Bradford White Brute MagnaTech BMGV1600 Installation And Operation Instructions Manual
  1. Manuals
  2. Brands
  3. Bradford White Manuals
  4. Water Heater
  5. Brute MagnaTech BMGV1600
  6. Installation and operation instructions manual

Bradford White Brute MagnaTech BMGV1600 Installation And Operation Instructions Manual

Hide thumbs Also See for Brute MagnaTech BMGV1600:
Table of Contents

Advertisement

Quick Links

Download this manual
Installation and Operation Instructions
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
If the information in these instructions is
Do not store or use gasoline or other
WHAT TO DO IF YOU SMELL GAS
• Do not touch any electrical switch; do not
Installation and
Operation Instructions for
Brute MagnaTech
Modulating Boiler
Model BMGH1600
Model BMGH2000
Model BMGH2500
Model BMGH3000
Model BMGH3500
Model BMGH4000
WARNING
Water Heater
Model BMGV1600
Model BMGV2000
Model BMGV2500
Model BMGV3000
Model BMGV3500
Model BMGV4000
AVERTISSEMENT
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
Document 1293H
®

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Brute MagnaTech BMGV1600 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Bradford White Brute MagnaTech BMGV1600

Summary of Contents for Bradford White Brute MagnaTech BMGV1600

  • Page 1 Installation and Operation Instructions Document 1293H Installation and Operation Instructions for Brute MagnaTech ® Modulating Boiler Water Heater Model BMGH1600 Model BMGV1600 Model BMGH2000 Model BMGV2000 Model BMGH2500 Model BMGV2500 Model BMGH3000 Model BMGV3000 Model BMGH3500 Model BMGV3500 Model BMGH4000 Model BMGV4000 FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, WARNING...

  • Page 2: Table Of Contents

    Table of Contents Section 6 – WATER CONNECTIONS, Section 1 - GENERAL INFORMATION Introduction ............1 BOILER Boiler System Piping: Hot Supply Safety Notes ............. 1 Connections ............ 22 The Rating Plate (Model Nomenclature) ..2 Boiler Cold Water Make-Up ......22 Warranty ............2 Boiler Freeze Protection .........22 Unit Overviews ( all sizes ) ......3-5...
  • Page 3 Section 11 – MAINTENANCE Section 9 – NAVIGATING THE TOUCH SCREEN 11.1 System Maintenance........80 The Touch Screen ..........56 11.2 Maintenance Notes .........80 Using the Touch Screen ........56 11.2.1 Burner ............. 80 Parameters ............58 11.2.2 Modulating Gas Valve/ Venturi ......80 While Operating - Checking Individual 11.2.3 Controller ............81 Parameters ............59 11.2.4 Spark Ignition Electrodes .......

  • Page 5: Section 1 - General Information

    Page 1 Section 1 GENERAL INFORMATION Introduction This manual includes information which will help you to install, operate, and maintain the 1600, 2000, 2500, 3000, 3500 and 4000 MBH systems. Please read this manual Rating completely before proceeding with the installation. If Plate you have any questions regarding this equipment, please consult the manufacturer, or a local manufacturer’s...

  • Page 6: The Rating Plate (Model Nomenclature)

    Warranty 2 5 0 0 = 2,499,000 BTU/hr input 3 0 0 0 = 3,000,000 BTU/hr input Bradford White MagnaTech boilers and volume 3 5 0 0 = 3,500,000 BTU/hr input water heaters are covered by a limited warranty. The...

  • Page 7: Unit Overviews ( All Sizes )

    Page 3 Unit Overviews The next 3 pages give a visual reference to the basic component locations of the unit. Control Panel ntrol Pane Blower Manual Gas Valve Spark Generator Rating Plate (on outside of panel) On all models, the Control Panel Touch Screen hinges forward for easy access to wiring and to the heat exchanger.
  • Page 8 Page 4 Control Panel Control Blower Manual Gas Valve Spark Generator Rating Plate. (on outside of panel) Touch Screen Heat Exchanger Condensing Unit Field Gas Supply Electrical Connections Air Intake and Filter Power Pack Main Power Connections Water Outlet Water Inlet Vent Models 2500 and 3000 Condensate...
  • Page 9 Page 5 Blower Manual Gas Valve (hidden behind main gas valve) Spark Generator Rating Plate. (on outside of panel) Touch Screen Control Panel Heat Exchanger Condensing Unit Gas Supply Air Intake and Filter Field Main Power Electrical Connections Connections ns s Water Outlet Power Pack Water Inlet...

