Setting the standard for comfort and efficiency for your heating and hot water system.

Heat Transfer Products, Inc. 120 Braley Road East Freetown, MA 02717

USING THIS MANUAL

USING THIS MANUAL
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during heater installation.

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.

B. 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 are as defined by the ANSI Z535.A Standard.

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
SECTION 1

General Information
SECTION 2

Pg. 3 Pg. 4 Pg. 9 Pg. 10 Pg.13 Pg. 15 Pg. 15 Pg. 17 Pg. 29

Installation of your Vision I System
SECTION 3

Wire Functions
SECTION 4

Programming the Controller
SECTION 5

Programming The Central Heat Curve
SECTION 6

Status Menu
SECTION 7

Test Mode
SECTION 8

Piping and Wiring the Vision System
SECTION 9

Appendix
2

GENERAL INFORMATION

SECTION 1. GENERAL INFORMATION
THE VISION I SYSTEM You have purchased the Vision I System, which is the first truly advanced control system that eliminates the need for those expensive auxiliary controls. The Vision I System will allow the installing contractor to take the highly efficient modulating 92% AFUE Munchkin Heater 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 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). 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 outside temperature. This gives you a higher comfort level and further increases the efficiency of the Munchkin Heater. Details within this manual will show you the proper piping and wiring of the Vision I System. Only factory authorized trained contractors are qualified to install the Vision I system to assure quality of the installation for each system. If you have any questions, please call your factory representative or call technical service line at 1-800-323-9651. SYSTEM OPERATION 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 in the sense that both turning points of the curve can be moved. If the outside temperature sensor is not connected, the set point is the user set point for the central heating. When the heater calls for heat, a minimum “burner on” time is defined. If, during this time the temperature exceeds the set point temperature, the burner will remain fired until the timer has ended. This is done to give the heater a chance to start modulating after ignition. This can be very useful in cases where there is a low heat request. As soon as the supply temperature exceeds the set point of the central heating curve or user set point, the burner will switch off. The circulator will continue to run (Note: This will occur only if thermostats are calling). The anti-cycling time begins at the completion of a heating cycle (either the indirect fired water heater or central heat.) There is a one minute anti-cycling time that prevents the burner from coming on unless there is a call from either the indirect fired water heater or central heat. The purpose of the anti-cycling feature is to prevent the burner from erratic cycling. Regulation is based upon set point central heating. The maximum capacity of the Munchkin can be limited by step modulation. The Munchkin has a 6-step function programmed into the controller. (Note: This 6step function cannot be changed.) When the Munchkin burner is activated, the burner output is regulated in one minute intervals. As shown in the chart, Section 9, Fig. 9.2, Appendix. Note: These percentages are based on the rated maximum output. This feature helps the Munchkin from overshooting the heat set point and minimizes short cycling. As soon as the central heating is active (including pre-purge), step modulation begins. When in operation, the step will be increased. Once the heating demand is satisfied the step modulation will start from the beginning of its cycle. The Vision I also has a Fault Code Alarm Output. This is activated if the Munchkin Boiler goes into a lockout. The Fault Code Alarm wire is rated at 3 amp max. and is connected to the main control board of the Munchkin Boiler. This alarm can be connected to an external relay or an audible alarm.

3

GENERAL INFORMATION / INSTALLATION
PARTS INCLUDED IN THE VISION I SYSTEM

1. Outside sensor 1 Pc

7250P-319

(See Resistance table in the Appendix Section 9)

2. Indirect Tank Sensor 1 Pc. 7250P-325 3. Light green wires 2 Pcs. (Outdoor Sensing) 4. Light blue wires 2 Pcs. (Indirect sensor or standard 4080b-1395 control) 5. Purple wire 1 Pc. (Hot Lead for the 120 Volt connection to the Indirect circulator,) 6. Pink wire 1 pc. (Neutral lead for the 120 volt connection to the Indirect circulator) 7. Green wire 1 Pc. (Ground lead for the 120 volt connection to the Indirect circulator) 8. Red Wire 1 Pc. (Hot Lead for the 120-volt connection to the fault code alarm) 9. Installation Manual 1 Pc. 10. Warranty Registration Card Note: Only Products Manufactured by Heat Transfer Products will be covered under this warranty.

