Instruction/ maintenance manual of the product BWCH Bradford-White Corp
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Installation and Operation Instructions Document 1270 H2214401F Installation and Operation Instructions for W ARNING If the information in this manual is not followed exactly , a re or explosion may result causing property damage, personal injury or loss of life.
Page 2 B RADFORD W HITE C ORP . SECTION 1. General Information 1.1 Introduction ...................................................... 4 1.2 Model Identication .......................................... 4 1.3 W arranty .............................
Page 3 COPPER BRUTE II (500 - 2000) SECTION 6. Operating Instructions 6.1 Sequence of Operation .................................. 36 6.2 Filling the Boiler System ................................ 36 6.3 Programming the T emperature Control ......... 37 6.
Page 4 B RADFORD W HITE C ORP . SECTION 1. General Information USING THIS MANUAL – Because the Copper Brute II Boilers and Copper Brute II W ater Heaters are identical appliances, with the exception.
Page 5 COPPER BRUTE II (500 - 2000) Model Character Designation 1-3 Model Series Designation B W C = Bradfrod White, Copper Brute II 4 Usage H = Hydronic V = V olume W ater 5-8 Size 0 5 0 0 = 500,000 .
Page 6 B RADFORD W HITE C ORP . Figure 1. Dimensional Data. SHIPPING WEIGHT SIZE lbs. kg 500 425 193 750 505 229 1000 615 279 1250 675 306 1500 760 345 1750 825 375 2000 955 434 *Add 55 lbs. (25kg) for pump-mounted units. AIR VENT HORIZ. A B C D E F G H CONN.
Page 7 COPPER BRUTE II (500 - 2000) 1.6 Locating Pump-Mounted W ater Heater with Respect to Storage T ank(s) For best results, a pump-mounted Copper Brute II water heater should be located within 15 feet (4.6m) of the storage tank(s). The pump is sized for 30 feet (9.
Page 8 B RADFORD W HITE C ORP . Figure 2. Combustion Air and V ent Through Roof. EACH OPENING* SIZE SQUARE INCHES SQUARE CM 500 125 807 750 188 1213 1000 250 1613 1250 313 2020 1500 375 2420 1750 438 .
Page 9 COPPER BRUTE II (500 - 2000) length allowed is 50 feet (15.2m). Three elbows have been calculated into the 50-foot (15.2m) linear run. Subtract 10 allowable linear feet (3.0m) for every additional elbow used (see T able 2 ). When fewer than 3 elbows are used, the maximum linear pipe length allowed is still 50 feet (15.
Page 10 B RADFORD W HITE C ORP . U.S. Installations (see note 1) Canadian Installations (see note 2) A = Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony B = Clearance to window or door that may be 4 feet (1.
Page 1 1 COPPER BRUTE II (500 - 2000) appliances. If assistance is required in determining how a blocked vent safety system should be connected to a Bradford White product, please call Applications Engineering at the Rochester phone number listed on back cover of this manual.
Page 12 B RADFORD W HITE C ORP . 2.3.3 V ertical V ent T erminal When the unit is vented through the roof, the vent must extend at least 3 feet (0.9m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6m) higher than any portion of a building within a horizontal distance of 10 feet (3.
Page 13 COPPER BRUTE II (500 - 2000) DIST ANCE FROM GAS METER OR LAST ST AGE REGULA TOR SIZE AND GAS TYPE 0-100' 0-31m 100-200' 31-61m 200-300' 61-91m 500 natural 1-1/2" 3.8cm 2" 5.1cm 2" 5.1cm 500 propane 1" 2.5cm 1-1/2" 3.
Page 14 B RADFORD W HITE C ORP . 20°F 25°F 30°F 35°F SIZE ow H/L ow H/L ow H/L ow H/L gpm feet gpm feet gpm feet gpm feet 500 43 1.7 34 1.1 28 0.9 24 0.7 750 64 3.3 51 2.3 43 1.7 36 1.2 1000 85 5.0 68 3.6 57 3.1 49 2.2 1250 106 8.1 85 6.