  • Page 10: Dimensions

    Page 6 Dimensions Model Inches (cm ) 1600 29.3 (75 ) 79.8 (203 ) 38 (96 ) 57.5 (147 ) 49.8 (126 ) 4.8 (12 ) 60.8 (154 ) 2.6 (7 ) 2000 29.3 (75 ) 79.8 (203 ) 38 (96 ) 57.5 (147 ) 49.8 (126 ) 4.8 (12 )

  • Page 11: Unpacking And The Installation Kit

    Page 7 Unpacking and the Installation Kit The unit is shipped in a single crate. Carefully disassemble the crate and inspect the unit for any damage during shipping. Included in the crate and yet outside of the unit is the ‘Installation Kit’ box. Inspect the contents of the box (The Installation Kit), making sure that all parts are there and not damaged during shipping.

  • Page 12: Locating The Appliance

    Page 8 Note - When located on the same wall, the Unit Section 2 combustion air intake terminal must be installed a LOCATING THE APPLIANCE minimum of 12” ( below the exhaust terminal. 30cm) There must also be a minimum horizontal distance from intake to the exhaust terminal Locating the Appliance of 84”...

  • Page 13: Section 3 - Venting And Combustion Air

    Page 9 Section 3 VENTING AND COMBUSTION AIR General Venting This product requires a special venting system. Refer Do not mix venting suppliers and models in venting systems. Failure to comply could result in personal to venting supplier’s instructions for complete parts list and method of installation.

  • Page 14: Combustion Air

    Page 10 Combustion Air shall communicate directly, or by ducts, with the Boilers and water heaters must have provisions for outdoors or spaces that freely communicate with combustion and ventilation air in accordance with the the outdoors. When directly communicating with the applicable requirements for Combustion Air Supply outdoors, or when communicating to the outdoors and Ventilation in the National Fuel Gas Code, ANSI...

  • Page 15: Ducted Combustion Air

    Page 11 Venting Other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed WARNING Selection of improper vent materials for above. installations that are installed in closets, or will be In Canada, consult local building and safety codes operated in high ambient temperature levels, may or, in absence of such requirements, follow CAN/...

  • Page 16: Common Venting

    Page 12 If the system temperatures are unknown at the The venting must be correct to allow the condensate time of installation, class IIC or higher venting to run back to the Unit to drain. Route the vent pipe material is recommended. to the heater as directly as possible.

  • Page 17: Locating The Vent And Combustion Air Terminals

    Page 13 It is the responsibility of the appropriately licensed technician installing this unit to use ULC requirements as described in the Venting and Combustion Air section. than 135°C, but not more than 245°C. 135°C or less. four temperature ratings as follows: Up to and including 65°C / 149°F Up to and including 90°C / 194°F Up to and including 110°C / 230°F and...
  • Page 18 Page 14 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 opened Other than Direct vent: 4 ft (1.2m) below or to C= Clearance to permanently closed window See note 4 See note 5...

  • Page 19: Side Wall Combustion Air Terminal

    Page 15 determine it should be higher, depending upon local conditions. If the Unit is side-wall vented to the same wall, use Figure 5 to determine the proper mounting locations. Multiple vent kits should be installed such that the horizontal distance between outlet group and inlet group is 84”...

  • Page 20: Installations In The Commonwealth Of Massachusetts

    Page 16 3.4.5 Installations in the Commonwealth of Massachusetts In Massachusetts the following items are required if the side-wall exhaust vent termination is less than of the venting, including but not limited to decks and porches. (From Massachusetts Rules and regulations 248 CMR 5.08.) 1.
  • Page 21 Page 17 Au moment du retrait d’une chaudiére existante, At the time of removal of an existing boiler, the following steps shall be followed with each chaque appareil toujurs raccordé au systéme appliance remaining connected to the common d’évacuation commun et qui fonctionne alors que venting system placed in operation, while the other d’autres appareils toujours raccordés au système appliances remaining connected to the common...

  • Page 22: Outdoor Installation

    Page 18 Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000 Air intake screen for unit placed outdoors CA0011904 CA011901 CA011901 CA011902 CA0011903 CA0011903 Vent terminal for unit placed outdoors CA011803 CA011801 CA011801 CA011802 CA011803 CA011803 Table 10. Air & Vent Accessories for units placed outdoors Outdoor Installation If installing outdoors in a location that may experience freezing temperatures, precautions must be taken to...
  • Page 23 Page 19 The following are gas line sizing examples from the National Fuel Gas Code. Size your gas lines properly, based on your installation, and all applicable codes. SCH 40 METAL PIPE CAPACITY FOR 0.60 SPECIFIC GRAVITY NATURAL GAS NOMINAL PIPE SIZE @ 0.30” W.C. PRESSURE DROP Nominal: 2½...

  • Page 24: Boiler Flow And Head Requirements

    Page 20 Section 5 WATER FLOW REQUIREMENTS Boiler Flow and Head Requirements 25°F 30°F 35°F 40°F Flow Flow Flow Flow Head Loss Head Loss Head Loss Head Loss Head loss* Head loss* Head Head Feet Feet Feet Feet Output SIZE 25°...

