Bradford White Brute BNTH1000, Brute BNTV1000, Brute BNTH1200, Brute BNTV1200 Installation And Operation Instructions Manual
Page 1
Installation and Operation Instructions Document 1266C
Installation and
Operation Instructions for
TM
Brute
Modulating Boiler Water Heater
Model BNTH1000 Model BNTV1000
1,000 MBTU/h 1,000 MBTU/h
Model BNTH1200 Model BNTV1200
1,200 MBTU/h 1,200 MBTU/h
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualied in hot water boiler and heater installation and maintenance. Improper installation and/or operation
could create carbon monoxide gas in ue 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 re or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
ammable 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 re department.
Installation and service must be performed
by a qualied installer, service agency, or gas
supplier.
Assurez-vous de 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 inammables 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 sservice des incendies.
L’installation et l’entretien doivent être assurés par
un installateur ou un service d’entretien qualié ou
par le fournisseur de gaz.
AVERTISSEMENT
H2360900C
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Table of Contents
B
RADFORD WHITE
Section 1
GENERAL INFORMATION ....................................... 1
1.1 Introduction ............................................... 1
1.2 About the Touch Screen ........................... 1
1.3 Safety Notes ............................................. 3
1.4 ModelIdentication/Nomenclature ......... 3
1.5 Warranty ................................................... 4
1.6 BruteComponents .................................... 4
1.7 Dimensions ............................................... 5
1.8 Unpacking ................................................. 5
Section 2
LOCATING THE APPLIANCE .................................. 6
2.1 LocatingtheAppliance ............................. 6
2.2 Correct Vent Distance
fromOutsideWallorRoofTermination ..... 6
Section 3
VENTING AND COMBUSTION AIR ......................... 7
3.1 CombustionAir ......................................... 7
3.1.1 CombustionAirFromRoom ..................... 7
3.1.2 DuctedCombustionAir ............................. 8
3.2 Venting ...................................................... 9
3.2.1 CommonVenting ...................................... 9
3.2.3 VentingRequirementsUniquetoCanada 9
3.3 LocatingtheVentandCombustionAir
Terminals ................................................ 10
3.3.1 SideWallVentTerminal .......................... 10
3.3.2 SideWallCombustionAirTerminal ......... 12
3.3.3 VerticalVentTerminal ............................. 13
3.3.4 VerticalCombustionAirTerminal ............ 13
3.3.5 InstallationsintheCommonwealthof
Massachusetts ........................................ 13
3.4 CommonVentTest ................................. 13
3.5 Outdoor Installation ................................ 14
3.6 CondensateTrap .................................... 14
Section 4
GAS SUPPLY AND PIPING ................................... 15
4.1 GasSupplyandPiping ........................... 15
Distance&PipeSize,Tables .................. 16
Section 5
PUMP REQUIREMENTS ....................................... 17
5.1 BruteBoilerFlowandHead
Requirements ......................................... 17
5.2 BruteWaterHeaterFlowand ....................
HeadRequirements ................................ 17
Section 6
WATER CONNECTIONS ....................................... 18
Section 6A - BNTH Systems................................... 18
6A.1 BNTHSystemPiping:HotSupply
Connections ............................................ 18
6A.2 BNTHColdWaterMake-Up ................... 18
6A.3 BNTHFreezeProtection ........................ 19
6A.4 BNTHSuggestedPipingSchematics ..... 19
6A.5 CondensateTrap .................................... 19
Section 6B - BNTV Systems................................... 25
6B.1 BNTV Water Quality ............................... 25
6B.2 BNTVPipingRequirements .................... 25
6B.3 BNTVColdWaterMake-Up .................... 26
6B.4 BNTVFreezeProtection ......................... 26
6B.5 BNTVSuggestedPipingSchematics ..... 26
6B.6 BNTVSuggestedPumps ........................ 27
6B.7 CondensateTrap .................................... 27
Section 7
ELECTRICAL CONNECTIONS .............................. 28
7.1 MainPower ............................................. 28
7.2 PumpConnections ................................. 28
7.3 24VACTransformerwithIntegral
CircuitBreaker ........................................ 30
7.4 SignalConnections ................................. 30
7.5 OptionalLowWaterCutOff(LWC O ) .... 30
7.6 OtherOptionalFieldConnections .......... 30
7.7 LadderDiagrams .................................... 31
WiringDiagrams ..................................... 32
Section 8
USING THE TOUCH SCREEN AND GAUGES...... 34
8.1 TheTouchScreenandGaugesontheFront
of the Brute ............................................. 34
8.2 UsingtheTouchScreen .......................... 34
8.3 WhileOperating–CheckingLead/Lag
OperatingInformation ............................. 36
8.4 CheckingLead/LagMaster ..................... 36
8.5 WhileOperating-CheckingIndividual
Parameters ............................................. 37
8.6 CheckingIndividualDetails .................... 38
8.7 ConguringParametersonIndividual
Controllers .............................................. 38
8.8 VericationProcessforSafety-Related
Parameters ............................................. 39
8.9 OptionalVariableSpeedPumpControl ...... 41
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Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Section9–
SETUP AND CONFIGURATION ............................ 42
9.1 ReviewofLead/LagControlSystem ...... 42
10.3 ShuttingDowntheBrute ......................... 87
10.4 RestartingtheBrute ................................ 87
9.1.1 AboutLead/LagOperation ..................... 42
9.1.2 Lead/LagModulationCycle .................... 43
9.1.3 BNTHLead/LagwithIndirect
DomesticHotWater ................................ 44
9.2 ConnectionTerminals ............................. 44
9.3 BruteSystemCongurations ................ 44-52
9.4 Installation Jobs ...................................... 53
A NoteforSystemsUsingCommon
Venting .................................................... 53
B NamingtheControllers ........................... 53
C MakeOneControltheLead/Lag
Master ..................................................... 54
D DisabletheLead/LagMasterFunction
ontheLead/LagSlaves .......................... 55
E SetuptheModbusControlAddressing .. 56
F SettheFlapValveIDs ............................ 57
G DisconnectUnusedOperator
Interfaces ................................................ 61
H ConnecttheModbusWiring ................... 61
Section 11
MAINTENANCE ..................................................... 88
11.1 SystemMaintenance .............................. 88
11.2 Maintenance Notes ................................. 88
11.2.1 Burner ..................................................... 88
11.2.2 ModulatingGasValve/Venturi ................ 88
11.2.3 Controllers .............................................. 89
11.2.4 IgnitorAssembly ..................................... 89
11.2.5 FlameSensor ......................................... 89
11.2.6 TransformerwithIntegral
CircuitBreaker ........................................ 89
11.2.7 Blower ..................................................... 90
11.2.8 HeatExchangerCoils ............................. 90
11.2.9 GasPressureSwitches(optional) .......... 90
11.2.10Natural/PropaneGasConversion ......... 91
11.2.11 CondensateTrap .................................. 91
11.2.12 Battery(Date&TimeBack-Up) ............ 91
I SettheParametersUsedbythe
Lead/LagSystem .................................... 62
Aboutthe“TimeofDay”Function ........... 66
J InstalltheSystemSensorandAdjust
theSetpoint ............................................ 66
K SettheLead/LagOutdoorResetand
WarmWeatherShutdown ....................... 66
About“OutdoorReset” ........................... 67
L BuildingAutomationorMultipleBoiler
ControlThermostatDemand ................. 68
M BuildingAutomationorMultipleBoiler
4-20mASetpointControl ....................... 68
N BuildingAutomationorMultipleBoiler
4-20mAModulationControl .................... 69
O Combustion Setup Procedure ............. 69
Section 12
TROUBLESHOOTING ........................................... 92
12.1 PotentialSetupandSynchronization
Problems ................................................ 92
12.1.1 ControllerSynchronization ..................... 92
12.1.2 FlapValveStatusChecks ....................... 93
12.2 AboutLockouts,Holds,andAlerts .......... 93
12.2.1 RespondingtoaLockout,Hold,
or Alert .................................................... 93
12.2.2 ViewingtheLockoutandAlert
Histories .................................................. 94
12.3 TroubleshootingTables(allcodes)......96-110
12.4 DiagnosticTestsandInput/Output
Indicators ............................................... 111
P SettingtheDateandTimeonthe
SystemDisplay ....................................... 74
9.5 SetupforDomesticHotWaterona
Lead/LagSystem .................................... 75
SetupType1 ........................................... 75
SetupType2 ........................................... 76
12.5 Lead/LagSlaveDiagnostics .................. 112
12.6 Statistics ................................................11 2
12.7 Analysis .................................................11 2
12.8 ControlSnapshot ................................... 113
12.9 OperatingSequence .............................. 113
SetupType3 ........................................... 77
9.6 GatewayConnectionstoa
BuildingAutomationSystem ................... 78
9.7 InstallerParameters .......................... 79-85
Section 13
REPLACEMENT PARTS .......................................116
13.1 GeneralInformation ............................... 116
13.2 Parts List ................................................ 116
Section 10 -
13.3 Parts Illustrations .................................. 122
INITIAL STARTUP INSTRUCTIONS ...................... 86
10.1 FillingtheBoilerSystem ......................... 86
ii
10.2 InitialBurnerOperation ........................... 87
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RADFORD WHITE
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Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 1
Section 1
GENERAL INFORMATION
1.1 Introduction
This manual includes information which will help you
to install, operate, and maintain the Brute 1000 &
1200 systems. Please read this manual completely
before proceeding with the installation. If you have
any questions regarding this equipment, please
consult the Bradford White factory, or a local factory
representative. Many operating problems are caused
by improper installation.
Touch Screen Display
(behind the plastic cover
which slides downward)
Pressure and
temperature
gauge
Power switch
If eld conditions require modications, consult
the factory representative before initiating such
modications.
1.2 About the Brute’s
Touch Screen Display
The Brute 1000 & 1200 have an advanced control
system which can perform many functions. This is
part of the reason why the Brute can deliver such
outstanding performance. You can access the
control system using the ‘Touch Screen Display’
(see Section 8). There are several “branches” in the
control software, and many different display screens.
For clarity, throughout this manual we have made a
special effort to show you how to reach each of the
important setup and operating functions. We have
done this in two ways:
• In many cases, we have shown you the actual
touch screen display that you will see while
performing a function.
• Sometimes, instead of showing the screens,
we have just listed the series of choices you
should make in order to reach the section you
want.
The arrangement of the control software is actually
quite logical, and after you have worked with it a bit,
you will not have any problems “nding your way
around.” We just want to give you some help with
the rst part of the process, when you are “getting
used to” the control system .
WARNING
Brute 1000 & 1200 units 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 1000 & 1200 units
must conform to the Standard for Controls
and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1. Any
modications to the boiler, its gas controls,
or wiring may void the warranty.
Later in this manual, we will detail information on the
setup and operating procedures. There are a couple
of concepts you will need to understand right from
the start.
• Each boiler has two controllers (internal
electronic burner controllers) and two burners,
as shown in Figure 1.
• A single Touch Screen is used to communicate
with these two controllers.
Boiler 1
Touch
Screen
Primary
controller
Gas
valve
Gas
valve
Secondary
controller
Primary
burner
Secondary
burner
Figure 1. Control Arrangement in a Single-Boiler
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RADFORD WHITE
Installation
• Each controller and burner work together. Each
boiler includes two of these controller/burner
combinations.
Notice the different terms we are using here.
The term boiler refers to the whole appliance –
the complete Brute 1000 & 1200. Each boiler
includes two separate controller/burner pairs.
• Brute 1000 & 1200 units are always set up for
“Lead/Lag” operation. The term “Lead/Lag”
means that, as the heating load increases, the
control system brings additional burners on
automatically.
Touch
Screen
Boiler 1
Addr1Addr2Addr3Addr4Addr5Addr6Addr7Addr
Lead Lag
Master and
Slave 1
Slave 2
Boiler 2
Slave 3
Slave 4
Boiler 3
Slave 5
Slave 6
Boiler 4
8
Slave 7
Slave 8
burner pairs will refer back to that single value.
On the Touch Screen, from the ‘home’ screen
you can reach all of the Lead/Lag functions by
pressing the View Lead Lag button. Figure 3.
• INDIVIDUAL FUNCTIONS, Other functions
apply only to each separate controller/burner
pair. As an example, each controller/burner has
a name, and this can be changed.
The ‘home’ screen on the Touch Screen will
show icons for each of the controller/burner
pairs connected to the system. To reach one of
the functions for an individual controller/burner,
press the icon for that controller/burner. On the
following screen, press the Congure button.
This will take you to all of the conguration
options for that individual controller/burner.
Figure 2. Lead/Lag Arrangement in a Multiple-
Boiler Installation
On a multiple-boiler installation, each of the individual
boilers is still set up as shown in Figure 2 above, but
the controller/burner pairs on all of the boilers are
arranged in a “daisy chain.”
Up to four boilers, with up to eight controller/burner
pairs, can be connected in this way.
In all Brute 1000 & 1200 multiple-boiler installations,
just one of the Touch Screens is active. It can
communicate with all of the controller/burner pairs in
the system, so it displays information from all of the
burners. A single system sensor provides the control
input for the system.
All Brute 1000 & 1200’s that are set up as a single
boiler will still uses a Lead/Lag operation. If the
heating load becomes too great for the rst burner,
the control system automatically starts the second
burner.
To work with this control system, you will need to
understand the difference between two kinds of
control functions:
• SYSTEM FUNCTIONS, Some of the functions
control all of the controller/burner pairs, working
together as part of the Lead/Lag system. As
an example, the setpoint for a whole multipleboiler system is set by a single value: “Central
Heat Lead/Lag Setpoint.” By changing this one
value, you change the setpoint used by the
whole system. The action of all of the controller/
Press here for
system setup
Press here to
see current
Lead/ Lag
performance
Press here
for individual
controller/
burner pairs
Press here
for Lead/ Lag
setup
Figure 3. Going to Lead/Lag and Individual
Functions
Note – For individual functions, if you want to
make a change on all of the controller/burner
pairs in the system, you will have to go to each
controller/burner separately and repeat the
change for each of them. If there are eight
controller/burners in the system, and you want
to make the same change on all of them, go
to each of the eight controller/burner pairs
separately.
As we go through the explanations in this manual,
we will point out whether a control function affects
the whole Lead/Lag system, or just an individual
controller/burner pair.
This has been just a quick introduction, but this
manual includes two longer sections that will help you
to work with the control system:
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Brute
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
• Section 8 – “Using the Touch Screen and the
Gauges.”
This section will explain how to “Navigate”
through the Touch Screen : how to enter and
change values, and so on.
• Section 9 – “Setup and Conguration”
The rst part of this section includes a more
complete explanation of the Lead/Lag system.
Carbon Monoxide Hazard
Improper adjustment of the burners may lead to poor
combustion quality, increasing the amount of carbon
monoxide produced. Excessive carbon monoxide
levels may lead to personal injury or death.
The rest of the section includes detailed setup
instructions.
If you are not familiar with the control system, the
installation and setup process will go much more
smoothly if you read through these three sections
before beginning work.
Electrical Shock Hazard
Electrical shock can cause severe injury, death or
property damage. Disconnect the power supply before
beginning installation or changing the wiring to prevent
electrical shock or damage to the equipment. It may
1.3 Safety Notes
be necessary to turn off more than one power supply
disconnect.
All electrical wiring is to be done in accordance with
WARNING
Fire or Explosion Hazard
Improper conguration can cause fuel buildup and
explosion. Improper user operation may result in
local codes, or in the absence of local codes, with:
1) The National Electrical Code ANSI/NFPA No.
70 - latest Edition, or 2) CSA STD. C22.1 “Canadian
Electrical Code - Part 1.” This appliance must be
electrically grounded in accordance with these codes.
property loss, severe physical injury, or death.
Any changes to safety-related conguration parameters
must only be done by experienced and/or licensed
burner/boiler operators and mechanics.
If any odor of gas is detected, or if the gas burner does
1.4 ModelIdentication
Consult the rating plate on the unit. The following
information describes the model number structure.
not appear to be functioning in a normal manner, close
the main gas shutoff valve. Do not shut off the power
switch. Contact your heating contractor, gas company,
or factory representative.
The Brute is protected against over-pressurization. A
pressure relief valve is included with each Brute 1000 &
1200.
The inlet gas pressure to the appliance must not exceed
13” W.C. (3.2 kPa).
All installations must be made in accordance with 1)
American National Standard Z223.1/NFPA54-Latest
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.
(1-3) Model Series Designation
B N T = Brute
(4) Usage
H = Hydronic
V = Volume Water
(5-8) Size
1 0 0 0 = 1,000,000 BTU/hr input
1 2 0 0 = 1,200,000 BTU/hr input
(9) Fuel
N = Natural Gas
P = LP Gas
(10) Options Code
J = CSD1 Version
X = Standard Unit
(11) Pump Options
X = No pump
(12) Revision
1 = First version
Page 3
WARNING
WARNING
(conguration available for all sizes)
Model Nomenclature
1 2 3 4 5 6 7 8 9 10 11 12
B N T
SERIES
B N T
USAGE
H - HYDRONIC
V - VOLUME
WATER
SIZE
MBTU/h
1 0 0 0
1 7 0 0
FUEL
N - NATURAL
P - PROPANE
OPTIONS CODE
J - CSD1
X - STANDARD
PUMP OPTIONS
X - NO PUMP
1
REVISION
1 - FIRST
Page 8
Page 4
1.5 Warranty
Bradford White’s Brute 1000 & 1200 are covered by
a limited warranty. The owner should complete the
warranty registration at:
http://www.BradfordWhite.com
All warranty claims must be made to an authorized
Bradford White representative. Claims must include
the serial number and model. (This information
can be found on the rating plate.) The claim must
also include the installation date and name of the
installer. Shipping costs are not included in the
warranty coverage.
Some accessory items may be shipped in separate
packages. Verify receipt of all packages listed on
1.6 Brute Components
B
RADFORD WHITE
the packing slip. Inspect everything for damage
immediately upon delivery, and advise the carrier
of any shortages or damage. Any such claims
should be led with the carrier. The carrier, not
the shipper, is responsible for shortages and
damage to the shipment whether visible or
concealed.
The Touchscreen does have an internal battery for
back-up of the date and time settings. To access the
battery, the front panel and the Touchscreen must
be removed so that the small plastic door on the
back of the touchscreen can be accessed.
The battery is a CR2032 ‘coin type’ battery and
has an expected life of 10 years.
Protective Cover
(slides downward)
Pressure and
temperature
gauge
Blower 1
(under bezel)
Automatic
gas valves
Manual
gas valve
Touchscreen
Power switch
Ducted air inlet
Electrical box
PRV and
ow switch
Outlet
temperature
sensors
Inlet
temperature
sensors
Blower 2
Figure 4. Components
Condensate
trap
Leveling feet
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Brute
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 5
Figure 5. Dimensions
1.7 Dimensions
The dimensions are shown in Figure 5
1.8 Unpacking
The Brute is shipped in a single crate. The standard
outdoor/system sensor kit is packed inside the same
crate.
1. Remove all packing and tie-down materials.
2. Check that the outdoor/system sensor kit is
included.
DANGER
• Water temperature over 125°F (52°C) can
cause severe burns instantly or death from
scalds.
• Children, disabled and elderly are at highest
risk of being scalded.
• See instruction manual before
setting temperature at
heating appliance.
• Feel water before
bathing or showering.
• If this appliance is used
to produce water that
could scald if too hot,
such as domestic hot water
use, adjust the outlet
control (limit) or use temperature limiting
valves to obtain a maximum water
temperature of 125°F (52°C).
Page 10
Page 6
Section 2
LOCATING THE APPLIANCE
2.1 Locating the Appliance
The Brute 1000 and 1200’s may be installed indoors
or outdoors. The unit may only be installed outdoors
in a location which will never experience freezing
temperatures. Choose a location for the unit which
allows clearances on all sides for maintenance and
inspection. See Table 1. Always install the unit on a
rm, level surface. Level the unit using the leveling
feet.
The unit 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 oors
of the structure.
When this type of location is not available, install a
suitable drain pan, adequately drained, under the
appliance.
The appliance is design-certied by CSAInternational for installation on combustible ooring;
in basements; in closets, utility rooms or alcoves.
Brute boilers 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 must be located as
close as practical to the vertical section of the 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 or the maximum expected snow line.
The dimensions and requirements that are shown in
Table 1 should be met when choosing the locations
for the appliance.
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RADFORD WHITE
APPLIANCE SUGGESTED SERVICE ACCESS CLEARANCE
SURFACE INCHES CM
Front 24 60.9
Left Side 12 30.5
Right Side 18 45.7
Back 24 60.9
Top 24 60.9
APPLIANCE REQUIRED CLEARANCE TO COMBUSTIBLES
SURFACE INCHES CM
Front 2 5.1
Left Side 0 0
Right Side 0 0
Back 0 0
Top 8 20.3
Vent 1 2.6
Table 1. Clearances
Installations in the U.S. require exhaust vent pipe that is PVC or
CPVC complying with ANSI/ASTM D1785 F441, polypropylene
complying with ULC-S636, or stainless steel complying with
UL1738. Installations in Canada require exhaust vent pipe that is
certied to ULC S636.
Intake (air) pipe must be PVC or CPVC that complies with ANSI/
ASTM D1785 F441, ABS that complies with ANSI/ASTM D1527,
stainless steel, or galvanized material.
Closet and alcove installations do not allow the use of PVC under
any circumstances
To calculate max equivalent length, measure the linear feet of the
pipe, and add 5 feet (1.5 m) for each elbow used.
6” 100 30
Brute
STANDARD MAX EQUIV.
VENT FT. M
Table 2. Vent / Air Pipe Sizes
2.2 Correct Vent Distance from
Outside Wall or Roof Termination
The forced draft combustion air blower in the
appliance has sufcient power to vent properly when
the guidelines in Table 2 are followed.
Note - When located on the same wall, the Brute
combustion air intake terminal must be installed a
minimum of 12” below the exhaust terminal. There
must also be a minimum horizontal distance from
intake to the exhaust terminal of 36.”
For the concentric vent terminal kit (optional), follow
the installation instructions included with the kit.
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 7
Section 3
VENTING AND COMBUSTION AIR
3.1.1 Combustion Air From Room
In the United States, the most common
requirements specify that the space shall
communicate with the outdoors in accordance with
3.1 Combustion Air
Brute 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 1000 & 1200 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.
Method 1 or 2. (See the following descriptions.)
Where ducts are used, they shall be of the same
cross-sectional area as the free area of the
openings to which they connect.
Method 1: Two permanent openings, one
commencing within 12” (300 mm) of the top and
one commencing within 12” (300 mm) 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
PVC CPVC Stainless Steel Polypropylene
Model Ducted Air Exhaust Ducted Air Exhaust Ducted Air Exhaust Ducted Air Exhaust
1,000 CA008100 CA008300 CA008100 CA008300 CA008200 D2004500 CA008500 CS008500
1,200 CA008100 CA008300 CA008100 CA008300 CA008200 D2004500 CA008500 CS008500
Table 3a - Horizontal Terminations for Indoor Use
PVC CPVC Stainless Steel Polypropylene
Model Ducted Air Exhaust Ducted Air Exhaust Ducted Air Exhaust Ducted Air Exhaust
1,000 CA008400 CA008300 CA008400 CA008300 CA008500 CA008500 CA008500 CA008500
1,200 CA008400 CA008300 CA008400 CA008300 CA008500 CA008500 CA008500 CA008500
Table 3b - Vertical Terminations for Indoor Use
Model Ducted Air Exhaust
1,000 CA008700 CA008900
1,200 CA008700 CA008900
Table 3c - Outdoor Terminations
Material United States Canada
ABS ANSI/ASTM D1527 The air pipe material must be chosen based upon
PVC, sch. 40 ANSI/ASTM D1785 or D2665
CPVC, sch. 40 ANSI/ASTM F441
Single wall galv. steel 26 gauge
Polypropylene ULC-S636 Class 2C
the intended application of the boiler, and must
be installed according to the vent manufacturer’s
installation instructions.
Table 3. Tables 3 A thru C not linked
Table 4. Required Combustion Air Pipe Material
Page 12
Page 8
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RADFORD WHITE
equipment in the enclosure. When communicating to
the outdoors through horizontal ducts, each opening
shall have a minimum free area of not less than
1 square 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” (300 mm) 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 1 square 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 conned 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/
CSA B149.
allowable linear ft. (1.5 m) for every elbow used.
When using polypropylene or stainless steel
materials in horizontal duct congurations, a single
elbow must be installed on the end of the air inlet
to act as an outdoor terminal. In vertical duct
applications, two elbows must be installed on the
end of the inlet to act as a vent terminal. In both
installation types, Bradford White part number
CA008500 (for Model 1,000 and 1,200) can then be
installed into the elbow to prevent foreign objects
from entering the air inlet system. The elbow(s)
required to complete the vent terminal is not
included.
The connection for the intake air pipe is on the back
panel.
*
*
*
*
*
3.1.2 Ducted 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-doors by means of a horizontal
wall terminal, shown in Table 3a. See Table 2 to
select the appropriate diameter air pipe. When taken
from the roof, a eld-supplied rain cap or an elbow
arrangement must be used to prevent entry of rain
water. (See Figure 6).
Use ABS, PVC, CPVC, polypropylene, stainless
steel, or galvanized pipe for the combustion air
intake. (See Table 5.) The intake must be sized per
Table 2. Route the intake to the boiler as directly
as possible. Seal all joints. Provide adequate
hangers. The unit must not support the weight of
the combustion air intake pipe. The maximum linear
pipe length allowed is 100 feet (39 m). Subtract 5
Installation Standards
Material United States Canada
Stainless steel UL 1738 Venting must be ULC-S636 certied for use as
PVC*, sch 40 ANSI/ASTM D178
CPVC, sch 40 ANSI/ASTM F441
Polypropylene UL-S636 Class 2C
* PVC cannot be used for the rst 12 inches of vent material
In Canada, refer to CAN/CSA B199.1
*
*
Figure 6. Combustion Air and Vent Through Roof
venting material. The venting material class must
be chosen based upon the intended application
of the boiler, and must be installed according to
the maximum ue gas temperature and the vent
manufacturer’s instructions.
Table 5. Required Exhaust Vent Material
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 9
In addition to air needed for combustion, air shall
also be supplied for ventilation, including air required
for comfort and proper working conditions for
personnel. Refer to the applicable codes.
