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Bradford-White Corp BWCV manual

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Table of contents for the manual

  • Page 1

    Internet Version for Reference Only Installation and Operation Instructions Document 2142 H2316900- Installation and Operation Instructions for Copper Brute II Water Heater Model BWCV U.S. Reg. 2,765,423 WARNING If the information in this manual is not followed exactly, a re or explosion may result causing property damage, personal injury or los[...]

  • Page 2

    Internet Version for Reference Only Bradford White Page 2 Copper Brute II Page 3 SECTION 1. General Information 1.1 Introduction ........................................................ 3 1.2 Model Identication ............................................ 3 1.3 Warranty ............................................................ 4 1.4 Dimension[...]

  • Page 3

    Internet Version for Reference Only Bradford White Page 2 Copper Brute II Page 3 SECTION 1. General Information In the Commonwealth of Massachusetts, this appliance must be installed by a licensed plumber or gas tter . WARNING The Copper Brute II water heater must be installed in accordance with the procedures detailed in this manual, or the Bra[...]

  • Page 4

    Internet Version for Reference Only Bradford White Page 4 Copper Brute II Page 5 Model Character Designation 1-3 Model Series Designation B W C = Copper Brute II 4 Usage V = Volume Water 5-8 Size 0 5 0 0 = 500,000 BTU/h input 0 7 5 0 = 750,000 BTU/h input 1 0 0 0 = 999,000 BTU/h input 1 2 5 0 = 1,250,000 BTU/h input 1 5 0 0 = 1,500,000 BTU/h input [...]

  • Page 5

    Internet Version for Reference Only Bradford White Page 4 Copper Brute II Page 5 Figure 1. Dimensional Data. Air Vent Horiz. A B C D E F G H Conn. Conn. Vent Size in cm in cm in cm in cm in cm in cm in cm in cm W V Pipe 500 33 85 15 40 5 15 29 76 32 83 7 20 8 22 46 1 17 6 15 6 15 6 15 750 45 1 16 21 55 5 15 29 76 32[...]

  • Page 6

    Internet Version for Reference Only Bradford White Page 6 Copper Brute II Page 7 Required Recommended Appliance Clearance From Service Access Surface Combustible Material Clearance inches cm inches cm Left Side 1 2.5 24 61 Right Side 1 2.5 24 61 Top 1 2.5 12 30 Back 1 2.5 ** 12** 30** Front 1 2.5 36 91 Vertical (Category 1) 6* 15.2* Vent Horizontal[...]

  • Page 7

    Internet Version for Reference Only Bradford White Page 6 Copper Brute II Page 7 the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1 square inch per 2000 Btu/hr (1 1 square cm/kW) of total input rating of all equipment in the enclosure. T able 3 shows data for this sizing method, for each Copper Bru[...]

  • Page 8

    Internet Version for Reference Only Bradford White Page 8 Copper Brute II Page 9 2.2 Venting 2.2.1 Vent Categories Depending upon desired Copper Brute II venting, it may be considered a Category I or a Category III appliance. In general, a vertical vent system will be a Category I system. However , in rare instances, a Copper Brute II vertical vent[...]

  • Page 9

    Internet Version for Reference Only Bradford White Page 8 Copper Brute II Page 9 U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony B= Clearance to window or door that may be 4 feet (1.2 m) below or to side of opening; 36 inches (91 cm) o[...]

  • Page 10

    Internet Version for Reference Only Bradford White Page 10 Copper Brute II Page 11 the vent pipe. Horizontal runs must slope downwards not less than  inch per foot (2 cm/m) from the unit to the vent terminal. Reference T able 1 for the size of the Category III vent system. Up to three elbows can be used with 50 linear feet (15.2m) of pipe. Subtr[...]

  • Page 11

    Internet Version for Reference Only Bradford White Page 10 Copper Brute II Page 11 2. Locate the terminal so that it will not be subject to damage by accident or vandalism. 3. Locate the combustion air terminal so that it cannot be blocked by snow . The National Fuel Gas Code requires that it be at least 12 inches (30 cm) above grade, but the insta[...]