SECTION 2. INSTALLATION OF YOUR VISION I SYSTEM
You must use the wires supplied by Heat Transfer Products to connect your Vision I system to your existing Munchkin control. You may choose to leave out some connections that you may not need in your installation. Follow the diagram to connect the individual wire leads into the correct Molex to activate the designated functions on the main control board. Listed below is an explanation for the individual wire functions. (When making the connection, be sure that the black marking on the wire connector is facing upward as shown in the illustration shown in Fig. 2-1 this section.) You will note that there are two different types of connections. 1. 24 volt connections – 2 Pcs. light green wire leads (outdoor sensor) / 2 Pcs. light blue leads (Indirect Fired Water Heater sensor). 2. 120 volt connection – Purple (Neutral lead to DHW Circulator) and Pink (Hot lead to DHW Circulator) Green (Ground Lead to DHW Circulator) and Red (Hot lead to Fault Code Alarm). It is also important to note that the standard Munchkin comes with a 120 volt connection for the Central Heating Circulator and 2 gray wires for the Central Heating thermostat connection to the Munchkin Boiler. Install the wires based on the color diagrams, Figs. 2-1, 2-2 and Figs. 2-3 and 2-4 in this section showing the open port connection on the Molex Plug which will show where the wire will be connected to the appropriate Molex Port Connections.

4

INSTALLATION VISION CONNECTIONS AS VIEWED FROM THE FRONT ON A 140/199M MUNCHKIN

Fig. 2-1

VISION CONNECTIONS AS VIEWED FROM THE FRONT ON A T50/T80M/80M MUNCHKIN

Fig. 2-2
5

INSTALLATION

VISION I – MUNCHKIN WITH SPARK IGNITION

NOTE: Vision One connections are outlined in black.

Fig. 2-3: Vision I Molex and Color Wire Connections
6

INSTALLATION

VISION I – MUNCHKIN WITH HOT SURFACE IGNITION

NOTE: Vision One connections are outlined in black.

Fig. 2-4: Vision I Molex and Color Wire Connections for “HA” models
7

INSTALLATION

Fig. 2-5: Vision I Routing Connection

8

WIRE FUNCTIONS

SECTION 3. WIRE FUNCTIONS
1. Outdoor Sensor (2-Light Green Wires) are connected to the main controller on the Munchkin. Route wires from the Munchkin control to the external junction box, 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.

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.
Outdoor Sensor Function: The user can program 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 heater, the water temperature of the heater will adjust to run the heater more efficiently and provide greater comfort to the living space. See section 4: “Programming the Controller”. Connection Specification – Wire 22 AWG maximum to 100 feet or 18 AWG up to 150 feet. Length of wire run cannot exceed 150 feet. 2. Indirect Sensor (2-Light Blue Wires) are connected to the main control on the Munchkin. Route wires from the Munchkin control to the external junction box to the sensor (Included in The Vision I Package) or the mechanical control Honeywell Part # L4080b-1395 (Not included in Vision I Package) into the control well located in the front of the Super Stor Ultra Indirect Fired Water Heater. This will allow the installer to control the temperature of the indirect from the Munchkin and give the Super Stor Indirect Fired Water Heater priority over the Central Heating Circuit. Once the Water Heater is satisfied, the Munchkin will then switch back to the Central Heating Circuit only if there is a call for heat, otherwise the Munchkin will then shut down.

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 Super Stor Ultra tank 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). See section 4, “Programming the Controller”. Connection Specification – Wire 22 AWG maximum to 100 feet or 18 AWG up to 150 feet. Length of wire run cannot exceed 150 feet. 3. Indirect Circulator Lead (1-Pink Wires/1-Purple Wires/1-Green Wires) are connected to the main controller on the Munchkin. Route wires from the Munchkin control to the external junction box. Run the wire and connect it directly to the Super Stor Ultra Indirect circulating pump. The purple wire will be your neutral lead and the pink wire will be your hot. This will supply 120 volts to the Super Stor Ultra Indirect Water Heater Circulator directly (The Circulator is not supplied in the Vision-1 the Package).

