and boilers ordered with low temperature controls. To replace the switch, shut off the 120-volt power to the appliance. Remove the cover from the switch to access the mounting screws. Remove the screws, and pull the switch off the control panel. Remove the capilliary and bulb from the thermal well located in the header. Replace in reverse order.
7.2.6 Temperature Control
The temperature control is a Bradford White LHSC. To replace the control, shut off the 120-volt power to the appliance. Remove the cover from the control panel, and remove the mounting screws to remove the controller. Replace in reverse order.
7.2.7 Ignition Controls
The ignition controls ensure the proved interrupted-type ignition system. They control the hot surface ignitors and prove that the flame signal is appropriate for powering the gas valves. It also controls the blower’s pre-purge and post-purge. Copper Brute II sizes 500 and 750 have one ignition control. Sizes 1000 to 2000 have two ignition controls. On sizes 1000, one ignition control controls stages 1 and 2, and the second ignition control controls stage 3. On sizes 1250–2000, one ignition control is for stages 1 and 2, and the other is for stages 3 and 4.
To replace a control, shut off the 120-volt power to the appliance. Remove the cover from the control panel. Remove the electrical connectors from the ignition control. Take out the controller’s mounting screws, and pull the controller out. Replace in reverse order.
7.2.8 Ignitors
The ignitors used are 120v “Hot Surface” type. They are energized whenever there is a call for heat and switched off when ignition is established and the flame has been sensed. Copper Brute II sizes 500 and 750 have one ignitor. Sizes 1000 to 2000 have two ignitors. To replace the ignitor, shut off the 120-volt power to the appliance, remove the ignitor access panel, disconnect the Molex connector, remove the two mounting screws on the ignitor flange, and pull the ignitor out. Install in reverse order, always using a new ignitor gasket with the replacement ignitor.
Caution
Ignitor gets hot.
7.2.9 Ignition Sensors
The ignition sensors ensure that the main flame is ignited, so that raw gas is not allowed to fill the combustion chamber. Copper Brute II sizes 500 and 750 have one sensor. Sizes 1000 to 2000 have two sensors (one for each ignition control). The ignitors are the ignition sensors on Copper Brute II appliances. There are no separate ignition sensors.
7.2.10 Transformer
The Copper Brute II’s transformer is not capable of supplying control voltage for external devices such as zone valves, which must have their own separate power supply. Should a transformer need replacing, shut off the 120-volt power. Unplug the transformer wires, remove the mounting screws and remove the transformer. Replace transformer in the reverse order.
7.2.11 Blowers
The combustion air blowers bring the combustion air for the Copper Brute II from the upper chamber to the lower chamber. Mixing of the gas and air occurs in the burners. Sizes 500, 750 and 1000 each have one blower, and sizes 1250 to 2000 each have two blowers (one blower for stages 1 and 2, and one for stages 3 and 4). If a blower change is required, turn off the
120-volt power and gas supply to the unit. Remove the front panel. Disconnect the blower's wire harness. Remove the screws at the blower flange, and pull the blower out. Replace blower in reverse order, ensuring that all joints are made correctly. After replacement, ensure that the unit operates properly, by following the set-up procedure in this manual.
7.2.12 Flow Switch
The Copper Brute II uses a paddle-type flow switch to ensure that the unit has water flow before ignition is allowed.
7.2.13 Heat Exchanger Coil
WARNING
Black carbon soot buildup on a dirty heat exchanger can be ignited by a random spark or flame, thereby creating a risk of fire or explosion.. To prevent this from happening, dampen the soot deposits with a wet brush or fine water spray before servicing the heat exchanger.
The Copper Brute II has a pre-mixed burner system. These systems provide the burners with sufficient air for complete combustion, and black carbon sooting is seldom experienced. If sooting is suspected, view ports for inspection of the heat exchanger are provided on both sides of the boiler. They are located below the headers, and are accessed by opening the small round cover that is attached by one screw. In the unlikely event that there is a buildup of black carbon soot or other debris on the heat exchanger, clean per the following:
1.Disconnect the electrical supply to the unit.
2.Turn off the gas supply by closing the manual gas valve on the heater.
3.Disconnect and remove the wires, conduit and sensors from all components that are attached to the inlet/outlet header.
4.Isolate the heat exchanger from the water supply.
5.Disconnect header flanges from inlet and outlet.
