Bradford White Copper Brute II BWCH 2000 Installation And Operating Instructions Manual Download Page 13

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Page 9

Brute

HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS

1/2

(98)

3/4

(22)

1/2

(19)

(64)

All Indoor Brutes have a very similiar

component design with piping

dimensions/locations that increase as

the unit size increases.

Water and gas piping is always on the

left side of the unit. Table 1 gives the

exact dimensions for all of the different

model sizes.

500 MBH

Summary of Contents for Copper Brute II BWCH 2000

Page 1: ...s injury property damage or death Improper installation and or operation will void the warranty AVERTISSEMENT Assurez vous de bien suivres les instructions donn es dans cette notice pour r duire au mi...

Page 2: ...ements 25 Section 6A Water Connections BNTH Boiler 6A 1 BNTH System Piping Hot Supply Connections 26 6A 2 BNTH Cold Water Make Up 26 6A 3 Condensate Drain 27 6A 4 Freeze Protection 27 6A 5 BNTH Sugges...

Page 3: ...ing the Touch Screen 8 1 The Touch Screen 45 8 2 Using the Touch Screen 45 8 3 Login required for some parameters 46 8 4 Verification Process for Safety Related Parameters 47 8 5 Checking Individual P...

Page 4: ...BRADFORD WHITE...

Page 5: ...3 1 NFPA54 Latest Edition National Fuel Gas Code or 2 CSA B149 1 Natural Gas and Propane Installation Code or in Canada reference the B149 1 latest edition and with the requirement of the local utilit...

Page 6: ...have the On Off switch on the outside of the unit Both units have the Rating Plate on the outside panel to the right See Figure 2 and Figure 3 DOOR HANDLE PULL TO OPEN RELEASE BOTH LATCHES TO OPEN DOO...

Page 7: ...ATER OUTLET AIR INLET FILTER BOX GAS CONNECTION PRV must be added to this pipe during installation GAS CONNECTION EXHAUST VENT EXHAUST VENT WATER INLET WATER OUTLET AIR INLET CONDENSATE TRAP OUTLET Tr...

Page 8: ...ER OUTLET PRESSURE RELIEF VALVE AIR PRESSURE SWITCH DRAIN VALVE CONDENSATE TRAP AIR TRANSITION ON OFF SWITCH Figure 4 Location of Components Sizes 150 210 EXHAUST VENT CONNECTION GAS CONNECTION AIR PR...

Page 9: ...INLET CONNECTION DRAIN VALVE CONDENSATE TRAP GAS VALVE ON OFF SWITCH Figure 6 Location of Components Indoor Size 399 Figure 7 Location of Components Indoor Size 500 EXHAUST VENT CONNECTION PRESSURE RE...

Page 10: ...SURE SWITCH WATER INLET WATER OUTLET AIR INLET CONNECTION DRAIN VALVE CONDENSATE TRAP GAS VALVE MANUAL SHUTOFF GAS VALVE ON OFF SWITCH Figure 9 Location of Components Sizes 750 and 850 WATER INLET WAT...

Page 11: ...igure 10 Connection piping is on TOP for ALL Indoor Sizes Figure 11 Connection piping is on the BACK for ALL Outdoor Sizes PRV must be added to this pipe during installation RATING PLATE RATING PLATE...

Page 12: ...18 48 13 33 399 BNTV 25 64 5 13 19 50 4 11 14 37 18 47 19 49 16 42 21 55 18 48 13 33 500 BNTH 30 77 5 13 19 50 4 11 15 38 20 51 20 52 19 48 26 66 18 48 13 33 500 BNTV 30 77 5 13 19 50 4 11 15 38 20 5...

Page 13: ...4 22 7 1 2 19 25 64 All Indoor Brutes have a very similiar component design with piping dimensions locations that increase as the unit size increases Water and gas piping is always on the left side of...

Page 14: ...n cm in cm in cm in cm in cm in cm in cm in cm in cm 150 6 1 4 16 11 28 13 33 17 1 4 43 8 23 1 2 60 18 45 7 27 69 23 1 2 60 5 1 4 13 199 210 6 1 4 16 11 28 13 33 17 1 4 43 8 23 1 2 60 18 45 7 27 69 24...

Page 15: ...1 4 43 8 24 61 19 48 29 1 4 74 12 30 5 850 32 3 4 83 2 3 0 8 5 1 4 13 4 17 1 4 43 8 24 61 19 48 29 1 4 74 12 30 5 E F A B C D G J in cm in cm in cm in cm in cm 27 69 23 1 2 60 5 1 4 13 20 60 3 7 6 27...

