Installation and Operation Instructions
Document 1270
Installation and Operation
Instructions for
™
Copper Brute II
Hydronic Boiler
Model BWCH
Water Heater
Model BWCV
Sizes 500-2000
U.S. Reg. 2,765,423
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler installation and maintenance. Improper installation and/or operation could
create carbon monoxide gas in flue gases which could cause serious injury, property damage, or
death. Improper installation and/or operation will void the warranty. For indoor installations, as an
additional measure of safety, Bradford White strongly recommends installation of suitable Carbon
Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
AVERTISSEMENT
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d’incendie ou d’explosion ou
pour éviter tout dommage matériel, toute blessure
ou la mort.
WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from
a nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed
by a qualified installer, service agency, or gas
supplier.
Ne pas entreposer ni utiliser d’essence ni d’autres
vapeurs ou liquides inflammables dans le voisinage
de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous
servir des téléphones dansle bâtiment où vous
trouvez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions
du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés par
un installateur ou un service d’entretien qualifié ou
par le fournisseur de gaz.
238-50605-00A REV 12/13
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COPPER BRUTE II (500 - 2000)
Page 3
SECTION 6.
Operating Instructions
SECTION 7.
Maintenance
6.1
6.2
6.3
Sequence of Operation.................................. 36
Filling the Boiler System ................................ 36
Programming the Temperature Control ......... 37
7.1
System Maintenance..................................... 48
7.2
Appliance Maintenance and
Component Description................................. 48
7.2.1 Burners .......................................................... 48
7.2.2 Filter............................................................... 48
7.2.3 Gas Valves..................................................... 48
7.2.4 Manual Reset High Limit Control................... 48
7.2.5 Automatic Reset High Limit Control............... 48
7.2.6 Temperature Control...................................... 49
7.2.7 Ignition Controls............................................. 49
7.2.8 Ignitors........................................................... 49
7.2.9 Ignition Sensors............................................. 49
7.2.10 Transformer ................................................... 49
7.2.11 Blowers.......................................................... 49
7.2.12 Flow Switch ................................................... 49
7.2.13 Heat Exchanger Coil...................................... 49
6.3.1 System Piping................................................ 37
6.3.2 Choosing the Mode........................................ 37
6.3.3 Programming ................................................. 38
6.3.4 Choosing the Mode for your Application........ 40
6.4
Advanced Topics............................................ 42
6.4.1 Differential...................................................... 42
6.4.2 Staging Mode................................................. 42
6.4.3 Boiler Minimum (BOIL MIN)........................... 43
6.4.4 Boiler Maximum (BOIL MAX)......................... 43
6.4.5 Boiler Target Temperature ............................. 43
6.4.6 Pump Operation............................................. 43
6.4.7 Setpoint Operation ........................................ 44
6.4.8 Dedicated Domestic Hot Water ..................... 44
6.4.9 Outdoor Reset Operation............................... 44
6.4.10 External Boiler Operation .............................. 46
6.4.11 Limit Controls................................................. 46
6.4.12 Advanced Programming Mode...................... 46
SECTION 8.
Trouble Shooting
8.1
8.2
8.3
8.4
8.5
8.6
8.7
Resolving Lockouts........................................ 51
Delayed Ignition – Possible Causes.............. 51
Short Cycling – Boiler.................................... 51
Short Cycling – Water Heater........................ 51
High Gas Consumption.................................. 51
Troubleshooting the Temperature Control ..... 51
Troubleshooting Copper Brute II Controls ..... 51
6.5
Operating the Burner and Set Up.................. 46
6.5.1 Set Up for 0 to 2500 Feet Altitude.................. 46
6.5.2 High Altitude Adjustment and Set Up............. 47
6.6
6.5
Shutting Down the Copper Brute II................ 47
To Restart the Copper Brute II....................... 47
SECTION 9.
Replacement Parts
9.1
General Information....................................... 54
9.2
Parts List........................................................ 54
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BRADFORD WHITE CORP.
Page 4
1.1 Introduction
SECTION 1.
This manual provides information necessary
for the installation, operation, and maintenance of
Bradford White Corp, Copper Brute II copper tube
appliances. Read it carefully before installation.
All application and installation procedures
should be reviewed completely before proceeding
with the installation. Consult the Bradford White
factory, or local factory representative, with any issues
or questions regarding this equipment. Experience
has shown that most operating issues are caused by
improper installation.
General Information
USING THIS MANUAL – Because the
Copper Brute II Boilers and Copper Brute II Water
Heaters are identical appliances, with the exception
of materials of manufacture, labels and ultimate
use application, this manual provides information
for the proper installation, operation and
maintenance of both products. Where differences
exist between the application of the appliances and
their operation, the sections pertinent to only one
appliance or the other will be so identified.
In the Commonwealth of Massachusetts, this
appliance must be installed by a licensed plumber or
gas fitter.
The Copper Brute II appliance is protected
against over pressurization. A pressure relief valve
is fitted to all appliances. It is installed on the outlet
header, at the water outlet of the appliance.
IMPORTANT: The inlet gas pressure to the appliance
must not exceed 13" w.c. (3.2kPa).
WARNING
The Copper Brute II hydronic, boiler or water
heater must be installed in accordance with the
procedures detailed in this manual, or the Bradford
White warranty may be voided. The installation must
conform to the requirements of the local jurisdiction
having authority, and, in the United States, to the
latest edition of the National Fuel Gas Code, ANSI
Z223.1/NFPA54. In Canada, the installation must
conform to the latest edition of the Natural Gas
and Propane Installation Code, CSA B149.1 and/
or local codes. Where required by the authority
having jurisdiction, the installation of Copper Brute
II appliances must conform to the Standard for
Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1. Any modifications to
the boiler, its gas controls, or wiring may void the
warranty. If field conditions require modifications,
consult the factory representative before initiating
such modifications.
All installations must be made in accordance with:
1) In the U.S., the " National Fuel Gas
Code"ANSI Z223.1/NFPA54, Latest Edition and all
applicable local codes as required by the Authorities
Having Jurisdiction (AHJ), or
2) In Canada, the "Natural Gas and Propane
Installation Code", CSA B149.1, latest edition and all
applicable local codes as required by the AHJ.
All electrical wiring is to be done in accordance with:
1). In the U.S., the "National Electrical Code"
(NEC), ANSI/NFPA 70, latest Edition and all
applicable local codes as required by the AHJ, or
2). In Canada, the “Canadian Electrical Code
- Part 1”, CSA STD. C22.1 and all applicable local
codes as required by the AHJ.
This appliance must be electrically grounded in
accordance with the applicable codes and standards
referenced above.
1.2 Model Identification
Consult the rating plate on the unit. The
following information describes the model number
structure.
1
2
3
4
5
6
7
8
9
10
A
11
C
12
13
2
14
15
16
B
W
C
SERIES
SIZE
LOCATION
REVISION
USAGE
FUEL
ALTITUDE
FIRING
MODE
HEAT
EXCHANGER
OPTIONS
CODE
PUMP
OPTIONS
B
W
C
H
V
0
5
0
0
0
0
0
0
0
0
N
A
C
2
K (500/750)
N (1000)
B
C
K
N
P
S
X
J
L
X
H
N
S
0
1
1
1
1
2
7
0
2
5
7
0
5
0
5
0
5
0
P
L (1250-2000)
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COPPER BRUTE II (500 - 2000)
Page 5
Model Character Designation
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.
1-3 Model Series Designation
B W C = Bradfrod White, Copper Brute II
4
Usage
H = Hydronic
V = Volume Water
5-8 Size
0 5 0 0 = 500,000 BTU/h input
0 7 5 0 = 750,000 BTU/h input
1 0 0 0 = 999,000 BTU/h input
1 2 5 0 = 1,250,000 BTU/h input
1 5 0 0 = 1,500,000 BTU/h input
1 7 5 0 = 1,750,000 BTU/h input
2 0 0 0 = 1,999,000 BTU/h input
Fuel
1.4 Dimensions
See Figure 1.
1.5 Locating the Appliance
The appliance should be located to provide
clearances on all sides for maintenance and inspection.
It should not be located in an area where leakage of
any connections will result in damage to the area
adjacent to the appliance or to lower floors of the
structure.
9
N = Natural Gas
P = Propane
10 Altitude
A = 0-10,000 feet
11 Location
C = Indoor and Outdoor
12 Firing Mode
K = Two-stage (models 500 & 750)
When such a location is not available, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance.
The appliance is design certified by CSA-
N = Three-stage (model 1000)
International for installation on combustible flooring;
in basements; in closets, utility rooms or alcoves.
Copper Brute II Boilers or Water Heaters must
never be installed on carpeting. The location for the
appliance should be chosen with regard to the vent
pipe lengths and external plumbing. The unit shall be
installed such that the gas ignition system components
are protected from water (dripping, spraying, rain, etc.)
during operation and service (circulator replacement,
control replacement, etc.). When vented vertically, the
Copper Brute II must be located as close as practical
to a chimney or outside wall. If the vent terminal and/
or combustion air terminal terminate through a wall,
and there is potential for snow accumulation in the
local area, both terminals should be installed at an
appropriate level above grade.
L = Four-stage (models 1250 - 2000)
13 Revision
2 = Second version
14 Heat Exchanger
B = Glass-lined CI / copper / brz trim (std. BWCV)
C = Glass-lined cast iron / copper (standard BWCH)
K = Bronze / copper
N = Glass-lined cast iron / cu-nickel
P = Glass-lined cast iron / cu-nickel / brz trim
S = Bronze / cu-nickel
15 Option Code
X = Standard unit
J = CSD-1, FM, IRI, IL
L = MN and LDS (Indoor units only)
16 Pump Options
X = No Pump
The dimensions and requirements that are shown
in Table 1 should be met when choosing the locations
for the appliance.
H = Pump mounted, hard water pump
N = Pump mounted, normal pump
S = Pump mounted, soft water pump
REQUIRED
RECOMMENDED
1.3 Warranty
Bradford White, Copper Brute II appliances
are covered by a limited warranty. The owner should
fill out the warranty registration card and return it to
Bradford White.
All warranty claims must be made to an
authorized Bradford White representative or directly
to the factory. Claims must include the serial number
and model (this information can be found on the rating
plate), installation date, and name of the installer.
Shipping costs are not included in the warranty
coverage.
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BRADFORD WHITE CORP.
Page 6
pump-mounted units.
AIR
CONN.
W
VENT
CONN.
V
HORIZ.
VENT
PIPE
A
B
C
D
E
F
G
H
SIZE
500
750
in
cm
in
cm
in cm
in cm
in cm
in cm
in cm
in cm
33½ 85
45½ 116
15¾ 40
21¾ 55
5¾ 15
5¾ 15
5¾ 15
101/8 26
101/8 26
101/8 26
101/8 26
29¾ 76
29¾ 76
29¾ 76
30¾ 78
30¾ 78
30¾ 78
30¾ 78
32¾ 83
32¾ 83
32¾ 83
29½ 75
29½ 75
29½ 75
29½ 75
7¾ 20
7¾ 20
7¾ 20
8¾ 22
8¾ 22
8¾ 22
8¾ 22
8¾ 22
8¾ 22
46 117
58 147
70 178
80 203
91 231
6
6
8
8
8
8
15
8
20
8
8
8
8
8
8
20
15 10 25
20 10 25
20 12 30
20 12 30
20 14 36
20
20
20
20
20
1000 57½ 146 28¾ 73
1250 68 172 34 86
1500 78½ 199 39¾ 101
1750 89 226 44½ 113
2000 99½ 253 49¾ 126
7
18
8¾ 22
8¾ 22
8¾ 22 101 256
8¾ 22
0
B
284 12 30 14 36 12 3
*Air and vent connections may be on top or back of the Copper Brute II, and are field convertible.
Dimensions in inches cm.
Figure 1. Dimensional Data.
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COPPER BRUTE II (500 - 2000)
Page 7
1.6 Locating Pump-Mounted Water Heater
1.8 Locating Appliance for Correct
with Respect to Storage Tank(s)
For best results, a pump-mounted Copper Brute
II water heater should be located within 15 feet (4.6m)
of the storage tank(s). The pump is sized for 30 feet
(9.1m) of piping.
If the appliance must be installed with longer
piping runs, then larger diameter pipe or tubing shall
be used. Consult the factory for assistance.
Horizontal Vent/Ducted Air Distance
From Outside Wall
The forced draft combustion air blower/blowers
in the appliance has/have sufficient power to pull air
and vent properly when the following guidelines for
horizontal air and vent are followed (see Table 2).
NOTE: On all model sizes, the vent collar size is
larger than the size of the vent pipe that can be used.
Vent collar size and horizontal pipe diameters can
be found in Table 2. The larger vent collar size is to
accommodate Category I (vertical) vent systems.
1.7 Locating Pump-Mounted Boiler with
Respect to Return/Supply Header
For the best results, a pump-mounted Copper
Brute II Boiler should be located within 15 feet (4.6m)
of the supply and return headers. The pump is sized for
30 feet (9.1m) of piping.
If the appliance must be installed with longer
piping runs, then larger diameter tubing shall be used.
Consult the factory for assistance.
NOTE: When located on the same wall, the Copper
Brute II combustion air intake terminal must be
installed a minimum of 12" (30cm) below the exhaust
vent terminal and separated by a minimum of
36 inches (91cm) horizontally.
The air intake terminal must be installed high
enough to avoid blockage from snow, leaves and other
debris.
