Bradford-White BWCH, BWCV User Manual
Installation and Operation Instructions Document 1270
Copper Brute II
238-50605-00A REV 12/13
Installation and Operation
Instructions for
™
Hydronic Boiler
Model BWCH
Water Heater
Model BWCV
Sizes 500-2000
U.S. Reg. 2,765,423
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualied in hot water boiler 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. For indoor installations, as an
additional measure of safety, Bradford White strongly recommends installation of suitable Carbon
Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
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
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
H2214401F
Page 2
BRADFORD WHITE C ORP.
TABLE OF CONTENTS
SECTION 1.
General Information
1.1 Introduction ...................................................... 4
1.2 Model Identication .......................................... 4
1.3 Warranty .......................................................... 5
1.4 Dimensions ...................................................... 5
1.5 Locating the Appliance..................................... 5
1.6 Locating Pump-Mounted Water Heater
with Respect to Storage Tank(s) ...................... 7
1.7 Locating Pump-Mounted Boiler with
Respect to Return/Supply Header ................... 7
1.8 Locating Appliance for Correct Horizontal Vent/
Ducted Air Distance From Outside Wall .......... 7
SECTION 2.
Venting and Combustion Air
2.1 Combustion Air ................................................ 8
2.1.1 Combustion Air From Room ............................ 8
2.1.2 Intake Combustion Air...................................... 8
2.2 Venting ............................................................. 9
2.2.1 Vent Categories ............................................... 9
2.2.2 Category I Vent ................................................ 9
2.2.3 Common Venting Systems .............................. 9
2.2.4 Category III Vent .............................................. 1
2.3 Locating Vent & Combustion Air Terminals .....11
2.3.1 Side Wall Vent Terminal ..................................11
2.3.2 Side Wall Combustion Air Terminal .................11
2.3.3 Vertical Vent Terminal .................................... 12
2.3.4 Vertical Combustion Air Terminal ................... 12
2.4 Common Vent Test – Boilers ......................... 12
2.5 Vent Terminals for Outdoor Units ................... 12
SECTION 3.
Gas Supply and Piping
3.1 Gas Supply and Piping .................................. 13
SECTION 4A.
Water Connections – Boiler
4A.1 Heating System Piping:
Hot Supply Connections – Boiler ................... 14
4A.2 Cold Water Make-Up – Boiler ........................ 14
4A.3 Water Flow Requirements – Boiler ................ 14
4A.4 Freeze Protection – Boiler ............................. 14
SECTION 4B.
Water Connections – Water Heater
4B.1 Water System Piping – Water Heater ............ 20
4B.2 Hot Water Supply Piping – Water Heater ...... 20
4B.3 Water Flow Requirements – Water Heater .... 20
4B.4 Combined Water Heating (potable)
and Space Heating – Water Heater ............... 20
4B.5 Freeze Protection – Water Heater ................. 21
SECTION 5.
Electrical Connections
5.1 Main Power .................................................... 24
5.1.1 Power Circuits ................................................ 24
5.2 Temperature Control ..................................... 24
5.2.1 Temperature Control Description ................... 24
5.3 External Staging Control Wiring..................... 26
COPPER BRUTE II (500 - 2000)
Page 3
SECTION 6.
Operating Instructions
6.1 Sequence of Operation .................................. 36
6.2 Filling the Boiler System ................................ 36
6.3 Programming the Temperature Control ......... 37
6.3.1 System Piping ................................................ 37
6.3.2 Choosing the Mode........................................ 37
6.3.3 Programming ................................................. 38
6.3.4 Choosing the Mode for your Application ........ 40
6.4 Advanced Topics ............................................ 42
6.4.1 Differential ...................................................... 42
6.4.2 Staging Mode................................................. 42
6.4.3 Boiler Minimum (BOIL MIN) ........................... 43
6.4.4 Boiler Maximum (BOIL MAX) ......................... 43
6.4.5 Boiler Target Temperature ............................. 43
6.4.6 Pump Operation............................................. 43
6.4.7 Setpoint Operation ........................................ 44
6.4.8 Dedicated Domestic Hot Water ..................... 44
6.4.9 Outdoor Reset Operation............................... 44
6.4.10 External Boiler Operation .............................. 46
6.4.11 Limit Controls ................................................. 46
6.4.12 Advanced Programming Mode ...................... 46
6.5 Operating the Burner and Set Up .................. 46
6.5.1 Set Up for 0 to 2500 Feet Altitude.................. 46
6.5.2 High Altitude Adjustment and Set Up ............. 47
6.6 Shutting Down the Copper Brute II ................ 47
6.5 To Restart the Copper Brute II ....................... 47
SECTION 7.
Maintenance
7.1 System Maintenance ..................................... 48
7.2 Appliance Maintenance and
Component Description ................................. 48
7.2.1 Burners .......................................................... 48
7.2.2 Filter ............................................................... 48
7.2.3 Gas Valves ..................................................... 48
7.2.4 Manual Reset High Limit Control ................... 48
7.2.5 Automatic Reset High Limit Control ............... 48
7.2.6 Temperature Control ...................................... 49
7.2.7 Ignition Controls ............................................. 49
7.2.8 Ignitors ........................................................... 49
7.2.9 Ignition Sensors ............................................. 49
7.2.10 Transformer ................................................... 49
7.2.11 Blowers .......................................................... 49
7.2.12 Flow Switch ................................................... 49
7.2.13 Heat Exchanger Coil ...................................... 49
SECTION 8.
Trouble Shooting
8.1 Resolving Lockouts........................................ 51
8.2 Delayed Ignition – Possible Causes .............. 51
8.3 Short Cycling – Boiler .................................... 51
8.4 Short Cycling – Water Heater ........................ 51
8.5 High Gas Consumption.................................. 51
8.6 Troubleshooting the Temperature Control ..... 51
8.7 Troubleshooting Copper Brute II Controls ..... 51
SECTION 9.
Replacement Parts
9.1 General Information ....................................... 54
9.2 Parts List ........................................................ 54
Page 4
BRADFORD WHITE C ORP.
SECTION 1.
General Information
USING THIS MANUAL – Because the
Copper Brute II Boilers and Copper Brute II Water
Heaters are identical appliances, with the exception
of materials of manufacture, labels and ultimate
use application, this manual provides information
for the proper installation, operation and
maintenance of both products. Where differences
exist between the application of the appliances and
their operation, the sections pertinent to only one
appliance or the other will be so identied.
