Bradford-White BRHHV User Manual

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Installation and Operation Instructions

Docyment 1246

 

 

Installation and Operation

Instructions for

BRUTE MAGNUM

Modulating Boiler

Model BRHHH

Modulating Water Heater

Model BRHHV

U.S. Patent No. 6,644,393

Canada Patent Pending

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

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

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

Installation and service must be performed by a qualified installer, service agency, or gas

AVERTISSEMENT

Assurez-vousde bien suivres 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.

Ne pas entreposer ni utiliser d’essence ni d’autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

Ne pas tenter d’allumer d’appareils.

Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dansle bâtiment où vous vous trouvez.

Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.

Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.

H2343400-

238-49223-00AREV 4/11

Page 2

BRADFORDWHITECORP.

 

 

Brute Magnum

Page 3

 

 

Table of Contents

SECTION 1

 

General Information

 

1.1

Introduction......................................................

5

1.2

Model Identification..........................................

5

1.3

Warranty ..........................................................

6

1.4

Dimensions......................................................

6

1.5

Locating the Appliance.....................................

6

1.6

Locating Pump-MountedWater

 

 

Heater with Respect to Storage Tank(s)..........

6

1.7Locating Pump-MountedBoiler with

Respect to Return/Supply Header...................

6

1.8Locating Appliance for Correct Vent Distance

From Outside Wall or Roof Termination...........

7

5.5.3

Offset .............................................................

26

5.5.4

Throttling Range ............................................

26

5.5.5

Minimum Output Setting ................................

27

5.5.6

Integration Constant ......................................

27

5.6

Mixing System and Control............................

28

5.7

External Control Connections........................

29

5.8

Wiring Diagrams ............................................

29

SECTION 6

 

Operating Instructions

 

6.1

Filling the Boiler System ................................

36

6.2

Operating the Burner and Set Up ..................

36

6.3

Shutting Down the Brute Magnum.................

38

6.4

To Restart the Brute Magnum........................

38

SECTION 2

 

Venting and Combustion Air

 

2.1

Combustion Air ................................................

8

2.1.1

Combustion Air From Room ............................

8

2.1.2

Intake Combustion Air......................................

8

2.2

Venting.............................................................

9

2.3

Locating Vent & Combustion Air Terminals......

9

2.3.1

Horizontal Vent Terminal..................................

9

2.3.2

Side Wall Combustion Air Terminal................

12

2.3.3

Vertical Vent Terminal ....................................

12

2.3.4

Vertical Combustion Air Terminal...................

12

2.4

Common Vent Test – Boilers .........................

12

SECTION 3

 

Gas Supply and Piping

 

3.1

Gas Supply and Piping ..................................

13

SECTION 4A

 

Water Connections – BRHHH Boiler

 

4A.1

Heating System Piping:

 

 

Hot Supply Connections – Boiler...................

14

4A.2

Cold Water Make-Up– Boiler ........................

14

4A.3

Freeze Protection – Boiler .............................

15

SECTION 4B

Water Connections – BRHHV Water Heater

4B.1

Water System Piping – Water Heater............

15

4B.2

Hot Water Supply Piping – Water Heater ......

15

4B.3

Water Flow Requirements – Water Heater....

16

4B.4

Combined Water (potable)

 

 

Heating and Space Heating...........................

18

4B.5

Freeze Protection — Water Heater ...............

19

SECTION 5

 

Electrical Connections

 

5.1

Main Power....................................................

24

5.2

Pump Connections ........................................

24

5.3

Temperature Control – Boiler.........................

24

5.4

Temperature Control – Water Heater.............

24

5.4.1

Remote Water Heater Temperature Control ..

24

5.4.2

Internal Water Heater Temperature Control...

25

5.5

Temperature Control Features.......................

25

5.5.1

Temperature Setpoint ....................................

25

5.5.2

Differential Setting .........................................

25

SECTION 7

 

Maintenance

 

7.1 System Maintenance .....................................

38

7.2Appliance Maintenance and

 

Component Description .................................

38

7.2.1

Burner............................................................

40

7.2.2

Filter...............................................................

40

7.2.3

Modulating Gas Valve....................................

40

7.2.4

Safety Gas Valve ...........................................

41

7.2.5

Manual Reset High Limit Control...................

41

7.2.6

Temperature Control......................................

41

7.2.7

Auto Reset Temperature Limit .......................

41

7.2.8

Mixing Control................................................

41

7.2.9

Mixing Valves.................................................

41

7.2.10 Mixing Actuator ..............................................

42

7.2.11 Ignition Control...............................................

42

7.2.12 Ignitor / Flame Sensor Assembly...................

42

7.2.13 Transformers .................................................

42

7.2.14 Blower............................................................

42

7.2.15 Flow Switch....................................................

42

7.2.16 Heat Exchanger Coils....................................

42

7.2.17 Normally Open Vent Valve.............................

43

7.2.18 Motorized Safety Valve..................................

43

7.2.19 Gas Pressure Switches .................................

43

SECTION 8

 

Troubleshooting

 

8.1

Sequence of Operation..................................

43

8.2

Resolving Lockouts........................................

44

8.3

Delayed Ignition – Possible Causes ..............

44

8.3.1

High Lockup Pressure (LP Appliances)

 

 

- Occurs on Start-up ......................................

44

8.3.2

Gas Valve Regulation ....................................

44

8.3.3

Defective Burner - Occurs on

 

 

Startup or at Burner Shutdown ......................

44

8.4

Short Cycling – Boiler ....................................

44

8.5

Short Cycling – Water Heater ........................

45

8.6

High Gas Consumption..................................

45

SECTION 9

 

Replacement Parts

 

9.1

General Information.......................................

