Bradford-White BJVT User Manual

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Brute Mini Hydronic Boiler

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6.3 Grounding

WARNING

The boiler must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the latest edition of the National Electrical Code, ANSI/NFPA 70, in the U.S. and with latest edition of CSA C22.1 Canadian Electrical Code, Part 1, in Canada. Do not rely on the gas or water piping to ground the metal parts of the boiler. Plastic pipe or dielectric unions may isolate the boiler electrically. Service and maintenance personnel who work on or around the boiler may be standing on wet floors and could be electrocuted by an ungrounded boiler.

AVERTISSEMENT

La chaudière doit être mise à la terre selon les exigences officielles locales ou, en l’absence de toute instruction officelle, l’installation doit être conforme au National Electrical Code, ANSI/NFPA 70, aux États-Uniset avec la dernière édition du Code électrique canadien CSA C22.1, Partie 1, au Canada. N’utilisez pas la tuyauterie de gaz ou d’eau pour mettre à la terre les parties métalliques de la chaudière. Les unions diélectriques ou avec tuyau en plastique peuvent isoler la chaudière électriquement. Les membres du personnel de service et d’entretien qui travaillent sur et autour de la chaudiére peuvent marcher dur des planchers mouillés et pourraient se faire électrocuter par une chaudière non mise à la terre.

6.4 Auxiliary Devices

6.4.1 Flow Switch

If the system includes a flow switch, it should be wired in series with the high-limitswitch. The boiler will not fire unless the pump is running and the flow switch is closed.

Field installed safety devices and operating controllers, such as a valve end switch, draft switches, relays, timers, and outdoor temperature reset devices, can be connected to the boiler through the wall thermostat circuit. Do not exceed a draw of 30VA on the transformer secondary.

6.4.2 Heat Anticipator

For single zone installations, the wall thermostat heat anticipator should be set at 0.5 amperes. For multi-zoneinstallations, have a qualified electrical technician make the necessary measurements to properly set the thermostats.

SECTION 7.

Operating Instructions

7.1 Normal Operation

The Brute Mini BJVS and BJVT boilers are capable of automatic operation based on a call for heat at present temperatures. The boiler has an internal safety system which allows operation in a variety of conditions and prevents operation when certain adverse conditions are encountered.

When the wall thermostat calls for heat and the boiler is powered, an operating cycle is initiated. (On continuous pilot ignition models (BJVT) the pilot must also be lit). The pump relay turns on the pump, the damper activator rotates the damper blade to the open position and the indicator light comes on.

On spark ignition models (BJVS 50-75),if the water temperature is below the limit setting, the ignition module lights the pilot and checks the flame existence. After the pilot is proven to be lit, the ignition module opens the main gas valve and the main burners ignite.

On 2-Stagespark ignition models (BJVS 100225), if the water temperature is below the limit setting, the ignition module lights the pilot and checks the flame existence. After the pilot is proven to be lit, the ignition module opens the main gas valve and the main burners ignite. The main gas valve is controlled by thetwo-stageoperating control (see Figure 11) and will cycle between high, low and off as the load demands.

TEMPERATURE

RISE

BOILER INLET

SETPOINT (ADJUSTABLE, FACTORY SET AT 140°F)

BREAKS R-BMAKESR-W

LEFT SWITCH ON RISE DIFFERENTIAL

2BREAKS R-WMAKESR-BON FALL

LOW

FIRE INTERSTAGE DIFFERENTIAL

1

BREAKS R-B

MAKES R-W

RIGHT SWITCH ON RISE DIFFERENTIAL

2BREAKS R-WMAKESR-BON FALL

HIGH

FIRE

DIFFERENCE BETWEEN THE TEMPERATURES AT WHICH THE

1TWO SWITCHES MAKE R-W.FACTORY SET AT 10°F (6.6°C)

TWO SPDT SWITCHES OPERATE IN SEQUENCE. EACH

2SWITCH DIFFERENTIAL AT APPROXIMATELY 3°F (1.7°C)

Figure 11. L6008G Operation.

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On continuous pilot ignition models (BJVT), if the water temperature is below the limit setting, the ignition module opens the main gas valve, and the main burners ignite.

Operation will continue on all ignition systems until either the wall setting thermostat is satisfied or the high-limitthermostat opens. The burners and pilot (on BJVS models)shut-offand the pump relay turns off the pump. The damper activator rotates the damper blade to the closed position and the indicator light goes off.

When the room temperature falls below the wall thermostat setting, the cycle repeats.