In the Commonwealth of Massachusetts, this
appliance must be installed by a licensed plumber or
gas tter.
WARNING
The Copper Brute II hydronic, boiler or water
heater must be installed in accordance with the
procedures detailed in this manual, or the Bradford
White warranty may 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 the Natural Gas
and Propane Installation Code, CSA B149.1 and/
or local codes. Where required by the authority
having jurisdiction, the installation of Copper Brute
II appliances 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. If eld conditions require modications,
consult the factory representative before initiating
such modications.
1.1 Introduction
This manual provides information necessary
for the installation, operation, and maintenance of
Bradford White Corp, Copper Brute II copper tube
appliances. Read it carefully before installation.
All application and installation procedures
should be reviewed completely before proceeding
with the installation. Consult the Bradford White
factory, or local factory representative, with any issues
or questions regarding this equipment. Experience
has shown that most operating issues are caused by
improper installation.
The Copper Brute II appliance is protected
against over pressurization. A pressure relief valve
is tted to all appliances. It is installed on the outlet
header, at the water outlet of the appliance.
IMPORTANT: The inlet gas pressure to the appliance
must not exceed 13" w.c. (3.2kPa).
All installations must be made in accordance with:
1) In the U.S., the " National Fuel Gas
Code"ANSI Z223.1/NFPA54, Latest Edition and all
applicable local codes as required by the Authorities
Having Jurisdiction (AHJ), or
2) In Canada, the "Natural Gas and Propane
Installation Code", CSA B149.1, latest edition and all
applicable local codes as required by the AHJ.
All electrical wiring is to be done in accordance with:
1). In the U.S., the "National Electrical Code"
(NEC), ANSI/NFPA 70, latest Edition and all
applicable local codes as required by the AHJ, or
2). In Canada, the “Canadian Electrical Code
- Part 1”, CSA STD. C22.1 and all applicable local
codes as required by the AHJ.
This appliance must be electrically grounded in
accordance with the applicable codes and standards
referenced above.
1.2 Model Identication
Consult the rating plate on the unit. The
following information describes the model number
structure.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B W C A C 2
SERIES
B W C
USAGE
H
V
SIZE
0 5 0 0
0 7 5 0
1 0 0 0
1 2 5 0
1 5 0 0
1 7 5 0
2 0 0 0
FUEL
N
P
ALTITUDE
A
LOCATION
C
FIRING
MODE
K (500/750)
N (1000)
L (1250-2000)
REVISION
2
HEAT
EXCHANGER
B
C
K
N
P
S
OPTIONS
CODE
X
J
L
PUMP
OPTIONS
X
H
N
S
COPPER BRUTE II (500 - 2000)
Page 5
Model Character Designation
1-3 Model Series Designation
B W C = Bradfrod White, Copper Brute II
4 Usage
H = Hydronic
V = Volume Water
5-8 Size
0 5 0 0 = 500,000 BTU/h input
0 7 5 0 = 750,000 BTU/h input
1 0 0 0 = 999,000 BTU/h input
1 2 5 0 = 1,250,000 BTU/h input
1 5 0 0 = 1,500,000 BTU/h input
1 7 5 0 = 1,750,000 BTU/h input
2 0 0 0 = 1,999,000 BTU/h input
9 Fuel
N = Natural Gas
P = Propane
10 Altitude
A = 0-10,000 feet
11 Location
C = Indoor and Outdoor
12 Firing Mode
K = Two-stage (models 500 & 750)
N = Three-stage (model 1000)
L = Four-stage (models 1250 - 2000)
13 Revision
2 = Second version
14 Heat Exchanger
B = Glass-lined CI / copper / brz trim (std. BWCV)
C = Glass-lined cast iron / copper (standard BWCH)
K = Bronze / copper
N = Glass-lined cast iron / cu-nickel
P = Glass-lined cast iron / cu-nickel / brz trim
S = Bronze / cu-nickel
15 Option Code
X = Standard unit
J = CSD-1, FM, IRI, IL
L = MN and LDS (Indoor units only)
16 Pump Options
X = No Pump
H = Pump mounted, hard water pump
N = Pump mounted, normal pump
S = Pump mounted, soft water pump
Some accessory items are shipped in separate
packages. Verify receipt of all packages listed on
the packing slip. Inspect everything for damage
immediately upon delivery, and advise the carrier of
any shortages or damage. Any such claims should be
led with the carrier. The carrier, not the shipper, is
responsible for shortages and damage to the shipment
whether visible or concealed.
1.4 Dimensions
See Figure 1.
1.5 Locating the Appliance
The appliance should be located to provide
clearances on all sides for maintenance and inspection.
It should not be located in an area where leakage of
any connections will result in damage to the area
adjacent to the appliance or to lower oors of the
structure.
When such a location is not available, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance.
The appliance is design certied by CSAInternational for installation on combustible ooring;
in basements; in closets, utility rooms or alcoves.
Copper Brute II Boilers or Water Heaters must
never be installed on carpeting. The location for the
appliance should be chosen with regard to the vent
pipe lengths and external plumbing. The unit shall be
installed such that the gas ignition system components
are protected from water (dripping, spraying, rain, etc.)
during operation and service (circulator replacement,
control replacement, etc.). When vented vertically, the
Copper Brute II must be located as close as practical
to a chimney or outside wall. If the vent terminal and/
or combustion air terminal terminate through a wall,
and there is potential for snow accumulation in the
local area, both terminals should be installed at an
appropriate level above grade.
The dimensions and requirements that are shown
in Table 1 should be met when choosing the locations
for the appliance.
1.3 Warranty
Bradford White, Copper Brute II appliances
are covered by a limited warranty. The owner should
ll out the warranty registration card and return it to
Bradford White.
All warranty claims must be made to an
authorized Bradford White representative or directly
to the factory. Claims must include the serial number
and model (this information can be found on the rating
plate), installation date, and name of the installer.
Shipping costs are not included in the warranty
coverage.
REQUIRED RECOMMENDED
Page 6
BRADFORD WHITE C ORP.
SHIPPING WEIGHT
SIZE
lbs. kg
500 425 193
750 505 229
1000 615 279
1250 675 306
1500 760 345
1750 825 375
2000 955 434
*Add 55 lbs. (25kg) for
pump-mounted units.
AIR VENT HORIZ.
