Brute BNTH1000 Installation And Operation Instructions Manual
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Brute BNTH1000 Installation And Operation Instructions Manual

Brute BNTH1000 Installation And Operation Instructions Manual

Modulating boiler, water heater, 1,000 mbtu/h, 1,200 mbtu/h
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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 and heater 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.
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
Installation and
Operation Instructions for
Brute
Modulating Boiler
Model BNTH1000
1,000 MBTU/h
Model BNTH1200
1,200 MBTU/h
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.
Document 1266F
®
Water Heater
Model BNTV1000
1,000 MBTU/h
Model BNTV1200
1,200 MBTU/h
AVERTISSEMENT

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  • Page 1 Installation and Operation Instructions Document 1266F Installation and Operation Instructions for Brute ® Modulating Boiler Water Heater Model BNTH1000 Model BNTV1000 1,000 MBTU/h 1,000 MBTU/h Model BNTH1200 Model BNTV1200 1,200 MBTU/h 1,200 MBTU/h FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation...

  • Page 2: Table Of Contents

    RADFORD HITE Table of Contents SECTION 1 General Information SECTION 6 Water Connections Introduction ............5 Boiler systems ..........23 Warranty ............5 6.A.1 Boiler System Piping: Hot Supply Connections ......... 23 1.C Model Identification ........... 5 6.A.2 Boiler Cold Water Make-Up ......23 Safety Notes .............
  • Page 3 Brute BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® SECTION 9 Setup and Configuration SECTION 12 Troubleshooting Review of Lead Lag Control System ....51 12.A Potential Setup and Synch Problems ... 102 9.A.1 About Lead Lag Operation ......51 12.A.1 Controller Synchronization ......
  • Page 4 Page 4 RADFORD HITE...

  • Page 5: Section 1 General Information

    Power switch 1.A Introduction which slides downward) This manual includes information which will help you to install, operate, and maintain the Brute 100 and Rating Plate 1200 systems. Please read this manual completely before proceeding with the installation. If you have any questions regarding this equipment, please consult the Bradford White factory, or a local factory representative.

  • Page 6: D Safety Notes

    Page 6 RADFORD HITE 1.D Safety Notes Safety Notes are used thoughout this manual to bring attention to the presence of hazards with various risk levels and to off er important information concering the life of this product. There are 3 basic types. Indicates an imminently hazardous situation which, if not WARNING avoided, can or will result in death or serious injury and can or will result in catastrophic property damage.
  • Page 7 Brute Page 7 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® WARNING NOTE: All installations must be made in accordance with 1) American National Standard Z223.1/NFPA54-Latest Electrical Shock Hazard Edition “National Fuel Gas Code” or Electrical shock can cause severe injury, death or 2) CSA B149.1 “Natural Gas and Propane Installation property damage. Disconnect the power supply before Code”...

  • Page 8: E Model Overview

    Page 8 RADFORD HITE Model Overview Power switch Ducted air inlet Rating Plate Touchscreen Protective Cover (on outside panel) Electrical box (slides downward) Pressure and PRV and temperature flow switch gauge Blower 1 (under bezel) Outlet Automatic temperature gas valves sensors Inlet Manual gas valve temperature sensors Blower 2...

  • Page 9: G The Installation Kit

    Dimensional Data NeoTherm LC Brute Page 9 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 1000 & 1200 Dimensions (continued) Figure 3. Dimensions overall 1.G The Installation Kit The unit is shipped in a single crate with a boxed installation kit that contains these components.

  • Page 10: Section 2 Locating The Unit

    Page 10 RADFORD HITE SECTION 2 Locating the unit Note - When located on the same wall, the units 2.A Locating the unit combustion air intake terminal must be installed a minimum of 12” below the exhaust terminal. There This unit may be installed indoors or outdoors. must also be a minimum horizontal distance from If installing in a location that may experience intake to the exhaust terminal of 36.”...

  • Page 11: Section 3 Venting And Combustion Air

    Brute Page 11 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® SECTION 3 Venting and Combustion Air General Venting 3.A General Venting This product requires a special venting system. Refer to venting supplier’s instructions for complete parts list and method This unit requires a special venting system.

  • Page 12: B Combustion Air

    Page 12 RADFORD HITE 3.B Combustion Air following descriptions.) Where ducts are used, they shall be of the same cross-sectional area as the free These boilers and water heaters must have area of the openings to which they connect. provisions for combustion and ventilation air in accordance with the applicable requirements Method 1: Two permanent openings, one for Combustion Air Supply and Ventilation in the...

  • Page 13: Ducted Combustion Air

    Brute Page 13 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Method 2: One permanent opening, commencing duct applications, two elbows must be installed on within 12” (300 mm) of the top of the enclosure, the end of the inlet to act as a vent terminal. In shall be permitted.

