Munchkin Boiler Gas Fired Hot Water Circulating Heater User Manual

• Installation  
• Startup  
• Maintenance  
• Parts  
Installation  
Manual  
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.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
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.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
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.  
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  
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.  
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.  
When the Munchkin Contender is used to sup-  
ply potable water, it shall not be connected to  
any heating system or component(s) previously  
used with a non-potable water heating appli-  
ance.  
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.  
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.  
Before Installing  
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.  
WHEN SERVICING THE MUNCHKIN CONTENDER  
To avoid electric shock, disconnect electrical  
supply before performing maintenance.  
Do not use “homemade cures” or “boiler patent  
medicines.” Substantial property damage,  
damage to heater, and/or serious personal injury  
may result.  
To avoid severe burns, allow heater to cool  
before performing maintenance.  
MUNCHKIN CONTENDER OPERATION  
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  
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  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 1: PRODUCT AND SAFETY INFORMATION (CONT’D  
can cause internal corrosion in system  
components. Leaks in heater or piping must be  
repaired at once to prevent make-up water.  
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 man-  
ufacturer for specific instructions on the con-  
centration % as well as the freeze and burst pro-  
tection methods.  
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 pro-  
tect the system for the local climate of the instal-  
lation.  
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.  
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  
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.  
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.  
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.  
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.  
3. Gas Valve  
The gas valve senses suction from the blower,  
allowing gas to flow only if the gas valve is  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 2: HOW THE MUNCHKIN CONTENDER OPERATES (CONT’D)  
powered and combustion air is flowing.  
pump. Route low voltage wires through the  
opening to the left of the low voltage terminal  
strip. (See Field Wiring Instructions Part 9.)  
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.  
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.  
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.  
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.  
10. Burner  
14. The Vision 1 Optional System  
Made with metal fiber and stainless steel  
construction, the burner uses pre-mixed air  
and gas and provides a wide range of firing  
rates.  
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  
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  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 2: HOW THE MUNCHKIN CONTENDER OPERATES (CONT’D)  
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  
4
COMBUSTION AIR INLET CONNECTION  
EXHAUST VENT CONNECTION  
SYSTEM RETURN  
SYSTEM SUPPLY  
SYSTEM RELIEF  
1
2
3
ELECTRICAL BOX/CONTROL PANEL  
GAS LINE CONNECTION  
7
8
5
6
CONDENSATE CUP/DRAIN ASSEMBLY  
A
G
H
M
N
J
B
C
O
P
Q
8
7
S
K
L
1
3
D
E
R
2
F
RIGHT SIDE  
VIEW  
BACK VIEW  
LEFT SIDE  
VIEW  
FRONT VIEW  
MUNCHKIN CONTENDER HEATER DIMENSIONS AND SPECIFICATIONS  
COMBUSTION AIR  
BTU/HR BUT/HR  
LOW  
INLET/EXHAUST  
VENT  
SYSTEM  
RELIEF  
SYSTEM SUPPLY/  
SYSTEM RETURN/  
PIPE SIZE  
GAS  
LINE  
HEATER ENERGY DOE  
WATER FACTOR EFF.  
MODEL INPUT  
INPUT  
HIGH  
FIRE  
WATER APPROX.  
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
NUMBER LOW  
FIRE  
EFF.  
LTAAE  
SHIPPING  
WEIGHT  
CONNECTION PIPE SIZE  
SIZE  
CONN. VOLUME  
EF  
3
AFUE  
1
2
MC50 18,000 50,000 12.50 27.50 7.00 2.75 5.25  
MC80 19,000 80,000 12.50 27.50 7.00 2.75 5.25  
9.00  
9.00  
17.25 7.75 5.50  
17.25 7.75 5.50  
2.75 5.25 5.00 9.00 2.75 4.00 6.50 10.25 4.00  
2.75 5.25 5.00 9.00 2.75 5.25 6.50 10.25 4.00  
2.75 5.25 6.00 9.00 2.75 7.75 6.50 11.25 4.00  
2.75 5.25 6.00 9.00 2.75 7.75 6.50 11.25 4.00  
2.00  
2.00  
2.00  
2.00  
.75  
.75  
.75  
.75  
1.25  
1.25  
1.25  
1.25  
.75  
.75  
.75  
.75  
.58  
.67  
.96  
.96  
.91  
.93  
.95  
.95  
92%  
92%  
93%  
92%  
98%  
98%  
98%  
98%  
71 LBS  
74 LBS  
84 LBS  
84 LBS  
MC99 44,000 99,000 13.50 27.50 7.00 2.75 6.50 10.25 17.25 7.75 5.50  
MC120 44,000 120,000 13.50 27.50 7.00 2.75 6.50 10.25 17.25 7.75 5.50  
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  
National Electrical Code.  
A. INSTALLATIONS MUST COMPLY WITH:  
For Canada only: B149.1 or B149.2  
Installation Code, CSA C22.1 Canadian  
Electrical Code Part 1 and any local codes.  
Local, state, provincial, and national codes,  
laws, regulations and ordinances.  
National Fuel Gas Code, ANSI Z223.1 – latest  
edition.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 3: PREPARE MUNCHKIN CONTENDER LOCATION (CONTINUED)  
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  
1. Check for nearby connection to:  
System water piping  
Venting connections  
Gas supply piping  
Electrical power  
24"  
FRONT CLEARANCE  
2. Check area around heater. Remove any  
combustible materials, gasoline and other  
flammable liquids.  
24"  
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 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.  
6"  
6"  
SIDE  
CLEARANCE  
SIDE  
CLEARANCE  
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.  
Figure 3-1: Clearances required  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 3: PREPARE MUNCHKIN CONTENDER LOCATION (CONTINUED)  
the building and properly terminated. The air  
WARNING  
intake and exhaust vent piping lengths, routing  
and termination method must all comply with the  
methods and limits given in the Venting section.  
The space must be provided with combus-  
tion/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 ap-  
pliances. Failure to comply with the above warn-  
ings could result in severe personal injury, death  
or substantial property damage.  
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.  
D. RESIDENTIAL GARAGE INSTALLATION  
Precautions  
Take the following special precautions when  
installing the Munchkin Contender in a residen-  
tial garage. If the heater is located in a residen-  
tial 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.  
Table 3-2: Corrosive contaminants and sources  
Products to avoid  
Spray cans containing fluorocarbons  
Locate or protect the heater so it cannot be  
damaged by a moving vehicle.  
Permanent wave solutions  
Chlorinated waxes/cleaners  
Chlorine-based swimming pool chemicals  
Calcium chloride used for thawing  
Sodium chloride used for water softening  
Refrigerant leaks  
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 con-  
dense in the vent).  
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  
You must also install air intake piping from outside  
to the heater flue adaptor. The resultant installa-  
tion is categorized as direct vent (sealed combus-  
tion). Note: To prevent combustion air con-  
tamination see Table 3-2 in this section  
when considering exhaust vent and intake  
air vent termination.  
Areas likely to have contaminants  
Dry cleaning/laundry areas and establishments  
Swimming pools  
Metal fabrication plants  
Beauty shops  
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  
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  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 3: PREPARE MUNCHKIN CONTENDER LOCATION (CONTINUED)  
in which the appliances remaining connected  
G. WHEN REMOVING AN EXISTING HEATER  
FROM AN EXISTING COMMON VENT SYSTEM  
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.  