3.2 Venting
WARNING
Selection of improper vent materials for installations
that are installed in closets, or will be operated
in high ambient temperature levels, may lead to
property damage, personal injury, or death.
WARNING
A 12” or 305 mm section of CPVC must be
connected directly to the boiler before a PVC vent
system can be used. Connecting PVC directly to the
boiler’s ue collar may cause vent failure, leading to
property damage, personal injury, or death.
WARNING
Failure to use the appropriate vent material,
installation techniques, or glues and sealants could
lead to vent failure causing property damage,
personal injury or death.
WARNING
All venting must be installed according to this
manual and any other applicable local codes,
including but not limited to, ANSI Z223.1/NFPA 54,
CSA B149.1, CSAB149.2 and ULC-S636. Failure to
follow this manual and applicable codes may lead to
property damage, severe injury, or death.
TheuetemperatureoftheBrutechanges
dramatically with changes in operating water
temperature. Therefore, it is necessary to assess
the application of the boiler to determine the
requiredcertiedventclass.IftheBruteis
installed in an application where the ambient
temperature is elevated, and/or installed in
a closet/alcove, CPVC, polypropylene, or
stainless steel material is required. If the
system temperatures are unknown at the time of
installation, class IIC or higher venting material
is recommended.
The Brute is a Category IV appliance and may be
installed with PVC, CPVC that complies with ANSI/
ASTM D1785 F441, or polypropylene that complies
with ULC-S636 Class 2C, or a stainless steel venting
system that complies with the UL 1738 Standard.
(See Table 5.) The unit’s vent can terminate through
the roof, or through an outside wall.
The use of polypropylene vent material has
been accepted by CSA for use with exhaust and
combustion. The polypropylene vent manufacturer
shall have ULCS636 Class 2C approval or higher
with a recognized listing agency for all components
used in the venting system. All components used
must be from the same manufacturer and designed
for use with exhaust temperatures of 195°F
(90°C) or higher. When installing polypropylene
vent systems, please, refer to the vent supplier’s
installation instructions for proper installation
techniques.
When using PVC/CPVC for the vent material, the
rst 12 inches or 305 mm of vent must be connected
to the CPVC section included with the Brute. The
CPVC vent section included with the Brute may
be broken by CPVC ttings if necessary, but never
reduced in total length. See Table 2 to select the
appropriate vent pipe diameter.
When using polypropylene, all vent material must be
from the same manufacturer and UL-S636 rated.
All installations must be done following the vent
supplier’s recommended installation techniques. If
these are not available, refer to the Bradford White
recommendations for the material used.
The vent pipe must pitch upward, toward the
vent terminal, not less than 1/4” per foot, so that
condensate will run back to the Brute to drain.
Route the vent pipe to the heater as directly as
possible. Seal all joints. 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. Please see Table 2 for
proper diameter vs. length allowed.
3.2.1 Common Venting
A single vent that is shared by multiple Brute’s must
be engineered by a competent venting specialist,
and could involve the selection of draft inducing
equipment, hardware and controls to properly
balance ue gas pressures. Do not common
vent Brute’s unless the vent system meets this
requirement. Brute’s are never permitted to
share a vent with Category I appliances.
3.2.2 Venting Requirements Unique to
Canada
Brute 1000 & 1200 boilers and water heaters are
Vent Category IV appliances. Per the requirements
of CAN/CSA-B149.1, only BH vent systems can be
connected to these units and such vent systems,
either ULC S636 certied stainless steel or other
ULC S636 certied BH vent (eg. plastics) must
be installed per the vent manufacturer’s certied
installation instructions.
Page 14
Page 10
It is the responsibility of the appropriately licensed
technician installing this Brute to use ULC
S636 certied vent material consistent with the
requirements as described in the Venting and
Combustion Air section.
Class I venting systems are suitable for gas-red
appliances producing ue gas temperature of more
than 135°C, but not more than 245°C.
Class II venting systems are suitable for gas-red
appliances producing ue gas temperatures of 135°C
or less.
Class II venting systems are further classied into
four temperature ratings as follows:
A Up to and including 65°C
B Up to and including 90°C
C Up to and including 110°C, and
D Up to and including 135°C
B
RADFORD WHITE
Flue Gas Sampling Port -
It is also the responsibility of the installer to ensure
that a ue gas sampling port is installed in the vent
system. This ue gas sampling port must be installed
near the ue connection of the Brute: within 2 feet
of the ue connection. There is no ue gas sampling
port internal to the Brute, so one must be installed
in the vent system external to the Brute. A ue gas
sampling port available as a component of the ULC
S636 certied vent system is preferred. However, if
one is not available with the certied vent system,
Bradford White suggests using a tee with the branch
connection sized to allow for insertion of a ue gas
analyzer probe. The branch connection must be
resealable with a cap or other means to ensure the
vent system remains sealed. (See Figure 7.)
Consideration must be given to the placement and
orientation of the ue gas sampling port to ensure
that condensate is free to ow back into the Brute
and not collect anywhere in the vent system -
including in the ue gas sampling port.
Exhaust Vent Terminal -
An exhaust vent terminal must be installed. If an
exhaust vent terminal is not available with the
certied vent system, Bradford White suggests
the use of a coupler tting from the certied vent
system into which the vent terminal screen can be
installed. Be sure to install and terminate both vent
and combustion air pipes per the instructions in this
section.
Figure 7. Test Port
3.3 Locating the Vent and Combustion
Air Terminals
3.3.1 Side Wall Vent Terminal
The appropriate Bradford White side wall vent
terminal must be used. The terminal 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:
1. Figure 8 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, avoid locations under
windows or near doors.
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,
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Brute
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
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 See note 6 See note 6
B= Clearance to window or door that may be Direct vent only: 12 inches (30 cm); 36 inches (91 cm)
opened Other than Direct vent: 4 ft (1.2m) below or to
side of opening; 1 ft (30 cm) above opening
C= Clearance to permanently closed window See note 4 See note 5
D= Vertical clearance to ventilated soft located
above the terminal within a horizontal See note 4 See note 5
distance of 2 feet (61 cm) from the center
line of the terminal
E= Clearance to unventilated soft 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
extended above meter/regulator assembly See note 4 above the meter/regulator assembly
I= Clearance to service regulator vent outlet See note 4 3 feet (91 cm)
J= Clearance to nonmechanical air supply Direct vent only: 36” (91cm)
inlet to building or the combustion air inlet Other than Direct vent: 4 ft (1.2m) below 36 inches (91 cm)
to any other appliance or to side of opening; 1 ft (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
L= Clearance above paved sidewalk or paved Vent termination not allowed in this location 7 ft (2.1 m)
driveway located on public property for category IV appliances. See note 5
M= Clearance under veranda, porch, deck, See note 4 12 inches (30 cm)
or balcony See note 5
Notes:
1. In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.
2. In accordance with the current CAN/CSA-B149 Installation Codes.
3. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.
4. For clearances not specied 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 specied in CAN/CSA-B149, clearance is in accordance with local installation codes and the requirements of the
gas supplier.
6. IMPORTANT: All terminals must be placed so that they remain a minimum 12” above expected snow line. Local codes may have
more specic requirements, and must be consulted.
Page 11
Figure 8. Combustion Air and Vent Through Side Wall
*When vent terminal is less than 10 feet (3 m) horizontally
from a forced air inlet, the terminal must be at least 3 feet
(0.9 m) above the air inlet. (US only)
Page 16
Page 12
IMPORTANT: All terminals must be placed so that they remain at least
12” above the expected snow line. Local codes may have more specific
requirements, and must be consulted. Refer to the NFPA54 National Fuel
Gas Code and your local codes for all required clearances for venting.
B
RADFORD WHITE
Figure 9. Multiple Side-Wall
Terminals, Air and Vent
Figure 10. Minimum Venting Distance
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 surfaces
or objects.
7. If the boiler or water heater uses ducted
combustion air from an intake terminal located
on the same wall, see Figures 10 and 11 for
proper spacing and orientation.
If the vent termination is located in an area exposed
to high winds, an optional PVC tee (the same
diameter as the vent pipe) may be used. The tee’d
vent termination offers greater protection from wind
related operating issues.
3.3.2 Side Wall Combustion Air Terminal
The Bradford White side wall combustion air terminal
must be used when the heater takes air from a side
wall. (See Figure 9.) Contact Bradford White for
AL29-4C termination ttings. Consider the following
when installing the terminal. (See Figure 9 and
Figure 10).
1. Do not locate the air inlet terminal near a
source of corrosive chemical fumes (e.g.,
cleaning uid, 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 ( 2.1 m) 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
(30 cm) above grade, but the installer may
determine it should be higher, depending upon
local conditions.
4. If the Brute is side-wall vented to the same wall,
locate the vent terminal at least 1 foot (0.3 m)
above the combustion air terminal.
5. Multiple vent kits should be installed such that
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 13
the horizontal distance between outlet group
and inlet group is 36” (90 cm). (See Figure 10.)
6. The vent outlet must be at least 12” above the
top of the air inlet, and must be at least 36” (90
cm) horizontally from the air inlet.
3.3.3 Vertical Vent Terminal
When the unit is vented through the roof, the vent
must extend at least 3 feet (0.9 m) above the point
at which it penetrates the roof. It must extend at
least 2 feet (0.6 m) higher than any portion of a
building within a horizontal distance of 10 feet (3.0
m), and high enough above the roof line to prevent
blockage from snow. The vent terminal offered with
the Brute can be used in both vertical and horizontal
applications. When the combustion air is taken from
the roof, the combustion air must terminate at least
12” (30 cm) below the vent terminal.
3.3.4 Vertical Combustion Air Terminal
When combustion air is taken from the roof, a eld-
supplied rain cap or an elbow arrangement must be
used to prevent entry of rain water. The opening on
the end of the terminal must be at least 12” (30 cm)
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” (30 cm)
below the vent terminal.
3.3.5 Installations in the Commonwealth
of Massachusetts
In Massachusetts the following items are required if
the side-wall exhaust vent termination is less than
seven (7) feet above nished grade in the area
of the venting, including but not limited to decks
and porches. (From Massachusetts Rules and
regulations 248 CMR 5.08.)
1. Installation of Carbon Monoxide Detectors
At the time of installation of the side wall vented
gas fueled appliance, the installing plumber
or gas-tter shall observe that a hard-wired
carbon monoxide detector with an alarm battery
back-up is installed on the oor level where
the gas appliance is to be installed. In addition,
the installing plumber or gastter shall observe
that a battery operated or hard-wired carbon
monoxide detector with an alarm is installed on
each additional level of the dwelling, building
or structure served by the side-wall horizontally
vented gas fueled equipment. It shall be the
responsibility of the property owner to secure
the services of qualied licensed professionals
for installation of hard-wired carbon 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-wired carbon
monoxide with alarm and battery back-up may
be installed on the next adjacent oor level.
b. In the event that the requirements of the
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 be installed.
2. Approved Carbon Monoxide Detectors
Each carbon monoxide detector shall comply
with NFPA 720 and be ANSI/UL 2034 listed and
IAS certied.
3. Signage
A metal or plastic identication 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 horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print no less than one-half (1/2) 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 appliance 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) 1-4.
3.4 Common Vent Test
Note -This section does not describe a method for
common venting Brute’s. It describes what must be
done when a unit is removed from a common vent
system. Brute’s require special vent systems and
fans for common vent. Contact the factory if you
have questions about common venting Brute’s.
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.
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.
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RADFORD WHITE
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 or
other deciencies which could cause an unsafe
condition.
3. As much as possible, close all building doors
and windows. Also close 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 any clothes dryers or other appliances 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 any replace dampers.
4. Place in operation the appliance being
inspected. Follow the lighting instructions. Adjust
the thermostat so the appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening
after ve minutes of main burner operation. Use
the ame 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 the doors, windows, exhaust fans,
replace dampers and any other gas burning
appliances 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.
operation in outdoor installations, the boiler must
be equipped with the inlet air and exhaust terminal
kits listed in Table 3C. The bottom panel cover
plate must be removed. Additional instructions are
supplied with the terminal kits.
3.6 Condensate Drain Trap
A condensate drain trap is included with the Brute
and is designed to drain the boiler of condensate.
The vent condensate should be drained through
a drain tee located in the vent line. This will help
prevent excessive condensate from entering the
boiler condensate trap and preventing the boiler
from operating.
Connect a 3/4” PVC pipe between the drain
connection and a oor drain (or condensate pump if
a oor drain is not accessible).
The condensate drain must be installed to
prevent the accumulation of condensate. When
a condensate pump is not used, the tubing must
continuously slope downward toward the drain with
no spiraling.
Consult local codes for the disposal method.
Caution
Condensate is mildly acidic (pH=5), and may
harm some oor 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.
3.5 Outdoor Installation
The Brute 1000 & 1200’s may only be installed
outdoors in applications where the outdoor
temperature doesn’t drop below freezing. For proper
Page 19
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Brute
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Section 4
GAS SUPPLY AND PIPING
4.1 Gas Supply and Piping
Gas piping should be supported by suitable hangers
or oor stands, not the appliance.
Installers should refer to local building and safety
codes or, in the absence of such requirements,
follow the National Fuel Gas Code, ANSI Z223.1
NFPA 54 and/or CSA B149.1, Installation Codes.
Review the following instructions before proceeding
with the installation.
1. Verify that the appliance is tted for the proper
type of gas by checking the rating plate. The
Brute 1000 & 1200 will function properly
without the use of high altitude modication at
elevations up to 10,000 feet (3050 m).
2. The maximum inlet gas pressure must not
exceed 13” W.C. (3.2 kPa). The minimum inlet
gas pressure is 4” W.C. (1.0 kPa).
3. Refer to Tables 6A, 6B, 6C and 6D to size the
piping.
4. Run the gas supply line in accordance with all
applicable codes.
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.
7. All threaded joints should be coated with piping
compound resistant to the action of liqueed
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
(3.45 kPa).
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 (3.45 kPa).
10. The appliance and its gas connection must be
leak tested before placing it in operation.
11. Purge all air from gas lines.
Open ame can cause gas to ignite and result in
property damage, severe injury, or loss of life.
Note - The Brute appliance and all other gas ap-
pliances sharing the gas supply line must be ring
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. Some Brute’s are equipped
with low and high gas pressure switches that are
integrally vent limited. These types of devices do not
require venting to atmosphere.
Page 15
WARNING
Page 20
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RADFORD WHITE
Brute 1000 & 1200
NATURAL GAS
REQUIRED
CU FT
SIZE / HR.
1000 1000
1200 1200
TO SIZE PIPING:
Measure linear distance from meter outlet
to last boiler. Add total input of all boilers
and divide by 1000 to obtain cu ft / hr
required. Add total equivalent length of
ttings used according to Table 6B. Align
total length (pipe and ttings) on left side
column of Table 6C with highest cubic feet
of gas required.
Notes:
Consult and conrm with Applicable Fuel
Gas Code before beginning work.
Verify gas inlet pressure is between 4 and
13 in W.C. before starting boiler.
Table 6A - Natural Gas Requirements
EQUIVALENT LENGTHS OF STRAIGHT PIPE FOR TYPICAL
FITTING 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
90° ELBOW 3.6 4.4 5.2 6.6 7.4 8.5
TEE 4.2 5.3 6.6 8.7 9.9 12
SCH 40 FITTINGS
NOMINAL PIPE SIZE
LINEAR FEET
Table 6B - Equivalent Pipe Lengths
SCH 40 METAL PIPE CAPACITY FOR 0.60 SPECIFIC GRAVITY
NATURAL GAS
NOMINAL PIPE SIZE @ 0.30” W.C. PRESSURE DROP
LENGTH 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
FT CUBIC FEET OF GAS PER HOUR
20 92 190 350 730 1100 2100
40 130 245 500 760 1450
60 105 195 400 610 1150
80 90 170 350 530 990
100 150 305 460 870
Table 6C - Pipe Capacity for Natural Gas
SCHED 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC
GRAVITY UNDILUTED PROPANE
NOMINAL PIPE SIZE @ 11” W.C. INLET AND 0.5” W.C.
PRESSURE DROP
SIZE 1/2” 3/4” 1” 1-1/4” 1-1/2” 2”
LENGTH MAXIMUM CAPACITY IN THOUSANDS OF BTU PER
HOUR
20 200 418 787 1616 2422 4664
40 137 287 541 1111 1664 3205
60 110 231 434 892 1337 2574
80 94 197 372 763 1144 2203
100 84 175 330 677 1014 1952
Notes:
1. Follow all local and national LP gas codes for line sizing and
equipment requirements.
2. Verify that inlet gas pressure remains between 4 and 13 inches
of water column before and during operation.
Source: ANSI Z223.1-80 National Fuel Gas Code.
Table 6D - Pipe Capacity for Propane
Page 21
B
Intake Exhaust Maximum
(Air) (Vent) Allowable
Size Pipe Pipe EquivalentLength*
1000 6" 6" 100 ft 30 m
1200 6" 6" 100 ft 30 m
InstallationsintheU.S.requireexhaustventpipethatisacombinationofPVCand
CPVCcomplyingwithANSI/ASTMD1785F441,polypropylenepipethatcomplies
withULCS636,orstainlesssteelcomplyingwithUL1738.InstallationsinCanada
requireexhaustventpipethatiscertiedtoULCS636.
NOTE:Therst12"(30cm)ofventmustbeCPVCifusingaPVCventsystem.
Intake(air)pipemaybeABS,PVC,CPVCorgalvanizedmaterial.
ClosetandalcoveinstallationsdonotallowtheuseofPVCunderanycircumstances
*Tocalculatemaxequivalentlength,measurethelinearfeetofthepipe,andadd5
feet (1.5m) for each elbow used.
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Section 5
PUMP REQUIREMENTS
5.1 Brute Boiler Flow and Head Requirements
Temperature Rise in °F
20°F 25°F 30°F 35°F 40°F 45°F
Flow H/L Flow H/L Flow H/L Flow H/L Flow H/L Flow H/L
gpm feet gpm feet gpm feet gpm feet gpm feet gpm feet
95 30 75 20 62 15 54 11 48 9 42 7
114 37 91 26 76 18 65 13 57 10 51 8
Temperature Rise in °C
11°C 14°C 17°C 19°C 22°C 25°C
Flow H/L Flow H/L Flow H/L Flow H/L Flow H/L Flow H/L
lpm m lpm m lpm m lpm m lpm m lpm m
359 9.0 283 6.0 234 4.5 204 3.3 182 2.7 159 2.1
432 11.3 344 7.9 288 5.5 246 4.0 216 3.0 193 2.4
Page 17
Table 7. Water Flow Requirements
5.2 Brute Water Heater Flow and Head Requirements
Temperature Rise
20°F 11°C
Flow H/L Flow H/L
Size gpm feet lpm m
1000 95 30 359 9.0
1200 114 37 430 10.8
Maximum water hardness of 10 grains per gallon allowed.
Table 8. Brute Water Heater Flow Data
Page 22
Page 18
Section 6 WATER CONNECTIONS
B
RADFORD WHITE
Section 6 is divided into TWO parts.
Section 6A covers NTH units designed
for hydronic heating. Many installations
include indirect domestic hot water.
Section 6B covers NTV models, which are
designed exclusively for “volume water”
domestic hot water applications. Refer
to the proper section for instructions on
installing and piping your product. Refer
to Table 9 for the connection pipe sizes
required.
Section 6A - NTH Systems
6A.1 NTH System Piping:
Hot Supply Connections
Note -This appliance must be installed in a closed
pressure system with a minimum of 12 psi (82.7
kPa) static pressure at the boiler.
The hot water piping should be supported by
suitable hangers or oor stands. Do not support
the piping with this appliance. The hangers used
should allow for expansion and contraction of copper
pipe. Rigid hangers may transmit noise through
the system resulting from the piping sliding in the
hangers. We recommend that padding be used
when rigid hangers are installed. Maintain 1” (2.5
cm) clearance to combustibles for all 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-type expansion tank, a hydronic ow
check in the system supply loop, and any other
devices required by local codes. The minimum ll
pressure must be 12 psig (82.7 kPa). Install shutoff
valves where required by code.
NTH PIPE SIZE, NTV PIPE SIZE,
SIZE INCHES SIZE INCHES
1000 2 1000 2
1200 2 1200 2
Table 9. Table 9 - Water Connection Pipe Sizes
Suggested piping diagrams are shown in Figures
12 through 16. These diagrams are meant only as
guides. Components required by local codes must
be properly installed.
TheBrute’sefciencyishigherwithlowerreturn
water temperatures. Therefore, to get the best low
return temperature with multiple boilers, pipe as
shown in Figures 15 and 16.
6A.2 NTH Cold Water Make-Up
1. Connect the cold water supply to the inlet
connection of an automatic ll valve.
2. Install a suitable back ow preventer between
the automatic ll valve and the cold water
supply.
3. Install shut off valves where required.
In some installations, a hot water heating boiler is
connected to heating coils located in an air handling
appliance where the coils may be exposed to
refrigerated air circulation. In these cases, the boiler
piping system must be equipped with ow control
valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling
cycle.
WARNING
When a boiler is installed above radiation level, it
is required that a Low Water Cut-Off (LWCO) be
installed unless this requirement is superceded by
Jurisdictional requirements.
Specic instructions for the installation of a Low
Water Cut Off (LWCO) are the following:
Locate the wiring diagram within this manual. On the
wiring diagram, locate the connection points marked
LWCO or Field Interlocks. These are the electrical
connection points for the LWCO. Follow LWCO
Manufacturer’s Wiring Instructions.
Mechanically, install the LWCO device in a tee tting
in the supply piping above the highest point of the
boiler (unless the boiler has an existing tting for that
purpose). Follow LWCO Manufacturer’s Instructions
for minimum pipe sizing.
Note: This boiler is a water tube boiler that requires
water ow through the heat exchanger for proper
Page 23
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 19
operation. It does not have an operating water
level and must be full at all times. In accordance
with ANSI/ASME CSD-1 Section CW-210 and The
National Fuel Gas Code ANSI Z223.1/NFPA 54
Section 10.3.5 a water tube boiler shall have a water
ow proving device in lieu of a Low Water Cut Off.
6A.3 NTH Freeze Protection
WARNING
Glycol must not be used in domestic hot water
applications. Refer to Section 6B.4 for instructions
on freeze protection for NTV units (domestic hot
water).
Brute’s may be installed indoors or outdoors. If
installed outdoors, the NTH unit must never be
installed in a location which may experience freezing
temperatures. If installed indoors, and there is an
event such as a power outage, interruption of gas
supply, failure of system components, activation of
safety devices, etc., this may prevent a boiler from
ring. Any time a boiler is subjected to freezing
conditions,andtheboilerisnotabletore,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 may
result in bursting of pipes, or damage to the boiler,
and this could result in leaking or ooding conditions.
Do not use automotive antifreeze. To help prevent
freezing, Bradford White recommends the use
of inhibited glycol concentrations between 20%
and 35% glycol. Typically, this concentration will
serve as burst protection for temperatures down
to approximately -5°F (-20°C). If temperatures
are expected to be lower than -5°F (-20°C), glycol
concentrations up to 50% can be used. When
concentrations greater than 35% are used, water
owratesmustbeincreasedtomaintaina20°F
to25°Ftemperaturerisethroughtheboiler.
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 specications,
or the glycol manufacturer, for information about
specic products, maintenance of solutions, and set
up according to your particular conditions.
The following manufacturers offer glycols, inhibitors,
and anti foamants that are suitable for use in the
Brute. Please refer to the manufacturers instructions
for proper selection and application.
• Sentinel Performance Solutions Group
• Hercules Chemical Company
• Dow Chemical Company
6A.4 NTH Suggested Piping Schematics
Figure 11 through Figure 14 (the next several
pages) show suggested piping congurations for
NTH boilers. These diagrams are only meant as
guides. All components or piping required by local
code must be installed.
6A.5 Condensate Drain Trap
A condensate drain trap is included with the Brute
and is designed to drain the boiler of condensate.
The vent condensate should be drained through
a drain tee located in the vent line. This will help
prevent excessive condensate from entering the
boiler condensate trap and preventing the boiler
from operating.
Connect a 3/4” PVC pipe between the drain
connection and a oor drain (or condensate pump if
a oor drain is not accessible).
The condensate drain must be installed to
prevent the accumulation of condensate. When
a condensate pump is not used, the tubing must
continuously slope downward toward the drain with
no spiraling.
Consult local codes for the disposal method.
Caution
Condensate is mildly acidic (pH=5), and may
harm some oor 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.
Page 24
Page 20
Space heating zone circuit
Space heating zone circuits
B
RADFORD WHITE
Low temp. radiant zone
Air vent
Water feed
controls
4 pipe dia. max.
System pump
4 pipe dia. max. 4 pipe dia. max. 4 pipe dia. max.
Note This drawing is a schematic
representation of a piping style,
and is not intended to be used
as a working installation drawing.
Local code requirements
must be met.
Figure 11. Hydronic Piping — Single Boiler, Multiple Temperature Zones. Zoning with circulators
Page 25
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 21
Air vent
Water feed
controls
Expansion tank
Note This drawing is a schematic
representation of a piping style,
and is not intended to be used
as a working installation drawing.
Local code requirements
must be met.
4 pipe dia. max.
4 pipe
dia. max.
Anti-scald
mixing valve
Domestic
hot water
out
Indirect DHW tank
Cold
water
Figure 12. Hydronic Piping — Single Boiler, Zoning with Circulators, Indirect DHW Tank with Zone Pumps
Indirect tank directly off of boiler
Page 26
Page 22
Note This drawing is a schematic
representation of a piping style,
and is not intended to be used
as a working installation drawing.
Local code requirements
must be met.
B
RADFORD WHITE
Air vent
Expansion tank
4 pipe dia. max.
Low temp. radiant zone
Water feed controls
Indirect DHW tank
Low temp. radiant zone
Anti-scald
mixing
valve
Domestic
hot water
out
Cold water
Figure 13. Hydronic Piping — Single Boiler with Low Temperature Zones and Indirect DHW Tank
Indirect tank directly off of boiler
Page 27
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 23
Note This drawing is a schematic
representation of a piping style,
and is not intended to be used
as a working installation drawing.
Local code requirements
must be met.
Space heating zone circuit
Air vent
Water feed controls
Expansion tank
4 pipe dia. max.
