Installation and Operation Instructions Document 1295C Installation and Operation Instructions for Brute LX ® Wall-Mounted Modulating Boiler Model BLXH 50, 75, 100, 125, 150, 175 & 220 MBH Combination Boiler and Water Heater Model BLXC 125, 150 and 175 MBH FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler and heater installation and maintenance.
BRADFORD WHITE CORP. TABLE OF CONTENTS SECTION 1. General Information SECTION 4. Gas Supply and Piping 1.1 Introduction ......................................................... 1 4.1 Gas Supply and Piping........................................... 18 1.2 To Open the Brute LX.......................................... 1 1.3 Rating Plate......................................................... 1 1.4 Model Nomenclature........................................... 1 1.5 Brute LX Overview.............
Brute LX SECTION 8. CONTROL Setup and Operation SECTION 11. Maintenance 8.1 Digital Display.................................................... 33 11.1 System Maintenance ........................................ 44 8.2 CONTROLLER Modes..................................... 34 11.2 8.3 User Mode......................................................... 35 Appliance Maintenance and Component Description......................................................... 44 8.4 Installer Mode.................
BRADFORD WHITE CORP. SECTION 1. General Information THE Brute LX ® START-UP INSTRUCTIONS WIRING DIAGRAM RATING PLATE Figure 1. Opening the Brute LX. The top and bottom panels come off when pulled forward. This is true for all sizes. WARNING The Brute LX must be installed in accordance with the procedures detailed in this manual, or the Bradford White warranty will be voided.
Page 1 Brute LX 1.1 Introduction Edition “National Fuel Gas Code” or 2) CSA B149.1 “Natural Gas and Propane Installation Code” and with the requirement of the local utility or other authorities having jurisdiction. Such applicable requirements take precedence over the general instructions contained herein. All electrical wiring is to be done in accordance with the local codes, or in the absence of local codes, with: 1) The National Electrical Code ANSI/NFPA No. 70-latest Edition, or 2) CSA STD. C22.
Page 2 BRADFORD WHITE CORP. 1.
Brute LX 1.6 Start Up / Shut Down Instructions (Decal) The Start Up / Shut Down Instruction (Decal) can be found on the metal panel behind the Top Panel. See Figure 1. This Decal is also referred to as the Operating Instructions Label and/or Warning Label. FOR YOUR SAFETY READ BEFORE OPERATING "WARNING: If you do not follow these instuctions exectly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot.
Page 4 BRADFORD WHITE CORP. HYDRONIC OUTLET 1.7 Dimensions, Brute LX 17" 43 73 " 4 20 AIR ELIMINATION VENT AIR INLET 31 " 4 8 Gas and Hydronic fittings at both the top and the bottom of the unit. 31 " 4 8 BURNER SERVICE DOOR Exhaust Vent and Air Inlet Collars fit standard 2" PVC piping.
Page 5 Brute LX Model Dimension A B C D E F G H J* 50, 75 MBH 1" (3) 15-3/4" (40) 3-3/4" (9) 9-1/4" (24) 8" (20) 1-1/2" (4) 5-3/4" (14) 15-1/2" (39) -- 100 MBH 1" (3) 15-1/2" (39) 1-1/4" (3) 12-3/4" (33) 11" (28) 1-1/4" (3) 9-1/2" (24) 14-3/4" (37) -- 125 MBH 1" (3) 15-1/2" (39) 1-1/4" (3) 12-3/4" (33) 11" (28) 1-1/4" (3) 9-1/2" (24) 14-3/4" (37) 2-3/4" 150, 175 MBH 1-1/2" (4) 15-1/4" (39) 1-3/4" (4) 13" (33) 11-1/4" (28) 2-3/4" (7) 5-1/4" (14) 2" (5) 2-3/4
Page 6 BRADFORD WHITE CORP. 1.8 Unpacking and the Installation Kit All Brute LX's are shipped in a single box with an Installation Kit. See Figure 5. Unpack the unit and check that all components shown are included with your unit. The Installation Kit contains the following items. 3 2 1 4 1. Flow Restrictor 2. Outdoor Sensor 3. Ball Valve 4. Exhaust Terminal Assembly 5. Air intake terminal Assembly 6. Condensate Trap Assembly (1) 7. Wall Mount Bracket 8. Safety Wall Brackets (2) 9.
