Specifications | Bradford-White Corp BJVS Boiler User Manual

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.
H2343000-
Installation and service must be performed by
a qualified installer, service agency, or gas
supplier.
AVERTISSEMENT
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d’incendie ou d’explosion ou
pour éviter tout dommage matériel, toute
blessure ou la mort.
Ne pas entreposer ni utiliser d’essence ni
d’autres vapeurs ou liquides inflammables dans
le voisinage de cet appareil ou de tout autre
appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous
servir des téléphones dansle bâtiment où vous
vous trouvez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions
du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés par
un installateur ou un service d’entretien qualifié ou
par le fournisseur de gaz.
238-49219-00A REV 4/11
BRADFORD WHITE CORP.
Page 2
TABLE OF CONTENTS
SECTION 1.
General Information
SECTION 6.
Electrical
1.1
1.2
1.3
1.4
1.5
1.5.1
1.5.2
1.5.3
1.6
1.6.1
1.6.2
6.1
6.2
6.3
6.4
6.4.1
6.4.2
Introduction................................................... 3
Warranty ....................................................... 3
Codes and Standards ................................... 3
Technical Assistance.................................... 3
Materials Installer Must Provide ................... 3
Materials for All Installations ......................... 3
Materials for Most Installations ..................... 3
Diagnostic Tools ........................................... 4
Specifications ............................................... 4
General Specifications ................................. 4
Dimensions................................................... 4
SECTION 2.
Installation Instructions
2.1
2.2
2.3.1
2.3.2
Introduction................................................... 4
Field Assembly ............................................. 5
Clearances ................................................... 6
Flooring ........................................................ 6
SECTION 3.
Venting
3.1
3.2
3.3
3.4
3.4.1
3.4.2
Combustion Air Supply ................................. 7
Exhaust Venting ........................................... 7
Vent Pipe Sizing and General
Installation .................................................... 8
Common Venting Systems ........................... 8
Venting Multiple Appliances ......................... 8
Inspection of Commonly Vented
Appliances .................................................... 9
SECTION 7.
Operating Instructions
7.1
7.2
7.2.1
7.2.2
7.3
7.3.1
7.3.2
7.3.2.1
7.3.2.2
7.4
Normal Operation ....................................... 21
Start-up ....................................................... 22
Filling the System ....................................... 22
Boiler Start-up ............................................ 22
Lighting and Shutdown Procedures ........... 23
Lighting the Boiler ....................................... 23
Shutdown ................................................... 24
Main Burner Shutdown (BJVT Only) ............ 24
Complete Shutdown .................................... 24
High Altitude Burner
Air Shutter Adjustment ................................ 24
SECTION 8.
Maintenance
8.1
8.2
General Maintenance ................................. 25
Boiler Components and Their
Operation.................................................... 26
SECTION 9.
Troubleshooting
SECTION 4.
Gas Connections
9.1
9.2
9.3
4.1
4.2
9.4
Gas Supply and Piping ............................... 10
Special Precautions for LP Gas.................. 11
General Information .................................... 16
Main Power ................................................ 16
Grounding................................................... 21
Auxiliary Devices ........................................ 21
Flow Switch ................................................ 21
Heat Anticipator .......................................... 21
General Boiler Troubleshooting .................. 27
Troubleshooting Guide ............................... 28
Troubleshooting Honeywell S8600
Intermittent Pilot System ............................. 29
Electrical Troubleshooting .......................... 30
SECTION 5.
Water Connections
SECTION 10.
Glossary
5.1
5.1.1
5.2
5.3
5.4
5.5
5.6
10.1
Water Piping ............................................... 12
By-pass Piping ........................................... 12
Alternate Auto-Bypass Operation ............... 12
Flow Requirements .................................... 15
Chilled Water Systems ............................... 16
Oxygen Permeable Systems ...................... 16
Anti-Freeze ................................................. 16
Glossary of Terms ...................................... 30
SECTION 11.
Replacement Parts
11.1
11.2
11.3
Ordering Information .................................. 31
Parts List .................................................... 31
Exploded View............................................ 34
Brute Mini Hydronic Boiler
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 improper
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 (I.I.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 damage 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.
Page 3
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.
In the 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 call 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. A CSA listed manually operated gas valve to be
installed in the gas line outside of the boiler
jacket.
3. A suitable 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. A 115 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 of the 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
BRADFORD WHITE CORP.
Page 4
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 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 if motorized louvers do not open.
4. A suitable 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
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
½" NPT
½" 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:
1¼" 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
1.
12. Modification 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 adéquat peut
causer la nausée ou l’asphyxie en raison du
monoxyde de carbone présent dans les gaz de
combustion et même 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
3. Sufficient combustion and ventilation air
4. Properly sized gas meter and piping
5. Proper electrical wiring (if required)
6. Adequate water flow
This manual provides the information needed to
meet these requirements. Review all application and
installation procedures completely before continuing
the installation.
NOTE: The Brute Mini boiler is approved for indoor
installation only.
Brute Mini Hydronic Boiler
Page 5
Dimensions in inches cm
Dimensions
inches cm
Size*
A
B
C
50
13-3/8 34
27-3/4 71
23-5/8
75
13-3/8 34
27-3/4 71
24-1/8
100
16-7/8 43
28-3/4 73
24-1/8
125
16-7/8 43
28-3/4 73
23-5/8
160
20-3/8 52
28-3/4 73
23-5/8
225
25-5/8 65
31-1/2 80
23-1/4
* Values shown are for both BJVS and BJVT Models
60
61
61
60
60
59
D
21-3/4
21-3/4
22-3/4
22-3/4
22-3/4
23-3/4
55
55
58
58
58
63
E
26-1/2
27-1/2
27-1/2
27-1/2
27-1/2
27-1/2
67
70
70
70
70
70
4
5
5
6
6
7
Figure 1. Dimensional Information.
2.2 Field Assembly
1.
2.
3.
4.
5.
6.
Brute Mini boilers have built-in draft diverter for
natural draft operation.
Find the vent damper box which is located in the
boiler package.
Install the vent damper directly to the top of the
draft diverter outlet with the damper operator
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
bracket end of the harness should be connected
to the vent damper actuator.
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
standing (continuous) pilot boilers. For all
BJVT models, the damper plate hole should
never be blocked.
Do not modify the automatic vent damper
device. It is very important that no other vents
are closed. Provide at least six inches clearance
between the automatic vent damper and
combustible construction, and be sure to allow
access for servicing the damper.
Install the temperature/pressure gauge provided
in the parts box.
Figure 2. Field Assembly Items.
