Bradford White BEB-060-208 Brute® Electric Boilers (BEB) Manual

Bradford White BEB-060-208 Brute® Electric Boilers (BEB) Manual
Installation and Operation Instructions
Document 1447
Installation and
Operation
Instructions for
Brute®
Commercial
Electric
Boiler
60 kW - 300 kW
A
S
M
H
E
NOTE: Retain this manual for future reference.
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified
in hot water boiler and heater installation and maintenance. Improper installation and/or operation could cause
serious injury, property damage, or death. Improper installation and/or operation will void the warranty.
WARNING
Installer must comply with startup
and installation instructions to avoid a
dangerous situation.
AVERTISSEMENT
D’installation doit se conformer aux
instructions d’installation et de démarrage
pour éviter une situation dangereuse.
Electric Hot Water Boiler
BEB Series
Installation & Operating Manual
See Specification Table for specific model by voltage and kW size.
Evaluate utility service/utility transformer feed. BEB series boilers are manufactured to utilize either of
the two common 3-phase electrical feeds.
3-Phase Y, with neutral and ground – The internal wiring configuration of the BEB boiler does not require
a neutral. This unit is manufactured and shipped without ground fault protection. Certain state and
local codes may require the addition of ground fault protection. Be certain to research and follow these
codes.
3-Phase Delta, no neutral, dedicated service from the transformer with unbonded neutral – Theoretically,
the element life is increased with a 3-wire Delta service. A ground fault protection kit must be added to in
this instance. The addition of this kit to the BEB brings the boiler into “NEC Article 250.21, unbonded
neutral” compliance. This kit may be installed at our factory upon your request. In addition to the CSA
product certification, this safety control system is approved by Minnesota, North Dakota, and the South
Dakota State Boards of Electricity.
Safety grounding – a single point grounding electrode system must be established for the facility for either the
Y or Delta feeds. All points including utility transformer, service entrance, boiler utility transformer, building
service entrance ground lug, etc. must be bonded to the same facility grounding electrode system.
Application – retrofit, dual boiler – controls included for switchover from remote utility device or outdoor
temperature.
 New installation or replacement – sized for full load capacity, internal controls have backup
troubleshooting features for emergency heating.
Vessel – designed and fabricated to comply with ASME Section IV, with “H” Stamp and National Board of
Boiler and Pressure Vessel Registration, with a maximum working pressure of either 30 psi or 125 psi (design
pressure specified when placing order).
Heating elements – removable, low-watt density, Incoloy sheathed, top vessel plate screw-in element. Access
is made easy via top split enclosure top cover.
Piping – 3” NPT top supply, 3” NPT left side return, 3” left side inspection plug, 1” left side bottom drain, 1”
top vessel location for pressure relief and/or air relief. All system piping and pumps must be large enough to
meet the required GPM flow shown on the Specification Table for the vessel size.
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Table of Contents
Specification Table
1
Dimensional Drawings
2
Handling & Storage
3
Placement & Mechanical Information
3
Installation Requirements
5
Electrical Installation
Preparation
6
Power Feed
7
Control Box
7
Additional Safety Control Options
8
Multiple Boilers, Same System
8
Dual Boilers/Dual System
8
Setup/Programming
9
Understanding the Product Display
9
Hardware Setup
11
Software Setup
12
System Setup
13
Sensor Calibration
16
Fault Tracker
17
Outdoor Reset Parameters
18
Display Variables Defined
20
Multi-Boiler
20
Micro Reset
21
System Hookup
22
Pre-Start
25
Observations
25
Startup Inspection
27
Troubleshooting
28
Emergency Override
30
Replacement Parts
31
Boiler Maintenance
32
Drawings
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BH801
BH802
UAW452
BI810
Specification Table
Electric Supply
Model
Volts
kW
Amps 3-Phase
Total
Amps
Btu/h
Output
Feed #1†
Steps
Feed #2†
Element
Quantity
Flow Rate
@20° ∆T
Required GPM
Boiler
Weight
BEB-060-600X
600
60
58
204,729
58
–
5
5 @ 12
21
685
BEB-072-600X
600
72
70
245,675
70
–
6
6 @ 12
25
690
BEB-084-600X
600
84
81
286,620
81
–
7
7 @ 12
29
695
BEB-096-600X
600
96
93
327,566
93
–
8
8 @ 12
33
698
BEB-108-600X
600
108
104
368,512
58
47
9
9 @ 12
37
700
BEB-120-600X
600
120
116
409,458
58
58
10
10 @ 12
41
705
BEB-132-600X
600
132
128
450,403
70
58
11
11 @ 12
46
708
BEB-144-600X
600
144
139
491,349
70
12
12 @ 12
50
710
BEB-160-600X
600
160
155
545,943
155
70
–
8
8 @ 20
55
695
BEB-180-600X
600
180
174
614,186
97
78
9
9 @ 20
62
698
BEB-200-600X
600
200
193
682,429
97
97
10
10 @ 20
69
700
BEB-220-600X
600
220
212
750,672
116
97
11
11 @ 20
76
703
BEB-240-600X
600
240
231
818,915
116
116
12
12 @ 20
82
705
BEB-260-600X
600
260
251
887,157
135
116
13
13 @ 20
89
708
BEB-280-600X
600
280
270
955,400
135
135
14
14 @ 20
96
709
BEB-280-600H
600
278
268
948,576
135
133
13
7 @ 20/6 @ 23.3
95
709
BEB-300-600X
600
300
289
1,023,643
155
135
15
15 @ 20
103
710
BEB-300-600H
600
299
288
1,020,231
155
13 @ 23
103
750
480
60
73
204,729
73
133
–
13
BEB-060-480X
5
5 @ 12
21
690
BEB-072-480X
480
72
87
245,675
87
–
6
6 @ 12
25
693
BEB-084-480X
480
84
102
286,620
102
–
7
7 @ 12
29
695
BEB-096-480X
480
96
116
327,566
116
–
8
8 @ 12
33
693
BEB-108-480X
480
108
130
368,512
73
58
9
9 @ 12
37
700
BEB-120-480X
480
120
145
409,458
73
73
10
10 @ 12
41
705
BEB-132-480X
480
132
159
450,403
87
73
11
11 @ 12
46
708
BEB-144-480X
480
144
174
491,349
87
12
12 @ 12
50
710
BEB-160-480X
480
160
193
545,943
193
87
–
8
8 @ 20
55
695
BEB-180-480X
480
180
217
614,186
121
97
9
9 @ 20
62
689
BEB-200-480X
480
200
241
682,429
121
121
10
10 @ 20
69
700
BEB-220-480X
480
220
265
750,672
145
121
11
11 @ 20
76
703
BEB-240-480X
480
240
289
818,915
145
145
12
12 @ 20
82
705
BEB-260-480X
480
260
313
887,157
169
145
13
13 @ 20
89
708
BEB-280-480X
480
280
337
955,400
169
169
14
14 @ 20
96
709
BEB-280-480H
480
278
335
948,576
169
167
13
7 @ 20/6 @ 23
95
709
BEB-300-480X
480
300
361
1,023,643
193
169
15
15 @ 20
103
710
BEB-300-480H
480
299
360
1,020,231
194
13 @ 23
103
750
208
60
167
204,729
167
167
–
13
BEB-060-208X
4
4 @ 15
21
716
BEB-075-208X
208
75
209
255,911
209
–
5
5 @ 15
26
718
BEB-090-208X
208
90
250
307,093
250
–
6
6 @ 15
