HTP Munchkin Boiler Installation guide

Category
Water heaters & boilers
Type
Installation guide

This manual is also suitable for

HEAT TRANSFER PRODUCTS, INC.
120 BRALEY RD., E. FREETOWN, MA 02717
Installing, Operating & Maintaining
MUNCHKIN™ HIGH EFFICIENCY HEATER
with the “925” Controller
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch: do not use any phone in
your building.
Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
WARNING
This manual must only be used by a qualified heating installer / service
technician. Failure to comply could result in severe personal injury, death or
substantial property damage. It is also important to keep these Instructions
with the appliance.
MH27745
USING THIS MANUAL
2
SPECIAL ATTENTION BOXES
Throughout this manual you will see these
special attention boxes similar to this one,
which are intended to supplement the
instructions and make special notice of
potential hazards. These categories mean, in
the judgement of Heat Transfer Products, Inc.:
NOTICE
Heat Transfer Products manufactures both
ASME and Non-ASME boilers. It is the
responsibility of the installer that the correct
model has been selected for jurisdiction
requirements.
WARNINGS
THIS UNIT IS FOR CATEGORY IV VENTING - 2 PIPE ONLY. THIS IS A SEALED
COMBUSTION APPLIANCE.
THIS HEATER INSTALLATION MUST CONFORM TO THE LATEST EDITION OF THE
“NATIONAL FUEL GAS CODE” ANSI Z223.1 NFPA 54 AND OR CAN/CGA B149
INSTALLATION CODES. STATE AND LOCAL CODES MIGHT ALSO APPLY TO
INSTALLATION.
WHERE REQUIRED BY THE AUTHORITY HAVING JURISDICTION, THE
INSTALLATION MUST CONFORM TO THE STANDARDS FOR CONTROLS AND
SAFETY DEVICES FOR AUTOMATICALLY FIRED HEATERS, ANSI/ASME HEATER
AND PRESSURE VESSEL CODE, Section IV, ALONG WITH CSD1.
THE HEATER, GAS PIPING, WATER PIPING, VENTING AND ELECTRICAL MUST BE
INSTALLED BY TRAINED & QUALIFIED PERSONNEL FAMILIAR WITH
INSTALLATION PRACTICES, LOCAL CODE, LICENSING REQUIREMENTS.
IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY,
A FIRE OR EXPLOSION MAY RESULT; CAUSING PROPERTY DAMAGE, PERSONAL
INJURY, OR DEATH.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE;
THE USE OF A LOW WATER CUT-OFF DEVICE MAY BE REQUIRED BY STATE OR
LOCAL CODES IF THE MUNCHKIN IS INSTALLED ABOVE RADIATION LEVELS.
USING THIS MANUAL
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION Indicates a potentially hazardous
situtation which, if not avoided, may result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
TABLE OF CONTENTS
3
TABLE OF CONTENTS
PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8
GENERAL INFORMATION
A How It Operates . . . . . . . . . . . . . . . . . .4
B Munchkin Ratings and Dimensions . . .4
C Pre-installation Requirements . . . . . . .8
D Pressure Relief Valve . . . . . . . . . . . . . .9
PART 2 . . . . . . . . . . . . . . . . . . . . .9 thru 11
ELECTRICAL
A Electrical Connection . . . . . . . . . . . . . .9
PART 3 . . . . . . . . . . . . . . . . . . . .12 thru 13
GAS CONNECTION
A Gas Connection . . . . . . . . . . . . . . . . . .12
B Gas Piping . . . . . . . . . . . . . . . . . . . . . .12
C Gas Table . . . . . . . . . . . . . . . . . . . . . . .12
PART 4 . . . . . . . . . . . . . . . . . . . .14 thru 21
VENTING
A General . . . . . . . . . . . . . . . . . . . . . . . .14
B Approved Materials for Exhaust Vent
and Intake Air Pipe . . . . . . . . . . . . . . .14
C Exhaust/Vent / Air Intake
Pipe Location . . . . . . . . . . . . . . . . . . . .14
D Exhaust Vent and Intake Air
Pipe Sizing . . . . . . . . . . . . . . . . . . . . . .16
E Exhaust Vent and Air Intake
Pipe Installation . . . . . . . . . . . . . . . . . .16
F Heater Removal from a
Common Vent System . . . . . . . . . . . .18
G Condensate Removal . . . . . . . . . . . . .18
PART 5 . . . . . . . . . . . . . . . . . . . .22 thru 33
PIPING
A Hydronic piping with
Circulators or Zone Valves . . . . . . . . .22