V
10
13
13
15
15
18
Water
Gas
Conn. Conn.
in.
in.
1-1/4
1/2
1-1/4
1/2
1-1/4
1/2
1-1/4
1/2
1-1/4
1/2
1-1/4
*3/4**
**1/2 for propane
BRADFORD WHITE CORP.
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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 électrique ou le moteur sera
endommagé.
6 15
6 15
4*
10
6 15
Dimensions in inches cm.
*6" for models BJV160 to BJV225.
Figure 3. Closet and Alcove Installation (see Table 3).
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
Boiler Sizes
Clearances
Left side
in
6
50-125
cm
15
in
6
160-225
cm
15
Right side
Rear
Front
Flue
6
6
4
6
15
15
10
15
6
6
6
6
15
15
15
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.
Dégagements Minimaux à Assurer Entre Ics Parois de
L’appareil et leo Constructions Combustibles
combustible surfaces (see Table 1).
At least 15" (381mm) access must be available
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.
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 , is 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.
Figure 4. Typical Combustible Floor Installation.
Brute Mini 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 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).
Boiler Size
Outside
Air Air
Area*
Outside
Sq.
In. in Sq.sq
cm
Area
In.*
Inside
Air Air
Area*
Inside
Sq.in
In.Sq. In.*sq
cm
Area
(sq
cm)
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 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, CSAB149.1 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 drafts 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 à proximité des
bouches d’air de combustion ou dans la pièce.
Éviter de placer des tuyaux de ventilation pour
sécheuse à proximité des bouches d’air de
combustion. Le fait de laisser des maitières
corrosives se mélanger à l’air de combustion risque
de réduire 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
installation code as stated in the following warning.
BRADFORD WHITE CORP.
Page 8
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 diamètre des tuyaux de ventilation doit répondre
aux exigences du National Fuel Gas Code Z223.1
ou du code canadien des installations des appareils
à gaz CSA B149.1. Des tuyaux trop petits rispquent
d’entraîner une ventilation inadéquate 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’échapper
dans le bâtiment et causer des blessures graves ou
l’asphyxie par le monoxyde de carbone.
BJVS/BJVT
Size
50
75
100
125
160
225
Vent Pipe Diameter
inch
cm
4
10
5
13
5
13
6
15
6
15
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, ANSI 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 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 is 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 allowed to operate in
this condition, serious injury or death may occur.
Brute Mini Hydronic Boiler
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 système
d’évacuation bloqué peut provoquer des blessures
graves, voire la mort. Des dispositifs de sécurité
doivent être installés pour éviter le blocage des
systèmes d’évacuation. Si le fonctionnement de
tous les appareils connectés à un système
d’évacuation commun ne peut pas être assuré, y
compris la prévention de la dispersion des gaz
toxiques dans les espaces habités, on ne devrait
pas installer un système d’évacuation commun et
chaque appareil devrait être ventilé séparément.
It is for this reason that, in addition to following
proper vent sizing, construction and safety
requirements from the National Fuel Gas Code, ANSI
Z223.1 or in Canada, from CSA B149.1 as well as all
applicable local codes, it is required that installers
provide some means to prevent operation with a
blocked common vent. It is suggested that a blocked
vent safety system be employed such that if the switch
from one appliance trips due to excessive stack spill or
backpressure indicating a blocked vent condition, that
all appliances attached to the vent be locked out and
prevented from operating. 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
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
from the common vent, all the appliances must be
checked for proper venting.
Page 9
At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances
remaining connected to the common venting system
are not in operation.
1. Seal any unused openings in the common
venting system.
Sceller toutes les ouvertures non utilisées du
système d’évacuation.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
Inspecter de façon visuelle le système
d’évacuation pour déterminer la grosseur et
l’inclinaison horizontale qui conviennent et
s’assurer que le système est exampt
d’obstruction, d’étranglement, de fuite, de
corrosion et autres défaillances qui pourraient
présenter des risques.
3. Insofar as it is practical, close all building doors
and windows and all doors between the space in
which the appliances remaining connected to the
common venting system are located and other
spaces of the building. Turn on clothes dryers
and any appliance not connected to the common
venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
Dans la mesure du possible, fermer toutes les
portes et les fenêtres du bâtiment et toutes les
portes entre l’espace où les appareils toujours
raccordés au système d’évacuation sont installés
et les autres espaces du bùtiment. Mettre en
marche les sécheuses, tous les appareils non
raccordés au systéme d’évacuation commun et
tous les ventilateurs d’extraction comme les
hottes de cuisinière et les ventilateurs des salles
de bain. S’assurer que ces ventilateurs
fonctionnent à la vitesse maximale. Ne pas faire
fonctionner les ventilateurs d’été. Fermer les
registres des cheminées.
4. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust
thermostat so appliance will operate
continuously.
Mettre l’appareil inspecté en marche. Suivre les
instructions d’allumage. Régler le thermostat de
façon que l’appareil fonctionne de façon
continue.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
BRADFORD WHITE CORP.
Page 10
6.
7.
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
Faire fonctionner le brûleur principal pendant 5
min ensuite, déterminer si le coupe-tirage
déborde à l’ouverture de décharge. Utiliser la
flamme d’une allumette ou d’une chandelle ou la
fumée d’une cigarette, d’une cigare ou d’une
pipe.
After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas burning
appliance to their previous conditions of use.
Une fois qu’il a été déterminé, selon la méthode
inidquée ci-dessus, que chaque appareil raccordé
au système d’évacuation est mis à l’air libre de
façon adéquate. Remettre les portes et les
fenêtres, les ventilateurs, les registres de
cheminées et les appareils au gaz à leur position
originale.
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 système
d’évacuation commun devrait être corrigé de
façon que l’installation soit conforme au national
Fuel Gas Code, ANSI Z223.1 et (ou) aux codes
d}installation CSA-B149.1. Si la grosseur d’une
section du système d’évacuation doit être
modifiée, le système devrait être modifié pour
respecter les valeurs minimales des tableaux
pertinents de l’appendices F du National Fuel
Gas Code, ANSI Z2231.1 et (ou) des codes
d}installation 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.
AVERTISSEMENT
Les appareils de chauffage à faibles sont conçus
pour être utillsés avec du gaz naturel ou du gaz de
pétrole liquéfié (GPL). Vérifiez l’information inscrite
sur la plaque signalétique du pour vous assurer que
l’appareil est conçu pour le type de gaz fourni. NE
PAS ESSAYER DE CONVERTIR CET APPAREIL
À UN AUTRE TYPE DE GAZ.\
1.
2.
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.
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.
