Bradford-White Corp BWCV Operating the Burner and Set Up, Internet Version for Reference Only

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Internet Version for Reference Only

Copper Brute II

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signal to these terminals. The control energizes the heater pump (if equipped), energizes the Pmp-Pmp terminals, and turns on the heater pump segment in the display. The control also turns on stage 1 of the heater. 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.

6.3.11 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 17). 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.

6.3.12Advanced 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.

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.

6.4Operating the Burner and Set Up

6.4.1 Set 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 heater power switch located on the right side of the unit.

5.The heater 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 heater 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 heater.

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 heater in operation, the Burner Safety Shutoff Device must be tested. To test:

(a)Close gas shutoff valve with burner operating.

(b)The flame will go out and blower will continue to run for the post purge cycle. One additional attempt to light will follow. Ignition will not occur as the gas is off. The ignition control will lockout, and will have to be reset before the unit will operate.

(c)Open gas shutoff valve. Restart the appliance. The ignition sequence will start again and the burner will start. The appliance will return to its previous mode of operation.

NOTE: Models 1000 - 2000 have two ignition controls and two ignitors, which work independently of one another. If the ignition control for stages 1 and 2 fails to properly light the main burners for those stages, the second ignition control will still be active, and will be able to energize stages 3 and 4. This, of course, will only occur if all other safety devices confirm that the unit will run in a safe condition.

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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 Diagrams1.2 Model Identification SECTION General Information1.1 Introduction 1.5 Locating the Appliance 1.4 Dimensions1.3 Warranty 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 Wiring6.2 Programming the Temperature Control SECTION Operating Instructions6.1 Sequence of Operation “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 Topics6.3.3 Boiler Minimum BOIL MIN 6.3.1 Differential6.3.2 Staging Mode 6.3.5 Boiler Target Temperature 6.3.4 Boiler Maximum BOIL MAX6.3.6 Pump Operation 6.3.7 Set point Operation6.3.10 External Heater Operation 6.3.9 Outdoor Reset OperationOutdoor Design OUTDR DSGN - The 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 terminal designations are as indicated Note Positions of field wiring terminals may vary, butFigure 23. Field Wiring 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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