Note: When equipped with a pump delay option, the pump runs for a short time after the burners turn off and the damper closes.

7.2Start-up

7.2.1 Filling the System

NOTE: It is strongly recommended that the system be cleaned and flushed to remove scale, oil, paste, flux, etc., before the system is filled.

It is crucial to the efficient operation of the system that all air be removed from the circuit. For this reason, an air scoop and vent should be located close to the boiler outlet, and there should be a minimum distance between cold water feed and system purge valve.

1.When the system has been completely installed, close all air vents and open the makeup water valve. Allow the circuit to fill slowly.

2.Adjust the pressure to provide a minimum of 12 psi (82.7kPa) at the highest point in the circuit. If

apressure regulator is also installed in the line, adjust it to the same pressure.

3.Close all gate valves. Purge one circuit at a time as follows:

a.Open one circuit drain valve and let water drain out for at least 5 minutes. Be certain there are no air bubbles visible in the water stream before closing the drain valve.

b.Repeat this procedure for each circuit.

4.Open all gate valves after all circuits have been purged.

5.Run the system circulating pump for a minimum of 30 minutes with the boiler shut off.

6.Open all strainers in the system, and check for debris.

7.Recheck all air vents as described in Step 3 above.

8.Some expansion tanks require visual inspection of liquid level. If necessary, inspect the liquid level in the expansion tank. With the system full of water, and under normal operating pressure, to ensure proper water level in the expansion tank.

9.Start up boiler according to the procedures described in Section 7 and operate the system,

including the pump, boiler, and radiation units, for one hour.

10.Recheck the water level in the expansion tank, if necessary. If it exceeds ½ of the volume of

the tank, open the tank drain and reduce the water level.

11.Shut down the entire system, and vent all radiation units and high points in the system.

12.Close the water makeup valve and check the strainer in the pressure reducing valve for sediment or debris. Reopen the water makeup valve.

13.Verify system pressure with the boiler pressure gauge before beginning regular operation.

14.Within 3 days of start-up,recheck and bleed all air vents and the expansion tank using these instructions.

15.In systems piped with cross-linkedpolyethylene tubng (PEX) it is essential that all air is purged from all zones in the system to prevent PEX tubing failure.

7.2.2 Boiler Start-up

WARNING

For your safety, when starting the boiler, keep your head and face well away from the burner area to prevent any risk of personal injury.

AVERTISSEMENT

Pour votre sécurité personnelle lorsque vous mettez l’appareil en marche, tenez votre tête et votre visage loin du brûleur pour éviter tout risque de blessure.

WARNING

Vent pipes, and heater tops get hot! These surfaces can cause serious burns. Do not touch these surfaces while the heater is in operation.

AVERTISSEMENT

Les tuyaux d’aération et le dessus de l’appareil deviennent chauds! Ils peuvent causer de graves brûlures. Ne touchez pas à ces surfaces lorsque l’appareil est en marche.

Caution

Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water.

Attention

N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un technicien qualifié et remplacez toute partie du systéme de contrôle et toute commande qui ont été plongés dans l’eau.

Brute Mini Hydronic Boiler

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Caution

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

Attention

En cas de surchauffe ou si l’admission de gaz ne peut être coupée, ne pas couper ni débrancher l’alimentation électrique de la pompe. Fermer plutôt le robinet d’admission de gaz à l’extérieur de l’appareil.

Caution

Do not attempt repairs on the gas controls or appliance. Tampering is dangerous and voids all warranties.

Attention

Ne tentez pas d’effectuer des réparations au système de régulation du débit du gaz ou à l’appareil. Toute modification non autorisée est dangereuse et entraîne l’annulation de toutes les garanties.

Caution

Keep all objects off the top of the boiler. Blocking air flow could damage the heater, and may void the warranty.

Attention

Ne posez aucun objet sur le dessus de l’appareil. Il pourrait empêcher la circulation de l’air, ce qui risquerait d’endommager, l’appareil et d’annuler la garantie.

7.3 Lighting and Shutdown Procedures

WARNING

Do not attempt to light the boiler with the burner cover off. Doing so may cause severe bodily injury.

AVERTISSEMENT

Ne tentez pas d’allumer l’appareil sans que la soit en place. Vous pourriez être victime de blessures corporelles graves.

Before starting your boiler, be sure that all of the functions and limits of the BJVS and BJVT boilers have been set according to the previous section of this manual (Section 7.2). Follow the instructions outlined below. Read and follow all safety instructions first. A more detailed set of lighting and shutdown instructions are listed on the label located on the boiler.

