Installation and Operation Instructions
Document 1243
Installation and Operation
Instructions for
BRUTE ELITE
Modulating Boiler
Model BNTH
Sizes 080–850 MBTU/h
Water Heater
Model BNTV
Sizes 150–850 MBTU/h
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation
could 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
d’autres vapeurs ou liquides inflammables dans
le voisinage de cet appareil ou de tout autre
appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous
servir des téléphones dansle bâtiment où vous
vous trouvez.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
nearby phone. Follow the gas supplier's
instructions.
• 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.
238-49220-00A REV 4/11
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Brut e Elit e
Page 3
SECTION 9.
SECTION 11.
Maintenance
Modes of Operation
9.1
9.2
9.3
Hydronic Heating Demand ............................ 40
Hydronic Heating with Outdoor Reset ........... 40
Hydronic Heating with Domestic Hot
Water (DHW) Priority..................................... 40
11.1
11.2
System Maintenance ..................................... 46
Appliance Maintenance and Component
Description .................................................... 46
11.2.1 Burner............................................................ 46
11.2.2 Modulating Gas Valve / Venturi ..................... 46
11.2.3 Appliance Control .......................................... 46
11.2.4 Ignitor Assembly ............................................ 47
11.2.5 Flame Sensor ................................................ 47
11.2.6 Transformer with Integral Circuit Breaker ...... 48
11.2.7 Blower ........................................................... 48
11.2.8 Heat Exchanger Coils.................................... 48
11.2.9 Gas Pressure Switches (optional) ................. 49
11.2.10 Gas Conversion............................................. 49
9.4
9.5
9.6
Hydronic Heating Using External
Modulation Control ........................................ 40
Hydronic Heating Using Local Lead-Lag/
Cascading Feature ........................................ 41
Hydronic Heating Using Local Lead-Lag/
Cascading Feature with Indirect Hot Water ... 41
9.7
9.8
9.9
Warm Weather Shutdown ............................. 41
Domestic Hot Water Demand (BNTV only) ... 41
Domestic Hot Water Heating Using
External Modulation Control .......................... 42
9.10
Domestic Hot Water Heating Using Local
Section 12.
Lead-Lag/Cascading Feature ........................ 42
Trouble Shooting
12.1
12.2
12.3
Sequence of Operation ................................. 49
Short Cycling ................................................. 49
Error Codes ................................................... 49
Section 10.
Operating Instructions
10.1
10.2
Filling the Boiler System ................................ 43
Operating the Burner and Set Up .................. 43
Section 13.
Replacement Parts
10.2.1 Burner Operation ........................................... 43
10.2.2 Boiler Setup and Adjustment ......................... 44
10.3
10.4
13.1
13.2
General Information....................................... 52
Parts List ....................................................... 52
Shutting Down Brute Elite.............................. 44
To Restart Brute Elite .................................... 44
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BRADFORD WHITE CORP .
Page 4
All installations must be made in accordance with
1) American National Standard Z223.1/NFPA54-Latest
Edition “National Fuel Gas Code” or 2) CSA B149.1
“Natural Gas and Propane Installation Code” and with
the requirement of the local utility or other authorities
having jurisdiction. Such applicable requirements take
precedence over the general instructions contained herein.
All electrical wiring is to be done in accordance
with the local codes, or in the absence of local codes,
with: 1) The National Electrical Code ANSI/NFPA No.
70-latest Edition, or 2) CSA STD. C22.1 “Canadian
Electrical Code - Part 1”. This appliance must be
electrically grounded in accordance with these codes.
SECTION 1.
General Information
WARNING
Brute Elite units must be installed in accordance with
the procedures detailed in this manual, or the
Bradford White warranty will be voided. The
installation must conform to the requirements of the
local jurisdiction having authority, and, in the United
States, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1/NFPA54. In Canada, the
installation must conform to the latest edition of CSA
B149.1 Natural Gas and Propane Gas Installation
Code, and/or local codes. Where required by the
authority having jurisdiction, the installation of Brute
Elite boilers must conform to the Standard for
Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1. Any modifications to the
boiler, its gas controls, or wiring may void the
warranty. If field conditions require modifications,
consult the factory representative before initiating
such modifications.
1.2 Model Identification
Consult the rating plate on the unit. The following
information describes the model number structure.
(1-3) Model Series Designation
B N T = Brute Elite
(4) Usage
H = Hydronic
V = Volume Water
(5-7) Size
0 8 0 = 80,000 BTU/hr input
1 0 5 = 105,000 BTU/hr input
1 5 0 = 150,000 BTU/hr input
1 9 9 = 199,000 BTU/hr input
2 1 0 = 210,000 BTU/hr input
2 8 5 = 285,000 BTU/hr input
3 9 9 = 399,000 BTU/hr input
5 0 0 = 500,000 BTU/hr input
6 0 0 = 600,000 BTU/hr input
7 5 0 = 750,000 BTU/hr input
8 5 0 = 850,000 BTU/hr input
1.1 Introduction
This manual provides information necessary for
the installation, operation, and maintenance of Bradford
White Brute Elite appliances. Read it carefully before
installation.
All application and installation procedures should
be reviewed completely before proceeding with the
installation. Consult the Bradford White 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.
Brute Elite is protected against over pressurization.
A pressure relief valve is included with each Brute Elite.
Some Brute Elites may require that the PRV be installed
prior to filling the system. Refer to Figures 1-7 for PRV
locations.
(8) Fuel
N = Natural Gas
P = LP Gas
(9) Options Code
X = Standard Unit
C = Canadian
D = Canadian CSD-1
J = CSD-1, FM, GAP, IL Code (size 500-850 only)
(10) Pump Options
N = Pump included (80-500 only)
X = No pump (285-850)
(11) Revision
IMPORTANT: The inlet gas pressure to the appliance
must not exceed 13" W.C. (3.2kPa).
2 = Second version
Model Nomenclature
1
2
3
T
4
5
6
7
8
9
10
11
2
B
N
SERIES
SIZE
USAGE
H - HYDRONIC
FUEL
N - NATURAL
P - PROPANE
OPTIONS CODE
X - STANDARD
C - CANADIAN
PUMP OPTIONS
REVISION
2 - SECOND
MBTU/h
B
N
T
N - PUMP INCL.
0
1
1
1
2
2
3
5
6
7
8
8
0
5
9
1
8
9
0
0
5
5
0
5
0
9
0
5
9
0
0
0
0
(80-500 only)
V - VOLUME
WATER
X - NO PUMP
D - CANADIAN,
(285-850)
CSD-1
J - CSD-1,
FM, GAP,
IL (500-850 only)
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Page 5
Figure 1. Location of Components, Sizes 80–105.
Figure 2. Location of Components, Sizes 150-210.
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Page 6
Figure 3. Location of Components, Size 285.
Figure 4. Location of Components, Size 399.
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Figure 5. Location of Components, Size 500.
Figure 6. Location of Components, Size 600.
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BRADFORD WHITE CORP .
Page 8
Figure 7. Location of Components, Sizes 750 and 850.
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1.3 Appliance Overview
1.5 Unpacking
See Figures 1 through 7.
The Brute Elite is shipped in a single crate with the
following standard components packed with the
appliance (see Figure 8):
1.4 Warranty
A. exhaust vent terminal (US only)
Bradford White’s Brute Elite appliances are
covered by a limited warranty.
B. air intake terminal
C. temperature/pressure gauge kit
All warranty claims must be made to an authorized
Bradford White representative. Claims must include the
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.
D. circulator pump/wire harness (units with pump)
E. CPVC exhaust pipe section (80-500) (US only)
F. outdoor/system sensor kit
G. flow switch kit (399-850)
H. alternate size vent/terminal screens
J. exhaust vent adapter CPVC/ST ST (750-850)
K. 4x6 PVC adapter with 4x7 PVC pipe section
(750-850) (not to be used on exhaust in Canada)
Some accessory items may be 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.
1. Remove all packing and tie-down materials.
2. Check contents of the carton against items shown.
1.6 Dimensions
Dimensions are shown in Figure 9.
Figure 8. Contents of Shipping Package.
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BRADFORD WHITE CORP .
Page 10
CONNECTIONS
W
L
H
AIR INLET
VENT
GAS
NPT
½
½
½
SIZE
80
105
150
IN CM
IN
CM
IN CM
IN CM
IN CM
25 64 19½ 49 38¼ 97
25 64 19½ 49 38¼ 97
25 64 19½ 49 38¼ 97
2
2
3
3
5.1
5.1
7.6
7.6
2
2
3
3
5.1
5.1
7.6
7.6
199/210 25 64 26¾ 68 38¼ 97
½
285
399
500
600
750
850
25 64 26¾ 68 38¼ 97 4½ 11 4½ 11
25 64 31½ 80 38¼ 97 4½ 11 4½ 11
25 64 37¾ 96 38¼ 97 4½ 11 4½ 11
25 64 37¾ 96 38¼ 97 4½ 11 4½ 11
¾
¾
1
1
25 64
51 130 38¼ 97 4½ 11 6½ 17 1½
25 64 55¼ 130 38¼ 97 4½ 11 6½ 17 1½
Dimensions are nominal and are shown in inches, cm.
Brute Elite is shipped with adapters for the air and vent that accept
*
standard pipe of the proper size and type.