45

9.2

Parts List........................................................

45

Page 4 BRADFORDWHITECORP.

List of Tables

Table 1

Clearances ........................................................

6

Table 4

Required Combustion Air Piping Material

..........9

Table 2

Vent / Air Pipe Sizes..........................................

7

Table 5

Required Venting Material.................................

9

Table 3

Horizontal Vent and Air Terminals

 

Table 6

Gas Piping Sizes.............................................

13

 

for Indoor Installations.......................................

8

Table 7

Air & Gas Orifice Differentials at Full Fire

38

 

 

 

List of Figures

Figure 1

Dimensional Drawing ........................................

7

Figure 19

Wiring Diagram Size 1200, Code B.................

32

Figure 2

Combustion Air and Vent Through Roof............

8

Figure 20

Wiring Diagram, Sizess 1600, 2000 and

 

Figure 3

Combustion Air and Vent Through Side-Wall

10

 

2400, Code B ..................................................

33

Figure 21 Wiring Schematic, Size 1200,

 

Figure 4

Hydronic Piping – Multiple Boilers

16

 

 

Standard and Codes A and F

34

Figure 5

Hydronic Piping – Multiple Boilers (Alternate).17

 

Figure 22 Wiring Schematic, Sizes 1600, 2000 and

 

Figure 6

Hydronic Piping – One Boiler,

 

 

 

 

2400, Standard and Codes A and F

34

 

Multi-TemperatureSystem

18

 

 

Figure 23 Wiring Schematic, Size 1200, Code B

35

Figure 7

Internal Piping Schematic

19

Figure 24 Wiring Schematic, Sizes 1600, 2000 and

 

Figure 8

Water Heater Piping – One Heater, One Tank

20

 

 

2400, Code B

35

Figure 9

Water Heater Piping – Multiple Heaters,

 

 

 

Figure 25 Gas/Air Test Panel

37

 

One Tank

21

 

Figure 26 Test Panel Valves

37

Figure 10

Water Heater Piping – One Heater,

 

 

Figure 27

Gas Trains

39

 

Multiple Tanks

22

 

Figure 28

Gas Trains

40

Figure 11

Water Heater Piping – Multiple Heaters,

 

 

Multiple Tanks..................................................

23

Figure 29

Control Panel...................................................

41

Figure 12

Temperature Control........................................

24

Figure 30

Combustion Components................................

49

Figure 13

Proprotional Control ........................................

25

Figure 31

Gas Train/Combustion Air Components..........

50

Figure 14

Control Parameter Graph................................

26

Figure 32

Gas Train Components ...................................

51

Figure 15

Control Parameter Graph................................

27

Figure 33

Electrical Components ....................................

52

Figure 16

Control Parameter Possible Interference ........

28

Figure 34

Heat Exchanger / Water Path Components ....

53

Figure 17

Wiring Diagram, Size 1200,

 

Figure 35 Heat Exchanger / Water Path Components ....

54

 

Standard and Codes A and F ..........................

30

Figure 36

Jacket Components

55

Figure 18

Wiring Diagram, Sizes 1600, 2000 and

 

 

 

 

 

 

2400, Standard and Codes A and F ................

31

 

 

 

Brute Magnum

Page 5

 

 

Section 1

GENERAL INFORMATION

USING THIS MANUAL – Because the Brute Magnum Boilers and Brute Magnum Water Heaters are identical appliances, with the exception of materials of manufacture, labels and ultimate use application, this manual provides information for the proper installation, operation and maintenance of both products. Where differences exist between the application of the appliances and their operation, the sections pertinent to only one appliance or the other will be so identified.

WARNING

The Brute Magnum hydronic, boiler or water heater must be installed in accordance with the procedures detailed in this manual, or the Bradford White warranty will be voided. The installation must conform to the requirements of the local jurisdiction having authority, and, in the United States, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54. In Canada, the installation must conform to the latest edition of CSA B149.1 Natural Gas and Propane Gas Installation Code, and/

or local codes. Where required by the authority having jurisdiction, the installation of Brute Magnum boilers must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.Any modifications to the boiler, its gas controls, or wiring may void the warranty.

If field conditions require modifications, consult the factory representative before initiating such modifications.

1.1Introduction

This manual provides information necessary

for the installation, operation, and maintenance of Bradford White Brute Magnum (copper tube or cupronickel tubes) appliances. Read it carefully before installation.

All application and installation procedures should be reviewed completely before proceeding with the installation. Consult the Bradford White factory, or local factory representative, with any problems or questions regarding this equipment. Experience has shown that most operating problems are caused by

improper installation.

The Brute Magnum appliance is protected against over pressurization. A pressure relief valve is fitted to all appliances. It is installed inside the jacket, at the water outlet of the unit. (See Sections 4A and 4B for instructions on how to install a relief valve outlet.)

IMPORTANT: The inlet gas pressure to the appliance must not exceed 13" W.C. (3.2kPa).

All installations must be made in accordance with 1) American National Standard Z223.1/NFPA54Latest Edition “National Fuel Gas Code” or 2) CSA B149.1 “Natural Gas and Propane Installation Code” and with the requirement of the local utility or other authorities having jurisdiction. Such applicable requirements take precedence over the general instructions contained herein.

All electrical wiring is to be done in accordance with the local codes, or in the absence of local codes, with: 1) The National Electrical Code ANSI/NFPA No. 70-latestEdition, or 2) CSA STD. C22.1 “Canadian Electrical Code - Part 1”. This appliance must be electrically grounded in accordance with these codes.

1.2Model Identification

Consult the rating plate on the unit. The

following information describes the model number structure.

