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Bradford-White Corp BJVS Boiler User Manual

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2. Brute M ini Hydronic Boiler Page 19 VENT DAMPER TRANSFORMER A BK BLACK AQUASTAT HIGH RECEPTACLE BK s HOT OPTIONAL LIMIT Y 115 60HZ aa Ri oro Rogo OOO o T Ges A POWER SUPPLY Y YELLOW mE O OO y NEUTRAL BL BLUE NA i BR BROWN WALL e In BK i GROUNDING O ORANGE THERMOSTAT ZONE co P PURPLE FIELD PUMP G GREEN SUPPLIED S RELAY SPARK IGNITION WIRE o 115V FACTORY WIRED E R D gt 115V FIELD WIRED Te d E Ed 24V FACTORY WIRED ott BL lI PUMP 24V FIELD WIRED E BR NN FIELD TERMINAL PRWERVENTER 4 SUPPLIED STRIP SEE DOC 1077 Y IF ANY OF THE ORIGINAL Gap WIRE AS SUPPLIED WITH OO Oxo CONTROL THE APPLIANCE MUST uu ER S od uin Se BE REPLACED IT MUST BLOCKED ROLL OUT Q1 MV PILOT BE REPLACED WITH BK VENT SWITCH 2 MVIPV BURNER APPLIANCE WIRING SAFETY y Qs PV WITH SWITCH O 4 GND SPARK MATERIAL SUITABLE 9 5 ay GR ELECTRODE FOR 105 DEGREES C LO HI S ENSOR THE BOILER WILL NOT OPERATE WITHOUT THE Q7 THW PESE VAS AUTOMATIC VENT DAMPER THE VENT DAMPER WIRE e HARNESS MUST BE INSERTED INTO THE VENT I RIO 2 DAMPER RECEPTACLE amp o E MODEL BJVS IN CANADA SOME UNITS ARE SUPPLIED WITH VENT BL REMOTE FLAME SENSOR 100 225 DAMPER JUMPER PLUG DO NOT REMOVE JUMPER TWOSTAGE TWO STAGE HIGHALTITUDE UNLESS VENT DAMPER IS TO BE INSTALLED SK GASVALVE AQUASTAT OPTIONAL HW VR8304 H0267300 Figure 9e Wiring Diagram Spark Ignition Tw
3. 3 0 4 1 Flow SWIICH iier tette idee 21 1 5 1 Materials for All Installations 3 6 4 2 Heat Anticipator 21 1 5 2 Materials for Most Installations 3 1 5 3 Diagnostic Tools 4 SECTION 7 1 6 Specifications eee 4 Operating Instructions 1 6 1 General Specifications 4 71 Normal Operation 21 1 0 2 DEER manne 4 72 Start up ENEE 7 2 1 Filling the System raisni 22 SECTION 2 7 2 2 Boiler Start up sorri isinai 22 Installation Instructions 73 Lighting and Shutdown Procedures 23 2 1 Introduction 4 7 3 1 Lighting the Boiler 23 2 2 Field Assembly uuu ne eres 5 7 3 2 Sh tdOW erect 24 2 3 1 Clearances sss 6 7 3 2 1 Main Burner Shutdown BJVT Only 24 2 3 2 Flooring idee 6 7 3 2 2 Complete Shutdown 24 7 4 High Altitude Burner SECTION 3 Air Shutter Adjustment 24 Venting 3 1 Combustion Air Supply 7 SECTION 8 3 2 Exhaust Venir 7 Maintenance 3 3 Vent Pipe Sizing and General 8 1 General Maintenance s ss10110e1011011011n 25 IristallatiOtt es 8 8 2 Boiler Components and Their 3 4 Common Venting Systems 8 Operation cotation de 26 3 4 1 Venting Multiple Appliances 8 3 4 2 Inspection of C
4. GROUNDING CONDUCTOR Bum SPACE HEATING PUMP FIELD SUPPLIED THE BOILER WILL NOT OPERATE WITHOUT THE AUTOMATIC VENT DAMPER THE VENT DAMPER WIRE HARNESS MUST BE IN SERTED INTO THE VENT DAMPER RECEPTACLE IN CANADA SOME UNITS ARE SUPPLIED WITH VENT DAMPER JUMPER PLUG DO NOT REMOVE JUMPER UNLESS VENT DAMPER IS TO BE INSTALLED MODEL BJVT H2019600A Figure 9c Wiring Diagram Standing Pilot System BJVT 110V 110V Hot Neutral S Heati Zone pape tea ing ump i i Relay Field Supplied 1 3 Hc is Lo 115V 24V Fuse 2 Thermostat Zone Boiler Field Boiler Pump Zone Terminal Supplied Terminal Relay Pump 4 OL who R Relay T Boiler Optional High Zone Terminal ge Limit Le C Pump 6 A Se DEC Relay Vent 000 4 Damper Receptacle 000 A Power enter Roll Out J O O Receptacle Safety VO LC Switch I TH TR H B Tou Blocked Vent CL SH Gas Valve HW VR8300 Figure 9d Schematic Standing Pilot System BJVT
5. I I Ol l Se lese 3 I q Wirin g L 7 e 110V 60Hz I I D Power l 2 with Taco upply Wall 4 d i m 1 Thermostat Zone 2 Valve h kaku E Zone Valves L I Boilers N SANE S a 4 d Terminal S gt Strip 110V 24V KEE 4 SPST Relay Transformer Field Supplied d l r lt SSS upi NOTE The total power requirement I I I of the Zone Valves should not exceed I Wall l I the total capacity of the transformers w 115V Factory Wired M MG See Zone Valve manufacturer s Thermostat i Tee d 115V Field Wired I I installation instructions for valve n 24V Factory Wired I electrical requirements Wi ri ng with 24V Field Wired I I I I E Honeywell r H TT B EE d R Zone Valves 110V 60H Power Thermostat d i o upp d H w _ 2 i L 4 x 2 l Boiler s N loi l d Terminal Transformer Field Supplied Strip 110V 24V Zones switched with Wall Honeywell je 51006 switching relays or hu Sa ray equivalent d D Honeywell R845A1006 lt I I Wal o es I 4 Thermostat a 3 Boiler sed dui L ws I one1 w Strip I PUES Pet R ml vm wm LL wn vn vn ve e ae r3 I i Wiring i l 115V Factory Wired j j 1 I ry Wire 1 Thermostat Zone seam 118V Field Wired with Multiple Zone3 Fump 24V Factory Wired i i 24V Field Wired Zone Pumps L L I mov d QE Mamie I Power 1 Honeywell R
6. see Figure 6 Supply properly installed purge valves to eliminate air from each circuit A drain valve is supplied with the boiler and can be found in the plastic bag shipped with each boiler This valve is to be installed on the lower right side of the boiler see Figure 1 and 1s used for draining the unit To drain the boiler completely open the drain valve and remove the two drain plugs located on the lower left side of the boiler Be sure to include air vent devices located at the highest point in the system to eliminate trapped air and an air elimination device near the outlet side of the BJV boiler Manual vent valves are recommended Hot water piping should be supported by suitable hangers or floor stands NOT by the boiler Due to expansion and contraction of copper pipe consideration should be given to the type of hangers used Rigid hangers could transmit noise through the system caused by the piping sliding in the hangers It is recommended that padding be used when rigid hangers are installed Gas piping should also be supported by suitable hangers or floor stands not the boiler A properly sized expansion tank must be included in the system offers an aircharged diaphragm type expansion tank with an automatic feed valve which includes a pressure regulator set at 12 psig The part numbers are Less Than 20 Gallons in System A0066800 20 to 45 Gallons in System A0066900 5 1 1 By pass Piping The following informati
7. Assurez vous de bien suivres les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommage mat riel toute blessure ou la mort Ne pas entreposer ni utiliser d essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareils e Ne touchez aucun interrupteur Ne pas vous servir des t l phones dansle b timent o vous vous trouvez Appelez imm diatement 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 tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz Bes BRADFORD WHITE CO RPO RA TION 238 49219 00A REV 4 11 Page 2 BRADFORD WHITE CORP TABLE OF CONTENTS SECTION 1 SECTION 6 General Information Electrical 1 1 Intro ductlO itn ete 3 6 1 General Information 16 1 2 Warranty sites recede ETT 3 6 2 Main POWGF aiite eene guts 16 1 3 Codes and Standards 3 6 3 GOUGING E 21 1 4 Technical Assistance 3 6 4 Auxiliary Devices 21 1 5 Materials Installer Must Provide
8. debris Reopen the water makeup valve 13 Verify system pressure with the boiler pressure gauge before beginning regular operation 14 Within 3 days of start up recheck and bleed all air vents and the expansion tank using these instructions 15 In systems piped with cross linked polyethylene tubng PEX it is essential that all air is purged from all zones in the system to prevent PEX tubing failure 7 2 2 BoilerStart up WARNING For your safety when starting the boiler keep your head and face well away from the burner area to prevent any risk of personal injury AVERTISSEMENT Pour votre s curit personnelle lorsque vous mettez l appareil en marche tenez votre t te et votre visage loin du br leur pour viter tout risque de blessure WARNING Vent pipes and heater tops get hot These surfaces can cause serious burns Do not touch these surfaces while the heater is in operation AVERTISSEMENT Les tuyaux d a ration et le dessus de l appareil deviennent chauds Ils peuvent causer de graves br lures Ne touchez pas ces surfaces lorsque l appareil est en marche A Caution Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the heater and replace any part of the control system and any gas control which has been under water A Attention N utilisez pas cet appareil s il a t plong dans l eau m me partiell
9. AVERTISSEMENT Les appareils de chauffage faibles sont con us pour tre utills s avec du gaz naturel ou du gaz de p trole liqu fi GPL V rifiez l information inscrite sur la plaque signal tique du pour vous assurer que l appareil est concu pour le type de gaz fourni NE PAS ESSAYER DE CONVERTIR CET APPAREIL A UN AUTRE TYPE DE GAZ 1 Gas piping installation must be in accordance with the latest edition of ANSI Z223 1 and all local codes In Canada the installation must be in accordance with CSA B149 1 and all local codes that apply 2 Check the gas supply to be sure that it is the same as the gas indicated on the boiler s plate Brute Mini BJVS and BJVT boilers as shipped from the factory are certified to operate within the altitude range indicated on the rating plate If a field conversion to a different altitude range should be necessary conversion parts are available for changing the altitude range of the heater Contact factory for parts information A Caution Permanent damage to the gas valve will occur if the following procedures are not followed A Attention Vous endommagerez la soupape de gaz si vous ne respectez pas les proc dures suivantes 3 Use the figures in Table 4 to size the gas inlet piping from the gas meter to the heater Check all local codes for compliance before installing the heater Brute M ini Hydronic Boiler Page 11
10. Boiler Page 15 From System water temperature is 160 F 71 C and the outlet To temperature is 180 F 82 C at Normal Input Rate w System from the rating plate That means there is a 20 11 C er temperature rise through the boiler According to Valve OO Table 1 that would indicate a flow rate of 8 GPM n 0 5L S Temperature rise must be measured with the or optional longest highest head zone calling for heat alone thermostatic union Other factors to be considered before selecting a P N 2400 030 ERE Primary Secondary pump are pipe size the number of fittings throughout only the system smoothness of the interior surface of the pipe the quantity of water flowing through the pipe whether a glycol solution is being used and the total length of piping in the system Table 7 provides In Return examle pump selection criteria using Type L copper piping one zone valve and up to eight elbows for single zone systems Consult the factory or a qualified system designer if you have more fittings different size or type of pipe especially in retrofit situations or some other unique system configuraiton not Out Supply illustrated in this manual Left Side View 1 2 Pipe 3 4 Pipe 1 Pipe 1 1 4 Pipe A full size by pass must be installed Size Pum
11. Sieg CONTROL MODEL BJVS Somat O4 ev 50 amp 75 P PURPLE ETE O 5 24V GR SA Erres m 3 BR S7 mw PILOT BURNER 2AVEACTORY WIRED i O s NY WITH SPARK Saas 24V FIELD WIRED ELECTRODE H2019700C IF ANY OF THE ORIGINAL WIRE SENSOR KSPLIANCE MUST BE REPLACED GAS VALVE APPLIANCE WIRING MATERIAL FW VR8304 REMOTE FLAME SENSOR SUITABLE FOR 105 DEGREES C S OR ITS EQUIVALENT HIGH ALTITUDE OPTIONAL Figure 9a Wiring Diagram Spark Ignition System BJVS 50 amp 75 5 When using a or field supplied power venter the mS y proving switch must be connected in series with t eg the hi limit Zone Space Heating acs Dump Field Supplied 6 Check the boiler wiring and pump for correct ee N e oI E E 4 voltage frequency and phase If the pump circuit pe is other than 115V be sure there is an appropriate transformer or relay installed The ur pump relay is suitable for pumps of HP or PS less nav 7 For systems with multiple zone pumps or valves see Figure 10 Fic A means of disconnecting the electrical supply H Th itat Z must be provided within sight of the boiler The pump em Ji Em Dum D D DH one ot tah and boiler must be wired as shown to insure that the Pump 4 Ber Gees S pump is running whenever the boiler is firing Boiler Optional High Zone Terminal Aquastat Limit RP 2 EX Le Vent do n peers o Power Ignition Control Venter Jumper So Receptacle av Py w my esp hb OT Ov o o o o o Bl
