Vision 1 - Heat Transfer Products, Inc

Heat Transfer Products, Inc.120 Braley RoadEast Freetown, MA 02717Setting the standard forcomfort and efficiency for yourheating and hot water system.

USING THIS MANUALUSING THIS MANUALA. INSTALLATION SEQUENCEFollow the installation instructions provided inthis manual in the order shown. The order ofthese instructions has been set in order toprovide the installer with a logical sequence ofsteps that will minimize potential interferencesand maximize safety during heater installation.B. SPECIAL ATTENTION BOXESThroughout this manual you will see thesespecial attention boxes similar to this onewhich are intended to supplement theinstructions and make special notice ofpotential hazards. These categories are asdefined by the ANSI Z535.A Standard.DANGERDANGER indicates an imminently hazardoussituation which, if not avoided, will result indeath or serious injury.WARNINGWARNING indicates a potentially hazardoussituation which, if not avoided, could result indeath or serious injury.CAUTIONCAUTION Indicates a potentially hazardoussitutation which, if not avoided, may result inminor or moderate injury.CAUTIONCAUTION used without the safety alert symbolindicates a potentially hazardous situation which,if not avoided, may result in property damage.2TABLE OF CONTENTSSECTION 1General Information Pg. 3SECTION 2Installation of your Vision I System Pg. 4SECTION 3Wire Functions Pg. 9SECTION 4Programming the Controller Pg. 10SECTION 5Programming The Central Heat CurvePg.13SECTION 6Status Menu Pg. 15SECTION 7Test Mode Pg. 15SECTION 8Piping and Wiring the Vision System Pg. 17SECTION 9Appendix Pg. 29

SECTION 1. GENERAL INFORMATIONTHE VISION I SYSTEMGENERAL INFORMATIONYou have purchased the Vision I System, which is the first truly advanced control system thateliminates the need for those expensive auxiliary controls. The Vision I System will allow the installingcontractor to take the highly efficient modulating 92% AFUE Munchkin Heater and make it even moreefficient by controlling the temperature delivered to the central heating circuits based on the outsidetemperature. The Vision I system is also a two temperature system, one temperature for CentralHeating and the other temperature to the Super Stor Ultra Indirect water heater. This allows the userto increase the temperature supplied to the Super Stor Ultra indirect water heater to get a fast recoveryby 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 Isystem will switch back to the Central Heating Circuit to continue to heat the living space at atemperature based on outside temperature. This gives you a higher comfort level and further increasesthe efficiency of the Munchkin Heater. Details within this manual will show you the proper piping andwiring of the Vision I System. Only factory authorized trained contractors are qualified to install theVision I system to assure quality of the installation for each system. If you have any questions, pleasecall your factory representative or call technical service line at 1-800-323-9651.SYSTEM OPERATIONModulation during the central heating operation is based on the supply temperature. The set pointused for the control depends upon the programmed central heating curve. The slope of the heatingcurve can be changed by the installer of the Munchkin in the sense that both turning points of thecurve can be moved. If the outside temperature sensor is not connected, the set point is the user setpoint 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 fireduntil 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 setpoint, the burner will switch off. The circulator will continue to run (Note: This will occur only if thermostatsare calling). The anti-cycling time begins at the completion of a heating cycle (either the indirectfired water heater or central heat.) There is a one minute anti-cycling time that prevents theburner from coming on unless there is a call from either the indirect fired water heater or centralheat. The purpose of the anti-cycling feature is to prevent the burner from erratic cycling. Regulationis based upon set point central heating. The maximum capacity of the Munchkin can be limited bystep modulation. The Munchkin has a 6-step function programmed into the controller. (Note: This 6-step function cannot be changed.) When the Munchkin burner is activated, the burner output is regulatedin one minute intervals. As shown in the chart, Section 9, Fig. 9.2, Appendix. Note: These percentagesare based on the rated maximum output. This feature helps the Munchkin from overshootingthe 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. Oncethe 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 alockout. The Fault Code Alarm wire is rated at 3 amp max. and is connected to the main controlboard of the Munchkin Boiler. This alarm can be connected to an external relay or an audible alarm.3