A
B
C
D
E
F
G
J
K
M
N
SIZE
IN CM
IN CM
IN CM
IN CM
IN
CM
IN CM
IN CM
IN
CM
IN CM
IN
CM
IN CM
80 BNTH 13½ 34 9½ 24 18¼ 46 7½ 19 10¾ 28 11¾ 30 13¾ 35
21 53 10¾ 27 15¼ 39 13 33
105 BNTH 13½ 34
150 BNTH 13¼ 34 5¼ 14 18¼ 46 3¼ 8
150 BNTV 13¼ 34 5¼ 14 19 48 3¼ 8
210 BNTH 20½ 52 5¼ 14 18¼ 46 3¼ 8
199 BNTV 20½ 52 5¼ 14 19 48 3¼ 8
8
21 18¼ 46
6
16 10¾ 28 11¾ 30 14¼ 36
21 53
7½ 19 14¼ 36 19½ 49
7½ 19 14¼ 36 19½ 49
8¾ 22 15¼ 39 13 33
7½ 19 15¼ 39 13 33
7½ 19 15¼ 39 13 33
10¾ 28
10¾ 28
17¾ 45
17¾ 45
7½ 19 14¼ 36 19½ 49 11¾ 30 15¼ 39 13 33
7½ 19 14¼ 36 19½ 49 11¾ 30 15¼ 39 13 33
285 BNTH 20¼ 52 7¼ 19 19¼ 49 6¼ 16 11¼ 29 13½ 34
285 BNTV 20¼ 52 7¼ 19 19¾ 50 4¼ 16 11¼ 29 13½ 34
14 36
14 36
15 38
15 38
17 43 18¾ 48 13 33
17 43 18¾ 48 13 33
399 BNTH 25 64 5¼ 13 19¼ 49 4¼ 11 14¾ 37 18½ 47 19¼ 49 16½ 42 21¾ 55 18¾ 48 13 33
399 BNTV 25 64 5¼ 13 19¾ 50 4¼ 11 14¾ 37 18½ 47 19¼ 49 16½ 42 21¾ 55 18¾ 48 13 33
500 BNTH 30¼ 77 5¼ 13 19½ 50 4¼ 11 15¼ 38
500 BNTV 30¼ 77 5¼ 13 19¾ 50 4¼ 11 15¼ 38
20 51 20½ 52
20 51 20½ 52
19 48
19 48
19 48
26 66 18¾ 48 13 33
26 66 18¾ 48 13 33
26 66 18¾ 48 8¼ 21
600 (both) 29¾ 76
750 (both) 35½ 90
850 (both) 39¾ 101
5
6
6
13 19½ 50 4¼ 11
15 19½ 50 5¼ 13
15 19½ 50 5¼ 13
15 38
19 48 40½ 103 3¼
19 48 44¾ 114 3½
20 51
3
8
8
9
19 48 30¾ 78 18¾ 48 8¼ 21
19 48 35 89 18¾ 48 8¼ 21
Figure 9. Dimensional Drawing, Sizes 80-500.
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Page 11
SECTION 2.
Locating the Appliance
SUGGESTED SERVICE ACCESS CLEARANCE
2.1 Locating the Appliance
APPLIANCE
SURFACE
INCHES
CM
Brute Elite is for indoor installations only.
Left Side
Right Side
Top
Back
1
2.5
The appliance should be located to provide
12
24
6
31
61
15
15
61
61
–
clearances on all sides for maintenance and inspection.
It should not be located in an area where leakage of any
connections will result in damage to the area adjacent to
the appliance or to lower floors of the structure.
When such a location is not available, it is
Closet, Front (285-500)
Alcove, Front (285-500)
Front (600-850)
Vent
6
24
24
–
recommended that a suitable drain pan, adequately
drained, be installed under the appliance.
The appliance is design certified by CSA-
Certified by CSA for zero clearance to
combustible materials on all sides.
International for installation on combustible flooring; in
basements; in closets, utility rooms or alcoves. Brute
Elite Boilers must never be installed on carpeting.
The location for the appliance should be chosen with
regard to the vent pipe lengths and external plumbing
and on a level surface. The unit shall be installed such
that the gas ignition system components are protected
from water (dripping, spraying, rain, etc.) during
operation and service (circulator replacement, control
replacement, etc.). When vented vertically, the Brute
Elite must be located as close as practical to the vertical
section of the vent. If the vent terminal and/or
combustion air terminal terminate through a wall, and
there is potential for snow accumulation in the local
area, both terminals should be installed at an appropriate
level above grade or the maximum expected snow line.
The dimensions and requirements that are shown
in Table 1 should be met when choosing the locations
for the appliance.
Table 1. Clearances.
INTAKE / EXHAUST
STANDARD MAX EQUIV.
OPTIONAL MAX EQUIV.
SIZE
VENT
FT.
M
VENT
FT.
M
80
105
150
2"
2"
3"
40
6.1
3"
100
30.5
40
100
100
100
100
100
100
40
6.1
30.5
30.5
30
30
30
30
6.1
6.1
3"
100
—
—
—
—
—
—
100
100
30.5
—
—
—
—
—
—
30
30
n/a
n/a
n/a
n/a
n/a
n/a
6"
199/210 3"
285
399
500
600
750
850
4"
4"
4"
4"
4"
4"
40
6"
Installations in the U.S. require exhaust vent pipe that is a combination
of PVC & CPVC complying with ANSI/ASTM D1785 F441 or stainless
steel complying with UL1738. Installations in Canada require exhaust
vent pipe that is certified to ULC S636.
2.2 Locating Appliance for Correct Vent
Distance from Outside Wall or
Roof Termination
Intake (air) pipe must be PVC or CPVC that complies with ANSI/ASTM
D1785 F441, ABS that complies with ANSI/ASTM D1527 or
galvanized material.
The forced draft combustion air blower in the
appliance has sufficient power to vent properly when
the guidelines in Table 2 are followed.
NOTE: When located on the same wall, the Brute Elite
combustion air intake terminal must be installed a
minimum of 12" below the exhaust terminal.Models 399-
850 also require a minimum horizontal distance from
intake to exhaust terminal of 36".
Installer must comply fully with manufacturer's installation instructions,
including use of minimum exhaust length CPVC, to maintain ANSI
Z21.13 safety certification.
Closet and alcove installations do not allow the use of PVC under any
circumstances
To calculate max equivalent length, measure the linear feet of the
For concentric vent terminal kit (optional), follow
installation instructions included with the kit.
pipe, and add 5 feet (1.5m) for each elbow used.
Table 2. Vent / Air Pipe Sizes.
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Method 1: Two permanent openings, one
SECTION 3.
commencing within 12" (300mm) of the top and one
commencing within 12" (300mm) of the bottom, of the
enclosure shall be provided. The openings shall
communicate directly, or by ducts, with the outdoors or
spaces that freely communicate with the outdoors.
When directly communicating with the outdoors, or
when communicating to the outdoors through vertical
ducts, each opening shall have a minimum free area of 1
square inch per 4000 Btu/hr (550 square mm/kW) of
total input rating of all equipment in the enclosure.
When communicating to the outdoors through
horizontal ducts, each opening shall have a minimum
free area of not less than 1 square inch per 2000 Btu/hr
(1100 square mm/kW) of total input rating of all
equipment in the enclosure.
Venting and Combustion Air
3.1 Combustion Air
Brute Elite boilers and water heaters must have
provisions for combustion and ventilation air in
accordance with the applicable requirements for
Combustion Air Supply and Ventilation in the National
Fuel Gas Code, ANSI Z223 1; or in Canada, the Natural
Gas and Propane Installation Code, CSA B149.1. All
applicable provisions of local building codes must also
be adhered to.
A Brute Elite unit can take combustion air from
the space in which it is installed, or the combustion
air can be ducted directly to the unit. Ventilation air
must be provided in either case.
Method 2: One permanent opening, commencing
within 12" (300mm) of the top of the enclosure, shall be
permitted. The opening shall directly communicate with
the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces that directly
communicate with the outdoors and shall have a
minimum free area of 1 square inch per 3000 Btu/hr
(734 square mm/kW) of the total input rating of all
equipment located in the enclosure. This opening must
not be less than the sum of the areas of all vent
connectors in the confined space.
Other methods of introducing combustion and
ventilation air are acceptable, providing they conform to
the requirements in the applicable codes listed above.
In Canada, consult local building and safety codes or,
in absence of such requirements, follow CAN/CGA B149.
3.1.2 Ducted Combustion Air
3.1.1 Combustion Air From Room
In the United States, the most common
requirements specify that the space shall communicate
with the outdoors in accordance with method 1 or 2,
which follow. Where ducts are used, they shall be of the
same cross-sectional area as the free area of the
openings to which they connect.
HORIZONTAL INTAKE AND EXHAUST PVC VENT TERMINAL KITS
2" PVC
Standard Concentric
3" PVC
4" PVC
Standard
6" PVC
Standard
SIZE
Standard
Concentric
CA006000 CA005900 239-44069-01
80
105
included optional
included optional
optional
optional
included
included
optional
n/a
optional
optional
optional
optional
optional
n/a
n/a
n/a
n/a
n/a
150
199/210
285
399
500
600
750
850
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
The combustion air can be taken through the wall, or
through the roof. When taken from the wall, it must be
taken from out-of-doors by means of the horizontal wall
terminal, shown in Table(s) 3. See Table 2 to select the
appropriate diameter air pipe. When taken from the roof, a
field-supplied rain cap or an elbow arrangement must be
used to prevent entry of rain water (see Figure10).
Use ABS, PVC, CPVC or galvanized pipe for the
included
included
included
included
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
optional
included
included
n/a
n/a
n/a
n/a
n/a
Concentric vent terminal = 10 ft. pipe length.
Table 3a. PVC Vent Terminal Kits.
PRO TECH (FasNSeal)
HEAT FAB (Saf-T-Vent)
Z FLEX (Z-Vent)
Flue
SIZE
Boiler
Flue
Intake Air
Termination
FSAIH04
303888
Boiler
Adapter
Intermediate
Adapter
Flue
Intake Air
Boiler
Intake Air
Adapter
Termination
FSBS4
Termination Termination
Adapter
Termination
2SVSTP04
2SVSRCX04
Termination
9492
399-600
750-850
F303759
KB285600 9454BUREZ-1*
9414TERM
5400CI
2SVSLA04
2SVSTEX0490
FSRC4(R.C)
F303759
(intake only)
FSAIH04
303888
FSBS6
Table 3b. Approved Stainless Steel Terminations and Adapters.
