Bradford-White Corp BWCH Programming the Temperature Control, Parallel Piping, Choosing the Mode

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COPPER BRUTE II (500 - 2000)

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radiation units and high points in the system piping, as described in Step 4.

12.Close make-up water valve and check strainer in pressure reducing valve for sediment or debris from the make-up water line. Reopen make-up water valve.

13.Check gauge for correct water pressure and also check water level in the system. If the height indicated above the boiler insures that water is at the highest point in the circulating loop, then the system is ready for operation.

14.Refer to local codes and the make-up water valve manufacturer’s instructions as to whether the make-up water valve should be left open or closed.

15.After placing the unit in operation, the ignition system safety shutoff device must be tested. First, shut off the manual gas valve, and call the unit for heat. After the pre-purge and ignitor heat-up time, the main gas terminals will be energized, attempting to light, for four (4) seconds, and then will de-energize. The unit will go into lockout mode. Second, turn the power off and then on again, open the manual gas valve and allow the unit to light. While the unit is operating, close the manual gas valve and ensure that power to the main gas valve has been cut.

16.Within three (3) days of start-up, recheck all air bleeders and the expansion tank as described in Steps 4 and 8 above.

Important: The installer is responsible for identifying to the owner/operator the location of all emergency shutoff devices.

WARNING

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance

and to replace any part of the control system and any gas control that may have been

under water.

6.3 Programming the Temperature

Control

The same temperature control is used on all versions of the Copper Brute II (in two-and four-stage configurations), providing maximum flexibility to meet the needs of any system. Before start-up, you must program the temperature control for the type of system you have. You must determine the type of piping the system has, the mode the temperature control will operate in, and the various settings for that mode.

6.3.1System Piping “Primary Secondary Piping”

In the context of these instructions, “primary

secondary piping” means the boiler provides heat to a

plumbing loop that has, in turn, one or more plumbing loops connected to it, which provide heat to radiant tubing, radiators, DHW heat exchangers, etc. This plumbing loop is the “primary loop.”

In primary secondary piping modes, the temperature control monitors the primary loop temperature. The extra sensor that is shipped loose with Copper Brute II is installed in the primary loop. The temperature control fires the boiler stages to provide the “target temperature” at that sensor. Over time, the temperature control will learn the system curve and adjust the firing of the stages to meet the demand in the most efficient way.

For complex systems, with variable speed injection circulators, multiple temperature zones, etc., you may need to consult with a qualified engineer or Bradford White Applications Engineering.

“Parallel Piping”

The term “parallel piping” means the Copper Brute II is supplying heat directly to one or more storage tanks, radiators, radiant zones, etc., plumbed in series. In these systems, the target temperature is the boiler’s outlet temperature. An exception is for domestic hot water systems using mode 3, where the extra sensor is placed in the tank.

6.3.2 Choosing the Mode

There are six modes of operation for the Copper Brute II temperature control. The loose sensor must be installed and connected prior to programming the temperature control, as it provides sensing the “target” temperature. The location of the sensor is dependent on the type of piping used. Figures 4 through 8 show suggested locations for the temperature sensor in various hydronic piping configurations.

Modes 1 through 5 are the automatic modes, requiring the diagnostic panel’s AUTO/MAN switch (located on the slide-out control drawer) to remain in the default AUTO position. These modes enable the temperature control to fire the Copper Brute II’s stages to meet the demand of the system. In these modes, the Copper Brute II temperature control continuously samples the inlet, outlet and target temperatures.

Mode 6 is the manual mode, and the AUTO/ MAN switch must be moved to the MAN position. An external control, such as a building automation system or multiple boiler control, just be wired to the field wiring panel in order to fire the boiler, bypassing the temperature control (see Section 5.3 for important information about external staging controls and building automation systems).

Table 11 contains information to identify the mode you should use for your system.

6.3.3 Programming

Before programming, you must determine the type of piping you have, the mode you will use, and install the extra sensor if required for that mode. See Sections 6.3.1 and 6.3.2 for more information, or

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Contents Copper Brute Table of Contents Trouble Shooting MaintenanceReplacement Parts Operating InstructionsIntroduction General InformationModel Identification Dimensions WarrantyLocating the Appliance Dimensional Data Inches 91cm horizontally Combustion Air Venting and Combustion AirCombustion Air From Room Intake Combustion AirVent Categories VentingCategory I Vent Common Venting SystemsCombustion Air and Vent Through Side Wall Category III Vent Locating Vent & Combustion Air TerminalsSide Wall Vent Terminal Side Wall Combustion Air TerminalVent Terminals for Outdoor Units Common Vent Test BoilersVertical Vent Terminal Vertical Combustion Air Terminal61-91m Gas Supply and Piping4A.1 Heating System Piping Hot Supply Connections Boiler Water Connections Copper Brute II Boiler4A.2 Cold Water Make-Up Boiler 4A.3 Water Flow Requirements BoilerHydronic Piping Multiple Boilers, Primary Secondary System Hydronic Piping Multiple Boilers, Low Temperature System Hydronic Piping One Boiler, Multi-Temperature System Hydronic Piping Primary-Secondary, Reverse-Return Boiler CIRC. Pump Sized for Flow Through Boiler 4B.1 Water System Piping Water Heater Water Connections Copper Brute II Water Heater4B.2 Hot Water Supply Piping Water Heater 4B.3 Water Flow Requirements Water HeaterSupply 4B.5 Freeze Protection Water HeaterWater Heater Piping Multiple Heaters, One Tank Water Heater Piping Multiple Heaters, Multiple Tanks Temperature Control Main PowerElectrical Connections Field Wiring Panel Avertissement External Staging Control WiringCopper Brute II 500 750 Ladder Diagram Copper Brute II 1000 Ladder Diagram Copper Brute II 1250 2000 Ladder Diagram Copper Brute II 500 1000 Wiring Schematic Copper Brute II 1250 1500 Wiring Schematic Copper Brute II 1750 2000 Wiring Schematic Terminal designations are as indicated Field Wiring for Modes 1 Avertissement Sequence of Operation Operating InstructionsFilling the Boiler System Choosing the Mode Programming the Temperature ControlSystem Piping Primary Secondary Piping Parallel PipingFor ALL Other Modes Hydronic Primary/Secondary Mode Mechanical aquastat in a domestic hot water storage tank Choosing the Mode for your ApplicationMode 5 Primary secondary piping with outdoor reset Advanced Topics Staging ModeDifferential Boiler Minimum Boil MIN Boiler Target TemperatureBoiler Maximum Boil MAX Pump OperationSetpoint Operation Outdoor Reset OperationDedicated Domestic Hot Water Typical Gas Train Configuration Advanced Programming Mode Operating the Burner and Set UpSet Up for 0 to 2500 Feet Altitude External Boiler OperationShutting Down the Copper Brute High Altitude Adjustment and Set UpTo Restart the Copper Brute System Maintenance MaintenanceAppliance Maintenance Component Description Flow Switch Temperature ControlIgnition Controls IgnitorsBradford White Corp Trouble Shooting Troubleshooting Copper Brute Controls Troubleshooting the Temperature ControlCopper Brute II 500 Troubleshooting Error Codes Parts List Replacement PartsSee Figures 35 Heat Exchanger Components Electrical Components Gas Train Components Burner Manifold Assy, 4 Burners, Left, LP For reference Internal Components Copper Brute II Hydronic Electrical Components H2214401F
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