(1-3)Model Series Designation

B R H = Brute Magnum mid-sizedcommercial

(3)Model Efficiency

H = High Efficiency (condensing)

(4)Usage

H = Hydronic

V = Volume Water

(5-8)Size

1 2 0 0 = 1,200,000 BTU/hr input

1 6 0 0 = 1,600,000 BTU/hr input

2 0 0 0 = 2,000,000 BTU/hr input

2 4 0 0 = 2,400,000 BTU/hr input

(9)Fuel

N = Natural Gas

P = Liquid Propane

(10)Altitude

A = Universal Altitude (0' – 10,000') (0m – 3050m)

(11)Location I = Indoor

(12)Firing Mode

F = Modulating

Model Designation

1

2

3

 

4

5

 

6

7

8

9

 

 

10

11

 

12

 

 

13

 

14

 

15

 

16

 

 

 

17

 

B

R

 

H

 

H

 

 

 

 

 

 

 

 

0

0

 

 

 

 

 

 

A

 

 

 

I

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SERIES

 

 

USAGE

 

 

SIZE

 

 

 

FUEL

 

 

ALTITUDE

 

LOCATION

 

FIRING

 

REVISION

 

 

HEAT

 

OPTIONS

PUMP

 

R

 

H

H

 

 

H

 

1

2

0

0

 

 

N

 

 

 

A

 

 

I

 

MODE

 

1

 

 

EXCHANGER

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X

 

 

 

 

 

 

 

 

 

V

 

1

6

0

0

 

 

P

 

 

 

 

 

 

 

 

 

 

 

F

 

2

 

 

 

E

 

 

A

H

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

0

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

4

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 6

BRADFORDWHITECORP.

 

 

(13)Revision

2 = Second version

(14)Heat Exchanger

E = Glass-linedsteel with copper tubes

F = Glass-linedsteel with cupronickel tubes

(15)Control Option Code

X = Standard, meets CSD-1boiler standard A = Control Pack A:CSD-1,CA, FM, IL, IRI,

Alarm Bell

B = Control Pack B: CSD-1,CA, FM, IL, LDS, MN F = NonCSD-1

(16)Pump Options

N = Pump mounted, normal pump (standard) H = Pump mounted, hard water pump (BRHHV)

1.3Warranty

Bradford White’s Brute Magnum appliances

are covered by a limited warranty. The owner should fill out the warranty registration card and return it to Bradford White.

All warranty claims must be made to an authorized Bradford White representative or directly to the factory. Claims must include the serial number and model (this information can be found on the rating plate), installation date, and name of the installer. Shipping costs are not included in the warranty coverage.

Some accessory items are shipped in separate packages. Verify receipt of all packages listed on the packing slip. Inspect everything for damage immediately upon delivery, and advise the carrier of any shortages or damage. Any such claims should be filed with the carrier. The carrier, not the shipper, is

responsible for shortages and damage to the shipment whether visible or concealed.

1.4Dimensions

The overall dimensions are 34.5" (88cm)

wide, 65.75" (167cm) tall, 55" (140cm) deep. Other dimensions can be found in Figure 1.

1.5Locating the Appliance

The Brute Magnum is for indoor installations

only.

The appliance should be located to provide clearances on all sides for maintenance and inspection. It should not be located in an area where leakage of any connections will result in damage to the area adjacent to the appliance or to lower floors of the structure.

When such a location is not available, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance.

The appliance is design certified by CSAInternational for installation on combustible flooring; in basements; in closets, utility rooms or alcoves.

Brute Magnum Boilers or Water Heaters must never be installed on carpeting. The location for the

appliance should be chosen with regard to the vent pipe lengths and external plumbing. The unit shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.). When vented vertically, the Brute Magnum must be located as close as practical to a chimney or gas vent. If the vent terminal and/

or combustion air terminal terminate through a wall, and there is potential for snow accumulation in the local area, both terminals should be installed at an appropriate level above grade.

The dimensions and requirements that are shown in Table 1 should be met when choosing the locations for the appliance:

Appliance

Clearance From

Suggested Service

Surface

Combustible Material

Clearance

 

inches

inches

Piping Side

1

18

Opposite Side

1

1

Top

1

24

Back

1

36

Front

1

36

Vent

per UL1738 venting

 

 

system supplier’s

 

 

instructions

 

Table 1. Clearances.

1.6 Locating Pump-MountedWater Heater with Respect to Storage Tank(s)

For best results the Brute Magnum water heater should be located within 15 feet (4.6m) of the storage tank(s). The pump is sized for 30 feet (9.1m) of piping.

Water heater pumps are sized for water hardness; 7.6 to 17 grains per gallon for normal water, greater than 17 grains per gallon for hard water, and 1 to

7.5 grains per gallon for soft water. If the appliance must be installed with longer piping runs, then larger diameter pipe or tubing may be able to be used, in some instances. Consult the factory for assistance.

1.7 Locating Pump-MountedBoiler with Respect to Return/Supply Header

Brute Magnum units must be piped in primarysecondary fashion because of the internal pump and mixing system.

For the best results the Brute Magnum Boiler should be located within 15 feet (4.6m) of the supply and return headers. The pump is sized for 30 feet (9.1m) of piping, in most cases, enough for primarysecondary piping systems.

If the appliance must be installed with longer piping runs, then larger diameter tubing may be able to be used, in some instances. Consult the factory for assistance.

Brute Magnum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

“V”

 

“A”

 

“W”

“G” Gas Connects.

