Installation and Operation Instructions Document 1344G Installation and Operation Instructions for Brute® Modulating Boilers and Volume Water Heaters Indoor and Outdoor BNTH Sizes 399 – 850 MBTU/h BNTV Sizes 150 – 850 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 SECTION 6 WATER CONNECTIONS 1.A Introduction........................................................ 5 6.A Boiler...................................................... 34 1.B Warranty............................................................ 5 6.A.1 Boiler Water Piping ......................................... 34 1.C Model Identification............................................ 5 6.A.2 Boiler Cold Water Make-Up................
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS SECTION 8 USING THE TOUCH SCREEN SECTION 9 F IRST START UP AND ADJUSTMENT 8.A The Touch Screen........................................... 53 9.A Filling the Boiler System.................................. 77 8.B Using the Touch Screen.................................. 53 9.B First Operation................................................. 78 9.C Shutting Down the Unit.................................... 78 9.
BRADFORD WHITE
Brute Page 5 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS SECTION 1 GENERAL INFORMATION 1.A 1.C Introduction This manual provides information necessary for the installation, operation, and maintenance of Bradford White’s Brute boilers and water heaters. Read it carefully before starting the installation. All application and installation procedures should be reviewed completely before proceeding with the installation.
BRADFORD WHITE Page 6 1.D Safety Notes Safety Notes are used throughout this manual to bring attention to the presence of hazards with various risk levels and to offer important information concerning 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 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 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.
BRADFORD WHITE Page 8 1.E Model Overview These units are offered in both Indoor and Outdoor models for all sizes. NOTE: O utdoor Installation of volume water heaters not permitted in Canada. The physical appearance of the indoor and outdoor units is drastically different because the outdoor model offers a fully weathertight enclosure that hides the touchscreen. Whereas the indoor model is not fully weathertight and the touchscreen can be accessed without having to open the unit.
Brute Page 9 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS EXHAUST VENT CONNECTION PRESSURE RELIEF VALVE GAS CONNECTION WATER INLET WATER OUTLET AIR INLET CONNECTION TOUCHSCREEN AIR PRESSURE SWITCH ON / OFF SWITCH DRAIN VALVE HEAT EXCHANGER GAS VALVE AIR TRANSITION AIR/ GAS BLOWER CONDENSATE TRAP VENTURI Figure 2.
BRADFORD WHITE Page 10 EXHAUST VENT CONNECTION PRESSURE RELIEF VALVE WATER INLET WATER OUTLET GAS CONNECTION TOUCHSCREEN AIR INLET CONNECTION ON / OFF SWITCH HEAT EXCHANGER MANUAL SHUTOFF GAS VALVE AIR/ GAS BLOWER DRAIN VALVE CONDENSATE TRAP GAS VALVE VENTURI Figure 4.
Brute Page 11 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS EXHAUST VENT CONNECTION GAS CONNECTION PRESSURE RELIEF VALVE TOUCHSCREEN WATER INLET WATER OUTLET AIR INLET CONNECTION AIR PRESSURE SWITCH ON / OFF SWITCH MANUAL SHUTOFF GAS VALVE HEAT EXCHANGER GAS VALVE DRAIN VALVE CONDENSATE TRAP AIR/ GAS BLOWER VENTURI MANUAL SHUTOFF GAS VALVE Figure 6.
BRADFORD WHITE Page 12 GAS CONNECTION PRV EXHAUST VENT WATER OUTLET AIR INLET WATER INLET RATING PLATE Indoor 150 MBH CONDENSATE TRAP OUTLET (Trap is built-in) For piping dimensions/ locations for all Indoor units, See Table 1 on page 14 AIR INLET GAS CONNECTION PRV WATER OUTLET WATER INLET EXHAUST VENT RATING PLATE Indoor 850 MBH For piping dimensiona/locations for all Indoor units, See Table 1 on page 14 Figure 8.
Brute Page 13 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS EXHAUST VENT RATING PLATE AIR INLET FILTER BOX Outdoor 150 MBH * WATER OUTLET WATER INLET CONDENSATE TRAP OUTLET (Trap is built-in) For piping dimensions/ locations for all outdoor units, See Table 2 on page 16 GAS CONNECTION be added to this pipe *PRV must during installation.
BRADFORD WHITE Page 14 1.
Brute 8 3/4 8 3/4 (22) CE CLEARANCE (22) 38 1/2 (98) L All Indoor Units have a very similiar component design with piping dimensions/locations that increase as the unit size increases. Water and gas piping is always on the left side of the unit. Table 1 gives the exact dimensions for all of the different model sizes. ALL Models SUGGESTED SERVICE CLEARANCE See “Table 3.
