Installation / Operation Instruction Manual

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Installation and Operation Instructions Document 1257C

Installation and

Operation Instructions for

Residential

Gas-Fired

Hydronic Boilers

Model BJVS

These instructions are to be stored next to the boiler for reference purposes.

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,

qualied in hot water boiler installation and maintenance. Improper installation and/or operation could

create carbon monoxide gas in ue gases which could cause serious injury, property damage, or death.

Improper installation and/or operation will void the warranty.

WARNING

If the information in this manual is not followed

exactly, a re or explosion may result causing

property damage, personal injury or loss of life.

Do not store or use gasoline or other ammable

vapors and liquids in the vicinity of this or any

other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

nearby phone. Follow the gas supplier's

instructions.

• If you cannot reach your gas supplier, call the

re department.

Installation and service must be performed by

a qualied installer, service agency, or gas

supplier.

AVERTISSEMENT

Assurez-vous de bien suivres les instructions

données dans cette notice pour réduire au

minimum le risque d’incendie ou d’explosion

ou pour éviter tout dommage matériel, toute

blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ni

d’autres vapeurs ou liquides inammables dans

le voisinage de cet appareil ou de tout autre

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 êtes.

• 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 l’entretien doivent être assurés

par un installateur ou un service d’entretien

qualié ou par le fournisseur de gaz.

Vent damper is optional in some provinces of Canada..

Sizes 50-225

U.S. Patent No. 1,609,692

Canada Patent No. 383,318

H2359000C

Brute Mini

Summary of content (34 pages)