B Circulator Sizing . . . . . . . . . . . . . . . . .23
C Fill and Purge Heating System . . . . . .24
D Piping Illustrations . . . . . . . . . . . . . . .25
PART 6 . . . . . . . . . . . . . . . . . . . .34 thru 37
START UP PROCEDURES
A Sequence of operation . . . . . . . . . . . .34
B Items to be checked before
lighting the Munchkin . . . . . . . . . . . . .34
C Lighting Instructions . . . . . . . . . . . . . .35
D Operating Instructions . . . . . . . . . . . .35
E Adjusting the Temperature
on the Munchkin Display . . . . . . . . . .36
F Status Menu . . . . . . . . . . . . . . . . . . . .36
G Test Mode . . . . . . . . . . . . . . . . . . . . . .37
H To Turn Off Gas to Appliance . . . . . . .37
PART 7 . . . . . . . . . . . . . . . . . . . .38 thru 40
TROUBLESHOOTING
A Munchkin Error Code . . . . . . . . . . . . .38
B Boiler Error . . . . . . . . . . . . . . . . . . . . .38
C Boiler Fault . . . . . . . . . . . . . . . . . . . . .38
PART 8 . . . . . . . . . . . . . . . . . . . .40 thru 44
MAINTENANCE
A Maintenance Procedures . . . . . . . . . .41
B Before Each Heating Season . . . . . . .41
C Condensate Cleaning Instructions . . .41
D Combustion Chamber
Coil Cleaning Instructions . . . . . . . . . .42
E Munchkin Controller . . . . . . . . . . . . . .43
F Components Diagrams . . . . . . . . .44–45
GENERAL INFORMATION
4
B. MUNCHKIN RATINGS AND DIMENSIONS
PERFORMANCE RATINGS
*Net water
CONNECTION SIZES
ledoMnoitaludoMtupnIgnitaeHEODEUFAthgieWgnippihSRBI*
M05T000,05ot000,81000,64ot000,61%29.sbl85000,04
M08T000,08ot000,91000,47ot000,71%29.sbl85000,46
M08000,08ot000,72000,47ot000,52%29.sbl57000,46
M041000,041ot000,64000,921ot000,34%29.sbl101000,211
M991000,991ot000,66000,381ot000,16%29.sbl111000,951
PART 1. GENERAL INFORMATION
A. HOW IT OPERATES
When the room thermostat calls for heat, the Munchkin control board will start the circulator and start
to monitor the return temperature of the system before the heater will begin to heat the water. Once
the controller has sensed a drop in the return water temperature below the temperature set point
minus the differential set point, the heater will start to heat the water. This eliminates the Munchkin
starting every time the thermostat calls for heat. This feature keeps the system from short cycling.
Once the system has sensed the temperature difference, the Munchkin will activate the blower motor
for 5 seconds to pre-purge the system before starting the Munchkin
. The Munchkin controller will now
start to modulate the pre-mix burner based on analyzing the return temperature, supply water
temperature and the set point temperature. By compiling this information, the controller utilizes an
algorithm to fully adjust the firing rate while maintaining the desired output temperature. The pre-mix
burner fan has a direct drive current low-voltage motor with a pulse relay counting. This system allows
precise control over the fan speed and combustion air volumes. Coupled with the Dungs gas valve and
the the swirl plate system which are set to provide a one-to-one ratio of precisely measured volumes
of fuel to air, an accurate and instant burner output is achieved. This keeps the Munchkin running at
the highest efficiency.
When the thermostat is satisfied, the Munchkin will then go through a 4 second post-purge cycle before
shutting off. Every Munchkin heater is equipped with a display which will read the outlet temperature of
the heater and then will illuminate a green light showing flame on. If a problem occurs, the front indicator
light will turn red and the display will read a fault code; see Part 7, Section B/C.
B. MUNCHKIN RATINGS AND DIMENSIONS
ledoM
nruteR/ylppuS
noitcennoCeziSnoitcennoCsaG.aiDtneV
M05TTPN"4/11"4/3"2
M08TTPN"4/11"4/3"2
M08TPN"4/11"4/3"3
M041TPN"4/11"4/3"3
M991TPN"4/11"4/3"3
GENERAL INFORMATION
5
Figure 1-1
(NOTE: The Munchkin is rated at
zero clearance to combustibles.)