BRADFORD WHITE Page 16 1.G Dimensions, Outdoor Models SIZE 150 199 285 399 500 600 750 850 Table 2. A in cm 6-1/4" 16 6-1/4" 16 6" 15.5 8" 15.5 5" 13 33-1/2" 85 32-3/4" 83.2 32-3/4" 83.2 B in 11" 11" 11" 19-1/2" 17-3/4" 3.0" 3.0" 3.0" cm 28 28 28 50 45 8 8 8 in 13" 13" 5" 7-3/4" 5" 5" 5-1/4" 5-1/4" C cm 33 33 13 20 13 13 13.4 13.4 D in cm 17-1/4" 43.8 17-1/4" 43.8 17-1/4" 43.8 17-1/4" 43.8 8-1/4" 21 8-1/4" 21 17-1/4" 43.8 17-1/4" 43.
G n 7" 7" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" Brute cm 69 69 72 72 74 74 74 74 J SIZE in cm 23-1/2" 150 60 24-1/2" 199 60 12" 285 30.5 12" 399 30.5 12" 500 30.5 12" 600 30.5 12" 750 30.5 12" 850 30.5 Page 17 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS KA inin cm cm 5-1/4" 6-1/4" 13 16 5-1/4" 6-1/4" 13 16 7-1/4" 6" 18.4 15.5 6"8" 15.2 15.5 5.5" 5" 14 13 5-3/4" 33-1/2" 14.6 85 5-3/4" 32-3/4" 14.6 83.2 5-3/4" 32-3/4" 14.6 83.
BRADFORD WHITE Page 18 1.H The Installation Kit (installation parts box). The Indoor models are shipped in a single crate with the Installation Kit (cardboard box). Check the contents of the Installation Kit with the items listed in Figure 10 and Figure 11. Additional parts may be packed inside the unit.
Brute The OUTDOOR Model Installation Kits, in addition to what is shown in Figure 10 and Figure 11, will include: VIEW Vent Pipe Extender, Pipe Adapter, Bird Screen, PRV, NPT Pipe Tee NOTE: O utdoor Installation of this volume water heater is not permitted in Canada. 4 THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE PROPRIETARY TO LAARS HEATING SYSTEMS AND SHALL NOT BE REPRODUCED, TRANSFERRED TO OTHER DOCUMENTS, USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR ANY OTHER DWG NO.
BRADFORD WHITE Page 20 SECTION 2 LOCATING THE UNIT 2.A General Information The ‘Indoor’ unit is designed and CSA-certified for indoor installations only. The ‘Outdoor’ unit is designed and CSA-certified for outdoor installations only. Outdoor installation of this unit is not permitted in Canada. 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.
Brute Page 21 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS INTAKE / EXHAUST STANDARD SIZE VENT MIN EQUIV. INTAKE FT. M MIN EQUIV. VENT MAX EQUIV. FT. M FT. M OPTIONAL VENT MAX EQUIV. FT. M 150 3” * 0 0 3 1 100 30.5 n/a — — 199 3” * 0 0 3 1 100 30.5 n/a — — 285 4” * 0 0 3 1 100 30.5 n/a — — 399 4” * 0 0 3 1 100 30.5 n/a — — 600** 4” * 0 0 3 1 100 30.5 n/a — — 4” * 0 0 3 1 40 6.1 6” 100 30.5 750 4” * 0 0 3 1 40 6.
BRADFORD WHITE Page 22 Combustion Air From Room In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow. Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. Method 1: Two permanent openings, one commencing within 12” (300mm) of the top and one commencing within 12” (300mm) of the bottom, of the enclosure shall be provided.
Brute Page 23 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS air are acceptable, providing they conform to the requirements in the applicable codes listed above. Use ABS, PVC, CPVC or galvanized pipe for the combustion air intake. Route the intake to the boiler as directly as possible. Seal all joints. Provide adequate hangers. The unit must not support the weight of the combustion air intake pipe. Maximum linear pipe length allowed is shown in Table 4. Subtract 5 allowable linear ft. (1.
Page 24 WARNING When an existing Cat I appliance is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. Under no circumstances should an improperly sized vent be used. An improperly sized vent may cause operational and safety problems, and could result in serious injury, death, or property damage. 3.