PAGE 1
Installation and Operation Instructions Document 1257C Installation and Operation Instructions for Brute Mini Residential Gas-Fired Hydronic Boilers Model BJVS Sizes 50-225 U.S. Patent No. 1,609,692 Canada Patent No. 383,318 Vent damper is optional in some provinces of Canada.. These instructions are to be stored next to the boiler for reference purposes.
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Page 2 BRADFORD WHITE TABLE OF CONTENTS SECTION 1. General Information 1A. 1B. 1C. Introduction.....................................................3 Warranty.........................................................3 Heater Identification........................................4 SECTION 2. Boiler Assembly & Placement 2A. 2B. 2C. 2D. 2E. Field Assembly...............................................4 Boiler Placement............................................5 Flooring...................................
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Page 3 Brute Mini SECTION 1. General Information 1A. Introduction This manual provides information necessary for the installation, operation, and maintenance of the Bradford White Model BJVS low pressure, copper tube hydronic boiler. All application and installation procedures should be reviewed completely before proceeding with the installation. Consult the Bradford White factory, or local factory representative, with any problems or questions regarding this equipment.
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Page 4 BRADFORD WHITE 1C. Heater Identification Consult the rating plate on the boiler. The following example simplifies the heater identification: 1 2 3 4 B J V S BRADFORD WHITE MODEL J V IGNIT SYST S 5 6 7 SIZE 0 0 1 1 1 2 5 7 0 2 6 2 8 FUEL 0 5 0 5 0 5 N P 9 10 FIRING SYST CONST OPTION C D S I J 11 12 13 U 2 ALTITUDE COUNTRY REVISION S H I J U 2 Table 1. Boiler Model Identification.
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Page 5 Brute Mini 5. Do not modify the automatic vent damper device. It is very important that no other vents are closed. Provide at least six inches clearance between the automatic vent damper and combustible construction, and be sure to allow access for servicing the damper. Temperature/Pressure Gauge: Install the temp/ pressure gauge provided in the parts box. The Brute Mini can be installed on a combustible floor if a noncombustible base assembly, available from Bradford White, is used.
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Page 6 BRADFORD WHITE 2E. Dimensional Information 24 610 Dimensions in inches mm 7 180 Size A B C D E V 9 -1/4 240 Water Conn Gas Conn in. mm in. mm in. mm in. mm in. mm in.
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Page 7 Brute Mini Boiler Sizes 50 125 160 Clearances in - cm in - cm 225 Left side 6 15 6 15 Right side 6 15 6 15 Rear 6 15 6 15 Front 4 10 4 10 Flue 6 15 6 15 Top 23 58 36 91 Table 2A Minimum Boiler Clearances Note: C learances listed are manufacturer’s tested values. These are given as minimum values. Where local and national codes apply, and values are different than those listed use the greater value to ensure safe operation.
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Page 8 3B. BRADFORD WHITE Venting Vent Categories: Brute Mini BJVS is a natural draft appliance for Category I venting only. WARNING This boiler must be vented in accordance with Part 7, Venting of Equipment, of the latest edition of the National Fuel Gas code, ANSI Z223.1 and all applicable local building codes. In Canada, follow CAN/CGA B149 Installation codes.
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Page 9 Brute Mini 10 (3.0) OR LESS 2 (0.6) MIN. WALL OR PARAPET CHIMNEY 10 (3.0) OR LESS RIDGE 2 (0.6) MIN. CHIMNEY MORE THAN 10 (3.0) 3 (0.9) MIN. 3 (0.9) MIN. TERMINATION 10 FT. (3.0m) OR LESS FROM RIDGE, WALL OR PARAPET 3 (0.9) MIN. WALL OR PARAPET NOTE: NO HEIGHT ABOVE PARAPET REQUIRED WHEN FROM WALLS OR PARAPET IS MORE THAN 10 FT. (3.0m) CHIMNEY MORE THAN 10 (3.0) 10 (3.0) RIDGE 3 (0.9) MIN. 2 (0.6) MIN. Dimensions in feet (m). CHIMNEY Figure 5. Vertical Vent Termination.
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Page 10 BRADFORD WHITE 3D-2. Vent Connections The boiler vent collar must be fastened to the vent pipe with rustproof metal screws no longer than 1/2” (13mm) and sealed with high temperature (500ºF / 260ºC) silicone sealant. For larger diameter vent pipes, use a sealed reducer fastened directly to the boiler collar and seal all joints as indicated in Figure 7. Allow the sealant to cure for 24 hours before operating the boiler. The entire vent system must not exceed the size specified in Table 4.
