Burnham Minuteman II Installation, Operating And Service Instructions Download Page 36

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X. Repair Parts

All Minuteman

II Repair Parts may be obtained through your local U.S. Boiler Wholesale

distributor. Should you require assistance in locating a U.S. Boiler Distributor in your area,

or have questions regarding the availability of U.S. Boiler products or repair parts, please

contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408.

Key

No.

Description

[Quantity] Part Number

MMII4-70

MMII4-105

MMII5-105

MMII5-140

1. Heat Exchanger Assembly

[1] 61704042

[1] 61704052

2. Canopy/Blower Assembly

Canopy

[1] 61104044

[1] 61104043

[1] 61104053

[1] 61104054

Blower, Fasco #7062-3101

[1] 6111715

Flue Monitor

[1] 80160622

Vent Connector

See Key No. 11

Orifice Plate, Fan Outlet

[1] 71104055

[1] 71104056

[1] 71104057

[1] 71104058

Gasket, Fan Outlet (Included w/2B)

[2] 8206035

Gasket, Blower Mounting (Included w/2B)

[1] 8206049

Silicone Tubing, 3/16" I.D. x 22" Long

9016006 (Specify Length)

Silicone Tubing, 3/16" I.D. x 18" Long

9016007 (Specify Length)

Static Pressure Fitting, Dwyer #A308

[2] 822657

Nut, Hex Steel Panel, 3/8" -24

[1] 80860476

Washer, Flat 3/8"

[1] 80860656

Cap Screw, Hex Hd., 1/4" -20 x 1" Lg.

[4] 80861358

Washer, Flat 1/4", SAE, Plated

[12] 80860633

Lock Nuts 1/4" -20

[4] 80860456

Nut, Brass Hex, 1/4" -20 (Included w/2B)

[4] 80860424

3. Cerafelt Gasketing (not depicted)

Canopy to Heat Exchanger

[1] 7206016

Summary of Contents for Minuteman II

Page 1: ... 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 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 M M I I r e b m u N l a i r e S r e l i o B 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 C g n i t a e...

Page 2: ...ot Water Performance and Piping 9 V Gas Piping 10 VI Venting Air Intake Piping 12 VII Electrical 20 VIII System Start up 21 IX Service 28 X Repair Parts 36 DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious in...

Page 3: ... Supply Connection Inches Combustion Air Intake Connection Dia Inches Flue Vent Connection Dia Inches Water Capacity A Approx Shipping Weight Supply NPT Return NPT Water IN NPT Water OUT NPT Boiler Gallons Tank Gallons MMII4 70 1 1 4 1 1 4 1 2 1 2 1 2 4 3 2 1 2 17 6 5 7 8 307 lb MMII4 105 MMII5 105 3 5 1 8 345 lb MMII5 140 ...

Page 4: ... 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 inches from left side right side front and rear Service c...

Page 5: ...gen 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 materials in distribution system B Install Pressure Relief Valve See Figure 4 or 5 Pressure Relief Valve must be installed with spindle in vertical position Ins...

Page 6: ... Figure 4 Recommended Boiler Piping For Circulator Zoned Heating Systems ...

Page 7: ... Figure 5 Recommended Water Piping for Zone Valve Zoned Heating Systems ...

Page 8: ...mperature 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 F 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 m...

Page 9: ...for leaks Repair as necessary Table 1 Domestic Hot Water Ratings 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 C Connect hot water piping to NPT outlet of heater See Figure 7 WARNIN...

Page 10: ...ering 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 liquefied petroleum gas 3 Install sediment trap ground jo...

Page 11: ...tion Do not use matches candles open flames or other ignition source NOTICE USA boilers built for installation at altitudes greater than 2 000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1 000 feet above sea level per the National Fuel Gas Code ANSI Z223 1 Section 8 1 2 and Appendix F Canadian boilers orifice sizing is indicated on the rating label High...

Page 12: ...ing codes Contact local building or fire officials about restrictions and installation inspection in your area 2 This appliance requires a Special Gas Vent The product is designed to use supplied AL 29 4C Stainless Steel vent system components The following manufacturer s offer similar AL 29 4C components and are approved for use with this product Heat Fab Inc Saf T Vent 800 772 0739 Flex L Intern...

Page 13: ...peration the appliance being inspected Follow the Lighting or Operating Instructions Adjust thermo stat so appliance will operate continuously Table 7 Vent System Components 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 remain ...