80M/140M/199M
T50M/T80M
RECOMMENDED SERVICE CLEARANCES
Figure 1-2
GENERAL INFORMATION
6
Figure 1-3
T50M/T80M
DIMENSIONS
GENERAL INFORMATION
7
DIMENSIONS
80M
140M/199M
Figure 1-4
Figure 1-5
GENERAL INFORMATION
8
C. PRE-INSTALLATION REQUIREMENT
GENERAL
1. Munchkin Boilers are supplied complete-
ly assembled as packaged boilers. The
package should be inspected for damage
upon receipt and any damage to the unit
should be reported to the shipping com-
pany and wholesaler. This boiler should
be stored in a clean, dry area.
2. Carefully read these instructions and be
sure to understand the function of all
connections prior to beginning installa-
tion. Contact your Munchkin Sales
Representative or the Heat Transfer
Products, Inc. Customer Service
Department for help in answering ques-
tions.
3. This boiler must be installed by a quali-
fied contractor. The boiler warranty may
be voided if the boiler is not installed cor-
rectly.
4. This boiler needs to be installed on a
level floor. If the floor is not level, the
boiler must be pitched back (1/4” pitch
for the 80M and 3/8” for the 140/199M.)
This will assure proper flow to conden-
sate drain in the bottom of the boiler.
CODES & REGULATIONS
Installation and repairs are to be performed in
strict accordance with the requirements of state
and local regulating agencies and codes dealing
with boiler and gas appliance installation.
ACCESSIBILITY CLEARANCES
1. The Munchkin Boiler is certified for clos-
et installations with zero clearance to
combustible construction. In addition, it
is design certified for use on combustible
floors.
2. Refer to Figure 1.1 and Figure 1.2 for the
recommended clearance to allow for rea-
sonable access to the boiler. Local codes
or special conditions may require greater
clearances.
COMBUSTION AND VENTILATION AIR
1. The Munchkin Boiler is designed only for
operation with combustion air piped
from outside (sealed combustion). PVC
pipe must be supplied between the air
inlet connection at the rear of the boiler
through an outside wall.
2. No additional combustion or ventilation
air is required for this appliance.
3. Refer to Section 4 of this manual,
Venting, for specific instructions for pip-
ing combustion air.
PLANNING THE LAYOUT
1. Prepare sketches and notes showing the
layout of the boiler installation to mini-
mize the possibility of interferences with
new or existing equipment, piping, vent-
ing and wiring.
2. The following sections of this manual
should be reviewed for consideration of
limitations with respect to:
a. Electrical Wiring: Part 2
b. Gas Connection: Part 3
c. Venting: Part 4
f. Piping: Part 5
Note: It is important to refer to the
site installation checklist in the back
of this manual to assure proper and
effective installation.
WARNING
Liquefied Petroleum (LP) Gas or
Propane is heavier than air and, in the
event of a leak, may collect in low
areas such as basements or floor
drains. The gas may then ignite
resulting in a fire or explosion.
CAUTION
Do not install this boiler on carpeting.
GENERAL INFORMATION / ELECTRICAL
9
Note: Service clearance of the Munchkin: See Section 1, Figures 1-1 and 1-2.
If the Munchkin is set up for liquefied petroleum (LP) gas, some geographic areas follow the Uniform
Mechanical Code, section 304.6, “Liquefied petroleum gas burning appliances shall not be installed in
a pit, basement or similar location where heavier-than-air gas might collect. Appliances so fueled, shall
not be installed in a below grade under-floor space or basement unless such location is provided with
an approved means for removal of unburned gas.”
PART 2. ELECTRICAL
A. ELECTRICAL CONNECTION
The electrical connection for the Munchkin is on the left hand side of the unit. There is a ½” knockout
location for an electrical connection for both the incoming power and the central heating circulator
connection. All electrical wiring must be performed by a qualified licensed electrician in accordance
with National Electrical Code ANSI Z223.1//NFPA 54 to and/or the Canadian Electrical Code, Part 1 CSA
C22.1, or to the applicable codes and standards. For your convenience, we have labeled all the wires
that need to be connected to operate the Munchkin.
CAUTION
The Munchkin is certified as an indoor appliance. Do not install the Munchkin
outdoors or locate where it will be exposed to freezing temperature. This includes all
related piping and components. If the Munchkin is subjected to flood water or
submersed in water, the Munchkin must be replaced.