Indirect Circulator Program function: The Super Stor Ultra Indirect circulator program function will automatically start when the Super Stor Ultra 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 130 minutes. Connection Specification – Wire 18 AWG maximum. Length of wire run cannot exceed 100 feet.

9

WIRE FUNCTIONS / PROGRAMMING THE CONTROLLER
4. Fault Code Alarm Output (1-Red Wire) is connected to the main controller on the Munchkin. Route wire from the Munchkin controller 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. Connection Specification – Wire 18 AWG maximum. Length of wire run cannot exceed 100 feet.

CAUTION
Do not tie neutrals or hot wire leads to any other wires, go directly from the Munchkin controller to the circulator. It is also important to note that the Munchkin controller is fused up to 6.3 Amps. The Munchkin requires 2.0 amps or 3.0 amps (HA models only). If electrical requirements of either the Indirect circulator or the Central Heating Pump exceeds the 4.0 amps limit or 3.0 amps on (HA Models Only), please follow the wiring diagram Fig. 3-1, this page, to wire a relay if your circulators exceed load requirements.

Fig. 3-1

SECTION 4. PROGRAMMING THE CONTROLLER
CAUTION
Only Vision I contractors are authorized to program the individual settings on the Vision I. A pass code must be entered in order to get to the Programming Menu. This Pass code may change. Only Vision dealers will know where to locate the pass code. The Standard Munchkin Heater can only be upgraded to a Vision I by a Vision dealer.
10

PROGRAMMING THE CONTROLLER
The Vision I Dealer is the only one qualified to set the system limits and the heat curve for the Munchkin Heater. These system limits cannot be changed by anyone except an authorized Vision dealer once they are programmed. The Munchkin owner can make adjustments only to the hot water set point, the central heating differential and central heating temperature. Programming the Vision I system is quite simple, it is recommend that you write down the settings on the Control Program Reference Chart provided in section 5 Fig. 4-3 for future reference. All the functions featured can be programmed right from the display located inside the Munchkin Heater. 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 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 controller 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 – – – 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. 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 effective immediately but not directly stored until the S/4 key is pressed down for 3 seconds then the new values are stored.

CAUTION
The Heater cannot be programmed while there is a call for heat.
Listed below are the variety of functions the installer can program into the Vision I System.

Function
1 2 3

Default Value
de 149ºF 185ºF

Function Description
Not Applicable Not Applicable 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 185ºF Not Applicable 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 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 Outdoor temperature that you wish the central heating should be disabled—(warm weather shut-off) Range: 41ºF to 122ºF
11

4 5

36ºF 7ºF

6

0 Minutes

7

68ºF

PROGRAMMING THE CONTROLLER Function
*8

Default Value
5ºF

Function Description
Allows the installer to change the Minimum Outside Design Temperature. Range: –49ºF to 32ºF (See the chart on page 14, Fig. 5-1 to set outdoor reset curve) Allows the installer to change the Design Supply Water Temperature from the Munchkin based on the Minimum Outside Design Temperature (See the chart on page 14, Fig. 5-1 to set outdoor reset curve) Range: 203ºF to 77ºF Allows the installer to change the Maximum Outside Design Temperature for Central Heating. (See the chart on page 14, Fig. 5-1 to set outdoor reset curve) Range: 95ºF to 32ºF Allows the installer to change the Design Supply Water Temperature from the Munchkin based on the Maximum Outside Design Temperature. (See Fig. 5-1 on page 14) Range: 32ºF to 185ºF Allows the installer to set the lowest temperature on the Munchkin for Central Heating. Range: 32ºF to 194ºF Allows the installer to change the Central Heating Circulator Post Purge Time once the thermostat is satisfied. Range 0 to 10 minutes. 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 Bus address (0=zone master 1–8 — cascade slave) (Not currently used.) Interface Board Activation 0 = not active 1 = active WARNING: Never change the default 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 compatible) Step Modulation 1 = on 0 = off Indirect boiler set point (flow) Temperature default = 119° to 203° Not applicable

