Bradford-White Corp BWCV Internet Version for Reference Only, Boiler Start BOIL START The BOIL

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Boiler Start (BOIL START) The BOIL

Internet Version for Reference Only

Copper Brute II

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PUMP DLY (Pump Delay): On pump mounted units, the heater mounted pump continues to run for the time selected after the heat demand in the system is satisfied. This setting also affects the 24VAC output on the “PMP” “PMP” terminals (see section 5.2). These terminals can power a contactor for a larger system pump. Bradford White recommends a minimum pump delay setting of 5 minutes. See section 6.3.6 for more information. Note: In modes other than mode 6, the pump will run continuously if the “HtD” and “ComD” terminals are jumpered and not connected to a zone valve or pump end switch, or other “contact closure” device to indicate when the heat demand in the system is satisfied. The pump will never run, and the heater will never fire, if the jumper is removed and the terminals left empty.

OUTDOOR RESET (Modes 4 and 5) Outdoor reset adjusts the target temperature based on the outdoor air temperature and reset ratio. The reset ratio is determined from the Boiler Start, Boiler Design, Outdoor Start and Outdoor Design settings.

HEAT DEMAND – For heat demand to exist, there must be continuity between the Com D (common demand) and Ht D (heat demand) terminals. The heater ships with a jumper between these terminals.

The control also evaluates the sensor(s) installed in the system. If the control is not in warm weather shutdown (WWSD), and the sensor(s) are below the target temperature, the “Dem” segment is turned on in the display. The control energizes the pump (on pump mounted heater) and energizes the “PMP-PMP” terminals. The pump symbol appears in the display (see Figures 10 and 11). The control then operates the stages to maintain the set point temperature.

Boiler Start (BOIL START) The BOIL

START temperature is the theoretical heater supply temperature that the heating system requires when the outdoor air temperature equals the OUTDR START temperature setting.

EXAMPLE 1

DHW (Mode 3) Programming. For domestic hot water systems up to 175°F / 79°C, use Mode 3 as described below.

Step 1: Install the additional sensor into the

storage tank, wiring it to “SC2” and “SUPS” terminals on the field wiring panel (Figure 24).

Step 2: Press the three programming buttons to enter “ADJUST” mode (Figure 10). Press “Item” to select the programming item, and the arrow keys to adjust the setting. “TARGET TANK” is desired tank temperature. Recommended settings with a desired tank temperature of 125°F:

Example DHW Programming

Item

F°

C°

MODE

3

3

BOIL TARGET

140°F

60°C

TARGET TANK

125°F

52°C

DIFF TANK

2°F

1°C

BOIL MASS

1

1

DIFF

2°F

1°C

DLY

5:00

5:00

F°

F°

°C

Step 4: See section 6.3.11 Limit Controls. Set both high limits 25°F / 14°C higher than “BOIL TARGET” to allow for temperature rise across heat exchanger. Manual high limits on water heaters have a maximum 200°F / 93°C setting. (If water must be at 175°F / 79°C or higher with a volume water heater model, use Mode 1. For volume water applications exceeding 200°F / 93°C, contact the factory.)

Fine tuning: For faster staging, increase “BOIL TARGET” setting. Larger “DIFF TANK” and “DIFF” settings will slow response to demand, but may save energy.

If unit short cycles, enter Advanced Programming mode (Section 6.3) and increase “BOILER MAX” setting to the “BOIL TARGET” setting or higher. Set “BOILER MIN” to 120°F / 49°C, and “STGMODE” to PID. See section 6.3.12 Advanced Programming Mode to enter Advanced Programming mode, or contact the factory for assistance.

EXAMPLE 2

Hydronic Primary/Secondary (Mode 2) Programming. MODE 2 is used in primary-secondary piping hydronic systems without outdoor reset. Mode 5 adds outdoor reset.

Step 1: Install the additional sensor in the primary loop. This sensor should be installed as per Section 6.2.4 under Primary Secondary Piping in this manual, and wired to the “SC2” and “SUPS” terminals on the field wiring panel (Figure 24).

Step 2: Remove the factory-installed jumper between the “HtD” and “ComD” terminals on the field wiring panel (Figure 24), and connect a zone valve or pump end switch or other contact closure device (aquastat, etc.) to these terminals to provide an indication of heat demand in the system.

Note: The heater must have an indication of heat demand to fire. If a zone valve or pump end switch is not connected to the “HtD” and “ComD” terminals, the jumper must be left in place. However, the heater pump (if equipped) and any pump connected to a contactor wired to the PMP-PMP terminals on the field wiring panel will run continuously and not cycle off according to the setting for the Pump Delay. In addition, the LCD screen will always show “dem” (demand) and will not allow cycling of the display to verify all the sensor settings.

