INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR M I N U T E M AN ® I I D I R EC T VEN T GAS - FI RED BOI LER / WATER HEATER F o r s e r vi c e o r r e p a i r s to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r. W he n s e e k i ng i nfo r m a ti o n o n b o i le r, p r o vi d e B o i le r M o d e l Num b e r a nd S e r i a l Num b e r a s s ho wn o n Ra ti ng L a b e l.
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® II boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.
HOUSE HEATING PIPING CONNECTION (INCHES) BOILER MODEL DOMESTIC WATER COIL CONNECTION (INCHES) GAS SUPPLY CONNECTION (INCHES) SUPPLY RETURN WATER WATER (NPT) (NPT) IN (NPT) OUT (NPT) COMBUSTION FLUE VENT AIR INTAKE CONNECTION CONNECTION (DIA. - INCHES) (DIA. - INCHES) WATER CAPACITY 'A' APPROX. SHIPPING WEIGHT 5-7/8 307 LB . 5-1/8 345 LB . BOILER TANK (GALLONS) (GALLONS) MMII4-70 2-1/2 MMII4-105 MMII5-105 1-1/4 1-1/4 1/2 1/2 1/2 4 3 17.
I. Pre-Installation WARNING C a r e fu lly r e a d a ll in s t r u c t io n s b e fo r e in s ta llin g b o ile r. F a ilu r e to fo llo w a ll in s t r u c t io n s in p r o p e r o r d e r c a n c a u s e p e r s o n a l in ju r y o r d e a t h . A. Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements, installation must conform to: USA ANSI Z223.1, National Fuel Gas Code.
F. 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. WAR N IN G Ad e q u a t e c o m b u s t i o n a n d v e n t i l a t i o n a i r m u s t b e p r o v id e d t o a s s u r e p r o p e r c o m b u s t io n . This boiler is equipped with a fan which produces an induced draft through the unit.
C. Install Safety Relief Valve. See Figure 4. Safety Relief Valve must be installed with spindle in vertical position. Installation of the relief valve must be consistent with the ASME Boiler and Pressure Vessel Code, Section IV. Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems WAR N IN G S a fe t y r e lie f v a lv e d is c h a r g e p ip in g m u s t b e p ip e d n e a r flo o r t o e lim in a t e p o t e n t ia l o f s e v e r e b u r n s .
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 with valves located in bypass and supply outlet as illustrated in Figure 4 in order to regulate water flow to maintain higher boiler water temperatures. After the boiler is operational (reference Section VII. System Start-Up) set by-pass and boiler supply valves to half throttle position to start.
IV. Domestic Hot Water 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 Table 1 for ratings. Table 1: Domestic Hot Water Ratings B OIL E R M OD E L WATE R D RAW ( GP M ) P RE S S URE D ROP (P S I) M M II4 - 7 0 2 .9 14 M M II4 - 1 0 5 3 .1 16 M M II5 - 1 0 5 3 .1 16 M M II5 - 1 4 0 3 .3 18 Figure 7: Domestic Hot Water Piping B. Drain domestic water system. 1.
V. Gas Piping A. Size gas piping. Design system to provide adequate gas 4. Specific gravity of gas. Gas piping systems for gas with a specific gravity of 0.70 or less can be sized directly from Table 3, unless authority having jurisdiction specifies a gravity factor be applied. For specific gravity greater than 0.70, apply gravity factor from Table 5. If exact specific gravity is not shown choose next higher value. supply to boiler. Consider these factors: 1.
N OT IC E U S A b o ile r s b u ilt fo r in s t a lla t io n a t a lt it u d e s g r e a t e r t h a n 2 ,0 0 0 fe e t a b o v e s e a le v e l h a v e b e e n s p e c ia lly o r ific e d t o r e d u c e g a s in p u t r a t e 4 p e r c e n t p e r 1 ,0 0 0 fe e t a b o v e s e a le v e l p e r t h e N a tio n a l F u e l Ga s C o d e , AN S I Z2 2 3 .1 , S e c t io n 8 .1 .2 a n d Ap p e n d ix F. C a n a d ia n b o ile r s ' o r ific e s iz in g is in d ic a t e d o n t h e r a t in g la b e l.