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Page 11 Brute Mini 3E. Common Venting System 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 appliances remaining connected to it. 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.
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Page 12 BRADFORD WHITE SECTION 4. Gas Connections 4A Gas Supply and Piping WARNING The Brute Mini is designed for use with either natural gas or LP gas. Check the rating plate to be sure that the boiler is designed to use the type of gas being supplied. DO NOT ATTEMPT TO CONVERT THIS HEATER FOR USE WITH ANY OTHER TYPE OF FUEL. AVERTISSEMENT Les appareils de chauffage à faibles sont conçus pour être utillsés avec du gaz naturel ou du gaz de pétrole liquéfié (GPL).
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Page 13 Brute Mini 100-200' 30-60m 3/4 1 1 1 1-1/4 1-1/4 *Note: These figures are for Natural Gas (.65 Sp. Gr.), and are based on 1/2" water column pressure drop. Check supply pressure with a manometer, and local code requirements for variations. For LPG, reduce pipe diameter one size, but maintain a 1/2" minimum diameter. A 'normal' number of Tees and elbows have been taken into allowance. Table 6. Natural Gas Pipe Size Requirements* Gas Supply Inlet To Equipment Inlet Tee Fitting 3 in.
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Page 14 BRADFORD WHITE Brute MJV ini Single Circuit System Multi-Zone Pump System Multi-Zone Valve System Primary Secondary Multi-Zone Pump System BJV rute Mini Brute MJV ini PUMP CHECK VALVE Figure 10. Typical Plumbing Installations.
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Page 15 Brute Mini SECTION 5. Water Connections 5B By-pass Piping The following information and suggestions are made on by-pass piping as it affects the temperature rise at the boiler. A boiler temperature rise must be taken on all BJVS boiler installations. If the temperature rise exceeds 30°F (17°C) at full rate, it is an indication that the boiler is not receiving adequate water flow.
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Page 16 5C BRADFORD WHITE Adjusting the bypass: Refer to Figure 11. Provide a means of measuring temperature on the inlet pipe to the boiler such as using a strap on or infrared thermometer. Starting with both balancing valves fully open, start the boiler. Adjust the balancing valve on the return to the system slowly to provide 120°F (44°C) water at the inlet to the boiler, leaving the bypass balancing valve fully open. As the system warms up, this valve may need to be adjusted open.
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Brute Mini 5F Chilled Water Systems If the boiler is installed in conjunction with refrigeration systems, it shall be installed so that the chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the heating boiler.
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Page 18 BRADFORD WHITE The preferred piping configuration for JV boilers is always using primary/secondary piping. There are some applications that are acceptable without primary/secondary piping, see below.
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Page 19 Brute Mini SECTION 6. 6A. Electrical Wiring Follow these instructions to make the necessary initial electrical connections. 1. Remove the two screws attaching the front cover of the control box. 2. There are wires coiled in the area on the right side of the control box, supplied with wire nuts: black wires and white wires. 3. Follow the schematic in Figures 14A. and 14B.
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H Soupape De Gaz HW VR8304 Disconnect for 2 stage operation 2 1 BR Y 4 JUMPER CAVALIER 3 R R Limite Supérieure 1 2 3 PV C MV BK O Y BR Gas Valve HW VR8304 BK Blocked Vent Safety Switch BK (2-STAGE ONLY) BK Roll-Out Switch Limiteur De Retour De Falmme Y 4 5 6 High Limit Power Venter Receptacle See Doc.
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Brute Mini Page 21 JVS N 110 VAC N TEMP CONTROL PUMP 5A MAX R BK TRANSFORMER BK R GND FUSE 2A GND TEMP CONTROL R 4 2 DAMPER TEMP CONTROL HI LIMIT BL 1 P GAS ALVE POWER VENTER BK 4 BLOCKED VENT BK ROLLOUT SW BK IGNITION CONTROL 6 MV C PV 5 BR GAS VALVE Y MV O MV/PV PV TEMP CONTROL 3 BK H 2nd STAGE ONLY Figure 15B. Ladder Diagram JVS PILOT 1.25 (32) 0.10 TO 0.35 (3 to 9) MINIMUM FLAME LENGTH 0.50 (13) Figure 16. Main Burner/Pilot Flame Pattern.
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Page 22 BRADFORD WHITE COM HEAT Wiring with Taco Zone Valves COM HEAT Wiring with Honeywell Zone Valves COM HEAT Wiring with Multiple Zone Pumps Figure 17. Multiple Zone Wiring.