*9

201ºF

*10

68ºF

*11

95ºF

12 13

68º F 0 Minutes

14

30 Minutes

15 16

0 0

17

0

18

1

19 20

180° 1

* Central Heating Curve Function see Fig. 5-1 Section 5. ** The Munchkin Interface board allow the Munchkin Boiler to connect to either a building management system (0-10 volt) a Tekmar or allows the user to provide a boost function along with the Vision 1 to drop the outside sensor to the highest central heating set point. Once the parameters are stored and the S/4 key is pressed for 3 seconds, the unit will return to normal operation. All the new parameters will now be reflected in the operation of the Munchkin.
12

PROGRAMMING THE CONTROLLER / PROGRAMMING CENTRAL HEAT CURVE

DANGER
Water temperature over 125 degrees F. can cause severe burns instantly, or death from scalds. Children, disabled, and 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.
ADJUSTING TEMPERATURE The installer can program 1. Central Heating Temperature Range: 50ºF to 203ºF (Factory setting 180º) 2. Central Heating Differential Range: 5ºF to 30ºF (Factory setting 30º) 3. Super Stor Ultra Indirect Temperature Range: 95ºF to 185ºF (Factory setting 119º) 4. Temperature measurement with either F(Fahrenheit) or C(Celsius) (Factory default [F])

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.
Before you can change the temperature from the factory default setting. You must make sure that none of the thermostats are calling for heat. The Munchkin controller will not memorize a program setting while in a heating cycle. To adjust the Munchkin Supply Water Temperature, press in the S3/Program key for three seconds until you see a flashing C alternating to 180 . This number is the factory default set point of 180 degrees for the central heating. To change the temperature, push either the S1/- or S2/+ on the display. The S1/- button will decrease the temperature setting while the S2/+ will increase the maximum supply water temperature of the Munchkin. To change the next value (Central Heating differential) press in the S3/Program and the display will read ch alternating to a value of 30 . This number is the factory default set point of 30 degrees for the Central Heating differential. To change the temperature, push either the S1/- or S2/+ on the display. This represents the starting point as to when the Munchkin will activate the burner. So, if the factory setting is 180 degrees the Munchkin will not start the burner unless the thermostat is calling for heat and the return sensor is measuring a temperature below 150 degrees (180 – 30 = 150 degree start point for burner activation). This will help minimize short cycling of the Munchkin. To change the next value (Indirect Fired Water Heater) press in the S3/Program and the display will read de alternating value of 119F degree. This number is the factory default set point of 119 F degrees for the maximum Indirect Fired Water Heater (potable water). To change the temperature, push either the S1/- or S2/+ on the display. To change the next value (Fahrenheit F to Celsius C measurement) press in the S3/Program and the display will read t alternating value of F measurement in Fahrenheit. To change temperature measurement, push either S1/- or S2/+ on the display.

SECTION 5: PROGRAMMING THE CENTRAL HEAT CURVE
The central heating demand is detected when the room thermostat closes. When an outside sensor is also connected, the water temperature will depend on this as indicated in the Fig. 5-1. To set 1. 2. 3. 4. your heat curve you will have to set the following parameters Minimum outside design temperature: Function 8 Design Supply water temperature at the minimum design outside temperature: Function 9 Maximum outside design temperature: Function 10 Design Supply water temperature at the maximum outside temperature: Function 11

13

PROGRAMMING CENTRAL HEAT CURVE
CENTRAL HEATING CURVE Factory Default
212
201˚

CENTRAL HEATING CURVE Plot your Curve
212 203

203 194 185 176 167 SUPPLY OUTLET TEMPERATURE (F)
FUNCTION 9

194 185 176 167 158 149 131 122 113 104 95 86 77 68 59 50 41 32

SUPPLY OUTLET TEMPERATURE (F)

158
DEFAULT RESET CURVE

149 131 122 113 104 95 86 77 68 59 50 41 32
-59 -41 -24 -9 0 9 5˚ 27 45 63 81 68˚ 99

FUNCTION 11

FUNCTION 8

FUNCTION 10

-59

-41

-24

-9

0

9

27

45

63

81

99

OUTSIDE TEMPERATURE (F)

OUTSIDE TEMPERATURE (F)