31
719
BEB-105-208X
208
105
292
358,275
292
–
7
7 @ 15
36
721
BEB-120-208X
208
120
334
409,458
334
–
8
8 @ 15
41
725
BEB-135-208X
208
135
375
460,640
209
167
9
9 @ 15
47
728
BEB-150-208X
208
150
417
511,822
209
209
10
10 @ 15
52
731
BEB-165-208X
208
165
459
563,004
250
209
11
11 @ 15
57
735
BEB-180-208X
208
180
500
614,186
250
12
12 @ 15
62
737
BEB-060-240X
240
60
145
204,729
145
250
–
4
4 @ 15
21
716
BEB-075-240X
240
75
181
255,911
181
–
5
5 @ 15
26
717
BEB-090-240X
240
90
217
307,093
217
–
6
6 @ 15
31
719
BEB-105-240X
240
105
253
358,275
253
–
7
7 @ 15
36
721
BEB-120-240X
240
120
289
409,458
289
–
8
8 @ 15
41
725
BEB-135-240X
240
135
325
460,640
181
145
9
9 @ 15
47
728
BEB-150-240X
240
150
361
511,822
181
181
10
10 @ 15
52
731
BEB-165-240X
240
165
397
563,004
217
181
11
11 @ 15
57
735
BEB-180-240X
240
180
434
614,186
217
217
12
12 @ 15
62
737
†
Actual calculated amps, not service rating.
Options
BEB-***-***H – 125 psi vessel and relief valve.
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Dimensional Drawings
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Handling & Storage
Receiving
It is the receiver’s (person and/or company signing off on the receiving Bill of Lading) responsibility to
inspect for shipping damage. All shipping claims must be made by the receiver. Verify receipt of a
pallet.
Storage
This electric boiler, packed or unpacked, shall not be exposed to rain, snow, or other adverse
environment. This product is designed for in-building storage and installation only.
As much as possible both the control box and the main unit must be covered with plastic throughout the
construction phase to avoid accumulation of dust and moisture on the components and the complete
control box. The receiver and installing contractor are responsible for maintaining the cleanliness and
quality of this unit until installation is complete and approved by the user/end customer.
Main unit
The heavy construction of the cabinet and internal vessel allows for easy handling and moving of the unit
with either a pallet jack or forklift. The bottom openings on the side are arranged for standard pallet jack.
Forklift tines can be adjusted accordingly.
CAUTION
ANY FORKLIFT DAMAGE IS THE RESPONSIBILITY OF THE RECEIVER.
The main unit can be laid on its back and strapped to a stair jack.
Holding or lifting straps can be strung through the bottom openings.
Placement & Mechanical Information
Provide a firm and level foundation for this unit, see Specification Chart for weights.
Note: Combustible flooring material shall not be used for electric boilers.
See Dimensional Drawings for dimensions and minimum clearances.
Boiler Room
This must be an inside building installation with adequate ventilation to maintain reasonable maximum
temperatures within and around the electrical/electronic components.
Main unit – front electrical panel 122° F (50° C) maximum
Control box – 104° F (40° C) maximum
CAUTION
DO NOT USE THE BOILER HOUSING TOP AS SCAFFOLDING. SEE ABOVE SECTIONS ON
STORAGE, ETC.
Shipped Loose Items
Packed within there are loose items such as operational manuals, etc.
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Piping Connections
The pipe extensions outside of the boiler cabinet are permanently welded to the vessel. Caution must be
used to make sure field piping is properly threaded so damage does not result requiring field repair or a
replacement (not under warranty) vessel.
New Installation
Piping connections and valves must comply with state and/or local codes, in addition to compliance with
ANSI piping requirements.
Retrofit or Dual Systems
Make sure there is adequate valving between the two boilers for proper individual operation or proper
backup boiler room operation plan.
 The control design includes provisions for utility load control, also see Dual Boilers/Dual System.
Safety Pressure Relief Valve
As factory installed, there must be a 1” pipe between vessel and pressure relief valve. The provided relief
valve must be mounted with the relief lever up. Field add necessary drain pipe extension to a proper drain
location within the boiler room. 30 psi relief valve included with standard models. Special order 125 psi
models include 125 psi relief valve.
Vessel Drain Port/Inspection Opening
The left side bottom 1” pipe is provided for maintenance or vessel servicing drain, provide necessary
extension/access.
A 3” inspection opening is provided on the lower left side of the boiler.
Purge Eliminator/Air Vent/Expansion Tank, Etc.
All standard, best practices, hydronic components must be field provided and installed external to this
unit. This unit has an internal safety low water cutout and the necessary temperature safety cutout and
operating controls, see operating section. However, this unit does not have an interlock flow switch or
boiler room emergency stop switch. See Electrical Installation for terminal block connection provisions.
Expansion tank must be sized for the maximum Btu/h capacity.
This unit includes a small ½” integrated air vent used to assist in venting potential trapped air at the top of
the boiler vessel. It is not intended to be used as a system air vent.
Direction of Flow
The left side inlet is the return water and the top outlet is the supply.
System Flush/Boil-Out
Prior to final system fill and start-up, the entire system (including the boiler) must be thoroughly
flushed. Performing a pre-flush and chemical system flush significantly reduces the chances of any debris
or impurities causing premature failure to the boiler and its associated system components.
It is recommended to first flush the system with clean water to remove any major debris in the system.
Care should be taken to isolate the circulating pumps to avoid contaminating the pumps during this
process. Then proceed with a chemical flush to remove the remaining fine particles in the system. It is
recommended that a commercially available boil-out compound be used in this procedure. Follow the
manufacturer’s instructions for specifics regarding the boil-out procedure.
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Water Treatment
Water treatment is strongly suggested to prevent scale deposits, corrosion from acids, oxygen, and other
harmful elements within the specific water supply. It is the installer or user’s responsibility to verify
water quality and maintain acceptable water quality throughout the life of this product. A qualified water
treatment specialist should be consulted to establish proper water treatment program.