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.  
d. Place in operation the appliance being  
inspected. Follow the lighting instructions.  
Adjust thermostat so appliance will operate  
continuously.  
WARNING  
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.  
Failure to follow all instructions can result in flue  
gas spillage and carbon monoxide emissions,  
causing severe personal injury or death.  
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.  
At the time of removal of an existing heater, the fol-  
lowing steps shall be followed with each appliance  
remaining connected to the common venting sys-  
tem placed in operation, while the other appli-  
ances remaining connected to the common vent-  
ing system are not in operation.  
a. Seal any unused openings in the common  
venting system.  
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.  
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  
PART 4: PREPARE MUNCHKIN CONTENDER HEATER  
Care must be taken to place it in a safe location  
prior to installation on the wall to prevent dam-  
age to the bottom mechanical connections.  
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.  
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.  
A. REMOVE MUNCHKIN CONTENDER  
HEATER FROM BOX  
1. The Munchkin Contender is easy to handle.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 4: PREPARE MUNCHKIN CONTENDER (CONTINUED)  
D. INSTALLATION STEPS  
WARNING  
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.  
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-99-  
MC-120-  
84 lbs.  
]
Failure to comply with above could result in  
severe personal injury, death or substantial  
property damage.  
C. MUNCHKIN CONTENDER  
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.  
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.  
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 cen-  
ter. 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.  
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.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 5: MUNCHKIN CONTENDER PIPING  
A. RELIEF VALVE  
NOTICE  
Connect discharge piping to safe disposal loca-  
tion, following guidelines in the WARNING below.  
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.  
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.  
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.  
• 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 thread-  
ed, with a material serviceable for temperatures of  
375 °F or greater.  
If required:  
• Use a low water cutoff designed for  
hydronic installations that is an electrode  
probe type  
• Do not pipe the discharge to any place where freez-  
ing could occur.  
• Install in a tee on the supply piping above  
the heater  
• Follow low water cutoff manufacturer’s  
instructions  
• No shutoff valve shall be installed between the re-  
lief 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 pres-  
surizing 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 tem-  
perature and pressure relief valve installed. This re-  
lief valve shall comply with the standard for Relief  
Valves for Hot Water Supply Systems, ANSI  
Z21.22 CSA4.4.  
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.)  
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).  
• Failure to comply with the above guidelines could  
result in failure of the relief valve to operate, re-  
sulting 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.  
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.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 5: MUNCHKIN CONTENDER PIPING (CONTINUED)  
primary/secondary connection.  
CAUTION  
2. Size the piping and components in the space  
heating system using recognized design  
methods.  
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.  
G. HYDRONIC PIPING WITH CIRCULATORS,  
ZONE VALVES AND MULTIPLE HEATERS  
2. Expansion tank must be located as shown in  
Piping Part 5, or following recognized design  
methods. See tank manufacturer’s  
instructions for details.  
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 non-  
combustible 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  
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 closed-  
type 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 water-  
logging 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  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
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.  
Basic steps are listed below, with Illustration,  
which will guide you through the installation of  
the Munchkin.  
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.  
CAUTION  
The Munchkin Contender should not be  
operated as a potable Hot Water Heater.  
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.  
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.  
H. CIRCULATOR SIZING  
4. Install a Back Flow preventor on the Cold Feed  
Make-Up Water line.  
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 rec-  
ommended pump selection at a 20t design.  
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.  
Figure 5-1  
* NOTE: The recommended circulators are based on 1 gpm per 10,000 btu/hr with 20°t.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
20˚ǻt  
Friction  
25˚ǻt  
Friction  
30˚ǻt  
Friction  
35˚ǻt  
Friction  
40˚ǻt  
Friction  
45˚ǻt  
Friction  
Flow  
GPM  
5
Flow  
GPM  
4
Flow  
GPM  
3.3  
Flow  
GPM  
2.5  
Flow  
GPM  
N/R  
4
Flow  
GPM  
N/R  
3.5  
Feet  
6.5'  
7.8'  
9'  
Feet  
4.5'  
4.7'  
6'  
Feet  
3'  
Feet  
2'  
Feet  
N/R  
1.5'  
3.5'  
3.5'  
Feet  
N/R  
1'  
Model  
MC-50  
MC-80  
MC-99  
MC-120  
8
6.4  
9
2.9'  
5'  
5.3  
2'  
4.6  
10  
7.8  
4'  
6.3  
5.6  
6
2'  
4.8  
10'  
12  
7'  
9.6  
5'  
8
4'  
6.8  
2'  
5.3  
N/R = Not recommended  
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 opera-  
tion.  
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.  
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%.  
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.)  
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.  
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.  
2. The glycol solution should be tested at least  
once a year and as recommended by the  
glycol manufacturer.  
Repeat this procedure for additional zones  
(one at time).  
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.  
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.  
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.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
MUNCHKIN CONTENDER PIPING (CONTINUED)  
K. ZONING WITH CIRCULATORS  
CAUTION  
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.  
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.  
2. Install a separate circulator for each zone.  
3. Connect DHW (domestic hot water) piping to  
indirect storage water heater as shown.  
J. ZONING WITH ZONE VALVES  
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. 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.  
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.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
M. CONTENDER PIPING DETAILS  
Piping symbol legend  
circulator  
(w/ integral check valve)  
circulator  
(w/ isolation flanges)  
gate valve  
pressure reducing valve  
globe valve  
diff. pressure bypass  
anti-scald mixing valve  
ball valve  
swing-check valve  
T/P  
flow-check valve  
temperature /pressure  
gauge  
spring-loaded check valve  
3-way motorized  
mixing valve  
hose bib / heater drain  
Munchkin Contender Heater  
4-way motorized  
mixing valve  
TRV (straight)  
TRV angle  
purging valve  
pressure relief valve  
backflow preventer  
circuit setter  
manual 3-way valve  
zone valve  
float-type  
air vent  
union  
DHW temperature sensor  
Super Stor Ultra  
Indirect DHW Tank  
air separator  
aquastat  
Outdoor temperature  
sensor  
heat exchanger  
diaphragm-type  
expansion tank  
radiant manifold  
with valve actuators  
radiant manifold  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Standard Munchkin Con!tender Heater  
(zoning with valves)  
Space heating mode  
Drawing 1A  
zone valves  
see note 6  
make-up water  
P2  
closely  
spaced  
tees  
differential  
pressure  
bypass  
purge  
valve  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
8.  
9.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all c!irculators.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Standard Munchkin Contender Heater  
(zoning with valves)  
Domestic water heating mode  
Drawing 1B  
zone valves  
see note 6  
make-up water  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
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.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
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.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
8.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
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  
P2  
outdoor  
temperature  
sensor  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
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.  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Multiple Munchkin Contender Heaters  
Preferred piping  
Drawing 1F  
(zoning with circulators)  
Domestic water heating mode  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
8.  
9.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 6. MUNCHKIN CONTENDER PIPING WITH OPTIONAL VISION I SYSTEM  
(DHW PRIORITY WITH OUTDOOR RESET)  
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.  
