Bradford White Corp Boiler BJVS User Manual

InstallationandOperationInstructions  
Document1242  
Installation and Operation  
Instructions for  
BRUTE M INI  
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.  
AVERTISSEMENT  
WARNING  
Assurez-vous de bien suivres les instructions  
If the information in this manual is not  
données dans cette notice pour réduire au  
followed exactly, a fire or explosion may  
minimum le risque d’incendie ou d’explosion ou  
result causing property damage, personal  
pour éviter tout dommage matériel, toute  
injury or loss of life.  
blessure ou la mort.  
Ne pas entreposer ni utiliser d’essence ni  
Do not store or use gasoline or other  
d’autres vapeurs ou liquides inflammables dans  
flammable vapors and liquids in the vicinity  
le voisinage de cet appareil ou de tout autre  
of this or any other appliance.  
appareil.  
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.  
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.  
• If you cannot reach your gas supplier, call  
the fire department.  
• Si vous ne pouvez rejoindre le fournisseur de  
gaz, appelez le sservice des incendies.  
Installation and service must be performed by  
a qualified installer, service agency, or gas  
supplier.  
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  
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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  
SECTION 1.  
General Information  
1.1 Introduction  
following national codes for installation:  
This manual provides information necessary for  
the installation, operation, and maintenance of Model  
BJV copper tube hydronic boilers.  
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".  
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.  
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.  
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.  
1.4 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.  
1.2 Warranty  
Model BJV boilers are covered by a limited  
warranty. The owner should fill out the warranty  
registration card and return it to .  
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).  
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  
1.5.2 Materials for Most Installations  
In addition to the items listed above, the  
following items may be needed:  
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.  
1. Plumbing materials for the bypass piping, which  
is required for:  
a. Any system where the return water  
BRADFORD WHITE CORP .  
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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  
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  
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).  
configurations, conversion parts are available  
from. For more information or call the Customer  
Service Department.  
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  
1.6.2 Dimensions  
See Figure 1 for a diagram showing the boiler’s  
exterior dimensions and dimensions to critical  
connections on the boiler.  
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.  
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.  
1.6 Specifications  
1.6.1 General Specifications  
1. InstallationLocation:  
Certified for use in Indoor Applications only  
2. Minimum Clearance From Combustible  
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.  
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  
½" NPT  
LP  
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”).  
50-225  
½" NPT  
5. Inlet Gas Supply Pressure:  
Minimum  
Maximum  
10.5" WC  
13.0" WC  
Natural Gas:  
LP Gas:  
5.5" WC  
10.0" WC  
All gas-fired products require correct installation  
to assure safe operation. The requirements for boilers  
include the following:  
6. Water Pipe/Boiler Connection:  
1¼" NPT  
7. Water Flow Rate:  
See Table in Section 5.2  
1. Field assembly  
2. Appropriate site location (clearances) and  
flooring  
8. Pressure Relief Valve:  
30 PSI  
3. Sufficient combustion and ventilation air  
4. Properly sized gas meter and piping  
5. Proper electrical wiring (if required)  
6. Adequate water flow  
9. Recommended system pressure:  
12 PSI  
10. Exhaust Vent Connection Size:  
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.  
50  
4" Diameter  
75-100 5" Diameter  
125-160 6" Diameter  
225  
7" Diameter  
11. Electrical Supply:  
115 Volts AC  
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Dimensions in inches cm  
Dimensions  
Water Gas  
inches cm  
Conn. Conn.  
in.  
in.  
1/2  
Size*  
50  
75  
100  
125  
160  
225  
A
B
C
D
E
V
13-3/8 34  
13-3/8 34  
16-7/8 43  
16-7/8 43  
20-3/8 52  
25-5/8 65  
27-3/4 71  
27-3/4 71  
28-3/4 73  
28-3/4 73  
28-3/4 73  
31-1/2 80  
23-5/8 60  
24-1/8 61  
24-1/8 61  
23-5/8 60  
23-5/8 60  
23-1/4 59  
21-3/4 55  
21-3/4 55  
22-3/4 58  
22-3/4 58  
22-3/4 58  
23-3/4 63  
26-1/2 67  
27-1/2 70  
27-1/2 70  
27-1/2 70  
27-1/2 70  
27-1/2 70  
4
5
5
6
6
7
10  
1-1/4  
1-1/4  
1-1/4  
1-1/4  
1-1/4  
1-1/4  
13  
13  
15  
15  
18  
1/2  
1/2  
1/2  
1/2  
*3/4**  
* Values shown are for both BJVS and BJVT Models  
**1/2 for propane  
Figure 1. Dimensional Information.  
