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Bradford-White Corp Copper Brute II Hydronic Boiler manual

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Table of contents for the manual

  • Page 1

    Installation and Operation Instructions Document 1270 H2214401F Installation and Operation Instructions for W ARNING If the information in this manual is not followed exactly , a re or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other ammable vapors and liquids in the vicinity[...]

  • Page 2

    Page 2 B RADFORD W HITE C ORP . SECTION 1. General Information 1.1 Introduction ...................................................... 4 1.2 Model Identication .......................................... 4 1.3 W arranty .......................................................... 5 1.4 Dimensions ....................................................[...]

  • Page 3

    Page 3 COPPER BRUTE II (500 - 2000) SECTION 6. Operating Instructions 6.1 Sequence of Operation .................................. 36 6.2 Filling the Boiler System ................................ 36 6.3 Programming the T emperature Control ......... 37 6.3.1 System Piping ................................................ 37 6.3.2 Choosing the Mode.[...]

  • Page 4

    Page 4 B RADFORD W HITE C ORP . SECTION 1. General Information USING THIS MANUAL – Because the Copper Brute II Boilers and Copper Brute II 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 mainte[...]

  • Page 5

    Page 5 COPPER BRUTE II (500 - 2000) Model Character Designation 1-3 Model Series Designation B W C = Bradfrod White, Copper Brute II 4 Usage H = Hydronic V = V olume W ater 5-8 Size 0 5 0 0 = 500,000 BTU/h input 0 7 5 0 = 750,000 BTU/h input 1 0 0 0 = 999,000 BTU/h input 1 2 5 0 = 1,250,000 BTU/h input 1 5 0 0 = 1,500,000 BTU/h input 1 7 5 0 = 1,75[...]

  • Page 6

    Page 6 B RADFORD W HITE C ORP . Figure 1. Dimensional Data. SHIPPING WEIGHT SIZE lbs. kg 500 425 193 750 505 229 1000 615 279 1250 675 306 1500 760 345 1750 825 375 2000 955 434 *Add 55 lbs. (25kg) for pump-mounted units. AIR VENT HORIZ. A B C D E F G H CONN. CONN. VENT SIZE in cm in cm in cm in cm in cm in cm in cm in cm W V PIPE 500 33½ 85 15¾ [...]

  • Page 7

    Page 7 COPPER BRUTE II (500 - 2000) 1.6 Locating Pump-Mounted W ater Heater with Respect to Storage T ank(s) For best results, a pump-mounted Copper Brute II water heater should be located within 15 feet (4.6m) of the storage tank(s). The pump is sized for 30 feet (9.1m) of piping. If the appliance must be installed with longer piping runs, then la[...]

  • Page 8

    Page 8 B RADFORD W HITE C ORP . Figure 2. Combustion Air and V ent Through Roof. EACH OPENING* SIZE SQUARE INCHES SQUARE CM 500 125 807 750 188 1213 1000 250 1613 1250 313 2020 1500 375 2420 1750 438 2826 2000 500 3226 *Net Free Area in Square Inches / Square cm Area indicated is for one of two openings; one at oor level and one at the ceiling, [...]

  • Page 9

    Page 9 COPPER BRUTE II (500 - 2000) length allowed is 50 feet (15.2m). Three elbows have been calculated into the 50-foot (15.2m) linear run. Subtract 10 allowable linear feet (3.0m) for every additional elbow used (see T able 2 ). When fewer than 3 elbows are used, the maximum linear pipe length allowed is still 50 feet (15.2m). The connection for[...]

  • Page 10

    Page 10 B RADFORD W HITE C ORP . U.S. Installations (see note 1) Canadian Installations (see note 2) A = Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony B = Clearance to window or door that may be 4 feet (1.2 m) below or to side of opening; 36 inches (91 cm) opened 1 foot (30 cm) above opening C = Clearan[...]

  • Page 11

    Page 1 1 COPPER BRUTE II (500 - 2000) appliances. If assistance is required in determining how a blocked vent safety system should be connected to a Bradford White product, please call Applications Engineering at the Rochester phone number listed on back cover of this manual. Refer to the installation and operating instructions on all appliances to[...]