Space heating
zone circuits
Low temp. radiant zone
4 pipe dia. max. 4 pipe dia. max.
Common piping must be sized for the
combined water flow of all of the boilers.
Figure 14. Hydronic Piping — Multiple Boilers, Multiple Temperature Zones, Reverse Return
Zoning with circulators
Page 28
Page 24
Space heating zone circuit
Air vent
Space heating zone circuits
High temp. space heating zone circuit
B
RADFORD WHITE
Water feed
controls
Expansion tank
4 pipe dia. max.
Common piping must be sized for the
combined water flow of all the boilers.
Note This drawing is a schematic
representation of a piping style,
and is not intended to be used
as a working installation drawing.
Local code requirements
must be met.
4 pipe dia. max. 4 pipe dia. max.
Note Indirect pump
must be sized
for boiler and
indirect
Indirect
DHW tank
Anti-scald
mixing valve
Domestic
hot water
out
Cold
water
Figure 15. Hydronic Piping — Multiple Boilers, Indirect DHW Off of One Boiler
Section 6B - NTV Systems
6B.1 NTV Water Quality
NTV water heaters must be installed in water conditions
of 10 gpg hardness or less, with a pH range of 6.5 to
9.5 pH. Values outside of this range may reduce the life
expectancy of the product. Operating the NTV in water
with higher hardness levels will cause heat exchanger
fouling, erosion, or corrosion, leading to premature
component failure, reduced efciency, heat exchanger
failure or system failure. Failure of this type will not be
warranted. If the water in use exceeds the conditions
recommended, water softeners or other devices should
be installed to improve water quality.
Note In this piping arrangement,
the boiler pump must turn off
during DHW operation.
6B.2 NTV Piping Requirements
The water piping should be supported by suitable
hangers and oor stands. Do not support the piping
with this appliance. The hangers used should allow
for expansion and contraction of copper pipe. Rigid
hangers may transmit noise through the system
resulting from piping sliding in the hangers. We
recommend that padding be used when rigid hangers
are installed. Maintain 1” (2.5 cm) clearance to
combustibles for hot water pipes.
Pipe the discharge of the relief valve (full size) to the
drain or in a manner to prevent injury in the event of
pressure relief. Install a diaphragm-type expansion
tank, ow check, and shutoff valves where needed or
Page 29
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
as required by code.
The piping should be installed so that each pump
supplies ow only to the heater to which it is
attached.
6B.3 NTV Cold Water Make-Up
The cold water make-up may be connected to the
tank or to the inlet of the boiler as shown in Figures
17-19. Install back-ow preventers and shut-offs
where needed or required by code.
WARNING
When a water heater is installed above radiation
level, it is required that a Low Water Cut-Off
(LWCO) be installed unless this requirement is
superceded by Jurisdictional requirements.
Specic instructions for the installation of a Low
Water Cut Off (LWCO) are the following:
Locate the wiring diagram within this manual. On the
wiring diagram, locate the connection points marked
LWCO or Field Interlocks. These are the electrical
connection points for the LWCO. Follow LWCO
Manufacturer’s Wiring Instructions.
Mechanically, install the LWCO device in a tee
tting in the supply piping above the highest point
of the water heater (unless the water heater has
an existing tting for that purpose). Follow LWCO
Manufacturer’s Instructions for minimum pipe sizing.
Note: This water heater is a water tube boiler that
requires water ow through the heat exchanger
for proper operation. It does not have an operating
water level and must be full at all times. In
accordance with ANSI/ASME CSD-1 Section CW210 and The National Fuel Gas Code ANSI Z223.1/
NFPA 54 Section 10.3.5 a water tube water heater
shall have a water ow proving device in lieu of a
Low Water Cut Off
Page 25
Location
of pump
4
Expansion
tank
1
WARNING: This drawing shows
3
suggested piping conguration and
valving. Check with local codes and
ordinances for additional requirements.
Supply
TPRV
2
Building
return
Expansion
tank
4
Cold
water
supply
3
NOTES:
1. Optional CWMU & recirculation line location.
2. Locate NTV DHW sensor or remote aquastat well
in lower 1/3 of tank.
3. Back ow preventer may be required - check local codes.
4. Thermal expansion tank may be required - check local codes.
Figure 16. DHW Piping - One Heater, One Vertical Tank
Page 30
Page 26
B
RADFORD WHITE
6B.4 NTV Freeze Protection
The NTV unit must never be installed outdoors
in a location which may experience freezing
temperatures. If installed indoors, and there is an
event such as a power outage, component failure
or other issue when freezing is likely, the heater and
system must be drained to avoid the risk of damage
due to freezing. Glycol must not be used in volume
water heating applications.
6B.5 NTV Suggested Piping Schematics
Figures 17-19 show suggested piping congurations
for NTV boilers. These diagrams are only meant as
guides. All components or piping required by local
code must be installed.
3
Cold water
supply
6B.6 NTV Suggested Pumps
See Table 8 for water ow and head
requirements.
Note - The head loss for the piping, ttings,
and accessories must be calculated and added
to the heater head loss to get the total required
pump head. An undersized pump will result in
insufcient ow. The can result in scale buildup
and failure of the heat exchanger.
NOTES:
1. Optional CWMU & recirculation line location.
2. Locate the NTV DHW sensor or remote aquastat well
in lower 1/3 of tank.
3. Back ow preventer may be required - check local
codes.
Building
return
4. Thermal expansion tank may be required check local codes.
5. Caution: Pump sizing must be based upon water
hardness at job site.
Pump
Supply
Expansion
tank
TPRV
1
4
TPRV
2
2
Ball valve
(typical)
Figure 17. DHW Piping - One Heater, Two Vertical Tanks
WARNING: This drawing shows
suggested piping conguration and
valving. Check with local codes and
ordinances for additional requirements.
Page 31
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 27
NOTES:
1. Optional CWMU & recirculation
line location.
2. Locate the NTV DHW sensor
or remote aquastat well
in lower 1/3 of tank.
3. Back ow preventer may be
required - check local codes.
4. Thermal expansion tank may be
required - check local codes.
5. Caution: Pump sizing must
be based upon water
hardness at job site.
1
Pump
Check valve
Pump
Cold water
supply
3
4
3
4
Expansion
tank
TPRV
Building
return
2
WARNING: This drawing shows
suggested piping conguration and
valving. Check with local codes and
ordinances for additional requirements.
Supply
TPRV
2
Ball valve
(typical)
Check valve
Figure 18. DHW Piping - Two Heaters, Two Vertical Tanks
6B.7 Condensate Drain Trap
A condensate drain trap is included with the Brute
1000 & 1200 and is designed to drain the boiler
of condensate. The vent condensate should be
drained through a drain tee located in the vent line.
This will help prevent excessive condensate from
entering the boiler condensate trap and preventing
the boiler from operating.
Connect a 3/4” PVC pipe between the drain
connection and a oor drain (or condensate pump if
a oor drain is not accessible).
The condensate drain must be installed to
prevent the accumulation of condensate. When
a condensate pump is not used, the tubing must
continuously slope downward toward the drain with
no spiraling.
Consult local codes for the disposal method.
Caution
Condensate is mildly acidic (pH=5), and may harm
some oor 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.
Page 32
Page 28
Section 7
ELECTRICAL CONNECTIONS
WARNING
The Brute 1000 & 1200 appliances 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 oors and could be
electrocuted by an ungrounded boiler. Electrocution
can result in severe injury or death.
Single pole switches, including those included in
safety controls and protective devices, must not be
wired in a grounded line.
All electrical connections are made on the terminal
blocks that are located inside the control panel.
B
RADFORD WHITE
Caution
The supply voltage to the Brute must not be
disengaged, except for service or isolation, or
unless otherwise instructed by procedures outlined
in this manual. To signal a call for heat, use the
correct terminals as instructed in Section 9.
7.1 Main Power
For the convenience of the installer, a junction box
has been placed at the rear of the boiler (internal)
for power connections. These connections include
three pre-stripped wires (black, white and green) for
power connections. The Brute 1000 & 1200 use a
single 120-volt 15 Amp fused supply.
7.2 Pump Connections
The Brute energizes the appropriate pump contacts
when it receives a call for heat or domestic hot
water. Once the call for heat or DHW is satised, the
pump will remain on for the dened pump overrun
time.
Note - All internal electrical components have been
prewired. No attempt should be made to connect
electrical wires to any other locations except the
terminal blocks.
The wiring connections are shown in Figures 21 and22.
Note - Do not make and break the line voltage to the
Brute as a signal to call for heat.
On a system operating as a Lead/Lag installation A “call for heat/ end call for heat” must be connected
to the Primary TT or Interlock terminals (terminals 5
and 6 on TB7) on the controller which is acting as the
Lead/Lag master.
On a boiler operating individually A “call for heat/ end call for heat” must be connected
to the Primary Thermostat terminals (terminals 5
and 6 on TB7). Any jumper to the System terminals
(terminals 3 and 4 on TB6) must be removed. For
details, see Section 9.
Some Brute components are designed to have
constant voltage during normal operation. If the
Brute’s supply voltage is toggled as a call for heat
signal, premature failure of these components may
result.
The Brute does not recognize 4 mA as a signal to shut
off. If the call for heat is not connected between the eld
interlock terminals, Brute will remain in low re when it
sees 4 mA as a modulating signal.
Note - The contacts for the System and DHW
pumps are dry contacts. Appropriate voltage must
be supplied to the System and DHW pumps for
proper operation.
The Boiler pump is controlled using a 120V
single-phase 15 Amp power supply. The current
supplied by this source cannot exceed 7.4 FLA. If
more current is required, an additional relay/pump
contactor must be installed. Wire the relay so it is
energized from the contacts on the boiler to allow
the pump to be turned on and off with the demand.
The System pump connections are located on
terminal block 5 (5-6 on TB5) in the control panel.
(See Figure 20.) The System pump contacts are
rated for 120 VAC, 7.4 Amps. To use the contacts,
power must be supplied on one terminal with the
other terminal wired to the relay controlling the
pump.
The DHW pump connections are located on terminal
block 5 (7-8 on TB5) in the control panel and are
rated for 120 VAC, 7.4 Amps. To use the contacts,
power must be supplied on one terminal, and the
other terminal wired to the relay controlling the
pump. Additional 120 VAC circuits may be required
for the pumps.
Page 33
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 29
TB9
TB2
TB1
TB5
TB3
TB6
TB4
TB7
Secondary controller
(lower burner)
Figure 19. Electronics Panel Layout
Primary controller
(upper burner)
Model 1,000 1,200
Voltage 120 V AC 120 V AC
Current - FLA 10 A 12 A
Pump Connections Ratings
(Boiler, System,
and DHW Pumps)
Table 10 - Electrical Data
TB10
max 7.4 FLA max 7.4 FLA
Page 34
Page 30
1
2
24
13
1
2
24
13
OUTLET WATER
TEMP. SENSOR
STACK
TEMP. SENSOR
OUTLET WATER
TEMP. SENSOR
J8-4 SEC.
J8-4 PRIM.
J8-10 SEC.
J8-8 SEC.
J9-6 PRIM.
J9-4 PRIM.
J8-10 PRIM.
J8-8 PRIM.
J8-5
SEC.
J8-5
PRIM.
J8-9
SEC.
J9-5
PRIM.
J8-9
PRIM.
J9-5
SEC.
INLET WATER
TEMP. SENSOR
48
37
26
15
J9-6 SEC.
J9-4 SEC.
D
C
B
DWG NO.
E23460
SH
1
REV
A
BW
REVISIONS
REV.
CHANGE:
APPR
ENGR APPR
ECN
TEMP SENSOR. ZONE D-1
A 14-013 AH 2/12/14
DRAFT
CHECK
ADDED SECONDARY CONNECTORS TO THE STACK
D
DWG NO.
E23460
SH
1
REV
A
BW
REVISIONS
REV.
CHANGE:
APPR
ENGR APPR
ECN
TEMP SENSOR. ZONE D-1
A 14-013 AH 2/12/14
DRAFT
CHECK
ADDED SECONDARY CONNECTORS TO THE STACK
7.3 24 VAC Transformer with Integral
Circuit Breaker
24 VAC is supplied by a transformer mounted on the
control panel. All 24 VAC power is supplied through
a circuit breaker that is part of the transformer. The
transformer is then connected to terminal blocks 1
and 2 (TB1 and TB2).
7.4 Signal Connections
See Section 9 for details on the following
connections:
• System sensor
• Call for heat/thermostat
• Outdoor air temperature sensor
• Aquastat for domestic hot water
• External control connections
7.5 Optional Low Water Cut Off (LWCO)
Specic instructions for the installation of a Low
Water Cut Off (LWCO) are the following:
Locate the wiring diagram (Figure 22). On the wiring
diagram, locate the connection points marked
Low Water Cut Off. These are the electrical
connection points for the LWCO. Follow LWCO
Manufacturer’s Wiring Instructions.
J8-9
PRIM.
J9-5
PRIM.
J9-5
SEC.
J8-9
SEC.
J8-5
PRIM.
J8-5
SEC.
OUTLET WATER
TEMP. SENSOR
13
24
STACK
TEMP. SENSOR
15
26
37
48
OUTLET WATER
TEMP. SENSOR
13
24
INLET WATER
TEMP. SENSOR
J8-10 PRIM.
1
2
1
2
J8-8 PRIM.
J9-4 PRIM.
J9-6 PRIM.
J9-4 SEC.
J9-6 SEC.
J8-8 SEC.
J8-10 SEC.
J8-4 PRIM.
J8-4 SEC.
B
RADFORD WHITE
Mechanically, install the LWCO device in a tee tting
in the supply piping above the highest point of the
boiler (unless the boiler has an existing tting for that
purpose). Follow LWCO Manufacturer’s Instructions
for minimum pipe sizing.
WARNING
When a boiler is installed above radiation level, it
is required that a Low Water Cut-Off (LWCO) be
installed unless this requirement is superceded by
Jurisdictional requirements.
Note: This boiler is a water tube boiler that requires
water ow through the heat exchanger for proper
operation. It does not have an operating water
level and must be full at all times. In accordance
with ANSI/ASME CSD-1 Section CW-210 and The
National Fuel Gas Code ANSI Z223.1/NFPA 54
Section 10.3.5 a water tube boiler shall have a water
ow proving device in lieu of a Low Water Cut Off.
7.6 Other Optional Field Connections
Other Optional components, such as ow switches,
additional high limits and other eld supplied devices
can be installed as shown on the wiring diagram
(Figure 20).
ANALOG
INPUT PRIM.
ANALOG
INPUT SEC.
OUTDOOR
TEMP.
SENSOR
TEMP. SENSOR
PRIM.
TEMP. SENSOR
SYSTEM
TEMP.
SENSOR
ALARM
DHW
DHW
SEC.
{
+
J8-6 PRIM.
-
J8-7 PRIM.
{
+
J8-6 SEC.
-
J8-7 SEC.
{
J8-12 SEC.
J7-11 SEC.
{
J9-1 PRIM.
J9-2 PRIM.
{
J9-1 SEC.
J9-2 SEC.
{
J8-11 PRIM.
J8-12 PRIM.
J6-8 PRIM.
J6-8 SEC.
J6-7 PRIM.
J6-7 SEC.
FIELD
CONNECTIONS
Figure 20. Ladder Diagram, Field Connections
Page 35
B
21
21
21
FIELD
CONNECTIONS
AA
J5-2
PRIM.
OPTIONAL
HIGH GAS
PRESSURE SW
SEC.
J7-4 SEC.
J7-4 PRIM.
OPTIONAL LOW GAS
PRESSURE SW
J7-5 PRIM.
J7-5 SEC.
FLOW SWITCH
J7-6 SEC.
J7-6 PRIM.
SEC.PRIM.
THERMAL CUT-OUT
J6-1 SEC.
J6-1 PRIM.
2
P2
P1
LWCO
OPTIONAL
J6-2 SEC.
J6-2 PRIM.
OPTIONAL
ADDITIONAL
HIGH LIMIT
J7-1 SEC.
J7-1 PRIM.
CONDENSATE
SWITCH
J7-2 PRIM.
FLAPPER PRIM.
FLAPPER SEC.
J7-2 SEC.
J8-2
SEC.
J8-2
PRIM.
J8-1
SEC.
J8-1
PRIM.
OPTIONAL
HIGH GAS
PRESSURE SW
PRIM.
J6-3
PRIM.
J6-3
SEC.
VENTURI PRESSURE
SWITCHES PRIM.
VENTURI PRESSURE
SWITCHES SEC.
J5-1
PRIM.
J5-1
SEC.
J5-2
SEC.
GAS
VALVE
PRIM.
GAS
VALVE
SEC.
J8-3 PRIM.
J8-3 SEC.
T-T OR
INTERLOCKS
T-T OR
INTERLOCKS
ALARM
{
SYSTEM
TEMP.
SENSOR
{
DHW
TEMP. SENSOR
SEC.
{
DHW
TEMP. SENSOR
PRIM.
{
OUTDOOR
TEMP.
SENSOR
{
ANALOG
INPUT SEC.
ANALOG
INPUT PRIM.
{
-
+
-
+
J8-12 PRIM.
J8-11 PRIM.
J9-2 SEC.
J9-1 SEC.
J9-2 PRIM.
J9-1 PRIM.
J7-11 SEC.
J8-12 SEC.
J8-7 SEC.
J8-6 SEC.
J8-7 PRIM.
J8-6 PRIM.
8
7
6
5
4
3
2
1
1
2
3
4
TACH
FAN POWER
PWM OUT
FAN GND
1
2
3
4
TACH
FAN POWER
PWM OUT
FAN GND
15432
BLOWER
1 sec. 2
15432
BLOWER
1 prim. 2
AMBER
120 VAC
CIRCUIT BREAKER
24 VAC
4 A
J2 SEC.
78
3
2
4
5
ECOM
3
2
1
A
B
C
MB2
MB1
C
A
B
C
B
A
J4 - 7
PRIM.
MAIN
POWER SWITCH
BOILER PUMP
120 VAC N
TB1
TB2
TB4
N
TB3
24VAC
SPARK
GEN.
PRIM.
SPARK
GEN.
SEC.J5 - 7
PRIM.
J5 - 7
SEC.
J4 - 6
PRIM.
BOILER PUMP
RELAY
R1
62
OPTIONAL PUMPS (FIELD INSTALLED)
J2 PRIM.
J5-6
PRIM.
J5-6
SEC.
DISPLAY
J4-10
PRIM.
J4-10
SEC.
A
J3P
LINE
DHW PUMP
LINE
SYS PUMP
NEUTRAL
NEUTRAL
NEUTRAL
12
TB-5
R1
DHW
PUMP
SYSTEM
PUMP
J4 PRIM
J3S
8
7
6
5
4
3
2
1
12
11
10
9
ECOM
MB2
MB1
C
A
B
3
2
1
5
4
3
2
1
TB 9
TB10
SOLA R1
PRIM.
SOLA R1
SEC.
TB-5
43
PUMP POWER
ON
1,000 ONLY
PUMP POWER
ON
1,000 ONLY
DRY CONTACTS TO
BOILER PUMP
1,700 ONLY
J4 - 7
SEC.
J4 - 6
SEC
.
BOILER PUMP
RELAY
A
1
2
24
13
1
2
24
13
OUTLET WATER
TEMP. SENSOR
STACK
TEMP. SENSOR
OUTLET WATER
TEMP. SENSOR
J8-4 SEC.
J8-4 PRIM.
J8-10 SEC.
J8-8 SEC.
J9-6 PRIM.
J9-4 PRIM.
J8-10 PRIM.
J8-8 PRIM.
J8-5
SEC.
J8-5
PRIM.
J8-9
SEC.
J9-5
PRIM.
J8-9
PRIM.
J9-5
SEC.
INLET WATER
TEMP. SENSOR
48
37
26
15
J9-6 SEC.
J9-4 SEC.
MUST BE JUMPED
NOTE:
WHEN AN OPTIONAL COMPONENT
IS NOT PRESENT, THE SIGNAL
1
4
1
1/8"
DECIMALS .XX
3
2
DWG NO.
E23460
REV.
CHANGE:
ECN
.010
TEMP SENSOR. ZONE D-1
A
14-013
TITLE:
DIMENSIONS ARE IN INC HES.
TOLERANCES ARE:
ADDED SECONDARY CONNECTORS TO THE STACK
UNLESS OTHERWISE SPECIFIED:
DO NOT SCALE DRAWING.
THIRD ANGLE PROJECTION.
DECIMALS .X .1
.03
DECIMALS .XXX
ANGLES
FRACTIONS
ALARM
{
SYSTEM
TEMP.
SENSOR
{
DHW
SEC.
{
DHW
PRIM.
{
TEMP.
SENSOR
{
ANALOG
ANALOG
{
-
+
-
+
J6-7 SEC.
J6-7 PRIM.
J6-8 SEC.
J6-8 PRIM.
J8-12 PRIM.
J8-11 PRIM.
J9-2 SEC.
J9-1 SEC.
J9-2 PRIM.
J9-1 PRIM.
J7-11 SEC.
J8-12 SEC.
J8-7 SEC.
J8-6 SEC.
J8-7 PRIM.
J8-6 PRIM.
FIELD
CONNECTIONS
1
2
24
13
1
2
24
13
OUTLET WATER
TEMP. SENSOR
STACK
TEMP. SENSOR
OUTLET WATER
TEMP. SENSOR
J8-4 SEC.
J8-4 PRIM.
J8-10 SEC.
J8-8 SEC.
J9-6 PRIM.
J9-4 PRIM.
J8-10 PRIM.
J8-8 PRIM.
INLET WATER
TEMP. SENSOR
48
37
26
15
J9-6 SEC.
J9-4 SEC.
MUST BE JUMPED
NOTE:
WHEN AN OPTIONAL COMPONENT
IS NOT PRESENT, THE SIGNAL
D
C
B
E23460
SH
1
REV
A
BW
REVISIONS
REV.
CHANGE:
APPR
ENGR APPR
ECN
TEMP SENSOR. ZONE D-1
A
14-0 13
AH 2/12/14
DRAFT
CHECK
ADDED SECONDARY CONNECTORS TO THE STACK
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 31
7.6 Ladder and Wiring Diagrams
See Figure 20 and Figure 21.
Figure 21. Ladder Diagram
Caution
When servicing controls, label all wires prior to
disconnection. Wiring errors can cause improper
and dangerous operation. Verify proper operation
after servicing
Page 36
Page 32
BN/BK
BN/BK
Secondary
Primary
GY/BK
A
BN/BK
BN/BK
R
GY/BK
GY/BK
BN/Y BL/Y
VENTURI
PRESSR SWITCHES
GY/BK
PK/W
DKBL
DKBL
W/BL
OUTLET WATER
3
W/V
V/BK
2
INLET WATER
V
12
DKBL
1
4
DKBL
8
7
6
5
4
BY LAARS HEATING SYSTEMS CO.
PURPOSE EXCEPT AS SPECIFICALLY AUT HORIZED IN WRITING
REPRODUCED, TRANSFERRED TO OTHER DOCUME NTS, USED OR
DISCLOSED TO OTHERS FOR MANUFACTURING OR ANY OTHER
PROPRIETARY TO LAARS HEATING SYSTEMS CO. AND SHALL NOT BE
THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN A RE
BK BLACK OR ORANGE
BK/O BL ACK/ORANGE O R/BK ORANGE /BLAC K
BK/R BLACK/RED OR/W ORANGE/WHITE
BK/V BLACK/VIO LET PK PINK
BK/Y BLACK/YELLOW PK/BK PINK/BLACK
BL BLUE PK/W PINK/WHITE
BL/Y BLUE/YELLOW R RED
BL/R BLUE/RED R/BK RED/BLACK
BL/BK BLUE/BLACK TN TAN
BL/G BLUE/G REEN TN/BL TAN/BL UE
BL/R B LUE/RE D TN/R T AN/RED
BL/V BL UE/VIOL ET TN/Y TAN/YELL OW
BL/W BLUE/WHITE V VIOLET
BN BROWN V/BK VIOLET/BLACK
BN/BK BROWN/BLACK V/W VIOLE T/WHITE
BN/G BROWN/GREEN W WHITE
BN/R BROWN/RED W/BL WHITE/BLUE
BN/W BROWN/WHITE W/BK WHITE/BLACK
BN/Y BRO WN/YELLOW W/G WHITE/GREEN
DKBL DARKBLUE W/GY WHITE/GRAY
DKBL/Y DARKBLUE/YELLOW W/O WHITE/ORANGE
G GREEN W/R WHITE/RED
G/R GREEN/RED W/V WHITE/VIOLET
GY GRAY Y YEL LOW
GY/BK GRAY/BLACK Y/BK YELLOW/BLACK
GY/R GRAY /RED Y/G YE LLOW/GREE N
GY/V GRAY/VIO LET Y/R YELLOW/RED
GY/W GR AY/WHITE Y/W Y ELLOW/WHIT E
LTBL/W LIGHTB LUE/WHITE
Display
COM 1 COM 2
1 2 3 4 5 6 7 8
PK
PK/W
Y/R
TB9
AB
1
PK
2
PK/W
3
Y/R
4
W/G
5
BN/G
6
V
7
PK
8
PK/W
9
Y/R
10
W/G
11
BN/G
12
V
LWCO
PROBE
LOW WATER
CUTOFF
(OPTIONAL)
HX
THERMAL
CUTOUT
FLOW SWITCH
Figure 22. Wiring Diagram
WIRECOLORABBREVIA TIONS
24Vac
24V com
TO TB4-6B
V/BK
BN/Y
BK/O
Primary
BL/G
V
V/W
BN/Y
BK/O
GY/BK
GY/W
Y
Y/G
TO PRIMARY MB1-A
TO PRIMARY MB1-B
TO PRIMARY MB1-C
TO PRIMARY MB2-A
TO PRIMARY MB2-B
TO PRIMARY MB2-C
TO SECONDARY MB1-A
TO SECONDARY MB1-B
TO SECONDARY MB1-C
TO SECONDARY MB2-A
TO SECONDARY MB2-B
TO SECONDARY MB2-C
W
PROBE
CONNECT
2
1
P1
P2
Secondary
LOW GAS PRESSR.