2.2 Field Assembly  
1. Brute Mini boilers have built-in draft diverter for  
natural draft operation.  
2. Find the vent damper box which is located in the  
boiler package.  
3. 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.  
4. For Model BJVS only: Install the metal plug  
provided with the vent damper onto the damper  
plate hole. Disregard the metal plug in case of  
standing (continuous) pilot boilers. For all  
BJVT models, the damper plate hole should  
never be blocked.  
5. Do not modify the automatic vent damper  
device. It is very important that no other vents  
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.  
Figure 2. Field Assembly Items.  
6. Install the temperature/pressure gauge provided  
in the parts box.  
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.  
6 15  
6 15  
4*  
10  
6 15  
Attention  
Ne pas tourner le registre manuellement avec ou  
sans courant électrique ou le moteur sera  
endommagé.  
Dimensions in inches cm.  
*6" for models BJV160 to BJV225.  
Figure 3. Closet and Alcove Installation (see Table 3).  
2.3.2 Flooring  
2.3.1 Clearances  
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 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  
Right side  
Rear  
50-125  
160-225  
cm  
in  
6
6
cm  
15  
15  
15  
10  
15  
48  
in  
6
6
6
6
15  
15  
15  
15  
15  
91  
6
Front  
4
Flue  
Top  
6
23  
6
36  
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.  
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.  
Figure 4. Typical Combustible Floor Installation.  
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Inside Air Supply: When combustion is  
SECTION 3.  
Venting  
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).  
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.  
Note: In Canada, follow Canadian Standard, CSA-  
B149.1 or local codes.  
Exhaust Fans or Vents: Any equipment which  
exhausts air from the boiler room can deplete the  
combustion air supply or reverse the natural draft  
action of the venting system. This could cause flue  
products to accumulate in the boiler room. Additional  
air must be supplied to compensate for such exhaust.  
The information in Table 2 is not applicable in  
installations where exhaust fans or blowers of any  
type are used. Such installations must be designed by  
qualified engineers.  
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).  
Outside Air Area*  
Inside Air Area*  
Inside Air  
Outside Air  
Boiler Size  
Sq. In.  
sq cm  
Sq. In. sq cm  
Area in Sq. In.* (sq cm)  
Area in Sq. In.*  
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.  
50  
75  
15  
20  
25  
32  
40  
60  
100  
100  
100  
125  
160  
225  
645  
97  
645  
129  
161  
206  
258  
387  
100  
125  
160  
225  
645  
807  
1032  
1452  
The boiler must be completely isolated and  
protected from any source of corrosive chemical  
fumes such as those emitted by trichlorethylene,  
perchlorethylene, chlorine, etc.  
*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.  
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.  
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.  
AVERTISSEMENT  
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.  
N’entrepposeraucunproduitchimique,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.  
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.  
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 .  
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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.  
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  
poisoningorasphyxiation.  
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.  
AVERTISSEMENT  
Avoid terminating boiler vents near air  
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.  
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.  
BJVS/BJVT  
Size  
50  
Vent Pipe Diameter  
inch  
4
5
5
6
6
7
cm  
10  
13  
13  
15  
15  
18  
75  
100  
125  
160  
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.  
225  
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:  
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.  
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.  
Brut e M ini Hydronic Boile r  
Page 9  
At the time of removal of an existing boiler, the  
WARNING  
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.  
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.  
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.  
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  
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.  
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.  
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.  
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).  
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  
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.  
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.  
3.4.2 Inspection of Commonly Vented  
Appliances  
Mettre l’appareil inspecté en marche. Suivre les  
instructions d’allumage. Régler le thermostat de  
façon que l’appareil fonctionne de façon  
continue.  
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.  
5. Test for spillage at the draft hood relief opening  
after 5 minutes of main burner operation. Use the  
BRADFORD WHITE CORP .  
Page 10  
flame of a match or candle, or smoke from a  
SECTION 4.  
cigarette, cigar or pipe.  
Gas Connections  
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.  
4.1 Gas Supply and Piping  
Review the following general instructions before  
continuing the installation.  