Page 7 Brute LX SECTION 2. Locating the Appliance 2.1 Locating the Appliance Sizing Data WALL The Brute LX is designed for indoor wall-mounted installations only. Input Model MLX 50 Output BTU/h kW BTU/h kW 50,000 14.6 47,500 13.2 DHW AFUE Gas Output @ Conn. 75°F Rise inche - 95% 1/2” N The Brute LX must be mounted to a suitable wall by a MLX 75 75,000 21.9 71,250 20.8 95% 1/2” N qualified heating contractor under the guidelines of a MLX 100 100,000 29.3 95,000 27.
Overall Width 17 " Page 8 43.2 cm Bolts/Anchors (4) provided by installer, each is to be suitable for BRADFORD WHITE CORP. 160 lbs [73kg] minimum. Centered Wall Bracket (supplied) 12P3013 2" Air Inlet C 2.2 Wall Mount Hole Locations. 7 3 " 4 19.6 cm 32" Overall Width 17 " 43.2 cm A B 2 Exhaust and Concentric 3 1 " 4 8.1 cm 2" Air Inlet16” 40.6 cm 7 43 " 2" Exhaust and 19.6 cm Concentric 3 1 " 4 Bolts/Anchors 8.
Page 9 Brute LX SECTION 3 VENTING AND COMBUSTION AIR 3.1 General Venting This product requires a special venting system. Refer to venting supplier’s instructions for complete parts list and method of installation. The manufacturers and product lines listed on the following tables have been tested and authorized to safely operate with Bradford White equipment.
Page 10 BRADFORD WHITE CORP. Method 1: Two permanent openings, one commencing within 12" (300mm) of the top and one commencing Amps within 12" (300mm) of the bottom, of the enclosure shall 1.5 be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces 1.5 that 1.5 freely communicate with the outdoors. When directly communicating with the outdoors, or when 1.5 communicating to the outdoors through vertical ducts, 1.5 each 2.
Page 11 Brute LX INSTALLATION STANDARDS MATERIAL ABS PVC, sch 40 CPVC, sch 40 Polypropylene Single wall galv. steel Table 6. UNITED STATES ANSI/ASTM D1527 ANSI/ASTM D1785 or D2665 ANSI/ASTM F441 UL1738, ULC S636. 26 gauge Air pipe material must be chosen CPVC, sch 40, ANSI/ASTM, Polypropylene based upon the intended application of the boiler. Required Combustion Air Pipe Material.
Page 12 INSTALLATIONS IN CANADA require the use of venting material certified to ULCS636. All Gas vents connected to the Brute LX, plastic, stainless steel or otherwise must be certified to this ULC standard. Appropriate selection of vent material is very important for proper performance and safe operation of the Brute LX. The flue temperature of the Brute LX changes dramatically with changes in operating water temperature.
Page 13 Brute LX INSTALLATION STANDARDS MATERIAL Stainless Steel PVC, sch 40 CPVC, sch 40 Polypropylene Table 8. UNITED STATES UL 1738 ANSI/ASTM D178 ANSI/ASTM F441 UL1738 or ULC-S636 CANADA Venting must be ULC-S636 certified for use as venting material. The venting material must be chosen based upon the intended application of the boiler. Required Exhaust Vent Material. Allowable Polypropylene Vent Manufacturers / Trade Names 3.3.