INSTALLATION STANDARDS
MATERIAL
UNITED STATES
CANADA
ABS
ANSI/ASTM D1527
PVC, sch 40
CPVC, sch 40
Single wall galv. steel
ANSI/ASTM D1785 or D2665
ANSI/ASTM F441
26 gauge
Air pipe material must be chosen
based upon the intended application of the boiler.
Table 4. Required Combustion Air Pipe Material.
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Page 13
combustion air intake (see Table 4), sized per Table 2.
Route the intake to the boiler as directly as possible. Seal
all joints. Provide adequate hangers. The unit must not
support the weight of the combustion air intake pipe.
Maximum linear pipe length allowed is shown in Table 2.
Subtract 5 allowable linear ft. (1.5m) for every elbow used.
The connection for the intake air pipe is at the top of
the unit (see Figure 9a or Figure 9b).
The unit’s vent can terminate through the roof, or
through an outside wall.
When using PVC/CPVC for vent material, venting
must be connected to the CPVC section included with
Brute Elite sizes 80-600. The CPVC vent section
included with the Brute Elite may be broken by CPVC
fittings if necessary, but never reduced in total length.
See Table 2 to select the appropriate vent pipe diameter.
Vent pipe must pitch upward, toward the vent terminal,
not less than 1/4" per foot, so that condensate will run
back to the Brute Elite to drain. Route vent pipe to the
heater as directly as possible. Seal all joints and provide
adequate hangers as required in the venting system
manufacturer’s Installation Instructions. Horizontal
portions of the venting system must be supported to
prevent sagging and may not have any low sections that
could trap condensate. The unit must not support the
weight of the vent pipe. Please see Table 2 for proper
diameter vs. length allowed.
In addition to air needed for combustion, air shall
also be supplied for ventilation, including air required for
comfort and proper working conditions for personnel.
3.2 Venting
WARNING
Failure to use CPVC or stainless steel venting for the
first 20" (285-600) / 30" (80-210) of vent material or for
any part of the venting that is installed inside a closet
may lead to property damage, personal injury or death.
The proper length of this material is supplied with boiler.
Boilers in U.S. may use pipe included with boiler.
IMPORTANT NOTE ABOUT COMMON VENTING: A
single vent that is shared by multiple Brute Elite units
MUST be engineered by a competent venting
specialist, and involves the selection of draft inducing
equipment, hardware and controls to properly balance
flue gas pressures. Do not common vent Brute Elite
WARNING
Failure to use the appropriate vent material, installation
techniques, glues/sealants could lead to vent failure
causing property damage, personal injury or death.
WARNING
All venting must be installed according to this manual
and any other applicable local codes, including but not
limited to, ANSI Z223.1/NFPA 54, CSA B149.1,
CSAB149.2 and ULC-S636. Failure to follow this
manual and applicable codes may lead to property
damage, severe injury, or death.
The flue temperature of the Brute Elite changes
dramatically with changes in operating water
temperature. Therefore, it is necessary to assess the
application of the boiler to determine the required
certified vent class. If the Brute Elite is installed in
an application where the ambient temperature is
elevated, and/or installed in a closet/alcove, CPVC or
stainless steel material is required. If the system
temperatures are unknown at the time of
installation, class IIB or higher venting material is
recommended.
The Brute Elite is a Category IV appliance and
may be installed with PVC and CPVC that complies
with ANSI/ASTM D1785 F441, or a stainless steel
venting system that complies with UL 1738 Standard
(see Table 5).
Figure 10. Combustion Air and Vent Through Roof.
INSTALLATION STANDARDS
MATERIAL
UNITED STATES
UL 1738
ANSI/ASTM D178
ANSI/ASTM F441
CANADA
Stainless Steel
PVC, sch 40
CPVC, sch 40
Venting must be ULC-S636 certified for use as
venting material. The venting material must be chosen
based upon the intended application of the boiler.
Table 5. Required Exhaust Vent Material.
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BRADFORD WHITE CORP .
Page 14
units unless the vent system meets this
one must be installed in the vent system external to the
Brute Elite unit. A flue gas sampling port available as a
component of the ULC S636 certified vent system is
preferred. However, if one is not available with the
certified vent system, Bradford White suggests using a
tee with the branch connection sized to allow for
insertion of a flue gas analyzer probe. The branch
connection must be resealable with a cap or other by
other means to ensure the vent system remains sealed
(Figure 11).
Consideration must be given to the placement and
orientation of the flue gas sampling port to ensure that
condensate is free to flow back into the Brute Elite unit
and not collect anywhere in the vent system - including
in the flue gas sampling port.
An exhaust vent terminal must be installed. If an
exhaust vent terminal is not available with the certified
vent system, Bradford White suggests the use of a
coupler fitting from the certified vent system into which
the vent terminal screen, included with the Brute Elite
and shown in the Unpacking section of the Brute Elite
Installation & Operating Instructions, be installed. Be
sure to install and terminate both vent and combustion
air pipes per the Venting and Combustion Air section of
the Brute Elite instructions.
requirement. Brute Elite units are never permitted
to share a vent with Category I appliances.
A condensate drain trap is built into Brute Elite.
Connect a 3/4" PVC pipe between the drain
connection and a floor drain (or condensate pump if a
floor drain is not accessible).
The condensate drain must be installed so as to
prevent accumulation of condensate. When a con-
densate pump is not used, the tubing must continuously
slope downward toward the drain with no spiraling.
Consult local codes for disposal method.
Caution
Condensate is mildly acidic (pHꢀ5), and may harm
some floor drains and/or pipes, particularly those that
are metal. Ensure that the drain, drainpipe, and
anything that will come in contact with the
condensate can withstand the acidity, or neutralize
the condensate before disposal. Damage caused by
failure to install a neutralizer kit or to adequately
treat condensate will not be the manufacturer’s
responsibility.
3.2.1 Venting Requirements Unique to
Canada
3.3 Locating Vent & Combustion Air
Brute Elite boilers and water heaters are Vent
Category IV appliances. Per the requirements of CAN/
CSA-B149.1, only BH vent systems can be connected to
these units and such vent systems, either ULC S636
certified stainless steel or other ULC S636 certified BH
vent (eg. plastics) must be installed per the vent
manufacturer's certified installation instructions.
As a result, two items listed in the Unpacking
section (Figure 8) are not included with Brute Elite
units for Canada (underlined):
Terminals
3.3.1 Side Wall Vent Terminal
The appropriate Bradford White side wall vent
terminal must be used. The terminal must be located in
accordance with ANSI Z223.1/NFPA 54 and applicable
local codes. In Canada, the installation must be in
accordance with CSA B149.1 or .2 and local applicable
codes. Consider the following when installing the
terminal:
A. exhaust vent terminal (not included)
B. air intake terminal
C. temperature/pressure gauge kit
D. circulator pump/wire harness (units with pump)
E. CPVC exhaust pipe section (80-500) (not incl.)
F. outdoor/system sensor kit
G. flow switch kit (399-850)
H. alternate size vent/terminal screens
J. exhaust vent adapter CPVC/ST ST (750-850)
It is the responsibility of the appropriately licensed
technician installing this Brute Elite unit to use ULC
S636 certified vent material consistent with the
requirements as described in the Venting and
Combustion Air section.
IMPORTANT! It is also the responsibility of the
installer to ensure that a flue gas sampling port is
installed in the vent system. This flue gas sampling port
must be installed near the flue connection of the Brute
Elite unit: within 2 feet of the flue connection. There is
no flue gas sampling port internal to the Brute Elite, so
Figure 11. Test Port.
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Brut e Elit e
Page 15
1. Figure 12 shows the requirements for mechanical
vent terminal clearances for the U.S. and Canada.
2. Vent terminals for condensing appliances or
appliances with condensing vents are not
12" (30cm) away from the air inlet. Vent outlets
for models 399-850 must be at least 12" above the
top of the air inlet, and must be at least 36" (90cm)
horizontally from the air inlet (see Figure 14).
permitted to terminate above a public walkway, or
over an area where condensate or vapor could
create a nuisance or hazard.
3.3.3 Vertical Vent Terminal
When the unit is vented through the roof, the vent
must extend at least 3 feet (0.9m) above the point at
which it penetrates the roof. It must extend at least 2
feet (0.6m) higher than any portion of a building within
a horizontal distance of 10 feet (3.0m), and high enough
above the roof line to prevent blockage from snow. The
vent terminal included with the Brute Elite can be used
in both vertical and horizontal applications. When the
combustion air is taken from the roof, the combustion
air must terminate at least 12" (30cm) below the vent
terminal (see Figure 11).
3. Locate the vent terminal so that vent gases cannot
be drawn into air conditioning system inlets.
4. Locate the vent terminal so that vent gases cannot
enter the building through doors, windows, gravity
inlets or other openings. Whenever possible, avoid
locations under windows or near doors.
5. Locate the vent terminal so that it cannot be
blocked by snow. The installer may determine
that a vent terminal must be higher than the
minimum shown in codes, depending upon local
conditions.
6. Locate the terminal so the vent exhaust does not
settle on building surfaces or other nearby objects.
Vent products may damage surfaces or objects.
7. If the boiler or water heater uses ducted
combustion air from an intake terminal located on
the same wall, see Figures 12-14 for proper
spacing and orientation.
If the vent termination is located in an area
exposed to high winds, an optional PVC tee (the same
diameter as the vent pipe) may be used. The tee'd vent
termination offers greater protection from wind related
operating issues.
3.3.4 Vertical Combustion Air Terminal
When combustion air is taken from the roof, a
field-supplied rain cap or an elbow arrangement must be
used to prevent entry of rain water (see Figure 11). The
opening on the end of the terminal must be at least 12"
(30cm) above the point at which it penetrates the roof,
and high enough above the roof line to prevent blockage
from snow. When the vent terminates on the roof, the
combustion air must terminate at least 12" (30cm)
below the vent terminal.