Brute Page 25 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS INSTALLATION STANDARDS MATERIAL Stainless Steel PVC, sch 40 CPVC, sch 40 Polypropylene UNITED STATES CANADA UL 1738 ANSI/ASTM D1785 ANSI/ASTM F441 ULC-S636 Venting must be ULC-S636 certified for use as venting material. The venting material class must be chosen based upon the maximum flue gas temperature and the intended application of the boiler. Figure 16.
BRADFORD WHITE Page 26 3.D Common Venting High efficiency boilers and water heaters up to 500 MBTU/H may be common vented using Non-Return Valve kits and Centrotherm InnoFlue polypropylene venting. Go online to the manufacturer’s website and refer to the Common Venting Installation Instructions, document number 1427, for instructions on sizing and installing a common venting system.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 4. For concentric vent, follow instructions included with vent kit. 5. Multiple vent kits should be installed such that the horizontal distance between the outlet group and the inlet group is 36” (90cm). (Figure 19.) 6. The vent outlet for models 199-285 must be no lower than the center of the air inlet, and must be at least 12” (30cm) away from the air inlet.
BRADFORD WHITE Page 28 Canadian Installations1 U.S.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 2. Approved Carbon Monoxide Detectors Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. Signage A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for horizontally vented gas fueled heating appliance or equipment.
BRADFORD WHITE Page 30 3.F Common Vent Test NOTE: This section does not describe a method for common venting these high efficiency condensing units. It describes what must be done when a unit is removed from a common vent system. These units require special vent systems and fans for common vent. See Section “3.D Common Venting” on page 26, or contact the factory if you have questions about common venting these units.
Brute SECTION 4 GAS SUPPLY AND PIPING WARNING 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.
BRADFORD WHITE Page 32 4 Gas Supply and Piping (continued) EQUIVALENT LENGTHS OF STRAIGHT PIPE FOR TYPICAL SCH 40 FITTINGS SCHED 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC GRAVITY UNDILUTED PROPANE NOMINAL PIPE SIZE 1/2” FITTING 3/4” 1” 1-1/4” 1-1/2” 2” LINEAR FEET 90° ELBOW 3.6 4.4 5.2 6.6 7.4 8.5 TEE 4.2 5.3 6.6 8.7 9.9 12 NOMINAL PIPE SIZE @ 11” W.C. INLET AND 0.5” W.C.
600 750 850 75.9 95.0 108.0 150 210 285 399 500 600 750 850 Flow lpm 71.9 101.1 136.3 191.2 240.4 287.3 359.6 408.8 48.3 58.0 30.5 46.0 20.6 38.0 14.9 33.0 64.5 72.0 38.0 58.0 25.0 48.0 17.5 41.0 56.6 HIGH 81.0 34.8 65.0 BOILERS 23.9AND VOLUME 54.0 WATER 17.4HEATERS 46.0 Brute EFFICIENCY COMMERCIAL 8 H/L m 12.0 8.6 9.0 10.3 10.9 14.7 19.7 17.3 5.B Flow lpm 54.1 75.7 102.2 147.6 181.7 219.6 272.5 306.6 11 H/L m 7.3 4.8 5.8 6.9 6.8 9.3 11.6 10.6 Flow lpm 43.2 60.6 83.3 117.3 143.8 174.1 219.6 246.
BRADFORD WHITE Page 34 SECTION 6 WATER CONNECTIONS - Part A Section 6 is divided into two parts. Section 6A covers Boiler units designed for hydronic heating. 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 product. Refer to Table 9 for the connection pipe sizes required. 6.A Boiler 6.A.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Connect a 3/4” PVC pipe between the drain connection and a floor drain (or a condensate pump if a floor drain is not accessible). The condensate drain must be installed so as to prevent accumulation of condensate. When a condensate pump is not used, the tubing must continuously slope downward toward the drain with no spiraling. Consult local codes for the proper disposal method for the condensate.
Page 36 Figure 22.
Brute Figure 23.
Page 38 BRADFORD WHITE Figure 24. Hydronic Piping — Multiple Boilers, Zoning with Circulators Figure 25.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 39 Figure 26.
Page 40 BRADFORD WHITE Figure 27. Hydronic Piping — Heating Zones with Indirect DHW Tank Piped with Zone Pumps The indirect DHW tank is piped directly off of the boiler. The boiler pump must shut down during DHW operation.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Figure 28. Hydronic Piping, Multiple Boilers with Indirect DHW Off of One Boiler The boiler pump must shut down during DHW operation.
