Bradford-White Corp BRHHV manual

Installation and Operation Instructions Docyment 1246 H2343400- Modulating Boiler Model BRHHH Modulating W ater Heater Model BRHHV U.S. Patent No. 6,644,393 Canada Patent Pending 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[...]

B RADFORD W HITE C ORP . Page 2[...]

Brute Magnum Page 3 T able of Contents SECTION 1 General Information 1.1 Introduction ...................................................... 5 1.2 Model Identification .......................................... 5 1.3 W arranty .......................................................... 6 1.4 Dimensions ..............................................[...]

B RADFORD W HITE C ORP . Page 4 T able 1 Clearances ........................................................ 6 T able 2 V ent / Air Pipe Sizes .......................................... 7 T able 3 Horizontal V ent and Air T erminals for Indoor Installations ....................................... 8 Figure 1 Dimensional Drawing .....................[...]

Brute Magnum Page 5 Section 1 GENERAL INFORMA TION USING THIS MANUAL – Because the Brute Magnum Boilers and Brute Magnum W ater Heaters are identical appliances, with the exception of materials of manufacture, labels and ultimate use application, this manual provides information for the pr oper installation, operation and maintenance of both prod[...]

B RADFORD W HITE C ORP . Page 6 (13) Revision 2 = Second version (14) Heat Exchanger E = Glass-lined steel with copper tubes F = Glass-lined steel with cupronickel tubes (15) Control Option Code X = Standard, meets CSD-1 boiler standard A = Control Pack A: CSD-1, CA, FM, IL, IRI, Alarm Bell B = Control Pack B: CSD-1, CA, FM, IL, LDS, MN F = Non CSD[...]

Brute Magnum Page 7 Figure 1. Dimensional Drawing. Size Intake Exhaust Intake Exhaust Size Size Maximum Run Maximum Run 1200 6" (15 cm) dia. 6" (15 cm) dia. 50 linear feet with 5 elbows 50 linear feet with 5 elbows 1600 8" (20 cm) dia. 6" (15 cm) dia. 50 linear feet with 5 elbows 50 linear feet with 5 elbows 2000 8" (20 cm)[...]

B RADFORD W HITE C ORP . Page 8 2.1.2 Intake Combustion Air The combustion air can be taken through the wall, or through the roof. When taken from the wall, it must be taken from out-of-doors by means of the horizontal wall terminal, shown in T able 3. See T able 2 to select the appropriate diameter air pipe. When taken from the roof, a field-suppl[...]

Brute Magnum Page 9 T erm Description Pipe Single-wall galvanized steel pipe, 24 gauge minimum (sized per section 1.9) Joint Permanent duct tape or aluminum tape Sealing Insulation Not required, but recommended R5 insulation for cold installations (consult American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE) handbook [...]

B RADFORD W HITE C ORP . Page 10 Figure 3. Combustion Air and V ent Through Side Wall. *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. U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, 12 i[...]

Brute Magnum Page 1 1 1. The figure in this addendum shows the requirements for mechanical vent terminal clearances for the U.S. and Canada. 2. V ent 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 haz[...]

B RADFORD W HITE C ORP . Page 12 (c) MANUF ACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufactur er of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equi[...]

Brute Magnum Page 13 At the time of removal of an existing boiler , the following steps shall be followed with each appliance remaining connected to the common venting system 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[...]

B RADFORD W HITE C ORP . Page 14 7. All threaded joints should be coated with piping compound resistant to action of liquefied petroleum gas. 8. The appliance and its individual shutoff valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.45kpa). 9. The unit must[...]

Brute Magnum Page 15 medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler . The boiler piping system of a hot water heating boiler connected to heating coils located in air handling appliances where they may be exposed to refrigerated air circulation must be equipped with flow co[...]

B RADFORD W HITE C ORP . Page 16 4B.3 W ater Flow Requirements — W ater Heater In a water heating application (an open system), new water is constantly being introduced. W ith the new water comes a fresh supply of minerals that can be deposited on the unit’ s heat exchanger . This is commonly known as scaling. The amount of minerals will depend[...]

Brute Magnum Page 17 If the water at the inlet of the copper heat exchanger is less than 140°F (60°C), water from the outlet of the copper heat exchanger will be directed back to the inlet of the copper heat exchanger , and will mix to bring the inlet water up to 140°F (60°C). Once through the copper heat exchanger , the water picks up another [...]

