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Installation and Operation Instructions
This product must be installed and serviced by a professional service technician,
FOR YOUR SAFETY:
qualified in hot water boiler installation and maintenance. Improper installation and/or operation could
create carbon monoxide gas in flue gases which could cause serious injury, property damage, or
death. Improper installation and/or operation will void the warranty. For indoor installations, as an
additional measure of safety, Bradford White strongly recommends installation of suitable Carbon
Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from
a nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed
by a qualified installer, service agency, or gas
supplier.
WARNING
Installation and Operation
Instructions for
Copper Brute II
Hydronic Boiler
Model BWCH
Water Heater
Model BWCV
Sizes 500-2000
U.S. Reg. 2,765,423
AVERTISSEMENT
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d'incendie ou d'explosion ou
pour éviter tout dommage matériel, toute blessure
ou la mort.
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
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 1270
™
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Summary of Contents for Bradford White BWCH
- Page 1 Improper installation and/or operation will void the warranty. For indoor installations, as an additional measure of safety, Bradford White strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
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Page 2: Table Of Contents
Page 2 RADFORD HITE ORP. TABLE OF CONTENTS SECTION 1. SECTION 3. General Information Gas Supply and Piping Introduction ............4 Gas Supply and Piping ........13 Model Identification .......... 4 SECTION 4A. Warranty ............5 Water Connections – Boiler Dimensions ............ - Page 3 COPPER BRUTE II (500 - 2000) Page 3 SECTION 6. SECTION 7. Operating Instructions Maintenance Sequence of Operation ........36 System Maintenance ........48 Filling the Boiler System ........ 36 Appliance Maintenance and Component Description ......... 48 Programming the Temperature Control ..37 7.2.1 Burners ............
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Page 4: General Information
This manual provides information necessary General Information for the installation, operation, and maintenance of Bradford White Corp, Copper Brute II copper tube USING THIS MANUAL – Because the appliances. Read it carefully before installation. Copper Brute II Boilers and Copper Brute II Water... -
Page 5: Warranty
B = Glass-lined CI / copper / brz trim (std. BWCV) pipe lengths and external plumbing. The unit shall be C = Glass-lined cast iron / copper (standard BWCH) installed such that the gas ignition system components K = Bronze / copper are protected from water (dripping, spraying, rain, etc.) - Page 6 Page 6 RADFORD HITE ORP. SHIPPING WEIGHT SIZE lbs. 1000 1250 1500 1750 2000 *Add 55 lbs. (25kg) for pump-mounted units. VENT HORIZ. CONN. CONN. VENT SIZE PIPE 33½ 15¾ 5¾ 29¾ 76 32¾ 7¾ 20 8¾ 22 46 117 6 15 8 20 45½...
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Page 7: Locating Pump-Mounted Water Heater With Respect To Storage Tank(S)
COPPER BRUTE II (500 - 2000) Page 7 1.6 Locating Pump-Mounted Water Heater 1.8 Locating Appliance for Correct with Respect to Storage Tank(s) Horizontal Vent/Ducted Air Distance For best results, a pump-mounted Copper Brute From Outside Wall II water heater should be located within 15 feet (4.6m) The forced draft combustion air blower/blowers of the storage tank(s). -
Page 8: Venting And Combustion Air
The it must be taken from out-of-doors by means of the openings shall communicate directly, or by ducts, Bradford White horizontal wall terminal (see Table with the outdoors or spaces that freely communicate When taken from the roof, a field-supplied rain cap or with the outdoors. -
Page 9: Venting
COPPER BRUTE II (500 - 2000) Page 9 length allowed is 50 feet (15.2m). Three elbows have if multiple units are vented into the same vertical been calculated into the 50-foot (15.2m) linear run. vent, a barometric damper must be installed on each Subtract 10 allowable linear feet (3.0m) for every appliance, such that the flue draft does not exceed additional elbow used (see... - Page 10 Page 10 RADFORD HITE ORP. U.S. Installations (see note 1) Canadian Installations (see note 2) A = Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony B = Clearance to window or door that may be 4 feet (1.2 m) below or to side of opening;...