Page 15 COPPER BRUTE II (500 - 2000) PRIMARY/SECONDAR Y MANDITORY FOR ALL V ARIABLE FLOW SYSTEMS INST ALL AIR VENTS AT HIGH POINTS IN SYSTEM PIPIN G& SIZING OF EXP ANSION T ANK PER T ANK MANUFACTURER'S INSTRUCTIONS DIMENSION "C" (COMMON PIPING) TO BE FOUR PIPE DIAMETERS, MAX.
Page 16 B RADFORD W HITE C ORP . PRIMARY/SECONDAR Y MANDITORY FOR ALL V ARIABLE FLOW SYSTEMS INST ALL AIR VENTS AT HIGH POINTS IN SYSTEM PIPING & SIZING OF EXP ANSION T ANK PER T ANK MANUFACTURER'S INSTRUCTIONS DIMENSION "C" (COMMON PIPING) TO BE FOUR PIPE DIAMETERS, MAX.
Page 17 COPPER BRUTE II (500 - 2000) Figure 6. Hydronic Piping — One Boiler , Multi-T emperature System. PRIMARY/SECONDAR Y MANDITORY FOR ALL V ARIABLE FLOW SYSTEMS INST ALL AIR VENTS AT HIGH POINTS.
Page 18 B RADFORD W HITE C ORP . LEGEND CHECK VA LV E THERMOMETER TEMPERA TURE SENSOR GLOBE VA LV E EXP ANSION T ANK WITH AIR SCOOP AND AUTO AIR VENT 3-W AY VA LV E VA LV E CAUTION: THIS DRA WING SHOWS SUGGESTED PIPING CONFIGURA TION AND VA L VING , CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS.
Page 19 COPPER BRUTE II (500 - 2000) LEGEND CHECK VA LV E THERMOMETER TEMPERA TURE SENSOR GLOBE VA LV E EXP ANSION T ANK WITH AIR SCOOP AND AUTO AIR VENT 3-W AY VA LV E VA LV E PRESSURE REDUCING VA LV.
Page 20 B RADFORD W HITE C ORP . SECTION 4B. W ater Connections — Copper Brute II W ater Heater 4B.1 W ater System Piping — W ater Heater Hot water piping should be supported by suitable hangers or oor stands. Do not support piping with this appliance.
Page 21 COPPER BRUTE II (500 - 2000) Figure 9. W ater Heater Piping — One Heater , One T ank. NOTES: 6. CAUTION: PUMP SIZING MUST BE BASED UPON WA TER HARDNESS AT JOB SITE 1. OPTIONAL CWMU & RECIRC. LINE LOCA TION. 2. LOCA TE PENNANT DHW SENSOR OR REMOTE AQUAST AT WELL IN LOWER 1/3 OF T ANK.
Page 22 B RADFORD W HITE C ORP . Figure 10. W ater Heater Piping — Multiple Heaters, One T ank. Figure 1 1. W ater Heater Piping — One Heater , Multiple T anks.
Page 23 COPPER BRUTE II (500 - 2000) GPM FT TEMP RISE °F LPM M TEMP RISE°C SIZE S N H S N H S N H S N H S N H S N H 500 45 68 90 1.8 2.3 3.5 19 13 9 170 257 341 0.5 0.7 1.1 10 7 5 750 45 68 90 2.1 3.0 6.0 28 19 14 170 257 341 0.
Page 24 B RADFORD W HITE C ORP . SINGLE CIRCUIT CONNECTIONS PUMP HEA TER ONL Y W/O PUMP WITH PUMP 500 15 20 15 750 15 20 15 1000 20 25 15 1250 25 30 15 1500 25 30 15 1750 25 — 15 2000 25 — 20 T able 10. Electrical Data. Figure 13. Removing Jumpers.
Page 25 COPPER BRUTE II (500 - 2000) Figure 14. Field Wiring Panel Figure 15. External Control Connection Wiring. with the Copper Brute II is installed in the piping or tank, per the suggested piping diagrams, and connected to the “S C2” and “SUP S” terminals.
Page 26 B RADFORD W HITE C ORP . additional components. 5.3 External Staging Control Wiring W ARNING Improper eld wiring may result in re or explosion which can cause property damage, severe injury , or death. Make only wiring connections which are in accordance with the Installation and Operation manual.
Page 27 COPPER BRUTE II (500 - 2000) Figure 16. Copper Brute II 500 - 750 Ladder Diagram..