 

 

 

 

 

 

Vent Outlet

 

Air Inlet

 

Water

Control Packages

 

 

 

 

Size

Connection

 

Connection

Inlet/ Outlet

Std & A

 

B & E

 

B & E

“B”

 

 

 

 

 

 

 

 

 

Connection

 

 

 

 

 

 

 

 

 

 

 

 

 

Nat/ LP

 

Nat

 

LP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

inches

 

 

inches

 

 

NPT

NPT

 

NPT

 

NPT

inches

 

 

 

1200

6

 

 

6

 

 

2-1/2”

1’

 

1-1/2’

 

1-1/2”

34-1/4”

 

 

 

1600

6

 

 

8

 

 

2-1/2”

1-1/2’

 

2”

 

2’

34-1/4”

 

 

 

2000

7

 

 

8

 

 

3”

1-1/2’

 

2”

 

2”

34-1/4”

 

 

 

2400

10

 

 

8

 

 

3”

1-1/2”

 

2”

 

2”

32”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 1. Dimensional Drawing.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Size

 

Intake

 

Exhaust

 

 

Intake

 

 

 

Exhaust

 

 

 

Size

 

Size

 

Maximum Run

 

 

 

Maximum Run

1200

 

6" (15 cm) dia.

 

6" (15 cm) dia.

 

50 linear feet with 5 elbows

50 linear feet with 5 elbows

1600

 

8" (20 cm) dia.

 

6" (15 cm) dia.

 

50 linear feet with 5 elbows

50 linear feet with 5 elbows

2000

 

8" (20 cm) dia.

 

7" (18 cm) dia.

 

50 linear feet with 5 elbows

50 linear feet with 5 elbows

2400

 

8" (20 cm) dia.

 

10" (25 cm) dia.

 

50 linear feet with 5 elbows

50 linear feet with 5 elbows

Table 2. Vent / Air Pipe Sizes.

1.8Locating Appliance for Correct Vent Distance From Outside Wall or

Roof Termination

The forced draft combustion air blower in the appliance has sufficient power to vent properly when the guidelines in Table 2 are followed.

NOTE: When located on the same wall, the Brute Magnum combustion air intake terminal must be installed a minimum of 12" (30cm) below the exhaust vent terminal and separated by a minimum of

36inches (91cm) horizontally.

Page 8

BRADFORDWHITECORP.

 

 

Section 2

VENTING AND COMBUSTION AIR

2.1Combustion Air

Brute Magnum boilers and water heaters must

have provisions for combustion and ventilation air in accordance with the applicable requirements for Combustion Air Supply and Ventilation in the

National Fuel Gas Code, ANSI Z223 1; or in Canada, the Natural Gas and Propane Installation Code, CSA B149.1. All applicable provisions of local building codes must also be adhered to.

A Brute Magnum unit can take combustion air from the space in which it is installed, or the combustion air can be ducted directly to the unit. Ventilation air must be provided in either case.

2.1.1 Combustion Air From Room

In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow. Where ducts are used, they shall be of the same cross-sectionalarea as the free area of the openings to which they connect.

Method 1: Two permanent openings, one commencing within 12" (300mm) of the top and one commencing within 12" (300mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors. When directly communicating with the outdoors, or when communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4000 Btu/hr (550 square mm/kW) of

total input rating of all equipment in the enclosure. When communicating to the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1square inch per 2000 Btu/hr (1100 square mm/kW) of total input rating of all equipment in the enclosure.

Method 2: One permanent opening, commencing within 12" (300mm) of the top of the enclosure, shall be permitted. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that directly communicate with the outdoors and shall have a minimum free area of 1square inch per 3000 Btu/hr (734 square mm/kW) of the total input rating of all equipment located in the enclosure. This opening must not be less than the sum of the areas of all vent connectors in the confined space.

Other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed above.

In Canada, consult local building and safety codes or, in absence of such requirements, follow CAN/CGA B149.

2.1.2 Intake Combustion Air

The combustion air can be taken through the wall, or through the roof. When taken from the wall, it must be taken from out-of-doorsby means of the horizontal wall terminal, shown in Table 3. See Table 2 to select the appropriate diameter air pipe. When taken from the roof, afield-suppliedrain cap or an elbow arrangement must be used to prevent entry of rain water (see Figure 2).

Figure 2. Combustion Air and Vent Through Roof.

Use single-wallgalvanized pipe for the combustion air intake (see Table 4), sized per Section 1.8. Route the intake to the heater as directly as possible. Seal all joints with tape. Provide adequate hangers. The unit must not support the weight of the combustion air intake pipe. Maximum linear pipe length allowed is 50 feet (15.2m). Up to five elbows can be used with the 50 feet of pipe. Subtract 10 allowable linear feet for every additional elbow used.

The connection for the intake air pipe is in the back of the unit. Take the plate off the back to reveal the collar on the filter box. Run a bead of silicone around the collar and slide the pipe over the collar. Secure with sheet metal screws.

Size

Horizontal Combustion

Horizontal Vent

Air Terminal

Terminal

 

1200

20260701

D2004500

1600

20260703

D2004500

2000

20260703

D2004600

2400

20260703

D2006200

Table 3. Horizontal Vent and Air Terminals

for Indoor Installations.

Brute Magnum

Page 9

 

 

Term

Description

Pipe

Single-wallgalvanized steel pipe, 24 gauge

 

minimum (sized per section 1.9)

Joint

Permanent duct tape or aluminum tape

Sealing

 

Insulation

Not required, but recommended R5 insulation

 

for cold installations (consult American Society

 

of Heating, Refrigerating, and Air Conditioning

 

Engineers (ASHRAE) handbook

Table 4. Required Combustion Air Piping Material.

In addition to air needed for combustion, air shall also be supplied for ventilation, including all air required for comfort and proper working conditions for personnel. The Brute Magnum loses less than 1 percent of its input rating to the room, but other heat sources may be present.

