MunchkinメーカーGas-Fired Hot Water Boilerの使用説明書/サービス説明書
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W ARNING This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing. P erform steps in the order given. Failure to comply could result in severe personal injury , death or substantial property damage.
GAS -FIRED BOILER Boiler Manual 1 CONTENTS P art 1 – P roduct and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 4 P art 2 – How The Boiler Operates . . . . . . . . . . . . . . . . . . . . . . . . .
2 GAS -FIRED BOILER Boiler Manual CONTENTS (CONT ’D) P art 8 – Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47 A. Gas Connection B. Gas Piping C. Gas T able D . Dungs Gas V alve P art 9 – Field Wiring .
3 GAS -FIRED BOILER Boiler Manual P ART 1: PRODUCT AND SAFETY INFORMA TION SPECIAL A TTENTION BO XES The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the product.
4 GAS -FIRED BOILER Boiler Manual P ART 1: PRODUCT AND SAFETY INFORMA TION (CONT ’D) Before Installing WHEN SERVICING BOILER • T o avoid electric shock, disconnect electrical supply before performing maintenance. • T o avoid severe burns, allow boiler to cool before performing maintenance.
5 GAS -FIRED BOILER Boiler Manual P ART 2: HOW BOILER OPERA TES Munchkin Condensing T echnology is an intelli- gent system that delivers highly efficient hydron- ic heating, while maximizing efficiency by meas- uring the Data P arameters of your heating sys- tem.
6 GAS -FIRED BOILER Boiler Manual P ART 2: HOW BOILER OPERA TES (CONT ’D) Also, an increase in pipe size may be necessary to drain properly . Support of the condensation line may be necessary to avoid blockage of the condensate flow . 11. Spark ignition The burner flame is ignited by applying a high voltage to the system spark electrode.
7 GAS -FIRED BOILER Boiler Manual Figure 2-1 T50M/T80M DIMENSIONS PERFORMANCE RA TINGS Input Modulation DOE Heating AFUE Shipping W eight *IBR 18,000 to 50,000 16,000 to 46,000 92% 58 lbs. 40,000 19,000 to 80,000 17,000 to 74,000 92% 58 lbs. 64,000 27,000 to 80,000 25,000 to 74,000 92% 75 lbs.
8 GAS -FIRED BOILER Boiler Manual DIMENSIONS 80M 140M/199M Figure 2-2 Figure 2-3.
9 GAS -FIRED BOILER Boiler Manual P ART 3: PREP ARE BOILER LOCA TION (CONTINUED) C. BEFORE LOCA TING THE BOILER 1. Check for nearby connection to: • System water piping • V enting connections • Gas supply piping • Electrical power 2 . Check area around boiler .
10 GAS -FIRED BOILER Boiler Manual or rain during operation or service. 4. If the Munchkin Boiler is to replace an existing boiler , check for and correct any existing system problems such as: • System leaks. • Incorrectly-sized expansion tank. • Lack of freeze protection in boiler water causing system and boiler to freeze and leak.
GAS -FIRED BOILER Boiler Manual 11 GAS -FIRED BOILER Boiler Manual vent piping can be routed through the building and properly terminated. The air intake and exhaust vent piping lengths, routing and termi- nation method must all comply with the methods and limits given in the V enting section.
12 GAS -FIRED BOILER Boiler Manual W ARNING T o avoid water damage or scalding due to relief valve operation: • Discharge line must be connected to relief valve outlet and run to a safe place of disposal. T erminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the valve discharge.
13 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) B. GENERAL PIPING INFORMA TION C. SEP ARA TE LOW W A TER CUTOFF A low water cutoff may be required by state local code or some insurance companies. Check code requirements before installation of the Munchkin Boiler .
14 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) diagrams, the space heating system is isolated from the boiler loop by the primary/secondary connection. 2. Size the piping and components in the space heating system using recognized design methods.
15 GAS -FIRED BOILER Boiler Manual 10. The Safety Relief V alve is installed at the factory . Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief . Pipe the discharge 6” above the drain to a drain. Provide piping that is the same size as the safety relief valve outlet.
16 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) I. FILL AND PURGE HEA TING SYSTEM • Attach the hose to balance and purge hose connector or drain valve and run hose to nearest drain • Close the other side of the balance and purge valve or the shut off valve after the drain.