12. Systems The BJV boiler must not be direct connected to a heating system utilizing oxygen permeable tubing Provide a water to water heat exchanger between systems to prevent corrosion of ferrous metals such as the boiler s piping wet walls etc Air elimination devices are not sufficient protection and corrosion damage is not covered under the limited warranty 5 6 Anti Freeze Non toxic heating system anti freeze may be added to the hydronic system provided the concentration does not exceed 50 and the anti freeze contains an anti foamant Follow the anti freeze manufacturer s recommendations for yearly or biannual replacement of system anti freeze SECTION 6 Electrical WARNING ELECTRICAL SHOCK HAZARD This boiler contains wiring that carries high voltage Contact with these wires may result in severe injury or death AVERTISSEMENT POSSIBILIT DE CHOCS LECTRIQUES Ce syst me de chauffage contient du filage de haut voltage Un contact avec ces fils peut r sulter en des blessures s rieuses ou la mort A Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing A Attention Au moment de l entretien des commandes tiquetez tous les fils avant de les d brancher Des erreurs de cablage peuvent entrainer un fonctionnement inad quat et dangereux 6 1 General Information Wiring connec
13. and combustible construction and be sure to allow Figure 2 Field Assembly Items access for servicing the damper 6 Install the temperature pressure gauge provided in the parts box Page 6 BRADFORD WHITE CORP A Caution Do not force motor operation when operator is fastened to the damper by moving the damper blade turning the shaft or by turning the position indicator Attention Ne pas tourner le registre manuellement avec ou sans courant lectrique ou le moteur sera endommag 2 3 1 Clearances The boiler must be placed to provide clearances on all sides for maintenance and inspection There must also be minimum distances maintained from Dimensions in inches cm Boiler Sizes 50 125 160 225 Clearances in cm in cm Left side 6 15 6 15 Right side 6 15 6 15 Rear 6 15 6 15 Front 4 10 6 15 Flue 6 15 6 15 Top 23 48 36 91 Note Clearances listed in Table 1 are manufacturer s tested values These are given as minimum values Where local and national codes apply and values are different than those listed in Table 1 use the greater value to ensure safe operation Table 1 Minimum Boiler Clearances From Combustible Surfaces D gagements Minimaux a Assurer Entre Ics Parois de L appareil et leo Constructions Combustibles combustible surfaces see Table 1 At least 15 381mm access must be available
14. and duct must provide one square inch of flow area for each 2000 BTU h 0 6 kW These requirements are summarized in Table 2 Note that the required size of openings shall be based on the net free area of each opening Where the free area of louver or grille is known it shall be used in calculating the effective free area Where the free area are not known it shall be assumed that wood louvers will have 25 percent free area and metal louvers and grilles will have 75 percent free area Inside Air Supply When combustion is supplied from inside the building each opening should have a minimum free area of one square inch per 1 000 BTU h 0 3kW input of the total input rating of all appliances in the enclosed area These openings should never be less than 100 square inches 645 sq cm Note In Canada follow Canadian Standard CSA B149 1 or local codes Exhaust Fans or Vents Any equipment which exhausts air from the boiler room can deplete the combustion air supply or reverse the natural draft action of the venting system This could cause flue products to accumulate in the boiler room Additional air must be supplied to compensate for such exhaust The information in Table 2 is not applicable in installations where exhaust fans or blowers of any type are used Such installations must be designed by qualified engineers If a blower or fan is used to supply air to the boiler room the installer should make sure it does not create draf
15. confined spaces should be provided with two permanent air supply openings one within 12 inches 305mm of the ceiling the other within 12 inches 305mm of the floor see Table 2 Outside Air Area Inside Air Area Boiler Size Sq In sqcm Sq In sqcm 50 15 97 100 645 75 20 129 100 645 100 25 161 100 645 125 32 206 125 807 160 40 258 160 1032 225 60 387 225 1452 Area indicated is for one of two openings one at floor level and one at the ceiling so the total net free area would be double the figures indicated For special conditions refer to NFPA54 ANSI Z223 1 In Canada refer to the National Standard CSA B149 1 which differs from this table 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 2 Minimum Recommended Air Supply to Boiler Room Important See gas piping selection chart Table 3 for gas line sizing In all cases pipe size is larger than inlet connection on heater Run pipe size shown in chart and reduce at heater inlet Outside Air Supply When combustion air is supplied directly through an outside wall each opening should have a minimum free area of one square inch per 4 000 BTU h 1 2kW input of the total input rating of all appliances in the enclosed area If air is provided through horizontal ducts each opening
16. going D Check operation and setting of two stage operating control to high fire T Pump noisy A Air in volute A Bleed air from volute Check pump alignment B Worn coupling or bearings B Replace worn parts 8 Boiler pounding A Too low water flow through boiler A Check temperature rise between inlet and outlet boiler piping or knocking 15 F to 25 F temperature rise is recommended If temperature rise is over 25 F increase pipe size or pump capacity or locate obstruction Check for stuck closed zone valves Check for zone pumps not operating Check for closed valve in system 9 Boiler condensing A Low water temperature A Flue product moisture will condense at the start up until the boiler water temperature reaches the normal operating conditions 10 Pump cavitates A Defective fill valves or pressure regulator A Replace or low water B Oversized expansion tank B Replace pressure at boiler C Expansion tank piped incorrectly C Repipe expansion tank to suction size of pump gauge or bubbles in system at high temperature 11 Pressure relief A Water logged expansion tank A Drain 2 3 of the water from the expansion tank valve opens 12 Pilotislitbutmain A Gas valve not at on position BJVT A Turn knob to on position burners will not B Boiler off on hi limit control B Check for low water flow or hi limit setting come on C Boiler incorrectly wired C On single or multiple zone systems with zone valves room therm
17. heater must be serviced only by a qualified professional service technician AVERTISSEMENT PR CAUTIONS LORS DES R PARTATIONS ET DE L ENTRETIEN Certaines proc dures d entretien et de r paration des appareils de chauffage faibles missions pr sentent des changers car elles mettent en jeu des gaz combustibles des composants lectriques des pi ces mobiles et des proc dures qui n cessitent des mises l essai ou la d rivation temporaire des commandes de s curit Pour cette raison l appareil de chauffage doit tre entretenu et r par uniquement par un technicien professionnel qualifi DANGERS D UN ENTRETIEN INAD QUAT Les appareils de chauffage faibles missions comportent des caract ristiques techniques uniques Une r paration ou un entretien inad quat peut entrainer des blessures corporelles ou des dommages a la propri t Pour cette raison l appareil de chauffage doit tre entretenu et r par uniquement par un technicien professionnel qualifi Page 26 BRADFORD WhHITE CORP 1 Lubricate the water circulating pump per the strongly recommended that the basic items listed instructions on the pump below be inspected by a qualified service 2 fa strainer is employed in a pressure reducing technician every year valve or the piping clean it every six months a Water temperature controls 3 Atstart up and periodically thereafter the b Pilot safety system burner flame should be observed
18. just below a3 Immediately call your gas supplier from a the return water temperature and verify low fire neighbor s phone Follow the gas supplier s operation instructions i 18 BJVS 100 225 ONLY Set two stage operating a4 Ifyou cannot reach your gas supplier call control to desired low fire set point Generally the fire department 20 F below desired loop temp i e for 180 F All Models loop set two stage operating control at 160 F 4 Shut off electrical power to the boiler Adjust as necessary to maintain proper loop 5 Turn the gas valve knob clockwise C to OFF temperature Use only your hand to push in or turn the gas 19 Set the thermostat to the desired temperature control knob Never use tools If the knob will not push in or turn by hand don t try to repair it 7 3 2 Shutdown call a qualified service technician Force or 7 3 2 1 Main Burner Shutdown BJVT only attempted repair may result in a fire or explosion 1 Lower the wall thermostat setting so that there is 6 Wait five 5 minutes to clear out any gas Then no call for heat smell for gas including near the floor If you 2 To turn offthe main burners turn the gas valve smell gas STOP Follow 7 3 1 3 a If you don t knob clockwise until it stops at pilot smell gas go to the next step BJVS Models BJVT skip 7 7 3 2 2 Complete Shutdown 7 Turn gas valve knob counterclockwise D to ON 1 Lower the wall thermostat setting so that there is Restore power to the boile
19. on the terminal board If voltage is evident skip to step 6 If no voltage test the circuit between the red wire on the transformer and terminal 4 on the pump relay from terminal 6 on the pump relay and the A connection on the terminal board and from the purple wire terminal on the pump relay to the W connection on the terminal board If no output is found the connections or the pump relay could be defective Place the second lead on the orange wire terminal on the hi limit switch If no voltage across the switch check for defective hi limit open circuit due to excessive water temperature or a low temperature setting Place the second lead on the orange wire terminal on the blocked vent safety switch If voltage is present the vent damper is open If voltage isn t present connections or the vent damper could be defective Verify the voltage across the blocked vent and roll out safety switches On BJVT boilers test for voltage at the TH terminal on the gas valve If none is found follow steps 1 through 8 If it is determined that there is voltage to the gas valve the pilot is lit and the thermocouple is properly positioned and the thermostat is set high enough to call for heat the gas valve or the pilot thermocouple may be defective There are two tests necessary to make sure the problem is not in the pilot thermocouple The first test can be performed by unscrewing the compression fitting on the gas valve and plac
20. psi 82 7kPa at the highest point in the circuit If a pressure regulator is also installed in the line adjust it to the same pressure 3 Close all gate valves Purge one circuit at a time as follows a Open one circuit drain valve and let water drain out for at least 5 minutes Be certain there are no air bubbles visible in the water stream before closing the drain valve b Repeat this procedure for each circuit 4 Open all gate valves after all circuits have been purged 5 Run the system circulating pump for a minimum of 30 minutes with the boiler shut off 6 Open all strainers in the system and check for debris 7 Recheck all air vents as described in Step 3 above 8 Some expansion tanks require visual inspection of liquid level If necessary inspect the liquid level in the expansion tank With the system full of water and under normal operating pressure to ensure proper water level in the expansion tank 9 Start up boiler according to the procedures described in Section 7 and operate the system including the pump boiler and radiation units for one hour 10 Recheck the water level in the expansion tank if necessary If it exceeds 4 of the volume of the tank open the tank drain and reduce the water level 11 Shut down the entire system and vent all radiation units and high points in the system 12 Closethe watermakeup valve and check the strainer in the pressure reducing valve for sediment or