B RADFORD W HITE C ORP . Page 18 4B.4 Combined W ater (potable) Heating and Space Heating NOTE: These systems are not allowed in the Commonwealth of Massachusetts. Piping and components connected to this water heater for the space heating application shall be suitable for use with potable water . T oxic chemicals, such as used for boiler treatment,[...]

Brute Magnum Page 19 Figure 7. Internal Piping Schematic. 4B.5 Freeze Protection – W ater Heater Brute Magnum heaters are not designed to be placed outdoors, due to the potential for condensate to freeze in the unit. Power outage, interruption of gas supply , failure of system components, activation of safety devices, etc., may prevent a heater f[...]

B RADFORD W HITE C ORP . Page 20 Figure 8. W ater Heater Piping — One Heater , One T ank.[...]

Brute Magnum Page 21 Figure 9. W ater Heater Piping — Multiple Heaters, One T ank.[...]

B RADFORD W HITE C ORP . Page 22 Figure 10. W ater Heater Piping — One Heater , Multiple T anks.[...]

Brute Magnum Page 23 Figure 1 1. Water Heater Piping — Multiple Heaters, Multiple T anks.[...]

B RADFORD W HITE C ORP . Page 24 Section 5 ELECTRICAL CONNECTIONS W ARNING 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/NFP A 70, in the U.S. and with latest edition of CSA C[...]

Brute Magnum Page 25 temperature is less than 140°F (60°C), internal mixing will keep the outlet temperature at 160-165°F (71- 74°C), and this will mix with the tank temperature to maintain a lower temperature in the tank. If the return temperature is 140°F (60°C) or higher , the outlet temperature of the heater will be the return temperature[...]

B RADFORD W HITE C ORP . Page 26 tank is drawing down, the heater will react to sustain a minimum tank temperature. Boilers generally have higher differentials than water heaters, to minimize short cycling (see throttling range). The dif ferential is set by removing the cover of the A350 control and adjusting the potentiometer marked “DIFF” (se[...]

Brute Magnum Page 27 5.5.6 Integration Constant The proportional control used on the Brute Magnum has internal circuitry that helps to minimize overshoot that can sometimes be associated with proportional plus integral (PI) controls. There are three field-selectable integration constants (slow , medium and fast), and an off position on the proporti[...]

B RADFORD W HITE C ORP . Page 28 another 20-25°F (1 1-14°C) (when at high fire), and it leaves the boiler at 160-165°F (71-74°C). This hot water is then sent to the system. If the water at the inlet of the copper heat exchanger is 140°F (60°C), or higher , the water will be allowed to flow through the copper heat exchanger and directly to the[...]

Brute Magnum Page 29 The second menu “Add” has to do with the N2 address. Pressing enter when “Add” is displayed will display “255”, which stands for 255 unique addresses. The up and down arrows change this value, and enter saves the value if it is changed. Changing the “Add” value will have no affect on the Brute Magnum, unless a c[...]

B RADFORD W HITE C ORP . Page 30 Figure 17. Wiring Diagram, Size 1200, Standard and Codes A and F .[...]

Brute Magnum Page 31 Figure 18. Wiring Diagram, Sizes 1600, 2000 and 2400, Standard and Codes A and F .[...]

B RADFORD W HITE C ORP . Page 32 Figure 19. Wiring Diagram, Size 1200, Code B.[...]

Brute Magnum Page 33 Figure 20. Wiring Diagram, Sizes 1600, 2000 and 2400, Code B.[...]

B RADFORD W HITE C ORP . Page 34 Figure 21. Wiring Schematic, Model 1200, Standard and Codes A and F . Figure 22. Wiring Schematic, Models 1600, 2000 and 2400, Standard and Codes A and F .[...]

Brute Magnum Page 35 Figure 23. Wiring Schematic, Model 1200, Code B. Figure 24. Wiring Schematic, Models 1600, 2000 and 2400, Code B.[...]

B RADFORD W HITE C ORP . Page 36 Section 6 OPERA TING INSTRUCTIONS 6.1 Filling the Boiler System 1. Ensure the system is fully connected. Close all bleeding devices and open make-up water valve. Allow system to fill slowly . 2. If make-up water pump is employed, adjust pressure switch on pumping system to provide a minimum of 12 psi (81.8 kPa) at t[...]

Brute Magnum Page 37 Figure 25. Gas/Air T est Panel. Figure 26. T est Panel V alves. panel are closed (see Figure 26). 5. Remove the two plugs from the + and – ports of the air orifice taps, thread hose barbs into the 1/8" NPT connections, and attach the manometer pressure lines to the barbs. Be sure all connections are gas tight. 6. Switch [...]