3.3.5 Installations in the Commonwealth of
Massachusetts
In Massachusetts the following items are required if
the side-wall exhaust vent termination is less than seven (7)
feet above finished grade in the area of the venting,
including but not limited to decks and porches. From
Massachusetts Rules and regulations 248 CMR 5.08
1. Installation of Carbon Monoxide Detectors
At the time of installation of the side wall vented
gas fueled appliance, the installing plumber or gas-
fitter shall observe that a hard-wired carbon monox-
ide detector with an alarm battery back-up is instal-
led on the floor level where the gas appliance is to
be installed. In addition, the installing plumber or
gasfitter shall observe that a battery operated or
hard-wired carbon monoxide detector with an alarm
is installed on each additional level of the dwelling,
building or structure served by the side-wall hori-
zontally vented gas fueled equipment. It shall be the
responsibility of the property owner to secure the
services of qualified licensed professionals for in-
stallation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented
gas fueled equipment is installed in a crawl space or
an attic, the hard-wired carbon monoxide with alarm
and battery back-up may be installed on the next
adjacent floor level.
3.3.2 Side Wall Combustion Air Terminal
The side wall combustion air terminal, or
concentric terminal (see Table 3), must be used when
the heater takes air from a side wall. Contact Bradford
White for AL29-4C termination fittings. Consider the
following when installing the terminal (see Figures 12-
14):
1. Do not locate the air inlet terminal near a source of
corrosive chemical fumes (e.g., cleaning fluid,
chlorine compounds, etc.)
2. Locate the terminal so that it will not be subject to
damage by accident or vandalism. It must be at
least 7 feet (2.1m) above a public walkway.
3. Locate the combustion air terminal so that it
cannot be blocked by snow. The National Fuel Gas
Code requires that it be at least 12 inches (30cm)
above grade, but the installer may determine it
should be higher, depending upon local conditions.
4. If the Brute Elite is side-wall vented to the same
wall, locate the vent terminal at least 1 foot (0.3m)
above the combustion air terminal.
5. For concentric vent, follow instructions
included with vent kit.
6. Multiple vent kits should be installed such that the
horizontal distance between outlet group and inlet
group is 36" (90cm) (see Figure 13).
b. In the event that the requirements of the subdivi-
sion cannot be met at the time of completion of
installation, the owner shall have a period of thirty
(30) days to comply with the above requirements,
7. Vent outlet for models 80-285 must be no lower
than the center of the air inlet, and must be at least
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BRADFORD WHITE CORP .
Page 16
U.S. Installations (see note 1)
Canadian Installations (see note 2)
A= Clearance above grade, veranda, porch,
12 inches (30 cm)
See note 6
12 inches (30 cm)
See note 6
deck, or balcony
B= Clearance to window or door that may be
Direct vent only: 12 inches (30cm);
Other than Direct vent: 4 ft (1.2m) below or to
side of opening; 1 ft (30cm) above opening
36 inches (91 cm)
opened
C= Clearance to permanently closed window
See note 4
See note 5
See note 5
D= Vertical clearance to ventilated soffit located
above the terminal within a horizontal
distance of 2 feet (61cm) from the center
line of the terminal
See note 4
E= Clearance to unventilated soffit
F= Clearance to outside corner
G= Clearance to inside corner
See note 4
See note 5
See note 4
See note 5
3 feet minimum
3 feet (91cm) minimum
H= Clearance to each side of center line
3 feet (91 cm) within a height 15 feet
above the meter/regulator assembly
extended above meter/regulator assembly See note 4
I= Clearance to service regulator vent outlet
J= Clearance to nonmechanical air supply
See note 4
3 feet (91 cm)
Direct vent only: 12" (30cm) 80-285; 36" (91cm)
inlet to building or the combustion air inlet 399-850. Other than Direct vent: 4 ft (1.2m) below 36 inches (91 cm)
to any other appliance
or to side of opening; 1 ft (30cm) above opening
K= Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m)
6 feet (1.83 m)
horizontally
L= Clearance above paved sidewalk or paved Vent termination not allowed in this location
Vent termination not allowed in this
location for category IV appliances.
driveway located on public property
for category IV appliances.
M= Clearance under veranda, porch, deck,
See note 4
12 inches (30 cm) (see note 3)
or balcony
Notes:
1. In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.
2. In accordance with the current CAN/CGA-B149 Installation Codes.
3. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
4. For clearances not specified in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the requirements of the
gas supplier.
5. For clearances not specified in CAN/CGA-B149, clearance is in accordance with local installation codes and the requirements of the gas
supplier.
6. IMPORTANT: terminal must be placed such that it remains a minimum 12" above expected snow line. Local codes may have more
specific requirements, and must be consulted.
*When vent terminal is less than 10 feet (3m) horizontally
from a forced air inlet, the terminal must be at least 3 feet
(0.9m) above the air inlet.
Figure 12. Combustion Air and Vent Through Side Wall.
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Brut e Elit e
Page 17
one-half (1/2) inch in size: "GAS VENT DI-
RECTLY BELOW, KEEP CLEAR OF ALL
OBSTRUCTIONS".
4. Inspection
The state or local gas inspector of the side-wall
horizontally vented gas fueled appliance shall not
approve the installation unless, upon inspection, the
inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions
of 248 CMR 5.08(2)(a) 1-4.
3.4 Common Vent Test
NOTE: This section does not describe a method for
common venting Brute Elite units. It describes what
must be done when a unit is removed from a common
vent system. Brute Elite units require special vent
systems and fans for common vent. Contact the factory
if you have questions about common venting Brute Elite
units.
When an existing boiler is removed from a
common venting system, the common venting system is
likely to be too large for proper venting of the
appliances remaining connected to it.
At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation.
Figure 13. Multiple Side-Wall Terminals, Air and Vent.
provided, however, that during said thirty (30) day
period, a battery operated carbon monoxide detector
with an alarm be installed.
2. Approved Carbon Monoxide Detectors
Each carbon monoxide detector shall comply with
NFPA 720 and be ANSI/UL 2034 listed and IAS
certified.
3. Signage
A metal or plastic identification plate shall be
permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for
horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print no less than
1. Seal any unused openings in the common venting
system.
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.
Figure 14. Minimum Venting Distance.
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BRADFORD WHITE CORP .
Page 18
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
SECTION 4.
Gas Supply and Piping
4.1 Gas Supply and Piping
Gas piping should be supported by suitable
hangers or floor stands, not the appliance.
Review the following instructions before
proceeding with the installation.
maximum speed. Do not operate a summer exhaust
fan. Close fireplace dampers.
1. Verify that the appliance is fitted for the proper type of
gas by checking the rating plate. Brute Elite will
function properly without the use of high altitude
modification at elevations up to 10,000 feet (3050 m).
2. The maximum inlet gas pressure must not exceed
13" W.C. (3.2kPa). The minimum inlet gas
pressure is 4" W.C. (1.0kPa).
3. Refer to Tables 6A, 6B, 6C and 6D to size piping.
4. Run gas supply line in accordance with all
applicable codes.
5. Locate and install manual shutoff valves in
accordance with state and local requirements.
6. A sediment trap must be provided upstream of the
gas controls.
7. All threaded joints should be coated with piping
compound resistant to action of liquefied
petroleum gas.
4. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so the appliance will operate continuously.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
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.
7. Any improper operation of the common venting
system should be corrected so that the installation
conforms to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CSA B149.1, Installation
Codes. When resizing any portion of the common
venting system, the common venting system should
be resized to approach the minimum size as deter-
mined using the appropriate tables and guidelines in
the National Fuel Gas Code, ANSI Z223.1 NFPA
54 and/or CSA B149.1, Installation Codes.
8. The appliance and its individual shutoff valve
must be disconnected from the gas supply piping
during any pressure testing of that system at test
pressures in excess of 1/2 PSIG (3.45kPa).
9. The unit must be isolated from the gas supply
system by closing its individual manual shutoff
valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than
1/2 PSIG (3.45kPa).
10. The appliance and its gas connection must be leak
tested before placing it in operation.
11. Purge all air from gas lines.
WARNING:
Open flame can cause gas to ignite and result in
property damage, severe injury, or loss of life.
NOTE: The Brute Elite appliance and all other gas
appliances sharing the gas supply line must be firing at
maximum capacity to properly measure the inlet supply
pressure. The pressure can be measured at the supply
pressure port on the gas valve. Low gas pressure could
be an indication of an undersized gas meter, undersized
gas supply lines and/or an obstructed gas supply line.
Some Brute Elite units are equipped with low and high
gas pressure switches that are integrally vent limited.
These types of devices do not require venting to
atmosphere.
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Brut e Elit e
Page 19
BRUTE ELITE
NATURAL GAS
REQUIRED
SECTION 5.
Pump Requirements
TO SIZE PIPING:
CU FT
/ HR.
SIZE
Measure linear distance from meter outlet to last
boiler. Add total input of all boilers and divide by
1000 to obtain cu ft / hr required. Add total
equivalent length of fittings used according to
Table 6B. Align total length (pipe and fittings) on
left side column of Table 6C with highest cubic
feet of gas required.
80
80
5.1 Brute Elite Boiler Flow and Head
105
150
105
150
Requirements (see Table 7)
199/210 199/210
TEMPERATURE RISE IN °F
285
399
500
600
750
285
399
500
600
750
20°F
25°F
30°F
35°F
40°F
FLOW H/L
FLOW H/L FLOW H/L FLOW H/L FLOW H/L
GPM FT GPM FT GPM FT GPM FT
Notes:
SIZE GPM FT
Consult and confirm with Applicable Fuel Gas
Code before beginning work. Verify gas inlet
pressure is between 4 and 13 in W.C. before
starting boiler.