BRADFORD WHITE Page 42 SECTION 6 WATER CONNECTIONS - Part B Section 6 is divided into two parts. Section 6A covers Boiler units designed for hydronic heating. 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 product. Refer to Table 15 on page 34 for the connection pipe sizes required. 6.B 6.B.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 43 WARNING: This drawing shows suggested piping configuration and valving. Check with local codes and ordinances for additional requirements. NOTES: 1. Optional CWMU & Recirc. line location. 2. Locate 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. 5.
Page 44 BRADFORD WHITE NOTES: 1. Optional CWMU & Recirc. line location. 2. Locate 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. 5. Factory supplied pumps are sized for a max pipe length of 30’ total, 6-90° elbows, full pipe size. 6. Caution: Pump sizing must be based on water hardness at job site. WARNING: This drawing shows suggested piping configuration and valving.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS SECTION 7 INSTALLATION AND WIRING 7.A Installation Warnings 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 the latest edition of CSA C22.1 Canadian Electrical Code, Part 1, in Canada.
BRADFORD WHITE Page 46 Factory installed resistor Figure 33. Power & Control Panel Layout NOTE: All water heating units are shipped from the factory with a resistor (jumper) between the outdoor sensor terminals (terminals 1 and 2 on TB7). If this resistor is removed, the water heater will not be able to heat water above 140°F. 7.B.2 Variable Speed Pump Control Variable speed pump control (V.S.P.C.
Brute Page 47 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 7.C ydronic Heating Using External Modulation H Control About External Control - When the unit is used for hydronic heating with external modulation control, a call for heat must be supplied to the “T-T or Interlock” terminal. Once the call is supplied the control starts the Boiler and System pumps and begins the ignition process. Once in Run, the unit monitors the flame signal, call for heat, safeties, and water temperatures.
BRADFORD WHITE Page 48 7.E Lead Lag Connections These units can be connected in a Lead Lag series up to a total of 8 controllers. One as the Lead control and 7 more as the following controllers. See Figure 34. For general info and menu set-up for Lead Lag using your Touchscreen, See Section 8, page 69 ‘About Lead Lag’. Gateway Control (H2354400 Doc# 4236) Figure 34.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 49 Following Boiler COM2 C B A COM2 C B A TO CASCADING TO CASCADING UNITS 3 THRUUNITS 8 3 THRU 8 (TYP) (TYP) 7.F Building Automation System Connections These units can be controlled and monitored through the included Modbus ports. Gateway Control (H2354400 Doc# 4236).
BRADFORD WHITE Page 50 7.G System Wiring Diagram TO J4-10 TO GAS VALVE P1 TB4 24V COMMON 1 OPTIONAL SWITCH USED ON SOME MODELS. IF SWITCH IS NOT INSTALLED IN THIS LOCATION.
Brute Page 51 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS DISPLAY 24Vac 24V com TOUCH-SCREEN COM 1 COM 2 8 76 5 4 3 2 1 BL/GN TO TB3-1 TO TB4-1 Y/GN PRESSURE SWITCH OR/BLK BA VDC B A V- MB2 V+ MB1 DKB/Y DKB/Y MS-2 1 2 DKB 3 4 R1 OR R2 GY VT CRIMP NUT GY WH/GY DKB DKB DKB/Y OR TN/BRN DKB PUMP DHW DKB 2 NEUTRAL PUMP GND SW 1 L NEUTRAL L 6 TN/BLK OR J5-1 J5-2 J9-6 J9-5 J9-4 SYS TN/BL CONTROL MODULE (Honeywell) 1 TN/R TO TB6 P2 TO TB6 P1 WH
BRADFORD WHITE Page 52 7.H Ladder Diagram Figure 36.
Brute SECTION 8 USING THE TOUCH SCREEN The home screen shows a picture of the unit’s controller. The color of the controller depends on the status, as shown below. Color The Touch Screen on OUTDOOR units is located behind the front panel. Figure 37. Touch Screen 8.A Using the Touch Screen A screen saver is programmed into the display. Simply touch the screen to wake it up.
BRADFORD WHITE Page 54 Screen Menu Icons to go through an additional “verification” process. For more information, see the section on “Configuration.”) When a password is necessary, the system will present the keyboard screen. See Menu 3.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS information on logging in, see Section 8.2.) and asterisks will help you enter the correct number of characters for your password. When changing a numerical value, the system presents a numerical entry screen, as shown below. Page 55 2. If you make a change in any group that could affect the safe operation of the unit, the control system will ask you to “verify” the change before it is accepted. 3.