  • Page 25: Water Heater Flow And Head Requirements

    Page 21 Water Heater Flow and Head Requirements Water Hardness 1-10 grains per gallon Allowable pH: 6.5 to 9.5 Model Flow Rate Temp Rise Headloss Flow Rate Temp Rise Headloss °F °C 1600 31.0 11.1 10.1 2000 33.0 10.1 2500 33.7 13.9 10.0...

  • Page 26: Section 6 - Water Connections

    Page 22 Section 6 - WATER CONNECTIONS BOILERS System Piping: Hot Supply Connections Note -This appliance must be installed in a closed A boiler installed above radiation level, or as pressure system with a minimum of 12 psi (82.7 required by the authority having jurisdiction, must be kPa) static pressure at the boiler.

  • Page 27: Condensate Drain Trap

    Page 23 Different glycol products may provide varying The condensate drain must be installed to degrees of protection. Glycol products must be prevent the accumulation of condensate. When maintained properly in a heating system, or they may a condensate pump is not used, the tubing must continuously slope downward toward the drain with or the glycol manufacturer, for information about no spiraling.
  • Page 28 Page 24 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. Water feed controls 4 pipe dia. max. Note - This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing.
  • Page 29 Page 25 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. Low temp. radiant zone Low temp. radiant zone Air vent Water feed controls Expansion tank...
  • Page 30 Page 26 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 31 Page 27 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. max. Common piping must be sized for the combined water flow of all the boilers.

  • Page 32: Section 7 - Water Connections

    Page 28 Section 7 - WATER CONNECTIONS 7.2 Suggested Piping Schematics 7.1 Water Quality Figure 13 through Figure 15 show suggested piping Water heaters must be installed in water conditions are only meant as guides. All components or piping of 15 gpg hardness or less, with a pH range of 6.5 required by local code must be installed.

  • Page 33: Vol Water Cold Water Make-Up

    Page 29 drain or in a manner to prevent injury in the event of 7.5 Freeze Protection pressure relief. Install a diaphragm-type expansion If installing outdoors in a location that may experience freezing temperatures, precautions or as required by code. must be taken to prevent water in the heat The piping should be installed so that each pump exchanger and condensate inside and outside of...

  • Page 34: Vol Water Water Flow

    Page 30 NOTE: This drawing shows suggested piping Optional location for EXPANSION COLD WATER SUPPLY TANK Check with local codes and ordinances for additional requirements. BUILDING RETURN Location of pump Check valve Location of pump EXPANSION TANK Check valve BALL VALVE (TYPICAL) NOTES: 1.

  • Page 35: Section 8 - Electrical Connections

    Page 31 Section 8 WARNING ELECTRICAL CONNECTIONS The unit must be electrically grounded in accordance with the requirements of the authority Installation Warnings having jurisdiction or, in the absence of such requirements, with the latest edition of the National Electrical Code, ANSI/NFPA 70, in the U.S. and CAUTION with the latest edition of CSA C22.1 Canadian The supply voltage to the unit must not be...

  • Page 36: Pump Connections And Operation

    Page 32 8.3 Pump Connections and Operation is 7.4 amps, and an appropriately sized contactor The controller in the MagnaTech energizes the appropriate pump contacts when it receives a call for technician to ensure proper pump operation. Once the system has been installed, the “Pump The Boiler, System, and DHW pump terminals are adjust Pump control, Overrun time and Demand found on the Main control board TB1-15A through...

  • Page 37: Field Wiring

    Page 33 Both units are shown with outside panels removed for full servicing. Field Junction Box Electrical for Main Power Connections. Connections At the front of the unit. Available Electrical Raceway Available Knockouts for System Sensor and/or modbus, etc. VIEW from the BACK Figure 17.

  • Page 38: Field Connections For Single Systems

    Page 34 15 BOILER PUMP H Field Connections for 16 BOILER PUMP N Single unit installations. 17 SYSTEM PUMP H 18 SYSTEM PUMP N 19 DHW PUMP H 20 DHW PUMP N Power for Field Connections must be made at Outdoor Sensor/ 21 OUTDOOR/SYS System Sensor...

  • Page 39: Control Panel Layout

    Page 35 8.7 Control Panel Layout CONN CONN CONN 15 BOILER PUMP H 16 BOILER PUMP N 17 SYSTEM PUMP H 18 SYSTEM PUMP N 19 DHW PUMP H 20 DHW PUMP N 21 OUTDOOR/SYS 22 OUTDOOR/SYS 23 ANALOG (-) 24 ANALOG (+) 25 TT 26 TT...

