Heat Transfer Gas-fired Boiler Operating instructions

Brand: Heat Transfer

Model: Gas-fired Boiler

Category: Water heaters & boilers

Type: Operating instructions

This manual is also suitable for

MUNCHKIN

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

CONTROLS

USING THIS MANUAL

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

PART 1 . . . . . . . . . . . . . . . . . . . . . .4 thru 8

GENERAL INFORMATION

AHow It Operates . . . . . . . . . . . . . . . . . .4

BMunchkin Ratings and Dimensions . . .4

CPre-installation Requirements . . . . . . .8

DPressure Relief Valve . . . . . . . . . . . . . .9

PART 2 . . . . . . . . . . . . . . . . . . . . .9 thru 11

ELECTRICAL

AElectrical Connection . . . . . . . . . . . . . .9

PART 3 . . . . . . . . . . . . . . . . . . . .12 thru 13

GAS CONNECTION

AGas Connection . . . . . . . . . . . . . . . . . .12

BGas Piping . . . . . . . . . . . . . . . . . . . . . .12

CGas Table . . . . . . . . . . . . . . . . . . . . . . .12

PART 4 . . . . . . . . . . . . . . . . . . . .14 thru 21

VENTING

AGeneral . . . . . . . . . . . . . . . . . . . . . . . .14

BApproved Materials for Exhaust Vent

and Intake Air Pipe . . . . . . . . . . . . . . .14

CExhaust/Vent / Air Intake

Pipe Location . . . . . . . . . . . . . . . . . . . .14

DExhaust Vent and Intake Air

Pipe Sizing . . . . . . . . . . . . . . . . . . . . . .16

EExhaust Vent and Air Intake

Pipe Installation . . . . . . . . . . . . . . . . . .16

FHeater Removal from a

Common Vent System . . . . . . . . . . . .18

GCondensate Removal . . . . . . . . . . . . .18

PART 5 . . . . . . . . . . . . . . . . . . . .22 thru 33

PIPING

AHydronic piping with

Circulators or Zone Valves . . . . . . . . .22

BCirculator Sizing . . . . . . . . . . . . . . . . .23

CFill and Purge Heating System . . . . . .24

DPiping Illustrations . . . . . . . . . . . . . . .25

PART 6 . . . . . . . . . . . . . . . . . . . .34 thru 37

START UP PROCEDURES

ASequence of operation . . . . . . . . . . . .34

BItems to be checked before

lighting the Munchkin . . . . . . . . . . . . .34

CLighting Instructions . . . . . . . . . . . . . .35

DOperating Instructions . . . . . . . . . . . .35

EAdjusting the Temperature

on the Munchkin Display . . . . . . . . . .36

FStatus Menu . . . . . . . . . . . . . . . . . . . .36

GTest Mode . . . . . . . . . . . . . . . . . . . . . .37

HTo Turn Off Gas to Appliance . . . . . . .37

PART 7 . . . . . . . . . . . . . . . . . . . .38 thru 40

TROUBLESHOOTING

AMunchkin Error Code . . . . . . . . . . . . .38

BBoiler Error . . . . . . . . . . . . . . . . . . . . .38

CBoiler Fault . . . . . . . . . . . . . . . . . . . . .38

PART 8 . . . . . . . . . . . . . . . . . . . .40 thru 44

MAINTENANCE

AMaintenance Procedures . . . . . . . . . .41

BBefore Each Heating Season . . . . . . .41

CCondensate Cleaning Instructions . . .41

DCombustion Chamber

Coil Cleaning Instructions . . . . . . . . . .42

EMunchkin Controller . . . . . . . . . . . . . .43

FComponents Diagrams . . . . . . . . .44–45

GENERAL INFORMATION

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

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

Figure 1-3

T50M/T80M

DIMENSIONS

GENERAL INFORMATION

DIMENSIONS

80M

140M/199M

Figure 1-4

Figure 1-5

GENERAL INFORMATION

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

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.

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.

ELECTRICAL

NORMALLY OPEN

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

CONNECTION

THERMOSTAT

(NEUTRAL)

WHITE

BLACK

(HOT)

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.

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)

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!

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

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

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

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

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

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!

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

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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Heat Transfer Gas-fired Boiler Operating instructions

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Model: Gas-fired Boiler

Category: Water heaters & boilers

Type: Operating instructions

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