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 main-  
tained.  
C. ZONING WITH CIRCULATORS USING VISION I  
1. Connect the heater to the system as shown  
in piping details 3A through 3G.  
B. ZONING WITH ZONE VALVES USING VISION I  
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.  
1. Connect the heater to the system as shown  
in piping details 2A through 2C.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
D. HEATER 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  
zone  
valves  
differential  
pressure  
bypass  
make-up water  
purge  
valve  
Munchkin  
Contender  
Heater  
anti-scald mixing valve  
P1  
DHW  
temperature  
sensor  
(Vision 1 system)  
OFF  
T/P  
outdoor  
temperature  
sensor  
P2  
(Vision 1 system)  
purge  
thermal trap  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
8.  
9.  
9.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
(zoning with valves)  
Domestic water heating mode  
Drawing 2B  
optional high limit safety  
see note 6  
zone  
valves  
OFF  
differential  
pressure  
bypass  
make-up water  
purge  
valve  
see note 6  
Munchkin  
Contender  
Heater  
anti-scald mixing valve  
P1  
DHW  
temperature  
sensor  
OFF  
(Vision 1 system)  
T/P  
outdoor  
temperature  
sensor  
P2  
(Vision 1 system)  
purge  
thermal trap  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
(zoning with valves)  
Space heating mode (w/ submixing)  
Drawing 2C  
3-way  
(manually-set)  
mixing valve  
low temperature  
manifold station  
vent  
air handler  
optional high limit safety  
see note 6  
purge  
differential  
pressure  
bypass  
make-up water  
balancing  
valve  
valve  
see note 6  
anti-scald  
mixing valve  
Munchkin  
Contender  
Heater  
cold  
water  
DHW  
P1  
temperature  
sensor  
(Vision 1 system)  
OFF  
T/P  
outdoor  
temperature  
sensor  
P2  
(Vision 1 system)  
purge  
thermal trap  
(w/ drain plug)  
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.  
3.  
4.  
5.  
6.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
(zoning with circulators)  
Space heating mode  
Drawing 3A  
make-up water  
high limit safety  
zone  
circulators  
closely spaced tees  
purge  
see note 6  
anti-scald mixing valve  
Munchkin  
Contender  
Heater  
DHW  
P1  
temperature  
sensor  
(Vision 1 system)  
OFF  
T/P  
outdoor  
temperature  
sensor  
P2  
(Vision 1 system)  
purge  
thermal trap  
Super Stor Ultra  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
(zoning with circulators)  
Domestic water heating mode  
Drawing 3B  
make-up water  
high limit safety  
zone  
circulators  
closely spaced tees  
purge  
Munchkin  
Contender  
Heater  
anti-scald mixing valve  
OFF  
DHW  
P1  
temperature  
sensor  
(Vision 1 system)  
T/P  
outdoor  
temperature  
sensor  
P2  
see note 6  
(Vision 1 system)  
purge  
thermal trap  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
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  
optional high limit safety  
low temperature  
manifold station  
balancing  
valve  
purge  
make-up water  
see note 6  
anti-scald mixing valve  
Munchkin  
Contender  
Heater  
DHW  
P1  
temperature  
sensor  
(Vision 1 system)  
OFF  
T/P  
outdoor  
temperature  
sensor  
P2  
(Vision 1 system)  
purge  
thermal trap  
Super Stor Ultra  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
make-up  
water  
purge  
see note 6  
3-way (manually-set) mixing valve  
anti-scald mixing valve  
Munchkin  
Contender  
Heater  
DHW  
P1  
temp.  
sensor  
(Vision 1 system)  
OFF  
T/P  
outdoor  
P2  
temperature  
sensor  
(Vision 1 system)  
purge  
thermal trap  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
(zoning with circulators)  
Space heating mode (3 different supply temperatures)  
Drawing 3E  
3-way manually-set  
mixing valve  
vent  
air handler  
(higher temp.)  
vent  
low temperature  
manifold station  
optional high limit safety  
variable  
speed  
injection  
mixing  
medium  
temperature  
manifold station  
make-up  
water  
purge  
balancing  
valves  
purge  
see note 6  
anti-scald mixing valve  
Munchkin  
Contender  
Heater  
cold  
water  
DHW  
P1  
temp.  
sensor  
(Vision 1 system)  
OFF  
T/P  
outdoor  
P2  
temperature  
sensor  
(Vision 1 system)  
purge  
thermal trap  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
9.  
10.  
Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
Multiple high temperature priority loads controlled with zone valves  
Drawing 3F  
high temperature loads  
low temperature loads  
air handler  
make-up water  
zone  
circulators  
optional high limit safety  
air handler  
closely spaced tees  
purge  
multi-zone  
relay center  
Munchkin  
Contender  
Heater  
anti-scald  
mixing valve  
DHW  
tank  
aquastat  
OFF  
P1  
P2  
T/P  
outdoor  
see note 6  
temperature  
sensor  
(Vision 1 system)  
purge  
thermal trap  
Super Stor Ultra  
Indirect DHW Tank  
(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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
9.  
10. Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and the  
shut-off connection.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
Munchkin Contender Heater with optional VISION 1 system  
Multiple high temperature priority loads  
Drawing 3G  
controlled with zone circulators  
Multiple low temperature load controls with zone circulators  
high temperature loads  
low temperature loads  
air handler  
make-up water  
zone  
circulators  
optional high limit safety  
air handler  
closely spaced tees  
purge  
multi-zone  
relay center  
Munchkin  
Contender  
Heater  
anti-scald  
mixing valve  
DHW  
OFF  
tank  
aquastat  
P1  
P2  
T/P  
outdoor  
temperature  
sensor  
(Vision 1 system)  
purge  
see note 6  
thermal trap  
(w/ drain plug)  
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.  
All closely spaced tees shall be within 4 pipe diameters center to center spacing.  
2.  
3.  
4.  
5.  
6.  
A minimum of 6 pipe diameters of straight pipe shall be installed upstream & downstream of all closely spaced tees.  
The minimum pipe size for connecting a Super Stor Ultra Indirect Water Heater is 1-inch.  
The minimum pipe size for connecting the Munchkin Contender is 1.25-inch  
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.  
Optional Vision 1 system includes temperature sensors for DHW and outdoor air and must be purchased separately.  
The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.  
Install a minimum of 12 diameters of straight pipe upstream of all circulators.  
7.  
8.  
9.  
10. Winterization: When winterizing the Munchkin Contender, put a drain valve on both the supply and return between the union and  
the shut-off connection.  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL  
a. Non Foam Core PVC (Polyvinyl Chloride)  
DANGER  
Pipe conforming to ASTM D-1785).  
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.  
b. Non Foam Core CPVC (Chlorinated  
Polyvinyl 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.  
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.  
A. INSTALLING EXHAUST VENT AND  
INTAKE AIR VENT  
2. Cellular foam core piping may be used on air  
inlet piping only. Never use cellular foam core  
material for exhaust vent piping.  
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.  
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  
a. The vent piping for this heater is  
approved for zero clearance to  
combustible construction.  
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.  
Vent installations in Canada must comply  
with ULC S636. The Recommended  
manufacturer for this application is Ipex of  
Canada Model System 636.  