  • Page 40: Building Automation Systems Connections

    Page 36 Lead Unit Building Automation System Connections This commercial unit can be controlled and monitored with a Gateway BAS using the included Modbus ports. Doc# 4236. The Gateway Modbus Control (H2354400) Metasys N2 and LonWorks. Connect the Gateway Control to the COM2 A, B, and C, as shown in Figure 20.

  • Page 41: Lead Lag Connections

    Page 37 Lag Unit/s 8.9 Lead Lag Connections This commercial unit can be connected in Lead Lag up to a total of 8 units (controllers). One as the Lead control and up to 7 more as the Lag controllers. For Lead Lag Connections, COM2 A, B, and C must be connected together AND the MB2 A.

  • Page 42: Wiring Diagrams

    Page 38 THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE PROPRIETARY TO LAARS HEATING SYSTEMS CO. AND SHALL NOT BE REPRODUCED, TRANSFERRED TO OTHER DOCUMENTS, USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR ANY OTHER PURPOSE EXCEPT AS SPECIFICALLY AUTHORIZED IN WRITING BY LAARS HEATING SYSTEMS CO.
  • Page 43 Page 39 REVISIONS REV. DRAFT CHECK ENGR APPR AL 7/2/15 15-099N JAB 7/2/15 CHANGE: REMOVED HSI AND ADDED SPARK GENERATOR AND IGNITOR BLOWER FLAME ROD CONTROL CONNECTOR 8 POS CONN "C" INLET WATER TEMP OUTLET WATER TEMP STACK TEMP BR/R OR/W BR/G W/BK...
  • Page 44 Page 40 THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE PROPRIETARY TO LAARS HEATING SYSTEMS CO. AND SHALL NOT BE REPRODUCED, TRANSFERRED TO OTHER DOCUMENTS, USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR ANY OTHER PURPOSE EXCEPT AS SPECIFICALLY AUTHORIZED IN WRITING BY LAARS HEATING SYSTEMS CO.
  • Page 45 Page 41 REVISIONS REV. DRAFT CHECK ENGR APPR AL 4-7-15 15-028N JM 4-7-15 CHANGE: LOCATION C-8: SPARK GENERATOR WAS HSI, ADD SPARK IGNITOR FLAME ROD 8 POS CONN "C" INLET WATER TEMP OUTLET WATER TEMP STACK TEMP BR/R OR/W BR/G W/BK BK/O BR/V...

  • Page 46: High Voltage Wiring Diagrams

    Page 42 8.11 High Voltage Wiring Diagrams Figure 23. High voltage wiring diagram Model 1600, 120V...
  • Page 47 Page 43 Figure 24. High voltage wiring diagram Model 1600, 208V Single Phase...
  • Page 48 Page 44 8.11 High Voltage Wiring Diagrams (continued) Figure 25. High voltage wiring diagram Model 1600, 240V...
  • Page 49 Page 45 Figure 26. High voltage wiring diagram Model 2000, 120V...
  • Page 50 Page 46 8.11 High Voltage Wiring Diagrams (continued) 120V N 120V N 120V H 120V H Figure 27. High voltage wiring diagram Model 2000, 208V Single Phase...
  • Page 51 Page 47 Figure 28. High voltage wiring diagram Model 2000, 240V...
  • Page 52 Page 48 8.11 High Voltage Wiring Diagrams (continued) 120V N 120V N 120V H 120V H Figure 29. High voltage wiring diagram Model 2000 - 4000 three phase...

  • Page 53: Ladder Diagrams

    Page 49 8.12 Ladder Diagrams Figure 30. Model 1600 120V ladder diagram...
  • Page 54 Page 50 8.12 Ladder Diagrams (continued) Figure 31. Model 1600, 208V, 1 Phase, ladder diagram...
  • Page 55 Page 51 Figure 32. Model 1600 240V ladder diagram...
  • Page 56 Page 52 8.12 Ladder Diagrams (continued) Figure 33. Model 2000, 208V, 1 Phase, ladder diagram...
  • Page 57 Page 53 Figure 34. Model 2000, 120V ladder diagram...
  • Page 58 Page 54 8.12 Ladder Diagrams (continued) Figure 35. Model 2000, 240V ladder diagram...
  • Page 59 Page 55 Figure 36. Three-Phase Ladder Diagram...

  • Page 60: Section 9 - Navigating The Touch Screen

    Page 56 Section 9 NAVIGATING THE TOUCH SCREEN Touch Screen Open the front panel to access the Touch Screen Figure 37. To access the Touch Screen Figure 39. With Front Doors Open. The Touch Screen The Touch Screen is visible behind a protective cover and can be accessed by unlocking and Color Status...
  • Page 61 Page 57 To change some parameters, a password is required. The control system includes three levels of password protection: OEM Password Setup and parameter changes available only to the factory. Installer Password Setup and parameter changes made when the system is installed, and some diagnostic and troubleshooting functions.