  • Page 14: C Venting

    Page 14 RADFORD HITE 3.C Venting (See Table 7.) The vent can terminate through the roof, or through an outside wall. The use of polypropylene vent material has WARNING Selection of improper vent materials for been accepted by CSA for use with exhaust and installations that are installed in closets, or will be combustion.

  • Page 15: D Locating The Vent And Combust Air Terminals

    Brute Page 15 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® be installed per the vent manufacturers certified installation instructions. It is the responsibility of the appropriately licensed technician installing this unit to use ULC S636 certified vent material consistent with the requirements as described in the Venting and Combustion Air section.
  • Page 16 Page 16 RADFORD HITE 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 See note 6 See note 6 B= Clearance to window or door that may be Direct vent only: 12 inches (30 cm); 36 inches (91 cm) opened Other than Direct vent: 4 ft (1.2m) below or to side of opening; 1 ft (30 cm) above opening C= Clearance to permanently closed window See note 4 See note 5 D= Vertical clearance to ventilated soffit located...

  • Page 17: Side Wall Combustion Air Terminal

    Brute Page 17 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® IMPORTANT: All terminals must be placed so that they remain at least 12” above the expected snow line. Local codes may have more specific requirements, and must be consulted. Refer to the NFPA54 National Fuel Gas Code and your local codes for all required clearances for venting.

  • Page 18: Vertical Vent Terminal

    Page 18 RADFORD HITE above the combustion air terminal. for installation of hard-wired carbon monoxide detectors. Multiple vent kits should be installed such that the horizontal distance between outlet group a. In the event that the side-wall horizontally and inlet group is 36” (90 cm). (See Figure 8.) vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon The vent outlet must be at least 12”...

  • Page 19: F Outdoor Installation

    Brute Page 19 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® placed in operation, while the other appliances remaining connected to the common venting system Outdoor Installation are not in operation. This unit may only be installed outdoors in 1.

  • Page 20: Section 4 Gas Supply And Piping 8.B

    Page 20 RADFORD HITE SECTION 4 Gas Supply and Piping WARNING 4.A Gas Supply and Piping Open flame can cause gas to ignite and result in property damage, severe injury, or loss of life. All Installations must conform to the National Fuel Gas Code ANSI Z223.1/NFPA54, and/or local codes. In Canada, the installation must conform to the latest edition of CSA B149.1 Natural Gas and Propane Note - This unit and all other gas appliances...
  • Page 21 Brute Page 21 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® NATURAL GAS TO SIZE PIPING: REQUIRED Measure linear distance from meter outlet to last boiler. Add total input of all CU FT boilers and divide by 1000 to obtain cu ft SIZE / HR.

  • Page 22: Section 5 Pump Requirements

    Page 22 RADFORD HITE SECTION 5 Pump Requirements 5.A Boiler Flow and Head Requirements table 12 Flow and Head Requirements Flow Flow Flow Flow Flow Flow Flow feet feet feet feet feet feet 1000 43.6 26.7 17.8 12.8 10.1 42.2 1200 59.7 36.6...

  • Page 23: Section 6 Water Connections

    Brute Page 23 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® SECTION 6 Water Connections Section 6 is divided into TWO parts. water temperatures. Therefore, to get the best low Section 6A covers Boilers models designed return temperature with multiple boilers, pipe as for hydronic heating.

  • Page 24: Boiler Freeze Protection

    Page 24 RADFORD HITE purpose). Follow LWCO manufacturers instructions The following manufacturers offer glycols, inhibitors, for minimum pipe sizing. and anti foamants that are suitable for use in the unit. Please refer to the manufacturers instructions Note: This unit is a water tube design that requires for proper selection and application. water flow through the heat exchanger for proper •...
  • Page 25 Brute Page 25 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Low temp. radiant zone Space heating zone circuits Space heating zone circuit System pump Air vent 4 pipe dia. max. 4 pipe dia. max. 4 pipe dia. max.
  • Page 26 Page 26 RADFORD HITE 4 pipe dia. max. Air vent Water feed Anti-scald controls mixing valve 4 pipe Domestic dia. max. hot water Expansion tank Indirect DHW tank Note - This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing.
  • Page 27 Brute Page 27 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Note - This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met.
  • Page 28 Page 28 RADFORD HITE Space heating Note - zone circuits This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Low temp. radiant zone Space heating zone circuit Air vent 4 pipe dia.

  • Page 29: Water Heater Systems

    Brute Page 29 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Space heating zone circuits High temp. space heating zone circuit Space heating zone circuit Air vent 4 pipe dia. max. 4 pipe dia. max. Water feed controls Expansion tank 4 pipe dia.

  • Page 30: Heater Cold Water Make-Up

    Page 30 RADFORD HITE 6.B.5 Heater Pumps pressure relief. Install a diaphragm-type expansion tank, flow check, and shutoff valves where needed or These water heaters can be purchased with pumps. as required by code. The pumps are sized for the boiler headloss, plus The piping should be installed so that each pump 30 feet of full-sized piping, and a typical number of supplies flow only to the heater to which it is fittings. They are intended to be used in systems...

