Bradford-White Corp Modulating Boiler manual

Installation and Operation Instructions Document 1243 H2343100- W ARNING If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHA T TO DO I[...]

B RADFORD W HITE C ORP. Page 2 T ABLE OF CONTENTS SECTION 1. General Information 1.1 Introduction ...................................................... 4 1.2 Model Identification ......................................... 4 1.3 Appliance Overview ......................................... 4 1.4 Warranty ..............................................[...]

Brute Elite Page 3 SECTION 9. Modes of Operation 9.1 Hydronic Heating Demand ............................ 4 0 9.2 Hydronic Heating with Outdoor Reset ........... 40 9.3 Hydronic Heating with Domestic Hot Water (DHW) Priority ..................................... 40 9.4 Hydronic Heating Using External Modulation Control .............................[...]

B RADFORD W HITE C ORP. Page 4 SECTION 1. General Information WARNING Brute Elite units must be installed in accordance with the procedures detailed in this manual, or the Bradford White warranty will be voided. The installation must conform to the requirements of the local jurisdiction having authority, and, in the United States, to the latest edi[...]

Brute Elite Page 5 Figure 1. Location of Components, Sizes 80–105. Figure 2. Location of Components, Sizes 150-210.[...]

B RADFORD W HITE C ORP. Page 6 Figure 4. Location of Components, Size 399. Figure 3. Location of Components, Size 285.[...]

Brute Elite Page 7 Figure 6. Location of Components, Size 600. Figure 5. Location of Components, Size 500.[...]

B RADFORD W HITE C ORP. Page 8 Figure 7. Location of Components, Sizes 750 and 850.[...]

Brute Elite Page 9 Figure 8. Contents of Shipping Package. 1.3 Appliance Overview See Figures 1 through 7 . 1.4 Warranty Bradford White’s Brute Elite appliances are covered by a limited warranty. All warranty claims must be made to an authorized Bradford White representative. Claims must include the serial number and model (this information can b[...]

B RADFORD W HITE C ORP. Page 10 Figure 9. Dimensional Drawing, Sizes 80-500. Dimensions are nominal and are shown in inches , cm . * Brute Elite is shipped with adapters for the air and vent that accept standard pipe of the proper size and type. AB C D E F G J K M N SIZE IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM 80 BNTH 13½[...]

Brute Elite Page 11 SECTION 2. Locating the Appliance 2.1 Locating the Appliance Brute Elite is for indoor installations only. The appliance should be located to provide clearances on all sides for maintenance and inspection. It should not be located in an area where leakage of any connections will result in damage to the area adjacent to the appli[...]

B RADFORD W HITE C ORP. Page 12 HORIZONTAL INTAKE AND EXHAUST PVC VENT TERMINAL KITS 2" PVC 3" PVC 4" PVC 6" PVC SIZE Standard Concentric Standard Concentric Standard Standard CA006000 CA005900 239-44069-01 80 included optional optional optional n/ a n/ a 105 included optional optional optional n/ a n/ a 150 n/ a n/ a included o[...]

Brute Elite Page 13 INSTALLATION STANDARDS MATERIAL UNITED STATES CANADA Stainless Steel UL 1738 Venting must be ULC-S636 certified for use as PVC, sch 40 ANSI/ASTM D178 venting material. The venting material must be chosen CPVC, sch 40 ANSI/ASTM F441 based upon the intended application of the boiler. Table 5. Required Exhaust Vent Material. combus[...]

B RADFORD W HITE C ORP. Page 14 units unless the vent system meets this requirement. Brute Elite units are never permitted to share a vent with Category I appliances. A condensate drain trap is built into Brute Elite. Connect a 3/4" PVC pipe between the drain connection and a floor drain (or condensate pump if a floor drain is not accessible).[...]

Brute Elite Page 15 1. Figure 12 shows the requirements for mechanical vent terminal clearances for the U.S. and Canada. 2. Vent terminals for condensing appliances or appliances with condensing vents are not permitted to terminate above a public walkway, or over an area where condensate or vapor could create a nuisance or hazard. 3. Locate the ven[...]