NOTE: If your boiler is configured to operate on LP gas and the LP tank runs out of fuel, turn off gas at the boiler. After the tank is refilled, the boiler must be relit following the instructions found on the boiler. DO NOT attempt repairs on the gas control or heater. Tampering is dangerous and voids all warranties.

WARNING

If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

AVERTISSEMENT

Assurez-vousde bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

7.3.1 Lighting the Boiler

Lighting instructions are as follows:

1.Verify that the pump system is operating properly:

a.Shut off the manual gas valve located outside the boiler.

b.Raise the wall thermostat high enough to call for heat.

c.The pump should come on immediately. If it doesn't, test the electrical circuits.

2.Pilot Information:

a.The BJVS boilers do not require manual lighting. The pilot is controlled by the automatic ignition system.

b.The BJVT boilers do require manual pilot lighting. For access to the pilot burner, remove the louvered airbox cover by loosening the two thumb screws.

c.Different models of the BJV boiler utilize various gas valves. Although the gas valves may have different control knobs, they are all similar in operation. The BJVS gas valve has a two-positionknob, ON and OFF. The BJVT valve has athree-positionknob, ON, OFF and PILOT, some models come with extrapush-button(see Figure 12).

Figure 12. Gas Valves.

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3.BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

a. WHAT TO DO IF YOU SMELL GAS a.1 Do not try to light any appliance.

a.2 Do not touch any electric switch; do not use any phone in your building.

a.3 Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

a.4 If you cannot reach your gas supplier, call the fire department.

All Models:

4.Shut off electrical power to the boiler.

5. Turn the gas valve knob clockwise to OFF. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

6.Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow 7.3.1 (3.)a. If you don't smell gas, go to the next step.

BJVS Models: (BJVT skip 7 )

7. Turn gas valve knob counterclockwise to ON. Restore power to the boiler, and set the thermostat to the desired temperature. The pilot will automatically ignite when there is a call for heat.

BJVT Models: (Continuous Pilot) (BJVS skip to step 16)

8.Remove louvered burner cover by loosening the two thumb screws to access the pilot burner.

9.Remove the control box cover to fully access the gas valve.

10.Find pilot - follow metal tube from gas control. The pilot is on the right hand side of the first burner.

11.Turn knob on gas control counterclockwise to PILOT.

12.Push in control knob or push-buttonall the way and hold in. Immediately light the pilot with a match using the match holder. Continue to hold the control knob in for about one (1) minute after the pilot is lit. Release knob and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 2 through 8.

a.If the knob does not pop up when released, stop and immediately call your service technician or gas supplier.

b.If the pilot will not stay lit after several tries, turn the gas control knob to OFF and call your service technician or gas supplier.

13.Replace the louvered airbox cover and tighten the two thumb screws securely.

14.Turn gas control knob counterclockwise to ON.

15.Replace control box cover.

16.Restore power to the boiler and adjust the thermostat high enough to call for heat to verify the boiler is operating properly.

17.BJVS 100-225ONLY - Adjusttwo-stageoperating control setting to maximum, verify high fire operation. Reduce setting to just below the return water temperature and verify low fire operation.

18.BJVS 100-225ONLY - Settwo-stageoperating control to desired low fire set point. Generally 20°F below desired loop temp. i.e. for 180°F loop, set two stage operating control at 160°F. Adjust as necessary to maintain proper loop temperature.

19.Set the thermostat to the desired temperature.

7.3.2 Shutdown

7.3.2.1Main Burner Shutdown (BJVT only):

1.Lower the wall thermostat setting so that there is no call for heat.

2.To turn off the main burners turn the gas valve knob clockwise until it stops at pilot.

7.3.2.2Complete Shutdown:

1.Lower the wall thermostat setting so that there is no call for heat.

2.Turn off all electrical power to the boiler.

3.Turn the gas valve knob clockwise to “OFF”. Do not force the knob.

4.Shut off the external gas supply valve to the boiler.

7.4High Altitude Burner Air Shutter Adjustment

DANGER

This procedure must be followed exactly and must be performed by a qualified installer or warranty may be voided.

DANGER

Cette manière de procéder doit être faite exactement et accomplie par un installateur qualifié sous risque d’annulation de la garantie.

