Installation and Operation Instructions Document 1266F Installation and Operation Instructions for Brute ® Modulating Boiler Water Heater Model BNTH1000 Model BNTV1000 Model BNTH1200 Model BNTV1200 1,000 MBTU/h 1,200 MBTU/h 1,000 MBTU/h 1,200 MBTU/h 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 Table of Contents SECTION 1 General Information 1.A 1.B 1.C 1.D 1.E 1.F 1.G Introduction........................................................ 5 Warranty............................................................ 5 Model Identification............................................ 5 Safety Notes...................................................... 6 Model Overview................................................. 8 Dimensions........................................................
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h SECTION 9 Setup and Configuration 9.A Review of Lead Lag Control System............... 51 9.A.1 About Lead Lag Operation.............................. 51 9.A.2 Lead Lag Modulation Cycle............................. 52 9.A.3 Boiler Lead Lag with Indirect Domestic Hot Water........................................ 53 9.B Connection Terminals...................................... 53 9.C System Configurations....................................
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Brute SECTION 1 1.A Page 5 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® General Information Touch Screen Display (behind the plastic cover which slides downward) Introduction Power switch This manual includes information which will help you to install, operate, and maintain the Brute 100 and 1200 systems. Please read this manual completely before proceeding with the installation.
Page 6 1.D BRADFORD WHITE Safety Notes Safety Notes are used thoughout this manual to bring attention to the presence of hazards with various risk levels and to offer important information concering the life of this product. There are 3 basic types. 1 WARNING 2 CAUTION 3 Indicates an imminently hazardous situation which, if not avoided, can or will result in death or serious injury and can or will result in catastrophic property damage.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h WARNING Electrical Shock Hazard Electrical shock can cause severe injury, death or property damage. Disconnect the power supply before beginning installation or changing the wiring to prevent electrical shock or damage to the equipment. It may be necessary to turn off more than one power supply to disconnect.
Page 8 1.E BRADFORD WHITE Model Overview Protective Cover (slides downward) Touchscreen Power switch Rating Plate Ducted air inlet (on outside panel) Pressure and temperature gauge Electrical box PRV and flow switch Blower 1 (under bezel) Outlet temperature sensors Automatic gas valves Inlet temperature sensors Manual gas valve Blower 2 Condensate trap Figure 1. Components 1.F Dimensions Figure 2.
Dimensional Data BOILERS AND VOLUME Brute NeoTherm LC WATER HEATERS, 1,000 & 1,200 MBTU/h ® 1000 & 1200 Dimensions (continued) Figure 3. Dimensions overall 1.G The Installation Kit The unit is shipped in a single crate with a boxed installation kit that contains these components. • Vent Pipe Adapter, 6” PVC to 6” Steel • Vent Pipe, CPVC, 6” SCH 40 @ 6” dia. • Cable Tie for Vent Pipe. • Boxed Kit for tank and outdoor system sensor. 1. Remove all packing and tie-down materials. 2.
Page 10 SECTION 2 2.A BRADFORD WHITE Locating the unit Locating the unit This unit may be installed indoors or outdoors. If installing in a location that may experience freezing temperatures, precautions must be taken to prevent water in the heat exchanger and condensate inside and outside of the boiler from freezing. Damage due to freezing water or condensate is not covered by the warranty. This unit should be located to provide clearances on all sides for maintenance and inspection.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h SECTION 3 Page 11 Venting and Combustion Air General Venting 3.A General Venting This requires a specialventing ventingsystem. system. Refer supplier’s for complete parts list method Thisproduct unit requires a special Referto ventingDo not mix instructions venting suppliers and models in and venting of The manufacturers product lines listed on the following tablesto have been could testedresult and authorized to to installation.
Page 12 3.B BRADFORD WHITE Combustion Air These boilers and water heaters must have provisions for combustion and ventilation air in accordance with the applicable requirements for Combustion Air Supply and Ventilation in the National Fuel Gas Code, ANSI Z223 1; or in Canada, the Natural Gas and Propane Installation Code, CSA B149.1. All applicable provisions of local building codes must also be adhered to.
Brute ® Page 13 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Method 2: One permanent opening, commencing within 12” (300 mm) of the top of the enclosure, shall be permitted.
Page 14 3.C Venting WARNING Selection of improper vent materials for installations that are installed in closets, or will be operated in high ambient temperature levels, may lead to property damage, personal injury, or death. WARNING A 12” or 305 mm section of CPVC must be connected directly to the boiler before a PVC vent system can be used. Connecting PVC directly to the boiler’s flue collar may cause vent failure, leading to property damage, personal injury, or death.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 15 be installed per the vent manufacturers certified installation instructions. It is the responsibility of the appropriately licensed technician installing this unit to use ULC S636 certified vent material consistent with the requirements as described in the Venting and Combustion Air section. Class I venting systems are suitable for gas-fired appliances producing flue gas temperature of more than 135°C, but not more than 245°C.
Page 16 BRADFORD WHITE 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 (30 cm); Other than Direct vent: 4 ft (1.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 17 IMPORTANT: All terminals must be placed so that they remain at least 12” above the expected snow line. Local codes may have more specific requirements, and must be consulted. Refer to the NFPA54 National Fuel Gas Code and your local codes for all required clearances for venting. Figure 7. Multiple Side-Wall Terminals, Air and Vent Figure 8.