BRADFORD WHITE Page 56 4. The system will present a listing for each group of parameters that need verification See Menu 7. Menu 7. 5. 8.E Checking Individual Parameters 1. From the ‘Home’ screen (Menu 9), press the icon for the controller. Safety Parameter Confirmation For each group, check the list carefully. Press Yes if all of the parameters in the group have been entered correctly. For each group, you are given 30 seconds to select Yes/No.
Brute 8.F HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 57 etting the Date and Time on the S System Display The display includes an internal clock, which keeps track of the date and time. This setting is important, because log entries for Lockouts and Alerts include time listings. If the Date and Time setting for the boiler is not correct, the listings in the Lockout and Alert logs will be incorrect. To set the clock: 1. Start at the ‘Home’ screen. Menu 13. Display Setup Screen 4.
Page 58 BRADFORD WHITE 8.G The Configuration Menu is the gateway to the parameters that the factory, the installer, or the end user will need in order to setup, service, maintain, or adjust the unit. 8.G.1 8.G.2 8.G.3 8.G.4 8.G.5 8.G.6 8.G.7 8.G.8 8.G.9 8.G.10 8.G.11 8.G.12 8.G.13 8.G.14 8.G.15 8.G.16 8.G.17 8.G.18 There are eighteen (18) items in the Configuration Menu that can be viewed. Please Review Menu 17.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 59 The Configuration Sub-Menus ( ALL 18 ) 8.G. 1 __ 18 Some of these configurations will require a Login first. See Menu 3 on page 54 When using the unit for hydronic heating, a call for heat must be supplied to the “T-T” terminals found on TB7 labeled “T-T or Interlock”. Once a call for heat is established, the control will start the appropriate (selected) pumps, and begin the ignition process. 8.G.
BRADFORD WHITE Page 60 Choose S2 (J8-6) 4-20 mA, then press OK Then scroll over to the Modulation sub-menu and click onto Modulation rate source. 8.G.3 Outdoor Reset Configuration At this sub-menu, confirm that Central Heat is Enabled. Next, press onto the Maximum Outdoor Temperature, Minimum Outdoor Temperature, and Low Water Temperature to get to each and adjusting their setpoints in those sub-menus. 8.G.4 DHW - Domestic Hot Water Config Select Local, then press OK.
Brute 8.G.6 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Demand Priority Configuration Page 61 fed by 120V (violet wire) internally from the main power feed. The System and DHW contacts are dry contacts. Appropriate voltage must be supplied to the System and DHW pumps for proper operation. From the Demand Priority Configuration, the installer can adjust the priority of the different demand types.
BRADFORD WHITE Page 62 8.G.9 Statistics Configuration 8.G.12 Anti-Condensation Configuration Anti-condensation (frost protection) is enabled/disabled on this screen The statistics configuration sub-menu allows the installer to view Burner Cycles, Burner Run Time, DHW Pump Cycles, Boiler Pump Cycles, and System Pump Cycles. This sub-menu is ‘Read-Only’ 8.G.10 High Limits The outlet High limit can be adjusted using the installer password.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 8.G.15 Fan Configuration To increase/decrease the speed at which the fan control loop reacts to a decrease in fan speed, adjust the Fan gain down parameter. Similarly, to increase/decrease the speed at which the fan control loop reacts to an increase in fan speed, adjust the Fan gain up parameter. The minimum duty cycle is a view only parameter.
BRADFORD WHITE Page 64 8.G.17 Lead Lag Follower Configuration Note: The system sensor and outdoor sensor will need to be wired to the Master boiler only. The input from these sensors is used by the Master control to control the modulation rate of all the operating boilers it is connected to. See the manual for sensor and cascade wiring. When a boiler is operating as part of a Lead Lag system, it does not use the normal “CH set point” – it uses the “Lead Lag CH set point” on the Master control.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 65 8.G.17 Lead Lag Follower Config (continued) Return to the configuration menu by pressing the Back arrow. Next, you will need to confirm that the master configuration is Disabled. Then you will need to confirm that the Follower configuration is Enabled. Press ‘Lead Lag Save Configuration In the configuration menu, scroll down to the bottom and press onto Lead Lag Master Configuration.
