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Burnham Minuteman II 4-105, Installation & Service Instructions Manual

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Burnham Minuteman II 4-105 Installation & Service Instructions Manual Download Page 24

24

5.  Install main burners by reversing procedure to 

remove burners.

a.  Pilot burner must be installed in original 

location. See Table 10.

b.  Main burners must be properly secured in burner 

tray slot at rear of combustion chamber and over 
gas orifi ce with hitch pin in place. See Figure 25.

c.  Burner access panel must be securely in place.

d.  Verify that Combustion Air Diffuser is securely 

in place.

e.  If Flame Roll-out Switch wires were 

disconnected, they must be reconnected.

f.  Air Intake Box Cover must be installed.

G.

 Check operation.

 Follow steps C through L from 

Section VIII: System Start-up.

H.

 

Procedure for Measuring Fan Differential Pressure.

 

(See Figure 27).

1.  With boiler off, remove gray and black hoses at 

differential pressure switch.

2.  With tees, connect water manometer as shown with 

additional tubing.

3.  Start boiler and read pressure on manometer when 

boiler water temperature reaches operating 
temperature.  Refer to Table 11 for minimum 
readings.

 

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.

I. 

Lubrication

 

There are no parts requiring lubrication on the part of 
the Service Technician or the User.  Circulator bearings 
are water lubricated.  Combustion blower motor uses 
sealed bearings.  

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 fi ber gasketing from top of heat 

exchanger.

c.  Pry canopy from boiler sections.

7. Inspect fl ue passages.  Clean with fl ue brush.  See 

Figure 25.

8.  Inspect heating surface in combustion chamber.  

Clean with straight handle wire brush.

9.  Replace Canopy/Blower Assembly and seal using 

ceramic fi ber gasketing.  Refer to Key No. 2  in 
Repair Parts Section for quantity and part number.

10. Connect Silicone Tubing between Pressure Fittings  

  on Canopy Assembly and Pressure Switch.  See  
 Figure 26.

11. Install Jacket Top Panels.

12. Connect vent system.  See Figure 9.

13. Connect Blower Motor Wiring Harness.

F

.  Main Burners and Combustion Chamber.

1.  Vacuum combustion chamber.  Exercise care - do 

not damage base insulation.

2.  Clean main burners. Brush top of  burners with soft 

bristle brush. See Figure 25. Vacuum to remove any 
dirt and lint.

3.  Vacuum tip of pilot burner.

4.  Check gas orifi ces for lint and dirt. Clean as 

necessary.

Summary of Contents for Minuteman II 4-105

Page 1: ... 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 b o t s r i a p e r r o e c i v r e s r o F l e b a L g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e b m u N l e d o M r e l i o B _ _ _ _ _ _ _ I I M M r e b m u N l a i r e S r e l i o B _ _ _ _ _ _ _ 6 e t a D n o i t a l l a t s n I r o t c a r t n o...

Page 2: ...a m d e d i o v a t o n f i h c i h w y t r e p o r p r o y r u j n i r o n i m r o e t a r e d o m e g a m a d E C I T O N n o s n o i t c u r t s n i l a i c e p s s e t a c i d n I e c n a n e t n i a m r o n o i t a r e p o n o i t a l l a t s n i o t d e t a l e r t o n t u b t n a t r o p m i e r a h c i h w s d r a z a h y r u j n i l a n o s r e p The New York City Department of Buildings ...

Page 3: ...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 S E H C N I A I D Y T I C A P A C R E T A W A X O R P P A G N I P P I H S T H G I E W R E L I O B L E D O M Y L P P U S T P N N R U T E R T P N R E T A W T P N N I R E T A W T P N T U O R E L I O B S N O L L A G K N A T S N O L L A G 0 7 4 I I M M 4 1 1 4 1 1 2 1 2 1 2 1 4 3 2 1 2 6 7 1 8 7 5 B L 7 0 3 5 0 1 4 I I M M ...

Page 4: ...nces and Equipment and CSA C22 1 Canadian Electrical Code Part I B Appliance is design certified for installation on combustible flooring The boiler must not be installed on carpeting C Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance Refer to Figure 2 for minimum listed clearance from combustible material Recommended service clearance is 24 ...