  • Page 31: Water Heater Suggested Piping Schematics

    Brute Page 31 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 6.B.7 Water Heater Suggested Piping WARNING: This drawing shows suggested piping configuration and Schematics valving. Check with local codes and Figure 14 thru Figure 16 show suggested piping ordinances for additional requirements.

  • Page 32: Section 7 Electrical Connections

    Page 32 RADFORD HITE WARNING: This drawing shows suggested piping configuration and valving. Check with local codes and ordinances for additional requirements. NOTES: 1. Optional CWMU & recirculation line location. 2. Locate the Heater DHW sensor or remote aquastat well Building in lower 1/3 of tank. return 3. Back flow preventer may be required - check local codes.

  • Page 33: Main Power

    Brute Page 33 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® WARNING Caution This unit must be electrically grounded in The supply voltage to the unit must not be accordance with the requirements of the authority disengaged, except for service or isolation, or...
  • Page 34 Page 34 RADFORD HITE TB10 Panel slides outward Secondary controller Primary controller (lower burner) (upper burner) Figure 17. Electronics Panel Layout...

  • Page 35: Optional Variable Speed Pump Control

    Brute Page 35 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 7.C Optional Variable Speed Optional Low Water Cut Off (LWCO) Pump Control Specific instructions for the installation of a Low Water Cut Off (LWCO) are the following: V.S.P.C. is optional equipment on the hydronic boilers only. It is not available on the water heaters.

  • Page 36: Building Automation System Connections

    Page 36 RADFORD HITE 7.H Building Automation System Connections This unit can be controlled (in either single or cascade) and monitored through the included Modbus ports. Signals from a Building Automation System can be connected to the MB2 Modbus connections on the controller. Follow instructions included with the BAS control to mount it to the provided holes in the unit Control Panel as shown in Figure 18.

  • Page 37: Lead Lag Connections & Wiring Diagram

    Brute Page 37 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Lead Lag Connections & Wiring Diagram Units can be connected in a lead lag up to 4 units with their 8 controllers total. One as the Lead control and 7 more controllers (2 per unit) as the following controllers. See Figure 18...

  • Page 38: Wiring Diagram

    Page 38 RADFORD HITE Wiring Diagram SECONDARY SECONDARY WIRE VOLTAGE KEY VALVE 24V = BL/W 120V = OUTLET WATER PRIMARY PRIMARY W/BL TB1-6A VALVE BL/W BK/R BK/Y PUMP RELAY BLOWER WT/G PRIMARY W/BK FIELD WIRED TB2-6A R/BK BOILER PK/BK PUMP FLAME Line SYSTEM...
  • Page 39 Brute Page 39 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® FLAPPER GY/V GY/V PRIMARY OUTLET WATER STACK TEMP BL/V W/BL W/BL TB1-6A DKBL/Y DKBL/Y FLAPPER GY/V GY/V BK/R SECONDARY BL/V BL/BK BL/V DKBL/Y BK/R BLOWER WT/G BLOWER...

  • Page 40: Ladder Diagrams

    Page 40 RADFORD HITE 7.K Ladder Diagrams OUTLET WATER TEMP. SENSOR J8-8 PRIM. J8-9 PRIM. J8-10 PRIM. STACK TEMP. SENSOR J9-5 J9-4 PRIM. PRIM. J9-6 PRIM. J9-4 SEC. J9-5 SEC. J9-6 SEC. OUTLET WATER TEMP. SENSOR J8-8 SEC. J8-9 SEC. J8-10 SEC.
  • Page 41 Brute Page 41 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 120 VAC MAIN POWER SWITCH J8-1 J8-2 PRIM. PRIM. J4-10 PRIM. J8-1 J8-2 SEC. SEC. J4-10 SEC. J4 - 6 J4 - 7 PRIM. BOILER PUMP J7-2 SEC.

  • Page 42: About The Touch Screen Display

    Page 42 RADFORD HITE About the Touch Screen Display up for “Lead Lag” operation. The term “Lead This unit has an advanced control system which can Lag” means that, as the heating load increases, perform many functions. This is part of the reason why the control system brings additional burners on the models 1000 and 1200 can deliver such outstanding automatically.

  • Page 43: Section 8 Using The Touch Screen

    Brute Page 43 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® connected to the system. To reach one of the As we go through the explanations in this manual, we functions for an individual controller/burner, press will point out whether a control function affects the whole the icon for that controller/burner. On the following Lead Lag system, or just an individual controller/burner screen, press the Configure button. This will...

  • Page 44: Using The Touch Screen

    Page 44 RADFORD HITE SECTION 8 Using the touch screen On/Off switch Touch Screen Boiler outlet temperature and system pressure Figure 26. Touch Screen, shown with the ‘home’ screen of the lead boiler in a four boiler configuration, all conditions normal. Figure 27.
  • Page 45 Brute Page 45 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® When a password is necessary, the system will Useful Icons at the top of most screens present the keyboard screen. Login Home Upper Return to Home page...

