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Bradford White BWCV Installation And Operation Instructions Manual

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Installation and Operation Instructions
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 operation will void the warranty. For indoor installations, as an additional
measure of safety, Bradford White strongly recommends installation of suitable Carbon Monoxide
detectors in the vicinity of this appliance and in any adjacent occupied spaces.
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.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed
by a qualified installer, service agency, or gas
supplier.
WARNING
B
RADFORD
C
O
R
Installation and Operation
Instructions for
Copper Brute II
Water Heater
Model BWCV
U.S. Reg. 2,765,423
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d'incendie ou d'explosion
ou pour éviter tout dommage matériel, toute
blessure ou la mort.
Ne pas entreposer ni utiliser d'essence ni
d'autres vapeurs ou liquides inflammables dans
le voisinage de cet appareil ou de tout autre
appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d'allumer d'appareils.
• Ne touchez à aucun interrupteur. Ne pas vous
servir des téléphones dansle bâtiment où vous
vous trouvez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions
du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L'installation et l'entretien doivent être assurés par
un installateur ou un service d'entretien qualifié ou
par le fournisseur de gaz.
W
HITE
®
P
O
R
A
T
I
O
N
Document 2142
AVERTISSEMENT

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  • Page 1 WARNING RADFORD Installation and Operation Instructions for Copper Brute II Water Heater Model BWCV U.S. Reg. 2,765,423 AVERTISSEMENT Assurez-vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

  • Page 2: Table Of Contents

    SECTION 4. Water Connections – Copper Brute II Water Heater 4.1 Water System Piping – Water Heater... 13 4.2 Hot Water Supply Piping – Water Heater ... 13 4.3 Water Flow Requirements – Water Heater... 13 4.4 Combined Water Heating (potable) and Space Heating –...

  • Page 3: Section 1. General Information

    In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber or gas fitter. The Copper Brute II water heater must be installed in accordance with the procedures detailed in this manual, or the Bradford White warranty may be voided.

  • Page 4: Warranty

    L = Four-stage (models 1250 - 2000) 13 Revision 2 = Second version 14 Heat Exchanger B = Glass-lined CI / copper / brz trim (std. BWCV) C = Glass-lined cast iron / copper K = Bronze / copper N = Glass-lined cast iron / cu-nickel...
  • Page 5 Internet Version for Reference Only Copper Brute II PUMP PUMP 13.7 LEFT SIDE VIEW Size 500 331⁄2 153⁄4 750 451⁄2 116 213⁄4 1000 571⁄2 146 283⁄4 1250 68 1500 781⁄2 199 393⁄4 101 10 226 441⁄2 113 10 1750 89 2000 991⁄2 253 493⁄4 126 10 *Air and vent connections may be on top or back of the heater, and are field convertible.

  • Page 6: Locating Pump-Mounted Water Heater With Respect To Storage Tank(S)

    Table 2. Clearances. 1.6 Locating Pump-Mounted Water Heater with Respect to Storage Tank(s) For best results, a pump-mounted 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.

  • Page 7: Intake Combustion Air

    Internet Version for Reference Only Copper Brute II the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1 square inch per 2000 Btu/hr (11 square cm/kW) of total input rating of all equipment in the enclosure. Table 3 shows data for this sizing method, for each Copper Brute II model.

  • Page 8: Venting

    Internet Version for Reference Only Page 8 2.2 Venting 2.2.1 Vent Categories Depending upon desired Copper Brute II venting, it may be considered a Category I or a Category III appliance. In general, a vertical vent system will be a Category I system. However, in rare instances, a Copper Brute II vertical vent system may be considered Category III.
  • Page 9 Internet Version for Reference Only Copper Brute II A= Clearance above grade, veranda, porch, deck, or balcony B= Clearance to window or door that may be opened C= Clearance to permanently closed window D= Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61cm) from the center line of the terminal...

  • Page 10: Locating Vent & Combustion Air Terminals

    Vent products may damage such surfaces or objects. Bradford White If the water heater uses ducted combustion air from an intake terminal located on the same wall, locate the vent terminal at least 3 feet (0.9m) horizontally from the combustion air terminal, and locate the vent terminal at least 1 foot (0.3m)

  • Page 11: Vertical Vent Terminal

    Internet Version for Reference Only Copper Brute II Locate the terminal so that it will not be subject to damage by accident or vandalism. Locate the combustion air terminal so that it cannot be blocked by snow. The National Fuel Gas Code requires that it be at least 12 inches (30 cm) above grade, but the installer may determine it should be higher, depending upon local...

  • Page 12: Section 3. Gas Supply And Piping

    Internet Version for Reference Only Page 12 Outdoor Vent Model (Size) Terminal 20254701 20254703 1000 20254705 1250 D2007700 1500 D2007700 1750 D2007800 2000 D2007800 Table 6. Vent Terminals for Outdoor Units. SECTION 3. Gas Supply and Piping 3.1 Gas Supply and Piping Gas piping should be supported by suitable hangers or floor stands, not by the appliance.