A B C D E F G H CONN. CONN. VENT
SIZE in cm in cm in cm in cm in cm in cm in cm in cm W V PIPE
500 33½ 85 15¾ 40 5¾ 15 29¾ 76 32¾ 83 7¾ 20 8¾ 22 46 117 6 15 8 20 8 20
750 45½ 116 21¾ 55 5¾ 15 29¾ 76 32¾ 83 7¾ 20 8¾ 22 58 147 6 15 10 25 8 20
1000 57½ 146 28¾ 73 5¾ 15 29¾ 76 32¾ 83 7¾ 20 7 18 70 178 8 20 10 25 8 20
1250 68 172 34 86 101/8 26 30¾ 78 29½ 75 8¾ 22 8¾ 22 80 203 8 20 12 30 8 20
1500 78½ 199 39¾ 101 101/8 26 30¾ 78 29½ 75 8¾ 22 8¾ 22 91 231 8 20 12 30 8 20
1750 89 226 44½ 113 101/8 26 30¾ 78 29½ 75 8¾ 22 8¾ 22 101 256 8 20 14 36 8 20
2000 99½ 253 49¾ 126 101/8 26 30¾ 78 29½ 75 8¾ 22 8¾ 22 B 284 12 30 14 36 12 3
*Air and vent connections may be on top or back of the Copper Brute II, and are eld convertible. Dimensions in inches cm.
0
Figure 1. Dimensional Data.
COPPER BRUTE II (500 - 2000)
Page 7
1.6 Locating Pump-Mounted Water Heater
with Respect to Storage Tank(s)
For best results, a pump-mounted Copper Brute
II water heater should be located within 15 feet (4.6m)
of the storage tank(s). The pump is sized for 30 feet
(9.1m) of piping.
If the appliance must be installed with longer
piping runs, then larger diameter pipe or tubing shall
be used. Consult the factory for assistance.
1.7 Locating Pump-Mounted Boiler with
Respect to Return/Supply Header
For the best results, a pump-mounted Copper
Brute II Boiler should be located within 15 feet (4.6m)
of the supply and return headers. The pump is sized for
30 feet (9.1m) of piping.
If the appliance must be installed with longer
piping runs, then larger diameter tubing shall be used.
Consult the factory for assistance.
APPLIANCE CLEARANCE FROM SERVICE ACCESS
SURFACE
inches cm inches cm
Left Side 1 2.5 24 61
Right Side 1 2.5 24 61
Top 1 2.5 12 30
Back 1 2.5 **12** 30**
Front 1 2.5 36 91
Vertical
(Category 1) 6* 15.2*
Vent
Horizontal per UL1738 venting
(Category 3) system supplier’s
Vent instructions
*1" (2.5cm) when b-vent is used.
**When vent and/or combustion air connects to the back,
recommended clearance is 36" (91cm).
COMBUSTIBLE MATERIAL CLEARANCE
1.8 Locating Appliance for Correct
Horizontal Vent/Ducted Air Distance
From Outside Wall
The forced draft combustion air blower/blowers
in the appliance has/have sufcient power to pull air
and vent properly when the following guidelines for
horizontal air and vent are followed (see Table 2).
NOTE: On all model sizes, the vent collar size is
larger than the size of the vent pipe that can be used.
Vent collar size and horizontal pipe diameters can
be found in Table 2. The larger vent collar size is to
accommodate Category I (vertical) vent systems.
NOTE: When located on the same wall, the Copper
Brute II combustion air intake terminal must be
installed a minimum of 12" (30cm) below the exhaust
vent terminal and separated by a minimum of
36 inches (91cm) horizontally.
The air intake terminal must be installed high
enough to avoid blockage from snow, leaves and other
debris.
Table 1. Clearances.
HORIZONTAL AIR COLLAR
VENT COLLAR VENT PIPE & PIPE MAX. PIPE MAX. NO. SIDE WALL SIDE WALL
SIZE SIZE DIAMETER DIAMETER LENGTH OF ELBOWS VENT COMBUSTION
TERMINAL AIR TERMINAL
in. cm in. cm in. cm ft. m PART NUMBER PART NUMBER
500 8 20 6 15 6 15 50 15 3 CA001401 20260701
750 10 25 8 20 6 15 50 15 3 CA001402 20260701
1000 10 25 8 20 8 20 50 15 3 CA001402 20260703
1250 12 30 8 20 8 20 50 15 3 CA001403 20260703
1500 12 30 8 20 8 20 50 15 3 CA001403 20260703
1750 14 36 8 20 8 20 50 15 3 CA001403 20260703
2000 14 36 12 30 12 30 50 15 3 CA001404 20260706
Table 2. Horizontal Vent / Combustion Air Parameters.
Page 8
BRADFORD WHITE C ORP.
SECTION 2.
Venting and Combustion Air
2.1 Combustion Air
Copper Brute II boilers and water heaters must
have provisions for combustion and ventilation air
in accordance with Section 5.3, Air for Combustion
and Ventilation, of the National Fuel Gas Code, ANSI
Z223.1, or Sections 7.2, 7.3 or 7.4 of CSA B149.1,
Installation Codes, or applicable provisions of the local
building codes.
A Copper Brute II appliance may receive
combustion air from the space in which it is installed,
or it can be ducted directly to the unit from the outside.
Ventilation air must be provided in either case.
2.1.1 Combustion Air From Room
In the United States, the most common
requirements specify that the space shall communicate
with the outdoors in accordance with method 1 or 2,
which follow. Where ducts are used, they shall be of
the same cross-sectional area as the free area of the
openings to which they connect.
Method 1: Two permanent openings, one
commencing within 12 inches (30 cm) of the top
and one commencing within 12 inches (30 cm) 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 (5.5 square cm/kW) of total input rating of all
equipment in the enclosure. When communicating to
the outdoors through horizontal ducts, each opening
shall have a minimum free area of not less than
1 square inch per 2000 Btu/hr (11 square cm/kW) of
total input rating of all equipment in the enclosure.
Table 3 shows data for this sizing method, for each
Copper Brute II model.
Method 2: One permanent opening, commencing
within 12 inches (30 cm) 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 (7 square cm/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 CSA
B149.1.
2.1.2 Intake Combustion Air
The combustion air can be taken through the
wall, or through the roof. When taken from the wall,
it must be taken from out-of-doors by means of the
Bradford White horizontal wall terminal (see Table 2).
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 2).
Use single-wall galvanized pipe, per Table 4, for
the combustion air intake (see Table 2 for appropriate
size). Route the intake to the heater as directly as
possible. Seal all joints with tape. Provide adequate
hangers. The unit must not support the weight of the
combustion air intake pipe. Maximum linear pipe
EACH OPENING*
SIZE SQUARE INCHES SQUARE CM
500 125 807
750 188 1213
1000 250 1613
1250 313 2020
1500 375 2420
1750 438 2826
2000 500 3226
*Net Free Area in Square Inches / Square cm
Area indicated is for one of two openings; one at oor level and
one at the ceiling, so the total net free area could be double the
gures indicated.
