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Bradford White BRHHH Installation And Operation Manual

Modulating boiler / water heater
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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
BRUTE MAGNUM
WARNING
Installation and Operation
Instructions for
Modulating Boiler
Model BRHHH
Modulating Water Heater
Model BRHHV
U.S. Patent No. 6,644,393
Canada Patent Pending
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.
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 service 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.
Docyment 1246
238-49223-00A REV 4/11

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  • Page 1 Installation and Operation Instructions Docyment 1246 Installation and Operation Instructions for BRUTE MAGNUM Modulating Boiler Model BRHHH Modulating Water Heater Model BRHHV U.S. Patent No. 6,644,393 Canada Patent Pending 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.
  • Page 2 RADFORD HITE ORP. Page 2...

  • Page 3: Table Of Contents

    Brute Magnum Page 3 Table of Contents SECTION 1 5.5.3 Offset ............. 26 General Information 5.5.4 Throttling Range ..........26 5.5.5 Minimum Output Setting ........ 27 Introduction ............5 5.5.6 Integration Constant ........27 Model Identification .......... 5 Mixing System and Control ......28 Warranty ............
  • Page 4 RADFORD HITE ORP. Page 4 List of Tables Table 1 Clearances ............6 Table 4 Required Combustion Air Piping Material..9 Table 2 Vent / Air Pipe Sizes ..........7 Table 5 Required Venting Material .........9 Table 3 Horizontal Vent and Air Terminals Table 6 Gas Piping Sizes ..........13 for Indoor Installations ........8...

  • Page 5: General Information

    Brute Magnum Page 5 improper installation. Section 1 The Brute Magnum appliance is protected GENERAL INFORMATION against over pressurization. A pressure relief valve is fitted to all appliances. It is installed inside the jacket, USING THIS MANUAL – Because the Brute at the water outlet of the unit.

  • Page 6: Warranty

    RADFORD HITE ORP. Page 6 (13) Revision appliance should be chosen with regard to the vent 2 = Second version pipe lengths and external plumbing. The unit shall be (14) Heat Exchanger installed such that the gas ignition system components E = Glass-lined steel with copper tubes are protected from water (dripping, spraying, rain, etc.) F = Glass-lined steel with cupronickel tubes...

  • Page 7: Locating Appliance For Correct Vent Distance From Outside Wall Or Roof Termination

    Brute Magnum Page 7 “V” “A” “W” “G” Gas Connects. Vent Outlet Air Inlet Water Control Packages Size Connection Connection Inlet/ Outlet “B” Std & A B & E B & E Connection Nat/ LP inches inches inches 1200 2-1/2” 1’...

  • Page 8: Venting And Combustion Air

    RADFORD HITE ORP. Page 8 Section 2 2.1.2 Intake Combustion Air The combustion air can be taken through the VENTING AND COMBUSTION AIR wall, or through the roof. When taken from the wall, it must be taken from out-of-doors by means of the 2.1 Combustion Air horizontal wall terminal, shown in Table 3.

  • Page 9: Venting

    Brute Magnum Page 9 A condensate drain is built into the Brute Term Description Magnum. A pressure switch monitors the condensate Pipe Single-wall galvanized steel pipe, 24 gauge drain pan, and will trip if the condensate level gets too minimum (sized per section 1.9) high.

  • Page 10: Figure 3 Combustion Air And Vent Through Side-Wall

    RADFORD HITE ORP. Page 10 U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony B= Clearance to window or door that may be 4 feet (1.2 m) below or to side of opening;...
  • Page 11 Brute Magnum Page 11 The figure in this addendum shows the wall horizontal vented gas fueled equipment. It requirements for mechanical vent terminal shall be the responsibility of the property owner clearances for the U.S. and Canada. to secure the services of qualified licensed Vent terminals for condensing appliances or professionals for the installation of hard-wired appliances with condensing vents are not...

  • Page 12: Side Wall Combustion Air Terminal

    RADFORD HITE ORP. Page 12 (c) MANUFACTURER REQUIREMENTS – side wall. Consider the following when installing the terminal: GAS EQUIPMENT VENTING SYSTEM Do not locate the air inlet terminal near a source PROVIDED. When the manufacturer of of corrosive chemical fumes (e.g., cleaning fluid, Product Approved side wall horizontally chlorine compounds, etc.) vented gas equipment provides a venting...