  • Page 12

    Page 12 B RADFORD W HITE C ORP . 2.3.3 V ertical V ent T erminal When the unit is vented through the roof, the vent must extend at least 3 feet (0.9m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6m) higher than any portion of a building within a horizontal distance of 10 feet (3.0m), and high enough above the [...]

  • Page 13

    Page 13 COPPER BRUTE II (500 - 2000) DIST ANCE FROM GAS METER OR LAST ST AGE REGULA TOR SIZE AND GAS TYPE 0-100' 0-31m 100-200' 31-61m 200-300' 61-91m 500 natural 1-1/2" 3.8cm 2" 5.1cm 2" 5.1cm 500 propane 1" 2.5cm 1-1/2" 3.8cm 1-1/2" 3.8cm 750 natural 2" 5.1cm 2" 5.1cm 2-1/2" 6.4cm 750 pr[...]

  • Page 14

    Page 14 B RADFORD W HITE C ORP . 20°F 25°F 30°F 35°F SIZE ow H/L ow H/L ow H/L ow H/L gpm feet gpm feet gpm feet gpm feet 500 43 1.7 34 1.1 28 0.9 24 0.7 750 64 3.3 51 2.3 43 1.7 36 1.2 1000 85 5.0 68 3.6 57 3.1 49 2.2 1250 106 8.1 85 6.1 71 4.7 61 3.4 1500 128 10.0 102 7.2 85 5.5 73 4.2 1750 N/R N/R 1 19 10.5 99 8.4 85 5.8 2000 N/R[...]

  • Page 15

    Page 15 COPPER BRUTE II (500 - 2000) PRIMARY/SECONDAR Y MANDITORY FOR ALL V ARIABLE FLOW SYSTEMS INST ALL AIR VENTS AT HIGH POINTS IN SYSTEM PIPIN G& SIZING OF EXP ANSION T ANK PER T ANK MANUFACTURER'S INSTRUCTIONS DIMENSION "C" (COMMON PIPING) TO BE FOUR PIPE DIAMETERS, MAX. (NO ELBOWS OR VA L VES) BOILER CIRCUIT PIPING MUST BE [...]

  • Page 16

    Page 16 B RADFORD W HITE C ORP . PRIMARY/SECONDAR Y MANDITORY FOR ALL V ARIABLE FLOW SYSTEMS INST ALL AIR VENTS AT HIGH POINTS IN SYSTEM PIPING & SIZING OF EXP ANSION T ANK PER T ANK MANUFACTURER'S INSTRUCTIONS DIMENSION "C" (COMMON PIPING) TO BE FOUR PIPE DIAMETERS, MAX. (NO ELBOWS OR VA L VES) BOILER CIRCUIT PIPING MUST BE EQUA[...]

  • Page 17

    Page 17 COPPER BRUTE II (500 - 2000) Figure 6. Hydronic Piping — One Boiler , Multi-T emperature System. PRIMARY/SECONDAR Y MANDITORY FOR ALL V ARIABLE FLOW SYSTEMS INST ALL AIR VENTS AT HIGH POINTS IN SYSTEM PIPING & SIZING OF EXP ANSION T ANK PER T ANK MANUFACTURER'S INSTRUCTIONS DIMENSION "C" (COMMON PIPING) TO BE FOUR PIPE [...]

  • Page 18

    Page 18 B RADFORD W HITE C ORP . LEGEND CHECK VA LV E THERMOMETER TEMPERA TURE SENSOR GLOBE VA LV E EXP ANSION T ANK WITH AIR SCOOP AND AUTO AIR VENT 3-W AY VA LV E VA LV E CAUTION: THIS DRA WING SHOWS SUGGESTED PIPING CONFIGURA TION AND VA L VING , CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS. PRESSURE REDUCING VA LV E W/ FAST[...]