6. After it has been determined that each appliance  
remaining connected to the common venting  
system properly vents when tested as outlined  
above, return doors, windows, exhaust fans,  
fireplace dampers and any other gas burning  
appliance to their previous conditions of use.  
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.  
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.  
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.\  
7. Any improper operation of the common venting  
system should be corrected so the installation  
conforms with the National Fuel Gas Code,  
ANSI Z223.1. When resizing any portion of the  
common venting system, the common venting  
system should be resized to approach the  
minimum size as determined using the  
1. Gas piping installation must be in accordance  
with the latest edition of ANSI Z223.1 and all  
local codes. In Canada, the installation must be  
in accordance with CSA-B149.1 and all local  
codes that apply.  
appropriate tables in Appendix G in the National  
Fuel Gas Code, ANSI Z223.1.  
2. Check the gas supply to be sure that it is the  
same as the gas indicated on the boiler’s plate.  
Brute Mini BJVS and BJVT boilers, as shipped  
from the factory, are certified to operate within  
the altitude range indicated on the rating plate. If  
a field conversion to a different altitude range  
should be necessary, conversion parts are  
available for changing the altitude range of the  
heater. Contact factory for parts information.  
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.  
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.  
Brut e M ini Hydronic Boile r  
Page 11  
Supply Pressure  
Minimum  
5.5 Inches WC 10.5 Inches WC  
(1.3 kPa) (2.5 kPa)  
10.0 Inches WC 13.0 Inches WC  
(2.4 kPa) (3.1 kPa)  
Maximum  
Boiler Size  
Distance  
From Gas  
Meter  
50  
75  
100  
125  
160  
225  
Natural Gas  
Pipe Size  
0-50'  
0-15m  
50-100'  
15-30m  
100-200'  
30-60m  
LP Gas  
1/2  
3/4  
3/4  
3/4  
3/4  
1
3/4  
3/4  
1
3/4  
1
1
1
1
1-1/4  
1-1/4  
Table 5. Gas Supply Pressure Requirements.  
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.  
1
1-1/4  
*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.  
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.  
Table 4. Natural Gas Pipe Size Requirements*  
Gas Supply  
Inlet  
To Equipment  
Inlet  
Tee  
Fitting  
3 in.  
(76mm) Min.  
Nipple  
Caution  
Some leak test solutions (including soap and water)  
may cause corrosion or stress cracking. Rinse the  
piping with water after testing.  
Cap  
Figure 5. Typical design for a sediment trap/drip leg.  
4. 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.  
5. Install a manual gas shutoff valve for service and  
safety. Do not use a restrictive gas cock. Flexible  
gas connectors, if used, must be CSA rated for  
the total input rating of the boiler.  
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.  
6. Disconnect the boiler and its individual shutoff  
valve from the gas supply system during pressure  
testing of the system at pressures higher than 1/2  
pounds per square inch (psi) (3.45 kilopascals  
[kPa]). If the test pressure is equal to or less than  
1/2 psi (3.45 kPa), close the manual shutoff  
valve on the heater during the piping pressure  
test.  
7. 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.  
BRADFORD WHITE CORP .  
Page 12  
A full sized, 1¼" bypass with balancing valves is  
strongly recommended for all systems, and required  
when: 1) the boiler is installed without primary-  
secondary piping in a multiple zone system; 2) when  
the return water temperature can be expected to be  
lower than 120°F (44°C); or 3) whenever the system  
piping on the outlet side of the boiler may allow  
reduced flow through the heat exchanger, causing  
excessive temperature rise (see Section 5.2).  
Note: Bradford White strongly recommends a  
primary/secondary piping system for all installations,  
especially sizes 125, 160 and 225. In this system, a  
circulator is dedicated to pumping the boiler only. This  
circulator should be sized for the boiler head loss and  
flow rate.  
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.  
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 in-  
floor radiant and snow melt systems.  
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.  
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.  
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  
5.2 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.  
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.  
Brut e M ini Hydronic Boile r  
Page 13  
Figure 6. Typical Plumbing Installations.  
BRADFORD WHITE CORP .  
Page 14  
Multi-Zone  
BJV  
Boiler  
BJV  
Boiler  
Valve System  
Single Circuit System  
Multi-Zone  
BJV  
Boiler  
Pump  
System  
Figure 6A. Typical Plumbing Installations.  
Air Scoop  
Pump  
System  
Loop  
Feed  
Water  
Expansion  
Tank  
Figure 6B. Typical Plumbing Installations.  