80
105 10 23.1
150 14.3 28.5 11.4 19
7.6 14.9 6.1 10.1 5.1 7.1 4.3 5.8 3.8 4.6
17 6.7 12.4 5.7 9.6 7.6
9.5 13.6 8.1 11.2 7.1 8.8
16 16.7 13.4 11.6 11.3 9.9 6.9
8
5
850
850
210 20 24.1
285 27 25.5
399 39 28
500 48 24
600 58 44
750 72 37
850 81 33
9
Table 6A.
22 17.5 18 14
15 10.5 13
8
9
8
31 20
38 16
46 31
58 23
65 22
25 14.5 22 11 19
EQUIVALENT LENGTHS OF STRAIGHT PIPE FOR TYPICAL SCH 40 FITTINGS
32 12
38 22
48 17
54 15
27
9
24
NOMINAL PIPE SIZE
33 18
41 13
46 10
29 15
36 10
FITTING 1/2"
90° ELBOW 3.6
3/4"
1"
1-1/4" 1-1/2"
2"
LINEAR FEET
41
8
4.4
5.3
5.2
6.6
6.6
8.7
7.4
9.9
8.5
12
TEE
4.2
TEMPERATURE RISE IN °C
Table 6B.
11°C
14°C
17°C
19°C
22°C
FLOW H/L
FLOW H/L FLOW H/L FLOW H/L FLOW H/L
SIZE lpm
m
lpm lpm lpm lpm
m
m
m
m
SCH 40 METAL PIPE CAPACITY FOR 0.60 SPECIFIC GRAVITY NATURAL GAS
80
29 4.5
23 3.1
30 5.2
43 5.8
61 5.1
83 5.3
117 6.1
19 2.2 16 1.8 14 1.4
25 3.8 22 2.9 19 2.3
36 4.1 31 3.4 27 2.7
51 3.5 43 2.7 37 2.1
68 4.3 57 3.2 49 2.4
95 4.4 83 3.4 72 2.7
@
NOMINAL PIPE SIZE 0.30" W.C. PRESSURE DROP
105 38 7.0
150 54 8.7
210 76 7.3
285 102 7.8
399 148 8.5
500 182 7.3
LENGTH 1/2"
FT
3/4"
1"
1-1/4" 1-1/2"
2"
CUBIC FEET OF GAS PER HOUR
20
40
92
190
130
105
90
350
245
195
170
150
730
500
400
350
305
1100
760
610
530
460
2100
1450
1150
990
60
80
100
144 4.9 121 3.7 102 2.7 91 2.4
600 220 13.4 174 9.4 144 6.7 125 5.5 110 4.6
750 273 11.3 220 7.0 182 5.2 155 4.0 136 3.0
850 307 10.1 246 6.7 204 4.6 174 3.0 155 2.4
870
Table 6C.
Table 7. Water Flow Requirements.
SCHED 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC GRAVITY
UNDILUTED PROPANE
@
NOMINAL PIPE SIZE 11" W.C. INLET AND 0.5" W.C. PRESSURE DROP
5.2 Brute Elite Water Heater Flow and Head
SIZE
LENGTH
20
40
60
80
100
1/2"
3/4"
1"
1-1/4" 1-1/2"
2"
Requirements (see Table 8)
MAXIMUM CAPACITY IN THOUSANDS OF BTU PER HOUR
200
137
110
94
418
287
231
197
175
787
541
434
372
330
1616
1111
892
2422
1664
1337
1144
1014
4664
3205
2574
2203
1952
NORMAL WATER*
Flow
gpm
H/L Temp
feet Rise °F
Flow
lpm
H/L
m
Temp
Size
Rise °C
150
199
285
399
19
25
36
50
63
60
68
68
57
28
33
35
28
24
35
26
15
15
15
15
15
19
21
24
72
95
98
189
239
227
257
257
17.4
8.5
10.1
10.7
8.5
7.3
10.7
7.9
8
8
8
8
8
11
12
13
763
84
677
NOTES: 1. Follow all local and national LP gas codes for line sizing and
equipment requirements. 2. Verify that inlet gas pressure remains between
4 and 13 inches of water column before and during operation.
Source: ANSI Z223.1-80 National Fuel Gas Code.
500
600**
750**
850**
Table 6D.
*Maximum water hardness of 10 grains per gallon allowed.
**See section 6B.6 on page 30 for pump information.
Table 8. Brute Elite Water Heater Flow Data.
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Brute Elite's efficiency is higher with lower
return water temperatures. Therefore, to get the most
of low return temperature with multiple boilers, pipe as
shown in Figures 17-19.
SECTION 6A.
Water Connections - BNTH Boiler
Section 6 is divided into two parts. The first is
for BNTH models and is Section 6A. The
second is for BNTV models and is Section 6B.
Refer to the proper section for instructions in
installing and piping your product. Refer to
Table 9 for pipe sizes required.
Brute Elite BNTH models can be ordered with or
without a pump included.
Brute Elite with a pump MUST be piped in a
primary-secondary fashion (using either piping or a
hydraulic separator) such that the pump that is mounted
on the boiler ONLY serves the boiler.
When the pump is supplied by Bradford White, the
Brute Elite boiler must be located within 15 feet (4.6m)
of the supply and return header (or the hydraulic
separator). Pumps supplied by Bradford White are sized
for a maximum of 30 feet (9.1m) of piping and the
headloss of the boiler only (see Table 7).
If longer pipe lengths are required, the pump
should be sized for the boiler per Table 7 and for the
piping it will serve, and should be supplied to job
separately. Even with pumps supplied by others,
Bradford White strongly recommends primary-
secondary piping.
6A.1 BNTH System Piping:
Hot Supply Connections
NOTE: This appliance must be installed in a closed
pressure system with a minimum of 12 psi (82.7kPa)
static pressure at the boiler.
Hot water piping should be supported by suitable
hangers or floor stands. Do not support piping with this
appliance. Due to expansion and contraction of copper
pipe, consideration should be given to the type of
hangers used. Rigid hangers may transmit noise through
the system resulting from the piping sliding in the
hangers. It is recommended that padding be used when
rigid hangers are installed. Maintain 1" (2.5cm)
clearance to combustibles for hot water pipes.
Pipe the discharge of the relief valve (full size) to
a drain or in a manner to prevent injury in the event of
pressure relief. Install an air purger, an air vent, a
diaphragm-type expansion tank, and a hydronic flow
check in the system supply loop. Minimum fill pressure
must be 12psig (82.7kPa). Install shutoff valves where
required by code.
6A.2 BNTH Cold Water Make-Up
1. Connect the cold water supply to the inlet
connection of an automatic fill valve.
2. Install a suitable back flow preventer between the
automatic fill valve and the cold water supply.
3. Install shut off valves where required.
The boiler piping system of a hot water heating
boiler connected to heating coils located in air handling
appliances where they may be exposed to refrigerated
air circulation must be equipped with flow control
valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
A boiler installed above radiation level, or as
required by the authority having jurisdiction, must be
provided with a low water cutoff device either as a part
of the boiler or at the time of boiler installation.
Suggested piping diagrams are shown in Figures
15 through 21. These diagrams are meant only as a
guide. Components required by local codes must be
properly installed.
BNTH
SIZE
PIPE SIZE,
INCHES
BNTV
SIZE
PIPE SIZE,
INCHES
80
1
1
1
1¼
1¼
1¼
1½
1½
2
–
–
n/a
n/a
1¼
1¼
2
2
2
2
2
105
150
210
285
399
500
600
750
850
150
199
285
399
500
600
750
850
2
2
Table 9. Water Connection Pipe Sizes.
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6A.3 Freeze Protection
6A.4 BNTH Suggested Piping Schematics
Figures 15 through 21 show suggested piping
configurations for BNTH boilers. These diagrams are
only meant as a guide. All components or piping
required by local code must be installed.
WARNING
Glycol must not be used in domestic hot water
applications. Refer to Section 6B.4 for instructions on
BNTV, domestic hot water freeze protection.
6A.5 Recognized Chemicals
Brute Elite units are certified for indoor use only,
and are not design-certified for placement outdoors.
Proper precautions for freeze protection are
recommended for boiler installations in areas where the
danger of freezing exists.
The following manufacturers offer glycols,
inhibitors, and anti foamants that are suitable for use in
the Brute Elite. Please refer to the manufacturers
instructions for proper selection and application.
Power outage, interruption of gas supply, failure of
system components, activation of safety devices, etc.,
may prevent a boiler from firing. Any time a boiler is
subjected to freezing conditions, and the boiler is not
able to fire, and/or the water is not able to circulate,
there is a risk of freezing in the boiler or in the pipes
in the system. When water freezes, it expands which
may result in bursting of pipes, or damage to the boiler,
which could result in leaking or flooding conditions.
Do not use automotive antifreeze. To help prevent
freezing, Bradford White recommends the use of
inhibited glycol concentrations between 20% and 35%
glycol. Typically, this concentration will serve as burst
protection for temperatures down to approximately -5°F
(-20°C). If temperatures are expected to be lower than -
5°F (-20°C), glycol concentrations up to 50% can be
used. When concentrations greater than 35% are used,
water flow rates must be increased to maintain a 20°F
to 25°F temperature rise through the boiler. NOTE:
Bradford White supplied pumps are not all capable
of maintaining the reduced temperature rise
1. Sentinel Performance Solutions Group
2. Hercules Chemical Company
3. Dow Chemical Company
required with glycol concentrations greater than
35%. If glycol concentrations required are greater
than 35% a field supplied pump should be used.
IMPORTANT NOTES: Different glycol products may
provide varying degrees of protection. Glycol products
must be maintained properly in a heating system, or they
may become ineffective. Consult the glycol specifications,
or the glycol manufacturer, for information about specific
products, maintenance of solutions, and set up according
to your particular conditions.
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Figure 15. Hydronic Piping — Single Boiler (zoning with circulators).
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Figure 16. Hydronic Piping — Single Boiler, Low Temp Radiant Space Heating using Low Loss Header and Zone Valves.
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Figure 17. Hydronic Piping — Multiple Boilers (zoning with circulators).