2.2Venting

The Brute Magnum is a Category IV appliance

and must be installed with a stainless steel venting system that complies with the UL 1738 Standard (see Table 5). It must be installed per this installation manual and the venting system manufacturer’s Installation Instructions. The unit’s vent can terminate through the roof, or through an outside wall. It can be installed through walls that are from 3" (7.6cm) to 12" (30cm) in thickness.

See Table 2 to select the appropriate vent pipe diameter. The vent pipe must be pitch upward, toward the vent terminal, so that condensate will run back to the Brute Magnum, to drain. Route the vent pipe to the heater as directly as possible. Seal all joints and provide adequate hangers as required in the venting system manufacturer’s Installation Instructions. Horizontal portions of the venting system must be supported to prevent sagging and may not have any low sections that could trap condensate. The unit must not support the weight of the vent pipe. Horizontal runs must slope upwards not less than ¼ inch per foot (21mm/m) from the unit to the vent terminal. Up to five elbows can be used with the 50 feet (15.2m) of pipe. Subtract 10 allowable linear feet for every additional elbow used.

IMPORTANT NOTE ABOUT COMMON VENTING:

A single vent that is shared by multiple Brute Magnum units MUST be engineered by a competent venting specialist, and involves the selection of draft inducing equipment, hardware and controls to properly balance flue gas pressures. Do not common vent

Brute Magnum units unless the vent system meets this requirement. Brute Magnum units are never permitted to share a vent with Category I appliances.

A condensate drain is built into the Brute Magnum. A pressure switch monitors the condensate drain pan, and will trip if the condensate level gets too high. This will prevent the Brute Magnum from firing if there is a blockage or overflow.

Connect a clear plastic tube, minimum 3/8" diameter, between the drain connection and a floor drain (or condensate pump if a floor drain is not accessible).

Caution

Condensate is mildly acidic, and may harm some floor drains and/or pipes, particularly those that are metal. Ensure that the drain, drainpipe,

and anything that will come in contact with the condensate can withstand the acidity, or neutralize the condensate before disposal. Damage caused by failure to install a neutralizer kit or to adequately treat condensate will not be the manufacturer’s responsibility.

A neutralizer kit is available from Bradford White. The kit includes a condensate pump.

The condensate tray must be primed before starting the unit. Fill the tray with water through the exhaust vent connection on the back of the unit. Continue filling until water flows out of the condensate drain port. This prevents the flue gases from escaping through the condensate drain. The condensate drain must be installed so as to prevent accumulation of condensate. When a condensate pump is not used, the tubing must continuously slope downward (except for the trap loop) toward the drain with no spiraling.

Consult local codes for disposal method.

Term

 

Description

Venting

 

Sealed stainless steel

 

 

system certified to UL1738.

Insulation

 

Not required, but recommended R5

 

 

insulation with protective cover for cold

 

 

installations (consult American Society of

 

 

Heating, Refrigerating, and Air Conditioning

 

 

Engineers (ASHRAE) handbook)

 

Table 5. Required Venting Material.

2.3Locating Vent & Combustion Air Terminals

2.3.1 Horizontal Vent Terminal

The appropriate side wall vent hood must be used, and is listed in the installation and operation manual. The terminal provides a means of installing the vent piping through the building wall, and must be located in accordance with ANSI Z223.1/NFPA 54 and applicable local codes. In Canada, the installation must be in accordance with CSA B149.1 or .2 and local applicable codes. Consider the following when installing the terminal:

Page 10

BRADFORDWHITECORP.

 

 

 

 

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 opened

4 feet (1.2 m) below or to side of opening;

36 inches (91 cm)

1 foot (30 cm) above opening

 

C=

Clearance to permanently closed window

See note 4

See note 5

D=

Vertical clearance to ventilated soffit located

 

 

 

above the terminal within a horizontal

See note 4

See note 5

 

distance of 2 feet (61cm) from the center line

 

 

 

of the terminal

 

 

E=

Clearance to unventilated soffit

See note 4

See note 5

F=

Clearance to outside corner

See note 4

See note 5

G=

Clearance to inside corner

See note 4

See note 5

H=

Clearance to each side of center line

 

3 feet (91 cm) within a height 15 feet above

 

extended above meter/regulator assembly

See note 4

the meter/regulator assembly

I=

Clearance to service regulator vent outlet

See note 4

3 feet (91 cm)

J=

Clearance to nonmechanical air supply inlet

 

 

 

to building or the combustion air inlet to

4 feet (1.2 m) below or to side of opening;

36 inches (91 cm)

 

any other appliance

1 foot (30 cm) above opening

 

K=

Clearance to a mechanical air supply inlet

3 feet (91 cm) above if within 10 feet (3 m)

6 feet (1.83 m)

 

 

horizontally

 

 

 

 

Vent termination not allowed in this location

 

 

Vent termination not allowed in this location

for category IV appliances. A vent shall not

L=

Clearance above paved sidewalk or paved

for category IV appliances. For Category III

terminate directly above a sidewalk or paved

 

driveway located on public property

appliances, vent must terminate at least 7

driveway that is located between two single

 

 

feet (2.13m) above the sidewalk or driveway.

family dwellings and serves both dwellings.

 

 

 

For Category III appliances that do not violate

 

 

 

the previous condition, vent must terminate at

 

 

 

least 7 feet (2.13m) above the sidewalk or

 

 

 

driveway.

M=

Clearance under veranda, porch, deck,

See note 4

12 inches (30 cm) (see note 3)

 

or balcony

 

 

Notes:

1.In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.

2.In accordance with the current CAN/CGA-B149Installation Codes.

3.Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

4.For clearances not specified in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the requirements of the gas supplier.

5.For clearances not specified in CAN/CGA-B149,clearance is in accordance with local installation codes and the requirements of the gas supplier.

