Bradford-White BWCH, BWCV User Manual

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Installation and Operation Instructions

Document 1270

 

 

Installation and Operation

Instructions for

Copper BruteII

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, qualified in hot water boiler installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty. 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 fire or explosion may result causing property damage, personal injury or loss of life.

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

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

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

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

If you cannot reach your gas supplier, call

the fire department.

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

AVERTISSEMENT

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 inflammables dans le voisinage de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

Ne pas tenter d’allumer d’appareils.

Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dansle bâtiment où vous 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 qualifié ou par le fournisseur de gaz.

H2214401F

Page 2

BRADFORD WHITE CORP.

 

 

 

 

TABLE OF CONTENTS

SECTION 1.

 

SECTION 3.

 

General Information

 

Gas Supply and Piping

 

1.1

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

4

3.1

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

13

1.2

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

4

SECTION 4A.

 

1.3

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

5

 

1.4

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

5

Water Connections – Boiler

 

1.5

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

5

4A.1

Heating System Piping:

14

1.6

Locating Pump-Mounted Water Heater

 

 

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

 

4A.2

Cold Water Make-Up – Boiler

14

 

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

7

1.7

Locating Pump-Mounted Boiler with

 

4A.3

Water Flow Requirements – Boiler.................

14

 

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

7

4A.4

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

14

1.8Locating Appliance for Correct Horizontal Vent/

 

Ducted Air Distance From Outside Wall...........

7

SECTION 4B.

 

 

 

 

Water Connections – Water Heater

 

SECTION 2.

 

4B.1

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

20

Venting and Combustion Air

 

4B.2

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

20

2.1

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

8

4B.3

Water Flow Requirements – Water Heater.....

20

2.1.1

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

8

4B.4

Combined Water Heating (potable)

20

2.1.2

Intake Combustion Air

8

 

and Space Heating – Water Heater...............

4B.5

Freeze Protection – Water Heater

21

2.2

Venting

9

 

 

 

2.2.1

Vent Categories................................................

9

SECTION 5.

 

2.2.2

Category I Vent

9

 

Electrical Connections

 

2.2.3

Common Venting Systems...............................

9

5.1

Main Power

24

2.2.4

Category III Vent

1

5.1.1

Power Circuits

24

2.3

Locating Vent & Combustion Air Terminals

11

5.2

Temperature Control

24

2.3.1

Side Wall Vent Terminal

11

5.2.1

Temperature Control Description

24

2.3.2

Side Wall Combustion Air Terminal

11

5.3

External Staging Control Wiring

26

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

 

 

 

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

7.2Appliance 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 CORP.

 

 

 

 

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 identified.

In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber or gas fitter.

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 modifications to the boiler, its gas controls, or wiring may void the warranty. If field conditions require modifications, consult the factory representative before initiating such modifications.

1.1Introduction

This manual provides information necessary

for the installation, operation, and maintenance of Bradford White 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 fitted 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.

1.2Model Identification

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

 

 

USAGE

 

 

SIZE

 

 

 

FUEL

 

 

ALTITUDE

 

LOCATION

 

 

FIRING

 

REVISION

 

 

HEAT

 

OPTIONS

 

 

PUMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

W

C

 

 

H

 

0

5

0

0

 

 

N

 

 

 

A

 

 

C

 

 

MODE

 

2

 

 

EXCHANGER

 

 

CODE

 

OPTIONS

 

 

 

 

 

 

 

 

 

 

K (500/750)

 

 

 

 

 

 

X

 

 

 

 

 

 

 

 

 

V

 

0

7

5

0

 

 

P

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

0

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N (1000)

 

 

 

 

 

 

 

C

 

 

 

J

 

 

H

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

2

5

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L (1250-2000)

 

 

 

 

 

 

 

K

 

 

 

L

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

1

5

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

7

5

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

0

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COPPER BRUTE II (500 - 2000)

Page 5

 

 

 

 

Model Character Designation

1-3 Model Series Designation

B W C = Bradfrod White, Copper Brute II

4Usage

H = Hydronic

V = Volume Water

5-8 Size

05 0 0 = 500,000 BTU/h input

07 5 0 = 750,000 BTU/h input

10 0 0 = 999,000 BTU/h input

12 5 0 = 1,250,000 BTU/h input

15 0 0 = 1,500,000 BTU/h input

17 5 0 = 1,750,000 BTU/h input

2 0 0 0 = 1,999,000 BTU/h input

9Fuel

N = Natural Gas

P = Propane

10Altitude

A = 0-10,000 feet

11Location

C = Indoor and Outdoor

12Firing Mode

K = Two-stage (models 500 & 750) N = Three-stage (model 1000)