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Figure 18. Hydronic Piping — Multiple Boilers with Indirect DWH Tank Piped from System Loop.
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Figure 19. Hydronic Piping — Multiple Boilers, Reverse Return, Multi-Temp Zones (zoning with circulators).
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Figure 20. Hydronic Piping — Heating zones with indirect DWH tank piped with zone pumps (indirect directly off boiler).
Boiler pump must shut down during DHW.
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Figure 21. Hydronic Piping, multiple boilers with indirect DWH off one boiler. Boiler pump must shut-down during DHW.
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6B.2 Piping Requirements
SECTION 6B.
Water piping should be supported by suitable
hangers and floor stands. Do not support piping with the
appliance. Due to expansion and contraction of copper
pipe, consideration should be given to the type of
hangers and supports used. Rigid hangers may transmit
noise through the system resulting from piping sliding
in the hangers. It is recommended that padding be used
when rigid hangers are installed. Maintain 1" (2.5cm)
clearance to combustibles for hot water pipes.
Water Connections - BNTV Water Heater
Section 6 is divided into two parts. The first is
for BNTH models and is Section 6A. The
second is for BNTV models and is Section 6B.
Refer to the proper section for instructions in
installing and piping your product. Refer to
Table 9 for pipe sizes required.
Pipe the discharge of the relief valve (full size) to
the drain or in a manner to prevent injury in the event of
pressure relief. Install a diaphragm-type expansion tank,
flow check, and shutoff valves where needed or as
required by code.
Brute Elite 80-500 can be ordered with pumps.
Whether the factory pumps or other pumps are installed
the piping should be installed such that the pump
supplies flow to the heater it is attached to only. The
factory pumps are sized for 30 feet and 6 elbows of total
pipe length, so the heater should be placed within 15
feet of the tank. If longer runs are required, properly-
sized field-supplied pumps should be used.
6B.1 BNTV Water Quality
BNTV water heaters must be installed in water
conditions of 10gpg hardness or less with a pH range of
8.2 to 9.5. Operating the BNTV in water with higher
hardness levels will cause heat exchanger fouling,
erosion, or corrosion leading to premature component
failure, reduced efficiency, heat exchanger failure or
system failure. Failure of this type will not be
warranted. If the water in use exceeds the conditions
recommended water softeners or other devices should
be installed to improve water quality.
WARNING: THIS DRAWING SHOWS
SUGGESTED PIPING CONFIGURATION AND
VALVING. CHECK WITH LOCAL CODES AND
ORDINANCES FOR ADDITIONAL REQUIREMENTS.
NOTES:
1. Optional CWMU & Recirc. line location.
2. Locate BNTV DHW sensor or remote aquastat well
in lower 1/3 of tank.
3. Back flow preventer may be required - check local codes.
4. Thermal expansion tank may be required - check local codes.
5. Factory mounted pumps are sized for a max pipe length of
30' total, 6-90° elbows, full pipe size.
6. Caution: Pump sizing must be based opon water hardness at job site.
Figure 23. DHW Piping, One Heater, One Vertical Tank.
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6B.3 Cold Water Make-Up
6B.5 BNTV Suggested Piping Schematics
Figures 23-26 show suggested piping
configurations for BNTV boilers. These diagrams are
only meant as a guide. All components or piping
required by local code must be installed.
The cold water make-up may be connected to the
tank or to the inlet of the boiler as shown in Figures 23-
26. Install back flow preventers and shut offs where
needed or required by code.
6B.4 Freeze Protection
6B.6 BNTV Suggested Pumps
Brute Elite heaters are not certified for outdoor
installation, so the chance of freezing is minimized. In
an event such as power outage, component failure or
other issue when freezing is likely, the heater and
system must be drained to avoid the risk of damage due
to freezing. Glycol must NOT be used in volume water
heating applications.
Possible pumps for BNTV sizes 600-850 are
Grundfos model TP 40-160/2B, or for size 600 (only) is
Armstrong model E22B. See Table 8 for water flow and
head requirements.
NOTES:
1. Optional CWMU & Recirc. line location.
2. Locate BNTV DHW sensor or remote aquastat well
in lower 1/3 of tank.
3. Back flow preventer may be required - check local codes.
4. Thermal expansion tank may be required - check local codes.
5. Factory mounted pumps are sized for a max pipe length of
30' total, 6-90° elbows, full pipe size.
6. Caution: Pump sizing must be based opon water
hardness at job site.
WARNING: THIS DRAWING SHOWS
SUGGESTED PIPING CONFIGURATION AND
VALVING. CHECK WITH LOCAL CODES AND
ORDINANCES FOR ADDITIONAL REQUIREMENTS.
Figure 24. DHW Piping, One Heater, Two Vertical Tanks.
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NOTES:
1. Optional CWMU & Recirc. line location.
2. Locate BNTV DHW sensor or remote aquastat
well in lower 1/3 of tank.
3. Back flow preventer may be required - check
local codes.
4. Thermal expansion tank may be required -
check local codes.
5. Factory mounted pumps are sized for a max
pipe length of 30' total, 6-90° elbows, full pipe size.
6. Caution: Pump sizing must be based opon
water hardness at job site.
WARNING: THIS DRAWING SHOWS
SUGGESTED PIPING CONFIGURATION AND
VALVING. CHECK WITH LOCAL CODES AND
ORDINANCES FOR ADDITIONAL REQUIREMENTS.
Figure 25. DHW Piping, Two Heaters, One Vertical Tank.
NOTES:
1. Optional CWMU & Recirc.
line location.
WARNING: THIS DRAWING SHOWS
SUGGESTED PIPING CONFIGURATION AND
VALVING. CHECK WITH LOCAL CODES AND
ORDINANCES FOR ADDITIONAL REQUIREMENTS.
2. Locate BNTV DHW sensor
or remote aquastat well
in lower 1/3 of tank.
3. Back flow preventer may be
required - check local codes.
4. Thermal expansion tank may be
required - check local codes.
5. Factory mounted pumps are sized
for a max pipe length of 30' total,
6-90° elbows, full pipe size.
6. Caution: Pump sizing must
be based opon water
hardness at job site.
Figure 26. DHW Piping, Two Heaters, Two Vertical Tanks.
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Important Note: DO NOT MAKE/BREAK BRUTE
ELITE LINE VOLTAGE TO SIGNAL CALL FOR HEAT.
A “call for heat / end call for heat” MUST be connected
to the field interlock terminals. Some Brute Elite
components are designed to have constant voltage
during normal operation. If the Brute Elite's supply
voltage is toggled as a call for heat signal, premature
failure of these components may result.
SECTION 7.
Electrical Connections
WARNING
The appliance must be electrically grounded in
accordance with the requirements of the authority
having jurisdiction or, in the absence of such
requirements, with the latest edition of the National
Electrical Code, ANSI/NFPA 70, in the U.S. and with
latest edition of CSA C22.1 Canadian Electrical Code,
Part 1, in Canada. Do not rely on the gas or water piping
to ground the metal parts of the boiler. Plastic pipe or
dielectric unions may isolate the boiler electrically.
Service and maintenance personnel, who work on or
around the boiler, may be standing on wet floors and
could be electrocuted by an ungrounded boiler.
Electrocution can result in severe injury or death.
Brute Elite does not recognize 4mA as a signal to shut
off. If the call for heat is not connected between the field
interlock terminals, Brute Elite will remain in low fire
when it sees 4mA as a modulating signal.
Caution
Brute Elite supply voltage must not be disengaged,
except for service or isolation, or unless otherwise
instructed by procedures outlined in this manual. To
signal a call for heat, use the 24V field-interlock, as
shown in the wiring diagram(s).
Single pole switches, including those of safety
controls and protective devices must not be wired in a
grounded line.
7.1 Main Power
Connect a 15A fused, 120-volt supply to the main
power switch (hot leg is connected directly to switch).
Neutral leg is connected directly to the white wire.
Ground wire can be connected to the grounding lug in
the control panel (see Table 11).
All electrical connections are made on the terminal
blocks that are located inside the control panel.
NOTE: All internal electrical components have been
prewired. No attempt should be made to connect
electrical wires to any other location except the terminal
blocks.
Wiring connections are shown in Figures 29 and 30.
Figure 27. Control Panel Layout.
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7.4 Hydronic Call for Heat
BOILER
PUMP CONNECTIONS
RATINGS
Connect the call for heat to terminal block 7
(TB7), connections labeled "T-T or interlock" in the
control panel.
(Boiler, System Pump and
DHW Pump Connections)
SIZES
VOLTS PHASE AMPS
80–850
No Pump
115V – Maximum 1HP
or 7.4A max
120 Single 2*
7.5 Outdoor Air Temperature Sensor
Connect the outdoor air temperature sensor to
terminal block 7 (TB7), connections labeled Outdoor temp
sensor. The outdoor air temperature sensor is used for
warm weather shutdown and outdoor reset.
Less
120 Single than
6*
80-500
With Pump
115V – Maximum 1HP
or 7.4A max
*Minimum 15A circuit required
Table 10. BNTH Electrical Data.
7.6 Domestic Hot Water Connection
Connect a DHW sensor or aquastat to terminal
block 6 (TB6), connections labeled DHW stat. The
aquastat or sensor will be automatically detected and
initiate the DHW call as needed.
WATER HEATER
PHASE
SIZES
VOLTS
AMPS
150-500
No pump
120
Single
Single
Single
2*
7.7 System Sensor (lead lag/cascading
150-199
With pump
120
120
7*
8*
operation only)
Connect the system sensor to terminal block 6
(TB6), connections labeled system sensor. Can be used
in a well for DHW tank applications with lead/lag.
285-500
With pump
600-850
No pump
See Pump Rating Plate FLA
(must be less than 7.4 FLA; 1HP or less)
*Minimum 15A circuit required
7.8 External Control Connections
Connect 4-20mA signals from external controls or
building automation systems to terminal block 7 (TB7)
in the control panel. The connections are labeled
"Remote Anlaog Input". When making the connections
follow the polarity designations shown on the label.