Page 18 above the combustion air terminal. 5. Multiple vent kits should be installed such that the horizontal distance between outlet group and inlet group is 36” (90 cm). (See Figure 8.) 6. The vent outlet must be at least 12” above the top of the air inlet, and must be at least 36” (90 cm) horizontally from the air inlet. 3.D.3 Vertical Vent Terminal When the unit is vented through the roof, the vent must extend at least 3 feet (0.9 m) above the point at which it penetrates the roof.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h placed in operation, while the other appliances remaining connected to the common venting system are not in operation. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition. 3. As much as possible, close all building doors and windows.
Page 20 SECTION 4 4.A BRADFORD WHITE as Supply and G Piping Gas Supply and Piping All Installations must conform to the National Fuel Gas Code ANSI Z223.1/NFPA54, and/or local codes. In Canada, the installation must conform to the latest edition of CSA B149.1 Natural Gas and Propane Gas Installation Code, and/or local codes. Gas piping should be supported by suitable hangers or floor stands, not the appliance. Review the following instructions before proceeding with the installation. 1.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h NATURAL GAS REQUIRED SIZE CU FT / HR. 1000 1200 1000 1200 Page 21 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 9. Align total length (pipe and fittings) on left side column of Table 10 with highest cubic feet of gas required.
Page 22 BRADFORD WHITE SECTION 5 table 12 5.A Pump Requirements Boiler Flow and Head Requirements Flow and Head Requirements 15 table 12 25 30 Flow H/L Flow H/L Flow H/L Flow H/L Flow gpm feet gpm feet gpm feet gpm feet gpm feet gpm feet gpm 126 43.6 95 26.7 75 17.8 62 12.8 54 10.1 48 8.2 42.2 151 59.7 114 Flow and Head Requirements 36.6 91 24.8 76 18.2 65 13.9 57 11.1 50.7 15 gpm feet 1000 1000 126 20 35 H/L 6" gpm 6" feet95 100 gpm11 26.
Brute ® SECTION 6 Water Connections Section 6 is divided into TWO parts. Section 6A covers Boilers models designed for hydronic heating. Many installations include indirect domestic hot water. Section 6B covers Heater models, which are designed exclusively for “volume water” domestic hot water applications. Refer to the proper section for instructions on installing and piping your unit/model. Refer to Table 15 for the connection pipe sizes required. 6.
Page 24 purpose). Follow LWCO manufacturers instructions for minimum pipe sizing. Note: This unit is a water tube design that requires water flow through the heat exchanger for proper operation. It does not have an operating water level and must be full at all times. In accordance with ANSI/ASME CSD-1 Section CW-210 and The National Fuel Gas Code ANSI Z223.1/NFPA 54 Section 10.3.5 a water tube boiler shall have a water flow proving device in lieu of a Low Water Cut Off. 6.A.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 25 Low temp. radiant zone Space heating zone circuits Space heating zone circuit Air vent System pump Water feed controls 4 pipe dia. max. 4 pipe dia. max. 4 pipe dia. max. 4 pipe dia. max. Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Figure 9. Hydronic Piping — Single Boiler, Multiple Temperature Zones.
Page 26 BRADFORD WHITE 4 pipe dia. max. Air vent Expansion tank Water feed controls 4 pipe dia. max. Anti-scald mixing valve Domestic hot water out Indirect DHW tank Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Cold water Figure 10.
Brute ® Page 27 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Low temp. radiant zone Low temp. radiant zone Air vent Water feed controls Expansion tank 4 pipe Dia. Max 4 pipe dia. max. Anti-scald mixing valve Indirect DHW tank Domestic hot water out Cold water Figure 11.
Page 28 BRADFORD WHITE Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Space heating zone circuits Low temp. radiant zone Space heating zone circuit Air vent Water feed controls 4 pipe dia. max. 4 pipe dia. max. Expansion tank 4 pipe dia. max. Common piping must be sized for the combined water flow of all of the boilers. Figure 12.
Brute ® Page 29 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Space heating zone circuits High temp. space heating zone circuit Space heating zone circuit Air vent Water feed controls 4 pipe dia. max. 4 pipe dia. max. Expansion tank 4 pipe dia. max. Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. 4 pipe Dia.
Page 30 BRADFORD WHITE pressure relief. Install a diaphragm-type expansion tank, flow check, and shutoff valves where needed or as required by code. The piping should be installed so that each pump supplies flow only to the heater to which it is attached. 6.B.3 Heater Cold Water Make-Up The cold water make-up may be connected to the tank or to the inlet of the boiler as shown in Figure 14 thru Figure 16. Install back-flow preventers and shutoffs where needed or required by code.
Brute ® Page 31 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h 6.B.7 W ater Heater Suggested Piping Schematics Figure 14 thru Figure 16 show suggested piping configurations for water heaters. These diagrams are only meant as guides. All components or piping required by local code must be installed. 4 Expansion tank WARNING: This drawing shows suggested piping configuration and valving. Check with local codes and ordinances for additional requirements.
Page 32 BRADFORD WHITE WARNING: This drawing shows suggested piping configuration and valving. Check with local codes and ordinances for additional requirements. NOTES: 1. Optional CWMU & recirculation line location. 2. Locate the Heater DHW sensor or remote aquastat well in lower 1/3 of tank. 3. Back flow preventer may be required - check local codes. 4. Thermal expansion tank may be required - check local codes.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h WARNING This unit 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.