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.  
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  
d. Provide a minimum of 1 foot distance  
from any door, operable window, or  
gravity intake into any building.  
C. APPROVED MATERIALS FOR EXHAUST  
VENT AND INTAKE AIR VENT  
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.  
1. Use only Non Foam Core venting material.  
The following materials are approved for use  
as vent pipe for this heater:  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
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.  
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.  
g. Do not locate the exhaust over public  
walkways where condensate could drip  
and/or freeze and create a nuisance or  
hazard.  
b. Do not locate intake air vent in a parking  
area where machinery may damage the  
pipe.  
h. The vent for this appliance shall not  
terminate over public walkways; or near  
soffit vents or crawl space vents or other  
area where condensate or vapor could  
create a nuisance or hazard or cause  
property damage; or where condensate  
or vapor could cause damage or could be  
detrimental to the operation of  
regulators, relief valves, or other  
equipment.  
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.  
i. Do not locate the exhaust directly under  
roof overhangs to prevent icicles from  
forming.  
E. EXHAUST VENT AND INTAKE AIR VENT  
SIZING  
j. Provide 4 feet clearance from the inside  
CONDENSATE PIPING  
SUGGESTED SETUP FOR  
CONDENSATE REMOVAL TO  
FLOOR DRAIN  
CONDENSATE PIPING W/PUMP  
SUGGESTED SETUP FOR  
CONDENSATE REMOVAL  
TO OUTSIDE SOURCE  
3/4" PIPE  
HANGER  
ASSEMBLIES  
3/4" PVC PIPE  
3/4" PIPE  
(LENGTH DETERMINED  
BY DISTANCE TO FLOOR)  
3/4" PVC PIPE  
(LENGTH DETERMINED BY  
DISTANCE TO FLOOR)  
HANGER  
ASSEMBLIES  
3/4" PVC  
90 ELBOW  
(2 SHOWN)  
3/4" PVC  
90 ELBOW  
(2 SHOWN)  
3/4" SOCKET X  
1/2" NPT THREAD  
3/4" SOCKET X  
1/2" THREAD  
PVC ADAPTER  
3/4" SOCKET X  
1/2" THREAD  
PVC ADAPTER  
(2 SHOWN)  
PVC ADAPTER  
(2 SHOWN)  
N1100 CONDENSATE  
NEUTRALIZER  
N1100 CONDENSATE  
NEUTRALIZER  
3/8" TUBE X  
3/4" NPT  
HOSE BARB  
HORIZONTAL LINES MUST  
BE INSTALLED WITH A  
PITCH OF 1/4" PER FOOT  
HORIZONATAL LINES MUST  
BE INSTALLED WITH A  
PITCH OF 1/4" PER FOOT  
3/8" ID TUBING  
3/4" NPT PVC NIPPLE  
CONDENSATE  
3/4" NPT FEMALE  
FLOOR DRAIN  
CUP ASSEMBLY  
PVC UNION  
CONDENSATE  
PUMP  
DETAILS  
3/4" SOCKET  
PVC TEE  
CONDENSATE  
SWITCH  
3/4" THREAD X  
SOCKET PVC  
ADAPTER  
CONDENSATE  
CUP ASSEMBLY  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
EXHAUST PIPING  
AROUND OBSTRUCTIONS  
(SUGGESTED SETUP FOR PIPING  
AROUND BEAMS IN ORDER  
BUILDING  
STRUCTURE  
TO ELIMINATE CONDENSATION)  
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  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)  
1. The exhaust vent and intake air vent pipes  
should be 2" or greater, Schedule 40 or 80.  
exhaust vent.  
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 heater.  
a. The equivalent length of elbows, tees,  
and other fittings are listed in the Friction  
Loss Table 7.6.  
*Friction loss for long radius elbow is 1 foot less.  
b. For example: If the exhaust vent has two  
a. Transitions should always be made in  
vertical sections of pipe to prevent the  
condensate from pooling in the vent  
pipe.  
Table 7.6  
FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS  
b. Use a 3” x 2” reducing coupling to  
transition from the 2” connections to a 3”  
vent.  
FITTINGS OR PIPING  
EQUIVALENT FEET  
2"  
5'  
3"  
5'  
90 DEGREE ELBOW*  
c. The maximum equivalent length for the  
increased diameter vent pipes is 125 feet.  
45 DEGREE ELBOW  
COUPLING  
3'  
3'  
0'  
0'  
d. If the transition occurs at a distance  
greater than 15 equivalent feet from the  
heater, the maximum equivalent length  
will be reduced. See Table 7.7. The  
standard Vent Pipe for Munchkin  
Contender is 2".  
AIR INLET TEE  
0'  
0'  
STRAIGHT PIPE  
CONCENTRIC VENT KIT  
V500 2" VENT KIT  
V1000 3" VENT KIT  
1'  
1'  
3'  
3'  
1'  
N/A  
1'  
N/A  
F. EXHAUST VENT AND INTAKE AIR PIPE  
Table 7.7: Vent Termination Kits  
90° elbows and 10 feet of PVC pipe we  
will calculate:  
Transition  
Point  
TEL of  
Standard  
2" Vent  
TEL of  
Oversized  
2" or 3" Vent  
Pipe (ft)  
Exhaust Vent Pipe Equivalent Length = (2x5)+10=20 feet  
Maximum  
TEL of all  
(ft from  
heater)  
Further, if the intake air vent pipe has two  
90° elbows, one 45° elbow and 10 feet of  
PVC pipe, the following calculation  
applies:  
Vent Pipe (ft)  
Pipe (ft)  
15  
20  
30  
40  
50  
60  
70  
80  
85  
95  
77-1/2  
60-1/2  
43  
125  
117-1/2  
110-1/2  
103  
25  
Intake Air Vent Pipe Equivalent Length = (2x5)+3+10=23 feet  
30  
Finally, if a concentric vent kit is used we  
find:  
35  
26  
96  
40  
8-1/2  
0
88-1/2  
85  
Total Combined Equivalent Length = 20+23+3=46 feet  
None  
Therefore, the total combined equivalent  
length is 46 feet which is well below the  
maximum of 85 feet.  
TEL = Total Equivalent Length  
INSTALLATION  
c. The intake air vent pipe and the exhaust  
vent are intended to penetrate the same  
wall or roof of the building.  
1. On the Munchkin Contender the 2" exhaust  
vent connection is located on the top, right  
side of the unit and the air intake is on the  
top, left side. Sealant or adhesive is required  
for all fittings.  
d. Effort should be made to keep a  
minimum difference in equivalent length  
between the intake air vent pipe and the  
2. Use only solid PVC, CPVC, or ABS schedule  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)  
40 or 80 pipe. FOAM CORE PIPING IS NOT  
APPROVED.  
G. HEATER REMOVAL FROM A COMMON  
VENT SYSTEM  
3. Remove all burrs and debris from joints and  
fittings.  
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 com-  
mon venting system are not operating.  
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.  
1. Seal any unused openings in the common  
venting system.  
5. Horizontal lengths of exhaust vent must slope  
2. Visually inspect the venting system for proper  
size and horizontal pitch to determine if there  
is blockage, leakage, corrosion or other defi-  
ciencies that could cause an unsafe condition.  