BRADFORD WHITE Page 66 8.G.18 Lead Lag Leader Configuration Wiring Connections for Lead Lag The controller in each boiler includes two wiring terminals for the Modbus system, labeled “MB1” and “MB2.” MB1 has the wiring connections to the User Interface display on each unit, and MB2 is used to communicate with the other boilers in the Lead Lag system. F or wiring connections to Lead Lag, see Figure 34 on page 48 To reach the controller, open the cabinet of the unit.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 67 8.G.18 Lead Lag Leader Config (continued) With the Master Control now Enable, press the setting box labeled ‘CH setpoint’. Here you can adjust the desired Lead/ Lag system setpoint. With desired CH Setpoint set, then press ‘Advanced Settings’. From this screen, use the Left or Right arrows to scroll to other screens. Make adjustments if needed.
BRADFORD WHITE Page 68 8.G.18 Lead Lag Leader Config (continued) Note: In the Lead Lag Follower Sub-Menu, Identify each control (including the Lead Lag Master) as a Follower by turning on ‘Follower Enable. From the Status Summary Screen, press the ‘Configure’ button. Press ‘Disabled’’ Choose ‘Enable Follower for built-in Lead Lag Master’ Then press ‘OK’. The lead boiler (Master control) is now configured.
Brute Page 69 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 8.G.18.a About Lead Lag Operation You can cascade up to eight (150 - 850 MBH) boilers or water heaters. F or wiring connections to Lead Lag, see Figure 34 on page 48 Caution You should set the Modbus addresses before you connect the Modbus wiring. If the wiring is attached before the Modbus addresses on the controls are changed, there will be multiple controls with the same address, and the system will not work.
BRADFORD WHITE Page 70 Touch Screen Lead Lag Master Addr 1 Addr 2 Addr 3 Addr 4 Addr 5 Addr 6 Addr 7 Addr 8 Boiler 1 Boiler 2 Boiler 3 Boiler 4 Boiler 5 Boiler 6 Boiler 7 Boiler 8 Figure 41. “ Lead Lag” Operation in a System with Eight Boilers. Note: The Displays on Boilers 2 through 8 will display information pertaining only to that specific boiler.
Brute 8.H HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 71 onfigure for a C Building Automation System These units can be controlled and monitored through the included Modbus ports. If communication protocols are desired, manufacturer offers the Gateway Control to allow BACnet, LON, and other communications protocols. The Modbus Connections must be completed as shown in Figure 33 on page 46, and Figure 34 on page 48.
BRADFORD WHITE Page 72 8.I Combustion Setup In this section, we will explain how to adjust the gas valve so the unit will run efficiently at both the High Fire and Low Fire conditions. Required tools: Screwdrivers, Torx bits, Allen Wrench Set, Combustion Analyzer WARNING Improper adjustment may lead to poor combustion quality, increasing the amount of carbon monoxide produced. Excess carbon monoxide levels may lead to personal injury or death. 1.
Brute 7. HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Confirm that the boiler is running and then press ‘Start Test’ Page 73 10. Press ‘Minimum Modulation’ 11. Press ‘Start Test’. You will have 5 minutes to adjust Low-Fire CO2. Press ‘Stop Test’ when done. 12. Repeat steps 6 through 11 a few times to confirm that both Hi-Fire and Low-Fire are within the acceptable levels for your unit. See Figure 45 thru Figure 47. 8. Press ‘Maximum Modulation’.
BRADFORD WHITE Page 74 8.J Adjusting CO2 These units use 3 different gas valves depending on the the size of the model. All of them have a Hi-Fire and Low-Fire adjustment. See page 74 for models 150-285, See page 75 for models 399-500, and See page 76 for models 600-850. 150–285 The Gas Valve in the 150 thru 285 is at the front of the unit and can be reached after the front panel is pulled forward and then off.
Brute Page 75 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS The Gas Valve in the 399 and 500 is at the front of the unit and can be reached after the front panel is pulled forward and then off. Always be patient with your combustion analyzer when making adjustments to the valve at both Hi-Fire and Low-Fire. 399 500 Figure 46. Gas Valve 399 - 500 Mbtu GAS TYPE HIGH FIRE, CO2 LOW FIRE, CO2 MANIFOLD PRESSURE Natural 8.8 to 9.0% Propane 9.8 to 10.0% 0.
Inlet gas pressure High fire CO2 adjustment (under cap) Page 76 BRADFORD WHITE Gas pressure tap The Gas Valve in the 600 is at the front of the unit and can be reached after the front panel is pulled forward and then off. Low fire CO2 adjustment Outlet gas pressure 600 750, 850 Inlet gas pressure Outlet Gas Pressure gas pressure (manifold pressure) The Gas Valve in the 750 and 850 models can only be reached by removing the top panel of the unit.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 77 SECTION 9 F IRST START UP AND ADJUSTMENT 9. Shut down the entire system and vent all radiation units and high points in the system piping, as described in Step 4. 1. Ensure the system is fully connected. Close all bleeding devices and open the make-up water valve. Allow the system to fill slowly. 10. 2. If a make-up water pump is employed, adjust the pressure switch on the pumping system to provide a minimum of 12 psi (81.