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Contents Copper Brute Internet Version for Reference OnlyInstallation and Operation Instructions for Installation and Operation InstructionsSECTION 9. Wiring Diagrams TABLE OF CONTENTSSECTION 7. Maintenance SECTION 8. Trouble Shooting1.2 Model Identification SECTION General Information1.1 Introduction 1.5 Locating the Appliance 1.4 Dimensions1.3 Warranty Figure 1. Dimensional Data 2.1 Combustion Air SECTION Venting and Combustion Air1.6 Locating Pump-Mounted Water Heater with Respect to Storage Tanks From Outside Wall2.1.2 Intake Combustion Air 2.2.3 Common Venting Systems 2.2 Venting2.2.1 Vent Categories 2.2.2 Category I VentFigure 3. Combustion Air and Vent Through Side Wall 2.3.2 Side Wall Combustion Air Terminal 2.3 Locating Vent & Combustion Air TerminalsImportant Note Massachusetts Code Requirement 2.3.1 Side Wall Vent Terminal2.3.4 Vertical Combustion Air Terminal 2.4 Common Vent Test2.5 Vent Terminals for Outdoor Units 2.3.3 Vertical Vent Terminal3.1 Gas Supply and Piping SECTION Gas Supply and Piping4.3 Water Flow Requirements - Water Heater SECTION Water Connections Copper Brute II Water Heater4.1 Water System Piping Water Heater 4.2 Hot Water Supply Piping - Water HeaterFigure 4. Water Heater Piping - One Heater, One Tank Table 8. Water Flow RequirementsFigure 5. Water Heater Piping - Multiple Heaters, One Tank Figure 6. Water Heater Piping - One Heater, Multiple Tanks Figure 7. Water Heater Piping - Multiple Heaters, Multiple Tanks 4.5 Freeze Protection - Water Heater 5.1 Main PowerSECTION Electrical Connections 4.4 Combined Water Heating potable and Space Heating - Water HeaterAVERTISSEMENT 5.3 External Staging Control Wiring6.2 Programming the Temperature Control SECTION Operating Instructions6.1 Sequence of Operation 6.2.3 Programming 6.2.1 System Piping “Primary Secondary Piping”“Parallel Piping” 6.2.2 Choosing the Mode6.3.3 for more information BOIL MAX Boiler Maximum Temperature Boiler Start BOIL START The BOIL Mechanical aquastat in a domestic hot water storage tank 6.2.4 Choosing the Mode for your ApplicationMode 5 Primary secondary piping with outdoor reset 6.3 Advanced Topics6.3.3 Boiler Minimum BOIL MIN 6.3.1 Differential6.3.2 Staging Mode 6.3.7 Set point Operation 6.3.4 Boiler Maximum BOIL MAX6.3.5 Boiler Target Temperature 6.3.6 Pump Operation6.3.10 External Heater Operation 6.3.9 Outdoor Reset OperationOutdoor Design OUTDR DSGN - The 6.3.12 Advanced Programming Mode 6.4 Operating the Burner and Set Up6.4.1 Set Up for 0 to 2500 Feet Altitude 6.3.11 Limit Controls6.6 To Restart the Copper Brute SECTION Maintenance7.1 System Maintenance 6.5 Shutting Down the Copper Brute7.2 Appliance Maintenance and Component Description 7.2.2 Filter 7.2.4 Manual Reset High Limit Control7.2.5 Automatic Reset High Limit Control 7.2.1 Burners7.2.11 Blowers 7.2.12 Flow Switch7.2.9 Ignition Sensors 7.2.10 Transformer8.3 Short Cycling SECTION Trouble Shooting8.1 Resolving Lockouts 8.2 Delayed Ignition - Possible CausesDESCRIPTION OF ERROR ERROR DISPLAYED8.6 Troubleshooting Copper Brute II Controls Figure 18. Copper Brute II 500 - 750 Ladder Diagram SECTION Wiring DiagramsFigure 19. Copper Brute II 1000 Ladder Diagram Figure 20. Copper Brute II 1250 - 2000 Ladder Diagram Figure 21. Copper Brute II 500 - 1000 Wiring Schematic Figure 22. Copper Brute II 1250 - 2000 Wiring Schematic terminal designations are as indicated Note Positions of field wiring terminals may vary, butFigure 23. Field Wiring MODE Reference OnlyWiring for Modes 1 Figure 24. FieldCopper Brute II 1250, 1500, 1750 & 2000 4-Stage Heater Version for Reference Only25. Field Wiring for Mode Internet
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