WARNING  
All joints of positive pressure vent systems  
must be sealed completely to prevent leakage  
of flue products into the living space.  
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.  
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.  
4. Place in operation the appliance being  
inspected. Follow the lighting instructions.  
Adjust the thermostat so the appliance will  
operate continuously.  
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.  
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.  
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.  
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.  
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.  
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  
Table 7.8: Vent Termination Kits  
Description  
Stock Code  
KGAVT0501CVT  
KGAVT0601CVT  
V500  
2" PVC Concentric Vent Termination Kit  
3" PVC Concentric Vent Termination Kit  
2" Stainless Steel Vent Termination Kit  
3" Stainless Steel Vent Termination Kit  
V1000  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL (CONTINUED)  
H. CONDENSATE REMOVAL SYSTEM  
NOTICE  
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 start-  
ed. 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 crys-  
tals, 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 vacu-  
um 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 conden-  
sate flow.  
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  
PVC schedule 40  
United States Canada  
ANSI/ASTM D1785  
Vent or air  
pipe and  
fitting  
PVC-DWV  
ANSI/ASTM D2665  
CPVC schedule 40  
ANSI/ASTM F441  
ULC S636  
ABS-DWV schedule 40 ANSI/ASTM D2661 certified  
only  
PVC  
ANSI/ASTM D2564  
ANSI/ASTM F493  
ANSI/ASTM D2235  
Pipe  
cement/ CPVC  
primer  
ABS  
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 heater tee, resulting in potential  
water damage to property.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
I. DIAGRAMS FOR SIDEWALL VENTING  
SIDEWALL VENTING WITH KIT  
1" MIN.  
VENT KIT  
INTAKE  
INTAKE  
(TEE)  
12" MIN.  
EXHAUST  
TOP VIEW  
EXHAUST  
EXTERIOR WALL  
(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.  
EXHAUST  
(STRAIGHT  
COUPLING)  
SUPPORT BRACKETS  
MUST BE USED ON  
ALL HORIZONTAL  
INTAKE  
(TEE)  
AND VERTICAL PIPING  
RIGHT SIDE VIEW  
Fig. 7-10 2” sidewall vent with V500 kit  
SIDEWALL VENT WITH  
CONCENTRIC VENT KIT  
EXTERIOR WALL  
INTAKE  
1"  
MIN.  
IMPORTANT:  
INTAKE LEG MUST  
BE FACING UP  
SUPPORT BRACKETS  
MUST BE USED ON  
ALL HORIZONTAL  
AND VERTICAL PIPING  
EXHAUST  
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).  
FRONT VIEW  
Fig. 7-11 2” sidewall 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.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
24" MIN.  
12" OVER MAXIMUM  
SNOW LEVEL OR 24"  
WHICHEVER IS GREATER  
EXHAUST  
(STRAIGHT  
COUPLING)  
10'-0" MIN.  
10'-0" MIN.  
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.  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 8: GAS PIPING  
B. GAS PIPING  
WARNING  
Failure to follow all precautions could result in  
fire, explosion or death!  
1. Run the gas supply line in accordance with all  
applicable codes.  
2. Locate and install manual shutoff valves in  
accordance with state and local  
requirements.  
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 kPa),  
and a mini-  
mum of 3.5"  
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)  
water column.  
The entire pip-  
Fig. 8-1  
Nominal  
ing 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 connect-  
ed 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 mandato-  
ry 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 per-  
formed, the piping must be leak tested. If the  
leak test requirement is a higher test pressure  
than the maximum inlet pressure, you must iso-  
late 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.  
Iron Pipe Internal  
Length of Pipe (Feet)  
Size  
Diameter  
(inches) (inches) 10 20 30 40 50 60 70  
3/4  
1
1 1/4  
1 1/2  
.824  
1.049  
278 190 152 130 115 105 96 BTU'S  
520 350 285 245 215 195 180 PER  
1.380 1,050 730 590 500 440 400 370 HOUR  
1.610 1,600 1,100 890 760 670 610 560 x1,000  
}
80 90 100 125 150 175 200  
90 84 79 72 64 59 55 BTU'S  
170 160 150 130 120 110 100 PER  
350 320 305 275 250 225 210 HOUR  
530 490 460 410 380 350 320 x1,000  
3/4  
1
1 1/4  
1 1/2  
.824  
1.049  
1.380  
1.610  
}
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  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
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  
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"  
ANALYZER  
SEE PART 12 SECTION  
"D" FOR COMBUSTION  
SETTING TABLE.  
WARNING  
For a heater already installed,  
you must turn off gas supply,  
turn off power and allow  
h e a t e r t o c o o l b e f o r e  
proceeding. You must also  
completely test the heater  
after conversion to verify  
PRESSURE  
TAP INLET  
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!  
GAS VALVE  
GAS SHUT OFF  
VALVE  
Fig. 8-3  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 9: FIELD WIRING  
front right hand side of the unit. The electrical junc-  
tion box has a 24 volt terminal compartment and  
120 volt terminal compartment. Each terminal con-  
nection is clearly marked to assure correct instal-  
lation.  
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.  
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.  
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.  
2. Wire the Heater Primary Circulator (P1) to the  
terminal strip. See wiring diagram in this  
section.  
D. THERMOSTAT  
Heater must be electrically grounded as  
required by National Electrical Code ANSI/NFPA  
70 — latest edition.  
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.  
A. INSTALLATION MUST COMPLY WITH:  
1. National Electrical Code and any other  
national, state, provincial or local codes or  
regulations.  
3. Thermostat anticipator (if applicable):  
a. If connected directly to heater, set for 0.1  
amps.  
2. In Canada, CSA C22.1 Canadian Electrical  
Code Part 1, and any local codes.  
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.  
B. FIELD WIRING  
For you convenience we have located the electri-  
cal connection of the Munchkin Contender on the  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 9: FIELD WIRING (CONTINUED)  
Fig. 9-3  
Fig. 9-1  
Fig. 9-2  
Fig. 9-4  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 9: FIELD WIRING (CONTINUED)  
Fig. 9-5  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 10: FIELD WIRING – VISION 1 OPTION  
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.  
Once the outdoor sensor (Light Green Wires) is  
connected to the control board, the water tem-  
perature of the heater will adjust to run the  
heater more efficiently and provide greater com-  
fort to the living space.  
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.  
Connection Specification – Wire 22 AWG  
maximum to 100 feet or 18 AWG up to  
150 feet. Length of wire run cannot  
exceed 150 feet.  
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.  
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.  
Indirect Circulator (P2) is connected to the  
terminal strip on the Munchkin Contender. Run  
the wire to the Super Stor Ultra Indirect circulat-  
ing 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.  
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.  
Fault Code Alarm Output is connected to  
the main controller on the Munchkin Contender.  
Route wire from the Munchkin Contender con-  
troller 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.  
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).  
CAUTION  
Do not tie neutrals or hot wire leads to any  
o t h e r w i r e s , g o d i r e c t l y f r o m t h e  
Munchkin Contender controller to the circulator.  
Connection Specification – Wire 18 AWG  
maximum. Length of wire run cannot  
exceed 100 feet.  