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Page 11: Category Iii Vent
NFPA 54 and applicable local codes. In Canada, the to a Bradford White product, please call Applications installation must be in accordance with CSA B149.1 or Engineering at the Rochester phone number listed on .2 and local applicable codes. -
Page 12: Vertical Vent Terminal
Page 12 RADFORD HITE ORP. cigarette, cigar or pipe. After it has been determined that each appliance 2.3.3 Vertical Vent Terminal remaining connected to the common venting When the unit is vented through the roof, the system properly vents when tested as outlined vent must extend at least 3 feet (0.9m) above the point above, return doors, windows, exhaust fans, at which it penetrates the roof. -
Page 13: Gas Supply And Piping
COPPER BRUTE II (500 - 2000) Page 13 SECTION 3. A sediment trap must be provided upstream of the gas controls. Gas Supply and Piping All threaded joints should be coated with piping compound resistant to action of liquefied 3.1 Gas Supply and Piping petroleum gas. -
Page 14: Section 4A
Copper Brute II is 120°F (49°C) to avoid condensing N/R = not recommended. on the copper coils. Table 8. Water Flow Requirements - BWCH. 4A.4 Freeze Protection — Boiler Boiler installations are not recommended in areas where the danger of freezing exists unless proper... - Page 15 COPPER BRUTE II (500 - 2000) Page 15 COLD WATER MAKE-UP SYSTEM RETURN SYSTEM SYSTEM PUMP SUPPLY PUMP LOCATION FOR NON-PUMP-MOUNTED UNITS CAUTION: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURATION AND VALVING, CHECK PUMP LOCATION FOR PUMP-MOUNTED UNITS WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS.
- Page 16 Page 16 RADFORD HITE ORP. COLD WATER MAKE-UP SYSTEM SYSTEM SUPPLY SYSTEM PUMP RETURN ADJUSTMENT PROCEDURE TO MAINTAIN 120°F INLET TEMP: 1. Turn on boiler and open valves A & B. 2. After steady-state operation, if T1 is less than 120°F, slowly close valve B until T1 climbs to 120°F.
- Page 17 COPPER BRUTE II (500 - 2000) Page 17 150°F COLD WATER MAKE-UP 180°F 130°F 180°F SYSTEM PUMP NOTES: 1. BOILER LOOP IN EXAMPLE IS MAINTAINED AT 180°F. PUMP LOCATION FOR 2. ZONE THERMOSTATS CAN BE INTERLOCKED WITH BOILER, NON-PUMP-MOUNTED UNITS SO THAT BOILER FIRES UPON CALL FOR HEAT FROM ANY ZONE.
- Page 18 Page 18 RADFORD HITE ORP. COLD WATER MAKE-UP SYSTEM RETURN SYSTEM SYSTEM PUMP SUPPLY PUMP LOCATION FOR NON-PUMP-MOUNTED UNITS PUMP LOCATION FOR PUMP-MOUNTED UNITS PRIMARY/SECONDARY MANDITORY FOR ALL CAUTION: THIS DRAWING SHOWS SUGGESTED VARIABLE FLOW SYSTEMS PIPING CONFIGURATION AND VALVING, CHECK WITH LOCAL CODES AND ORDINANCES FOR INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM ADDITIONAL REQUIREMENTS.
- Page 19 COPPER BRUTE II (500 - 2000) Page 19 COLD WATER MAKE-UP SYSTEM RETURN SYSTEM SYSTEM PUMP SUPPLY ADJUSTMENT PROCEDURE TO MAINTAIN 120°F INLET TEMP: 1. Turn on boiler and open valves A & B. 2. After steady-state operation, if T1 is less than 120°F, slowly close valve B until T1 climbs to 120°F.
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Page 20: Section 4B
Contact a Pipe the outlet from the heater’s relief valve Bradford White Representative if you have questions such that any discharge from the relief valve will be or concerns about water quality. conducted to a suitable place for disposal when relief Pump-mounted water heaters can be ordered occurs. -
Page 21: Freeze Protection - Water Heater
Contact the local factory representative or installations are not recommended in areas subject to Bradford White for additional information. freezing temperatures, unless proper precautions are taken. Power outage, interruption of gas supply, failure... - Page 22 Page 22 RADFORD HITE ORP. Figure 10. Water Heater Piping — Multiple Heaters, One Tank. Figure 11. Water Heater Piping — One Heater, Multiple Tanks.
- Page 23 COPPER BRUTE II (500 - 2000) Page 23 Figure 12. Water Heater Piping — Multiple Heaters, Multiple Tanks. TEMP RISE °F LPM TEMP RISE °C SIZE 1000 1250 1500 1750 2000 10.0 10.0 10.0 NOTES: 1. S = soft water (1 to 7.5 grains hardness) 2.
