Burnham Hydronics MMII manual

81404025R13-1/07 Price - $3.00 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S N A M E T U N I M ® I I T N E V T C E R I D R E T A E H R E T A W / R E L I O B D E R I F - S A G , r e l i o b n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o [...]

2 T able of Contents N O I T U A C t u o h t i w t r a t s e r t o n d n a n w o d t u h s o t r e l i o b e h t e s u a c y a m h c i h w s l o r t n o c s n i a t n o c r e l i o b s i h T t f e l e b t o n d l u o h s m e t s y s g n i t a e h e h t , y t i l i b i s s o p a s i s e p i p n e z o r f o t e u d e g a m a d f I . e c i v r e s e h[...]

3 Figure 1: Dimensional Drawing G N I T A E H E S U O H G N I P I P N O I T C E N N O C ) S E H C N I ( R E T A W C I T S E M O D N O I T C E N N O C L I O C ) S E H C N I ( Y L P P U S S A G N O I T C E N N O C ) S E H C N I ( N O I T S U B M O C E K A T N I R I A N O I T C E N N O C ) S E H C N I - . A I D ( T N E V E U L F N O I T C E N N O C ) [...]

4 I. Pre-Installation G N I N R A W e r o f e b s n o i t c u r t s n i l l a d a e r y l l u f e r a C l l a w o l l o f o t e r u l i a F . r e l i o b g n i l l a t s n i e s u a c n a c r e d r o r e p o r p n i s n o i t c u r t s n i . h t a e d r o y r u j n i l a n o s r e p A . Installation must conform to the requirements of the authority[...]

5 II. Unpack Boiler N O I T U A C r e l i o b p m u b t o n o D . r e l i o b p o r d t o n o D . r o o l f t s n i a g a t e k c a j A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Remove outside container with all other inside protective spacers and bracing. Save two of the wooden slats from the container sleev[...]

6 Figure 4: Recommended W ater Piping for Zone V alve Zoned Heating Systems C. Install Safety Relief V alve. See Figure 4. Safety Relief V alve must be installed with spindle in vertical position. Installation of the relief valve must be consistent with the ASME Boiler and Pressure V essel Code, Section IV . G N I N R A W e b t s u m g n i p i p e [...]

7 Figure 6: Recommended Bypass Piping Figure 5: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems Figure 5a: Internal W ater Piping System Diagram Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in Figure 4. Bypass should be same size as the supply and return lines[...]

8 IV . Domestic Hot W ater Performance and Piping A . 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 T able 1 for ratings. Figure 7: Domestic Hot W ater Piping E . Fill domestic hot water system. 1. Open all faucets to allow air to purge fro[...]

9 V . Gas Piping A. 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. Minimum gas valve inlet pres[...]

10 T able 5: Speci fi c Gravity Correction Factors C. 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 psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolat[...]

11 VI. V enting / Air Intake Piping A. General Guidelines. 1. V ent system installation must be in accordance with National Fuel Gas Code , ANSI Z223.1, V enting of Equipment, or applicable provisions of local building codes. Contact local building or fi re of fi cials about restrictions and installation inspection in your area. 2. This appliance[...]

12 Figure 9: V ent Connector Installation 4. Do not install venting system components on the exterior of the building except as speci fi cally required by these instructions. 5. Thickness of exterior walls through which vent-air intake system may be installed: Minimum: 3", Maximum: 12". B. Removal of Existing Boiler . For installations n[...]

13 4. Secure vent connector with washers and locknuts. Do not overtighten. D. Install V ent Pipe, General. 1. Plan venting system to avoid possible contact with plumbing or electrical wires. Start at vent connector . W ork toward vent terminal. 2. Use non-combustible ¾ inch pipe strap to support horizontal runs and maintain vent location and slope[...]

14 Figure 10B: Burnham Gasketed V ent Joint Detail b. Align weld seams in pipes and use a slight twisting motion to FULL Y insert male end into female end of joint. Ensure bead in male end of pipe is below locking band and rest against the end of the female pipe. V erify the factory- installed gasket is not dislodged or cut. c. T ighten locking ban[...]

15 Figure 1 1: Recommended Horizontal V ent Installation a. Recommended Installation: slope toward vent terminal. See Figure 1 1. b. Alternate Installation (where recommended installation is not practical): slope toward boiler . Horizontal vent drain tee (see T able 7 for part number) required. See Figure 12. N O I T U A C s e c a f r u s n o m r o[...]

16 Figure 13: Horizontal V ent Pipe Wall Penetration Figure 14: Horizontal Air Intake Pipe W all Penetration 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 (th[...]

17 Figure 16: V ertical V ent Installation b. Secure to vertical vent tee with hose clamp or plastic cable tie. c. Run condensate drain line to fl oor drain or condensate pump. Condensate disposal must be acceptable to authority having jurisdiction. 3. Slope horizontal runs minimum ¼ inch per foot. Slope toward vertical vent drain tee. Position w[...]

18 VII. Electrical A. General. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Code , ANSI/NFP A 70, and/or the CSA C22.1 Electric Code. B. Install thermostat. Locate on inside wall approximately 4 feet above fl oor . Do not install on out[...]

19 VIII. System Start-up A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests speci fi ed in American National Standar d for Gas-Fir ed Low- Pr essur e Steam and Hot W ater Boilers, ANSI Z21.13. B . FILL ENTIRE HEA TING SYSTEM WITH W A TER and vent air from [...]

20 Figure 22: Operating Instructions G. Check main burner fl ame. See Figure 23. Flame should have clearly de fi ned inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping. H. Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. I. Check domestic hot [...]