GENERAL INFORMATION / INSTALLATIONPARTS INCLUDED IN THE VISION I SYSTEM(See Resistance table in the1. Outside sensor 1 Pc 7250P-319Appendix Section 9)2. Indirect Tank Sensor 1 Pc. 7250P-3253. 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 CardNote: Only Products Manufactured by Heat Transfer Products will be covered under this warranty.SECTION 2. INSTALLATION OF YOUR VISION I SYSTEMYou must use the wires supplied by Heat Transfer Products to connect your Vision I system to yourexisting Munchkin control. You may choose to leave out some connections that you may not need inyour installation. Follow the diagram to connect the individual wire leads into the correct Molex toactivate the designated functions on the main control board. Listed below is an explanation for theindividual wire functions. (When making the connection, be sure that the black marking on the wireconnector is facing upward as shown in the illustration shown in Fig. 2-1 this section.) You will notethat 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 DHWCirculator) 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 CentralHeating Circulator and 2 gray wires for the Central Heating thermostat connection to the MunchkinBoiler. Install the wires based on the color diagrams, Figs. 2-1, 2-2 and Figs. 2-3 and 2-4 in this sectionshowing the open port connection on the Molex Plug which will show where the wire will be connectedto the appropriate Molex Port Connections.4

INSTALLATIONVISION CONNECTIONS AS VIEWED FROM THE FRONT ON A 140/199M MUNCHKINFig. 2-1VISION CONNECTIONS AS VIEWED FROM THE FRONT ON A T50/T80M/80M MUNCHKINFig. 2-25

INSTALLATIONVISION I – MUNCHKIN WITH SPARK IGNITIONNOTE: Vision One connections are outlined in black.Fig. 2-3: Vision I Molex and Color Wire Connections6

INSTALLATIONVISION I – MUNCHKIN WITH HOT SURFACE IGNITIONNOTE: Vision One connections are outlined in black.Fig. 2-4: Vision I Molex and Color Wire Connections for “HA” models7

INSTALLATIONFig. 2-5: Vision I Routing Connection8

WIRE FUNCTIONSSECTION 3. WIRE FUNCTIONS1. 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 willallow the user to change the temperature going to the Central Heating loop automatically. Place theoutdoor sensor preferably to the north or northwest or to the side which will be affected by changingweather conditions outside. NOTE: Do not locate the sensor in the direct sunlight.CAUTIONThe 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 onthe 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 temperatureof the heater will adjust to run the heater more efficiently and provide greater comfort to the livingspace. See section 4: “Programming the Controller”.Connection Specification – Wire 22 AWG maximum to 100 feet or 18 AWG up to 150feet. 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 inThe Vision I Package) or the mechanical control Honeywell Part # L4080b-1395 (Not included inVision I Package) into the control well located in the front of the Super Stor Ultra Indirect FiredWater Heater. This will allow the installer to control the temperature of the indirect from theMunchkin and give the Super Stor Indirect Fired Water Heater priority over the Central HeatingCircuit. Once the Water Heater is satisfied, the Munchkin will then switch back to the CentralHeating 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 UltraIndirect Fired Water Heater is from 1-60 minutes. The Super Stor Ultra tank temperature can only beadjusted when using a sensor (not a mechanical control). Temperature adjustments are from 95 to185 degrees, plus a differential 1-18 degrees (Note: It is recommend that you do not exceed 5 minuteson 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 150feet. Length of wire run cannot exceed 150 feet.3. Indirect Circulator Lead (1-Pink Wires/1-Purple Wires/1-Green Wires) areconnected to the main controller on the Munchkin. Route wires from the Munchkin control tothe external junction box. Run the wire and connect it directly to the Super Stor Ultra Indirectcirculating 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 (TheCirculator is not supplied in the Vision-1 the Package).Indirect Circulator Program function: The Super Stor Ultra Indirect circulator program functionwill automatically start when the Super Stor Ultra sensor reads a call for heat, the installer can alsoprogram the post purge function on the circulator. The Post purge circulator function ranges from 1-30 minutes.Connection Specification – Wire 18 AWG maximum. Length of wire run cannot exceed100 feet.9