L = Four-stage (models 1250 - 2000)

13Revision

2 = Second version

14Heat 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

15Option Code

X = Standard unit

J = CSD-1, FM, IRI, IL

L = MN and LDS (Indoor units only)

16Pump Options

X = No Pump

H = Pump mounted, hard water pump N = Pump mounted, normal pump

S = Pump mounted, soft water pump

1.3Warranty

Bradford White, Copper Brute II appliances

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

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

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

1.4Dimensions

See Figure 1.

1.5Locating 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 floors of the structure.

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

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

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.

REQUIRED RECOMMENDED

Page 6

BRADFORD WHITE CORP.

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

B

 

C

 

 

D

 

E

 

F

 

G

 

H

AIR

VENT

HORIZ.

 

in

in

in

 

in

in

in

in

in

CONN.

CONN.

VENT

SIZE

cm

cm

cm

cm

cm

cm

cm

cm

 

W

V

 

PIPE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

500

33½

85

15¾

40

 

15

29¾

76

32¾

83

20

22

46

117

6

15

8

20

8

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

750

45½

116

21¾

55

 

15

29¾

76

32¾

83

20

22

58

147

6

15

10

25

8

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1000

57½

146

28¾

73

 

15

29¾

76

32¾

83

20

7

18

70

178

8

20

10

25

8

20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1250

68

172

34

86

101/8 26

30¾

78

29½

75

22

22

80

203

8

20

12

30

8

20

1500

78½

199

39¾

101

101/8

26

30¾

78

29½

75

22

22

91

231

8

20

12

30

8

20

1750

89

226

44½

113

101/8

26

30¾

78

29½

75

22

22

101 256

8

20

14

36

8

20

2000

99½

253

49¾

126

101/8

26

30¾

78

29½

75

22

22

B

284

12 30

14

36

12

30

 

 

 

 

 

*Air and vent connections may be on top or back of the Copper Brute II, and are field convertible.

 

 

 

Dimensions in inches cm.

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

COMBUSTIBLE MATERIAL

CLEARANCE

 

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

6*

 

 

 

(Category 1)

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).

Table 1. Clearances.

1.8Locating Appliance for Correct

Horizontal Vent/Ducted Air Distance

From Outside Wall

The forced draft combustion air blower/blowers in the appliance has/have sufficient 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.

 

 

 

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 CORP.

 

 

 

 

SECTION 2.

Venting and Combustion Air

2.1Combustion 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 confined space.

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

In Canada, consult local building and safety codes or, in absence of such requirements, follow 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 field-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 floor level and one at the ceiling, so the total net free area could be double the figures 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 filter 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 flanges are reversible by removing the mounting screws and orienting the flanges in the desired position. Replace the screws after positioning flanges. 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), defines 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 flue 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 qualified 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 infiltrate 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 flue 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

Bradford-White BWCH, BWCV User Manual

Page 10

BRADFORD WHITE CORP.

 

 

 

 

 

 

U.S. Installations (see note 1)

Canadian Installations (see note 2)

A = Clearance above grade, veranda, porch, 12 inches (30 cm)

12 inches (30 cm)

deck, or balcony

 

B = Clearance to window or door that may be opened

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

36 inches (91 cm)

1 foot (30 cm) above opening

 

C =

Clearance to permanently closed window

See note 4

See note 5

D =

Vertical clearance to ventilated soffit located

 

 

 

above the terminal within a horizontal

See note 4

See note 5

 

distance of 2 feet (61cm) from the center

 

 

 

line of the terminal

 

 

E =

Clearance to unventilated soffit

See note 4

See note 5

F =

Clearance to outside corner

See note 4

See note 5

G =

Clearance to inside corner

See note 4

See note 5

H =

Clearance to each side of center line

 

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

 

extended above meter/regulator assembly

See note 4

the meter/regulator assembly

I =

Clearance to service regulator vent outlet

See note 4

3 feet (91 cm)

J =

Clearance to nonmechanical air supply inlet

 

 

 

to building or the combustion air inlet to

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

36 inches (91 cm)

 

any other appliance

1 foot (30 cm) above opening

 

K =

Clearance to a mechanical air supply inlet

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

6 feet (1.83 m)

 

 

horizontally

 

 

 

 

Vent termination not allowed in this location

L =

 

Vent termination not allowed in this location

for category IV appliances. A vent shall not

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 floor.