Page 34 BRADFORD WHITE TB9 TB2 TB1 TB5 TB3 TB6 TB4 TB7 TB TB10 Panel slides outward Secondary controller (lower burner) Figure 17.
Brute ® 7.C ptional Variable Speed O Pump Control V.S.P.C. is optional equipment on the hydronic boilers only. It is not available on the water heaters. With variable speed pump control, the pump speed is controlled to maintain a user-chosen temperature rise between the inlet and outlet of the unit of the hydronic boiler. V.S.P.C. will operate the boiler pump at maximum flow during boiler startup to ensure stable operation is reached before introducing variable water flow.
Page 36 7.H BRADFORD WHITE Building Automation System Connections This unit can be controlled (in either single or cascade) and monitored through the included Modbus ports. Signals from a Building Automation System can be connected to the MB2 Modbus connections on the controller. Follow instructions included with the BAS control to mount it to the provided holes in the unit Control Panel as shown in Figure 18. Laars Gateway Control (Kit and Instructions, H2354400 Doc# 4236).
Brute ® 7.I BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 37 Lead Lag Connections & Wiring Diagram Units can be connected in a lead lag up to 4 units with their 8 controllers total. One as the Lead control and 7 more controllers (2 per unit) as the following controllers. See Figure 18 For general info and menu set-up for Lead Lag using your units touchscreen, Please see Section 9.
Page 38 7.
Brute Page 39 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 7 8 2 3 4 DKBL/Y DKBL 6 1 DKBL DKBL DKBL 5 1 4 5 3 6 4 3 2 1 2 J8 PRIMARY J9 PIM 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 7 6 5 4 3 2 1 6 5 4 3 2 4 3 2 1 J2 J1 J4 J8 SECONDARY 1 2 3 4 5 6 7 8 9 10 11 12 J9 J5 PIM J6 POWER FLAME ALARM RESET J10 J11 MB1 MB2 ECOM ABC ABC 1 2 3 ABC A BC 1 2 3 PK B9-2A B9-3A TO TB9-6A TO TB9-5A PK/W Y/R V BN/G 2 V/BK 1 W/G TO TB9-7A TO TB9-8A TO
M. C. Page 40 7.K BRADFORD WHITE Ladder Diagrams OUTLET WATER TEMP. SENSOR A 1 2 J8-9 PRIM. 3 4 J8-8 PRIM. J8-10 PRIM. STACK TEMP. SENSOR J9-5 PRIM. 1 2 3 4 J9-5 SEC. J9-4 PRIM. 5 6 7 8 J9-6 PRIM. J9-4 SEC. J9-6 SEC. OUTLET WATER TEMP. SENSOR 1 2 J8-9 SEC. J8-8 SEC. 3 4 J8-10 SEC. J8-4 PRIM. 1 2 J8-5 PRIM. INLET WATER TEMP. SENSOR J8-5 SEC. 1 2 { { { { { { ANALOG INPUT PRIM. ANALOG INPUT SEC. OUTDOOR TEMP. SENSOR DHW TEMP. SENSOR PRIM. DHW TEMP. SENSOR SEC. SYSTEM TEMP.
Brute Page 41 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 120 VAC N MAIN POWER SWITCH TB1 A TB2 A J4-10 PRIM. PUMP POWER ON 1,000 ONLY J4 - 7 PRIM. J4 - 6 PRIM. BOILER PUMP RELAY J4 - 7 SEC. J4 - 6 SEC. BOILER PUMP RELAY J4-10 SEC. TB5-3B R1 6 BOILER PUMP J2 PRIM. TACH 1 5 PRIM. LINE DHW PUMP 3 FAN POWER 2 PWM OUT 3 FAN GND 4 J7-2 PRIM. J7-1 PRIM. 2 CONDENSATE SWITCH J7-1 SEC. J6-2 PRIM. OPTIONAL ADDITIONAL HIGH LIMIT J6-2 SEC. P1 NEUTRAL DHW PUMP 2 J7-2 SEC.
Page 42 7.L BRADFORD WHITE About the Touch Screen Display up for “Lead Lag” operation. The term “Lead Lag” means that, as the heating load increases, the control system brings additional burners on automatically. This unit has an advanced control system which can perform many functions. This is part of the reason why the models 1000 and 1200 can deliver such outstanding performance. You can access the control system using the ‘Touch Screen Display’ (see Section 8).
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h connected to the system. To reach one of the functions for an individual controller/burner, press the icon for that controller/burner. On the following screen, press the Configure button. This will take you to all of the configuration options for that individual controller/burner.
Page 44 SECTION 8 BRADFORD WHITE sing the touch U screen On/Off switch Touch Screen Boiler outlet temperature and system pressure Figure 26. Touch Screen, shown with the ‘home’ screen of the lead boiler in a four boiler configuration, all conditions normal. Figure 27. Touch Screen and Gauges 8.A Using the Touch Screen This unit uses a color touch screen to get input from the operator or installer, and to present information about the operation of the boiler.