  • Page 46: The Gauges

    Page 46 RADFORD HITE At the bottom of the screen shown in Menu 4, the Color and Status system is telling you that it wants you to log in. Blue Normal operation Lockout Gray Standby mode (Burner switch off) Gray and Communication crossed out problem Yellow...

  • Page 47: Checking Individual Parameters

    Brute Page 47 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® You can change the setpoints from this screen. When you press the yellow box beside Setpoint, the controller presents this screen: Menu 8. Setpoints Screen Menu 10.

  • Page 48: Checking Individual Details

    Page 48 RADFORD HITE Checking Individual Details 8.G Configuring Parameters on Individual Controllers The Details button on the Status Summary screen leads to a series of screens that show all of the In this section, we will just give you a quick setup parameters entered for the controller you have explanation of how to change parameters on one of selected. Let’s say that the first screen presented in...

  • Page 49: Erification Process For Safety Parameters

    Brute Page 49 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Press the Configure button to start a configuration session for the selected controller. See Menu 15. Menu 17. Numeric Entry Screen 8.H Verification Process for Safety- Related Parameters Menu 15. Configuration Screen When you start to change a parameter that...
  • Page 50 Page 50 RADFORD HITE Menu 20. Edit Safety Data Menu 19. Verification Needed Once you are done changing safety Notes – parameters, press Confirm. The system will • Once you change one of these safety-related present a listing for each group of parameters parameters, you must finish the verification which includes a changed safety parameter.

  • Page 51: A Review Of Lead Lag Control System

    Brute Page 51 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® SECTION 9 Setup and Configuration 9.A Review of Lead Lag Control System 9.A.1 About Lead Lag Operation All units are set up for Lead Lag operation. Even...

  • Page 52: Lead Lag Modulation Cycle

    Page 52 RADFORD HITE In either kind of installation, a system sensor is Let’s consider the following example: usually used to monitor the demand. The input from Four units are tied together via Modbus connections. this sensor is used to control the modulation rates of Here are the Leader/Follower assignments and the the operating burners.

  • Page 53: Boiler Lead Lag With Indirect Domestic Hot Water

    Brute Page 53 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 9.A.3 Boiler Lead Lag with Indirect up and begin firing at 35% fan speed. After this, Domestic Hot Water both of the active burners will modulate up or down So far, we have been describing a system which together, in reaction to the changes in demand.

  • Page 54: C System Configurations

    Page 54 RADFORD HITE 9.C System Configurations These units can be installed in many different Following the table, look up the specific arrangements. The steps in the installation will be installation jobs for your system in Section different, depending on the number of boilers in 9.4. The jobs are identified using letters (Job the system, the venting arrangements, the control A through Job P). Then go to the System # signals used, outdoor reset, etc. In this section, we list starting on page 56 to find your System will list the steps necessary to do the most common # and the required Jobs to configure your...
  • Page 55 Brute Page 55 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Table 18. The Many System Configurations for Unit System Multiple System Common Setpoint Modulation Outdoor or single or local vent control control, 4-20 reset boilers boiler 4-20 ma...
  • Page 56 Page 56 RADFORD HITE 9.C Unit System Configurations (continued) Table 19. System # List System 1 – Single boiler, Local control Job I Set the parameters used by the Lead Lag system Job J Install the System sensor and adjust the setpoint Job O Set up the combustion on each of the burners Job P...
  • Page 57 Brute Page 57 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® System 5 – Multiple boilers, Local control, Common vent Job A Note on common venting Job B Set up the names for each of the controllers Job C...
  • Page 58 Page 58 RADFORD HITE 9.C Unit System Configurations (continued) System 9 – Multiple boiler, System control, Outdoor reset Job B Set up the names for each of the controllers Job C Make one control the Lead Lag Leader Job D On each of the controllers that will act as a follower, disable the Lead Lag Leader Job E Set up the Modbus control addressing to assign addresses for each of the controls...
  • Page 59 Brute Page 59 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Job C Make one control the Lead Lag Leader Job D On each of the controllers that will act as a follower, disable the Lead Lag Leader...
  • Page 60 Page 60 RADFORD HITE 9.C Unit System Configurations (continued) System 18 – Multiple boiler, System control, 4-20 mA modulation control, Outdoor reset Job N Building automation or multiple boiler control 4-20 mA modulation control Job O Set up the combustion on each of the burners Job P Set the date and time on the system System 19 –...
  • Page 61 Brute Page 61 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® System 21 – Multiple boiler, System control, Common vent, 4-20 mA modulation control Job A Note on common venting Job B Set up the names for each of the controllers...