17 GAS -FIRED BOILER Boiler Manual P ART 5: BOILER PIPING (CONTINUED) J . ZONING WITH ZONE V AL VES 1. Connect boiler to system as shown in 2A and 2B in Piping Details when zoning with zone valves. The primary/secondary piping shown ensures the boiler loop will have sufficient flow .
18 GAS -FIRED BOILER Boiler Manual Piping Symbol Legend circulator (w/ isolation flanges) gate valve globe valve ball valve swing-check valve flow-check valve spring-loaded check valve hose bib / boil.
19 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with valves) Space heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 2A make-up water zone valves NOTES: 1. This drawing is meant to show system piping concept only.
20 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with valves) Domestic water heating mode Munchkin boiler P1 Super Stor indirect DHW tank T/P Drawing 2B make-up water V1 zone valves anti-scald mixing valve purging valves closely spaced tees differential pressure bypass valve P2 NOTES: 1.
21 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
22 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (zoning with circulators) Domestic water heating mode Munchkin boiler make-up water Super Stor indirect DHW tank closely spaced tees P2 zone circulators T/P space heating zone circuit Drawing 2D purging valves NOTES: 1.
23 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
24 GAS -FIRED BOILER Boiler Manual Standard Munchkin boiler Preferred piping (multiple boilers / zoning with circulators) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
25 GAS -FIRED BOILER Boiler Manual P ART 6. BOILER PIPING WITH VISION I SYSTEM (DHW PRIORITY WITH OUTDOOR RESET) A. VISION I SYSTEM PIPING It is important that the system piping is done correctly when using the Vision 1 System. F ollow the piping diagrams 2A through 3G when piping your Munchkin Boiler with Vision I.
26 GAS -FIRED BOILER Boiler Manual D . BOILER PIPING DET AILS WITH THE VISION I SYSTEM Munchkin VISION 1 system (zoning with valves) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
27 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with valves) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
28 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with valves) Space heating mode (w/ submixing) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
29 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
30 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Domestic water heating mode NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
31 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode (w/ submixing) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
32 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode (3 fully reset supply temperatures) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
33 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system (zoning with circulators) Space heating mode (3 different supply temperatures) NOTES: 1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment & detailing required by local codes.
34 GAS -FIRED BOILER Boiler Manual anti-scald mixing valve Munchkin heater closely spaced tees purge purge make-up water high limit safety zone circulators outdoor temperature sensor thermal trap (w/ .
35 GAS -FIRED BOILER Boiler Manual Munchkin VISION 1 system Multiple high temperature priority loads controlled with zone circulators Multiple low temperature load controls with zone circulators NOTES: 1. This drawing is meant to show system piping concept only.
36 GAS -FIRED BOILER Boiler Manual b . Non Foam Core CPVC (Chlorinated P olyvinyl Chloride) Pipe conforming to ASTM D -1785. c . Non F oam Core ABS (Acrylonitrile - Butadiene- Styrene) Pipe conforming to ASTM D3965 Class 3-2-2-2-2. 2. Cellular foam core piping may be used on air inlet piping only .
37 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) f . P rovide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators and relief equipment.
38 GAS -FIRED BOILER Boiler Manual Location of exit terminals of mechanical draft and direct -vent venting systems. (Reference: National F uel Gas Code ANSI Z223.1/NFP A 54 2002). Fig. 7-2 Multiple V ent Spacing* *Note: Exhaust must extend out 1 foot Figure 7-4 Multiple Boiler Installations Fig.
39 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) E. EXHAUST VENT AND INT AKE AIR VENT SIZING 1. The exhaust vent and intake air vent pipes should be 2" for the T50/T80, 3" for the 80M/140M/199M and 4" for the 399M.
40 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) 40 or 80 pipe. FOAM CORE PIPING IS NO T APPROVED . 2. Remove all burrs and debris from joints and fittings. 3. All joints must be properly cleaned, primed, and cemented.
41 GAS -FIRED BOILER Boiler Manual P ART 7: VENTING, COMBUSTION AIR & CONDENSA TE REMOVAL (CONTINUED) I. CONDENSA TE REMOV AL SYSTEM This is a condensing high efficiency appliance, therefore this unit has a condensate removal system.
42 GAS -FIRED BOILER Boiler Manual J . DIA GRAMS FOR SIDEWALL VENTING GENERAL NOTE: All vent pipes must be glued, properly supported and the exhaust must be pitched a minimum of a ¼" per foot back to the heater (to allow drainage of condensate).