  • Page 62: Parameters

    Page 58 Menu 6. Parameter Safety Warning Menu 4. Login Required WARNING Changing safety parameters should only be The screen used to Login is similar to the Keyboard screen. conducted by experienced, licensed boiler operators and mechanics. Hazardous burner conditions can happen with improper operations keys on this screen.

  • Page 63: Parameters

    Page 59 Menu 8. Safety Parameter Reset When the process is complete, the system will tell you to reset the control system. The Reset button is located on the front of the controller. Figure 40. Reset Button on Controller You must press the Reset button within 30 The system will present a listing for each A count-down timer is shown at the bottom of the screen.

  • Page 64: Controllers

    Page 60 Menu 10. Status Summary Screen Menu 12. Status Summary Screen Notice the four buttons at the bottom of each Status Summary screen: some of the setup parameters used by the system. A password may be required. • Operation – Used to adjust the setpoints, change the fan speed, turn a burner on or off, or turn the pumps on or off.

  • Page 65: Setting The Date And Time On The System Display

    Page 61 Setting the Date and Time on the System Display The display includes an internal clock, which keeps Press the Display Setup button at the bottom track of the date and time. This setting is important, of the screen. because log entries for Lockouts and Alerts include time listings.
  • Page 66 Page 62 The following sections give overviews of Menu 18. Home Screen the controller icon on the home screen to access the Status Summary screen, This menu will display information regarding software, date codes, model numbers and program name, as well as giving the installer access to re-name the boiler and to change the modbus addresses for lead lag operation.
  • Page 67 Page 63 A factory supplied Outdoor air temperature sensor is used with the Outdoor Reset and Warm Weather Shutdown features. Wiring For single boiler operation, the outdoor sensor will be connected to TB1-21A and 22A. For Lead Lag operation of multiple boilers, the outdoor sensor will be connected to TB1-21A and 22A on the Lag Boiler, and the system sensor (supplied with boiler) will be connected to TB1-21A and 22A on the Lead boiler.

  • Page 68: High Limits

    Page 64 9.7.11 Stack Limits contacts when it receives a call for heat. Once the call for pump overrun time. The Boiler, System, and DHW pump terminals are found on the Main control board TB1-15A through 20A. They are fed 120 Volts internally from the main power feed.

  • Page 69: Burner Control Ignition

    Page 65 9.7.14 Burner Control Ignition The Pilot test hold function allows the installer to set The outdoor temperature can be read from the outdoor sensor that is shipped with the Unit, or from 22, without turning on the Main valve. With a call for an Envirocom outdoor sensor (sold separately).
  • Page 70 Page 66 9.7.17 Lag (Slave) across all of the available units so that any one unit The Lead Lag controller tracks the run times for all About Lead Lag Operation - of the units, and uses this to calculate the starting order for the units.
  • Page 71 Page 67 Number of boilers Base load value installed Low demand - The first boiler in sequence fires at less than 65% Demand increases - Once the first boiler reaches 65%, the second boiler switches on, and both modulate Table 20. Base Load Settings together between 20% and 65% (this can be adjusted up to 20% and 85%).
  • Page 72 Page 68 type in ‘LNT’ and press OK. Then you can select Slave Enable. Select ‘Enable Slave for built-in Lead Lag Master’ . Then select OK Then select a Modbus address (number) for that unit. Then select OK Repeat on all units, keeping them in a sensible sequencial order.

  • Page 73: Parameter Defaults And Ranges

    Page 69 All Connections to the Lag units must be made prior to Wiring Connections for Lead Lag - Now you can make the Modbus wiring connections Set up the Lead (Master) controller by going to the Lead between the units. See Figure 20 on page 36 The controller in each unit includes two wiring to communicate with the other units in the Lead Lag...
  • Page 74 Page 70 Parameter Defaults and Ranges (continued) Boost During Priority Time Priority Method Drop After Priority Time DHW Config Drop After Priority Time DHW Sensor Outlet Sensor Auto:DHW (S6) or Outlet Modulation Sensor Inlet Sensor DHW Config Only Auto: DHW (S6) or Inlet Sensor Auto: DHW (S6) or Outlet Sensor Setpoint 40F - 200F...
  • Page 75 Page 71 Anti- Short Cycle Time 0 min 0 sec - 15 min 0 sec 1 min 0 sec System Config Low Fire Cutoff Time 0 min 0 sec - 5 min 0 sec 0 min 0 sec System Config Burner Off Inhibit Time 0 min 0 sec - 5 min 0 sec 0 min 20 sec...
  • Page 76 Page 72 Parameter Defaults and Ranges (continued) Enable Lead Lag Master Config- Enable Disabled Disable Adv Settings - Outdoor Reset Lead Lag Master Config- Maximum Outdoor Temperature 40F - 150F Adv Settings - Outdoor Reset Lead Lag Master Config- -40F - 90F Minimum Outdoor Temperature Adv Settings - Outdoor Reset Lead Lag Master Config-...
  • Page 77 Page 73 (Building Automation System) If communication protocols are desired, this commercial unit can be controlled and monitored through the included Modbus ports. The Modbus wiring must be completed according to the diagrams shown in Section 8. See Figure 20 on page 36. For additional information on purchasing and setting up Modbus and other communication protocols, contact your Manufacturer’s Representative.

