Burnham Hydronics MMII User Manual

DNAGNITAREPO,NOITALLATSNI

ROFSNOITCURTSNIECIVRES

®

NAMETUNIM

II

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81404025R13-1/07 Price - $3.00

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.asp for the latest Approval Code or ask
your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels, or to important information concerning product life.

REGNAD

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GNINRAW

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Table of Contents

I. Pre-Installation ...............................4

II. Unpack Boiler ................................ 5

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ECITON

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,htaednitluserdluoc,dediovatonfi,hcihw

.sd

razahyrujnilanosrep

VI. Venting/Air Intake Piping ............. 11

VII. Electrical ....................................... 17

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ecnanetniamro,noitarepo,noitallatsni

otdetalertontubtnatropmierahcihw

III. Boiler Water Piping .........................5

IV. Domestic Hot Water Piping ............ 8

V. Gas Piping ......................................9

2

VIII. System Start-up ............................. 18

IX. Service Instructions ....................... 22

X. Repair Parts ..................................29

NOITUAC

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Figure 1: Dimensional Drawing

3

I. Pre-Installation

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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.
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.

CANADA CAN/CGA B149.1 or .2 Installation Codes

for Gas Burning Appliances and Equipment,
and CSA C22.1 Canadian Electrical Code,
Part I.

B. Appliance is design certifi ed for installation on

combustible fl ooring. The boiler must not be installed
on carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local fi re
ordinance. Refer to Figure 2 for minimum listed
clearance from combustible material. Recommended
service clearance is 24 inches from left side, right side,
front and rear. Service clearances may be reduced to
minimum clearances to combustible materials.

D. Install on level fl oor. For basement installation provide

concrete base if fl oor is not perfectly level or if water
may be encountered on fl oor around boiler.

E. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).

Figure 2: Minimum Clearances to Combustible Surfaces

4

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.

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II. Unpack Boiler

This boiler is equipped with a fan which produces an

induced draft through the unit. 100% of combustion air
is pulled in from outdoors and the fl ue gases are
exhausted to the outdoors through the intake air/vent
system. Refer to Section VI.

G. Do not install boiler where gasoline or other fl ammable

vapors or liquids, or sources of hydrocarbons (i.e.
bleaches, cleaners, chemicals, sprays, paint removers,
fabric softeners, etc.) are used or stored.

NOITUAC

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A. Move boiler to approximate installed position.
B. Remove all crate fasteners.

Figure 3: Removal From Skid

III. Water Piping and Trim

C. Remove outside container with all other inside

protective spacers and bracing. Save two of the

reliobpmubtonoD.reliobpordtonoD

wooden slats from the container sleeve for use in Steps
E and F.

D. Remove four (4) boiler hold-down fasteners. See

Figure 3.

E. Tilt the boiler to one side and slide a wooden slat under

the two nylon glides.

F. Tilt the boiler to the other side and slide another

wooden slat under the two nylon glides.

G. Slide the boiler forward or backward off the skid using

the two wooden slats as runners.

H. Move boiler to its permanent location.

NOITUAC

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A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water.

Oxygen contamination sources are system leaks

requiring addition of makeup water, fi ttings, and
oxygen permeable materials in distribution system.
Eliminate oxygen contamination by repairing system
leaks, repairing fi ttings, and using nonpermeable
materials in distribution system.

B. Connect system supply and return piping to boiler.

See Figure 4. Also consult I=B=R Installation and
Piping Guides. Maintain a clearance between hot water
piping and combustible construction as required by
local codes. In the absence of local codes, ½" clearance
should be used. Note that a system circulator is
required and is not supplied with the Minuteman II.

5

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

GNINRAW

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D. 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. Also consult I=B=R
Installation and Piping Guides.

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Refer to Figure 5a for a diagram of the water piping

system inside the Minuteman

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llatsnitonoD.ruccodluocgnizeerferehw

E. If boiler is connected to heating coils located in air

handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
fl ow control valves to prevent gravity circulation of
boiler water during operation of cooling system.

®

II's jacket.

