Bradford-White Corp BNTV, BNTH warranty SECTION Operating Instructions, Filling the Boiler System

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SECTION 10.

Brute Elite

Page 43

 

 

SECTION 10.

Operating Instructions

10.1 Filling the Boiler System

1.Ensure the system is fully connected. Close all bleeding devices and open make-up water valve. Allow system to fill slowly.

2.If make-up water pump is employed, adjust pressure switch on pumping system to provide a minimum of 12 psi (81.8 kPa) at the highest point in the heating loop.

3.If a water pressure regulator is provided on the make-up water line, adjust the pressure regulator to provide at least 12 psi (81.8 kPa) at the highest point in the heating loop.

4.Open bleeding devices on all radiation units at the high points in the piping throughout the system, unless automatic air bleeders are provided at such points.

Note that there is an air bleed located on the left side of Brute Elite, on top of the water manifold.

5.Cycle the boiler pump on and off 10 times, 10 seconds on and 10 seconds off to remove all air from the heat exchanger. Then run system and appliance pump for a minimum of 30 minutes with the gas shut off.

10.1 Filling the Boiler System WARNING

Failure to remove all air from the heat exchanger could lead to property damage, severe injury or death.

6.Open all strainers in the circulating system, check flow switch operation (if equipped), and check for debris. If debris is present, clean out to ensure proper circulation.

7.Recheck all air bleeders as described in Step 4.

8.Check liquid level in expansion tank. With the system full of water and under normal operating pressure, the level of water in the expansion tank should not exceed ¼ of the total, with the balance filled with air.

9.Start up boiler according to the procedure in this manual. Operate the entire system, including the pump, boiler, and radiation units for one (1) hour.

10.Recheck the water level in the expansion tank. If the water level exceeds ¼ of the volume of the expansion tank, open the tank drain, and drain to that level.

11.Shut down the entire system and vent all 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.Prime condensate trap with water (not required for BNTH 600, 750, 850).

15.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.

16.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. Main gas terminals will be energized, attempting to light, for four (4) seconds, and then will de-energize. The unit will go into lockout after the required number of trial for ignition periods.

Second, turn the power off, press the manual reset button on the boiler control, or the user display, 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.

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

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

10.2 Operating the Burner and Set Up 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.

10.2 Operating the Burner and Set Up

Initial 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 boiler resulting from improper setup is not covered by the limited warranty.

10.2.1 Burner Operation

REQUIRED TOOLS: differential pressure gauge capable of reading negative 0.01 inches W.C. (0.002kPa), screw drivers, torx bits, combustion analyzer.

1.Using this manual, make sure the installation is complete and in full compliance with the instructions and all local codes.

