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Bradford-White Corp BJVT manual

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Table of contents for the manual

  • Page 1

    H2343000- FOR YOUR SAFETY : This product must be installed and serviced by a professional service technician, qualified in hot water boiler installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury , property damage, or death. Improper installation and/or ope[...]

  • Page 2

    B RADFORD W HITE C ORP. Page 2 T ABLE OF CONTENTS SECTION 1. General Information 1.1 Introduction ................................................... 3 1.2 Warranty ....................................................... 3 1.3 Codes and Standards ................................... 3 1.4 Technical Assistance .................................... 3 1[...]

  • Page 3

    Brute Mini Hydronic Boiler Page 3 SECTION 1. General Information 1.1 Introduction This manual provides information necessary for the installation, operation, and maintenance of Model BJV copper tube hydronic boilers. All application and installation procedures should be reviewed completely before proceeding with the installation. Consult the factor[...]

  • Page 4

    B RADFORD W HITE C ORP. Page 4 temperature may be less than 120°F, such as in-floor radiant systems, snow melt systems or other systems where a “cold start” is expected frequently due to thermostat setbacks, etc. See Figure 11. b. Any system where the temperature rise across the heat exchanger is above 30°F (see Section 5 and Figure 7). 2. Co[...]

  • Page 5

    Brute Mini Hydronic Boiler Page 5 2.2 Field Assembly 1. Brute Mini boilers have built-in draft diverter for natural draft operation. 2. Find the vent damper box which is located in the boiler package. 3. Install the vent damper directly to the top of the draft diverter outlet with the damper operator facing to the front of the boiler, and with the [...]

  • Page 6

    B RADFORD W HITE C ORP. Page 6 Caution Do not force motor operation when operator is fastened to the damper by moving the damper blade, turning the shaft or by turning the position indicator. Attention Ne pas tourner le registre manuellement avec ou sans courant électrique ou le moteur sera endommagé. 2.3.1 Clearances The boiler must be placed to[...]

  • Page 7

    Brute Mini Hydronic Boiler Page 7 SECTION 3. V enting 3.1 Combustion Air Supply The boiler location must provide sufficient air supply for proper combustion, and ventilation of the surrounding area as outlined in the latest edition of ANSI standard Z223.1 or in Canada, CSA-B149.1, and any local codes that may be applicable. In general, these requir[...]

  • Page 8

    B RADFORD W HITE C ORP. Page 8 WARNING Vent pipe diameter must be as required by the National fuel Gas Code Z223.1 or the Canadian Installation Codes for Gas Appliances CSA-B149.1. Undersize pipe can result in inadequate venting and oversize pipe can result in vent condensation. In either case the result can be release of combustion products to the[...]

  • Page 9

    Brute Mini Hydronic Boiler Page 9 WARNING Operation of appliances with a blocked common vent may lead to serious injury or death. Safety devices must be implemented to prevent blocked common vent operation. If safe operation of all appliances connected to a common vent cannot be assured, including prevention of spillage of flue gasses into living s[...]

  • Page 10

    B RADFORD W HITE C ORP. Page 10 SECTION 4. Gas Connections 4.1 Gas Supply and Piping Review the following general instructions before continuing the installation. WARNING The Brute Mini BJVS and BJVT boilers are designed for use with either natural gas or LP gas. Check the rating plate to be sure that the boiler is designed to use the type of gas b[...]

  • Page 11

    Brute Mini Hydronic Boiler Page 11 NOTE : The boiler and all other gas appliances sharing the boiler gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. Low gas pressure could be an indication of an undersize gas meter and/or obstructed gas supply line. 8. The correct high fire burner manifold gas press[...]

  • Page 12

    B RADFORD W HITE C ORP. Page 12 A full sized, 1¼" bypass with balancing valves is strongly recommended for all systems, and required when: 1) the boiler is installed without primary- secondary piping in a multiple zone system; 2) when the return water temperature can be expected to be lower than 120°F (44°C); or 3) whenever the system pipin[...]