APPLIANCE
SURFACE
CLEARANCE FROM
SERVICE ACCESS
CLEARANCE
COMBUSTIBLE MATERIAL
inches
cm
inches
24
24
12
**12**
36
cm
61
61
30
30**
91
Left Side
Right Side
Top
1
1
1
1
1
2.5
2.5
2.5
2.5
2.5
Back
Front
Vertical
(Category 1)
Vent
Horizontal
(Category 3)
Vent
6*
15.2*
per UL1738 venting
system supplier’s
instructions
*1" (2.5cm) when b-vent is used.
**When vent and/or combustion air connects to the back,
recommended clearance is 36" (91cm).
Table 1. Clearances.
HORIZONTAL
VENT PIPE
DIAMETER
AIR COLLAR
& PIPE
DIAMETER
VENT COLLAR
SIZE
MAX. PIPE
LENGTH
MAX. NO.
OF ELBOWS
SIDE WALL
VENT
TERMINAL
SIDE WALL
COMBUSTION
AIR TERMINAL
PART NUMBER
20260701
20260701
20260703
20260703
20260703
20260703
SIZE
in.
8
cm
20
25
25
30
30
36
36
in.
6
cm
15
20
20
20
20
20
30
in. cm
ft.
m
PART NUMBER
CA001401
CA001402
CA001402
CA001403
CA001403
CA001403
500
750
1000
1250
1500
1750
2000
6
6
15
15
20
20
20
20
30
50 15
50 15
50 15
50 15
50 15
50 15
50 15
3
3
3
3
3
3
3
10
10
12
12
14
14
8
8
8
8
8
8
8
8
8
12
12
CA001404
20260706
Table 2. Horizontal Vent / Combustion Air Parameters.
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BRADFORD WHITE CORP.
Page 8
total input rating of all equipment in the enclosure.
Table 3 shows data for this sizing method, for each
Copper Brute II model.
SECTION 2.
Venting and Combustion Air
2.1 Combustion Air
Copper Brute II boilers and water heaters must
have provisions for combustion and ventilation air
in accordance with Section 5.3, Air for Combustion
and Ventilation, of the National Fuel Gas Code, ANSI
Z223.1, or Sections 7.2, 7.3 or 7.4 of CSA B149.1,
Installation Codes, or applicable provisions of the local
building codes.
Method 2: One permanent opening, commencing
within 12 inches (30 cm) of the top of the enclosure,
shall be permitted. The opening shall directly
communicate with the outdoors or shall communicate
through a vertical or horizontal duct to the outdoors
or spaces that directly communicate with the outdoors
and shall have a minimum free area of 1 square inch
per 3000 Btu/hr (7 square cm/kW) of the total input
rating of all equipment located in the enclosure. This
opening must not be less than the sum of the areas of
all vent connectors in the confined space.
Other methods of introducing combustion and
ventilation air are acceptable, providing they conform
to the requirements in the applicable codes listed
above.
A Copper Brute II appliance may receive
combustion air from the space in which it is installed,
or it can be ducted directly to the unit from the outside.
Ventilation air must be provided in either case.
2.1.1 Combustion Air From Room
In the United States, the most common
requirements specify that the space shall communicate
with the outdoors in accordance with method 1 or 2,
which follow. Where ducts are used, they shall be of
the same cross-sectional area as the free area of the
openings to which they connect.
In Canada, consult local building and safety
codes or, in absence of such requirements, follow CSA
B149.1.
Method 1: Two permanent openings, one
2.1.2 Intake Combustion Air
commencing within 12 inches (30 cm) of the top
and one commencing within 12 inches (30 cm) of
the bottom, of the enclosure shall be provided. The
openings shall communicate directly, or by ducts,
with the outdoors or spaces that freely communicate
with the outdoors. When directly communicating
with the outdoors, or when communicating to the
outdoors through vertical ducts, each opening shall
have a minimum free area of 1 square inch per 4000
Btu/hr (5.5 square cm/kW) of total input rating of all
equipment in the enclosure. When communicating to
the outdoors through horizontal ducts, each opening
shall have a minimum free area of not less than
1 square inch per 2000 Btu/hr (11 square cm/kW) of
The combustion air can be taken through the
wall, or through the roof. When taken from the wall,
it must be taken from out-of-doors by means of the
Bradford White horizontal wall terminal (see Table 2).
When taken from the roof, a field-supplied rain cap or
an elbow arrangement must be used to prevent entry of
rain water (see Figure 2).
Use single-wall galvanized pipe, per Table 4, for
the combustion air intake (see Table 2 for appropriate
size). Route the intake to the heater as directly as
possible. Seal all joints with tape. Provide adequate
hangers. The unit must not support the weight of the
combustion air intake pipe. Maximum linear pipe
EACH OPENING*
SIZE
500
SQUARE INCHES
SQUARE CM
807
125
188
250
313
375
438
500
750
1213
1000
1250
1500
1750
2000
1613
2020
2420
2826
3226
*Net Free Area in Square Inches / Square cm
Area indicated is for one of two openings; one at floor level and
one at the ceiling, so the total net free area could be double the
figures indicated.
This chart is for use when communicating directly with the
outdoors. For special conditions and alternate methods, refer to
the latest edition of ANSI Z223.1.
Note: Check with louver manufacturers for net free area of
louvers. Correct for screen resistance to the net free area
if a screen is installed. Check all local codes applicable to
combustion air.
Table 3. Combustion Air Openings.
Figure 2. Combustion Air and Vent Through Roof.
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COPPER BRUTE II (500 - 2000)
Page 9
length allowed is 50 feet (15.2m). Three elbows have
been calculated into the 50-foot (15.2m) linear run.
Subtract 10 allowable linear feet (3.0m) for every
additional elbow used (see Table 2). When fewer than
3 elbows are used, the maximum linear pipe length
allowed is still 50 feet (15.2m).
The connection for the intake air pipe is on the
filter box. The Copper Brute II appliances may have
venting and combustion air ducting attached to the top
or the back. They are shipped with the connections
at the top. For attaching either or both pipes to the
back, the mounting flanges are reversible by removing
the mounting screws and orienting the flanges in the
desired position. Replace the screws after positioning
flanges. Run a bead of silicone around the collar and
slide the pipe over the collar. Secure with sheet metal
screws.
if multiple units are vented into the same vertical
vent, a barometric damper must be installed on each
appliance, such that the flue draft does not exceed
(negative) 0.1" w.c.
If using a power venter for any type of Category
I venting, the draft should be set between (negative)
0.01 and 0.10" w.c.
2.2.3 Common Venting Systems
Copper Brute II units are Category I fan-assisted
when vented vertically and adhering to all applicable
codes. Copper Brute II units are not allowed to be
vented into a common horizontal vent system, unless
a properly sized vent fan is used, and the common
vent system is properly designed by the vent fan
manufacturer or a qualified engineer. When common
venting Copper Brute II fan-assisted unit with other
appliances through one shared vertical duct called a
“common vent”, special care must be taken by the
installer to ensure safe operation. In the event that
the common vent is blocked, it is possible, especially
for fan-assisted devices, to vent backwards through
non-operating appliances sharing the vent, allowing
combustion products to infiltrate occupied spaces.
If the appliances are allowed to operate in this
condition, serious injury or death may occur.
In addition to air needed for combustion, air
shall also be supplied for ventilation, including all air
required for comfort and proper working conditions
for personnel. The Copper Brute II loses less than 1
percent of its input rating to the room, but other heat
sources may be present.
2.2 Venting
2.2.1 Vent Categories
Depending upon desired Copper Brute II venting,
it may be considered a Category I or a Category III
appliance. In general, a vertical vent system will
be a Category I system. However, in rare instances,
a Copper Brute II’s vertical vent system may be
considered Category III. In the U.S., the National Fuel
Gas Code (ANSI Z223.1-Latest Edition), or in Canada
the CSA B149.1 (latest edition), defines a Category
I vent system, and includes rules and tables to size
these vent systems. If the Copper Brute II’s vertical
vent system does not satisfy the criteria for Category I
venting, it must be vented as a Category III system.
All Copper Brute II vent systems which
WARNING
Operation of appliances with a blocked common
vent may lead to serious injury or death. Safety
devices must be implemented to prevent blocked
common vent operation. If safe operation of all
appliances connected to a common vent cannot
be assured, including prevention of spillage of flue
gasses into living spaces, common venting should
not be applied, and appliances should each be
vented separately.
It is for this reason that, in addition to
following proper vent sizing, construction and safety
requirements from the National Fuel Gas Code,
ANSI Z223.1 or in Canada, from CSA B149.1 as
well as all applicable local codes, it is required that
installers provide some means to prevent operation
with a blocked common vent. It is suggested that a
blocked vent safety system be employed such that if
the switch from one appliance trips due to excessive
stack spill or backpressure indicating a blocked vent
condition, that all appliances attached to the vent be
locked out and prevented from operating. Note that
the Copper Brute II is equipped with a blocked vent
safety (pressure) switch, as shipped. However, this
safety switch has only been designed and tested to be
effective in installations where the Copper Brute II
is vented separately and NOT common vented with
other appliances. As an additional precaution, it is
recommended that a Carbon Monoxide (CO) alarm be
installed in all enclosed spaces containing combustion
discharge horizontally (without the use of a power
venter) are considered Category III vent systems.
2.2.2 Category I Vent
When vented as a category I appliance, the
vent system must conform to the National Fuel Gas
Code (ANSI Z223.1-Latest Edition) in the U.S., or
in Canada, to CSA B149.1 (latest edition). The vent
system must be sized and installed for a Category I
Fan-Assisted Appliance.
If chimney height is greater than 25 feet, or
TERM
DESCRIPTION
Pipe
Single-wall galvanized steel pipe, 24 gauge
minimum (either insulated or non-insulated)
Joint
Permanent duct tape or aluminum tape
Sealing
Table 4. Required Combustion Air Piping Material.
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BRADFORD WHITE CORP.
Page 10
U.S. Installations (see note 1)
Canadian Installations (see note 2)
A = Clearance above grade, veranda, porch,
12 inches (30 cm)
12 inches (30 cm)
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
opened
C = Clearance to permanently closed window
See note 4
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 4
See note 4
See note 5
See note 5
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
extended above meter/regulator assembly See note 4
I = Clearance to service regulator vent outlet
See note 4
3 feet (91 cm)
J = Clearance to nonmechanical air supply inlet
to building or the combustion air inlet to
any other appliance
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
36 inches (91 cm)
K = Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m)
6 feet (1.83 m)
horizontally
Vent termination not allowed in this location
Vent termination not allowed in this location for category IV appliances. A vent shall not
L = Clearance above paved sidewalk or paved for category IV appliances. For Category III terminate directly above a sidewalk or paved
driveway located on public property
appliances, vent must terminate at least 7
driveway that is located between two single
feet (2.13m) above the sidewalk or driveway. family dwellings and serves both dwellings.
For Category III appliances that do not violate
the previous condition, vent must terminate
at least 7 feet (2.13m) above the sidewalk or
driveway.
M = Clearance under veranda, porch, deck,
See note 4
12 inches (30 cm) (see note 3)
or balcony
Notes:
1. In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.
2. In accordance with the current CSA-B149.1 Installation Codes.
3. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
4. For clearances not specified in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the requirements of
the gas supplier.
5. For clearances not specified in CSA-B149.1, clearance is in accordance with local installation codes and the requirements of the gas supplier.
Figure 3. Combustion Air and Vent Through Side Wall.
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COPPER BRUTE II (500 - 2000)
Page 11
appliances. If assistance is required in determining
how a blocked vent safety system should be connected
to a Bradford White product, please call Applications
Engineering at the Rochester phone number listed on
back cover of this manual.
and must be located in accordance with ANSI Z223.1/
NFPA 54 and applicable local codes. In Canada, the
installation must be in accordance with CSA B149.1 or
.2 and local applicable codes. Consider the following
when installing the terminal:
1. Figure 3 shows the requirements for mechanical
vent terminal clearances for the U.S. and Canada.
2. Vent terminals for condensing appliances or
appliances with condensing vents are not
permitted to terminate above a public walkway,
or over an area where condensate or vapor could
create a nuisance or hazard.
3. Locate the vent terminal so that vent gases cannot
be drawn into air conditioning system inlets.
4. Locate the vent terminal so that vent gases cannot
enter the building through doors, windows,
gravity inlets or other openings. Whenever
possible, locations under windows or near doors
should be avoided.
5. Locate the vent terminal so that it cannot be
blocked by snow. The installer may determine
that a vent terminal must be higher than the
minimum shown in codes, depending upon local
conditions.
6. Locate the terminal so the vent exhaust does
not settle on building surfaces or other nearby
objects. Vent products may damage such
surfaces or objects.
7. If the boiler or water heater uses ducted
combustion air from an intake terminal located
on the same wall, locate the vent terminal at least
3 feet (0.9m) horizontally from the combustion
air terminal, and locate the vent terminal at least
1 foot (0.3m) above the combustion air terminal.
Refer to the installation and operating
instructions on all appliances to be common vented
for instructions, warnings, restrictions and safety
requirements. If safe operation of all appliances
connected to a common vent cannot be assured,
including prevention of spillage of flue gasses into
living spaces, common venting should not be applied,
and appliances should each be vented separately.
2.2.4 Category III Vent
When the Copper Brute II is vented with
horizontal discharge, it must be installed per
this installation manual and the venting system
manufacturer’s installation instructions. The vent
system must be sealed stainless steel, per Table 5.