  • Page 13: Gas Supply And Piping

    Brute Magnum Page 13 At the time of removal of an existing boiler, the as determined using the appropriate tables following steps shall be followed with each appliance and guidelines in the National Fuel Gas Code, remaining connected to the common venting system ANSI Z223.1 NFPA 54 and/or CSA B149.1, placed in operation, while the other appliances Installation Codes.

  • Page 14: Section 4A

    RADFORD HITE ORP. Page 14 All threaded joints should be coated with to a drain or in a manner to prevent injury in the event piping compound resistant to action of liquefied of pressure relief. Install an air purger, an air vent, petroleum gas.

  • Page 15: Freeze Protection - Boiler

    Brute Magnum Page 15 medium is piped in parallel with the boiler with Section 4B appropriate valves to prevent the chilled medium from WATER CONNECTIONS — entering the boiler. BRUTE MAGNUM WATER HEATER The boiler piping system of a hot water heating boiler connected to heating coils located in air handling appliances where they may be exposed to 4B.1 Water System Piping —...

  • Page 16: Water Flow Requirements - Water Heater

    RADFORD HITE ORP. Page 16 Figure 4. Hydronic Piping - Multiple Boilers. 4B.3 Water Flow Requirements — tube erosion. For extremely soft or hard water, cupro- nickel tubes are available. Contact a Bradford White Water Heater Representative if you have questions or concerns about In a water heating application (an open system), water quality.

  • Page 17: Figure 5 Hydronic Piping – Multiple Boilers (Alternate)

    Brute Magnum Page 17 Figure 5. Hydronic Piping — Multiple Boilers (Alternate). If the water at the inlet of the copper heat directly to the outlet of the Brute Magnum, and there exchanger is less than 140°F (60°C), water from the will be a 20-25°F (11-14°C) temperature rise between outlet of the copper heat exchanger will be directed the inlet and outlet of the unit, when the unit is at high...

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

    RADFORD HITE ORP. Page 18 Figure 6. Hydronic Piping — One Boiler, Multi-Temperature System. 4B.4 Combined Water (potable) Heating water used for space heating. This water heater when used to supply potable and Space Heating water shall not be connected to any heating system NOTE: These systems are not allowed in the or component(s) previously used with a non-potable Commonwealth of Massachusetts.

  • Page 19: Freeze Protection - Water Heater

    Brute Magnum Page 19 4B.5 Freeze Protection – Water Heater Brute Magnum heaters are not designed to be placed outdoors, due to the potential for condensate to freeze in the unit. Power outage, interruption of gas supply, failure of system components, activation of safety devices, etc., may prevent a heater from firing.

  • Page 20: Figure 8 Water Heater Piping – One Heater, One Tank

    RADFORD HITE ORP. Page 20 Figure 8. Water Heater Piping — One Heater, One Tank.

  • Page 21: Figure 9 Water Heater Piping – Multiple Heaters One Tank

    Brute Magnum Page 21 Figure 9. Water Heater Piping — Multiple Heaters, One Tank.

  • Page 22: Figure 10 Water Heater Piping – One Heater Multiple Tanks

    RADFORD HITE ORP. Page 22 Figure 10. Water Heater Piping — One Heater, Multiple Tanks.

  • Page 23: Figure 11 Water Heater Piping – Multiple Heaters Multiple Tanks

    Brute Magnum Page 23 Figure 11. Water Heater Piping — Multiple Heaters, Multiple Tanks.

  • Page 24: Electrical Connections

    RADFORD HITE ORP. Page 24 Section 5 ELECTRICAL CONNECTIONS WARNING The appliance must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the latest edition of the National Electrical Code, ANSI/NFPA 70, in the U.S.

  • Page 25: Internal Water Heater Temperature Control

    Brute Magnum Page 25 temperature is less than 140°F (60°C), internal mixing The offset determines where the throttling range will keep the outlet temperature at 160-165°F (71- begins. 74°C), and this will mix with the tank temperature The throttling range is the temperature range to maintain a lower temperature in the tank.