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Page 23 Brute Mini SECTION 7. SECTION 8. 7A Filling the System Operating Procedures It is crucial to the efficient operation of the system that all air be removed from the circuit. For this reason, an air scoop and vent should be located close to the boiler outlet, and there should be a minimum distance between cold water feed and system purge valve. 1. When the system has been completely installed, close all air vents and open the makeup water valve. Allow the circuit to fill slowly. 2.
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Page 24 BRADFORD WHITE 8C.
PAGE 25
Page 25 Brute Mini 1. Control Access Panel 2. Figure 18A. 8.D Operating Temperature Controls Note: The Temperature Controllers, the Dip switch panel, and the LED panel can be found under the Control Access Panel after removing the bolts. Two temperature controls are now standard on all JVS boilers. 1. The primary temperature controller maintains all normal heating operations. 2. A secondary, mechanical high-limit aquastat provides safe shutdown, should the primary controller fail.
PAGE 26
Page 26 BRADFORD WHITE DHW Operation The boiler target for DHW calls is fixed at 180 deg F. Note: There is no control of a DHW pump, so the boiler pump runs with the call for DHW. Limiting The boiler target is limited to a minimum and a maximum target to ensure that the water temperature does not exceed the limits. 1. Target Min - The boiler target minimum is the point at which the stages will start to turn on to maintain a minimum water temperature.
PAGE 27
Brute Mini SECTION 9. 9A. Maintenance 1. 2. 3. 4. 5. 6. 7. 8. 9. Lubricate the water circulating pump per the instructions on the pump. If a strainer is employed in a pressure reducing valve or the piping, clean it every six months. At start-up, and periodically thereafter, the burner and pilot flames should be observed. If the flame has the appearance of “sooting” tips, check for debris near the orifices and call the service technician.
PAGE 28
Page 28 9B. Electrical Troubleshooting 1. 2. 3. 4. 5. Remove the control box cover on the front of the boiler. Verify that 115 volts is reaching the boiler by testing across the black wire and the white wire on the transformer. Verify 24 volts transformer output by placing the meter leads on the yellow and red wires. If 24 volts is not evident, replace the transformer. Perform the following series of tests with one meter lead attached to the yellow wire on the transformer.
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Page 29 Brute Mini # Symptom Cause Remedy 1 Pump not operating No power . . . . . Pump defective . . . . . Incorrectly wired . . . . . Check circuit breakers and power source. Replace. Recheck wiring diagrams. 2 Pilot outage Inlet gas pressure too low . . . . . Consult gas utility company. Inlet gas pressure to boiler should be 5.5" (1.4 kPa) to 9.0" (2.2 kPa) water column on natural gas. 10.0" (2.5k Pa) to 14.0" (3.4 kPa) on propane gas.
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Page 30 BRADFORD WHITE Troubleshooting Honeywell SV9501/SV9601 Hot Surface Pilot System START • TURN GAS SUPPLY OFF • SET THERMOSTAT TO CALL FOR HEAT SV9501/SV9601 IS POWERED (24 VAC NOMINAL) NO YES IGNITER WARMS UP AND GLOWS RED PILOT VALVE OPENS NO CHECK: • LINE VOLTAGE POWER • LOW VOLTAGE TRANSFORMER • LIMIT CONTROLLER • THERMOSTAT • WIRING • FAN PROVING SWITCH ON COMBUSTION AIR BLOWER UNPLUG IGNITER MEASURE VOLTAGE AT TWO BOTTOM TERMINAL OF SV9501/SV9601 (24 VAC NOMINAL) NO REPLACE SV9501/ SV9
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Brute Mini Page 31 SECTION 10. Replacement Parts 10A Glossary of Terms Air Vent A device used to purge air from the Circuit. Should be located at the highest point in the Circuit. Branch The section(s) of supply and return piping, including the heat distribution units connected directly to the trunk. Also referred to as a “zone”. By-Pass A section of pipe (including an adjustable valve) that diverts part of the water flow from undersized piping to the boiler.
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Page 32 BRADFORD WHITE 10C Parts List JVS Mini-Therm JVS JVS-50 BJVS-50 JVS-75 BJVS-75 JVS-100 BJVS-100 Size JVS-125 BJVS-125 JVS-160 BJVS-160 JVS-225 BJVS-225 R0061600 W0039600 R0061600 W0039600 R0061600 W0039600 R0061600 W0039600 R0061600 W0039600 R0061600 W0039600 R0385100 V0077500 L0052601 L0052500 L0056500 L0055900 R0385100 V0077500 L0052602 L0052500 L0056500 L0055900 R0407700 V0079100 L0052603 L0052500 L0056500 L0055900 R0407700 V0079100 L0052604 L0052500 L0056500 L0055900 R0407700
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Page 33 Brute Mini 19 18 9 15 20 7 5 17 8 16 22 23 21 6 26 28 13B 12 (on left side) 25 13A 26 11 2 24 27 29 4 3 1 Figure 19B. JVS Parts Identification.
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Page 34 H2359000C BRADFORD WHITE 200 Lafayette St. Middleville, MI 49333 Warranty: (800) 531-2111 www.BradfordWhite.com Litho in U.S.A.