Page 16: ...2 Doc ument Bag all documents in one bag Term inal Block Jumper the Terminal Block Jumper is in the document bag Sen sor Kits Tank Outdoor and System Sensors all in the same bag 2 boxes a sensor and a...

Page 17: ...PAT BRASS 2 2 A2116000 FLANGE PUMP 1 1 2 NPT BRASS 3 7 16 BOLT PAT BRASS D C B 2 DWG NO 50D4140 SH 1 REV A CJ 5 17 16 REVISIONS REV CHANGE APPR ENGR APPR ECN DRAFT CHECK REMOVED ITEM 2 A2116100 FROM...

Page 18: ...iance 2 2 Locating Appliance for Correct Vent Distance from Outside Wall or Roof Termination The forced draft combustion air blower in the appliance has sufficient power to vent properly when the guid...

Page 19: ...er 5x01BOI FSAAUx 2SVSAxx OD 2SVSTTAxx ID Horizontal Termination bird screen 9x92 FSBSx 2SVSTPXxx Vertical Termination rain cap 5X00CI FSRCx 2SVSRCxx Inlet Air Termination 9xTERM FSAIHXX 2SVSTEXxx90 A...

Page 20: ...ABS ANSI ASTM D1527 PVC sch 40 ANSI ASTM D1785 or D2665 Air pipe material must be chosen CPVC sch 40 ANSI ASTM F441 based upon the intended application of the boiler Single wall galv steel 26 gauge PR...

Page 21: ...ssible Please see Table 4 on page 14 for proper diameter vs length allowed NOTE The vent pipe must pitch upward toward the vent terminal not less than 1 4 per foot so that condensate will run back to...

Page 22: ...ure pressure gauge kit D circulator pump wire harness units with pump E CPVC exhaust pipe section 80 500 not incl F outdoor system sensor kit G flow switch kit 399 850 H alternate size vent terminal s...

Page 23: ...avity inlets or other openings Whenever possible avoid locations under windows or near doors 5 Locate the vent terminal so that it cannot be blocked by snow The installer may determine that a vent ter...

Page 24: ...gas appliance is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additi...

Page 25: ...g or the combustion air inlet 399 850 Other than Direct vent 4 ft 1 2m below 36 inches 91 cm to any other appliance or to side of opening 1 ft 30cm above opening NT 80 only 12 inches 30 cm K Clearance...

Page 26: ...Page 22 BRADFORD WHITE 150 285 Figure 23 Minimum Venting Distance...

Page 27: ...oche de la taille minimale d termin e en utilisant les tableaux appropri s et des lignes directrices dans le National Code de gaz combustible ANSI Z223 1 NFPA 54 et ou CSA B149 1 Codes d installation...

Page 28: ...ressure port on the gas valve Low gas pressure could be an indication of an undersized gas meter undersized gas supply lines and or an obstructed gas supply line Some Brute units are equipped with low...

Page 29: ...L FLOW H L FLOW H L SIZE GPM FT GPM FT GPM FT GPM FT GPM FT 150 14 3 28 5 11 4 19 9 5 13 6 8 1 11 2 7 1 8 8 199 210 20 24 1 16 16 7 13 4 11 6 11 3 9 9 9 6 9 285 27 25 5 22 17 5 18 14 15 10 5 13 8 399...

Page 30: ...cycle A boiler installed above radiation level or as required by the authority having jurisdiction must be provided with a low water cutoff device either as a part of the boiler or at the time of boil...

Page 31: ...a boiler from firing Any time a boiler is subjected to freezing conditions and the boiler is not able to fire and or the water is not able to circulate there is a risk of freezing in the boiler or in...

Page 32: ...Page 28 BRADFORD WHITE Figure 24 Hydronic Piping Single Boiler Zoning with Circulators Brute TM...

Page 33: ...Page 29 Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Figure 25 Hydronic Piping Single Boiler Low Temp Radiant Space Heating Using Low Loss Header and Zone Valves Brute TM...

Page 34: ...BRADFORD WHITE Figure 26 Hydronic Piping Multiple Boilers Zoning with Circulators Figure 27 Hydronic Piping Multiple Boilers with Indirect DHW Tank Piped from System Loop Brute TM Brute TM Brute TM B...

Page 35: ...31 Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Figure 28 Hydronic Piping Multiple Boilers Reverse Return Multi Temp Zones Zoning with Circulators Brute TM Brute TM Brute TM Brut...