As a minimum the following water properties must be considered:
 Hardness (ppm): 0-10
 pH: 7.5 – 10
 Iron Content (ppm): 0-20
 Oxygen Content (ppm): 0
 Total Dissolved Solids: 0-5000
Up to a 50/50 propylene glycol mixture is acceptable for use in these boilers.
Installation Requirements
1. All installation work must be performed by trained, qualified contractors or technicians. Bradford
White Corporation sponsors installation and service schools to assist the installer. Visit our web site
at www.bradfordwhite.com for upcoming service schools.
WARNING
ALL ELECTRICAL WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE
AND LOCAL ELECTRIC CODES, ORDINANCES, AND REGULATIONS.
WARNING
OBSERVE ELECTRIC POLARITY AND WIRING COLORS. FAILURE TO OBSERVE COULD
CAUSE ELECTRIC SHOCK AND/OR DAMAGE TO THE EQUIPMENT.
CAUTION
This unit can only be used for its intended design as described in this manual. Any internal
wiring changes, modifications to the circuit board, modifications or bypass of any controls, or
installation practices not according to the details of this manual will void the product warranty,
the CSA/us certification label, and manufacturer product liability. Bradford White Corporation
cannot be held responsible for field modifications, incorrect installations, and conditions which
may bypass or compromise the built-in safety features and controls.
2. This installation manual and Bradford White boiler products relate only to the addition of the Bradford
White boiler to the hydronics system. The owner/ installer assumes all responsibility and/or liability
associated with any needed installation of the gas/oil boiler, pump, plumbing, system design, hydronics
systems or backup gas/oil boiler, etc. Any instructions or comments made within this manual (or factory
phone assistance) relating to the gas/oil furnace are provided as comments of assistance and “helps”
only.
CAUTION
Hazards or unsafe practices could result in property damage, product damage, severe personal
injury and/or death.
3. Remember, safety is the installer’s responsibility and the installer must know this product well
enough to instruct the end user on its safe use.
At Bradford White, the safety of the installer and the end user is of highest priority. Remember,
safety is the installer’s responsibility and the installer must know this product well enough to instruct
the end user on its safe use. Professional installers should be trained and experienced in the areas of
handling electrical components, sheet metal products, and material handling processes.
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Electrical Installation – Preparation
Typical external requirements – depending upon the electrical utility servicing the site, this model
typically is added to the general service as a 3 Ø “Y” source.
 If the service is delta (unbonded neutral) with dedicated utility transformer, verify ground fault, a
ground fault monitor may be required to maintain warranty.
 See nameplate and/or Specification Table for 3-phase operating voltage rating and kW rating to
determine service entrance size.
Service feed – depending upon model, but generally this unit is fed by two service entrance 3-phase
feeds. These are not parallel feeds, the internal distribution blocks are independent loads having a fixed
number of electric element stages apply to each feed.
 See Specification Table for service feed sizing and distribution.
External or service wire size – the internal service feed distribution blocks are rated for copper or
aluminum wire. It is the installer’s responsibility to have proper electrical connection at this main unit’s
distribution block to prevent any overheat within the main unit cabinet.


Wire insulation rating within the main unit cabinet must be 75° C or greater.
Wire size, protection, routing, temperature rating, etc. is the responsibility of the installing
contractor, local and national codes. See nameplate and/or Specification Table for voltage and
main unit kW rating.
Safety grounding – a single point grounding electrode system must be established for the facility. Both
the transformer cabinet and the general service transformer grounding conductor with the main building
service entrance grounding lug must be all bonded to the same facility grounding electrode system.
 The main unit ground lug, next to the service feed distribution block must be connected to the
facility grounding electrode system, per NEC or CEC codes. The conductor size from these main
unit internal ground lugs depends upon the service feed size and must be per NEC or CEC code.
System setup – this is further defined in its own section, but there are many setup possibilities relating to
various applications, control options, and troubleshooting. These factory defaults are set up from the
factory, so system setup is not necessarily required but may be necessary if the “out of the box” settings
from the boiler do not meet the application.
 Set Point (outdoor sensor not connected)
 Base temp, high mass – 90° F (32° C)
 Base temp, low mass – 120° F (49° C)
 Maximum stages, coordinates with the number of stages for the shipped model number
External R-W device – a contact closure is required between R and W for heat active operation. Do not
simply jumper R to W or use for the load control relay. Utility load control is provided at the left blue
jumper TB. In the case of hot boiler this is probably the system on external pump switch. As a
minimum, suggest a flow switch contact proofing the continuous pump. Product liability and warranty is
exempt if R to W has a jumper wire and pumps fail causing no flow.
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Electric Installation – Power Feed
Using the information from the previous section, it is the installer’s responsibility for proper 3-phase
power feed and safety grounding per NEC and CEC electric codes.


See Specification Table for distribution between the two feeder terminal blocks. Feed #1 always
has 8 or less stages.
Prepare service conductor cables and torque as required within the terminal block as required for
the installer selected cable type and size.
Some local codes and CEC electric code require single disconnect and single feed. If this is the case,
installer must provide disconnect with multiple feeds per drawing BH802.
Electrical Installation – Control Box
120, single phase, 15A general service or main building service panel source – provide and route to
the upper left corner CB and neutral block.
Note: A green wire ground from this general service panel is not required or suggested because the ground
lug within the control box is connected to the main safety ground in the main unit. Based upon grounding
details in the Electrical Installation – Preparation section, the main unit ground lug is bonded to the
building grounding electrode system.
Remote operating thermostat or operating device – there must be a closed contact between R and W to
initially active the electric elements and the pump relay on the board. This also activates the Sequencer
for the staging contactor.

If operating as a hot boiler with continuous pump, typically a system on/off switch controls the R
and W. Provisions need to be made to make sure it is continuous pump, suggest with this
arrangement a flow switch is connected in this R and W contact loop.
Main circulating pump – determine whether pump is continuous on or is operated by the R to W input
signal, use the pump relay (the larger cube relay) on the board. When using the top two terminals this has
a 25-amp, 120V or 240V, rating. Route and clearance protect these line voltage wires in and out of the
control box as required by NEC/CEC code. This contact can be used to drive an external contactor for 3phase or higher voltage pumps.
Utility load control – if this is a required part of this installation, remove the left blue and route two
wires to the utility load receiver.
Outdoor sensor (OT) – this product is factory shipped with a 25’ (7.6 meter) cable and OT sensor. It has
three tabs on the board, bottom left. From the factory, this sensor is shipped loose. If the outdoor sensor is
required for the application, simply connect the sensor to the board (power cycle required).
Note wire colors and labeling, sensor cable can be disconnected for installation. Do not route OT sensor
cable along line voltage Romex or line voltage wiring. Crossing is okay, but when there is a somewhat
parallel route the sensor tip must be installed up, cable end must remain dry. Install at any shaded sun
outside temperature location.