CAUTION
Condensation removal: This is a condensing high efficiency appliance, therefore
condensation removal must be addressed to avoid damage to surrounding area or
appliance. See Part (4) Section E for Condensate Requirements.
WARNING
D. PRESSURE RELIEF VALVE
A pressure relief valve is installed into the front right side manifold. We recommend a WATTS ¾"
M 335 MI valve or equivalent and meets the requirements of ANSI/ASME Heater and Pressure
Vessel Code, Section IV or CSA B51; Heater, Pressure Vessel and Piping Code as applicable for
heating heaters. A ¾" pipe must be directed to a floor drain or suitable location within 6" of a drain
or floor. Protect from freezing, do not plug or cap pressure relief valve. Serious explosion causing
property damage and or loss of life could result. Under no circumstances should the relief valve
be eliminated, capped or plugged.
10
ELECTRICAL
The electrical requirements are for standard 120 volts, 60 Hz 15 Amp service. This unit is wired with
#18 awg and fused for no more than 15 Amps.
There are two ground points in the electrical compartment that must be connected to the building
ground system. Connect the building ground to the green ground screw and the green ground wire
inside electrical box provided.
The Incoming Power Supply is connected to the Black (Hot) and the White (Neutral).The Munchkin
Control board is polarity sensitive. If the polarity is reversed, the Munchkin control will not sense a
flame and lock out the system. The Orange and Brown wire are provided to the supply of 120 volts to
the Central Heating Circulator. Connect the Orange (Hot) and the Brown (Neutral) directly to the Central
Heating Circulator.
Connect the gray wires to your heating thermostat (TT) connection. Your thermostat heat anticipator
setting is .056 amp.
It is important that the electrical power is not turned on at this time. Double check all connections and then
turn the power on. The display that is provided with the Munchkin should now be reading the outlet
temperature. Note: see Part 6/Startup Procedure section in the manual to change the temperature setting
or run the heater.
CAUTION
Electrical wiring on the Incoming Power and Central Heating Circulator shall be
connected directly to the intended connection source and not be connected together
inside the electric box provided. An Electrical Short will result and the Control board
will have to be replaced! If Electrical Requirements of the Central Heating Circulator
exceeds 4 amps (or 3 amps on HA models only) please follow the wiring diagrams on
Figures 2-1, 2-2 and 2-3 (this section).
DANGER
IT IS EXTREMELY IMPORTANT THAT THIS UNIT BE PROPERLY GROUNDED!
DANGER
IT IS VERY IMPORTANT THAT THE BUILDING GROUND IS INSPECTED BY A
QUALIFIED ELECTRICIAN PRIOR TO MAKING THIS CONNECTION!
DANGER
The Orange wire for the Central Heating Circulator is Switched Hot and must have a
wire nut if not connected to the Central Heating Circulator. Failure to follow this
instruction will result in a short, and the Control Board will have to be replaced.
CAUTION
Do not power zone valves directly from the heater transformer. Doing so will greatly
reduce the life of the transformer. Use a separate transformer sized to handle the total
electric load of all zone valves.
11
ELECTRICAL
NORMALLY OPEN
T
T
GROUND
BUS
SWITCH JUNCTION BOX
120V 60 HZ
ELECTRICAL
SWITCH JUNCTION BOX
120V 60 HZ
ELECTRICAL
NORMALLY OPEN
THERMOSTAT
CONNECTION
WIRING DIAGRAM WITHOUT CONNECTION TO CIRCULATOR
GREEN
(GROUND)
GRAY
GRAY
CONNECTION
THERMOSTAT
(NEUTRAL)
WHITE
BLACK
(HOT)
GRAY
T
T
GRAY
WIRING DIAGRAM CONNECTING TO CIRCULATOR
BLACK
WHITE (NEUTRAL)
GREEN (GROUND)
DIAGRAM "A"
(HOT)
BLACK
GREEN
(GROUND)
(NEUTRAL)
WHITE
DIAGRAM "B"
BROWN (NEUTRAL)
ORANGE (HOT)
GREEN (GROUND)
ORANGE (HOT)
BROWN (NEUTRAL)
GREEN (GROUND)
IMPORTANT NOTE:
BE CERTAIN THAT THE ORANGE
WIRE IS SECURELY CAPED.
FAILURE TO DO SO COULD
RESULT IN INJURY OR FIRE
AND COULD DAMAGE THE CONTROL.