This chart is for use when communicating directly with the
outdoors. For special conditions and alternate methods, refer to
the latest edition of ANSI Z223.1.
Note: Check with louver manufacturers for net free area of
louvers. Correct for screen resistance to the net free area
if a screen is installed. Check all local codes applicable to
combustion air.
Table 3. Combustion Air Openings.
Figure 2. Combustion Air and Vent Through Roof.
COPPER BRUTE II (500 - 2000)
Page 9
length allowed is 50 feet (15.2m). Three elbows have
been calculated into the 50-foot (15.2m) linear run.
Subtract 10 allowable linear feet (3.0m) for every
additional elbow used (see Table 2). When fewer than
3 elbows are used, the maximum linear pipe length
allowed is still 50 feet (15.2m).
The connection for the intake air pipe is on the
lter box. The Copper Brute II appliances may have
venting and combustion air ducting attached to the top
or the back. They are shipped with the connections
at the top. For attaching either or both pipes to the
back, the mounting anges are reversible by removing
the mounting screws and orienting the anges in the
desired position. Replace the screws after positioning
anges. Run a bead of silicone around the collar and
slide the pipe over the collar. Secure with sheet metal
screws.
In addition to air needed for combustion, air
shall also be supplied for ventilation, including all air
required for comfort and proper working conditions
for personnel. The Copper Brute II loses less than 1
percent of its input rating to the room, but other heat
sources may be present.
2.2 Venting
2.2.1 Vent Categories
Depending upon desired Copper Brute II venting,
it may be considered a Category I or a Category III
appliance. In general, a vertical vent system will
be a Category I system. However, in rare instances,
a Copper Brute II’s vertical vent system may be
considered Category III. In the U.S., the National Fuel
Gas Code (ANSI Z223.1-Latest Edition), or in Canada
the CSA B149.1 (latest edition), denes a Category
I vent system, and includes rules and tables to size
these vent systems. If the Copper Brute II’s vertical
vent system does not satisfy the criteria for Category I
venting, it must be vented as a Category III system.
All Copper Brute II vent systems which
discharge horizontally (without the use of a power
venter) are considered Category III vent systems.
2.2.2 Category I Vent
When vented as a category I appliance, the
vent system must conform to the National Fuel Gas
Code (ANSI Z223.1-Latest Edition) in the U.S., or
in Canada, to CSA B149.1 (latest edition). The vent
system must be sized and installed for a Category I
Fan-Assisted Appliance.
If chimney height is greater than 25 feet, or
TERM DESCRIPTION
Pipe Single-wall galvanized steel pipe, 24 gauge
minimum (either insulated or non-insulated)
Joint Permanent duct tape or aluminum tape
Sealing
Table 4. Required Combustion Air Piping Material.
if multiple units are vented into the same vertical
vent, a barometric damper must be installed on each
appliance, such that the ue draft does not exceed
(negative) 0.1" w.c.
If using a power venter for any type of Category
I venting, the draft should be set between (negative)
0.01 and 0.10" w.c.
2.2.3 Common Venting Systems
Copper Brute II units are Category I fan-assisted
when vented vertically and adhering to all applicable
codes. Copper Brute II units are not allowed to be
vented into a common horizontal vent system, unless
a properly sized vent fan is used, and the common
vent system is properly designed by the vent fan
manufacturer or a qualied engineer. When common
venting Copper Brute II fan-assisted unit with other
appliances through one shared vertical duct called a
“common vent”, special care must be taken by the
installer to ensure safe operation. In the event that
the common vent is blocked, it is possible, especially
for fan-assisted devices, to vent backwards through
non-operating appliances sharing the vent, allowing
combustion products to inltrate occupied spaces.
If the appliances are allowed to operate in this
condition, serious injury or death may occur.
WARNING
Operation of appliances with a blocked common
vent may lead to serious injury or death. Safety
devices must be implemented to prevent blocked
common vent operation. If safe operation of all
appliances connected to a common vent cannot
be assured, including prevention of spillage of ue
gasses into living spaces, common venting should
not be applied, and appliances should each be
vented separately.
It is for this reason that, in addition to
following proper vent sizing, construction and safety
requirements from the National Fuel Gas Code,
ANSI Z223.1 or in Canada, from CSA B149.1 as
well as all applicable local codes, it is required that
installers provide some means to prevent operation
with a blocked common vent. It is suggested that a
blocked vent safety system be employed such that if
the switch from one appliance trips due to excessive
stack spill or backpressure indicating a blocked vent
condition, that all appliances attached to the vent be
locked out and prevented from operating. Note that
the Copper Brute II is equipped with a blocked vent
safety (pressure) switch, as shipped. However, this
safety switch has only been designed and tested to be
effective in installations where the Copper Brute II
is vented separately and NOT common vented with
other appliances. As an additional precaution, it is
recommended that a Carbon Monoxide (CO) alarm be
installed in all enclosed spaces containing combustion
Page 10
U.S. Installations (see note 1) Canadian Installations (see note 2)
A = Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm)
deck, or balcony
B = Clearance to window or door that may be 4 feet (1.2 m) below or to side of opening; 36 inches (91 cm)
opened 1 foot (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 (61cm) 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 above
extended above meter/regulator assembly See note 4 the meter/regulator assembly
I = Clearance to service regulator vent outlet See note 4 3 feet (91 cm)
J = Clearance to nonmechanical air supply inlet
to building or the combustion air inlet to 4 feet (1.2 m) below or to side of opening; 36 inches (91 cm)
any other appliance 1 foot (30 cm) above opening
K = Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m) 6 feet (1.83 m)
horizontally
Vent termination not allowed in this location
Vent termination not allowed in this location for category IV appliances. A vent shall not
L = Clearance above paved sidewalk or paved for category IV appliances. For Category III terminate directly above a sidewalk or paved
driveway located on public property appliances, vent must terminate at least 7 driveway that is located between two single
feet (2.13m) above the sidewalk or driveway. family dwellings and serves both dwellings.
For Category III appliances that do not violate
the previous condition, vent must terminate
at least 7 feet (2.13m) above the sidewalk or
driveway.
