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.
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.
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.
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 Pg. 3
SECTION 2
Installation of your Vision I System Pg. 4
SECTION 3
Wire Functions Pg. 9
SECTION 4
Programming the Controller Pg. 10
SECTION 5
Programming The Central Heat Curve Pg.13
SECTION 6
Status Menu Pg. 15
SECTION 7
Test Mode Pg. 15
SECTION 8
Piping and Wiring the Vision System Pg. 17
SECTION 9
Appendix Pg. 29

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 ther-
mostats are calling). The anti-cycling time begins at the completion of a heating cycle (either the indi-
rect 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 6-
step function cannot be changed.) When the Munchkin burner is activated, the burner output is reg-
ulated in one minute intervals. As shown in the chart, Section 9, Fig. 9.2, Appendix. Note: These per-
centages are based on the rated maximum output. This feature helps the Munchkin from over-
shooting 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

(See Resistance table in the

1. Outside sensor 1 Pc 7250P-319 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 liv-
ing 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 min-
utes 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 1-
30 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 Default Value Function Description

1 de
2 149ºF
3 185ºF
4 36ºF
5 7ºF
6 0 Minutes
7 68ºF
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
 PROGRAMMING THE CONTROLLER

Function Default Value Function Description

*8 5ºF 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)
*9 201ºF 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
*10 68ºF 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
*11 95ºF 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
12 68º F Allows the installer to set the lowest temperature on the
Munchkin for Central Heating. Range: 32ºF to 194ºF
13 0 Minutes Allows the installer to change the Central Heating Circulator Post
Purge Time once the thermostat is satisfied. Range 0 to 10
minutes.
14 30 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
15 0 Bus address (0=zone master 1–8 — cascade slave) (Not currently
used.)
16 0 Interface Board Activation
0 = not active
1 = active
WARNING: Never change the default setting without the
Munchkin Interface Board installed.**
17 0 Interface Board Function
0 = Building Management
1 = Enables Tekmar Modulating control.
(Consult with Tekmar to assure the Tekmar Control is compatible)
18 1 Step Modulation
1 = on
0 = off
19 180° 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 man-
agement 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 alternat-
ing 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 set-
ting 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 alter-
nating 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 your heat curve you will have to set the following parameters
1. Minimum outside design temperature: Function 8
2. Design Supply water temperature at the minimum design outside temperature: Function 9
3. Maximum outside design temperature: Function 10
4. Design Supply water temperature at the maximum outside temperature: Function 11

13
 PROGRAMMING CENTRAL HEAT CURVE

CENTRAL HEATING CURVE CENTRAL HEATING CURVE

Factory Default Plot your Curve
212 212

203 203
201˚
FUNCTION 9 194
194

185 185

176 176

167 167

SUPPLY OUTLET TEMPERATURE (F)

158
SUPPLY OUTLET TEMPERATURE (F)

158
DEFAULT RESET CURVE
149 149

131 131

122 122

113 113

104 104

95 95
FUNCTION 11
86 86

77 77
FUNCTION 10
FUNCTION 8

68 68

59 59

50 50

41 41

32 32
0 0
-59 -41 -24 -9 9 27 45 63 81 99 -59 -41 -24 -9 9 27 45 63 81 99

5˚ 68˚ OUTSIDE TEMPERATURE (F)

OUTSIDE TEMPERATURE (F)

Fig. 5-1 Fig. 5-2

CONTROL PROGRAM REFERENCE CHART

Function Default Setting Programmed Setting
1 de No Change allowed
2 149 F No Change allowed
3 185 F
4 36 F No Change allowed
5 7F
6 0 minutes
7 68 F
8 5F
9 201 F
10 68 F
11 95 F
12 68 F
13 0 minutes
14 30 minutes
15 0
16 0
17 0
18 1
19 194°F
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 tem-
perature. 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 val-
ues cannot be changed. To exit this menu, simply press S3/Program key to resume normal operation.
Function Value
d1/ Actual Temperature from outlet sensor
d2/ Actual Temperature from inlet sensor
d3/ 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.
d4/ Not used
d5/ Actual Temperature from the outdoor sensor
d6/ Actual Fan speed multiplied by 10 (Example: If fan speed displayed is
410 RPM x 10 = 4100 actual fan speed)
d7/ Actual Ionization current read from Flame Rectification probe
d8/ Actual Status of the Central Heating Circulator Off = 0 , On = 1
d9/ Actual Status of the Indirect Fired Circulator Off = 0 , On = 1
d10/ Actual Status bus communication co = connected, no = not connected
d11/ Central Heating Set Point
d12/ 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 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 Propane LP