  • Page 19

    Page 19 COPPER BRUTE II (500 - 2000) LEGEND CHECK VA LV E THERMOMETER TEMPERA TURE SENSOR GLOBE VA LV E EXP ANSION T ANK WITH AIR SCOOP AND AUTO AIR VENT 3-W AY VA LV E VA LV E PRESSURE REDUCING VA LV E W/ FAST FILL BYP ASS PURGE VA LV E PUMP CAUTION: THIS DRA WING SHOWS SUGGESTED PIPING CONFIGURA TION AND VA L VING , CHECK WITH LOCAL CODES AND ORD[...]

  • Page 20

    Page 20 B RADFORD W HITE C ORP . SECTION 4B. W ater Connections — Copper Brute II W ater Heater 4B.1 W ater System Piping — W ater Heater Hot water piping should be supported by suitable hangers or oor stands. Do not support piping with this appliance. Due to expansion and contraction of copper pipe, consideration should be given to the type[...]

  • Page 21

    Page 21 COPPER BRUTE II (500 - 2000) Figure 9. W ater Heater Piping — One Heater , One T ank. NOTES: 6. CAUTION: PUMP SIZING MUST BE BASED UPON WA TER HARDNESS AT JOB SITE 1. OPTIONAL CWMU & RECIRC. LINE LOCA TION. 2. LOCA TE PENNANT DHW SENSOR OR REMOTE AQUAST AT WELL IN LOWER 1/3 OF T ANK. 3. BACK FLOW PREVENTER MA YB E REQUIRED. CHECK LOCA[...]

  • Page 22

    Page 22 B RADFORD W HITE C ORP . Figure 10. W ater Heater Piping — Multiple Heaters, One T ank. Figure 1 1. W ater Heater Piping — One Heater , Multiple T anks.[...]

  • Page 23

    Page 23 COPPER BRUTE II (500 - 2000) GPM FT TEMP RISE °F LPM M TEMP RISE°C SIZE S N H S N H S N H S N H S N H S N H 500 45 68 90 1.8 2.3 3.5 19 13 9 170 257 341 0.5 0.7 1.1 10 7 5 750 45 68 90 2.1 3.0 6.0 28 19 14 170 257 341 0.6 0.9 1.8 16 10 8 1000 45 68 90 2.3 3.6 6.1 38 25 19 170 257 341 0.6 1.1 1.9 2[...]

  • Page 24

    Page 24 B RADFORD W HITE C ORP . SINGLE CIRCUIT CONNECTIONS PUMP HEA TER ONL Y W/O PUMP WITH PUMP 500 15 20 15 750 15 20 15 1000 20 25 15 1250 25 30 15 1500 25 30 15 1750 25 — 15 2000 25 — 20 T able 10. Electrical Data. Figure 13. Removing Jumpers. SECTION 5. Electrical Connections W ARNING The appliance must be electrically grounded in accorda[...]

  • Page 25

    Page 25 COPPER BRUTE II (500 - 2000) Figure 14. Field Wiring Panel Figure 15. External Control Connection Wiring. with the Copper Brute II is installed in the piping or tank, per the suggested piping diagrams, and connected to the “S C2” and “SUP S” terminals. See Section 6.3 for “Mode” denitions and Figures 22 to 24 for eld wirin[...]

  • Page 26

    Page 26 B RADFORD W HITE C ORP . additional components. 5.3 External Staging Control Wiring W ARNING Improper eld wiring may result in re or explosion which can cause property damage, severe injury , or death. Make only wiring connections which are in accordance with the Installation and Operation manual. A VERTISSEMENT Un câblage incorrect [...]

  • Page 27

    Page 27 COPPER BRUTE II (500 - 2000) Figure 16. Copper Brute II 500 - 750 Ladder Diagram.[...]

  • Page 28

    Page 28 B RADFORD W HITE C ORP . Figure 17. Copper Brute II 1000 Ladder Diagram.[...]

  • Page 29

    Page 29 COPPER BRUTE II (500 - 2000) Figure 18. Copper Brute II 1250 - 2000 Ladder Diagram.[...]

  • Page 30

    Page 30 B RADFORD W HITE C ORP . Figure 19. Copper Brute II 500 - 1000 Wiring Schematic.[...]