M = Clearance under veranda, porch, deck, See note 4 12 inches (30 cm) (see note 3)
or balcony
Notes:
1. In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.
2. In accordance with the current CSA-B149.1 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 CSA-B149.1, clearance is in accordance with local installation codes and the requirements of the gas supplier.
BRADFORD WHITE C ORP.
Figure 3. Combustion Air and Vent Through Side Wall.
COPPER BRUTE II (500 - 2000)
Page 11
appliances. If assistance is required in determining
how a blocked vent safety system should be connected
to a Bradford White product, please call Applications
Engineering at the Rochester phone number listed on
back cover of this manual.
Refer to the installation and operating
instructions on all appliances to be common vented
for instructions, warnings, restrictions and safety
requirements. If safe operation of all appliances
connected to a common vent cannot be assured,
including prevention of spillage of ue gasses into
living spaces, common venting should not be applied,
and appliances should each be vented separately.
2.2.4 Category III Vent
When the Copper Brute II is vented with
horizontal discharge, it must be installed per
this installation manual and the venting system
manufacturer’s installation instructions. The vent
system must be sealed stainless steel, per Table 5.
Route the vent pipe to the heater as directly as
possible. Seal all joints and provide adequate hangers
as required in the venting system manufacturer’s
Installation Instructions. Horizontal portions of the
venting system must be supported to prevent sagging
and may not have any low sections that could trap
condensate. The unit must not support the weight of
the vent pipe. Horizontal runs must slope downwards
not less than ¼ inch per foot (2 cm/m) from the unit to
the vent terminal. Reference Table 2 for the size of the
Category III vent system. Up to three elbows can be
used with 50 linear feet (15.2m) of pipe. Subtract 10
allowable linear feet (3.0m) for every additional elbow
used.
and must be located in accordance with ANSI Z223.1/
NFPA 54 and applicable local codes. In Canada, the
installation must be in accordance with CSA B149.1 or
.2 and local applicable codes. Consider the following
when installing the terminal:
1. Figure 3 shows the requirements for mechanical
vent terminal clearances for the U.S. and Canada.
2. Vent terminals for condensing appliances or
appliances with condensing vents are not
permitted to terminate above a public walkway,
or over an area where condensate or vapor could
create a nuisance or hazard.
3. Locate the vent terminal so that vent gases cannot
be drawn into air conditioning system inlets.
4. Locate the vent terminal so that vent gases cannot
enter the building through doors, windows,
gravity inlets or other openings. Whenever
possible, locations under windows or near doors
should be avoided.
5. Locate the vent terminal so that it cannot be
blocked by snow. The installer may determine
that a vent terminal must be higher than the
minimum shown in codes, depending upon local
conditions.
6. Locate the terminal so the vent exhaust does
not settle on building surfaces or other nearby
objects. Vent products may damage such
surfaces or objects.
7. If the boiler or water heater uses ducted
combustion air from an intake terminal located
on the same wall, locate the vent terminal at least
3 feet (0.9m) horizontally from the combustion
air terminal, and locate the vent terminal at least
1 foot (0.3m) above the combustion air terminal.
WARNING
The outdoor vent terminal gets hot. Unit must be
installed in such a way as to reduce the risk of
burns from contact with the vent terminal.
2.3 Locating Vent & Combustion Air
Terminals
2.3.1 Side Wall Vent Terminal
The appropriate Bradford White side wall vent
hood must be used, and is listed in the installation and
operation manual. The terminal provides a means of
installing the vent piping through the building wall,
TERM DESCRIPTION
Pipe Must comply with UL Standard 1738
such as Type 29-4C Stainless Steel
(either insulated or non-insulated).
Joint Follow vent manufacturer’s instructions
Sealing
Table 5. Required Horizontal Venting Material.
2.3.2 Side Wall Combustion Air Terminal
The Bradford White side wall combustion air
terminal (listed in Table 2) must be used when the
unit takes its combustion air through a duct from a
side wall. Consider the following when installing the
terminal:
1. Do not locate the air inlet terminal near a source
of corrosive chemical fumes (e.g., cleaning uid,
chlorinated compounds, etc.)
2. Locate the terminal so that it will not be subject
to damage by accident or vandalism.
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 Copper Brute II is side-wall vented to the
same wall, locate the vent terminal at least 3
feet (0.9m) horizontally from the combustion air
terminal, and locate the vent terminal at least 1
foot (0.3m) above the combustion air terminal
(see Figure 3).
Page 12
BRADFORD WHITE C ORP.
2.3.3 Vertical Vent Terminal
When the unit is vented through the roof, the
vent must extend at least 3 feet (0.9m) above the point
at which it penetrates the roof. It must extend at least
2 feet (0.6m) higher than any portion of a building
within a horizontal distance of 10 feet (3.0m), and high
enough above the roof line to prevent blockage from
snow. When the combustion air is taken from the roof,
the combustion air must terminate at least 12" (30cm)
below the vent terminal (see Figure 2).
2.3.4 Vertical Combustion Air Terminal
When combustion air is taken from the roof, a
eld-supplied rain cap or an elbow arrangement must
be used to prevent entry of rain water (see Figure 2).
The opening on the end of the terminal must be at least
12" (30cm) above the point at which it penetrates the
roof, and high enough above the roof line to prevent
blockage from snow. When the vent terminates on the
roof, the combustion air must terminate at least 12"
(30cm) below the vent terminal.
2.4 Common Vent Test — Boilers
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.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion and
other deciencies which could cause an unsafe
condition.
3. Insofar as it is practical, close all building doors
and windows and all doors between the space in
which the appliances remaining connected to the
common venting system are located and other
spaces of the building. Turn on clothes dryers
and any appliance not connected to the common
venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close replace dampers.
4. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use
the 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 doors, windows, exhaust fans,
replace dampers and any other gas burning
appliance to their previous conditions of use.
7. Any improper operation of the common venting
system should be corrected so that the installation
conforms to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CSA B149.1, Installation
Codes. When resizing any portion of the common
venting system, the common venting system
should be resized to approach the minimum size
as determined using the appropriate tables in Part
II of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and/or CSA B149.1, Installation Codes.
2.5 Vent Terminals for Outdoor Units
For outdoor applications, the vent and
combustion air openings must be covered with proper
terminals to prevent rain, snow and other objects from
falling into the Copper Brute II.
If local codes allow, outdoor installations may
use 1' of appropriately sized galvanized single wall
or B-Vent and a rain cap for exhaust vent termination
in the default conguration (venting out of the top).