Route the vent pipe to the heater as directly as
possible. Seal all joints and provide adequate hangers
as required in the venting system manufacturer’s
Installation Instructions. Horizontal portions of the
venting system must be supported to prevent sagging
and may not have any low sections that could trap
condensate. The unit must not support the weight of
the vent pipe. Horizontal runs must slope downwards
not less than ¼ inch per foot (2 cm/m) from the unit to
the vent terminal. Reference Table 2 for the size of the
Category III vent system. Up to three elbows can be
used with 50 linear feet (15.2m) of pipe. Subtract 10
allowable linear feet (3.0m) for every additional elbow
used.
WARNING
2.3.2 Side Wall Combustion Air Terminal
The Bradford White side wall combustion air
terminal (listed in Table 2) must be used when the
unit takes its combustion air through a duct from a
side wall. Consider the following when installing the
terminal:
1. Do not locate the air inlet terminal near a source
of corrosive chemical fumes (e.g., cleaning fluid,
chlorinated compounds, etc.)
The outdoor vent terminal gets hot. Unit must be
installed in such a way as to reduce the risk of
burns from contact with the vent terminal.
2.3 Locating Vent & Combustion Air
Terminals
2.3.1 Side Wall Vent Terminal
The appropriate Bradford White side wall vent
hood must be used, and is listed in the installation and
operation manual. The terminal provides a means of
installing the vent piping through the building wall,
2. Locate the terminal so that it will not be subject
to damage by accident or vandalism.
3. Locate the combustion air terminal so that it
cannot be blocked by snow. The National Fuel
Gas Code requires that it be at least 12 inches (30
cm) above grade, but the installer may determine
it should be higher, depending upon local
conditions.
4. If the Copper Brute II is side-wall vented to the
same wall, locate the vent terminal at least 3
feet (0.9m) horizontally from the combustion air
terminal, and locate the vent terminal at least 1
foot (0.3m) above the combustion air terminal
(see Figure 3).
TERM
DESCRIPTION
Pipe
Must comply with UL Standard 1738
such as Type 29-4C Stainless Steel
(either insulated or non-insulated).
Follow vent manufacturer’s instructions
Joint
Sealing
Table 5. Required Horizontal Venting Material.
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BRADFORD WHITE CORP.
Page 12
cigarette, cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas burning
appliance to their previous conditions of use.
7. Any improper operation of the common venting
system should be corrected so that the installation
conforms to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CSA B149.1, Installation
Codes. When resizing any portion of the common
venting system, the common venting system
should be resized to approach the minimum size
as determined using the appropriate tables in Part
II of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and/or CSA B149.1, Installation Codes.
2.3.3 Vertical Vent Terminal
When the unit is vented through the roof, the
vent must extend at least 3 feet (0.9m) above the point
at which it penetrates the roof. It must extend at least
2 feet (0.6m) higher than any portion of a building
within a horizontal distance of 10 feet (3.0m), and high
enough above the roof line to prevent blockage from
snow. When the combustion air is taken from the roof,
the combustion air must terminate at least 12" (30cm)
below the vent terminal (see Figure 2).
2.3.4 Vertical Combustion Air Terminal
When combustion air is taken from the roof, a
field-supplied rain cap or an elbow arrangement must
be used to prevent entry of rain water (see Figure 2).
The opening on the end of the terminal must be at least
12" (30cm) above the point at which it penetrates the
roof, and high enough above the roof line to prevent
blockage from snow. When the vent terminates on the
roof, the combustion air must terminate at least 12"
(30cm) below the vent terminal.
2.5 Vent Terminals for Outdoor Units
For outdoor applications, the vent and
combustion air openings must be covered with proper
terminals to prevent rain, snow and other objects from
falling into the Copper Brute II.
If local codes allow, outdoor installations may
use 1' of appropriately sized galvanized single wall
or B-Vent and a rain cap for exhaust vent termination
in the default configuration (venting out of the top).
An appropriately sized galvanized 90° ell, positioned
with the opening facing down, may be used on the
combustion air inlet in the default configuration on
the back of the unit. Note that some local codes may
require a higher vertical vent height, extending above
any perimeter fencing, etc. In installations where the
appearance of the vent is objectionable, the low profile
vent terminals in Table 6 may be used.
2.4 Common Vent Test — Boilers
When an existing boiler is removed from a
common venting system, the common venting system
is likely to be too large for proper venting of the
appliances remaining connected to it.
At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances
remaining connected to the common venting system
are not in operation.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
Part numbers for the low profile terminals to
cover the vent and combustion air openings are shown
in Table 6.
3. Insofar as it is practical, close all building doors
and windows and all doors between the space in
which the appliances remaining connected to the
common venting system are located and other
spaces of the building. Turn on clothes dryers
and any appliance not connected to the common
venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
OUTDOOR
VENT
OUTDOOR
COMBUSTION
SIZE
TERMINAL
20254703
20254705
20254705
D2007700
D2007700
D2007800
D2007800
AIR TERMINAL
D2007900
D2007900
D2008000
D2008000
D2008000
D2008000
D2008200
500
750
1000
1250
1500
1750
2000
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
Table 6. Vent Terminals for Outdoor Units.
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COPPER BRUTE II (500 - 2000)
Page 13
6. A sediment trap must be provided upstream of
SECTION 3.
Gas Supply and Piping
the gas controls.
7. All threaded joints should be coated with
piping compound resistant to action of liquefied
petroleum gas.
3.1 Gas Supply and Piping
Gas piping should be supported by suitable
hangers or floor stands, not by the appliance.
The Copper Brute II’s gas train allows the user to
pipe the gas from either the right side or the left side
of the unit. As shipped, the right side of the gas train is
capped off, and there is a manual valve on the left side.
If desired, the manual valve on the left side of the gas
train may be moved to the right side, and the cap on
the right side may be moved to the left.
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).
Review the following instructions before
proceeding with the installation.
10. The appliance and its gas connection must be
leak tested before placing it in operation.
11. Purge all air from gas lines.
1. Verify that the appliance is fitted for the proper
type of gas by checking the rating plate. Copper
Brute II appliances are equipped to operate at
elevations up to 10,000 feet (3050m). Copper
Brute II appliances may be adjusted to operate
properly at altitudes above 2500 feet (see Section
6.5.2) and the input will be reduced if the heating
value of the gas supply is below sea level values.
2. The maximum inlet gas pressure must not
exceed 13" w.c. (3.2kPa). The minimum inlet gas
pressure is 5" w.c. (1.2kPa).
3. Refer to Table 7, size supply.
4. Run gas supply line in accordance with all
applicable codes.
5. Locate and install manual shutoff valves in
accordance with state and local requirements.
WARNING
Do not use open flame to check for leaks. An open
flame could lead to explosion, which could result in
property damage, serious injury or death.
NOTE: The Copper Brute II appliance and all other
gas appliances sharing the gas supply line must be
firing at maximum capacity to properly measure the
inlet supply pressure. The pressure can be measured
at the supply pressure port on the gas valve. Low
gas pressure could be an indication of an undersized
gas meter, undersized gas supply lines and/or an
obstructed gas supply line.
DISTANCE FROM GAS METER
OR LAST STAGE REGULATOR
SIZE AND
GAS TYPE
0-100'
0-31m
100-200' 31-61m
200-300' 61-91m
500 natural
500 propane
1-1/2"
1"
3.8cm
2.5cm
2"
1-1/2"
5.1cm
3.8cm
2"
1-1/2"
5.1cm
3.8cm
750 natural
750 propane
2"
1-1/2"
5.1cm
3.8cm
2"
1-1/2"
5.1cm
3.8cm
2-1/2"
2"
6.4cm
5.1cm
1000 natural
1000 propane
2"
1-1/2"
5.1cm
3.8cm
2-1/2"
2"
6.4cm
5.1cm
3"
2-1/2"
7.6cm
6.4cm
1250 natural
1250 propane
2-1/2"
2"
6.4cm
5.1cm
2-1/2"
2"
6.4cm
5.1cm
3"
2-1/2"
7.6cm
6.4cm
1500 natural
1500 propane
2-1/2"
2"
6.4cm
5.1cm
3"
2-1/2"
7.6cm
6.4cm
3"
2-1/2"
7.6cm
6.4cm
1750 natural
1750 propane
2-1/2"
2"
6.4cm
5.1cm
3"
2-1/2"
7.6cm
6.4cm
3"
2-1/2"
7.6cm
6.4cm
2000 natural
2000 propane
3"
2-1/2"
7.6cm
6.4cm
3"
2-1/2"
7.6cm
6.4cm
3-1/2"
3"
8.9cm
7.6cm
Notes:
1.These figures are based on 1/2" (0.12kPa) water column pressure drop.
2.Check supply pressure and local code requirements before proceeding with work.
3.Pipe fittings must be considered when determining gas pipe sizing.
Table 7. Gas Piping Size.
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BRADFORD WHITE CORP.
Page 14
Components required by local codes must be properly
installed.
SECTION 4A.
Water Connections —
Copper Brute II Boiler
Note the recommended location of the
temperature sensor on the diagrams; you must provide
a location for the additional sensor shipped with
the Copper Brute II. This sensor may be strapped
onto pipe from 1" to 4" diameter, or inserted into an
immersion well.
4A.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.
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.
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.
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.
Pipe the discharge of the relief valve (full size)
to a drain or in a manner to prevent injury in the event
of pressure relief. Install an air purger, an air vent,
a diaphragm-type expansion tank, and a hydronic
flow check in the system supply loop. Minimum fill
pressure must be 12psig (82.7kPa). Install shutoff
valves where required by code.
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.
Suggested piping diagrams are shown in Figures
4 through 8. These diagrams are meant only as a guide.
20°F
25°F
30°F
35°F
SIZE
flow
H/L
flow
H/L
flow
H/L
flow
H/L
gpm
feet
gpm
34
51
68
85
feet
gpm
28
43
57
71
85
feet
gpm
24
36
49
61
73
85
feet
500
750
1000
1250
1500
1750
2000
43
64
85
106 8.1
1.7
3.3
5.0
1.1
2.3
3.6
6.1
0.9
1.7
3.1
4.7
5.5
8.4
0.7
1.2
2.2
3.4
4.2
5.8
8.3
4A.3 Water Flow Requirements — Boiler
A hydronic heating (closed loop) application
re-circulates the same fluid in the piping system. As a
result, no new minerals or oxygen is introduced into
the system. To ensure a proper operating temperature
leading to long boiler life, a flow rate has been
established based on the fluid temperature rise for this
specific size boiler.
Pump-mounted boilers can be ordered for use in
primary secondary piping systems. The pumps used
are sized for the headloss through the heater, plus 30
feet (9.1m) of full-sized piping (same size as boiler
outlet) and a normal number of fittings.
Table 8 specifies water flow rates for boilers,
which will enable the user to size a pump. The
headloss shown is for the heater only, and the user
will need to add the headloss of the system piping to
properly size the pump.
The minimum inlet water temperature for the
Copper Brute II is 120°F (49°C) to avoid condensing
on the copper coils.
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
17°C
19°C
SIZE
flow
H/L
flow
H/L
flow
H/L
flow
H/L
lpm
m
lpm
m
lpm
m
lpm
m
500
750
1000
1250
1500
1750
2000
161 0.5 129 0.3 107 0.3
92
0.2
241 1.0 193 0.7 161 0.5 138 0.4
321 1.5 257 1.1 214 0.9 184 0.7
401 2.5 322 1.9 269 1.4 231 1.0
483 3.0 386 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 for boiler’s heat exchanger only.
N/R = not recommended.
Table 8. Water Flow Requirements - BWCH.
4A.4 Freeze Protection — Boiler
Boiler installations are not recommended in
areas where the danger of freezing exists unless proper
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COPPER BRUTE II (500 - 2000)
Page 15
COLD WATER
MAKE-UP
SYSTEM
RETURN
C
C
SYSTEM
SUPPLY
SYSTEM PUMP
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PUMP LOCATION FOR PUMP-MOUNTED UNITS
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLE FLOW SYSTEMS
INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM
LEGEND
PIPING & SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
EXPANSION TANK
THERMOMETER
WITH AIR SCOOP AND
AUTO AIR VENT
PURGE
VALVE
TEMPERATURE
SENSOR
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATE ALTERNATE LOCATIONS
3-WAY VALVE
VALVE
GLOBE VALVE
CHECK VALVE
PUT BOILER CONTROL SENSOR IN THE SYSTEM
SUPPLY WHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PUMP
Figure 4. Hydronic Piping — Multiple Boilers, Primary Secondary System.
precautions are made for freeze protection. A non
toxic, heating system, anti-freeze may be added to
the hydronic system provided that the concentration
does not exceed 50% and the anti freeze contains an
anti foamant. When a 50/50 mixture is used, increase
the water flow requirements by 15%, and increase the
headloss requirements by 20%.
Power outage, interruption of gas supply, failure
of system components, activation of safety devices,
etc., may prevent a boiler from firing. Any time a
boiler is subjected to freezing conditions, and the
boiler is not able to fire, and/or the water is not able
to circulate, there is a risk of freezing in the boiler
or in the pipes in the system. When water freezes,
it expands. This can result in bursting of pipes in the
system, or damage to the boiler, which could result in
leaking or flooding conditions.