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

5.For clearances not specified in CSA-B149.1, clearance is in accordance with local installation codes and the requirements of the gas supplier.

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 flue 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.

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.

2.3Locating 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.

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.

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 fluid, 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 CORP.

 

 

 

 

2.3.3 Vertical Vent Terminal

When the unit is vented through the roof, the vent must extend at least 3 feet (0.9m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6m) higher than any portion of a building within a horizontal distance of 10 feet (3.0m), and high enough above the roof line to prevent blockage from snow. When the combustion air is taken from the roof, the combustion air must terminate at least 12" (30cm) below the vent terminal (see Figure 2).

2.3.4 Vertical Combustion Air Terminal

When combustion air is taken from the roof, a field-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.

2.4Common 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 deficiencies which could cause an unsafe condition.

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

4.Place in operation the appliance being inspected. Follow the lighting instructions.

Adjust thermostat so appliance will operate continuously.

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

cigarette, cigar or pipe.

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

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

2.5Vent 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 configuration (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 configuration 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 profile vent terminals in Table 6 may be used.

Part numbers for the low profile 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

3.1Gas Supply and Piping

Gas piping should be supported by suitable

hangers or floor 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 fitted 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 liquefied petroleum gas.

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

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

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

11.Purge all air from gas lines.

WARNING

Do not use open flame to check for leaks. An open flame 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 firing at maximum capacity to properly measure the inlet supply pressure. The pressure can be measured at the supply pressure port on the gas valve. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line.

 

 

DISTANCE FROM GAS METER

 

 

SIZE AND

 

OR LAST STAGE REGULATOR

 

 

0-100'

0-31m

100-200'

31-61m

200-300'

61-91m

GAS TYPE

500 natural

1-1/2"

3.8cm

2"

5.1cm

2"

5.1cm

500 propane

1"

2.5cm

1-1/2"

3.8cm

1-1/2"

3.8cm

750 natural

2"

5.1cm

2"

5.1cm

2-1/2"

6.4cm

750 propane

1-1/2"

3.8cm

1-1/2"

3.8cm

2"

5.1cm

1000 natural

2"

5.1cm

2-1/2"

6.4cm

3"

7.6cm

1000 propane

1-1/2"

3.8cm

2"

5.1cm

2-1/2"

6.4cm

1250 natural

2-1/2"

6.4cm

2-1/2"

6.4cm

3"

7.6cm

1250 propane

2"

5.1cm

2"

5.1cm

2-1/2"

6.4cm

1500 natural

2-1/2"

6.4cm

3"

7.6cm

3"

7.6cm

1500 propane

2"

5.1cm

2-1/2"

6.4cm

2-1/2"

6.4cm

1750 natural

2-1/2"

6.4cm

3"

7.6cm

3"

7.6cm

1750 propane

2"

5.1cm

2-1/2"

6.4cm

2-1/2"

6.4cm

2000 natural

3"

7.6cm

3"

7.6cm

3-1/2"

8.9cm

2000 propane

2-1/2"

6.4cm

2-1/2"

6.4cm

3"

7.6cm

Notes:

1.These figures are based on 1/2" (0.12kPa) water column pressure drop. 2.Check supply pressure and local code requirements before proceeding with work.

3.Pipe fittings must be considered when determining gas pipe sizing.

Table 7. Gas Piping Size.

Page 14

BRADFORD WHITE CORP.

 

 

 

 

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 floor stands. Do not support piping with this appliance. Due to expansion and contraction of copper pipe, consideration should be given to the type of hangers used. Rigid hangers may transmit noise through the system resulting from the piping sliding in the hangers. It is recommended that padding be used when rigid hangers are installed. Maintain 1" 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 flow check in the system supply loop. Minimum fill pressure must be 12psig (82.7kPa). Install shutoff valves where required by code.

Suggested piping diagrams are shown in Figures 4 through 8. These diagrams are meant only as a guide.