An appropriately sized galvanized 90° ell, positioned
with the opening facing down, may be used on the
combustion air inlet in the default conguration on
the back of the unit. Note that some local codes may
require a higher vertical vent height, extending above
any perimeter fencing, etc. In installations where the
appearance of the vent is objectionable, the low prole
vent terminals in Table 6 may be used.
Part numbers for the low prole terminals to
cover the vent and combustion air openings are shown
in Table 6.
OUTDOOR OUTDOOR
SIZE VENT COMBUSTION
TERMINAL AIR TERMINAL
500 20254703 D2007900
750 20254705 D2007900
1000 20254705 D2008000
1250 D2007700 D2008000
1500 D2007700 D2008000
1750 D2007800 D2008000
2000 D2007800 D2008200
Table 6. Vent Terminals for Outdoor Units.
COPPER BRUTE II (500 - 2000)
Page 13
SECTION 3.
Gas Supply and Piping
3.1 Gas Supply and Piping
Gas piping should be supported by suitable
hangers or oor stands, not by the appliance.
The Copper Brute II’s gas train allows the user to
pipe the gas from either the right side or the left side
of the unit. As shipped, the right side of the gas train is
capped off, and there is a manual valve on the left side.
If desired, the manual valve on the left side of the gas
train may be moved to the right side, and the cap on
the right side may be moved to the left.
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. Copper
Brute II appliances are equipped to operate at
elevations up to 10,000 feet (3050m). Copper
Brute II appliances may be adjusted to operate
properly at altitudes above 2500 feet (see Section
6.5.2) and the input will be reduced if the heating
value of the gas supply is below sea level values.
2. The maximum inlet gas pressure must not
exceed 13" w.c. (3.2kPa). The minimum inlet gas
pressure is 5" w.c. (1.2kPa).
3. Refer to Table 7, size supply.
4. Run 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 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 (3.45kpa).
9. The unit must be isolated from the gas supply
system by closing its individual manual shutoff
valve during any pressure testing of the gas
supply piping system at test pressures equal to or
less than 1/2 PSIG (3.45kpa).
10. The appliance and its gas connection must be
leak tested before placing it in operation.
11. Purge all air from gas lines.
WARNING
Do not use open ame to check for leaks. An open
ame could lead to explosion, which could result in
property damage, serious injury or death.
NOTE: The Copper Brute II appliance and all other
gas appliances 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.
DISTANCE FROM GAS METER
SIZE AND
GAS TYPE
500 natural 1-1/2" 3.8cm 2" 5.1cm 2" 5.1cm
500 propane
750 natural
750 propane
1000 natural
1000 propane
1250 natural
1250 propane
1500 natural
1500 propane
1750 natural
1750 propane
2000 natural
2000 propane
Notes:
1. These gures are based on 1/2" (0.12kPa) water column pressure drop.
2. Check supply pressure and local code requirements before proceeding with work.
3. Pipe ttings must be considered when determining gas pipe sizing.
0-100' 0-31m 100-200' 31-61m 200-300' 61-91m
1" 2.5cm 1-1/2" 3.8cm 1-1/2" 3.8cm
2" 5.1cm 2" 5.1cm 2-1/2" 6.4cm
1-1/2" 3.8cm 1-1/2" 3.8cm 2" 5.1cm
2" 5.1cm 2-1/2" 6.4cm 3" 7.6cm
1-1/2" 3.8cm 2" 5.1cm 2-1/2" 6.4cm
2-1/2" 6.4cm 2-1/2" 6.4cm 3" 7.6cm
2" 5.1cm 2" 5.1cm 2-1/2" 6.4cm
2-1/2" 6.4cm 3" 7.6cm 3" 7.6cm
2" 5.1cm 2-1/2" 6.4cm 2-1/2" 6.4cm
2-1/2" 6.4cm 3" 7.6cm 3" 7.6cm
2" 5.1cm 2-1/2" 6.4cm 2-1/2" 6.4cm
3" 7.6cm 3" 7.6cm 3-1/2" 8.9cm
2-1/2" 6.4cm 2-1/2" 6.4cm 3" 7.6cm
OR LAST STAGE REGULATOR
Table 7. Gas Piping Size.
Page 14
BRADFORD WHITE C ORP.
SECTION 4A.
Water Connections —
Copper Brute II Boiler
4A.1 Heating System Piping:
Hot Supply Connections — Boiler
NOTE: This appliance must be installed in a closed
pressure system with a minimum of 12 psi (82.7kPa)
static pressure at the boiler.
Hot water piping should be supported by suitable
hangers or oor stands. Do not support piping with
this appliance. Due to expansion and contraction of
copper pipe, consideration should be given to the type
of hangers used. Rigid hangers may transmit noise
through the system resulting from the piping sliding in
the hangers. It is recommended that padding be used
when rigid hangers are installed. Maintain 1" clearance
to combustibles for hot water pipes.
Pipe the discharge of the relief valve (full size)
to a drain or in a manner to prevent injury in the event
of pressure relief. Install an air purger, an air vent,
a diaphragm-type expansion tank, and a hydronic
ow check in the system supply loop. Minimum ll
pressure must be 12psig (82.7kPa). Install shutoff
valves where required by code.
Suggested piping diagrams are shown in Figures
4 through 8. These diagrams are meant only as a guide.
20°F 25°F 30°F 35°F
SIZE ow H/L ow H/L ow H/L ow H/L
500 43 1.7 34 1.1 28 0.9 24 0.7
750 64 3.3 51 2.3 43 1.7 36 1.2
1000 85 5.0 68 3.6 57 3.1 49 2.2
1250 106 8.1 85 6.1 71 4.7 61 3.4
1500 128 10.0 102 7.2 85 5.5 73 4.2
1750 N/R N/R 119 10.5 99 8.4 85 5.8
2000 N/R N/R 136 12.5 113 10.4 97 8.3
Metric Equivalent
11°C 14°C 17°C 19°C
SIZE ow H/L ow H/L ow H/L ow H/L
500 161 0.5 129 0.3 107 0.3 92 0.2
750 241 1.0 193 0.7 161 0.5 138 0.4
1000 321 1.5 257 1.1 214 0.9 184 0.7
1250 401 2.5 322 1.9 269 1.4 231 1.0
1500 483 3.0 386 2.2 322 1.7 276 1.3
1750 N/R N/R 451 3.2 375 2.6 322 1.8
2000 N/R N/R 515 3.8 429 3.2 368 2.5
Notes: gpm = gallons per minute, lpm = liters per minute,
H/L = headloss, ft = headloss in feet, m = headloss in meters.
