Bradford-White Corp BWCV warranty Advanced Topics, Internet Version for Reference Only

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Internet Version for Reference Only

Copper Brute II

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If the heater is not a pump mounted model, a 24VAC pump contactor may be connected to the “PMP” terminals to control a field installed pump.

Program the temperature control to use “Mode 2.” The AUTO/MAN switch must be in the AUTO position in this mode.

Mode 4: Hydronic outdoor reset system without primary / secondary piping.

Bradford White strongly suggests the use of primary secondary piping with the Copper Brute II heater. This piping style best ensures that the Copper Brute II will have proper water flow. However, non- primary secondary methods can be used successfully, so this section has been included.

Install the outdoor reset sensor, Bradford White part number R2014000, and connect the leads to the “OD S” and “S C2” terminals.

You must provide an indication of the system’s heat demand by removing the jumper across the “ComD” and “HtD” terminals on the field wiring panel and connecting a zone valve or zone pump end switch, thermostat, aquastat or other contact closure to these terminals. If the “ComD” and “HtD” terminals are left jumpered, the control will always see a heat demand and remain in “Dem” mode, with the boiler pump running continuously. See Section 5.2 for more information.

Reset Override: An additional thermostat or aquastat may be connected to the “Set D” and “Com D” terminals. A call for heat from either of these controls will start the heater’s pump and cause the heater to fire.

If the heater is not a pump mounted model, a 24VAC pump contactor may be connected to the “PMP” terminals to control a field installed pump.

Program the temperature control to use “Mode 4.” The AUTO/MAN switch must be in the AUTO position in this mode.

Mode 5: Primary secondary piping with outdoor reset.

Install the outdoor reset sensor, Bradford White part number R2014000, and connect the leads to the “OD S” and “S C2” terminals. Install a “supply sensor” in the primary loop using the Bradford White part number R2014800 sensor (included with every heater). Connect the sensor to the “S C2” and “SUP S” terminals.

You must provide an indication of the system’s heat demand by removing the jumper across the “ComD” and “HtD” terminals on the field wiring panel and connecting a zone valve or zone pump end switch, thermostat, aquastat or other contact closure to these terminals. If the “ComD” and “HtD” terminals are left jumpered, the control will always see a heat demand and remain in “Dem” mode, with the heater pump running continuously. See Section 5.2 for more information.

A secondary aquastat, such as for a separate heat exchanger for DHW, can be connected to the “Set D” and “Com D” terminals. A call for heat from these controls will start the heater pump and cause the heater to fire.

If the heater is not a pump mounted model, a 24VAC pump contactor may be connected to the “PMP” terminals to control a field installed pump.

Program the temperature control to use “Mode 5.” The AUTO/MAN switch must be in the AUTO position in this mode.

Mode 6: Heater with external staging control (multiple boiler control, building automation system, energy management system, etc.)

Leave the jumper installed between “Ht D” and “Com D” terminals. There are terminals on the field wiring panel that must be wired per the instructions in section 5.3 of this manual. Other wiring methods may be unsafe. The wiring in section 5.3 of this manual must be used.

The AUTO/MAN switch is located on the circuit board in the slide-out control panel on the front of the heater. This switch is placed in the manual position (MAN) when an external control is controlling the heater stages.

Program the temperature control to use Mode 6. Mode 6 tells the heater control that an external staging control is being used.

6.3 Advanced Topics

For most installations, section 6.2 provides all the information required to set up the Copper Brute II heater, and this section should be skipped. Continue setup in section 6.4.

This section provides definitions of the

programming parameters, advanced programming topics, and other information that may be of interest. 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 not required in most applications, and is intended for advanced installers only.

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 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.

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Contents Installation and Operation Instructions for Internet Version for Reference OnlyInstallation and Operation Instructions Copper BruteSECTION 7. Maintenance TABLE OF CONTENTSSECTION 8. Trouble Shooting SECTION 9. Wiring Diagrams1.1 Introduction SECTION General Information1.2 Model Identification 1.3 Warranty 1.4 Dimensions1.5 Locating the Appliance Figure 1. Dimensional Data 1.6 Locating Pump-Mounted Water Heater with Respect to Storage Tanks SECTION Venting and Combustion AirFrom Outside Wall 2.1 Combustion Air2.1.2 Intake Combustion Air 2.2.1 Vent Categories 2.2 Venting2.2.2 Category I Vent 2.2.3 Common Venting SystemsFigure 3. Combustion Air and Vent Through Side Wall Important Note Massachusetts Code Requirement 2.3 Locating Vent & Combustion Air Terminals2.3.1 Side Wall Vent Terminal 2.3.2 Side Wall Combustion Air Terminal2.5 Vent Terminals for Outdoor Units 2.4 Common Vent Test2.3.3 Vertical Vent Terminal 2.3.4 Vertical Combustion Air Terminal3.1 Gas Supply and Piping SECTION Gas Supply and Piping4.1 Water System Piping Water Heater SECTION Water Connections Copper Brute II Water Heater4.2 Hot Water Supply Piping - Water Heater 4.3 Water Flow Requirements - 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 SECTION Electrical Connections 5.1 Main Power4.4 Combined Water Heating potable and Space Heating - Water Heater 4.5 Freeze Protection - Water HeaterAVERTISSEMENT 5.3 External Staging Control Wiring6.1 Sequence of Operation SECTION Operating Instructions6.2 Programming the Temperature Control “Parallel Piping” 6.2.1 System Piping “Primary Secondary Piping”6.2.2 Choosing the Mode 6.2.3 Programming6.3.3 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 Topics6.3.2 Staging Mode 6.3.1 Differential6.3.3 Boiler Minimum BOIL MIN 6.3.5 Boiler Target Temperature 6.3.4 Boiler Maximum BOIL MAX6.3.6 Pump Operation 6.3.7 Set point OperationOutdoor Design OUTDR DSGN - The 6.3.9 Outdoor Reset Operation6.3.10 External Heater Operation 6.4.1 Set Up for 0 to 2500 Feet Altitude 6.4 Operating the Burner and Set Up6.3.11 Limit Controls 6.3.12 Advanced Programming Mode7.1 System Maintenance SECTION Maintenance6.5 Shutting Down the Copper Brute 6.6 To Restart the Copper Brute7.2 Appliance Maintenance and Component Description 7.2.5 Automatic Reset High Limit Control 7.2.4 Manual Reset High Limit Control7.2.1 Burners 7.2.2 Filter7.2.9 Ignition Sensors 7.2.12 Flow Switch7.2.10 Transformer 7.2.11 Blowers8.1 Resolving Lockouts SECTION Trouble Shooting8.2 Delayed Ignition - Possible Causes 8.3 Short CyclingDESCRIPTION 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 Figure 23. Field Wiring Note Positions of field wiring terminals may vary, butterminal designations are as indicated Wiring for Modes 1 Reference OnlyFigure 24. Field MODE25. Field Wiring for Mode Version for Reference OnlyInternet Copper Brute II 1250, 1500, 1750 & 2000 4-Stage Heater
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