low high low high
Carbon CO ppm
0 –10 ppm 70 ppm –135 ppm 0 – 20 ppm 70 – 95 ppm
Monoxide
Carbon CO2%
8.5% – 9 .5% 8.5% – 9.5% 9.5% –10.5% 9.5% –10.5%
Dioxide

HONEYWELL GAS VALVE

DO NOT REMOVE THIS SCREW 24 VOLT DC ELECTRICAL CONNECTION
OR ATTEMPT TO MAKE
ANY ADJUSTMENT TO THIS SCREW.
V2 V1

MIN
OUT

1/2" NPT
GAS INLET

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
AIR INLET, KEEP FREE
PROPER OPERATION. TURNING THE SCREW CLOCKWISE
OF DEBRIS
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
 PIPING AND WIRING

COMBUSTION SETTINGS FOR HONEYWELL GAS VALVE

HIGH FIRING RATES and LOW FIRING RATES
Natural Gas Propane LP
low high low high
Carbon CO ppm
0 – 20 ppm 70 ppm –135 ppm 0 – 20 ppm 80 –150 ppm
Monoxide
Carbon CO2%
8.5% – 9 .5% 8.5% – 9.5% 9.5% –10.5% 9.5% –10.5%
Dioxide
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 instal-
lation guidelines. If the Vision has a installation which requires different piping or wiring, it is rec-
ommend 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 pressure reducing valve

Legend diff. pressure bypass

circulator 3-way thermostatic

(w/ isolation flanges)

circulator w/ pressure gauge

integral flow check

gate valve
4-way motorized
mixing valve Munchkin heater
globe valve

ball valve 3-way motorized

mixing valve
swing-check valve
pressure relief valve
flow-check valve P&T relief valve

spring-loaded check valve backflow preventer

hose bib / boiler drain float -type

air vent

TRV (straight) union

temperature / pressure
T/P gauge
TRV angle

circuit setter

manual 3-way valve Super Stor

indirect DHW tank
zone valve
radiant manifold

air separator

diaphragm-type
expansion tank

heat exchanger

Fig. 8-1

18
 PIPING

Munchkin VISION 1 system Drawing 3A

(zoning with valves)
Space heating mode

zone
high limit safety valves

make-up water
purge differential
pressure
bypass
purge

valve

anti-scald mixing valve

cold
water

P1
DHW
temperature
sensor outdoor
temperature
sensor

OFF

T/P
P2

purge

thermal trap
Super Stor (w/ drain plug) Munchkin boiler
indirect DHW tank

NOTES:
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 downstream
of 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 pressure
drop operates by itself.
Fig. 8-2

19
 PIPING

Munchkin VISION 1 system Drawing 3B

(zoning with valves)
Domestic water heating mode

zone
high limit safety valves
OFF
make-up water
purge differential
pressure
bypass
purge

valve

anti-scald mixing valve

cold
water

OFF
DHW
temperature P1
sensor outdoor
temperature
sensor

T/P
P2

purge

thermal trap
Super Stor (w/ drain plug) Munchkin boiler
indirect DHW tank

NOTES:
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 downstream
of 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 pressure
drop operates by itself.
Fig. 8-3

20
 PIPING

Munchkin VISION 1 system Drawing 3C

(zoning with valves)
Space heating mode (w/ submixing)

3-way
(manually-set)
mixing valve

vent low temperature

manifold station
air handler

high limit safety

make-up water
purge differential
pressure
bypass
purge

balancing valve
valve

anti-scald
mixing valve
cold
water

DHW
temperature P1
sensor outdoor
temperature
sensor

OFF

T/P

P2

purge

thermal trap
Super Stor (w/ drain plug)
indirect DHW tank Munchkin boiler

NOTES:
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 downstream
of 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 pressure
drop operates by itself.
11. 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 Drawing 4A