21. to the common venting system are not in operation Seal any unused openings in the common venting system Sceller toutes les ouvertures non utilis es du syst me d vacuation 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 Inspecter de fa on visuelle le syst me d vacuation pour d terminer la grosseur et l inclinaison horizontale qui conviennent et s assurer que le syst me est exampt d obstruction d tranglement de fuite de corrosion et autres d faillances qui pourraient pr senter des risques Insofar as it 1s 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 Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre l espace o les appareils toujours raccord s au syst me d vacuation sont install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s au syst m
22. where the temperature rise across the heat exchanger is above 30 F see Section 5 and Figure 7 2 Combustion air grates for openings sized in accordance with Section 3 1 3 Field interlock wiring for any motorized combustion air louvers to ensure the boiler does not fire 1f motorized louvers do not open 4 Asuitable non combustible base if installed on a combustible floor see Section 2 3 2 1 5 3 Diagnostic Tools The following materials are needed to verify correct installation 1 Gas manometer to verify gas pressure 2 Strap on digital or infrared thermometer to check temperature rise across the heat exchanger 3 Suggested Draft gauge and combustion test equipment 1 6 Specifications 1 6 1 General Specifications 1 Installation Location Certified for use in Indoor Applications only 2 Minimum Clearance From Combustible Material See Table 1 in Section 2 3 1 3 Supply Gas Type Certified for use with Natural Gas and LP Gas 4 Gas Pipe Boiler Gas Valve Connection Nat LP 50 225 V NPT V NPT 5 Inlet Gas Supply Pressure Minimum Maximum Natural Gas 5 5 WC 10 5 WC LP Gas 10 0 WC 13 0 WC 6 Water Pipe Boiler Connection 14 NPT 7 Water Flow Rate See Table in Section 5 2 8 Pressure Relief Valve 30 PSI 9 Recommended system pressure 12 PSI 10 Exhaust Vent Connection Size 50 4 Diameter 75 100 5 Diameter 125 160 6 Diameter 225 7 Diameter 11 Electrical Supply 115 Volts AC 12 M
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24. 27 3 4 71 24 1 8 61 21 3 4 55 27 1 2 70 5 13 1 1 4 1 2 100 16 7 8 43 28 3 4 73 24 1 8 61 22 3 4 58 27 1 2 70 5 13 1 1 4 1 2 125 16 7 8 43 28 3 4 73 23 5 8 60 22 3 4 58 27 1 2 70 6 15 1 1 4 1 2 160 20 3 8 52 28 3 4 73 23 5 8 60 22 3 4 58 27 1 2 70 6 15 1 1 4 1 2 225 25 5 8 65 31 1 2 80 23 1 4 59 23 3 4 63 27 1 2 70 7 18 1 1 4 3 4 Values shown are for both BUVS and BJVT Models 1 2 for propane Figure 1 Dimensional Information 2 2 Field Assembly Vent Vent 1 Brute Mini boilers have built in draft diverter for Damper Damper natural draft operation Harness 2 Findthe vent damper box which is located in the S boiler package f Draft 3 Install the vent damper directly to the top of the bd draft diverter outlet with the damper operator TM facing to the front of the boiler and with the flow direction arrow pointing upward Use the vent damper wire harness provided with the boiler to connect the vent damper to the boiler The Ten bracket end of the harness should be connected Pre Ve to the vent damper actuator Gauge 4 For Model BJVS only Install the metal plug provided with the vent damper onto the damper plate hole Disregard the metal plug in case of O standing continuous pilot boilers For all mp BJVT models the damper plate hole should never be blocked 5 Do not modify the automatic vent damper device It is very important that no other vents 7 are closed Provide at least six inches clearance between the automatic vent damper
25. 845A1006 I Supply i I l I II i I i i I For primary secondary pumping Connect II to W in lieu of A Boiler relay is used for boiler pump and connection to W will ee u energize boiler pump when any zone is k 1 J 2 6 4 4 calling for heat Figure 10 Multiple Zone Wiring Brute M ini Hydronic Boiler Page 21 6 3 Grounding WARNING The boiler 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 AVERTISSEMENT La chaudi re doit tre mise la terre selon les exigences officielles locales ou en l absence de toute instruction officelle l installation doit tre conforme au National Electrical Code ANSI NFPA 70 aux tats Unis et avec la derni re dition du Code lectrique canadien CSA C22 1 Partie 1 au Canada N utilisez pas la tuyauterie de gaz ou d eau pour mettre la terre les parties m talliques de la ch
26. F 8 C 20 F 11 C 25 F 14 C Size Flow Rate Headloss Flow Rate Headloss Flow Rate Headloss gpm I s ft m gpm I s ft m gpm I s ft m 50 5 3 0 3 0 3 0 1 4 0 3 0 2 0 1 3 2 0 2 0 1 0 75 8 0 5 0 6 0 2 6 0 4 0 3 0 1 4 8 0 3 0 2 0 1 100 10 7 0 7 1 3 0 4 8 0 5 0 7 0 2 6 4 0 4 0 5 0 2 125 13 3 0 8 2 2 0 7 10 0 6 1 3 0 4 8 0 5 0 8 0 2 160 17 1 1 2 5 0 8 12 8 0 8 1 8 0 5 10 2 0 6 1 2 0 4 225 24 1 5 5 1 5 18 1 1 3 1 0 9 14 4 0 9 1 9 0 6 gpm Water Flow in gallons per minute e Water flow in liters per second ft Pressure drop headloss through the boiler in feet of water m Pressure drop headloss through the boiler in meters of water Notes 1 Shaded area is the recommended flow and temperature rise 2 Temperature rise and associated flow rates are based on high fire operation at the Normal Input Rate from the rating plate Table 6 Temperature Rise F C Page 16 BRADFORD WHITE CORP 5 4 Chilled Water Systems Ifthe boiler is installed in conjunction with refrigeration systems it shall be installed so that the chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the heating boiler When boiler piping is connected to heating coils which are in close proximity to refrigerated air circulation there must be flow control valves or other automatic methods to prevent gravity circulation of the boiler water during the cooling cycle 5 5 Oxygen Permeable
27. H2343000 Installation and Operation Instructions Document 1242 Installation and Operation Instructions for BRUTE MINI Residential Gas Fired Hydronic Boilers Models BJVS BJVT Sizes 50 225 U S Patent No 1 609 692 Canada Patent No 383 318 Vent damper is optional in some provinces of Canada These instructions are to be stored in the packet provided on the boiler 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 WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or gas supplier AVERTISSEMENT
28. Hydronic Boiler Page 13 The preferred piping configuration for BJV boilers is always using primary secondary piping There are some applications that are acceptable without primary secondary piping see below LOW TEMP SYSTEMS Pump 77 Tempering Isolation Valve 7a LA Valve From Tempering j System Valve lt _ 7 Pump Isolation Primary Secondary vave System Loop with Tempering Valve and Pump with Boiler Loop with Tempering Valve and Pump Isolation Valve Balancing Balancing XZ Valve Pump Isolation From Valve System Primary Secondary Piping with Field Balancing for Fixed Low Return Temperatures Variable Speed SH ES Ontrol Isolation Valve System gt Pump Isolation From Valve System Primary Secondary Piping with Variable Speed Injection Tempering f Valve Isolation Valve gt From System Pump Isolation Val Tempering Valve with System Loop uid and Boiler Loop Pump Isolation o System From System Pump Isolation Valve Primary Secondary Piping with Automatic By Pass Balancing Isolation To System gt Pump Isolation From Valve System Primary Secondary Piping with By Pass for Fixed Low Return Temperatures Laars Thermostatic f lt Union Isolation To PN 2400 030 Valve System Balancing N Valve Pump Isolation From Valve System Primary Secondary Piping with Laars Thermostat
29. I 223 1 latest edition or the applicable provisions of the local building codes 2 In Canada CSA B149 1 The draft diverter outlet is to be connected to an unobstructed vent pipe of the same or larger diameter terminating outside the building The vent pipe must have a listed vent cap and extend at least two feet above any object with a ten foot radius All connections should be made with rustproof sheet metal screws IMPORTANT NOTE Do not use sheet metal screws at the snap lock joints of Type B gas vents Do not weld or fasten the vent pipe to the boiler draft diverter The weight of the stack must not rest on the boiler The draft diverter and boiler top must be easily removable for normal boiler service and inspection Avoid horizontal runs of the vent pipe and 90 elbows reductions and restrictions Horizontal runs should have at least a 1 4 rise per foot 20mm per meter in the direction of flow A vent connector shall be supported for the design and weight of the material employed to maintain clearances and prevent physical damage and separation of joints Avoid terminating boiler vents near air conditioning or air supply fans The fans can pick up exhaust flue products from the boiler and return them inside the building creating a possible health hazard Do not located the vent terminal where flue products could strike against building materials and cause degradation Always use double wall or insulated vent pipe when
30. If the flame c Automatic gas valves has the appearance of sooting tips check for d Flow sensing safety devices debris near the orifices and call the service e Vent dampers and power venters technician f Ventng system 4 Inspect the venting system for obstruction NOTE The Warranty does not cover damage caused leakage or corrosion at least once a year by lack of required maintenance lack of water flow or 5 Do not store or use gasoline or other flammable improper operating practices vapors liquids or chemicals in the vicinity of 12 Fouling on the external surfaces of the heat this or any other appliance exchanger is caused by incomplete combustion Ne pas entreposer ni utiliser d Seier e and 1s a sign of venting and or combustion air d autres vapeurs ou liquides inflammables problems The heat exchanger can be inspected proxmnte de cet appareil ou de tout autre by using a flashlight and placing a mirror under appareil the burners An alternate method is to remove the 6 Do not use this boiler if any part has been under venting and top panel to inspect the exchanger water Immediately call a qualified service from above The vent system should be technician to inspect the heater and replace any inspected at the same time If cleaning is part of the control system and any gas control required which has been under water a Shut off all power to the boiler N utilisez pas cet appareil s il a t plong dans b Remove t
31. LOZOLL SOLOCOLL SOLOCOLL vOLOCOLL vOLOCOLL OLOCOLL 0LOCOLL ZOLOZOLL cOLOCOLL VOLOCOLL LOLOCOLL JeueAiqueJq sjueuoduio xog 2114 pue yoyoer 00999004 00999004 00999004 00999004 00999004 00999004 00999004 00999004 00999004 00999004 00999004 0099900d LdN c L8AIEAUIRIQ ooegsoz3 00 8S0cd OOE8SO7TA 00 8S0c3 00 8S0cd OOE8GOZA 00 8S027 00 8S0cd 00 8S027 00 8S027 00 8S0cd 00 8S0c3 UOISISUIUUI OM 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v 0006900v ISd0 ONE eJnsseJq 0010000 00L0000v 0010000v 00L0000v 00L0000v 00L0000v 00L0000v 0010000 00L0000v 0010000v 00L0000v 00L0000v e6neseunsseJg eunje1eduue 9009v0LL 9009v0LL SO009vOLL SOO9TOLL vOO9TOLL YOOQYOLL 009vOLL 009vOLL cOO9vVOLL cOO9VOLL LOO9YOLL LOO9TOLL JeDueuox3 jeeH ul9js S 19 2M SCC LACFH SZCSACgH 09LLACH 09LSACH SCLLACH SCESAPFgS 00LLACH 00LSACH SZLLACH SZSAPS OS LACA OS SACA Z S IPPON uonduoseq Page 34 BRADFORD WhHITE CORP 11 3bExploded View Vent Damper Connection Harness Vent Damper Pressure gt Relief Valve Draft Diverter A Inlet Pipe B 4 1 2 x3 4 Pipe C Outlet Pipe Gap Closure 1 1 4 Hold 1 1 8 Hold 1 1 4 Hold 4 1 7 8 Hold Top Heat Exchanger Temperature Pressure Gauge Refractory Front Flue Collector Aquastat Bulb e Refractory Blocked Cov
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33. Note These figures are for Natural Gas 65 Sp Gr and are based on 1 2 water column pressure drop Check supply pressure with a manometer and local code requirements for variations For LPG reduce pipe diameter one size but maintain a 1 2 minimum diameter A normal number of Tees and elbows have been taken into allowance Table 4 Natural Gas Pipe Size Requirements Gas Supply Inlet Sg pose To Equipment Tee Inlet Fitting a o 4 3 in k J lt Nipple 76mm Min CS N Cap Figure 5 Typical design for a sediment trap drip leg 4 sediment trap drip leg must be installed ahead of the gas controls see Figure 5 Fit the trap with a threaded cap which can be removed for cleaning 5 Install a manual gas shutoff valve for service and safety Do not use a restrictive gas cock Flexible gas connectors if used must be CSA rated for the total input rating of the boiler 6 Disconnect the boiler and its individual shutoff valve from the gas supply system during pressure testing of the system at pressures higher than 1 2 pounds per square inch psi 3 45 kilopascals kPa If the test pressure is equal to or less than 1 2 psi 3 45 kPa close the manual shutoff valve on the heater during the piping pressure test 7 Ifthe gas supply pressure is less than required check for undersized pipe between the meter and the boiler a restrictive fitting or an unders