Ground fault detector – if the primary 3-phase power is configured as a Delta service, a ground fault
monitor may be required. Contact factory for options.
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Additional Safety Control Options
Remote or boiler room stop switch – a field provided stop switch with a normally closed contact can be
easily wired into TB1-1 and 2. Simply remove the factory provided black/yellow jumper between 1 and 2
and connect the normally closed stop switch. If it is a push/pull (internal to stop switch), the alarm
monitor LED will identify this function.
Additional external low water cutoff – this can also be looped into the TB1-1 and 2 mentioned above.
If the external LWCO has a manual reset function, it will need to be reset at that component.
 Alarm monitor “EM stop” is the monitor for opening TB1-1 and 2.
External water flow switch – this closed to flow contact can also be added to the TB1-1 and 2 black/yel
jumper loop. Its function will keep all power contactor coils de-energized whenever 1 and 2 are open
(also sets alarm 4).
 Another suggestion for hot boiler and continuous pump, use the water flow switch as a contact for
opening the R and W system on switch (see Electrical Installation – Preparation section, bottom
paragraph).
Multiple Boilers, Same System
Piping/pumps – boilers are plumbed in parallel, each flowing equally into a header or primary loop.
Steps need to be taken to make sure there is an evenly divided flow into the header, related to the number
of boilers in parallel. Depending upon pump sizing, the primary loop pumping system could be equal size
pumps at each boiler supply pipe. See Specification Table for required flow through each vessel.
Boiler identification – each boiler is the same model and the standard equipped unit. Water flow design
and operation will be considerably easier if each boiler is the same kW size and in fact the exact same
model number, see Specification Table.
System or boiler room temperature control – each boiler has its own safety LWCO, HL1, and HL2
temperature limits. The system temperature controller must be external and have a 0-10VDC analog
output or a building energy management system. The temperature sensing for this central temperature
controller would be in the header pipe away from any individual boiler. The output of this system
temperature controller (0-10VDC) is connected to (in parallel to each boiler) the control board.
NOTE: If this is a multiple boiler configuration of two, and both are Bradford White Electric Boilers,
each boiler has a built-in LEAD/LAG control. This allows the two boilers to spread the system demands
(system cycles) evenly between the two boilers. This does require special system setup. If application is
greater than two boilers, a field provided controller must be added.
Dual Boilers/Dual System
Utility load control – when a utility receiver is connected to the system as shown on BH801, the electric stages
are terminated and a switch closure is made on “SB OUT” connection. This can be connected directly to the
fossil fuel boiler R and W terminal. In this case the R and W at the Bradford White Electric Boiler module
controls “SB OUT” connection. The fossil fuel boiler should not have R and W jumpered or go to a room type
thermostat.
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Setup/Programming
This boiler is supplied with a display. There are a multitude of setup functions on this display.
Exhaustive research has been done to determine a “typical” application for the boiler. From the factory,
this boiler is set to meet this typical application. Using the display, the Boiler can be reconfigured to meet
your application.
Understanding the Product Display

The Boiler includes a 4-line OLED display with a set of navigation buttons. Note: This is a
display and a system interface with which to customize and reconfigure the operating parameters
to better meet the requirements of your particular application.
LINE
LINES Description
1
2
Mode – Displays the current mode.
MISC Data– Displays active system faults as well as various system
status
Temperatures – Displays Supply Temperature (ST) and Outdoor
Temperature (OT)
Temperatures – Displays Return Temperature (RT) and Desired
Temperature (DT)
3
4
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Display Line 1, MODES
OFF
EL HEAT ON
SB HEAT ON
FAULT
If there is no active heat call to the Boiler, the OLED will display a mode of “OFF”. This means no heat
is being generated from the heating system.
Indicates there is a heat call requirement from the system thermostat. The Electric boiler portion of the
heating system is receiving this input, and is actively working to heat the space. The stand by boiler is
not active (if applicable).
Only applicable when a backup fossil fuel boiler is connected to this Boiler.
Indicates there heat call requirement from the system thermostat. The standby fossil fuel boiler portion
of the heating system is receiving this input, and is actively working to heat the space. The electric
boiler is not active.
This indicates one of the system faults has gone active. Display LINE 2 will signify which system fault
has gone active
Display Lines 2, VARIOUS INFORMATION
STAGES
SINGLE / LEAD / LAG
FAULTS
AUTO HL
BENDER
LOW
WATER
EM STOP
MANUAL
HL
FREEZE
With the system thermostat active, and the system in electric mode, the “STAGES”
indicates how many stages of the electric boiler are active at a given time. The user
can expect to see the stages shift up and down depending on the relationship of ST to
DT
A software setting in the MULTI-BOILER section of the setup menu will be
displayed alongside the stages indicator.
System faults are communicated via line 2 of the OLED display. The below is a run
through of the possible faults.
There is a mechanical auto resetting high limit located on the top of the boiler tank. This high
limit is in direct contact with the water inside the tank (not a dry well). Should the water in the
tank reach a temperature of 210°F, this limit will open. Should this limit open, all electric
boiler elements will be disabled. (O-210 / C-185)
If this boiler has a ground fault bender connected (DELTA transformer only), this fault will
indicate if the bender has detected a ground fault. All electric boiler elements will be disabled
and appropriate fault will be displayed should this condition be detected.
Included with this Boiler is a low water cut off. Should this control system detect a low water
situation, the electric boiler elements will be disabled and the appropriate fault will be
displayed.
Provisions have been made within this Boiler to allow for a field provided remote switch or
emergency stop. Simply place your field provided switch in series with the EM STOP circuit
located inside this Boiler. All electric boiler elements will be disabled and appropriate fault
will be displayed should this condition be detected.
There is a mechanical manual high limit located on the top of the tank. This is a surface
mount component measuring vessel temperature. Should the boiler vessel reach a temperature
of 220°F, this limit will open. Should this limit open, all electric boiler elements will be
disabled. This limit will have to be manually reset.
Should the ST (supply sensor) sensor detect a value less than 45° F (7° C), a freeze condition
is declared. All electric boiler elements will remain enabled and appropriate fault will be
displayed should this condition be detected.
Display Lines 3 & 4, TEMPERATURES
ST
OT
RT
DT
ST is short for “Supply Temperature”. This is the temperature of the water as it leaves the Boiler. If the ST sensor is not
working, the LED will display “BAD” after the ST on the OLED display.
OT is short for “Outdoor Temperature”. This is the outdoor temperature. If the OT was detected upon power-up, and is
no longer working, the OLED will display “BAD” after the OT on the OLED display.
RT is short for “Return Temperature”. This is the temperature of the water as it enters the Boiler. If the RT sensor is not
working, the OLED will display “BAD” after the RT on the OLED display.