  • Page 78: Variable Speed Flow Control (V.s.p.c.) System

    Page 74 9.10 Variable Speed Flow Control (V.S.P.C.) System and runs the pump output at 100% (10 VDC, or 20 V.S.P.C. is a variable pump control that is standard mA). equipment on all boilers. Pump speed is controlled Once the Main Gas valve is energized the PCB to maintain a user-chosen temperature rise between will maintain pump output at 100% for 60 seconds to allow the system to stabilize.

  • Page 79: Combustion Setup Procedure

    Page 75 9.11 Combustion Setup Procedure In this section, we will explain how to set up the gas Fire and Low Fire conditions. Required tools: Screwdrivers, Torx bits, Allen Wrench Set, Combustion Analyzer WARNING Improper adjustment may lead to poor combustion quality, increasing the amount of carbon monoxide produced.
  • Page 80 Page 76 turn “OFF” the pilot test hold. Unit is equipped with a zero governing, negative regulator valve. The valve throttle offset adjustment is only to be done at low icon, then touch, Diagnostics. On the I/O status screen press “Diagnostic Tests” and enter the installer password by pressing the padlock in the upper right corner.
  • Page 81 Page 77 Model Gas Type High Fire CO Low Fire CO Pressure Differential Natural 9.0% ± 0.2 0.5” to 1.2” wc* 1,600 Propane 10.0% ± 0.2 0.5” to 1.2” wc* Natural 9.0% ± 0.2 0.5” to 1.2” wc* 2,000 Propane 10.0% ±...

  • Page 82: Section 10 - Initial Startup Instructions

    Page 78 Section 10 INITIAL STARTUP INSTRUCTIONS 10.1 Filling the Boiler System Ensure the system is fully connected. Close all 12. Close the make-up water valve. Check the bleeding devices and open the make-up water strainer in the pressure reducing valve for sediment or debris from the make-up water line.

  • Page 83: Initial Operation

    Page 79 10.2 Initial Operation Caution The initial setup must be checked before the unit is If any odor of gas is detected, or if the gas put into operation. Problems such as failure to start, burner does not appear to be functioning rough ignition, strong exhaust odors, etc.

  • Page 84: Section 11 - Maintenance

    Page 80 Section 11 WARNING MAINTENANCE Disconnect all power to the unit before attempting any service procedures. Contact with 11.1 System Maintenance electricity can result in severe injury or death. Do the following once a year: Lubricate all the pumps in the system, per the instructions on the pump.

  • Page 85: Controller

    Page 81 11.2.5 Flame Sensor After the valve has been removed, reassemble in reverse order making sure to include all gaskets and O-rings. Turn on the manual gas valves and check for gas leaks. Turn on the main power. Place the unit in operation following the instructions in Section 10.

  • Page 86: Heat Exchanger Tubes

    Page 82 WARNING 11.2.7 Heat Exchanger Tubes Failure to rinse the debris from the heat Black carbon soot buildup on the external surfaces exchanger and temporary drain line may of the heat exchanger is caused by one or more of lead to clogged condensate lines, traps and neutralizers.

  • Page 87: Battery Back Up For Date And Time

    Page 83 11.2.9 Battery Back Up for Date and Time The touchscreen does have an internal battery for back-up of the date and time settings. The battery is a CR2032 ‘coin type’ battery and has an expected service life of 6 years. If the battery needs to be replaced, there is a battery cover on the back of the touchscreen display and it can be easily reached when the panel that the Touchscreen is...

  • Page 88: Section 12 - Troubleshooting

    Page 84 Section 12 TROUBLESHOOTING Lockout will appear in an orange bar across the bottom of the screen. If you tap the orange bar, 12.1 Lockouts, Holds, and Alerts the system will present more information about The control system on the Unit responds to three the Lockout.
  • Page 89 Page 85 3. Press the long Yellow Alert or Yellow Lockout Bar If you choose ‘LOCKOUTS’, this menu will appear. (the long bar will be a long Grey ‘History’ Bar if not currently in Alert or Lockout). Menu 37. Lockout History Menu 35.

