER Installation Manual P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED) Default Function Function Value Description 14 30 Min. Allows the installer to set the Maximum run time for the Indirect Fired W ater Heater and the Minimum run time for Central Heating.
58 GAS -FIRED HEA TER Installation Manual Fig. 13-3 P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED) 50 32 41 167 158 149 131 122 113 104 77 59 68 86 95 212 203 194 185 176 201˚ SU.
59 GAS -FIRED HEA TER Installation Manual A. MUNCHKIN ERROR CODE 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.
60 GAS -FIRED HEA TER Installation Manual P ART 14: TROUBLESHOOTING (CONTINUED) T able 14-2: 925 Control Board F AUL T Codes Code Description Remedy F00 High Limit Exceeded.
61 GAS -FIRED HEA TER Installation Manual P ART 15: MAINTENANCE A. MAINTENANCE PROCEDURES P eriodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is in safe efficient operation.
62 GAS -FIRED HEA TER Installation Manual 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 .
63 GAS -FIRED HEA TER Installation Manual P ART 15: MAINTENANCE (CONTINUED) REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Composite Module 7500P-010 (MC50) 14 Gasket (Air Cha.
64 GAS -FIRED HEA TER Installation Manual REPLACEMENT PARTS Item # Description Part # 1 Concentric Flue Outlet (w/Gasket) 7500P-025 2 Gasket (Concentric Flue Outlet) 7500P-008 3 PVC Pipe (2" Sch. 40 - 12" Long) 7500P-097 4 Flue Adapter 7500P-007 5 Flue ECO 7500P-002 6 O-Ring (S.
65 GAS -FIRED HEA TER Installation Manual P ART 15: MAINTENANCE (CONTINUED) REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Cover Filler Plate(w/Screws) 7500P-044 (MC50/MC80) 1.
66 GAS -FIRED HEA TER Installation Manual Light Off Activities 1) Fill the heating system Check all piping and gas connections, verify they are all tight Pressurize System (12-15 PSI) _____PSI Add Wat.
67 GAS -FIRED HEA TER Installation Manual Inspection Activities Piping 1st Year 2nd Year 3rd Year 4th Year* Near Heater Piping Check heater and system piping for any sign of leakage, verify proper sup.
68 GAS -FIRED HEA TER Installation Manual Condensate 1st Year 2 Year 3 Year 4 Year* Condensate Neutralizer Check condensate neutralizer, replace if necessary Condensate Cup Disconnect condensate cup, .
69 MAINTENANCE NOTES.
70 MAINTENANCE NOTES.
© 2007, 2006 Heat T ransfer P roducts, Inc. LP -171 REV . 3 / 20/07.
An important point after buying a device Munchkin Gas-Fired Hot Water Circulating Heater (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Munchkin Gas-Fired Hot Water Circulating Heater yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Munchkin Gas-Fired Hot Water Circulating Heater - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Munchkin Gas-Fired Hot Water Circulating Heater you will learn all the available features of the product, as well as information on its operation. The information that you get Munchkin Gas-Fired Hot Water Circulating Heater will certainly help you make a decision on the purchase.
If you already are a holder of Munchkin Gas-Fired Hot Water Circulating Heater, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Munchkin Gas-Fired Hot Water Circulating Heater.
However, one of the most important roles played by the user manual is to help in solving problems with Munchkin Gas-Fired Hot Water Circulating Heater. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Munchkin Gas-Fired Hot Water Circulating Heater along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