ORANGE
BROWN
GREEN
Figure 2-1: Connection Wiring Directly to
Central Heating Circulator
Figure 2-2: Connection Wiring without Wiring
Central Heating Circulator
Note to Electrical Contractor: The orange
wire is 120 Volt/4 Amp maximum for central
heating circulator only. Loads greater than 4
amps or 3 amps for HA models only will blow the
fuse on the board. The brown wire is the neu-
tral wire for the central heating pump only.
Figure 2-3: For circulator amp loads greater
than 4 amps (3 amps for “HA” models) use the
wiring diagram shown above. The brown and
orange wires on the Munchkin boiler will not be
used in this application and should be
terminated so they do not cause a short circuit.
5
T
1
2
3
6
4
T
1K1 1K2
BOILER
"TT"
GRAY
ZONE
CIRCULATOR
120 VOLT
L1 HOT (BLACK)
GRAY
BOILER
"TT"
THERMOSTAT
ZONE
R845A
SWITCHING
RELAY ZONE
1K1
L2 NEUTRAL
(WHITE)
12
GAS CONNECTION
PART 3. GAS CONNECTION
A. GAS CONNECTION
The gas supply shall have a maximum inlet pressure of less
than 14" water column (350 mm), ½ pound pressure (3.5 kPa),
and a minimum of 3.5" water column. The entire piping
system, gas meter and regulator must be sized properly to
prevent pressure drop greater than 0.5" as stated in the National
Fuel Gas Code. This information is listed on the rating plate. It is
very important that you are connected to the type of gas as noted on
the rating plate. "LP" for liquefied petroleum, propane gas or, "Nat"
natural or city gas. All gas connections must be approved by the local gas supplier, or utility in addition
to the governing authority, prior to turning the gas supply on. The nipple provided is ½" and it is
mandatory that a ¾" to ½" reducing coupling (provided) is used, threaded into the branch of a ¾" tee,
and a drip leg fabricated, as per the National Fuel Gas code. You must ensure that the entire gas line
to the connection at the Munchkin is no smaller than ¾". Once all the inspections have been
performed, the piping must be leak tested. If the leak test requirement is a higher test pressure than
the maximum inlet pressure, you must isolate the Munchkin from the gas line. In order to do this, you
must shut the gas off using factory and field-installed gas cocks (following the lighting instructions in
Part 6 Section B.) This will prevent high pressure. Failure to do so may damage the gas valve. In the
event the gas valve is exposed to a pressure greater than ½ PSI, 14" water column, the gas valve must
be replaced. Never use an open flame (match, lighter, etc.) to check gas connections.
B. GAS PIPING
1. 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.
C. GAS TABLE
Refer to Table (1) to size the supply piping to minimize pressure drop between meter or regulator
and unit.
Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0.5 psi or Less and a
Pressure Drop of 0.3 Inch water Column
(TABLE 1) (Based on a 0.60 Specific Gravity Gas)
Nominal
Iron Pipe Internal Length of Pipe (Feet)
Size Diameter
(inches) (inches) 10 20 30 40 50 60 70 80 90 100 125 150 175 200.
3/4 .824 278 190 152 130 115 105 96 90 84 79 72 64 59 55} BTU'S
1 1.049 520 350 285 245 215 195 180 170 160 150 130 120 110 100} PER
1 1/4 1.380 1,050 730 590 500 440 400 370 350 320 305 275 250 225 210} HOUR
1 1/2 1.610 1,600 1,100 890 760 670 610 560 530 490 460 410 380 350 320} X 1,000
WARNING
Failure to follow all precautions could result in fire, explosion or death!
13
WARNING
Failure to follow all precautions could result in fire, explosion or death!
GAS CONNECTION
It is recommended that a soapy solution be used to detect leaks. Bubbles will appear on the pipe to
indicate a leak is present. The gas piping must be sized for the proper flow and length of pipe, to avoid
pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1" WC, the meter, regulator or gas line is undersized or
in need of service. You can attach a manometer to the incoming gas drip leg, by removing the cap and
installing the manometer. The gas pressure must remain between 3.5" and 14" during stand-by (static)
mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum
of 10 feet from the Munchkin. It is very important that the gas line is properly purged by the gas
supplier or utility. Failure to properly purge the lines or improper line sizing, will result in ignition
failure. This problem is especially noticeable in NEW LP installations and also in empty tank situations.