  • Page 62: D Installation Jobs

    Page 62 RADFORD HITE 9.D Installation Jobs Note – To install your system (your particular system configuration), you will not need to do all of the installation jobs listed here in Section 9.4. You only need to perform the jobs listed sequencially for your type of system previously. Please refer to Table 18 on page 55 and Table 19 on page 56 for a list of specific installation jobs necessary to install your system.
  • Page 63 Brute Page 63 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Now you can rename the other control on Press the button for Lead Lag Leader. Fig. 57 Boiler 1 – the Secondary control. Press the shows the screen that follows.
  • Page 64 Page 64 RADFORD HITE When the controllers arrive at the factory, they will Menu 32. Configuration Screen all be configured as followers. Your job in this step Scroll down through the list until you find the is to disable the Lead Lag Leader function on each line for LL Leader Configuration. See Fig. 62. of the controls, except for the one control that will be used as the Lead Lag Leader –...
  • Page 65 Brute Page 65 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® boilers there will be eight separate controllers. the Modbus control address. Let’s set up the You will need to give each of these controllers Modbus address for the first controller in the a unique Modbus address. (Notice that this is line - the Primary controller on Boiler 1. Press different from the name of the controller. We...
  • Page 66 Page 66 RADFORD HITE flap valves be identified correctly. Boiler 2 Primary (address = 3) and Boiler 2 Secondary (address = 4). Each controller in the system needs to know how many controllers are included in the whole system. 12. Repeat steps 3 - 10 for each of the other You will need to enter this information in each of the controllers connected to the system.
  • Page 67 Brute Page 67 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® This is the total number of controllers in Press the icon for the controller you want to the whole system. (For example, in a work with. The system will take you to the system with four boilers, there will be eight Status Summary screen for that controller.
  • Page 68 Page 68 RADFORD HITE controls should be numbered for each of the boilers. In this example, we are still working with the Primary control for Boiler 1. From the table, you can see that this control should have a flap valve ID of “1.” Enter the correct ID from Table 22 in this field.
  • Page 69 Brute Page 69 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Job G – Disconnect Unused Touch Screens Once a Lead Lag system is set up and operating, the monitoring functions will all be handled from one Touch Screen – the one connected to the controller operating as the Lead Lag Leader.
  • Page 70 Page 70 RADFORD HITE are arranged in a “daisy chain.” The wiring from (TB9) on each panel. the Secondary controller on one boiler (TB9 - pins Figure 35 shows how to make the connections. 7 through 12) to the Primary controller on the next The following table lists the connections from boiler (TB9 - pins 1 through 6). See Figure 35. Use Boiler 1 to Boiler 2. 22 AWG or thicker shielded twisted pair wire with drain. Two twisted pairs or three conductors are Boiler 1 needed.
  • Page 71 Brute Page 71 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® To see the other settings related to the Lead Lag functions, press the button for Advanced Settings. This leads to a “ring” of related screens, and you can scroll through the list by pressing one of the left- or right-arrow symbols.
  • Page 72 Page 72 RADFORD HITE Press the left-arrow or right-arrow until you Press the left-arrow or right-arrow until you see the Domestic Hot Water screen. see the Central Heat screen. Menu 52. Domestic Hot Water Menu 51. Central Heat The arrangement for Domestic Hot Water can be set up in several ways.
  • Page 73 Brute Page 73 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Min. boiler water temperature - Press the left-arrow or right-arrow until you If a value is entered here, the temperature see the Outdoor Reset screen. in the boiler will never be allowed to drop below this temperature.
  • Page 74 Page 74 RADFORD HITE the system shuts down after the outdoor temperature rises above the setpoint. The Number Base load min. options are Shutdown immediately/ After of boilers demand ends/ Disabled. Installed Setpoint - If the outdoor temperature is higher than this, the system will shut off the Lead Lag Central Heating functions.
  • Page 75 Brute Page 75 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Job K - Set the Lead Lag Outdoor Reset and the normal setpoints) in the system at certain times of the day. Normally this function is used to switch Warm Weather Shutdown to lower temperatures at night, when the central (This is a Lead Lag function –...
  • Page 76 Page 76 RADFORD HITE When enabled, the Warm Weather Shutdown green line in the display. For cold outdoor feature will turn off the Central Heating temperatures (below 32°F), the setpoint remains functions when the outdoor temperature unchanged (120°F). As the temperature begins exceeds the setpoint. This prevents the to rise above 32°F, the Outdoor Reset function system from running when there is no need for causes the setpoint to be lowered.
  • Page 77 Brute Page 77 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® There is one other part of this system, and it is from the Building Automation System or located on a different screen: multiple boiler control. Connect to terminals 3 and 4 on TB7.
  • Page 78 Page 78 RADFORD HITE On each controller in the system, check set up separately. Here’s a quick summary of the terminals 3 and 4 on TB6 to ensure that the procedure: System sensor is not connected. (For this • You shut off one controller/burner combination, type of operation, the Lead Lag system is and work with the other.
  • Page 79 Brute Page 79 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Boiler 1 Operator Primary Primary interface controller burner valve High-Fire valve adjustment Secondary Secondary controller burner Low-Fire adjustment Figure 39. Primary and Secondary Burners in a Boiler Menu 64.
  • Page 80 Page 80 RADFORD HITE controller, based on the heat load. Set this item to Auto at the end of the test. Manual in Run - The Manual in Run control will only set the fan speed when the control has proven flame and the unit has entered the Run mode. Manual in Run and Standby - Using this setting, the manual control will set the fan speed whether the boiler is operating...
  • Page 81 Brute Page 81 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Negative connection point Positive connection point Figure 41. Connections for Pressure Gauge, NT 1000 and NT 1200 turn the screw counter-clockwise. Secondary controller. 15. The adjustment you made for the Low Fire •...
  • Page 82 Page 82 RADFORD HITE Job P - Setting the Date and Time on the high fire and at low fire. The final CO values at high fire should be as listed in Table 24 System Display ±0.2%. At low fire, the CO should be about (This is a Lead Lag function – do this once for the whole 0.5% lower than the high fire CO reading. Lead Lag system. Use the controller set up as the Lead (The offset is more important than the actual Lag Leader –...