Page 28 B RADFORD W HITE C ORP . Figure 17. Copper Brute II 1000 Ladder Diagram..
Page 29 COPPER BRUTE II (500 - 2000) Figure 18. Copper Brute II 1250 - 2000 Ladder Diagram..
Page 30 B RADFORD W HITE C ORP . Figure 19. Copper Brute II 500 - 1000 Wiring Schematic..
Page 31 COPPER BRUTE II (500 - 2000) Figure 20. Copper Brute II 1250 - 1500 Wiring Schematic..
Page 32 B RADFORD W HITE C ORP . Figure 21. Copper Brute II 1750 - 2000 Wiring Schematic..
Page 33 COPPER BRUTE II (500 - 2000) Figure 22. Field Wiring. Note: Positions of eld wiring terminals may vary , but terminal designations are as indicated.
Page 34 B RADFORD W HITE C ORP . Figure 23. Field Wiring for Modes 1 - 5. Note: Positions of eld wiring terminals may vary , but terminal designations are as indicated.
Page 35 COPPER BRUTE II (500 - 2000) Figure 24. Field Wiring for Mode 6. 1C 1NO 2C 2NO 3C 3NO 4C 4NO 4C 3C 4NO 3NO 2C 1C 2NO 1NO 4s tage boiler using 4 control outputs 4s tage boiler using 2 control o.
Page 36 B RADFORD W HITE C ORP . SECTION 6. Operating Instructions 6.1 Sequence of Operation A call for heat can be initiated either automatically (auto mode) under thermostatic control by the Copper Brute II temperature control, or by an external contact closure (manual mode).
Page 37 COPPER BRUTE II (500 - 2000) radiation units and high points in the system piping, as described in Step 4. 12. Close make-up water valve and check strainer in pressure reducing valve for sediment or debris from the make-up water line. Reopen make-up water valve.
Page 38 B RADFORD W HITE C ORP . APPLICA TION MODE SYSTEM SETTING SENSORS USED • Parallel piping (non- primary/secondary) hydronic system 1 • None • DHW with or without a tank aquastat • Prima.
Page 39 COPPER BRUTE II (500 - 2000) Figure 27. T emperature Control T arget T emperature Graph. delay setting of 5 minutes. See Section 6.4.6 for more information.
Page 40 B RADFORD W HITE C ORP . 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 (see Figure 4 ), and wired to the “SC2” and “SUPS” terminals on the eld wiring panel (Figure 23).
Page 41 COPPER BRUTE II (500 - 2000) Caution If the tank temperature control is set too high, a potential for hot water scalding may exist. Mode 2: Primary secondary piping. Install a “supply sensor” in the primary loop using the Bradford White part number R2014800 sensor (included with every Copper Brute II unit).
Page 42 B RADFORD W HITE C ORP . Figure 28. T emperature Control Interstage Differential. 6.4 Advanced T opics For most installations, Section 6.3 provides all the information required to set up the Copper Brute II boiler , and this section should be skipped.
Page 43 COPPER BRUTE II (500 - 2000) Figure 29. T emperature Control Min & Max. minimum amount of time before turning on the next stage. After the minimum time delay between stages has expired, the control examines the control error to determine when the next stage is to re.
Page 44 B RADFORD W HITE C ORP . Figure 30. T emperature Control Outdoor Start Graph. the time selected (between 0 and 10 minutes). When OFF is selected, there is no purging. When ON is selected, pump operation is continuous. Also, during outdoor reset, with the pump delay set to ON , the pump continues to run even during W arm W eather Shut Down.
Page 45 COPPER BRUTE II (500 - 2000) Figure 31. T ypical Gas T rain Conguration. Figure 32. T ypical Control Panel. the typical coldest temperature of the year where the building is located. This temperature is used when doing heat loss calculations for the building.
Page 46 B RADFORD W HITE C ORP . 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.
Page 47 COPPER BRUTE II (500 - 2000) (b) The ame 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.
Page 48 B RADFORD W HITE C ORP . SECTION 7. Maintenance 7.1 System Maintenance 1. Lubricate the system water-circulating pump, if required, per the instructions on the pump. 2. If a strainer is employed in a pressure reducing valve or the piping, clean it every six months.