  • Page 12

    Internet Version for Reference Only Bradford White Page 12 Copper Brute II Page 13 Outdoor Vent Outdoor Model (Size) Terminal Combustion Air Terminal 500 20254701 D2007900 750 20254703 D2007900 1000 20254705 D2008000 1250 D2007700 D2008000 1500 D2007700 D2008000 1750 D2007800 D2008000 2000 D2007800 D2008200 Table 6. Vent Terminals for Outdoor Units[...]

  • Page 13

    Internet Version for Reference Only Bradford White Page 12 Copper Brute II Page 13 Warning Do not use open ame to check for leaks. An open ame could lead to explosion, which could result in property damage, serious injury or death. NOTE : The Copper Brute II appliance and all other gas appliances sharing the gas supply line must be ring at[...]

  • Page 14

    Internet Version for Reference Only Bradford White Page 14 Copper Brute II Page 15 Figure 4. Water Heater Piping — One Heater, One Tank. NOTES: 6. CAUTION: PUMP SIZING MUST BE BASED UPON WA TER HARDNESS A T JOB SITE 1. OPTIONAL CWMU & RECIRC. LINE LOCA TION. 2. LOCA TE PENNANT DHW SENSOR OR REMOTE AQUAST A T WELL IN LOWER 1/3 OF T ANK. 3. BAC[...]

  • Page 15

    Internet Version for Reference Only Bradford White Page 14 Copper Brute II Page 15 Figure 5. Water Heater Piping — Multiple Heaters, One Tank. SUPPL Y RECIRC. CWMU CAUTION: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURA TION AND V AL VING , CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS. NOTES: 7. CAUTION: PUMP SIZING MUST BE BA[...]

  • Page 16

    Internet Version for Reference Only Bradford White Page 16 Copper Brute II Page 17 Figure 6. Water Heater Piping — One Heater, Multiple Tanks. CAUTION: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURA TION AND V AL VING , CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS. LEGEND CHECK V AL VE THERMOMETER TEMPERA TURE SENSOR GLOBE V A[...]

  • Page 17

    Internet Version for Reference Only Bradford White Page 16 Copper Brute II Page 17 Figure 7. Water Heater Piping — Multiple Heaters, Multiple Tanks. CAUTION: THIS DRAWING SHOWS SUGGESTED PIPING CONFIGURA TION AND V AL VING , CHECK WITH LOCAL CODES AND ORDINANCES FOR ADDITIONAL REQUIREMENTS. LEGEND CHECK V AL VE THERMOMETER TEMPERA TURE SENSOR GLO[...]

  • Page 18

    Internet Version for Reference Only Bradford White Page 18 Copper Brute II Page 19 4.4 Combined Water Heating (potable) and Space Heating — Water Heater NOTE: These systems are not allowed in all localities. Be sure to consult local codes. Piping and components connected to this water heater for the space heating application shall be suitable for[...]

  • Page 19

    Internet Version for Reference Only Bradford White Page 18 Copper Brute II Page 19 5.3 External Staging Control Wiring WARNING Improper eld wiring may result in re or explosion which can cause property damage, severe injury, or death. Make only wiring connections which are in accordance with the Installation and Operation manual. AVERTISSEMEN[...]

  • Page 20

    Internet Version for Reference Only Bradford White Page 20 Copper Brute II Page 21 Most of the time, the number of stages from the external control will match the number of stages on the heater . However , in some instances, the controller will not have enough staging capability to work with all of the stages on a heater (for instance, using an 8-s[...]

  • Page 21

    Internet Version for Reference Only Bradford White Page 20 Copper Brute II Page 21 you have. Y ou must determine the type of piping the system has, the Mode the temperature control will operate in, and the various settings for that mode. 6.2.1 System Piping “Primary Secondary Piping” In the context of these instructions, “primary secondary pi[...]