*When vent terminal is less than 10 feet (3m) horizontally from a forced air inlet, the terminal must be at least 3 feet

(0.9m) above the air inlet.

Figure 3. Combustion Air and Vent Through Side Wall.

Brute Magnum

Page 11

 

 

1.The figure in this addendum shows the requirements for mechanical vent terminal clearances for the U.S. and Canada.

2.Vent terminals for condensing appliances or appliances with condensing vents are not permitted to terminate above a public walkway, or over an area where condensate or vapor could create a nuisance or hazard.

3.Locate the vent terminal so that vent gases cannot be drawn into air conditioning system inlets.

4.Locate the vent terminal so that vent gases cannot enter the building through doors, windows, gravity inlets or other openings. Whenever possible, locations under windows or near doors should be avoided.

5.Locate the vent terminal so that it cannot be blocked by snow. The installer may determine that a vent terminal must be higher than the minimum shown in codes, depending upon local conditions.

6.Locate the terminal so the vent exhaust does not settle on building surfaces or other nearby objects. Vent products may damage such surfaces or objects.

7.If the boiler or water heater uses ducted combustion air from an intake terminal located on the same wall, locate the vent terminal at least 3 feet (0.9m) horizontally from the combustion air terminal, and locate the vent terminal at least 1 foot (0.3m) above the combustion air terminal.

From Massachusetts Rules and Regulations 248 CMR 5.08:

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those

owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1.INSTALLATION OF CARBON MONOXIDE DETECTORS

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard-wiredcarbon monoxide detector with an alarm and batteryback-upis installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated orhard-wiredcarbon monoxide detector with an alarm is installed on each additional level of the

dwelling, building or structure served by the side

wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard-wiredcarbon monoxide detectors.

a.In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wiredcarbon monoxide detector with alarm and batteryback-upmay be installed on the next adjacent floor level.

b.In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2.APPROVED CARBON MONOXIDE

DETECTORS

Each carbon monoxide detector as required in accordance with the above provisions shall

comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3.SIGNAGE

A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half(½) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS."

4.INSPECTION.

The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b)EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1.The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2.Product Approved side wall horizontal vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

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(c)MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1.Detailed instructions for the installation of the venting system design or the venting system components; and

2.A complete parts list for the venting system design or venting system.

(d)MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the fuel gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1.The identification of each “special venting system” shall include either the listing of the website, phone number or manufacturer’s address where the venting system installation instructions can be obtained; and

2.The “special venting systems” shall be Product Approved by the Board, and the instructions provided with that system shall include a parts list and detailed installation instructions.

(e)A copy of all installation instructions for the Product Approved side wall horizontally vented gas fueled equipment, and all the venting instructions, parts lists, and/or design instructions for the venting system shall remain with the appliance or equipment at the completion of the installation.

Contact factory with questions about venting system installation.

2.3.2 Side Wall Combustion Air Terminal

The side wall combustion air terminal (see Table 4) must be used when the heater takes air from a

side wall. Consider the following when installing the terminal:

1.Do not locate the air inlet terminal near a source of corrosive chemical fumes (e.g., cleaning fluid, chlorine compounds, etc.)

2.Locate the terminal so that it will not be subject to damage by accident or vandalism. It must be at least 7 feet (2.1m) above a public walkway.

3.Locate the combustion air terminal so that it cannot be blocked by snow. The National Fuel Gas Code requires that it be at least 12 inches (30cm) above grade, but the installer may determine it should be higher, depending upon local conditions.

4.If the Brute Magnum is side-wallvented to the same wall, locate the vent terminal at least 3 feet (0.9m) horizontally from the combustion air terminal, and locate the vent terminal at least 1 foot (0.3m) above the combustion air terminal (see Figure 3).

2.3.3 Vertical Vent Terminal

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 (3.0m), and high enough above the roof line to prevent blockage from snow. When the combustion air is taken from the roof, the combustion air must terminate at least 12" (30cm) below the vent terminal (see Figure 2).

2.3.4 Vertical Combustion Air Terminal

When combustion air is taken from the roof, a field-suppliedrain cap or an elbow arrangement must be used to prevent entry of rain water (see Figure 2). The opening on the end of the terminal must be at least 12" (30cm) above the point at which it penetrates the roof, and high enough above the roof line to prevent blockage from snow. When the vent terminates on the roof, the combustion air must terminate at least 12" (30cm) below the vent terminal.

2.4 Common Vent Test — Boilers

NOTE: This section does not describe a method for common venting Brute Magnum units. It describes what must be done when a unit is removed from a common vent system. Brute Magnum units require special vent systems and fan for common vent. Contact the factory if you have questions about common venting Brute Magnum units.

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

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At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1.Seal any unused openings in the common venting system.

2.Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3.Insofar as it is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

5.Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

6.After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.

7.Any improper operation of the common venting system should be corrected so that the installation conforms to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Installation Codes. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size

as determined using the appropriate tables and guidelines in the National Fuel Gas Code, ANSI Z223.1 NFPA 54 and/or CSA B149.1, Installation Codes.

Section 3

GAS SUPPLY AND PIPING

3.1Gas Supply and Piping

Gas piping should be supported by suitable

hangers or floor stands, not the appliance. Review the following instructions before

proceeding with the installation.

1.Verify that the appliance is fitted for the proper type of gas by checking the rating plate. Appliances are normally equipped to operate at elevations up to 2000 feet (610m). However,

the appliance will function properly without the use of high altitude modification at elevations up to 10,000 feet (3050 m).

2.The maximum inlet gas pressure must not exceed 13" W.C. (3.2kPa). The minimum inlet natural gas pressure is 4" W.C. (1.0kPa) and minimum inlet propane gas pressure is 6" (1.5kPa).