WIRE FUNCTIONS / PROGRAMMING THE CONTROLLER4. Fault Code Alarm Output (1-Red Wire) is connected to the main controller on theMunchkin. 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 connectedto the neutral on the incoming power to the Munchkin.Connection Specification – Wire 18 AWG maximum. Length of wire run cannot exceed100 feet.CAUTIONDo not tie neutrals or hot wire leads to any other wires, go directly from theMunchkin controller to the circulator. It is also important to note that the Munchkincontroller is fused up to 6.3 Amps. The Munchkin requires 2.0 amps or 3.0 amps (HAmodels only). If electrical requirements of either the Indirect circulator or the CentralHeating Pump exceeds the 4.0 amps limit or 3.0 amps on (HA Models Only), pleasefollow the wiring diagram Fig. 3-1, this page, to wire a relay if your circulators exceedload requirements.Fig. 3-1SECTION 4. PROGRAMMING THE CONTROLLERCAUTIONOnly Vision I contractors are authorized to program the individual settings on theVision I. A pass code must be entered in order to get to the Programming Menu. ThisPass 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

The Vision I Dealer is the only one qualified to set the system limits and the heat curve for the MunchkinHeater. These system limits cannot be changed by anyone except an authorized Vision dealer oncethey are programmed. The Munchkin owner can make adjustments only to the hot water set point, thecentral heating differential and central heating temperature.Programming the Vision I system is quite simple, it is recommend that you write down the settings onthe Control Program Reference Chart provided in section 5 Fig. 4-3 for future reference. All thefunctions featured can be programmed right from the display located inside the Munchkin Heater.VISION 1 PROGRAM ACCESSTo start, press down and hold the S/3 and S/4 simultaneously for three seconds. You will notice thatthe display will change to 000 . Then, with your S1/- key on the display press down until you see925 . This is the pass code. To confirm that the pass code is correct, you will need to press and holdthe S3/Program for 1 second to confirm. If the pass code is entered incorrectly, the controller programfunction 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. Thedisplay will than show a 1 alternating to de . This first function verifies that the control will addressthe requirements of the Superstor Indirect Fired Water Heater.VISION 1 PROGRAM NAVIGATIONNext you will have to press the S/3 key to move through each function. To increase or decrease avalue, you will need to press either the S/1- key or S/2+ key to change the default values. If there isno key action for 1 minute, the display returns to normal operation. Changes are effective immediatelybut not directly stored until the S/4 key is pressed down for 3 seconds then the new values are stored.Listed below are the variety of functions the installer can program into the Vision I System.Function Default Value Function Description1 de Not Applicable2 149ºF Not Applicable3 185ºF Maximum Domestic Delivery Water Temperature Setpoint theInstaller will program for SuperStor Indirect Fired Water Heater(Note: Does not apply if used with Mechanical Control) Range:95ºF to 185ºF4 36ºF Not ApplicableCAUTIONPROGRAMMING THE CONTROLLERThe Heater cannot be programmed while there is a call for heat.5 7ºF Allows the installer to change the differential in the Indirect FiredWater Heater (Does not apply if used with a Mechanical Control)Range: 1ºF to 18ºF6 0 Minutes Allows the installer to change the Indirect Circulator Post PurgeTime once the sensor is satisfied (NOTE: it is recommend thatCirculator Post Purge Time be set no greater than 5 minutes).Range: 0 to 60 minutes7 68ºF Outdoor temperature that you wish the central heating should bedisabled—(warm weather shut-off) Range: 41ºF to 122ºF11

Function Default Value Function DescriptionPROGRAMMING THE CONTROLLER*8 5ºF Allows the installer to change the Minimum Outside DesignTemperature. Range: –49ºF to 32ºF (See the chart on page 14,Fig. 5-1 to set outdoor reset curve)*9 201ºF Allows the installer to change the Design Supply Water Temperaturefrom the Munchkin based on the Minimum Outside DesignTemperature (See the chart on page 14, Fig. 5-1 to set outdoor resetcurve) Range: 203ºF to 77ºF*10 68ºF Allows the installer to change the Maximum Outside DesignTemperature for Central Heating. (See the chart on page 14, Fig.5-1 to set outdoor reset curve) Range: 95ºF to 32ºF*11 95ºF Allows the installer to change the Design Supply WaterTemperature from the Munchkin based on the Maximum OutsideDesign Temperature. (See Fig. 5-1 on page 14) Range: 32ºF to185ºF12 68º F Allows the installer to set the lowest temperature on theMunchkin for Central Heating. Range: 32ºF to 194ºF13 0 Minutes Allows the installer to change the Central Heating Circulator PostPurge Time once the thermostat is satisfied. Range 0 to 10minutes.14 30 Minutes Allows the installer to set the Maximum run time for the IndirectFired Water Heater and the Minimum run time for CentralHeating. Range 0 to 60 Minutes15 0 Bus address (0=zone master 1–8 — cascade slave) (Not currentlyused.)16 0 Interface Board Activation0 = not active1 = activeWARNING: Never change the default setting without theMunchkin Interface Board installed.**17 0 Interface Board Function0 = Building Management1 = Enables Tekmar Modulating control.(Consult with Tekmar to assure the Tekmar Control is compatible)18 1 Step Modulation1 = on0 = off19 180° Indirect boiler set point (flow)Temperature default = 119° to 203°20 1 Not applicable* Central Heating Curve Function see Fig. 5-1 Section 5.** The Munchkin Interface board allow the Munchkin Boiler to connect to either a building managementsystem (0-10 volt) a Tekmar or allows the user to provide a boost function along with theVision 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 tonormal operation. All the new parameters will now be reflected in the operation of the Munchkin.12