Fig. 5-1

Fig. 5-2

CONTROL PROGRAM REFERENCE CHART Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Default Setting de 149 F 185 F 36 F 7F 0 minutes 68 F 5F 201 F 68 F 95 F 68 F 0 minutes 30 minutes 0 0 0 1 194°F Programmed Setting No Change allowed No Change allowed No Change allowed

Fig. 5-3
14

STATUS MENU / TEST MODE

SECTION 6: STATUS MENU
Installers are also able to check the current status of the Munchkin parameters by pressing S4/RESET key for 3 seconds. Once activated, 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. Function d1/ d2/ d3/ Value Actual Temperature from outlet sensor Actual Temperature from inlet sensor If using a standard mechanical control, the control will display 1 for closed 0 for open If the sensor is connected to the SuperStor Indirect Fired Water Heater it will measure the actual temperature. Not used Actual Temperature from the outdoor sensor Actual Fan speed multiplied by 10 (Example: If fan speed displayed is 410 RPM x 10 = 4100 actual fan speed) Actual Ionization current read from Flame Rectification probe Actual Status of the Central Heating Circulator Off = 0 , On = 1 Actual Status of the Indirect Fired Circulator Off = 0 , On = 1 Actual Status bus communication co = connected, no = not connected Central Heating Set Point Power on time. (Example: Hours ÷ 1000 [Ex. 0.1 = 100 hrs. or 1.0 = 1000 hrs.]) Central Heating Hours (CH – Hrs. ÷ 1000) Indirect Heating Hours (IND – Hrs. ÷ 1000) Passed ignition (Passed Ignition ÷ 1000)

d4/ d5/ d6/ d7/ d8/ d9/ d10/ d11/ d12/ d13/ d14/ d15/

SECTION 7: TEST MODE
This function is intended to simplify the gas valve adjustment if needed. Listed below are the recommended limits on each Munchkin Heater and the Combustion Settings (Fig. 7-2, pg. 16). Automatic modulation does not take place when the controller is in Test mode, only temperature limitation based on the Munchkin Central Heating set point. The user will be allowed to increase or decrease the fan speed by 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 combustion levels should always be taken at the highest and lowest fan speed. After 10 minutes, the Test mode stops automatically. To exit Test Mode press S1/- and S2/+ key together for 1 second.

15

TEST MODE / PIPING AND WIRING DUNGS GAS VALVE

Fig. 7-1
COMBUSTION SETTINGS FOR DUNGS GAS VALVE HIGH FIRING RATES and LOW FIRING RATES
Natural Gas low Carbon CO ppm Monoxide Carbon CO2% Dioxide 0 –10 ppm 8.5% – 9 .5% high 70 ppm –135 ppm 8.5% – 9.5% low 0 – 20 ppm 9.5% –10.5% Propane LP high 70 – 95 ppm 9.5% –10.5%

HONEYWELL GAS VALVE
DO NOT REMOVE THIS SCREW OR ATTEMPT TO MAKE ANY ADJUSTMENT TO THIS SCREW.
V1 V2

24 VOLT DC ELECTRICAL CONNECTION

OUTLET PRESSURE TAP

INLET PRESSURE TAP

THROTTLE ADJUSTMENT SCREW. NOTE: IF FOR ANY REASON THE SCREW IS ADJUSTED, A "COMBUSTION ANALYZER" MUST BE USED TO ENSURE SAFE AND PROPER OPERATION. TURNING THE SCREW CLOCKWISE DECREASES YOUR GAS FLOW WHICH WILL LOWER THE CO/CO2 % LEVELS. TURNING THE SCREW COUNTER-CLOCKWISE INCREASES YOUR GAS FLOW WHICH WILL RAISE THE CO/CO2 % LEVELS.