3.Refer to Table 6, size supply.

4.Run gas supply line in accordance with all applicable codes.

Note: If you have a boiler/water heater with a normally open vent valve, install a vent line from the vent valve to an outside location

as required by your installation code or IRI requirement. Do not remove 3/4 inch pipe plug from the vent valve if venting from the normally open vent valve is not required by your installation code.

5.Locate and install manual shutoff valves in accordance with state and local requirements.

6.A sediment trap must be provided upstream of the gas controls.

Size and

 

 

Distance from Gas Meter or Last Stage Regulator

 

 

Gas Type

0-50feet

0-15m

50-100feet

15-31m

100-200feet

31-61m

200-300feet

61-91m

1200 natural

2"

5.1cm

2-1/2"

6.4cm

2-1/2"

6.4cm

3"

7.6cm

1200 propane

1-1/2"

3.8cm

2"

5.1cm

2"

5.1cm

2-1/2"

6.4cm

1600 natural

2-1/2"

6.4cm

2-1/2"

6.4cm

3"

7.6cm

3"

7.6cm

1600 propane

2"

5.1cm

2"

5.1cm

2-1/2"

6.4cm

2-1/2"

6.4cm

2000 natural

3"

7.6cm

3"

7.6cm

3"

7.6cm

3-1/2"

8.9cm

2000 propane

2-1/2"

6.4cm

2-1/2"

6.4cm

2-1/2"

6.4cm

3"

7.6cm

2400 natural

2-1/2"

6.4cm

3"

7.6cm

3"

7.6cm

3-1/2"

8.9cm

2400 propane

2"

5.1cm

2-1/2"

6.4cm

2-1/2"

6.4cm

3"

7.6cm

Notes: 1. These figures are based on 1/2" 0.12kPa water column pressure drop.

2. Check supply pressure and local code requirements before proceeding with work. 3. Pipe fittings must be considered when determining gas pipe sizing.

Table 6. Gas Piping Sizes.

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7.All threaded joints should be coated with piping compound resistant to action of liquefied petroleum gas.

8.The appliance and its individual shutoff valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.45kpa).

9.The unit must be isolated from the gas supply system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.45kpa).

10.The appliance and its gas connection must be leak tested before placing it in operation.

11.Purge all air from gas lines.

WARNING

Open flame can cause gas to ignite and result in property damage, severe injury, or loss of life.

NOTE: The Brute Magnum appliance and all other gas appliances sharing the gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. The pressure can be measured at the supply pressure port on the gas valve. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line. A bleed line from thediaphragm-typeautomatic valve shall be vented per local code requirements. Brute Magnum units are

equipped with low and high gas pressure switches that are integrally vent limited. These types of devices do not require venting to atmosphere.

Section 4A

WATER CONNECTIONS —

BRUTE MAGNUM BOILER

4A.1 Heating System Piping:

Hot Supply Connections — Boiler

NOTE: This appliance must be installed in a closed pressure system with a minimum of 12 psi (82.7kPa) static pressure at the boiler.

Hot water piping should be supported by suitable hangers or floor stands. Do not support piping with this appliance. Due to expansion and contraction of copper pipe, consideration should be given to the type of hangers used. Rigid hangers may transmit noise through the system resulting from the piping sliding in the hangers. It is recommended that padding be used when rigid hangers are installed. Maintain 1" (2.5cm) clearance to combustibles for hot water pipes.

Pipe the discharge of the relief valve (full size)

to a drain or in a manner to prevent injury in the event of pressure relief. Install an air purger, an air vent,

a diaphragm-typeexpansion tank, and a hydronic flow check in the system supply loop. Minimum fill pressure must be 12psig (82.7kPa). Install shutoff valves where required by code.

Suggested piping diagrams are shown in Figures 4, 5, and 6. These diagrams are meant only as a guide. Components required by local codes must be properly installed. The Brute Magnum boiler’s efficiency

is higher with lower return water temperatures. Therefore, to get the most of low return temperature with multiple boilers, pipe as shown in Figure 4.

The Brute Magnum boiler has an internal mixing system that ensures that the condensation does not occur on the finned copper heat exchanger, with boiler return temperature down to 50°F (10°C). This system, that consists of automatically actuated and linked valves, is set up at the factory, and is non-adjustable. The return water goes through the stainless steel heat exchanger, then to the mixing system (see Figure 7).

If the water at the inlet of the copper heat exchanger is less than 140°F (60°C), water from the outlet of the copper heat exchanger will be directed back to the inlet of the copper heat exchanger, and will mix to bring the inlet water up to 140°F (60°C). Once through the copper heat exchanger, the water picks up another 20-25°F(11-14°C)(when at high fire), and

it leaves the boiler at 160-165°F(71-74°C).This hot water is then sent to the system.

If the water at the inlet of the copper heat exchanger is 140°F (60°C), or higher, the water will be allowed to flow through the copper heat exchanger and directly to the outlet of the Brute Magnum, and there will be a 20-25°F(11-14°C)temperature rise between the inlet and outlet of the unit, when the unit is at high fire.

The pump in the boiler is sized for the boiler’s heat exchangers, the internal mixing system, and 30 feet of full-sizedpiping, with a normal number of fittings taken into consideration. The piping must be primary/secondary, ensuring that the boiler’s pump is only used for the boiler, and that the system pump(s) do not interfere with the Brute Magnum pump or mixing system.

The minimum inlet water temperature for the Brute Magnum is 50°F (10°C) to avoid condensing on the copper coils.

4A.2 Cold Water Make-Up— Boiler

1.Connect the cold water supply to the inlet connection of an automatic fill valve.