Brute Mini Hydronic Boiler

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DANGER

Read and understand this entire procedure prior to proceeding. Improper adjustment of high altitude shutters may result in a fire, explosion, and/or high levels of toxic gases which may cause property damage, personal injury, or loss of life.

DANGER

Lisez la manière de procéder dans sa totalité et comprenez-labien avant de commencer. Un ajustement inadéquat des volets en haute altitude peut provoquer un incendie, une explosion, et/ou des niveaux élevés de gaz toxiques qui pourraient causer des dégâts matériels, des blessures personnelles, voire la mort.

1.STOP! Read the safety information above.

2.Perform System Start-Upin accordance with Section 7.2 of this manual.

3.Remove burner cover by loosening two (2) thumbscrews.

4.Observe flame pattern on all burners. If the flame on any burner is pulsing, unstable or lifting continue with this procedure. Otherwise skip to step 10.

5.On all burners exhibiting an abnormal flame, loosen but do not remove the air shutter locking screw using a 5/16 inch wrench (see Figure 12).

6.On each affected burner, slowly close the air shutter until a normal flame is observed then retighten its associated locking screw.

7.Turn the boiler off.

8.Perform System Start-Upin accordance with Section 2A of this manual.

9.Observe flame pattern on all burners. If the flame on any burner is pulsing, unstable or lifting then repeat steps 5 and 6 until all burners are exhibiting a normal flame.

10.Re-installthe burner cover and tighten it in place.

LOCKING SCREW

(5/16" HEAD)

AIR SHUTTER

BURNER

Figure 13. Air Shutter Adjustment.

SECTION 8.

Maintenance

8.1 General Maintenance

WARNING

Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury, or death.

AVERTISSEMENT

Une installation ou un entretien inadéquat peut causer la nausée ou l’asphyxie en raison du monoxyde de carbone présent dans les gaz de combustion et même entraîner des blessures graves ou la mort.

WARNING SERVICING SAFETY

Some of the servicing procedures for the Brute Mini BJVS and BJVT boilers are hazardous because they involve fuel gas, electricity, moving parts and procedures which require testing or temporary bypass of safety controls. For this reason, the heater must be serviced only by a qualified professional service technician.

IMPROPER SERVICE HAZARD

The Brute Mini BJVS and BJVT boilers incorporate unique design features. Incorrect service of this boiler can result in personal injury or damage to property. To avoid such hazards, the heater must be serviced only by a qualified professional service technician.

AVERTISSEMENT PRÉCAUTIONS LORS DES RÉPARTATIONS ET DE L’ENTRETIEN

Certaines procédures d’entretien et de réparation des appareils de chauffage à faibles émissions présentent des changers, car elles mettent en jeu des gaz combustibles, des composants électriques, des pièces mobiles et des procédures qui nécessitent des mises à l’essai ou la dérivation temporaire des commandes de sécurité. Pour cette raison, l’appareil de chauffage doit être entretenu et réparé uniquement par un technicien professionnel qualifié

DANGERS D’UN ENTRETIEN INADÉQUAT

Les appareils de chauffage à faibles émissions comportent des caractéristiques techniques uniques. Une réparation ou un entretien inadéquat peut entraîner des blessures corporelles ou des dommages à la propriété. Pour cette raison, l’appareil de chauffage doit être entretenu et réparé uniquement par un technicien professionnel qualifié.

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1.Lubricate the water circulating pump 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.

3.At start-up,and periodically thereafter, the burner flame should be observed. If the flame has the appearance of ‘sooting’ tips, check for debris near the orifices and call the service technician.

4.Inspect the venting system for obstruction, leakage or corrosion at least once a year.

5.Do not store or use gasoline or other flammable vapors, liquids or chemicals in the vicinity of this or any other appliance.

Ne pas entreposer ni utiliser d’essence ni d’autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil.

6.Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water.

N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un technicien qualifié et remplac ez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.

7.Be sure that all combustion air and ventilation openings are unobstructed.

8.Upon completion of the installation, inspect the external surfaces of the heat exchanger for fouling based on the following schedule:

24 hours 7 days 30 days 90 days Once every six months thereafter.

9.If the boiler is not going to be used for long periods of time in locations where freezing occurs, it should be completely drained of all water. To accomplish this, there is a drain valve on the right side of the boiler which can be opened. This will drain the right side of the boiler. There are two plugs located on the left side of the heater which must be removed to drain that side. Both sides must be drained.

