Munchkin Gas-Fired Hot Water Boiler CONTENTS

2

GAS-FIRED BOILER Boiler Manual

CONTENTS

(CONT’D)

Part 8 – Gas Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47

A. Gas Connection

B. Gas Piping

C. Gas Table

D. Dungs Gas Valve

Part 9 – Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-49

A. Installation Must Comply With

B. Field Wiring

C. Line Voltage Wiring

D. Thermostat

Part 10 – Field Wiring – Vision 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Part 11 – Start Up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-53

A. Check/Control Water Chemistry

B. Freeze Protection (when used)

C. Fill and Test Water System

D. Purge Air from Water System

E. Check for Gas Leaks

F. Check Thermostat Circuit(s)

G. Condensate Removal

H. Final Checks Before Starting Boiler

Part 12 – Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-55

A. Operating Instructions

B. Adjusting the Set Point

C. Status Menu

D. Test Mode

Part 13 – Start-Up Procedures With The Vision 1 Option . . . . . . . . . . . . . . . . . . . . . . 55-58

A. Programming the Vision I Option

B. Vision I Program Access

C. Vision I Program Navigation

Part 14 – Trouble Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-61

A. Munchkin Error Code

B. Boiler Error

C. Boiler Fault

Part 15 – Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-66

A. Maintenance Procedures

B. Combustion Chamber Coil Cleaning Instructions

Part 16 – Boiler Inspection and Maintenance Start-Up Charts . . . . . . . . . . . . . . . . . . 67-69

Contents

Main Page CONTENTS Page PART 1: PRODUCT AND SAFETY INFORMATION Before Installing Page PART 2: HOW BOILER OPERATES PART 3: PREPARE BOILER LOCATION INCORRECT CORRECT 7 T50M/T80M DIMENSIONS PERFORMANCE RATINGS CONNECTION SIZES FAN SPEEDS Page NOTICE Precautions Page PART 4: PREPARE BOILER PART 5: BOILER PIPING Expansion tank and make-up water Diaphragm (or bladder) expansion tank Sizing space heat system piping Page Page Page Page Piping Symbol Legend M.BOILER PIPING DETAILS Standard Munchkin boiler Preferred piping (zoning with valves) Space heating mode P1 Drawing 2A V1 NOTES: Standard Munchkin boiler Preferred piping (zoning with valves) Domestic water heating mode P1 Drawing 2B V1 P2 Standard Munchkin boiler Preferred piping (zoning with circulators) Space heating mode P2 P1 NOTES: Drawing 2C Standard Munchkin boiler Preferred piping (zoning with circulators) Domestic water heating mode P2 P1 Drawing 2D NOTES: Drawing 2E PB2 PB1 P2 NOTES: Drawing 2F PB2 PB1 P2 PART 6. BOILER PIPING WITH VISION I SYSTEM D. BOILER PIPING DETAILS WITH THE VISION I SYSTEM Munchkin VISION 1 system (zoning with valves) Space heating mode purge NOTES: Drawing 3A P1 P2 (zoning with valves) Domestic water heating mode Drawing 3B purge Munchkin VISION 1 system (zoning with valves) Space heating mode (w/ submixing) NOTES: Drawing 3C purge P1 P2 Space heating mode Drawing 4A Munchkin VISION 1 system (zoning with circulators) Domestic water heating mode NOTES: Drawing 4B P1 P2 purge Space heating mode (w/ submixing) Drawing 4C purge Space heating mode (3 fully reset supply temperatures) Drawing 4E purge P2 Space heating mode (3 different supply temperatures) Drawing 4F purge P2 P1 P2 Munchkin VISION 1 system Multiple high temperature priority loads controlled with zone valves NOTES: Drawing 4G NOTES: Drawing 4H P1 P2 PART 7: VENTING, COMBUSTION AIR & CONDENSATE REMOVAL Page Page Page Page Page 42 J. DIAGRAMS FOR SIDEWALL VENTING Figure 7-9 Figure 7-10 AND COUPLING (EXHAUST) SIDEWALL VENTING WITH TEE (INTAKE) AND COUPLING (EXHAUST) SIDEWALL VENTING WITH TEE (INTAKE) 43 SIDWALL 1" MIN. MUST BE FACING UP Figure 7-11 Figure 7-12 K. DIAGRAMS FOR VERTICAL VENTING RIGHT SIDE VIEW WHICHEVER IS GREATER ALL HORIZONTAL } 46 PART 8: GAS PIPING D. DUNGS GAS VALVE FOR T50/T80/80M/140M/199M PART 9: FIELD WIRING Page Page PART 10: FIELD WIRING VISION 1 PART 11. START-UP PREPARATION Water pH between 6.0 and 8.0 Hardness less than 7 grains. Chlorine concentration less than 200 ppm Clean system to remove sediment Page PART 11. START-UP PREPARA TION PART 12. START-UP PROCEDURE FOR YOUR OWN SAFETY READ BEFORE OPERATING WHAT TO DO IF YOU SMELL GAS Page PART 12. START-UP PROCEDURE PART 13: START-UP PROCEDURES WITH THE VISION 1 PART 13: START-UP PROCEDURES WITH THE VISION 1 The Boiler cannot be programmed while there is a call for heat. PART 13: START-UP PROCEDURES WITH THE VISION 1 NOTICE PART 13: START-UP PROCEDURES WITH THE VISION 1 OPTION PART 14: TROUBLESHOOTING 60 PART 14: TROUBLESHOOTING F Nc PP F33 PART 15: MAINTENANCE Outside Temperature (F) Resistance (ohms) Boiler and Indirect Temperature (F) Resistance (ohms) PART 14: TROUBLESHOOTING Page T50M/T80M T50M/T80M REPLACEMENT PARTS REPLACEMENT PARTS SWITCH T50M/T80M T50M/T80M BOILER OUTLET CONDENSATE 80M/140M/199M Fig. 15-1 80M/140M/199M Fig. 15-2 Page Page BOILER START UP REPORT Light Off Activities Date completed _______________ BOILER INSPECTION AND MAINTENANCE SCHEDULE Date last completed Inspection Activities BOILER INSPECTION AND MAINTENANCE SCHEDULE Date last completed Inspection Activities