Brute ® Useful Icons at the top of most screens Home Bell Padlock Back Page 45 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Upper left-hand corner Return to Home page Upper left-hand corner System in Lockout, Reset required Login lnt 1 2 3 4 5 6 7 8 9 0 - = q w e r t y u i o p [ ] a Upper right-hand corner Shows whether a password has been entered so parameters can be changed Upper right-hand corner Return to previous screen Sometimes a screen is used to pr
Page 46 BRADFORD WHITE At the bottom of the screen shown in Menu 4, the system is telling you that it wants you to log in. Menu 4. Login Required Color and Status 2. Blue Normal operation Red Lockout Gray Standby mode (Burner switch off) Gray and crossed out Communication problem Yellow Hold state. This could be Anti short cycle, fan speed transitions, etc. Press the View Lead Lag button to go to a screen that shows the status of the whole Lead Lag system.
Brute ® 2. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h You can change the setpoints from this screen. When you press the yellow box beside Setpoint, the controller presents this screen: Menu 8. Setpoints Screen Menu 10. Select the setpoint you want to change, then enter the new value 3. 8.E If you press the Details button, the control software leads you to a “ring” of screens that include some information about the way the Lead Lag system is set up.
Page 48 8.F Checking Individual Details The Details button on the Status Summary screen leads to a series of screens that show all of the setup parameters entered for the controller you have selected. Let’s say that the first screen presented in this series is the screen for Frost Protection. BRADFORD WHITE 8.G C onfiguring Parameters on Individual Controllers In this section, we will just give you a quick explanation of how to change parameters on one of the controllers.
Brute ® 3. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Press the Configure button to start a configuration session for the selected controller. See Menu 15. Menu 17. Menu 15. Configuration Screen This screen lists all of the configuration groups. (The list is actually longer – scroll down using the bar on the right side of the screen) Many of the items will not be useful to an installer or end-user. 4. Page 49 8.H 1.
Page 50 Menu 19. BRADFORD WHITE Verification Needed Notes – • Once you change one of these safety-related parameters, you must finish the verification process for the group that includes the parameter, or the control system will not let the boiler operate. You can wait to do the verification until you have changed parameters in other groups, but before you return the boiler to service, you have to do the verification for all of the groups you changed.
Brute ® SECTION 9 9.A Page 51 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Setup and Configuration eview of Lead Lag Control R System 9.A.1 About Lead Lag Operation All units are set up for Lead Lag operation. Even in a single-unit installation, there are two controllers and two burners, as shown in Figure 29. The controller for the upper burner is set up as the Primary control. For control purposes, this is the Lead Lag Leader and also operates as Lead Lag Follower 1.
Page 52 BRADFORD WHITE In either kind of installation, a system sensor is usually used to monitor the demand. The input from this sensor is used to control the modulation rates of the operating burners. Let’s consider the following example: Four units are tied together via Modbus connections.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h up and begin firing at 35% fan speed. After this, both of the active burners will modulate up or down together, in reaction to the changes in demand. See Figure 31. If the system loop temperature rises above the LL CH setpoint, then the two burners will simultaneously drop their fan speeds. If both boilers drop to their minimum fan speeds (29%), then the second burner will drop out.
Page 54 9.C BRADFORD WHITE System Configurations These units can be installed in many different arrangements. The steps in the installation will be different, depending on the number of boilers in the system, the venting arrangements, the control signals used, outdoor reset, etc. In this section, we will list the steps necessary to do the most common installations. 1. 2. Table 18 on page 55 lists most of the possible systems configurations. There are a lot of them.
Brute ® Page 55 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Table 18.
Page 56 BRADFORD WHITE 9.C Unit System Configurations (continued) Table 19.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 57 System 5 – Multiple boilers, Local control, Common vent Job A Note on common venting Job B Set up the names for each of the controllers Job C Make one control the Lead Lag Leader Job D On each of the controllers that will act as a follower, disable the Lead Lag Leader Job E Set up the Modbus control addressing to assign addresses for each of the controls Job F Set up the addresses for the flap valves Job G Disconnect the Touch Screen
Page 58 BRADFORD WHITE 9.
Brute ® Job C Job D Job E Job F Job G Job H Job I Job L Job M Job O Job P BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 59 Make one control the Lead Lag Leader On each of the controllers that will act as a follower, disable the Lead Lag Leader Set up the Modbus control addressing to assign addresses for each of the controls Set up the addresses for the flap valves Disconnect the Touch Screens that will not be used Connect the Modbus wiring Set the parameters used by the Lead Lag system Bu
Page 60 BRADFORD WHITE 9.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 61 System 21 – Multiple boiler, System control, Common vent, 4-20 mA modulation control Job A Note on common venting Job B Set up the names for each of the controllers Job C Make one control the Lead Lag Leader Job D On each of the controllers that will act as a follower, disable the Lead Lag Leader Job E Set up the Modbus control addressing to assign addresses for each of the controls Job F Set up the addresses for the flap valves Job
Page 62 9.D BRADFORD WHITE Installation Jobs Note – To install your system (your particular system configuration), you will not need to do all of the installation jobs listed here in Section 9.4. You only need to perform the jobs listed sequencially for your type of system previously. Please refer to Table 18 on page 55 and Table 19 on page 56 for a list of specific installation jobs necessary to install your system. Job A – Note for Systems Using Common Venting Menu 24. 3.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h 6. Now you can rename the other control on Boiler 1 – the Secondary control. Press the Home button in the top left-hand corner to go back to the ‘home’ screen which shows the different controls. 7. This time, press the icon for the Secondary control. Repeat steps 1 through 5. Change the name to “Boiler 1 Secondary.” 8. Go to the Touch Screen for the next boiler in the system.