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

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Contents BRUTE ELITE Installation and Operation InstructionsDocument Installation and Operation Instructions forGeneral Information TABLE OF CONTENTSBrute Elite Control Setup and Operation SECTIONSECTION Modes of Operation SECTION MaintenanceTrouble Shooting Replacement PartsModel Nomenclature SECTION General Information1.1 Introduction 1.2 Model IdentificationFigure 2. Location of Components, Sizes Figure 1. Location of Components, SizesFigure 4. Location of Components, Size Figure 3. Location of Components, SizeFigure 6. Location of Components, Size Figure 5. Location of Components, SizeFigure 7. Location of Components, Sizes 750 and 1.5 Unpacking 1.4 Warranty1.6 Dimensions 1.3 Appliance OverviewDimensions are nominal and are shown in inches, cm Figure 9. Dimensional Drawing, SizesSECTION Locating the Appliance Brute Elite is for indoor installations only2.1 Locating the Appliance 3.1.2 Ducted Combustion Air SECTION Venting and Combustion Air3.1 Combustion Air 3.1.1 Combustion Air From RoomFigure 10. Combustion Air and Vent Through Roof 3.2 VentingTable 5. Required Exhaust Vent Material E. CPVC exhaust pipe section 80-500 not incl 3.3 Locating Vent & Combustion Air Terminals3.2.1 Venting Requirements Unique to Canada A. exhaust vent terminal not included3.3.3 Vertical Vent Terminal 3.3.5 Installations in the Commonwealth of Massachusetts3.3.2 Side Wall Combustion Air Terminal 5. For concentric vent, follow instructions included with vent kitFigure 12. Combustion Air and Vent Through Side Wall 4. Inspection 3.4 Common Vent Test2. Approved Carbon Monoxide Detectors 3. Signage4.1 Gas Supply and Piping SECTION Gas Supply and Piping3. Refer to Tables 6A, 6B, 6C and 6D to size piping Table 6A SECTION Pump Requirements5.1 Brute Elite Boiler Flow and Head Requirements see Table 5.2 Brute Elite Water Heater Flow and Head Requirements see Table6A.1 BNTH System Piping Hot Supply Connections SECTION 6A Water Connections - BNTH Boiler6A.2 BNTH Cold Water Make-Up 1. Sentinel Performance Solutions Group 2. Hercules Chemical Company 6A.4 BNTH Suggested Piping Schematics6A.3 Freeze Protection 6A.5 Recognized ChemicalsFigure 15. Hydronic Piping - Single Boiler zoning with circulators Page Figure 17. Hydronic Piping - Multiple Boilers zoning with circulators Page Brute ElitePage Page Brute ElitePage Water Connections - BNTV Water Heater SECTION 6B6B.1 BNTV Water Quality 6B.2 Piping Requirements6B.6 BNTV Suggested Pumps 6B.5 BNTV Suggested Piping Schematics6B.3 Cold Water Make-Up 6B.4 Freeze Protectionwater hardness at job site Figure 25. DHW Piping, Two Heaters, One Vertical TankFigure 26. DHW Piping, Two Heaters, Two Vertical Tanks Caution Pump sizing must be based oponSECTION Electrical Connections 7.1 Main Power7.4 Hydronic Call for Heat 7.10 Lead Lag/ Cascading Wiring Connections7.2 Pump Connections 7.3 24Vac Transformer with Integral Circuit BreakerFigure 28. Lead-Lag / Cascading Wiring Connections Figure 29. Ladder Diagram 7.11 Wiring Diagrams see Figures 29 andFigure 30. Wiring Diagram all sizes 8.1 Display Navigation SECTION Brute Elite Control Setup and Operation8.2 Ignition Control- Sequence of Events 8.7 Outlet Water Temperature 8.3 Modulation Control8.5 Anti-Short Cycle ASC 8.5 High Limit8.12.2 Lead Lag Master/Slave Selection 8.12.5 Lead Lag Base Load Setting8.13 Boiler Pump Interrupt 8.12.1 Lead Lag Setpoint9.1 Hydronic Heating Demand 9.2 Hydronic Heating with Outdoor Reset9.4 Hydronic Heating Using External Modulation Control SECTION Modes of OperationLet’s consider the following example 9.5 Hydronic Heating Using Local Lead- Lag/Cascading Feature9.7 Warm Weather Shutdown 9.8 Domestic Hot Water Demand BNTV only9.9 Domestic Hot Water Heating Using External Modulation Control 10.2.1 Burner Operation 10.2 Operating the Burner and Set UpSECTION Operating Instructions 10.1 Filling the Boiler System3. WAIT FIVE 5 MINUTES 10.2.2 Boiler Setup and Adjustment10.3 Shutting Down Brute Elite 10.4 To Restart Brute EliteFigure 33A. Brute Elite Gas Valves 285, 399 and 80-285Figure 33B. Brute Elite Gas Valves 600, 750 and yearly, unless otherwise noted SECTION Maintenance11.1 System Maintenance 11.2 Appliance Maintenance and Component Description11.2.5 Flame Sensor 11.2.4 Ignitor AssemblyIgniters and sensors get hot and can cause burns or injury 11.2.7 Blower 11.2.6 Transformer with Integral Circuit Breaker11.2.8 Heat Exchanger Coils 12.1 Sequence of Operation SECTION Trouble Shooting12.3 Error Codes - See Table 11.2.9 Gas Pressure Switches optionalCODE# PROBLEMSOLUTION continued next pagesee Section Table 18. Error CodesJacket Components - See Figure SECTION Replacement Parts13.2 Parts List 13.1 General InformationGas Train Components - See Figure Heat Exchanger Components - See Figure Electrical Components - See Figure Contact Customer Service at 800 900-9275Figure 35. Jacket Components Figure 36B. Internal Components, Sizes Figure 36A. Internal Components, SizesFigure 36C. Internal Components, Sizes Figure 37A. Gas Train Components, Sizes Figure 37B. Gas Train Components, Sizes Figure 38. Heat Exchanger Components Figure 39. Electrical Components Page Ambler, PA Tech. Service 800Service Parts 800 Warranty Service 800
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