F. Use a boiler bypass if the boiler is to be operated in a

system which has a large volume or excessive radiation
where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).

6

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 fl ow 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. Operate boiler until
system water temperature reaches normal operating
range.

Adjust valves to provide 180° to 200°F supply water

temperature. Opening the boiler supply valve will raise
system temperature, while opening the by-pass valve
will lower system supply temperature.

G. A hot water boiler installed above radiation level

must be provided with a low water cut-off device as
part of installation.

If a low water cut-off is required, it must be mounted in

the system piping above the boiler.

The minimum safe water level of a hot water boiler is

just above the highest water containing cavity of the
boiler; that is, a hot water boiler must be full of water to
operate safely.

It is required to perform a long term pressure test of the

hydronic system, the boiler should fi rst be isolated to
avoid a pressure loss due to the escape of air trapped in
the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must fi rst be removed from the
boiler.

A loss of pressure during such a test, with no visible

water leakage, is an indication that the boiler contained
trapped air.

H. Oil, grease, and other foreign materials which

accumulate in new hot water boilers and a new or
reworked system should be boiled out, and then
thoroughly fl ushed. A qualifi ed water treatment
chemical specialist should be consulted for
recommendations regarding appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.

Figure 5: Recommended Piping for Combination

Heating & Cooling (Refrigeration)

Systems

Figure 5a: Internal Water Piping System Diagram

I. After the boiler and system have been cleaned and

fl ushed, and before refi lling the entire system add
appropriate water treatment chemicals, if necessary, to
bring the pH between 7 and 11.

Figure 6: Recommended Bypass Piping

7

IV. Domestic Hot Water Performance and Piping

A. 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

RELIOB

LEDOM

07-4IIMM9.241

501-4IIMM1.361

501-5IIMM1.361

041-5IIMM3.381

WARDRETAW

)MPG(

B. Drain domestic water system.

1. Shut off cold water supply at main shutoff valve.

2. Open 1 or more system faucets to relieve pressure.
Open system drain valve, leaving faucets open to
relieve vacuum.

3. Disconnect exiting domestic hot water heating
system ( if applicable).

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Figure 7: Domestic Hot Water Piping

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C. Connect hot water piping to ½" NPT outlet of heater.

See Figure 7.

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D. Connect cold water piping to ½" NPT inlet of heater.

See Figure 7.

E. Fill domestic hot water system.

1. Open all faucets to allow air to purge from heater
and piping.

2. Open domestic hot water shutoff valve (if used).

3. Open cold water inlet shutoff valve.

4. Purge air from domestic water system. Close
faucets.

5. Check system for leaks. Repair as necessary.

8

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 pressure is stamped on the
rating label located in the boiler's vestibule
compartment.

2. Maximum gas demand. Table 2 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. cooking equipment).

3. Length of piping and number of fi ttings. Refer to
Table 3 for maximum capacity of Schedule 40 pipe.
Table 4 lists equivalent pipe length for standard
fi ttings.

Table 2: Rated Input

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4. Specifi c gravity of gas. Gas piping systems for gas
with a specifi c gravity of 0.70 or less can be sized
directly from Table 3, unless authority having
jurisdiction specifi es a gravity factor be applied. For
specifi c gravity greater than 0.70, apply gravity
factor from Table 5. If exact specifi c gravity is not
shown choose next higher value.

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, NFPA 54/
ANSI Z223.1, or size system using standard
engineering methods acceptable to authority having
jurisdiction.

B. Connect boiler gas valve to gas supply system.

1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, ANSI Z223.1.

2. Use thread (joint) compounds (pipe dope) resistant
to action of liquefi ed petroleum gas.

3. Install sediment trap, ground-joint union and manual

)sehcnI(eziS

shut-off valve upstream of boiler gas control valve
and outside of jacket. See Figure 8.

4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, ANSI/NFP A 70.

Table 3: Maximum Capacity of Schedule 40 Pipe in CFH For Gas Pressures of 0.5 psig or Less

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01231872025050,1571063086004,1

0229091053037021052564059

033725158209579002573077

043603154200528071023066

056551151204437151582085

0605501591004668310620

07646908107316521042094

08340907105375811022064

09044806102335011502034

001839705150305301591004

½¾ 1 ¼1½¾1¼1

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35

9

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Table 4: Fitting Equivalent Lengths

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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, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.

