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TABLE OF CONTENTS

SECTION 1   Caring For Your Copper Brute ll ............ 3
1.A 

General Care ............................................ 3

1.B 

Annual Inspection of Flue and Vents ........ 3

1.C 

In the Event of a Power Failure ................ 3

1.D 

Full Service Every Three (3) Years ........... 3

SECTION 2  Touchscreen and System Ops ............... 4
2.A 

The Home Screen .................................... 4

2.A.1 

Home Screen Status Window................... 4

2.A.2 

Home Screen Active Icons ....................... 5

2.B 

Lock/Unlock Display Screen ..................... 6 

2.C  

Keypad Operations ................................... 7

2.D 

Quick Start   .............................................. 8

2.D.1 

CH /DHW  ................................................. 8

2.D.1.a   CH1 /DHW11 ............................................ 8
2.D.1.b 

CH2/DHW2 2 ............................................ 8

2.D.2 DHW/DHW3 

 ............................................ 9

2.D.3 

Outdoor Reset  ......................................... 9

2.D.4 

Warm Weather Shut Down  ...................... 9

2.D.5 

Anti-Short Cycle ..................................... 10

2.D.6 

Time & Date  ........................................... 10

SECTION 3  Electrical Connections ..........................11
3.A 

Installation Warnings ...............................11

3.B 

Line Voltage Connections ........................11

3.B.1 

Main Power..............................................11

3.B.2 

Pump Power ............................................11

3.B.3 

Boiler/Heater Pump  ................................11

3.B.4 

Auxiliary Power Output ............................11

3.C 

Low Voltage Connections ....................... 12

3.C.1 

Field Wiring - Inputs................................ 12

3.C.1.a 

Safety Interlocks ..................................... 12

3.C.1.b 

BWCH/BWCV Heat Demands ................ 12

3.C.1.c 

Field Inputs (Open/Closed)..................... 12

3.C.1.d 

Temperature Sensors ............................. 12

3.C.2 

Field Wiring - Outputs  ............................ 13

3.C.2.a 

Dry Contacts ........................................... 13

3.C.1.e 

Analog (BAS) Input ................................. 13

3.C.2.b 

Cascade RS485 ..................................... 14

3.C.2.c 

BAS RS485 ............................................ 14

3.C.2.d 24VAC .................................................... 14
3.D 

Cascade Wiring Connections ................. 15

SECTION 4  Burner Set Up ...................................... 15
4.A 

Set Up for 0 to 2500 Feet Altitude .......... 15

4.B  

Set Up for High Altitude  

 

( >2500 Feet ) ......................................... 16

Summary of Contents for Copper Brute ll BWCH

Page 1: ...utre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareils Ne touchez à aucun interrupteur Ne pas vous servir des téléphones dansle bâtiment où vous vous trouvez Appelez immédiatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur de gaz appelez le sservice des incendies L installation et ...

Page 2: ...ather Shut Down 9 2 D 5 Anti Short Cycle 10 2 D 6 Time Date 10 SECTION 3 Electrical Connections 11 3 A Installation Warnings 11 3 B Line Voltage Connections 11 3 B 1 Main Power 11 3 B 2 Pump Power 11 3 B 3 Boiler Heater Pump 11 3 B 4 Auxiliary Power Output 11 3 C Low Voltage Connections 12 3 C 1 Field Wiring Inputs 12 3 C 1 a Safety Interlocks 12 3 C 1 b BWCH BWCV Heat Demands 12 3 C 1 c Field Inp...

Page 3: ...affected parts replaced by a qualified service person 1 C In the Event of a Power Failure The Copper Brute ll can not be operated during an electrical power outage If there is an extended power outage with danger from freezing then the Copper Brute ll and all other water systems should be drained completely When draining the boiler turn off main electrical disconnect switch When placing back in se...

Page 4: ...us Burner Bank 1 Burner Bank 2 Staging on off Blower Speed high low OAT Outdoor Ambient Temperature when connected Pennant Inlet Outlet Temperature System Inlet Outlet Temperature System Supply Return Temperature when connected DHW Temperature when connected Heat Demand Setpoints NOTE The heat demand set point will turn green in color when active Pump Status 2 A 1 Home Screen Status Window The cen...