  • Page 26: Offset

    RADFORD HITE ORP. Page 26 tank is drawing down, the heater will react to sustain through which the unit will modulate. This will tell a minimum tank temperature. Boilers generally have the controller how fast to respond to a change in higher differentials than water heaters, to minimize temperature.

  • Page 27: Minimum Output Setting

    Brute Magnum Page 27 Figure 15. Control Parameter Graph. 25% and 100% of full fire between 46°C and 49°C. 5.5.6 Integration Constant Between 46°C and 49°C, the unit will remain at low The proportional control used on the Brute fire. Between 38°C and 41°C, the unit will be at full Magnum has internal circuitry that helps to minimize fire.

  • Page 28: Mixing System And Control

    RADFORD HITE ORP. Page 28 Figure 16. Control Parameter Possible Interference. changed. This setting will be the best suited to most another 20-25°F (11-14°C) (when at high fire), and Brute Magnum installations. it leaves the boiler at 160-165°F (71-74°C). This hot Fast: Switch 4 to ON position and all others water is then sent to the system.

  • Page 29: External Control Connections

    Brute Magnum Page 29 The second menu “Add” has to do with the N2 located to the right of, and behind the front panel. The address. Pressing enter when “Add” is displayed will terminal strip is labeled “0-10VDC +” and 0-10VDC display “255”, which stands for 255 unique addresses.
  • Page 30 RADFORD HITE ORP. Page 30 Figure 17. Wiring Diagram, Size 1200, Standard and Codes A and F.

  • Page 31: Figure 18 Wiring Diagram, Sizes 1600, 2000 And 2400, Standard And Codes A And F

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

  • Page 32: Figure 19 Wiring Diagram Size 1200, Code B

    RADFORD HITE ORP. Page 32 Figure 19. Wiring Diagram, Size 1200, Code B.
  • Page 33 Brute Magnum Page 33 Figure 20. Wiring Diagram, Sizes 1600, 2000 and 2400, Code B.
  • Page 34 RADFORD HITE ORP. Page 34 Figure 21. Wiring Schematic, Model 1200, Figure 22. Wiring Schematic, Models 1600, 2000 and Standard and Codes A and F. 2400, Standard and Codes A and F.
  • Page 35 Brute Magnum Page 35 Figure 24. Wiring Schematic, Models 1600, 2000 Figure 23. Wiring Schematic, Model 1200, Code B. and 2400, Code B.

  • Page 36: Operating Instructions

    RADFORD HITE ORP. Page 36 Section 6 14. Refer to local codes and the make-up water valve manufacturer’s instructions as to whether OPERATING INSTRUCTIONS the make-up water valve should be left open or closed. 6.1 Filling the Boiler System 15. After placing the unit in operation, the ignition Ensure the system is fully connected.

  • Page 37: Figure 25 Gas/Air Test Panel

    Brute Magnum Page 37 panel are closed (see Figure 26). Remove the two plugs from the + and – ports of the air orifice taps, thread hose barbs into the 1/8" NPT connections, and attach the manometer pressure lines to the barbs. Be sure all connections are gas tight.

  • Page 38: Shutting Down The Brute Magnum

    RADFORD HITE ORP. Page 38 Open gas shutoff valve. Restart the Section 7 appliance. The ignition sequence will MAINTENANCE start again and the burner will start. The appliance will return to its previous mode WARNING of operation. Disconnect all power to the appliance before Caution attempting any service to the appliance.

  • Page 39: Figure 27 Gas Trains

    Brute Magnum Page 39 Figure 27. Gas Trains.

  • Page 40: Burner

    RADFORD HITE ORP. Page 40 Control Pack B Gas Train Figure 28. Gas Trains. The gas and electric controls on the appliance factory parts. To access the filter, remove the unit’s are engineered for long life and dependable operation, front panel. Disengage latch on top of filter box and but the safety of the equipment depends on their remove the filter box cover.

  • Page 41: Safety Gas Valve

    Brute Magnum Page 41 shutoff valve. Remove the front and right-side panels from the unit. Disconnect the union between the valve body and the blower. Label the four pressure tubes that are connected to the valve actuator, to ensure that they will be replaced correctly. Remove the valve actuator, per the instructions above.