Maximum temperature rise is 35°F (19°C), as shown.
Headloss is for boiler’s heat exchanger only.
N/R = not recommended.
gpm feet gpm feet gpm feet gpm feet
lpm m lpm m lpm m lpm m
Table 8. Water Flow Requirements - BWCH.
Components required by local codes must be properly
installed.
Note the recommended location of the
temperature sensor on the diagrams; you must provide
a location for the additional sensor shipped with
the Copper Brute II. This sensor may be strapped
onto pipe from 1" to 4" diameter, or inserted into an
immersion well.
4A.2 Cold Water Make-Up — Boiler
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.
NOTE: The boiler, when used in connection with a
refrigeration system, must be installed so the chilled
medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium from
entering the boiler.
The boiler piping system of a hot water heating
boiler connected to heating coils located in air
handling appliances where they may be exposed to
refrigerated air circulation must be equipped with ow
control valves or other automatic means to prevent
gravity circulation of the boiler water during the
cooling cycle.
A boiler installed above radiation level, or as
required by the authority having jurisdiction, must be
provided with a low water cutoff device either as a part
of the boiler or at the time of boiler installation.
4A.3 Water Flow Requirements — Boiler
A hydronic heating (closed loop) application
re-circulates the same uid in the piping system. As a
result, no new minerals or oxygen is introduced into
the system. To ensure a proper operating temperature
leading to long boiler life, a ow rate has been
established based on the uid temperature rise for this
specic size boiler.
Pump-mounted boilers can be ordered for use in
primary secondary piping systems. The pumps used
are sized for the headloss through the heater, plus 30
feet (9.1m) of full-sized piping (same size as boiler
outlet) and a normal number of ttings.
Table 8 species water ow rates for boilers,
which will enable the user to size a pump. The
headloss shown is for the heater only, and the user
will need to add the headloss of the system piping to
properly size the pump.
The minimum inlet water temperature for the
Copper Brute II is 120°F (49°C) to avoid condensing
on the copper coils.
4A.4 Freeze Protection — Boiler
Boiler installations are not recommended in
areas where the danger of freezing exists unless proper
COPPER BRUTE II (500 - 2000)
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLEFLOW SYSTEMS
INSTALLAIR VENTS AT HIGH POINTS IN SYSTEM
PIPING&SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATEALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
C
PUMP LOCATION FOR PUMP-MOUNTED UNITS
SYSTEM PUMP
MAKE-UP
COLD WATER
SUPPLY
SYSTEM
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
RETURN
SYSTEM
SUPPLYWHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
C
LEGEND
CHECK VALVE
THERMOMETER
TEMPERATURE
SENSOR
GLOBE VALVE
EXPANSIONTANK
WITH AIR SCOOP AND
AUTOAIR VENT
3-WAY VALVE
VALVE
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATIONAND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PURGE
VALVE
PUMP
Page 15
Figure 4. Hydronic Piping — Multiple Boilers, Primary Secondary System.
precautions are made for freeze protection. A non
toxic, heating system, anti-freeze may be added to
the hydronic system provided that the concentration
does not exceed 50% and the anti freeze contains an
anti foamant. When a 50/50 mixture is used, increase
the water ow requirements by 15%, and increase the
headloss requirements by 20%.
Power outage, interruption of gas supply, failure
of system components, activation of safety devices,
etc., may prevent a boiler from ring. Any time a
boiler is subjected to freezing conditions, and the
boiler is not able to re, and/or the water is not able
to circulate, there is a risk of freezing in the boiler
or in the pipes in the system. When water freezes,
it expands. This can result in bursting of pipes in the
system, or damage to the boiler, which could result in
leaking or ooding conditions.
IMPORTANT NOTES: Different glycol products
may provide varying degrees of protection. Glycol
products must be maintained properly in a heating
system, or they may become ineffective. Consult the
glycol specications, or the glycol manufacturer, for
information about specic products, maintenance
of solutions, and set up according to your particular
conditions.
Page 16
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLEFLOW SYSTEMS
INSTALLAIR VENTS AT HIGH POINTS IN SYSTEM
PIPING & SIZING OF EXPANSIONTANK
PER TANK MANUFACTURER'S INSTRUCTIONS
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATEALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
C
PUMP LOCATION FOR PUMP-MOUNTED UNITS
SYSTEM PUMP
MAKE-UP
COLD WATER
SUPPLY
SYSTEM
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
RETURN
SYSTEM
SUPPLYWHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
C
ADJUSTMENT PROCEDURE TO MAINTAIN
120°F INLET TEMP:
1. Turn on boiler and open valves A&B.
2. After steady-state operation, if T1 is less than
slowly close valveBuntil T1 climbs to
120°F.
3. If T1 is greater than 120°F,slowly close
until T1 dropsto 120°F.
4. Check after system operating temperature
has stabilized. Make final adjustments.
120°F,
valve A
A
B
T1
B
A
T1
LEGEND
CHECK VALVE
THERMOMETER
TEMPERATURE
SENSOR
GLOBE VALVE
EXPANSIONTANK
WITH AIR SCOOPAND
AUTOAIR VENT
3-WAY VALVE
VALVE
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PURGE
VALVE
PUMP
BRADFORD WHITE C ORP.
Figure 5. Hydronic Piping — Multiple Boilers, Low Temperature System.
COPPER BRUTE II (500 - 2000)
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLEFLOW SYSTEMS
INSTALLAIR VENTS AT HIGH POINTS IN SYSTEM
PIPING & SIZING OF EXPANSIONTANK
PER TANK MANUFACTURER'S INSTRUCTIONS
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATEALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
PUMP LOCATION FOR PUMP-MOUNTED UNITS
SYSTEM PUMP
MAKE-UP
COLD WATER
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
SUPPLYWHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
C
C
C
C
180°F
180°F
150°F
130°F
NOTES:
1. BOILER LOOP IN EXAMPLE IS MAINTAINEDAT 180°F.
2. ZONE THERMOSTATS CAN BE INTERLOCKED WITH BOILER,
SO THAT BOILER FIRES UPON CALL FOR HEAT FROM ANY
ZONE.
3. ZONE PIPING AND INTERLOCK WIRING TO BE DESIGNED
BY SYSTEM ENGINEER.