Caution
Permanent damage to the gas valve will occur if the
following procedures are not followed.
Attention
Vous endommagerez la soupape de gaz si vous ne
respectez pas les procédures 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 Mini Hydronic Boiler
Distance
From Gas
Meter
0-50'
0-15m
50-100'
15-30m
100-200'
30-60m
Page 11
Supply Pressure
Boiler Size
50
75
100
125
160
225
LP Gas
10.0 Inches WC 13.0 Inches WC
(2.4 kPa)
(3.1 kPa)
3/4
1
1
3/4
3/4
3/4
1
1
1-1/4
Table 5. Gas Supply Pressure Requirements.
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. The correct 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.
To Equipment
Inlet
Nipple
Cap
Figure 5. Typical design for a sediment trap/drip leg.
7.
10.5 Inches WC
(2.5 kPa)
3/4
Tee
Fitting
6.
5.5 Inches WC
(1.3 kPa)
3/4
Gas Supply
Inlet
5.
Natural Gas
1/2
Table 4. Natural Gas Pipe Size Requirements*
4.
Maximum
Pipe Size
*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.
3 in.
(76mm) Min.
Minimum
A 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.
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.
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.
If the gas supply pressure is less than required,
check for undersized pipe between the meter and
the boiler, a restrictive fitting, or an undersized
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.
Caution
Some leak test solutions (including soap and water)
may cause corrosion or stress cracking. Rinse the
piping with water after testing.
Attention
Certaines solultions d’essai d’étanchéité (y compris
l’eau et le savon) peuvent causer de la corrosion ou
de la fissuration. Rincez les tuyaux à l’eau apprès
l’essai d’étanchéité.
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
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
(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 is 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 information 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.
BRADFORD WHITE CORP.
A full sized, 1¼" bypass with balancing valves is
strongly recommended for all systems, and required
when: 1) the boiler is installed without primarysecondary 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 zone of the highest head loss
is open.
A full size, 1¼" 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 infloor 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 Mini Hydronic Boiler
Figure 6. Typical Plumbing Installations.
Page 13
BRADFORD WHITE CORP.
Page 14
Multi-Zone
Valve System
BJV
Boiler
Single Circuit System
Multi-Zone
Pump
System
BJV
Boiler
Figure 6A. Typical Plumbing Installations.
Air Scoop
Pump
System
Loop
Expansion
Tank
Figure 6B. Typical Plumbing Installations.
Feed
Water
BJV
Boiler
Brute Mini Hydronic Boiler
Page 15
water temperature is 160°F (71°C), and the outlet
temperature is 180°F (82°C) at Normal Input Rate
from the rating plate. That means there is a 20° (11°C)
temperature rise through the boiler. According to
Table 1, that would indicate a flow rate of 8 GPM
(0.5L/S). Temperature rise must be measured with the
longest (highest head) zone calling for heat alone.
Other factors to be considered before selecting a
pump are pipe size, the number of fittings throughout
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
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
illustrated in this manual.
To
System
From
System
Balancing
Valve
Balancing Valve
or optional
thermostatic union,
P/N 2400-030.
(Primary/Secondary
only)
In
(Return)
Out
(Supply)
Drip
Leg
Left Side View
A full size by-pass must be installed.
Figure 7. By-pass Piping.
5.3 Flow Requirements
75
All high recovery, low volume water boilers must
have adequate flow for efficient operation. Pump
selection is critical to this goal, and pumps should be
selected to provide for system design water
temperature rise. Table 6 details temperature rise and
water flow (GPM) for the Brute Mini boilers.
100
125
160
225
1" Pipe
1-1/4" Pipe
Pump
H.P.
Pump
H.P.
Pump
H.P.
Failure to insure proper water flow through the
heat exchanger of the boiler will void the warranty.
Flow can be verified by measuring the difference in
water temperatures between the boiler inlet and outlet.
For example: For a BJV-100 installation, the inlet
15°F 8°C
Flow Rate
1/6 1/25 1/12 1/6
50
99
390 680
*
*
*
*
*
35
160 300
460 640
*
*
*
*
77 150
260 330 620
27
80
140 170 360 600
*
*
25
72
57
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
160 330 190 480
*
110
*
69
330
Table 7. Maximum Suggested Circuit Length in Feet.
20°F 11°C
Headloss
*
1/25 1/12 1/6
*A circulator and/or primary/secondary piping are required. Consult
factory.
1. Chart is based on 30°F (17°C) maximum temperature rise.
2. Calculations are based on Type L copper tubing with one
zone valve and eight elbows.
3. Typical circulating pumps: 1/ 25 HP=Taco 007, B&G LR-20 or
SLC-25, Grundfos UP15-42F, or equivalent. 1/ 12 HP=B&G LR12, Grundfos UP26-42F, or equivalent. 1/ 6 HP=B&G series
HV, Grundfos UP43-75, or equivalent.
Damage from improper flow is not warranted.
50
3/4" Pipe
Pump
H.P.
1/25 1/12 1/25 1/12
50
Size
1/2" Pipe
Size
Flow Rate
25°F 14°C
Headloss
Flow Rate
Headloss
gpm
l/s
ft
m
gpm
l/s
ft
m
gpm
l/s
ft
m
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. l/s = 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.
BRADFORD WHITE CORP.
Page 16
5.4 Chilled Water Systems
6.1 General Information
If the 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.
Wiring connections 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
5.5 Oxygen Permeable 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 antifreeze 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
POSSIBILITÉ DE CHOCS ÉLECTRIQUES. Ce
système de chauffage contient du filage de haut
voltage. Un contact avec ces fils peut résulter en
des blessures sérieuses ou la mort.
Caution
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
Attention
Au moment de l’entretien des commandes, étiquetez
tous les fils avant de les débrancher. Des erreurs de
câblage peuvent entraîner un fonctionnement
inadéquat et dangereux.
GRN - Ground
BLK - Hot
WHT - Neutral
Power
Supply
115V AC
60 Hz
WHT - Neutral
BRN - Hot
On = Call
for heat
To Pump
115V AC
3/4 H.P.
Max
115V Field Wiring
115V Factory Wiring
BRN WHT
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 lead 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 Mini Hydronic Boiler
Page 17
Figure 9a. Wiring Diagram, Spark Ignition System (BJVS 50 & 75).
5.