 

20°F

25°F

30°F

35°F

SIZE

flow

H/L

flow

H/L

flow

H/L

flow

H/L

 

gpm

feet

gpm

feet

gpm

feet

gpm

feet

500

43

1.7

34

1.1

28

0.9

24

0.7

750

64

3.3

51

2.3

43

1.7

36

1.2

1000

85

5.0

68

3.6

57

3.1

49

2.2

1250

106

8.1

85

6.1

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

flow

H/L

flow

H/L

flow

H/L

flow

H/L

 

lpm

m

lpm

m

lpm

m

lpm

m

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.

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 fill valve.

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

3.Install shut off valves where required.

NOTE: The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.

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

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

4A.3 Water Flow Requirements — Boiler

A hydronic heating (closed loop) application re-circulates the same fluid 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 flow rate has been established based on the fluid temperature rise for this specific 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 fittings.

Table 8 specifies water flow 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)

Page 15

 

 

 

 

COLD WATER

MAKE-UP

SYSTEM

RETURN

C C

SYSTEM PUMP

SYSTEM

SUPPLY

 

PUMP LOCATION FOR

NON-PUMP-MOUNTED UNITS

CAUTION: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND VALVING, CHECK

WITH LOCAL CODES AND ORDINANCES FOR PUMP LOCATION FOR PUMP-MOUNTED UNITS

ADDITIONAL REQUIREMENTS.

 

 

 

 

PRIMARY/SECONDARY MANDITORY FOR ALL

 

 

 

 

VARIABLE FLOW SYSTEMS

LEGEND

 

 

INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM

 

 

PIPING & SIZING OF EXPANSION TANK

 

 

 

 

THERMOMETER

 

EXPANSION TANK

PER TANK MANUFACTURER'S INSTRUCTIONS

 

WITH AIR SCOOP AND

DIMENSION "C" (COMMON PIPING) TO BE FOUR

 

 

 

PURGE

AUTO AIR VENT

PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)

TEMPERATURE

 

 

BOILER CIRCUIT PIPING MUST BE EQUAL

VALVE

 

 

SENSOR

 

 

TO BOILER WATER CONNECTION SIZE

 

 

 

GLOBE VALVE

3-WAY VALVE

BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER

 

 

DOTTED DEVICES INDICATE ALTERNATE LOCATIONS

 

 

CHECK VALVE

VALVE

 

PRESSURE REDUCING VALVE

 

W/ FAST FILL BYPASS

PUMP

PUT BOILER CONTROL SENSOR IN THE SYSTEM SUPPLY WHEN USING THIS PIPING STYLE.

MINIMUM BOILER INLET WATER TEMPERATURE MUST BE AT LEAST 120°F.

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 flow 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 firing. Any time a boiler is subjected to freezing conditions, and the boiler is not able to fire, and/or the water is not able to circulate, there is a risk of freezing in the boiler or in the pipes in the system. When water freezes, it expands. This can result in bursting of pipes in the system, or damage to the boiler, which could result in

leaking or flooding conditions.

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

Page 16

BRADFORD WHITE CORP.

 

 

 

 

COLD WATER

MAKE-UP

 

C

C

 

 

 

 

SYSTEM

SYSTEM

 

SYSTEM PUMP

SUPPLY

 

 

RETURN

B

B

 

 

A

A

 

 

 

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 valve B until T1 climbs to

 

 

120°F.

 

 

 

3. If T1 is greater than 120°F, slowly close

 

 

valve A until T1 drops to 120°F.

 

 

PUMP LOCATION FOR

4. Check after system operating temperature

 

NON-PUMP-MOUNTED UNITS

has stabilized. Make final adjustments.

 

T1

T1

 

CAUTION: THIS DRAWING SHOWS SUGGESTED

 

 

PIPING CONFIGURATION AND VALVING, CHECK

PUMP LOCATION FOR PUMP-MOUNTED UNITS

WITH LOCAL CODES AND ORDINANCES FOR

ADDITIONAL REQUIREMENTS.