LEGEND
CHECK VALVE
THERMOMETER
TEMPERATURE
SENSOR
GLOBE VALVE
EXPANSIONTANK
WITH AIR SCOOPAND
AUTOAIR VENT
3-WAY VALVE
VALVE
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PURGE
VALVE
PUMP
Page 17
Figure 6. Hydronic Piping — One Boiler, Multi-Temperature System.
Page 18
LEGEND
CHECK VALVE
THERMOMETER
TEMPERATURE
SENSOR
GLOBE VALVE
EXPANSIONTANK
WITH AIR SCOOP AND
AUTOAIR VENT
3-WAY VALVE
VALVE
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PURGE
VALVE
PUMP
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLEFLOW SYSTEMS
INSTALLAIR VENTS AT HIGH POINTS IN SYSTEM
PIPING&SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATEALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
C
PUMP LOCATION FOR PUMP-MOUNTED UNITS
SYSTEM PUMP
MAKE-UP
COLD WATER
SUPPLY
SYSTEM
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
RETURN
SYSTEM
SUPPLYWHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
BRADFORD WHITE C ORP.
Figure 7. Hydronic Piping - Primary-Secondary, Reverse-Return.
COPPER BRUTE II (500 - 2000)
LEGEND
CHECK VALVE
THERMOMETER
TEMPERATURE
SENSOR
GLOBE VALVE
EXPANSIONTANK
WITH AIR SCOOP AND
AUTOAIR VENT
3-WAY VALVE
VALVE
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PURGE
VALVE
PUMP
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLEFLOW SYSTEMS
INSTALLAIR VENTS AT HIGH POINTS IN SYSTEM
PIPING & SIZING OF EXPANSIONTANK
PER TANK MANUFACTURER'S INSTRUCTIONS
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATEALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
PUMP LOCATION FOR PUMP-MOUNTED UNITS
SUPPLYWHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
C
SYSTEM PUMP
MAKE-UP
COLD WATER
SUPPLY
SYSTEM
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
RETURN
SYSTEM
T1 T1
A
B
A
B
ADJUSTMENT PROCEDURE TO MAINTAIN
120°F INLET TEMP:
1. Turn on boiler and open valves A&B.
2. After steady-state operation, if T1 is less than
120°F, slowly close valveBuntil T1 climbs to
120°F.
3. If T1 is greater than 120°F,slowly close valve
A until T1 dropsto 120°F.
4. Check after system operating temperature has
stabilized. Make final adjustments.
Page 19
Figure 8. Hydronic Piping - Primary-Secondary, Reverse-Return, Low Temperature.
Page 20
BRADFORD WHITE C ORP.
SECTION 4B.
Water Connections —
Copper Brute II Water Heater
4B.1 Water System Piping —
Water Heater
Hot water piping should be supported by suitable
hangers or oor stands. Do not support piping with
this appliance. Due to expansion and contraction of
copper pipe, consideration should be given to the type
of hangers used. Rigid hangers may transmit noise
through the system resulting from the piping sliding in
the hangers. It is recommended that padding be used
when rigid hangers are installed.
The Copper Brute II can be used with several
different types of readily available storage tanks. A
pump draws water from the storage tank and pumps
the water through the heater and back into the tank.
Pump-mounted units have a circulating pump built
into the water heater. The pumps used are sized for the
headloss through the heater, plus 30 feet (9.1m) of full-
sized piping (same size as boiler outlet) and a normal
number of ttings. Pumps used on pump-mounted unit
are sized for soft/normal or hard water, so make sure
a pump-mounted unit matches the water quality of the
installation.
Pipe the outlet from the heater’s relief valve
such that any discharge from the relief valve will be
conducted to a suitable place for disposal when relief
occurs. Do not reduce line size or install any valves in
this line. The line must be installed to allow complete
drainage of both the valve and the line.
Suggested piping diagrams are shown in Figures
9 through 12. These diagrams are meant only as a
guide. Components required by local codes must be
properly installed.
Note the recommended location of the
temperature sensor on the diagrams. The Copper Brute
II is shipped with an additional sensor that can be used
for more full-featured domestic water heating control.
To get these features, you must provide a location for
the additional sensor. It can be strapped to a pipe from
1" to 4" diameter, or inserted into a tank immersion
well.
The minimum inlet water temperature for the
Copper Brute II is 120°F (49°C) to avoid condensing
on the copper coils.
4B.2 Hot Water Supply Piping —
Water Heater
Follow the tank manufacturer’s guidelines for
completion of the hot water system connections.
NOTE: A listed temperature and pressure relief
valve listed as complying with the Standard for
Relief Valves and Automatic Gas Shutoff Devices
for Hot Water Supply Systems (ANSI Z21.22 /
CSA 4.4) of suitable discharge capacity must be
installed in the separate storage tank system.
If the Copper Brute II water heater is installed
in a closed water supply system, such as one having a
backow preventer in the cold water supply line, the
relief valve may discharge periodically, due to thermal
expansion. Means (such as a properly-sized expansion
tank) shall be provided to control thermal expansion.
Contact the water supplier or local plumbing inspector
on how to control this situation.
4B.3 Water Flow Requirements —
Water Heater
In a water heating application (an open system),
new water is constantly being introduced. With the
new water comes a fresh supply of minerals that can
be deposited on the unit’s heat exchanger. This is
commonly known as scaling. The amount of minerals
will depend upon the hardness of the water. Water can
also be aggressive, and can erode metals, including
copper, if the water is moved too quickly. The water
ow requirements for the Copper Brute II water heater
are based upon the hardness of the water. The water
ow is kept high enough to prevent scaling, but low
enough to prevent tube erosion. For extremely soft or
hard water, cupro-nickel tubes are available. Contact a
Bradford White Representative if you have questions
or concerns about water quality.
Pump-mounted water heaters can be ordered
with standard pumps for soft or normal water or with
pumps for hard water. The pumps used are sized for
the headloss through the heater, plus 30 feet (9.1m)
of full-sized piping (same size as heater outlet) and a
normal number of ttings.
Table 9 species water ow rates for water
heaters, which will enable the user to size a pump.
The headloss shown is for the heater only, and the user
will need to add the headloss of the piping system to
properly size the pump.
4B.4 Combined Water Heating (potable)
and Space Heating — Water Heater
NOTE: These systems are not allowed in the
Commonwealth of Massachusetts.
Piping and components connected to this water
heater for the space heating application shall be
suitable for use with potable water.
Toxic chemicals, such as used for boiler
treatment, shall not be introduced into the potable
water used for space heating.
This water heater when used to supply potable
water shall not be connected to any heating system
or component(s) previously used with a non-potable
water heating appliance.
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