Brut e M ini Hydronic Boile r  
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  
1/2" Pipe  
3/4" Pipe  
1" Pipe  
1-1/4" Pipe  
A full size by-pass must be installed.  
Size Pump  
H.P.  
Pump  
H.P.  
Pump  
H.P.  
Pump  
H.P.  
Figure 7. By-pass Piping.  
1/25 1/12 1/25 1/12 1/6 1/25 1/12 1/6 1/25 1/12 1/6  
50 50 99 390 680  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
5.3 Flow Requirements  
75  
35 160 300 460 640  
*
*
*
*
*
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  
100  
125  
160  
225  
77 150 260 330 620  
*
*
*
*
27 80 140 170 360 600  
25  
72 57 160 330 190 480  
*
*
110  
69 330  
*
*
*
*
*
temperature rise. Table 6 details temperature rise and  
water flow (GPM) for the Brute Mini boilers.  
*Acirculatorand/orprimary/secondarypipingarerequired.Consult  
factory.  
1. Chart is based on 30°F (17°C) maximum temperature rise.  
Damage from improper flow is not warranted.  
2. Calculations are based on Type L copper tubing with one  
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  
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 LR-  
12, Grundfos UP26-42F, or equivalent. 1/6 HP=B&G series  
HV, Grundfos UP43-75, or equivalent.  
Table 7. Maximum Suggested Circuit Length in Feet.  
15°F 8°C  
20°F 11°C  
Flow Rate  
25°F 14°C  
Size  
Flow Rate  
Headloss  
Headloss  
Flow Rate  
Headloss  
gpm  
l/s  
ft  
m
gpm  
l/s  
ft  
m
gpm  
l/s  
ft  
m
50  
75  
100  
125  
160  
225  
5.3  
8
10.7  
13.3  
17  
0.3  
0.5  
0.7  
0.8  
1.1  
1.5  
0.3  
0.6  
1.3  
2.2  
2.5  
5
0.1  
0.2  
0.4  
0.7  
0.8  
1.5  
4
6
8
10  
12.8  
18  
0.3  
0.4  
0.5  
0.6  
0.8  
1.1  
0.2  
0.3  
0.7  
1.3  
1.8  
3.1  
0.1  
0.1  
0.2  
0.4  
0.5  
0.9  
3.2  
4.8  
6.4  
8
10.2  
14.4  
0.2  
0.3  
0.4  
0.5  
0.6  
0.9  
0.1  
0.2  
0.5  
0.8  
1.2  
1.9  
0
0.1  
0.2  
0.2  
0.4  
0.6  
24  
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.  
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.  
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.  
Pump Relay  
Transformer BLK  
Power  
Supply  
115V AC  
60 Hz  
GRN - Ground  
BLK - Hot  
WHT - Neutral  
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.  
To Pump  
115V AC  
3/4 H.P.  
Max  
WHT - Neutral  
BRN - Hot  
On = Call  
for heat  
115V Field Wiring  
115V Factory Wiring  
BRN WHT  
Figure 8. Field Wiring Connections.  
5.6 Anti-Freeze  
Non-toxic heating system anti-freeze may be  
added to the hydronic system provided the  
concentration does not exceed 50%, and the anti-  
freeze contains an anti foamant. Follow the anti-freeze  
manufacturer’s recommendations for yearly or  
biannual replacement of system anti-freeze.  
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.  
SECTION 6.  
Electrical  
WARNING  
ELECTRICALSHOCKHAZARD. Thisboiler  
contains wiring that carries high voltage. Contact  
with these wires may result in severe injury or  
death.  
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).  
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.  
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.  
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  
câblagepeuvententraînerunfonctionnement  
inadéquatetdangereux.  
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.  
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Page 17  
Figure 9a. Wiring Diagram, Spark Ignition System (BJVS 50 & 75).  
5. When using a or field supplied power venter, the  
proving switch must be connected in series with  
thehi-limit.  
110V  
Hot  
110V  
Neutral  
Space Heating  
Pump  
(Field Supplied)  
Zone  
Pump  
Relay  
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.  
1
3
115V  
24V  
7. For systems with multiple zone pumps or valves,  
see Figure 10.  
Fuse  
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.  