IMPORTANT NOTES: Different glycol products
may provide varying degrees of protection. Glycol
products must be maintained properly in a heating
system, or they may become ineffective. Consult the
glycol specifications, or the glycol manufacturer, for
information about specific products, maintenance
of solutions, and set up according to your particular
conditions.
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BRADFORD WHITE CORP.
Page 16
COLD WATER
MAKE-UP
C
A
C
A
SYSTEM
SUPPLY
SYSTEM
RETURN
SYSTEM PUMP
B
B
ADJUSTMENT PROCEDURE TO MAINTAIN
120°F INLET TEMP:
1. Turn on boiler and open valves A & B.
2. After steady-state operation, if T1 is less than
120°F, slowly close valve B until T1 climbs to
120°F.
3. If T1 is greater than 120°F, slowly close
valve A until T1 drops to 120°F.
4. Check after system operating temperature
has stabilized. Make final adjustments.
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
T1
T1
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PUMP LOCATION FOR PUMP-MOUNTED UNITS
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLE FLOW SYSTEMS
INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM
PIPING & SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
LEGEND
EXPANSION TANK
THERMOMETER
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
WITH AIR SCOOP AND
AUTO AIR VENT
PURGE
VALVE
TEMPERATURE
SENSOR
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
3-WAY VALVE
VALVE
GLOBE VALVE
CHECK VALVE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATE ALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
SUPPLY WHEN USING THIS PIPING STYLE.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PUMP
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
Figure 5. Hydronic Piping — Multiple Boilers, Low Temperature System.
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COPPER BRUTE II (500 - 2000)
Page 17
150°F
C
COLD WATER
MAKE-UP
C
180°F
C
130°F
180°F
C
SYSTEM PUMP
NOTES:
1. BOILER LOOP IN EXAMPLE IS MAINTAINED AT 180°F.
2. ZONE THERMOSTATS CAN BE INTERLOCKED WITH BOILER,
SO THAT BOILER FIRES UPON CALL FOR HEAT FROM ANY
ZONE.
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
3. ZONE PIPING AND INTERLOCK WIRING TO BE DESIGNED
BY SYSTEM ENGINEER.
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PUMP LOCATION FOR PUMP-MOUNTED UNITS
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLE FLOW SYSTEMS
INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM
LEGEND
PIPING & SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
EXPANSION TANK
THERMOMETER
WITH AIR SCOOP AND
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
AUTO AIR VENT
PURGE
VALVE
TEMPERATURE
SENSOR
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
3-WAY VALVE
VALVE
GLOBE VALVE
CHECK VALVE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATE ALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
SUPPLY WHEN USING THIS PIPING STYLE.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
PUMP
Figure 6. Hydronic Piping — One Boiler, Multi-Temperature System.
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BRADFORD WHITE CORP.
Page 18
COLD WATER
MAKE-UP
SYSTEM
RETURN
C
SYSTEM
SUPPLY
SYSTEM PUMP
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
PUMP LOCATION FOR PUMP-MOUNTED UNITS
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLE FLOW SYSTEMS
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM
PIPING & SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
LEGEND
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
EXPANSION TANK
THERMOMETER
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
WITH AIR SCOOP AND
AUTO AIR VENT
PURGE
VALVE
TEMPERATURE
SENSOR
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATE ALTERNATE LOCATIONS
3-WAY VALVE
VALVE
GLOBE VALVE
CHECK VALVE
PUT BOILER CONTROL SENSOR IN THE SYSTEM
SUPPLY WHEN USING THIS PIPING STYLE.
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PUMP
Figure 7. Hydronic Piping - Primary-Secondary, Reverse-Return.
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COPPER BRUTE II (500 - 2000)
Page 19
COLD WATER
MAKE-UP
SYSTEM
RETURN
C
SYSTEM
SUPPLY
SYSTEM PUMP
ADJUSTMENT PROCEDURE TO MAINTAIN
120°F INLET TEMP:
1. Turn on boiler and open valves A & B.
2. After steady-state operation, if T1 is less than
120°F, slowly close valve B until T1 climbs to
120°F.
B
B
A
A
3. If T1 is greater than 120°F, slowly close valve
A until T1 drops to 120°F.
4. Check after system operating temperature has
stabilized. Make final adjustments.
PUMP LOCATION FOR
NON-PUMP-MOUNTED UNITS
T1
T1
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
PUMP LOCATION FOR PUMP-MOUNTED UNITS
PRIMARY/SECONDARY MANDITORY FOR ALL
VARIABLE FLOW SYSTEMS
INSTALL AIR VENTS AT HIGH POINTS IN SYSTEM
LEGEND
PIPING & SIZING OF EXPANSION TANK
PER TANK MANUFACTURER'S INSTRUCTIONS
EXPANSION TANK
THERMOMETER
WITH AIR SCOOP AND
DIMENSION "C" (COMMON PIPING) TO BE FOUR
PIPE DIAMETERS, MAX. (NO ELBOWS OR VALVES)
AUTO AIR VENT
PURGE
VALVE
TEMPERATURE
SENSOR
BOILER CIRCUIT PIPING MUST BE EQUAL
TO BOILER WATER CONNECTION SIZE
3-WAY VALVE
VALVE
GLOBE VALVE
CHECK VALVE
BOILER CIRC. PUMP SIZED FOR FLOW THROUGH BOILER
DOTTED DEVICES INDICATE ALTERNATE LOCATIONS
PUT BOILER CONTROL SENSOR IN THE SYSTEM
SUPPLY WHEN USING THIS PIPING STYLE.
PRESSURE REDUCING VALVE
W/ FAST FILL BYPASS
PUMP
MINIMUM BOILER INLET WATER TEMPERATURE
MUST BE AT LEAST 120°F.
Figure 8. Hydronic Piping - Primary-Secondary, Reverse-Return, Low Temperature.
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BRADFORD WHITE CORP.
Page 20
for Hot Water Supply Systems (ANSI Z21.22 /
CSA 4.4) of suitable discharge capacity must be
installed in the separate storage tank system.
SECTION 4B.
Water Connections —
Copper Brute II Water Heater
If the Copper Brute II water heater is installed
in a closed water supply system, such as one having a
backflow preventer in the cold water supply line, the
relief valve may discharge periodically, due to thermal
expansion. Means (such as a properly-sized expansion
tank) shall be provided to control thermal expansion.
Contact the water supplier or local plumbing inspector
on how to control this situation.
4B.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.
4B.3 Water Flow Requirements —
Water Heater
In a water heating application (an open system),
new water is constantly being introduced. With the
new water comes a fresh supply of minerals that can
be deposited on the unit’s heat exchanger. This is
commonly known as scaling. The amount of minerals
will depend upon the hardness of the water. Water can
also be aggressive, and can erode metals, including
copper, if the water is moved too quickly. The water
flow requirements for the Copper Brute II water heater
are based upon the hardness of the water. The water
flow is kept high enough to prevent scaling, but low
enough to prevent tube erosion. For extremely soft or
hard water, cupro-nickel tubes are available. Contact a
Bradford White Representative if you have questions
or concerns about water quality.
Pump-mounted water heaters can be ordered
with standard pumps for soft or normal water or with
pumps for hard water. The pumps used are sized for
the headloss through the heater, plus 30 feet (9.1m)
of full-sized piping (same size as heater outlet) and a
normal number of fittings.
The Copper Brute II can be used with several
different types of readily available storage tanks. A
pump draws water from the storage tank and pumps
the water through the heater and back into the tank.
Pump-mounted units have a circulating pump built
into the water heater. The pumps used are sized for the
headloss through the heater, plus 30 feet (9.1m) of full-
sized piping (same size as boiler outlet) and a normal
number of fittings. Pumps used on pump-mounted unit
are sized for soft/normal or hard water, so make sure
a pump-mounted unit matches the water quality of the
installation.
Pipe the outlet from the heater’s relief valve
such that any discharge from the relief valve will be
conducted to a suitable place for disposal when relief
occurs. Do not reduce line size or install any valves in
this line. The line must be installed to allow complete
drainage of both the valve and the line.
Suggested piping diagrams are shown in Figures
9 through 12. These diagrams are meant only as a
guide. Components required by local codes must be
properly installed.
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.
Note the recommended location of the
temperature sensor on the diagrams. The Copper Brute
II is shipped with an additional sensor that can be used
for more full-featured domestic water heating control.
To get these features, you must provide a location for
the additional sensor. It can be strapped to a pipe from
1" to 4" diameter, or inserted into a tank immersion
well.
The minimum inlet water temperature for the
Copper Brute II is 120°F (49°C) to avoid condensing
on the copper coils.
4B.4 Combined Water Heating (potable)
and Space Heating — Water Heater
NOTE: These systems are not allowed in the
Commonwealth of Massachusetts.
Piping and components connected to this water
heater for the space heating application shall be
suitable for use with potable water.
Toxic chemicals, such as used for boiler
treatment, shall not be introduced into the potable
water used for space heating.
This water heater when used to supply potable
water shall not be connected to any heating system
or component(s) previously used with a non-potable
water heating appliance.
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
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COPPER BRUTE II (500 - 2000)
Page 21
LOCATION OF
FACTORY-MOUNTED
PUMP
KEY:
WATER CATEGORY
GRAIN HARDNESS PER GALLON
S = SOFT
N = NORMAL 7.6 THROUGH 17
H = HARD
OVER 17
1 THROUGH 7.5
5
PPM / 17.1 = Grains Per Gallon
1
2
3
4
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND VALVING, CHECK
WITH LOCAL CODES AND ORDINANCES FOR
ADDITIONAL REQUIREMENTS.
NOTES:
LEGEND
1. OPTIONAL CWMU & RECIRC. LINE LOCATION.
THERMOMETER
EXPANSION TANK
2. LOCATE PENNANT DHW SENSOR OR REMOTE AQUASTAT
WELL IN LOWER 1/3 OF TANK.
TEMPERATURE
SENSOR
TPRV
PRV
3. BACK FLOW PREVENTER MAY BE REQUIRED. CHECK LOCAL CODES.
4. THERMAL EXPANSION TANK MAY BE REQUIRED. CHECK LOCAL CODES.
3-WAY VALVE
VALVE
GLOBE VALVE
CHECK VALVE
5. WHEN USING FACTORY MOUNTED PUMP, MAX PIPE LENGTH IS
30 FEET TOTAL, SIX 90° ELBOWS , FULL PIPE SIZE.
PRESSURE REDUCING
VALVE
6. CAUTION: PUMP SIZING MUST BE BASED UPON WATER HARDNESS AT
JOB SITE
PUMP
Figure 9. Water Heater Piping — One Heater, One Tank.
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.
of system components, activation of safety devices,
etc., may prevent a heater from firing. Any time a
heater is subjected 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.
4B.5 Freeze Protection – Water Heater
Although Copper Brute II water heaters are
design-certified for outdoor installations, such
installations are not recommended in areas subject to
freezing temperatures, unless proper precautions are
taken.
Contact the local factory representative or
Bradford White for additional information.
Power outage, interruption of gas supply, failure
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BRADFORD WHITE CORP.
Page 22
Figure 10. Water Heater Piping — Multiple Heaters, One Tank.
Figure 11. Water Heater Piping — One Heater, Multiple Tanks.
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COPPER BRUTE II (500 - 2000)
Page 23
Figure 12. Water Heater Piping — Multiple Heaters, Multiple Tanks.
GPM
N
FT
TEMP RISE °F
LPM
M
TEMP RISE °C
SIZE
500
S
H
S
N
H
S
N
H
S
N
H
S
N
H
S
N
H
5
45
45
45
68
68
68
68
68
68
68
68
68
90
90
90
90
90
90
1.8 2.3 3.5
2.1 3.0 6.0
2.3 3.6 6.1
3.8 3.8 6.3
3.9 3.9 6.5
4.0 4.0 6.7
10.0 10.0 10.0
19
28
38
31
38
44
30
13
19
25
31
38
44
30
9
170 257 341
170 257 341
170 257 341
257 257 341
257 257 341
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
1.2 1.2 2.0
3.0 3.0 3.0
10
16
21
17
21
24
17
7
750
14
19
24
28
33
30
10
14
17
21
24
17
8
1000
1250
1500
1750
2000
10
13
16
18
17
112 112 112
NOTES: 1. S = soft water (1 to 7.5 grains hardness)
2. N = normal water (7.6 to 17 grains hardness)
3. H = hard water (more than 17 grains hardness)
4. gpm = gallons per minutes, lpm = liters per minute, ft = headless in feet, m = headloss in meters
5. Headloss is for heater’s heat exchanger only
Table 9. Water Flow Requirements – BWCV.
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BRADFORD WHITE CORP.
Page 24
Copper Brute II 1750-2000 will require two 120-
volt fused supplies. Heater circuit can be identified
with 10AWG wires to include black, white and green
(all solid colors). Pump circuit can be identified with
three 12AWG wires to include a black wire with a
white tracer (stripe), a white and green wire.
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 boiler.
5.1.2 Pump Circuit
Conversion to separate pump circuit will
necessitate removing the three jumpers within
the internal wiring of the 120-volt portion of the
heater (see Figure 13). Only do this with the power
disconnected to the unit.
To rewire the pump circuit, bring in another
120-volt fused supply (L2, N2 & Ground). Connect
incoming power (L2) to the main power switch using
spade (fork) terminal. From the other side of the main
power switch connect to the main terminal block using
a ¼" female insulated quick connect. This will be
the same position where the jumper had terminated.
Connect N2 and Ground to the main terminal block
using ¼" female insulated quick connect (refer to
Figure 13).