DT is short for “Desired Temperature”. This value will either be the fixed set point or the outdoor reset calibrated set
point.
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Hardware Setup
The boiler includes an outdoor sensor which is disconnected from the factory.
Based on the condition of this outdoor sensor upon boiler power-up (connected or disconnected), the
boiler will work to formulate its desired set point output temperature upon system thermostat demand in
one of two ways:
Connected:
If the outdoor sensor is connected upon system power-up, the boiler will enable its outdoor reset function.
This function allows the boiler to adjust its set point output water temperature based on the outdoor
temperature. This function can be further adjusted by using the display to adjust a software variable
known as “OT @ 0°F SP” (outdoor temperature at 0°F set point). This allows you to adjust the outdoor
reset curve to better meet you application.
NOTE: If sensor is connected upon system power-up, it must be located outside.
Disconnected:
If the outdoor sensor is not connected, the boiler will disable its outdoor reset function and operate based
on a fixed set point value. This fixed set point can be adjusted to better meet the application by using the
display and adjust a software variable known as “SET POINT”. This is the fixed output water
temperature the boiler will target when there is a heat demand from the system thermostat.
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Software Setup
Understanding System Setup and Configuration
The display and configuration section of the display allows for system setup and calibration.
NOTES:
All changes made to the system will happen immediately. It is best not to make changes while the Boiler
is actively operating (active heat call). Satisfy thermostat call before entering the setup up section of the
display.
General Layout and Navigation
The next section will overview the various sections embedded within the SETUP / FAULT section of the
product display. Deeper in the manual, we’ll discuss the options imbedded within these setting in more
detail. Below is meant to be a brief overview with the goal of introducing you to the various buttons and
general navigation of the display.
Saving your Changes
The display uses the “BACK” and “HOME” buttons to compare changes and prompt you to save your
changes.
Let’s run through an example.
We’re going to set the boiler up as a multi-boiler system designating this boiler as the “LEAD”
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SYSTEM SETUP
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SYSTEM SETUP:
SETUP / FAULTS:
SET POINT: When operating this boiler in NON-outdoor reset mode (outdoor sensor not connected
upon power-up), this value is the fixed set point output water temperature the boiler will try and achieve
and maintain upon an active thermostat heat call.
o RANGE 40°F – 195°F
o Default from factory is 155°F
0 – 10VDC: If an external controller (EX: Automated Building System Management Controller) will be
used to operate this boiler with a 0 – 10VDC control signal, this set up parameter must be set to “YES”.
o Options are “YES” / “NO”
o Factory default is “NO”
o If set to “YES”, boiler will still need a switch closure between R & W upon 0 – 10VDC
heat demand
o If set to “YES”, all Boiler temperature sensing will be disabled
WARNING
There is no temperature sensing, no control, etc. in this mode. It is the technician’s
responsibility to manually control the water temperature.
STAGE SEQ MINS: This option allows the user to delay the boiler stage up sequence.
EX: If it is determined that the boiler must not reach full output for 1 hour and boiler has 10
stages. You would set this variable to 6. This would indicate that the boiler can only add another
stage of heat every 6 minutes. This timer is only used upon an initial heat demand. Once at full
output (timer expired), it will not be reset until the next thermostat heat call.
o Factory is 1 minute
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DIFFERENTIAL: This is used to indicate to the logic board (non 0-10VDC mode) how tightly to
maintain boiler target temperature. It must be noted that the lower the value used, the more boiler cycling
will occur. This has direct relation to life span of the boiler contactors and other components.
MAX STAGES: This is typically a factory setup screen, as the boiler is manufactured, we indicate to the
logic board the amount of stages it has to work with (4 – 15 stages depending on boiler kW).
FACTORY RESET: To reset the boiler back to its factory settings, use this setting.

NOTE the boiler will reset, if boiler is active while you reset it, it will shut down and restart.
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SENSOR CALIBRATION
Use “ENTER” Button to increase value of digit selected.
Use UP and DOWN buttons to move curser up and down
Use LEFT and RIGHT buttons to move curser left and right
OFFSET ST: If there is a need to calibrate the supply temperature sensor, enter in the desired offset.
 NOTE: The value entered is the offset, not sensor temperature. Pressing 075° will add 75° to the
existing sensor reading. It will not cause the sensor to now equal 075°.
OFFSET RT: If there is a need to calibrate the return temperature sensor, enter in the desired offset.
 NOTE: The value entered is the offset, not sensor temperature. Pressing 075° will add 75° to the
existing sensor reading. It will not cause the sensor to now equal 075°.
OFFSET OT: If there is a need to calibrate the outdoor temperature sensor, enter in the desired offset.
NOTE: The value entered is the offset, not sensor temperature. Pressing 075° will add 75° to the existing
sensor reading. It will not cause the sensor to now equal 075°.
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FAULT TRACKER
Fault tracker is a read only function of the display. It allows you to view a history of the various faults for
this boiler.
You can clear / reset all faults by accessing the last screen in the string of screens. Press “YES” in the
“CLEAR ALL” option will reset all to 0.
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OUTDOOR RESET PARAMETERS
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OT @ 0°F SP: When operating this Boiler in outdoor reset mode (outdoor sensor connected upon powerup), set this value to your desired set point output water temperature when the outdoor temperature is 0°F.
As the outdoor temperature fluctuates, the output water temperature desired with shift in an attempt
balance the boiler output with the heat load requirement of the space.
 RANGE 40°F to 195°F.
 Factory Default: 155°F
MIN HI MASS: If the application has a requirement for OT @ 0°F SP to be less than 160°F, the
application is considered to be high mass (concrete slab, for example). MIN HIGH MASS setting is then
used to set the minimum value for the boiler to target based on the outdoor temperature.
 Range: 70 – 110°F
 Factory default is 90°F
MIN LO MASS: If the application has a requirement for OT @ 0°F SP to be greater than 160°F, the
application is considered to be low mass (basBEBoard heat, for example). MIN LOW MASS setting is
then used to set the minimum value for the boiler to target based on the outdoor temperature.
 Range: 120 – 140°F
 Default: 120°F
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DISPLAY VARIABLES DEFINED
MULTI-BOILER
BOILER: Enter the role this boiler will play in the heating system.
Options:
 SINGLE: This indicates there are no other Boilers in this application. It will not attempt to
interface with another boiler that does not exist.
 LEAD: This indicates that there is another Boiler in this application. LEAD setting tells this
boiler that it is the lead boiler and it is in control of an external boiler. The LEAD boiler will
control all LEAD / LAG sequencing.