110V
Hot
110V
Neutral
Space Heating
Pump
(Field Supplied)
Zone
Pump
Relay
1
3
115V
24V
Fuse
Zone
Pump 4
Relay
Zone
Pump 6
Relay
Boiler
Terminal
Thermostat
Field
Supplied
R
Boiler
Terminal
Zone
Pump
Relay
Boiler
Terminal
W
Optional
Aquastat
R
High
Limit
A
Vent
Damper
Receptacle
Jumper
Ignition Control
Power
Venter
Receptacle
Blocked
Vent
Safety
Switch
24V
6
PV
3
MV/
PV
2
MV
1
PV
MV/
PV
MV
24V
GND GND
4
5
Roll-Out
Safety
Switch
SPARK
When using a or field supplied power venter, the
proving switch must be connected in series with
the hi-limit.
6. Check the boiler wiring and pump for correct
voltage, frequency and phase. If the pump circuit
is other than 115V, be sure there is an
appropriate transformer or relay installed. The
pump relay is suitable for pumps of ¾ HP or
less.
7. For systems with multiple zone pumps or valves,
see Figure 10.
A means of disconnecting the electrical supply
must be provided within sight of the boiler. The pump
and boiler must be wired as shown to insure that the
pump is running whenever the boiler is firing.
Gas Valve
HW VR8304
Remote Flame Sensor
High Altitude (Optional)
Figure 9b. Schematic, Spark Ignition System
(BJVS 50 & 75).
Page 18
Figure 9c. Wiring Diagram, Standing Pilot System (BJVT).
Figure 9d. Schematic, Standing Pilot System (BJVT).
BRADFORD WHITE CORP.
Brute Mini Hydronic Boiler
Page 19
Figure 9e. Wiring Diagram, Spark Ignition, Two-Stage (BJVS 100-225).
110V
Hot
110V
Neutral
Space Heating
Pump
(Field Supplied)
Zone
Pump
Relay
1
3
115V
Fuse
Zone
Pump 4
Relay
Zone
Pump 6
Relay
Boiler
Terminal
24V
Thermostat
Field
Supplied
Boiler
Terminal
R
Boiler
Terminal
Zone
Pump
Relay
W
Optional
Aquastat
R
High
Limit
A
Vent
Damper
Receptacle
Ignition Control
Power
Venter
Receptacle
Blocked
Vent
Safety
Switch
Roll-Out
Safety
Switch
MV
C
PV
LO
HI
W
W
B
B
R
R
HI
Two-Stage
Gas Valve
HW VR8304
Figure 9f. Schematic, Two-Stage (BJVS 100-225).
Two-Stage
Aquastat
1 MV
2 MV/PV
3 PV
4 GND
5 24V (GR)
6 24V
7 TH-W
8 MV
9 SPARK
Pilot Burner With
Spark Electrode
Sensor
SPARK
Jumper
Remote Flame Sensor
High Altitude
(Optional)
Page 20
BRADFORD WHITE CORP.
Wiring
with Taco
Zone Valves
Wiring with
Honeywell
Zone Valves
Wiring
with Multiple
Zone Pumps
For primary/secondary pumping: Connect
to "W" in lieu of "A." Boiler relay is used for
boiler pump and connection to "W" will
energize boiler pump when any zone is
calling for heat.
Figure 10. Multiple Zone Wiring.
Brute Mini Hydronic Boiler
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 chaudière doit être mise à la terre selon les
exigences officielles locales ou, en l’absence de
toute instruction officelle, l’installation doit être
conforme au National Electrical Code, ANSI/NFPA
70, aux États-Unis et avec la dernière édition du
Code électrique canadien CSA C22.1, Partie 1, au
Canada. N’utilisez pas la tuyauterie de gaz ou
d’eau pour mettre à la terre les parties métalliques
de la chaudière. Les unions diélectriques ou avec
tuyau en plastique peuvent isoler la chaudière
électriquement. Les membres du personnel de
service et d’entretien qui travaillent sur et autour de
la chaudiére peuvent marcher dur des planchers
mouillés et pourraient se faire électrocuter par une
chaudière non mise à 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.
Page 21
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 thermostat calls for heat and the
boiler is powered, an operating cycle is initiated. (On
continuous pilot ignition models (BJVT) 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 100225), 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.
TEMPERATURE
RISE
BREAKS R-B
MAKES R-W
LEFT SWITCH ON RISE
DIFFERENTIAL
BREAKS R-W
2
MAKES R-B
ON FALL
LOW
FIRE
INTERSTAGE
DIFFERENTIAL
1
BOILER INLET
SETPOINT
(ADJUSTABLE,
FACTORY SET
AT 140°F)
BREAKS R-B
MAKES R-W
RIGHT SWITCH ON RISE
DIFFERENTIAL
BREAKS R-W
2
MAKES R-B
ON FALL
HIGH
FIRE
1
DIFFERENCE BETWEEN THE TEMPERATURES AT WHICH THE
TWO SWITCHES MAKE R-W. FACTORY SET AT 10°F (6.6°C)
2
TWO SPDT SWITCHES OPERATE IN SEQUENCE. EACH
SWITCH DIFFERENTIAL AT APPROXIMATELY 3°F (1.7°C)
Figure 11. L6008G Operation.
BRADFORD WHITE CORP.
Page 22
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
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,
10.
11.
12.
13.
14.
15.
including the pump, boiler, and radiation units,
for one hour.
Recheck the water level in the expansion tank,
if necessary. If it exceeds ½ of the volume of
the tank, open the tank drain and reduce the water
level.
Shut down the entire system, and vent all
radiation units and high points in the system.
Close the water makeup valve and check the strainer
in the pressure reducing valve for sediment or
debris. Reopen the water makeup valve.
Verify system pressure with the boiler pressure
gauge before beginning regular operation.
Within 3 days of start-up, recheck and bleed all
air vents and the expansion tank using these
instructions.
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 Boiler Start-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 sécurité personnelle lorsque vous mettez
l’appareil en marche, tenez votre tête et votre visage
loin du brûleur pour éviter 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’aération et le dessus de l’appareil
deviennent chauds! Ils peuvent causer de graves
brûlures. Ne touchez pas à ces surfaces lorsque
l’appareil est en marche.
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.
Attention
N’utilisez pas cet appareil s’il a été plongé dans
l’eau, même partiellement. Faites inspecter
l’appareil par un technicien qualifié et remplacez
toute partie du systéme de contrôle et toute
commande qui ont été plongés dans l’eau.
Brute Mini Hydronic Boiler
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 être coupée, ne pas couper ni débrancher
l’alimentation électrique de la pompe. Fermer plutôt
le robinet d’admission de gaz à l’extérieur de
l’appareil.
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 réparations au
système de régulation du débit du gaz ou à
l’appareil. Toute modification non autorisée est
dangereuse et entraîne l’annulation de toutes les
garanties.