(zoning with circulators)
Space heating mode

make-up water
zone
circulators
high limit safety

make-up water
purge
closely spaced tees
purge

anti-scald mixing valve

cold
water

DHW
temperature P1
sensor outdoor
temperature
sensor

OFF

T/P
P2

purge

thermal trap
Super Stor (w/ drain plug)
indirect DHW tank Munchkin boiler

NOTES:
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 downstream
of 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. 8-5

22
 PIPING

Munchkin VISION 1 system Drawing 4B

(zoning with circulators)
Domestic water heating mode

OFF

OFF

OFF
zone
circulators
high limit safety

make-up water
purge
closely spaced tees
purge

anti-scald mixing valve

cold
water

OFF
DHW
temperature P1
sensor outdoor
temperature
sensor

T/P
P2

purge

thermal trap
Super Stor (w/ drain plug)
indirect DHW tank Munchkin boiler

NOTES:
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 downstream
of 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. 8-6

23
 PIPING

Munchkin VISION 1 system Drawing 4C

(zoning with circulators)
Space heating mode (w/ submixing)
3-way
(manually-set)
mixing valve

vent
air handler

high limit safety low temperature

manifold station

make-up water
purge balancing
valve
purge

anti-scald mixing valve

cold
water

DHW
temperature P1
sensor outdoor
temperature
sensor

OFF

T/P

P2

purge

thermal trap
Super Stor (w/ drain plug)
indirect DHW tank Munchkin boiler

NOTES:
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 downstream
of 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. 8-7

24
 PIPING

Munchkin VISION 1 system Drawing 4E

(zoning with circulators)
Space heating mode (3 fully reset supply temperatures)

medium temperature
vent manifold station

air handler
(higher temp.)
vent

high limit safety

make-up water
low temperature
purge manifold station
purge

balancing
valves

3-way (manually-set) mixing valve

anti-scald mixing valve
cold
water

DHW
temp.
P1
outdoor
sensor temperature
sensor

OFF

T/P

P2

purge

thermal trap
Super Stor (w/ drain plug)
indirect DHW tank Munchkin boiler

NOTES:
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 downstream
of 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. 8-8

25
 PIPING

Munchkin VISION 1 system Drawing 4F

(zoning with circulators)
Space heating mode (3 different supply temperatures)

3-way manually-set
mixing valve
vent

air handler
(higher temp.)
vent
low temperature
manifold station

high limit safety

variable
make-up water speed
injection
purge mixing
purge

balancing
valves
medium
temperature
manifold station
anti-scald
mixing valve
cold
water purge

DHW
temp.
P1
outdoor
sensor temperature
sensor

OFF

T/P

P2

purge

thermal trap
Super Stor (w/ drain plug)
indirect DHW tank Munchkin boiler

NOTES:
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 downstream
of 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. 8-9

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
high limit safety
air handler

closely spaced tees

purge

purge
multi-zone
relay center

anti-scald
mixing valve

OFF

P1
outdoor
temperature
sensor

T/P
P2

differential pressure purge

bypass valve
thermal trap
Super Stor (w/ drain plug) Munchkin heater
indirect DHW tank

NOTES:
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 downstream
of 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 center

Fig. 8-10

27
 PIPING

Munchkin VISION 1 system Drawing 4H

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

OFF
make-up water
zone
circulators
high limit safety
air handler

closely spaced tees

purge

multi-zone purge
relay center

anti-scald
mixing valve

OFF

P1
outdoor
temperature
sensor

T/P
P2

purge

thermal trap
Super Stor (w/ drain plug) Munchkin heater
indirect DHW tank

NOTES:
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 downstream
of 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 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) Boiler & Indirect Temperature ( F) Resistance (ohms)
-22 171800 32 32550
-13 129800 41 25340
-4 98930 50 19870
5 76020 59 15700
14 58880 68 12490
23 45950 77 10000
32 36130 86 8059
41 28600 95 6535
50 22800 104 5330
59 18300 113 4372
68 14770 122 3605
77 12000 131 2989
86 9804 140 2490
95 8054 149 2084
104 6652 158 1753
113 5522 167 1481
176 1256
185 1070
194 915
203 786
212 667
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