Thermostat  
Field  
Supplied  
Zone  
Pump  
Relay  
R
Boiler  
Terminal  
R
Boiler  
Terminal  
W
Zone  
Pump  
Relay  
4
Boiler  
Terminal  
Optional  
Aquastat  
High  
Limit  
Zone  
Pump  
Relay  
A
6
Vent  
Damper  
Receptacle  
Ignition Control  
MV/  
Power  
Venter  
Receptacle  
24V  
MV GND GND  
Jumper  
24V PV  
6
PV  
2
3
1
4
5
Roll-Out  
Safety  
Switch  
Blocked  
Vent  
Safety  
Switch  
PV MV/ MV  
PV  
Remote Flame Sensor  
High Altitude (Optional)  
Gas Valve  
HW VR8304  
Figure 9b. Schematic, Spark Ignition System  
(BJVS 50 & 75).  
BRADFORD WHITE CORP .  
Page 18  
Figure 9c. Wiring Diagram, Standing Pilot System (BJVT).  
Figure 9d. Schematic, Standing Pilot System (BJVT).  
Brut e M ini Hydronic Boile r  
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  
24V  
Thermostat  
Field  
Supplied  
Zone  
Pump  
Relay  
R
Fuse  
Boiler  
Terminal  
R
Boiler  
Terminal  
W
Zone  
Pump  
Relay  
4
Boiler  
Terminal  
Optional  
Aquastat  
High  
Limit  
Zone  
Pump  
Relay  
A
6
Vent  
Damper  
Receptacle  
Ignition Control  
Power  
Venter  
Receptacle  
Jumper  
Roll-Out  
Safety  
Switch  
Blocked  
Vent  
Safety  
Switch  
1
2
3
4
5
6
7
8
9
MV  
MV/PV  
PV  
GND  
24V (GR)  
24V  
TH-W  
MV  
SPARK  
Pilot Burner With  
Spark Electrode  
Sensor  
LO HI  
W
B
W
B
MV  
C
R
R
PV  
Remote Flame Sensor  
High Altitude  
(Optional)  
HI  
Two-Stage  
Aquastat  
Two-Stage  
Gas Valve  
HW VR8304  
Figure 9f. Schematic, Two-Stage (BJVS 100-225).  
BRADFORD WHITE CORP .  
Page 20  
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.  
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Page 21  
6.3 Grounding  
SECTION 7.  
Operating Instructions  
WARNING  
The boiler must be electrically grounded in  
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 100-  
225), if the water temperature is below the limit  
setting, the ignition module lights the pilot and checks  
the flame existence. After the pilot is proven to be lit,  
the ignition module opens the main gas valve and the  
main burners ignite. The main gas valve is controlled  
by the two-stage operating control (see Figure 11) and  
will cycle between high, low and off as the load  
demands.  
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.  
BREAKS R-B  
MAKES R-W  
ON RISE  
LEFT SWITCH  
DIFFERENTIAL  
TEMPERATURE  
RISE  
BREAKS R-W  
MAKES R-B  
ON FALL  
2
6.4 Auxiliary Devices  
6.4.1 Flow Switch  
LOW  
FIRE  
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.  
INTERSTAGE  
DIFFERENTIAL  
1
BREAKS R-B  
MAKES R-W  
ON RISE  
RIGHT SWITCH  
DIFFERENTIAL  
BOILER INLET  
SETPOINT  
(ADJUSTABLE,  
FACTORY SET  
AT 140°F)  
BREAKS R-W  
MAKES R-B  
ON FALL  
2
HIGH  
FIRE  
6.4.2 Heat Anticipator  
DIFFERENCE BETWEEN THE TEMPERATURES AT WHICH THE  
TWO SWITCHES MAKE R-W. FACTORY SET AT 10°F (6.6°C)  
1
2
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.  
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  
including the pump, boiler, and radiation units,  
for one hour.  
10. 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.  
11. Shut down the entire system, and vent all  
radiation units and high points in the system.  
12. Closethewatermakeupvalveandcheckthestrainer  
in the pressure reducing valve for sediment or  
debris. Reopen the water makeup valve.  
13. Verify system pressure with the boiler pressure  
gauge before beginning regular operation.  
14. Within 3 days of start-up, recheck and bleed all  
air vents and the expansion tank using these  
instructions.  
15. In systems piped with cross-linked polyethylene  
tubng (PEX) it is essential that all air is purged  
from all zones in the system to prevent PEX  
tubing failure.  
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.  
7.2.2 BoilerStart-up  
WARNING  
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.  
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.  
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.  
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.  