PROGRAMMING THE CONTROLLER / PROGRAMMING CENTRAL HEAT CURVEDANGERWater temperature over 125 degrees F. can cause severe burnsinstantly, or death from scalds. Children, disabled, and elderlyare at highest risk of being scalded. See instruction manualbefore setting temperature at water heater. Feel water beforebathing or showering! Temperature limiting valves are available.ADJUSTING TEMPERATUREThe installer can program1. 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])NOTICEIt is important to note that the homeowner can adjust the heat curve down by adjustingthe central heating temperature to a lower setting.Before you can change the temperature from the factory default setting. You must make sure thatnone of the thermostats are calling for heat. The Munchkin controller will not memorize a programsetting while in a heating cycle. To adjust the Munchkin Supply Water Temperature, press in theS3/Program key for three seconds until you see a flashing C alternating to 180 . This number is thefactory default set point of 180 degrees for the central heating. To change the temperature, pusheither the S1/- or S2/+ on the display. The S1/- button will decrease the temperature setting whilethe S2/+ will increase the maximum supply water temperature of the Munchkin. To change the nextvalue (Central Heating differential) press in the S3/Program and the display will read ch alternatingto a value of 30 . This number is the factory default set point of 30 degrees for the CentralHeating differential. To change the temperature, push either the S1/- or S2/+ on the display. Thisrepresents the starting point as to when the Munchkin will activate the burner. So, if the factory settingis 180 degrees the Munchkin will not start the burner unless the thermostat is calling for heatand the return sensor is measuring a temperature below 150 degrees (180 – 30 = 150 degree startpoint for burner activation). This will help minimize short cycling of the Munchkin. To change thenext value (Indirect Fired Water Heater) press in the S3/Program and the display will read de alternatingvalue of 119F degree. This number is the factory default set point of 119 F degrees for themaximum Indirect Fired Water Heater (potable water). To change the temperature, push either theS1/- 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 inFahrenheit. To change temperature measurement, push either S1/- or S2/+ on the display.SECTION 5: PROGRAMMING THE CENTRAL HEAT CURVEThe central heating demand is detected when the room thermostat closes. When an outside sensoris also connected, the water temperature will depend on this as indicated in the Fig. 5-1.To set your heat curve you will have to set the following parameters1. Minimum outside design temperature: Function 82. Design Supply water temperature at the minimum design outside temperature: Function 93. Maximum outside design temperature: Function 104. Design Supply water temperature at the maximum outside temperature: Function 1113

PROGRAMMING CENTRAL HEAT CURVE212203201˚194SUPPLY OUTLET TEMPERATURE (F)1851761671581491311221131049586776859504132-59 -41CENTRAL HEATING CURVEFactory DefaultFUNCTION 9FUNCTION 11FUNCTION 8DEFAULT RESET CURVEFUNCTION 100-24 -9 9 27 45 63 81 995˚68˚OUTSIDE TEMPERATURE (F)Fig. 5-1 Fig. 5-2SUPPLY OUTLET TEMPERATURE (F)2122031941851761671581491311221131049586776859504132-59CENTRAL HEATING CURVEPlot your Curve0-41 -24 -9 9 27OUTSIDE TEMPERATURE (F)45 63 81 99CONTROL PROGRAM REFERENCE CHARTFig. 5-3Function Default Setting Programmed Setting1 de No Change allowed2 149 F No Change allowed3 185 F4 36 F No Change allowed5 7 F6 0 minutes7 68 F8 5 F9 201 F10 68 F11 95 F12 68 F13 0 minutes14 30 minutes15 016 017 018 119 194°F14