  • Page 13: Section 4. Water Connections - Copper Brute Ii Water Heater

    Pump- mounted units have a circulating pump built into the water heater. The pumps used are sized for the head loss through the heater, plus 30 feet (9.1m) of full- sized piping (same size as heater outlet) and a normal number of fittings.
  • Page 14 TEMPERATURE TPRV SENSOR GLOBE VALVE CHECK VALVE PRESSURE REDUCING VALVE Figure 4. Water Heater Piping — One Heater, One Tank. temp rise °F 10.0 10.0 Table 8. Water Flow Requirements NOTES: 1. OPTIONAL CWMU & RECIRC. LINE LOCATION. EXPANSION TANK 2.
  • Page 15 SENSOR GLOBE VALVE CHECK VALVE PRESSURE REDUCING VALVE Figure 5. Water Heater Piping — Multiple Heaters, One Tank. NOTES: 1. OPTIONAL CWMU & RECIRC. LINE LOCATION. 2. LOCATE PENNANT DHW SENSOR OR REMOTE AQUASTAT EXPANSION TANK WELL IN LOWER 1/3 OF TANK.
  • Page 16 SENSOR GLOBE VALVE CHECK VALVE PRESSURE REDUCING VALVE Figure 6. Water Heater Piping — One Heater, Multiple Tanks. NOTES: 1. OPTIONAL CWMU & RECIRC. LINE LOCATION. EXPANSION TANK 2. LOCATE PENNANT DHW SENSOR OR REMOTE AQUASTAT WELL IN LOWER 1/3 OF TANK.
  • Page 17 SENSOR GLOBE VALVE CHECK VALVE PRESSURE REDUCING VALVE Figure 7. Water Heater Piping — Multiple Heaters, Multiple Tanks. NOTES: 1. OPTIONAL CWMU & RECIRC. LINE LOCATION. 2. LOCATE PENNANT DHW SENSOR OR REMOTE AQUASTAT EXPANSION TANK WELL IN LOWER 1/3 OF TANK.

  • Page 18: Combined Water Heating (Potable) And Space Heating - Water Heater

    Toxic chemicals, such as used for heater treatment, shall not be introduced into the potable water used for space heating. This water heater when used to supply potable water shall not be connected to any heating system or component(s) previously used with a non-potable water heating appliance.

  • Page 19: External Staging Control Wiring

    Internet Version for Reference Only Copper Brute II Figure 8. Field Wiring Panel Other Field Interlocks: To install other field- wired devices to interlock with the switches, flow switches, etc.), remove the jumper between the “COM” and “NO” terminals and wire the device in series across these terminals.

  • Page 20: Section 6. Operating Instructions

    Internet Version for Reference Only Page 20 Most of the time, the number of stages from the external control will match the number of stages on the heater. However, in some instances, the controller will not have enough staging capability to work with all of the stages on a heater (for instance, using an 8-stage external control with four 4-stage Copper Brute II units.) In these instances, it is very important to follow...

  • Page 21: System Piping

    Internet Version for Reference Only Copper Brute II you have. You must determine the type of piping the system has, the Mode the temperature control will operate in, and the various settings for that mode. 6.2.1 System Piping “Primary Secondary Piping” In the context of these instructions, “primary secondary piping”...
  • Page 22 Internet Version for Reference Only Page 22 Figure 10. Temperature Control. Figure 11. Temperature Control Symbol Description. The first item is “Mode”; enter the mode number as determined above. The Temperature Control will then present you with some or all of the following options, depending on the mode you have chosen: In mode 6, external heater control, you will not see the following options.
  • Page 23 Manual high limits on water heaters have a maximum 200°F / 93°C setting. (If water must be at 175°F / 79°C or higher with a volume water heater model, use Mode 1. For volume water applications exceeding 200°F / 93°C, contact the factory.) Fine tuning: For faster staging, increase “BOIL...

  • Page 24: Choosing The Mode For Your Application

    Application This section describes various applications and the recommended field wiring and Mode selections. Water heater systems with Copper Brute II heater(s) and tank(s) will almost always use either mode 1 or mode 3. All other modes are for boiler applications.

  • Page 25: Advanced Topics

    Internet Version for Reference Only Copper Brute II If the heater is not a pump mounted model, a 24VAC pump contactor may be connected to the “PMP” terminals to control a field installed pump. Program the temperature control to use “Mode 2.”...

  • Page 26: Differential

    Internet Version for Reference Only Page 26 6.3.1 Differential Differential has an abbreviated name of DIFF. An on/off heat source must be operated with a differential in order to prevent short cycling. The differential is divided around the boiler target temperature (see Figure 13).