VI. Venting / Air Intake Piping N OT IC E T h e g a s k e te d v e n t s y s te m c o m p o n e n ts p ic tu r e d b e lo w in F ig u r e A a r e b e in g p h a s e d in a n d e a c h v e n t c o m p o n e n t is in te r c h a n g e a b le w ith th e p r e v io u s ly s u p p lie d g a s k e t- le s s v e n tin g c o m p o n e n t s .
Table 7: Burnham Vent System Components B ur nha m Ve nt S ys te m C o m p o ne nt B ur nha m P a rt Num b e r E q ui va le nt Feet of Pi pe 3" D i a. Pi pe x 1 Ft 8 11 6 2 9 6 U 1 3" D i a. Pi pe x 3 Ft 8 11 6 2 9 8 U 3 3" D i a. Pi pe x 5 Ft 8 11 6 3 0 0 U 5 3 " D i a . P i p e x A d jus ta b le 8 11 6 3 1 9 U E q ua l to Ins ta lle d L e ng th ( 1 .0 6 to 1 .6 4 ) 3 " D i a . 9 0 ° E lb o w 8 11 6 2 9 4 U 5 3 " D i a . 4 5 ° E lb o w 8 11 6 2 9 2 U 5 3 " D i a .
4. Secure vent connector with washers and locknuts. Do not overtighten. D. Install Vent Pipe, General. 1. Plan venting system to avoid possible contact with plumbing or electrical wires. Start at vent connector. Work toward vent terminal. 2. Use non-combustible ¾ inch pipe strap to support horizontal runs and maintain vent location and slope while preventing sags in pipe. Do not restrict thermal expansion or movement. Maximum support spacing is 5 feet.
e. Tighten locking band by HAND with a 5/16" nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM! Figure 10B: Burnham Gasketed Vent Joint Detail b. Align weld seams in pipes and use a slight twisting motion to FULLY 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. Verify the factoryinstalled gasket is not dislodged or cut. f.
a. Recommended Installation: slope toward vent 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. C AU T ION M o is t u r e a n d ic e m a y fo r m o n s u r fa c e s a r o u n d v e n t t e r m i n a l . To p r e v e n t d e t e r io r a t io n , s u r fa c e s s h o u ld b e in g o o d r e p a ir ( s e a le d , p a in t e d e t c .) 2.
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. 6. Insert vent pipe through thimble/opening from outside and join to vent system. Apply sealant between vent pipe and opening/thimble to provide weathertight seal. 3. Use double wall thimble when passing through combustible outside wall (thimble use optional for noncombustible wall). Insert thimble through wall from outside.
6. Whenever possible install vent straight through roof. Refer to Figure 17 if offset is necessary. Maintain 5 inch minimum clearance to combustible materials. Figure 16: Vertical Vent Installation b. Secure to vertical vent tee with hose clamp or plastic cable tie. c. Run condensate drain line to floor 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.
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, fittings, firestop(s), roof flashing and storm collar available at most heating distributors. 4. Maintain minimum of ¼ inch per foot slope in horizontal runs to air intake terminal. Slope down toward air intake terminal. 5. Seal all joints gas-tight, using silicone caulk or selfadhesive aluminum tape. 6.
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 specified in American National Standard for Gas-Fired LowPressure Steam and Hot Water Boilers, ANSI Z21.13. B. FILL ENTIRE HEATING SYSTEM WITH WATER and vent air from system. Use the following procedure on a Series Loop System equipped with zone valves. (See Figure 4). 1. Close isolation valve in boiler supply piping. 2.
Figure 22: Operating Instructions D. Follow Operating Instructions to place boiler in operation. See Figure 22. E. Sequence of Operation. See Figure 21. If boiler fails to operate properly, see Troubleshooting Tree on pages 26-27. G. Check main burner flame. See Figure 23. Flame should have clearly defined inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping. H. Check thermostat operation.
Figure 23: Main Burner Flame 3. Main burners and pilot burner will extinguish and blower stop when water pressure drops below 10 psi. Verify limit, thermostat or other controls have not shut off boiler. 4. Close drain valve. 5. Adjust thermostat to lowest setting. Refill boiler. L. Check Boiler High Limit. 1. Adjust thermostat to highest setting. 2. Observe temperature gauge. When temperature is indicated, adjust limit to setting below observed temperature.