B RADFORD W HITE C ORP. Page 16 *When vent terminal is less than 10 feet (3m) horizontally from a forced air inlet, the terminal must be at least 3 feet (0.9m) above the air inlet. Figure 12. Combustion Air and Vent Through Side Wall. U.S. Inst allations (see note 1) Canadian Inst allations (see note 2) A= Clearance above grade, veranda, porch, 12 [...]

Brute Elite Page 17 provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm be installed. 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 [...]

B RADFORD W HITE C ORP. Page 18 SECTION 4. Gas Supply and Piping 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. B[...]

Brute Elite Page 19 SCHED 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC GRAVITY UNDILUTED PROPANE NOMINAL PIPE SIZE @ 11" W.C. INLET AND 0.5" W.C. PRESSURE DROP SIZE 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" LENGTH MAXIMUM CAPACITY IN THOUSANDS OF BTU PER HOUR 20 200 418 787 1616 2422 4664 40 137 287 541 1111 1664 3205 60 110[...]

B RADFORD W HITE C ORP. Page 20 Brute Elite's efficiency is higher with lower return water temperatures. Therefore, to get the most of low return temperature with multiple boilers, pipe as shown in Figures 17-19 . Brute Elite BNTH models can be ordered with or without a pump included. Brute Elite with a pump MUST be piped in a primary-secondar[...]

Brute Elite Page 21 6A.3 Freeze Protection WARNING Glycol must not be used in domestic hot water applications. Refer to Section 6B.4 for instructions on BNTV, domestic hot water freeze protection. Brute Elite units are certified for indoor use only, and are not design-certified for placement outdoors. Proper precautions for freeze protection are re[...]

B RADFORD W HITE C ORP. Page 22 Figure 15. Hydronic Piping — Single Boiler (zoning with circulators).[...]

Brute Elite Page 23 Figure 16. Hydronic Piping — Single Boiler, Low Temp Radiant Space Heating using Low Loss Header and Zone Valves.[...]

B RADFORD W HITE C ORP. Page 24 Figure 17. Hydronic Piping — Multiple Boilers (zoning with circulators).[...]

Brute Elite Page 25 Figure 18. Hydronic Piping — Multiple Boilers with Indirect DWH Tank Piped from System Loop.[...]

B RADFORD W HITE C ORP. Page 26 Figure 19. Hydronic Piping — Multiple Boilers, Reverse Return, Multi-Temp Zones (zoning with circulators).[...]

Brute Elite Page 27 Figure 20. Hydronic Piping — Heating zones with indirect DWH tank piped with zone pumps (indirect directly off boiler). Boiler pump must shut down during DHW.[...]

B RADFORD W HITE C ORP. Page 28 Figure 21. Hydronic Piping, multiple boilers with indirect DWH off one boiler. Boiler pump must shut-down during DHW.[...]

Brute Elite Page 29 6B.2 Piping Requirements Water piping should be supported by suitable hangers and floor stands. Do not support piping with the appliance. Due to expansion and contraction of copper pipe, consideration should be given to the type of hangers and supports used. Rigid hangers may transmit noise through the system resulting from pipi[...]

B RADFORD W HITE C ORP. Page 30 6B.3 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 Figures 23- 26. Install back flow preventers and shut offs where needed or required by code. 6B.4 Freeze Protection Brute Elite heaters are not certified for outdoor installation, so the chance of fre[...]

Brute Elite Page 31 Figure 25. DHW Piping, Two Heaters, One Vertical Tank. Figure 26. DHW Piping, Two Heaters, Two Vertical Tanks. NOTES: 1. Optional CWMU & Recirc. line location. 2. Locate BNTV 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 r[...]

B RADFORD W HITE C ORP. Page 32 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.[...]

Brute Elite Page 33 7.2 Pump Connections Brute Elite energizes the pump contacts upon a call for heat. Once the call for heat is satisfied the pump will remain on for the defined pump overrun time. NOTE: System and DHW contacts are dry contacts. Appropriate voltage must be supplied to the System and DHW pumps for proper operation. Boiler pump conta[...]