Page 14 BRADFORD WHITE CORP. 3.4 Locating Vent & Combustion Air Terminals 3.4.1 Side Wall Vent Terminal The appropriate Bradford White side wall vent terminal must be used. The terminal must be located in accordance with ANSI Z223.1/NFPA 54 and applicable local codes. In Canada, the installation must be in accordance with CSA B149.1 or .2 and local applicable codes. Consider the following when installing the terminal: 1.
Page 15 Brute LX U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) See note 6 12 inches (30 cm) See note 6 B= Clearance to window or door that may be opened Direct vent only: 12 inches (30cm); Other than Direct vent: 4 ft (1.
Page 16 3.4.3 Vertical Vent Terminal When the unit is vented through the roof, the vent must extend at least 3 feet (0.9m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6m) higher than any portion of a building within a horizontal distance of 10 feet (3.0m), and high enough above the roof line to prevent blockage from snow. When the combustion air is taken from the roof, the combustion air must terminate at least 12" (30cm) below the vent terminal (see Figure 10). 3.
Page 17 Brute LX 3.5 Common Vent Test NOTE: This section does not describe a method for common venting Brute LX units. It describes what must be done when an existing unit is removed from a common vent system. Brute LX units require special vent systems and fans for common vent. See Section 3.2.1 or contact the factory if you have questions about common venting Brute LX units.
Page 18 SECTION 4. Gas Supply and Piping BRADFORD WHITE CORP. WARNING: Open flame can cause gas to ignite and result in property damage, severe injury, or loss of life. 4.1 Gas Supply and Piping Gas piping should be supported by suitable hangers or floor stands, not the appliance. Review the following instructions before proceeding with the installation. 1. Verify that the appliance is fitted for the proper type of gas by checking the rating plate.
Page 19 Brute LX SECTION 5. Pump Capacity Brute LX NATURAL GAS REQUIRED SIZE CU FT / HR INPUT RATE. 50 75 100 125 150 175 220 50 75 100 125 150 175 220 5.1 Brute LX Heating System Capacity TO SIZE PIPING: Measure linear distance from meter outlet to last boiler. Add total input of all boilers and divide by 1000 to obtain cu ft / hr required. Add total equivalent length of fittings used according to Table 6B.
Page 20 Brute LX's efficiency is higher with lower return water temperatures. Bradford White strongly recommends that Brute LX be piped in a primary-secondary fashion (using either piping or a hydraulic separator) such that the pump that is mounted on the boiler ONLY serves the boiler. Brute LX boiler must be located within 15 feet (4.6m) of the supply and return header (or the hydraulic separator). The pump is sized for a maximum of 30 feet (9.1m) of piping and the headloss of the boiler only.
Page 21 Brute LX 6.7 Condensate Trap Installation The condensate kit for your unit is part of the installation kit. See Section 1.11. For wall mounted models sized 50 and 75 MBH, fasten the condensate trap to the condensate tray using the two hose clamps and the hose. See Figure 12. Then secure the condensate trap to the unit using the wire-tie. Two hose clamps and the hose A condensate drain must be installed to prevent accumulation of condensate.
Page 22 BRADFORD WHITE CORP. For models sized 100 to 220 MBH, fasten the condensate trap to the condensate pan using the two hose clamps and the hose. See Figure 13 and Figure 14 Fasten the bracket to the bottom of the unit using the included two mounting screws. Then secure the condensate trap to the bracket using the two wire-ties. Bracket Two wireties to fasten the condensate trap to the mounting bracket Two mounting screws Figure 13.
Page 23 Brute LX 6.8 Piping Schematics Figure 15 through Figure 20 illustrate typical piping configurations for Brute LX boilers. Although these illustrations show a wall mounted model or models, they are appropriate for floorstanding models as well and are only intended as a guide. All components or piping required by local codes must be installed in their appropriate locations. 1-1/4" Primary Loop Figure 16. DHW Connections with Flow Switch, Anti-Scald Valve and Flow Restrictor. Figure 15.