 

 

PRIMARY/SECONDARY MANDITORY FOR ALL

 

 

 

 

 

 

 

 

VARIABLE FLOW SYSTEMS

 

 

 

 

INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM

LEGEND

 

 

PIPING & SIZING OF EXPANSION TANK

 

 

 

 

 

 

EXPANSION TANK

PER TANK MANUFACTURER'S INSTRUCTIONS

THERMOMETER

 

DIMENSION "C" (COMMON PIPING) TO BE FOUR

 

WITH AIR SCOOP AND

 

 

 

 

PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)

 

 

AUTO AIR VENT

TEMPERATURE

PURGE

 

 

 

VALVE

 

 

BOILER CIRCUIT PIPING MUST BE EQUAL

SENSOR

 

 

 

 

3-WAY VALVE

TO BOILER WATER CONNECTION SIZE

GLOBE VALVE

 

BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER

 

 

 

 

 

 

 

CHECK VALVE

 

VALVE

 

DOTTED DEVICES INDICATE ALTERNATE LOCATIONS

 

 

 

 

 

 

PUT BOILER CONTROL SENSOR IN THE SYSTEM

 

 

 

 

PRESSURE REDUCING VALVE

 

 

SUPPLY WHEN USING THIS PIPING STYLE.

 

 

 

W/ FAST FILL BYPASS

PUMP

 

MINIMUM BOILER INLET WATER TEMPERATURE

 

 

 

 

MUST BE AT LEAST 120°F.

Figure 5. Hydronic Piping — Multiple Boilers, Low Temperature System.

COPPER BRUTE II (500 - 2000)

Page 17

 

 

 

 

150°F

C

 

 

 

COLD WATER

 

 

 

 

MAKE-UP

 

C

 

 

C

180°F

130°F

 

 

 

 

 

 

C

180°F

 

 

 

 

 

 

 

 

SYSTEM PUMP

 

 

 

 

NOTES:

 

 

PUMP LOCATION FOR

 

1. BOILER LOOP IN EXAMPLE IS MAINTAINED AT 180°F.

 

 

 

2. ZONE THERMOSTATS CAN BE INTERLOCKED WITH BOILER,

 

NON-PUMP-MOUNTED UNITS

 

 

 

SO THAT BOILER FIRES UPON CALL FOR HEAT FROM ANY

 

 

 

 

 

 

ZONE.

 

 

 

 

3. ZONE PIPING AND INTERLOCK WIRING TO BE DESIGNED

 

 

 

BY SYSTEM ENGINEER.

 

CAUTION: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND VALVING, CHECK PUMP LOCATION FOR PUMP-MOUNTED UNITS

WITH LOCAL CODES AND ORDINANCES FOR

ADDITIONAL REQUIREMENTS.

 

 

 

 

PRIMARY/SECONDARY MANDITORY FOR ALL

 

 

 

 

VARIABLE FLOW SYSTEMS

LEGEND

 

 

INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM

 

 

 

 

 

 

 

PIPING & SIZING OF EXPANSION TANK

THERMOMETER

 

EXPANSION TANK

PER TANK MANUFACTURER'S INSTRUCTIONS

 

 

 

WITH AIR SCOOP AND

DIMENSION "C" (COMMON PIPING) TO BE FOUR

 

 

 

 

AUTO AIR VENT

PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)

 

PURGE

 

 

TEMPERATURE

 

 

 

VALVE

 

 

BOILER CIRCUIT PIPING MUST BE EQUAL

SENSOR

 

 

 

 

 

TO BOILER WATER CONNECTION SIZE

 

 

 

 

GLOBE VALVE

3-WAY VALVE

 

CHECK VALVE

VALVE

 

PRESSURE REDUCING VALVE

 

W/ FAST FILL BYPASS

PUMP

BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER

DOTTED DEVICES INDICATE ALTERNATE LOCATIONS

PUT BOILER CONTROL SENSOR IN THE SYSTEM SUPPLY WHEN USING THIS PIPING STYLE.

MINIMUM BOILER INLET WATER TEMPERATURE MUST BE AT LEAST 120°F.

Figure 6. Hydronic Piping — One Boiler, Multi-Temperature System.

Page 18

BRADFORD WHITE CORP.