B RADFORD W HITE C ORP. Page 34 Figure 28. Lead-Lag / Cascading Wiring Connections.[...]

Brute Elite Page 35 Figure 29. Ladder Diagram. 7.11 Wiring Diagrams (see Figures 29 and 30) Caution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing[...]

B RADFORD W HITE C ORP. Page 36 Figure 30. Wiring Diagram (all sizes).[...]

Brute Elite Page 37 SECTION 8. Brute Elite Control Setup and Operation The Brute Elite control is an integrated electronic control that replaces many of the individual components found on older appliances. The control acts as the ignition control, pump control, high limit and cascading/ lead lag control and is setup using the display on the applian[...]

B RADFORD W HITE C ORP. Page 38 4. Prepurge timer is started once the prepurge RPM is achieved. 5. Pre ignition time of 2 seconds to check the flame sensor operation and status. During this period an intermittent spark can be seen. 6. Trial for ignition period, 4 seconds. The direct spark ignition switches to constant spark for three seconds, durin[...]

Brute Elite Page 39 NAME FUNCTION VALUE CH on Burner demand begins when the 5°F differential outlet water temperature reaches "Outlet water temperature setpoint" minus "CH on differential" CH off Burner demand ends when the 5°F differential outlet water temperature reaches "Outlet water temperature setpoint" plus &qu[...]

B RADFORD W HITE C ORP. Page 40 SECTION 9. Modes of Operation The Brute Elite control allows the boiler to operate in many different modes of operation. The mode must be selected based upon the requirements of the installation. The following sections describe the basic operation of the Brute Elite in each of the different modes. Familiarize yoursel[...]

Brute Elite Page 41 setpoint is used to limit the maximum water temperature leaving the boiler only. The modulation rate is controlled by a 4-20mA (0-10Vdc using converter) signal supplied by an external control. When setting up a system using an external control care must be taken to set the external control algorithms to prevent the boiler from s[...]

B RADFORD W HITE C ORP. Page 42 firing rate is controlled by the DHW setpoint temperature and the water temperature at the heat exchanger outlet. Once the DHW call is supplied the control starts the boiler and DHW pumps and begins the ignition process. The ignition process consists of a prepurge, trial for ignition, and run period. The prepurge per[...]

Brute Elite Page 43 13. Check gauge for correct water pressure and also check water level in the system. If the height indicated above the boiler insures that water is at the highest point in the circulating loop, then the system is ready for operation. 14. Prime condensate trap with water (not required for BNTH 600, 750, 850). 15. Refer to local c[...]

B RADFORD W HITE C ORP. Page 44 in Table 16 . If the CO 2 is not within the range shown, adjustments may be made. To adjust the low fire CO 2 , locate the low fire adjuster screw according to the appropriate figure. Slowly make adjustments in 1/16 of a revolution increments until the CO 2 is within the range identified. 4. Repeat steps 2 and 3 to c[...]

Brute Elite Page 45 Figure 33B. Brute Elite Gas Valves (600, 750 and 850). 600 750, 850 Figure 33A. Brute Elite Gas Valves (285, 399 and 500). 80–285 500 399[...]

B RADFORD W HITE C ORP. Page 46 SECTION 1 1. 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. Lubricate the system water-circulating pump, if required, per the instructio[...]

Brute Elite Page 47 appliance and shut off all manual gas valves to the appliance. Remove the front door to the appliance and the control panel plastic bezel. 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 a[...]

B RADFORD W HITE C ORP. Page 48 11.2.6 Transformer with Integral Circuit Breaker The appliance has a 24Vac transformer with integral 4 amp circuit breaker installed for supplying the control voltage required for the appliance only. The transformer is sized for the appliance load only and should not be used to supply power to additional field device[...]

Brute Elite Page 49 SECTION 12. T rouble Shooting 12.1 Sequence of Operation Brute Elite 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. 1. Upon a call for heat: (a) the internal pump and system pump will start; (b) the blower[...]