(OPTIONAL)
FIELD CONNECTIONS
AB
TB10
BL/G
TO TB3-6B
OPTIONED
CONFIGURATION
BK/O
GY/BK
GY/W
R
1
2
3
4
5
120V
HOT
NEUTRAL
GND
WIRE VOLTAGE KEY
24V =
120V =
NOTES:
MODEL 1700 TERMINALS TB5-3A & TB5-4A ARE 1.
DRY CONTACTS FOR FIELD INSTALLED BOILER PUMP.
to BLOWER Secondary W/R
to BLOWER Primary W/BK
AA
BN/BK
BN/BK
GY/BK
GY/BK
R
BN/Y
ADDTN'L HIGH LIMIT
(OPTIONAL)
Primary
R
HIGH GAS PRESS.
R
GY/BK
(OPTIONAL)
GY/BK
Secondary
FIELD WIRED
BOILER
PUMP
MODEL 1000
SHOWN
(SEE NOTE 1)
Line
SYSTEM
Neutral
PUMP
Line
DHW
PUMP
Neutral
to BLOWER Secondary BK/R
to BLOWER Primary BK
to xformer BK/BL
MAIN
TB1
POWER
SWITCH
W
BK
G
Y
BL/Y
BK/O
W
to xformer W
PRIMARY
Spark
Spark
Gen
Gen
SECONDARY
Spark
Gen
TO TB4-6B
TO TB3-4A
Primary
VENTURI
PRESSR SWITCHES
Secondary
BK
G
TB2
BL
BN
GY/BK
GY/BK
G
G
W
BK
B
A
B
A
W/BK
R/BK
1000 PRIM J4-7
12
BL
BN
G
G
3
21
3
BN/BK
1000 TB2-6A
1700 PRIM J4-7
1700 PRIM J4-7
1700 SEC J4-7
TB5
5
1000 SEC
J4-7
5
4
1000 TB5-4B
W/R
R
BN/BK
1
2
3
4
5
6
7
8
6
BK/R
6
W
BA
SECONDARY
SECONDARY
GAS
VALVE
PRIMARY
PRIMARY
GAS
VALVE
PUMP RELAY
2
6
8
7
W
BN
OR
V
TN/R
TN/BL
GY/V
GY/R
BK
W
BK/R
B
RADFORD WHITE
BL
Y/W
BN
BL/W
Y/W
BL
BL/W
BN
BK/Y
1000 TB1-1B
1700 TB5-4B
R/BK
STANDARD
CONFIGURATION
HX THERMAL CUTOUT
TB2
BK
FLAME
G
12
11
10
9
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
PrimarySecondary
FLOW SWITCH
TB1
W/BK
ROD
J4
J5
J6
J7
TO TB9-1A
TO TB9-2A
TO TB9-3A
BN/Y
BK/O
GY/BK
GY/W
BK/Y
BK
G
POWER
FLAME
ALARM
RESET
A
BK/O
GY/BK
1000 TB1-6A
1700 TB5-4B
1
BLOWER
23
PRIMARY
PK/BK
41
2
5
6
3
J1
PRIMARY
J3
MB2
MB1
C
BAABC
GY/W
JUMPER
G/R
5
4
23
1
3
4
2
1
J2
PIM
ECOM
3
21
PK
TO TB9-6A
TO TB9-5A
TO TB9-4A
W/BL
BK/R
WT/G
R/BK
J8
J9
J10
J11
GY/BK
GY/BK
1
2
6
7
8
9
10
11
12
1
2
3
4
5
6
7
2
3
4
5
6
7
8
1
2
3
4
5
6
7
Y/R
Page 37
B
286 9 1075431
BN/BK
BN/BK
Secondary
Primary
GY/BK
GY/BK
GY/BK
AA
BN/BK
BN/BK
R
GY/BK
GY/BK
BN/Y BL/Y
VENTURI
PRESSR SWITCHES
GY/BK
DKBL/Y
BK/R
BN/G
Y/R
1
2
3
7
TO
TB10-2A
TO
DISPLAY
PIN 7
J3
MB1
MB2
ECOM
ECOM
PK/W
PK
A
B
B
A
ABBA
Y/BK
1
4
5
1
65
6
8
9
10
12
11
2
3
4
5
3
5
6
9
10
7
5
4
3
SECONDARYPRIMARY
TB7
PIM
3
5
6
7
12
11
10
9
8
7
6
1
Alarm
OUTLET WATER
ROD
FLAME
TB1
1
23
4
5
23
TB4
Y/R
Y/R
Y/BK
Y/BK
Y/WY/W
BL/Y
V
DKBL
DKBL
W/BL
W/BL
R/BK
WT/G
G/R
PK
GY/VGY/V
SWITCH
CONDENSATE
TB6
J5
J6
J7
J4
RESET
ALARM
FLAME
POWER
STACK TEMP
DKBL
OUTDOOR
ANALOG INPUT
P
-
OUTLET WATER
FLAPPER
PRIMARY
FLAPPER
SECONDARY
W
BK
3
Y
BL
W/V
W/BL
G
J8
J9
J10
J11
J2
PIM
V
V/BK
W/GY
W/O
3
2
1CB
A
CBA
1
2
6
2
3
4
5
6
7
8
1
2
3
4
5
6
7
1
2
7
2
Y
BL/Y
DKBL/Y
DKBL
BK/O
LTBL/W
DHW Secondary
6
5
4
3
1
2
6
2
1
3
4
5
TB3
4
1
2
5
6
3
4
3
6
2
1
6
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
1
7
6
5
4
3
J9
J8
J2
J1
J10
J11
4
7
4
6
5
3
2
1
8
7
4
2
1
12
11
8
7
6
5
4
3
2
1
1
23
5
PK/BK
R/BK
WT/G
G/R
SECONDARY
G
2
INLET WATER
2
1
2
1
V/BK
3
21
C
INLET WATER
V
12
BL/BK
BL/R
DKBL
BL/V
BL/V
DKBL/Y
DKBL
DKBL
BL/V
GY/V
DHW Primary
System
BL/V
GY/V
BL/G
Y/G
OR/BK
TAN
V/W
O/W
OR
2
1
4
5
3
4
21
2
1
3
4
TO TB9-9A
TO TB9-8A
TO TB9-7A
TO TB9-10A
TO TB9-11A
TO TB9-12A
TO TB9-6A
TO TB9-5A
TO TB9-4A
XFORMER
24V
120V
BN/W
TO TB1
PIN 5A
TO TB2
PIN 4A
1
4
W/R
123
456 8
4
BN
TN/Y
W/G
W/BL
W/V
T-T or INTERLOCK
P
ANALOG INPUT
S
-
ANALOG INPUT
S +
ANALOG INPUT
P +
T-T or INTERLOCK
S
BL
LTBL/W
BL
BLOWER
TB2
BK/R
DKBL
3
3
87
4
DKBL
DKBL
DKBL/Y
APPROVALS
INTENDED SIZE:
D
C
B
4
32
.010
TOLERANCES ARE:
1/8"
JM 1-10- 12
1
D
W
G
N
O
.
SOFTWARE
R
E
V
S
H
E
2
3
4
5
9
1
A
BW
REVISIONS
REV.
CHANGE:
APPR
ENGR APPR
ECN
DWG. NO:
TITLE:
CONNECTOR
A
14-013N-01
AH 1/30 /14
E23459
CHECK
CHANGED STACK SENSOR FROM 4 PIN TO 8 PIN
A
DRAFT
REV.
D
WIRING DIAGRAM, NT 1.0/1.7
FRACTIONS
1
DECIMALS .XXX
.1
AL 7-14 -12
S
NA
NA
FINISH
MATERIAL:
DECIMALS .XX .03
DECIMALS .X
DIMENSIONS ARE IN INCHES.
UNLESS OTHERWISE SPECIFIED:
APPR
ENGR
DRAFT
ANGLES
DO NOT SCALE DRAWING.
THIRD ANGLE PROJECTION.
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 33
Page 38
Page 34
B
RADFORD WHITE
Section 8
USING THE TOUCH SCREEN AND
GAUGES
8.1 The Touch Screen and Gauges
There are only a few gauges on the front of the
Brute. See Figure 23. Other than the On/Off switch,
ALL of the control functions are can be accessed by
using the Touch Screen.
On/Off
switch
Touch
Screen
Boiler
outlet
temperature
and system
pressure
Fig. 23 Touch Screen and Gauges
In multiple boiler congurations, each Brute will
still have it’s own Touch Screen, but only the Touch
Screen on the lead boiler will be active. Up to 8
controllers (4 boilers) can be displayed on the ‘home’
screen. See Fig. 24B
Fig. 24B - Touch Screen, shown with the ‘home’
screen of the lead boiler in a four boiler
conguration, all conditions normal.
The icons on the ‘home’ screen for each controller
may appear in one of four colors, indicating their
basic operational status (See Section 8.3)
Almost all of the control functions are done using the
Touch Screen There only a few functions that must
be done manually by opening the front panel.
8.2 Using the Touch Screen
The Brute uses a color Touch Screen to get
input from the operator or installer, and to present
information about the operation of the boiler.
See Figs 23 and 24.
Fig. 24 - Touch Screen, shown with the ‘home’
screen of a single boiler conguration,
all conditions normal.
So let’s get started by selecting the lead boiler
control icon. Here’s a typical screen or “page”
presented by the system:
Fig. 25 - Status Summary Screen
There are some icons at the top of this screen (and
most of the other screens) that will help you move
around the system:
Page 39
B
Login
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 35
Home Upper
Return to Home page
left-hand
corner
Bell Upper
left-hand
System in Lockout,
Reset required
corner
Padlock Upper
right-hand
corner
Shows whether a
password has been
entered so parameters
can be changed
Back Upper
Return to previous screen
right-hand
corner
Sometimes a screen is used to present a list, and
often the list is too long to present on a single screen
view. To see the rest of the list, pull down on the bar
on the right side of the screen, or use the up- and
down-arrows.
To make a change, or to get more information about
one of the items on the list, press on the line for that
item.
If you are installing the system you will nd many
situations where you will need to enter a name or
password. The control system includes three levels
of password protection:
OEM Password Setup and parameter changes
made at the factory.
Installer Password Setup and parameter changes
made when the system is
installed, and some diagnostic
and troubleshooting functions.
The installer level password is
“lnt” (lower case “LNT.”)
User Level Non-critical adjustments and
functions, including adjusting
the Central Heat and Domestic
Hot Water setpoints, monitoring
the input and output variables,
reading parameters from the
controller, and reading the error
log
(For some special safety-related functions, besides
entering the correct password, the system will
ask you to go through an additional “verication”
process. For more information, see the section on
“Conguration.”)
When a password is necessary, the system will
present the keyboard screen. See Fig. 26.
1 2 3 4 5 6 7 8 9 0 - =
q w e r t y i o p [ ]u
a s d f g h j k l : *
z x c v b n m , . /
Shift Backspace
OK Clear Cancel
Fig. 26 - Keyboard Screen
The passwords used by this system are “case
sensitive” – it matters whether a letter in the
password is capitalized or not. Pressing the Shift
key changes all of the keys to produce capital
letters. Press Shift again to go back to lower-case
letters. “BS” stands for “Back Space,” and also
works as a Delete key.
It may be difcult for some operators to press the
small keys on this screen. In this case, use the
back of a plastic pen, or the eraser section at the
back of a pencil. (Do not use sharp metal tools –
these will scratch the plastic surface of the screen.)
You can also tap a key with the tip of your nger,
using the ngernail. Each time you press a key, the
system will respond with a beep. If you are entering
a password, an asterisk (*) will appear for each
character you enter. The beeps and asterisks will
help you to enter the correct number of characters
for your password.
The process would be the same if you wanted to
change a numerical value, except that system would
present a numeric entry screen. See Fig. 27.
Fig. 27 - Numeric Entry Screen
Anyone can view all of the parameters. However,
to change most of the parameters, you will need a
password.
Page 40
Page 36
B
RADFORD WHITE
At the bottom of the screen shown in Fig. 28, the
system is telling you that it wants you to log in.
Fig. 28 - Login Required
The screen used to Login is similar to the Keyboard
screen shown in Fig. 26.
8.3 While Operating - Checking
Lead/Lag Operating Information
The Lead/Lag function controls the operation of all
of the boilers connected to the system, and some
system components. For a complete explanation of
Lead/Lag, see the beginning of Section 9.
In this section, we will explain how to check the
Lead/Lag information while the system is running.
Blue Normal operation
Gray and
crossed out
2. Press the View Lead Lag button to go to a
Fig. 30 - Lead/Lag Screen
In the example shown here, the complete
Yellow Hold state. This
screen that shows the status of the whole
Lead/Lag system. See Fig. 30.
system includes two burners. Both burners
are ring at 35% fan speed.
Communication
problem
could be Anti short
cycle, fan speed
transitions, etc.
1. Start at the ‘home’ screen (Fig. 29).
Fig. 29 - ‘home’ screen. Single NeoTherm system
Blue Normal operation
Red Lockout
Gray Standby mode
(Burner switch off)
8.4 Checking the Lead/Lag Master
The system also gives you a way to check some of
the details of the Lead/Lag setup.
1. From the ‘home’ screen (Fig. 29), press the
button for Lead/Lag Master.
Fig. 31 - Lead/Lag Master Screen
Page 41
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 37
2. You can change the setpoints from this
screen. When you press the yellow box
beside Setpoint, the controller presents this
screen:
Fig. 32 - Setpoints Screen
Select the setpoint you want to change, then
enter the new value
3. If you press the Details button, the control
software leads you to a “ring” of screens that
include some information about the way the
Lead/Lag system is set up. The screens in
this section are “read only” – you can read the
values, but you cannot change them using
these screens.
8.5 While Operating - Checking
Individual Parameters
As we said, the Lead/Lag functions control the
operation of the whole system. You might also
want to check the functions on one of the individual
controllers, and the system gives you a way to do
this.
1. From the ‘home’ screen (Fig. 33), press the
icon for the individual controller you want to
check. In this example, we will press the icon
on the left.
will appear. This shows the current operating
condition of that controller, and also shows
some of the conguration settings. See Fig. 34.
Fig. 34 - Status Summary Screen Showing
Setpoint Information
Notice the four buttons at the bottom of each
Status Summary screen:
• Congure – Allows an installer to change
some of the setup parameters used by the
system. A password may be required.
• Operation – Used to adjust the setpoints,
change the fan speed, turn a burner on or
off, or turn the pumps on or off.
• Diagnostics – Allows you to run diagnostic
tests, or check the inputs and outputs used
by the system.
• Details – Allows you to check the status of
all of the setup parameters on the control
system.
3. You can also press the button for Modulation
(on the right side of the screen) to bring
up another version of this screen showing
modulation information. See Fig. 35.
Fig. 33 - ‘home’ screen
2. The Status Summary page for that controller
Fig. 35 - Status Summary Screen Showing
Modulation Information
Page 42
Page 38
8.6 Checking Individual Details
The Details button on the Status Summary screen
leads to a series of screens that show all of the
setup parameters entered for the controller you have
selected. Let’s say that the rst screen presented in
this series is the screen for Frost Protection. See Fig.
36.
B
RADFORD WHITE
8.7 Conguring Parameters on
Individual Controllers
In this section, we will just give you a quick
explanation of how to change parameters on one of
the controllers. (This is an individual function. You
would set this kind of parameter on one controller at
a time.)
The Brute unit is always set up for “Lead/Lag”
operation, so most of your conguration changes
would be made using the Lead/Lag section of the
control software, and this uses a different procedure.
(A Lead/Lag parameter controls a collective function.
You change one parameter that controls the whole
Lead/Lag system, and all of the controllers at once.)
For an explanation of the Lead/Lag setup, see
Section 9.1.
For now, we’ll explain how to change a setting on
just a single controller.
Fig. 36 - Typical Details Screen – Frost Protection
The list presented here is too long to t onto a single
screen, so you must scroll down to see the rest. The
bar graph on the left side of the screen shows the
current performance in relation to a setpoint or the
total load or signal range.
You can get more detailed information on a
parameter by touching the line for that parameter.
The screens presented under Details are “read
only” – you can read the parameters, but you can’t
change them from these screens. (To go to screens
that allow you to change the parameters, use the
Congure button.)
The screen shown in Fig. 36 is part of a large
loop that covers all of the parameters used by the
system. To go to another part of the loop, press the
left-arrow or right-arrow at the top of the screen.
Here are the screens which are included in the loop:
Burner Control
Demand and Modulation
Fan
DHW Pump
Boiler Pump
System Pump
Flame Detection
Statistics
Stack Limit
CH Frost Protection
Lead Lag Slave
Lead Lag Master
1. From the Home Page screen (Fig. 37),
press the icon for the controller you want to
congure. In this example, we will change
some settings for the Primary controller, so we
will press the icon on the left.
Fig. 37 - Home Page Screen
2. The Status Summary page for that controller
will appear. See Fig. 38.
Fig. 38 - Status Summary Page
Page 43
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Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
3. Press the Congure button to start a
conguration session for the selected
controller. See Fig. 39.
Fig. 41 - Numeric Entry Screen
8.8 Verication Process for Safety-
Related Parameters
Fig. 39 - Conguration Screen
1. When you start to change a parameter that
This screen lists all of the conguration
groups. (The list is actually longer – scroll
down using the bar on the right side of the
screen.) Many of the items will not be useful
to an installer or end-user.
4. Next, we will show you how to change one of
these parameters. Let’s turn on the Central
Heat function. On the Conguration Screen
(Fig. 39), scroll down and press the line for
CH – Central Heat Conguration. Figure 40
shows the screen which follows.
is related to safety, the system will present a
warning which looks like this:
Page 39
Fig. 40 - Central Heat Conguration
On the screen, you can see the Central Heat
function is currently disabled. To turn on the
Central Heat function, press the space beside
CH Enable. The system will tell you that you
must login and enter a password to change
this entry.
5. The process would be the same if you wanted
to change a numerical value, except that
system would present a numeric entry screen.
See Fig. 41.
Fig. 42 - Parameter Safety Warning
Press OK to continue. The system will ask
you to login before you make a change. (For
more information on logging in, see Section
8.2.)
Note that any changes you make will apply
only to one controller – the controller you
have already selected. If you want the same
change to apply to other controllers, you must
change each of them separately.
2. If you make a change in any group that could
affect the safe operation of the unit, the control
system will ask you to “verify” the change
before it is accepted. As an example, let’s say
that we wanted to change the conguration
for one of the ap valves. See Fig. 43. A
line printed in red at the bottom of the screen
indicates that the system wants to do a safety
verication. (All of the parameters in this
group have safety-related functions. If you
change any of them, you will have to do the
verication for the whole group.)
Page 44
Page 40
B
RADFORD WHITE
Fig. 43 - Verication Needed
Notes –
• Once you change one of these safety-related
parameters, you must nish the verication
process for the group that includes the parameter,
or the control system will not let the boiler
operate. You can wait to do the verication until
you have changed parameters in other groups,
but before you return the boiler to service, you
have to do the verication for all of the groups you
changed.
• At the end of the verication process, you
must press the Reset button on the front of the
controller. See Fig. 44. You have to do this within
30 seconds, or the verication will be cancelled.
To make it easy to reach the Reset button, open
the door on the front of the boiler and slide out the
control panel before beginning the verication.
Fig. 45 - Edit Safety Data
5. Once you are done changing safety parameters,
press Conrm. The system will present a listing
for each group of parameters which includes a
changed safety parameter. See Fig. 46.
Fig. 46 - Safety Parameter Conrmation
6. For each group, check the list carefully. Press
Yes if all of the parameters in the group have
been entered correctly.
If you made changes in other safety-related
groups, verify the entries in those groups in the
same way. When the process is complete, the
system will tell you to reset the control system.
Fig. 44 - Reset Button on Controller
3. Don’t press the Reset button yet. We just want
to show you where the Reset button is located.
Change the parameter(s) you want to change.
4. When you are done entering parameters, the
next job is to do the verication. Login to the
system and press Begin.
Fig. 47 - Safety Parameter Reset
7. The Reset button is located on the front of
the controller. See Fig. 44. You must press
the Reset button within 30 seconds, or the
verication will be cancelled.
Page 45
B
VARI-PRIMETM: The Laars variable pump control that, when used with a variable speed pump, maintains a user-chosen
temperature rise between the inlet and outlet of the boiler.
FOR YOUR SAFETY: This procedure must be performed by a professional service technician, quali ed in
hot water boiler installation. Improper connections could create an electrical hazard, which could cause
serious injury, property damage, or death.
Document 7025C
CA009900
VARI-PRIME
TM
Installation Kit for
Modulating Boilers
Model NTH.
NEOTHERM
®
LC
Sizes 1000-1200 MBTU/h
FIELD CONNECTIONS: (continued)
• Using the two (2) supplied thermistor cables, connect one Shielded
cable to the 1 and 2 landing points on terminal block (TB2) of the
VARI-PRIME board.
Important: This wire will be run to the OUTLET sensor.
• Connect one end of the VFD signal wire to
the VFD on the chosen pump as instructed
in pump manual. Connect the other end
to the 3 and 4 landing points on terminal
block (TB3).
Important: #3 landing point is for
0-10 VDC (+) and #4 is for 0-10 VDC(-).
• Connect the other Shielded cable to the 3 and 4 landing points on
terminal block (TB2) of the VARI-PRIME board.
Important: This wire will be run to the INLET sensor.
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
8.9 Optional Variable Speed Pump Control.
Pump speed is controlled to maintain a user-chosen temperature rise between the inlet and outlet of the
NeoTherm.
For the entire kit and the complete 6 page instruction sheet, Reference Kit # CA009900
Page 41
CA009900
OPTIONAL VARIABLE SPEED PUMP CONTROL KIT FOR
VARI-PRIME
TM
Installation Kit for
NEOTHERM
Modulating Boilers
Model NTH.
FOR YOUR SAFETY: This procedure must be performed by a professional service technician, quali ed in
hot water boiler installation. Improper connections could create an electrical hazard, which could cause
serious injury, property damage, or death.
GENERAL PCB OPERATION:
1. The desired Delta T can be set to any of the following values by moving or adding jumpers to the (JP2) terminal on the control:
See Figure 2.
15 deg F/8 deg C 20 deg F/10 deg C 25 deg F/13 deg C 30 deg F/ 16 deg C
By adding a second jumper, one on “15 deg F” and one on “20 deg F”, it is possible to achieve 35 deg F /19 deg C.
By adding a second jumper, one on “15 deg F” and one on “25 deg F”, it is possible to achieve 40 deg F/22 deg C.
2. As shipped, the VARI-PRIME has a jumper on the (JP4) terminal, to operate a 0-10 VDC output. If a 4-20 mA output is needed,
move the jumper to the (JP5) terminal.
3. VARI-PRIME can operate in °F or °C. A jumper on the (JP1) terminal has set the default to °F. Remove that jumper for °C.
4 If Main Gas valve is “OFF” AND a call for heat is “TRUE” then the PCB overrides the PID control and runs the pump
output at 100% (10 VDC, or 20 mA).
5. Once the Main Gas valve is energized the PCB will maintain pump output at 100% for 60 seconds to allow the system to
stabilize. Once the 60 second timer has expired, the PCB will then run the pump output speed based on the jumper setpoint.
6. When “T-T” is satisfi ed, the PCB will run pump at 100% output for the duration of the pump overrun time.
7. The VARI-PRIME PCB has a low end cap to prevent nuisance low fl ow trips. The cap is factory programmed to 2 VDC.
8. Factory settings are: Degrees - Fahrenheit Output Signal - 0 -10VDC
• Tap two ¼” NPT threaded holes into water pipes for the sensors. One in the supply pipe and the other in the return. Both
sensors need to be inserted into the pipe no more than 12” away from the outside of the boiler jacket. These two sensors will
be the Delta T. (Note: Delta T is the difference between supply and return water temperatures) The amount of Delta T is
chosen on Vari-Prime terminal block (JP2). Install the Sensors.
Sizes 1000-1200 MBTU/h
Document 7025C
Brute
®
LC
TM
H2352500C
Page 46
Page 42
Section 9
SETUP AND CONFIGURATION
9.1 Review of Lead/Lag Control
System
9.1.1 About Lead/Lag Operation
The boilers in this series are always set up for Lead/
Lag operation. In a single-boiler installation, there
are two controllers and two burners, as shown in
Fig. 49. The controller for the upper burner is set up
as the Primary control. For control purposes, this is
the Lead/Lag Master and also operates as Lead/Lag
Slave 1. The control for the lower burner is set up
as the Secondary control and operates as Lead/Lag
Slave 2.
B
RADFORD WHITE
On a multiple-boiler installation, each individual boiler
is still set up as shown in Fig. 48. The boiler controls
are arranged in a “daisy chain” using a Modbus
connection, with the Secondary control of one boiler
connected to the Primary control of the next boiler.
Up to four boilers, with up to eight controllers, can be
connected in this way. See Fig. 49.
Boiler 1
Operator
interface
Primary
controller
Gas
valve
Gas
valve
Secondary
controller
Primary
burner
Secondary
burner
Fig. 48 – Lead/Lag Arrangement in a Single-Boiler Installation
Boiler 1
Operator
interface
Addr1Addr2Addr3Addr4Addr5Addr6Addr7Addr
Boiler 2
Boiler 3
Boiler 4
8
Lead Lag
Master and
Slave 1
Fig. 49 – Lead/Lag Arrangement in a Multiple-Boiler Installation
Slave 2
Slave 3
Slave 4
Slave 5
Slave 6
Slave 7
Slave 8
Page 47
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Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 43
In either kind of installation, a system sensor is
usually used to monitor the demand. The input from
this sensor is used to control the modulation rates of
the operating burners.
Table 11 – Master/Slave Assignments and Modbus Control Addresses
Boiler Burner
Control Master/Slave
Position
1 Upper Primary Lead/Lag Master,
1 Lower Secondary Slave 2 2
2 Upper Primary Slave 3 3
2 Lower Secondary Slave 4 4
3 Upper Primary Slave 5 5
3 Lower Secondary Slave 6 6
4 Upper Primary Slave 7 7
4 Lower Secondary Slave 8 8
9.1.2 Lead/Lag Modulation Cycle
Let’s consider the following example:
Four Brute boilers are tied together via Modbus
connections. Here are the Master/Slave
assignments and the Modbus control addresses:
Modbus
Assignment
Control
Address
1
also Slave 1
Note - We will explain the modulation cycle here,
in case you need to understand how the Lead/Lag
system actually operates. If you are just installing
the unit(s) and want to skip this section, just
remember that, as the heating demand increases,
the Lead/Lag system puts more burners on-line.