4. Determine Input Rate. Multiply gas flow rate by gas heating value. Table 9: Gas Flow Rate in Cubic Feet per Hour 5. Compare measured input rate to input rate stated on rating plate. S e c o nd s fo r One Re vo luti o n One -Ha lf C u. F t. One C u. F t. Two C u. F t. 30 60 120 240 32 56 11 3 225 34 53 106 212 36 50 100 200 38 47 95 189 40 45 90 180 Remove Main Burners per procedure in Section IX: Service. 42 43 86 172 44 41 82 164 ii. Remove gas orifices.
IX. Service A. 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. CAUTION L a b e l a ll w ir e s p r io r to d is c o n n e c tio n w h e n s e r v ic in g c o n tr o ls . W ir in g e r r o r s c a n c a u s e i m p r o p e r a n d d a n g e r o u s o p e r a t i o n . Ve r i f y p r o p e r o p e r a tio n a fte r s e r v ic in g . B.
See Figure 9. Disconnect vent connector and vent pipe from blower outlet. 3. Remove Jacket Top Panels. 4. Disconnect Red and Black Silicone Tubing from Canopy. Pull tubing through Blower Access panel into vestibule. 5. Disconnect wiring harness from Blower Motor. 6. Remove Canopy/Blower Assembly. a. Remove four (4) machine screws securing canopy to heat exchanger. b. Remove ceramic fiber gasketing from top of heat exchanger. 5. Install main burners by reversing procedure to remove burners. a.
Figure 25: Burner and Flueway Cleaning 25
Figure 26: Silicone Tubing Assembly Table 10: Pilot Burner Location Figure 27: Differential Pressure Measurement B o i le r Mo d e l Ma i n B urne r wi th 6 0 ° P i lo t B ra c k e t * P i lo t B urne r L o c a te d B e twe e n Ma i n B urne rs * MM11 4 -7 0 & MM11 4 -1 0 5 3 3 & 4 MM11 5 -1 0 5 & MM11 5 -1 4 0 4 4 & 5 * M a i n b ur ne r s num b e r e d le ft to r i g ht a s vi e we d fr o m fr o nt o f b o i le r.
Im p o r t a n t P r o d u c t S a fe t y In fo r m a t io n R e fr a c t o r y C e r a m ic F ib e r P r o d u c t Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. After this product is fired, 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.
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 regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408. [Qua nti ty] P a rt Numb e r K e y No . D e s c r i p ti o n M M II4 -7 0 1 .
Key D e s c r i p ti o n No . [Qua nti ty] P a rt Numb e r M M II4 -7 0 M M II4 -1 0 5 M M II5 -1 0 5 M M II5 -1 4 0 3 .
Key No . [Qua nti ty] P a rt Num b e r D e s c r i p ti o n M M II4 -7 0 M M II4 -1 0 5 (Na t.
[Qua nti ty] P a rt Numb e r K e y No . D e s c r i p ti o n M M II4 -7 0 M M II4 -1 0 5 M M II5 -1 0 5 5 .
[Qua nti ty] P a rt Num b e r K e y No . D e s c r i p ti o n M M II4 -7 0 M M II4 -1 0 5 M M II5 -1 0 5 M M II5 -1 4 0 6 . D o m e s tic Wa te r Ta n k As s e m b ly 6 Ins ula te d Ta nk A s s e m b ly [1 ] 6 0 3 0 4 0 3 2 6A Ta nk A s s e m b ly [1 ] 6 0 3 0 4 0 3 1 6B J a c k e t A tta c hm e nt B r a c k e t [8 ] 7 0 4 0 4 0 11 6C S e lf- Ta p p i ng S c r e w, 1 /4 " - 2 0 x 1 /2 " L g .
[Qua nti ty] P a rt Numb e r K e y No . D e s c r i p ti o n M M II4 -7 0 M M II4 -1 0 5 M M II5 -1 0 5 M M II5 -1 4 0 7 .
[Qua nti ty] P a rt Numb e r K e y No . D e s c r i p ti o n M M II4 -7 0 11 . Ve n t Ac c e s s o r y C a r to n M M II4 -1 0 5 M M II5 -1 0 5 [1 ] 6 111 0 1 2 9 11 A Ve nt C o nne c to r [1 ] 8 11 6 3 0 7 11 B Ve nt Te r m i na l [1 ] 8 11 6 3 1 0 1 2 .
Limited Warranty FOR MINUTEMAN® II BOILER/WATER HEATER 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/WATER HEATER U.S. Boiler Co., Inc.