  • Page 83: E Setup For Domestic Hot Water On A Lead Lag System

    Brute Page 83 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® There are three ways that a Unit system can be set up to provide domestic hot water. Two of them involve the use of an indirect water heater. In...
  • Page 84 Page 84 RADFORD HITE From the ‘home’ screen, press the View Lead arrow or right-arrow until you see the Domestic Lag button. Hot Water screen. Menu 71. ‘home’ screen Menu 74. Domestic Hot Water Press the button for Lead Lag Leader. An entry on this screen allows you to give priority to the DHW function.
  • Page 85 Brute Page 85 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® mode. You can think of each of these boilers except priority is given to domestic hot water, and as a separate two-burner Lead Lag system. there is no input for the central heating function.
  • Page 86 Page 86 RADFORD HITE this screen. Menu 78. Lead Lag Leader Configuration Press the button for Advanced Settings. This leads to a “ring” of related screens, and you can scroll through the list by pressing one of the left- or right-arrow symbols. Press the left- arrow or right-arrow until you see the Domestic Hot Water screen.

  • Page 87: F Gateway Connections To A Building Automation System

    Brute Page 87 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Gateway Connections to a Building Automation System These units can be controlled and monitored through the included Modbus ports. The manufacturer offers the “Gateway Controller” to allow BACnet, LON, and other communications protocols. The Modbus wiring should be completed according to the instructions in this manual.

  • Page 88: G Installer Parameters

    Page 88 RADFORD HITE 9.G Installer Parameters This is a list of all of the parameters which can be accessed using the Installer password. Label Description How to Reach 4 mA water If a 4 – 20 mA input is used to adjust the <’home’...
  • Page 89 Brute Page 89 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Label Description How to Reach CH (Central This controls whether a local Central Heat If Lead Lag enabled – Heat) has demand has priority over the control asserted by <’home’...
  • Page 90 Page 90 RADFORD HITE Label Description How to Reach CH (Central This setpoint is used when the time-of-day input If Lead Lag enabled – Heat) is off. If the outdoor reset function is active, this <’home’ screen> Lead Lag Leader button Setpoint setpoint provides one coordinate for the outdoor <Lead Lag Leader screen> Configure reset curve.
  • Page 91 Brute Page 91 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Label Description How to Reach The DHW pump (Pump C) can be turned <’home’ screen> Select a controller (Domestic on manually, or it can be set to operate <Status Summary screen> Configure Hot Water) automatically. If it is turned on then it remains button <Configuration Menu> Pump...
  • Page 92 Page 92 RADFORD HITE Label Description How to Reach Lead lag D This is part of the damping function <’home’ screen> Lead Lag Leader button gain (“Derivative”) used when the controller interprets <Lead Lag Leader screen> Configure the input from the System sensor. button <Lead Lag Leader Configuration screen> Advanced Settings button/ Left- or Right- arrow buttons <Modulation screen>...
  • Page 93 Brute Page 93 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Label Description How to Reach Lead lag on When the Lead Lag function is enabled, the If Lead Lag enabled – hysteresis control system will not fire the boilers until the <’home’ screen> Lead Lag Leader button temperature at the System sensor drops to the <Lead Lag Leader screen> Configure...
  • Page 94 Page 94 RADFORD HITE Label Description How to Reach Modbus Each controller must have a unique Modbus <’home’ screen> Setup button <Setup address address. screen> Control setup button/ Change address button Number of Each controller needs to know how many flap <’home’ screen> Select a controller controllers in valves are included in the whole system.

  • Page 95: Variable Speed Pump Control

    Brute Page 95 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 9.H Variable Speed Pump Control V.S.P.C. is optional equipment on hydronic boilers only. It is not available for the water heater models. Pump speed is controlled to maintain a user-chosen temperature rise between the inlet and outlet of the unit.

