Bradford White Corp Water Heater BMT2H User Manual

InstallationandOperationInstructions

Document1245

Installation and Operation Instructions for

BRUTE DELUXE

Hydronic Boiler

Model BMT2H

Volume Water Heater

Model BMT2V

Sizes 500–2000 MBTU/h

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.

AVERTISSEMENT

WARNING

Assurez-vous de bien suivres les instructions

If the information in this manual is not

données dans cette notice pour réduire au

followed exactly, a fire or explosion may

minimum le risque d’incendie ou d’explosion ou

result causing property damage, personal

pour éviter tout dommage matériel, toute

injury or loss of life.

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.

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.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas vous

servir des téléphones dansle bâtiment où

vous vous trouvez.

• Appelez immédiatement votre fournisseur de

gaz depuis un voisin. Suivez les instructions

du fournisseur.

• If you cannot reach your gas supplier, call

the fire department.

• Si vous ne pouvez rejoindre le fournisseur de

gaz, appelez le sservice des incendies.

Installation and service must be performed by

a qualified installer, service agency, or gas

supplier.

L’installation et l’entretien doivent être assurés par

un installateur ou un service d’entretien qualifié ou

par le fournisseur de gaz.

238-49222-00A REV 4/11

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Brute Deluxe (500-2000)

Page 3

most operating issues are caused by improper

installation.

The Brute Deluxe 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.

SECTION 1.

General Information

USING THIS MANUAL – Because Brute

Deluxe Boilers and 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 all

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.

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.

In the Commonwealth of Massachusetts, this app-

liance must be installed by a licensed plumber or gas fitter.

WARNING

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.

The Brute Deluxe 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 appliances must conform to the

Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1. Any

modifications to the unit, its gas controls, or wiring

may void the warranty. If field conditions require

modifications, consult the factory representative

1.2 Model Identification

Consult the rating plate on the unit. The following

information describes the model number structure.

1-4 Model Series Designation

B M T 2 = Brute Deluxe

Usage

H = Hydronic

V = Volume Water

before initiating such modifications.

1.1 Introduction

5-8 Size

0 5 0 0 = 500,000 BTU/h input

This manual provides information necessary for the

installation, operation, and maintenance of Bradford

White Brute Deluxe copper tube appliances. Read it

carefully before installation.

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

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

SERIES

SIZE

LOCATION

REVISION

USAGE

FUEL

ALTITUDE

FIRING

MODE

K 2-Stage

HEAT

OPTIONS

CODE

PUMP

EXCHANGER

OPTIONS

BMT2V: H

BMT2H:

BMT2V:

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BRADFORD WHITE CORP.

Page 4

Fuel

the appliance or to lower floors of the structure.

N = Natural Gas

P = Propane

When such a location is not available, it is

recommended that a suitable drain pan, adequately

drained, be installed under the appliance.

10 Altitude

A = 0–10,000 feet

11 Location

C = Indoor and Outdoor

The appliance is design certified by CSA-

International for installation on combustible flooring; in

basements; in closets, utility rooms or alcoves. Brute

Deluxe Boilers or Water Heaters must never be

installed on carpeting. The location for the appliance

should be chosen with regard to the vent pipe lengths

and external plumbing. The unit shall be installed such

that the gas ignition system components are protected

from water (dripping, spraying, rain, etc.) during

operation and service (circulator replacement, control

replacement, etc.). When vented vertically, the Brute

Deluxe 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.

12 Firing Mode

K = Two-stage

13 Revision

1 = First version of design

14 Heat Exchanger

B = Glass-lined cast iron / copper / bronze trim

(std. on BMT2V)

C = Glass-lined cast iron / copper

(std. on BMT2H)

K = Bronze / copper

N = Glass-lined cast iron / cupro-nickel

(n/a on water heaters)

P = Glass-lined cast iron / cu-nickel / bronze trim

S = Bronze / cupro-nickel

The dimensions and requirements that are shown in

Table 1 should be met when choosing the locations for

the appliance.

15 Option Code

X = Standardunit

J = CSD-1, FM, IRI, IL

1.6 Locating Pump-Mounted Water Heater

16 Pump Options

with Respect to Storage Tank(s)

For best results, a pump-mounted Brute Deluxe

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.

H = Pump mounted BMT2V, hard water pump

N = Pump mounted (any), normal water pump

1.3 Warranty

If the appliance must be installed with longer piping

runs, then larger diameter pipe or tubing shall be used.

Consult the factory for assistance.

Bradford White’s appliances are covered by a

limited warranty. Owners should submit online warranty

registration at www.branfordwhite.com.

All warranty claims must be made to an authorized

Bradford White representative or directly to Customer

Service. 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.

1.7 Locating Pump-Mounted Boiler with

Respect to Return/Supply Header

For the best results, a pump-mounted Brute Deluxe

REQUIRED

CLEARANCEFROM

COMBUSTIBLEMATERIAL

RECOMMENDED

SERVICEACCESS

CLEARANCE

APPLIANCE

SURFACE

inches

Left Side

Right Side

Top

2.5

**12**

30**

Back

Front

Vertical

(Category 1)

Vent

Horizontal

(Category 3)

Vent

1.4 Dimensions

15.2*

See Figures 1 and 2.

per UL1738 venting

system supplier’s

instructions

1.5 Locating the Appliance

The appliance should be located to provide

*1" (2.5cm) when b-vent is used.

**When vent and/or combustion air connects to the back, recommended

clearance is 36" (91cm).

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

Table 1. Clearances.

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Brute Deluxe (500-2000)

Page 5

Air

Conn.

Vent

Conn.

Shipping Weight¹

Size

500

lbs

33¾ 85

16¾ 43

6½ 17

10 25

12 30

14 36

425 193

505 229

615 279

675 306

760 345

825 375

955 434

750

45¾ 116

57¾ 147

68¼ 173

78¾ 200

89¼ 227

99¾ 253

22¾ 53

28¾ 73

6½ 17

10¼ 26

10 25

9½ 24

1000

1250

1500

1750

2000

39½ 100

44¾ 113

49¾ 127

12 30

NOTES: 1. Add 55 lbs (25kg) for pump-mounted units.

Dimensions in inches cm.

Figure 1. Dimensional Data (standard units).

1.8 Locating Appliance for Correct

Horizontal Vent/Ducted Air Distance

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.

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).

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Page 6

Air

Conn.

Vent

Conn.

Size

500

33¾

45¾

57¾

68¼

78¾

89¼

99¾

16¾ 43

6½ 17

10 25

46¼

58¼

70¼

80¾

91¼

117

148

178

205

232

750

116

147

173

200

227

253

22¾ 58

28¾ 73

34¼ 87

39½ 100

44¾ 113

49¾ 127

6½ 17

10¼ 26

10 25

9½ 24

10 25

12 30

14 36

1000

1250

1500

1750

2000

101¾ 258

112¼ 285

12 30

Figure 2. Dimensional Data (pump-mounted models).

HORIZONTAL

VENTPIPE

DIAMETER

AIR COLLAR

&PIPE

DIAMETER

VENT COLLAR

SIZE

MAX.PIPE

LENGTH

MAX.NO.

OF ELBOWS

SIDEWALL

COMBUSTION

AIRTERMINAL

SIZE

VENT

TERMINAL

PARTNUMBER

CA001401

CA001402

CA001403

CA001404

PARTNUMBER

20260701

20260703

20260706

500

750

50 15

1000

1250

1500

1750

2000

Table 2. Horizontal Vent / Combustion Air Parameters.