Page 49 COPPER BRUTE II (500 - 2000) and boilers ordered with low temperature controls. T o 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.
Page 50 B RADFORD W HITE C ORP . 6. Allow the heat exchanger to drain. Remove the front cover(s) by removing the rubber access strip(s) and the retaining screws. Remove the venting and remove the top, by removing the screws that attach the top to the side panels.
Page 51 COPPER BRUTE II (500 - 2000) a load distribution problem. See Section 6.3 regarding controller setup. Contact your Bradford White representative to discuss possible remedies.
Page 52 B RADFORD W HITE C ORP . 8.6 T roubleshooting the T emperature Control See T able 12. 8.7 T roubleshooting Copper Brute II Controls The Copper Brute II series consists of two 2-stage models (500 and 750), one 3-stage model (1000), and four 4-stage models (1250 to 2000).
Page 53 COPPER BRUTE II (500 - 2000) T able 12. T roubleshooting Error Codes..
Page 54 B RADFORD W HITE C ORP . Item Description Size Size Size Size Size Size Size 500 750 1000 1250 1500 1750 2000 Sheet Metal Components See Figure 33 1 Panel, Jacket, Side Left 5C3420 5C3420 5C34.
Page 55 COPPER BRUTE II (500 - 2000) Internal Components See Figures 35 and 34 17 Base Assembly 5C1020 7C1020 10C1020 12C1020 15C1020 17C1020 20C1020 18 Chamber , Front 5C2003 7C2003 10C2003 12C2003 1.
Page 56 B RADFORD W HITE C ORP . (1) (1) (2) (2) 36 Tile, Rear T2015700 (1) 37 Tile, Rear , Left Side T2017500 T2016600 T2016600 T2016600 T2016600 T2016600 (1) (1) (1) (1) (1) (1) 37A Tile, Rear , Rig.
Page 57 COPPER BRUTE II (500 - 2000) Item Description Size Size Size Size Size Size Size 500 750 1000 1250 1500 1750 2000 Relief V alve, BWCV , 125 PSI RA0001200 RA0001200 RA0001200 RA0001200 A0064400.
Page 58 B RADFORD W HITE C ORP . 71 High Limit, Manual Reset, BWCH RE0015900 RE0015900 RE0015900 RE0015900 RE0015900 RE0015900 RE0015900 High Limit, Manual Reset, BWCV , 210F Max.
Page 59 COPPER BRUTE II (500 - 2000) Burner Manifold Assy , 4 Burners, Left, LP 10C6520 10C6500 10C6520 10C6520 (2) (2) (2) (4) 78 V alve, Gas, Combination V2017600 V2017600 V2017600 V2017600 V2017600.
Page 60 B RADFORD W HITE C ORP . Figure 33. Sheet Metal Components. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 16B 16C 16D 16A BASE SHOWN FOR REFERENCE NOTE: Model 2000 shown for reference.
Page 61 COPPER BRUTE II (500 - 2000) Figure 34. Internal Components. See Electrical Components for detail..
Page 62 B RADFORD W HITE C ORP . Figure 35. Heat Exchanger Components. See pump chart below for pump numbers. Copper Brute II Hydronic SIZE PUMP P/N 500 A2001700 750 A2001700 1000 A2001800 1250 A20018.
Page 63 COPPER BRUTE II (500 - 2000) Figure 36. Electrical Components..
H2214401F BradfordWhiteCorp.reservestherighttochangespecications,components,features,ortodiscontinueproductswithoutnotice. Ambler , P A 19002 T ech. Service (800) 334-3393 Service Parts (800) 538-2020 www .
An important point after buying a device Bradford-White Corp BWCH (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Bradford-White Corp BWCH yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Bradford-White Corp BWCH - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Bradford-White Corp BWCH you will learn all the available features of the product, as well as information on its operation. The information that you get Bradford-White Corp BWCH will certainly help you make a decision on the purchase.
If you already are a holder of Bradford-White Corp BWCH, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Bradford-White Corp BWCH.
However, one of the most important roles played by the user manual is to help in solving problems with Bradford-White Corp BWCH. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Bradford-White Corp BWCH along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