SECTION 6: STATUS MENUSTATUS MENU / TEST MODEInstallers are also able to check the current status of the Munchkin parameters by pressing S4/RESETkey 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/4key to go to the next displayed value. Listed below are the values which can be displayed. These valuescannot be changed. To exit this menu, simply press S3/Program key to resume normal operation.Function Valued1/ Actual Temperature from outlet sensord2/ Actual Temperature from inlet sensord3/ If using a standard mechanical control, the control will display 1 for closed 0 for openIf the sensor is connected to the SuperStor Indirect Fired Water Heater it will measurethe actual temperature.d4/ Not usedd5/ Actual Temperature from the outdoor sensord6/ Actual Fan speed multiplied by 10 (Example: If fan speed displayed is410 RPM x 10 = 4100 actual fan speed)d7/ Actual Ionization current read from Flame Rectification probed8/ Actual Status of the Central Heating Circulator Off = 0 , On = 1d9/ Actual Status of the Indirect Fired Circulator Off = 0 , On = 1d10/ Actual Status bus communication co = connected, no = not connectedd11/ Central Heating Set Pointd12/ Power on time. (Example: Hours ÷ 1000 [Ex. 0.1 = 100 hrs. or 1.0 = 1000 hrs.])d13/ Central Heating Hours (CH – Hrs. ÷ 1000)d14/ Indirect Heating Hours (IND – Hrs. ÷ 1000)d15/ Passed ignition (Passed Ignition ÷ 1000)SECTION 7: TEST MODEThis function is intended to simplify the gas valve adjustment if needed. Listed below are therecommended 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 temperaturelimitation based on the Munchkin Central Heating set point. The user will be allowed to increase ordecrease 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. Onceactivated, you will see in the display Ser and the actual fan speed. The measurement of thecombustion levels should always be taken at the highest and lowest fan speed. After 10 minutes, theTest mode stops automatically. To exit Test Mode press S1/- and S2/+ key together for 1 second.15

TEST MODE / PIPING AND WIRINGDUNGS GAS VALVEFig. 7-1COMBUSTION SETTINGS FOR DUNGS GAS VALVEHIGH FIRING RATES and LOW FIRING RATESCarbon CO ppmMonoxideCarbon CO 2 %DioxideNatural GasPropane LPlow high low high0 –10 ppm 70 ppm –135 ppm 0 – 20 ppm 70 – 95 ppm8.5% – 9 .5% 8.5% – 9.5% 9.5% –10.5% 9.5% –10.5%HONEYWELL GAS VALVEDO NOT REMOVE THIS SCREWOR ATTEMPT TO MAKEANY ADJUSTMENT TO THIS SCREW.24 VOLT DC ELECTRICAL CONNECTIONMINOUTV1 V21/2" NPTGAS INLETOUTLET PRESSURE TAPINLET PRESSURE TAPTHROTTLE ADJUSTMENT SCREW.NOTE: IF FOR ANY REASON THE SCREW IS ADJUSTED, A"COMBUSTION ANALYZER" MUST BE USED TO ENSURE SAFE ANDPROPER OPERATION. TURNING THE SCREW CLOCKWISEDECREASES YOUR GAS FLOW WHICH WILL LOWER THE CO/CO2 %LEVELS. TURNING THE SCREW COUNTER-CLOCKWISE INCREASESYOUR GAS FLOW WHICH WILL RAISE THE CO/CO2 % LEVELS.Fig. 7-1AAIR INLET, KEEP FREEOF DEBRISWARNINGFailure to follow all precautions could result in fire, explosion or death!16