  • Page 90: Troubleshooting Table

    Page 86 12.2 Troubleshooting Table This table includes a listing of the fault codes that may be displayed. Some of these can be corrected by changing a parameter, while other conditions are more complicated, and will require a service technician. the orange bar at the bottom of the screen.
  • Page 91 Page 87 Internal fault: Safety relay test failed due to safety relay OFF Internal fault: Internal fault Safety relay test failed due to safety 1. Reset module relay not OFF 2. If fault repeats, replace module. Internal fault: Safety relay test failed due to feedback not ON Internal fault: Safety RAM write...
  • Page 92 Page 88 Modulation fault Internal sub-system fault. Pump fault 1. Review alert messages for possible trends. Motor tachometer fault 2. Correct possible problems. AC input phases reversed 1. Check the module and display connections. 2. Check the module power supply and make sure that both frequency and voltage meet the 3.
  • Page 93 Page 89 Outlet high limit H or L 1. Check wiring and correct any possible errors. 2. Replace the outlet high limit. 3. If previous steps are correct and fault persists, replace the module. DHW (Domestic Hot Water) high limit H or L 1.
  • Page 94 Page 90 Pressure Sensor Fault 1. Verify the Pressure Sensor is a 4-20 ma source. 2. Check wiring and correct any possible errors. 3. Test Pressure Sensor for correct operation. 4. Replace the Pressure sensor. 5. If previous steps are correct and fault persists, replace the module.
  • Page 95 Page 91 Lightoff rate proving failed 1. Check wiring and correct any potential wiring errors. 2. Check VFD’s (Variable-speed Fan Drive) ability to change speeds. 3. Change the VFD 4. If the fault persists, replace the module. Purge rate proving failed 1.
  • Page 96 Page 92 Flame detected H or L to Flame Establishing period. Flame not detected Sequence returns to standby and restarts sequence at the beginning of Purge after the HF check up to Flame Establishing period. Purge Fan switch On H or L 1.
  • Page 97 Page 93 Invalid BLOWER / SPARK output setting Invalid Delta T limit enable setting Invalid Delta T limit response setting Invalid DHW (Domestic Hot Water) high limit enable setting selected parameters, reverify and reset module. Invalid DHW (Domestic Hot Water) high 2.
  • Page 98 Page 94 Invalid DHW (Domestic Hot Water) demand source setting Invalid Flame threshold setting Invalid Outlet high limit setpoint setting Invalid DHW (Domestic Hot Water) high limit setpoint setting Invalid Stack limit setpoint setting selected parameters, reverify and reset module. Invalid Modulation output setting 2.

  • Page 99: Diagnostic Tests And Input/Output Indicators

    Page 95 12.3 Diagnostic Tests and Input/ Output Indicators Two kinds of screens are grouped together in this section: • Detailed indications of the input and output signals • Diagnostic tests of the pumps and burner modulation Note that these functions apply to just one selected controller.

  • Page 100: Lead/Lag Diagnostics

    Page 96 12.4 Lead Lag Diagnostics 12.6 Analysis The control system includes a diagnostic screen that The control system includes an Analysis branch lists some information on the Lag (Slave) units in the that can display the behavior over a period of time system.

  • Page 101: Control Snapshot

    Page 97 12.7 Control Snapshot 12.8 Operating Sequence The software allows you to take a “snapshot” of When there is a call for heat, the unit will close pump the current state of the controller, including setup contacts to energize the customer supplied relay/ information and operating information.

  • Page 102: Section 13 - Replacement Parts

    Page 98 Section 13 REPLACEMENT PARTS Use only genuine Manufacturer replacement parts. 13.1 General Information To order or purchase parts for the Manufacturer Unit, contact your nearest Manufacturer dealer or distributor. If they cannot supply you with what you need, contact Customer Service. (See the back cover for addresses, and for telephone and fax numbers.) AC DISTRIBUTION BOX DETAIL E...

  • Page 103: Component Illustrations, Parts Lists, And Part Numbers

    Page 99 13.2 Component Illustrations, Parts Lists, and Part Numbers 13.2.1 Frame and Jacket Assembly, Part Numbers 1600 2000 2500 3000 3500 4000 Item # Description Part No. Part No. Part No. Part No. Part No. Part No. Base assembly 16N1000 20N1000 30N1000...
  • Page 104 Page 100 DETAIL A DETAIL Final Assembly...

  • Page 105: Final Assembly

    Page 101 View from Back 13.2.2 Final Assembly, Part Numbers 1600 2000 2500 3000 3500 4000 Item # Description Part No. Part No. Part No. Part No. Part No. Part No. Heat Exchanger Assembly R16N2070 R20N2070 R30N2070 R30N2070 R40N2070 R40N2070 Plate, rear panel, gas pipe 20N3034 30N3034...