34. S69vOL cOS69vOL c0OS69vOL L0S69vOL L0S69v0L JBAOD 8IIL 90 S8evOL 90ES870l OLEG8SYOL OLES8YOL LLEGBSYOL LLES8VOL 60 S8vOL 60 S8v0L 80 S8v0L 90 S8v0L LOESSTOL LOESsrOL eyjeg JeDueuox3 yea 90Lv6vOL 90Lv6vOL GOLYEYOL GOLY6YOL CON900GOL c0900S80L 20900S0L 20900S0L L10900S0L 10900804 L10900S0L 10900S0L 18109 JeuJng 008SvOLL O08SvOLL 0O08SvOLL O08STOLL OO8STOLL O08STOLL O08SvOLL OO08STOLL 00898007 00898002 00898002 00898002 xog 101 U09 19402 00 SvOLL 007SvOLL OOZGVOIL 007SvOLL 00Z2SvOLL 00Z7SvOLL O00ZSvOLL 007SvOLL 00898007 00898002 00898002 0089800c X0g101 U09 eseg 006S S0L O06GEGOL O06GEGOL 006S S0L O06GEGOL OO6GEGOL 006S S0L O06GEGOL O006S SO0L O06GEGOL 006S S0L O06GEGOL 487 XH Ieued sseo v 906 00 906YE00C SO6veO0c GO6GYEOOZ vOGVEOO0c ODC E06FF00Z2 E O6YEOOC cO6vEO0c cO6vCcO0c LO6vEO0c L06vC 00c 10798109 n d 9097v0LL 90927011 v092vOLV v092vVOLL v0O92vVOLL v09ZvOLL 097v0LL 097v0LL vO97vVOLL v0O97vOLL 097v0LL 097v0LL eunso dec 90v6LOLL QOYGLOLL SOv6LOLL SOVGLOLL vOVGLOLL vOVGLOLL OvGLOLL 0OvGLOLL cOVGLOLL cOVGLOLL LOYGLOLL LOVGLOLL dol QOE6LOLL 9086101 SOE6LOLL GOEGLOLL 086101 EOEGLOLL 0O 6LOLL EOEGLOLL LOEGLOLL LOEGLOLL LOEGLOLL LOEGLOLL Jexyoer 90COCOLL 90c0cO0LL SOZOZOLL SOCOCOLL OCOCOLL 0cOcCOLL 0OcOCOLL 0cOCOLL LOZOCOLL LOCOCOLL LOZOCOLL LOCOCOLL oueg Jees QOLOZOLL 90O
35. T APPROXIMATELY 3 F 1 7 C Figure 11 L6008G Operation Page 22 BRADFORD WHITE CORP On continuous pilot ignition models BJVT if the water temperature is below the limit setting the ignition module opens the main gas valve and the main burners ignite Operation will continue on all ignition systems until either the wall setting thermostat is satisfied or the high limit thermostat opens The burners and pilot on BJVS models shut off and the pump relay turns off the pump The damper activator rotates the damper blade to the closed position and the indicator light goes off When the room temperature falls below the wall thermostat setting the cycle repeats Note When equipped with a pump delay option the pump runs for a short time after the burners turn off and the damper closes 7 2 Start up 7 2 1 Filling the System NOTE It is strongly recommended that the system be cleaned and flushed to remove scale oil paste flux etc before the system is filled It is crucial to the efficient operation of the system that all air be removed from the circuit For this reason an air scoop and vent should be located close to the boiler outlet and there should be a minimum distance between cold water feed and system purge valve 1 When the system has been completely installed close all air vents and open the makeup water valve Allow the circuit to fill slowly 2 Adjust the pressure to provide a minimum of 12
36. allow System Purge Valve A device used to purge air from the circuit Should be located as close as possible to the cold water feed but not immediately after the cold water feed Trunk The section of piping which connects the boiler return and supply with the branch es Also known as a main or header Should be same size as boiler inlet outlet connections Vent Damper optional in Canada Standard on BJV boilers This energy saving device prevents heated air from exiting the open vent when the boiler is not operating Zone Pump Circulators installed in branch piping that divert hot water coming from the boiler into various areas zones of a building Zone Valve Diverts hot water from the boiler into various areas zones of a building SECTION 11 Replacement Parts 11 1 Ordering Information To order or purchase parts for the Brute Mini BJVS or BJVT boiler contact your nearest Representative If you need assistance in finding a local dealer or distributor contact the Technical Service Department NOTE To supply the correct part it is important that you state the model number serial number and type of gas when applicable This information is on the rating plate on the heater 11 2 Parts List The following pages contain a parts list and a general exploded view to aid in parts identification Please refer to these pages when ordering parts for your BJVS or BJVT boiler BRADFORD WHITE CORP Page 32
37. amage caused by improper assembly installation operation or field modification 1 3 Codes and Standards The BJV Hydronic Boiler or Brute Mini is design certified by CSA Canadian Standards Association as complying with the latest edition of the Standard for Gas Fired Low Pressure Steam and Hot Water Boilers ANSI Z21 13 in the USA and CAN1 4 9 in Canada All boilers must be installed in accordance with the local building and installation codes as per the utility or authorities having jurisdiction All local codes take precedence over national codes In the absence of local codes refer to the following national codes for installation 1 Inthe United States the latest edition of The National Fuel and Gas Code ANSI Z223 1 Specifically refer to Chapter 10 Venting of Equipment 2 In Canada the latest edition of The Installation Codes for Gas Burning appliances and Equipment CSA B149 1 Any changes to the boiler gas controls gas orifices wiring draft diverter or improper installation may void the warranty If change is required to any of the above consult the factory 1 4 Technical Assistance Consult Bradford White or your local factory representative with any questions or problems involving the specifications installation and operation of your equipment An experienced technical support staff is ready to assist you in assuring the proper performance and application of products For technical support cal
38. ation code as stated in the following warning Page 8 BRADFORD WHITE CORP WARNING Vent pipe diameter must be as required by the National fuel Gas Code Z223 1 or the Canadian Installation Codes for Gas Appliances CSA B149 1 Undersize pipe can result in inadequate venting and oversize pipe can result in vent condensation In either case the result can be release of combustion products to the indoors This can cause serious injury or death by carbon monoxide poisoning or asphyxiation AVERTISSEMENT Le diam tre des tuyaux de ventilation doit r pondre aux exigences du National Fuel Gas Code Z223 1 ou du code canadien des installations des appareils gaz CSA B149 1 Des tuyaux trop petits rispquent d entrainer une ventilation inad quate et des tuyaux trop gros risquent de provoquer une condensation dans les tuyaux Dans un cas comme dans l autre des produits de combustion risquent de s chapper dans le b timent et causer des blessures graves ou l asphyxie par le monoxyde de carbone BJVS BJVT Vent Pipe Diameter Size inch cm 50 4 10 75 5 13 100 5 13 125 6 15 160 6 15 225 7 18 Table 3 Exhaust Vent Connection Size 3 3 Vent Pipe Sizing and General Installation All vent installations and boiler stacking must be designed and installed in accordance with all local state or provincial codes and with 1 Chapter 7 Venting of Equipment of the national Fuel Gas Code ANS
39. audi re Les unions di lectriques ou avec tuyau en plastique peuvent isoler la chaudi re lectriquement Les membres du personnel de service et d entretien qui travaillent sur et autour de la chaudi re peuvent marcher dur des planchers mouill s et pourraient se faire lectrocuter par une chaudi re non mise la terre 6 4 Auxiliary Devices 6 4 1 Flow Switch If the system includes a flow switch it should be wired in series with the high limit switch The boiler will not fire unless the pump is running and the flow switch is closed Field installed safety devices and operating controllers such as a valve end switch draft switches relays timers and outdoor temperature reset devices can be connected to the boiler through the wall thermostat circuit Do not exceed a draw of 30VA on the transformer secondary 6 4 2 Heat Anticipator For single zone installations the wall thermostat heat anticipator should be set at 0 5 amperes For multi zone installations have a qualified electrical technician make the necessary measurements to properly set the thermostats SECTION 7 Operating Instructions 7 1 Normal Operation The Brute Mini BJVS and BJVT boilers are capable of automatic operation based on a call for heat at present temperatures The boiler has an internal safety system which allows operation in a variety of conditions and prevents operation when certain adverse conditions are encountered When the wall thermo
40. ch must be removed to drain that side Both sides must be drained i 10 The gas and electric controls on the boiler are p Boiler Components and Ihem engineered for long life and dependable Operation operation but the safety of the equipment 1 Gas Valve Regulator The gas valve controls depends on their proper functioning It is Figure 14 1 BUVS Pilot 2 BJVH Pilot 3 Main Burner Flame Pattern 4 BJVT Pilot gas flow into the manifold It provides flow only when the temperature control requires heat and only if all safety controls enable operation It is also a positive pressure regulator It regulates the gas pressure in the manifold to specifications addressed earlier in this manual This is necessary for proper operation of the burner system BJVS 100 225 Only Gas Valve Regulator has two output stages controlled by two stage temperature control Brute Mini Hydronic Boiler Page 27 A Caution Two stage Operating Control BUV100 225 ONLY Factory setting is 140 F 60 C This setting is correct for most hydronic heating applications Adjustments to this setting must be made by an authorized service technician 2 Two stage Temperature Control BJVS 100 225 are equipped with a two stage temperature control which senses inlet water temperature It is used to control the firing rate of the main burners cycling the gas valve between low high and off 3A Ignition Control BJVS Whe
41. e d vacuation commun et tous les ventilateurs d extraction comme les hottes de cuisini re et les ventilateurs des salles de bain S assurer que ces ventilateurs fonctionnent la vitesse maximale Ne pas faire fonctionner les ventilateurs d t Fermer les registres des chemin es Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Mettre l appareil inspect en marche Suivre les instructions d allumage R gler le thermostat de facon que l appareil fonctionne de facon continue Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the Page 10 BRADFORD WHITE CORP flame of a match or candle or smoke from a cigarette cigar or pipe Faire fonctionner le br leur principal pendant 5 min ensuite d terminer si le coupe tirage d borde l ouverture de d charge Utiliser la flamme d une allumette ou d une chandelle ou la fum e d une cigarette d une cigare ou d une pipe 6 Afterit 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 Une fois qu il a t d termin selon la m thode inidqu e ci dessus que chaque appareil raccord au syst me d vacuation est mis
42. ead from a 115V power supply to both wires Secure the three wires with the wire nut The white neutral wire should be joined to the other neutral lead coming from the 115V power supply and the neutral lead coming from the pump The brown wire attaches to the hot side of the pump NOTE No external junction box is required 4 Attach the leads from the wall thermostat to the R and W terminals on the terminal strip located on the left side of the control box Brute M ini Hydronic Boiler Page 17 o VENT DAMPER TRANSFORMER AQUASTAT HIGH RECEPTACLE g gp BW LLL sor HOT OPTIONAL LIMIT 115 60HZ DIM E OF Ww i Wa fh POWER SUPPLY ma ou OP NEUTRAL R Y G ALL P R L J 1 GROUNDING THERMOSTAT CONDUCTOR FIELD l SUPPLIED 1 4 FY n Z I Spes d SE A Q 1 Mie TERMINAL x SUPPLIED STRIP POWER VENTER RECEPTACLE SEE DOC 1077 THE BOILER WILL NOT OPERATE WITHOUT THE E AUTOMATIC VENT DAMPER OQ HARNESS MUST BE IN nex cs E BLOCKED IN CANADA SOME UNITS ER VENT ARE SUPPLIED WITH VENT ze SAFETY DAMPER JUMPER PLUG aK SWITCH UNLESS VENT DAMPER S TO BE INSTALLED ROLLOUT ro BICBLACK SWITCH ae F IGNITION YELLOW S