Page 64 BRADFORD WHITE When the controllers arrive at the factory, they will all be configured as followers. Your job in this step is to disable the Lead Lag Leader function on each of the controls, except for the one control that will be used as the Lead Lag Leader – usually the Primary control on Boiler 1. 1. Menu 32. 4. Scroll down through the list until you find the line for LL Leader Configuration. See Fig. 62. From the ‘home’ screen, press the icon for the controller you want to work with.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h boilers there will be eight separate controllers. You will need to give each of these controllers a unique Modbus address. (Notice that this is different from the name of the controller. We set the controller names in a previous step.) 2. Power up all of the boilers in the system. It will take a minute for each Touch Screen to “synchronize” with its two controllers. 3. Start at the ‘home’ screen on the first boiler. Menu 34. 4.
Page 66 BRADFORD WHITE flap valves be identified correctly. Boiler 2 Primary (address = 3) and Boiler 2 Secondary (address = 4). Each controller in the system needs to know how many controllers are included in the whole system. You will need to enter this information in each of the controllers separately. 12. Repeat steps 3 - 10 for each of the other controllers connected to the system.
Brute ® 2. Page 67 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h This is the total number of controllers in the whole system. (For example, in a system with four boilers, there will be eight controllers.) See Table 20. Press the icon for the controller you want to work with. The system will take you to the Status Summary screen for that controller. You need to set both of these values on the Flap Valve Configuration screen for each controller in the system. Table 20.
Page 68 BRADFORD WHITE controls should be numbered for each of the boilers. In this example, we are still working with the Primary control for Boiler 1. From the table, you can see that this control should have a flap valve ID of “1.” Enter the correct ID from Table 22 in this field. WARNING If the controller cannot find a signal from one of the flap valves, the control system will act to prevent backflow by energizing the blower of the control with the bad flap valve.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 69 Job G – Disconnect Unused Touch Screens Menu 45. Safety Parameter Confirmation Check the list carefully. Press Yes if all of the parameters in the group have been entered correctly. 12. The system will tell you to reset the control system. Menu 46.
Page 70 BRADFORD WHITE are arranged in a “daisy chain.” The wiring from the Secondary controller on one boiler (TB9 - pins 7 through 12) to the Primary controller on the next boiler (TB9 - pins 1 through 6). See Figure 35. Use 22 AWG or thicker shielded twisted pair wire with drain. Two twisted pairs or three conductors are needed. You can also reference Figure 18 on page 36 for connections. (TB9) on each panel. 2. Figure 35 shows how to make the connections.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h 4. Menu 48. 2. Lead Lag Leader Screen Press the Configure button. The display will present the Lead Lag Leader Configuration Screen. Page 71 To see the other settings related to the Lead Lag functions, press the button for Advanced Settings. This leads to a “ring” of related screens, and you can scroll through the list by pressing one of the left- or right-arrow symbols.
Page 72 6. BRADFORD WHITE Press the left-arrow or right-arrow until you see the Central Heat screen. Menu 51. Central Heat Setpoint source This sets the source of the System sensor input used to control the system. The options here are Local and 4-20 mA. (For instructions on setting up for a 4-20 mA input, see Job #5 in the section on “Installation Options.”) Setpoint This is the same as the LL CH Setpoint on the Lead Lag Leader Configuration screen (Menu 49).
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 73 Min. boiler water temperature 8. Press the left-arrow or right-arrow until you see the Outdoor Reset screen. If a value is entered here, the temperature in the boiler will never be allowed to drop below this temperature. This will protect the boiler against possible damage due to expansion of ice inside the unit. 9. Menu 53.
Page 74 BRADFORD WHITE the system shuts down after the outdoor temperature rises above the setpoint. The options are Shutdown immediately/ After demand ends/ Disabled. Setpoint If the outdoor temperature is higher than this, the system will shut off the Lead Lag Central Heating functions. Number of boilers Installed Base load min. 1 65% 2 50% 3 30% 4 30% Table 23. 11. Press the left-arrow or right-arrow until you see the Rate Allocation screen.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h the normal setpoints) in the system at certain times of the day. Normally this function is used to switch to lower temperatures at night, when the central heating or domestic hot water demand is reduced. When the controller acting as the Lead Lag Leader receives a time of day input, the controller shifts to the special setpoints entered for central heat and domestic hot water.
Page 76 BRADFORD WHITE When enabled, the Warm Weather Shutdown feature will turn off the Central Heating functions when the outdoor temperature exceeds the setpoint. This prevents the system from running when there is no need for heat. Enable These options determine how quickly the system shuts down after the outdoor temperature rises above the setpoint. The options are Shutdown immediately/ After demand ends/ Disabled.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h There is one other part of this system, and it is located on a different screen: LL CH setpoint - Page 77 from the Building Automation System or multiple boiler control. Connect to terminals 3 and 4 on TB7. 2. On a system set up for Outdoor Reset, this will be the maximum water temperature setting. This is located on the main Lead Lag Configuration screen. On the Lead Lag Leader settings, change the setpoint source to 4-20 mA.