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Brute Deluxe (500-2000)

Page 7

NOTE: 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.

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.

NOTE: When located on the same wall, the Brute Deluxe

combustion air intake terminal must be installed a minimum

of 12" (30cm) below the exhaust vent terminal and sep-

arated 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.

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 IntakeCombustionAir

SECTION 2.

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 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 3).

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 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).

Venting and Combustion Air

2.1 Combustion Air

Brute Deluxe 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 Brute Deluxe 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 CombustionAirFromRoom

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.

The connection for the intake air pipe is on the

filter box. The Brute Deluxe appliances have venting

and combustion air ducting attached to the top.

In addition to air needed for combustion, air shall

also be supplied for ventilation, including all air required

for comfort and proper working conditions for personnel.

The Brute Deluxe loses less than 1 percent of its input

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

EACHOPENING*

UNIT

SIZE

SQUAREINCHES

SQUARECM

500

750

125

188

250

313

375

438

500

807

1213

1613

2020

2420

2826

3226

1000

1250

1500

1750

2000

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 Brute

Deluxe model.

*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.

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

Thischartisforusewhencommunicatingdirectlywiththeoutdoors.

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.

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Page 8

rating to the room, but other heat sources may be present.

may lead to serious injury or death. 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 Venting

2.2.1 VentCategories

Depending upon desired Brute Deluxe 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 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 Brute Deluxe’s

vertical vent system does not satisfy the criteria for

Category I venting, it must be vented as a Category III

system.

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 must be followed.

As an additional precaution, it is recommended that

a Carbon Monoxide (CO) alarm be installed in all

enclosed spaces containing combustion appliances.

Brute Deluxe 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.

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.

All Brute Deluxe vent systems which discharge

horizontally (without the use of a power venter) are

considered Category III vent systems.

2.2.2 CategoryIVent

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 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.

2.2.4 CategoryIIIVent

When the Brute Deluxe 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 (see 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 Instal-

2.2.3 CommonVentingSystems

Brute Deluxe units are Category I fan-assisted

when vented vertically and adhering to all applicable

codes.

When common venting Brute Deluxe 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

TERM

DESCRIPTION

Single-wall galvanized steel pipe, 24 gauge

minimum (either insulated or non-insulated)

Pipe

Joint

Permanent duct tape or aluminum tape

Sealing

Table 4. Required Combustion Air Piping Material.

Figure 3. Combustion Air and Vent Through Roof.

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Brute Deluxe (500-2000)

Page 9

lation 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 1 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.

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 SideWallCombustionAirTerminal

The side wall combustion air terminal (see Table

2) must be used when the unit takes its combustion air

through a duct from a side wall. Consider the following

wheninstallingtheterminal:

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.

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

3. Locate the combustion air terminal so that it cannot

be blocked by snow. The National Fuel gas code

requires that it be at a minimum of 12" above

grade. Depending on local conditions, the installer

should ensure that it remains at least 12" above the

maximum potential snow line. Seek local

The appropriate side wall vent hood must be used,

and is listed in the installation and operation manual.

The terminal provides a means of installing the vent

piping through the building wall, and must be located in

accordance with ANSI Z223.1/NFPA 54 and applicable

local codes. In Canada, the installation must be in

accordance with CSA B149.1 or .2 and local applicable

codes. Consider the following when installing the

terminal:

municipalities and their codes for appropriate

installation techniques.

WARNING: It is critical that the combustion air

intake and the vent terminals remain at least 12"

above the maximum potential snow line. If either

the vent terminal or the air terminal is blocked by

snow, there may be potential for the unit to

produce excess carbon monoxide and or

recirculate flue gasses into the building/dwelling.

Personal injury or DEATH may occur. Natural

snowfall, drifting, and banking should all be taken

into account when locating the terminals in a

potentialsnowenvironment.

1. Figure 4 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. When possible, locations

under windows or near doors should be avoided.

5. Locate the vent terminal so that it cannot be

blocked by snow. The National Fuel gas code

requires that it be at a minimum of 12" above

grade. In a location that has the possibility of snow

accumulation, it is critical the installer places the

vent at least 12" higher than the maximum potential

snow line. Seek local municipalities and their

codes for appropriate installation techniques.

6. Locate the terminal so the vent exhaust does not settle

4. If the Brute Deluxe 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 4).

2.3.3 VerticalVentTerminal

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 3). Seek local

TERM

DESCRIPTION

Pipe

Must comply with UL Standard 1738

such as Type 29-4C Stainless Steel

(either insulated or non-insulated).

Joint

Sealing

Follow vent manufacturer’s instructions

municipalities and their codes for appropriate

installation techniques.

Table 5. Required Horizontal Venting Material.

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U.S. Installations (see note 1)

Canadian Installations (see note 2)

A= Clearance above grade, veranda, porch,

12 inches (30 cm)

36 inches (91 cm)

See note 5

deck, or balcony

B= Clearance to window or door that may be

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

1 foot (30 cm) above opening

See note 4

opened

C= Clearance to permanently closed window

D= Vertical clearance to ventilated soffit located

above the terminal within a horizontal

distance of 2 feet (61cm) from the center

line of the terminal

See note 4

See note 5

E= Clearance to unventilated soffit

F= Clearance to outside corner

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

the meter/regulator assembly

3 feet (91 cm)

extended above meter/regulator assembly

See note 4

I= Clearance to service regulator vent outlet

J= Clearance to nonmechanical air supply inlet

to building or the combustion air inlet to

any other appliance

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

1 foot (30 cm) above opening

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

horizontally

36 inches (91 cm)

6 feet (1.83 m)

K= Clearance to a mechanical air supply inlet

Vent termination not allowed in this location

for category IV appliances. A vent shall not

terminate directly above a sidewalk or paved

driveway that is located between two single

Vent termination not allowed in this location

L= Clearance above paved sidewalk or paved for category IV appliances. For Category III

driveway located on public property

appliances, vent must terminate at least 7

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 currentANSI 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 inANSI 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 4. Combustion Air and Vent Through Side Wall.

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Brute Deluxe (500-2000)

Page 11

of a ProductApproved side wall horizontally vented gas fueled

From Massachusetts Rules and Regulations 248 CMR 5.08:

(a) For all side wall horizontally vented gas fueled equipment

installed in every dwelling, building or structure used in

whole or inpart for residential purposes, including those

owned or operated by the Commonwealth and where the

side wall exhaust vent termination is less than seven (7)

feet above finished grade in the area of the venting,

including but not limited to decks and porches, the

following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented gas

fueled equipment, the installing plumber or gasfitter shall

observe that a hard-wired carbon monoxide detector with an

alarm and battery back-up is installed on the floor level where

the gas equipment is to be installed. In addition, the installing

plumber or gasfitter shall observe that a battery operated or

hard-wired carbon monoxide detector with an alarm is installed

on each additional level of the dwelling, building or structure

served by the side wall horizontal vented gas fueled equipment.