B RADFORD W HITE C ORP. Page 50 CODE# PROBLEM PROBABLE CAUSE SOLUTION COMMON LOCKOUT CODES 27 Internal error Flame rod to ground Check wiring / probe grounded, dirty probe 47 Flame rod to ground leakage Faulty flame detector Clean or replace flame detector 49 24VAC voltage low/high Faulty transformer Check/correct supply line voltage; replace fault[...]

Brute Elite Page 51 49 Maximum cycle count Control operates correctly, was reached however the cycle count will not increment any higher than 999,999 cycles Replace controller or adjust the count using blue display 50 Maximum hours count Control operates correctly, was reached however the hours count will not increment any higher than 999,999 hours[...]

B RADFORD W HITE C ORP. Page 52 13.2 Parts List SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE ITEM DESCRIPTION BNTH 80 BNTH 105 BNTH 150 BNTH 210 BNTH 285 BNTH 399 BNTH 500 BNTH 600 BNTH 750 BNTH 850 BNTV 150 BNTV 199 BNTV 285 BNTV 399 BNTV 500 BNTV 600 BNTV 750 BNTV 850 Jacket Components – See Figure 35 1 Front Panel Assembly R60D3200 R60D32[...]

Brute Elite Page 53 SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE ITEM DESCRIPTION BNTH 80 BNTH 105 BNTH 150 BNTH 210 BNTH 285 BNTH 399 BNTH 500 BNTH 600 BNTH 750 BNTH 850 BNTV 150 BNTV 199 BNTV 285 BNTV 399 BNTV 500 BNTV 600 BNTV 750 BNTV 850 24 Brace, Front, R20D1005 R20D1005 R20D1005 R20D1005 R85D1005 R85D1005 R85D1005 R60D1005 R85D1005 R85D[...]

B RADFORD W HITE C ORP. Page 54 SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE ITEM DESCRIPTION BNTH 80 BNTH 105 BNTH 150 BNTH 210 BNTH 285 BNTH 399 BNTH 500 BNTH 600 BNTH 750 BNTH 850 BNTV 150 BNTV 199 BNTV 285 BNTV 399 BNTV 500 BNTV 600 BNTV 750 BNTV 850 51 Duct/Venturi Transition R10D5021 R10D5021 R10D5021 R105013 R30D5013 — R50D5017 R60D50[...]

Brute Elite Page 55 SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE SIZE ITEM DESCRIPTION BNTH 80 BNTH 105 BNTH 150 BNTH 210 BNTH 285 BNTH 399 BNTH 500 BNTH 600 BNTH 750 BNTH 850 BNTV 150 BNTV 199 BNTV 285 BNTV 399 BNTV 500 BNTV 600 BNTV 750 BNTV 850 70 Front Refractory Tile RT2109000 RT2109000 RT2109000 RT2109000 RT2109000 RT2109000 RT2109000 RT21090[...]

B RADFORD W HITE C ORP. Page 56 Figure 35. Jacket Components.[...]

Brute Elite Page 57 Figure 36A. Internal Components, Sizes 80–210. Figure 36B. Internal Components, Sizes 285–600.[...]

B RADFORD W HITE C ORP. Page 58 Figure 36C. Internal Components, Sizes 750-850.[...]

Brute Elite Page 59 Figure 37A. Gas Train Components, Sizes 80-500.[...]

B RADFORD W HITE C ORP. Page 60 Figure 37B. Gas Train Components, Sizes 600-850.[...]

Brute Elite Page 61 Figure 38. Heat Exchanger Components.[...]

B RADFORD W HITE C ORP. Page 62 Figure 39. Electrical Components.[...]

Brute Elite Page 63[...]

H2343100- Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement. Ambler , P A 19002 T ech. Service (800) 334-3393 Service Parts (800) 538-2020 www.BradfordWhite.com W arranty Service (800) 531-21 1 1 Litho in U.S.A. © Bradford White 1 102 Document 1243 ®[...]