  • Page 13

    Brute Mini Hydronic Boiler Page 13 Figure 6. Typical Plumbing Installations.[...]

  • Page 14

    B RADFORD W HITE C ORP. Page 14 Figure 6A. Typical Plumbing Installations. System Loop Expansion T ank Pump Air Scoop Feed W ater Single Circuit System Multi-Zone Valve System Multi-Zone Pump System Figure 6B. Typical Plumbing Installations. BJV Boiler BJV Boiler BJV Boiler[...]

  • Page 15

    Brute Mini Hydronic Boiler Page 15 5.3 Flow Requirements All high recovery, low volume water boilers must have adequate flow for efficient operation. Pump selection is critical to this goal, and pumps should be selected to provide for system design water temperature rise. Table 6 details temperature rise and water flow (GPM) for the Brute Mini boil[...]

  • Page 16

    B RADFORD W HITE C ORP. Page 16 5.4 Chilled Water Systems If the boiler is installed in conjunction with refrigeration systems, it shall be installed so that the chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the heating boiler. When boiler piping is connected to heati[...]

  • Page 17

    Brute Mini Hydronic Boiler Page 17 Figure 9a. Wiring Diagram, Spark Ignition System (BJVS 50 & 75). Switch Safety Roll-Out Blocked V ent Safety Switch Sp ace Heating Pump (Field Supplied) Receptacle Damper V ent Receptacle V enter Power Jumper R W R A Zone Pump Relay Zone Pump Relay Field Thermostat Supplied Limit High Optional Aquastat T ermin[...]

  • Page 18

    B RADFORD W HITE C ORP. Page 18 Figure 9c. Wiring Diagram, Standing Pilot System (BJVT). Figure 9d. Schematic, Standing Pilot System (BJVT).[...]

  • Page 19

    Brute Mini Hydronic Boiler Page 19 SP ARK MV MV/PV PV GND 24V (GR) 24V TH-W MV SP ARK 1 2 3 4 5 6 7 8 9 W W B B R R LO HI MV C PV HI Pilot Burner With Sp ark Electrode Sensor Remote Flame Sensor High Altitude (Optional) T wo-Stage Aquastat Tw o- St a g e Gas V alve HW VR8304 Switch Safety Roll-Out Blocked V ent Safety Switch Sp ace Heating Pump (Fi[...]

  • Page 20

    B RADFORD W HITE C ORP. Page 20 Figure 10. Multiple Zone Wiring. For primary/secondary pumping: Connect to "W" in lieu of "A." Boiler relay is used for boiler pump and connection to "W" will energize boiler pump when any zone is calling for heat. Wiring with T aco Zone V alves Wiring with Honeywell Zone V alves Wiring [...]

  • Page 21

    Brute Mini Hydronic Boiler Page 21 6. 3 Grounding WARNING The boiler 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 Electric[...]

  • Page 22

    B RADFORD W HITE C ORP. Page 22 On continuous pilot ignition models (BJVT), if the water temperature is below the limit setting, the ignition module opens the main gas valve, and the main burners ignite. Operation will continue on all ignition systems until either the wall setting thermostat is satisfied or the high-limit thermostat opens. The burn[...]

  • Page 23

    Brute Mini Hydronic Boiler Page 23 Caution Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance. Attention En cas de surchauffe ou si l’admission de gaz ne peut être coupée, ne pas couper ni débranch[...]

  • Page 24

    B RADFORD W HITE C ORP. Page 24 14. Turn gas control knob counterclockwise to ON. 15. Replace control box cover. 16. Restore power to the boiler and adjust the thermostat high enough to call for heat to verify the boiler is operating properly. 17. BJVS 100-225 ONLY - Adjust two-stage operating control setting to maximum, verify high fire operation.[...]

  • Page 25

    Brute Mini Hydronic Boiler Page 25 DANGER Read and understand this entire procedure prior to proceeding. Improper adjustment of high altitude shutters may result in a fire, explosion, and/or high levels of toxic gases which may cause property damage, personal injury, or loss of life. DANGER Lisez la manière de procéder dans sa totalité et compre[...]

