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Table of Contents
Related Manuals for Burnham MINUTEMAN II
Summary of Contents for Burnham MINUTEMAN II
- Page 1 ® 81404025R14-12/08 Price - $3.00...
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Page 2: Table Of Contents
The New York City Department of Buildings has approved the Minuteman® II boiler: Approval No. MEA 332-93-E. The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Minuteman® II boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative. - Page 3 House Heating Domestic Water Coil Combustion Piping Connection Water Capacity Gas Supply Flue Vent Approx. Connection (Inches) Boiler Air Intake (Inches) Connection Connection Shipping Model Connection (Inches) (Dia. - Inches) Weight Supply Return Water IN Water OUT Boiler Tank (Dia. - Inches) (NPT) (NPT) (NPT)
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Page 4: Pre-Installation
I. Pre-Installation Appliance is design certified for installation on WARNING combustible flooring. The boiler must not be installed on carpeting. Carefully read all instructions before installing boiler. Failure to follow all instructions in proper Provide clearance between boiler jacket and order can cause personal injury or death. combustible material in accordance with local fire ordinance. Refer to Figure 2 for minimum listed . -
Page 5: Unpack Boiler
This boiler is equipped with a fan which produces an Provide combustion and ventilation air in accordance induced draft through the unit. 100% of combustion air with applicable provisions of local building codes, or is pulled in from outdoors and the flue gases are National Fuel Gas Code, ANSI Z223.1, Section 5.3, Air exhausted to the outdoors through the intake air/vent for Combustion and Ventilation. - Page 8 If boiler is used in connection with refrigeration Use a boiler bypass if the boiler is to be operated in a systems, boiler must be installed with chilled medium system which has a large volume or excessive radiation piped in parallel with the heating boiler using where low boiler water temperatures may be appropriate valves to prevent chilled medium from encountered (i.e.
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Page 9: Domestic Hot Water Performance And Piping
IV. Domestic Hot Water Performance and Piping . Domestic hot water ratings for the Minuteman II are ® based two 5 minute draws with 10 minute recovery period at 100°F average temperature rise. Refer to Table 1 for ratings. Table 1: Domestic Hot Water Ratings Boiler Model Water Draw Pressure Drop... -
Page 10: Gas Piping
V. Gas Piping 4. Specific gravity of gas. Gas piping systems for gas Size gas piping. Design system to provide adequate gas with a specific gravity of 0.60 or less can be sized supply to boiler. Consider these factors: directly from Table 3, unless authority having 1. Allowable pressure drop from point of delivery to jurisdiction specifies a gravity factor be applied. For boiler. Maximum allowable system pressure is ½ specific gravity greater than 0.60, apply gravity psig. - Page 11 NOTICE USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers' orifice sizing is indicated on the rating label. High altitude boiler models are identifiable by the model number suffix "H"...
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Page 12: Venting/Air Intake Piping
VI. Venting / Air Intake Piping NOTICE The gasketed vent system components pictured below in Figure A are being phased in and each vent component is interchangeable with the previously supplied gasket-less venting components. The newer vent components are generally quicker and easier to join, as they do not require the sealant application and their clamp bands are attached. - Page 13 5. Test for spillage at the drafthood relief opening after Table : Vent System Components 5 minutes of main burner operation. Use the flame Equivalent Feet of a match or candle, or smoke from a cigarette, Vent System Component Part Number of Pipe cigar or pipe. 3" Dia. Pipe x 1 Ft 8116296U 6.
- Page 14 Polybac #500 RTV, Sil-bond RTV 4500 (Acetoxy) Install Vent Pipe, General. and Sil-bond RTV 6500. Do not use other adhesives 1. Plan venting system to avoid possible contact with or sealants. plumbing or electrical wires. Start at vent connector. Work toward vent terminal. Install Vent Pipe, U.S. Boiler Gasket-Less Vent System. 2. Use non-combustible ¾ inch pipe strap to support horizontal runs and maintain vent location and slope 1. Procedure for Joining U.S. Boiler Gasket-Less Vent while preventing sags in pipe. Do not restrict Pipe and Fittings. See Figure 10A. thermal expansion or movement. Maximum support spacing is 5 feet. Do not penetrate any part of the vent system with fasteners. 3. Provide and maintain minimum 5 inch clearance to combustible materials. Use double wall thimble (Part No. 8116115) when penetrating combustible wall. Other wall thimble manufacturers are American Metal Products, Hart & Cooley, and Metal Fab. 4. Once a vent pipe manufacturer and system is chosen never mix and match vent systems. 5. If a non-standard length pipe is required: Figure 10A: U.S. Boiler Gasket-Less Vent Joint Detail The use of the adjustable length pipe (P/N 8116319U) is recommended to complete a non- a. Clean joints of pipe or fittings using an alcohol standard pipe length. This pipe requires a minimum pad to remove any dirt and grease.