5.1 Main Power
Single pole switches, including those of safety
controls and protective devices must not be wired in a
grounded line.
All electrical connections are made in the field
wiring terminal strip, which is located at the right side
of the appliance.
Ladder diagrams are shown in Figures 16
through 18, while wire diagrams are shown in Figures
19 through 21.
NOTE: All internal electrical components have been
prewired. No attempt should be made to connect
elec-trical wires to any other location except the wiring
box.
5.2 Temperature Control
5.2.1 Temperature Control Description
The field wiring panel is located on the right
side of the Copper Brute II (shown in Figure 14).
The following components are connected to the field
wiring panel:
5.1.1 Power Circuits
All Copper Brute II non-pump-mounted heaters
require a single 120-volt fused supply.
Temperature sensor: The sensor supplied loose
Pump-mounted Copper Brute IIs models 500-
1500 also uses a single 120-volt fused supply and
models 1750-2000 use two 120-volt fused supplies.
The installer can change the pump mounted
single service heaters to use a separate circuit for the
pump, if desired. Instructions to make this change are
found in Section 5.1.2.
Copper Brute II 500-1500 main power (L1, N1
& Ground) shall be connected to the three wires (10
AWG) supplied. Over current protection ratings can be
found in Table 10.
SINGLE CIRCUIT CONNECTIONS
HEATER
PUMP
ONLY
W/O PUMP
WITH PUMP
500
750
15
15
20
25
25
25
25
20
20
25
30
30
—
—
15
15
15
15
15
15
20
1000
1250
1500
1750
2000
Table 10. Electrical Data.
Figure 13. Removing Jumpers.
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COPPER BRUTE II (500 - 2000)
Page 25
wired devices to interlock with the boiler (louver
with the Copper Brute II is installed in the piping
or tank, per the suggested piping diagrams, and
connected to the “S C2” and “SUP S” terminals. See
Section 6.3 for “Mode” definitions and Figures 22 to
24 for field wiring schematics.
Outdoor Reset Sensor: The outdoor reset
sensor, if used, is connected to the “OD S” and “S C2”
terminals.
Field Installed Pump: A pump contactor can
be wired to the “PMP” and “PMP” terminals (these
terminals supply 24VAC to close the contactor
whenever the boiler pump would be operated).
NOTE: In some cases, the boiler pump is operated
continuously.
External Alarm: An external power supply and
alarm can be connected to the “ALRM” and “ALRM”
terminals. In the event of an ignition system lockout, a
contact closure occurs across these terminals.
External Heat Demand Indication: 24VAC
is present across the “HT OUT” and “LWCO GND”
terminals whenever the temperature control sees a
system heat demand. This can be used to power a
contactor (0.5 Amp, maximum) for devices operated
whenever the boiler could fire (combustion air fans,
motorized louvers, etc.) NOTE: In some cases, the
temperature control will always see a heat demand
in the system, such as when the “Ht D” and Com D”
terminals are jumpered.
switches, flow switches, etc.), remove the jumper
between the “COM” and “NO” terminals and wire the
device in series across these terminals. (See Section
5.3 for important information about external staging
controls and building automation systems.)
System Heat Demand: Remove the jumper
across the “COM D” and “Ht D” terminals, and con-
nect the zone pump or valve end switch, thermostat,
aquastat, or other indication of system heat demand
to these terminals. If no indication of a system heat
demand will be provided, the jumper must remain in
place. When jumpered, the temperature control will
always see a heat demand, and the Copper Brute II
pump (if equipped) or any pump with its contactor
connected to the “PMP” and “PMP” terminals will
run continuously. In addition, any device connected
through the “HT OUT” and “LWCO GND” terminals
for an external indication of the heat demand will
run continuously. See Section 6 for more information
on the system heat demand for various modes of
operation.
Refer to Figures 22 through 24 for field wiring of
Other Field Interlocks: To install other field-
Figure 14. Field Wiring Panel
Figure 15. External Control Connection Wiring.
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BRADFORD WHITE CORP.
Page 26
additional components.
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.
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 Manuel d’installation et
d’exploitation.
The wiring methods in this section must be
used to connect an external staging control, such as a
multiple boiler control, building automation system,
energy management system, etc.) Other wiring
methods may be unsafe.
Figure 15 shows how to wire the external
controller to the Copper Brute II’s field wiring panel,
which is located on the right side of the Copper Brute
II.
Most of the time, the number of stages from the
external control will match the number of stages on
the Copper Brute II. However, in some instances, the
controller will not have enough staging capability to
work with all of the stages on a Copper Brute II unit
(for instance, using an 8-stage external control with
four 4-stage Copper Brute II units.) In these instances,
it is very important to follow the instructions in this
section Figure 15 shows how to combine stages on the
Copper Brute II for those instances when the external
controller cannot control all the stages available.
NOTE: The only time Copper Brute II stages should
be jumpered is when the Copper Brute II has an
external control, and the Copper Brute II is used in
Mode 6. In all other modes, when the Copper Brute II
controls its stages, the terminals shown in Figure 15
must NOT be jumpered.
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COPPER BRUTE II (500 - 2000)
Page 27
Figure 16. Copper Brute II 500 - 750 Ladder Diagram.
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Page 28
Figure 17. Copper Brute II 1000 Ladder Diagram.
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COPPER BRUTE II (500 - 2000)
Page 29
Figure 18. Copper Brute II 1250 - 2000 Ladder Diagram.
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Page 30
Figure 19. Copper Brute II 500 - 1000 Wiring Schematic.
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COPPER BRUTE II (500 - 2000)
Page 31
Figure 20. Copper Brute II 1250 - 1500 Wiring Schematic.
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Figure 21. Copper Brute II 1750 - 2000 Wiring Schematic.
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COPPER BRUTE II (500 - 2000)
Page 33
Figure 22. Field Wiring.
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BRADFORD WHITE CORP.
Page 34
Figure 23. Field Wiring for Modes 1 - 5.
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COPPER BRUTE II (500 - 2000)
Page 35
Figure 24. Field Wiring for Mode 6.
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BRADFORD WHITE CORP.
Page 36
display, and the energizing of additional burner stages
is indicated by front panel lights.
SECTION 6.
Operating Instructions
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 module is used.)
When the call for heat is satisfied, the gas
valve(s) closes and the blower(s) continues to run
for 30 seconds. The pump will continue to run for a
minimum of 20 seconds and up to a programmable
maximum of 10 minutes.
If a call for heat is prevented from being satisfied
either by a safety interlock or due to an ignition
lockout, the red SERVICE indicator on the front panel
will light. To reset the standard ignition module,
the reset button on the module must be pressed.
Interrupting power to this module will not reset the
lockout.
6.1 Sequence of Operation
A call for heat can be initiated either
automatically (auto mode) under thermostatic control
by the Copper Brute II temperature control, or by an
external contact closure (manual mode).
In auto mode, the Copper Brute II burner will
fire its stages of input to maintain a target temperature
programmed into the temperature control. The
controller can be programmed per Section 6.3.
In manual mode, an external control will control
the Copper Brute II stages, as long as the Copper
Brute II control is set to mode 6, and the auto/manual
switch (located inside the control compartment) is set
to manual.
The amber READY light on the front panel
indicates that the control system is energized. Upon
a call for heat, the green HEAT indicator on the front
panel will light.
The Copper Brute II 1000–2000 models have
two ignition modules that control different burners. If
one module should fail for any reason, the remaining
module can operate its burner(s) independently.
If the unit is pump-mounted, the pump will be
energized. The pump terminals on the field-wiring
terminals strip will energize a field pump that is
properly interlocked with the Copper Brute II. The
green PUMP indicator on the front panel will light.
Once the water flow switch makes, and if all of
the safety interlocks are closed, the ignition module
will energize the blower(s) for a 15-second pre-purge,
followed by a 20-second period to allow the ignitor to
heat.
Energizing the blower pressurizes the air box
(which supplies air to the burners) and closes the
normally-open contact(s) of the airflow pressure
switch(es). This allows the ignition module to proceed
with the ignition sequence.
The blocked flue pressure switch senses the
pressure in the plenum. It will interrupt the airflow
sensing circuit if this pressure exceeds a maximum
value. If airflow is not proven, the ignition module
will lockout.
The ignition module checks that the ignitor
current has reached a minimum value and energizes
the gas valve at the end of the ignitor heating period.
The green STAGE 1 indicator on the front panel will
light, indicating that the stage 1 gas valve is open.
After a 4-second trial for ignition, the ignitor
switches off, and unless a flame is detected by the
flame sensor, the gas valve will close and the ignition
module will either attempt ignition again (up to three
times) or will lockout (if the optional lockout ignition
module is used).
6.2 Filling the Boiler System
1. Ensure the system is fully connected. Close all
bleeding devices and open make-up water valve.
Allow system to fill slowly.
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.
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 boiler according to the procedure in this
manual. Operate the entire system, including the
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.
If flame is sensed, the burner will continue to
fire as long as there is a call for heat. In Auto mode,
additional stages are delayed by a minimum of 60
seconds (less prepurge and ignitor warm-up time) and
once energized, must fire for at least 30 seconds. The
request for additional stages is indicated on the control
11. Shut down the entire system and vent all
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COPPER BRUTE II (500 - 2000)
Page 37
plumbing loop that has, in turn, one or more plumbing
loops connected to it, which provide heat to radiant
tubing, radiators, DHW heat exchangers, etc. This
plumbing loop is the “primary loop.”
radiation units and high points in the system
piping, as described in Step 4.
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.
In primary secondary piping modes, the
temperature control monitors the primary loop
temperature. The extra sensor that is shipped loose
with Copper Brute II is installed in the primary loop.
The temperature control fires the boiler stages to
provide the “target temperature” at that sensor. Over
time, the temperature control will learn the system
curve and adjust the firing of the stages to meet the
demand in the most efficient way.
For complex systems, with variable speed
injection circulators, multiple temperature zones, etc.,
you may need to consult with a qualified engineer or
Bradford White Applications Engineering.
“Parallel Piping”
The term “parallel piping” means the Copper
Brute II is supplying heat directly to one or more
storage tanks, radiators, radiant zones, etc., plumbed
in series. In these systems, the target temperature is
the boiler’s outlet temperature. An exception is for
domestic hot water systems using mode 3, where the
extra sensor is placed in the tank.
6.3.2 Choosing the Mode
There are six modes of operation for the Copper
Brute II temperature control. The loose sensor must
be installed and connected prior to programming the
temperature control, as it provides sensing the “target”
temperature. The location of the sensor is dependent
on the type of piping used. Figures 4 through 8 show
suggested locations for the temperature sensor in
various hydronic piping configurations.
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.
Modes 1 through 5 are the automatic modes,
requiring the diagnostic panel’s AUTO/MAN switch
(located on the slide-out control drawer) to remain in
the default AUTO position. These modes enable the
temperature control to fire the Copper Brute II’s stages
to meet the demand of the system. In these modes,
the Copper Brute II temperature control continuously
samples the inlet, outlet and target temperatures.
Mode 6 is the manual mode, and the AUTO/
MAN switch must be moved to the MAN position. An
external control, such as a building automation system
or multiple boiler control, just be wired to the field
wiring panel in order to fire the boiler, bypassing the
temperature control (see Section 5.3 for important
information about external staging controls and
building automation systems).
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 Programming the Temperature
Control
The same temperature control is used on all
versions of the Copper Brute II (in two-and four-stage
configurations), providing maximum flexibility to meet
the needs of any system. Before start-up, you must
program the temperature control for the type of system
you have. You must determine the type of piping the
system has, the mode the temperature control will
operate in, and the various settings for that mode.
Table 11 contains information to identify the
mode you should use for your system.
6.3.3 Programming
6.3.1 System Piping
“Primary Secondary Piping”
In the context of these instructions, “primary
secondary piping” means the boiler provides heat to a
Before programming, you must determine the
type of piping you have, the mode you will use, and
install the extra sensor if required for that mode. See
Sections 6.3.1 and 6.3.2 for more information, or
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BRADFORD WHITE CORP.
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contact the factory.
BOIL MASS (Boiler Mass): Always choose “1”.
BOIL TARGET (Boiler Target Temperature):
Your desired set-point temperature. See Section 6.4.5
and Figure 26 for more information.
BOIL MIN (Boiler Minimum Temperature): This
setting tells the Temperature Control to maintain at
least this temperature, even if the PID logic determines
a lower setting would save energy. The BOIL MIN
should always be 120°F (49°C) or higher to prevent
condensation, and can be set up to 10°F below your
BOIL TARGET temperature. See Section 6.4.3 for
more information.
There are three black programming buttons on
the Temperature Control (see Figure 25). Press and
hold all three programming buttons until the word
ADJUST appears in the upper right corner of the LCD
display (it replaces the word VIEW).
Pressing ITEM cycles you through the items you
need to program. UP ARROW increases the value of
that item, while DOWN ARROW decreases it. ADJUST
mode exits if you don’t press a button for 20 seconds.
To return to ADJUST mode, simply press and hold the
three buttons again.
The first item is MODE; enter the mode number
as determined above. The Temperature Control will
then present you with some or all of the following
options, depending on the mode you have chosen:
In mode 6 (external boiler control), you will not
see the following options. Refer to Section 6.4.10 for
setup information for mode 6.