  • Page 31

    Page 31 COPPER BRUTE II (500 - 2000) Figure 20. Copper Brute II 1250 - 1500 Wiring Schematic.[...]

  • Page 32

    Page 32 B RADFORD W HITE C ORP . Figure 21. Copper Brute II 1750 - 2000 Wiring Schematic.[...]

  • Page 33

    Page 33 COPPER BRUTE II (500 - 2000) Figure 22. Field Wiring. Note: Positions of eld wiring terminals may vary , but terminal designations are as indicated.[...]

  • Page 34

    Page 34 B RADFORD W HITE C ORP . Figure 23. Field Wiring for Modes 1 - 5. Note: Positions of eld wiring terminals may vary , but terminal designations are as indicated. TST AT TST AT - - - - - - - - - - - - - - 1C 1N O2 C2 NO 3C 3N O SET D COM DH TD HT OU T4 C4 NO IN SS C1 OUT SO DS SC 2 SUP S COM NO NO COM ALRM ALRM COM NO NC LW CO GND PM PP MP[...]

  • Page 35

    Page 35 COPPER BRUTE II (500 - 2000) Figure 24. Field Wiring for Mode 6. 1C 1NO 2C 2NO 3C 3NO 4C 4NO 4C 3C 4NO 3NO 2C 1C 2NO 1NO 4s tage boiler using 4 control outputs 4s tage boiler using 2 control outputs Jumper Jumper 4C 3C 4NO 3NO 2C 1C 2NO 1NO 4s tage boiler using 3 control outputs Jumper Jumper 4C 3C 4NO 3NO 4s tage boiler using 1 control out[...]

  • Page 36

    Page 36 B RADFORD W HITE C ORP . SECTION 6. Operating Instructions 6.1 Sequence of Operation A call for heat can be initiated either automatically (auto mode) under thermostatic control by the Copper Brute II temperature control, or by an external contact closure (manual mode). In auto mode, the Copper Brute II burner will re its stages of input[...]

  • Page 37

    Page 37 COPPER BRUTE II (500 - 2000) radiation units and high points in the system piping, as described in Step 4. 12. Close make-up water valve and check strainer in pressure reducing valve for sediment or debris from the make-up water line. Reopen make-up water valve. 13. Check gauge for correct water pressure and also check water level in the sy[...]

  • Page 38

    Page 38 B RADFORD W HITE C ORP . APPLICA TION MODE SYSTEM SETTING SENSORS USED • Parallel piping (non- primary/secondary) hydronic system 1 • None • DHW with or without a tank aquastat • Primary/secondary hydronic system 2 • Bradford White System (pref'd by Bradford White) S e ns o r (s h i p p ed • No outdoor reset with each Coppe[...]

  • Page 39

    Page 39 COPPER BRUTE II (500 - 2000) Figure 27. T emperature Control T arget T emperature Graph. delay setting of 5 minutes. See Section 6.4.6 for more information. NOTE: In modes other than mode 6, the pump will run continuously if the “HtD” and “ComD” terminals are jumpered and not connected to a zone valve or pump end switch, or other ?[...]

  • Page 40

    Page 40 B RADFORD W HITE C ORP . Programming. Mode 2 is used in primary-secondary piping hydronic systems without outdoor reset. Mode 5 adds outdoor reset. Step 1: Install the additional sensor in the primary loop (see Figure 4 ), and wired to the “SC2” and “SUPS” terminals on the eld wiring panel (Figure 23). Step 2: Remove the factory-[...]

  • Page 41

    Page 41 COPPER BRUTE II (500 - 2000) Caution If the tank temperature control is set too high, a potential for hot water scalding may exist. Mode 2: Primary secondary piping. Install a “supply sensor” in the primary loop using the Bradford White part number R2014800 sensor (included with every Copper Brute II unit). Connect the sensor to the “[...]

  • Page 42

    Page 42 B RADFORD W HITE C ORP . Figure 28. T emperature Control Interstage Differential. 6.4 Advanced T opics For most installations, Section 6.3 provides all the information required to set up the Copper Brute II boiler , and this section should be skipped. Continue setup in Section 6.5. This section provides denitions of the pro- gramming par[...]