  • Page 106: Waterway Outlet Assembly

    Page 102 MGH ONLY 13.2.3 Waterway Outlet Assembly, Part Numbers 1600 2000 2500 3000 3500 4000 Item # Description Part No. Part No. Part No. Part No. Part No. Part No. Pipe, outlet manifold 20N4023 20N4023 30N4020 30N4020 40N4020 40N4020 PRV 75# (MGH) A0002700 A0002700...

  • Page 107: Blower Assy, Model 1600

    Page 103 DETAIL 13.2.4 Blower Burner Assembly, Part Numbers (Model 1600) W2014100 16N5074 A2132700 Spark Generator 20N3060...

  • Page 108: Blower Assy, Model 2000

    Page 104 DETAIL 13.2.5 Blower Burner Assembly, Part Numbers (Model 2000) 2000 Item # Description Part No. Burner L2019500 Gasket, burner S2125500 Adapter plate 20N5037 Sight glass RF0044800 Flame sensor W2014900 Gasket, blower outlet flange S2125600 Venturi / Air intake assembly A2123300 Gasket, blower intake 20N5095...
  • Page 109 Page 105 SEE DETAIL A FOR PILOT TUBE PLACEMENT DETAIL A DETAIL 13.2.6 Blower Burner Assembly, Part Numbers (Models 2500 and 3000) 2500 3000 Item # Description Part No. Part No. Burner L2020600 L2020600 Gasket, burner S2125100 S2125100 Adapter plate 30N5037 30N5037 Sight glass...
  • Page 110 Page 106 PART N 40N5 40N5 S2125300 GASKET F2037700 WASHE 40N6021 GAS TR...
  • Page 111 Page 107 13.2.7 Blower Burner Assembly, Part Numbers (Models 3500 and 4000) 3500 4000 Item # Description Part No. Part No. Burner L2019900 L2019900 Gasket, burner S2124100 S2124100 Gasket, spacer 40N5092 40N5092 Pilot tube 40N5090 40N5090 Gasket, blower outlet flange 40N5093 40N5093 Flow sensor, diff pressure...
  • Page 112 Page 108 Gas Train Assembly (Models 1600, 2000, 2500 and 3000)

  • Page 113: Gas Train Assembly, Models 1600 Thru 3000

    Page 109 13.2.8 Gas Train Assembly, Part Numbers (Models 1600, 2000, 2500 and 3000) 1600 2000 2500 3000 Item # Description Part No. Part No. Part No. Part No. Pressure switch, low gas R2004100 R2004100 R2004100 R2004100 Pressure switch, high gas R2004000 R2004000 R2004000...
  • Page 114 Page 110 70-236 W200030 S2123500 P2089600 P2089300 40N6040 Gas Train Assembly (Models 3500 and 4000)
  • Page 115 Page 111 13.2.9 Gas Train Assembly, Part Numbers (Models 3500 and 4000) 3500 4000 Item # Description Part No. Part No. Pressure switch, low gas R2004100 R2004100 Pressure switch, high gas R2004000 R2004000 Elbow, 45°, 2" P2090900 P2090900 Nipple, 2"x14" P2091000 P2091000 Union, 2"...

  • Page 116: Control Panel Assembly

    Page 112 13.2.10 Control Panel Assembly, Part Numbers 1600 2000 2500 3000 3500 4000 Item # Description Part No. Part No. Part No. Part No. Part No. Part No. DIN rail assembly 30N7040 30N7040 30N7040 30N7040 30N7040 30N7040 Low water cutoff RE2075100 RE2075100 RE2075100...
  • Page 117 Page 113 13.2.11 AC Distribution Box Assemblies and Part Numbers (Model 1600) AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODEL1600)

  • Page 118: Distribution Box Assemblies

    Page 114 13.2.12 AC Distribution Box Assembly and Blower Part Numbers (Model 2000) AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS AND BLOWER (MODEL 2000)
  • Page 119 Page 115 E DETAIL A FOR LOT TUBE PLACEMENT AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS AND BLOWERS (MODELS 2500 TO 4000) 13.2.13 AC Distribution Box Assembly and Blower Part Numbers (Models 2500 to 4000) 2500 3000 3500 4000 208V 480V 600V 208V 480V...
  • Page 120 MagnaTech Boilers and Water Heaters Notes: 200 Lafayette St. Middleville, MI 49333 Litho in U.S.A. © Bradford White 1710 Document 1293H Warranty: (800) 531-2111...

This manual is also suitable for:

Brute magnatech bmgh1600Brute magnatech bmgh2000Brute magnatech bmgv2000Brute magnatech bmgh2500Brute magnatech bmgv2500Brute magnatech bmgh3000 ... Show all

Table of Contents