BRADFORD WHITE Page 78 9.B First Operation the gas is off. The ignition control will lockout after a single try or a third try depending on the controller model. Caution The initial setup must be checked before the unit is put in operation. Problems such as failure to start, rough ignition, strong exhaust odors, etc. can be due to improper setup. Damage to the boiler resulting from improper setup is not covered by the limited warranty.
Brute Page 79 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS SECTION 10 MAINTENANCE WARNING Disconnect all power to the appliance before attempting any service. Contact with electricity can result in severe injury or death. 10.A System Maintenance Do the following once every 6 months. 1. On Outdoor models only as needed per air quality, remove and inspect the air filter. Clean with soapy water if needed. Be sure that filter is dry before re-inserting back into air filter box.
BRADFORD WHITE Page 80 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 and Venturi assembly to be removed to facilitate inspection and cleaning. Figure 49. Torque Pattern askets are properly seated and the mating surfaces are clear and properly aligned.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS gas valves to the appliance. Remove the front door to the appliance and the plastic bezel and the control panel. Remove all wire connections from the control board. The control board connections are keyed to only allow connection in the proper location, but proper handling techniques should be used to avoid damage to the wiring or connectors.
BRADFORD WHITE Page 82 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 by the debris left behind, possibly causing property damage. 1. Shut off the 120 Volt power supply to the boiler 2. Turn off all manual gas valves connecting the boiler to the main gas supply line. 3.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 10.D Gas Conversion These units can easily be converted from natural to propane gas or from propane to natural gas in the field. Some units require the addition of a gas orifice along with proper gas valve adjustment. Other units require no additional parts - only proper gas valve adjustment. Please contact the manufacturer for specific information regarding the gas conversion of a particular appliance.
BRADFORD WHITE Page 84 Section 11 TROUBLESHOOTING 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. 11.A Lockouts, Holds, and Alerts The control system responds to three kinds of trouble indications: • LOCKOUT: A “lockout” is caused by a serious problem that might involve a safety issue.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 3. Press the long Yellow Alert or Yellow Lockout Bar (the long bar will be a long Grey ‘History’ Bar if not currently in Alert or Lockout). Menu 3. OK, Lockouts, Alerts, or Silence. Choose which history list you would like to see. OK: brings you back to the status summary screen. LOCKOUTS brings you to a list of the last 15 lockout events. Page 85 If you choose ‘LOCKOUTS’, this menu will appear. Menu 5. Lockout History 4.
BRADFORD WHITE Page 86 11.B Troubleshooting Table This table includes a listing of the fault codes that may be displayed. Some of these can be corrected by 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. The second column lists the text as it will appear on the Touch Screen.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Code Description Lockout Procedure or Hold 16 L 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 3246 47 48 Internal fault: Safety relay test failed due to safety relay OFF Internal fault: Safety relay test failed due to safety relay not OFF Internal fault: Safety relay test failed due to feedback not ON Internal fault: Safety RAM write Internal fault: Internal fault: Flame ripple and overflow Internal fault: Flame number of sample
BRADFORD WHITE Page 88 Code Description Lockout Procedure or Hold 49 24 VAC voltage low/high H 50 Modulation fault H 51 Pump fault H 52 Motor tachometer fault H 53 AC input phases reversed L 59 Internal Fault: Mux pin shorted L 61 62 63 Anti short cycle Fan speed not proved H H H Rollout switch, is regarding the SAFETY CHAIN (OFF) Could be one of the following: 1. Check the module and display connections. 2.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Code Description Lockout Procedure or Hold 64 PII (Pre-Ignition Interlock) OFF H or L 67 ILK (Interlock) OFF H or L 68 ILK (Interlock) ON H or L 70 Wait for leakage test completion H 78 Demand Lost in Run H 79 Outlet high limit H or L 80 DHW (Domestic Hot Water) high limit H or L 81 Delta T limit H or L 82 Stack limit H or L 91 Inlet sensor fault H Page 89 1. Check wiring and correct any faults. 2.