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Page 24: Section
Page 24 RADFORD HITE ORP. SECTION 5. Copper Brute II 1750-2000 will require two 120- volt fused supplies. Heater circuit can be identified Electrical Connections with 10AWG wires to include black, white and green (all solid colors). Pump circuit can be identified with WARNING three 12AWG wires to include a black wire with a The appliance must be electrically grounded in... - Page 25 COPPER BRUTE II (500 - 2000) Page 25 with the Copper Brute II is installed in the piping wired devices to interlock with the boiler (louver or tank, per the suggested piping diagrams, and switches, flow switches, etc.), remove the jumper between the “COM”...
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Page 26: External Staging Control Wiring
Page 26 RADFORD HITE ORP. additional components. 5.3 External Staging Control Wiring WARNING Improper field wiring may result in fire or explosion which can cause property damage, severe injury, or death. Make only wiring connections which are in accordance with the Installation and Operation manual. - Page 27 COPPER BRUTE II (500 - 2000) Page 27 Figure 16. Copper Brute II 500 - 750 Ladder Diagram.
- Page 28 Page 28 RADFORD HITE ORP. Figure 17. Copper Brute II 1000 Ladder Diagram.
- Page 29 COPPER BRUTE II (500 - 2000) Page 29 Figure 18. Copper Brute II 1250 - 2000 Ladder Diagram.
- Page 30 Page 30 RADFORD HITE ORP. Figure 19. Copper Brute II 500 - 1000 Wiring Schematic.
- Page 31 COPPER BRUTE II (500 - 2000) Page 31 Figure 20. Copper Brute II 1250 - 1500 Wiring Schematic.
- Page 32 Page 32 RADFORD HITE ORP. Figure 21. Copper Brute II 1750 - 2000 Wiring Schematic.
- Page 33 COPPER BRUTE II (500 - 2000) Page 33 Figure 22. Field Wiring.
- Page 34 Page 34 RADFORD HITE ORP. Figure 23. Field Wiring for Modes 1 - 5.
- Page 35 COPPER BRUTE II (500 - 2000) Page 35 Figure 24. Field Wiring for Mode 6.
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Page 36: Operating Instructions
Page 36 RADFORD HITE ORP. SECTION 6. display, and the energizing of additional burner stages is indicated by front panel lights. Operating Instructions If there is a subsequent loss of flame signal, the burner will attempt re-ignition up to three times (only 6.1 Sequence of Operation once if optional lockout ignition module is used.) A call for heat can be initiated either... -
Page 37: Programming The Temperature Control
Bradford White Applications Engineering. 15. After placing the unit in operation, the ignition “Parallel Piping” system safety shutoff device must be tested. First, The term “parallel piping”... - Page 38 5.2). These • Advanced control each Copper Brute II) terminals can power a contactor for a larger system capability pump. Bradford White recommends a minimum pump • No outdoor reset • Parallel piping (non-reset • Bradford White outdoor primary/secondary) sensor (optional...
- Page 39 COPPER BRUTE II (500 - 2000) Page 39 EXAMPLE 1 delay setting of 5 minutes. See Section 6.4.6 for more DHW (Mode 3) Programming. For domestic information. hot water systems up to 175°F / 79°C, use mode 3 as NOTE: In modes other than mode 6, the pump will described below.
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Page 40: Choosing The Mode For Your Application
5:00 this mode. F° F° °C Mode 3: Bradford White R2014800 sensor Step 4: See Section 6.4.11 Limit Controls. installed in the domestic hot water both high limit controls at least 25°F / 14°C higher storage tank. than the BOIL TARGET to allow for temperature rise The Copper Brute II ships with a jumper between across the heat exchanger. -
Page 41: Outdoor Reset
Install a “supply sensor” in the primary loop Mode 5: Primary secondary piping with using the Bradford White part number R2014800 sensor (included with every Copper Brute II unit). outdoor reset. Connect the sensor to the “S C2” and “SUP S”... -
Page 42: Advanced Topics
Page 42 RADFORD HITE ORP. Interstage Differential (STG DIFF) – The 6.4 Advanced Topics interstage differential is the temperature drop at which For most installations, Section 6.3 provides the next stage will turn on. Once a stage turns on, the all the information required to set up the Copper Brute next stage cannot turn on until the temperature drops II boiler, and this section should be skipped. -
Page 43: Boiler Minimum (Boil Min)
COPPER BRUTE II (500 - 2000) Page 43 minimum amount of time before turning on the next lowest water temperature that the control is allowed stage. After the minimum time delay between stages to use as a target temperature. During mild conditions, has expired, the control examines the control error to if the control calculates a target temperature that is determine when the next stage is to fire. -
Page 44: Setpoint Operation
Page 44 RADFORD HITE ORP. the time selected (between 0 and 10 minutes). When uses outdoor reset to control the water temperature. is selected, there is no purging. When Outdoor reset adjusts the target temperature based selected, pump operation is continuous. Also, during on the outdoor air temperature and reset ratio. - Page 45 COPPER BRUTE II (500 - 2000) Page 45 the typical coldest temperature of the year where the building is located. This temperature is used when doing heat loss calculations for the building. Boiler Design (BOIL DSGN) – The BOIL DSGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the OUTDR DSGN temperature.