BOIL MAX (Boiler Maximum Temperature):
This setting tells the Temperature Control to limit the
maximum outlet temperature to this setting or below,
and determines how quickly the temperature control
“stages down” or off. If the BOIL MAX setting is
much higher than the BOIL TARGET temperature, the
temperature control will fire all stages until the target
temperature is reached, and then shut down all stages
at once. To enable gradual staging down of the boiler
as you approach your target temperature, set the BOIL
MAX to the same setting as the target temperature. See
Section 6.4.4 for more information.
DIFF (Boiler Differential): This setting is divided
above and below the target temperature. The water
will be allowed to cool ½ this setting below the target
temperature before first stage fires, and will heat to ½
this setting above the target temperature before staging
the boiler down. See Section 6.4.1 and Figure 28 for
more information.
FOR ALL OTHER MODES:
APPLICATION
MODE
SYSTEM
SETTING
SENSORS USED
• Parallel piping (non-
primary/secondary)
hydronic system
• DHW with or without
a tank aquastat
1
2
• None
• Primary/secondary
hydronic system
(pref'd by Bradford White)
• No outdoor reset
• Bradford White System
Sensor (shipped
with each Copper Brute II)
PUMP DLY (Pump Delay): On pump mounted
units, the boiler mounted pump continues to run for
the time selected after the heat demand in the system is
satisfied. This setting also affects the 24VAC output on
the “PMP” “PMP” terminals (see Section 5.2). These
terminals can power a contactor for a larger system
pump. Bradford White recommends a minimum pump
• Parallel piping (non-
primary/secondary)
hydronic system
• DHW
• Advanced control
capability
3
• Bradford White System
Sensor (shipped (with
each Copper Brute II)
• No outdoor reset
• Parallel piping (non-reset
primary/secondary)
hydronic system
• Advanced control
capability
• Bradford White outdoor
sensor (optional
part #R2014000)
4
5
• Outdoor reset
• Primary/secondary
hydronic system
(preferred by
• Bradford White System
Sensor (shipped
with each
Bradford White)
• Outdoor reset
Copper Brute II)
• Bradford White outdoor
reset sensor (optional part
# R2014000)
• Building automation
control
• Multiple boiler system
control
6
• None
• Energy management
system
• Other external control
Table 11. Modes and Sensors for Applications.
Figure 25. Temperature Control.
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COPPER BRUTE II (500 - 2000)
Page 39
EXAMPLE 1
delay setting of 5 minutes. See Section 6.4.6 for more
DHW (Mode 3) Programming. For domestic
hot water systems up to 175°F / 79°C, use mode 3 as
described below.
information.
NOTE: In modes other than mode 6, the pump will
run continuously if the “HtD” and “ComD” terminals
are jumpered and not connected to a zone valve or
pump end switch, or other “contact closure” device
to indicate when the heat demand in the system is
satisfied. The pump will never run, and the boiler will
never fire, if the jumper is removed and the terminals
left empty.
Step 1: Install the additional sensor into the
storage tank, wiring it to “SC2” and “SUPS” terminals
on the field wiring panel (Figure 23).
Step 2: Press the three programming buttons
to enter ADJUST mode (Figure 25). Press ITEM to
select the programming item, and the arrow keys to
adjust the setting. TARGET TANK is desired tank
temperature. Recommended settings with a desired
tank temperature of 125°F:
OUTDOOR RESET (modes 4 and 5): Outdoor
reset adjusts the target temperature based on the
outdoor air temperature and reset ratio. The reset ratio
is determined from the Boiler Start, Boiler Design,
Outdoor Start and Outdoor Design settings.
HEAT DEMAND – For heat demand to exist,
there must be continuity between the Com D (common
demand) and Ht D (heat demand) terminals. The
Copper Brute II ships with a jumper between these
terminals.
The control also evaluates the sensor(s) installed
in the system. If the control is not in warm weather
shutdown (WWSD), and the sensor(s) are below the
target temperature, the “Dem” segment is turned on in
the display. The control energizes the pump (on pump
mounted boilers) and energizes both “PMP” terminals.
The pump symbol appears in the display (see Figures
25 and 26). The control then operates the stages to
maintain the setpoint temperature.
Example DHW Programming
Item
MODE
F°
3
C°
3
BOIL TARGET
TARGET TANK
DIFF TANK
BOIL MASS
DIFF
140°F
125°F
2°F
1
2°F
5:00
F°
60°C
52°C
1°C
1
1°C
5:00
°C
DLY
F°
Step 4: See Section 6.4.11 Limit Controls.
Set both high limits 25°F / 14°C higher than BOIL
TARGET to allow for temperature rise across heat
exchanger. Manual high limits on water heaters have
a maximum 200°F / 93°C setting. (If water must be
at 175°F / 79°C or higher with a volume water heater
model, use mode 1. For volume water applications
exceeding 200°F / 93°C, contact the factory.)
Fine tuning: For faster staging, increase BOIL
TARGET setting. Larger DIFF TANK and DIFF
settings will slow response to demand, but may save
energy.
Boil Start (Boiler Start): The BOIL START
temperature is the theoretical boiler supply
temperature that the heating system requires when the
outdoor air temperature equals the OUTDR START
temperature setting.
If unit short cycles, enter Advanced
Programming mode (Section 6.4) and increase
BOILER MAX setting to the BOIL TARGET setting
or higher. Set BOILER MIN to 120°F / 49°C, and
STGMODE to PID. See Section 6.4.12 Advanced
Programming Mode to enter Advanced Programming
mode, or contact the factory for assistance.
EXAMPLE 2
Hydronic Primary/Secondary (Mode 2)
Figure 27. Temperature Control Target Temperature
Graph.
Figure 26. Temperature Control Symbol Description.
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BRADFORD WHITE CORP.
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Programming. Mode 2 is used in primary-secondary
piping hydronic systems without outdoor reset. Mode
5 adds outdoor reset.
Step 1: Install the additional sensor in the
primary loop (see Figure 4), and wired to the “SC2”
and “SUPS” terminals on the field wiring panel
(Figure 23).
Step 2: Remove the factory-installed jumper
between the “HtD” and “ComD” terminals on the
field wiring panel (Figure 14), and connect a zone
valve or pump end switch or other contact closure
device (aquastat, etc.) to these terminals to provide an
indication of heat demand in the system.
This is not recommended for other applications.
The Copper Brute II is shipped with a jumper
between the “Com D” and “Ht D” terminals, which
must remain in place to allow the unit to fire. The unit
will fire whenever the outlet temperature cools below
the target temperature.
Important Note: If the Copper Brute II is pump-
mounted at the factory, or if a field-supplied pump
contractor is connected to the Copper Brute II’s pump
contactors
(Pmp Pmp), the user must program the controller’s
pump delay (DLY) setting to ON. When ON is selected,
pump operation is continuous. The unit’s inlet and
outlet sensors must be able to detect the temperature
in the storage tank in order to control it. Without the
tank water continuously running through the heater,
the heater will have no way of knowing what the
temperature in the tank is, and will not be able to
respond to a change in tank temperature. Short cycling
or lack of hot water may result if the pump does not
run continuously.
Note: The boiler must have an indication of heat
demand to fire. If a zone valve or pump end switch is
not connected to the “HtD” and “ComD” terminals, the
jumper must be left in place. However, the boiler pump
(if equipped) and any pump connected to a contactor
wired to the PMP-PMP terminals on the field wiring
panel will run continuously and not cycle off according
to the setting for the Pump Delay. In addition, the LCD
screen will always show “dem” (demand) and will not
allow cycling of the display to verify all the sensor
settings.
Mechanical aquastat in a domestic hot
water storage tank.
Remove the jumper from the “Com D” and
“HtD” terminals and connect the aquastat’s leads to
these terminals. This connection uses a standard, non-
powered mechanical aquastat. When the aquastat calls
for heat, the Copper Brute II’s temperature control will
respond and start the boiler pump (if equipped) and
fire the boiler.
If the Copper Brute II is not a pump mounted
model, a 24VAC pump contactor may be connected to
the “PMP” terminals to control a field installed pump.
(If desired, the pump can run continuously, with the
aquastat telling the heater when to fire.)
Step 3: Press the three programming buttons
to enter ADJUST mode (Figure 25). Press Item to
select the programming item, and the ARROW keys
to adjust the setting. See Section 6.3 Programming
the Temperature Control if more programming
instructions are needed.
Recommended settings for hydronic system with
180°F / 83°C primary loop temperature:
Item
F°
2
180
1
20
5:00
F°
C°
2
83
1
10
5:00
°C
MODE
BOIL TARGET
BOIL MASS
DIFF
DLY
F°
Program the temperature control to use Mode 1.
The AUTO/MAN switch must be in the AUTO position in
this mode.
Mode 3: Bradford White R2014800 sensor
installed in the domestic hot water
storage tank.
The Copper Brute II ships with a jumper between
the “Com D” and “Ht D” terminals. Verify this jumper
is in place, and connect the sensor leads to the “S C2”
and “SUP S” terminals. When the sensor detects a
temperature below the target temperature, the control
will respond and start the heater pump (if equipped)
and fire the heater.
Step 4: See Section 6.4.11 Limit Controls. Set
both high limit controls at least 25°F / 14°C higher
than the BOIL TARGET to allow for temperature rise
across the heat exchanger.
6.3.4 Choosing the Mode for your
Application
This section describes various applications and
the recommended field wiring and Mode selections.
If the heater is not a pump mounted model, a
24VAC pump contactor may be connected to the
“PMP” terminals to control a field installed pump. (If
desired, the pump can run continuously).
Program the temperature control to use Mode 3.
The AUTO/MAN switch must be in the AUTO position in
this mode.
Mode 1: Boiler operates using its own inlet
and outlet sensors only, not relying
on a remote thermostat, aquastat,
or external sensor.
This setup is most commonly found in domestic
hot water applications with a continuous run pump.
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COPPER BRUTE II (500 - 2000)
Page 41
If the boiler is not a pump mounted model, a
Caution
24VAC pump contactor may be connected to the
“PMP” terminals to control a field installed pump.
Program the temperature control to use Mode 4.
The AUTO/MAN switch must be in the AUTO position in
this mode.
If the tank temperature control is set too high, a
potential for hot water scalding may exist.
Mode 2: Primary secondary piping.
Install a “supply sensor” in the primary loop
using the Bradford White part number R2014800
sensor (included with every Copper Brute II unit).
Connect the sensor to the “S C2” and “SUP S”
terminals.
You must provide an indication of the system’s
heat demand by removing the jumper across the
“ComD” and “HtD” terminals on the field wiring
panel and connecting a zone valve or zone pump end
switch, thermostat, aquastat or other contact closure to
these terminals. If the “ComD” and “HtD” terminals
are left jumpered, the control will always see a heat
demand and remain in “Dem” mode, with the boiler
pump running continuously. See Section 5.2 for more
information.
Mode 5: Primary secondary piping with
outdoor reset.
Install the outdoor reset sensor, Bradford White
part number R2014000, and connect the leads to
the “OD S” and “S C2” terminals. Install a “supply
sensor” in the primary loop using the Bradford White
part number R2014800 sensor (included with every
Copper Brute II unit). Connect the sensor to the “S
C2” and “SUP S” terminals.
You must provide an indication of the system’s
heat demand by removing the jumper across the
“ComD” and “HtD” terminals on the field wiring
panel and connecting a zone valve or zone pump end
switch, thermostat, aquastat or other contact closure to
these terminals. If the “ComD” and “HtD” terminals
are left jumpered, the control will always see a heat
demand and remain in “Dem” mode, with the boiler
pump running continuously. See Section 5.2 for more
information.
A secondary aquastat, such as for a separate heat
exchanger for DHW, can be connected to the “Set D”
and “Com D” terminals. A call for heat from these
controls will start the boiler pump and cause the boiler
to fire.
If the boiler is not a pump mounted model, a
24VAC pump contactor may be connected to the
“PMP” terminals to control a field installed pump.
Program the temperature control to use Mode 2.
The AUTO/MAN switch must be in the AUTO position in
this mode.
A secondary aquastat, such as for a separate heat
exchanger for DHW, can be connected to the “Set D”
and “Com D” terminals. A call for heat from these
controls will start the boiler pump and cause the boiler
to fire.
If the boiler is not a pump mounted model, a
24VAC pump contactor may be connected to the
“PMP” terminals to control a field installed pump.
Program the temperature control to use Mode 5.
The AUTO/MAN switch must be in the AUTO position in
this mode.
Mode 4: Hydronic outdoor reset system
without primary / secondary piping.
Bradford White strongly suggests the use of
primary secondary piping with the Copper Brute II
boiler. This piping style best ensures that the Copper
Brute II will have proper water flow. However, non-
primary secondary methods can be used successfully,
so this section has been included.
Install the outdoor reset sensor, Bradford White
part number R2014000, and connect the leads to the
“OD S” and “S C2” terminals.
You must provide an indication of the system’s
heat demand by removing the jumper across the
“ComD” and “HtD” terminals on the field wiring
panel and connecting a zone valve or zone pump end
switch, thermostat, aquastat or other contact closure to
these terminals. If the “ComD” and “HtD” terminals
are left jumpered, the control will always see a heat
demand and remain in “Dem” mode, with the boiler
pump running continuously. See Section 5.2 for more
information.
Reset Override: An additional thermostat or aquastat
may be connected to the “Set D” and “Com D”
terminals. A call for heat from either of these controls
will start the boiler’s pump and cause the boiler to fire.
Mode 6: Boiler with external staging control
(multiple boiler control, building
automation system, energy
management system, etc.)