  • Page 42: Mixing Actuator

    RADFORD HITE ORP. Page 42 7.2.10 Mixing Actuator panel, the two side access panels, and the top jacket panel off. (If there is enough clearance on the side, the The mixing actuator connects to both mixing top may not have to be removed.) Disconnect the gas valves and takes its signal from the mixing control to properly set the valves to protect the copper heat union between the blower and gas valves.

  • Page 43: Normally Open Vent Valve

    Brute Magnum Page 43 Clean the heat exchanger: A light accumulation shutoff valve and 120V power and check appliance of soot or corrosion on the outside of the heat operation and tightness of gas valve connections. exchanger can be easily removed. Use a wire brush to remove loose soot and scale from the 7.2.19 Gas Pressure Switches heat exchanger.

  • Page 44: Resolving Lockouts

    RADFORD HITE ORP. Page 44 When the call for heat is complete, or the unit 8.3 Delayed Ignition - Possible Causes reaches its setpoint temperature, the gas valve will close, and the fan will continue to run for 8.3.1 High Lockup Pressure (LP Appliances) its 30 second post-purge.

  • Page 45: Short Cycling - Water Heater

    Brute Magnum Page 45 8.5 Short Cycling — Water Heater Section 9 Short cycling will generally occur only in REPLACEMENT PARTS combination space heating and water heating Only genuine Bradford White replacement parts applications when the water heater is operating in the should be used.

  • Page 46: Parts List

    RADFORD HITE ORP. Page 46 9.2 Parts List COMBUSTION COMPONENTS – See Figure 30 1200 1600 2000 2400 Base assembly 24A1200 24A1200 24A1200 24A1200 Panel, top, combustion chamber 24B2600 24B2600 24B2600 24B2600 Panel, bottom, combustion chamber 24A2400 24A2400 24A2400 24A2400 Panel, left, combustion chamber 24A2100 24A2100...
  • Page 47 Brute Magnum Page 47 1200 1600 2000 2400 Tubing/Fittings (gas train repair kit) R2020700 R2020700 R2020700 R2020700 Air filter box assembly (with gasket and hardware) Nat 12B5000 16B5000 20B5000 24B5000 Air filter box assembly (with gasket and hardware) LP 12B5020 16B5020 20B5020 24B5020...
  • Page 48 RADFORD HITE ORP. Page 48 1200 1600 2000 2400 105 Switch, Low water cutoff, Manual Reset RE2075100 RE2075100 RE2075100 RE2075100 HEAT EXCHANGER / WATER PATH – See Figures 34 and 35 110 Header cover 12A4200 16A4200 20A4200 24A4200 111 Water barrier assembly 12B4100 16B4100 20B4100...

  • Page 49: Figure 30 Combustion Components

    Brute Magnum Page 49 Figure 30. Combustion Components.

  • Page 50: Gas Train/Combustion Air Components

    RADFORD HITE ORP. Page 50 Figure 31. Gas Train/Combustion Air Components.

  • Page 51: Figure 32 Gas Train Components

    Brute Magnum Page 51 Figure 32. Gas Train Components.

  • Page 52: Figure 33 Electrical Components

    RADFORD HITE ORP. Page 52 Figure 33. Electrical Components.

  • Page 53: Figure 34 Heat Exchanger / Water Path Components

    Brute Magnum Page 53 Figure 34. Heat Exchanger / Water Path Components.

  • Page 54: Figure 35 Heat Exchanger / Water Path Components

    RADFORD HITE ORP. Page 54 Figure 35. Heat Exchanger / Water Path Components.

  • Page 55: Figure 36 Jacket Components

    Brute Magnum Page 55 Figure 36. Jacket Components.
  • Page 56 ® Bradford White Company reserves the right to change specifications, components, features, or to discontinue products without notice. Ambler, PA 19002 Tech. Service (800) 334-3393 www.BradfordWhite.com Service Parts (800) 538-2020 Warranty Service (800) 531-2111 Litho in U.S.A. © Bradford White 1102 Document 1246...

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