10.The gas and electric controls on the boiler are engineered for long life and dependable operation, but the safety of the equipment depends on their proper functioning. It is

Figure 14. 1) BJVS Pilot; 2) BJVH Pilot;

3) Main Burner Flame Pattern; 4) BJVT Pilot.

strongly recommended that the basic items listed below be inspected by a qualified service technician every year.

a.Water temperature controls

b.Pilot safety system.

c.Automatic gas valves.

d.Flow sensing safety devices.

e.Vent dampers and power venters.

f.Venting system.

NOTE: The Warranty does not cover damage caused by lack of required maintenance, lack of water flow, or improper operating practices.

12.Fouling on the external surfaces of the heat exchanger is caused by incomplete combustion, and is a sign of venting and/or combustion air problems. The heat exchanger can be inspected by using a flashlight and placing a mirror under the burners. An alternate method is to remove the venting and top panel to inspect the exchanger from above. The vent system should be inspected at the same time. If cleaning is required:

a.Shut off all power to the boiler.

b.Remove the draft hood, venting top, flue collector, and heat exchanger baffles.

c.Remove the burners by lifting them off the orifices and pulling them out of the boiler.

d.Use a hand-operatedspray bottle filled with water, and a wire brush to clean soot and loose scale from the underside of the heat exchanger. DO NOT USE COMPRESSED AIR, HIGH PRESSURE WATER OR A GARDEN HOSE.

e.Clean any fallen debris from the bottom of the unit.

f.Check to make sure the burner ports and pilot assembly are free of debris before returning the burners to their original position.

g.Reassemble the boiler in reverse order, making sure to replace the heat exchanger baffles.

8.2Boiler Components and Their Operation

1.Gas Valve / Regulator - The gas valve controls gas flow into the manifold. It provides flow only when the temperature control requires heat and only if all safety controls enable operation. It is also a positive pressure regulator. It regulates the gas pressure in the manifold to specifications addressed earlier in this manual. This is necessary for proper operation of the burner system. BJVS 100-225 Only - Gas Valve / Regulator has two output stages controlled by two-stage temperature control.

Brute Mini Hydronic Boiler

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Caution

Two-stageOperating Control(BJV100-225ONLY): Factory setting is 140°F (60°C). This setting is correct for most hydronic heating applications. Adjustments to this setting must be made by an authorized service technician.

2.Two-stageTemperature Control -BJVS 100225 are equipped with a two-stage temperature control which senses inlet water temperature. It is used to control the firing rate of the main burners, cycling the gas valve between low, high

and off.

3A. Ignition Control, BJVS - When the thermostat calls for heat and all limits are satisfied a pilot trial for ignition is initiated. If pilot is not established a 5 minute minimum delay is implemented prior to the next trial for ignition. This cycle repeats until pilot is established or the system is shut down manually.

BJVS 100-225only - Once pilot is established the main valve is enabled and controlled by thetwo-stagetemperature control.

BJVS 50-75only - Once pilot is established the main valve will open until the limit circuit opens.

3B. BJVT Flame Control - The standing pilot BJVT models rely on a flame sensor on the gas valve. When the thermostat calls for heat and adequate pilot flame is sensed, the gas valve will open. The valve will remain open until the limit circuit opens.

4.Pilot Assembly

BJVS - The pilot assembly utilizes an electrode that is used to generate spark to ignite the pilot flame as well as sense flame presence.

BJVT - The BJVT pilot is lit manually and senses pilot flame via a thermocouple which generates a signal that allows the gas valve to open.

5.Hi-Limit Switch: Factory setting is 190°F (88°C). This setting is correct for normal operations, and should only be changed by an authorized service technician. Under no circumstances should the setting exceed 220°F (104°C).

6.Blocked Vent Switch - BJVS and BJVT boilers are equipped with a manual reset blocked vent switch designed to shut the boiler down in the event the vent is completely blocked. The switch is located in the draft diverter opening on the rear of the boiler.

7.Rollout Switch - BJVS and BJVT boilers are equipped with a manual reset rollout switch designed to shut the boiler down in the event a flame rollout situation occurs causing excessive temperatures. The switch is located on the burner cover.

SECTION 9.

Troubleshooting

9.1 General Boiler Troubleshooting

Table 8 lists some of the more common problems, causes and solutions encountered when running the boiler. Most problems occur when the boiler is being started for the first time after installation. Careful installation and maintenance will help ensure years of trouble free use from your Brute Mini boiler.

WARNING SERVICING SAFETY

Some of the servicing procedures for the Brute Mini BJVS and BJVT boilers are hazardous because they involve fuel gas, electricity, moving parts and procedures which require testing or temporary bypass of safety controls. For this reason, the boiler must be serviced only by a qualified professional service technician.