Page 24 BRADFORD WHITE CORP. CAUTION Scalding Risk: Bradford White recommends the use of a thermostatic mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding. Contact Bradford White for recommended models. 1-1/4" Primary Loop __________________________________________ Figure 17. Hydronic Piping (only) — with an indirect tank as a zone.
Page 25 1-1/4" Primary Loop Brute LX Figure 18. Hydronic Piping — BLXC Multi boilers for large homes with long / multiple baseboard zones.
Page 26 1-1/4" Primary Loop BRADFORD WHITE CORP. Figure 19. Hydronic Piping — BLXC Multi boilers for large homes with long / multiple radiant zones.
Page 27 Increase from 3/4" to 1-1/4" 1-1/4" Primary Loop Increase from 3/4" to 1-1/4" Brute LX Figure 20. Hydronic Piping — BLXC Heating zones piped with zone pumps.
Page 28 Increase from 3/4" to 1-1/4" 1-1/4" Primary Loop BRADFORD WHITE CORP. Figure 21. Hydronic Piping — Heating zones piped with zone valves.
Page 29 Brute LX SECTION 7. Electrical Connections WARNING The appliance must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the latest edition of the National Electrical Code, ANSI/ NFPA 70, in the U.S. and with latest edition of CSA C22.1 Canadian Electrical Code, Part 1, in Canada. Do not rely on the gas or water piping to ground the metal parts of the boiler.
2 REVISIONS Page 30 C 7.10 BRADFORD WHITE ECN DRAFT CORP. REV.
Brute LX 3.
B 40 O O O V G G BK R BL BR GY BL O V R BK Y GY BL 21 W Y G FWB FACE DOWN 20 1 SAFETY O INTERLOCK MODBUS A GND GROUND DC OUT DC IN + + - DHW SENSOR TANK AQUASTAT FIELD T INTERLK T SYSTEM SENSOR OUTDOOR SENSOR R FROM X8 FRO M X4 FRO M H-X/DHW SEN SO R BK GY LINE 24 DHW PUMP RELAY SYSTEM PUMP RELAY PUMPS BY OTHERS WHEN REQ'D R R BOILER PUMP BR FROM PWB PWB FACE UP SPARE ALARM CONTACTS Y W/GY GY COMBI UNITS ONLY 3 WAY VALVE G G R BK BL BR W/V W
Page 33 Brute LX SECTION 8. Control Setup and Operation sensors. The control regulates the boiler set temperatures and operating modes. For typical heating and DHW operation, the control is programmed to give priority to domestic hot water. The control is setup using the User Interface which contains 5 buttons and a digital display. The Brute LX control is an integrated electronic control that includes flame control, safety device monitoring and pump regulating functions.
Page 34 BRADFORD WHITE CORP. 3 4 5 8 7 1 6 2 Up (next) Looping Scroll Down (next) 10 9 Reset 11 12 13 Cancel 14 15 SELECT / OK Figure 26. Display Icons These icons and numbers are always displayed (either outlined or 'Darkened') 1- Current or set temperature, parameter number, modulation percentage. 2- Set temperature, parameter value, error code, announcement code. 3- Temperature unit (will show either Fahrenheit or Celsius). 4- Percentage or temperature set point.
Page 35 Brute LX 8.3 USER Mode The USER Mode is for a homeowner or service technician to adjust the most common operating parameters (See Table 14). In the USER Mode, when the boiler is ON and operating normally, the USER can scroll Up and Down using the Arrow Keys. Of the 7 viewable parameters, 4 can be adjusted (depending on if they are installed). The USER adjustable parameters are the Outlet Temp, DHW Setpoint, and Outdoor Air Temp.
Page 36 BRADFORD WHITE CORP. 8.4 INSTALLER Mode INSTALLER Mode is an extensive set of parameters that can be changed to suit the individual installation and should only be accessed by a trained service technician or installer. To access the INSTALLER Mode, hold 'Select/OK' and the down ˅ arrow key simultaneously until U00 is displayed. Press 'Select/OK' again and then release. Change the value to 15 and then press 'Select/ OK' again.