Page 14: ...or pipe NOTICE Cut must be square with pipe and filed or sanded smooth before joining Carefully ensure roundness of cut pipe by hand with gloves before installing Seal joint with RTV specified in this manual 6 Seal all U S Boiler Gasket Less vent U S Boiler mixed vent Gasket Less and Gasketed and field cut joints using Dow Corning Silastic 732 RTV Dow Corning Silastic 736 RTV GE RTV106 Polybac 500...

Page 15: ... Boiler Gasket Less Male and Gasketed Female Vent Joint Detail Figure 10D U S Boiler 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 seam...

Page 16: ...el 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 above any forced air inlet located within 10 feet c Minimum 1 foot below 1 foot horizontally from or 1 foot above any door openable window gravity air inlet or buil...

Page 17: ...terminal to vent pipe Locate vent terminal between 3 and 6 from wall when joined to inside vent piping See Figure 13 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 Figure 15 Vent Air Intake Terminal Relationship Horizontal thru wall or Vertical thru roof I Vertical Through Roof Vent In...

Page 18: ...a Locate roof opening to allow vertical vent penetration Size opening to maintain 5 inch minimum clearance from combustible materials Figure 17 Attic Offset b Vertical venting requires use of roof flashing P N 8116250 and storm collar P N 8116251 to prevent moisture from entering the structure c Extend vent pipe to maintain minimum vertical and horizontal distance of 12 inches from roof surface Al...

Page 19: ...igure 19 Vertical Air Intake Termination Extend Vent Air Intake Piping to maintain minimum vertical X and minimum horizontal Y distance of twelve 12 inches from roof surface Allow additional vertical X distance for expected snow accumulation ...

Page 20: ...flow hot or cold water pipes lighting fixtures television or sunlight Allow free air movement by avoiding placement of furniture near thermostat C Wire thermostat Provide Class II circuit between thermostat and boiler Set thermostat heat anticipator to 0 6 amps See Figure 20 D Wire boiler Boiler is rated for 120 VAC 60 hertz less than 12 amperes A separate electrical circuit must be run from the m...

Page 21: ...e first Repeat this step until all zones have been purged but always have one zone open At completion open all zone valves 9 Close hose bib continue filling the system until the pressure gauge reads between 12 and 15 psi Close fill valve WARNING DO NOT install an automatic fill valve with this boiler 10 Open isolation valve in boiler supply piping 11 Remove hose from hose bib C Prepare to check op...

Page 22: ...22 Figure 21 Operating Instructions ...

Page 23: ...less than 1 1 µA System may not operate reliably over time Service call recommended Note This indication may flash temporarily during or shortly after lightoff on some applications Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection OFF No Flame or Flame Signal Below minimum threshold for system operation N A a Flash Code Descriptions Heartbeat Cons...

Page 24: ...econdary voltage supply below 15 5 Vac Control remains in wait mode When the fault corrects control resumes normal operation after one minute delay Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer 6 2 5 minute Retry Delay On every third retry on same Call for Heat Initiate new trial for ignition after retry delay completed Check g...

Page 25: ...25 Figure 23 Troubleshooting Guide ...

Page 26: ...ould have clearly defined inner cone with no yellow tipping Orange yellow streaks should not be confused with true yellow tipping Figure 26 Main Burner Flame H Check thermostat operation Raise and lower temperature setting to start and 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...

Page 27: ...ing M Adjust gas input rate to boiler 1 Adjust thermostat to highest setting 2 Check manifold gas pressure Pressure should 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 ga...

Page 28: ... 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 Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing B Inspect domestic hot water coil gasket for water leakage Tighte...

Page 29: ...ication 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 Disc...

Page 30: ...30 Figure 27 Burner and Flueway Cleaning ...

Page 31: ...ferential Pressure Switch Settings Boiler Model Main Burner with 60 Plot Bracket Pilot Burner Located Between Main Burners MMII4 70 MMII4 105 3 3 4 MMII5 105 MMII5 140 4 4 5 Main burners numbered left to right as viewed from front of boiler Boiler Model Minimum Pressure MMII4 70 0 80 w c MMII4 105 MMII5 105 0 69 w c MMII5 140 ...

Page 32: ... 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 used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not clas...

Page 33: ...33 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 34: ...34 ...

Page 35: ...35 ...