43 GAS -FIRED BOILER Boiler Manual VIEW TOP VIEW AND VERTICAL PIPING SUPPORT BRACKETS MUST BE USED ON ALL HORIZONTAL VENT KIT RIGHT SIDE EXTERIOR WALL NOTE: EXTENDED VENT RUNS WHEN TRANSITIONING TO A LARGER DIAMETER MUST ALWAYS TAKE PLACE IN A VERTICAL POSITION TO PREVENT CONDENSATE BLOCKAGE.
44 GAS -FIRED BOILER Boiler Manual Figure 7-13 Figure 7-14 K. DIAGRAMS FOR VERTICAL VENTING 10'-0" MIN. WHICHEVER IS GREATER 12" OVER MAXIMUM SNOW LEVEL OR 24" AND COUPLING (EXHAUS.
45 GAS -FIRED BOILER Boiler Manual A. GAS CONNECTION The gas supply shall have a maximum inlet pressure of less than 14" water column (350 mm), ½ pound pressure (3.5 kP a), and a mini- mum of 3.5" water column. The entire piping system, gas meter and regulator must be sized properly to prevent pressure drop greater than 0.
46 GAS -FIRED BOILER Boiler Manual P ART 8: GAS PIPING (CONTINUED) D . DUNGS GAS V AL VE FOR T50/T80/80M/140M/199M OFF SET ADJUSTMENT CAUTION: DO NOT REMOVE THIS SCREW OR ATTEMPT TO MAKE ANY ADJUSTMENT TO THIS SCREW WITHOUT A COMBUSTION ANALYZER SEE PART 12 SECTION "D" FOR COMBUSTION SETTING TABLE.
47 GAS -FIRED BOILER Boiler Manual P ART 9: FIELD WIRING A. INST ALLA TION MUST COMPL Y WITH: 1 . National Electrical Code and any other national, state, provincial or local codes or regulations. 2. In Canada, CSA C22.1 Canadian Electrical Code P art 1, and any local codes.
48 GAS -FIRED BOILER Boiler Manual P ART 9: FIELD WIRING (CONTINUED) Fig. 9-4 Fig. 9-3 Fig. 9-1 Fig. 9-2.
49 GAS -FIRED BOILER Boiler Manual P ART 9: FIELD WIRING (CONTINUED) Fig. 9-5.
50 GAS -FIRED BOILER Boiler Manual Outdoor Sensor Function The user can pro- gram the desired supply temperature based on the heat transmitter (Baseboard, Radiant Floor , Air Handler) that will be used in the installation.
51 GAS -FIRED BOILER Boiler Manual P ART 11. ST ART-UP PREP ARA TION A. CHECK/CONTROL WA TER CHEMISTRY W ater pH between 6.0 and 8.0 1. Maintain boiler water pH between 6.0 and 8.0. Check with litmus paper or have chemically analyzed by water treatment company .
52 GAS -FIRED BOILER Boiler Manual P ART 11. ST ART-UP PREP ARA TION (CONTINUED) 5. The system may have residual substances that could affect water chemistry . After the system has been filled and leak tested, verify water pH and chlorine concentrations are acceptable.
53 GAS -FIRED BOILER Boiler Manual P ART 11. ST ART-UP PREP ARA TION (CONTINUED) G . CHECK CONDENSA TE REMOV AL 1. The Munchkin Boiler is a high efficiency condensing boiler , there, the unit has a condensation drain.
54 GAS -FIRED BOILER Boiler Manual P ART 12. ST ART-UP PROCEDURE (CONTINUED) A. OPERA TING INSTRUCTIONS Remove boiler cover . If you smell gas, STOP . F ollow listed safety instructions. If you do not smell gas, follow the next steps. 1. T urn on all electric power to appliance.
55 GAS -FIRED BOILER Boiler Manual P ART 12. ST ART-UP PROCEDURE (CONTINUED) P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 Function V alue d5 — Actual T emperature from the outdoor sensor .
56 GAS -FIRED BOILER Boiler Manual P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 (CONTINUED) 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 con- troller program function will be cancelled and the control returns to normal operation.