2.Install a suitable back flow preventer between the automatic fill valve and the cold water supply.

3.Install shut off valves where required.

NOTE: The boiler, when used in connection with a refrigeration system, must be installed so the chilled

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medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.

The boiler piping system of a hot water heating boiler connected to heating coils located in air handling appliances where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

A boiler installed above radiation level, or as required by the authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation.

4A.3 Freeze Protection – Boiler

Brute Magnum units are not designed to be placed outdoors, due to the potential for condensate to freeze in the unit.

Proper precautions for freeze protection are recommended for boiler installations in areas where the danger of freezing exists.

Power outage, interruption of gas supply, failure of system components, activation of safety devices, etc., may prevent a boiler from firing. Any time a boiler is subjected to freezing conditions, and the boiler is not able to fire, and/or the water is not able to circulate, there is a risk of freezing in the boiler or in the pipes in the system. When water freezes,

it expands. This can result in bursting of pipes in the system, or damage to the boiler, which could result in leaking or flooding conditions.

Do not use automotive anti-freeze.Maintaining a mixture of minimum 50% water and maximum 50% properly inhibited HVAC glycol, which contains an antifoamant, is the preferred method of freeze

protection for Brute Magnum boilers. The percentage of glycol used in the Brute Magnum boiler must not exceed 50%. Typically, this mixture will

serve as burst protection for temperatures down to approximately –35°F(-30°C).

IMPORTANT NOTES: Different glycol products may provide varying degrees of protection. Glycol products must be maintained properly in a heating system, or they may become ineffective. Consult the glycol specifications, or the glycol manufacturer, for information about specific products, maintenance of solutions, and set up according to your particular conditions.

For installations where temperatures are expected to fall below 15°F inside the boiler cabinet, the actuating gas valve must be equipped with a gas valve heater, part number R2010100. Note that some gas trains such as the IRI option may have double actuators, and may require 2 gas valve heaters.

Section 4B

WATER CONNECTIONS — BRUTE MAGNUM WATER HEATER

4B.1 Water System Piping — Water Heater

Hot water piping should be supported by suitable hangers or floor stands. Do not support piping with this appliance. Due to expansion and contraction of copper pipe, consideration should be given to the type of hangers used. Rigid hangers may transmit noise through the system resulting from the piping sliding in the hangers. It is recommended that padding be used when rigid hangers are installed.

The Brute Magnum can be used with several different types of readily available storage tanks. A pump draws water from the storage tank and pumps the water through the heater and back into the tank. Pump-mountedunits have a circulating pump built into the water heater.

Pipe the outlet from the heater’s relief valve such that any discharge from the relief valve will be conducted to a suitable place for disposal when relief occurs. Do not reduce line size or install any valves in this line. The line must be installed to allow complete drainage of both the valve and the line.

Suggested piping diagrams are shown in Figures 8, 9, 10, and 11. These diagrams are meant only as a guide. Components required by local codes must be properly installed.

The minimum inlet water temperature for the Brute Magnum is 50°F (10°C) to avoid condensing on the copper coils.

4B.2 Hot Water Supply Piping — Water Heater

Follow the tank manufacturer’s guidelines for completion of the hot water system connections.

NOTE: A listed temperature and pressure relief valve listed as complying with the Standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, 1). ANSI Z21.22 latest edition, or 2). CSA 4.4, of suitable discharge capacity must be installed in the separate storage tank system.

If the Brute Magnum water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold water supply line, the relief valve may discharge periodically, due to thermal expansion. Means (such as a properly-sizedexpansion tank) shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 4. Hydronic Piping - Multiple Boilers.

4B.3 Water Flow Requirements — Water Heater

In a water heating application (an open system), new water is constantly being introduced. With the new water comes a fresh supply of minerals that can be deposited on the unit’s heat exchanger. This is commonly known as scaling. The amount of minerals will depend upon the hardness of the water. Water can also be aggressive, and can erode metals, including copper, if the water is moved too quickly. Pump sizing for the Brute Magnum water heater is based upon the hardness of the water. The water flow is kept high enough to prevent scaling, but low enough to prevent

tube erosion. For extremely soft or hard water, cupronickel tubes are available. Contact a Bradford White Representative if you have questions or concerns about water quality.

The Brute Magnum water heater has an internal mixing system that ensures that the condensation does not occur on the finned copper heat exchanger, with heater return temperature down to 50°F (10°C). This system, that consists of automatically actuated and linked valves, is set up at the factory, and is non-adjustable. The return water goes through the stainless steel heat exchanger, then to the mixing system. (see Figure 7).

Brute Magnum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Figure 5. Hydronic Piping — Multiple Boilers (Alternate).

If the water at the inlet of the copper heat exchanger is less than 140°F (60°C), water from the outlet of the copper heat exchanger will be directed back to the inlet of the copper heat exchanger, and will mix to bring the inlet water up to 140°F (60°C). Once through the copper heat exchanger, the water picks up another 20-25°F(11-14°C)(when at high fire), and

it leaves the boiler at 160-165°F(71-74°C).This hot water is then sent to the system.

If the water at the inlet of the copper heat exchanger is 140°F (60°C), or higher, the water will be allowed to flow through the copper heat exchanger and

directly to the outlet of the Brute Magnum, and there will be a 20-25°F(11-14°C)temperature rise between the inlet and outlet of the unit, when the unit is at high fire.

The pump in the heater is sized for the heater’s heat exchangers, the internal mixing system, and 30 feet of full-sizedpiping, with a normal number of fittings taken into consideration.

The minimum inlet water temperature for the Brute Magnum is 50°F (10°C) to avoid condensing on the copper coils.

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BRADFORDWHITECORP.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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