 LAG: This indicates that there is another Boiler in this application. LAG setting tells this boiler
that it is the lag boiler and that another, external boiler is in control of it. The LAG boiler will
only respond to the LEAD boiler LEAD / LAG sequencing.
o Default: SINGLE
LAG BLR DELAY: The function of this setting depends the BOILER setting above.
 SINGLE: If “BOILER” is set to “SINGLE”, the LAG BLR DELAY has no function.
 LEAD: If “BOILER” is set to “LEAD”, LAG BLR DELAY will be the amount of time the
LEAD boiler will wait to active either itself, or the LAG boiler, based on which side of the lead /
lag cycle it is on.
 LAG: If “BOILER” is set to “LAG” the LAG BLR DELAY will act as a redundancy system
protection function. Once there is a demand for heat to the boilers, (R & W switch closure), this
timer will start. If the LAG boiler does not receive a “GO” signal from the LEAD boiler in this
amount of time, an additional 60 minute timer will be started. If this timer expires without getting
the “GO” signal from the LEAD boiler, the LAG boiler will override the LEAD boiler and begin
heating. Should LEAD boiler ever go down, this will prevent the building from freezing.
o It is suggested both the LEAD and LAG boilers have identical values placed in LAG
BLR DELAY.
 Default: 015
NOTE: Display will show an asterisk (*) to indicate status of the “LAG BLR DELAY” timer.
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MICRO RESET
Certain setting changes made by display require a reset of the microcontroller. A power down reset of the
boiler is an option, otherwise you can select to reset the microcontroller via this software selection.
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SYSTEM HOOKUP
PRIMARY
APPLICATION
WITH LMC
SYSTEM HOOKUP
PRIMARY
APPLICATION
WITHOUT LMC
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SYSTEM HOOKUP
LEAD LAG BOILER
SYSTEM HOOKUP
0 – 10VDC HOOKUP
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SYSTEM HOOKUP
SENSORS
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Pre-Start
General inspection – inspect all components, external and internal to assure there has been no damage
during shipment or installation. Verify proper cabinet clearances on both sides and top and the internal is
free of construction dirt and debris. Blowing out with an air hose is suggested. Verify all electrical
connections are properly tightened and correct.
 It is assumed the system is purged and water filled prior to attempting the following paragraphs
(see System Flush/Boil-Out and Water Treatment).
Main unit inside panel “door switch” – the inside dead front panel must be secured before the element
power contactors are energized. This door switch is on the upper left inside cabinet flange.
Condition control board to hardware STANDBY – either remove one LMC blue wire or jumper
common to SB SW tab (this is a pre-start process).
Control power on – close the control box upper left 120 CB. The control board green LED should be
on, see the Operations section for definition of other LED’s. There should not be an alarm.
LWCO – should be in normal or non-reset mode, red LED on.
On initial power the low water cut-off will be in the fault or “open” position. Press the LWCO button
located on the control board on initial power-up or after a power failure.
 If not, alarm will count 3 and LWCO board LED is off.
 Verify system is water filled, no air at vessel top, etc.
 Reset at the board, right center pushbutton
Control device or mode – with power now on the control board, the procedure from the previous control
programming section can easily be run. .
Reestablish non-standby – turn off the control box 120 CB. Reference 3rd paragraph under this section,
return LMC blue wire loop or remove SB SW jumper/switch.
Observations
Become familiar with the main PCB module.
LEDs
 Green – control power, control 120 CB on, proper fuse, 24-volt transformer
 Red-W – operating thermostat on, R to W closed
 Red-SYS – control 24VAC at J3-8 going to seq. J3-8 (via auto-reset HL)
Control box 120 CB – general service panel control circuit source.
Audible alarm – continuous alarm indicates a manual reset required.
Staging CB’s, main unit – one per element stage, interrupts power from the power distribution block.
Main unit, monitor lights – indicates element contactor is active. This is one per stage or power
contactor.
LWCO control – red LED on indicates proper vessel water level.
*See Component Information, Familiarization section for further details regarding alarm.
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Temperature limits information – there are three temperature sensing monitors which will control the
sequencer and electric elements.
 The control main control board, with its supply sensor, controls the stages to maintain a supply
temperature represented by system configuration. This sensing monitor and control applies to
outdoor reset or no outdoor reset.
 Auto reset limit, HL-2 – probe at the vessel top, fixed at 210° F (99° C), signals sequencer to shut
down (auto resets at approximately 195° F (90.5° C)).
 Primary safety limit, HL-1 – mounted on vessel top, fixed 225° F (107° C), manual reset (resets
at approximately 160° F (71° C)).
Stage sequencing – in normal operation there is a progressive stage up or stage down timing. The delay
between stages is not always the same, it depends upon the differential between existing and the next
stage command.



The sequencer plug-in software chip has a version 1.** with a dash number. The dash number
must match the number of stages for the specific boiler unit model number (see Specification
Table, stage number). This should be verified to make sure your installation and your specific
model is setup for the correct maximum number of stages. This provides the correct sequence
and operation for the progressive stage-up/stage-down timing.
During alarm conditions, there is only 1-second between stages.
For test purposes the sequencer can be setup to only have 1-second between stages. Next to the
J3 connector is a W1 test point wire. Simply jumper this test point wire to ground (do not apply a
voltage to W1) and all staging will now be 1-second for either up or down.
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Startup Inspection
Comment – the words “power service” or “power source” refer to the 480/208/240 3-phase source
dedicated to the electric elements.
1. All main unit staging CB’s should be off. The dead front inside panel is still probably off; this is
okay because the installer needs to check the source voltage. The panel interlock switch is open thus
contactors cannot pull in.
2. Verify the control box 120 CB is off and R to W input is open or off.
3. Verify previous Pre-Start and Setup section and the above Operations section have been completed
and have the necessary the familiarity to proceed.
4. Verify main unit and control box are free of construction debris, dust and moisture, proper electrical
connections, connection terminals are properly tightened, etc.
5. Remove one main unit top cover panel and verify the vessel top is free of debris and all electric
element connections are in place with no foreign material which may cause an electrical short.
Secure top cover to make sure the top of the vessel remains safe and clean.
6. Verify system is water solution filled, flushed, purged, free of air, and at 10-20 psig.
7. Be prepared to activate the power service source.
8. Turn on the control box upper left 120 control source CB. If installed a Bender alarm should be
active indicating no power service source.
9. Turn on the power service main disconnect source (208/240/480).
CAUTION
THE INDIVIDUAL STAGING CB’S DO NOT REMOVE ALL 480V POWER FROM INSIDE THE
BOILER. THE TOP DISTRIBUTION BLOCK AND WIRING FROM THAT DISTRIBUTION
BLOCK BECOMES LIVE AS SOON AS THE MAIN DISCONNECT IS CLOSED.