  • Page 26

    B RADFORD W HITE C ORP. Page 26 1. Lubricate the water circulating pump per the instructions on the pump. 2. If a strainer is employed in a pressure reducing valve or the piping, clean it every six months. 3. At start-up, and periodically thereafter, the burner flame should be observed. If the flame has the appearance of ‘sooting’ tips, check f[...]

  • Page 27

    Brute Mini Hydronic Boiler Page 27 Caution Two-stage Operating Control (BJV100-225 ONLY): Factory setting is 140°F (60°C). This setting is correct for most hydronic heating applications. Adjustments to this setting must be made by an authorized service technician. 2. Two-stage Temperature Control - BJVS 100- 225 are equipped with a two-stage temp[...]

  • Page 28

    B RADFORD W HITE C ORP. Page 28 Table 8. Troubleshooting Guide. # Symptom Cause Remedy 1. Pump not A. No power A. Check circuit breakers and power source. operating B. Pump defective B. Replace. C. Incorrectly wired C. Recheck wiring diagrams. 2. Pilot outage A. Inlet gas pressure too low A. Consult gas utility company. Inlet gas pressure to boiler[...]

  • Page 29

    Brute Mini Hydronic Boiler Page 29 T T T T T T T TT T T T Note: Before troubleshooting, familiarize yourself with the start-up and checkout procedure. Check line voltage power, low voltage transformer, hi- limit switch, thermostat (controller) and wiring. Pull ignition lead and check spark at module. Spark okay? • Check ignition cable ground wiri[...]

  • Page 30

    B RADFORD W HITE C ORP. Page 30 9.4 Electrical Troubleshooting 1. Remove the control box cover on the front of the boiler. 2. Verify that 115V is reaching the boiler by testing across the black wire on the pump relay and the white wire on the transformer. 3. Verify 24V transformer output by placing the meter leads on the yellow and red wires. If 24[...]

  • Page 31

    Brute Mini Hydronic Boiler Page 31 Heat Distribution Units Transfers heat from the water supplied by the boiler to the area to be heated through the use of baseboard, convector, radiator, finned tube. Also known as "radiation." Isolation Valve Used to isolate the boiler from the circuit. It minimizes the amount of water drained from the s[...]

  • Page 32

    B RADFORD W HITE C ORP. Page 32 Description Model, Size BJVS-50 BJVT-50 BJVS-75 BJVT-75 BJVS-100 BJVT-100 BJVS-125 BJVT-125 BJVS-160 BJVT-160 BJVS-225 BJVT-225 Pilot Gas System Pilot Assy (Nat.) W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 Pilot Assy (LP) W0039600 W0040901 W0039600 W004[...]

  • Page 33

    Brute Mini Hydronic Boiler Page 33 Description Model, Size BJVS-50 BJVT-50 BJVS-75 BJVT-75 BJVS-100 BJVT-100 BJVS-125 BJVT-125 BJVS-160 BJVT-160 BJVS-225 BJVT-225 Water System Heat Exchanger 11046001 11046001 11046002 11046002 11046003 11046003 11046004 11046004 11046005 11046005 11046006 11046006 Temperature/Pressure Gauge A0000100 A0000100 A00001[...]

  • Page 34

    B RADFORD W HITE C ORP. Page 34 Figure 15. Parts Identification. 11.3 Exploded View V ent Damper Draft Diverter To p Rear Panel Burner with Pilot Bracket Pilot Assembly Gas Manifold Base Assembly Refractory , Rear Refractory , Front Gap Closure HX Access Panel Heat Exchanger Flue Collector     1-1/4” Hold 1-1/8” Hold 1-1/4” Hold 1[...]

  • Page 35

    Brute Mini Hydronic Boiler Page 35[...]

  • Page 36

    Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement. H2343000- 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 1 101 Document 1242[...]