It shall be the responsibility of the property owner to secure the

services of qualified licensed professionals for the installation

of hard-wired carbon monoxide detectors.

equipment does not provide the parts for venting the fuel gases,

but identifies "special venting systems", the following require-

ments shall be satisfied by the manufacturer:

1. The identification of each "special venting system" shall include

either the listing of the website, phone number or

manufacturer's address where the venting system installation

instructions can be obtained; and

2. The "special venting systems" shall be ProductApproved by the

Board, and the instructions provided with that system shall

include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for the Product

Approved side wall horizontally vented gas fueled

equipment, and all the venting instructions, parts lists,

and/or design instructions for the venting system shall

remain with the appliance or equipment at the completion

of the installation.

Manufacturers' websites where venting system installation

instructions may be obtained is located on the website at:

http://www..com.

2.3.4 VerticalCombustionAirTerminal

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 3). 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.

a. In the event that the side wall horizontally vented gas fueled

equipment is installed in a crawl space or an attic, the hard-

wired carbon monoxide detector with alarm and battery back-

up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision cannot

be met at the time of completion of installation, the owner shall

have a period of thirty (30) days to comply with the above

requirements; provided, however, that during said thirty (30)

day period, a battery operated carbon monoxide detector with

an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.Each

carbon monoxide detector as required in accordance with the

above provisions shall comply with NFPA720 and beANSI/UL

2034 listed and IAS certified.

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 con-

nected to the common venting system are not in operation.

1. Seal any unused openings in the common venting

system.

3. SIGNAGE.A metal or plastic identification plate shall be

permanently mounted to the exterior of the building at a

minimum height of eight (8) feet above grade directly in line

with the exhaust vent terminal for the horizontally vented gas

fueled heating appliance or equipment. The sign shall read, in

print size no less than one-half (½) inch in size, "GAS VENT

DIRECTLYBELOW. KEEPCLEAR OFALLOBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall

horizontally vented gas fueled equipment shall not approve the

installation unless, upon inspection, the inspector observes

carbon monoxide detectors and signage installed in accor-

dance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from

248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment Not

Required To Be Vented" in the most current edition of NFPA 54

as adopted by the Board; and

2. ProductApproved side wall horizontal vented gas fueled

equipment installed in a room or structure separate from the

dwelling, building or structure used in whole or in part for

residential purposes.

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.

VENTING SYSTEM PROVIDED. When the manufacturer of

ProductApproved side wall horizontally vented gas equipment

provides a venting system design or venting system compo-

nents with the equipment, the instructions provided by the

manufacturer for installation of the equipment and the venting

system shall include:

1. Detailed instructions for the installation of the venting system

design or the venting system components; and

4. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat

so appliance will operate continuously.

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

system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT

VENTING SYSTEMNOT PROVIDED. When the manufacturer

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Page 12

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.

3.1 Gas Supply and Piping

Gas piping should be supported by suitable

hangers or floor stands, not by the appliance.

Brute Deluxe’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. Brute

DISTANCE FROM GAS METER

SIZE

OR LAST STAGE REGULATOR

AND

GAS TYPE

0-100'

100-200'

200-300'

500 natural

1½"

500 propane

1½"

750 natural

2½"

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

Brute Deluxe.

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). 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.

Combustion air inlets consist of appropriately sized

galvanized pipe and elbows to allow the open end to

face down aside the boiler. This is available as a

Commercial Kit from the manufacturer.

Part numbers for the low profile terminals to cover the

vent and combustion air openings are shown in Table 6.

750 propane

1½"

1000 natural

1½"

2½"

1000 propane

1250 natural

1250 propane

1500 natural

2½"

1500 propane

1750 natural

1750 propane

2000 natural

2½"

3½"

2000 propane

Metric Equivalent

DISTANCE FROM GAS METER

OR LAST STAGE REGULATOR

SIZE

AND

GAS TYPE

0-31m

31-61m

61-91m

500 natural

3.8cm

2.5cm

5.1cm

3.8cm

5.1cm

3.8cm

500 propane

750 natural

5.1cm

3.8cm

5.1cm

3.8cm

6.4cm

5.1cm

750 propane

1000 natural

5.1cm

3.8cm

6.4cm

5.1cm

7.6cm

6.4cm

1000 propane

SECTION 3.

1250 natural

6.4cm

5.1cm

6.4cm

5.1cm

7.6cm

6.4cm

1250 propane

Gas Supply and Piping

1500 natural

6.4cm

5.1cm

6.4cm

5.1cm

7.6cm

6.4cm

7.6cm

6.4cm

7.6cm

6.4cm

7.6cm

6.4cm

1500 propane

OUTDOOR

COMBUSTION

AIRTERMINAL

OUTDOOR VENT

1750 natural

SIZE

TERMINAL

1750 propane

500

750

20254703

20254705

D2007700

D2007800

D2007900

D2008000

D2008200

2000 natural

7.6cm

6.4cm

7.6cm

6.4cm

8.9cm

7.6cm

2000 propane

1000

1250

1500

1750

2000

NOTES: 1. These figures are based on 1/2" (0.12kPa) water column

pressuredrop.

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 Sizes.

Table 6. Vent Terminals for Outdoor Units.

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Brute Deluxe (500-2000)

Page 13

Deluxe appliances are equipped to operate at

elevations up to 10,000 feet (3050m). Brute

Deluxe appliances may be adjusted to operate

properly at altitudes above 2500 feet (see Section

6.6.2) 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).

NOTE: The Brute Deluxe 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.

3. Refer to Table 7, size supply.

SECTION 4A.

Water Connections — Boiler

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.

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.

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.

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

20°F

H/L

25°F

flow

30°F

H/L

35°F

flow

WARNING

Do not use open flame to check for leaks. An open

SIZE

flow

gpm

H/L

flow

H/L

feet

1.7

3.3

5.0

8.1

gpm

feet

gpm

feet

0.9

1.7

3.1

4.7

5.5

8.4

gpm

flame could lead to explosion, which could result in

property damage, serious injury or death.

500

750

1.1

2.3

3.6

6.1

0.7

1.2

2.2

3.4

4.2

5.8

8.3

1000

1250

1500

1750

2000

106

128 10.0 102 7.2

N/R N/R 119 10.5 99

N/R N/R 136 12.5 113 10.4 97

Metric Equivalent

11°C

14°C

flow

lpm

17°C

H/L

19°C

flow

lpm

SIZE

flow

lpm

H/L

flow

lpm

H/L

500

750

1000

1250

1500

1750

2000

161

241

321

401

483

0.5

1.0

1.5

2.5

3.0

129 0.3 107 0.3

0.2

193 0.7 161 0.5 138 0.4

257 1.1 214 0.9 184 0.7

322 1.9 269 1.4 231 1.0

386 2.2 322 1.7 276 1.3

N/R N/R 451 3.2 375 2.6 322 1.8

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

forboiler’sheatexchangeronly. N/R=notrecommended.

Figure 5. Typical Gas Train Configuration.

Table 8. Water Flow Requirements — BMT2H.

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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 (see Figures

6 through 14). These diagrams are meant only as a

guide. Components required by local codes must be

properly installed.

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.

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.

SECTION 4B.

Water Connections —

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.

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.

The Brute Deluxe 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 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.

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 Brute

Deluxe is 120°F (49°C) to avoid condensing on the

copper coils.

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.

4A.4 Freeze Protection — Boiler

Boiler installations are not recommended in areas

where the danger of freezing exists unless proper

Suggested piping diagrams are shown in Figures 10

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Brute Deluxe (500-2000)

Page 15

through 13. These diagrams are meant only as a guide.