 

 

 

 

COLD WATER

MAKE-UP

SYSTEM

RETURN

C

SYSTEM PUMP

PUMP LOCATION FOR

NON-PUMP-MOUNTED UNITS

PUMP LOCATION FOR PUMP-MOUNTED UNITS

CAUTION: THIS DRAWING SHOWS SUGGESTED

PRIMARY/SECONDARY MANDITORY FOR ALL

VARIABLE FLOW SYSTEMS

PIPING CONFIGURATION AND VALVING, CHECK

 

WITH LOCAL CODES AND ORDINANCES FOR

INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM

ADDITIONAL REQUIREMENTS.

 

PIPING & SIZING OF EXPANSION TANK

PER TANK MANUFACTURER'S INSTRUCTIONS

LEGEND

THERMOMETER

 

TEMPERATURE

PURGE

VALVE

SENSOR

 

GLOBE VALVE

 

CHECK VALVE

 

PRESSURE REDUCING VALVE W/ FAST FILL BYPASS

EXPANSION TANK

WITH AIR SCOOP AND AUTO AIR VENT

3-WAY VALVE

VALVE

PUMP

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 INDICATE ALTERNATE LOCATIONS

PUT BOILER CONTROL SENSOR IN THE SYSTEM SUPPLY WHEN USING THIS PIPING STYLE.

MINIMUM BOILER INLET WATER TEMPERATURE MUST BE AT LEAST 120°F.

SYSTEM SUPPLY

Figure 7. Hydronic Piping - Primary-Secondary, Reverse-Return.

COPPER BRUTE II (500 - 2000)

Page 19

 

 

 

 

COLD WATER

MAKE-UP

SYSTEM

RETURN

 

C

 

SYSTEM

 

 

 

 

 

SYSTEM PUMP

SUPPLY

 

 

 

 

B

ADJUSTMENT PROCEDURE TO MAINTAIN

B

120°F INLET TEMP:

 

A

A

1. Turn on boiler and open valves A & B.

 

 

2. After steady-state operation, if T1 is less than

 

 

120°F, slowly close valve B until T1 climbs to

 

 

120°F.

 

 

 

3. If T1 is greater than 120°F, slowly close valve

 

 

A until T1 drops to 120°F.

 

 

 

4. Check after system operating temperature has

PUMP LOCATION FOR

 

stabilized. Make final adjustments.

 

NON-PUMP-MOUNTED UNITS

 

 

 

T1

T1

 

 

CAUTION: THIS DRAWING SHOWS SUGGESTED

PIPING CONFIGURATION AND VALVING, CHECK

WITH LOCAL CODES AND ORDINANCES FOR PUMP LOCATION FOR PUMP-MOUNTED UNITS

ADDITIONAL REQUIREMENTS.

PRIMARY/SECONDARY MANDITORY FOR ALL VARIABLE FLOW SYSTEMS

INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM

LEGEND

 

 

 

PIPING & SIZING OF EXPANSION TANK

THERMOMETER

 

EXPANSION TANK

PER TANK MANUFACTURER'S INSTRUCTIONS

 

 

 

WITH AIR SCOOP AND

DIMENSION "C" (COMMON PIPING) TO BE FOUR

 

 

 

 

AUTO AIR VENT

PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)

 

PURGE

 

TEMPERATURE

 

 

VALVE

 

BOILER CIRCUIT PIPING MUST BE EQUAL

SENSOR

 

 

 

 

TO BOILER WATER CONNECTION SIZE

GLOBE VALVE

 

3-WAY VALVE

BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER

 

 

 

 

 

CHECK VALVE

 

VALVE

DOTTED DEVICES INDICATE ALTERNATE LOCATIONS

 

 

 

 

 

 

 

 

PUT BOILER CONTROL SENSOR IN THE SYSTEM

PRESSURE REDUCING VALVE

 

SUPPLY WHEN USING THIS PIPING STYLE.

 

 

W/ FAST FILL BYPASS

PUMP

MINIMUM BOILER INLET WATER TEMPERATURE

 

 

 

MUST BE AT LEAST 120°F.

Figure 8. Hydronic Piping - Primary-Secondary, Reverse-Return, Low Temperature.

Page 20

BRADFORD WHITE CORP.

 

 

 

 

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

The 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 fullsized piping (same size as boiler outlet) and a normal number of fittings. 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 backflow 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 flow requirements for the Copper Brute II water heater are based upon the hardness of the water. The water flow is kept high enough to prevent scaling, but low enough to prevent tube erosion. For extremely soft or hard water, 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 fittings.

Table 9 specifies water flow 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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