IMPROPER SERVICE HAZARD

The Brute Mini BJVS and BJVT boilers incorporate unique design features. Incorrect service of this heater can result in personal injury or damage to property. To avoid such hazards, the boiler must be serviced only by a qualified professional service technician.

AVERTISSEMENT PRÉCAUTIONS LORS DES RÉPARTATIONS ET DE L’ENTRETIEN

Certaines procédures d’entretien et de réparation des appareils de chauffage à faibles émissions présentent des changers, car elles mettent en jeu des gaz combustibles, des composants électriques, des pièces mobiles et des procédures qui nécessitent des mises à l’essai ou la dérivation temporaire des commandes de sécurité. Pour cette raison, l’appareil de chauffage doit être entretenu et réparé uniquement par un technicien professionnel qualifié

DANGERS D’UN ENTRETIEN INADÉQUAT

Les appareils de chauffage à faibles émissions comportent des caractéristiques techniques uniques. Une réparation ou un entretien inadéquat peut entraîner des blessures corporelles ou des dommages à la propriété. Pour cette raison, l’appareil de chauffage doit être entretenu et réparé uniquement par un technicien professionnel qualifié.

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9.2

Troubleshooting Guide

 

#

Symptom

Cause

Remedy

1.

Pump not

A. No power

A. Check circuit breakers and power source.

 

operating

B. Pump defective

B. Replace.

 

 

C. Incorrectly wired

C. Recheck wiring diagrams.

2.

Pilot outage

A. Inlet gas pressure too low

A. Consult gas utility company. Inlet gas pressure to boiler

 

 

 

should be 5.5" to 10.5" water column on natural gas. 0.0" to

 

 

B. Inlet gas pressure too high causing

13.0" on propane gas.

 

 

B. Pressure should be regulated within limits shown above.

 

 

an unstable blowing pilot

C. Replace thermocouple.

 

 

C. Weak or defective thermocouple

 

 

D. Damaged pilot or thermocouple

D. Replace.

 

 

E. Dirty pilot

E. Blow dust or lint out of pilot.

 

 

F. Plugged or undersized pilot orifice

F. Clean or replace pilot orifice.

3.

Flame roll-out

A. Blocked flue

A. Remove blockage.

 

on start-up

B. Pilot out of position (delayed ignition)

B. Correct pilot position.

 

 

C. Blocked heat exchanger or flue

C. Clean and correct as necessary.

 

 

D. Refractory tile out of place

D. Correct or replace tile as necessary.

 

 

E. Altered draft diverter

E. Install factory-provideddraft diverter.

4.

Spillage at

A. Cold chimney

A. Allow boiler to operate 5 minutes to create draft action.

 

draft hood

B. Vent pipe pitches down to chimney

B. Reinstall vent pipe to pitch up from boiler to chimney.

 

 

C. Blocked chimney

C. Remove blockage.

 

 

D. Draft hood altered

D. Install factory-provideddraft diverter.

 

 

E. Pre-fabricatedchimney with incorrect cap

E. Install U.L. listed vent cap.

5.

Flame has

A. Low primary air

A. Correct manifold pressure according to rating plate. Correct

 

lazy yellow tip

 

orifice size if necessary (see parts list). Clean burner ports if

 

 

 

dirty. Verify correct fuel type.

6.

Not enough heat

A. Inadequate gas supply

A. Gas meter too small. Gas line from meter to boiler too small.

 

 

B. Low manifold gas pressure

B. Gas pressure on boiler manifold (at normal firing rate)

 

 

 

should be adjusted to 4.0"W.C. natural gas, 9.0"W.C.

 

 

C. Boiler size inadequate

propane.

 

 

C. Replace with boiler of higher input.

 

 

D. BJVS 100-225only - Boiler not going

D. Check operation and setting of two-stageoperating control.

 

 

to high fire.

 

7.

Pump noisy

A. Air in volute

A. Bleed air from volute. Check pump alignment.

 

 

B. Worn coupling or bearings

B. Replace worn parts.

8.

Boiler pounding

A. Too low water flow through boiler

A. Check temperature rise between inlet and outlet boiler piping.

 

or knocking

 

15°F to 25°F temperature rise is recommended. If temperature

 

 

 

rise is over 25°F, increase pipe size or pump capacity or

 

 

 

locate obstruction. Check for stuck closed zone valves.