Components required by local codes must be properly

installed.

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.

When the system requires water for heating at

temperatures higher than required for other uses, an

anti-scald mixing or tempering valve shall be

installed to temper the water for those uses in order

to reduce scald hazard potential.

The minimum inlet water temperature for the Brute

Deluxe 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 Brute Deluxe 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.5 Freeze Protection – Water Heater

Although Brute Deluxe water heaters are design-

certified for outdoor installations, such installations are

not recommended in areas subject to freezing

temperatures, unless proper precautions are taken.

Power outage, interruption of gas supply, failure of

system components, activation of safety devices, etc., may

prevent a heater from firing. Any time a heater is sub-

jected to freezing conditions, and the heater is not able

to fire, and/or the water is not able to circulate, there is

a risk of freezing in the heater 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 heater,

which could result in leaking or flooding conditions.

Contact the local factory representative or for

additionalinformation.

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 Brute Deluxe 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

Representative if you have questions or concerns about

water quality.

SECTION 5.

Electrical Connections

WARNING

The appliance must be electrically grounded in

accordance with the requirements of the authority

having jurisdiction or, in the absence of such

requirements, with the latest edition of the National

Electrical Code, ANSI/NFPA 70, in the U.S. and with

latest edition of CSA C22.1 Canadian Electrical Code,

Part 1, in Canada. Do not rely on the gas or water

piping to ground the metal parts of the boiler. Plastic

pipe or dielectric unions may isolate the boiler

electrically. Service and maintenance personnel, who

work on or around the boiler, may be standing on wet

floors and could be electrocuted by an ungrounded

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.

boiler.

Single pole switches, including those of safety

controls and protective devices must not be wired in a

grounded line.

4B.4 Combined Water Heating (potable)

and Space Heating — Water Heater

All electrical connections are made in the field

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Figure 6. Hydronic Piping — Multiple Boilers, Primary Secondary System.

Figure 7. Hydronic Piping — Multiple Boilers, Low Temperature System.

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Figure 8. Hydronic Piping — One Boiler, Multi-Temperature System.

Figure 9. Hydronic Piping - Primary-Secondary, Reverse-Return.

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Figure 10. Hydronic Piping - Primary-Secondary, Reverse-Return, Low Temperature.

Figure 11. Water Heater Piping — One Heater, One Tank.

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Figure 12. Water Heater Piping — Multiple Heaters, One Tank.

Figure 13. Water Heater Piping — One Heater, Multiple Tanks.

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Figure 14. Water Heater Piping — Multiple Heaters, Multiple Tanks.

gpm

Temp Rise °F

lpm

Temp Rise °C

Size

500

750

1000

1250

1500

1750

2000

16 10

1.8

2.1

2.3

3.8

3.9

4.0

2.3

3.0

3.6

3.8

3.9

4.0

3.5

6.0

6.1

6.3

6.5

6.7

19 13

170 257 341

257 257 341

424 424 424

0.5 0.7 1.1

0.6 0.9 1.8

0.6 1.1 1.9

1.2 1.2 1.9

1.2 1.2 2.0

3.0 3.0 3.0

28 19 14

38 25 19

31 31 24

38 38 28

44 44 33

30 30 30

21 14 10

17 17 13

21 21 16

24 24 18

17 17 17

112 112 112

10.0 10.0 10.0

NOTES: S = soft water (1 to 7.5 grains hardness).

N = normal water (7.6 to 17 grains hardness).

H = hard water (more than 17 grains hardness).

gpm = gallons per minute; lpm = liters per minute; ft = headloss in feet; m = headloss in meters.

Headloss is for heater's heat exchanger only.

Table 9. Water Flow Requirements — BMT2V.

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Brute Deluxe (500-2000)

Page 21

wiring terminal strip, which is located at the right side of

the appliance.

NOTE: All internal electrical components have been pre-

wired. No attempt should be made to connect electrical

wires to any other location except the wiring box.

NOTE: This pump control is equipped with a delay on

break typically set for 3 minutes, but can be adjusted

between 0.1 and 10 minutes.

Field Interlocks: To install other field-wired

devices to interlock with the boiler (tank stats, louver

switches, flow switches, etc.), remove the jumper

between terminals 3 and 4 and wire the device in series

across these terminals. These terminals are located in

the upper main control panel.

External Control Wiring: These terminals are

located in the upper main control panel (see Section 5.3).

Optional Alarm Contacts: As an option, the Brute

Deluxe is available with an alarm kit. This alarm kit

contains a dry contact for up to 120V which is available

within the 120V field wiring panel. These terminals will be

clearly labeled "Alarm" and are rated up to 10 amps.

5.1 Main Power

The main power requires a 120-volt fused supply that

is connected to the “main power” terminal strip. The over

current protection must be sized as specified ( Figure 15).

The BMT2 pump (pump-mount units) requires a

separate (additional) 120-volt fused supply connected to

the pump terminal strip (also specified in Figure 15).

5.2 Field Wiring

Main Power: The main 120V field wiring panel is

located on the right side of the unit, under the main

power switch. Within this panel are the terminals for

incoming 120V single-phase power clearly labeled on

the right-hand side as “120V (L1)”, “NEUTRAL” and

“GROUND”.

Pump Power: Also located on the 120V field

wiring panel is the pump terminal strip. This strip is

located on the left side (denoted as “120V L2”, “N2

(Pump mounted)” and “GROUND 2 (Pump Mounted)”).

External Pumps: External Pump: All non-pump-

mounted BMT2 units have an internal (dry) contact rated

for 20Amps. A field-supplied pump can be connected

directly to this contact if it does not draw more than 20

Amps. If more current is required, a separate pump

contactor must be installed.

To utilize this internal pump contact, supply 120

volt single-phase power to the terminal marked “120V

(L2)” and supply the pump using the terminal marked

“L2 LOAD (EXT. PUMP)”.

SIZE

500

750

1000

1250

1500

1750

2000

PUMP CIRCUIT MAIN CIRCUIT

15A

20A

15A

20A

Figure 15. Field Wiring.

Figure 16. Brute Deluxe (500–750) Wiring Diagram.

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Figure 17. Brute Deluxe (1000) Wiring Diagram.

Figure 18. Brute Deluxe (1250–2000) Wiring Diagram.

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Brute Deluxe (500-2000)

Page 23

Figure 19. Brute Deluxe (500–750) Connection Diagram.

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Figure 20. Brute Deluxe (1000) Connection Diagram.

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Brute Deluxe (500-2000)

Page 25

Figure 21. Brute Deluxe (1250–2000) Connection Diagram.

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When pressure circuit has been satisfied, proving

combustion air and adequate water flow, the hot surface

igniter will initiate. The ignition control checks that the

igniter current reached a predetermined level then will

dwell momentarily. When dwell time is complete the gas

valve will open.

5.3 External Staging Control Wiring

WARNING

Improper field wiring may result in fire or explosion

which can cause property damage, severe injury, or

death. Make only wiring connections which are in

accordance with the Installation and Operation manual.

After a 4-second trial for ignition, the igniter

switches off. Unless a flame is detected by the flame

sensor (a minimum value of 0.4µA), the gas valve will

close and The ignition module will either attempt

ignition again (up to three times) or will lock out if the

optional lockout ignition module is used.