As the heating demand is reduced, the Lead/Lag
system shuts off some of the burners.
A Run sequence is initiated when the system
temperature falls to the setpoint less the On
Hysteresis value. The default setting for On
Hysteresis is -5°F, but this is adjustable. The
setpoint used to initiate the Run sequence is the
Lead/Lag Central Heat setpoint.)
The Lead/Lag controller decides which burner is
assigned to start rst. This assignment is rotated
across all of the available burners so that any one
burner does not run signicantly longer than the
others. The Lead/Lag controller tracks the run
times for all of the available burners, and uses
this to calculate the starting order for the burners.
This means that each time the system starts up, a
different burner may start rst. It also means that the
Primary burner on a particular boiler may start rst
one time, and the Secondary burner for that boiler
may start rst the next time.
When the Run sequence is initiated, the burner with
the least amount of runtime will re. If the heating
demand increases so that the ring rate of that
rst burner rises to 65% fan speed (the Base Load
value), the next burner in the sequence will start
up and begin ring at 35% fan speed. After this,
both of the active burners will modulate up or down
together, in reaction to the changes in demand. See
Fig. 50.
If the system loop temperature rises above
the LL CH setpoint, then the two burners will
simultaneously drop their fan speeds. If both boilers
drop to their minimum fan speeds (29%), then the
second burner will drop out.
If the heating demand continues to increase, and the
system loop temperature continues to drop, then the
two burners will increase their fan speeds together.
When they reach 65%, the next burner in the
sequence will start up and be added to the group.
All three boilers will continue to re simultaneously
at equal input rates.
If the modulation rate for all three burners drops
to the minimum fan speed (29%), the last burner
started will drop out. If the demand continues to
drop, the second burner started will also drop out.
If the system temperature reaches the LL CH
setpoint value plus the Off Hysteresis gure, all of
the burners will shut off. (The default setting for Off
Hysteresis is +5°F, but this is adjustable.)
If any of the boilers approaches its high limit
temperature, that boiler will modulate back to stay
below the high limit.
As the heating demand continues to change, the
Lead/Lag Master will continue to add, remove, or
modulate the additional boilers in the system.
Page 48
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B
RADFORD WHITE
Low demand The first burner* in
sequence fires at
less than 65%
Demand increases Once the first burner
reaches 50%,
the second burner*
switches on, and
both modulate
together between 29%
and 65%
Demand increases Once the first two
burners reach 65%,
the third burner*
switches on, and all
three modulate together
between 29% and 65%
Nearing max. demand The fourth burner* is
active. Once all four
reach 65%, all are
allowed to go over
65%
Boiler X
First
burner*
Second
burner*
Boiler Y
Third
burner*
Fourth
burner*
9.1.3 NTH Lead/Lag with Indirect
Domestic Hot Water
So far, we have been describing a system which
handles the Central Heat function only. There are
several ways the Domestic Hot Water can be set up
on a Lead/Lag system. For a detailed description,
see Section 9.5.
9.2 Connection Terminals
Figure 51 shows some of the connection terminals
on the circuit board inside the cabinet.
WARNING
Before connecting or disconnecting any wiring
inside a boiler, be absolutely sure to turn off all
electrical power to the unit. Failure to do this
could result in property damage, serious injury or
death.
* - The Lead/Lag controller will change the firing order of the
burners, based on the run time of each burner.
Fig. 50 – Lead/Lag Activity in a Multi-Boiler
System
9.3 Brute System Congurations
Brute’s can be installed in many different
arrangements. The steps in the installation will be
different, depending on the number of boilers in
the system, the venting arrangements, the control
signals used, and so on. In this section, we will
list the steps necessary to do the most common
installations.
1. Table 12 lists most of the common
congurations for Brute systems. Look
through the table until you nd a line that
exactly describes your system. Make a
note of the system number shown in the left
column.
2. Following the table, look up the specic
installation jobs for your system in Section 9.4.
The jobs are identied using letters (Job A
through Job P).
If you are not familiar with the Brute’s or the
Lead/Lag control system, you may want to
review the information in Section 9.1. This
may be helpful as you read the installation
instructions which follow.
Page 49
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Page 45
Fig. 51 – Connection Terminals
Page 50
Page 46
Table 12 – Installations for Special Options
B
RADFORD WHITE
System Multiple
or single
boilers
1 Single
boiler
2 Single
boiler
3 Multiple
boiler
4 Multiple
boiler
5 Multiple
boiler
6 Multiple
boiler
7 Single
boiler
8 Single
boiler
9 Multiple
boiler
10 Multiple
boiler
11 Single
boiler
12 Single
boiler
13 Multiple
boiler
14 Multiple
boiler
System Multiple
or single
boilers
System
or local
boiler
control
Local No No No No
Local No No No Yes
Local No No No No
Local No No No Yes
Local Yes No No No
Local Yes No No Yes
System No No No No
System No No No Yes, from
System No No No No
System No No No Yes, from
System No Yes No No
System No Yes No Yes, from
System No Yes No No
System No Yes No Yes, from
System
or local
boiler
control
Common
vent
Common
vent
Setpoint
control
4-20 ma
Setpoint
control
4-20 ma
Modulation
control, 4-20
ma
Modulation
control, 4-20
ma
Outdoor
reset
system
system
system
system
Outdoor
reset
Page 51
B
Brute
TM
RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Table 12 – Installations for Special Options (continued)
Page 47
15 Single
boiler
16 Single
boiler
17 Multiple
boiler
18 Multiple
boiler
19 Multiple
boiler
20 Multiple
boiler
21 Multiple
boiler
22 Multiple
boiler
System No No Yes No
System No No Yes Yes, from
System No No Yes No
System No No Yes Yes, from
System Ye s Yes No No
System Ye s Yes No Yes, from
System Ye s No Ye s No
System Ye s No Ye s Yes, from
System 1 –
Single boiler, Local control
Job I Set the parameters used by the Lead/Lag system
Job J Install the System sensor and adjust the setpoint
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
system
system
system
system
System 2 –
Single boiler, Local control, Outdoor reset
Job I Set the parameters used by the Lead/Lag system
Job J Install the System sensor and adjust the setpoint
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 3 –
Multiple boilers, Local control
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job J Install the System sensor and adjust the setpoint
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
Page 52
Page 48
B
RADFORD WHITE
System 4 –
Multiple boilers, Local control, Outdoor reset
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job J Install the System sensor and adjust the setpoint
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 5 –
Multiple boilers, Local control, Common vent
Job A Note on common venting
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job J Install the System sensor and adjust the setpoint
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 6 –
Multiple boilers, Local control, Common vent, Outdoor reset
Job A Note on common venting
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job J Install the System sensor and adjust the setpoint
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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System 7 –
Single boiler, System control
Job I Set the parameters used by the Lead/Lag system
Job L Building automation or multiple boiler control thermostat demand
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 8 –
Single boiler, System control, Outdoor reset
Job I Set the parameters used by the Lead/Lag system
Job L Building automation or multiple boiler control thermostat demand
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 9 –
Multiple boiler, System control, Outdoor reset
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job L Building automation or multiple boiler control thermostat demand
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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System 10 –
Multiple boiler, System control, Outdoor reset
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job L Building automation or multiple boiler control thermostat demand
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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System 11 –
Single boiler, System control, 4-20 mA setpoint control
Job I Set the parameters used by the Lead/Lag system
Job M Building automation or multiple boiler control 4-20 mA setpoint control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 12 –
Single boiler, System control, 4-20 mA setpoint control, Outdoor reset
Job I Set the parameters used by the Lead/Lag system
Job M Building automation or multiple boiler control 4-20 mA setpoint control
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 13 –
Multiple boiler, System control, 4-20 mA setpoint control
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job L Building automation or multiple boiler control thermostat demand
Job M Building automation or multiple boiler control 4-20 mA setpoint control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 14 –
Multiple boiler, System control, 4-20 mA setpoint control, Outdoor reset
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job M Building automation or multiple boiler control 4-20 mA setpoint control
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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System 15 –
Single boiler, System control, 4-20 mA modulation control
Job N Building automation or multiple boiler control 4-20 mA modulation control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 16 –
Single boiler, System control, 4-20 mA modulation control, Outdoor reset
Job N Building automation or multiple boiler control 4-20 mA modulation control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 17 –
Multiple boiler, System control, 4-20 mA modulation control
Job N Building automation or multiple boiler control 4-20 mA modulation control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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System 18 –
Multiple boiler, System control, 4-20 mA modulation control, Outdoor reset
Job N Building automation or multiple boiler control 4-20 mA modulation control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 19 –
Multiple boiler, System control, Common vent, 4-20 mA setpoint control
Job A Note on common venting
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job M Building automation or multiple boiler control 4-20 mA setpoint control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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System 20 –
Multiple boiler, System control, Common vent, 4-20 mA setpoint control, Outdoor reset
Job A Note on common venting
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job M Building automation or multiple boiler control 4-20 mA setpoint control
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 21 –
Multiple boiler, System control, Common vent, 4-20 mA modulation control
Job A Note on common venting
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job N Building automation or multiple boiler control 4-20 mA modulation control
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
System 22 –
Multiple boiler, System control, Common vent, 4-20 mA modulation control, Outdoor reset
Job A Note on common venting
Job B Set up the names for each of the controllers
Job C Make one control the Lead/Lag master
Job D On each of the controllers that will act as a slave, disable the Lead/Lag Master
Job E Set up the Modbus control addressing to assign addresses for each of the controls
Job F Set up the addresses for the ap valves
Job G Disconnect the Touch Screens that will not be used
Job H Connect the Modbus wiring
Job I Set the parameters used by the Lead/Lag system
Job N Building automation or multiple boiler control 4-20 mA modulation control
Job K Lead/Lag outdoor reset and warm weather shutdown
Job O Set up the combustion on each of the burners
Job P Set the date and time on the system
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9.4 Installation Jobs
Note – To install your system, you will not need to do
all of the installation jobs listed here. Please refer
to Section 9.3 for a list of specic installation jobs
necessary to install your system.
Job A – Note for Systems Using Common
Venting
If multiple Brute’s share a single vent, the system
must be engineered by a competent venting
specialist. The design involves the selection of
draft-inducing equipment, hardware and controls
to properly balance ue gas pressures. Do not
common vent Brute’s unless the vent system meets
this requirement. Brute’s are never permitted to
share a vent with Category I appliances.
Fig. 53 – Status Summary Screen
3. Select the “Congure” button in the bottom
left-hand corner of the display. Figure 54
shows the Conguration menu.
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Job B - Naming the Controllers
(This is an individual function – do this for each of the
controls. Use the separate Touch Screen on each boiler.)
Each boiler includes two separate controls, as
shown in Fig. 48. In a system with four boilers, there
will be eight separate controls. See Fig. 49. The
rst job is to name each of these controllers.
1. We will start by entering a name for the rst
controller in the line – the Primary controller on
Boiler 1. Start at the “Home” screen. Press
the icon for the Primary control.
Fig. 54 – Conguration Menu
4. Select the line for System Identication and
Access.
Fig. 52 – ‘home’ screen
2. The system will present the Status Summary
screen for that controller. See Fig. 53.
Fig. 55 - System Identication and Access
5. Go down to the line for Boiler Name to change
the name of the control. In this example,
we are working with the Primary control on
Boiler 1, so the name here should be “Boiler
1 Primary.” To change the entry, press on
the line for Boiler Name. The system will
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present the keyboard screen. Use the “BS”
(BackSpace) key to erase the existing name.
Enter the new name, then press OK.
6. Now you can rename the other control on
Boiler 1 – the Secondary control. Press the
Home button in the top left-hand corner to go
back to the ‘home’ screen which shows the
different controls (Fig. 52).
7. This time, press the icon for the Secondary
control. Repeat steps 1 through 5. Change
the name to “Boiler 1 Secondary.”
8. Go to the Touch Screen for the next boiler
in the system. Repeat steps 1 through 7 for
each of the controllers on that boiler. Be sure
the names you enter are correct – each name
should indicate the Boiler number and whether
the control will operate as the Primary or
Secondary.
9. Repeat the process for any other boilers in the
system.
Job C – Make One Control the Lead/Lag
Master
(This is an individual function – do this once for the control
that will act as the Lead/Lag Master. Use the Touch
Screen on Boiler 1.)
The Lead/Lag control system uses one controller
as the Lead/Lag Master. This controller supervises
the operation of the other controllers, and they all
operate together as part of the Lead/Lag system.
There is only one Lead/Lag Master in the system.
Usually, the controller used for this is the Primary
controller on Boiler 1. (Other controls in the system
can be set as the Lead/Lag Master, but we do
not recommend this because it may complicate
troubleshooting and technical support questions.)
The controller used as the Lead/Lag Master will also
do a second job, operating as Slave 1 in the Lead/
Lag system. A single controller performs both of
these functions. When it arrives from the factory, the
controller used for this should already be set up as a
slave – we will check that in a moment. For now, we
will just concentrate on enabling the Master function.
1. Start at the ‘home’ screen. See Fig. 56.
Fig. 56 – ‘home’ screen
2. Press the button for Lead Lag Master. Fig. 57
shows the screen that follows.
Fig. 57 – Lead/Lag Master Screen
3. Press the Congure button. The display will
present the Lead/Lag Master Conguration
Screen (Fig. 58).
Fig. 58 – Lead/Lag Master Conguration
4. This screen shows the most important settings
for the Lead/Lag system. The settings can be
changed from this screen. Some of them will
require passwords.
We will enter all of the Lead/Lag control values
in a moment. For now, just press on the line
for Master Enable. Change the setting to
Enable.
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Job D - Disable the Lead/Lag Master
Function on the Lead/Lag Slaves
(This is an individual function – do this for each of the
controls, except the one used as the Lead/Lag Master.
Use the separate Touch Screen on each boiler.)
At the beginning of this section, we described
the Master and Slave arrangement used with the
Lead/Lag system. In the previous section, we
explained how to set up one controller as the Lead/
Lag Master. As we said, the controller used as the
Master (usually the Primary controller for Boiler 1)
also serves as a Slave (usually Slave 1). A single
controller performs both functions.
When the controllers arrive from the Bradford White
factory, they will all be congured as slaves. Your
job in this step is to disable the Lead/Lag Master
function on each of the controls, except for the one
control that will be used as the Lead/Lag Master –
usually the Primary control on Boiler 1.
3. To disable the Master function on this
controller, press the Congure button. Figure
61 shows the Conguration screen.
Fig. 61 – Conguration Screen
4. Scroll down through the list until you nd the
line for LL Master Conguration. See Fig. 62.
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1. From the ‘home’ screen (Fig. 59), press
the icon for the controller you want to work
with. In this example, we will start with the
Secondary controller for Boiler 1, and make
sure this is not set up as a Master.
Fig. 59 – ‘home’ screen
2. The system will take you to the Status
Summary screen.
Fig. 62 – Lead/Lag Master Conguration
Press on the line for Master Enable. The
system will go to a separate screen and ask
you to login using a password. Enter the
password (see Section 8.2), return to the
Master Conguration screen, then press the
line for Master Enable again. Change the
entry to Disabled.
Don’t change any of the other entries on this
screen.
5. At this point, you have disabled the Master
function on one of the controllers. You will
need to repeat the process for each of the
other controllers in the system (except the
Primary Controller on Boiler 1).
Go to the Touch Screen on the next boiler.
Repeat steps 1 through 4 for the rst controller
on that boiler.
6. Repeat the steps listed above for each of the
other controllers on the system. Disable the
Master function on each of them.
Fig. 60 – Status Summary Screen
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Job E – Set Up the Modbus Control
Addressing
(This is an individual function – do this for each of the
controls Use the separate Touch Screen on each boiler.)
Do this on any system with multiple boilers.
Note – Do not connect the Modbus wiring yet. The
controls must be set up and addressed correctly
before the wiring is complete. If the wiring is
attached before the control Modbus addresses are
changed, there will be multiple controls with the
same address, and the system will not work.
1. When the system is operating under the
control of the Lead/Lag system, the Lead/Lag
Master needs a way to identify each controller
in each of the boilers. On a system with four
boilers there will be eight separate controllers.
You will need to give each of these controllers
a unique Modbus address. (Notice that this is
different from the name of the controller. We
set the controller names in a previous step.)
2. Power up all of the boilers in the system. It
will take a minute for each Touch Screen to
“synchronize” with its two controllers.
3. Start at the ‘home’ screen on the rst boiler.
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Fig. 65 – Control Setup Screen
6. The rst number on each line (01, 02, etc.) is
the Modbus control address. Let’s set up the
Modbus address for the rst controller in the
line - the Primary controller on Boiler 1. Press
the top line – Brute Primary.
7. Press the Change Address button. You need
to know the installer-level password to change
the address, so the system will ask you to log
in. (For more information on the passwords
and logging in, see the section on “Using the
Touchscreen.”) Press the padlock symbol in
the upper right-hand corner of the screen, then
type in the installer-level password and press
the OK button.
8. Press the Change Address button again. The
system will present a screen that lets you
change the address.
Fig. 63 – ‘home’ screen
4. Press the Setup button in the lower right-hand
corner to go to the Setup screen.
Fig. 64 – Setup Screen
5. Press the Control Setup button. Figure 65
shows the Control Setup screen.
Fig. 66 – Changing Modbus Address
9. Table 13 shows how the Modbus control
addressing should be set up. The system
is simple, but it is important to only use the
correct address listed in the table. Do not
use any other address than the one listed in
the table for the control you are addressing.
In this example, the correct address for the
Primary Control on Boiler 1 is “1.” If this is not
already set to “1”, enter the correct number,
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then press OK.
WARNING
If the addresses are not assigned properly, the
system could fail to operate correctly, or it might
operate in an unsafe manner. This could lead to
property damage, personal injury or death.
10. Now you can use the same process to set the
address for the Secondary control for Boiler 1.
On the Control Setup screen (Fig. 65), press
the second line – Brute Secondary. Change
the address to the correct address taken from
Table 3. In this case, the correct address
would be “2.”
11. Go to the Touch Screen for Boiler 2. Repeat
the process to change the addresses for
Boiler 2 Primary (address = 3) and Boiler 2
Secondary (address = 4).
12. Repeat steps 3 - 10 for each of the other
controllers connected to the system.
Job F - Set the Flap Valve IDs
(These are individual functions. Make the ap valve
assignment on each of the controllers. Use the Touch
Screen on each of the boilers.)
Do this on any system with multiple boilers.
Each boiler includes two burners, and each burner
has a ap valve. See Fig. 67.
A ap valve acts like a one-way valve or check
valve. If one burner in a boiler is operating, and
the other is not, one of the ap valves will close to
prevent exhaust air from moving backwards through
the burner that is not operating.
Before the Lead/Lag Master controller will allow
the system to operate, it must be able to determine
whether each of these ap valves is open or closed.
If the controller cannot nd a signal from one of the
ap valves, the control system will act to prevent
backow by energizing the blower of the control
with the bad ap valve. (The positive pressure from
the blower will prevent the exhaust air from moving
back through the burner.) If this cannot be done, the
Lead/Lag Master controller will not allow the whole
system to run. For this reason, it is important that all
of the ap valves be identied correctly.
Each controller in the system needs to know how
many controllers are included in the whole system.
You will need to enter this information in each of the
controllers separately.
Boiler 1
Operator
interface
Primary
controller
Flap
valve
Flap
valve
Secondary
controller
Primary
burner
Secondary
burner
Fig. 67 - Flap Valve Arrangement
Table 13 – Modbus Control Addressing
Boiler 1 Boiler 2 Boiler 3 Boiler 4
Primary control 1 3 5 7
Secondary control 2 4 6 8
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WARNING
If the ap valve identications are not congured
correctly, this could cause the equipment to
malfunction. This could lead to personal injury or
death, and could damage the equipment. If the
conguration is not correct, the control system
will present an error – “HOLD 119 – Control
Interaction Fault” on the display, and will prevent
the boiler(s) from operating.
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1. Let’s start by setting the Flap Valve ID for the
Primary control for Boiler 1. To do this, start
at the ‘home’ screen (Fig. 68). (To reach the
‘home’ screen, press the Home icon in the
upper left corner of any screen.)
Fig. 68 – ‘home’ screen
2. Press the icon for the controller you want to
work with. The system will take you to the
Status Summary screen for that controller.
Fig. 70 – Conguration Screen
4. Scroll through the listing on the Congure
menu to Flap Valve Conguration, and select
that line. See Fig. 71.
Fig. 71 – Flap Valve Conguration Screen
Two of the items on this screen can be
changed:
Fig. 69 – Status Summary Screen
3. Press the Congure button. Figure 70 shows
the Conguration screen.
Controller ID -
This is the ID number of the ap valve
associated with this controller. (We will set
the ID number for the other controller in this
boiler in a moment.)
Number of controllers -
This is the total number of controllers in
the whole system. (For example, in a
system with four boilers, there will be eight
controllers.) See Table 14.
You need to set both of these values on the
Flap Valve Conguration screen for each
controller in the system.
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Table 14 – Number of Controls
Number of
boilers
Number of
controls
2 4
3 6
4 8
For example, if your system has three boilers,
there would be a total of six controllers (two
for each boiler), so you would enter “6” for
Number of Controls.
5. Press the line for Controller ID. Because you
are changing a parameter that is related to
safety, the system will present a warning that
looks like this:
In this example, we are still working with the
Primary control for Boiler 1. From the table,
you can see that this control should have a
ap valve ID of “1.” Enter the correct ID from
Table 5 in this eld.
WARNING
If the controller cannot nd a signal from one
of the ap valves, the control system will act to
prevent backow by energizing the blower of the
control with the bad ap valve. If this cannot be
done the control will not allow the whole system to
run. For this reason, it is important that all of the
ap valves be identied correctly.
7. Set the address for the other controller on this
boiler in the same way.
8. At this point, you have set the ap valve ID’s
for both controllers on this boiler. Before you
leave, you must nish the verication process,
or the control system will not let the boiler
operate.
Press the Back arrow to return to the
Conguration screen.
Fig. 72 – Parameter Safety Warning
Press OK to continue. The system will ask
you to login before you make a change.
Note that any changes you make will apply
only to one controller – the controller you
have already selected. If you want the same
change to apply to other controllers, you must
change each of them separately.
Fig. 73 – Conguration Screen
Once you change one of these safety-related
parameters, you must nish the verication
process, or the control system will not let the
boiler operate. Each control in a boiler must
be veried separately.
6. Press again on the line for Controller ID. Table
9. In a moment, you will need to reset the
controller by pressing a button on the front of
the unit. See Fig. 74. The controllers for the
two boilers are mounted behind the door on
the front of the unit.
15 shows how the Primary and Secondary
controls should be numbered for each of the
boilers.
Table 15 – Flap Valve Controller ID Addressing
Boiler 1 Boiler 2 Boiler 3 Boiler 4
Primary control 1 3 5 7
Secondary control 2 4 6 8
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Fig. 76 – Safety Parameter Conrmation
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Fig. 74 – Reset Button on Controller
The control system allows 30 seconds to
press the reset button. Do not press the
Reset button yet! You will need to do this
in a moment. At this point, we just want to
alert you to something: In order to be able to
reach the controller within 30 seconds, it will
be helpful to open the door and slide out the
control panel rst.
When you are ready, press the Verify button
on the Conguration screen.
10. To begin the verication, login to the system
and press Begin.
Fig. 75 – Edit Safety Data
11. The system will present a listing of a group
which includes the parameter you changed
(the ap valve ID). See Fig. 76.
Check the list carefully. Press Yes if all of the
parameters in the group have been entered
correctly.
12. The system will tell you to reset the control
system.
Fig. 77 – Safety Parameter Reset
You must press the Reset button within 30
seconds, or the verication will be cancelled.
13. At this point, you have set the ap valve
address for one of the controllers in the
boiler. The next job is to set the ap valve
identication for the other control on this boiler.
(In this example, this would be the Secondary
control on Boiler 1). Press the Home button in
the upper left-hand corner of the display.
14. Press the icon for the Secondary control.
Repeat steps 3 through 12 for the Secondary
control for Boiler 1. (From Table 15, you can
see that the address for this control should be
“2.”)
15. At this point, you have set the ap valve ID’s
for both controllers on one of the boilers. Now
you must repeat the process for all of the
controllers on each of the other boilers.
Job G – Disconnect Unused Touch Screens
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Once a Lead/Lag system is set up and operating,
the monitoring functions will all be handled from one
Touch Screen – the one connected to the controller
operating as the Lead/Lag Master. If the extra
displays remain connected to the Lead/Lag system,
this will slow down the communications through
the system. (Each display would be considered a
leader on the Lead/Lag system.) To eliminate this
slowdown, disconnect the power from all of the
displays on the network except the display that is
connected to the controller operating as the Lead/
Lag Master.
Here is the procedure for disconnecting power to
one of the displays:
1. Turn off the power to the boiler which includes
the display you want to disconnect.
2. Open the front door to get access to the
electronics panel.
3. Locate terminal block 10 (TB10). See Fig. 78.
Remove the jumper connecting pins 1 and 2
on TB10.
AWG or thicker shielded twisted pair wire with drain.
Two twisted pairs or three conductors are needed.
Fig. 78 – Disconnecting an Unused Touch Screen
4. Close the front door and turn on power to the
boiler.
Job H - Connect the Modbus Wiring
(This is an individual function – do this on each of the
controls.)
In an installation with multiple boilers, the controllers
are arranged in a “daisy chain.” The wiring from
the Secondary controller on one boiler (TB9 - pins
7 through 12) to the Primary controller on the next
boiler (TB9 - pins 1 through 6). See Fig. 79. Use 22
Fig. 79 - Modbus Connections
Note – The Modbus wiring should be done last. The
controllers must be set up and addressed correctly
before the wiring is complete. If the wiring is attached
before the Modbus addresses for the controllers
are set up, there might be multiple controls with the
same address, and the system will not work.
1. Turn off the power to all of the boilers to which
you will be making connections. On each
boiler, open the front door to gain access to
the electronics panel. Locate terminal block 9
(TB9) on each panel.
2. Figure 79 shows how to make the connections.
The following table lists the connections from
Boiler 1 to Boiler 2.