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-  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 11. START-UP PREPARATION  
ically due to degradation of inhibitors over time.  
Follow all fluid manufacturer’s instructions.  
A. CHECK/CONTROL WATER CHEMISTRY  
WARNING  
B. FREEZE PROTECTION (WHEN USED)  
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.  
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.  
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.  
Provide Munchkin Contender Heater owner  
with a material safety data sheet (MSDS) on the  
fluid used.  
Hardness less than 7 grains.  
1. Consult local water treatment companies for  
unusually hard water areas (above 7 grains  
hardness).  
1. Determine freeze protection fluid quantity  
using total system water content, following  
fluid manufacturer’s instructions. Remember  
to include expansion tank water content.  
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. Local codes may require back flow preventer  
or actual disconnect from city water supply.  
2. Do not use the heater to directly heat  
swimming pool or spa water.  
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.  
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.  
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.  
2. For zoned systems, flush each zone sepa-  
rately through a purge valve. (If purge valves  
and isolation valves are not already installed,  
install them to properly clean the system.)  
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.  
3. Flush system until water runs clean and you  
are sure piping is free of sediment.  
b. Pressure will rise when heater is turned  
on and system water temperature  
increases. Operating pressure must  
never exceed 25 psig.  
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.  
4. At initial fill and during heater startup and  
testing, check system thoroughly for any leaks.  
Repair all leaks before proceeding further.  
2. Freeze protection fluid must be replaced period-  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 11. START-UP PREPARATION (CONTINUED)  
one at a time, beginning with lowest  
floor. Close vent when water squirts out.  
Repeat with remaining vents.  
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.  
j. Refill to correct pressure.  
E. CHECK FOR GAS LEAKS  
WARNING  
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.  
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.  
CAUTION  
It is important that you purge the system of air  
to avoid damage to the heater.  
WARNING  
D. PURGE AIR FROM WATER SYSTEM  
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.  
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 make-  
up line.  
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).  
e. Open purge valve.  
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.  
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.  
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.  
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  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 11. START-UP PREPARATION (CONTINUED)  
condensate overflow, which, if not corrected,  
could cause property damage.  
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)  
3. 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.  
4. Do not expose the condensate to freezing  
temperatures.  
5. 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.  
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  
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.  
• 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.)  
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.  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 12. START-UP PROCEDURE (CONTINUED)  
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 set-  
ting 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 differen-  
tial 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°  
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.  
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  
DANGER  
Water temperature over 125  
degrees F. can cause severe  
burns instantly, or death from  
scalds. Children, disabled, and  
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.  
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.  
C. STATUS MENU  
B. ADJUSTING THE SETPOINT  
Installers are also able to check the current status  
of the Munchkin Contender Heater parameters by  
pressing {S4/RESET} key for 3 seconds. Once acti-  
vated, 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.  
1. Before you can change the temperature from  
the factory setting of 180 degrees. You must  
make sure that none of the thermostats are call-  
ing 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  
Function Value  
d1 — Actual Temperature from outlet sensor  
d2 — Actual Temperature from inlet sensor  
d3 — If using a standard mechanical control,  
the control will display |1| for closed |0|  
for open  
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 heater. In addition to  
changing the temperature you are also allowed  
to change three more settings in this model (1.  
Munchkin Contender Heater differential – 2.  
If the sensor is connected to the  
SuperStor Indirect Fired Water Heater  
it will measure the actual temperature.  
(Vision option.)  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 12. START-UP PROCEDURE (CONTINUED)  
Function Value  
d4 — Not used  
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  
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)  
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 com-  
bustion levels should always be taken at the high-  
est and lowest fan speed. After 10 minutes, the  
Test mode stops automatically. To exit Test Mode  
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.)  
press {S1/  
-
} and {S2/+} key together for 1 second.  
Fig. 12-1  
d10 — Actual Status bus communication  
|co| = connected, |no| = not connected  
COMBUSTION SETTINGS  
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  
HIGH FIRING RATES and LOW FIRING RATES ON ALL MODELS  
Natural Gas Propane LP  
low  
high  
low  
high  
Carbon  
Monoxide 0–20 ppm 70 ppm–135 ppm 0–20 ppm 80 ppm–150 ppm  
(CO %)  
D. TEST MODE  
Carbon  
This function is intended to simplify the gas valve  
adjustment if needed. Listed below are the  
Dioxide  
2
8½% – 9½% 8½% – 9½% 9½% – 10½% 9½% – 10½%  
(CO %)  
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 tem-  
perature 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 out-  
side temperature. This gives you a higher com-  
fort level and further increases the efficiency of  
the Munchkin Contender.  
A. PROGRAMMING THE VISION I OPTION  
The Vision I option allows the installer to set sys-  
tem 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 pro-  
gram 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  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 con-  
troller 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  
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  
---| 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.  
7
68ºF Outdoor temperature that you  
wish the central heating should be  
disabled—(warm weather shut-  
off) Range: 41ºF to 122ºF  
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 effec-  
tive 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 vari-  
ety of functions the installer can program into  
the Vision I System.  
*8  
5ºF Allows the installer to change the  
Minimum Outside Design  
Temperature. Range: –49ºF to  
32ºF (See Chart 13-1 to set out-  
door 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  
CAUTION  
*10  
*11  
68ºF Allows the installer to change the  
Maximum Outside Design  
Temperature for Central Heating.  
Range: 95ºF to 32ºF  
95ºF Allows the installer to change the  
Design Supply Water  
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.  
Temperature from the Munchkin  
based on the Maximum Outside  
Design Temperature. Range:  
32ºF to 180ºF  
Default Function  
Function Value Description  
1
2
3
de  
Not Applicable  
149ºF Not Applicable  
12  
68º F Allows the installer to set the low-  
est temperature on the Munchkin  
for Central Heating. Range: 32ºF  
to 180ºF  
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  
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.  
4
5
36ºF Not Applicable  
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  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED)  
Default Function  
The central heating demand is detected when  
the room thermostat closes. When an outside  
sensor is also connected, the supply tempera-  
ture will depend on the factory default central  
heating curve.  
Function Value Description  
14 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  
To set your heat curve you will have to set the  
following parameters  
15  
0
Bus address (0=zone master 1–8  
— cascade slave) (Not currently  
used.)  
1. Minimum outside design temperature:  
Function 8  
2. Design Supply water temperature at the  
minimum design outside temperature:  
Function 9  
16  
0
Interface Board Activation  
0 = not active  
1 = active  
3. Maximum outside design temperature:  
WARNING: Never change the de-  
fault setting without the Munchkin  
Interface Board installed.**  
Interface Board Function  
0 = Building Management  
1 = Enables Tekmar Modulating  
control.  
(Consult with Tekmar to assure  
the Tekmar Control is compati-  
ble)  
Function 10  
4. Design Supply water temperature at the  
maximum outside temperature: Function 11  
17  
18  
0
1
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.  
Step Modulation – Regulates the  
burner output in 6 steps in one-  
minute intervals. This reduces  
short cycling.  