 

 

 

Check for zone pumps not operating. Check for closed valve

 

 

 

in system.

9.

Boiler condensing

A. Low water temperature

A. Flue product moisture will condense at the start-upuntil the

 

 

 

boiler water temperature reaches the normal operating

 

 

 

conditions.

10.

Pump cavitates

A. Defective fill valves or pressure regulator

A. Replace.

 

or low water

B. Oversized expansion tank

B. Replace.

 

pressure at boiler

C. Expansion tank piped incorrectly

C. Repipe expansion tank to suction size of pump.

 

gauge or bubbles

 

 

 

in system at high

 

 

 

temperature

 

 

11.

Pressure relief

A. Water-loggedexpansion tank

A. Drain 2/3 of the water from the expansion tank.

 

valve opens

 

 

12.

Pilot is lit but main

A. Gas valve not at "on" position (BJVT)

A. Turn knob to "on" position.

 

burners will not

B. Boiler off on hi-limitcontrol

B. Check for low water flow or hi-limitsetting.

 

come on

C. Boiler incorrectly wired

C. On single or multiple zone systems with zone valves, room

 

 

 

thermostat should be wired to R & W terminals. For multiple

 

 

 

zone systems with zone pumps, thermostats for extra zones

 

 

D. Boiler off on blocked vent switch

should be wired to R & A terminals.

 

 

D. Remedy as in symptom #4. Reset the manual reset switch.

 

 

E. Boiler off on flame roll-outswitch

E. Remedy as in symptom #3. Reset the manual reset switch.

 

 

F. Broken wire in thermostat circuit

F. Check continuity through thermostat circuit with wires

 

 

or defective thermostat

disconnected from R & W.

 

 

G. BJVS 100-225Only -Two-stageoperating

G. Check continuity and operation through two-stage

 

 

control not functioning or loose contact.

operating control.

 

 

 

 

13.

Boiler short cycles

A. Heat anticipator in room thermostat

A. Increase setting (0.8 - 1.0 is usually satisfactory).

 

 

set too low

B. Increase size of pump or increase piping size.

 

 

B. Low water flow through boiler

 

 

C. Hi-limitswitch may be set too low

C. Increase setting to at least 20°F over outlet water temperature.

 

 

 

 

Table 8. Troubleshooting Guide.

Brute Mini Hydronic Boiler

Page 29

 

 

9.3 Troubleshooting Honeywell S8600 Intermittent Pilot System

Some boilers may be equipped with an ignition module that shuts off pilot gas if pilot fails to light.

Start

Turn off gas supply. Turn thermostat (controller) to call for heat.

Power to module (24V nominal).

YES

Spark across igniter/ sensor gap.

YES

Turn gas supply on. Pilot burner lights?

YES

Spark stops when pilot is lit?

YES

Main burner lights?

YES

System runs until call for heat ends?

YES

Call for heat ends. System shuts off?

YES

Troubleshooting ends

To reset, interrupt power to heater

Note: Before troubleshooting, familiarize yourself with thestart-upand checkout procedure.

 

Check line voltage power, low voltage transformer, hilimit switch,

 

 

 

NO

thermostat (controller) and wiring.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pull ignition lead and check spark at module.

 

 

 

 

NO

Spark okay?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

 

 

 

Check ignition cable ground wiring, ceramic insulator and gap, and correct.

 

 

 

 

Check boot of the ignition cable for signs of melting or buckling. Take

 

 

 

 

 

protective action to shield cable and boot from excessive temperatures.

 

 

 

 

 

 

 

 

 

 

Check that all manual gas valves are open, supply tubing and pressures

 

 

 

 

are good, and pilot burner orifice is not blocked.

 

 

Check electrical connections between module and pilot operator on gas

 

 

 

NO

 

 

 

 

control.

 

 

 

 

Check for 24 Vac across PV-MV/PVterminals on module. If voltage is

 

 

 

 

 

 

 

 

 

okay, replace gas valve; if not, replace module.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NO

Check continuity of ignition cable and ground wire.

 

 

 

 

 

 

Clean flame rod.

 

 

 

Check electrical connections between flame rod and module.

 

 

 

 

 

Check for cracked ceramic flame rod insulator.

 

 

 

 

Check that pilot flame covers flame rod and is steady and blue.

 

 

 

 

Adjust pilot flame.

 

 

 

 

If problem persists, replace module.