Page 23
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 données
dans cette notice pour réduire au minimum le risque
d’incendie ou d’explosion ou pour éviter tout
dommage matériel, toute blessure ou la mort.
7.3.1 Lighting the Boiler
Lighting instructions are as follows:
1.
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 empêcher 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 severe bodily injury.
AVERTISSEMENT
Ne tentez pas d’allumer l’appareil sans que la soit en
place. Vous pourriez être victime de blessures
corporelles graves.
2.
Verify that the pump system is operating
properly:
a.
Shut off the manual gas valve located
outside the boiler.
b. Raise the wall thermostat high enough to
call for heat.
c.
The pump should come on immediately. If
it doesn't, test the electrical circuits.
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).
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.
Figure 12. Gas Valves.
BRADFORD WHITE CORP.
Page 24
3.
BEFORE LIGHTING smell all around the
appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air
and will settle on the floor.
a. WHAT TO DO IF YOU SMELL GAS
a.1
a.2
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Do not try to light any appliance.
Do not touch any electric switch; do not use
any phone in your building.
a.3 Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
a.4 If you cannot reach your gas supplier, call
the fire department.
All Models:
Shut off electrical power to the boiler.
Turn the gas valve knob clockwise
to OFF.
Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, don't try to repair it,
call a qualified service technician. Force or
attempted repair may result in a fire or explosion.
Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
smell gas, STOP! Follow 7.3.1 (3.)a. If you don't
smell gas, go to the next step.
BJVS Models: (BJVT skip 7 )
Turn gas valve knob counterclockwise
to ON.
Restore power to the boiler, and set the thermostat
to the desired temperature. The pilot will
automatically ignite when there is a call for heat.
BJVT Models: (Continuous Pilot)
(BJVS skip to step 16)
Remove louvered burner cover by loosening the
two thumb screws to access the pilot burner.
Remove the control box cover to fully access the
gas valve.
Find pilot - follow metal tube from gas control.
The pilot is on the right hand side of the first
burner.
Turn knob on gas control counterclockwise
to PILOT.
Push in control knob or push-button all the way
and hold in. Immediately light the pilot with a
match using the match holder. Continue to hold
the control knob in for about one (1) minute after
the pilot is lit. Release knob and it will pop back
up. Pilot should remain lit. If it goes out, repeat
steps 2 through 8.
a.
If the knob does not pop up when released,
stop and immediately call your service
technician or gas supplier.
b. If the pilot will not stay lit after several
tries, turn the gas control knob to OFF and
call your service technician or gas supplier.
Replace the louvered airbox cover and tighten
the two thumb screws securely.
14. Turn gas control knob counterclockwise
to ON.
15. Replace control box cover.
16. Restore power to the boiler and adjust the
thermostat high enough to call for heat to verify
the boiler is operating properly.
17. BJVS 100-225 ONLY - Adjust two-stage
operating control setting to maximum, verify
high fire operation. Reduce setting to just below
the return water temperature and verify low fire
operation.
18. BJVS 100-225 ONLY - Set two-stage operating
control to desired low fire set point. Generally
20°F below desired loop temp. i.e. for 180°F
loop, set two stage operating control at 160°F.
Adjust as necessary to maintain proper loop
temperature.
19. Set the thermostat to the desired temperature.
1.
2.
1.
2.
3.
4.
7.3.2 Shutdown
7.3.2.1 Main Burner Shutdown (BJVT only):
Lower the wall thermostat setting so that there is
no call for heat.
To turn off the main burners turn the gas valve
knob clockwise until it stops at pilot.
7.3.2.2 Complete Shutdown:
Lower the wall thermostat setting so that there is
no call for heat.
Turn off all electrical power to the boiler.
Turn the gas valve knob clockwise to “OFF”. Do
not force the knob.
Shut off the external gas supply valve to the
boiler.
7.4 High Altitude Burner
Air Shutter Adjustment
DANGER
This procedure must be followed exactly and
must be performed by a qualified installer or
warranty may be voided.
DANGER
Cette manière de procéder doit être faite
exactement et accomplie par un installateur qualifié
sous risque d’annulation de la garantie.
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 manière de procéder dans sa totalité et
comprenez-la bien avant de commencer. Un
ajustement inadéquat des volets en haute altitude
peut provoquer un incendie, une explosion, et/ou
des niveaux élevés de gaz toxiques qui pourraient
causer des dégâts matériels, des blessures
personnelles, voire la mort.
1.
2.
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. On all 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 is observed then retighten its associated locking screw.
7. Turn the boiler off.
8. Perform 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.
LOCKING SCREW
(5/16" HEAD)
AIR SHUTTER
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 inadéquat peut
causer la nausée ou l’asphyxie en raison du
monoxyde de carbone présent dans les gaz de
combustion et même entraîner 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 heater must be
serviced only by a qualified professional service
technician.
AVERTISSEMENT
PRÉCAUTIONS LORS DES RÉPARTATIONS ET
DE L’ENTRETIEN
Certaines procédures d’entretien et de réparation
des appareils de chauffage à faibles émissions
présentent des changers, car elles mettent en jeu
des gaz combustibles, des composants électriques,
des pièces mobiles et des procédures qui
nécessitent des mises à l’essai ou la dérivation
temporaire des commandes de sécurité. Pour cette
raison, l’appareil de chauffage doit être entretenu et
réparé uniquement par un technicien professionnel
qualifié
DANGERS D’UN ENTRETIEN INADÉQUAT
Les appareils de chauffage à faibles émissions
comportent des caractéristiques techniques
uniques. Une réparation ou un entretien inadéquat
peut entraîner des blessures corporelles ou des
dommages à la propriété. Pour cette raison,
l’appareil de chauffage doit être entretenu et réparé
uniquement par un technicien professionnel
qualifié.
BRADFORD WHITE CORP.
Page 26
Lubricate the water circulating pump per the
instructions on the pump.
2. If a strainer is employed in a pressure reducing
valve or the piping, clean it every six months.
3. At start-up, and periodically thereafter, the
burner flame should be observed. If the flame
has the appearance of ‘sooting’ tips, check for
debris near the orifices and call the service
technician.
4. Inspect the venting system for obstruction,
leakage or corrosion at least once a year.
5. Do not store or use gasoline or other flammable
vapors, liquids or chemicals in the vicinity of
this or any other appliance.
Ne pas entreposer ni utiliser d’essence ni
d’autres vapeurs ou liquides inflammables à
proximité de cet appareil ou de tout autre
appareil.
6. 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.