1 = on  
0 = off  
19  
20  
180° Indirect heater set point (flow)  
Temperature default = 119° to  
180°  
1
Not applicable  
* Central Heating Curve Function  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED)  
CENTRAL HEATING CURVE  
CENTRAL HEATING CURVE  
Plot your Curve  
Factory Default  
212  
203  
194  
185  
176  
167  
158  
149  
131  
122  
113  
104  
95  
212  
203  
194  
185  
176  
167  
158  
149  
131  
122  
113  
104  
95  
201˚  
FUNCTION 9  
DEFAULT RESET CURVE  
FUNCTION 11  
86  
86  
77  
77  
68  
68  
59  
59  
50  
50  
41  
41  
32  
32  
0
0
-59  
-41  
-24  
-9  
9
63  
99  
27  
45  
81  
68˚  
-59  
-41  
-24  
-9  
9
63  
99  
27  
45  
81  
5˚  
OUTSIDE TEMPERATURE (F)  
OUTSIDE TEMPERATURE (F)  
Fig. 13-1  
Fig. 13-2  
CONTROL PROGRAM REFERENCE CHART  
Function  
Default Setting  
Programmed Setting  
1
2
3
de  
149 F  
160 F  
36 F  
No change allowed  
No change allowed  
4
No change allowed  
5
6
7
7 F  
0 minutes  
68 F  
8
9
5 F  
180 F  
68 F  
95 F  
68 F  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
0 minutes  
30 minutes  
0
0
0
1
180°F  
Fig. 13-3  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
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  
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 14-1.  
WARNING  
Do not use this appliance if any part has been under  
water. Improper or dangerous operation may result.  
Contact a qualified service technician immediately to  
inspect the heater and to repair or replace any part of  
the heater which has been under water.  
3. In the case of E00, E13, and E14 this error, if  
uncorrected, will go into a fault condition as  
described is Paragraph C (Heater Fault).  
C. HEATER FAULT  
CAUTION  
This appliance has wire function labels on all internal  
wiring. Observe the position of each wire before re-  
moving it. Wiring errors may cause improper and dan-  
gerous operation. Verify proper operation after servicing.  
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.  
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.  
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.  
Table 14-1 : 925 Control Board ERROR Codes  
Code  
Description  
Combustion Fan Speed Low.The  
heater combustion air fan speed less  
than 70% of expected.  
Duration  
Corrective Action  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
60 Sec.  
E13  
Combustion Fan Speed High. The  
heater combustion air fan speed is  
more than 130% of expected.  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
60 Sec.  
Until  
E14  
1. Assure that the system pressure is above 10 psig.  
Water Pressure Switch Open  
PR0  
Corrected 2. Check for leaks in the system piping.  
1. Assure that the vent is not blocked  
Until  
Blocked Vent Pressure Switch Open  
2. Check the switch operation by applying a jumper. (If  
Corrected  
FLU  
the switch is not functioning properly, replace it.)  
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 14: TROUBLESHOOTING (CONTINUED)  
Table 14-2: 925 Control Board FAULT Codes  
Code  
Description  
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.  
High Limit Exceeded.  
F00  
3. Check thermister reading on supply thermister. Replace switch if faulty.  
1. Push the red reset button on the vent temperature limit switch.  
2. Check the flue temperature during operation using a combustion analyzer.  
3. Replace the vent limit switch if faulty.  
Vent Temperature Limit Switch  
Exceeded.  
F01  
Interrupted or Shorted  
1. Check the electrical connection to the thermister on the outlet manifold.  
F02  
F03  
Supply (Outlet) Thermister.  
2. Replace thermister if necessary.  
Interrupted or Shorted  
Return (Inlet) Thermister.  
1. Check the electrical connection to the thermister on the inlet manifold.  
2. Replace thermister if necessary.  
1. Check circulation pump operation.  
Supply (Outlet)  
Temperature exceeds 230°F.  
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.  
F05  
1. Check circulation pump operation.  
Return (Inlet) Temperature  
Exceeded 230°F.  
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.  
F06  
1. Watch the igniter through the observation window provided.  
2. If there is no spark, check the spark electrode for the proper ¼” gap. Use  
2 quarters together as a gauge to check gap distance.  
3. Remove any corrosion from the spark electrode and flame rectifier  
probe.  
No flame detected – The heater  
will make three attempts at  
ignition before the control goes  
into this lockout condition. *See  
spark electrode detail.  
F09  
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.  
Loss of Flame Signal – The heater 3. Check to see if the green light on the display module is out while the  
will relight 4 times before the  
control goes into this lockout  
condition.  
heater is running.  
F10  
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.  
False Flame Signal – The heater  
will lock out if it senses a flame  
signal when there should be none  
present.  
F11  
Combustion Fan Speed Low – The  
heater will lock out if it senses that 1. Check the combustion air fan wiring.  
the fan speed is less than 70% of  
expected rate for more than 60  
seconds.  
2. Replace the combustion air fan.  
3. Replace the control board.  
F13  
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.  
1. Check the combustion air fan wiring.  
2. Replace the combustion air fan.  
3. Replace the control board.  
F14  
1. Make sure the connector is correctly connected to the gas valve.  
2. Check the electrical wiring from the valve to the control board.  
3. Replace the low voltage wiring harness assembly.  
4. Replace control board.  
Gas Valve Error  
F18  
Watchdog  
Call factory for further assistance.  
Call factory for further assistance.  
Call factory for further assistance.  
Call factory for further assistance.  
F30  
F31  
F32  
F33  
Parameter Memory  
Parameter Memory Write Error  
Programming Error  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 14: TROUBLESHOOTING (CONTINUED)  
Resistance Tables  
Indirect Sensor  
(7250P-320)  
Outdoor Sensor (7250P-319)  
Heater Sensor (7250P-059)  
Outside Temperature (°F) Resistance (ohms) Heater and Indirect Temperature (°F) Resistance (ohms)  
–22  
–13  
–4  
171800  
129800  
98930  
76020  
58880  
45950  
36130  
28600  
22800  
18300  
14770  
12000  
9804  
32  
41  
32550  
25340  
19870  
15700  
12490  
10000  
8059  
6535  
5330  
4372  
3605  
2989  
2490  
2084  
1753  
1481  
1256  
1070  
915  
50  
5
59  
14  
23  
32  
41  
50  
59  
68  
77  
86  
95  
104  
113  
68  
77  
86  
95  
104  
113  
122  
131  
140  
149  
158  
167  
176  
185  
194  
203  
212  
8054  
Fig. 14-2  
6652  
NOTE: If receiving an  
F09 fault code, check  
t h e g a p s p a c i n g  
between points on the  
electrode by holding  
two quarters together  
a n d s l i d i n g t h e m  
through the gap. There  
should be a slight  
resistance.  
5522  
786  
667  
Fig. 14-3  
PART 15: MAINTENANCE  
A. MAINTENANCE PROCEDURES  
WARNING  
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 contrac-  
tor 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.  
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.  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 15: MAINTENANCE (CONTINUED)  
Munchkin Contender side), so the flow  
can be observed.  
WARNING  
c. Disconnect connections from the gas  
valve, spark electrode and flame rectifi-  
cation 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.  
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.  
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 chem-  
ical 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. WARN-  
ING: 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.  
• 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  
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.  
Before powering up the Munchkin Contender follow  
the steps below  
B. COMBUSTION CHAMBER COIL  
CLEANING INSTRUCTIONS  
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.  