Page 5: ... t n o c III Water Piping and Trim Figure 3 Removal From Skid 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 fittings and oxygen permeable materials in distribution system Eliminate oxygen contamination by repairing system leaks repairing fittings and using nonpermeable m...

Page 6: ...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 Refer to Figure 5a for a diagram of the water piping system inside the Minuteman II s jacket E If boiler is connected to heating ...

Page 7: ...w 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 H Oil grease and other foreign materials which accumulate in new hot water boilers and a new or reworked system should be boiled out ...

Page 8: ...t 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 C Connect hot water piping to NPT outlet of heater See Figure 7 G N I N R A W g n i r e p m e t e v l a v g n i x i m c i t a m o t u a n a l l a t s n I k s i r d i o v ...

Page 9: ...nce 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 liquefied petroleum gas 3 Install sediment trap ground joint union and manual shut off valve upstream of boiler gas control valve and outside of jacket See Figure 8 4 All above ground gas piping upstre...

Page 10: ...s e c i f i r o s r e l i o b n a i d a n a C F x i d n e p p A d n a 2 1 8 n o i t c e S 1 3 2 2 Z I S N A e d o C s a G l e u F l a n o i t a N l e d o m e h t y b e l b a i f i t n e d i e r a s l e d o m r e l i o b e d u t i t l a h g i H l e b a l g n i t a r e h t n o d e t a c i d n i s i g n i z i s l e b a l g n i t a r e h t n o H x i f f u s r e b m u n Table 4 Fitting Equivalent Lengt...

Page 11: ... r u g i F n i w o l e b d e r u t c i p s t n e n o p m o c m e t s y s t n e v d e t e k s a g e h T g n i t n e v s s e l t e k s a g d e i l p p u s y l s u o i v e r p e h t h t i w e l b a e g n a h c r e t n i s i t n e n o p m o c t n e v o d y e h t s a n i o j o t r e i s a e d n a r e k c i u q y l l a r e n e g e r a s t n e n o p m o c t n e v r e w e n e h T s t n e n o p m o c d e h...

Page 12: ...or Operating Instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the drafthood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above retu...

Page 13: ...sive wheel Remove male bead end only female bell end accepts next fitting or pipe E C I T O N r o d e l i f d n a e p i p h t i w e r a u q s e b t s u m t u C y l l u f e r a C g n i n i o j e r o f e b h t o o m s d e d n a s h t i w d n a h y b e p i p t u c f o s s e n d n u o r e r u s n e V T R h t i w t n i o j l a e S g n i l l a t s n i e r o f e b s e v o l g l a u n a m s i h t n i d e ...

Page 14: ... Female Vent Joint Detail Figure 10D Burnham Gasket Less Female and Gasketed Male Vent Joint Detail a Clean joints of pipe or fittings using an alcohol pad to remove any dirt and grease b Slip a locking band over female bell end of pipe fitting c Apply a continuous inch bead of sealant around male end of joint no more than 1 8 inch from end d Align weld seams in pipes and use a slight twisting mot...

Page 15: ...e t n i a p d e l a e s r i a p e r 2 Vent terminal location restricted per following a Minimum 12 inches above grade or normally expected snow accumulation level or 7 feet above grade if located adjacent to public walkway Do not install over public walkways or areas where local experience indicates condensate or vapor from Category III appliances creates a nuisance or hazard b Minimum 3 feet abov...

Page 16: ...ze opening such that female bell end with locking band attached cannot pass through 5 Join vent terminal to vent pipe Locate vent terminal between 3 and 6 from wall when joined to inside vent piping See Figure 13 Figure 15 Vent Air Intake Terminal Relationship Horizontal thru wall or Vertical thru roof 6 Insert vent pipe through thimble opening from outside and join to vent system Apply sealant be...

Page 17: ...gure 19 Vertical Air Intake Termination 6 Whenever possible install vent straight through roof Refer to Figure 17 if offset is necessary Maintain 5 inch minimum clearance to combustible materials 7 Install Vent Terminal See Figure 18 a Locate roof opening to allow vertical vent penetration Size opening to maintain 5 inch minimum clearance from combustible materials b Vertical venting requires use ...

