Installation and Operation Instructions Document 1295A 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 4.1 Gas Supply and Piping .......................................... 17 1.1 Introduction ........................................................ 1 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 ................................................... 31 11.1 System Maintenance ....................................... 42 8.2 CONTROLLER Modes ..................................... 32 11.2 8.3 User Mode ........................................................ 33 Appliance Maintenance and Component Description ........................................................ 42 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 Brute LX units 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 17" 43 73 " 4 20 AIR ELIMINATION VENT AIR INLET EXHAUST VENT 1.7 Dimensions, Brute LX 31 " 4 8 31 " 4 8 GAS N HYDRONIC INLET TOP 23 " 4 7 M O FRONT CONDENSATE TRAP HYDRONIC INLET F C DHW OUTLET SIDE GAS HYDRONIC OUTLET E J D G A L BOTTOM K B H DHW INLET Figure 5.
Page 5 Brute LX Size 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" (7) 1 150, 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
Page 6 BRADFORD WHITE CORP. 1.8 Unpacking The Brute LX is shipped in a single crate with the standard components packed with the appliance See Figure 6: 1. Remove all packing and tie-down materials. 2. Check contents of the carton against items shown. 7 4 2 5 8 1 Bird Screen 3 6 1) PRV 2) PRV Pipe w/ washer 3) Wall attach bracket 9 4) Outdoor sensor 5) Exhaust terminal assy 6) Air intake terminal assy 7) Gas Supply Shut Off Valve 8) Washer 9) Flow restrictor Figure 6.
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. Size 75°F Rise inches - 95% 1/2” NPT 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” NPT 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 C Centered Wall Bracket (supplied) 12P3013 2" Air Inlet 2.2 Wall Mount Hole Locations. 7 43 " 32" Exhaust and 19.6 cm Concentric 3 1 " 4 8.1 cm Overall Width 17 " 43.2 cm A B 2" Air Inlet16” 40.6 cm 7 43 " 2" Exhaust and 19.6 cm Concentric 3 1 " 4 Bolts/Anchors 8.1 cm(4) Centered provided by installer, Wall top Bracket Desired of Brute LX each is to be suitable for (supplied) 160 lbs [73kg] 12P3013 minimum.
m m Page 9 Brute LX SECTION 3. Size and Combustion Air Venting Boiler Volts Phase TheMLX Brute LX includes a standard CPVC vent/combustion 50 120 Single air adapter. field connections require use of PVC/CPVC MLX If75 120 Single vent materials, MLX 100the installer must 120use proper adhesive Singleto joinMLX CPVC 125 and/or PVC pipe and fittings. 120 Single MLX 150 120 Single MLX 175 120 Single 3.1MLX Combustion Air 120 220 Single Amps sectional area as the free area of the openings to which 1.
Page 10 BRADFORD WHITE CORP. MATERIAL ABS PVC, sch 40 CPVC, sch 40 Polypropylene Single wall galv. steel Table 6. INSTALLATION STANDARDS UNITED STATES ANSI/ASTM D1527 ANSI/ASTM D1785 or D2665 ANSI/ASTM F441 UL1738, ULC S636. 26 gauge CANADA 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. Btu/hr (734 square mm/kW) of the total input rating of all equipment located in the enclosure.
Page 11 Brute LX All venting must be installed according to this manual and any other applicable local codes, including but not limited to, ANSI Z223.1/NFPA 54, CSA B149.1, CSAB149.2 and ULC-S636. Failure to follow this manual and applicable codes may lead to property damage, severe injury, or death. 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.
Page 12 BRADFORD WHITE CORP. 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 3.2.
Page 13 Brute LX 3.3 Locating Vent & Combustion Air Terminals 3.3.1 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. Figure 12 shows the requirements for mechanical vent terminal clearances for the U.S. and Canada.
Page 14 BRADFORD WHITE CORP. 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.
Brute LX 3.3.3 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 11). 3.