21 Figure 23: Main Burner Flame 3. Main burners and pilot burner will extinguish and blower stop when water pressure drops below 10 psi. V erify limit, thermostat or other controls have not shut off boiler . 4. Close drain valve. 5. Adjust thermostat to lowest setting. Re fi ll boiler . L. Check Boiler High Limit. 1. Adjust thermostat to highest s[...]

22 T able 9: Gas Flow Rate in Cubic Feet per Hour 4. Determine Input Rate. Multiply gas fl ow rate by gas heating value. 5. Compare measured input rate to input rate stated on rating plate. a. Boiler must not be over fi red. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.2 inch w .c. If boiler is still over fi red, [...]

23 1. Clean terminal screens. T erminals must be free of obstruction, undamaged, with screens securely in place. 2. T erminal and wall thimbles (if used) must be weathertight. 3. Pipe must be full round shape, and show no damage from impact or excessive temperature. 4. Pipe must be supported at minimum 5 foot intervals and must not sag. 5. All vent[...]

24 5. Install main burners by reversing procedure to remove burners. a. Pilot burner must be installed in original location. See T able 10. b. Main burners must be properly secured in burner tray slot at rear of combustion chamber and over gas ori fi ce with hitch pin in place. See Figure 25. c. Burner access panel must be securely in place. d. V [...]

25 Figure 25: Burner and Flueway Cleaning[...]

26 T able 10: Pilot Burner Location Figure 26: Silicone T ubing Assembly Figure 27: Differential Pressure Measurement T able 1 1: Differential Pressure Switch Settings R E L I O B L E D O M M U M I N I M E R U S S E R P 0 7 - 4 I I M Mc w " 0 8 . 0 5 0 1 - 4 I I M Mc w " 0 8 . 0 5 0 1 - 5 I I M Mc w " 9 6 . 0 0 4 1 - 5 I I M Mc w &qu[...]

27 n o i t a m r o f n I y t e f a S t c u d o r P t n a t r o p m I t c u d o r P r e b i F c i m a r e C y r o t c a r f e R W arning : This product contains refractory ceramic fi bers (RCF). RCF has been classi fi ed as a possible human carcinogen. After this product is fi red, RCF may , when exposed to extremely high temperature (>1800F),[...]

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30 X. Repair Parts All Minuteman ® 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 (7[...]

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33 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 0 7 - 4 I I M M5 0 1 - 4 I I M M5 0 1 - 5 I I M M0 4 1 - 5 I I M M y l b m e s s A e s a B . 3 A 3) n o i t a l u s n I o / w ( r e p p a r W e s a B 1 3 4 0 4 0 8 1 7 ] 1 [1 3 5 0 4 0 8 1 7 ] 1 [ 1 A 3n o i t a l u s n I e d i S t h g i R & t f e L e s a B 4 2 0 4 0 0[...]

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35 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 0 7 - 4 I I M M5 0 1 - 4 I I M M5 0 1 - 5 I I M M0 4 1 - 5 I I M M A 4e v l a V s a G 0 0 0 6 C 4 0 2 8 R V l l e w y e n o H ) . t a N ( 6 7 1 0 6 6 1 8 ] 1 [ 8 1 0 6 C 4 0 2 8 R V l l e w y e n o H ) P L (0 8 1 0 6 6 1 8 ] 1 [A / N B 4d l o f i n a M s a G 1 4 0 4 0 2 2 [...]

36 . o N y e Kn o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 0 7 - 4 I I M M5 0 1 - 4 I I M M5 0 1 - 5 I I M M0 4 1 - 5 I I M M y l b m e s s A t e k c a J . 5 5y l b m e s s A t e k c a J e t e l p m o C 2 0 0 4 0 4 0 6 ] 1 [ A 5l e n a P p o T t n o r F 5 1 4 0 4 0 6 ] 1 [ B 5l e n a P p o T r a e R 1 9 0 4 0 4 0 7 ] 1 [ C 5d u o r[...]

37 . o N y e Kn o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 0 7 - 4 I I M M5 0 1 - 4 I I M M5 0 1 - 5 I I M M0 4 1 - 5 I I M M y l b m e s s A k n a T r e t a W c i t s e m o D . 6 6y l b m e s s A k n a T d e t a l u s n I 2 3 0 4 0 3 0 6 ] 1 [ A 6y l b m e s s A k n a T 1 3 0 4 0 3 0 6 ] 1 [ B 6t e k c a r B t n e m h c a t t A t [...]

38 . o N y e Kn o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 0 7 - 4 I I M M5 0 1 - 4 I I M M5 0 1 - 5 I I M M0 4 1 - 5 I I M M s l o r t n o C d n a m i r T s u o e n a l l e c s i M . 7 A 75 0 - 8 0 4 - 0 1 o c a r b n o C , e v l a V f e i l e R 9 1 3 0 6 6 1 8 ] 1 [ B 71 0 0 5 D 5 8 2 8 R l l e w y e n o H , r e t n e C l o r t n[...]

39 . o N y e Kn o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 0 7 - 4 I I M M5 0 1 - 4 I I M M5 0 1 - 5 I I M M0 4 1 - 5 I I M M n o t r a C y r o s s e c c A t n e V . 1 1 9 2 1 0 1 1 1 6 ] 1 [ A 1 1r o t c e n n o C t n e V 7 0 3 6 1 1 8 ] 1 [ B 1 1l a n i m r e T t n e V 0 1 3 6 1 1 8 ] 1 [ l a n i m r e T e k a t n I r i A . 2 1 2[...]

Subject to the terms and conditions set forth below, U.S. Boiler™ Co., Inc., Lancaster, Pennsylvania (“U.S. Boiler Co., Inc.”) hereby extends the following limited warranties to the original owner of a Minuteman ® II Boiler/Water Heater manufactured and shipped on or after July 1, 1996: ONE YEAR LIMITED WARRANTY ON MINUTEMAN ® II BOILER/WAT[...]