  • Page 96: Section 10 Initial Startup Instructions

    Page 96 RADFORD HITE SECTION 10 Initial startup Instructions 10.A Filling the Boiler System Start up the boiler following the procedure Ensure the system is fully connected. Close all in this manual. Operate the entire system, bleeding devices and open the make-up water including the pump, boiler, and radiation units valve. Allow the system to fill slowly.

  • Page 97: B Initial Burner Operation

    Brute Page 97 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® optional pressure gas switches, you will need to reset the low pressure switch. 10.B Initial Burner Operation Find the low pressure switch and press The initial setup must be checked before the unit is the reset button.

  • Page 98: Section 11 Maintenance

    Page 98 RADFORD HITE SECTION 11 Maintenance WARNING Disconnect all power to the unit before 11.A System Maintenance attempting any service procedures. Contact with electricity can result in severe injury or death. Do the following once a year: Lubricate the System pump, if required, per the instructions on the pump.

  • Page 99: Controllers

    Brute Page 99 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 11.B.5 Flame Sensor The flame sensor is a single rod system. To replace to the gas valve. Remove the electrical connections the flame sensor electrode, shut off the 120 Volt to the gas valve. Remove the bolts connecting the power supply to the boiler. Turn off all manual gas Venturi flange to the blower. This allows the entire valves connecting the boiler to the main gas supply gas valve/Venturi assembly to be removed as an line.

  • Page 100: Heat Exchanger Coils

    Page 100 RADFORD HITE If it is necessary to replace the blower, turn off the Once the tubes have been brushed clean, 120 Volt power and the gas supply to the unit. Take rinse the tubes and combustion chamber with a the front panel off. Disconnect the 120 Volt and small amount of water to rinse all of the debris control signal connections to the blower.

  • Page 101: Natural/Propane Gas Conversion

    Brute Page 101 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 3” w.c. For propane, set the low pressure gas switch to 5” w.c. For natural and propane, set the high pressure gas switch to 14.” 11.B.12 Battery for Date and Time Back-Up 11.B.10...

  • Page 102: Section 12 Troubleshooting

    Page 102 RADFORD HITE SECTION 12 Troubleshooting 12.A Potential Setup and 12.A.1 Controller Synchronization Synchronization Problems On a multiple-boiler installation, the individual boiler controllers are arranged in a “daisy chain” using Because the unit uses a sophisticated control a Modbus connection, with the Secondary control system, it can constantly perform a series of self- of one boiler connected to the Primary control of checks.

  • Page 103: Flap Valve Status Check

    Brute Page 103 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® During a lockout condition, the image of the affected controller on the ‘home’ screen will 12.A.2 Flap Valve Status Check appear in red. A bell symbol will appear in the Each boiler includes two burners, and each burner upper left-hand corner of the control screen.

  • Page 104: Viewing The Lockout And Alert Histories

    Page 104 RADFORD HITE Correct the cause of the problem, and press the button on the screen to clear the Hold. If you press the Details button, the control If a serious problem continues, the system will software will present a screen similar to this. declare a Lockout.
  • Page 105 Brute Page 105 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Menu 88. Alert Log Screen To get more information on a particular alert, touch the entry for that alert on the screen.

  • Page 106: C Troubleshooting Table

    Page 106 RADFORD HITE 12.C Troubleshooting Table This table includes a listing of the faults that might be generated by the controllers, and displayed on the Touch Screen. Some of these can be corrected by an installer changing a parameter, while other conditions are more complicated, and will require a service technician.
  • Page 107 Brute Page 107 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Internal fault: Safety relay test failed due to feedback Internal fault 1. Reset module Internal fault: 2. If fault repeats, replace module. Safety relay test failed due to safety...
  • Page 108 Page 108 RADFORD HITE 24 VAC voltage low/high 1. Check the module and display connections. 2. Check the module power supply and make sure that frequency, voltage and VA meet the specifications. Modulation fault Internal sub-system fault. 1. Review alert messages for possible trends. 2.
  • Page 109 Brute Page 109 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® PII (Pre-Ignition Interlock) OFF H or L 1. Check wiring and correct any faults. 2. Check Preignition Interlock switches to assure proper functioning. 3. Check the valve operation. 4. Reset and sequence the module; monitor the PII status.
  • Page 110 Page 110 RADFORD HITE DHW (Domestic Hot Water) sensor fault 1. Check wiring and correct any possible errors. 2. Replace the DHW sensor. 3. If previous steps are correct and fault persists, replace the module. Header sensor fault 1. Check wiring and correct any possible errors. 2.
  • Page 111 Brute Page 111 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Flame lost in MFEP 1. Check main valve wiring and operation - correct any errors. 2. Check the fuel supply. Flame lost early in run 3. Check fuel pressure and repeat turndown tests.
  • Page 112 Page 112 RADFORD HITE Purge Fan switch On H or L 1. Purge fan switch is on when it should be off. 2. Check wiring and correct any errors. 3. Inspect the Purge Fan switch J6 terminal 3 and its connections. Make sure the switch is working Purge fan switch OFF H or L correctly and is not jumpered or welded.
  • Page 113 Brute Page 113 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Invalid BLOWER/ SPARK output setting Invalid Delta T limit enable setting Invalid Delta T limit response setting Code Description L or H Invalid DHW (Domestic Hot Water) high limit enable setting 1. R eturn to Configuration mode and recheck Invalid DHW (Domestic Hot Water) high selected parameters, reverify and reset module.
  • Page 114 Page 114 RADFORD HITE Invalid Prepurge time setting Invalid Purge rate proving setting Invalid Run flame failure response setting Invalid Run stabilization time setting Invalid Stack limit enable setting 1. R eturn to Configuration mode and recheck Invalid Stack limit response setting selected parameters, reverify and reset module. Unconfigured Delta T limit setpoint 2.