Page 16 BRADFORD WHITE CORP. 3.4 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 17 Brute LX SECTION 4. Gas Supply and Piping 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 18 BRADFORD WHITE CORP. 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 19 Brute LX 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 20 BRADFORD WHITE CORP. 6.7 Condensate Drain A condensate drain trap is built into the Brute LX. Connect a 3/4” PVC pipe between the drain connection and a condensate neutralizer before entering drainage system. The condensate drain and included trap must be installed. When a condensate pump is not used, the tubing must continuously slope downward toward the drain with no spiraling. Consult local codes for the disposal method. Figure 13. DHW Connections with Anti-Scald Valve and Flow Restrictor.
Page 21 Brute LX 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. 6.8 Piping Schematics Expansion tank and auto feed Air Eliminator Heating Supply * * * * * Figure 14. Hydronic Piping — High and low temp zones.
Expansion tank and auto feed Heating Supply 1" piping to DHW Sediment trap Heating Return * Closely spaced tee's - 4 pipe diameters apart * * Air Eliminator * * * * * * * * * Figure 15. Hydronic Piping (only) — with an indirect tank as a zone. * 18" heat trap Indirect DWH Tank Page 22 BRADFORD WHITE CORP.
* Zones with: -zone valves 24V -balancing valves DHW Sediment trap check valve * Closely spaced tee's - 4 pipe diameters apart * Purge/drain valves 1-41" Primary loop Expansion tank and auto feed Air seperator Multi Mascot LXs for Large house residential with long / muliple baseboard zones check valve DHW Brute LX Page 23 Figure 16. Hydronic Piping — BLXC Multi boilers for large homes with long / multiple baseboard zones.
* Zones with: -zone valves 24V -balancing valves Note: Expansion tank may be required if system volume is over 50 gallons Sediment trap * * Closely spaced tee's - 4 pipe diameters apart Purge/drain valves 1-41" Primary loop Expansion tank and auto feed residential with long / muliple radiant zones Page 24 BRADFORD WHITE CORP. Figure 17. Hydronic Piping — BLXC Multi boilers for large homes with long / multiple radiant zones.
Figure 18. Hydronic Piping — BLXC Heating zones piped with zone pumps.
Figure 19. Hydronic Piping — Heating zones piped with zone valves.
Page 27 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.
OOR OR 2 Page 28 TANK UASTAT X/DHW ENSOR ECN REV. 7.9 C DRAFT 14-016N-08 JM 5-22-14 CHECK 1 ENG CD 5 Ladder Diagram, Connections, and Wiring Diagrams CHANGE: GRAPHIC CORRECTION (see Figure 20 thru Figure 22) 120VAC NEUTRAL PWB PWB-3 TEM SOR ELD RLOCKS BRADFORD WHITE CORP.
Brute LX 3.00 Page 29 1.
B A 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 DOW N 20 1 SAFETY O INTERLOCK MODBUS GND GROUND DC OUT DC IN + + - DHW SENSOR TANK AQUASTAT FIELD T INTERLK T SYSTEM SENSOR OUTDOOR SENSOR BK GY R FROM X8 LINE W/V W 12 DHW PUMP RELAY SYSTEM PUMP RELAY PUMPS BY OTHERS WHEN REQ'D R R BOILER PUMP BR FROM PWB PWB FACE UP SPARE Y W/GY NEUT W ALARM CONTACTS GY COMBI UNITS ONLY 3 WAY VALVE G G R BK BL BR V O 24 W BL GY Y BK R
Page 31 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 32 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 24. 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 33 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.
Laars SIT Parameters BRADFORD WHITE CORP. Page 34 USER MODE 8.4 INSTALLER Mode CIRCULATION PUMPS BMS ANTICYCLING & FLAGS Control Service User settings Description DEFAULT PARAMETER Param INSTALLER Mode is an extensive set of parameters again. The INSTALLER Mode Parameters will then that can be changed to suit the individual installation and be accessible by pressing U000 DHW set point 120 °Fthe Up or Down arrows.