 

 

 

 

 

 

 

Check for 24 Vac across MV-MV/PVterminals. If no voltage, replace

 

 

 

NO

 

 

 

 

module.

 

 

 

 

Check electrical connections between module and gas valve. If okay,

 

 

 

 

 

 

 

 

 

replace gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

Check continuity of ignition cable and ground wire.

 

 

 

 

NO

 

 

 

 

Note: If ground is poor or erratic, shutdowns may occur occasionally even

 

 

 

 

 

though operation is normal at the time of checkout.

 

 

 

 

 

Check that pilot flame covers flame rod and is steady and blue.

If checks are okay, replace module.

 

 

 

 

Check for proper thermostat (controller) operation.

 

NO

 

Remove MV lead at module; if valve closes, recheck temperature

 

 

 

 

 

controller and wiring; if not, replace gas valve.

 

 

Repeat procedure until trouble-freeoperation is obtained.

Page 30

BRADFORDWHITECORP.

 

 

9.4 Electrical Troubleshooting

1.Remove the control box cover on the front of the boiler.

2.Verify that 115V is reaching the boiler by testing across the black wire on the pump relay and the white wire on the transformer.

3.Verify 24V transformer output by placing the meter leads on the yellow and red wires. If 24V is not evident, replace the transformer. Perform the following series of tests with one meter lead attached to the yellow wire on the transformer.

4.Place the second lead on the "W" connection on the terminal board. Turn the wall thermostat high enough to call for heat. If the meter fails to register 24V, the thermostat or its circuit may be defective.

5.Make sure thermostat is set high enough to call for heat. Place second lead on the "A" connection on the terminal board. If voltage is evident, skip to step 6. If no voltage, test the circuit between the red wire on the transformer and terminal 4 on the pump relay; from terminal 6 on the pump relay and the "A" connection on the terminal board; and from the purple wire terminal on the pump relay to the "W" connection on the terminal board. If no output is found, the

connections or the pump relay could be defective.

6.Place the second lead on the orange wire terminal on the hi-limitswitch. If no voltage across the switch, check for defectivehi-limit,open circuit due to excessive water temperature, or a low temperature setting.

7.Place the second lead on the orange wire terminal on the blocked vent safety switch. If voltage is present, the vent damper is open. If voltage isn't present, connections or the vent damper could be defective.

8.Verify the voltage across the blocked vent and roll-outsafety switches.

9.On BJVT boilers, test for voltage at the "TH" terminal on the gas valve. If none is found, follow steps 1 through 8.

10.If it is determined that there is voltage to the gas valve, the pilot is lit and the thermocouple is properly positioned, and the thermostat is set high enough to call for heat, the gas valve or the pilot thermocouple may be defective

11.There are two tests necessary to make sure the problem is not in the pilot thermocouple. The first test can be performed by unscrewing the compression fitting on the gas valve, and placing one millivoltmeter lead on the center post of the tube and the other lead on the copper tubing. If the meter shows a reading of approximately 30 millivolts, proceed to the second test. If it

doesn't, replace the pilot thermocouple. The second test requires the use of a Millivolt Reading Adapter to test the thermocouple under load. Once again, remove the pilot thermocouple compression fitting from the gas valve. Replace it with a Millivolt Reading Adapter, and screw the thermocouple fitting into the end of the adapter. Attach one lead from the millivoltmeter to either side of the adapter and the other lead to ground. Light the pilot and set the wall thermostat high enough to call for heat. With the boiler firing, take a millivolt reading. It should be in the 15 millivolt range. If it isn't, replace the pilot thermocouple.

Caution

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

ATTENTION

Au moment de l’entretien des commandes, mettez des étiquettes sur tous les fils avant de les débrancher. Des erreurs de câblage peuvent causer un fonctionnement inadéquat et dangereux. Vérifier que tout fonctionne bien après votre entretien.

SECTION 10.

Glossary

10.1 Glossary of Terms

Air Vent

Another device used to purge air from the circuit. Should be located at the highest point in the circuit.

Branch

The section(s) of supply and return piping, including the heat distribution units (see below), connected directly to the trunk. Also referred to as a "zone."

By-pass

A section of pipe (including an adjustable valve) that diverts part of the water flow from the boiler outlet to the inlet, adjusted to maintain minimum flow requirement (GPM) or inlet water temperature.

Circuit

Entire water circulation piping, beginning and ending at the boiler (Series Loop System).

Expansion Tank (Compression Tank)

Installed in the circuit to accommodate excess water produced by heat expansion, and to maintain the system pressure.