57 GAS -FIRED BOILER Boiler Manual P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 (CONTINUED) Default Function Function Value Description 14 30 Min. Allows the installer to set the Maximum run time for the Indirect Fired W ater Heater and the Minimum run time for Central Heating.
58 GAS -FIRED BOILER Boiler Manual Fig. 13-3 P ART 13: ST ART-UP PROCEDURES WITH THE VISION 1 OPTION (CONTINUED) 50 32 41 167 158 149 131 122 113 104 77 59 68 86 95 212 203 194 185 176 201˚ SUPPLY OU.
59 GAS -FIRED BOILER Boiler Manual A. MUNCHKIN ERROR CODE An error code may occur in the installation of the Munchkin. This condition may lead to a lock out condition of the controller , which will need to be manually reset through the S4/Reset but- ton.
60 GAS -FIRED BOILER Boiler Manual P ART 14: TROUBLESHOOTING (CONTINUED) T able 14-2: 925 Control Board F AUL T Codes Code Description Remedy F00 High Limit Exceeded.
61 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE A. MAINTENANCE PROCEDURES P eriodic maintenance should be performed once a year by a qualified service technician to assure that all the equipment is in safe efficient operation.
62 GAS -FIRED BOILER Boiler Manual B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS *Before beginning this procedure, you must have on hand the following items: – a nylon, stainless or brass brush (not steel) – “Rydlyme” (recommended for best results) (available on line www .
63 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) 5 2 3 6 7 42 41 40 39 4 38 37 36 35 34 33 32 31 30 29 28 27 23 26 25 23 24 25 22 8 9 10 11 12 21 13 14 15 16 20 19 17 18 5 1 43 T50.
64 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 E xhaust Vent Pipe - 2" PVC N/A 17 5 Pin Wiring Harnes.
65 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Thermistor 7250P-667 18 Air/Gas Channel 7250P-685 (80M) 2 Thermodisc Flue ECO 210 F 7250P-089 7250P-687 (140M/199M) 3 Steel Push Retainer (Thermodisc Flue ECO) 7250P-151 19 Gasket (Flame Rec.
66 GAS -FIRED BOILER Boiler Manual REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Blocked Vent Pressure Swi tch 7250P-150 16 Cabinet Latch and Gasket Kit (w/Screws) 7250P-668 .
67 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) 30 31 11 6 4 1 2 3 5 4 8 9 7 12 13 14 15 16 17 18 19 20 21 22 19 23 24 25 26 27 28 29 10 REPLACEMENT PARTS Item # Description Part .
68 GAS -FIRED BOILER Boiler Manual P ART 15: MAINTENANCE (CONTINUED) 28 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 SWITCH 29 30 31 14 8 BOILER CONDENSATE OUTLET REPLACEMENT PARTS Item # Description Part # Item # Description Part # 1 Blocked Vent Pressure Switch 7250P-150 17 PVC Nipple Sch.
69 GAS -FIRED BOILER Boiler Manual BOILER ST ART UP REPORT Light Off Activities 1) Fill the heating system Check all piping and gas connections, verify they are all tight Pressurize System (12-15 PSI).
70 GAS -FIRED BOILER Boiler Manual BOILER INSPECTION AND MAINTENANCE SCHEDULE Inspection Activities Piping 1st Year 2nd Year 3rd Year 4th Year* Near Heater Piping Check heater and system piping for an.
71 GAS -FIRED BOILER Boiler Manual BOILER INSPECTION AND MAINTENANCE SCHEDULE (CONTINUED) Condensate 1st Year 2 Year 3 Year 4 Year* Condensate Neutralizer Check condensate neutralizer, replace if necessary Gas Pressure Pressure Drop Measure drop in pressure on light off (no more than 1" W.
72 MAINTENANCE NOTES.
73 MAINTENANCE NOTES.
74 MAINTENANCE NOTES.
© 2007 Heat T ransfer P roducts, Inc. LP -185 REV . 2 / 20/07.
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Munchkin Gas-Fired Hot Water Boilerをまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはMunchkin Gas-Fired Hot Water Boilerの技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Munchkin Gas-Fired Hot Water Boilerの取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Munchkin Gas-Fired Hot Water Boilerで得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Munchkin Gas-Fired Hot Water Boilerを既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はMunchkin Gas-Fired Hot Water Boilerの不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Munchkin Gas-Fired Hot Water Boilerに関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちMunchkin Gas-Fired Hot Water Boilerデバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