Page 5: ...es Will show an Exclamation when there is a message Clicking onto the Message icon will take you to the message itself The USB functionality will show the USB Icon at this location if being used Active Demands Will show icons that indicate the active parameters that are currently in demand Navigation Bar The Navigation Bar is the constant indicator of where you are as you navigate into and out of ...

Page 6: ...up and commissioning The installer password is 17 When unlocked in the Installer mode the icon will change to OEM Password Setup and parameter changes available only to the factory Walk Away Result The unit will either Lock or stay Un locked if you walk away What it will do is displayed in the bottom right corner The default delay time to lock is 5 minutes of inactivity This time duration can be a...

Page 7: ...me screens may only allow you to set one or the other while some other screens example pump selection will allow you to select any or all of the options These windows will reflect the allowable ranges that the setting can be adjusted to Shows the current setting of the Parameter NOTE You can always tell exactly where you have navigated to by looking at the icons in the Navigation Bar In this examp...

Page 8: ...n the input terminal strip Screen 6 CH DHW Quick Start Selection Screen Touching CH1 DHW1 navigates to the CH1 DHW1 Quick Start Screen 2 D 1 a CH1 DHW1 1 Screen 7 CH1 DHW1 Quick Start Screen NOTE CH1 applies to hydronic units BWCH while DHW1 applies to volume water units BWCV Enable Disable This allows CH1 DHW1 to be enabled disabled The default setting is Enabled Set Point This is the temperature...

Page 9: ...re at which the Copper Brute ll will limit the boiler outlet temperature to the Minimum Water Temperature Minimum Ambient Temperature The outdoor temperature at which the Copper Brute ll will maximize the boiler outlet temperature to the Maximum Water Temperature NOTE Outdoor functionality is applicable to hydronic units only and is explained in Installation Manual Doc 1392 2 D 4 Warm Weather Shut...

Page 10: ...ent of the following parameters Hour The hour that will be displayed in the upper banner on each screen and the time captured in the date time stamp for lock out conditions displayed on the history screen Minute The minute that will be displayed in the upper banner on each screen and the time captured in the date time stamp for lock out conditions displayed on the history screen Month The month th...

Page 11: ...power L1 N1 and Ground shall be connected to the three wires supplied This main power circuit is identified by three solid colored wires 10 AWG black L1 white N1 and green Ground Copper Brute ll sizes 1750 2000 main power L1 N1 and Ground is identified by three solid colored wires 10 AWG black L1 white N1 and green Ground The pump circuit is identified by three 12 AWG wires 3 B 2 Pump Power The pu...

Page 12: ... Field Input 1 controls the Auxiliary Dry Contact If Field Input 1 is open the Auxiliary Dry Contact is open If Field Input 1 is closed the Auxiliary Dry Contact is closed Only dry contacts can be connected to Field Input 1 Field Input 2 Field Input 2 if used is connected across terminals 11 and 12 of the input terminal strip When connected Field Input 2 controls the Auxiliary Power Output If Fiel...

Page 13: ... this contact when Field Input 1 is closed otherwise this contact remains open Contact ratings are 250VAC 1 5A maximum function The controller automatically detects the presence of this sensor and initiates a call for heat when the DHW temperature drops below the DHW set point by the value of the DHW On Hysteresis DHW Set Point DHW On Hysteresis DHW heat demand The DHW heat demand is satisfied whe...

Page 14: ...nd on one end of the cable to avoid ground loop issues If more than two Copper Brute ll units are cascaded together daisy chain the wiring from Copper Brute ll to Copper Brute ll keeping the cables as short as possible A system supply sensor must be installed and connected to the lead boiler see System Supply in Section 5 3 1 4 Temperature Sensors The lead boiler will use this system supply sensor...

Page 15: ...stallation is complete and fully in compliance with the instructions 2 Determine that the appliance and system are filled with water and all air has been bled from both Open all valves 3 Observe all warnings on the Operating Instructions label and turn on gas and electrical power to appliance 4 Switch on the appliance power switch located on the right side of the unit 5 The Copper Brute ll will en...

Page 16: ...r device capable of reading a pressure of 2 5 3 0 inches w c 0 62 0 75 kPa Start the adjustment process by checking the CO2 in the as installed condition Adjust the air shutter s so that the CO2 is about 8 or the O2 is about 6 8 for appliances operating on Natural Gas For appliances operating on LP Gas adjust the air shutter s so that the CO2 is about 9 2 or the O2 is about 6 8 Appliances with two...

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