  • Page 43

    Page 43 COPPER BRUTE II (500 - 2000) Figure 29. T emperature Control Min & Max. minimum amount of time before turning on the next stage. After the minimum time delay between stages has expired, the control examines the control error to determine when the next stage is to re. The control error is determined using PID logic. Proportional compa[...]

  • Page 44

    Page 44 B RADFORD W HITE C ORP . Figure 30. T emperature Control Outdoor Start Graph. the time selected (between 0 and 10 minutes). When OFF is selected, there is no purging. When ON is selected, pump operation is continuous. Also, during outdoor reset, with the pump delay set to ON , the pump continues to run even during W arm W eather Shut Down. [...]

  • Page 45

    Page 45 COPPER BRUTE II (500 - 2000) Figure 31. T ypical Gas T rain Conguration. Figure 32. T ypical Control Panel. the typical coldest temperature of the year where the building is located. This temperature is used when doing heat loss calculations for the building. Boiler Design ( BOIL DSGN ) – The BOIL DSGN temperature is the water temperat[...]

  • Page 46

    Page 46 B RADFORD W HITE C ORP . The control then operates the boiler stages to maintain the programmed boiler target temperature. The reset override operation is not affected by WWSD. 6.4.10 External Boiler Operation When mode 6 is selected, the control allows for an external control to operate the Copper Brute II’ s stages. In this mode, the co[...]

  • Page 47

    Page 47 COPPER BRUTE II (500 - 2000) (b) The ame will go out and blower will continue to run for the post purge cycle. One additional attempt to light will follow . Ignition will not occur as the gas is off. The ignition control will lockout, and will have to be reset before the unit will operate. (c) Open gas shutof f valve. Restart the applian[...]

  • Page 48

    Page 48 B RADFORD W HITE C ORP . SECTION 7. Maintenance 7.1 System Maintenance 1. Lubricate the system water-circulating pump, if required, 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. Inspect the venting system for obstruction or leakage at least once a yea[...]

  • Page 49

    Page 49 COPPER BRUTE II (500 - 2000) and boilers ordered with low temperature controls. T o replace the switch, shut off the 120-volt power to the appliance. Remove the cover from the switch to access the mounting screws. Remove the screws, and pull the switch off the control panel. Remove the capilliary and bulb from the thermal well located in th[...]

  • Page 50

    Page 50 B RADFORD W HITE C ORP . 6. Allow the heat exchanger to drain. Remove the front cover(s) by removing the rubber access strip(s) and the retaining screws. Remove the venting and remove the top, by removing the screws that attach the top to the side panels. Remove the side panels. Remove the front lower panels sealing the combustion area. T o[...]

  • Page 51

    Page 51 COPPER BRUTE II (500 - 2000) a load distribution problem. See Section 6.3 regarding controller setup. Contact your Bradford White representative to discuss possible remedies. 8.4 Short Cycling — W ater Heater Short cycling will generally occur only in combination space heating and water heating applications when the water heater is operat[...]

  • Page 52

    Page 52 B RADFORD W HITE C ORP . 8.6 T roubleshooting the T emperature Control See T able 12. 8.7 T roubleshooting Copper Brute II Controls The Copper Brute II series consists of two 2-stage models (500 and 750), one 3-stage model (1000), and four 4-stage models (1250 to 2000). The 2-stage models have one ignition module, and the 3- and 4-stage mod[...]

  • Page 53

    Page 53 COPPER BRUTE II (500 - 2000) T able 12. T roubleshooting Error Codes.[...]

  • Page 54

    Page 54 B RADFORD W HITE C ORP . Item Description Size Size Size Size Size Size Size 500 750 1000 1250 1500 1750 2000 Sheet Metal Components See Figure 33 1 Panel, Jacket, Side Left 5C3420 5C3420 5C3420 5C3420 5C3420 5C3420 5C3420 2 Panel, Jacket, Side Right 5C3521 5C3521 5C3521 5C3521 5C3521 5C3521 5C3521 3 Panel, Jacket, Front 5C3320 7C3320 10C33[...]