This can also occur when a utility company shuts off service to an area to provide maintenance to their
lines. This gas valve must not be replaced with a conventional gas valve under any circumstances. As
an additional safety feature, this gas valve has a flanged connection to the Venturi and blower.
DUNGS GAS VALVE
THROTTLE ADJUSTER
(NOTE: IF FOR ANY
REASON THE THROTTLE
NEEDS TO BE
ADJUSTED
,
IT IS
VERY IMPORTANT THAT
A "COMBUSTION
ANAYLYZER" BE USED
TO ENSURE SAFE AND
PROPER OPERATION.
TURN THE ADJUSTER
TO THE (+) TO
INCREASE GAS OR THE
(-) TO DECREASE THE
GAS SUPPLY. THIS
ADJUSTMENT COULD
AFFECT CO/CO%
LEVELS. MAKE SURE
THE LEVELS
CORRESPOND TO THE
CHART IN COMBUSTION
SETTINGS.)
Fig. 3-1
14
VENTING
A. GENERAL
1. Install the boiler venting system in accor-
dance with these instructions and with the
National Fuel Gas Code, ANSI Z223.1/NFPA
54, CAN/CGA B149, and/or applicable provi-
sions of local building codes.
2. This boiler is a direct vent appliance and is
listed as a Category IV appliance with
Underwriters Laboratories, Inc. VENT AND
INTAKE AIR PIPE
B. APPROVED MATERIALS FOR EXHAUST
VENT AND INTAKE AIR PIPE
1. Use only Non Foam Core venting material.
The following materials are approved for use
as vent pipe for this boiler:
a. Non Foam Core PVC (Polyvinyl Chloride)
Pipe conforming to ASTM D-1784 Class
12454-B (formerly designated Type 1, Grade
1).
b. Non Foam Core CPVC (Chlorinated Polyvinyl
Chloride) Pipe conforming to ASTM D-1784
Class 23447-B (formerly designated Type IV,
Grade 1).
c. Non Foam Core ABS (Acrylonitrile-
Butadiene- Styrene) Pipe conforming to
ASTM D3965 Class 3-2-2-2-2.
2. Cellular foam core piping may be used on air
inlet piping only. Never use cellular foam core
material for exhaust piping.
C. EXHAUST/VENT / AIR INTAKE PIPE
LOCATION
1. Determine exhaust vent location:
a. The vent piping for this boiler is approved for
zero clearance to combustible construction.
b. See Figure 4.1 for an illustration of clear-
ances for location of exit terminals of direct-
vent venting systems.
c. This boiler vent system shall terminate at
least 3 feet (0.9 m) above any forced air
intake located within 10 ft (3 m). Note: this
does not apply to the combustion air intake
of a direct-vent appliance.
d. Provide a minimum of 1 foot distance from
any door, operable window, or gravity intake
into any building.
e. Provide a minimum of 1 foot clearance from
the bottom of the exit terminal above the
expected snow accumulation level. Snow
removal may be necessary to maintain
clearance.
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 afore-
mentioned equipment unless the 4 foot hor-
izontal distance is maintained.
g. Do not locate the exit terminal over public
walkways where condensate could drip
and/or freeze and create a nuisance or haz-
ard.
h. When adjacent to a public walkway, locate
exit terminal at least 7 feet above grade.
i. Do not locate the exit termination directly
under roof overhangs to prevent icicles
from forming.
j. Provide 3 feet clearance from the inside cor-
ner of adjacent walls.
2. Determine air intake pipe location.
a. Provide 1 foot clearance from the bottom of
the air inlet pipe and the level of maximum
snow accumulation. Snow removal may be
necessary to maintain clearances.
b. Do not locate air intake pipe in a parking area
where machinery may damage the pipe.
c. When venting with a two pipe system, max-
imum distance between air intake and
exhaust vent is 6 feet (1.8 m). Minimum dis-
tance between exhaust vent and air intake
on single boiler is 8” (0.2 m) center-to-cen-
ter. Minimum distance between vents and
intakes on multiple boilers is 8” (0.2 m) cen-
ter-to-center. See Figure 4.2.
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.
WARNING
Follow these venting instructions carefully. Failure
to do so may result in severe personal injury, death,
or substantial property damage.
WARNING
Do not use Foam Core Pipe in any portion of the
exhaust piping from this boiler. Use of Foam Core
Pipe may result in severe personal injury, death, or
substantial property damage.
PART 4. VENTING
15
VENTING
Location of exit terminals of mechanical draft and direct-vent venting systems.
(Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002).
Fig. 4.2 Multiple Vent Spacing*
*Note: Exhaust must extend out 1 foot
Figure 4.5: Multiple Boiler Installations
Fig. 4.3 Multiple Stainless Steel Vertical Vent
Kit Installation – Front View
Fig. 4.4 Multiple Stainless Steel Horizontal Vent Kit Installation – Front View
Fig. 4.1
16
D. EXHAUST VENT AND INTAKE AIR PIPE
SIZING
1. For the T50 and T80 Boilers the exhaust vent
and air intake pipes should be 2" Schedule 40
or 80.
2. For the 80M, 140M, 199M the exhaust vent
and air intake pipes should be 3" Schedule 40
or 80.
3. The total combined equivalent length of
exhaust vent and intake air pipe should not
exceed 85 feet.
a. The equivalent length of elbows, tees, and
other fittings are listed in the Friction Loss
Table 4.1.
*Friction loss for long radius elbow is 1 foot less.
b. For example: If the exhaust vent has two 90°
elbows and 10 feet of PVC pipe we will cal-
culate:
Exhaust Vent Pipe Equivalent Length = (2x5)+10=20 feet
Further, if the intake air pipe has two 90°
elbows, one 45° elbow and 10 feet of PVC
pipe, the following calculation applies:
Air Intake Pipe Equivalent Length = (2x5)+3+10=23 feet
Finally, if a concentric vent kit is used we
find:
Total Combined Equivalent Length = 20+23+3=46 feet
Therefore, the total combined equivalent
length is 46 feet which is well below the
maximum of 85 feet.
c. The intake air pipe and the exhaust vent are
intended to penetrate the same wall or roof
of the building.
d. Effort should be made to keep a minimum
difference in equivalent length between the
air intake pipe and the exhaust vent.
4. The minimum combined equivalent length is
16 equivalent feet.
5. The maximum combined equivalent length
can be extended by increasing the diameter
of the vent pipe. However, the transitions
should begin a minimum of 15 equivalent feet
from the boiler.
a. Transitions should always be made in verti-
cal sections of pipe to prevent the conden-
sate from pooling in the vent pipe.
b. Use a 3” x 2” reducing coupling to transition
from the T50 and T80 boiler connections to
a 3” vent.
c. Use a 4” x 3” reducing coupling to transition
from the 80M, 140M, and 199M boiler con-
nections to 4” vent.
d. The maximum equivalent length for the
increased diameter vent pipes is 125 feet.
e. If the transition occurs at a distance greater
than 15 equivalent feet from the boiler, the
maximum equivalent length will be reduced.
See Table 4.2. Standard Vent Pipe is 2" and
Oversized Vent Pipe is 3" for T50 and T80.
Standard Vent Pipe is 3" and Oversized Vent
Pipe is 4" for 80M through 199M.
E. EXHAUST VENT AND AIR INTAKE PIPE
INSTALLATION
1. On the T50 and T80 the 2" exhaust vent con-
nection is located on the top, right side of the
boiler and the air intake is on the top, left side.
See Figure 10.1. The air intake connection is
intended for a slip fit. No sealant or adhesive
is required.
2. On the 80M, 140M, and 199M Boilers the 3"
exhaust vent connection is located on the rear
of the boiler and the air intake is higher and
toward the left side when the boiler is viewed
from the front. The air intake connection is
intended for a slip fit. No sealant or adhesive
is required.
VENTING
Transition
Point
(ft from
boiler
TEL of
Standard 2"
or 3" Vent
Pipe (ft)
TEL of
Oversized 3"
or 4" Vent
Pipe (ft)
Maximum
TEL of all
Vent Pipe (ft)
15 30 95 125
20 40 77-1/2 117-1/2
25 50 60-1/2 110-1/2
30 60 43 103
35 70 26 96
40 80 8-1/2 88-1/2
None 85 0 85
TEL = Total Equivalent Length
FRICTION LOSS EQUIVALENT IN PIPING AND FITTINGS
FITTINGS OR PIPING EQUIVALENT FEET
2" 3" 4"
6"
90 DEGREE ELBOW* 5' 5' 3'
1'
45 DEGREE ELBOW 3' 3' 1'
1'
COUPLING 0' 0' 0'
0'
AIR INLET TEE 0' 0' 0' 0'
STRAIGHT PIPE 1' 1' 1'
0.5
CONCENTRIC VENT KIT 3' 3' N/A N/A
V500 2" VENT KIT 1' N/A N/A N/A
V1000 3" VENT KIT N/A 1' N/A N/A
V2000 4" VENT KIT N/A N/A 1' N/A
Table 4.2: Vent Termination Kits
Table 4.1
17
VENTING
3. Use only solid PVC, CPVC, or ABS schedule
40 or 80 pipe. FOAM CORE PIPING IS NOT
APPROVED.