  • Page 27: Boiler Maximum (Boil Max)

    Internet Version for Reference Only Copper Brute II 6.3.4 Boiler Maximum (BOIL MAX) The boiler maximum (BOIL MAX) is the highest water temperature that the control is allowed to use as a target temperature. If the control does target BOIL MAX, and the heater outlet sensor is near the BOIL MAX temperature, the MAX segment turns on in the LCD while the target, inlet, outlet or supply temperature is viewed (see Figure 14).

  • Page 28: Outdoor Reset Operation

    Reset Override (SET POINT DEMAND) – This is used when override of the outdoor reset curve is needed, such as when an indirect water heater is served by the heating system. A set point demand is required whenever heat is required for the set point load.

  • Page 29: Limit Controls

    Internet Version for Reference Only Copper Brute II signal to these terminals. The control energizes the heater pump (if equipped), energizes the Pmp-Pmp terminals, and turns on the heater pump segment in the display. The control also turns on stage 1 of the heater. Section 5.3 contains important information about external staging controls and building automation systems.

  • Page 30: High Altitude Adjustment And Set Up

    Internet Version for Reference Only Page 30 6.4.2 High Altitude Adjustment and Set Copper Brute II appliances may be operated at high altitude (7700 ft., 2347 m) with a reduction in output of approximately 10%. At altitudes of less than or more than 7700 ft.

  • Page 31: Appliance Maintenance And Component Description

    Internet Version for Reference Only Copper Brute II Low water cutoffs, if installed, should be checked every 6 months. Float type low water cutoff should be flushed periodically. Inspect flue passages, and clean with brushes/ vacuums, if necessary. Sooting in flue passages indicates improper combustion.

  • Page 32: Burners

    Internet Version for Reference Only Page 32 The gas and electric controls on the appliance are engineered for long life and dependable operation, but the safety of the equipment depends on their proper functioning. It is strongly recommended that a qualified service technician inspect the basic items listed below every year.

  • Page 33: Ignition Sensors

    Internet Version for Reference Only Copper Brute II ignitor out. Install in reverse order, always using a new ignitor gasket with the replacement ignitor. Ignitor gets hot. 7.2.9 Ignition Sensors The ignition sensors ensure that the main flame is ignited, so that raw gas is not allowed to fill the combustion chamber.

  • Page 34: Section 8. Trouble Shooting

    If the heating load drops below the minimum input of the water heater for an extended period, the water heater will have a tendency to short cycle. If short cycling is frequently experienced, regardless of the control’s attempt to limit it, the heating load should be redistributed to control it.
  • Page 35 Internet Version for Reference Only Copper Brute II ERROR DISPLAYED VIEW VIEW BOIL VIEW BOIL OUT VIEW BOIL IN VIEW BOIL IN VIEW BOILSUP VIEW BOILSUP OUTDR VIEW OUTDR VIEW VIEW TANK VIEW TANK DESCRIPTION OF ERROR The control was unable to read a piece of information from its EEPROM. The control will stop operation until all settings in the Adjust menu have been checked by the user or installer.

  • Page 36: Troubleshooting Copper Brute Ii Controls

    Internet Version for Reference Only Page 36 8.6 Troubleshooting 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 models have two ignition modules capable of independent operation.

  • Page 37: Section 9. Wiring Diagrams

    Internet Version for Reference Only Copper Brute II Page 37 SECTION 9. Wiring Diagrams Figure 18. Copper Brute II 500 - 750 Ladder Diagram.
  • Page 38 Internet Version for Reference Only Bradford White Page 38 Figure 19. Copper Brute II 1000 Ladder Diagram.

  • Page 39: Ladder Diagrams

    Internet Version for Reference Only Copper Brute II Page 39 Figure 20. Copper Brute II 1250 - 2000 Ladder Diagram.

  • Page 40: Wiring Schematics

    Internet Version for Reference Only Bradford White Page 40 Figure 21. Copper Brute II 500 - 1000 Wiring Schematic.

  • Page 41: Wiring Schematics

    Internet Version for Reference Only Copper Brute II Page 41 Figure 22. Copper Brute II 1250 - 2000 Wiring Schematic.

  • Page 42: Field Wiring

    Internet Version for Reference Only Bradford White Page 42 Figure 23. Field Wiring.
  • Page 43 Internet Version for Reference Only Copper Brute II Page 43 Figure 24. Field Wiring for Modes 1 - 5.

  • Page 44: Field Wiring

    Internet Version for Reference Only Figure 25. Field Wiring for Mode 6. ® Ambler, PA 19002 Tech. Service (800) 334-3393 RADFORD HITE ® Service Parts (800) 538-2020 www.Bradford White.com Warranty Service (800) 531-2111 O R P O R A T I O N Litho in U.S.A.

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