N’utilisez pas cet appareil s’il a été plongé dans
l’eau, même partiellement. Faites inspecter
l’appareil par un technicien qualifié et remplac
ez toute partie du système de contrôle et toute
commande qui ont été plongés dans l’eau.
7. Be sure that all combustion air and ventilation
openings are unobstructed.
8. Upon completion of the installation, inspect the
external surfaces of the heat exchanger for
fouling based on the following schedule:
24 hours 7 days 30 days 90 days
Once every six months thereafter.
9. If the boiler is not going to be used for long
periods of time in locations where freezing
occurs, it should be completely drained of all
water. To accomplish this, there is a drain valve
on the right side of the boiler which can be
opened. This will drain the right side of the
boiler. There are two plugs located on the left
side of the heater which must be removed to
drain that side. Both sides must be drained.
10. The gas and electric controls on the boiler are
engineered for long life and dependable
operation, but the safety of the equipment
depends on their proper functioning. It is
strongly recommended that the basic items listed
below be inspected by a qualified service
technician every year.
a.
Water temperature controls
b. Pilot safety system.
c.
Automatic gas valves.
d. Flow sensing safety devices.
e.
Vent dampers and power venters.
f.
Venting system.
1.
Figure 14. 1) BJVS Pilot; 2) BJVH Pilot;
3) Main Burner Flame Pattern; 4) BJVT Pilot.
NOTE: The Warranty does not cover damage caused
by lack of required maintenance, lack of water flow, or
improper operating practices.
12. Fouling on the external surfaces of the heat
exchanger is caused by incomplete combustion,
and is a sign of venting and/or combustion air
problems. The heat exchanger can be inspected
by using a flashlight and placing a mirror under
the burners. An alternate method is to remove the
venting and top panel to inspect the exchanger
from above. The vent system should be
inspected at the same time. If cleaning is
required:
a.
Shut off all power to the boiler.
b. Remove the draft hood, venting top, flue
collector, and heat exchanger baffles.
c.
Remove the burners by lifting them off the
orifices and pulling them out of the boiler.
d. Use a hand-operated spray bottle filled with
water, and a wire brush to clean soot and
loose scale from the underside of the heat
exchanger. DO NOT USE COMPRESSED
AIR, HIGH PRESSURE WATER OR A
GARDEN HOSE.
e.
Clean any fallen debris from the bottom of
the unit.
f.
Check to make sure the burner ports and
pilot assembly are free of debris before
returning the burners to their original
position.
g. Reassemble the boiler in reverse order,
making sure to replace the heat exchanger
baffles.
8.2 Boiler Components and Their
Operation
1.
Gas Valve / Regulator - The gas valve controls
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
Caution
Two-stage Operating Control (BJV100-225 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 100225 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 - When 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 completely 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.
Page 27
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
service technician.
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
PRÉCAUTIONS LORS DES RÉPARTATIONS ET
DE L’ENTRETIEN
Certaines procédures d’entretien et de réparation
des appareils de chauffage à faibles émissions
présentent des changers, car elles mettent en jeu
des gaz combustibles, des composants électriques,
des pièces mobiles et des procédures qui
nécessitent des mises à l’essai ou la dérivation
temporaire des commandes de sécurité. Pour cette
raison, l’appareil de chauffage doit être entretenu et
réparé uniquement par un technicien professionnel
qualifié
DANGERS D’UN ENTRETIEN INADÉQUAT
Les appareils de chauffage à faibles émissions
comportent des caractéristiques techniques
uniques. Une réparation ou un entretien inadéquat
peut entraîner des blessures corporelles ou des
dommages à la propriété. Pour cette raison,
l’appareil de chauffage doit être entretenu et réparé
uniquement par un technicien professionnel
qualifié.
BRADFORD WHITE CORP.
Page 28
9.2 Troubleshooting Guide
#
Symptom
Cause
Remedy
1.
Pump not
operating
A. No power
B. Pump defective
C. Incorrectly wired
A. Check circuit breakers and power source.
B. Replace.
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. Pressure should be regulated within limits shown above.
B. Inlet gas pressure too high causing
an unstable blowing pilot
C. Weak or defective thermocouple
D. Damaged pilot or thermocouple
E. Dirty pilot
F. Plugged or undersized pilot orifice
C. Replace thermocouple.
D. Replace.
E. Blow dust or lint out of pilot.
F. Clean or replace pilot orifice.
3.
Flame roll-out
on start-up
A. Blocked flue
B. Pilot out of position (delayed ignition)
C. Blocked heat exchanger or flue
D. Refractory tile out of place
E. Altered draft diverter
A. Remove blockage.
B. Correct pilot position.
C. Clean and correct as necessary.
D. Correct or replace tile as necessary.
E. Install factory-provided draft diverter.
4.
Spillage at
draft hood
A. Cold chimney
B. Vent pipe pitches down to chimney
C. Blocked chimney
D. Draft hood altered
E. Pre-fabricated chimney with incorrect cap
A. Allow boiler to operate 5 minutes to create draft action.
B. Reinstall vent pipe to pitch up from boiler to chimney.
C. Remove blockage.
D. Install factory-provided draft diverter.
E. Install U.L. listed vent cap.
5.
Flame has
lazy yellow tip
A. Low primary air
A. Correct manifold pressure according to rating plate. Correct
orifice size if necessary (see parts list). Clean burner ports if
dirty. Verify correct fuel type.
6.
Not enough heat
A. Inadequate gas supply
B. Low manifold gas pressure
A. Gas meter too small. Gas line from meter to boiler too small.
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. Replace with boiler of higher input.
D. Check operation and setting of two-stage operating control.
C. Boiler size inadequate
D. BJVS 100-225 only - Boiler not going
to high fire.
7.
Pump noisy
A. Air in volute
B. Worn coupling or bearings
A. Bleed air from volute. Check pump alignment.
B. Replace worn parts.
8.
Boiler pounding
or knocking
A. Too low water flow through boiler
A. Check temperature rise between inlet and outlet boiler piping.
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
or low water
pressure at boiler
gauge or bubbles
in system at high
temperature
A. Defective fill valves or pressure regulator
B. Oversized expansion tank
C. Expansion tank piped incorrectly
A. Replace.
B. Replace.
C. Repipe expansion tank to suction size of pump.
11.
Pressure relief
valve opens
A. Water-logged expansion tank
A. Drain 2/3 of the water from the expansion tank.
12.
Pilot is lit but main
burners will not
come on
A. Gas valve not at "on" position (BJVT)
B. Boiler off on hi-limit control
C. Boiler incorrectly wired
A. Turn knob to "on" position.
B. Check for low water flow or hi-limit setting.
C. On single or multiple zone systems with zone valves, room
thermostat should be wired to R & W terminals. For multiple
zone systems with zone pumps, thermostats for extra zones
should be wired to R & A terminals.