Page 78 1. 2. BRADFORD WHITE On each controller in the system, check terminals 3 and 4 on TB6 to ensure that the System sensor is not connected. (For this type of operation, the Lead Lag system is disabled.) Connect the 4-20 mA input to each controller in the system. • On the Primary controller in each boiler, connect to terminals 3 and 4 on TB7. • On the Secondary controller in each boiler, connect to terminals 7 and 8 on TB7. 3. Enable a central heat call for each control on the system.
Brute ® Page 79 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Boiler 1 Operator interface Primary controller Primary burner Gas valve Gas valve High-Fire adjustment Low-Fire adjustment Secondary controller Figure 39. Primary and Secondary Burners in a Boiler Menu 64. Figure 40. Menu 63. 5. H igh and Low Fire Adjustments on Gas Valve - NT 1000 and NT 1200 Status Summary Screen Press the Operation button. The system will present the Operation screen for the Secondary burner.
Page 80 BRADFORD WHITE controller, based on the heat load. Set this item to Auto at the end of the test. Manual in Run The Manual in Run control will only set the fan speed when the control has proven flame and the unit has entered the Run mode. Manual in Run and Standby - Menu 65. Using this setting, the manual control will set the fan speed whether the boiler is operating or not. Operation Screen For this test, select Manual in Run. 9.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 81 Negative connection point Positive connection point Figure 41. C onnections for Pressure Gauge, NT 1000 and NT 1200 turn the screw counter-clockwise. 15. The adjustment you made for the Low Fire setting could affect the High Fire setting, so you need to re-check the High Fire setting. Go back to the Operations screen and set the Firing Rate back to 8000 RPM.
Page 82 high fire and at low fire. The final CO2 values at high fire should be as listed in Table 24 ±0.2%. At low fire, the CO2 should be about 0.5% lower than the high fire CO2 reading. (The offset is more important than the actual CO2 value) Monitor the CO2 and CO levels for one complete operating cycle. The CO should never be more than 150 ppm. The CO2 level should also track between the high and low limits listed in the table.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 83 There are three ways that a Unit system can be set up to provide domestic hot water. Two of them involve the use of an indirect water heater. In a system including an indirect water heater, hot water is circulated through a piping loop which runs through an insulated water tank. Heat from the water in the loop is transferred to the water in the tank, and the heated water in the tank is used as domestic hot water.
Page 84 1. From the ‘home’ screen, press the View Lead Lag button. Menu 71. 2. BRADFORD WHITE ‘home’ screen Press the button for Lead Lag Leader. arrow or right-arrow until you see the Domestic Hot Water screen. Menu 74. Domestic Hot Water An entry on this screen allows you to give priority to the DHW function. Setup Type 2 – As a second option, a system can be set up so that only one or two boilers respond to a demand for domestic hot water.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h mode. You can think of each of these boilers as a separate two-burner Lead Lag system. except priority is given to domestic hot water, and there is no input for the central heating function. Once a system is set up this way, if there is no DHW demand, the system will operate like any other Lead Lag system. If a demand for DHW arrives, the boilers used for DHW will stop providing heat for central heat.
Page 86 BRADFORD WHITE this screen. Menu 78. 4. Lead Lag Leader Configuration Press the button for Advanced Settings. This leads to a “ring” of related screens, and you can scroll through the list by pressing one of the left- or right-arrow symbols. Press the leftarrow or right-arrow until you see the Domestic Hot Water screen. Menu 79. Domestic Hot Water Set the last line to give priority to the DHW function.
Brute ® 9.F BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 87 ateway Connections to a G Building Automation System These units can be controlled and monitored through the included Modbus ports. The manufacturer offers the “Gateway Controller” to allow BACnet, LON, and other communications protocols. The Modbus wiring should be completed according to the instructions in this manual.
Page 88 BRADFORD WHITE 9.G Installer Parameters This is a list of all of the parameters which can be accessed using the Installer password. Label Description How to Reach 4 mA water temperature If a 4 – 20 mA input is used to adjust the setpoint, this entry sets the low limit of the control range. (In the example shown here, an input of 4 mA would result in a setpoint of 90°F.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 89 Label Description How to Reach CH (Central Heat) has priority over LL (Lead Lag) This controls whether a local Central Heat demand has priority over the control asserted by the LL Leader, when this controller is enabled as a follower.
Page 90 BRADFORD WHITE Label Description How to Reach CH (Central Heat) Setpoint This setpoint is used when the time-of-day input is off. If the outdoor reset function is active, this setpoint provides one coordinate for the outdoor reset curve. See the section for the CH Outdoor Reset parameter.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 91 Label Description How to Reach DHW (Domestic Hot Water) pump control The DHW pump (Pump C) can be turned on manually, or it can be set to operate automatically. If it is turned on then it remains on until changed back to Auto. In Auto mode it operates according to the DHW demand, the start delay timer and the overrun time.
Page 92 BRADFORD WHITE Label Description How to Reach Lead lag D gain This is part of the damping function <’home’ screen> Lead Lag Leader button (“Derivative”) used when the controller interprets Configure the input from the System sensor. button Advanced Settings button/ Leftor Right- arrow buttons Lead lag DHW demand switch This indicates source of the aquastat signal used to control the Domestic Hot Water loop.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 93 Label Description How to Reach Lead lag on hysteresis When the Lead Lag function is enabled, the control system will not fire the boilers until the temperature at the System sensor drops to the Lead Lag CH setpoint minus a hysteresis value (normally about 10°F).