Fig. 7-1A

WARNING
Failure to follow all precautions could result in fire, explosion or death!
16

MIN OUT

1/2" NPT GAS INLET

AIR INLET, KEEP FREE OF DEBRIS

PIPING AND WIRING
COMBUSTION SETTINGS FOR HONEYWELL GAS VALVE HIGH FIRING RATES and LOW FIRING RATES
Natural Gas low Carbon CO ppm Monoxide Carbon CO2% Dioxide 0 – 20 ppm 8.5% – 9 .5% high 70 ppm –135 ppm 8.5% – 9.5% low 0 – 20 ppm 9.5% –10.5% Propane LP high 80 –150 ppm 9.5% –10.5%

Fig. 7-2

SECTION 8: PIPING AND WIRING THE VISION SYSTEM
CAUTION
Piping and wiring must be done correctly or overheating of the flooring will cause damage!
Various drawings have been included in this section to show the Vision contractor the correct installation guidelines. If the Vision has a installation which requires different piping or wiring, it is recommend that you contact the factory at 1-800-323-9651. These drawings are for reference purpose only. It is important to note that the Vision I system is normally used as a Two Temperature/Two Circulator System (One Circulator for the SuperStor Indirect Fired Water Heater and One Circulator for Central Heating). The Vision I can also be used without the Indirect Fired Water Heater.

CAUTION
The drawings included in this manual are for reference purpose only. Heat Transfer Products, Inc. will not be held responsible for any installation that is not piped or wired correctly.

CAUTION
Installation of additional controls or valves to the system design is not the responsibility of Heat Transfer Products, Inc. Certain components which are not supplied with the Vision I system may be recommended and should not be considered an endorsement from Heat Transfer Products, Inc.

17

PIPING

Piping Symbol Legend
circulator (w/ isolation flanges) circulator w/ integral flow check gate valve globe valve ball valve swing-check valve flow-check valve spring-loaded check valve hose bib / boiler drain TRV (straight)
T/P

pressure reducing valve diff. pressure bypass 3-way thermostatic pressure gauge

4-way motorized mixing valve 3-way motorized mixing valve pressure relief valve P&T relief valve backflow preventer float -type air vent union temperature / pressure gauge

Munchkin heater

TRV angle circuit setter manual 3-way valve zone valve

Super Stor indirect DHW tank

radiant manifold air separator

diaphragm-type expansion tank

heat exchanger

Fig. 8-1
18

PIPING

Munchkin VISION 1 system (zoning with valves) Space heating mode

Drawing 3A

high limit safety make-up water purge

zone valves

anti-scald mixing valve cold water

purge

differential pressure bypass valve

P1
DHW temperature sensor outdoor temperature sensor

OFF
T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself.

Fig. 8-2
19

PIPING

Munchkin VISION 1 system (zoning with valves) Domestic water heating mode

Drawing 3B

make-up water purge

high limit safety OFF

zone valves

anti-scald mixing valve cold water OFF DHW temperature sensor

purge

differential pressure bypass valve

P1

outdoor temperature sensor

T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself.

Fig. 8-3
20

PIPING

Munchkin VISION 1 system (zoning with valves) Space heating mode (w/ submixing)
3-way (manually-set) mixing valve vent air handler

Drawing 3C

low temperature manifold station

high limit safety

make-up water purge differential pressure bypass valve

purge

balancing valve

cold water

anti-scald mixing valve

DHW temperature sensor

P1

outdoor temperature sensor

OFF
T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressure drop operates by itself. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.

Fig. 8-4
21

PIPING

Munchkin VISION 1 system (zoning with circulators) Space heating mode

Drawing 4A

make-up water zone circulators high limit safety make-up water purge closely spaced tees

anti-scald mixing valve cold water

DHW temperature sensor

purge

P1
outdoor temperature sensor

OFF
T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown.

Fig. 8-5
22

PIPING

Munchkin VISION 1 system (zoning with circulators) Domestic water heating mode

Drawing 4B

OFF

OFF

OFF

zone circulators

high limit safety make-up water purge closely spaced tees

anti-scald mixing valve cold water
OFF

DHW temperature sensor

purge

P1

outdoor temperature sensor

T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown.

Fig. 8-6
23

PIPING

Munchkin VISION 1 system (zoning with circulators) Space heating mode (w/ submixing)
3-way (manually-set) mixing valve vent air handler

Drawing 4C

high limit safety

low temperature manifold station

make-up water purge balancing valve

anti-scald mixing valve cold water

DHW temperature sensor

purge

P1

outdoor temperature sensor

OFF
T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.