43. ement Faites inspecter l appareil par un technicien qualifi et remplacez toute partie du syst me de contr le et toute commande qui ont t plong s dans l eau Brute M ini Hydronic Boiler Page 23 A Caution Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance Attention En cas de surchauffe ou si l admission de gaz ne peut tre coup e ne pas couper ni d brancher l alimentation lectrique de la pompe Fermer plut t le robinet d admission de gaz l ext rieur de l appareil A Caution Do not attempt repairs on the gas controls or appliance Tampering is dangerous and voids all warranties Attention Ne tentez pas d effectuer des r parations au syst me de r gulation du d bit du gaz ou l appareil Toute modification non autoris e est dangereuse et entraine l annulation de toutes les garanties A Caution Keep all objects off the top of the boiler Blocking air flow could damage the heater and may void the warranty Attention Ne posez aucun objet sur le dessus de l appareil Il pourrait emp cher la circulation de l air ce qui risquerait d endommager l appareil et d annuler la garantie 7 3 Lighting and Shutdown Procedures WARNING Do not attempt to light the boiler with the burner cover off Doing so may cause s
44. er big Safe Control Mo Switch Con Nipple Switch Model 50 G Terminal and 100 lt ransformer ump Relay Assembly HX Access Panel Burner with Pilot Bracket Rear Panel Pilot Assembly 1 2 Coupling Gas Manifold Model 50 and 100 P0005200 Orifices Jacket One Piece Pilot Gas Tube Wraparound Gas Valve 2 Stage Operating Control 100 225 Burner Cover Flame Roll Out Safety Switch Figure 15 Parts Identification Brute M ini Hydronic Boiler Page 35 Hydronics Industry Alliance H2343000 Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement Ambler PA 19002 Tech Service 800 334 3393 Speen BRADFORD WHITE Service Parts 800 538 2020 www BradfordWhite com CORPORA TION Warranty Service 800 531 2111 Litho in U S A Bradford White 1101 Document 1242
45. evere bodily injury AVERTISSEMENT Ne tentez pas d allumer l appareil sans que la soit en place Vous pourriez tre victime de blessures corporelles graves Before starting your boiler be sure that all of the functions and limits of the BJVS and BJVT boilers have been set according to the previous section of this manual Section 7 2 Follow the instructions outlined below Read and follow all safety instructions first A more detailed set of lighting and shutdown instructions are listed on the label located on the boiler NOTE If your boiler is configured to operate on LP gas and the LP tank runs out of fuel turn off gas at the boiler After the tank is refilled the boiler must be relit following the instructions found on the boiler DO NOT attempt repairs on the gas control or heater Tampering is dangerous and voids all warranties WARNING If the information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death AVERTISSEMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommage mat riel toute blessure ou la mort 7 3 1 Lighting the Boiler Lighting instructions are as follows 1 Verify that the pump system is operating properly a Shut off the manual gas valve located outside the boiler b Raisethe wall ther
46. fety 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 As an additional precaution it is recommended that a Carbon Monoxide CO alarm be installed in all enclosed spaces containing combustion appliances If assistance is required in determining how a blocked vent safety system should be connected to a product please call Applications Engineering see back cover for info 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 4 living spaces common venting should not be applied and appliances should each be vented separately 3 4 2 Inspection of Commonly Vented Appliances If the instrumentation of this boiler replaces an older boiler in a common vent system with other appliances or if you remove additional appliances 5 from the common vent all the appliances must be checked for proper venting 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
47. form System Start Up in accordance with Section 2A of this manual 9 Observe flame pattern on all burners If the flame on any burner is pulsing unstable or lifting then repeat steps 5 and 6 until all burners are exhibiting a normal flame 10 Re install the burner cover and tighten it in place N po ss LOCKING SCREW 5 16 HEAD AIRSHUTTER BURNER Figure 13 Air Shutter Adjustment SECTION 8 Maintenance 8 1 General Maintenance WARNING Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury or death AVERTISSEMENT Une installation ou un entretien inad quat peut causer la naus e ou l asphyxie en raison du monoxyde de carbone pr sent dans les gaz de combustion et m me entrainer des blessures graves ou la mort WARNING SERVICING SAFETY Some of the servicing procedures for the Brute Mini BJVS and BJVT boilers are hazardous because they involve fuel gas electricity moving parts and procedures which require testing or temporary bypass of safety controls For this reason the heater must be serviced only by a qualified professional service technician IMPROPER SERVICE HAZARD The Brute Mini BJVS and BJVT boilers incorporate unique design features Incorrect service of this boiler can result in personal injury or damage to property To avoid such hazards the
48. he draft hood venting top flue l eau m me partiellement Faites inspecter collector and heat exchanger baffles l appareil par un technicien qualifi et remplac c Remove the burners by lifting them off the ez toute partie du systeme de contr le et toute orifices and pulling them out of the boiler commande qui ont t plong s dans l eau d Use a hand operated spray bottle filled with 7 Be sure that all combustion air and ventilation water and a wire brush to clean soot and openings are unobstructed loose scale from the underside of the heat 8 Upon completion of the installation inspect the exchanger DO NOT USE COMPRESSED external surfaces of the heat exchanger for AIR HIGH PRESSURE WATER OR A fouling based on the following schedule GARDEN HOSE 24 hours 7 days 30 days 90 days e Clean any fallen debris from the bottom of Once every six months thereafter he wink 9 If the boiler is not going to be used for long f Check to make sure the burner ports and periods of time in locations where freezing pilot assembly are free of debris before occurs it should be completely drained of all returning the burners to their original water To accomplish this there is a drain valve position on the right side of the boiler which can be g Reassemble the boiler in reverse order opened This will drain the right side of the making sure to replace the heat exchanger boiler There are two plugs located on the left baffles side of the heater whi
49. ic Union as an Automatic Bypass NON LOW TEMPERATURE SYSTEMS 120 F Return Temps lt lt Isolation To System Pump Isolation From Valve System Simple Primary Secondary Piping Hydronic Not Low Temp NOTE All closed loop systems should include air elimination expansion tank and feed water inlet Place at point of lowest pressure typically at the inlet of pump NOTE Ball valves should not be used as balancing valves Only use for shutoff apps Figure 6 Typical Plumbing Installations Page 14 BRADFORD WhHITE CORP Air Cushion Type Expansion Tank Optional Feed Water Bypass Valve Ball Valve ve im 2 x x Bypass Valve Xo po Ball Valve lt Optional Pump Location Valve System Boiler Multi Zone BJV i E Air Scoop Inlet installed at proper places Bypass B Valves Zone Pumps must be sized properly lt gt Flo Checks Multi Zone BN CH Feed Pump Boiler Air Scoop Inlet System fe n KEY PUMP EI CHECK VALVE Ka VALVE D ZONE VALVE E UNION E AUTO AIR BLEEDER LT Figure 6A Typical Plumbing Installations Air Scoop Pump System oop ft Feed Expansion Sot Water Figure 6B Typical Plumbing Installations Brute M ini Hydronic
50. in front of the boiler for burner removal Consult local codes for clearances to hot water pipes and accessories If the boiler is to be installed in a garage all burners and burner ignition devices must have a minimum 18 457mm clearance above the floor The Model BJV 50 through BJV 100 boilers can be installed in a closet as long as the minimum clearances shown in Table 1 and Figure 3 are observed Special attention should be paid to clearances between the front of the boiler and the closet door when it is closed Consult the American National Standard Z21 13 for more information concerning closet installations In Canada refer to the latest edition of CSA B149 1 6 for models BJV160 to BJV225 Figure 3 Closet and Alcove Installation see Table 3 2 3 2 Flooring The boiler shall be installed on a level floor of noncombustible construction or on fire resistant slabs or arches Noncombustible flooring is defined as flooring material and surface finish not capable of being ignited and burning and with no combustible materials against the underside Acceptable materials are those consisting entirely of a combination of steel iron brick tile concrete slate glass or plaster Do not install the heater directly on a combustible wood or carpet floor without placing a noncombustible platform between the floor and the heater The boiler can be installed on a combustible floor if a noncombustible base assembly available from i
51. ing one millivoltmeter lead on the center post of the tube and the other lead on the copper tubing If the meter shows a reading of approximately 30 millivolts proceed to the second test If it doesn t replace the pilot thermocouple The second test requires the use of a Millivolt Reading Adapter to test the thermocouple under load Once again remove the pilot thermocouple compression fitting from the gas valve Replace it with a Millivolt Reading Adapter and screw the thermocouple fitting into the end of the adapter Attach one lead from the millivoltmeter to either side of the adapter and the other lead to ground Light the pilot and set the wall thermostat high enough to call for heat With the boiler firing take a millivolt reading It should be in the 15 millivolt range If it isn t replace the pilot thermocouple A Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing A ATTENTION Au moment de l entretien des commandes mettez des tiquettes sur tous les fils avant de les d brancher Des erreurs de cablage peuvent causer un fonctionnement inad quat et dangereux V rifier que tout fonctionne bien apr s votre entretien SECTION 10 Glossary 10 1 Glossary of Terms Air Vent Another device used to purge air from the circuit Should be located at the highest point in the circuit Branch The sec
52. ized gas meter Gas supply pressures to the heater are listed in Table 5 NOTE The maximum inlet gas pressure must not exceed the specified value The minimum value listed is for the purpose of input adjustment Refer to Table 5 Distance Boiler Size Supply Pressure Minimum Maximum l rm Gas 50 75 100 125 160 225 Natural Gas 5 5 Inches WC 10 5 Inches WC SS Pipe Size 1 3 kPa 2 5 kPa 0 50 LP Gas 10 0 Inches WC 13 0 Inches WC 1 2 3 4 3 4 3 4 1 1 0 15m 2 4 kPa 3 1 kPa deii 3 4 3 4 3 4 1 1 1 1 4 Table 5 Gas Supply Pressure Requirements 30m 100 200 S ee 3 4 1 1 1 1 1 4 1 1 4 NOTE The boiler and all other gas appliances sharing the boiler gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure Low gas pressure could be an indication of an undersize gas meter and or obstructed gas supply line 8 Thecorrect high fire burner manifold gas pressure is stamped on the rating plate The regulator is pre set at the factory and normally requires no further adjustment For two stage units BJVS 100 225 be sure unit is able to fire at both high and low fire 9 Before operating the boiler the complete gas supply system and all connections must be tested for leaks using a leak detector solution Do not use an open flame A Caution Some leak test solutions including soap and water may cause corrosion or stress cracking Rinse the piping with water after testi