3. Close all gate valves. Purge one circuit at a time  
as follows:  
AVERTISSEMENT  
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.  
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.  
b. Repeat this procedure for each circuit.  
4. Open all gate valves after all circuits have been  
purged.  
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.  
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.  
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.  
9. Start up boiler according to the procedures  
described in Section 7 and operate the system,  
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Page 23  
NOTE: If your boiler is configured to operate on LP  
Caution  
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.  
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.  
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.  
Caution  
Do not attempt repairs on the gas controls or  
appliance. Tampering is dangerous and voids all  
warranties.  
Attention  
7.3.1 Lighting the Boiler  
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.  
Lighting instructions are as follows:  
1. Verify that the pump system is operating  
properly:  
a. Shut off the manual gas valve located  
outside the boiler.  
b. Raise the wall thermostat high enough to  
call for heat.  
Caution  
Keep all objects off the top of the boiler. Blocking air  
flow could damage the heater, and may void the  
warranty.  
c.  
The pump should come on immediately. If  
it doesn't, test the electrical circuits.  
2. Pilot Information:  
Attention  
a. The BJVS boilers do not require manual  
lighting. The pilot is controlled by the  
automatic ignition system.  
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.  
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.  
7.3 Lighting and Shutdown Procedures  
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).  
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.  
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.  
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.  
a. WHAT TO DO IF YOU SMELL GAS  
a.1 Do not try to light any appliance.  
a.2 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.  
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.  
All Models:  
4. Shut off electrical power to the boiler.  
5. 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.  
6. 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.  
19. Set the thermostat to the desired temperature.  
7.3.2 Shutdown  
7.3.2.1 Main Burner Shutdown (BJVT only):  
1. Lower the wall thermostat setting so that there is  
no call for heat.  
2. To turn off the main burners turn the gas valve  
knob clockwise until it stops at pilot.  
BJVS Models: (BJVT skip 7 )  
7. Turn gas valveknobcounterclockwise  
7.3.2.2 Complete Shutdown:  
1. Lower the wall thermostat setting so that there is  
no call for heat.  
toON.  
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)  
2. Turn off all electrical power to the boiler.  
3. Turn the gas valve knob clockwise to “OFF”. Do  
not force the knob.  
(BJVS skip to step 16)  
4. Shut off the external gas supply valve to the  
boiler.  
8. Remove louvered burner cover by loosening the  
two thumb screws to access the pilot burner.  
9. Remove the control box cover to fully access the  
gas valve.  
7.4 High Altitude Burner  
Air Shutter Adjustment  
10. Find pilot - follow metal tube from gas control.  
The pilot is on the right hand side of the first  
burner.  
11. Turn knob on gas control counterclockwise  
to PILOT.  
DANGER  
This procedure must be followed exactly and  
must be performed by a qualified installer or  
warranty may be voided.  
12. 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.  
DANGER  
Cette manière de procéder doit être faite  
exactement et accomplie par un installateur qualifié  
sous risque d’annulation de la garantie.  
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.  
13. Replace the louvered airbox cover and tighten  
the two thumb screws securely.  
Brut e M ini Hydronic Boile r  
Page 25  
SECTION 8.  
DANGER  
Readandunderstandthisentireprocedure  
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.  
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.  
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.  
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  
SERVICINGSAFETY  
1. STOP! Read the safety information above.  
2. Perform System Start-Up in accordance with  
Section 7.2 of this manual.  
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  
professionalservicetechnician.  
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.  
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.  
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 re-  
tighten its associated locking screw.  
7. Turn the boiler off.  
8. Perform System Start-Up in accordance with  
Section 2A of this manual.  
AVERTISSEMENT  
PRÉCAUTIONS LORS DES RÉPARTATIONS ET  
DE L’ENTRETIEN  
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.  
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  
LOCKING SCREW  
(5/16" HEAD)  
AIR SHUTTER  
BURNER  
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.  
Figure 13. Air Shutter Adjustment.  
BRADFORD WHITE CORP .  
Page 26  
1. Lubricate the water circulating pump per the  
instructions on the pump.  
strongly recommended that the basic items listed  
below be inspected by a qualified service  
technician every year.  
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.  
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.  
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.  
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:  
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.  
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.  
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  
e. Clean any fallen debris from the bottom of  
the unit.  
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  
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.  
Figure 14. 1) BJVS Pilot; 2) BJVH Pilot;  
3) Main Burner Flame Pattern; 4) BJVT Pilot.  