  • Page 55

    Page 55 COPPER BRUTE II (500 - 2000) Internal Components See Figures 35 and 34 17 Base Assembly 5C1020 7C1020 10C1020 12C1020 15C1020 17C1020 20C1020 18 Chamber , Front 5C2003 7C2003 10C2003 12C2003 15C2003 17C2003 20C2003 18A Chamber , Left Side, Front 5C2015 5C2015 5C2015 5C2015 5C2015 5C2015 5C2015 18B Chamber , Right Side, Front 5C2016 5C2016 5[...]

  • Page 56

    Page 56 B RADFORD W HITE C ORP . (1) (1) (2) (2) 36 Tile, Rear T2015700 (1) 37 Tile, Rear , Left Side T2017500 T2016600 T2016600 T2016600 T2016600 T2016600 (1) (1) (1) (1) (1) (1) 37A Tile, Rear , Right Side T2016600 T2016600 T2018100 T2016600 T2018100 T2016600 (1) (1) (1) (1) (1) (1) 37B T ile, Rear , Center T2017200 T2017200 T2017200 T2017200 (1)[...]

  • Page 57

    Page 57 COPPER BRUTE II (500 - 2000) Item Description Size Size Size Size Size Size Size 500 750 1000 1250 1500 1750 2000 Relief V alve, BWCV , 125 PSI RA0001200 RA0001200 RA0001200 RA0001200 A0064400 A0064400 A0066400 50 T ee, Adapter , Outlet, Cast Iron 20130001 20130001 20130001 20130002 20130002 20130002 20130002 T ee, Adapter , Outlet, Bronze [...]

  • Page 58

    Page 58 B RADFORD W HITE C ORP . 71 High Limit, Manual Reset, BWCH RE0015900 RE0015900 RE0015900 RE0015900 RE0015900 RE0015900 RE0015900 High Limit, Manual Reset, BWCV , 210F Max. E2217800 E2217800 E2217800 E2217800 E2217800 E2217800 E2217800 72 Relay , Pump (SPST) E0098300 E0098300 E0098300 E0098300 E0098300 E0098300 E0098300 Relay , Fan (DPDT) E0[...]

  • Page 59

    Page 59 COPPER BRUTE II (500 - 2000) Burner Manifold Assy , 4 Burners, Left, LP 10C6520 10C6500 10C6520 10C6520 (2) (2) (2) (4) 78 V alve, Gas, Combination V2017600 V2017600 V2017600 V2017600 V2017600 V2017600 V2017600 (2) (3) (3) (5) (5) (6) (6) 79 V alve, Manual Shutof f V2000200 V2000200 V2000200 V2000200 V2000200 V2000200 V2000200 (2) (3) (3) ([...]

  • Page 60

    Page 60 B RADFORD W HITE C ORP . Figure 33. Sheet Metal Components. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 16B 16C 16D 16A BASE SHOWN FOR REFERENCE NOTE: Model 2000 shown for reference. 5A[...]

  • Page 61

    Page 61 COPPER BRUTE II (500 - 2000) Figure 34. Internal Components. See Electrical Components for detail.[...]

  • Page 62

    Page 62 B RADFORD W HITE C ORP . Figure 35. Heat Exchanger Components. See pump chart below for pump numbers. Copper Brute II Hydronic SIZE PUMP P/N 500 A2001700 750 A2001700 1000 A2001800 1250 A2001800 1500 A2001900 1750 A2001900 2000 A2109700 Copper Brute II W ater Heater PUMP P/N SIZE Soft W ater Normal Water Hard Water 500 A2001700 A2001700 A20[...]

  • Page 63

    Page 63 COPPER BRUTE II (500 - 2000) Figure 36. Electrical Components.[...]

  • Page 64

    H2214401F BradfordWhiteCorp.reservestherighttochangespecications,components,features,ortodiscontinueproductswithoutnotice. 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 121 1 [...]