BRADFORD WHITE Page 90 Code Description Lockout Procedure or Hold 92 Outlet sensor fault H 93 DHW (Domestic Hot Water) sensor fault H 94 Header sensor fault H 95 Stack sensor fault H 96 Outdoor sensor fault H 97 98 L L 100 Internal Fault: A2D mismatch. Internal Fault: Exceeded VSNSR voltage tolerance Internal Fault: Exceeded 28V voltage tolerance Pressure Sensor Fault H 105 Flame detected out of sequence H or L 99 L 1. Check wiring and correct any possible errors. 2.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Code Description Lockout Procedure or Hold 106 Flame lost in MFEP L 107 Flame lost early in run L 108 Flame lost in run L 109 Ignition failed L 110 Ignition failure occurred H 111 Flame current lower than weak threshold (min flame current 0.8mA).
BRADFORD WHITE Page 92 Code Description Lockout Procedure or Hold 155 Purge fan switch OFF H or L 156 Combustion pressure and flame ON H or L 157 Combustion pressure and flame OFF L 158 Main valve ON L 159 Main valve OFF L 160 Ignition ON L 161 Ignition OFF L 164 Block intake ON L 165 Block intake OFF L 172 174 175 176 178 Main relay feedback incorrect Safety relay feedback incorrect Safety relay open Main relay ON at safe start check Safety relay ON at safe start check Control
Brute 11.C HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Page 93 Diagnostic Tests and Input/ Output Indicators 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. To access the diagnostic functions, from the home screen, touch the control icon, then touch the ‘Diagnostics’ button. 1. Menu 10.
BRADFORD WHITE Page 94 11.D Lead/Lag Slave Diagnostics The control system includes a diagnostic screen that lists some information on the Lead/Lag slaves in the system. See Menu 13 Menu 15. Analysis Setup Screen Menu 13. Lead/Lag Diagnostics To use this function, select the parameter you want to track from the pull-down list. The system will present a graph that tracks that variable. To see the graph for the currently-selected function, press the View button.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS 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 18. Menu 18. Typical Control Snapshot The Show Status button captures the current status of the I/O of the control only. Show Configuration captures the current parameter settings and the control setup. You can save the snapshot, give it a name, or send a copy to the USB port. Page 95 11.
BRADFORD WHITE Page 96 Section 12 REPLACEMENT PARTS Use only genuine replacement parts. 12.A General Information To order or purchase parts, contact your nearest manufacturer’s dealer or distributor. If they cannot supply you with what you need, contact Customer Service. (See the back cover for the address, telephone and fax numbers.) 12.
Brute Page 97 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS ITEM DESCRIPTION SIZE --HEATER 150 SIZE --HEATER 199 SIZE --HEATER 285 SIZE BOILER 399 HEATER 399 SIZE BOILER 500 HEATER 500 SIZE BOILER 600 HEATER 600 SIZE BOILER 750 HEATER 750 SIZE BOILER 850 HEATER 850 43 Gas/Air Venturi — — — — RA2116700 A2115000 A2115000 A2115000 44 Manual Gas Valve — — — RV2000200 V2003000 (2) V2003000 V2003200 V2003200 44A Manual Gas Valve — — — — RV2000200
BRADFORD WHITE Page 98 ITEM DESCRIPTION SIZE --HEATER 150 SIZE --HEATER 199 SIZE --HEATER 285 SIZE BOILER 399 HEATER 399 SIZE BOILER 500 HEATER 500 SIZE BOILER 600 HEATER 600 SIZE BOILER 750 HEATER 750 SIZE BOILER 850 HEATER 850 73 Flame Sensor w/gasket R2069200 R2069200 R2069200 R2069200 R2069200 R2069200 R2071400 R2071400 74 Ignitor w/gasket R2069300 R2069300 R2069300 R2069300 R2069300 R2071500 R2071500 R2069300 74A Ignitor Gasket RW2013300 RW2013300 RW2013300 RW2013300 RW
Brute Page 99 HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Parts Illustration 2. I nternal Components, Sizes 150–199 Parts Illustration 3.
BRADFORD WHITE Page 100 Parts Illustration 4.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Sizes 150-285 Parts Illustration 5.
BRADFORD WHITE Page 102 Parts Illustration 6.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS Sizes 285 - 68A Parts Illustration 7.
Brute HIGH EFFICIENCY COMMERCIAL BOILERS AND VOLUME WATER HEATERS (Front) Touchscreen (Back) Battery ( CR2032 ) Parts Illustration 8. Electrical Components HLW 200 Lafayette St. Middleville, MI 49333 Warranty: (800) 531-2111 H2374700G Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement. www.BradfordWhite.com Litho in U.S.A.