Brut e M ini Hydronic Boile r  
Page 27  
SECTION 9.  
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.  
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.  
2. Two-stage Temperature Control - BJVS 100-  
225 are equipped with a two-stage temperature  
control which senses inlet water temperature. It  
is used to control the firing rate of the main  
burners, cycling the gas valve between low, high  
and off.  
3A. Ignition Control, BJVS - 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.  
WARNING  
SERVICINGSAFETY  
Some of the servicing procedures for the Brute Mini  
BJVS and BJVT boilers are hazardous because they  
involve fuel gas, electricity, moving parts and  
procedures which require testing or temporary  
bypass of safety controls. For this reason, the boiler  
must be serviced only by a qualified professional  
servicetechnician.  
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.  
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.  
4. Pilot Assembly  
AVERTISSEMENT  
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.  
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  
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.  
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.  
Pumpnot  
operating  
A. No power  
A. Check circuit breakers and power source.  
B. Pump defective  
C.Incorrectly wired  
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. Inlet gas pressure too high causing  
an unstable blowing pilot  
B. Pressure should be regulated within limits shown above.  
C.Weak or defective thermocouple  
D.Damaged pilot or thermocouple  
E. Dirty pilot  
C.Replacethermocouple.  
D.Replace.  
E. Blow dust or lint out of pilot.  
F. Clean or replace pilot orifice.  
F. Plugged or undersized pilot orifice  
3.  
4.  
Flame roll-out  
on start-up  
A. Blocked flue  
A. Remove blockage.  
B. Pilot out of position (delayed ignition)  
C.Blocked heat exchanger or flue  
D.Refractory tile out of place  
E. Altered draft diverter  
B. Correct pilot position.  
C.Clean and correct as necessary.  
D.Correct or replace tile as necessary.  
E. Install factory-provided draft diverter.  
Spillage at  
draft hood  
A. Cold chimney  
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.  
B. Vent pipe pitches down to chimney  
C.Blocked chimney  
D.Draft hood altered  
D.Install factory-provided draft diverter.  
E. Install U.L. listed vent cap.  
E. Pre-fabricated chimney with incorrect cap  
5.  
6.  
Flame has  
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.  
lazy yellow tip  
Not enough heat  
A. Inadequate gas supply  
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.  
B. Low manifold gas pressure  
C.Boiler size inadequate  
D.BJVS 100-225 only - Boiler not going  
to high fire.  
C.Replace with boiler of higher input.  
D.Check operation and setting of two-stage operating control.  
7.  
8.  
Pumpnoisy  
A. Air in volute  
A. Bleed air from volute. Check pump alignment.  
B. Replace worn parts.  
B. Worn coupling or bearings  
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  
A. Defective fill valves or pressure regulator  
B. Oversized expansion tank  
A. Replace.  
or low water  
B. Replace.  
pressure at boiler C.Expansion tank piped incorrectly  
C.Repipe expansion tank to suction size of pump.  
gauge or bubbles  
in system at high  
temperature  
11. Pressure relief  
valve opens  
A. Water-logged expansion tank  
A. Drain 2/3 of the water from the expansion tank.  
12. Pilot is lit but main A. Gas valve not at "on" position (BJVT)  
A. Turn knob to "on" position.  
burners will not  
come on  
B. Boiler off on hi-limit control  
C.Boiler incorrectly wired  
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.Boiler off on blocked vent switch  
E. Boiler off on flame roll-out switch  
F. Broken wire in thermostat circuit  
or defective thermostat  
D.Remedy as in symptom #4. Reset the manual reset switch.  
E. Remedy as in symptom #3. Reset the manual reset switch.  
F. Checkcontinuitythroughthermostatcircuitwithwires  
disconnected from R & W.  
G.BJVS 100-225 Only - Two-stage operating G.Checkcontinuityandoperationthroughtwo-stage  
controlnotfunctioningorloosecontact.  
operatingcontrol.  
13. Boiler short cycles A. Heat anticipator in room thermostat  
set too low  
A. Increase setting (0.8 - 1.0 is usually satisfactory).  
B. Low water flow through boiler  
B. Increase size of pump or increase piping size.  
C.Hi-limit switch may be set too low  
C.Increase setting to at least 20°F over outlet water temperature.  
Table 8. Troubleshooting Guide.  
