Bradford-White Corp BWCH, BWCV warranty Operating the Burner and Set Up, External Boiler Operation

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BRADFORD WHITE CORP.

 

 

 

 

The control then operates the boiler stages to maintain the programmed boiler target temperature. The reset override operation is not affected by WWSD.

6.4.10 External Boiler Operation

When mode 6 is selected, the control allows for an external control to operate the Copper Brute II’s stages. In this mode, the control operates the pump in order to provide purging and exercising. The staging operation is provided by an external device such as an Energy Management System (EMS) or External Staging Control.

Heat Demand – A heat demand is generated when stage one is wired properly, and the external control closes the contacts on the stage one terminals (1C-1NO), calling the Copper Brute II for heat. The Copper Brute II is shipped with a jumper between the Com D and Ht D terminals, and this jumper must remain in place when and external control is providing the heat demand signal to these terminals. The control energizes the boiler pump (if equipped), energizes the Pmp-Pmp terminals, and turns on the boiler pump segment in the display. The control also turns on stage 1 of the boiler. Section 5.3 contains important information about external staging controls and building automation systems. Other wiring methods may be unsafe. The wiring in Section 5.3 of this manual must be used.

6.4.11 Limit Controls

In addition to the temperature control, Copper Brute II appliances are fitted with a manual reset high limit and an automatic reset high limit. These are located near the rear of the cabinet on the right side, behind the slide out drawer (see Figure 32). Both controls should be set at least 25°F higher than the target temperature to avoid short cycling. To set these controls, remove the control panel cover and pull the control panel out to gain access. Appliances with reversed heat exchangers have the limit controls relocated to the left side of the appliance. The left access door must be removed to gain access to the limit controls on these appliances.

6.4.12Advanced Programming Mode

Advanced programming mode allows the

installer to set the temperature control for proportional staging. In advanced programming mode, the interstage differential, interstage delay, interstage on and off delay, and minimum time on and off are all set manually.

NOTE: Advanced programming mode is rarely required. It is intended for advanced installers, and only when the application demands such programming.

access the dip switch. The dip switch is mounted on a circuit board.

Locate the letter “A” on the circuit board and slide the corresponding dip switch toward the letter “A”. The default setting of this dip switch is toward the OFF lettering on the circuit board.

6.5 Operating the Burner and Set Up

6.5.1Set Up for 0 to 2500 Feet Altitude

The Copper Brute II appliance utilizes a modular

design to achieve its stage-firing. The setup must be checked before the unit is put in operation. Problems such as failure to start, rough ignition, strong exhaust odors, etc. can be due to improper setup. Damage to the Copper Brute II resulting from improper setup is not covered by the limited warranty.

1.Using this manual, make sure the installation is complete and fully in compliance with the instructions.

2.Determine that the appliance and system are filled with water and all air has been bled from both. Open all valves.

3.Observe all warnings on the Operating

Instructions label and turn on gas and electrical power to appliance.

4.Switch on the appliance power switch located on the right side of the unit.

5.The Copper Brute II will enter the start sequence, as long as the unit is being called for heat. The blower and pump come on for pre-purge, then the ignitor warm-up sequence starts and after the ignitor warm-up is complete and all safety devices are verified, the gas valves open. If ignition doesn’t occur, check that there is proper gas supply. Wait 5 minutes and start the unit again. During initial start up, air in the gas line may cause the Copper Brute II to "lock out" during the first few trials for ignition. Depending on the ignition modules installed, the manual reset button on the ignition modules may need to be depressed to restart the Copper Brute II.

6.When the unit is running, the supply gas pressure must be checked. Inlet gas pressure must not exceed 13" w.c. (3.2kPa). The minimum inlet gas pressure is 5" w.c. (1.2kPa).

7.Once the inlet gas pressure is verified, the outlet gas pressure from each valve (manifold gas pressure) must be checked, and adjusted, if necessary. The manifold gas pressure must be 2.5" w.c. (0.62kPa).

8.Complete the setup by checking the CO2 at the outlet of the unit. The CO2 should be 8% for natural gas, or 9.2% for propane.

9.After placing the appliance in operation, the Burner Safety Shutoff Device must be tested.

To enter advanced programming mode, remove the bezel on the temperature control by pulling out at the bottom. Remove the small phillips head screw to

To test:

(a)Close gas shutoff valve with burner operating.

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Contents Copper Brute Table of Contents Replacement Parts MaintenanceTrouble Shooting Operating InstructionsIntroduction General InformationModel Identification Dimensions WarrantyLocating the Appliance Dimensional Data Inches 91cm horizontally Combustion Air From Room Venting and Combustion AirCombustion Air Intake Combustion AirCategory I Vent VentingVent Categories Common Venting SystemsCombustion Air and Vent Through Side Wall Side Wall Vent Terminal Locating Vent & Combustion Air TerminalsCategory III Vent Side Wall Combustion Air TerminalVertical Vent Terminal Common Vent Test BoilersVent Terminals for Outdoor Units Vertical Combustion Air TerminalGas Supply and Piping 61-91m4A.2 Cold Water Make-Up Boiler Water Connections Copper Brute II Boiler4A.1 Heating System Piping Hot Supply Connections 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.2 Hot Water Supply Piping Water Heater Water Connections Copper Brute II Water Heater4B.1 Water System Piping Water Heater 4B.3 Water Flow Requirements Water Heater4B.5 Freeze Protection Water Heater SupplyWater Heater Piping Multiple Heaters, One Tank Water Heater Piping Multiple Heaters, Multiple Tanks Temperature Control Main PowerElectrical Connections Field Wiring Panel External Staging Control Wiring AvertissementCopper 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 System Piping Primary Secondary Piping Programming the Temperature ControlChoosing the Mode Parallel PipingFor ALL Other Modes Hydronic Primary/Secondary Mode Choosing the Mode for your Application Mechanical aquastat in a domestic hot water storage tankMode 5 Primary secondary piping with outdoor reset Advanced Topics Staging ModeDifferential Boiler Maximum Boil MAX Boiler Target TemperatureBoiler Minimum Boil MIN Pump OperationSetpoint Operation Outdoor Reset OperationDedicated Domestic Hot Water Typical Gas Train Configuration Set Up for 0 to 2500 Feet Altitude Operating the Burner and Set UpAdvanced Programming Mode External Boiler OperationShutting Down the Copper Brute High Altitude Adjustment and Set UpTo Restart the Copper Brute System Maintenance MaintenanceAppliance Maintenance Component Description Ignition Controls Temperature ControlFlow Switch IgnitorsBradford White Corp Trouble Shooting Troubleshooting the Temperature Control Troubleshooting Copper Brute ControlsCopper Brute II 500 Troubleshooting Error Codes Replacement Parts Parts ListSee 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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