P35 BMS Rate at Minimum Voltage 200 0.01VDC 2.0 VDC P36 BMS Rate at Maximum Voltage 1000 0.01VDC 10.0 VDC Brute LX P37 BMS Temperature Set Point at Min Voltage 140 °F P38 P39 P40 P41 P42 P43 P44 P45 P46 P47 P48 P49 P50 P51 P52 P53 P54 P55 P56 P57 P58 P59 P60 P61 P62 P63 P64 P65 P66 P67 P68 P69 P70 P71 P72 P73 P74 P75 180 30 60 60 60 60 60 15 250 0 0 3276 3276 120 10 15 15 20 60 140 40 35 5 40 180 65 120 68 5 0 0 0 44 189 10 20 30 °F Seconds Seconds Seconds Seconds Seconds Seconds °F 0.
Page 38 8.6 Modulation Control The control uses a PID algorithm to adjust the firing rate of the boiler as the control point is approached. The goal of the control is to operate at a minimum firing rate to match the load on the appliance. 8.7 Pump Control The boiler pump is active anytime there is a call for heat applied to the control. When there is a central heat call the system pump relay is active. If there is a DHW call while the central heat call is active the system pump turns off.
Page 39 Brute LX Op era tin gc on dit ion (warm weather shutdown) 9.4 Warm Weather Shutdown Figure 27. Outdoor Reset Setpoint Temperatures. The Brute LX can use an external 0-10VDC signal to control its fan speed (modulation rate), or to control its outlet setpoint. The 0-10V signal may also be used to create a heat demand eliminating the need to supply a separate “TT call”. 9.3.a External Signal to Control Modulation.
Page 40 9.7 Cascade Auto Configuration To operate up to 8 boilers in cascade, the boilers must be “daisy chained” together using Modbus terminals A, B and GND, located on the boilers terminal block. The wiring should be completed with at least three wire shielded cable with ground. The ground wire should be connected to a suitable chassis ground on one end of the daisy chain only. Wire each boilers terminal A in series with the next boilers terminal A until all are connected.
Page 41 Brute LX SECTION 10. Set Up Instructions 10.1 Filling the Boiler System 1. Ensure the system is fully connected. Close all bleeding devices and open make-up water valve. Allow system to fill slowly. 2. Move manual lever on 3-way valve actuator to "open" position, allowing air to purge from boiler loop. Valve is normally in DHW position until there is a call for Central Heat via "T-T" contacts. 3. Adjust the pressure regulator/make up water to provide at least 12 psi (81.
Page 42 BRADFORD WHITE CORP. again. 5. Turn Brute LX on. 6. After placing the appliance in operation, the Burner Safety Shutoff Device must be tested: (a) Close gas shutoff valve with burner operating. (b) Flame will go out and blower will continue to run for the post purge cycle. Three additional attempts to light will follow including pre-purge, ignitor on, valve/flame on and post purge. Ignition will not occur as the gas is off. The ignition control will lockout. (c) Open gas shutoff valve.
Page 43 Brute LX Adjustment Screws on Gas Valve Close door first, before measuring CO2 Range High-fire Adjustment (2.5 mm Hex) Manifold Pressure Screw (under cap) + Low-fire Adjustment (4 mm Hex) (under slotted cap) Figure 28. Adjustment Screws and Settings for CO2 GAS TYPE Natural Propane CO2 (%) RANGE ) 8.9 __ 9.9 9.9 __ 10.9 Table 17. CO2 Range and Pressure Settings. Note: H igh and Low Fire CO2 settings should be approximately equal.