Fig. 8-7
24

PIPING

Munchkin VISION 1 system Drawing 4E (zoning with circulators) Space heating mode (3 fully reset supply temperatures)
vent medium temperature manifold station

air handler (higher temp.) vent

high limit safety

make-up water purge low temperature manifold station

purge

balancing valves 3-way (manually-set) mixing valve

anti-scald mixing valve cold water

DHW temp. sensor

P1

outdoor temperature sensor

OFF
T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F. Do not use valve actuators on manifolds supplied by manually-set 3-way mixing vaalves. A purging valve may be used in lieu of the ball valve / hose bib combination shown. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.

Fig. 8-8
25

PIPING

Munchkin VISION 1 system Drawing 4F (zoning with circulators) Space heating mode (3 different supply temperatures)
vent 3-way manually-set mixing valve

air handler (higher temp.) vent low temperature manifold station high limit safety variable speed injection mixing

make-up water purge

purge

balancing valves

medium temperature manifold station

cold water

anti-scald mixing valve purge

DHW temp. sensor

P1

outdoor temperature sensor

OFF
T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin boiler

NOTES:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F. Follow all instructions for installation of injection mixing system. A purging valve may be used in lieu of the ball valve / hose bib combination shown. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.

Fig. 8-9
26

PIPING

Munchkin VISION 1 system

Drawing 4G

Multiple high temperature priority loads controlled with zone valves

high temperature loads

low temperature loads

air handler
OFF OFF OFF

make-up water

zone circulators

air handler

high limit safety

closely spaced tees purge
multi-zone relay center

anti-scald mixing valve

purge

OFF

P1

outdoor temperature sensor

T/P

P2
differential pressure bypass valve Super Stor indirect DHW tank thermal trap (w/ drain plug) purge

Munchkin heater

NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown. High temperature loads cannot operate simultaneously with low temperature loads. Supply water temperature to high temperature loads is not reset based on outdoor temperature. Domestic water heating is highest priority load, and controlled through priority zone of multi-zone relay center

Fig. 8-10
27

PIPING

Drawing 4H Munchkin VISION 1 system Multiple high temperature priority loads controlled with zone circulators Multiple low temperature load controls with zone circulators

high temperature loads

low temperature loads

air handler

OFF

OFF

make-up water

OFF

zone circulators

air handler

high limit safety

closely spaced tees
multi-zone relay center

purge

anti-scald mixing valve

purge

OFF

P1

outdoor temperature sensor

T/P

P2
purge Super Stor indirect DHW tank thermal trap (w/ drain plug)

Munchkin heater

NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 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 diameter center to center spacing. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees. The minimum pipe size for connecting a Super Stor water heater is 1 inch. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches. All pumps are shown with isolation flanges and integral flow check valves. The alternative is standard flanges with full port ball valves and a separate flow check valve. 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. A purging valve may be used in lieu of the ball valve / hose bib combination shown. High temperature loads cannot operate simultaneously with low temperature loads. Supply water temperature to high temperature loads is not reset based on outdoor temperature. Domestic water heating is highest priority load, and controlled through priority zone of multi-zone relay center

Fig. 8-11
28

APPENDIX

SECTION 9: APPENDIX
RESISTANCE TABLES
Outdoor Sensor (7250P-319) Boiler Sensor (7250P-059) Indirect Sensor (7250P-320)

Outside Temperature ( F) Resistance (ohms) -22 171800 -13 129800 -4 98930 5 76020 14 58880 23 45950 32 36130 41 28600 50 22800 59 18300 68 14770 77 12000 86 9804 95 8054 104 6652 113 5522

Boiler & Indirect Temperature ( F) 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212

Resistance (ohms) 32550 25340 19870 15700 12490 10000 8059 6535 5330 4372 3605 2989 2490 2084 1753 1481 1256 1070 915 786 667

Fig. 9-1

Fig. 9-2

29

NOTES

30

NOTES

31

SuperStor Ultra, SuperStor, Voyager, Voyager Sanitizer, and Everlast are registered trademarks of Heat Transfer Products, Inc.

© 2006, 2005, 2004 Heat Transfer Products, Inc.

LP-102 REV. 1/1/06