- Page 15 SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM! f. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid condensate will not escape. 2. Procedure for joining the female end of U.S. Boiler Gasket-Less Vent with the male end of U.S. Boiler Gasketed Vent.
- Page 16 b. Alternate Installation (where recommended areas where local experience indicates installation is not practical): slope toward boiler. condensate or vapor from Category III Horizontal vent drain tee (see Table 7 for part appliances creates a nuisance or hazard . number) required. See Figure 12. b.
- Page 17 3. Use double wall thimble when passing through combustible outside wall (thimble use optional for noncombustible wall). Insert thimble through wall from outside. Secure outside flange to wall with nails or screws, and seal OD, ID and vent holes with sealant material. Install inside flange to inside wall, secure with nails or screws, and seal with sealant material.
- Page 18 Figure 1: Attic Offset Figure 1B: Vertical Vent Drain Tee Installation b. Secure to vertical vent tee with hose clamp or b. Vertical venting requires use of roof flashing (P/N 8116250) and storm collar (P/N 8116251) plastic cable tie. to prevent moisture from entering the structure. c. Run condensate drain line to floor drain or c.
- Page 19 Figure 18: Vertical Vent Termination Figure 1: Vertical Air Intake Termination Extend Vent/Air Intake Piping to maintain minimum vertical ("X") and minimum horizontal ("Y") distance of twelve (12) inches from roof surface. Allow additional vertical ("X") distance for expected snow accumulation.
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Page 20: Electrical
VII. Electrical General. Install wiring and ground boiler in accordance . Wire thermostat. Provide Class II circuit between with requirements of authority having jurisdiction, or in thermostat and boiler. Set thermostat heat anticipator to absence of such requirements the National Electrical 0.6 amps. -
Page 21: System Start-Up
VIII. System Start-up 10. Open isolation valve in boiler supply piping. Safe operation and other performance criteria were met with gas manifold and control assembly provided 11. Remove hose from hose bib. on boiler when boiler underwent tests specified in American National Standard for Gas-Fired Low- Prepare to check operation. Pressure Steam and Hot Water Boilers, ANSI Z21.13. - Page 22 Figure 21: Operating Instructions...
- Page 23 Table 9: Yellow LED Flame Codes Yellow LED Indicates Recommended Service Action Flash Code Heartbeat Normal Flame Signal Weak Flame Signal - System will operate reliably but flame signal is less than desired. Perform routine maintenance to Note: This indication may flash temporarily assure optimum flame signal.
- Page 24 Table 10: Green LED Status Codes Green Flash Indicates Next System Action Recommended Service Action Code (X + Y) No “Call for Heat” None Startup - Flame sense Flash Fast None calibration Heartbeat Normal operation None If system fails to light on next trial for 5 minute Retry Delay- ignition check gas supply, pilot burner, Initiate new trial for ignition after retry...
- Page 25 Figure 23: Troubleshooting Guide...
- Page 26 Sequence of Operation. See Figure 24. If boiler fails Check pilot burner flame. See Figure 25. Flame to operate properly, see Troubleshooting Tree on pages should be steady, medium hard blue enveloping 3/8 to 34 and 35. ½ inch of sensing probe. Figure 25: Pilot Burner Flame Check main burner flame.
- Page 27 a. Boiler must not be overfired. Reduce input rate . Ignition system safety device test. Disconnect ignitor/ by decreasing manifold pressure. Do not reduce sensor cable from Terminal 9 (SPARK). Gas valve more than 0.2 inch w.c. If boiler is still overfired, should close and pilot and main burners should contact your U.S. Boiler distributor or Regional extinguish.
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Page 28: Service
IX. Service 1. Clean terminal screens. Terminals must be free of General. Inspection and service should be conducted obstruction, undamaged, with screens securely in annually. Turn off electrical power and gas supply while place. conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. - Page 29 See Figure 9. Disconnect vent connector and vent 5. Install main burners by reversing procedure to pipe from blower outlet. remove burners. 3. Remove Jacket Top Panels. a. Pilot burner must be installed in original location. See Table 12. 4. Disconnect Red and Black Silicone Tubing from b.