D. Remedy as in symptom #4. Reset the manual reset switch.
E. Remedy as in symptom #3. Reset the manual reset switch.
F. Check continuity through thermostat circuit with wires
disconnected from R & W.
G. Check continuity and operation through two-stage
operating control.
D. Boiler off on blocked vent switch
E. Boiler off on flame roll-out switch
F. Broken wire in thermostat circuit
or defective thermostat
G. BJVS 100-225 Only - Two-stage operating
control not functioning or loose contact.
13.
Boiler short cycles
A. Heat anticipator in room thermostat
set too low
B. Low water flow through boiler
C. Hi-limit switch may be set too low
A. Increase setting (0.8 - 1.0 is usually satisfactory).
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 Mini Hydronic Boiler
Page 29
9.3 Troubleshooting Honeywell S8600 Intermittent Pilot System
T
YES
Spark across igniter/
sensor gap.
T T
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
checkout procedure.
Turn off gas supply.
Turn thermostat
(controller) to call for
Check line voltage power, low voltage transformer, hi- limit switch,
heat.
NO thermostat (controller) and wiring.
Power to module
(24V nominal).
NO
YES
Spark stops when pilot
is lit?
T
• 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.
NO
NO
T
NO
NO
T
T
YES
Troubleshooting ends
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace
module.
• Check electrical connections between module and gas valve. If okay,
replace gas valve.
• Check continuity of ignition cable and ground wire.
Note: 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.
T
YES
Call for heat ends.
System shuts off?
Check continuity of ignition cable and ground wire.
Clean flame rod.
Check electrical connections between flame rod and module.
Check for cracked ceramic flame rod insulator.
Check that pilot flame covers flame rod and is steady and blue.
Adjust pilot flame.
If problem persists, replace module.
T
YES
System runs until call
for heat ends?
•
•
•
•
•
•
•
T
YES
Main burner lights?
• Check that all manual gas valves are open, supply tubing and pressures
are good, and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas
control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is
okay, replace gas valve; if not, replace module.
T T
T
YES
T
YES
T
Turn gas supply on.
Pilot burner lights?
Pull ignition lead and check spark at module.
Spark okay?
NO
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature
controller and wiring; if not, replace gas valve.
Repeat procedure until trouble-free operation is obtained.
BRADFORD WHITE CORP.
Page 30
9.4 Electrical Troubleshooting
1.
Remove the control box cover on the front of the
boiler.
2. Verify that 115V is reaching the boiler by testing
across the black wire on the pump relay and the
white wire on the transformer.
3. 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.
4. 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.
5. Make sure thermostat is set high enough to call
for heat. Place second lead on the "A"
connection 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.
6. 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.
7. 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.
8. Verify the voltage across the blocked vent and
roll-out safety switches.
9. On BJVT boilers, test for voltage at the "TH"
terminal on the gas valve. If none is found,
follow steps 1 through 8.
10. 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
11. 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 placing
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.
Caution
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
ATTENTION
Au moment de l’entretien des commandes, mettez
des étiquettes sur tous les fils avant de les
débrancher. Des erreurs de câblage peuvent
causer un fonctionnement inadéquat et dangereux.
Vérifier que tout fonctionne bien après 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 section(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 Mini Hydronic Boiler
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 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.
Page 31
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.
Electrical System
Relay, DPNO
Transformer 115/24V
(40VA)
Ignition Control
Limit Switch
Two-Stage Operating Control
Control Panel Wiring Harness
Power Venter Jumper
Terminal Strip
Hi-Tension Lead
Blocked Vent Safety Switch
Roll-out Safety Switch
Fuse, 2 amp
BJVT-50
BJVS-75
BJVT-75
BJVS-100
BJVT-100
BJVS-125
BJVT-125
BJVS-160
BJVT-160
BJVS-225
BJVT-225
20406501
20036700
E0098500
10449514
E0121000
E2103200
E2043600
E0121000
E2103200
E2043600
20406501
20036700
E0098500
E0098700
E0086100
L0032900
L0052601
L0032900
L0052601
E0086100
E2102800
E0098700
L0032200
L0032200
L0032200
E0088400
V2002100
V2002100
E0088400
V0077500
V0077500
20406501
20036700
E0098500
10449514
E0121000
E2103200
E2043600
E0086100
E2102800
E0098700
E0088400
L0032900
L0052602
V2002000
V2002000
L0056500
L0052500
L0055900
V0077400
L0056500
L0052500
L0055900
V0077400
L0056500
L0052500
L0055900
E0121000
E2103200
E2043600
20406501
20036700
E0098500
E0098700
E0086100
E0088400
L0032900
L0052602
L0032200
L0056500
L0052500
L0055900
E0086100
E2102800
E0098700
E0093200
20406501
20036700
E0098500
10449514
E0121000
E2103200
E2043600
E0088400
L0032900
L0052603
L0032200
V2002100
V0079100
V2002000
V0079000
L0056500
L0052500
L0055900
E0121000
E2103200
E2043600
20406501
20036700
E0098500
E0098700
E0086100
E0088400
L0032900
L0052603
L0032200
L0056500
L0052500
L0055900
E0086100
E2102800
E0098700
E0093200
20406501
20036700
E0098500
10449514
E0121000
E2103200
E2043600
E0088400
L0032900
L0052604
L0032200
V2002100
V0079100
V2002000
V0079000
L0056500
L0052500
L0055900
E0121000
E2103200
E2043600
20406501
20036700
E0098500
E0098700
E0086100
E0088400
L0032900
L0052604
L0032200
L0056500
L0052500
L0055900
E0086100
E2102800
E0098700
E0093200
20406501
20036700
E0098500
10449515
E0121000
E2103200
E2043600
E0088400
L0032900
L0052605
L0032600
V2002100
V0079100
V2002000
V0079000
L0056500
L0052500
L0055900
E0121000
E2103200
E2043600
20406501
20036700
E0098500
E0098700
E0086100
E0088400
L0032900
L0052605
L0032600
L0056500
L0052500
L0055900
E0086100
E2102800
E0098700
E0093200
20406501
20036700
E0098500
10449516
E0121000
E2103200
E2043600
E0088400
L0032900
L0052606
L0050700
V2002100
V0079100
V2002000
V0079000
L0056500
L0052500
L0055900
E0121000
E2103200
E2043600
20406501
20036700
E0098500
E0098700
E0086100
E0088400
L0032900
L0052606
L0050700
L0056500
L0052500
L0055900
W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 W0030600 W0040900 W0030600 W0040900
W0039600 W0040901 W0039600 W0040901 W0039600 W0040901 W0039600 W0040901 W0039600 W0040901 W0039600 W0040901
W0036500
W0036500
W0036500
W0036500
W0036500
W0036500
Model, Size BJVS-50
Main Gas System
Burner w/Pilot Bracket
Burner, Main
Burner/Air Shutter
Gas Valve,
HW VR8304 (Nat.)
