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Burnham Hydronics MMII Installation & Service Instructions Manual

Minuteman ii series direct vent gas - fired boiler / water heater
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Summary of Contents for Burnham Hydronics MMII

  • Page 1 81404025R13-1/07 ® Price - $3.00...

  • 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 either a Licensed Master Plumber or a Fire Suppression Piping Contractor supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Minuteman®...
  • Page 3 4 I I 4 I I 5 I I 5 I I Figure 1: Dimensional Drawing...

  • Page 4: Pre-Installation

    I. Pre-Installation . Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements, installation must conform to: ANSI Z223.1, National Fuel Gas Code. Where required by the authority having jurisdiction, the installation must also conform to ANSI/ASME CSD-1 Standard for Controls and Safety Devices for Automatically Fired Boilers.

  • Page 5: Unpack Boiler

    Provide combustion and ventilation air in accordance with applicable provisions of local building codes, or National Fuel Gas Code, ANSI Z223.1, Section 5.3, Air for Combustion and Ventilation. II. Unpack Boiler Move boiler to approximate installed position. Remove all crate fasteners. Figure 3: Removal From Skid III.
  • Page 6 Install Safety Relief Valve. See Figure 4. Safety Relief Valve must be installed with spindle in vertical position. Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler, see Figure 5.
  • Page 7 along with second tee in supply piping as shown in Figure 4. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figure 4 in order to regulate water fl...
  • Page 8 IV. Domestic Hot Water Performance and Piping . Domestic hot water ratings for the Minuteman 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 4 I I 4 I I 5 I I...

  • Page 9: Gas Piping

    V. Gas Piping Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information.
  • Page 10 t l i " " Table 4: Fitting Equivalent Lengths t t i ½ ° 5 ° 0 Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect boiler gas control valve. For all testing over ½...

  • Page 11: Venting/Air Intake Piping

    Contact local building or fi re offi cials about restrictions and installation inspection in your area. 2. This appliance requires a Special Gas Vent. The product is designed to use Burnham supplied ® AL 29-4C Stainless Steel vent system components.
  • Page 12 Table 7: Burnham Vent System Components " 3 " 3 " 3 " 3 " 3 ° 0 " 3 ° 5 " 3 " 3 " 3 " 3 4. Do not install venting system components on the exterior of the building except as specifi cally required by these instructions.
  • Page 13 Remove male (bead) end only – female (bell) end accepts next fi tting or pipe. 6. Seal all Burnham Gasket-Less vent, Burnham mixed Install Vent Pipe, Burnham Gasket-Less Vent System. 1. Procedure for Joining Burnham Gasket-Less Vent Figure 10A: Burnham Gasket-Less Vent Joint Install Vent Pipe, Burnham Gasketed Vent System.
  • Page 14 Install Vent Pipe, Burnham Gasket-Less & Gasketed Vent System. 1. Procedure for joining the male end of Burnham Gasket-Less Vent with the female end of Burnham Gasketed Vent. See Figure 10C. Figure 10C: Burnham Gasket-Less Male and Gasketed Female Vent Joint Detail a.
  • Page 15 terminal. See Figure 11. b. Alternate Installation (where recommended installation is not practical): slope toward boiler. Horizontal vent drain tee (see Table 7 for part number) required. See Figure 12. Figure 11: Recommended Horizontal Vent Installation Figure 12: Alternate Horizontal Vent Installaltion 2.
  • Page 16 d. Minimum 4 feet (6 feet in Canada) horizontally from electric meters, gas meters, regulators, and relief equipment. e. Minimum 12 inches from overhang or corner. 3. Use double wall thimble when passing through combustible outside wall (thimble use optional for noncombustible wall).
  • Page 17 Size opening to maintain 5 inch minimum clearance from combustible materials. b. Vertical venting requires use of roof fl ashing (available from Burnham - P/N 8116250) and storm collar (available from Burnham - P/N 8116251) to prevent moisture from entering the structure.

  • Page 18: Electrical

    may be installed with vertical venting and sidewall combustion air inlet if installation conditions do not allow alternate arrangement. 2. Use 4 inch diameter single wall metal pipe, fi ttings, fi restop(s), roof fl ashing and storm collar available at most heating distributors. 3.

  • Page 19: System Start-Up

    VIII. System Start-up Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specifi ed in American National Standard for Gas-Fired Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13. .
  • Page 20 Follow Operating Instructions to place boiler in operation. See Figure 22. Sequence of Operation. See Figure 21. If boiler fails to operate properly, see Troubleshooting Tree on pages 26-27. Check pilot burner fl ame. See Figure 24. Flame should be steady, medium hard blue enveloping 3/8 to ½...
  • Page 21 Figure 24: Pilot Burner Flame 20°F below boiler high limit setting to allow tank water to reach desired temperature before boiler water reaches the high limit setting. . Ignition system safety device test. Disconnect ignitor/ sensor cable from Terminal 9 (SPARK). Gas valve should close and pilot and main burners should extinguish.
  • Page 22 Do not reduce more than 0.2 inch w.c. If boiler is still overfi red, contact your Burnham distributor or Regional Offi ce for replacement Gas Orifi ces. b. Increase input rate if less than 98% of rating plate input.
  • Page 23 IX. Service General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 22. . Inspect domestic hot water coil gasket for water leakage.
  • Page 24 NOTE: If switch drops-out before boiler reaches temperature or if differential pressure readings are below minimums shown in Table 11, check for cracks in hoses or contact your nearest Burnham representative. 4. Stop boiler, remove manometer and reconnect hoses to pressure switch. See Figure 26.
  • Page 25 Figure 25: Burner and Flueway Cleaning...
  • Page 26 Figure 26: Silicone Tubing Assembly Table 10: Pilot Burner Location ° 0 & & Figure 27: Differential Pressure Measurement Table 11: Differential Pressure Switch Settings & & 4 I I " 0 4 I I " 0 5 I I "...
  • Page 27 Warning: This product contains refractory ceramic fi bers (RCF). RCF has been classifi ed as a possible human carcinogen. After this product is fi red, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health.

  • Page 30: Repair Parts

    II Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions re- garding the availability of Burnham products or repair parts, please contact Burnham Customer Ser- vice at (717) 481-8400 or Fax (717) 481-8408.
  • Page 33 & - l l " 2 - f l " 4 - f l " 6 " 6 " 6 4 I I " 2 " 8 " 1 " 2 " 2 " 4 t i t 4 I I 5 I I 5 I I...
  • Page 35 ) . t f i r " 8 - f l " 4 5 I I 4 I I l l i o l l l i r - - - l i r - - - - - - "...
  • Page 36 4 I I " 2 t i t 4 I I 5 I I 5 I I...
  • Page 37 - f l " 8 4 I I " 4 " 2 t i t 4 I I 5 I I 5 I I...
  • Page 38 , t i t i t 4 I I 4 I I 5 I I 5 I I...
  • Page 39 t i t 4 I I 4 I I 5 I I 5 I I...
  • Page 40 ® II Boiler/ if requested by U.S. Boiler Co., Inc., to ship these parts prepaid to Burnham Hydronics at the above address for inspection or repair. In addition, the owner agrees to make all reasonable efforts to settle any disagreement arising with a claim before resorting to legal remedies in the courts.

This manual is also suitable for:

Minuteman ii 4-70Minuteman ii 4-105Minuteman ii 5-105Minuteman ii 5-140