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Page 46: External Boiler Operation
Page 46 RADFORD HITE ORP. The control then operates the boiler stages to maintain access the dip switch. The dip switch is mounted on a the programmed boiler target temperature. The reset circuit board. override operation is not affected by WWSD. Locate the letter “A”... -
Page 47: High Altitude Adjustment And Set Up
COPPER BRUTE II (500 - 2000) Page 47 (b) The flame will go out and blower will pressure and replaced after the adjustments have been continue to run for the post purge cycle. completed and the fitting, hose and manometer have One additional attempt to light will follow. -
Page 48: Maintenance
Component Description order. Ensure o-rings are properly installed for both inlet and outlet. Turn on manual gas shutoff valve and Only genuine Bradford White replacement parts should 120 volt power and check appliance operation and be used. tightness of gas valve connections. -
Page 49: Temperature Control
Replace transformer in the reverse order. 7.2.6 Temperature Control The temperature control is a Bradford White 7.2.11 Blowers LHSC. To replace the control, shut off the 120-volt The combustion air blowers bring the combustion power to the appliance. - Page 50 Scale can build up on the inner surface of the heat exchanger tubes, which can restrict water flow. If the tubes show signs of scaling, clean the internal surface. Bradford White offers a tube cleaning kit part number R0010000.
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Page 51: Trouble Shooting
There are many causes of lockouts. The three most common causes are: (1) inadequate gas supply, controller setup. Contact your Bradford White (2) poor combustion, (3) ignitor failure. representative to discuss possible remedies. Inadequate gas supply: Before proceeding, ensure that the gas supply has not been shutoff or the LP 8.4 Short Cycling —... -
Page 52: Troubleshooting The Temperature Control
Page 52 RADFORD HITE ORP. 8.6 Troubleshooting the Temperature 2, and ignition module #2 handles stage 3. The single blower is energized directly through the “inducer” Control terminals of either ignition module. The 24V power to Table 12. the T’STAT terminal of both ignition modules is routed through the safety interlocks. - Page 53 COPPER BRUTE II (500 - 2000) Page 53 Table 12. Troubleshooting Error Codes.
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Page 54: Replacement Parts 9.1 General Information
Page 54 RADFORD HITE ORP. - Page 55 COPPER BRUTE II (500 - 2000) Page 55...
- Page 56 Page 56 RADFORD HITE ORP.
- Page 57 COPPER BRUTE II (500 - 2000) Page 57...
- Page 58 Page 58 RADFORD HITE ORP.
- Page 59 COPPER BRUTE II (500 - 2000) Page 59...
- Page 60 Page 60 RADFORD HITE ORP. NOTE: Model 2000 shown for reference. BASE SHOWN FOR REFERENCE Figure 33. Sheet Metal Components.
- Page 61 COPPER BRUTE II (500 - 2000) Page 61 Electrical Components for detail. Figure 34. Internal Components.
- Page 62 Page 62 RADFORD HITE ORP. See pump chart below for pump numbers. Copper Brute II Water Heater Copper Brute II Hydronic PUMP P/N SIZE Soft Water Normal Water Hard Water SIZE PUMP P/N A2001700 A2001700 A2001900 A2001700 A2001700 A2001700 A2001900 A2001700 1000 A2001700...
- Page 63 COPPER BRUTE II (500 - 2000) Page 63 Figure 36. Electrical Components.
- Page 64 Bradford White Corp. 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 1211 Document 1270...
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