Page 94 BRADFORD WHITE Label Description How to Reach Modbus address Each controller must have a unique Modbus address. <’home’ screen> Setup button Control setup button/ Change address button Number of controllers in Flap Valve system Each controller needs to know how many flap valves are included in the whole system. On a system with 4 boilers, there would be a total of 8 flap valves.
Brute ® 9.H Page 95 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Variable Speed Pump Control V.S.P.C. is optional equipment on hydronic boilers only. It is not available for the water heater models. Pump speed is controlled to maintain a user-chosen temperature rise between the inlet and outlet of the unit.
Page 96 BRADFORD WHITE SECTION 10 Initial startup Instructions 10.A Filling the Boiler System 8. Start up the boiler following the procedure in this manual. Operate the entire system, including the pump, boiler, and radiation units for one hour. 9. Shut down the entire system and vent all radiation units and high points in the system piping, as described in Step 4. If a water pressure regulator is provided on the make-up water line, adjust the pressure regulator to provide at least 12 psi (81.
Brute ® optional pressure gas 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 start again and the burner will start. The appliance will return to its previous mode of operation. 10.B Initial Burner Operation The initial setup must be checked before the unit is put into operation. Problems such as failure to start, rough ignition, strong exhaust odors, etc. can be due to improper setup.
Page 98 BRADFORD WHITE SECTION 11 Maintenance 11.A System Maintenance Do the following once a year: 1. Lubricate the System pump, if required, per the instructions on the pump. 2. Inspect the venting system for obstruction or leakage. Periodically clean the screens in the vent terminal and combustion air terminal (when used). 3. Keep the area around the unit clear and free of combustible materials, gasoline, or other flammable vapors or liquids. 4.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 99 11.B.5 Flame Sensor to the gas valve. Remove the electrical connections to the gas valve. Remove the bolts connecting the Venturi flange to the blower. This allows the entire gas valve/Venturi assembly to be removed as an assembly to facilitate inspection and cleaning. After the valve has been removed, reassemble in reverse order making sure to include all gaskets and O-rings. Turn on the manual gas valves and check for gas leaks.
Page 100 If it is necessary to replace the blower, turn off the 120 Volt power and the gas supply to the unit. Take the front panel off. Disconnect the 120 Volt and control signal connections to the blower. Disconnect the bolts connecting the Venturi to the blower housing. Disconnect the fan 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.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h 3” w.c. For propane, set the low pressure gas switch to 5” w.c. For natural and propane, set the high pressure gas switch to 14.” 11.B.10 Conversion Natural/Propane Gas These units can easily be converted from natural to propane gas or from propane to natural gas.
Page 102 BRADFORD WHITE SECTION 12 Troubleshooting 12.A P otential Setup and Synchronization Problems 12.A.1 Controller Synchronization On a multiple-boiler installation, the individual boiler controllers are arranged in a “daisy chain” using a Modbus connection, with the Secondary control of one boiler connected to the Primary control of the next boiler. Up to four boilers, with up to eight controllers, can be connected in this way. See Figure 44.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h During a lockout condition, the image of the affected controller on the ‘home’ screen will appear in red. A bell symbol will appear in the upper left-hand corner of the control screen. The system maintains a “history” of the 15 most recent lockouts. 12.A.2 Flap Valve Status Check Each boiler includes two burners, and each burner has a flap valve. See Figure 45.
Page 104 Correct the cause of the problem, and press the button on the screen to clear the Hold. 2. If a serious problem continues, the system will declare a Lockout. A brief explanation of the cause of the Lockout will appear in an orange bar across the bottom of the screen. If you tap the orange bar, the system will present more information about the Lockout. BRADFORD WHITE 3. If you press the Details button, the control software will present a screen similar to this.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Menu 88. Alert Log Screen To get more information on a particular alert, touch the entry for that alert on the screen.
Page 106 BRADFORD WHITE 12.C Troubleshooting Table This table includes a listing of the faults that might be generated by the controllers, and displayed on the Touch Screen. Some of these can be corrected by an installer changing a parameter, while other conditions are more complicated, and will require a service technician. The first column lists the code number that will appear at the beginning of the Lockout or Hold message in the orange bar at the bottom of the screen.
Brute ® 15 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Internal fault: L Safety relay test failed due to feedback ON 16 Internal fault: Internal fault L Safety relay test failed due to safety relay OFF 17 Internal fault: L Safety relay test failed due to safety relay not OFF 18 Internal fault: L Safety relay test failed due to feedback not ON 19 Internal fault: L Safety RAM write 20 Internal fault: H Internal fault: Flame ripple and overflow 21 Internal fault: H Flame numb
Page 108 49 24 VAC voltage low/high BRADFORD WHITE H 1. Check the module and display connections. 2. Check the module power supply and make sure that frequency, voltage and VA meet the specifications. 50 Modulation fault H Internal sub-system fault. 1. Review alert messages for possible trends. 2. Correct possible problems. 51 Pump fault H Internal sub-system fault. 1. Review alert messages for possible trends. 2. Correct possible problems.
Brute ® 64 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h PII (Pre-Ignition Interlock) OFF Page 109 H or L 1. Check wiring and correct any faults. 2. Check Preignition Interlock switches to assure proper functioning. 3. Check the valve operation. 4. Reset and sequence the module; monitor the PII status. 5. If code persists, replace the module. 67 ILK (Interlock) OFF H or L 1. Check wiring and correct any possible shorts. 2. Check Interlock (ILK) switches to assure proper function.