Table 11. BNTV Electrical Data.
7.2 Pump Connections
Brute Elite energizes the pump contacts upon a
call for heat. Once the call for heat is satisfied the pump
will remain on for the defined pump overrun time.
7.9 Optional Field Connections
Terminal block 8 (TB8) in the control panel can be
used for connecting optional components, such as, low
water cutoffs, flow switches, additional high limits and
other field supplied devices that must be interlocked
with the boiler. All safeties or end switches must be
wired in series by removing the supplied jumpers.
NOTE: System and DHW contacts are dry contacts.
Appropriate voltage must be supplied to the System
and DHW pumps for proper operation. Boiler pump
contact (max 7.4 FLA) is fed by 120V (violet wire)
internally from main power feed.
System pump connections are located on terminal
block 5 (TB5) in the control panel (see Figure 27). The
system pump contacts are rated for 120Vac, 7.4 amps.
To use the contacts, power must be supplied on one
terminal with the other terminal wired to the pump or a
relay controlling the pump.
DHW pump connections are located on terminal
block 5 (TB5) in the control panel and are rated for
120Vac, 7.4 amps. To use the contacts, power must be
supplied on one terminal, and the other terminal wired
to the pump or a relay controlling the pump.
7.10 Lead Lag/ Cascading Wiring
Connections
Connect each boiler in the cascade system
together by daisy chaining each control from Modbus
port 1 (MB1) of the first boiler to the second and so on.
This can be done using 22awg or thicker shielded
twisted pair wire with drain. Two twisted pairs or three
conductors are needed.
a.
To daisy-chain the boilers connect a wire from Modbus
port 1 (MB1) terminal A of the first boiler to Modbus
port 1 (MB1) terminal A of the second boiler.
7.3 24Vac Transformer with Integral Circuit
b. If there are more boilers in the system connect a
wire from Modbus port 1 terminal A of boiler 2 to
Modbus port 1 terminal A of boiler 3.
c. Repeat these steps until all Modbus port1 terminal
A connections are wired.
Breaker
24Vac is supplied by a transformer mounted to the
backside or underneath the control panel, depending
upon the appliance. All 24Vac power is supplied
through a circuit breaker that is part of the transformer.
The transformer is then connected to terminal blocks 3
and 4 (TB3 and TB4).
d. Repeat the above steps for Modbus port 1 terminal
B and C connections to complete the wiring.
e. Connect the drain wire from the twisted pair wire
to ground on one end of the wire only.
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Figure 28. Lead-Lag / Cascading Wiring Connections.
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7.11 Wiring Diagrams (see Figures 29 and 30)
Caution
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing
Figure 29. Ladder Diagram.
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Figure 30. Wiring Diagram (all sizes).
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Once the value is adjusted the NEXT or DONE button
SECTION 8.
can be pressed. The DONE button returns you to the
Home screen. The NEXT button increments the display
to the next item in the menu structure.
Brute Elite Control Setup
and Operation
USER mode is the home screen shown on the
control. If the display is not in USER mode wait for the
display timeout period to be reached or press the Done
button to return to the USER menu.
SETUP mode is accessed by holding the up and
down arrow keys simultaneously for 3 seconds.
DIAGNOSTIC mode is accessed by holding the
NEXT button for 3 seconds.
The Brute Elite control is an integrated electronic
control that replaces many of the individual components
found on older appliances. The control acts as the
ignition control, pump control, high limit and cascading/
lead lag control and is setup using the display on the
appliance.
8.2 Ignition Control- Sequence of Events
1. Call for heat
2. Safety chain check
3. Fan starts and waits to achieve prepurge RPM
MENU ITEM
DEFINITION
F or C
Selects temperature units
LBTHODLOD Outdoor reset enable/disable -
enables menu items
LBT
Low boiler setpoint during outdoor reset
see Figure 29
HOD
LOD
High outdoor temperature setpoint
see Figure 29
Low outdoor temperature setpoint
see Figure 29
Figure 31. Control Buttons on User Interface.
8.1 Display Navigation
RMT Add
LL
HS
bL
Sd
Used for Lead/Lag (follow menus)
The display is divided into three menu structures,
USER, SETUP and DIAGNOSTIC. The menu structure
and variables in each are shown in Tables 12-14. Once
in a particular menu structure navigation consists of
pressing the next button to scroll from item to item and
then pressing the up and down arrows to change values.
Lead/Lag enable/disable - enables menu items
Hysteresis - temp range between on/off cycles
Base Load % - input rate before next boiler fires
Warm weather shut-down temperature
Anti short cycle - minutes of delay between
startup
ASC
bAC
PAS
Future use - Press DONE to exit menu.
Future use - Press DONE to exit menu.
MENU ITEM
FUNCTION
RANGE
DEFAULT
Outlet water Displays the current outlet 55-190°F 120°F
temperature water temperature & allows
the setpoint to be adjusted
NOTE: When enabling/disabling functions, select "Done" and wait 30
seconds before scrolling.
Inlet water
Displays the current inlet
—
—
Table 13. Setup Mode Parameters.
temperature water temperature
MENU ITEM
DESCRIPTION
Delta T
Displays the current
temperature rise across
the heat exchanger
—
—
mA
Display the flame sense signal
Displays the current alert code
Displays the current lockout code
Displays outlet temperature limit
Displays Domestic Hot Water limit setting
Displays Stack limit setting
Alert codes
Lockout code
Outlet Limit
DHW limit
DHW water Displays the current DHW 60-182°F 120°F
temperature temperature & allows the
setpoint to be adjusted
Stack
Displays the current stack
—
—
temperature temperature
Stack Limit
Outdoor
temperature air temperature
LL
Displays the current outdoor
—
—
Min. firing rate Displays the minimum firing rate allowed
Min. forced
firing rate
Max forced
firing rate
Rate indicator Displays a indicator of the firing rate based
off of the fan RPM. Actual firing rate may
vary depending upon setup.
Allows the user to force the boiler to fire at
the minimum firing rate
Allows the user to force the boiler to fire at
the maximum firing rate
Displays the current system 60-190°F 120°F
temperature and allows the
setpoint to be adjusted
Firing Rate Displays an indicator of the
current firing rate based
—
—
upon fan RPM. The actual
firing rate may vary.
Table 14. Diagnostic Mode Menu Structure.
Table 12. User Mode Menu Structure.
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4. Prepurge timer is started once the prepurge RPM is
achieved.
8.5 Anti-Short Cycle (ASC)
The anti short cycle period is started whenever the
gas valve turns off. This period is to help prevent short
cycling. Depending upon the time selected the control
will wait up to 10 minutes before attempting to start the
trial for ignition sequence. The ASC time can be
adjusted by entering setup mode.
5. Pre ignition time of 2 seconds to check the flame
sensor operation and status. During this period an
intermittent spark can be seen.
6. Trial for ignition period, 4 seconds. The direct
spark ignition switches to constant spark for three
seconds, during which time the gas valve is open.
For the last second of the ignition period direct
spark is de-energized and the flame sensor checks
for established flame. If flame is sensed the control
enters "Run" to satisfy the demand. If flame is not
established the control enters a retrystarting from
step 2. If flame has not been established in the
appropriate number of retries the control will
lockout with a 109 error code.
7. Call for heat complete
8. Gas valve off
9. Fan and pump over run times active to purge the
system
This sequence is the basic operating sequence of
the appliance whether there is a DHW, or hydronic call
for heat.
8.5 High Limit
The control uses a dual thermistor sensor to
monitor the Brute Elite's maximum temperature. The
high limit sensor is installed in the outlet water. A dual
thermistor sensor is used, so that the two temperatures
can be monitored and compared to confirm accuracy.
The control will automatically reduce the firing of the
Brute Elite to prevent the high limit from tripping. The
high limit setpoint is not adjustable.
8.7 Outlet Water Temperature
The outlet water temperature is a dual thermistor
sensor and is limit rated. The control compares each of
the temperature readings to determine accuracy. The
outlet sensor is used as the primary control point for
high limit, temperature operation, and modulation. The
operating setpoint can be adjusted through the USER
menu structure.
8.3 Modulation Control
The control uses a PID algorithm to adjust the
firing rate of the boiler as the control point is
8.8 Inlet Water Temperature
The inlet water temperature uses a single
thermistor sensor and is used to calculate the delta T of
the system.
approached. The goal of the control is to operate at a
minimum firing rate to match the load on the appliance.
This is done by using a setpoint, and on / off
differentials. The control modulates to achieve the
setpoint temperature, which could be several degrees
away from the actual off point. The off point is
calculated by adding the setpoint + off differential. The
setpoint and differentials used in operation is dependent
upon the call for heat being applied. If there is a DHW
call the DHW setpoint and off differentials are used. If
there is a hydronic call the CH setpoint and off
differential is used. When the setpoint + off differential
is achieved the control interrupts appliance firing until
the water temperatures reaches the setpoint - on
differential. Both the hydronic and DHW setpoints are
adjustable through the USER mode menu structure.
8.9 Heat Exchanger Temperature Rise
The heat exchanger temperature rise is calculated
from the outlet and inlet sensor temperatures. The result
is displayed in the USER menu structure.
8.10 Stack Temperature
The stack temperature is a dual thermistor sensor
and is limit rated. The control compares each of the
temperature readings to determine accuracy. The stack
sensor is used as a limiting feature to avoid excessive
temperatures in the venting.
8.4 Pump Control
8.11 Domestic Hot Water Temperature
The domestic hot water temperature sensor is used
to monitor the DHW demand. The control uses the
DHW sensor to control the operation and modulation
rate of the appliance when there is a DHW demand. The
DHW setpoint can be adjusted through the USER menu
structure.