4. Remove all burrs and debris from joints and
fittings.
5. 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.
6. Horizontal lengths of exhaust vent must slope
back towards the boiler not less than ¼" per
foot to allow condensate to drain from the
vent pipe. If the vent pipe must be piped
around an obstacle that causes a low point in
the pipe, a drain pipe must be connected to
allow condensate to drain.
7. All piping must be fully supported. Use pipe
hangers at a minimum of 4 foot intervals to
prevent sagging of the pipe where conden-
sate may form.
8. Do not use the boiler to support any piping.
9. A screened straight coupling is provided with
the boiler for use as an outside exhaust termi-
nation.
10. A screened inlet air tee is provided with the
boiler to be used as an outside intake termi-
nation.
11. The following information on Table 4.3 are
optional intake air/exhaust vent terminations
available from Heat Transfer Products, Inc.
WARNING
All joints of positive pressure vent systems must be
sealed completely to prevent leakage of flue
products into the living space.
Description
Stock
Code
2" PVC Concentric Vent Termination Kit KGAVT0601CVT
3" PVC Concentric Vent Termination Kit KGAVT0501CVT
2" Stainless Steel Vent Termination Kit V500
3" Stainless Steel Vent Termination Kit V1000
4" Stainless Steel Vent Termination Kit V2000
Table 4.3: Vent Termination Kits
VENTING
18
F. HEATER REMOVAL FROM A COMMON VENT SYSTEM
At the time of removal of an existing heater, the following steps shall be followed with each appli-
ance remaining connected to the common venting system placed in operation, while the other appli-
ances remaining connected to common venting system are not operating.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch to determine if there
is blockage, leakage, corrosion or other deficiencies that could cause an unsafe condition.
3. If practical, close all building doors, windows and all doors between the space in which the
appliance remains connected to the common venting system located and other spaces in the
building. Turn on clothes dryers and any appliances not connected to the common venting
system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum
speed. Do not operate a summer exhaust fan. Close all fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the
thermostat so the appliance will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use
the flame of a match or candle or smoke from a cigarette.
6. After it has been determined that each appliance remaining connected to common venting
system properly vents when tested as outlined, return doors, windows, exhaust fans, fire-
place dampers and any other gas burning appliance to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installa-
tion conforms with the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of
the common venting system, the common venting system should be resized to approach the
minimum size as determined using the appropriate tables in Appendix G in the National Fuel
Gas Code , ANSI Z 223.1
G. CONDENSATE REMOVAL
This is a condensing high efficiency appliance, therefore this unit has a condensate removal system.
Condensate is nothing more than water vapor, derived from the combustion products, similar to an
automobile when it is initially started. It is very important that the condensate line is sloped away
from and down to a suitable inside drain, if the condensate outlet on the Munchkin is lower than the
drain, you must use a condensate removal pump (kit available from Heat Transfer Products, Inc.) A
condensate filter, if required by local authorities can be made up of lime crystals, marble or
phosphate chips will neutralize the condensate. This can be done in the field by the installer or you
may purchase one from Heat Transfer Products, Inc. It is also very important that the condensate line
is not exposed to freezing temperatures, or any other type of blockage. Plastic tubing should be the
only material used for the condensate line. Steel, brass, copper or others will be subject to corrosion
or deterioration. A second vent may be necessary to prevent condensate line vacuum lock if a long
horizontal run is used. Also, an increase in pipe size may be necessary to drain properly. Support of
the condensation line may be necessary to avoid blockage of the condensate flow.
DANGER
The Munchkin is not intended to be common vented with any other
existing appliance!
19
VENTING
GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).
DIAGRAMS FOR SIDEWALL VENTING
Figure 4-1a Figure 4-2a
VENTING
20
Figure 4-3a
Figure 4-4a
GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a
minimum of a ¼" per foot back to the heater (to allow drainage of condensate).
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HTP Munchkin Boiler Installation guide

Category
Water heaters & boilers
Type
Installation guide
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