Munchkin Gas-Fired Hot Water Boiler T50M/T80M

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GAS-FIRED BOILER Boiler Manual

PART 15: MAINTENANCE (CONTINUED)

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T50M/T80M

REPLACEMENT PARTS

Item

#Description Part # Item

#Description Part #

1 Thermodisc Flue ECO 210 F 7250P-089 22 Nut M5 (Aluminum Elbow to Air Channel) 7250P-063

2 Steel Push Retainer (Thermodisc Flue ECO) 7250P-151 23 Gasket (Flame Rec./Spark Electrode) 7250P-005

3 PVC Black Tubing 1/8 ID (Thermodisc Flue ECO) 7250P-311 24 Spark Electrode (w/Gasket) 7250P-421 (T50M)

4 Relief Valve 7250P-080 7250P-058 (T80M)

5 Thermistor 7250P-059 25 Screws M4 x 8MM (Probe/Electrode) 7250P-069

6 Water Pressure Switch 7250P-081 26 Flame Rectification Probe (w/Gasket) 7250P-049

7 ECO High Limit Sensor 7250P-019 27 Screws Torx M5 X 22MM (Air Channel to Burner Door) 7250P-206

8 Aluminum Elbow 7250P-445 28 Air Channel 7250P-178

9 Screws M5 X 25MM (Aluminum Elbow to Air Channel) 7250P-061 29 Gasket (Burner Door to Air Channel) 7250P-170

10 Gasket (Aluminum Elbow to Air Channel) 7250P-003 30 Nuts M6 (Burner Door) 7500P-067

11 Gasket (Aluminum Elbow to Combustion Blower) 7250P-144 31 Burner Door 7250P-169

12 Combustion Blower 7250P-085 32 Burner Door Ceramic Refractory 7250P-702

13 Gas Valve Adapter Plate (w/Screws) 7250P-644 33 Gasket (Burner) 7250P-070

14 Screws M5 x 12MM (Gas Valve Adapter Plate) 7250P-484 34 Burner 7250P-216 (T50M)

15 Swirl Plate 7500P-091 (T50M) 7250P-248 (T80M)

7500P-092 (T80M) 35 Screws (Burner) 7250P-204

16 Dungs Gas Valve 7250P-448 (T50M) 36 Screw M4 x 8MM (Ceramic Target Wall) 7250P-704

7250P-449 (T80M) 37 Washer M4 (Ceramic Target Wall) 7500P-109

17 Gas Piping Assembly (w/Shut-off Valve, Screws) N/A 38 Ceramic Target Wall 7250P-160

18 Screws M4 x 12MM (Gas Valve Piping Assy) 7500P-099 39 Brass 90 Street Elbow 3/4 NPT 7250P-212

19 O-Ring (Gas Valve Piping Assy) 7500P-094 40 Brass Nipple 3/4 NPT x 3" SN1018

20 Screws M4 x 18MM (Gas Valve) 7250P-716 (T50M) 41 Brass 90 Elbow 3/4 NPT 7250P-313

Screws M4 x 19MM (Gas Valve) 7250P-717 (T80M) 42 Gasket (Top Flue Exhaust to Module) 7250P-428

21 Screw M5 x 20MM (Combustion Blower) 7250P-060 43 Top Flue Exhaust 7250P-394

T50M/T80M

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