AVERTISSEMENT

Un câblage incorrect lors de l’installation peut causer

un incendie ou une explosion pouvant entraîner des

dommages matériels, de graves blessures ou la mort.

Ne faire seulement que les connexions conformes au

Manueld’installationetd’exploitation.

If flame is sensed, the burner will continue to fire

as long as there is a call for heat and adequate flame

signal. If there is a subsequent loss of flame signal, the

burner will attempt re-ignition up to three times (only

once if optional lockout ignition is used.) When the call

for heat is satisfied, the gas valves(s) close and the

blowers continues to run for 30 seconds.

If controlling the stages of the BMT2 from an

external source (multiple boiler control, BAS, etc.), wire

Stage 1 to the terminals marked "Input Stage 1" and

"Stage 1", and wire Stage 2 to the terminals marked

"Input Stage 2" and "Stage 2". The "Local/Remote"

selector switch above the terminal strip must be placed

in the "Remote" position for the external controller to

manage the staging.

The pump will continue to run for 0.1 to 10

minutes, depending on what the pump time delay has

been set to. Brute Deluxe sizes 1,000-2,000 have two

ignition controls that control the individual stages. If one

ignition control should fail for any reason, the remaining

module can operate its burners independently. (Note that

if a single blower is disabled on units 1250-2000, the

other fan will continue to operate and safely allow the

boiler to run with a single stage.)

If it is intended to use the BMT2's on-board 2-

stage controller, no extra wiring is necessary. Ensure the

Local/Remote selector switch is in the "Local" position.

SECTION 6.

Operating Instructions

6.2 Filling the System

1. Ensure the system is fully connected. Close all

bleeding devices and open make-up water valve.

Allow system to fill slowly.

6.1 Sequence of Operation

Upon initiation of the main power switch, 120V

will be sent to multiple items. Among these are the open

contact fan relays, open contact ignitor relay, open

contact pump relay, ignition control module(s) and open

contact lock out indicators (the optional alarm package

uses this). In addition to these, 24V will travel through

the optional gas pressure switches and optional auto

reset high limit. 24V will then travel through the block

flue switch and the manual reset high limit to the

temperature controller.

2. If make-up water pump is employed, adjust

pressure switch on pumping system to provide a

minimum of 12 psi (81.8 kPa) at the highest point

in the heating loop.

3. If a water pressure regulator is provided on the

make-up water line, adjust the pressure regulator to

provide at least 12 psi (81.8 kPa) at the highest

point in the heating loop.

4. Open bleeding devices on all radiation units at the

high points in the piping throughout the system,

unless automatic air bleeders are provided at such

points.

5. Run system circulating pump for a minimum of 30

minutes with the boiler shut off.

Upon a call for heat from the BMT2’s internal

control or an external staging control, 24V travels

through the field interlock (if closed) and then to the

ignition control(s) “T-stat” terminal (500-750 models are

equipped with one ignition control and models 1000-

2000 are equipped with two ignition controls).

When “T-stat” on an ignition control is energized,

its fan will energize and the ignition control will seek

signal from the “pressure circuit”. The pressure circuits

consist of the flow switch and proof of fan.

Sizes 500-1000 calls for fan, fan prove, initiate

pump then prove flow, after which “pressure circuit” has

been satisfied.

Sizes 1250-2000 calls for pump, proof of flow,

initiate fan then prove fan, after which “pressure circuit”

has been satisfied. The fan prove will only occur for the

active stage that has been called.

6. Open all strainers in the circulating system, check

flow switch operation, and check for debris. If debris

is present, clean out to ensure proper circulation.

7. Recheck all air bleeders as described in Step 4.

8. Check liquid level in expansion tank. With the

system full of water and under normal operating

pressure, the level of water in the expansion tank

should not exceed ¼ of the total, with the balance

filled with air.

9. Start up system according to the procedure in this

manual. Operate the entire system, including the

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Brute Deluxe (500-2000)

Page 27

pump, boiler, and radiation units for one (1) hour.

10. Recheck the water level in the expansion tank. If

the water level exceeds ¼ of the volume of the

expansion tank, open the tank drain, and drain to

that level.

Because the Brute Deluxe controller senses inlet

water and the manual reset high limit senses outlet water,

the high limit should be set 40-50°F higher than the

controller, to avoid nuisance lockout of the manual reset

highlimit.

11. Shut down the entire system and vent all radiation

units and high points in the system piping, as

described in Step 4.

6.4 External Boiler Operations

If controlling the stages of the BMT2 from an

external source (multiple boiler control, BAS, etc) the

"Local/Remote" selector switch above the terminal strip

must be placed in the "Remote" position. In this mode,

the controller that is mounted on the BMT2 will no

longer have control of the unit. The 24V from the unit

waits at the input terminal, and the external control

switches this 24V from the input terminal to the stage

terminal.

12. Close make-up water valve and check strainer in

pressure reducing valve for sediment or debris

from the make-up water line. Reopen make-up

water valve.

13. Check gauge for correct water pressure and also

check water level in the system. If the height

indicated above the boiler insures that water is at

the highest point in the circulating loop, then the

system is ready for operation.

14. Refer to local codes and the make-up water valve

manufacturer’s instructions as to whether the make-

up water valve should be left open or closed.

15. After placing the unit in operation, the ignition

system safety shutoff device must be tested. First,

shut off the manual gas valve, and call the unit for

heat. After the pre-purge and ignitor heat-up time,

the main gas terminals will be energized, attempting

to light, for four (4) seconds, and then will de-

energize. The unit will go into lockout mode.

Second, turn the power off and then on again, open

the manual gas valve and allow the unit to light.

While the unit is operating, close the manual gas

valve and ensure that power to the main gas valve

has been cut.

6.5 Limit Controls

The manual reset high limit control is provided as

standard equipment on all heaters. An additional

automatic reset switch is optional.A high limit

temperature-sensing bulb is always located in the heater

outlet. Burners will automatically shut down whenever

overheating occurs.

6.6 Operating the Burner and Set Up

6.6.1 Set Up for 0 to 2500 Feet Altitude

The Brute Deluxe appliance utilizes a modular

16. Within three (3) days of start-up, recheck all air

bleeders and the expansion tank as described in

Steps 4 and 8 above.

Important: The installer is responsible for identifying to

the owner/operator the location of all emergency shutoff

devices.

WARNING

Do not use this appliance if any part has been under

water. Immediately call a qualified service technician

to inspect the appliance

and to replace any part of the control system and any

gas control that may have been

under water.

6.3 Operating Temperature Control

All Brute Deluxe's are equipped with a two-stage

aquastat. To utilize this mounted controller be sure to

have the "Local/Remote" selector switch to "Local". Set

the controller to the desired operating set point. The

controller has an interstage differential that can be

adjusted from 3°F to 10°F. This allows the user to have

some control over how stage 2 and stage 1 call for heat

(see Figure 22).

Difference between the temperatures at which the two switches

make R-W. Adjustable from 3°F to 10°F (1.7°C to 5.6°C) on standard

models, or from 3.6°F to 12°F (2.0°C to 6.7°C); 55°F to 175°F (13°C

to 79°C) models.

2 Two DPDT switches operate in sequence. Each switch

differential is fixed at approximately 3°F (1.7°C) on standard models,

or 3.6°F (2.0°C); 55°F to 175°F (13°C to 79°C) models.