53. l air libre de facon ad quate Remettre les portes et les fen tres les ventilateurs les registres de chemin es et les appareils au gaz leur position originale 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 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 Appendix G in the National Fuel Gas Code ANSI Z223 1 Tout mauvais fonctionnement du syst me d vacuation commun devrait tre corrig de facon que l installation soit conforme au national Fuel Gas Code ANSI Z223 1 et ou aux codes djinstallation CSA B 149 1 Si la grosseur d une section du syst me d vacuation doit tre modifi e le syst me devrait tre modifi pour respecter les valeurs minimales des tableaux pertinents de l appendices F du National Fuel Gas Code ANSI Z2231 1 et ou des codes djinstallation CSA B149 1 SECTION 4 Gas Connections 4 1 Gas Supply and Piping Review the following general instructions before continuing the installation WARNING The Brute Mini BJVS and BJVT boilers are designed for use with either natural gas or LP gas Check the rating plate to be sure that the boiler is designed to use the type of gas being supplied DO NOT ATTEMPT TO CONVERT THIS HEATER FOR USE WITH ANY OTHER TYPE OF FUEL
54. l the Bradford White Technical Service Department 1 5 Materials Installer Must Provide 1 5 1 Materials for All Installations The following items are needed and are to be supplied by the installer for all Brute Mini boiler installations 1 The correct size gas pipe to supply the gas to the boiler see Section 4 1 for correct gas pipe size 2 ACSA listed manually operated gas valve to be installed in the gas line outside of the boiler jacket 3 Asuitable gas union joint or other removable connector to connect the boiler to the gas line outside of the boiler 4 Plumbing items needed to provide a sediment trap drip leg in the gas line between the manual gas valve and the union to the boiler 5 A115 VAC power supply A junction box is not needed at the boiler connections are made inside of the boiler s control panel see Figure 8 6 Vent pipe ofthe same or larger diameter as the vent damper or draft diverter outlet see Section 3 3 for venting instructions 1 5 2 Materials for Most Installations In addition to the items listed above the following items may be needed 1 Plumbing materials for the bypass piping which is required for a Any system where the return water Page 4 BRADFORD WHITE CORP temperature may be less than 120 F such as in floor radiant systems snow melt systems or other systems where a cold start is expected frequently due to thermostat setbacks etc See Figure 11 b Any system
55. mostat high enough to call for heat c The pump should come on immediately If it doesn t test the electrical circuits 2 Pilot Information a The BJVS boilers do not require manual lighting The pilot is controlled by the automatic ignition system b The BJVT boilers do require manual pilot lighting For access to the pilot burner remove the louvered airbox cover by loosening the two thumb screws c Different models of the BJV boiler utilize various gas valves Although the gas valves may have different control knobs they are all similar in operation The BJVS gas valve has a two position knob ON and OFF The BJVT valve has a three position knob ON OFF and PILOT some models come with extra push button see Figure 12 De Figure 12 Gas Valves Page 24 BRADFORD WHITE CORP 3 BEFORE LIGHTING smell all around the 14 Turn gas control knob counterclockwise appliance area for gas Be sure to smell next to to ON the floor because some gas is heavier than air 15 Replace control box cover and will settle on the floor 16 Restore power to the boiler and adjust the thermostat high enough to call for heat to verify a WHAT TO DO IF YOU SMELL GAS the boiler is j ARMAR a l Donottry to light any appliance 17 BJVS 100 225 ONLY Adjust two stage a 2 Do not touch any electric switch do not use operating control setting to maximum verify any phone in your building high fire operation Reduce setting to
56. n the thermostat calls for heat and all limits are satisfied a pilot trial for ignition is initiated If pilot is not established a 5 minute minimum delay is implemented prior to the next trial for ignition This cycle repeats until pilot is established or the system is shut down manually BJVS 100 225 only Once pilot is established the main valve is enabled and controlled by the two stage temperature control BJVS 50 75 only Once pilot is established the main valve will open until the limit circuit opens 3B BJVT Flame Control The standing pilot BJVT models rely on a flame sensor on the gas valve When the thermostat calls for heat and adequate pilot flame is sensed the gas valve will open The valve will remain open until the limit circuit opens 4 Pilot Assembly BJVS The pilot assembly utilizes an electrode that is used to generate spark to ignite the pilot flame as well as sense flame presence BJVT The BJVT pilot is lit manually and senses pilot flame via a thermocouple which generates a signal that allows the gas valve to open 5 Hi Limit Switch Factory setting is 190 F 88 C This setting is correct for normal operations and should only be changed by an authorized service technician Under no circumstances should the setting exceed 220 F 104 C 6 Blocked Vent Switch BJVS and BJVT boilers are equipped with a manual reset blocked vent switch designed to shut the boiler down in the event the vent is comple
57. ng A Attention Certaines solultions d essai d tanch it y compris l eau et le savon peuvent causer de la corrosion ou de la fissuration Rincez les tuyaux l eau appr s l essai d tanch it 4 2 Special Precautions for LP Gas LP Gas is heavier than air and can therefore more readily collect or pool in enclosed areas if provision for proper ventilation is not made Be sure to pay special attention to proper ventilation for LP gas Locate boilers a safe distance from LP gas cylinders and filling equipment In the United States consult the National Fuel Gas Code NFPA 54 ANSI Z223 1 latest edition or in Canada the Propane Installation Code CSA B149 1 any local codes and fire protection authorities about specific installation restrictions in your area Page 12 BRADFORD WHITE CORP SECTION 5 Water Connections 5 1 Water Piping Figure 6 shows typical plumbing installations Be sure to provide unions and isolation valves at the boiler inlet and outlet so it can be isolated for service Check local codes for specific plumbing requirements before beginning the installation An ASME pressure relief valve is supplied on all BJV boilers and is pre set at 30 PSI The valve outlet piping must discharge to a drain Under no circumstances should the relief valve piping be a closed circuit A pressure reducing valve automatic feed must be used to maintain system at constant proper pressure
58. o Stage BJVS 100 225 Figure 9f Schematic Two Stage BJVS 100 225 Fuse Zone Pump 4 Relay Zone Pump 6 Relay Jumper oo oo 110V 110V Hot Neutral Zone Space Heating Pump i i Relay Field Supplied 1 3 RE t H lt Bus e Done 1 SF 115V Ka P 24V Thermostat Zone Boiler Field Boiler Pump Terminal Supplied Terminal Relay ie ro fr te ee w o R o 34 qu Boiler Optional High Terminal Aquastat Limit CE SC Vent e Damper 000 Receptacle 000 A Power Ignition Control Venter Receptacle op T Blocked Roll Out Vent sorely witci Safety i Pilot Burner With Spark Electrode FN GR Sensor LO HI x lt H e i Remote Flame Sensor Two Stage Two Stage High Altitude DK Ga Valve Aquastat Optional HW VR8304 Page 20 BRADFORD WHITE CORP I Ooj I 1 NOTE The total power requirement I 3 I of the Zone Valves should not exceed L J Loti 1 the total capacity of the transformers 115V Factory Wired 2 1 I See Zone Valve manufacturer s 115V Field Wired Wai I I installation instructions for valve 24V Factory Wired a Z 1 Val I electrical requirements 24V FiedWied 1 Thermostat m i
59. ocked Roll Out A Vent Safety x Safety Switch Switch 3 In PV MV MV PV Remote Flame Sensor Gas Vale High Altitude Optional HW VR8304 Figure 9b Schematic Spar BJVS 50 amp 75 k Ignition System Page 18 BRADFORD WHITE CORP AQUASTAT OPTIONAL HIGH LIMIT o VENT DAMPER RECEPTACLE 7 Y C Ort M OO ef WALL THERMOSTAT FIELD SUPPLIED v EJ RI JI w BL A STRIP JUMPER TERMINAL POWER VENTER RECEPTACLE SEE DOC 1077 P ORe v BK ROLL OUT R RED Y YELLOW BL BLUE BR BROWN O ORANGE P PURPLE G GREEN 115V FIELD WIRED 24V FIELD WIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE IT MUST BE REPLACED WITH APPLIANCE WIRING MATERIAL SUITABLE FOR 105 DEGREES C OR ITS EQUIVALENT BLOCKED BK BLACK SAFETY T DE SWITCH SPARK IGNITION WIRE 115V FACTORY WIRED 24V FACTORY WIRED PPLIANCE MUST BE REPLACED SWITCH VENT BR TH TR ILO K GAS VALVE HW VR8300 PILOT BURNER amp THERMOCOUPLE 115 60HZ POWER SUPPLY NEUTRAL
60. odification of Boiler for High Altitude Brute Mini Boilers are normally shipped from the factory in the low altitude sea level operational configuration When requested the boilers can be configured and shipped for higher altitudes For field conversions to change altitude configurations conversion parts are available from For more information or call the Customer Service Department 1 6 2 Dimensions See Figure 1 for a diagram showing the boiler s exterior dimensions and dimensions to critical connections on the boiler SECTION 2 Installation Instructions 2 1 Introduction WARNING Improper installation or maintenance can cause nausea or asphyxiation from carbon monoxide in flue gases which could result in severe injury or death AVERTISSEMENT Une installation ou un entretien in ad quat peut causer la naus e ou l asphyxie en raison du monoxyde de carbone pr sent dans les gaz de combustion et m me entrainer des blessures graves ou la mort Install the Brute Mini boilers and vent dampers in accordance with the procedures in this manual local codes and ordinances and in accordance with the latest edition of the appropriate national code see Section 1 3 Codes and Standards All gas fired products require correct installation to assure safe operation The requirements for boilers include the following 1 Field assembly 2 Appropriate site location clearances and flooring Sufficient combusti
61. oltage transformer hi limit switch heat NO thermostat controller and wiring Power to module 24V nominal YES Pull ignition lead and check spark at module NO Spark okay Spark across igniter sensor gap YES YES Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot from excessive temperatures Check that all manual gas valves are open supply tubing and pressures are good and pilot burner orifice is not blocked Turn gas supply on NO Check electrical connections between module and pilot operator on gas Pilot burner lights control Check for 24 Vac across PV MV PV terminals on module If voltage is YES okay replace gas valve if not replace module Check continuity of ignition cable and ground wire Spark Bus when pilot NO Clean flame rod ziii Check electrical connections between flame rod and module YES Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame f problem persists replace module Check for 24 Vac across MV MV PV terminals If no voltage replace Main burner lights NO module Check electrical connections between module and gas valve If okay YES replace gas valve Check continuit
62. ommonly Vented SECTION 9 elei rte 9 Troubleshooting 9 1 General Boiler Troubleshooting 27 SECTION 4 9 2 Troubleshooting Guide 28 Gas Connections 9 3 Troubleshooting Honeywell S8600 4 1 Gas Supply and Piping 10 Intermittent Pilot System 29 4 2 Special Precautions for LP Gas 11 9 4 Electrical Troubleshooting 30 SECTION 5 SECTION 10 Water Connections Glossary 5 1 Water Piping 11 12 10 1 Glossary of Terms pessier 30 5 1 1 By pass Piping 12 5 2 Alternate Auto Bypass Operation 12 SECTION 11 5 3 Flow Requirements 15 Replacement Parts 9 4 Chilled Water Systems 16 11 1 Ordering Information 31 29 Oxygen Peta egener 19 342 Pars Tl uama acter arat 31 SEH APRES sS SSS 1 MF Epod Vi sits 34 Brute Mini Hydronic Boiler Page 3 SECTION 1 General Information 1 1 Introduction This manual provides information necessary for the installation operation and maintenance of Model BJV copper tube hydronic boilers All application and installation procedures should be reviewed completely before proceeding with the installation Consult the factory or local factory representative with any problems or questions regarding this equipment Experience has shown that most operating problems are caused by imprope