Page 18: ...0 hertz less than 12 amperes A separate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions Connect circuit to black and white wires and green ground screw See Figure 20 Figure 20 Wiring Diagram may be installed with vertical venting and sidewall combust...

Page 19: ...pen hose bib 6 Open manual fill valve Make up water line should be located directly above isolation valve in boiler supply piping 7 Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds 8 Open zone valve to the second zone to be purged then close the first Repeat this step until all zones have been purged but always have one zone open At completion open all zo...

Page 20: ...d stop boiler operation I Check domestic hot water tank aquastat operation Raise and lower temperature setting to start and stop boiler operation Tank aquastat should be set at least 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 F Check pilot burner flame S...

Page 21: ... be stamped on the rating label located in the boiler s vestibule compartment Adjust gas valve pressure regulator as necessary turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure If pressure cannot be attained check gas valve inlet pressure If less than minimum indicated on the boiler s rating label contact gas supplier for assistance 3 C...

Page 22: ...dure in Section IX Service ii Remove gas orifices Drill one 1 drill size larger drill size is stamped on orifice or see Key No 4C in Section X Repair Parts iii Reinstall gas orifices and main burners Measure input rate 6 Recheck Main Burner Flame 7 Return other gas fired appliances to previous conditions of use N Review User s Information Manual and system operation with owner or operator s d n o ...

Page 23: ...ly while conducting service or maintenance Follow instructions TO TURN OFF GAS TO APPLIANCE See Figure 22 N O I T U A C n e h w n o i t c e n n o c s i d o t r o i r p s e r i w l l a l e b a L e s u a c n a c s r o r r e g n i r i W s l o r t n o c g n i c i v r e s y f i r e V n o i t a r e p o s u o r e g n a d d n a r e p o r p m i g n i c i v r e s r e t f a n o i t a r e p o r e p o r p B In...

Page 24: ...cation There are no parts requiring lubrication on the part of the Service Technician or the User Circulator bearings are water lubricated Combustion blower motor uses sealed bearings 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 Disco...

Page 25: ...25 Figure 25 Burner and Flueway Cleaning ...

Page 26: ... M c w 0 8 0 5 0 1 4 I I M M c w 0 8 0 5 0 1 5 I I M M c w 9 6 0 0 4 1 5 I I M M c w 9 6 0 r e l i o B l e d o M h t i w r e n r u B n i a M t e k c a r B t o l i P 0 6 d e t a c o L r e n r u B t o l i P s r e n r u B n i a M n e e w t e B 0 7 4 1 1 M M 5 0 1 4 1 1 M M 3 4 3 5 0 1 5 1 1 M M 0 4 1 5 1 1 M M 4 5 4 f o t n o r f m o r f d e w e i v s a t h g i r o t t f e l d e r e b m u n s r e n r...

Page 27: ...ive gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard use...

Page 28: ...28 ...

Page 29: ...29 ...

Page 30: ...N y e K e e S E 2 t e l t u O n a F e t a l P e c i f i r O 5 5 0 4 0 1 1 7 1 6 5 0 4 0 1 1 7 1 7 5 0 4 0 1 1 7 1 8 5 0 4 0 1 1 7 1 F 2 B 2 w d e d u l c n i t e l t u O n a F t e k s a G 5 3 0 6 0 2 8 2 G 2 B 2 w d e d u l c n i g n i t n u o M r e w o l B t e k s a G 9 4 0 6 0 2 8 1 H 2 g n o L 2 2 x D I 6 1 3 g n i b u T e n o c i l i S h t g n e L y f i c e p S 6 0 0 6 1 0 9 J 2 g n o L 8 1 x ...

Page 31: ...31 ...

Page 32: ...32 ...