Page 110 93 DHW (Domestic Hot Water) sensor fault BRADFORD WHITE H 1. Check wiring and correct any possible errors. 2. Replace the DHW sensor. 3. If previous steps are correct and fault persists, replace the module. 94 Header sensor fault H 1. Check wiring and correct any possible errors. 2. Replace the header sensor. 3. If previous steps are correct and fault persists, replace the module. 95 Stack sensor fault H 1. Check wiring and correct any possible errors. 2. Replace the stack sensor. 3.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Page 111 106 Flame lost in MFEP L 1. Check main valve wiring and operation - correct any errors. 107 Flame lost early in run L Code Description L or H 108 Flame lost in run L 109 Ignition failed L 110 Ignition failure occurred H Hold time of recycle and hold option. Will not be a lockout fault. Hold Only. Internal hardware test. Not a lockout. 111 Flame current lower than weak threshold (min flame current 0.
Page 112 154 Purge Fan switch On BRADFORD WHITE H or L 1. Purge fan switch is on when it should be off. 2. Check wiring and correct any errors. 155 Purge fan switch OFF 3. Inspect the Purge Fan switch J6 terminal 3 and its connections. Make sure the switch is working H or L correctly and is not jumpered or welded. 4. Reset and sequence the relay module. 5. If the fault persists, replace the relay module. 156 Combustion pressure and flame ON H or L 1.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h 184 Invalid BLOWER/ SPARK output setting L 185 Invalid Delta T limit enable setting L 186 Invalid Delta T limit response setting L Code Description L or H 187 Invalid DHW (Domestic Hot Water) high limit enable setting L 188 Invalid DHW (Domestic Hot Water) high limit response setting L 189 Invalid flame sensor type setting L 192 Invalid igniter on during setting L 193 Invalid ignite failure delay setting L 194 Inva
Page 114 BRADFORD WHITE 214 Invalid Prepurge time setting L 215 Invalid Purge rate proving setting L 216 Invalid Run flame failure response setting L 217 Invalid Run stabilization time setting L 218 Invalid Stack limit enable setting L 219 Invalid Stack limit response setting L 1. Return to Configuration mode and recheck selected parameters, reverify and reset module. 220 Unconfigured Delta T limit setpoint setting L 2. If fault repeats, verify electrical grounding.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h 12.D Diagnostic Tests and Input/Output Indicators 3. Page 115 The button for Analog I/O displays items that change continuously between two limits. Two kinds of screens are grouped together in this section: • Detailed indications of the input and output signals • Diagnostic tests of the pumps and burner modulation Note that these functions apply to just one selected controller.
Page 116 BRADFORD WHITE 12.E Lead Lag Follower Diagnostics 12.G Analysis The control system includes a diagnostic screen that lists some information on the Lead Lag followers in the system. See Menu 94. The control system includes an Analysis branch that can display the behavior over a period of time for several different parameters: fan speed, outlet temperature, inlet temperature, etc.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h the current state of the controller, including setup information and operating information. This information can be helpful during troubleshooting. How to get there – Home Page Setup Screen Control Snapshot Screen Menu 98. Control Snapshot List Screen Select one of the controllers listed on the right side of the screen. Press one of the buttons below the right column to see the snapshot. See Menu 99.
Page 118 sensor. (The setpoint or modulation can also be controlled by an external 4 – 20 mA control.) 2. The Boiler pump and System pump are energized. The water temperature in the System loop drops until it reaches the LL Central Heat Setpoint minus the LL Central Heat On Hysteresis value. 3. The controller prepares to start the burner. The controller does a system check, flap valve check, and safety chain test. The blower fan is switched on. 4.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h During the Standby Period: Page 119 During the Run Period: • All of the checks made under Synchronization, plus: • All of the checks made under Synchronization, plus: • Locks out if the Flame signal is present after 240 seconds. • Locks out if an internal system fault occurs. • Locks out if the Preignition Interlock is open for more than 30 seconds.
Page 120 BRADFORD WHITE SECTION 13 Replacement Parts Use only genuine Manufacturer replacement parts. 13.A General Information To order or purchase parts for this unit, contact your nearest Manufacturer dealer or distributor. . (See the back cover for addresses, and for telephone and fax numbers.) 13.B Parts List Key No. Part No. Model 1000 Description 10J1213 Part # Model 1200 __ < Same 1 2 E2334702 E2344904 SWITCH, PRESSURE, AIR/GAS, 0.18” SET POINT 3 E2334900 SWITCH, PRESSURE, AIR/GAS, 0.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Key No. Part No.
Page 122 Key No. Part No.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Key No. Part No.
Page 124 13.C Parts Illustrations Figure 46.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Figure 47. Front Panels and Covers Figure 48.
Page 126 BRADFORD WHITE Figure 49. Burners and Combustion Chamber Figure 50.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Figure 51. Heat Exchanger Components Figure 52.
Brute ® BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h Figure 53. Electronic Components H2360900F Figure 54. Condensate Trap 200 Lafayette St. Middleville, MI 49333 Warranty: (800) 531-2111 www.BradfordWhite.com Litho in U.S.A.