63. on and suggestions are made on by pass piping as it affects the temperature rise at the boiler A boiler temperature rise must be taken on all BJV boiler installations If the temperature rise exceeds 30 F 17 C at full rate it is an indication that the boiler is not receiving adequate water flow Check the pump for any obstruction replace the pump with a larger size where necessary or install a system by pass as indicated in Figures 6 and 7 A full sized 1 4 bypass with balancing valves is strongly recommended for all systems and required when 1 the boiler is installed without primary secondary piping in a multiple zone system 2 when the return water temperature can be expected to be lower than 120 F 44 C or 3 whenever the system piping on the outlet side of the boiler may allow reduced flow through the heat exchanger causing excessive temperature rise see Section 5 2 Note Bradford White strongly recommends a primary secondary piping system for all installations especially sizes 125 160 and 225 In this system a circulator is dedicated to pumping the boiler only This circulator should be sized for the boiler head loss and flow rate All precautions must be taken by the installer to insure that a maximum temperature rise through the boiler does not exceed 30 F 17 C The temperature rise on boilers installed in multi zone systems using zone valves must be taken when the zone of the longest length and or the z
64. on and ventilation air Properly sized gas meter and piping Proper electrical wiring if required Adequate water flow This manual provides the information needed to meet these requirements Review all application and installation procedures completely before continuing the installation PE aad NOTE The Brute Mini boiler is approved for indoor installation only Brute Mini Hydronic Boiler Page 5 mm Vent D Draft Vent Damper Gemen Divergr NN optional in Canada 1 1 4 NPT i IG 4 i In Return I tC PRV 8 D i i 9 1 7 17 3 4 Out S h a re qu t 451 kaso c i O Q T amp P Gauge Left L Front Side O Top J View View View Y Dimensions in inches cm i S lt A Dimensions Water Gas inches cm Conn Conn Size A B C D E V in in 50 13 3 8 34 27 84 71 23 5 8 60 21 3 4 55 26 12 67 4 10 14 4 172 75 13 3 8 34
65. one of the highest head loss is open A full size 1 4 diameter by pass with balancing valve must be installed if a return water temperature below 120 F 44 C is expected under operating conditions regardless of boiler size This may be expected in many systems including in floor radiant and snow melt systems Adjusting the bypass Refer to figure 7 Provide a means of measuring temperature on the inlet pipe to the boiler such as using a strap on or infrared themometer Starting with both balancing valves fully open start the boiler Adjust the balancing valve on the return to the system slowly to provide 120 F 44 C water at the inlet to the boiler leaving the bypass balancing valve fully open As the system warms up this valve may need to be adjusted open In rare cases this valve will have to be kept fully open and the bypass balancing valve adjusted toward closed to prevent heated bypass water from satisfying the call for heat when the system is up to temperature 5 2 Alternate Auto Bypass Operation Use of the themostatic union p n 2400 030 can provide automatic bypass operation in primary secondary piped systems but cannot be used when primary secondary piping is not used The thermostatic union is installed on the outlet piping after the bypass assembly It can be used in place of a balancing valve It opens fully at 140 F see Figure 6 Contact the factory for more information Brute M ini
66. ostat should be wired to R amp W terminals For multiple zone systems with zone pumps thermostats for extra zones should be wired to R amp A terminals D Boiler off on blocked vent switch D Remedy as in symptom 4 Reset the manual reset switch E Boiler off on flame roll out switch E Remedy as in symptom 3 Reset the manual reset switch F Broken wire in thermostat circuit F Check continuity through thermostat circuit with wires or defective thermostat disconnected from R amp W G BJVS 100 225 Only Two stage operating G Check continuity and operation through two stage control notfunctioning orloose contact operating control 13 Boiler short cycles A Heatanticipator in room thermostat A Increase setting 0 8 1 0 is usually satisfactory set too low B Low water flow through boiler C Hi limit switch may be set too low B Increase size of pump or increase piping size C Increase setting to at least 20 F over outlet water temperature Table 8 Troubleshooting Guide Brute M ini Hydronic Boiler Page 29 9 3 Troubleshooting Honeywell S8600 Intermittent Pilot System Some boilers may be equipped with an ignition module that shuts off pilot gas if pilot fails to light To reset interrupt power to heater Start Note Before troubleshooting familiarize yourself with the start up and Turn off gas supply checkout procedure Turn thermostat controller to call for Check line voltage power low v
67. p Pump Pump Pump H P H P H P H P Figure 7 By pass Piping 1 25 1 12 1 25 1712 1 6 1 25 112 1 6 1 25 112 1 6 50 50 99 390 680 x x x 5 3 Flow Requirements 75 35 160 300 460 640 x x x All high recovery low volume water boilers must 100 a 77 150 260 330 620 a gt have adequate flow for efficient operation Pump 425 27 80 1401170 aen 600 w x selection is critical to this goal and pumps should be dedit ue wm abs 22 ee A60 330 190 480 selected to provide for system design water temperature rise Table 6 details temperature rise and ee pe Ne water flow GPM for the Brute Mini boilers Acirculator and or primary secondary piping are required Consult factory Damage from improper flow is not warranted 1 Chart is based on 30 F 17 C maximum temperature rise 2 Calculations are based on Type L copper tubing with one Failure to insure proper water flow through the zone valve and eight elbows heat exchanger of the boiler will void the warranty 3 i piece tha ECH e ee T S D 49 Grundtos E Or equivalent 12 Flow can be verified by measuring the difference in 12 Grundfos UP26 42F or equivalent HP B amp G series water temperatures between the boiler inlet and outlet HV Grundfos UP43 75 or equivalent For example For a BJV 100 installation the inlet Table 7 Maximum Suggested Circuit Length in Feet 15
68. r and set the thermostat no call for heat to the desired temperature The pilot will 2 Turn off all electrical power to the boiler automatically ignite when there is a call for heat 3 Turn the gas valve knob clockwise to OFF Do BJVT Models Continuous Pilot not force the knob BJVS skip to step 16 4 Shut off the external gas supply valve to the 8 Remove louvered burner cover by loosening the boiler two thumb screws to access the pilot burner 9 EC control box cover to fully access the 7 4 High Altitude Burner 10 Find pilot follow metal tube from gas control Air Shutter Adjustment The pilot is on the right hand side of the first burner f DANGER li N P on gas control counterclockwise E This procedure must be followed exactly and O Ig D 12 Push in control knob or push button all the way must ih jid bin Si j gualitgd installerer and hold in Immediately light the pilot with a warranty may De voided match using the match holder Continue to hold the control knob in for about one 1 minute after A DANGER the pilot is lit Release knob and it will pop back Cette mani re de proc der doit tre faite up Pilot should remain lit If it goes out repeat exactement et accomplie par un installateur qualifi steps 2 through 8 sous risque d annulation de la garantie a Ifthe knob does not pop up when released stop and immediately call your service technician or gas supplier b Ifthe pilot will not stay lit after several t
69. r installation These boilers are available in two configurations the BJVT has a thermocouple continuous burning pilot and the BJVS has an electronic intermittent ignition device LI D Look for the model designation on the rating plate which can be found on top of the boiler in the right rear corner The automatic vent dampers are standard on all U S and Canadian models The side wall power venters can be used on both BJVS and BJVT models Special instructions for their installation are included in the vent damper and power venter package Read them carefully before installation 1 2 Warranty Model BJV boilers are covered by a limited warranty The owner should fill out the warranty registration card and return it to All warranty claims must be made to an authorized representative or directly to the factory Claims must include the boiler serial number and model this information can be found on the rating plate installation date and name of the installer Shipping costs are not included in the warranty coverage Some accessory items are shipped in separate packages Verify receipt of all packages listed on the packing slip Inspect everything for damage immediately upon delivery and advise the carrier of any shortages or damage Any such claims should be filed with the carrier The carrier not the shipper is responsible for shortages and damage to the shipment whether visible or concealed The warranty does not cover d
70. ries turn the gas control knob to OFF and call your service technician or gas supplier 13 Replace the louvered airbox cover and tighten the two thumb screws securely Brute Mini Hydronic Boiler Page 25 DANGER Read and understand this entire procedure prior to proceeding Improper adjustment of high altitude shutters may result in a fire explosion and or high levels of toxic gases which may cause property damage personal injury or loss of life DANGER Lisez la mani re de proc der dans sa totalit et comprenez la bien avant de commencer Un ajustement inad quat des volets en haute altitude peut provoquer un incendie une explosion et ou des niveaux lev s de gaz toxiques qui pourraient causer des d gats mat riels des blessures personnelles voire la mort STOP Read the safety information above Perform System Start Up in accordance with Section 7 2 of this manual 3 Remove burner cover by loosening two 2 thumbscrews 4 Observe flame pattern on all burners If the flame on any burner is pulsing unstable or lifting continue with this procedure Otherwise skip to step 10 5 Onall burners exhibiting an abnormal flame loosen but do not remove the air shutter locking screw using a 5 16 inch wrench see Figure 12 6 On each affected burner slowly close the air shutter until a normal flame 1s observed then re tighten its associated locking screw Turn the boiler off Per
71. rmocouple D Damaged pilot or thermocouple D Replace E Dirty pilot E Blow dust or lint out of pilot F Plugged or undersized pilot orifice F Clean or replace pilot orifice 3 Flame roll out A Blocked flue A Remove blockage on start up B Pilot out of position delayed ignition B Correct pilot position C Blocked heat exchanger or flue C Clean and correct as necessary D Refractory tile out of place D Correct or replace tile as necessary E Altered draft diverter E Install factory provided draft diverter 4 Spillage at A Cold chimney A Allow boiler to operate 5 minutes to create draft action draft hood B Vent pipe pitches down to chimney B Reinstall vent pipe to pitch up from boiler to chimney C Blocked chimney C Remove blockage D Draft hood altered D Install factory provided draft diverter E Pre fabricated chimney with incorrect cap E Install U L listed vent cap 5 Flame has A Low primary air A Correct manifold pressure according to rating plate Correct lazy yellow tip orifice size if necessary see parts list Clean burner ports if dirty Verify correct fuel type 6 Not enough heat A Inadequate gas supply A Gas meter too small Gas line from meter to boiler too small B Low manifold gas pressure B Gas pressure on boiler manifold at normal firing rate should be adjusted to 4 0 W C natural gas 9 0 W C propane C Boiler size inadequate C Replace with boiler of higher input D BJVS 100 225 only Boiler not