B RADFORD W HITE C ORP . Page 38 (c) Open gas shutoff valve. Restart the appliance. The ignition sequence will start again and the burner will start. The appliance will return to its previous mode of operation. Caution Should any odor of gas be detected, or if the gas burner does not appear to be functioning in a normal manner , CLOSE MAIN SHUTOFF [...]

Brute Magnum Page 39 Figure 27. Gas T rains.[...]

B RADFORD W HITE C ORP . Page 40 Figure 28. Gas T rains.                    ?[...]

Brute Magnum Page 41 shutoff valve. Remove the front and right-side panels from the unit. Disconnect the union between the valve body and the blower . Label the four pr essure tubes that are connected to the valve actuator , to ensur e that they will be replaced corr ectly . Remove the valve actuator , per the instructions above. Unscrew the valve [...]

B RADFORD W HITE C ORP . Page 42 7.2.10 Mixing Actuator The mixing actuator connects to both mixing valves and takes its signal from the mixing control to properly set the valves to protect the copper heat exchanger . T o remove the actuator, remove the screw on the front to take the cover off. Disconnect the wires. T ake the 2 nuts off the U-bolt,[...]

Brute Magnum Page 43 8. Clean the heat exchanger: A light accumulation of soot or corrosion on the outside of the heat exchanger can be easily removed. Use a wire brush to remove loose soot and scale from the heat exchanger . Do not use water or compressed air for cleaning. 9. NOTE: While the heat exchanger is out of the unit, inspect the firewall [...]

B RADFORD W HITE C ORP . Page 44 6. When the call for heat is complete, or the unit reaches its setpoint temperature, the gas valve will close, and the fan will continue to run for its 30 second post-purge. If a pump time delay is used, the pump will continue to run for the specified amount of time (adjustable from 0.1 to 10 minutes). 8.2 Resolving[...]

Brute Magnum Page 45 8.5 Short Cycling — W ater Heater Short cycling will generally occur only in combination space heating and water heating applications when the water heater is operating in the space-heating mode. Because the Brute Magnum is a modulating water heater and its input will reduce when there is a reduction in heating load, short cy[...]

B RADFORD W HITE C ORP . Page 46 9.2 Parts List COMBUSTION COMPONENTS – See Figure 30 1200 1600 2000 2400 2 Base assembly 24A1200 24A1200 24A1200 24A1200 3 Panel, top, combustion chamber 24B2600 24B2600 24B2600 24B2600 4 Panel, bottom, combustion chamber 24A2400 24A2400 24A2400 24A2400 5 Panel, left, combustion chamber 24A2100 24A2100 24A2100 24A[...]

Brute Magnum Page 47 50 T ubing/Fittings (gas train repair kit) R2020700 R2020700 R2020700 R2020700 51 Air filter box assembly (with gasket and hardware) Nat 12B5000 16B5000 20B5000 24B5000 51 Air filter box assembly (with gasket and hardware) LP 12B5020 16B5020 20B5020 24B5020 52 Air filter A2108300 A2108300 A2108300 A2108300 53 Gasket kit, air[...]

B RADFORD W HITE C ORP . Page 48 105 Switch, Low water cutof f, Manual Reset RE2075100 RE2075100 RE2075100 RE2075100 HEA T EXCHANGER / W A TER P A TH – See Figures 34 and 35 1 10 Header cover 12A4200 16A4200 20A4200 24A4200 1 1 1 W ater barrier assembly 12B4100 16B4100 20B4100 24B4100 1 12 Gasket, heat exchanger cover S201 1900 S2102500 S2102600 [...]

Brute Magnum Page 49 Figure 30. Combustion Components.[...]

B RADFORD W HITE C ORP . Page 50 Figure 31. Gas T rain/Combustion Air Components.[...]

Brute Magnum Page 51 Figure 32. Gas T rain Components.                              ?[...]

B RADFORD W HITE C ORP . Page 52 Figure 33. Electrical Components.[...]

Brute Magnum Page 53 Figure 34. Heat Exchanger / W ater Path Components.[...]

B RADFORD W HITE C ORP . Page 54 Figure 35. Heat Exchanger / W ater Path Components.[...]

Brute Magnum Page 55 Figure 36. Jacket Components.[...]

H2343400- ® 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 1246 Bradford White Company reserves the right to change specifications, components, features, or to discontinue products without notice.[...]