Bradford-White Corp BWCH, BWCV warranty Operating the Burner and Set Up, External Boiler Operation

Page 46 BRADFORD WHITE CORP.

The control then operates the boiler stages to maintain the programmed boiler target temperature. The reset override operation is not affected by WWSD.

6.4.10 External Boiler Operation

When mode 6 is selected, the control allows for an external control to operate the Copper Brute II’s stages. In this mode, the control operates the pump in order to provide purging and exercising. The staging operation is provided by an external device such as an Energy Management System (EMS) or External Staging Control.

Heat Demand – A heat demand is generated when stage one is wired properly, and the external control closes the contacts on the stage one terminals (1C-1NO), calling the Copper Brute II for heat. The Copper Brute II is shipped with a jumper between the Com D and Ht D terminals, and this jumper must remain in place when and external control is providing the heat demand signal to these terminals. The control energizes the boiler pump (if equipped), energizes the Pmp-Pmp terminals, and turns on the boiler pump segment in the display. The control also turns on stage 1 of the boiler. 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.

6.4.11 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 32). 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.

6.4.12Advanced 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.

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.

6.5 Operating the Burner and Set Up

6.5.1Set 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 appliance power switch located on the right side of the unit.

5.The Copper Brute II 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 Copper Brute II 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 Copper Brute II.

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 appliance in operation, the Burner Safety Shutoff Device must be tested.

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

To test:

(a)Close gas shutoff valve with burner operating.