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Boiler 1
(Lead/Lag Master) Boiler 2
Secondary Primary
TB9, pin 7 connect to TB9, pin 1
TB9, pin 8 connect to TB9, pin 2
TB9, pin 9 connect to TB9, pin 3
TB9, pin 10 connect to TB9, pin 4
TB9, pin 11 connect to TB9, pin 5
TB9, pin 12 connect to TB9, pin 6
3. Repeat the process for Boiler 2 and 3, and
Boiler 3 and 4. The connections to the other
boilers follow the pattern we just described.
Use Fig. 79 as your reference.
4. Connect the drain wires from all of the wire
assemblies together and ground the drain wire
on one end of the assembly only.
5. Turn on the power to all of the boilers when
you are nished.
Fig. 81 – Lead/Lag Master Screen
2. Press the Congure button. The display will
present the Lead/Lag Master Conguration
Screen (Fig. 82).
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Job I – Set the Parameters Used by the
Lead/Lag System
(This is a Lead/Lag function – do this once for the whole
Lead/Lag system. Use the controller set up as the Lead/
Lag Master – usually the Primary controller on Boiler 1.)
We have already explained how the Lead/Lag
Master controls the operation of the Lead/Lag
system. Your job at this point is to enter the control
values that the Lead/Lag system will use.
Fig. 80 - ‘home’ screen
1. From the ‘home’ screen (Fig. 80), press the
Lead Lag Master button. Figure 81 shows the
screen that follows.
Fig. 82 – Lead/Lag Master Conguration
3. This screen shows the most important settings
for the Lead/Lag system. The settings can be
changed from this screen. Some of them will
require passwords.
Here are the settings on this screen:
Master enable -
Enabled = Lead/Lag system enabled
CH setpoint -
Setpoint for LL Central Heating
CH time of day setpoint -
Separate Time-of-Day Setpoint for Central
Heating (See the material on “About the
‘Time of Day’ Function at the end of this
section)
DHW setpoint -
Setpoint for Domestic Hot Water
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DHW time of day setpoint -
Separate Time-of-Day Setpoint for Domestic
Hot Water (See the material on “About the
‘Time of Day’ Function at the end of this
section)
Modbus port -
Always use MB1
4. To see the other settings related to the Lead/
Lag functions, press the button for Advanced
Settings. This leads to a “ring” of related
screens, and you can scroll through the list
by pressing one of the left- or right-arrow
symbols. The screens in this ring are:
Modulation
Central Heat
Domestic Hot Water
Frost Proection
Outdoor Reset
Warm Weather Shutdown
Algorithms
Rate Allocation
Add Stage
Drop Stage
System sensor reaches the LL CH Setpoint
minus an additional “hysteresis” value.
P, I, D Gain -
These control the “damping” used by the
temperature control. The three control
values are P (proportional), I (integral) and
D (derivative). If you understand how these
variables affect the function of the unit,
you can change them to adjust for unusual
operating conditions. The default settings
for the Lead/Lag conguration are: P = 30,
I = 20, and D = 0.
6. Press the left-arrow or right-arrow until you
see the Central Heat screen (Fig. 84).
5. Press the left-arrow or right-arrow until you
see the Modulation screen (Fig. 83).
Fig. 83 – Modulation
Three of the items on this screen can be
changed:
Off hysteresis -
The system will not shut off the burners
until the System sensor reaches the CH
Setpoint plus an additional “hysteresis”
value.
On hysteresis -
The system will not re the burners until the
Fig. 84 – Central Heat
Setpoint source -
This sets the source of the System sensor
input used to control the system. The
options here are Local and 4-20 mA.
(For instructions on setting up for a 4-20
mA input, see Job #5 in the section on
“Installation Options.”)
Setpoint -
This is the same as the LL CH Setpoint on
the Lead/Lag Master Conguration screen
(Fig. 82).
Time of day setpoint -
This is the same as the LL CH Time-Of-
Day Setpoint on the Lead/Lag Master
Conguration screen (Fig. 82). (See
the material on “About the ‘Time of Day’
Function at the end of this section)
4 mA water temperature -
If a 4 – 20 mA input is used to adjust the
setpoint, this entry sets the low limit of the
control range. (In the example shown here,
an input of 4 mA would result in a setpoint of
90°F.)
20 mA water temperature -
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If a 4 – 20 mA input is used to adjust the
setpoint, this entry sets the high limit of the
control range. (In the example shown here,
an input of 20 mA would result in a setpoint
of 120°F.)
7. Press the left-arrow or right-arrow until you
see the Domestic Hot Water screen (Fig. 85).
Fig. 85 – Domestic Hot Water
The arrangement for Domestic Hot Water can
be set up in several ways. For details, see the
section on “Lead/Lag Domestic Hot Water.”
DHW Setpoint -
This is the same as the DHW Setpoint on
the Lead/Lag Master Conguration screen.
DHW Time of day setpoint -
This is the same as the DHW Time-Of-
Day Setpoint on the Lead/Lag Master
Conguration screen. (See the material on
“About the ‘Time of Day’ Function at the end
of this section.)
DHW Priority method -
This determines the way the system gives
priority to the DHW demand (if DHW is
given priority on the bottom line of the
screen.)
DHW priority override time -
If Domestic Hot Water has priority (see
the next line below), this sets how long the
DHW loop will have priority before returning
to control by the Lead/Lag Central Heat
setpoint.
DHW has priority over CH? -
Choose Central Heating priority or Domestic
Hot Water priority.
8. Press the left-arrow or right-arrow until you
see the Outdoor Reset screen (Fig. 86).
Fig. 86 – Outdoor Reset
“Outdoor Reset” allows the system to adjust
the Central Heat setpoint to compensate
for changes in the outdoor temperature.
This allows the whole system to run more
efciently. For details, see the section on
“About Outdoor Reset.”
Enable -
Enable = Outdoor Reset feature turned on
Max. outdoor temp. -
If the outdoor temperature reaches this
value or above, the system will use the
Low Water Temp value as the setpoint. In
the example shown in Fig. 86, the Max.
Outdoor Temp. is set to 70°F. If the outdoor
temperature is 70°F or above, the system
will use 100°F (the Low Water Temp.) as the
setpoint.
Min. outdoor temp. -
If the outdoor temperature reaches
this value or below, the system will not
compensate for the outdoor temperature.
In the example shown in Fig. 86, the Min.
Outdoor Temp. is set to 32°F. If the outdoor
temperature reaches 32°F or below, the
system will use the normal Lead/Lag System
setpoint (120°F in this example).
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Low water temp. -
If the outdoor temperature reaches the Max.
Outdoor Temp. or higher, the system will
use the Low Water Temp value as the new
setpoint. In the example shown in Fig. 86,
the Max. Outdoor Temp. is set to 70°F. If the
outdoor temperature reaches 70°F or above,
the system will use the Low Water Temp.
value (100°F) as the setpoint.
Min. boiler water temperature -
If a value is entered here, the temperature
in the boiler will never be allowed to drop
below this temperature. This will protect
the boiler against possible damage due to
expansion of ice inside the unit.
9. The Show Line button at the bottom of the
screen displays a curve which shows how
the system will behave at different outdoor
temperatures. See Fig. 87. (This screen
is also explained in the section on “About
Outdoor Reset.”)
When enabled, the Warm Weather Shutdown
feature will turn off the Central Heating
functions when the outdoor temperature
exceeds the setpoint. This prevents the
system from running when there is no need for
heat.
Enable -
These options determine how quickly
the system shuts down after the outdoor
temperature rises above the setpoint. The
options are Shutdown immediately/ After
demand ends/ Disabled.
Setpoint -
If the outdoor temperature is higher than
this, the system will shut off the Lead/Lag
Central Heating functions.
11. Press the left-arrow or right-arrow until you
see the Rate Allocation screen (Fig. 89).
Fig. 87 – Outdoor Reset Display
10. From the Outdoor Reset screen, press the leftarrow or right-arrow until you see the Warm
Weather Shutdown screen (Fig. 88).
Fig. 88 – Warm Weather Shutdown
Fig. 89 – Rate Allocation
As the load on the system increases, the rst
boiler in the Lead/Lag chain will increase the
fan speed until it reaches a certain percentage
of the total output (the “base load”). At that
point, the controller will start the second boiler
in the lead/lag chain. See the explanation at
the beginning of this section and Fig. 50.
Base Load Common -
As the demand increases, this sets the point
at which the controller starts another burner
in the Lead/Lag chain.
To prevent short-cycling, the base load setting
should be set at the values shown in Table 16,
or set to higher values.
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Table 16 – Base Load Settings
Number
Base load min.
of boilers
Installed
1 65%
2 50%
3 30%
4 30%
About the “Time of Day” Function
If the “time of day” function is enabled, the control
system can be set to maintain different temperatures
for central heat and domestic hot water (other than
the normal setpoints) in the system at certain times
of the day. Normally this function is used to switch
to lower temperatures at night, when the central
heating or domestic hot water demand is reduced.
When the controller acting as the Lead/Lag Master
receives a time of day input, the controller shifts to
the special setpoints entered for central heat and
domestic hot water.
The input for the Time of Day function must be wired
to pins 2 and 3 on connector J10.
Job J - Install the System Sensor and
Adjust the Setpoint
(This is a Lead/Lag function – do this once for the whole
Lead/Lag system. Make the connections to the controller
set up as the Lead/Lag Master – usually the Primary
controller on Boiler 1.)
1. Install the System sensor at the location
shown in Fig. 91. Connect the System sensor
to the System terminals on the controller
acting as the Lead/Lag Master (usually the
Primary controller on Boiler 1.) Use terminals
3 and 4 on TB6.
2. Adjust the Lead/Lag Central Heat Setpoint
to the desired temperature to be used by the
system.
How to get there – Adjust CH Setpoint
Home Page <Press View Lead Lag button> Lead
Lag Screen <Press Lead Lag Master button> Lead
Lag Screen <Press Congure button> Lead Lag
Master Conguration Screen
Line 2 = CH Setpoint
Pins 2 and 3 on
connector J10
Fig. 90 – Connections for “Time of Day” Function
Fig. 91 – Mounting Location for System Sensor
Job K - Set the Lead Lag Outdoor Reset and
Warm Weather Shutdown
(This is a Lead/Lag function – do this once for the whole
Lead/Lag system. Use the controller set up as the Lead/
Lag Master – usually the Primary controller on Boiler 1.)
For more information on the outdoor reset function,
see the explanation which follows.
1. Install the outdoor air temperature sensor
and make the connections to the outdoor air
sensor terminals on the controller acting as
the Lead/Lag Master (usually the Primary
controller on Boiler 1.) Use terminals 1 and 2
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on TB7.
2. Set the outdoor reset and warm weather
shutdown parameters as desired.
How to get there – Outdoor Reset Screen and
Warm Weather Shutdown Screen
Home Page <Press View Lead/ Lag button> Lead/
Lag Screen <Press Lead/ Lag Master button>
Lead/ Lag Screen <Press Congure button> Lead/
Lag Master Conguration Screen <Press Advanced
Settings button>
Select the Outdoor Reset Screen or the Warm
Weather Shutdown Screen
the system shuts down after the outdoor
temperature rises above the setpoint. The
options are Shutdown immediately/ After
demand ends/ Disabled.
Setpoint -
If the outdoor temperature is higher than
this, the system will shut off the Lead/Lag
Central Heating functions.
About Outdoor Reset
The Outdoor Reset feature calculates a correction
for the Lead/Lag setpoint depending on the outdoor
temperature. This allows the system to adjust for
changes in the outdoor temperature and run more
efciently.
The Show Line button at the bottom of the Outdoor
Reset screen displays a curve which shows
how the system will behave at different outdoor
temperatures. See Fig. 94.
Fig. 92 – Outdoor Reset
For a detailed explanation of the Outdoor
Reset function, see the section titled “About
Outdoor Reset” which follows.
Fig. 93 – Warm Weather Shutdown
When enabled, the Warm Weather Shutdown
feature will turn off the Central Heating
functions when the outdoor temperature
exceeds the setpoint. This prevents the
system from running when there is no need for
heat.
Enable -
These options determine how quickly
Fig. 94 – Show Line Screen
The display shown above show the action of the
system with one possible group of settings. The
green line shows the setpoint used by the system.
• Without Outdoor Reset, this would be a
constant 120°F (or whatever value you chose),
regardless of the outdoor temperature. The
green line in the graph would run straight
across the display.
• However, with the Outdoor Reset feature
turned on, the system will adjust for changes
in the outdoor temperature. Let’s take a
detailed look at behavior of the setpoint,
shown by the green line in the display. For
cold outdoor temperatures (below 32°F), the
setpoint remains unchanged (120°F). As the
temperature begins to rise above 32°F, the
Outdoor Reset function causes the setpoint to
be lowered. At these warmer temperatures,
the heating load on the system is not as
great, so the system does not have to reach
as high a temperature to handle the load. As
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you can see from the display, at an outdoor
temperature of about 70°F, the system stops
adjusting the setpoint. Above 70°F, the
setpoint is constant at 100°F.
When Outdoor Reset is enabled, and the outdoor
temperature falls between the maximum and
minimum outdoor temperatures (70° and 32° in
the example above), the setpoint will be adjusted
down by about 1° for every 2° increase in the
outdoor temperature. For example, if the outdoor
temperature rises by 10°, the Outdoor Reset
function will adjust the setpoint down by about 5°.
(This ratio between outdoor temperature and water
temperature is adjustable.)
When you set up the Outdoor Reset feature, you
can set the “turning points” on the adjusted setpoint
curve. If you go back to Fig. 91, the Outdoor Reset
screen, you see that the system records these
values:
Enable -
Enable = Outdoor Reset feature turned on
Max. outdoor temp. -
If the outdoor temperature reaches this
value or above, the system will use the
Low Water Temp value as the setpoint. In
the example shown in Fig. 91, the Max.
Outdoor Temp. is set to 70°F. If the outdoor
temperature is 70°F or above, the system
will use 100°F (the Low Water Temp.) as the
setpoint.
Min. outdoor temp. -
If the outdoor temperature reaches
this value or below, the system will not
compensate for the outdoor temperature.
In the example shown in Fig. 91, the Min.
Outdoor Temp. is set to 32°F. If the outdoor
temperature reaches 32°F or below, the
system will use the normal Lead/Lag System
setpoint (120°F in this example).
Low water temp. -
If the outdoor temperature reaches the Max.
Outdoor Temp. or higher, the system will
use the Low Water Temp value as the new
setpoint. In the example shown in Fig. 91,
the Max. Outdoor Temp. is set to 70°F. If the
outdoor temperature reaches 70°F or above,
the system will use the Low Water Temp.
value (100°F) as the setpoint.
There is one other part of this system, and it is
located on a different screen:
LL CH setpoint -
On a system set up for Outdoor Reset, this
will be the maximum water temperature
setting. This is located on the main Lead/
Lag Conguration screen.
How to get there – Lead/Lag Master
Conguration Screen
Home Page <Press Lead/ Lag Master button>
Lead/ Lag Screen <Press Congure button> Lead/
Lag Master Conguration Screen
Job L - Building Automation or Multiple
Boiler Control Thermostat Demand
(This is a Lead/Lag function – do this once for the whole
Lead/Lag system. Make the connections to the controller
set up as the Lead/Lag Master – usually the Primary
controller on Boiler 1.)
1. Supply the controller which is acting as
the Lead/Lag Master (usually the Primary
controller on Boiler 1) with a thermostat
closure from the Building Automation System
or multiple boiler control. Connect to terminals
5 and 6 on TB7.
2. Adjust the Lead Lag Central Heat setpoint.
How to get there – Lead/ Lag Central Heat
Setpoint
Home Page <Press Lead/ Lag Master button>
Lead/ Lag Screen <Press Congure button> Lead/
Lag Master Conguration Screen
Line 2 = CH Setpoint
Note - Bradford White offers “gateways” to
allow connections to BACnet, LON, and other
communications protocols. See Section 9.6.
Job M - Building Automation or Multiple
Boiler 4-20 mA Setpoint Control
(This is a Lead/Lag function – do this once for the whole
Lead/Lag system.)
In this type of installation, the CH Setpoint is
changed or modulated by a source outside of the
boiler. The low limit of the 4-20 mA signal (4 mA)
sets the low limit of the setpoint, and the high limit of
the 4-20 mA signal (20 mA) sets the high limit of the
setpoint.
1. Supply the controller which is acting as
the Lead/Lag Master (usually the Primary
controller on Boiler 1) with the 4-20 mA input
from the Building Automation System or
multiple boiler control. Connect to terminals 3
and 4 on TB7.
2. On the Lead/Lag Master settings, change the
setpoint source to 4-20 mA.
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How to get there – Lead/ Lag Setpoint Control
Home Page <Press Lead/ Lag Master button>
Lead/ Lag Screen <Press Congure button> Lead
Lag Master Conguration Screen <Press Advanced
Settings button> <Press Left- or right-arrow button>
Central Heat
Setpoint Source = 4-20 mA
Fig. 95 – Lead Lag Central Heat Conguration
3. Change the 4 mA water temperature to match
the lowest water temperature setting on the
Building Automation System or multiple boiler
control.
4. Change the 20mA water temperature to match
the highest water temperature setting on the
Building Automation System or Multiple boiler
control.
Note - Bradford White offers “gateways” to
allow connections to BACnet, LON, and other
communications protocols. See Section 9.6.
Job N - Building Automation or Multiple
Boiler 4-20 mA Modulation Control
(This is an individual function – do this on each of the
controls.)
In this type of installation, the fan speed of each
boiler is changed or modulated by a source outside
of the boiler. All active burners must operate at the
same modulation rate while operating. The system
will not operate correctly if some of the burners
are being asked to operate at full rate while other
burners are operating at minimum rates.
Note - The system can also operate using 0 - 10V
dc using a converter (Bradford White part number
CA006100.)
1. On each controller in the system, check
terminals 3 and 4 on TB6 to ensure that the
System sensor is not connected. (For this
type of operation, the Lead/Lag system is
disabled.)
2. Connect the 4-20 mA input to each controller
in the system.
• On the Primary controller in each boiler,
connect to terminals 3 and 4 on TB7.
• On the Secondary controller in each boiler,
connect to terminals 7 and 8 on TB7.
3. Enable a central heat call for each control
on the system. This function must be set up
for each controller separately. This function
operates outside of the Lead/Lag system.
How to get there – Central Heat Enable
Home Page <Press the icon for one of the
controllers> Brute Primary Screen <Press Congure
button> Primary Conguration Menu <Select line CH Central Heat Conguration>
4. Fig. 96 shows the setup screen.
Fig. 96 - Central Heat Conguration
5. Enable the Central Heat function on the top
line. Give the CH function the priority using
the lower line.
Note - Bradford White offers “gateways” to
allow connections to BACnet, LON, and other
communications protocols. See Section 9.6.
Job O – Combustion Setup Procedure
(These are individual functions. Do the combustion setup
for each of the burners.)
In this section, we will explain how to set up the gas
valve so both burners in each boiler run efciently
at both the High Fire and Low Fire conditions. As
we said, a boiler includes two controllers (Primary
and Secondary), which control two burners (Primary
and Secondary). See Fig. 97. Each burner has
a separate gas valve, and each of these must be
set up separately. Here’s a quick summary of the
procedure:
• You shut off one controller/burner combination,
and work with the other.
• You set the working burner to run at High Fire,
and adjust the gas valve to get the correct CO2
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Boiler 1
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High re adjustment
Low re adjustment
Operator
interface
Primary
controller
Gas
valve
Gas
valve
Secondary
controller
Primary
burner
Secondary
burner
Fig. 97 – Primary and Secondary Burners in a Boiler
the same adjustments there.
WARNING
Improper adjustment may lead to poor combustion
quality, increasing the amount of carbon monoxide
produced. Excess carbon monoxide levels may
lead to personal injury or death.
Fig. 98 – High and Low Fire Adjustments on
Gas Valve - BNT1000 and BNT1200
reading.
• Next you set the same burner to run at Low
Fire, and make another adjustment on the gas
valve to get the desired CO2 reading.
• When you are through, you shut off the
controller/burner you have been working with,
turn on the other controller/burner, and make
Required tools: Screwdrivers, Torx bits, combustion
analyzer
In the rest of this section we will explain the setup
procedure in more detail.
1. On the gas valve for the Primary burner on the
boiler, locate the adjustments for the high re
CO2 and low re CO2. See Fig. 98 and 99.
Table 17 lists the CO2 readings you should see
at high re and low re.
2. To start the setup, turn on the call for heat.
3. Before you can set up the Primary burner, you
must shut off the Secondary burner. Go to the
‘home’ screen on the display. Press the icon
for the control labeled Secondary.
Fig. 100 – ‘home’ screen
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4. The system will present the Status Summary
screen.
Fig. 101 – Status Summary Screen
5. Press the Operation button. The system
will present the Operation screen for the
Secondary burner.
Press the Burner Enable switch in the upper
left-hand corner of the screen. Since you
selected the Secondary control for this boiler,
this will turn off the Secondary burner. The
system will ask you to log in as you do this.
6. Now you can work with the Primary burner for
this boiler. Press the Home icon to go back
to the ‘home’ screen on the display (Fig. 100).
Press the icon for the control labeled Primary.
7. The system will present the Status Summary
screen for the Primary burner. Press the
Operation button.
8. The system will present the Operation screen
for the Primary burner.
Fig. 103 – Operation Screen
9. You can change the fan speed of the burner
by adjusting the value entered for Firing Rate
on the right side of the display. (Remember, a
Fig. 102 – Operation Screen
moment ago you selected the Primary control
for this boiler, so this change will only affect
the Primary burner.) Press the yellow box
beside the Firing Rate label.
10. The system will ask you to log in using a
password. Enter the installer-level password,
then press OK.
11. Press the box for Firing Rate again. The
Model Gas Type High Fire CO
Low Fire CO
2
2
1,000 Natural 8.5% ± 0.2 0.5% lower than high re CO
Propane 9.5% ± 0.2 0.5% lower than high re CO
1,200 Natural 9.0% ± 0.2 0.5% lower than high re CO
Propane 9.5% ± 0.2 0.5% lower than high re CO
Table 17 – CO2 Range and Pressure Differential
* - Only check the pressures if there are problems getting the CO2 and CO values in range.
Pressure Differential
0.5” to 1.2” wc*
2
0.5” to 1.2” wc*
2
0.5” to 3.6” wc*
2
0.5” to 3.6” wc*
2
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Positive connection point
Negative connection point
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Fig. 105 – Connections for Pressure Gauge
BNT1000 and BNT1200
controller will present the Manual Firing Rate
screen shown in Fig. 104.
Fig. 104 - Manual Firing Rate
12. Notice the three options on the left side of the
screen:
Auto -
The ring rate will be set automatically by the
controller, based on the heat load. Set this
item to Auto at the end of the test.
Manual in Run -
The Manual in Run control will only set the fan speed
when the control has proven ame and the unit has
entered the Run mode.
Manual in Run and Standby -
Using this setting, the manual control will set the fan
speed whether the boiler is operating or not.
For this test, select Manual in Run.
13. Type in a value for high re RPM. Enter 8000 RPM.
(The actual RPM will not go this high – the control will
limit the fan speed to the maximum set at the factory.)
By using the manual control, and entering a high RPM
value, this forces the burner to run at full combustion
so you can adjust the gas valve for the correct CO2
output.
Figures 105 and 106 show the adjusting points on the
gas valve. Adjust the High Fire screw to get the proper
CO2 level for high re. See Table 17. To raise the high
re CO2 level, turn the High Fire adjustment screw
counter-clockwise. To lower the high re CO2 level,
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turn the screw clockwise.
(Make the adjustment in small steps of 1/8
turn to avoid “overshooting” the correct setting.
The valve is built with a bit of “backlash.” This
makes it appear that changing the adjustment
does not change the CO
level when you
2
rst stop turning the control in one direction,
and start turning it the other way. Once the
backlash has been taken up, the control will
be quite sensitive.)
14. Repeat step 13, except this time set the fan
speed RPM to 1200rpm. (Again, the actual
RPM will not go this low – the control will
limit the fan speed to the minimum set at the
factory.) This will force the boiler to operate in
low re. Adjust the Low Fire screw so the CO
is 0.5% lower than the high re CO2. To raise
the low re CO2, turn the Low Fire adjustment
screw clockwise. To lower the low re CO2,
turn the screw counter-clockwise.
15. The adjustment you made for the Low Fire
setting could affect the High Fire setting, so
you need to re-check the High Fire setting.
Go back to the Operations screen and set
the Firing Rate back to 8000 RPM. The CO2
should still be about at the level listed in Table
17. If the CO2 is not correct, repeat the steps
listed above.
16. Set the Firing Rate back to 1200 RPM, and
re-check the CO2 during Low Fire.
17. Once the CO2 values are correct for both High
Fire and Low Fire, go back to the Operation
screen and select Automatic operation. At this
point, you have set up the Primary burner for
this boiler.
18. Now you can do the same setup for the
Secondary burner on this boiler. To do this,
you need to shut off the Primary burner. On
the Secondary control, you set the High and
Low Fire RPM and check the CO2 output for
each condition. We will review the process
quickly here:
• On the ‘home’ screen, press the icon for the
Primary controller.
• On the Status Summary screen, press the
Operation button.
• On the Operation screen, turn off the
Primary burner by pressing the Operation
Enable button.
• On the ‘home’ screen, press the icon for the
Secondary controller.
• On the Status Summary screen, press the
Operation button.
• On the Operation screen for the Secondary
burner, press the yellow box for the Firing
Rate. Login using the installer-level password,
then press OK.
• Now you can change the Firing Rate entry
for the Secondary burner. Enter 8000 RPM
for the High Fire value. Adjust the High Fire
screw to get the CO
level listed in Table 17.
2
• Set the Firing Rate to 1200rpm. Adjust the
Low Fire screw so the CO
level reaches the
2
CO2 level listed in Table 17.
• Re-check the High Fire setting at 8000
RPM. The CO2 should still be about 8.5% or
9.0%, depending on the model size.
• Re-check the CO2 during Low Fire at 1200
2
RPM.
• Once the CO2 values are correct for both
High Fire and Low Fire, go back to the
Operation screen for the Secondary burner
and select Automatic operation. At this point,
you have set up the Secondary burner for this
boiler.
• Go back to the ‘home’ screen and press the
icon for the Primary control. On the Status
Summary screen, press the Operation button.