Page 36: ...053 1 61104054 2B Blower Fasco 7062 3101 1 6111715 2C Flue Monitor 1 80160622 2D Vent Connector See Key No 11 2E Orifice Plate Fan Outlet 1 71104055 1 71104056 1 71104057 1 71104058 2F Gasket Fan Outlet Included w 2B 2 8206035 2G Gasket Blower Mounting Included w 2B 1 8206049 2H Silicone Tubing 3 16 I D x 22 Long 9016006 Specify Length 2J Silicone Tubing 3 16 I D x 18 Long 9016007 Specify Length 2...

Page 37: ...37 ...

Page 38: ...38 ...

Page 39: ...2 3E Burner Access Panel Assembly 1 62104045 1 62104055 3E1 Burner Access Panel 1 721040411 1 721040511 3E2 Flame Roll Out Switch w Mounting Bracket 1 6016060 3F Combustion Air Diffuser 1 72104045 1 72104055 3G Base Front Panel Assembly Insulation attached 1 61804044 1 61804054 3H Backing Plate Manifold Seal 1 71804010 3J Gasket Manifold Seal 1 8180402 3K Burner Enclosure Top Panel Insulation atta...

Page 40: ...40 ...

Page 41: ...ge 7 822640 LP 57 5 822656 54 Black 5 822635 4D Hitch Pin Clip 5 822604 7 822604 4E Pilot Tubing 1 8 O D x 30 Lg 1 8236110 4F Ignition Sensor Cable Honeywell 394803 2 1 8236121 4G Pilot Assembly Nat Gas Honeywell Q348A1333 1 8236104 LP Honeywell Q348A1341 1 8236107 N A 4H Main Gas Burner w Pilot Bracket 1 8236116 4J Main Gas Burner Less Pilot Bracket 4 8236115 6 8236115 4K Machine Screw 10 32 x 3 ...

Page 42: ...40415 5B Rear Top Panel 1 70404091 5C Fan Shroud 1 71104004 5D Upper Rear Panel 1 6040414 5E Lower Rear Panel 1 6040413 5F Right Side Panel 1 6040411 5G Vestibule Panel 1 6040417 5H Kick Panel 1 7040111 5J Left Side Panel 1 6040412 5K Lower Front Panel 1 70404021 5L Removable Door 1 70404041 5M Snap Bushing 3 8136257 5N Sheet Metal Screw 8 x 1 2 Lg 57 80860000 ...

Page 43: ...k Assembly 1 60304032 6A Tank Assembly 1 60304031 6B Jacket Attachment Bracket 8 70404011 6C Self Tapping Screw 1 4 20 x 1 2 Lg 16 80860700 6D Front Insulation 1 72004067 6E Domestic Hot Water Coil 1 6030401 6F Hex Nut 3 8 16 10 80860423 6G Coil Gasket 1 8206036 6H Tank Wrapper Insulation 1 72004069 6J Rear Insulation 1 72004068 ...

Page 44: ...ch 1 80160191 7E Ignition Module Honeywell S8670E3003 1 100959 01 7F Tank Aquastat Honeywell L6189A2092 1 80160499 7G DPST Relay Honeywell R8222V1029 1 80160135 7H Circulator Taco 007 1 8056007 7J Drain Valve Conbraco 35 302 03 1 806603061 7K DPST Relay Honeywell R8222U1006 1 80160096U 7L Pressure Temperature Gauge 1 100282 01 7M Boiler High Limit Honeywell L4189B2012 1 80160460 7N Differential Pr...

Page 45: ...Key No Description Quantity Part Number MMII4 70 MMII4 105 MMII5 105 MMII5 140 11 Vent Accessory Carton 1 61110129 11A Vent Connector 1 8116307 11B Vent Terminal 1 8116310 12 Air Intake Terminal 1 8110402 ...

Page 46: ...46 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 47: ...warranty is effective for one 1 year beginning with the date of original purchase This warranty shall begin from the date of manufacture as indicated by the serial number COVERAGE The warranty covers any component part of the Alliance SL Water Heater proven to be defective in workmanship or material Subject to prior Company approval COMPANY OBLIGATION The warranty covers any component of the Allia...

Page 48: ...einstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from U S Boiler Company Inc b Components that are part of the heating system but were not furnished by U S Boiler Company Inc as part of the residential boiler c Improper burner adjustment control settings care or maintenance d This warranty cannot be considered as a g...

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