PIPING AND WIRINGCOMBUSTION SETTINGS FOR HONEYWELL GAS VALVEHIGH FIRING RATES and LOW FIRING RATESFig. 7-2Carbon CO ppmMonoxideCarbon CO 2 %DioxideNatural GasPropane LPlow high low high0 – 20 ppm 70 ppm –135 ppm 0 – 20 ppm 80 –150 ppm8.5% – 9 .5% 8.5% – 9.5% 9.5% –10.5% 9.5% –10.5%SECTION 8: PIPING AND WIRING THE VISION SYSTEMCAUTIONPiping and wiring must be done correctly or overheating of the flooringwill cause damage!Various drawings have been included in this section to show the Vision contractor the correct installationguidelines. If the Vision has a installation which requires different piping or wiring, it is recommendthat you contact the factory at 1-800-323-9651. These drawings are for reference purposeonly. It is important to note that the Vision I system is normally used as a Two Temperature/TwoCirculator System (One Circulator for the SuperStor Indirect Fired Water Heater and One Circulatorfor Central Heating). The Vision I can also be used without the Indirect Fired Water Heater.CAUTIONThe drawings included in this manual are for reference purpose only. Heat TransferProducts, Inc. will not be held responsible for any installation that is not piped orwired correctly.CAUTIONInstallation of additional controls or valves to the system design is not theresponsibility of Heat Transfer Products, Inc. Certain components which are notsupplied with the Vision I system may be recommended and should not be consideredan endorsement from Heat Transfer Products, Inc.17

PIPINGPiping SymbolLegendpressure reducing valvediff. pressure bypasscirculator(w/ isolation flanges)circulator w/integral flow checkgate valveglobe valveball valveswing-check valveflow-check valvespring-loaded check valvehose bib / boiler drainTRV (straight)3-way thermostaticpressure gauge4-way motorizedmixing valve3-way motorizedmixing valvepressure relief valveP&T relief valvebackflow preventerfloat -typeair ventunionMunchkin heaterTRV angleT/Ptemperature / pressuregaugecircuit settermanual 3-way valvezone valveair separatorradiant manifoldSuper Storindirect DHW tankdiaphragm-typeexpansion tankheat exchangerFig. 8-118

PIPINGMunchkin VISION 1 system(zoning with valves)Space heating modeDrawing 3Ahigh limit safetyzonevalvesmake-up waterpurgepurgedifferentialpressurebypassvalvecoldwateranti-scald mixing valveDHWtemperaturesensorOFFP1outdoortemperaturesensorP2T/PpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressuredrop operates by itself.Fig. 8-219

PIPINGMunchkin VISION 1 system(zoning with valves)Domestic water heating modeDrawing 3Bmake-up waterpurgepurgehigh limit safetyOFFzonevalvesdifferentialpressurebypassvalvecoldwateranti-scald mixing valveDHWtemperaturesensorOFFP1outdoortemperaturesensorP2T/PpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressuredrop operates by itself.Fig. 8-320

PIPINGMunchkin VISION 1 system(zoning with valves)Space heating mode (w/ submixing)Drawing 3Cair handler3-way(manually-set)mixing valveventlow temperaturemanifold stationhigh limit safetymake-up waterpurgepurgebalancingvalvedifferentialpressurebypassvalvecoldwateranti-scaldmixing valveDHWtemperaturesensorOFFP1outdoortemperaturesensorP2T/PpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. Adjust differential pressure bypass valve to eliminate any flow velocity noise when zone with highest pressuredrop operates by itself.11. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.Fig. 8-421

PIPINGMunchkin VISION 1 system(zoning with circulators)Space heating modeDrawing 4Amake-up waterhigh limit safetyzonecirculatorsmake-up waterpurgeclosely spaced teespurgecoldwateranti-scald mixing valveDHWtemperaturesensorOFFP1outdoortemperaturesensorP2T/PpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.Fig. 8-522

PIPINGMunchkin VISION 1 system(zoning with circulators)Domestic water heating modeDrawing 4Bhigh limit safetyOFFOFFOFFzonecirculatorsmake-up waterpurgeclosely spaced teespurgecoldwateranti-scald mixing valveDHWtemperaturesensorOFFP1outdoortemperaturesensorP2T/PpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.Fig. 8-623

PIPINGMunchkin VISION 1 system(zoning with circulators)Space heating mode (w/ submixing)Drawing 4C3-way(manually-set)mixing valveair handlerventhigh limit safetylow temperaturemanifold stationmake-up waterpurgebalancingvalvepurgecoldwateranti-scald mixing valveDHWtemperaturesensorOFFP2P1T/PoutdoortemperaturesensorpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.Fig. 8-724