Page 35 Table 16.
Page 36 8.8 High Limit The control uses a dual thermistor sensor to monitor the Brute LX's maximum temperature. The high limit sensor is installed in the outlet water. A dual thermistor sensor is used, so that the two temperatures can be monitored and compared to confirm accuracy. The control will automatically reduce the firing of the Brute LX to prevent the high limit from tripping. The high limit setpoint is not adjustable. 8.
Page 37 Brute LX 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 38 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 39 Brute LX SECTION 10. Set Up Instructions 10.1 Filling the Boiler System 1. 2. 3. 4. Ensure the system is fully connected. Close all bleeding devices and open make-up water valve. Allow system to fill slowly. 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.
Page 40 BRADFORD WHITE CORP. 4. Brute LX will enter the start sequence. Blower and pump will energize for pre-purge, then the ignition sequence starts. After all safety devices are verified, the gas valve opens. If ignition doesn’t occur, turn off the Brute LX, check that there is proper gas supply. Wait 5 minutes and start the unit 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.
Page 41 Brute LX Note: High and Low Fire CO2 settings should be approximately equal. Adjustment Screws on Gas Valve Close door first, before measuring CO2 Range High-fire setting Manifold Pressure Screw (under cap) Figure 26. Adjustment Screws and Settings for CO2 GAS TYPE CO2 (%) RANGE Natural 8.9 __ 9.9 Propane 9.9 __ 10.9 ) Table 17. CO2 Range and Pressure Settings.
Page 42 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 43 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 44 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 46 E001 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 47 Brute LX This Page Is Intentionally Blank
Page 48 BRADFORD WHITE CORP. 12 SECTION 13. Replacement Parts 13.1 11 42 Exploded Parts Views, and their Bradford White Part Numbers See Figure 31 and Figure 32, for blower and combustion parts 43 44 14 47 46 45 26 40 13 34 10 28 7 37 38 35 32 31 39 29 33 4 41 5 6 30 3 Figure 30.
2P3002 2P2003 Ref 2P9102 2P9103 2p2000 E2356900 2P7008 2P3002 2P2003 2P4000 2p2000 2P3003 2P4000 2P3001 2P3003 10 11 12 13 14 15 16 17 1 18 2 19 3 19 3 19 4 20 5 21 6 22 7 23 8 24 9 24 10 24 11 24 12 25 13 26 14 27 26 15 26 16 26 17 26 18 26 19 26 19 26 19 20 27 27 21 28 22 28 23 28 24 29 24 30 24 31 24 32 25 33 26 34 27 26 35 26 37 26 38 26 39 26 40 26 41 26 41 27 42 27 43 28 44 28 45 28 46 46 29 46 30 47 31 47 32 33 34 35 37 38 E2357200 P2074600 P2074500 E2357300 Brute LX E2357500 S2105400 2-
Page 50 BRADFORD WHITE CORP. 20 18 4 19 15 16 25 24 23 21 22 27 26 Figure 31.
E2356900 2P7008 2P3002 Ref 2P9102 2P2003 2P9103 E2356900 2P7008 2p2000 2P3002 2P2003 2p2000 2P4000 2P3003 2P4000 2P3001 5 E2359000 6 RE2356900 7 E2356800 8 Brute E2335100 LX 9 E2318900 10 E2357200 11 P2074600 12 P2074500 13 E2357300 2-Jun-14 Part # PN Laars 14 E2357500 1 P2067603 15 S2105400 2 S2116300 16 12P2065 3 A 2117500 17 S2124500 3 R2076000 18 S2127600 4 P2093100 19 RA2112400 5 EA2122500 2359000 19 6 RE2356900 19 RA2114200 7 E2356800 20 V2022700 8 E2335100 21 RW2013400 22 W2014200
BRADFORD WHITE CORP. H2364001A Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement. 200 Lafayette St. Middleville, MI 49333 Warranty: (800) 531-2111 www.BradfordWhite.com Litho in U.S.A.