Figure 22. Honeywell L8008G.

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design to achieve its stage-firing. The setup must be

checked before the unit is put in operation. Problems

such as failure to start, rough ignition, strong exhaust

odors, etc. can be due to improper setup. Damage to the

Brute Deluxe resulting from improper setup is not

covered by the limited warranty.

light the main burners for that stage, the second ignition

control will still be active, and will be able to energize

stage 2. This, of course, will only occur upon call for

stage 2 and if all other safety devices confirm that the

unit will run in a safe condition.

1. Using this manual, make sure the installation is

complete and fully in compliance with the

instructions.

6.6.2 HighAltitudeAdjustmentandSetUp

Brute Deluxe appliances may be operated at high

altitude (7700 ft., 2347 m) with a reduction in output of

approximately 10%. At altitudes of less than or more than

7700 ft. (2347 m) the appliance will perform equally as

well, but with differing reductions in output. At elevations

higher than 7700 ft. (2347 m) the reduction in output will

exceed 10% and at elevations below 7700 ft. (2347 m) it

will be less than 10%. High altitude adjustment must not be

made on appliances operating at elevations below 2500 ft.

(762 m).

2. Determine that the appliance and system are filled

with water and all air has been bled from both.

Open all valves.

3. Observe all warnings on the Operating Instructions

label and turn on gas and electrical power to

appliance.

4. Switch on the appliance power switch located on

the right side of the unit.

5. The Brute Deluxe will enter the start sequence, as

long as the unit is being called for heat. The blower

and pump come on for pre-purge, then the ignitor

warm-up sequence starts and after the ignitor

warm-up is complete and all safety devices are

verified, the gas valves open. If ignition doesn’t

occur, check that there is proper gas supply. Wait 5

minutes and start the unit again. During initial start

up, air in the gas line may cause the Brute Deluxe

to "lock out" during the first few trials for ignition.

Depending on the ignition modules installed, the

manual reset button on the ignition modules may

need to be depressed to restart the Brute Deluxe.

6. When the unit is running, the supply gas pressure

must be checked. Inlet gas pressure must not

exceed 13" W.C. (3.2kPa). The minimum inlet gas

pressure is 5" W.C. (1.2kPa).

No orifice changes are required to adjust the Brute

Deluxe appliances for high altitude. High altitude

adjustment is accomplished by adjustment of the gas

valve manifold pressure and the air shutter(s). The

required instruments used to assist in these adjustments

are a CO₂or O₂Analyzer and a U-Tube Manometer or

other device capable of reading a pressure of 2.5-3.0

inches W.C. (0.62-0.75 kPa).

Start the adjustment process by checking the CO₂

in the “as installed” condition. Adjust the air shutter(s)

so that the CO₂is about 8% or the O₂is about 6.8% for

appliances operating on Natural Gas. For appliances

operating on LP Gas adjust the air shutter(s) so that the

CO₂is about 9.2% or the O₂is about 6.8%. Appliances

with two blowers should be adjusted so that the air

shutters below each blower are open the same amount.

Once the CO₂or O₂has been set, the manifold

pressure may be adjusted. Remove the 1/8 NPT plug

from the lower side of the gas valve that is to be set and

install a fitting, hose and manometer. Start the appliance

and observe the manifold pressure. Manifold pressure

must be adjusted to 3.0 in. W.C. (0.75 kPa) (for high

altitude only, standard operating pressure is 2.5 in. W.C.

(0.62 kPa)). It is adjusted by removing the slotted cap on

the gas valve and turning the adjustment screw (beneath

the cap) clockwise to increase pressure and replaced

after the adjustments have been completed and the

fitting, hose and manometer have been removed and the

1/8" plug has been replaced. Repeat this process until all

gas valves have been set. Note: The pressure can be set

only when the appliance is operating and only when the

particular gas valve being adjusted is energized by a call

for heat from the staging control.

7. Once the inlet gas pressure is verified, the outlet

gas pressure from each valve (manifold gas

pressure) must be checked, and adjusted, if

necessary. The manifold gas pressure must be 2.5"

W.C. (0.62kPa).

8. Complete the setup by checking the CO at the

outlet of the unit. The CO should be 8% for

natural gas, or 9.2% for propane.

9. After placing the appliance in operation, the

Burner Safety Shutoff Device must be tested.

(a) Close gas shutoff valve with burner operating.

(b) The flame will go out and blower will

continue to run for the post purge cycle. One

additional attempt to light will follow. Ignition

will not occur as the gas is off. The ignition

control will lockout, and will have to be reset

before the unit will operate.

After all of the gas valve manifold pressures have

been set, the CO₂or O₂must be reset. CO₂or O₂will

have changed when the manifold pressure was adjusted.

Open the air shutter(s) to reduce the CO₂or O₂to the

values achieved previously.

The procedure is complete when all gas valves are

adjusted to a manifold pressure of 3.0 in. W.C. (0.75

kPa) and the CO₂is adjusted to 8.0% for Natural Gas

The ignition sequence will start again and the

burner will start. The appliance will return to

its previous mode of operation.

NOTE: Unit sizes 1000–2000 have two ignition controls

and two ignitors, which work independently of one

another. If the ignition control for stage 1 fails to properly

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Brute Deluxe (500-2000)

Page 29

appliances or 9.2% for LP appliances (to be checked

only at full fire). When using an O₂analyzer, the correct

O₂is 6.8% for both Natural Gas and LP appliances.

protected from freezing.

6. Low water cutoffs, if installed, should be checked

every 6 months. Float type low water cutoff should

be flushed periodically.

7. Inspect flue passages, and clean with brushes/

vacuums, if necessary. Sooting in flue passages

indicates improper combustion. Determine the

cause and correct.

8. Inspect the vent system and air intake system, and

if the vent system is Category III, ensure that all

joints are sealed properly. If joints need to be

resealed, completely remove existing sealing

material, and clean with alcohol. Apply new sealing

material, and re-assemble.

Caution

Should any odor of gas be detected, or if the gas

burner does not appear to be functioning in a normal

manner, close main shutoff valve, do not shut off

switch, and contact your heating contractor, gas

company, or factory representative.

6.7 Shutting Down the Brute Deluxe

1. Switch off the main electrical disconnect switch.

2. Close all manual gas valves.

3. If freezing is anticipated, drain the Brute Deluxe and

be sure to also protect building piping from freezing.

This step to be performed by a qualified service

person.

7.2 Appliance Maintenance and

Component Description

Only genuine replacement parts should be used.

Caution

6.8 To Restart the Brute Deluxe

If drained, follow Section 6.2 in this manual for

proper filling and purging.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dan-

gerous operation. Verify proper operation after servicing.

1. Switch off the main electrical disconnect switch.

2. Close all manual gas valves.

3. WAIT FIVE (5) MINUTES.

See Figure 5 for location of gas train components.

The gas and electric controls on the appliance are

engineered for long life and dependable operation, but

the safety of the equipment depends on their proper

functioning. It is strongly recommended that a qualified

service technician inspect the basic items listed below

every year.

4. Set the aquastat or thermostat to its lowest setting.

5. Open all manual gas valves.

6. Reset all safety switches (pressure switch, manual

reset high limit, etc.).

7. Set the temperature controller to the desired

temperature setting and switch on electrical power.