Page 33: ... c A r e n r u B 5 4 0 4 0 1 2 6 1 5 5 0 4 0 1 2 6 1 1 E 3 l e n a P s s e c c A r e n r u B 1 1 4 0 4 0 1 2 7 1 1 1 5 0 4 0 1 2 7 1 2 E 3 t e k c a r B g n i t n u o M w h c t i w S t u O l l o R e m a l F 0 6 0 6 1 0 6 1 F 3 r e s u f f i D r i A n o i t s u b m o C 5 4 0 4 0 1 2 7 1 5 5 0 4 0 1 2 7 1 G 3 d e h c a t t a n o i t a l u s n i y l b m e s s A l e n a P t n o r F e s a B 4 4 0 4 0 8...

Page 34: ...34 ...

Page 35: ... 4 5 5 3 6 2 2 8 5 D 4 p i l C n i P h c t i H 4 0 6 2 2 8 5 4 0 6 2 2 8 7 E 4 g L 0 3 x D O 8 1 g n i b u T t o l i P 0 1 1 6 3 2 8 1 F 4 2 3 0 8 4 9 3 l l e w y e n o H e l b a C r o s n e S n o i t i n g I 1 2 1 6 3 2 8 1 G 4 t o l i P y l b m e s s A 3 3 3 1 A 8 4 3 Q l l e w y e n o H s a G t a N 4 0 1 6 3 2 8 1 1 4 3 1 A 8 4 3 Q l l e w y e n o H P L 7 0 1 6 3 2 8 1 A N H 4 t e k c a r B t o...

Page 36: ... 5 d u o r h S n a F 4 0 0 4 0 1 1 7 1 D 5 l e n a P r a e R r e p p U 4 1 4 0 4 0 6 1 E 5 l e n a P r a e R r e w o L 3 1 4 0 4 0 6 1 F 5 l e n a P e d i S t h g i R 1 1 4 0 4 0 6 1 G 5 l e n a P e l u b i t s e V 7 1 4 0 4 0 6 1 H 5 l e n a P k c i K 1 1 1 0 4 0 7 1 J 5 l e n a P e d i S t f e L 2 1 4 0 4 0 6 1 K 5 l e n a P t n o r F r e w o L 1 2 0 4 0 4 0 7 1 L 5 r o o D e l b a v o m e R 1 4...

Page 37: ...a T 1 3 0 4 0 3 0 6 1 B 6 t e k c a r B t n e m h c a t t A t e k c a J 1 1 0 4 0 4 0 7 8 C 6 g L 2 1 x 0 2 4 1 w e r c S g n i p p a T f l e S 0 0 7 0 6 8 0 8 6 1 D 6 n o i t a l u s n I t n o r F 7 6 0 4 0 0 2 7 1 E 6 l i o C r e t a W t o H c i t s e m o D 1 0 4 0 3 0 6 1 F 6 6 1 8 3 t u N x e H 3 2 4 0 6 8 0 8 0 1 G 6 t e k s a G l i o C 6 3 0 6 0 2 8 1 H 6 n o i t a l u s n I r e p p a r W k ...

Page 38: ...d o M n o i t i n g I 8 0 1 0 6 1 0 8 1 F 7 2 9 0 2 A 9 8 1 6 L l l e w y e n o H t a t s a u q A k n a T 9 9 4 0 6 1 0 8 1 G 7 9 2 0 1 V 2 2 2 8 R l l e w y e n o H y a l e R T S P D 5 3 1 0 6 1 0 8 1 H 7 7 0 0 o c a T r o t a l u c r i C 7 0 0 6 5 0 8 1 J 7 3 0 2 0 3 5 3 o c a r b n o C e v l a V n i a r D 1 6 0 3 0 6 6 0 8 1 K 7 6 0 0 1 U 2 2 2 8 R l l e w y e n o H y a l e R T S P D U 6 9 0 0 ...

Page 39: ...Q 0 7 4 I I M M 5 0 1 4 I I M M 5 0 1 5 I I M M 0 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 1 r o t c e n n o C t n e V 7 0 3 6 1 1 8 1 B 1 1 l 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 0 4 0 1 1 8 1 ...

Page 40: ...ance with U S Boiler Co Inc s recommendations and hydronics industry standards These warran ties will be inapplicable if the Minuteman II Boiler Water Heater is used or operated over its rated capacity is subjected to unauthorized modification or is damaged as a result of being otherwise improperly operated or serviced including but not limited to damage from any of the following operation with in...

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