  • Page 115: D Diagnostic Tests & Input/Output Indicators

    Brute Page 115 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 12.D Diagnostic Tests and Input/Output The button for Analog I/O displays items that Indicators change continuously between two limits. Two kinds of screens are grouped together in this section: •...

  • Page 116: E Lead Lag Follower Diagnostics

    Page 116 RADFORD HITE 12.E Lead Lag Follower Diagnostics 12.G Analysis The control system includes a diagnostic screen that The control system includes an Analysis branch lists some information on the Lead Lag followers in that can display the behavior over a period of time the system.

  • Page 117: I Operating Sequence

    Brute Page 117 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® 12.I Operating Sequence the current state of the controller, including setup information and operating information. This information can be helpful during troubleshooting. Initiation Each controller enters the Initiation sequence after How to get there –...
  • Page 118 Page 118 RADFORD HITE Lead Lag Modulation Sequence sensor. (The setpoint or modulation can also be controlled by an external 4 – 20 mA For a detailed explanation, see Section 9. control.) The Boiler pump and System pump are Domestic Hot Water Priority energized. The water temperature in the System loop drops until it reaches the LL The start-up sequence for a Domestic Hot Water Central Heat Setpoint minus the LL Central...
  • Page 119 Brute Page 119 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® During the Standby Period: During the Run Period: • All of the checks made under Synchronization, • All of the checks made under Synchronization, plus: plus: •...

  • Page 120: Section 13 Replacement Parts

    Page 120 RADFORD HITE SECTION 13 Replacement Parts Use only genuine Manufacturer replacement parts. 13.A General Information To order or purchase parts for this unit, contact your nearest Manufacturer dealer or distributor. . (See the back cover for addresses, and for telephone and fax numbers.) 13.B Parts List Part No. - Part # Description Model 1000 Model 1200 __ Same 10J1213 RAIL, FRONT LEG, JACKET < E2334702 E2344904 SWITCH, PRESSURE, AIR/GAS, 0.18”...
  • Page 121 Brute Page 121 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Part No. - Part # Description Model 1000 Model 1200 __ Same 10J3030 GASKET, HX OUTLET < __ Same 10J1265 PANEL ASSY, DOOR < __ Same 10J1268 CLAMP, ATTACHING, BEZEL <...
  • Page 122 Page 122 RADFORD HITE Part No. - Part # Description Model 1000 Model 1200 __ Same E2339400 THERMISTOR, NTC, 1/8” NPT, STAINLESS STEEL WELL < __ Same E2359200 SENSOR, TEMPERATURE, STACK, 1/4” NPT < __ Same P2079200 PLUG, PIPE, 1” NPT, CI (Boiler) < __ Same P0001100 BUSHING 1” NPT X 3/4” NPT BLK (Boiler CSD-1) <...
  • Page 123 Brute Page 123 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Part No. - Part # Description Model 1000 Model 1200 __ Same RW2013300 GASKET, IGNITOR < __ Same S2112600 FLANGE NUT, M6 SERRATED < __ Same RS2114200 ASSEMBLY, DOOR, HEAT EXCHANGER <...

  • Page 124: C Parts Illustrations

    Page 124 RADFORD HITE 13.C Parts Illustrations Figure 46. Machine Frame - NT1000 and NT1200...
  • Page 125 Brute Page 125 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Figure 47. Front Panels and Covers Figure 48. Rear Panel...
  • Page 126 Page 126 RADFORD HITE Figure 49. Burners and Combustion Chamber Figure 50. Flow Switch...
  • Page 127 Brute Page 127 BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Figure 51. Heat Exchanger Components Figure 52. Burner Detail...
  • Page 128 Brute BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h ® Figure 53. Electronic Components Figure 54. Condensate Trap 200 Lafayette St. www.BradfordWhite.com Middleville, MI 49333 Litho in U.S.A. © Bradford White 20-04 Document 1266F Warranty: (800) 531-2111...

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