PIPINGMunchkin VISION 1 systemDrawing 4E(zoning with circulators)Space heating mode (3 fully reset supply temperatures)ventmedium temperaturemanifold stationair handler(higher temp.)venthigh limit safetymake-up waterpurgelow temperaturemanifold stationpurgebalancingvalves3-way (manually-set) mixing valvecoldwateranti-scald mixing valveDHWtemp.sensorOFFP2P1T/PoutdoortemperaturesensorpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Do not use valve actuators on manifolds supplied by manually-set 3-way mixing vaalves.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.Fig. 8-825

PIPINGMunchkin VISION 1 systemDrawing 4F(zoning with circulators)Space heating mode (3 different supply temperatures)vent3-way manually-setmixing valveair handler(higher temp.)ventlow temperaturemanifold stationhigh limit safetymake-up waterpurgevariablespeedinjectionmixingcoldwateranti-scaldmixing valvepurgebalancingvalvespurgemediumtemperaturemanifold stationDHWtemp.sensorOFFP2P1T/PoutdoortemperaturesensorpurgeNOTES:Super Storindirect DHW tankthermal trap(w/ drain plug)Munchkin boiler1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Follow all instructions for installation of injection mixing system.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. Adjust 3-way manually-set mixing valve to yield proper supply temperature to lower temperature load.Fig. 8-926

PIPINGMunchkin VISION 1 systemDrawing 4GMultiple high temperature priority loads controlled with zone valveshigh temperature loadslow temperature loadsair handlerair handlermake-up waterhigh limit safetyOFFOFFOFFzonecirculatorsclosely spaced teesmulti-zonerelay centerpurgepurgeanti-scaldmixing valveOFFP1outdoortemperaturesensorP2T/PSuper Storindirect DHW tankdifferential pressurebypass valvethermal trap(w/ drain plug)purgeMunchkin heaterNOTES:1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. High temperature loads cannot operate simultaneously with low temperature loads.11. Supply water temperature to high temperature loads is not reset based on outdoor temperature.12. Domestic water heating is highest priority load, and controlled through priority zone of multi-zone relay centerFig. 8-1027

Munchkin VISION 1 systemDrawing 4HMultiple high temperature priority loadscontrolled with zone circulatorsMultiple low temperature load controls with zone circulatorsPIPINGhigh temperature loadslow temperature loadsair handlerair handlermake-up waterhigh limit safetyOFFOFFOFFzonecirculatorsclosely spaced teesmulti-zonerelay centerpurgepurgeanti-scaldmixing valveOFFP1outdoortemperaturesensorP2T/PpurgeSuper Storindirect DHW tankthermal trap(w/ drain plug)Munchkin heaterNOTES:1. This drawing is meant to show system piping concept only.Installer is responsible for all equipment & detailing required by local codes.2. All closely spaced tees shall be within 4 pipe diameter center to center spacing.3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstreamof all closely spaced tees.4. The minimum pipe size for connecting a Super Stor water heater is 1 inch.5. The minimum pipe size for connecting a Munchkin boiler shall be 1.25 inches.6. 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.7. The anti-scald mixing valve is recommended if the DHW temperature is set above the factory setting of 119˚F.8. Install a minimum of 12 diameters of straight pipe upstream of all circulators.9. A purging valve may be used in lieu of the ball valve / hose bib combination shown.10. High temperature loads cannot operate simultaneously with low temperature loads.11. Supply water temperature to high temperature loads is not reset based on outdoor temperature.12. Domestic water heating is highest priority load, and controlled through priority zone of multi-zone relay centerFig. 8-1128

APPENDIXSECTION 9: APPENDIXRESISTANCE TABLESOutdoor Sensor (7250P-319)Boiler Sensor (7250P-059) Indirect Sensor (7250P-320)Outside Temperature ( F) Resistance (ohms) Boiler & Indirect Temperature ( F) Resistance (ohms)-22 171800 32 32550-13 129800 41 25340-4 98930 50 198705 76020 59 1570014 58880 68 1249023 45950 77 1000032 36130 86 805941 28600 95 653550 22800 104 533059 18300 113 437268 14770 122 360577 12000 131 298986 9804 140 249095 8054 149 2084104 6652 158 1753113 5522 167 1481176 1256185 1070194 915203 786212 667Fig. 9-1Fig. 9-229

30NOTES

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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