*Before beginning this procedure, you must have on  
hand the following items:  
– a nylon, stainless or brass brush (not steel)  
– “Rydlyme” (recommended for best  
r e s u l t s ) ( a v a i l a b l e o n l i n e  
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  
h. Re-connect the condensate hose to the  
outside connection.  
b. Disconnect the condensate hose from  
the outside connection, (not from the  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 15: MAINTENANCE (CONTINUED)  
1
2
HEATER LIMIT  
FUSE CONNECTION  
5
3
4
6
8
7
9
11  
10  
16  
21  
10  
12  
13  
14  
18  
17  
15  
22  
23  
19  
20  
24  
REPLACEMENT PARTS  
Item  
#
Item  
#
Description  
Part #  
Description  
Part #  
1
Composite Module  
7500P-010 (MC50)  
7500P-012 (MC80)  
14 Gasket (Air Channel to Combustion Blower)  
7500P-075  
15 Combustion Blower (w/Screws)  
7500P-031  
7250P-254  
7250P-644  
7500P-014 (MC99/MC120) 16 Screws M5 x 14MM (Combustion Blower)  
2
3
Ceramic Target Wall  
7250P-160  
7500P-076  
17 Gas Valve Adapter Plate (w/Screws)  
Burner Door Ceramic Refractory  
18 Screws M4 x 12MM (Gas Valve Adapter Plate) 7500P-105  
4
5
6
Burner Door (w/Nuts)  
Nuts - M6 (Burner Door)  
NIT Burner  
7500P-078  
19 Gas Valve Swirl Plate  
7500P-091(MC50)  
7500P-067  
7500P-092 (MC80)  
7500P-015 (MC50)  
7500P-016 (MC80)  
7500P-017 (MC99/MC120)  
7500P-074  
7500P-093 (MC99/MC120)  
7250P-448 (MC50)  
20 Gas Valve (w/Swirl Plate, Screws)  
7250P-449 (MC80)  
7
Gasket (Burner)  
7000P-862 (MC99/MC120)  
8
9
Air/Gas Channel (w/Torx Screws)  
Torx Screws (Air/Gas Channel)  
7500P-079  
7500P-068  
21 Screws M4 x 18MM (Gas Valve)  
Screws M4 x 19MM (Gas Valve)  
Screws M4 x 25MM (Gas Valve)  
7250P-716 (MC50)  
7250P-717 (MC80)  
10 Gasket (Flame Rec./Spark Electrode) 7250P-005  
Flame Rectification Probe  
(w/Gasket)  
7250P-718 (MC99/MC120)  
11  
7500P-039  
22 O-Ring (Gas Valve Piping Assy)  
7500P-094  
12 Spark Electrode (w/Gasket)  
7500P-040  
23 Gas Valve Piping Assembly (w/O-ring, Screws) 7500P-095  
13 Screws M4 x 8MM (Probe/Electrode) 7250P-069  
24 Screws M4 x 12MM (Gas Valve Piping Assy)  
7500P-099  
Fig. 15-1  
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 15: MAINTENANCE (CONTINUED)  
1
2
6
8
9
7
3
10  
4
11  
12  
5
13  
REPLACEMENT PARTS  
Description  
Item #  
Part #  
1
2
3
4
Concentric Flue Outlet (w/Gasket)  
Gasket (Concentric Flue Outlet)  
PVC Pipe (2" Sch. 40 - 12" Long)  
Flue Adapter  
7500P-025  
7500P-008  
7500P-097  
7500P-007  
5
6
Flue ECO  
O-Ring (S.S. Barbed Fitting)  
7500P-002  
7250P-152  
14  
15  
7
S.S. Barbed Fitting  
7250P-154  
8
Water Pressure Switch  
7250P-096  
7500P-124  
7000P-805  
7500P-003  
7500P-100  
7500P-077  
7500P-080  
7500P-026  
9
O-Ring (Water Pressure Switch)  
Clear Tubing 3/16 ID x 5/16 OD  
Water Pressure Switch Adapter  
O-Ring (Water Pressure Switch Adapter)  
Water Pressure Switch Clip  
10  
11  
12  
13  
14  
15  
16  
17  
Supply/Return Manifold Clip  
O-Ring (Supply/Return Manifold)  
18  
16  
17  
Thermistor  
High Limit Sensor  
7250P-059  
7500P-033  
18  
19  
Relief Valve  
7250P-080  
7500P-029  
Supply Manifold Assembly (w/O-Ring, Relief  
Valve, Temperature/Pressure Gauge)  
19  
20  
21  
Return Manifold Assembly (w/O-Ring)  
Temperature/Pressure Gauge  
7500P-030  
7500P-098  
20  
21  
Fig. 15-2  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
PART 15: MAINTENANCE (CONTINUED)  
1
2
21  
3
5
6
9
4
10  
7
8
11  
12  
11  
14  
13  
16  
17  
15  
20  
18  
19  
REPLACEMENT PARTS  
Item  
Item  
#
Description  
Part #  
Description  
Part #  
#
1
Cover Filler Plate(w/Screws)  
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  
2
3
Blocked Vent Pressure Switch  
7250P-150  
7500P-047  
14 Supply/Return Filler Plate (w/Screws)  
7500P-022 (MC50/MC80)  
Screws 8-32x3/8 (Blocked Vent Pressure  
Switch)  
7500P-023 (MC99/MC120)  
4
5
6
Control Board (w/Screws)  
7250P-317  
7500P-055  
7500P-054  
15 Lip Style Grommet - 1"  
16 Lip Style Grommet - 1/2"  
17 Gas Inlet Plate  
7500P-050  
7500P-049  
7500P-043  
5 Pin Wiring Harness (location)  
9 Pin Wiring Harness (location)  
7
8
9
Low Voltage Wiring Harness (location)  
Screws # 6 x 1/2 - Control Board  
7500P-053  
7250P-480  
18 Condensate Float Switch  
7500P-041  
7500P-090  
Condensate Cup w/Engagement  
Switch  
19  
Clamp -Module to Bracket (w/Screws)  
7500P-073  
7500P-069  
20 Control Board Display  
7500P-058  
10 Screws M4x6 (Clamp)  
21 Contender Cover  
7500P-027 (MC50/MC80)  
7500P-028 (MC99/MC120)  
11 CTB-27ST Spring Clamp (Condensate Hose) 7250P-012  
Fig. 15-3  
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GAS-FIRED HEATER  
Installation Manual  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE NOTES  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE NOTES  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
© 2007, 2006 Heat Transfer Products, Inc.  
LP-171 REV. 3/20/07  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Moxa Technologies Network Card CP 114 Series User Manual
National Instruments Network Card NI PXIe 6672 User Manual
NETGEAR Switch GSS108E User Manual
New Buck Corporation Stove CDVB200 User Manual
Night Owl Optics Home Security System CAM MINI B700 User Manual
Olympus Camera Lens VN595201 User Manual
Olympus Microcassette Recorder DS 50 User Manual
Omega Vehicle Security Thermometer HH501AJ User Manual
Oster Griddle CKSTGRFM18 User Manual
Panasonic Printer KX P7100 series User Manual