On the Operation screen, press the Burner
button to turn on the Primary burner.
19. Once both burners are set up properly,
operate both burners together as described
below, and check the CO2 levels with the unit
operating at high re and at low re. The nal
CO2 values at high re should be as listed in
Table 17 ±0.2%. At low re, the CO2 should
be about 0.5% lower than the high re CO2
reading. (The offset is more important than the
actual CO2 value)
Monitor the CO2 and CO levels for one
complete operating cycle. The CO should
never be more than 150 ppm. The CO2 level
should also track between the high and low
limits listed in the table.
Setting the fan speed RPMs for both burners
operating together -
• It is important that both burners operate at
the same fan speed. Before changing the fan
speeds, turn off the call for heat.
• Set the fan speed for each burner
separately, using the procedure we described
earlier - steps 6 though 11 for the Primary
burner, and step 18 for the Secondary burner.
On each burner, enter a value of 8000 RPM
for the high re test.
• Once you have set both burners to run at
8000 RPM, turn on the call for heat, and check
the results as described above.
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• Turn off the call for heat, and set both
burners to run at 1200 RPM for low re.
Turn on the call for heat, and check the
performance again.
20. If the CO
limits, there is a possibility that one of the
burners has not been set up correctly. If
this occurs, repeat the setup procedure to
conrm that each burner is set up correctly.
If this condition persists, call the factory for
assistance. Before calling, be prepared to
supply the factory with the conditions at the
site where the boiler is installed - for example,
vent lengths, gas supply pressures with all
boilers operating, CO2 and CO for each burner
individually and together, etc. Be able to
describe the ignition characteristics and the
color of the ame seen through the sight glass
of each burner.
21. When troubleshooting a burner setup, it is
sometimes helpful to watch the pressure
differential between the gas inlet and outlet.
To measure this, install a differential pressure
gauge capable of reading negative 0.01
inches W.C. (0.002kPa). Attach the gauge to
the positive and negative ports shown in Fig.
104. When the testing is complete, remove the
pressure gauge, and plug the ports. Repeat
the test setup on each burner.
doesn’t track between the correct
2
Here is the procedure:
1. Start at the ‘home’ screen.
Fig. 107 – ‘home’ screen
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2. Press the Setup button. The system will
present the Setup screen.
Job P - Setting the Date and Time on the
System Display
(This is a Lead/Lag function – do this once for the whole
Lead/Lag system. Use the controller set up as the Lead/
Lag Master – usually the Primary controller on Boiler 1.)
The display acting as the Lead/Lag Master includes
an internal clock, which keeps track of the date and
time. This setting is important, because all of the
log entries for any Lockouts and Alerts include time
listings. If the Date and Time setting for the Lead/
Lag Master is not correct, the listings in the Lockout
and Alert logs will be incorrect.
The current version of the display does not include a
battery backup. This means that, if the boiler which
includes the display loses power, the Date and Time
setting for the system will be lost. (Any Faults or
Alerts recorded before the boiler lost power will have
the correct date and time listed.)
For this reason, it is important that you set the Date
and Time in two situations:
• When you rst set up the Lead/Lag system.
• After each occasion when the power to the
boiler is interrupted.
Fig. 108 – Setup Screen
3. Press the Display Setup button. The Display
Setup screen is shown in Fig. 106.
Fig. 109 – Display Setup Screen
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
hydronic temperature and the maximum DHW outlet
4. Select Date and Time. Figure 107 shows the
setup screen.
Fig. 110 – Date and Time
temperature.
The setup for this is all done from within the Lead/
Lag system. You will need to set up an LL CH
setpoint and a separate LL DHW setpoint, and
assign the priority to the DHW demand.
The input from the aquastat is brought to terminals
5 and 6 on TB6 on the controller which is acting as
the Lead/Lag Master. (Usually, this is the Primary
controller on Boiler 1.)
1. From the ‘home’ screen (Fig. 111), press the
View Lead Lag button.
9.5 Setup for Domestic Hot Water on
a Lead/Lag System
There are three ways that a Brute system can be
set up to provide domestic hot water. Two of them
involve the use of an indirect water heater. In
a system including an indirect water heater, hot
water is circulated through a piping loop which runs
through an insulated water tank. Heat from the
water in the loop is transferred to the water in the
tank, and the heated water in the tank is used as
domestic hot water.
Setup Type 1 –
All of the boilers in the system can be set up to react
together if there is a call for domestic hot water.
This arrangement can be used for BNTH or BNTV
units. When BNTH units are used in this kind of
setup, the demand for domestic hot water (DHW) is
given priority over the demand for central heat (CH).
If the system is producing heat for a CH demand,
and a call for DHW arrives, all of the boilers will
stop producing heat for CH, and the whole system
will respond to the DHW demand. The DHW pump
will start circulating water through the loop in the
indirect water heater. The System sensor is used to
control modulation in this conguration, so sensor
placement is critical.
This arrangement can be cumbersome if the
demand for domestic hot water is a lot less than
the demand for central heating. This can result in
multiple boilers “idling” as they wait for the DHW
demand to be satised.
Fig. 111 – ‘home’ screen
2. Press the button for Lead Lag Master. Fig.
112 shows the screen that follows.
Fig. 112 – Lead/Lag Master Screen
3. Press the Congure button. The display will
present the Lead/Lag Master Conguration
Screen (Fig. 113).
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Caution
For BNTH units - This arrangement can only be
used in applications where all of the components
in the system are rated for both the maximum
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Fig. 113 – Lead/Lag Master Conguration
Entries on this screen allow you to set the CH
setpoint and DHW setpoint.
4. Press the button for Advanced Settings. This
leads to a “ring” of related screens, and you
can scroll through the list by pressing one of
the left- or right-arrow symbols. Press the leftarrow or right-arrow until you see the Domestic
Hot Water screen (Fig. 114).
Fig. 114 – Domestic Hot Water
An entry on this screen allows you to give
priority to the DHW function.
Setup Type 2 –
As a second option, a system can be set up so that
only one or two boilers respond to a demand for
domestic hot water. This allows the other boilers in
the system to continue to service the demand for
central heating. This system is more exible, but the
setup is a bit more complicated:
• All of the boilers are tied together in the
normal way, using the Modbus connections.
• The DHW demand must switch over a whole
boiler (including both burners), not just a
single burner. Both burners in a boiler should
always use the same setpoint.
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• The plumbing must be set up so that, during
DHW demand, each boiler used for DHW
is pumped by the DHW pump, and the
boiler pump is turned off. This will keep the
temperature zones separate.
• Each of the boilers that will handle DHW is
wired with an input from the aquastat used to
indicate DHW demand. The aquastat demand
should be jumpered from the Primary control
in each boiler (terminals 5 and 6 on TB6 to
terminals 7 and 8 on TB6).
• The LL CH setpoint used by all of the boilers is
set in the normal way, working from the Lead/
Lag section of the software.
• On each of the boilers used for DHW, priority
is given to the DHW function. Because this
affects individual boilers, rather than the whole
system, this part of the setup is done from
outside the Lead/Lag system.
• On each of the boilers used for DHW, the two
burners in that boiler will operate in Lead/Lag
mode. You can think of each of these boilers
as a separate two-burner Lead/Lag system.
Once a system is set up this way, if there is no DHW
demand, the system will operate like any other
Lead/Lag system. If a demand for DHW arrives,
the boilers used for DHW will stop providing heat
for central heat. On the DHW boilers, the pump(s)
for the DHW loops will start, and those boilers will
provide heat to just the indirect water heaters.
Because this affects an individual boiler, and not the
whole Lead/Lag system, the conguration is done
from outside the Lead/Lag section of the software.
Remember that the boiler includes two controller/
burner combinations. You have to set the DHW
priority on both of the controller/burners.
1. Start at the ‘home’ screen. Press the icon for
the controller you want to congure.
2. The Status Summary page for that controller
will appear. Press the Congure button.
3. The system will present the Conguration
Menu screen. Scroll down until you see the
line labeled “DHW Priority vs CH.”
Fig. 115 – DHW Conguration Screen
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4. Select that line by pressing it. If you want to
change the DHW priority, the system will ask
you to log in using the installer-level password.
For this kind of installation, the entry should be
“DHW> CH.”
5. Go to the line for “DHW Priority vs Lead Lag.”
For this kind of installation, the entry should be
“DHW> LL.”
6. Remember to change the settings on the other
controller/burner for this boiler.
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Setup Type 3 –
The third possibility is to set up a single boiler that just
provides domestic hot water. The model BNTV unit
is designed for this kind of “volume water” service.
The water is heated as it moves through the boiler,
and that same water is supplied directly for domestic
use. This is really like a conventional Lead/Lag setup,
except priority is given to domestic hot water, and
there is no input for the central heating function.
• On each boiler which will operate this way,
connect a DHW sensor or the input from the
aquastat to terminals 5 and 6 on TB6. Be
sure there is no thermostat connected (check
terminals 5 and 6 on TB7).
• The two burners in each boiler will operate in
the Lead/Lag mode. You can think of each
boiler as a separate two-burner Lead/Lag
system.
• The setpoint used is the LL DHW setpoint, set
as part of the Lead/Lag system.
• In the Lead/Lag setup, DHW is given priority.
1. Start at the ‘home’ screen (Fig. 116).
Fig. 117 – Lead/Lag Master Screen
3. Press the Congure button. The display will
present the Lead/Lag Master Conguration
Screen (Fig. 118). Set the DHW setpoint on
this screen.
Fig. 118 – Lead/Lag Master Conguration
4. Press the button for Advanced Settings. This
leads to a “ring” of related screens, and you
can scroll through the list by pressing one of
the left- or right-arrow symbols. Press the leftarrow or right-arrow until you see the Domestic
Hot Water screen (Fig. 119).
Fig. 116 – ‘home’ screen
2. Press the Lead Lag Master button. Fig. 117
shows the screen that follows.
Fig. 119 – Domestic Hot Water
Set the last line to give priority to the DHW
function.
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9.6 Gateway Connections to a
Building Automation System
Brute boilers can be controlled and monitored
through the included Modbus ports. The
Modbus wiring should be completed according
to the instructions in this manual. If alternate
communication protocols are desired, Bradford
White offers “gateways” to allow BACnet, LON, and
other communications protocols. Signals from a
Building Automation System can be connected to
TB10. See Fig. 120. For additional information
on setting up Modbus and other communication
protocols, contact the factory.
B
RADFORD WHITE
Enabling Modbus Port 2 -
For this system to work correctly, Modbus Port 2 on
the unit operating as the Lead/Lag Master must be
enabled. From the ‘home’ screen, press the Setup
button to go to the Setup screen. Press the Display
Setup button to go to the Display Setup screen. On
the Display Setup screen, press the COM2 tab to
bring up the setup screen for the COM2 function.
Click the box labeled “Enable COM2 Port.” See Fig.
121.
Fig. 120 - BAS Connections
Fig. 121 - Enabling COM2
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
9.7 Installer Parameters
This is a list of all of the parameters which can be accessed using the Installer password.
Label Description How to Reach
4 mA water
temperature
20 mA water
temperature
Anti Short
Cycle Time
Boiler pump
control
Boiler Pump
Cycle Count
Boiler Name This parameter allows the installer to give
Burner
Cycle Count
Burner
Enable
Switch
Burner Run
Time
CH (Central
Heat) D gain
CH (Central
Heat)
Enable
CH (Central
Heat) Frost
Protection
Enable
If a 4 – 20 mA input is used to adjust the
setpoint, this entry sets the low limit of the
control range. (In the example shown here,
an input of 4 mA would result in a setpoint of
90°F.)
If a 4 – 20 mA input is used to adjust the
setpoint, this entry sets the high limit of the
control range. (In the example shown here,
an input of 20 mA would result in a setpoint of
120°F.)
This can be set to prevent the system from
cycling on and off quickly if the heat demand
is near the setpoint and changes quickly.
The Boiler pump (Pump A) can be turned
on manually, or it can be set to operate
automatically. If it is turned on, then it remains
on until the control is changed back to Auto.
In Auto mode it operates according to the
demand and overrun time.”
Boiler pump cycle count. Can be written to
a new value (e.g. if the pump or controller is
replaced).
each controller a unique name.
This is incremented on each entry to Run. It
can be written to a with a new value if the
burner or controller is replaced.
This parameter enables or disables the burner
control. When it is off, the burner will not re.
This measures the time spent in the Run
state. It can be written to with a new value if
the burner or controller is replaced.
This gain is applied to the Differential term of
the PID equation for the CH loop.
This parameter determines whether the Central
Heat loop is enabled or disabled. When it is
disabled, heat demand caused by the input
assigned to the CH loop is ignored. It may be
disabled to turn it off temporarily, or because
the application does not use this feature.
The CH frost protection feature can be
enabled to run a pump (or pumps) and
possibly re the burner whenever the CH
input sensor is too cold.
<’home’ screen> Lead Lag Master button
<Lead Lag Master screen> Congure
button <Lead Lag Master Conguration
screen> Advanced Settings button <Central
Heat screen>
<’home’ screen> Lead Lag Master button
<Lead Lag Master screen> Congure
button<Lead Lag Master Conguration
screen> Advanced Settings button<Central
Heat screen>
<’home’ screen> Select a controller <Status
Summary screen> Congure button
<Conguration Menu> Select System
Conguration <System Conguration screen>
<’home’ screen> Select a controller <Status
Summary screen> Conguration button
<Pump Conguration> Left- or Right- arrow
buttons <Boiler Pump screen> Control
Settings button
<’home’ screen> Select a controller
<Status Summary screen> Congure button
<Conguration Menu> Select Statistics
Conguration line
<’home’ screen> Select a controller <Status
Summary screen> Conguration button
<Conguration Menu> System ID and
Access
<’home’ screen> Select a controller <Status
Summary screen> Congure button
<Conguration Menu> Select Statistics
Conguration line
<’home’ screen> Select a controller <Status
Summary screen> Operation button
<Operation screen>
<’home’ screen> Select a controller
<Status Summary screen> Congure button
<Conguration Menu> Select Statistics
Conguration line
<’home’ screen> Select a controller <Status
Summary screen> Conguration button
<Central Heat Conguration> Arrow keys
<Modulation screen>
‘home’ screen/ Select controller/ Status
Summary screen/ Conguration button/
Central Heat Conguration/ Arrow keys/
Central Heat screen
‘home’ screen/ Select controller/ Status
Summary screen/ Conguration button/
Anti-Condensation Conguration/
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Label Description How to Reach
CH (Central
Heat) has
priority over
LL (Lead/
Lag)
CH (Central
Heat) I gain
CH (Central
Heat)
Modulation
Sensor
CH (Central
Heat)
Outdoor
Reset Low
Water
Temperature
CH (Central
Heat) ODR
(Outdoor
Reset) Max.
Outdoor
Temperature
CH (Central
Heat) Off
Hysteresis
CH (Central
Heat) On
Hysteresis
CH (Central
Heat)
Outdoor
Reset Enable
CH (Central
Heat) P gain
CH (Central
Heat) Pump
Control
This controls whether a local Central Heat
demand has priority over the control asserted by
the LL Master, when this controller is enabled as
a slave.
This gain is applied to the Integral term of the
PID equation for the CH loop.
This selects the sensor used for modulation and
burner demand for the CH loop.
This parameter provides the CH Outdoor Reset
setpoint when the outdoor temperature is at
or above the maximum specied by the Max.
Outdoor Temperature.
This parameter determines the maximum
outdoor temperature for the CH outdoor reset
graph. At or above the maximum outdoor
temperature, the water temperature setpoint will
be at the low water temperature.
The off hysteresis is added to the CH setpoint to
determine the temperature at which the burner
demand turns off.
The on hysteresis is subtracted from the CH
Setpoint to determine the temperature at which
the burner demand turns on.
If outdoor reset is enabled, then the current
outdoor temperature is used to determine the
setpoint by interpolation using the CH Setpoint
(or the CH Time-Of-Day Setpoint if the Time-OfDay feature is on), the low water temperature,
and the min. and max. outdoor temperatures.
This gain is applied to the proportional term of
the PID equation for the CH loop.
The CH pump (System pump – Pump C) can be
turned on manually, or it can be set to operate
automatically. If it is turned on then it remains
on until changed back to Auto. In Auto mode
it operates according to the demand sources
listed above and the overrun time.
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button Leftand Right-arrow buttons <Domestic Hot
Water screen>
<’home’ screen> Select a controller
<Status Summary screen> Conguration
button <Central Heat Conguration
screen> Left- and Right arrow buttons
<Modulation screen>
<’home’ screen> Select a controller
<Status Summary screen> Conguration
button <Central Heat Conguration> Leftand Right-arrow buttons <Modulation
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
<’home’ screen> Select controller
<Status Summary screen> Conguration
button <Central Heat Conguration>
Arrow keys <Modulation screen>
<’home’ screen> Select a controller
<Status Summary screen> Conguration
button <Central Heat Conguration
screen> Arrow keys <Modulation screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
<’home’ screen> Select a controller
<Status Summary screen> Conguration
button <Central Heat Conguration
screen> Arrow keys <Modulation screen>
<’home’ screen> Select a controller
<Status Summary screen> Conguration
screen <Pump Conguration screen>
Left- or Right- arrow buttons <System
Pump screen> Control Settings button
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RADFORD WHITE
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Label Description How to Reach
CH (Central
Heat)
Setpoint
CH (Central
Heat) “Time
of Day”
Setpoint
This setpoint is used when the time-of-day input
is off. If the outdoor reset function is active, this
setpoint provides one coordinate for the outdoor
reset curve. See the section for the CH Outdoor
Reset parameter.
This setpoint is used when the time-of-day input
is on. If the outdoor reset function is active,
this Setpoint provides one coordinate for the
shifted outdoor reset curve, because the timeof-day switch is on. See the section for the CH
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
Outdoor Reset parameter.”
DHW
(Domestic
Hot Water) D
Gain
DHW
(Domestic
Hot Water)
Enable
This gain applied to the Differential term of the
PID equation for the DHW loop.
This parameter determines whether the
Domestic Hot Water loop is enabled or disabled.
When it is disabled, the demand caused by the
DHW sensor is ignored. It may be disabled to
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Domestic Hot Water
Conguration screen>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Domestic Hot Water
Conguration screen>
turn it off temporarily or because the application
does not use this feature.
DHW
(Domestic
Hot Water)
has priority
over CH
(Central
This parameter determines the priority of
Domestic Hot Water vs. Central Heat callfor-heat, when both of these are enabled and
active. (The DHW priority also may shift for a
period of time, as specied by DHW Priority
time and method parameters.)”
<’home’ screen> Lead Lag Master <Lead
Lag Master screen> Congure button
<Lead Lag Master Conguration screen>
Advanced Settings button/ Left- and
Right- arrow buttons <Domestic Hot
Water screen>
Heat)
DHW
(Domestic
Hot Water) I
gain
DHW
(Domestic
Hot Water)
off hysteresis
DHW
(Domestic
Hot Water)
on hysteresis
DHW
(Domestic
Hot Water) P
gain
DHW
(Domestic
Hot Water)
priority
override time
This gain applied to the Integral term of the PID
equation for the DHW loop.
The off hysteresis is added to the Domestic Hot
Water Setpoint to determine the temperature at
which the DHW burner demand turns off.
The on hysteresis is subtracted from the
Domestic Hot Water Setpoint to determine the
temperature at which the DHW burner demand
turns on.
This gain applied to the Proportional term of the
PID equation for the DHW loop.
If this parameter is non-zero then a Domestic
Hot Water demand will shift its priority vs. other
demand sources according to the specied
time. The priority override timing is reset when
demand from the DHW source turns off.
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Domestic Hot Water
Conguration>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Domestic Hot Water
Conguration screen>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Domestic Hot Water
Conguration>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Domestic Hot Water
Conguration screen>
<’home’ screen> Lead Lag Master button
<Lead Lag Master screen> Congure
button <Lead Lag Master Conguration
screen> Advanced Settings button
<Domestic Hot Water screen>
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Label Description How to Reach
DHW
(Domestic
Hot Water)
pump control
DHW
(Domestic
Hot Water)
pump cycle
count
DHW
(Domestic
Hot Water)
Setpoint
DHW
(Domestic
Hot Water)
TOD (Time of
Day) Setpoint
Flap valve
controller ID
Lead lag CH
outdoor reset
enable
Lead lag CH
setpoint
Lead lag
CH setpoint
source
Lead lag CH
TOD setpoint
The DHW pump (Pump C) can be turned
on manually, or it can be set to operate
automatically. If it is turned on then it remains
on until changed back to Auto. In Auto mode it
operates according to the DHW demand, the
start delay timer and the overrun time.
This can be written to a new value if the pump
or controller is replaced.
This setpoint is used for Domestic Hot Water
whenever the Time-Of-Day switch is off or not
connected (unused).
This setpoint is used for Domestic Hot Water
when the Time-Of-Day switch is on.
Each ap valve has a unique ID number. On
a system with 4 boilers, there would be 8 ap
valves, numbered 1 through 8.
This line is used to turn on the Outdoor Reset
function when the Lead/Lag system is enabled.
This is the setpoint used for Central Heat when
the Lead/Lag system is enabled.
When Lead/Lag is enabled, this sets the source
of the System sensor input used to control the
system. The options here are Local and 4-20
mA.
This is a different setpoint used for Central Heat
when the Lead/Lag system is enabled and the
input from the Time Of Day switch is “true.”
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Pump
Conguration/ Left- or Right- arrow
buttons <DHW Pump screen> Control
Settings button
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select
Statistics Conguration line
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
<’home’ screen> Select a controller
<Status Summary screen> Congurate
button <Flap Valve Conguration screen>
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
‘home’ screen/ View Lead/Lag button/
Lead/Lag screen/ Lead/Lag Master
button/ Lead/Lag Master screen/
Congure button/ Lead/Lag Master
Conguration screen/ Advanced Settings
button/ Left- or Right- arrow buttons/
Central Heat screen
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
B
RADFORD WHITE
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Label Description How to Reach
Lead lag D
gain
This is part of the damping function
(“Derivative”) used when the controller interprets
the input from the System sensor.
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Left-
or Right- arrow buttons <Modulation
screen>
Lead lag
DHW
demand
switch
This indicates source of the aquastat signal
used to control the Domestic Hot Water loop.
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Domestic Hot
Water screen>
Lead lag
DHW has
priority over
CH
Choose Central Heating priority or Domestic Hot
Water priority.
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Domestic Hot
Water screen>
Lead Lag
DHW priority
override time
If Domestic Hot Water has priority, this sets how
long the DHW loop will continue to have control
after the DHW demand stops.
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Domestic Hot
Water screen>
Lead lag
DHW
setpoint
This is the setpoint used for Domestic Hot Water
when the Lead/Lag system is enabled.
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
Lead lag
DHW TOD
setpoint
Lead lag I
gain
This is a different setpoint used for Domestic
Hot Water when the Lead/Lag system is enabled
and the input from the Time Of Day switch is
“true.”
This is part of the damping function (“Integral”)
used when the controller interprets the input
from the System sensor.
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Left-
or Right- arrow buttons <Modulation
screen>
Lead lag
master
enable/
disable
One of the controllers must be set up as the
Lead/Lag Master to supervise the Lead/lag
system. Usually this is the Primary controller on
Boiler 1. The master function must be disabled
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
on all of the other controllers. See the section
on “About Lead/Lag.”
Lead lag off
hysteresis
When the Lead/Lag function is enabled, the
control system will not shut off the boilers until
the temperature at the System sensor rises
to the Lead/Lag CH setpoint plus a hysteresis
value (normally about 10°F).
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Left-
or Right- arrow buttons <Modulation
screen>
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Label Description How to Reach
Lead lag on
hysteresis
Lead lag P
gain
Lead/Lag
Slave Enable
Lead/
Lag Slave
Sequence
Order
Lead/
Lag Slave
Modbus
Address
Lead/Lag
Outdoor
Reset Enable
Lead/Lag
Outdoor
Reset
low water
temperature
Lead/Lag
Outdoor
Reset max
outdoor
temperature
Lead/Lag
Outdoor
Reset min
outdoor
temperature
When the Lead/Lag function is enabled, the
control system will not re the boilers until the
temperature at the System sensor drops to the
Lead/Lag CH setpoint minus a hysteresis value
(normally about 10°F).
This is part of the damping function
(“Proportional”) used when the controller
interprets the input from the System sensor.
Select Enable Slave for Built-in Lead/Lag
Master. Be sure this is turned on for each
controller in the system.
Enter the position of this Slave in the sequence.
Be sure to enter this for each Slave in the
system.
Each slave must have a unique Modbus
address. Be sure to enter this for each controller
in the system.
Enable = Outdoor Reset feature turned on <’home’ screen> Lead/Lag Master button
This parameter is used as the normal setpoint
above the point where Outdoor Reset stops
adjusting for a higher outdoor temperature (the
Max. Outdoor Temperature value)
If Lead/Lag is enabled, this is the maximum
outdoor temperature at which the Outdoor Reset
feature will be active.
If Lead/Lag is enabled, this is the minimum
outdoor temperature at which the Outdoor Reset
feature will be active.
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Left-
or Right- arrow buttons <Modulation
screen>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select line
for LL Slave Conguration <Lead/Lag
Slave Conguration screen>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select line
for LL Slave Conguration <Lead/Lag
Slave Conguration screen>
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select line
for LL Slave Conguration <Lead/Lag
Slave Conguration screen>
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Leftor Right- arrow buttons <Outdoor Reset
screen>
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Label Description How to Reach
Modbus
address
Each controller must have a unique Modbus
address.
<’home’ screen> Setup button <Setup
screen> Control setup button/ Change
address button
Number of
controllers in
Flap Valve
system
Outdoor
temperature
source
System
pump cycle
count
Each controller needs to know how many ap
valves are included in the whole system. On a
system with 4 boilers, there would be a total of 8
ap valves.
This congures which source is used to
provide outdoor temperature data: S5 sensor,
S10 sensor, Enviracom sensor, or Modbus
communication”
System pump cycle count. Can be written to
a new value (e.g. if the pump or controller is
replaced).
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select Flap
Valve Conguration
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select
Sensor Conguration
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select
Statistics Conguration
Temperature
units
This parameter determines whether temperature
is represented in units of Fahrenheit or Celsius
degrees.
