Munchkin 399M manual Part 5. Piping, Venting / Piping, Condensate Requirements

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VENTING / PIPING

E. CONDENSATE REQUIREMENTS

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.

PART 5. PIPING

A. HYDRONIC PIPING WITH CIRCULATORS OR ZONE VALVES

The Munchkin is designed to function in a closed loop 15 PSI System. To assure you that you have adequate pressure in the system, we have installed in the outlet manifold, a pressure switch that will not let the Munchkin operate without a minimum of 10 PSI water pressure. This assures you that if the system does have leak, the Munchkin 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 should be located on the Munchkin outlet to monitor the system pressure and outlet temperature from the Munchkin. It is important to note that the Munchkin has a minimal amount of pressure drop and must be figured in when sizing the circulators. Each Munchkin installation must have an Air Elimination device which will remove air from the system. Install the Munchkin so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation 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 installed above radiation level, some states and local codes require a low water cut off device at the time of installation. If the Munchkin 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 specially formulated for this purpose. It includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain that the system fluid is checked for the correct glycol 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.

CAUTION

The Munchkin should not be operated as a potable Hot Water Heater. It should not be used as a direct Hot Water Heating Device.

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

1. Connect the system return marked “Heater In”, make sure to install with pipe sealant com-

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Contents What to do if YOU Smell GAS Munchkin High Efficiency 399M Commercial BoilerUsing this Manual Using this ManualTable of Contents Part 1. General Information Munchkin Ratings and DimensionsGeneral Information HOW IT OperatesDimensions PRE-INSTALLATION Requirements General Information / Electrical Part 2. ElectricalPressure Relief Valve Electrical ConnectionElectrical Electrical / GAS Connection Part 3. GAS ConnectionGAS Connection GAS ConnectionGAS Piping GAS TableMunchkin Burnertech GAS Valve Combustion SettingsVenting Part 4. VentingApproved Venting Materials Venting the Munchkin in 4 or 6 Plastic PipeVenting Important Note Fittings or Piping Equivalent Feet Longer Vent Runs Using a Combination 4 to 6 PipeHeater Removal from a Common Vent System Diagrams for Sidewall VentingDiagram for Vertical Venting Venting / Piping Part 5. PipingCondensate Requirements Hydronic Piping with Circulators or Zone ValvesCirculator Sizing PipingFill and Purge Heating System Piping Illustrations Piping Symbol LegendZone valves Make-up water Zone valves Mixing valve Zone valves Make-up water Piping Space heating zone circuit Zone Circulators Make-up water PB1 PB2 PB1 PB2 START-UP Procedures Part 6. START-UP ProceduresItems to be Checked Before Lighting the Munchkin Lighting InstructionsOperating Instructions Adjusting the Temperature on the Munchkin DisplayTo Turn OFF GAS to Appliance Test ModeStatus Menu Munchkin Temporary Fault Condition START-UP Procedures / ServicingPart 7. Servicing Sequence of OperationServicing Munchkin Fault Requiring Manual ResetServicing Remedy Call Factory for further assistance Resistance Tables Maintenance Part 8. MaintenanceLeaks Munchkin Controller Control Wiring LayoutMaintenance Maintenance Page Page Heat Transfer Products, Inc LP-121 REV /20/04
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