10. Using a volt meter, verify service power phase to phase voltage.
11. Install the main unit inside dead front panel. This should close the safety interlock switch (upper left)
allowing the contactors to activate as required in the next steps.
12. Close the external thermostat type R to W device. One minute delay, pump relay closes first.
13. Verify pump is on and water flow circulation.
14. The unit should begin staging elements in order to satisfy system desired temperature

Staging is verified by the behind the door staging monitor lights next to each staging CB

Main unit CB’s are still off
15. Turn on one inside staging breaker at a time. The power source current should increase as the stages
step in. All stages relating to the specific model number should now be on.
 If not, review the setup “maximum stages” entry and/or the sequencer chip code dash number.
 Also, the next section has further information.
16. Open the external R to W contact.
17. The system should be ready for a thermostat call (R to W).
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Troubleshooting
Power Source
Electric element supply – the boiler vessel elements are fed from the main unit inside terminal block.
Depending upon model number and configuration this may require 480, 208, or 240 3-phase. See
Specification Table for specific installation requirement. This boiler is designed and wired for a Delta
electric element load arrangement. However, it can be serviced from a Y (no neutral current or hookup)
depending upon the utility transformer and the disconnect/wiring within the facility.
 If it is a true Delta service, a specific fault detector may be required.
24-volt control source, no PWR ON LED – verify 120 control power and control box upper left CB.
Verify 24-volt transformer, verify fuse, etc.
 If 24VAC is measured at the control module center left terminals and no PWR ON LED, control
board is inoperative.
 If there is no 24VAC at control module, troubleshoot transformer, fuse, 120 source, etc.
Component Information, Familiarization
Low water cutout (LWCO) – information on enclosure should be adequate.
On initial power the low water cut-off will be in the fault or “open” position. Press the LWCO button
located on the control board on initial power-up or after a power failure.
 Sensor is on vessel, violet wire to LCO terminal.
 120 control power is at L1 and L2 tabs. The limit loop is from the CB to COM tab, NO tab, to
PCB J7 connector (K4 NC from HL-1 reset) to HL1 inside TB.
 Test switch is adjacent to the LWCO control. When pressed, the LWCO must be reset via the
reset button located on the lower right side of the control board.
Emergency stop switch field jumper – if the TB1-1 and 2 jumper is removed and a remote contact is put
in its place, when this contact is opened there is an alarm, four LED pulses. This is not a manual reset
latching circuit, the reset would need to be built into the remote connected device(s).
Manual reset hi-limit – this is the round, surface mount, limit installed on the vessel top plate. The TB12 (L1) 120 passes through this limit (red and black wire) loop back to TB1-3 jumper. Internally at TB1-3
this 120 supplies all of the Sequencer pilot relay “COM” contacts (sequencer J1-10 and J2-8). When the
boiler top plate surface mount limit trips, the L1 120 switches from the black to the brown wire and via
TB1-5 provides an HL-1 monitor input to the Temp Sensing and Alarm module. This module has a
latching circuit (K4, two wire blk/yel loop, LWCO-5 to TB1-1) and the power for the Sequencer remains
interrupted until HL pushbutton reset.
Automatic reset hi-limit – screwed into the vessel top plate is a probe thermostat which has normally
closed contacts in series with 24VAC Sequencer 24V J3-8 (feeding into J3-5). Thus the automatic reset
removes all control power from the Sequencer. Also there is an HL-2 monitor wire fed to the control
module which activates an alarm.
Bad sensor– the OLED display indicates which sensor is faulty. In this instance, “faulty” means not
connected, shorted cable, or for some reason there is no digital bit pattern on the black wire. It does not
mean it’s an incorrect value, there is simply no data transmitted.
 This alarm is for notification, it does not cause a safety total shutdown same as LWCO, high
temp, Bender, etc.
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Faulty sensor default – the OLED display indicates a sensor issue, but the boiler continues to function
based upon a fixed default temperature within the logic.
 RT sensor – no default, this is not critical
 OT sensor – this is only active when outdoor sensor connected during power-up. If faulty,
internal logic sets OT to 0° F (-18° C), boiler should be operating at full output and probably all
stages on
 ST sensor – Internal logic sets ST to 50° F (10° C), all stages are probably on because this is
significantly well below set point
Alarm, freeze – the ST sensor is sensing a value less than 45° F (7° C).
Door switch – this is at the main unit top inside flange and activates when the dead front main unit inside
panel is removed.
Alarm voltage interface – this chart can help check sensor output or wire connections.
Pulses
1
2
3
4
5
Name
Auto Reset HL-2
Field added device
LWCO
Option Switch
Man Reset HL-1
Non-Alarm
J1Port
4 – 24VAC
19 – 5V
7 – 24VDC
18 – 5V
2 – 0VAC
16 – 0V
1 – 120VAC
15 – 5V
3 – 0VAC
17 – 5V
Active Alarm
J1
Port
4 – 0V
19 – 0V
7 – <2VDC
18 – 0V
2 – 120VAC
16-5V
1 – 0VAC
15 – 0V
3 – 120VAC
17 – 0V
Main unit staging CB’s, staging contactors, power source electric element wiring – this should be
straightforward from the attached wiring schematic. As stated above, the common or neutral for all
contactors is via TB1-4 and the “door switch” neutral wire. The L1 side of each contactor coil is from
TB1-2, through the manual reset limit (TB1-3), and through each stage pilot relay at the Sequencer board.
Sequencer – this rotating relay output board receives 16-bit binary information from the control module.
This 16-bit binary code is on 4 wires, J3-1 through 4.







Bit 0 is considered no stages on.
Bits 1 through 15 represent the 15 stages. This means when the sequencer receives a new bit
code it steps in or out to that specific stage. During transition (staging up or staging down going
to the next stage number) the change in stage code number is not recognized or examined.
Time between stage-up is 4 seconds each, time between stage-down is 2 seconds each.
An SYS-ON signal or wire (J3-8) is the external “turn on/turn off” function.
The output pilot duty relay contacts associated with each connector are all commoned from J2-10
and J3-8. As the staging relays pull in and out this voltage (typical 120 for contactor coil) is fed
to each of the staging contactors.
At J3-6 24VDC must be there at all times. J3-5 is common or reference.
Note – the vessel top automatic reset limit (HL-2) is in series with the SYS-ON wire thus it
interrupts the Sequencer, but the Sequencer times its stage-down and stage-up function.
STAGE CODE: Should there be a scenario where you’d like to have the boiler force a certain amount of
stages on (calculation GPM for example), this is where you would indicate the amount of stages you’d
like activated.
FORCE STAGES: Should there be a scenario where you’d like to have the boiler force a certain amount
of stages on (calculation GPM for example), this is where you would active this sequence. Once “YES”
has been selected, the amount of stages selected in the above description (STAGE CODE) will be
activated.
