Bradford-White Corp BWCV, BWCH, Copper Brute II Hydronic Boiler warranty Trouble Shooting

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COPPER BRUTE II (500 - 2000)

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SECTION 8.

Trouble Shooting

8.1Resolving Lockouts

There are many causes of lockouts. The three

most common causes are: (1) inadequate gas supply,

(2) poor combustion, (3) ignitor failure.

1.Inadequate gas supply: Before proceeding, ensure that the gas supply has not been shutoff or the LP tank (LP boilers) is not empty. Then, restart the boiler and observe the operational cycle. After

a 15-second fan pre-purge, the ignitor will heat up for 20 seconds, and then the unit will light.

If it does not, check the gas supply pressure to the appliance, after resetting the appliance and attempting another start-up. The gas pressure to the appliance must be above 5" w.c. (1.2kPa) throughout the entire start-up cycle. If it is not, correct the supply problem (check gas valves or supply piping). If the supply pressure is adequate, consult the factory for assistance.

2.Poor Combustion: Poor combustion should be suspected if there is a strong flue gas odor. The odor may result from an improper gas/air ratio (high or low O2 or CO2). Copper Brute II appliances operate best with 45% excess air (8% CO2 on natural gas, 9.2% CO2 on LP). Check the CO2 of the appliance and adjust if necessary.

3.Ignitor failure: If the boiler goes through a normal start cycle but combustion does not occur, ignitor failure should be suspected. Check the ignitor by unplugging the ignitor plug and measuring the ignitor resistance. It should be

50-80 ohms. If the resistance is not 50-80 ohms, replace the ignitor. If the resistance is correct, reset the boiler and check for 120 VAC at the ignitor plug during the start cycle. If there is no voltage, replace the faulty ignitor wire harness or the ignition control.

8.2Delayed Ignition — Possible Causes

A defective burner can cause a delayed ignition.

If the gas supply pressure is proper and the gas valves are functioning properly, then burners should be inspected. There should be no distortion or perforations in the burners outside of the active burner port area. Replace if indicated.

8.3Short Cycling — Boiler

Because the Copper Brute II is a stage-fired

boiler, and its input will decrease when there is a reduction in heating load, short cycling is greatly reduced. If the heating load drops below the minimum input of the boiler for an extended period, the boiler will have a tendency to short cycle. This can be a symptom of improper control strategy or setpoints, or

a load distribution problem. See Section 6.3 regarding controller setup. Contact your Bradford White representative to discuss possible remedies.

8.4Short Cycling — Water Heater

Short cycling will generally occur only in

combination space heating and water heating applications when the water heater is operating in the space-heating mode. Because the Copper Brute II is a stage-fired water heater and its input will reduce when there is a reduction in heating load, short cycling is greatly reduced. If the heating load drops below the minimum input of the water heater for an extended period, the water heater will have a tendency to short cycle. If short cycling is frequently experienced, regardless of the control’s attempt to limit it, the heating load should be redistributed to control it. See Section 6.3 regarding controller setup.

If short cycling occurs in a water heater application, it is probably caused by undersized piping between the water heater and the storage tank or by some other factor that restricts proper water flow through the water heater. The cause should be determined and corrected.

8.5High Gas Consumption

Appliances operating with an improper air/

fuel ratio are very inefficient and consequently, have very high gas consumption. Because efficiency is high when the CO2 is high (or O2 is low), appliances operating with low CO2or high O2 (especially LP appliances) consume more gas. Adjust the CO2 or O2 for optimum efficiency. If no combustion analyzing equipment (CO2 or O2) is available then a proper adjustment of the air/fuel ratio (CO2 or O2) cannot be accomplished. However, by briefly sniffing the flue gases it is possible to determine if the CO2 or O2 is within the proper range. No significant flue gas odor should be detected when combustion is proper. A strong piercing smell indicates poor combustion and generally a lean mixture - low CO2 or high O2 . The CO2 should be 8% at high fire. To check the CO2, first verify that the supply gas pressure is within 5" to 13" w.c. (1.2 to 3.2 kPa) With the Copper Brute II running with all stages firing, set the air box pressure to 1.5" w.c. (0.37 kPa) (as a starting point), by adjusting the air shutter(s) at the bottom of the fan(s). Check the CO2, and adjust the air shutters if further adjustment to the CO2 is needed. Sizes 1250 to 2000 have two blowers and two air chambers (boxes). The pressure of each air box must be equal when the final adjustment is made.

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Contents Copper Brute Table of Contents Operating Instructions MaintenanceTrouble Shooting Replacement PartsGeneral Information IntroductionModel Identification Warranty DimensionsLocating the Appliance Dimensional Data Inches 91cm horizontally Intake Combustion Air Venting and Combustion AirCombustion Air Combustion Air From RoomCommon Venting Systems VentingVent Categories Category I VentCombustion Air and Vent Through Side Wall Side Wall Combustion Air Terminal Locating Vent & Combustion Air TerminalsCategory III Vent Side Wall Vent TerminalVertical Combustion Air Terminal Common Vent Test BoilersVent Terminals for Outdoor Units Vertical Vent Terminal61-91m Gas Supply and Piping4A.3 Water Flow Requirements Boiler Water Connections Copper Brute II Boiler4A.1 Heating System Piping Hot Supply Connections Boiler 4A.2 Cold Water Make-Up 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.3 Water Flow Requirements Water Heater Water Connections Copper Brute II Water Heater4B.1 Water System Piping Water Heater 4B.2 Hot Water Supply Piping Water HeaterSupply 4B.5 Freeze Protection Water HeaterWater Heater Piping Multiple Heaters, One Tank Water Heater Piping Multiple Heaters, Multiple Tanks Main Power Temperature ControlElectrical 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 Operating Instructions Sequence of OperationFilling the Boiler System Parallel Piping Programming the Temperature ControlChoosing the Mode System Piping Primary Secondary 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 Staging Mode Advanced TopicsDifferential Pump Operation Boiler Target TemperatureBoiler Minimum Boil MIN Boiler Maximum Boil MAXOutdoor Reset Operation Setpoint OperationDedicated Domestic Hot Water Typical Gas Train Configuration External Boiler Operation Operating the Burner and Set UpAdvanced Programming Mode Set Up for 0 to 2500 Feet AltitudeHigh Altitude Adjustment and Set Up Shutting Down the Copper BruteTo Restart the Copper Brute Maintenance System Maintenance Appliance Maintenance Component Description Ignitors Temperature ControlFlow Switch Ignition ControlsBradford 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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