72. s used See the boiler rating plate or the Parts List Section 11 of this manual for the appropriate base part number Boilers must never be installed directly on carpeting As an alternative to the noncombustible base plate in the United States the National Fuel Gas Code allows a heater to be placed on a combustible surface when there is a platform under the heater made of hollow masonry no less than 4 inches 102 millimeters mm thick covered with sheet metal at least 24 gauge thick and extending beyond the full width and depth of the heater by at least 12 inches 305mm in all directions The masonry must be laid with ends unsealed and joints matched to provide free circulation of air from side to side through the masonry see Figure 4 If the boiler is installed in a carpeted alcove the entire floor of the alcove must be covered by a noncombustible platform 12 Min lt Hollow Concrete Block Sheet Metal Cover Min Thickness 24 Gauge Galvanized Figure 4 Typical Combustible Floor Installation Brute M ini Hydronic Boiler Page 7 SECTION 3 Venting 3 1 Combustion Air Supply The boiler location must provide sufficient air supply for proper combustion and ventilation of the surrounding area as outlined in the latest edition of ANSI standard Z223 1 or in Canada CSA B149 1 and any local codes that may be applicable In general these requirements specify that boiler rooms which represent
73. stat calls for heat and the boiler is powered an operating cycle is initiated On continuous pilot ignition models BJV T the pilot must also be lit The pump relay turns on the pump the damper activator rotates the damper blade to the open position and the indicator light comes on On spark ignition models BJVS 50 75 if the water temperature is below the limit setting the ignition module lights the pilot and checks the flame existence After the pilot is proven to be lit the ignition module opens the main gas valve and the main burners ignite On 2 Stage spark ignition models BJVS 100 225 if the water temperature is below the limit setting the ignition module lights the pilot and checks the flame existence After the pilot is proven to be lit the ignition module opens the main gas valve and the main burners ignite The main gas valve is controlled by the two stage operating control see Figure 11 and will cycle between high low and off as the load demands BREAKS R B T AKES RAN LEFT SWITCH ON RISE TEMPERATURE Lz DIFFERENTIAL RISE BREAKS R W MAKES R B ON FALL LOW FIRE INTERSTAGE DIFFERENTIAL BREAKS R B BQILER INLET Z DIFFERENTIAL ADJUSTABLE BREAKS R W ORY SET Y _ MAKES R B 140 ON FALL HIGH FIRE DIFFERENCE BETWEEN THE TEMPERATURES AT WHICH THE TWO SWITCHES MAKE R W FACTORY SET AT 10 F 6 6 C TWO SPDT SWITCHES OPERATE IN SEQUENCE EACH SWITCH DIFFERENTIAL A
74. t de r paration des appareils de chauffage faibles missions pr sentent des changers car elles mettent en jeu des gaz combustibles des composants lectriques des pi ces mobiles et des proc dures qui n cessitent des mises l essai ou la d rivation temporaire des commandes de s curit Pour cette raison l appareil de chauffage doit tre entretenu et r par uniquement par un technicien professionnel qualifi DANGERS D UN ENTRETIEN INAD QUAT Les appareils de chauffage faibles missions comportent des caract ristiques techniques uniques Une r paration ou un entretien inad quat peut entrainer des blessures corporelles ou des dommages a la propri t Pour cette raison l appareil de chauffage doit tre entretenu et r par uniquement par un technicien professionnel qualifi Page 28 BRADFORD WHITE CORP 9 2 Troubleshooting Guide Symptom Cause Remedy Pump not A No power A Check circuit breakers and power source operating B Pump defective B Replace C Incorrectly wired C Recheck wiring diagrams 2 Pilot outage A Inlet gas pressure too low A Consult gas utility company Inlet gas pressure to boiler should be 5 5 to 10 5 water column on natural gas 0 0 to 13 0 on propane gas B Inlet gas pressure too high causing B Pressure should be regulated within limits shown above an unstable blowing pilot C Weak or defective thermocouple C Replace the
75. tely blocked The switch is located in the draft diverter opening on the rear of the boiler 7 Rollout Switch BJVS and BJVT boilers are equipped with a manual reset rollout switch designed to shut the boiler down in the event a flame rollout situation occurs causing excessive temperatures The switch is located on the burner cover SECTION 9 Troubleshooting 9 1 General Boiler Troubleshooting Table 8 lists some of the more common problems causes and solutions encountered when running the boiler Most problems occur when the boiler is being started for the first time after installation Careful installation and maintenance will help ensure years of trouble free use from your Brute Mini boiler WARNING SERVICING SAFETY Some of the servicing procedures for the Brute Mini BJVS and BJVT boilers are hazardous because they involve fuel gas electricity moving parts and procedures which require testing or temporary bypass of safety controls For this reason the boiler must be serviced only by a qualified professional servicetechnician IMPROPER SERVICE HAZARD The Brute Mini BJVS and BJVT boilers incorporate unique design features Incorrect service of this heater can result in personal injury or damage to property To avoid such hazards the boiler must be serviced only by a qualified professional service technician AVERTISSEMENT PR CAUTIONS LORS DES R PARTATIONS ET DE L ENTRETIEN Certaines proc dures d entretien e
76. tion s of supply and return piping including the heat distribution units see below connected directly to the trunk Also referred to as a Zone By pass A section of pipe including an adjustable valve that diverts part of the water flow from the boiler outlet to the inlet adjusted to maintain minimum flow requirement GPM or inlet water temperature Circuit Entire water circulation piping beginning and ending at the boiler Series Loop System Expansion Tank Compression Tank Installed in the circuit to accommodate excess water produced by heat expansion and to maintain the system pressure Brute M ini Hydronic Boiler Page 31 Heat Distribution Units Transfers heat from the water supplied by the boiler to the area to be heated through the use of baseboard convector radiator finned tube Also known as radiation Isolation Valve Used to isolate the boiler from the circuit It minimizes the amount of water drained from the system Primary Secondary Piping Two or more interconnecting circulating loops each with its own pump Reverse return Piping Balanced equal flow first in last out piping Utilized with multiple boilers and or radiation Applied with single system pumps or primary secondary pumps Side Wall Power Venter This accessory allows the boiler exhaust to be routed horizontally through an adjoining outside wall rather than gravity venting with a chimney or stack when local codes
77. tions must be made exactly as shown in the wiring diagram found on the inside of the control box cover see Figure 8 The boiler must include a definite means of grounding There is a bonding lug where a bond wire must be attached Transformer BLK Pump Relay Power GRN Ground Supply ei BLK Hot 115V AC Mime WHT Neutral 60 Hz 115V AC 3 4 H P WHT Neutral To Pump Max for heat mmm 115V Field Wiring w 115V Factory Wiring Figure 8 Field Wiring Connections 6 2 Main Power Electrical wiring must be in accordance with the latest edition of the National Electric Code NEC ANSI National Fire Protection Association NFPA 70 unless local code requirements indicate otherwise The heater comes factory wired intended for use with 115 Volt 60 Hz AC field electrical supply Making electrical connections must be done by a certified electrician only as with all wiring Be sure that the power source to the heater is turned off or disconnected before servicing To wire the Brute Mini boiler to a 115V 60 Hertz Hz electrical source 1 Remove the two screws attaching the front cover of the control box 2 There are four wires coiled in the area on the right side of the control box supplied with wire nuts 2 black wires twisted together a white wire and a brown wire see Figure 8 3 Follow the schematics in Figure 9 Remove the wire nut from the two black wires and connect the hot l
78. ts which could cause nuisance shutdowns of the pilot If a blower is necessary to provide adequate combustion air to the boiler a suitable switch or equivalent must be wired into the boiler control circuit to prevent the boiler from firing unless the blower is operating The boiler must be completely isolated and protected from any source of corrosive chemical fumes such as those emitted by trichlorethylene perchlorethylene chlorine etc WARNING Do not store any chemical cleaners or other corrosive material near combustion air openings or in the room Avoid locating dryer vents in the vicinity of combustion air openings Failure to prevent corrosive materials from mixing with combustion air can result in reduced boiler life and unsafe boiler operation AVERTISSEMENT N entrepposer aucun produit chimique produit nettoyant ou produit corrosif proximit des bouches d air de combustion ou dans la pi ce viter de placer des tuyaux de ventilation pour s cheuse proximit des bouches d air de combustion Le fait de laisser des maiti res corrosives se m langer l air de combustion risque de r duire le cycle de vie de l appareil de chauffage et de compromettre son fonctionnement 3 2 Exhaust Venting Vent piping must be of the same or larger diameter as the vent damper or draft diverter outlet The only correct procedure for vent pipe sizing is to do so in accordance with Table 3 and the applicable install
79. used as a chimney Type B or equivalent In cold weather uninsulated outside vents can chill the rising flue products blocking the natural draft action of the venting system This can create a health hazard by spilling flue products into the boiler room Use engineered venting tables acceptable to the authority having jurisdiction to size the venting pipe or liner Avoid oversize vent piping or extremely long runs of the pipe which may cause excessive cooling and condensation Before connecting a vent connector to a chimney the chimney passageway shall be examined to ascertain that it 1s clear and free of obstructions When inspection reveals that an existing chimney is not safe for the intended application it shall be rebuilt to conform to nationally recognized standards see National Building Code or ANSI NFPA 211 lined or relined with a suitable liner or replaced with a vent or chimney suitable for the equipment to be attached 3 4 Common Venting Systems 3 4 1 Venting Multiple Appliances When common venting BJVS or BJVT natural draft boilers with other appliances through one shared 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 allo
80. wed to operate in this condition serious injury or death may occur Brute Mini Hydronic Boiler Page 9 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 AVERTISSEMENT Le fonctionnement des appareils avec un syst me d vacuation bloqu peut provoquer des blessures graves voire la mort Des dispositifs de s curit doivent tre install s pour viter le blocage des syst mes d vacuation Si le fonctionnement de tous les appareils connect s un syst me d vacuation commun ne peut pas tre assur y compris la pr vention de la dispersion des gaz toxiques dans les espaces habit s on ne devrait pas installer un syst me d vacuation commun et chaque appareil devrait tre ventil s par ment 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 sa
81. y of ignition cable and ground wire System runs until call NO Note i e for heat ends ote If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue If checks are okay replace module YES Call for heat ends Check for proper thermostat controller operation System shuts off NO Remove MV lead at module if valve closes recheck temperature YES controller and wiring if not replace gas valve Troubleshooting ends Repeat procedure until trouble free operation is obtained Page 30 BRADFORD WHITE CORP 9 4 Electrical Troubleshooting l 2 Remove the control box cover on the front of the boiler Verify that 115V is reaching the boiler by testing across the black wire on the pump relay and the white wire on the transformer Verify 24V transformer output by placing the meter leads on the yellow and red wires If 24V is not evident replace the transformer Perform the following series of tests with one meter lead attached to the yellow wire on the transformer Place the second lead on the W connection on the terminal board Turn the wall thermostat high enough to call for heat If the meter fails to register 24V the thermostat or its circuit may be defective Make sure thermostat is set high enough to call for heat Place second lead on the A connection

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