8. Burner will go through a prepurge period and

ignitor warm-up period, followed by ignition.

a. Ignitioncontrols

b. Ignitors

c. Water temperature control

d. Automatic gas valve

e. Pressure switches

SECTION 7.

Maintenance

Blowers

7.2.1 Burners

7.1 System Maintenance

Close main manual gas valve before proceeding.

Checking the burners for debris - Remove the ignitor

inspection panels(s) and ignitor(s) and inspect the burners

through the ignitor hole(s) using a flashlight to illuminate.

If there is any indication of debris on the burners that are

visible, all the burners will need to be inspected more

thoroughly. Remove the screws from around the front of

the air box (large panel from which the ignitor inspection

panel(s) were removed), and remove the large panel.

Remove the gas manifold assemblies and the burner

panels. Inspect the burners. Clean burners, if necessary,

by blowing compressed air from the outside of the

burners into the center of the burner. A dirty burner may

be an indication of improper combustion or dirty

combustion air. Determine the cause, and correct.

Replace the burners in the reverse order

1. Lubricate the system water-circulating pump, if

required, per the instructions on the pump.

2. If a strainer is employed in a pressure reducing

valve or the piping, clean it every six months.

3. Inspect the venting system for obstruction or

leakage at least once a year. Periodically clean the

screens in the vent terminal and combustion air

terminal (when used).

4. Keep the appliance area clear and free from

combustible materials, gasoline, and other

flammable vapors and liquids.

5. If the appliance is not going to be used for

extended periods in locations where freezing

normally occurs, it should be isolated from the

system and completely drained of all water. All

systems connected to it should also be drained or

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7.2.2 Filter

7.2.7 Ignitors/Sensor

The filter used in the Brute Deluxe is washable

with an 83% arrestance. Since the filter is washable, it

will only need replacement when unwashable,

deteriorated or damaged. If filter replacement is needed,

it should only be replaced with a factory part. Inspect the

air filter. If there is debris on the air filter, remove it from

the filter box, and wash it with mild soap and water.

Ensure that the filter is completely dry before re-

installing, in reverse order.

The ignitor/sensor used are 120v "hot surface"

type. They are energized whenever there is a call for

heat and switched off when ignition is established and

flame has been sensed. Brute Deluxe sizes 500 and 750

have one ignitor/sensor. Sizes 1000 to 2000 have two

ignitor/sensors. To replace the ignitor/sensor, shut off the

120-volt power to the appliance, remove the ignitor

access panel, disconnect the Molex connector, remove

the two mounting screws on the ignitor/sensor flange and

pull the ignitor out. ((Hot Surface) Ignitor and the Flame

Sensor are the same items). Install in reverse order,

always using a new ignitor gasket with the replacement

ignitor.

7.2.3 Gas Valves

The gas valves are designed to operate with supply

pressures of 4-13 inches w.c. (1.0 to 3.2 kPa).

To remove a valve, shut off 120-volt power and the

manual gas shutoff valve. Remove the top front panel from

the unit. Disconnect the wires to the valve. Disengage the

flanged fitting before and after the valve, and remove the

valve. Re-install in reverse order. Ensure o-rings are

properly installed for both inlet and outlet. Turn on manual

gas shutoff valve and 120 volt power and check appliance

operation and tightness of gas valve connections.

Caution

Ignitor gets hot.

7.2.8Transformer

The transformer is not capable of supplying control

voltage for external devices such as zone valves, which

must have their own separate power supply. Should a

transformer need replacing, shut off the 120-volt power.

Unplug the transformer wires, remove the mounting

screws and remove the transformer. Replace transformer

in the reverse order.

7.2.4 ManualResetHighLimitControl

The high limit switch is manual reset switch with an

adjustable set point, up to 240°F (116°C) on boiler

models and 200°F (93°C) on water heater models and

boilers ordered with low temperature controls. To

replace the switch, shut off the 120-volt power to the

appliance. Remove the cover from the switch to access

the mounting screws. Remove the screws, and pull the

switch off the control panel. Remove the capilliary and

bulb from the thermal well located in the header.

Replace in reverse order.

7.2.9 Blowers

The combustion air blowers bring the combustion

air for the Brute Deluxe from the upper chamber to the

lower chamber. Mixing of the gas and air occurs in the

burners. Sizes 500, 750 and 1000 each have one blower,

and sizes 1250 to 2000 each have two blowers. If a

blower change is required, turn off the 120-volt power

and gas supply to the unit. Remove the front panel.

Disconnect the blower's wire harness. Remove the

screws at the blower flange, and pull the blower out.

Replace blower in reverse order, ensuring that all joints

are made correctly. After replacement, ensure that the

unit operates properly, by following the set-up procedure

in this manual.

7.2.5 TemperatureControl

The temperature control is a Honeywell L6008. To

replace the control, shut off the 120-volt power to the

appliance. Remove the cover from the control panel, and

remove the mounting screws to remove the controller.

Replace in reverse order.

7.2.6 IgnitionControls

7.2.10 Flow Switch

The ignition controls ensure the proved interrupted-

type ignition system. They control the hot surface

ignitors and prove that the flame signal is appropriate for

powering the gas valves. It also controls the blower’s

pre-purge and post-purge. Brute Deluxe sizes 500 and

750 have one ignition control. Sizes 1000 to 2000 have

two ignition controls. On sizes up to 750, one ignition

control controls stages 1 and 2. On unit sizes 1000–

2000, one ignition control is for stage 1, and the other is

for stage 2.

To replace a control, shut off the 120-volt power to

the appliance. Remove the cover from the control panel.

Remove the electrical connectors from the ignition control.

Take out the controller’s mounting screws, and pull the

controller out. Replace in reverse order.

The Brute Deluxe uses a paddle-type flow switch

to ensure that the unit has water flow before ignition is

allowed.

7.2.11 Heat Exchanger Coil

WARNING

Black carbon soot buildup on a dirty heat exchanger

can be ignited by a random spark or flame, thereby

creating a risk of fire or explosion.. To prevent this

from happening, dampen the soot deposits with a wet

brush or fine water spray before servicing the heat

exchanger.

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Brute Deluxe (500-2000)

Page 31

The Brute Deluxe has a pre-mixed burner system.

These systems provide the burners with sufficient air for

complete combustion, and black carbon sooting is

seldom experienced. If sooting is suspected, view ports

for inspection of the heat exchanger are provided on the

right side of the boiler. They are located below the

headers, and are accessed by opening the small round

cover that is attached by one screw. In the unlikely event

that there is a buildup of black carbon soot or other

debris on the heat exchanger, clean per the following:

flow. If the tubes show signs of scaling, clean the

internal surface. offers a tube cleaning kit, part

number R0010000.

11. Reassemble in the reverse order, and check

appliance operation after start-up.

NOTE: The Warranty does not cover damage caused

by lack of required maintenance, lack of water flow,

or improper operating practices.

1. Disconnect the electrical supply to the unit.

SECTION 8.

2. Turn off the gas supply by closing the manual gas

Trouble Shooting

valve on the heater.

3. Disconnect and remove the wires, conduit and

sensors from all components that are attached to

the inlet/outlet header.

8.1 Resolving Lockouts

There are many causes of lockouts. The three most

common causes are: (1) inadequate gas supply, (2) poor

combustion, (3) ignitor failure.