  • Page 22

    Internet Version for Reference Only Bradford White Page 22 Copper Brute II Page 23 The rst item is “Mode”; enter the mode number as determined above. The T emperature Control will then present you with some or all of the following options, depending on the mode you have chosen: In mode 6, external heater control, you will not see the followi[...]

  • Page 23

    Internet Version for Reference Only Bradford White Page 22 Copper Brute II Page 23 PUMP DL Y (Pump Delay): On pump mounted units, the heater mounted pump continues to run for the time selected after the heat demand in the system is satised . This setting also af fects the 24V AC output on the “PMP” “PMP” terminals (see section 5.2). Thes[...]

  • Page 24

    Internet Version for Reference Only Bradford White Page 24 Copper Brute II Page 25 Step 3: Press the three programming buttons to enter “ADJUST” mode (Figure 10). Press “Item” to select the programming item, and the arrow keys to adjust the setting. See section 6.2 Programming the T emperature Control if more programming instructions are ne[...]

  • Page 25

    Internet Version for Reference Only Bradford White Page 24 Copper Brute II Page 25 If the heater is not a pump mounted model, a 24V AC pump contactor may be connected to the “PMP” terminals to control a eld installed pump. Program the temperature control to use “Mode 2.” The AUTO/MAN switch must be in the AUTO position in this mode. Mode[...]

  • Page 26

    Internet Version for Reference Only Bradford White Page 26 Copper Brute II Page 27 Minimum Off T ime (MIN OFF) – The minimum off time is the minimum amount time that a stage must be off before it is allowed to turn on. Once a stage turns off, it cannot turn on until a minimum off time elapses. The minimum off time is adjustable through the MIN OF[...]

  • Page 27

    Internet Version for Reference Only Bradford White Page 26 Copper Brute II Page 27 6.3.4 Boiler Maximum (BOIL MAX) The boiler maximum (BOIL MAX) is the highest water temperature that the control is allowed to use as a target temperature. If the control does tar get BOIL MAX, and the heater outlet sensor is near the BOIL MAX temperature, the MAX seg[...]

  • Page 28

    Internet Version for Reference Only Bradford White Page 28 Copper Brute II Page 29 The heater target temperature is set using the BOIL T ARGET item in the Adjust menu. Note: External demand is not required in this mode of operation. T ank Differential – A differential setting that operates  above and below the T ANK T ARGET is selectable using[...]

  • Page 29

    Internet Version for Reference Only Bradford White Page 28 Copper Brute II Page 29 signal to these terminals. The control ener gizes the heater pump (if equipped), energizes the Pmp-Pmp terminals, and turns on the heater pump segment in the display . The control also turns on stage 1 of the heater . Section 5.3 contains important information about [...]

  • Page 30

    Internet Version for Reference Only Bradford White Page 30 Copper Brute II Page 31 6.4. 2 High Altitude Adjustment and Set Up Copper Brute II appliances may be operated at high altitude (7700 ft., 2347 m) with a reduction in output of approximately 10%. At altitudes of less than or more than 7700 ft. (2347 m) the appliance will perform equally as w[...]

  • Page 31

    Internet Version for Reference Only Bradford White Page 30 Copper Brute II Page 31 6. Low water cutoffs, if installed, should be checked every 6 months. Float type low water cutoff should be ushed periodically . 7. Inspect ue passages, and clean with brushes/ vacuums, if necessary . Sooting in ue passages indicates improper combustion. Det[...]

  • Page 32

    Internet Version for Reference Only Bradford White Page 32 Copper Brute II Page 33 The gas and electric controls on the appliance are engineered for long life and dependable operation, but the safety of the equipment depends on their proper functioning. It is strongly recommended that a qualied service technician inspect the basic items listed b[...]