Page 36: ...E Figure 29 Hydronic Piping Heating Zones with Indirect DHW Tank Piped with Zone Pumps The indirect DHW tank is piped directly off of the boiler The boiler pump must shut down during DHW operation 4 p...

Page 37: ...GH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Figure 30 Hydronic Piping Multiple Boilers with Indirect DHW Off of One Boiler The boiler pump must shut down during DHW operation Brute TM Br...

Page 38: ...flow Section 6B WATER CONNECTIONS BNTV WATER HEATER Section 6 is divided into two parts Section 6A covers BNTH units designed for hydronic heating Section 6B covers BNTV models which are designed exc...

Page 39: ...be drained to avoid the risk of damage due to freezing Glycol must not be used in volume water heating applications 6B 6 BNTV Suggested Piping Schematics Figure 31 through Figure 34 show suggested pip...

Page 40: ...water hardness at job site WARNING This drawing shows suggested piping configuration and valving Check with local codes and ordinances for additional requirements NOTES 1 Optional CWMU Recirc line loc...

Page 41: ...een the field interlock terminals the Brute will remain in low fire when it sees 4mA as a modulating signal See Section 7 4 for more details 7 2 Main Power Connections Connect a 15A fused 120 volt sup...

Page 42: ...iler System Pump and DHW Pump Connections 199 850 120 Single 2 115V Maximum 1HP No Pump or 7 4A max 199 500 Less With Pump 120 Single than 115V Maximum 1HP 6 or 7 4A max Minimum 15A circuit required T...

Page 43: ...in series by removing the supplied jumpers See Figure 35 7 4 Hydronic Heating Using External Modulation Control About External Control When the Brute is used for hydronic heating with external modulat...

Page 44: ...6 Lead Lag Connections Brute boilers can be connected in a Lead Lag series up to a total of 8 controllers One as the Lead control and 7 more as the following controllers See Figure 36 For general info...

Page 45: ...cluded Modbus ports Gateway Control H2354400 Doc 4236 Connect the 4 20mA signal from an external control or building automation system to terminal block 7 TB7 in the control panel See Figure 35 The co...

Page 46: ...T OR INTERLOCK ANALOG INPUT ANALOG INPUT OUTDOOR TEMP SENSOR TB7 FIELD CONNECTIONS SAFETY CHAIN TB4 24V COMMON TB3 24V HOT Y R TN TN Y BR BR WH R Y R GY R Y DKB Y BLK WH R Y GY BL Y GY R LOW WATER CU...

Page 47: ...POWER INPUT CONTROL MODULE Honeywell R PUR PUR BLK WH BL DKB DKB Y DKB FS 2 DKB DKB WH BL WH BL WH R WH R FS 1 DKB Y PK R BLK WH GN GR R WH CL CL CL CL CL WH R GN TN BRN OR TN BL TN R Y VT WH WH BLK...

Page 48: ...Page 44 BRADFORD WHITE Figure 38 Ladder Diagram 7 9 Ladder Diagram...

Page 49: ...lay Simply touch the screen to wake it up While under normal operation the Touch Screen will automatically present this Home Screen See Menu 1 Menu 1 Home Screen Menu 2 Status Summary The home screen...

Page 50: ...nstaller level password is lnt lower case LNT See Menu 3 User no password required Non critical adjustments and functions including adjusting the Central Heat and Domestic Hot Water setpoints monitori...

Page 51: ...ge For more information on logging in see Section 8 2 2 If you make a change in any group that could affect the safe operation of the unit the control system will ask you to verify the change before i...

Page 52: ...be cancelled A count down timer is shown at the bottom of the screen 8 5 Checking Individual Parameters 1 From the Home screen Menu 9 press the icon for the controller Menu 9 Home screen 2 The Status...

Page 53: ...tart at the Home screen Menu 11 Home screen 2 Press the Setup button on the lower right corner of the screen The system will present the Setup screen Menu 12 Setup Screen 3 Press the Display Setup but...

Page 54: ...nfiguration Menu From the Configuration Menu there are 18 Configuration Sub Menus Use the scroll tab on the right to view them all The next section of this manual will show the installer these sub men...

Page 55: ...row then Click onto Local Click onto the down arrow to see further options When using the Brute for hydronic heating a call for heat must be supplied to the T T terminals found on TB7 labeled T T or I...

Page 56: ...Low Water Temperature to get to each and adjusting their setpoints in those sub menus 8 7 4 DHW Domestic Hot Water Configuration DHW Domestic Hot Water is used to configure the DHW temperature paramet...

Page 57: ...nal 120VAC circuits may be required for the pumps 8 7 6 Demand Priority Configuration From the Demand Priority Configuration the installer can adjust the priority of the different demand types Central...