Leave the jumper installed between “Ht D” and
“Com D” terminals. There are terminals on the field
wiring panel that must be wired per the instructions in
Section 5.3 of this manual. Other wiring methods
may be unsafe. The wiring in Section 5.3 of this
manual must be used.
The AUTO/MAN switch is located on the circuit
board in the slide-out control panel on the front of the
Copper Brute II. This switch is placed in the manual
position (MAN) when an external control is controlling
the Copper Brute II stages.
Program the temperature control to use Mode
6. Mode 6 tells the Copper Brute II control that an
external staging control is being used.
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Interstage Differential (STG DIFF) – The
interstage differential is the temperature drop at which
the next stage will turn on. Once a stage turns on, the
next stage cannot turn on until the temperature drops
the interstage differential below the temperature at
which the previous stage turned on. The interstage
differential is adjustable through the STG DIFF
setting in the Adjust menu (see Figure 28).
Interstage Delay On (ON DLY) – The interstage
delay on is the amount of time that must elapse before
turning on the next stage. Once a stage turns on, the
next stage cannot turn on until the interstage delay
on time elapses. The interstage delay on is adjustable
through the ON DLY setting in the Adjust menu.
Interstage Delay Off (OFF DLY) – The
interstage delay off is the amount of time that must
elapse before turning off the next stage. Once a stage
turns off, the next stage cannot turn off until the
interstage delay off time elapses. The interstage delay
off is adjustable through the OFF DLY setting in the
Adjust menu.
Minimum On Time (MIN ON) – The minimum
on time is the minimum amount time that a stage must
be on before it is allowed to turn off. Once a stage
turns on, it cannot turn off until a minimum on time
elapses. The minimum on time is adjustable through
the MIN ON setting in the Adjust menu.
6.4 Advanced Topics
For most installations, Section 6.3 provides
all the information required to set up the Copper Brute
II boiler, and this section should be skipped. Continue
setup in Section 6.5.
This section provides definitions of the pro-
gramming parameters, advanced programming topics,
and other information that may be of interest.
Advanced programming mode allows the
installer to set the temperature control for proportional
staging. In advanced programming mode, the
interstage differential, interstage delay, interstage on
and off delay, and minimum time on and off are all set
manually.
NOTE: Advanced programming mode is not required
in most applications, and is intended for advanced
installers only.
To enter advanced programming mode, remove
the bezel on the temperature control by pulling out at
the bottom. Remove the small phillips head screw to
access the dip switch. The dip switch is mounted on
a circuit board. Locate the letter “A” on the circuit
board and slide the corresponding dip switch toward
the letter “A”. The default setting of this dip switch is
toward the OFF lettering on the circuit board.
6.4.1 Differential
Minimum Off Time (MIN OFF) – The
Differential has an abbreviated name of DIFF. An
on/off heat source must be operated with a differential
in order to prevent short cycling. The differential
is divided around the boiler target temperature (see
Figure 28). The first stage contact will close when the
water temperature at the operating sensor is one-half of
the differential setting below the target temperature. It
will open when the water temperature at the operating
sensor is one-half of the differential setting above the
target temperature. The remaining stages will operate
sequentially, based on the staging mode selected.
minimum off time is the minimum amount time that a
stage must be off before it is allowed to turn on. Once
a stage turns off, it cannot turn on until a minimum
off time elapses. The minimum off time is adjustable
through the MIN OFF setting in the Adjust menu.
Proportional & Integral & Derivative (PID)
– PID staging allows the control to determine when
the next stage is required to turn on. The control
automatically determines the settings that are manually
selected in proportional staging mode. After each stage
is turned on in the firing sequence, the control waits a
6.4.2 Staging Mode
The Copper Brute II 500 and 750 control
operates two stages. The Copper Brute II 1000 control
operates three stages. The Copper Brute II control for
models 1250–2000 operates four stages. The method
of staging used by the control is either P (proportional)
or PID (proportional & integral & derivative), and is
selected using the STGMODE item in the ADJUST
menu.
Proportional (P) – Proportional staging, also
known as step staging, is based on manually adjusted
settings which determine when the next stage is
required to turn on. These manual settings are based
on temperature and time. The interstage differential
sets the temperature drop at which the next stage turns
on. However, in order for a stage to fire, the interstage
delay on and minimum off times must first elapse.
Figure 28. Temperature Control Interstage Differential.
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COPPER BRUTE II (500 - 2000)
Page 43
minimum amount of time before turning on the next
stage. After the minimum time delay between stages
has expired, the control examines the control error to
determine when the next stage is to fire. The control
error is determined using PID logic.
Proportional compares the actual operating
sensor temperature to the boiler target temperature.
The colder the temperature, the sooner the next stage
is turned on.
lowest water temperature that the control is allowed
to use as a target temperature. During mild conditions,
if the control calculates a target temperature that is
below this setting, the target temperature is adjusted to
at least the minimum setting. During this condition, if
the unit is operating, the MIN segment turns on in the
LCD while the target temperature or operating sensor
temperature is viewed. For Copper Brute II units, this
must be set no lower than 120°F (49°C) to protect the
unit
Integral compares the actual operating sensor
temperature to the boiler target temperature over a
period of time.
from condensing on the heat exchanger (see Figure 29).
Derivative determines how fast or slow the
operating sensor temperature is changing. If the
temperature is increasing slowly, the next stage is
turned on sooner. If the temperature is increasing
quickly, the next stage is turned on later, if at all.
Boiler Mass (BOIL MASS) – The boiler mass
setting allows the installer to adjust the control to the
thermal mass of different types of heat sources used.
The boiler mass setting automatically determines the
interstage differential, interstage delay on, interstage
delay off, minimum on time and minimum off time of
the stages when PID staging is used. A higher thermal
mass setting provides slower staging, while a lower
thermal mass setting provides faster staging. Copper
Brute II boilers and water heaters are low-mass
appliances, and therefore, should be used with the
lower thermal mass setting. Set BOIL MASS to “1”.
6.4.4 Boiler Maximum (BOIL MAX)
The boiler maximum (BOIL MAX) is the highest
water temperature that the control is allowed to use
as a target temperature. If the control does target
BOIL MAX, and the boiler outlet sensor is near the
BOIL MAX temperature, the MAX segment turns on
in the LCD while the target, inlet, outlet or supply
temperature is viewed (see Figure 29).
6.4.5 Boiler Target Temperature
The target temperature is determined from
the mode of operation. The control displays the
temperature that is currently trying to maintain at the
operating sensor as BOIL TARGET in the View menu.
The operating sensor for modes 1, 3 and 4 is the outlet
sensor (on the Copper Brute II). The operating sensor
for modes 2 and 5 is the supply sensor (in the system
or primary loop). If the control does not presently have
a requirement for heat, it displays “- - -” in the LCD.
There is no target temperature generated in mode 6
(external controller mode).
6.4.3 Boiler Minimum (BOIL MIN)
The minimum boiler setting (BOIL MIN) is the
6.4.6 Pump Operation
The pump terminals (Pmp Pmp) are energized
with 24 VAC to control a field supplied pump
contactor. During setpoint operation (modes 1 and 2),
the terminals are energized whenever there is a heat
demand. During dedicated DHW operation (mode
3), the terminals are energized whenever there is an
internal heat demand. During outdoor reset (modes 4
and 5), the terminals are energized whenever there is
either a heat demand and the control is not in Warm
Weather Shut Down (WWSD), or whenever there is
a setpoint demand. During WWSD, if the pump has
not operated at least once every 70 hours, the control
energizes the terminals for 10 seconds. This minimizes
the possibility of the pump seizing during a long
period of inactivity. During External Boiler Operation
(mode 6), the pump contact closes whenever there is a
heat demand.
Boiler Purge (PUMP DLY) – After a demand
is satisfied, the control continues to operate the pump
for a period of time. The length of time that the
pump continues to run is based on the pump delay
setting. Once the last stage of the control turns off,
the control keeps the pump contacts energized for
Figure 29. Temperature Control Min & Max.
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BRADFORD WHITE CORP.
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the time selected (between 0 and 10 minutes). When
OFF is selected, there is no purging. When ON is
selected, pump operation is continuous. Also, during
outdoor reset, with the pump delay set to ON, the pump
continues to run even during Warm Weather Shut
Down.
uses outdoor reset to control the water temperature.
Outdoor reset adjusts the target temperature based
on the outdoor air temperature and reset ratio. The
reset ratio is determined from the Boiler Start, Boiler
Design, Outdoor Start and Outdoor Design settings.
Heat Demand – For “heat demand” to exist,
there must be continuity between the Com D (common
demand) and the Ht D (heat demand) terminals. The
Copper Brute II ships with a jumper between these
terminals.
The control also evaluates the sensor(s) installed
in the system. If the control is not in warm weather
shutdown (WWSD), and the sensor(s) are below the
target temperature, the Dem segment is turned on
in the display. The control energizes the pump (on
pump mounted boilers) and energizes the Pmp-Pmp
terminals, and the boiler pump segment is turned on
in the display. The control then operates the stages to
maintain the setpoint temperature.
6.4.7 Setpoint Operation
When either mode 1 or 2 is selected, the control
controls the water temperature based on a fixed
setpoint. The setpoint temperature is set using the
BOIL TARGET item in the ADJUST menu.
Heat Demand – For “heat demand” to exist,
there must be continuity between the Com D (common
demand) and the Ht D (heat demand) terminals. The
Copper Brute II ships with a jumper between these
terminals.
The control also evaluates the sensor(s) installed
in the system, including the outlet sensor provided on
the boiler when using mode 1. When the control senses
continuity between Com D and Ht D terminals, and
that the sensor reading is below the target temperature,
the control will activate the Dem segment in the
display.
Boiler Start (BOIL START) – The BOIL
START temperature is the theoretical boiler supply
water temperature that the heating system requires
when the outdoor air temperature equals the OUTDR
START temperature setting. The BOIL START is
typically set to the desired building temperature (see
Figure 30).
The control energizes the pump (on pump
mounted boilers) and energizes the Pmp Pmp
terminals. The boiler pump segment is turned on in
the display. The control then operates the stages to
maintain the setpoint temperature.
Outdoor Start (OUTDR START) – The
OUTDR START temperature is the outdoor air
temperature at which the control provides the BOIL
START water temperature to the system. The OUTDR
START is typically set to the desired building
temperature.
Outdoor Design (OUTDR DSGN) – The
OUTDR DSGN is the outdoor air temperature that is
6.4.8 Dedicated Domestic Hot Water
When mode 3 is selected, the control provides
dedicated domestic hot water operation.
Internal DHW Demand – A sensor is required
to be connected on the SC2 and Sup/S terminals.
An internal demand for DHW is generated when the
temperature demand for DHW sensor drops ½ of the
tank differential setting below the desired DHW tank
temperature. The TANK TARGET setting is used to
set the desired DHW tank temperature.
Once an internal demand is generated, the
Dem segment turns on in the LCD. The control then
closes the Pmp Pmp contact, which starts the pump
and the control turns on the boiler pump segment in
the display. The control then operates the stages to
maintain the programmed boiler target temperature at
the boiler outlet sensor.
The boiler target temperature is set using the
BOIL TARGET item in the Adjust menu. NOTE:
External demand is not required in this mode of
operation.
Tank Differential – A differential setting that
operates ½ above and below the TANK TARGET is
selectable using the TANK DIFF item in the Adjust
menu.
6.4.9 Outdoor Reset Operation
When either mode 4 or 5 is selected, the control
Figure 30. Temperature Control Outdoor Start Graph.
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COPPER BRUTE II (500 - 2000)
Page 45
the typical coldest temperature of the year where the
building is located. This temperature is used when
doing heat loss calculations for the building.
Boiler Design (BOIL DSGN) – The BOIL
DSGN temperature is the water temperature required
to heat the boiler zones when the outdoor air is as cold
as the OUTDR DSGN temperature.
Warm Weather Shut Down (WWSD) – When
the outdoor air temperature rises above the WWSD
setting, the control turns on the WWSD segment
in the display. When the control is in WWSD,
the Dem segment is displayed if there is a heat
demand. However, the control does not operate the
heating system to satisfy this demand. The control
does respond to a setpoint demand and operates as
described in the Reset Override section (next).
Reset Override (SETPOINT DEMAND) – This
is used when override of the outdoor reset curve is
needed, such as when an indirect water heater is served
by the heating system. A setpoint demand is required
whenever heat is required for the setpoint load. The
setpoint demand overrides the reset water temperature.
The control turns on the Setp Dem pointer in the
display. The control energizes the pump (on pump-
mounted boilers), energizes the Pmp-Pmp terminals,
and turns on the boiler pump segment in the display.
Figure 31. Typical Gas Train Configuration.
Figure 32. Typical Control Panel.
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BRADFORD WHITE CORP.
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The control then operates the boiler stages to maintain
the programmed boiler target temperature. The reset
override operation is not affected by WWSD.
access the dip switch. The dip switch is mounted on a
circuit board.
Locate the letter “A” on the circuit board and
slide the corresponding dip switch toward the letter
“A”. The default setting of this dip switch is toward
the OFF lettering on the circuit board.
6.4.10 External Boiler Operation
When mode 6 is selected, the control allows for
an external control to operate the Copper Brute II’s
stages. In this mode, the control operates the pump in
order to provide purging and exercising. The staging
operation is provided by an external device such as
an Energy Management System (EMS) or External
Staging Control.