<’home’ screen> Select a controller
<Status Summary screen> Congure
button <Conguration Menu> Select
System Conguration
Lead/
Lag Warm
Weather
Shutdown
Enable
Warm
weather
shutdown
setpoint
When the Lead/Lag system is enabled, and this
feature is enabled, this feature will turn off the
whole system (for Central Heating functions)
when the outdoor temperature is warm enough.
This prevents the system from running when
there is no need for heat.
If the outdoor temperature is higher than this,
the system will be shut off for Central Heating
functions.
If Lead/Lag enabled –
<’home’ screen> Lead/Lag Master button
<Lead/Lag Master screen> Congure
button <Lead/Lag Master Conguration
screen> Advanced Settings button/ Left-
or Right- arrow buttons
If Lead/Lag enabled –
‘home’ screen/ View Lead/Lag button/
Lead/Lag screen/ Lead/Lag Master
button/ Lead/Lag Master screen/
Congure button/ Lead/Lag Master
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Section 10
INITIAL STARTUP INSTRUCTIONS
10.1 Filling the Boiler System
1. Ensure the system is fully connected. Close all
bleeding devices and open the make-up water
valve. Allow the system to ll slowly.
2. If a make-up water pump is employed, adjust
the pressure switch on pumping system to
provide a minimum of 12 psi (81.8 kPa) at the
highest point in the heating loop.
3. If a water pressure regulator is provided on
the make-up water line, adjust the pressure
regulator to provide at least 12 psi (81.8 kPa)
at the highest point in the heating loop.
4. Open any bleeding devices on all radiation
units at the high points in the piping throughout
the system, unless automatic air bleeders are
provided at those points.
Note - There is an air bleed located on the right
side of the Brute 1000 & 1200, on top of the water
manifold.
5. To remove all air from the heat exchanger,
cycle the boiler pump on and off 10 times, 10
seconds on and 10 seconds off. Then run the
System and Boiler pumps for a minimum of 30
minutes with the gas shut off.
WARNING
Failure to remove all air from the heat exchanger
could lead to property damage, severe injury or
death.
6. Open all strainers in the circulating system,
check the operation of the ow switch (if
equipped), and check for debris. If debris is
present, clean out the strainers to ensure
proper circulation.
7. Recheck all air bleeders as described in Step
4.
8. Check the liquid level in the expansion tank.
With the system full of water and under normal
operating pressure, the level of water in the
expansion tank should not exceed ¼ of the
total, with the balance lled with air.
9. Start up the boiler following the procedure
in this manual. Operate the entire system,
including the pump, boiler, and radiation units
for one hour.
10. Recheck the water level in the expansion tank.
If the water level exceeds ¼ of the volume of
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RADFORD WHITE
the expansion tank, open the tank drain, and
drain to that level.
11. Shut down the entire system and vent all
radiation units and high points in the system
piping, as described in Step 4.
12. Close the make-up water valve. Check the
strainer in the pressure reducing valve for
sediment or debris from the make-up water
line. Reopen the make-up water valve.
13. Check the gauge for correct water pressure,
and also check the water level in the system.
If the height indicated above the boiler
ensures that water is at the highest point in the
circulating loop, then the system is ready for
operation.
14. Refer to local codes and the make-up water
valve manufacturer’s instructions as to whether
the make-up water valve should be left open or
closed.
15. After placing the unit in operation, the ignition
system safety shutoff device must be tested.
First, shut off the manual gas valve, and call
the unit for heat. The main gas terminals will be
energized, attempting to light, for four seconds,
and then will de-energize. The unit will go into
lockout after the required number of trial for
ignition periods.
Second, turn the power off, press the manual
reset button on the boiler control, or the user
display, open the manual gas valve and allow
the unit to light. While the unit is operating,
close the manual gas valve and ensure that
power to the main gas valve has been cut.
16. Within three days of start-up, recheck all air
bleeders and the expansion tank as described
in Steps 4 and 8 above.
Note - The installer is responsible for identifying to
the owner/operator the location of all emergency
shutoff devices.
WARNING
Do not use this appliance if any part has been
under water. Immediately call a qualied service
technician to inspect the appliance and to replace
any part of the control system and any gas control
that may have been under water.
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Page 87
10.2 Initial Burner Operation
The initial setup must be checked before the unit is
put into operation. Problems such as failure to start,
rough ignition, strong exhaust odors, etc. can be due
to improper setup. Damage to the boiler resulting
from improper setup is not covered by the limited
warranty.
For Combustion Setup Procedure, See
Section 9.4 -O
For CO2 Values, See “Table 17 – CO2 Range
and Pressure Differential” on page 71
WARNING
Improper adjustment may lead to poor combustion
quality, increasing the amount of carbon monoxide
produced. Excessive carbon monoxide levels may
lead to personal injury or death.
1. Using this manual, make sure the installation
is complete and in full compliance with the
instructions and all local codes.
2. Determine that the unit and system are lled
with water and all air has been bled from both.
Open all valves.
3. Observe all warnings on the Operating
Instructions label and turn on gas and electrical
power to the unit.
4. The Brute will enter the start sequence. The
blower and pump will energize for pre-purge,
then the ignition sequence will start. After all
safety devices are veried, the gas valve will
open. If ignition doesn’t occur, turn off the Brute
1000 & 1200. Check that there is proper supply
of gas. Wait ve minutes and start the unit
again.
5. If ignition starts normally, leave the Brute
turned on.
6. After placing the unit in operation, the Burner
Safety Shutoff Device must be tested:
(a) Close the gas shutoff valve with the
burner operating.
(b) The ame will go out, and the blower will
continue to run for the post purge cycle. A
few additional attempts to light will follow
including pre-purge, ignitor on, valve/
ame on and post purge. Ignition will not
occur because the gas is turned off. The
ignition control will lockout.
(c) Open the gas shutoff valve. Reset the
boiler control by pressing the Reset
button on the control. Restart the
appliance. The ignition sequence will
start again and the burner will start. The
appliance will return to its previous mode
of operation.
Caution
If any odor of gas is detected, or if the gas burner
does not appear to be functioning in a normal
manner, close the main gas shutoff valve.
Do not shut off the power switch. Contact your
heating contractor, gas company, or factory
representative.
10.3 Shutting Down the Brute 1000 & 1200
This step must be performed by a qualied
service person.
1. Turn off the main electrical disconnect switch.
2. Close all manual gas valves.
3. If freezing is anticipated, drain the Brute and
be sure to also protect the building piping from
freezing. All water must be removed from the
heat exchanger or damage from freezing may
occur.
10.4 Restarting the Brute 1000 & 1200
If the system has been drained, see Section 10.1 for
instructions on proper lling and purging.
1. Turn off the main electrical disconnect switch.
2. Close all manual gas valves.
3. Wait ve minutes.
4. Set the aquastat or thermostat to its lowest
setting.
5. Open all manual gas valves.
6. Reset all safety switches (pressure switch,
manual reset high limit, etc.).
7. Set the temperature controller to the desired
temperature setting and switch on the
electrical power.
8. Each burner will go through a prepurge period
and ignitor warm-up period, followed by
ignition.
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Section 11
MAINTENANCE
WARNING
Disconnect all power to the unit before attempting
any service procedures. Contact with electricity
can result in severe injury or death.
Do the following once every six months:
1. If a strainer is employed in a pressure reducing
valve or the piping, clean it every six months.
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RADFORD WHITE
11.1 System Maintenance
Do the following once a year:
1. Lubricate the System pump, if required, per the
instructions on the pump.
2. Inspect the venting system for obstruction
or leakage. Periodically clean the screens in
the vent terminal and combustion air terminal
(when used).
3. Keep the area around the unit clear and free
of combustible materials, gasoline, or other
ammable vapors or liquids.
4. If the unit is not going to be used for extended
periods in locations where freezing normally
occurs, it should be isolated from the system
and completely drained of all water.
5. Low water cutoffs, if installed, should be
checked every year. Float type low water
cutoffs should be ushed periodically.
6. Inspect and clean the condensate collection,
oat switch and disposal system yearly.
7. When a means is provided to neutralize
condensate, ensure that the condensate is
being neutralized properly.
8. Inspect the ue passages, and clean them
using brushes or vacuums, if necessary.
Sooting in ue passages indicates improper
combustion. Determine the cause of the
problem and correct it.
9. Inspect the vent system and air intake system,
and ensure that all joints are sealed properly.
If any joints need to be resealed, completely
remove the existing sealing material, and clean
with alcohol. Apply new sealing material, and
reassemble.
10. Once a year, the items listed below should be
inspected by a qualied service technician:
a. Appliance control f. Flow switch
b. Automatic gas valve g. Low water cutoff
c. Pressure switches h. Burner
d. Blower i. Heat exchanger
e. Pump
11.2 Maintenance Notes
Use only genuine Bradford White replacement parts.
Caution
When servicing the controls, label all wires before
disconnecting them. Wiring errors can cause improper and dangerous operation. Verify proper operation
after servicing.
The gas and electric controls in the Brute 1000 &
1200 are engineered for long life and dependable
operation, but the safety of the equipment depends
on their proper functioning.
11.2.1 Burner
Check the burner for debris. Remove the blower
arm assembly to access the burner. Remove the 4
bolts connecting the blower to the arm. (See Figure
34). Remove the 5 bolts which hold the burner
arm in place. Pull the burner up and out. Clean the
burner, if necessary, by blowing compressed air
from the outside of the burner into the center of the
burner, and wipe the inside of the burner clean with
glass cleaner. A dirty burner may be an indication
of improper combustion or dirty combustion air.
Determine the cause of the problem, and correct
it. If the burner gasket is damaged, replace it when
replacing the burner.
Note - When installing the burner, make sure the
ange is aligned with the mating surface, as each is
keyed to control t.
11.2.2 Modulating Gas Valve/ Venturi
The modulating gas valve consists of a valve body
that incorporates the On/Off gas ow control and
a negative pressure regulator. It provides the air/
gas ratio control in combination with the Venturi to
the unit. It is designed to operate with gas supply
pressure between 4 and 13 inches w.c.. To remove
the gas valve and or Venturi, shut off the 120 Volt
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Page 89
power supply to the boiler. Turn off all manual gas
valves connecting the boiler to the main gas supply
line. Remove the front door of the boiler to gain
access to the gas valve and Venturi. Disconnect the
four ange bolts connecting the gas manifold pipe
to the gas valve. Remove the electrical connections
to the gas valve. Remove the bolts connecting the
Venturi ange to the blower. This allows the entire
gas valve/Venturi assembly to be removed as an
assembly to facilitate inspection and cleaning.
After the valve has been removed, reassemble in
reverse order making sure to include all gaskets and
O-rings. Turn on the manual gas valves and check
for gas leaks. Turn on the 120 Volt power. Place the
unit in operation following the instructions in Section
10. Once the boiler is operating, check for leaks
again and conrm all fasteners are tight.
Check the setup for the unit according to the
instructions in Section 9.
11.2.3 Controllers
Each Brute 1000 & 1200 has two integrated
controllers that incorporate manual reset high limit
control, operating temperature control, modulating
control, ignition control, outdoor reset control, pump
control and many other features. If any of these
features are thought to be defective, please consult
the factory for proper troubleshooting practices
before replacing a control.
If it is necessary to replace a controller, turn off
all power to the unit and shut off all manual gas
valves to the unit. Remove the front door to the
unit and the control panel plastic bezel. Remove
all wire connections from the control board. The
control board connections are keyed to only allow
connection in the proper location, but proper
handling techniques should be used to avoid
damage to the wiring or connectors. To remove the
control, undo the mounting screws. To replace the
control repeat the steps listed above in the reverse
order making sure to connect all wires in the proper
locations. Place the unit in operation following the
steps outlined in Section 10.
11.2.4 Ignitor Assembly
The ignitor assembly is a two rod system that
consists of a ground rod and a sense rod. To
remove the ignitor assembly, shut off the 120 Volt
power supply to the unit. Turn off all manual gas
valves connecting the unit to the main gas supply
line. Remove the front door of the boiler to gain
access to the ignitor assembly. Remove the two
wires connected to the assembly. Then remove the
two bolts connecting the ignitor assembly to the
burner door. Remove and replace the old ignitor
assembly gasket. If the old assembly is determined
to be defective, install a new ignitor assembly in the
reverse order. Replace the gasket if necessary.
11.2.5 Flame Sensor
The ame sensor is a single rod system. To replace
the ame sensor electrode, shut off the 120 Volt
power supply to the boiler. Turn off all manual gas
valves connecting the boiler to the main gas supply
line. Remove the front door of the boiler to gain
access to the ame sensor electrode. Remove the
ame sensor wire from the electrode. Remove the
two bolts fastening the electrode to the burner doors.
Remove and replace the old ame sensor gasket.
If the old electrode is determined to be defective,
reinstall a new ame sensor electrode in the reverse
order.
Caution
The igniters and sensors get become very hot. If
you touch these parts accidentally, this can cause
burns or injury.
11.2.6 Transformer with Integral Circuit
Breaker
The appliance has a 24 VAC transformer with
integral 4 amp circuit breaker installed for supplying
the control voltage required for the unit only. The
transformer is sized for the load produced by the
unit only and should not be used to supply power
to additional eld devices. If additional loads are
added or a short occurs during installation, the
integral circuit breaker may trip. If this happens, be
sure to reset the circuit breaker before replacing the
transformer.
If the transformer must be replaced, turn off the 120
VAC power to the unit. Remove the transformer
wires from the terminal blocks. Remove the
fasteners holding the transformer, and remove the
transformer. Replace with a new transformer in
reverse order.
If the transformer is replaced with a part other
than the OEM transformer, be sure to add circuit
protection if it is not integral to the new transformer.
WARNING
Failure to include proper circuit protection may
lead to premature component failure, re, injury or
death.
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11.2.7 Blower
The combustion air blower is a high-pressure
centrifugal blower with a variable speed motor. The
speed of the motor is determined by the control
logic. 120 Volts are supplied to the blower at all
times.
If it is necessary to replace the blower, turn off the
120 Volt power and the gas supply to the unit. Take
the front panel off. Disconnect the 120 Volt and
control signal connections to the blower. Disconnect
the bolts connecting the Venturi to the blower
housing. Disconnect the fan outlet bolts from the
burner door blower arm. If the fan is determined to
be defective replace the existing fan with a new one
reversing the steps listed above. Be sure to install
all of the required O-rings and gaskets between the
blower arm and the blower and blower face and
Venturi ange.
11.2.8 Heat Exchanger Coils
Black carbon soot buildup on the external surfaces
of the heat exchanger is caused by one or more of
the following; incomplete combustion, combustion air
problems, venting problems or heater short cycling.
Soot buildup or other debris on the heat exchanger
may restrict the ue passages.
If black carbon soot buildup on the heat exchanger
is suspected, disconnect the electrical supply to
the unit, and turn off the gas supply by closing the
manual gas valve on the unit. Access the heat
exchanger through the burner door at the front of
the boiler, and inspect the tubing using a ashlight.
If there is a buildup of black carbon soot or other
debris on the heat exchanger, clean per the
following:
Caution
Black carbon soot buildup on a dirty heat
exchanger can be ignited by a random spark or
ame. To prevent this from happening, dampen
the soot deposits with a wet brush or ne water
spray before servicing the heat exchanger.
1. Shut off the 120 Volt power supply to the boiler.
2. Turn off all manual gas valves connecting the
boiler to the main gas supply line.
3. Remove the nuts located on the outside
diameter of the burner door to the heat
exchanger.
4. Remove the burner door/burner assembly from
the heat exchanger.
5. Disconnect the condensate drain line.
bucket.
7. Clean the heat exchanger by brushing away
any light accumulations of soot and debris. Use
a non metallic brush with soft bristles to avoid
damaging the surfaces of the heat exchanger
tubes.
8. Once the tubes have been brushed clean,
rinse the tubes and combustion chamber with a
small amount of water to rinse all of the debris
out of the bottom of the ue collector and into
the longer condensate trap line, which is being
diverted into a separate container.
Note - The Warranty does not cover damage
caused by lack of required maintenance, lack of
water ow, or improper operating practices.
WARNING
Failure to rinse the debris from the heat
exchanger and temporary drain line may lead to
clogged condensate lines, traps and neutralizers.
Condensate pumps (if used) may also be
damaged from the debris left behind, possibly
causing property damage.
9. To place the unit back in operation, install
all removed components in the reverse
order. Be sure all gaskets are in place as
the components are installed. Replace any
damaged gaskets. Do not reuse damaged
gaskets.
10. Place the appliance in operation according to
Section 9, checking all gas connections for
leaks. Conrm all fasteners are tight.
11.2.9 Gas Pressure Switches (optional)
The high and low gas pressure switches are 24V
manual reset switches that act to cut power to the
gas valves if the gas pressure is too low or too high
for proper operation. The gas pressure switches
used are integrally vent limited, and do not require
venting to atmosphere. To remove a switch, remove
the screw on the plastic housing and pull the clear
cover off. Disconnect the two wires from the screw
terminals. Twist the switch off the pipe nipple.
Reassemble in reverse order. For natural gas, set
the low gas pressure switch to 3” w.c. For propane,
set the low gas pressure switch to 5” w.c. For natural
and propane, set the high gas pressure switch to
14.”
6. Attach a longer hose to the drain and run it to a
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
11.2.10 Natural/Propane Gas Conversion
Brute 1000 & 1200’s can easily be converted from
natural to propane gas or from propane to natural
gas. If a gas conversion is performed, the unit must
be identied with the appropriate gas labels and a
conversion sticker to allow technicians performing
maintenance in the future to properly identify the gas
type of the appliance.
NT size (mbtu) Kit Number
1000 CA006207
1200 CA006207
Table 18 - Gas Conversion Kit
11.2.12 Battery (Date and Time Back-Up for
Touchscreen Display)
The touchscreen does have an internal battery for
back-up of the date and time settings. To access the
battery, the front panel and the touch screen display
must be removed so that the small plastic door on
the back of the touchscreen can be accessed.
The battery is a CR2032 ‘coin type’ battery and
has an expected shelf life of 10 years.
11.2.11 Condensate Trap
A condensate drain trap is included with the Brute
1000 & 1200 and is designed to drain the boiler
of condensate. The vent condensate should be
drained through a drain tee located in the vent line.
This will help prevent excessive condensate from
entering the boiler condensate trap and preventing
the boiler from operating.
Connect a 3/4” PVC pipe between the drain
connection and a oor drain (or condensate pump if
a oor drain is not accessible).
The condensate drain must be installed to
prevent the accumulation of condensate. When
a condensate pump is not used, the tubing must
continuously slope downward toward the drain with
no spiraling.
Consult local codes for the disposal method.
Page 91
Caution
Condensate is mildly acidic (pH=5), and may
harm some oor 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.
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Section 12
TROUBLESHOOTING
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12.1 Potential Setup and
Synchronization Problems
Because the Brute uses a sophisticated control
system, it can constantly perform a series of selfchecks. For example, as a burner is lighted, the
controller checks each stage of the purge and
ignition process. If part of the process does not
happen on time, or takes too long to occur, the
controller stops the process. We have detailed
these self-checks in the section on “Operating
Sequence.”
Two of these self-checks are particularly important:
• Controller synchronization
• Flap valve status
If the control system is not satised with the results
of both of these checks, it will not allow the system
to run. Sometimes the reason for this may not be
obvious at rst – that’s why we are describing them
at the start of this section on Troubleshooting.
12.1.1 Controller Synchronization
On a multiple-boiler installation, the individual boiler
controllers are arranged in a “daisy chain” using
a Modbus connection, with the Secondary control
of one boiler connected to the Primary control of
the next boiler. Up to four boilers, with up to eight
controllers, can be connected in this way. See Fig.
122.
As part of the setup process, each of these
controllers must be given a unique address. (For
details, see Section 9 - Installation and Setup.” The
controls must be set up and addressed correctly
before the Modbus wiring is completed. If the wiring
is attached before the Modbus control addresses
are changed, there will be multiple controls with the
same address, and the system will not work.
When a Lead/Lag system is rst powered up, the
controller acting as the Lead/Lag Master goes
through a “synchronization” process. During
synchronization, the controller establishes
communications with each of the Slave controllers
via the Modbus link. The Slave controllers download
some setup parameters and operating history
information. (On a system with several boilers, this
phase can take several minutes.) If the Master
cannot establish communications with one of the
Slaves, it triggers a Hold or Lockout.
Boiler 1
Operator
interface
Addr1Addr
Lead Lag
Master and
Slave 1
Slave 2
Fig. 122 – Lead/Lag Arrangement in a Multiple-Boiler Installation
Boiler 2
Addr3Addr
2
Slave 3
4
Slave 4
Boiler 3
Addr5Addr
Slave 5
Slave 6
Boiler 4
Addr7Addr
6
Slave 7
8
Slave 8
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
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12.1.2 Flap Valve Status Check
Each boiler includes two burners, and each burner
has a ap valve. See Fig. 123.
If one burner in a boiler is operating, and the other
is not, the ap valve for the burner that is off will
remain closed to prevent air from moving backwards
through the burner that is not operating. Before the
Lead/Lag Master controller will allow the system
to operate, it must be able to determine whether
each of these ap valves is open or closed. If
the controller cannot nd a signal from one of the
ap valves, the control system will act to prevent
backow by energizing the blower of the control
with the bad ap valve. If this cannot be done the
control will not allow the whole system to run. If
the ap valve identications are not set correctly, the
control system will present a “HOLD 119 – Control
Interaction Fault” on the display. For this reason, it
is important that all of the ap valves be identied
correctly.
12.2 About Lockouts, Holds, and
Alerts
The control system on the Brute responds to three
kinds of trouble indications:
• A “lockout” is caused by a serious problem
that might involve a safety issue. Once
the controller enters a lockout, the burners
will shut down, and will not be allowed to
run again until the cause of the problem is
corrected, and you reset the control system.
The controller will also trigger a lockout if you
change a safety-related parameter, but do not
nish the “verication” process. (For more
information on verication, see Section 8.8)
During a lockout condition, the image of the
affected controller on the ‘home’ screen will
appear in red. A bell symbol will appear in the
upper left-hand corner of the control screen.
The system maintains a “history” of the 15
most recent lockouts.
• The system may enter a “hold” for a period
of time before locking out. This allows the
controller to see if the error becomes resolved
prior to the hard lockout. Holds can occur
while the boiler is operating.
• An “alert” indicates that some feature of the
control system’s operation was not correct,
delayed or waiting for a response. This
indicates a change in state of the control
system and doesn’t necessarily mean there
is a problem. For example, Alerts occur as
the fan speed transitions from the pre-purge
RPM to the startup RPM. This indicates that
the control system is waiting for a condition
to be satised. No Reset is required to
recover from an alert. The system maintains
a “history” of the 15 most recent alerts.
Sometimes it can be helpful to check this list
as a troubleshooting aid.
12.2.1 Responding to a Lockout, Hold, or
Alert
1. If a problem occurs while the system is
starting up, the system will declare a Hold. A
brief explanation of the cause of the Hold will
appear in an orange bar across the bottom
of the screen. If you tap the orange bar, the
system will present more information about
the Hold.
Boiler 1
Fig. 123 - Flap Valve Arrangement
Operator
interface
Primary
controller
Flap
valve
Flap
valve
Secondary
controller
Primary
burner
Secondary
burner
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Correct the cause of the problem, and press
the button on the screen to clear the Hold.
2. If a serious problem continues, the system will
declare a Lockout. A brief explanation of the
cause of the Lockout will appear in an orange
bar across the bottom of the screen. If you tap
the orange bar, the system will present more
information about the Lockout.
Correct the cause of the problem, and press
the Reset button.
3. If an Alert occurs while the system is running,
the system will present a note across the
bottom of the screen. If you tap the orange
bar, the system will present more information
about the Alert.
Press the OK button to indicate that you have
seen the Alert.
4. If an audible alarm on the display is active,
you can use the Silence button to stop it.
12.2.2 Viewing the Lockout and Alert
Histories
1. To view the Lockout history, start at the ‘home’
screen (Fig. 124).
3. If you press the Details button, the control
software will present a screen similar to this
(Fig. 126).
Fig. 126 – Typical Details Screen
4. To see a record of the recent lockouts and
alerts, press the History button. The system
will present the Lockout History screen
(Fig. 127).
Fig. 124 – ‘home’ screen
2. Press the Lead/ Lag Master button. Figure 125
shows the Lead/ Lag Master screen.
Fig. 125 – Lead/ Lag Master Screen
Fig. 127 – Lockout History Screen
The most recent lockouts appear at the top of
the list. Any lockout that has not been cleared
will appear in red.
5. You can see more detailed information on any
lockout by touching the entry on the screen.
Correct the cause of the problem, then press
Clear Lockout to clear the lockout.
6. You can also press the Alerts button to see a
list of recent alerts. See Fig. 128.
Note – The Alert Log only lists the most recent
occurrence for each type of alert.
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RUTE. BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Fig. 128 – Alert Log Screen
To get more information on a particular alert,
touch the entry for that alert on the screen.
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12.3 Troubleshooting Table
This table includes a listing of the faults that might be generated by the controllers, and displayed on the
Touch Screen. Some of these can be corrected by an installer changing a parameter, while other conditions
are more complicated, and will require a service technician.
The rst column lists the code number that will appear at the beginning of the Lockout or Hold message in
the orange bar at the bottom of the screen. The second column lists the text as it will appear on the Touch
Screen. The third column shows whether the condition will cause a Hold, or Lockout, or both. The fourth
column lists some suggestions for corrective action.
Code Description L or H Procedure
1 Uncongured safety data L 1. New device, complete device conguration and
safety verication.
2. If fault repeats, replace module
2 Waiting for safety
data verication
3 Internal fault:
Hardware fault
4 Internal fault:
Safety Relay key feedback error
5 Internal fault:
Unstable power (DC DC) output
6 Internal fault:
Invalid processor clock
7 Internal fault:
Safety relay drive error
8 Internal fault:
Zero crossing not detected
9 Internal fault:
Flame bias out of range
10 Internal fault:
Invalid burner control state
Code Description L or H Procedure
L 1. Device in Conguration mode and safety
parameters need verication and a device
needs reset to complete verication.
2. Conguration ended without verication, re
enter conguration, verify safety
parameters and reset device to complete
verication.
3. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
H Internal fault
1. Reset module
2. If fault repeats, replace module.
L Internal fault
1. Reset module
2. If fault repeats, replace module.
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