Page 58: ...details on Safety Verification 8 7 11 Stack Limits 8 7 12 Anti Condensation Configuration Anti condensation frost protection is enabled disabled on this screen 8 7 13 Frost Protection Frost protection...

Page 59: ...ter Similarly to increase decrease the speed at which the fan control loop reacts to an increase in fan speed adjust the Fan gain up parameter The minimum duty cycle is a view only parameter To set a...

Page 60: ...ead Lag Leader A Run sequence is initiated when the system temperature falls to the Lead Lag Central Heat setpoint Actually this is the LL CH setpoint less the On Hysteresis value The default setting...

Page 61: ...Base Load Settings Figure 43 Lead Lag Operation in a System with Eight Boilers Note The Displays on Boilers 2 through 8 will display information pertaining only to that specific boiler Touch Screen L...

Page 62: ...wiring When a boiler is operating as part of a Lead Lag system it does not use the normal CH set point it uses the Lead Lag CH set point on the Master control It is STRONGLY recommended to start each...

Page 63: ...uilt in Lead Lag Leader Then select OK Return to the configuration menu by pressing the Back arrow Next you will need to confirm that the master configuration is Disabled Then you will need to confirm...

Page 64: ...the Modbus system labeled MB1 and MB2 MB1 has the wiring connections to the User Interface display on each unit and MB2 is used to communicate with the other boilers in the Lead Lag system For wiring...

Page 65: ...ed press the arrow to advance to the Rate Allocation screen Adjust the Base Load Common value to the number of boilers in the cascade system See chart for values Chart for base values From this screen...

Page 66: ...ollower by turning on Follower Enable From the Status Summary Screen press the Configure button Scroll down and press Lead Lag Follower Configuration Press Disabled Choose Enable Follower for built in...

Page 67: ...40 And you must set up your CH Configuration for SetPoint and Modulation as shown on Menu 19 on page 51 For additional information on setting up Modbus and other communication protocols contact the f...

Page 68: ...y lead to personal injury or death 1 On the Gas Valve locate the adjustments for High Fire and Low Fire See Figure 47 on page 66 thru Figure 49 on page 68 Refer to Table 17 on page 66 and Table 18 on...

Page 69: ...to 5 to 5 minutes Be sure to give your combustion analyzer time to get a stable reading after making the Hi Fire adjustment at the gas valve 9 Once Hi Fire CO2 is within an acceptable range press Sto...

Page 70: ...e front panel is pulled forward and then off Always be patient with your combustion analyzer when making adjustments to the valve at both Hi Fire and Low Fire Be sure to put the cap back onto the valv...

Page 71: ...lower than 005 to Propane 9 8 to 10 0 high fire setting 015 wc Table 18 Commercial sizes 399 850 Mbtu CO2 Range and Manifold Pressure 399 500 The Gas Valve in the 399 and 500 is at the front of the u...

Page 72: ...s at the front of the unit and can be reached after the front panel is pulled forward and then off The Gas Valve in the 750 and 850 models can only be reached by removing the top panel of the unit It...

Page 73: ...e and system are filled with water and all air has been bled from both Open all valves Section 9 First Start Up and Adjustment 9 1 Filling the Boiler System 1 Ensure the system is fully connected Clos...

Page 74: ...he unit has the optional gas pressure switches you will need to reset the low pressure switch Find the low pressure switch and press the reset button Restart the appliance The ignition sequence will s...

Page 75: ...are engineered for long life and dependable operation but the safety of equipment depends on their proper functioning Only a qualified service technician should inspect the basic items listed below ev...

Page 76: ...are keyed to only allow connection in the proper location but proper handling techniques should be used to avoid damage to the wiring or connectors To remove the control push in on the two tabs on th...

Page 77: ...outlet bolts from the burner door blower arm If the fan is determined to be defective replace the existing fan with a new one reversing the steps listed above Be sure to install all of the required O...

Page 78: ...tural gas set the low gas pressure switch to 3 w c For propane set the low gas pressure switch to 5 w c For natural and propane set the high gas pressure switch to 14 BNT size mbtu Kit number 150 CA00...

Page 79: ...urge to the startup This indicates that the control system is waiting for a condition to be satis ed No Reset is required to recover from an alert The system maintains a history of the 15 most recent...

Page 80: ...st 15 Lockout occurances Press Alerts to bring up a list of the last 15 Alerts and Silence Alarm in the event of a lockout condition By silencing the alarm the audible alert has been disabled However...