Brut e M ini Hydronic Boile r  
Page 29  
9.3 Troubleshooting Honeywell S8600 Intermittent Pilot System  
Some boilers may be equipped with an ignition module that shuts off pilot gas if pilot fails to light.  
To reset, interrupt power to heater  
Start  
Note: Before troubleshooting, familiarize yourself with the start-up and  
checkout procedure.  
Turn off gas supply.  
Turnthermostat  
(controller) to call for  
heat.  
Check line voltage power, low voltage transformer, hi- limit switch,  
thermostat (controller) and wiring.  
NO  
NO  
Power to module  
(24V nominal).  
YES  
Pull ignition lead and check spark at module.  
Spark okay?  
Spark across igniter/  
sensor gap.  
YES  
YES  
• Check ignition cable ground wiring, ceramic insulator and gap, and correct.  
• Check boot of the ignition cable for signs of melting or buckling. Take  
protective action to shield cable and boot from excessive temperatures.  
• Check that all manual gas valves are open, supply tubing and pressures  
are good, and pilot burner orifice is not blocked.  
• Check electrical connections between module and pilot operator on gas  
Turn gas supply on.  
Pilot burner lights?  
NO  
NO  
control.  
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is  
okay, replace gas valve; if not, replace module.  
YES  
• Check continuity of ignition cable and ground wire.  
• Clean flame rod.  
Spark stops when pilot  
is lit?  
• 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.  
YES  
• If problem persists, replace module.  
• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace  
module.  
NO  
NO  
Main burner lights?  
• Check electrical connections between module and gas valve. If okay,  
replace gas valve.  
YES  
• Check continuity of ignition cable and ground wire.  
System runs until call  
for heat ends?  
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.  
YES  
Call for heat ends.  
System shuts off?  
• Check for proper thermostat (controller) operation.  
NO  
• Remove MV lead at module; if valve closes, recheck temperature  
controller and wiring; if not, replace gas valve.  
YES  
Repeat procedure until trouble-free operation is obtained.  
Troubleshooting ends  
BRADFORD WHITE CORP .  
Page 30  
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.  
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.  
Caution  
Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and  
dangerous operation. Verify proper operation after  
servicing.  
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"  
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.  
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.  
SECTION 10.  
Glossary  
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.  
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.  
8. Verify the voltage across the blocked vent and  
Branch  
roll-out safety switches.  
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."  
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  
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.  
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  
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.  
Brut e M ini Hydronic Boile r  
Page 31  
Heat Distribution Units  
SECTION 11.  
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."  
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.  
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.  
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.  
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.  
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.  
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.  
BRADFORD WHITE CORP .  
Page 32  
Brut e M ini Hydronic Boile r  
Page 33  
BRADFORD WHITE CORP .  
Page 34  
11.3Exploded View  
Vent Damper Connection Harness  
Vent Damper  
Draft Diverter  
Pressure  
Relief Valve  
A - Inlet Pipe  
B - 4-1/2”x3/4” Pipe  
C - Outlet Pipe  
B
ƒ
Gap Closure  
1-1/4” Hold  
1-1/8” Hold  
1-1/4” Hold  
1-7/8” Hold  

ƒ
Top  
ƒ

Heat Exchanger  
C
B
A
Temperature/  
Pressure Gauge  
Immersion Well  
Refractory, Front  
Flue Collector  
Aquastat  
Bulb  
Refractory,  
Rear  
Blocked  
Vent  
Safety  
Switch  
Cover,  
Control  
Box  
½” Close  
Nipple  
(Model 50  
and 100)  
Terminal  
Strip  
Tile Cover  
Transformer  
Pump Relay  
High  
Limit  
Base  
Assembly  
HX Access  
Panel  
Drain  
Valve  
Burner with Pilot Bracket  
Pilot Assembly  
Gas Manifold  
Rear Panel  
1/2" Coupling  
(Model 50 and 100)  
P0005200  
Orifices  
Pilot Gas Tube  
Jacket, One Piece  
Wraparound  
Gas Valve  
2-Stage Operating Control (100-225)  
Burner Cover  
Flame Roll-Out  
Safety Switch  
Figure 15. Parts Identification.  
Brut e M ini Hydronic Boile r  
Page 35  
Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement.  
Ambler, PA19002  
Tech. Service (800) 334-3393  
Service Parts (800) 538-2020  
Warranty Service (800) 531-2111  
Litho in U.S.A. © Bradford White 1101 Document 1242  

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