4. Isolate the heat exchanger from the water supply.

5. Disconnect the header flanges from the inlet and

1. Inadequate gas supply: Before proceeding, ensure

that the gas supply has not been shutoff or the LP tank

(LP boilers) is not empty. Then, restart the boiler and

observe the operational cycle. After a 15-second fan

pre-purge, the ignitor will heat up for 20 seconds, and

then the unit will light. If it does not, check the gas

supply pressure to the appliance, after resetting the

appliance and attempting another start-up. The gas

pressure to the appliance must be above 5" W.C.

(1.2kPa) throughout the entire start-up cycle. If it is

not, correct the supply problem (check gas valves or

supply piping). If the supply pressure is adequate,

consult the factory for assistance.

outlet.

6. Allow the heat exchanger to drain. Remove the

front cover(s) by removing the rubber access

strip(s) and the retaining screws. Remove the

venting and remove the top, by removing the

screws that attach the top to the side panels.

Remove the side panels. Remove the front lower

panels sealing the combustion area. To remove the

gas train, disconnect the unions located below the

intermediate pan and the field installed union

located outside the cabinet, and pull up, bringing

the union end connectors through the grommets in

the intermediate pan. To remove the intermediate

pan, remove the slide out control assembly and

blower(s) to reveal the screws. Remove the screws

holding the intermediate pan, and lift up to remove

it. The heat exchanger has integral metal sections

attached, which connect to the frame of the boiler.

Locate and remove the screws along the front, rear

and bottom of the integral metal sections, and

remove the heat exchanger and metal sections by

lifting up. On the larger appliances, a center heat

exchanger support must be unbolted before it can

be removed.

7. Remove the heat exchanger from the unit. Note:

The heat exchangers are heavy and may require

two people to remove to avoid personal injury.

8. Clean the heat exchanger: A light accumulation of

soot or corrosion on the outside of the heat exchanger

can be easily removed. Use a wire brush to remove

loose soot and scale from the heat exchanger. Do not

use water or compressed air for cleaning.

9. Note: While the heat exchanger is out of the unit,

inspect the firewall refractory insulation. Replace if

necessary.

10. Inspect the inside of the copper tubes for scale

buildup. Scale can build up on the inner surface of

the heat exchanger tubes, which can restrict water

2. Poor combustion: Poor combustion should be

suspected if there is a strong flue gas odor. The

odor may result from an improper gas/air ratio

(high or low O₂or CO₂). Brute Deluxe appliances

operate best with 45% excess air (8% CO₂on

natural gas, 9.2% CO₂on LP). Check the CO₂of

the appliance and adjust if necessary.

3. Ignitor failure: If the boiler goes through a normal

start cycle but combustion does not occur, ignitor

failure should be suspected. Check the ignitor by

unplugging the ignitor plug and measuring the

ignitor resistance. It should be 50-80 ohms at room

temperature. If the resistance is not 50-80 ohms,

replace the ignitor. If the resistance is correct, reset

the boiler and check for 120 VAC at the ignitor

plug during the start cycle. If there is no voltage,

replace the faulty ignitor wire harness or the

ignitioncontrol.

8.2 Delayed Ignition — Possible Causes

A defective burner can cause a delayed ignition. If

the gas supply pressure is proper and the gas valves are

functioning properly, then burners should be inspected.

There should be no distortion or perforations in the

burners outside of the active burner port area. Replace if

indicated.

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BRADFORD WHITE CORP.

Page 32

8.3 Short Cycling — Boiler

SECTION 9.

Because the Brute Deluxe is a stage-fired boiler,

and its input will decrease when there is a reduction in

heating load, short cycling is greatly reduced. If the

heating load drops below the minimum input of the

boiler for an extended period, the boiler will have a

tendency to short cycle. This can be a symptom of

improper control strategy or setpoints, or a load

distribution problem. Contact your representative to

discuss possible remedies.

Replacement Parts

Only genuine replacement parts should be used.

9.1 General Information

To order or purchase parts for the Brute Deluxe,

contact your nearest dealer or distributor. If they cannot

supply you with what you need, contact Customer

Service (see back cover for information).

9.2 Parts List - see next page.

8.4 Short Cycling — Water Heater

Short cycling will generally occur only in

combination space heating and water heating

applications when the water heater is operating in the

space-heating mode. Because the Brute Deluxe is a

stage-fired water heater and its input will reduce when

there is a reduction in heating load, short cycling is

greatly reduced. If the heating load drops below the

minimum input of the water heater for an extended

period, the water heater will have a tendency to short

cycle. If short cycling is frequently experienced,

regardless of the control’s attempt to limit it, the heating

load should be redistributed to control it.

If short cycling occurs in a water heater application,

it is probably caused by undersized piping between the

water heater and the storage tank or by some other factor

that restricts proper water flow through the water heater.

The cause should be determined and corrected.

8.5 High Gas Consumption

Appliances operating with an improper air/fuel

ratio are very inefficient and consequently, have very

high gas consumption. Because efficiency is high when

the CO₂is high (or O₂is low), appliances operating with

low CO₂or high O₂(especially LP appliances) consume

more gas. Adjust the CO₂or O₂for optimum efficiency.

If no combustion analyzing equipment (CO₂or O₂) is

available then a proper adjustment of the air/fuel ratio

(CO₂or O₂) cannot be accomplished. However, by

briefly sniffing the flue gases it is possible to determine

if the CO₂or O₂is within the proper range. No

significant flue gas odor should be detected when

combustion is proper. A strong piercing smell indicates

poor combustion and generally a lean mixture - low CO₂

or high O₂. The CO₂should be 8% at high fire. To check

the CO₂, first verify that the supply gas pressure is

within 5" to 13" w.c. (1.2 to 3.2 kPa) With the Brute

Deluxe running with all stages firing, set the air box

pressure to 1.5" w.c. (0.37 kPa) (as a starting point), by

adjusting the air shutter(s) at the bottom of the fan(s).

Check the CO₂, and adjust the air shutters if further

adjustment to the CO₂is needed. Sizes 1250 to 2000

have two blowers and two air chambers (boxes). The

pressure of each air box must be equal when the final

adjustment is made.

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Brute Deluxe (500-2000)

Page 33

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BRADFORD WHITE CORP.

Page 34

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Brute Deluxe (500-2000)

Page 35

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BRADFORD WHITE CORP.

Page 36

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Brute Deluxe (500-2000)

Page 37

Figure 23. Sheet Metal Components.

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BRADFORD WHITE CORP.

Page 38

Figure 24. Internal Components.

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Brute Deluxe (500-2000)

Page 39

Brute Deluxe Water Heater

Brute Deluxe Hydronic Boiler

Size

Pump p/n

Size

500

750

1000

1250

1500

1750

2000

Pump p/n

A2001700

A2001800

A2001900

A2109700

Soft Water

A2001700

A2001900

A2109700

Normal Water

A2001700

A2001800

A2001900

A2109700

Hard Water

A2001900

A2109700

500

750

1000

1250

1500

1750

2000

Figure 25. Heat Exchanger Components.

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BRADFORD WHITE CORP.

Page 40

Figure 26. Electrical Components.

Bradford White Company reserves the right to change specifications, components, features, or to discontinue products without notice.

Ambler, PA19002

Tech. Service (800) 334-3393

Service Parts (800) 538-2020

Warranty Service (800) 531-2111

www.BradfordWhite.com

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