Table 5: Specifi c Gravity Correction Factors

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05.001.103.170.1

55.040.104.140.1

06.000.105.100.1

56.069.006.179.0

07.039.007.149.0

57.009.0

08.078.0

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2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonfl ammable
solution. Do not use matches, candles, open fl ames,
or other ignition source.

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10

Figure 8: Recommended Gas Piping

VI. Venting / Air Intake Piping

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Figure A: Burnham Vent

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A. General Guidelines.

1. Vent system installation must be in accordance with
National Fuel Gas Code, ANSI Z223.1, Venting of
Equipment, or applicable provisions of local
building codes. 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.
The following manufacturer's offer similar AL 29­4C® components and are approved for use with this
product: Heat-Fab Inc. - Saf-T-Vent, Flex-L
International Inc. - Star-34, Protech Systems, Inc. ­FasNSeal™, and Z-Flex U. S., Inc. - Z-Vent. The
use of these alternate manufacturer's venting
systems will require adapters to connect to the
Burnham supplied vent connector and vent terminal.
These adapters are not supplied with this unit and
should be obtained from the supplier of the alternate
manufacturer's venting system. See Table 7 for
complete parts list.

.tnalaesdnadnabpmalcahtiwdeilppussitnenopmoctnevssel-teksaghcaE

GNINRAW

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3. Vent length restrictions are based on equivalent
length of vent pipe (total length of straight pipe plus
equivalent length of fi ttings). Maximum vent length
is listed in Table 6. Do not exceed maximum vent/
air intake lengths. Table 7 lists equivalent length for
fi ttings. Do not include Vent Terminal or Vent
Connector in equivalent feet calculation.

Table 6: Vent/Air Intake Length

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403,dezinavlaghtiwreliobsihtesutonoD

nonrehtoynaroleetssselniats613ro

11

Table 7: Burnham Vent System Components

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tF5xepiP.aiD"3U00361185

elbatsujdAxepiP.aiD"3U9136118

woblE°09.aiD"3U49261185

woblE°54.aiD"3U29261185

eeTniarDlatnoziroH.aiD"3U2036118½

eeTn

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elbmihTllaWelgniS"36116118---

elbmihTllaWelbuoD"35116118---

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4. Do not install venting system components on the
exterior of the building except as specifi 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 not

involving the replacement of an existing boiler, proceed
to Step C.

When an existing boiler is removed from a common

venting system, the common venting system is likely to
be too large for proper venting of the remaining
appliances. At the time of removal of an existing boiler,
the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system
are not in operation:

1. Seal any unused openings in the common venting
system.

2. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
defi ciencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maxi mum
speed. Do not operate a summer exhaust fan. Close
fi replace dampers.

4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.

tnelaviuqE

epiPfoteeF

Adjust thermo stat so appliance will operate
continuously.

5. Test for spillage at the drafthood relief opening after
5 minutes of main burner operation. Use the fl ame
of a match or candle, or smoke from a cigarette,
cigar or pipe.

6. After it has been determined that each appliance
remain ing connected to the common venting system

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)46.1ot60.1(

properly vents when tested as outlined above, return
doors, win dows, exhaust fans, fi replace dampers and
any other gas burning appliance to their previous
conditions of use.

7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code,
ANSI Z223.1 and/or CAN/CGA B149, Installation
Codes. When resizing any portion of the common
venting system, the common venting system
should be resized to approach the minimum size as
determined using the appropriate tables in Part 11 in
the National Fuel Gas Code, ANSI Z223.1 and/or
CAN/CGA B149, Installation Codes.

C. Install Vent Connector.

1. Remove vent connector from vent accessory carton.

2. Remove gaskets, orifi ce plate and hardware from
blower outlet fl ange.

3. Assemble orifi ce plate gaskets, orifi ce plate, and
vent connector. See Figure 9.

Figure 9: Vent Connector Installation

12