Page 44 BRADFORD WHITE CORP. SECTION 11. Maintenance WARNING Disconnect all power to the appliance before attempting any service to the appliance. Contact with electricity can result in severe injury or death. 11.1 System Maintenance (yearly, unless otherwise noted) 1. If a strainer is employed in a pressure reducing valve or the piping, clean it every six months. 2. Inspect the venting system for obstruction or leakage at least once a year.
Page 45 Brute LX the fastening points on the right side of the control to remove the hooks from the control panel. To replace the control repeat the steps above in the reverse order making sure to connect all wires in the proper location. Place the appliance in operation following the steps outlined in Section 10. 11.2.3 Ignitor Assembly The ignitor assembly is a two rod system that consists of a ground rod and a sense rod.
Page 46 BRADFORD WHITE CORP. WARNING Failure to rinse the debris from the heat exchanger and temporary drain line may lead to clogged condensate lines, traps and neutralizers. Condensate pumps (if used) may also be damaged from the debris left behind, possibly causing property damage. 10. Install all components removed in the reverse order to place the appliance back in operation. Make sure all gaskets are in place as components are installed. Replace any damaged gaskets. Do NOT reuse damaged gaskets.
Brute LX SECTION 12. Troubleshooting 12.1 Sequence of Operation Brute LX is a cold start appliance that should start only on a call for heat from a tank aquastat, room thermostat, zone valve end switch or other space temperature control device (flow switch for DHW). 1. Upon a call for heat: (a) the internal pump and system pump will start; (b) the blower will begin a short pre-purge. 2. Following the prepurge cycle the direct spark ignition will spark and will begin a 4 second trial for ignition.
LOCKOUT CODES CODE DESCRIPTION Page E001 48 Memory error lockout E002 Fan speed error E003 Flame present when not in run 12.3 Codes - See E004 Error Outlet auto-reset hi Table limit 18.
Page 49 Brute LX 12 SECTION 13. Replacement Parts 11 42 13.1 Exploded Parts Views, and their Bradford White Part Numbers See Figure 33, For blower and combustion parts 43 44 14 47 46 4 45 26 40 13 34 10 28 7 37 38 35 32 31 39 29 33 4 41 5 6 30 3 Figure 32.
3 2 3 0 900 8 2 3 0 0 3 01 3 11 P2074600 12 P2074500 13 E2357300 Page 50 14 E2357500 15 S2105400 2-Jun-14 16 12P2065 Part # Laars PN 17 S2124500 1 P2067603 18 S2127600 2 S2116300 19 RA2112400 3 AA2122500 2117500 19 3 R2076000 19 RA2114200 4 PV2022700 2093100 20 5 E 2359000 21 RW2013400 6 RE2356900 22 W2014200 7 E2356800 23 W2014300 8 E2335100 24 RL2018401 9 E2318900 24 RL2018402 10 E2357200 24 RL2018403 11 P2074600 24 RL2018404 12 P2074500 25 S2127300 13 E2357300 26 S2127200 27 RW2013300 14 E
Page 51 Brute LX 20 18 4 19 15 16 25 24 23 21 22 27 26 Figure 33.
2 32 3 6900 08 2 3 0 0 3 0 1 3 8 9 10 11 12 13 14 1 15 2 16 3 17 3 18 4 19 5 19 6 19 7 20 8 21 22 9 23 10 24 11 24 12 24 13 24 14 25 15 26 16 27 17 26 18 26 19 26 19 26 19 26 20 26 21 26 22 27 23 27 24 28 24 28 24 28 24 29 25 30 26 31 27 32 26 33 26 34 26 35 26 37 26 38 26 39 26 40 27 41 27 41 28 42 28 43 28 44 29 45 30 46 31 46 32 46 33 47 34 47 35 E2335100 CIRCUIT BREAKER, 2A x x x x x x x E2318900 CIRCUIT BREAKER, 10 AMP x x x x x x x E2357200 SENSOR, DUPLEX, FLUE x x x x x x x Brute LX P20