Heat Demand – A heat demand is generated
when stage one is wired properly, and the external
control closes the contacts on the stage one terminals
(1C-1NO), calling the Copper Brute II for heat. The
Copper Brute II is shipped with a jumper between
the Com D and Ht D terminals, and this jumper must
remain in place when and external control is providing
the heat demand signal to these terminals. The control
energizes the boiler pump (if equipped), energizes
the Pmp-Pmp terminals, and turns on the boiler pump
segment in the display. The control also turns on
stage 1 of the boiler. Section 5.3 contains important
information about external staging controls and
building automation systems. Other wiring methods
may be unsafe. The wiring in Section 5.3 of this
manual must be used.
6.5 Operating the Burner and Set Up
6.5.1 Set Up for 0 to 2500 Feet Altitude
The Copper Brute II appliance utilizes a modular
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 Copper Brute II resulting from improper setup is
not covered by the limited warranty.
1. Using this manual, make sure the installation
is complete and fully in compliance with the
instructions.
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 Copper Brute II 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 Copper Brute II 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 Copper Brute II.
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).
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 CO2 at the
outlet of the unit. The CO2 should be 8% for
natural gas, or 9.2% for propane.
6.4.11 Limit Controls
In addition to the temperature control, Copper
Brute II appliances are fitted with a manual reset
high limit and an automatic reset high limit. These
are located near the rear of the cabinet on the right
side, behind the slide out drawer (see Figure 32).
Both controls should be set at least 25°F higher than
the target temperature to avoid short cycling. To set
these controls, remove the control panel cover and
pull the control panel out to gain access. Appliances
with reversed heat exchangers have the limit controls
relocated to the left side of the appliance. The left
access door must be removed to gain access to the
limit controls on these appliances.
6.4.12 Advanced Programming Mode
Advanced programming mode allows the
installer to set the temperature control for proportional
staging. In advanced programming mode, the
interstage differential, interstage delay, interstage on
and off delay, and minimum time on and off are all set
manually.
NOTE: Advanced programming mode is rarely
required. It is intended for advanced installers,
and only when the application demands such
programming.
9. After placing the appliance in operation, the
Burner Safety Shutoff Device must be tested.
To test:
To enter advanced programming mode, remove
the bezel on the temperature control by pulling out at
the bottom. Remove the small phillips head screw to
(a) Close gas shutoff valve with burner
operating.
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COPPER BRUTE II (500 - 2000)
Page 47
(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.
(c) Open gas shutoff valve. Restart the
appliance. The ignition sequence will
start again and the burner will start. The
appliance will return to its previous mode
of operation.
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.
After all of the gas valve manifold pressures
have been set, the CO2 or O2 must be reset. CO2 or O2
will have changed when the manifold pressure was
adjusted. Open the air shutter(s) to reduce the CO2 or
O2 to 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 CO2 is adjusted to 8.0% for Natural Gas
appliances or 9.2% for LP appliances. When using an
O2 analyzer, the correct O2 is 6.8% for both Natural
Gas and LP appliances.
NOTE: Sizes 1000–2000 have two ignition controls
and two ignitors, which work independently of one
another. If the ignition control for stages 1 and 2 fails
to properly light the main burners for those stages, the
second ignition control will still be active, and will be
able to energize stages 3 and 4. This, of course, will
only occur if all other safety devices confirm that the
unit will run in a safe condition.
Caution
6.5.2 High Altitude Adjustment and Set Up
Copper Brute II appliances may be operated at
high altitude (7700 ft., 2347 m) with a reduction in
output of approx-imately 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).
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.
6.6 Shutting Down the Copper Brute II
1. Switch off the main electrical disconnect switch.
2. Close all manual gas valves.
3. If freezing is anticipated, drain the Copper Brute
II and be sure to also protect building piping
from freezing.
No orifice changes are required to adjust the
Copper Brute II 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
adjust-ments are a CO2 or O2 Analyzer 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 CO2 is about 8% or the O2 is about 6.8% for
appliances operating on Natural Gas. For appliances
operating on LP Gas adjust the air shutter(s) so that the
CO2 is about 9.2% or the O2 is 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 CO2 or O2 has 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
This step to be performed by a qualified
service person.
6.7 To Restart the Copper Brute II
If drained, follow Section 6.1 in this manual for
proper filling and purging.
1. Switch off the main electrical disconnect switch.
2. Close all manual gas valves.
3. WAIT FIVE (5) MINUTES.
4. Set the aquastat or thermostat to its lowest
setting.
5. Open all manual gas valves.
6. Reset all safety switches (pressure switch,
manual reset high limit, etc.).
7. Set the temperature controller to the desired
temperature setting and switch on electrical
power.
8. Burner will go through a prepurge period and
ignitor warm-up period, followed by ignition.
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7.2.1 Burners
SECTION 7.
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
7.1 System Maintenance
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
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.
7.2.2 Filter
The filter used in the Copper Brute II 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.
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.
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.
7.2 Appliance Maintenance and
Component Description
Only genuine Bradford White replacement parts should
be used.
Caution
7.2.4 Manual Reset High Limit Control
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.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
See Figures 31 and 32 for location of gas train
and control 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:
7.2.5 Automatic Reset High Limit Control
An automatic reset high limit is used in addition
to the manual reset high limit. The high limit switch
has an adjustable set point, up to 240°F (116°C) on
boiler models and 200°F (93°C) water heater models
a. Ignition controls
b. Ignitors
c. Water temperature
control
d. Automatic gas valve
e. Pressure switches
f. Blowers
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COPPER BRUTE II (500 - 2000)
Page 49
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.
7.2.10 Transformer
The Copper Brute II’s 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.
7.2.6 Temperature Control
The temperature control is a Bradford White
LHSC. 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.
7.2.11 Blowers
The combustion air blowers bring the combustion
air for the Copper Brute II 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
(one blower for stages 1 and 2, and one for stages 3
and 4). 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.
7.2.7 Ignition Controls
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.
Copper Brute II sizes 500 and 750 have one ignition
control. Sizes 1000 to 2000 have two ignition controls.
On sizes 1000, one ignition control controls stages 1
and 2, and the second ignition control controls stage 3.
On sizes 1250–2000, one ignition control is for stages
1 and 2, and the other is for stages 3 and 4.
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.
7.2.12 Flow Switch
The Copper Brute II uses a paddle-type flow
switch to ensure that the unit has water flow before
ignition is allowed.
7.2.13 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.
7.2.8 Ignitors
The ignitors used are 120v “Hot Surface” type.
They are energized whenever there is a call for heat
and switched off when ignition is established and the
flame has been sensed. Copper Brute II sizes 500 and
750 have one ignitor. Sizes 1000 to 2000 have two
ignitors. To replace the ignitor, 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 flange, and pull the
ignitor out. Install in reverse order, always using a new
ignitor gasket with the replacement ignitor.
The Copper Brute II 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 both sides 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:
1. Disconnect the electrical supply to the unit.
2. Turn off the gas supply by closing the manual gas
valve on the heater.
3. Disconnect and remove the wires, conduit and
sensors from all components that are attached to
the inlet/outlet header.
Caution
Ignitor gets hot.
7.2.9 Ignition Sensors
The ignition sensors ensure that the main flame
is ignited, so that raw gas is not allowed to fill the
combustion chamber. Copper Brute II sizes 500 and
750 have one sensor. Sizes 1000 to 2000 have two
sensors (one for each ignition control). The ignitors
are the ignition sensors on Copper Brute II appliances.
There are no separate ignition sensors.
4. Isolate the heat exchanger from the water supply.
5. Disconnect header flanges from inlet and outlet.
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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. 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 flow. If the tubes show signs of scaling,
clean the internal surface. Bradford White 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.
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COPPER BRUTE II (500 - 2000)
Page 51
SECTION 8.
Trouble Shooting
8.1 Resolving Lockouts
a load distribution problem. See Section 6.3 regarding
controller setup. Contact your Bradford White
representative to discuss possible remedies.
There are many causes of lockouts. The three
most common causes are: (1) inadequate gas supply,
(2) poor combustion, (3) ignitor failure.
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.
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 O2 or CO2). Copper Brute II
appliances operate best with 45% excess air (8%
CO2 on natural gas, 9.2% CO2 on LP). Check the
CO2 of 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. 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 ignition control.
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 Copper Brute II 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. See
Section 6.3 regarding controller setup.
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 CO2 is high (or O2 is low), appliances
operating with low CO2or high O2 (especially LP
appliances) consume more gas. Adjust the CO2 or O2
for optimum efficiency. If no combustion analyzing
equipment (CO2 or O2) is available then a proper
adjustment of the air/fuel ratio (CO2 or O2) cannot be
accomplished. However, by briefly sniffing the flue
gases it is possible to determine if the CO2 or O2 is
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
CO2 should 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 Copper Brute II 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 CO2 is 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.
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.
8.3 Short Cycling — Boiler
Because the Copper Brute II 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
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BRADFORD WHITE CORP.
Page 52
2, and ignition module #2 handles stage 3. The single
blower is energized directly through the “inducer”
terminals of either ignition module. The 24V power to
the T’STAT terminal of both ignition modules is routed
through the safety interlocks.
8.6 Troubleshooting the Temperature
Control
See Table 12.
8.7 Troubleshooting Copper Brute II
The ladder diagram for sizes 1250 to 2000 is
Controls
The Copper Brute II series consists of two
2-stage models (500 and 750), one 3-stage model
(1000), and four 4-stage models (1250 to 2000). The
2-stage models have one ignition module, and the 3-
and 4-stage models have two ignition modules capable
of independent operation.
shown in Figure 18. These 4-stage models have two
ignition modules, each with its own blower, and each
controlling 2 stages. The blowers are energized by
the ignition modules indirectly via switching relays.
When either ignition module receives a call for heat, it
switches its blower to high speed and the blower of the
idle ignition module to low speed.
A diagnostic panel, that includes test points, as
well as diagnostic lights, is provided in the control
module. It is located on the right side of the module,
behind the display. To access, remove the retaining
screws from the display cover panel and remove
it. Grasp the control module at its base and pull it
outward. Ladder diagrams are shown in Figures 16
through 18. Voltage test points on the diagnostic
panel are indicated by solid circles connected by short
diagonal lines.
Figure 16 shows the diagram for the 2-stage sizes
500 and 750. These have one blower and one ignition
module. The blower is energized directly through the
“inducer” terminals F1 and F2 of the (Fenwal) ignition
module. The 24V power to the 2nd stage gas valve is
routed through the 1st stage VALVE terminal, so that
stage 2 cannot fire unless the stage 1 gas valve is open.
The 750 differs from the 500 only in that the 750 has
two gas trains in stage 1, while the 500 has only one.
The ladder diagram for the size 1000 is shown
in Figure 17. Ignition module #1 handles stages 1 and
The wiring schematics for the Copper Brute II
500 – 1000 are shown in Figure 19, the schematics for
the 1250–1500 are shown in Figure 20, and Figure 21
shows the schematic for 1750–2000. All 24V wiring
is routed through the diagnostic PC board. Wiring
harnesses connect between the diagnostic PC board
and the control components, indicator board, or field
wiring terminal strip. The diagnostic board contains
LEDs that indicate open status of the safety interlocks,
and quick-connect terminals that provide tests points
for checking voltage/continuity at various points in the
control circuit. Line-voltage connections are routed via
the line-voltage terminal buss.
Certain control elements that may need to be
re-wired in the field are connected via the field wiring
terminal strip rather than to the diagnostic PC board.
These include the low-water cutoff (LWCO), water
flow switch, and inlet/outlet water temperature sensors.
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COPPER BRUTE II (500 - 2000)
Page 53
Table 12. Troubleshooting Error Codes.
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BRADFORD WHITE CORP.
Page 54
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COPPER BRUTE II (500 - 2000)
Page 55
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BRADFORD WHITE CORP.
Page 56
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COPPER BRUTE II (500 - 2000)
Page 57
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BRADFORD WHITE CORP.
Page 58
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COPPER BRUTE II (500 - 2000)
Page 59
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BRADFORD WHITE CORP.
Page 60
NOTE: Model 2000 shown
for reference.
13
14
16A
6
7
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BASE SHOWN
FOR REFERENCE
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Figure 33. Sheet Metal Components.
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COPPER BRUTE II (500 - 2000)
Page 61
See
Electrical Components
for detail.
Figure 34. Internal Components.
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BRADFORD WHITE CORP.
Page 62
See pump chart below
for pump numbers.
Copper Brute II Water Heater
Copper Brute II Hydronic
PUMP P/N
SIZE
500
750
1000
1250
1500
1750
2000
Soft Water
A2001700
A2001700
A2001700
A2001700
A2001700
A2001900
A2109700
Normal Water
Hard Water
A2001900
A2001900
A2001900
A2001900
A2001900
A2001900
A2109700
SIZE
500
750
1000
1250
1500
1750
2000
PUMP P/N
A2001700
A2001700
A2001800
A2001800
A2001900
A2001900
A2109700
A2001700
A2001700
A2001800
A2001800
A2001900
A2001900
A2109700
Figure 35. Heat Exchanger Components.
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COPPER BRUTE II (500 - 2000)
Page 63
Figure 36. Electrical Components.
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Bradford White Corp. reserves the right to change specifications, components, features, or to discontinue products without notice.
Ambler, PA 19002
Tech. Service (800) 334-3393
Service Parts (800) 538-2020
Warranty Service (800) 531-2111
Litho in U.S.A. © Bradford White 1211 Document 1270
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