 To exit this operation, “NO” must be selected.
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Emergency Override
If this is not a dual boiler installation and in case of an absolute necessity to maintain building heat or
freeze-up, the service technician or maintenance technician can consider rewire and manually operate the
Sequencers.
CAUTION
WHEN OVERRIDING THE BUILT-IN CONTROLLERS IN THE FOLLOWING STEPS, ALL
ALARM LIMITS ARE STILL ACTIVE AND WITHIN THE CONTROL CIRCUITRY. IT IS
STRONGLY RECOMMENDED NO FURTHER BYPASS BE CONTEMPLATED OR USED IN
ORDER TO MAINTAIN PROPER SAFETY.
Green LED off or no 10VDC at test point W2 – depending upon the sequencer, circuitry or wiring can
be provided directly into the Sequencer to stage in the contactors.
Sequencer – interface is at the J3 connector. 24VAC is required at J3-8 (yel/blk) and 16VDC-24VDC is
required at J3-6 (red), J3-5 (gray) is common. Worst case, the 16VDC will work with two 9-volt batteries
in series.
Either with 4 switches or jumpers setup the appropriate stage code based upon the following table.
Heating Stage
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
J3-1
J3-2
J3-3
X
X
X
X
X
X
X
X
X
X
X
X
X
X
J3-4
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
The X’s in any horizontal stage column would mean a jumper to ground or control common. The
Sequencer will immediately go to that specific stage. Example – stage 10, J3-1 and J3-3 both pulled
down.
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Replacement Parts
1
Part Number
Description
L5683
Circuit Breaker, 30-amp, 3 Pole, 480V ETA
14
Part Number
Description
L5531
High Limit, Manual Reset 220° F
1
L5685
Circuit Breaker, 50-amp, 3 Pole, 480V ETA
15
LUSW1145
Door Safety Switch Power Panel
2
LEBNTB5669
Main Control Board
16
LULAMP2289
Indicator Light Green, 125VAC
3
LEBNDS5670
17
L5086
Terminal Block 6 Position, 30-amp
4
LEBNSQ5639
18
LVLUG3660
Terminal Block, 3 Pole, 380-amp Main Power
5
L5529
Display Interface with Keypad
Element Sequencer Control Board (must specify
boiler size when ordering)
Contactor, 60-amp, 3 Pole Square D
19
LVLUG2340
Ground Lug 250M-6 GA
6
LEBNB5515
Heating Element 15 kW 208V w/gasket
20
LVLUG5000
Ground Lug 2-14 GA
6
LEB5517
Heating Element 15 kW 240V w/gasket
21
L5457
Temperature/Pressure Gauge
6
LEB5516
Heating Element 12 kW 480V w/gasket
22
L5465
Air Vent
6
LEB5518
Heating Element 20 kW 480V w/gasket
23
L5452
Pressure Relief Valve 30psi
6
LEB5518-23
Heating Element 23 kW 480V w/gasket
23
L5454
Pressure Relief Valve 125psi
7
L5575
24
L5541
Transformer 24VAC, 40VA Control
8
LUFUSE0443
25
LUFUSE0440
Fuse, 250V, 2-amp Glass Fast Acting
9
LXPLG5580
Element Gasket
Fuse, 32V, 2-amp Mini Blade Fast Acting
(Control Board)
Element Hole Plug
26
L5681
Circuit Breaker, 15-amp, 1 Pole ,120V Square D
10
L5734
Low Water Cutoff Control Module
NS
LWFSB
Temperature Sensor Supply Water
11
L5735
Low Water Cutoff Sensor Probe
NS
LWFSNR
Temperature Sensor Return Water
12
LUSW9156
Low Water Cutoff Pushbutton Switch
NS
LWFS25F
Temperature Sensor Outdoor
13
L5539
High Limit, Auto Reset 210° F
NS = Not Shown
10/23/2019
31
BI810
Boiler Maintenance
The boilers are designed to give years of worry free service. Just like any other piece of mechanical
heating equipment they require annual inspection and maintenance for optimal performance.
Improper maintenance and missed inspection can lead to such issues as wire connection failure, electrical
component failure, excessive noise, and element failure.
CAUTION
ALWAYS DISCONNECT ELECTRIC POWER FROM BOILER BEFORE PERFORMING MAINTENANCE.
1. Boiler Water – water treatment is strongly suggested to prevent scale deposits, corrosion, and
other chemicals that can be harmful to the boiler elements and internal components. Periodic
testing of the boiler water should be performed to maintain water properties as described in this
manual, see water treatment section. A qualified water treatment specialist should be consulted to
establish a proper water treatment program.
2. Electrical System – dust build up, foreign matter, and excessive moisture can cause damage to
boiler contactors, relays, and wiring connections. Inspect both the interior and exterior of the
boiler and clean as needed. Always clean the interior of the boiler with source power OFF.
a. Electrical Connections – with power OFF, routinely check the tightness of electrical
connections. This includes power entrance lugs, fuses or contactors, and circuit breakers.
b. Contactor Inspection – check for burned contacts, discolored wire connections, and
overheated coils. Contactors that chatter or hum should be thoroughly cleaned and
inspected. Replace as needed.
c. Heating Element Inspection – make sure wire connections are tight and corrosion free.
d. Overall Inspection – check the entire boiler wiring harness for frayed or damaged wires.
Replace any damaged wires that may come in contact with metal parts.
3. Boiler Mechanical System – routinely inspect the boiler and adjacent piping for any signs of
water leaks or corrosion.
CAUTION
ALWAYS DISCONNECT POWER WHEN SERVICING INTERNAL COMPONENTS OF THE BOILER.
a. Boiler Elements – these are screw-in elements with gasket. If there is indication of a leak
near an element, remove the element and inspect the element gasket. Clean the element
and boiler threads. Clean or replace the element gasket as needed. DO NOT
OVERTIGHTEN ELEMENTS.
b. Check for leaks – repair any leaks on the boiler or piping near the boiler which may cause
water to enter the boiler enclosure.
c. Boiler Vessel Inspection – the interior of the boiler vessel must be inspected annually.
Remove the 3” inspection plug on the inlet side of the boiler. If there is evidence of scale
or excessive sediment inside the boiler vessel, proper steps must be taken to flush and
clean the boiler. Consult a local water treatment company for the best course of action.
Scale formation will shorten the life of the elements and cause unpredictable control
issues as well as excessive noise.
d. While inspecting the boiler vessel, remove and clean the low water cut off probe.
10/23/2019
32
BI810
Brute Commercial Electric Boiler
Notes:
200 Lafayette St.
Middleville, MI 49333
(800) 523-2931
www.BradfordWhite.com
Litho in U.S.A. © Bradford White 1909 Document 1447-BW
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