- Page 30 Figure 2: Burner and Flueway Cleaning...
- Page 31 Figure 28: Silicone Tubing Assembly Table 12: Pilot Burner Location Boiler Main Burner with Pilot Burner Located Figure 2: Differential Pressure Measurement Model 60° Plot Bracket * Between Main Burners * MMII4-70 & 3 & 4 Table 13: Differential Pressure Switch Settings MMII4-105 Boiler Model Minimum Pressure...
- Page 32 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
- Page 33 SERVICE RECORD DATE SERVICE PERFORMED...
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Page 36: Repair Parts
X. Repair Parts All Minuteman II Repair Parts may be obtained through your local U.S. Boiler Wholesale ® distributor. Should you require assistance in locating a U.S. Boiler Distributor in your area, or have questions regarding the availability of U.S. Boiler products or repair parts, please contact U.S. - Page 39 [Quantity] Part Number Description MMII4-70 MMII4-105 MMII5-105 MMII5-140 3. Base Assembly Base Wrapper (w/o Insulation) [1] 718040431 [1] 718040531 Base Left & Right Side Insulation [2] 72004024 Base Rear Insulation [1] 72004022 [1] 72004023 Base Plate Assembly (Insulation attached) [1] 61804046 [1] 61804056 Burner Tray [1] 72104044...
- Page 41 [Quantity] Part Number Description MMII4-70 MMII4-105 MMII5-105 MMII5-140 (Nat.) Honeywell VR8204C6000 [1] 81660176 Gas Valve (LP) Honeywell VR8204C6018 [1] 81660180 Gas Manifold [1] 82204041 [1] 82204051 #49 Drill (Yellow) [5] 822655 [7] 822655 Natural Gas #43 Drill (Red) [5] 822634 Main Burner #44 Drill (Orange)
- Page 42 [Quantity] Part Number Description MMII4-70 MMII4-105 MMII5-105 MMII5-140 5. Jacket Assembly Complete Jacket Assembly [1] 60404002 Front Top Panel [1] 6040415 Rear Top Panel [1] 70404091 Fan Shroud [1] 71104004 Upper Rear Panel [1] 6040414 Lower Rear Panel [1] 6040413 Right Side Panel [1] 6040411 Vestibule Panel...
- Page 43 [Quantity] Part Number Description MMII4-70 MMII4-105 MMII5-105 MMII5-140 . Domestic Water Tank Assembly Insulated Tank Assembly [1] 60304032 Tank Assembly [1] 60304031 Jacket Attachment Bracket [8] 70404011 Self-Tapping Screw, 1/4" -20 x 1/2" Lg. [16] 80860700 Front Insulation [1] 72004067 Domestic Hot Water Coil [1] 6030401 Hex, Nut, 3/8"...
- Page 44 [Quantity] Part Number Description MMII4-70 MMII4-105 MMII5-105 MMII5-140 . Miscellaneous Trim and Controls Relief Valve, Conbraco 10-408-05 [1] 81660319 Control Center, Honeywell R8285D5001 [1] 80160155U Reverse-Acting Thermal Switch [1] 80160126 Water Pressure Switch [1] 80160191 Ignition Module, Honeywell S8670E3003 [1] 100959-01 Tank Aquastat, Honeywell L6189A2092 [1] 80160499 DPST Relay, Honeywell R8222V1029...
- Page 45 [Quantity] Part Number Description MMII4-70 MMII4-105 MMII5-105 MMII5-140 11. Vent Accessory Carton [1] 61110129 Vent Connector [1] 8116307 Vent Terminal [1] 8116310 12. Air Intake Terminal [1] 8110402...
- Page 46 SERVICE RECORD DATE SERVICE PERFORMED...
- Page 47 Alliance™ SL was originally installed. Optional Lifetime replacement 3. Any failure or malfunction that does not result from improper or negligent Warranty is not effective unless U.S. Boiler Company, Inc. - Burnham operation, accident, abuse (including freezing), misuse, unauthorized Hydronics receives completed registration card and payment within 30 days alteration or improper maintenance.
- Page 48 Burnham Hydronics Repair Parts Pricing where the heat exchanger last grade boiler involved. Some states do not allow the exclusion or limitation of appeared or the current retail price of the then nearest equivalent heat exchanger.