  • Page 33

    Internet Version for Reference Only Bradford White Page 32 Copper Brute II Page 33 ignitor out. Install in reverse order , always using a new ignitor gasket with the replacement ignitor . Caution Ignitor gets hot. 7.2.9 Ignition Sensors The ignition sensors ensure that the main ame is ignited, so that raw gas is not allowed to ll the combusti[...]

  • Page 34

    Internet Version for Reference Only Bradford White Page 34 Copper Brute II Page 35 10. Inspect the inside of the copper tubes for scale buildup. Scale can build up on the inner surface of the heat exchanger tubes, which can restrict water ow . If the tubes show signs of scaling, clean the internal surface. Bradford White of fers a tube cleaning [...]

  • Page 35

    Internet Version for Reference Only Bradford White Page 34 Copper Brute II Page 35 OUT BOIL BOIL OUT BOIL IN BOIL IN BOILSUP BOILSUP OUTDR OUTDR T ANK T ANK VIEW VIEW VIEW VIEW VIEW VIEW VIEW VIEW VIEW VIEW VIEW ERROR DISPLA YED DESCRIPTION OF ERROR The control is no longer able to read the heater supply sensor due to an open circuit. In this case,[...]

  • Page 36

    Internet Version for Reference Only Bradford White Page 36 Copper Brute II Page 37 8.6 Troubleshooting Copper Brute II Controls The Copper Brute II series consists of two 2- stage models (500 and 750), one 3-stage model (1000), and four 4-stage models (1250 to 2000). The 2-stage models have one ignition module, and the 3- and 4-stage models have tw[...]

  • Page 37

    Internet Version for Reference Only Bradford White Page 36 Copper Brute II Page 37 Figure 18. Copper Brute II 500 - 750 Ladder Diagram. SECTION 9. Wiring Diagrams[...]

  • Page 38

    Internet Version for Reference Only Bradford White Page 38 Copper Brute II Page 39 Figure 19. Copper Brute II 1000 Ladder Diagram.[...]

  • Page 39

    Internet Version for Reference Only Bradford White Page 38 Copper Brute II Page 39 Figure 20. Copper Brute II 1250 - 2000 Ladder Diagram.[...]

  • Page 40

    Internet Version for Reference Only Bradford White Page 40 Copper Brute II Page 41 Figure 21. Copper Brute II 500 - 1000 Wiring Schematic. Note: Positions of eld wiring terminals may vary, but terminal designations are as indicated.[...]

  • Page 41

    Internet Version for Reference Only Bradford White Page 40 Copper Brute II Page 41 Figure 22. Copper Brute II 1250 - 2000 Wiring Schematic. Note: Positions of eld wiring terminals may vary, but terminal designations are as indicated.[...]

  • Page 42

    Internet Version for Reference Only Bradford White Page 42 Copper Brute II Page 43 Figure 23. Field Wiring. HEA TER HEA TER Note: Positions of eld wiring terminals may vary, but terminal designations are as indicated.[...]

  • Page 43

    Internet Version for Reference Only Bradford White Page 42 Copper Brute II Page 43 TST AT TST A T - - - - - - - - - - - - - - 1 C 1 NO 2 C 2 NO 3 C 3 NO SET D COM D HT D HT OUT 4C 4 NO IN S S C1 OUT S OD S S C2 SUP S COM NO NO COM ALRM ALRM COM NO NC L W CO GND PMP PMP L W CO OTHER INTS FLOW SWITCH TERMINAL STRIP MODE 1 MODE 2 MODE 3 MODE 4 MODE 5 [...]

  • Page 44

    Internet Version for Reference Only C O R P O R A T I O N B W R A D FO R D H ITE ® H2316900- Ambler , P A 19002 T ech. Service (800) 334-3393 Service Parts (800) 538-2020 W arranty Service (800) 531-21 1 1 ® Figure 25. Field Wiring for Mode 6. 1C 1NO 2C 2NO 3C 3NO 4C 4NO 4C 3C 4NO 3NO 2C 1C 2NO 1NO 4 stage h using 4 control outputs eater 4 stage [...]