Gas Valve,
HW VR8300 (Nat.)
Gas Valve,
HW VR8304 (LP)
Gas Valve,
HW VR8300 (LP)
Gas Orifice
(Nat. 0-2000ft)
Gas Orifice
(LP 0-5000ft)
Gas Manifold
Pilot Gas System
Pilot Assy (Nat.)
Pilot Assy (LP)
Thermocouple
Description
Page 32
BRADFORD WHITE CORP.
Model, Size BJVS-50
11020101
11020201
11019301
11019401
11047603
20034901
10535900
20086800
20086800
10500601
10485301
10469501
T0022001
T0021701
T0027300
10467101
10466701
E2071501
E0099100
Jacket and Fire Box Components
Draft Diverter
11020101
Rear Panel
11020201
Jacket
11019301
Top
11019401
Gap Closure
11047603
Flue Collector
20034901
Access Panel HX, (L&R)
10535900
Base, Control Box
20086800
Cover, Control Box
20086800
Burner Cover
10500601
Heat Exchanger Baffle
10485301
Tile Cover
10469501
Refractory, Front
T0022001
Refractory, Rear
T0021701
Insulation, Fiberglass
T0027300
Base Assembly
10467101
Combustible Base
10466701
Vent Damper Components
Automatic Vent Damper
Assy., Effikal PC
Damper Connection Harness
E2071501
E0099100
11046001
A0000100
A0069000
E2058300
P0066600
BJVT-50
11046001
A0000100
A0069000
E2058300
P0066600
Water System
Heat Exchanger
Temperature/Pressure Gauge
Pressure Relief Valve, 30PSI
Well, Immersion
Drain Valve 1/2" NPT
Description
E2071502
E0099100
11020102
11020201
11019301
11019402
11047604
20034902
10535900
20086800
20086800
10500601
10485308
10469502
T0022002
T0021702
T0027300
10467102
10466701
11046002
A0000100
A0069000
E2058300
P0066600
BJVS-75
E2071502
E0099100
11020102
11020201
11019301
11019402
11047604
20034902
10535900
20086800
20086800
10500601
10485308
10469502
T0022002
T0021702
T0027300
10467102
10466701
11046002
A0000100
A0069000
E2058300
P0066600
BJVT-75
E2071502
E0099100
11020103
11020203
11019303
11019403
11047603
20034903
10535900
11045700
11045800
10500602
10485309
10469503
T0022003
T0021703
T0027300
10467103
10466702
11046003
A0000100
A0069000
E2058300
P0066600
BJVS-100
E2071502
E0099100
11020103
11020203
11019303
11019403
11047603
20034903
10535900
11045700
11045800
10500602
10485309
10469503
T0022003
T0021703
T0027300
10467103
10466702
11046003
A0000100
A0069000
E2058300
P0066600
BJVT-100
E2071503
E0099101
11020104
11020203
11019303
11019404
11047604
20034904
10535900
11045700
11045800
10500602
10485311
10469504
T0022004
T0021704
T0027300
10467104
10466702
11046004
A0000100
A0069000
E2058300
P0066600
BJVS-125
E2071503
E0099101
11020104
11020203
11019303
11019404
11047604
20034904
10535900
11045700
11045800
10500602
10485311
10469504
T0022004
T0021704
T0027300
10467104
10466702
11046004
A0000100
A0069000
E2058300
P0066600
BJVT-125
E2071503
E0099101
11020105
11020205
11019305
11019405
11047604
20034905
10535900
11045700
11045800
10494105
10485310
10469505
T0022005
T0021705
T0027300
10467105
10466703
11046005
A0000100
A0069000
E2058300
P0066600
BJVS-160
E2071503
E0099101
11020105
11020205
11019305
11019405
11047604
20034905
10535900
11045700
11045800
10494105
10485310
10469505
T0022005
T0021705
T0027300
10467105
10466703
11046005
A0000100
A0069000
E2058300
P0066600
BJVT-160
E2071504
E0099101
11020106
11020206
11019306
11019406
11047606
20034906
10535900
11045700
11045800
10494106
10485306
10469506
T0022006
T0021706
T0027300
10467106
10466704
11046006
A0000100
A0069000
E2058300
P0066600
BJVS-225
E2071504
E0099101
11020106
11020206
11019306
11019406
11047606
20034906
10535900
11045700
11045800
10494106
10485306
10469506
T0022006
T0021706
T0027300
10467106
10466704
11046006
A0000100
A0069000
E2058300
P0066600
BJVT-225
Brute Mini Hydronic Boiler
Page 33
BRADFORD WHITE CORP.
Page 34
11.3Exploded View
Vent Damper Connection Harness
Vent Damper
Pressure
Relief Valve
Draft Diverter
A - Inlet Pipe
B - 4-1/2”x3/4” Pipe
C - Outlet Pipe
ƒB
Gap Closure

‚
ƒ
„
1-1/4” Hold
1-1/8” Hold
1-1/4” Hold
1-7/8” Hold
ƒ
‚
„
Top
Heat Exchanger
B
C
A
Temperature/
Pressure Gauge
Immersion Well
Refractory, Front
Flue Collector
Aquastat
Bulb
Refractory,
Rear
½” Close
Nipple
(Model 50
and 100)
Cover,
Control
Box
Terminal
Strip
Blocked
Vent
Safety
Switch
Tile Cover
Transformer
Pump Relay
High
Limit
Base
Assembly
Drain
Valve
Burner with Pilot Bracket
Pilot Assembly
Gas Manifold
Orifices
Pilot Gas Tube
Gas Valve
2-Stage Operating Control (100-225)
Burner Cover
Flame Roll-Out
Safety Switch
Figure 15. Parts Identification.
HX Access
Panel
Rear Panel
1/2" Coupling
(Model 50 and 100)
P0005200
Jacket, One Piece
Wraparound
Brute Mini Hydronic Boiler
Page 35
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
Service Parts (800) 538-2020
Warranty Service (800) 531-2111
www.BradfordWhite.com
Litho in U.S.A. © Bradford White 1101 Document 1242
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