Page 81: ...fault repeats replace module 2 Waiting for safety data veri cation L 1 Device in Con guration mode and safety parameters need veri cation and a device needs reset to complete veri cation 2 Con gurati...

Page 82: ...24 Internal fault Spark voltage stuck low or high H 25 Internal fault Spark voltage changed too much during ame sensing time H 26 Internal fault Static ame ripple H 27 Internal fault Flame rod shorte...

Page 83: ...Rollout switch is regarding the SAFETY CHAIN OFF Could be one of the following Flow Switch Standard Equipment Sizes 399 and Up Additional High Limit Field Supplied Optional Pressure Switch Size 399 On...

Page 84: ...ts for proper operation 2 Recheck the Delta T Limit to con rm proper setting 3 If previous steps are correct and fault persists replace the module 82 Stack limit H or L 1 Check wiring and correct any...

Page 85: ...peration correct any errors 2 Check the fuel supply 3 Check fuel pressure and repeat turndown tests 4 Check ignition transformer electrode ame detector ame detector siting or ame rod position 5 If ste...

Page 86: ...module 155 Purge fan switch OFF H or L 1 Purge fan switch is off when it should be on 2 Check wiring and correct any errors 3 Inspect the Purge Fan switch J6 terminal 3 and its connections Make sure...

Page 87: ...tage across the switch Supply voltage should be present If not the Block Intake Switch is defective and needs replacing 5 If the fault persists replace the relay module 165 Block intake OFF L 172 Main...

Page 88: ...lid interlock start check setting L 199 Invalid LCI Limit Control Input enable setting L 200 Invalid lightoff rate setting L 201 Invalid lightoff rate proving setting L 202 Invalid MFEP Main Flame Est...

Page 89: ...of inputs and outputs displayed The Burner Control I O button leads to Menu 8 Menu 8 Burner Control I O Screen A green dot indicates a function that is on 2 Press the Digital I O button to see paramet...

Page 90: ...er a period of time for several different parameters fan speed outlet temperature inlet temperature etc Menu 15 Analysis Setup Screen To use this function select the parameter you want to track from t...

Page 91: ...sequence The unit is equipped with a low and high re air pressure switch The unit will pre purge at 65 fan for 30 seconds and prove fan through the blocked intake switch Once fan is proven the blower...

Page 92: ...02 Stanchion 24 Brace Front 20D1005 20D1005 85D1005 85D1005 85D1005 60D1005 85D1005 85D1005 HX Stanchion 24A Brace Rear 20D1007 20D1007 R50D1005 85D1005 85D1005 85D1005 85D1005 85D1005 HX Stanchion 25...

Page 93: ...30D4110 R40D4110 R50D4110 BNTH BNTH BNTH BNTH BNTH 15D4040 50D4040 50D4040 50D4040 BNTV BNTV BNTV BNTV 62 Low Water Cutoff Switch RE2076500 RE2076500 RE2076500 RE2076500 63 Inlet Water Temp Sensor RE2...

Page 94: ...020 R50D2020 R50D2020 R50D2020 R50D2020 Electrical Components See Parts Illustration 8 80 Control Panel Enclosure R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 81 Transformer...

Page 95: ...Page 91 Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Parts Illustration 2 Internal Components Sizes 150 210 Parts Illustration 3 Internal Components Sizes 285 600...

Page 96: ...Page 92 BRADFORD WHITE Parts Illustration 4 Internal Components Sizes 750 850...

Page 97: ...Page 93 Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Parts Illustration 5 Gas Train Components Sizes 150 500 Sizes 150 285...

Page 98: ...Page 94 BRADFORD WHITE Parts Illustration 6 Gas Train Components Sizes 600 850...

Page 99: ...Page 95 Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Parts Illustration 7 Heat Exchanger Components 68A Sizes 285...

Page 100: ...Page 96 BRADFORD WHITE Parts Illustration 8 Electrical Components Front Battery CR2032 Touchscreen Back...

Page 101: ...P NTOD 150 500 62 LONG 1 3 15D3115 TOP PANEL PUMP COVER NTOD 1 4 15D3116 SIDE PANEL PUMP COVER NTOD 2 5 F0024300 SCREW 10 16 X 5 8 STL HX WSHR HD 3 PT 4 NeoTherm Outdoor Volume Water Pump Assembly Bil...

Page 102: ...Page 98 BRADFORD WHITE Notes...

Page 103: ...Page 99 Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Notes...

Page 104: ...ance with our policy of continuous product improvement Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS HLW 200 Lafayette St Middleville MI 49333 Warranty 800 531 2111 www BradfordWhi...

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