The control can operate three pumps. The boiler
pump is active anytime there is a call for heat applied to
the control. The DHW and system pumps are active
based upon the call and priority of the heat demand
being supplied. When there is a hydronic call supplied
the system pump is active. If there is a DHW call
supplied while the hydronic call is active the system
pump turns off and the DHW turns on. This happens
because of domestic hot water priority, which forces the
control to attempt to satisfy the domestic water demand
prior to the hydronic demand. When the last heat
demand is satisfied the boiler pump enters an overrun
time.
8.12 Lead Lag / Cascading
Lead Lag/Cascading allows multiple boilers to be
connected together and controlled from one common
sensor input. Up to 8 boilers can be connected together
in a single system. To setup Lead/Lag or cascading
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will help reduce the chance of short cycling.
DANGER
8.12.5 Lead Lag Base Load Setting
• Water temperature over 125°F (52°C) can cause
severe burns instantly or death from scalds.
• Children, disabled and elderly are at hightest risk of
being scalded.
• See instruction manual before
setting temperature at
The lead lag system uses a base load setting that is
set through the "setup" menu called "bL". The base load
setting identifies the firing rate that the operating boiler
must achieve before the next boiler in the system is
allowed to operate. The default setting is 50% to avoid
short cycling and operating the boilers at higher, less
efficient, firing rates.
heating appliance.
• Feel water before
bathing or showering.
8.13 Boiler Pump Interrupt
• If this appliance is used to
produce water that could
WARNING
scald if too hot, such
Failure to plumb, pump and install the appliance
correctly when using this feature may lead to reduced
or no water flow through the heat exchanger, causing
premature failure of the heat exchanger, personal
injury or death. Please consult the factory with any
questions regarding the use of this feature.
as domestic hot water
use, adjust the outlet
control (limit) or use temperature limiting valves to
obtain a maximum water temperature of 125°F (52°C).
operation there are several settings in the "setup" menu
structure that must be adjusted for the specific
installation, each is covered in the following sections.
8.12.1 Lead Lag Setpoint
The boiler pump interrupt feature is used in some
applications when the boiler is being used for both
hydronic and domestic hot water heating. The interrupt
jumper is used to turn off the boiler pump during a
domestic hot water demand. For this to work properly
the system must be plumbed and pumped to allow the
domestic hot water pump to supply the flow and head
requirements for the boiler and indirect water heater
together. It is not necessary to use the interrupt jumper
in all applications. Specific modes of operation that may
require the use of this feature are shown in Section 6.
The lead lag setpoint is set from the "user" menu
using the "LL" variable. This is the temperature the
boiler is attempting to maintain at the system sensor.
This setting doesn't control the boiler outlet
temperature, so the water temperature at the boiler outlet
may be much hotter than the system temperature
setpoint. Adjust the LL setpoint to the desired operating
temperature of the system.
8.12.2 Lead Lag Master/Slave Selection
In the SETUP menu structure, the "LL" menu
allows the lead lag system to be turned on and the boiler
to be configured as a master or slave control. In each
lead lag system there can only be one master control, so
proper selection is important to avoid operating issues.
To set the boiler to lead lag "master" operation the LL
menu should be set to "LDR". To set the boiler to slave,
"SLA" should be selected.
NAME
FUNCTION
VALUE
CH on
Burner demand begins when the
5°F
differential outlet water temperature reaches
"Outlet water temperature setpoint"
minus "CH on differential"
CH off
Burner demand ends when the
5°F
differential outlet water temperature reaches
"Outlet water temperature setpoint"
plus "CH off differential"
8.12.3 Lead Lag Address
DHW on
Burner demand begins when the
2°F
(80-285)
differential outlet water temperature reaches
"Outlet water temperature setpoint"
minus "DHW on differential"
The Lead Lag address must be set for each boiler
connected to the lead lag system. Each boiler must have
a unique address selected for the system to work
properly. Typically, the lead or master boiler should be
set to address one and the remaining boilers should be
set to values 2–8 depending upon how many boilers are
installed in the system.
5°F
(399-850)
DHW off
Burner demand ends when the
10°F
(80-285)
differential outlet water temperature reaches
"Outlet water temperature setpoint"
plus "DHW off differential"
5°F
(399-850)
Pump
overrun
Operates the pump for the overrun
time after the burner demand
has ended
Locks the boiler out when the high
limit temperature is reached
(requires manual reset)
Flame signals lower than the flame
threshold interrupt burner operation
Time for domestic hot water priority
1 or 5
minutes
8.12.4 Lead Lag Hysteresis
The lead lag system uses a hysteresis value set in
the setup menu, called, "HS". The hysteresis and
setpoint values control the on and off points of the
boiler. If the lead lag setpoint is adjusted to 120°F with
a hysteresis value of 5°F the boiler will turn off when
the water temperature reaches 125°F and will turn back
on when the water temperature reaches 115°F. Set the
hysteresis values to match the boiler to the system
operating characteristics. Setting this value correctly
High
limit
200°F
Flame
threshold
DHW
priority time
0.8Vdc
60 min.
Table 15. Default Control Settings.
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once the fan RPM reaches a preset level. The trial for
ignition period follows once the start-up RPM of the fan
is reached. The trial for ignition period lasts 4 seconds
during which, the direct spark ignition system and gas
valve are energized. At the end of the trial for ignition
period the flame signal is compared with the preset
flame threshold value. If the flame signal is higher than
the flame threshold the Brute Elite enters "run". If the
flame signal is below the threshold the Brute Elite
returns to pre-purge and starts the ignition process over.
In "run" the Brute Elite monitors the flame signal, call
for heat, safeties, and water temperatures modulating as
needed between 100% and 20% of rate to satisfy the call
for heat. When a DHW demand is applied during a
hydronic call for heat the priority feature forces the
boiler to switch to the DHW demand for the priority
time. The DHW priority demand forces the control to
operate to the DHW setpoint, de-energizes the system
pump and energizes the DHW pump.
SECTION 9.
Modes of Operation
The Brute Elite control allows the boiler to operate
in many different modes of operation. The mode must
be selected based upon the requirements of the
installation. The following sections describe the basic
operation of the Brute Elite in each of the different
modes. Familiarize yourself with each mode and how
the operation of the boiler varies, depending upon the
installation and inputs the control is monitoring.
9.1 Hydronic Heating Demand
When using the Brute Elite for hydronic heating a
call for heat must be supplied to the "T-T or Interlock"
terminal. Once the call is supplied the control starts the
boiler and system pumps and begins the ignition
process. The ignition process consists of a prepurge,
trial for ignition, and run period. The prepurge period
starts on a call for heat once the fan RPM reaches a
preset level. The trial for ignition period follows once
the start-up RPM of the fan is reached. The trial for
ignition period lasts 4 seconds during which the direct
spark ignition system and gas valve are energized. At
the end of the trial for ignition period the flame signal is
compared with the preset flame threshold value. If the
flame signal is higher than the flame threshold the Brute
Elite enters "run". If the flame signal is below the
threshold the Brute Elite returns to prepurge and starts
the ignition process over. In "run" the Brute Elite
monitors the flame signal, call for heat, safeties, and
water temperatures and modulates as needed between
100% and 20% of rate to satisfy the call for heat.
9.4 Hydronic Heating Using External
Modulation Control
When using the Brute Elite for hydronic heating
with external modulation control a call for heat must be
supplied to the "T-T or Interlock" terminal. Once the
call is supplied the control starts the boiler and system
pumps and begins the ignition process. The ignition
process consists of a prepurge, trial for ignition, and run
period. The prepurge period starts on a call for heat
once the fan RPM reaches a preset level. The trial for
ignition period follows once the start-up RPM of the fan
is reached. The trial for ignition period lasts 4 seconds
during which the direct spark ignition system and gas
valve are energized. At the end of the trial for ignition
period the flame signal is compared with the preset
flame threshold value. If the flame signal is higher than
the flame threshold the Brute Elite enters "run". If the
flame signal is below the threshold the Brute Elite
returns to prepurge and starts the ignition process over.
In "run" the Brute Elite monitors the flame signal, call
for heat, safeties, and water temperatures. The boiler
9.2 Hydronic Heating with Outdoor Reset
Outdoor reset varies the control point setpoint
based on the actual outdoor temperature. The reset
function works as shown in Figure 32. When the
outdoor air temperature reaches the "high outdoor
temperature setpoint (HOD), the control point setting is
adjusted to the low boiler temperature setpoint (LBT).
When the outdoor air temperature reaches the low
outdoor temperature setpoint (LOD), the control
setpoint is adjusted to the CH/Outlet water setpoint
temperature. HOD, LOD and LBT can be adjusted by
accessing SETUP mode. CH setpoint is adjustable from
the USER menu structure.
9.3 Hydronic Heating with Domestic Hot
Water (DHW) Priority
When using the Brute Elite for hydronic heating
with domestic hot water priority a call for heat must be
supplied to the "T-T or Interlock" terminal. Once the
call is supplied the control starts the boiler and system
pumps and begins the ignition process. The ignition
process consists of a prepurge, trial for ignition, and run
period. The pre-purge period starts on a call for heat
Figure 32. Outdoor Reset Setpoint Temperatures.
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Brut e Elit e
Page 41
setpoint is used to limit the maximum water temperature
leaving the boiler only. The modulation rate is
controlled by a 4-20mA (0-10Vdc using converter)
signal supplied by an external control. When setting up
a system using an external control care must be taken to
set the external control algorithms to prevent the boiler
from short cycling or "hunting " to prevent premature
component failure.
All three boilers will continue to fire simultaneously at
equal input rates or…
1. Modulation rate approaches minimum firing rate
(20%), in which case Slave2 will first drop out,
and then Slave1, accordingly.
2. System temperature reaches 10F (HS- hysteresis
value) above setpoint (e.g. 160F), in which case
remaining boiler will shut off
3. Any of the boilers approach its high limit tempera-
ture the individual boiler will modulate back.
9.5 Hydronic Heating Using Local Lead-
Lag/Cascading Feature
9.6 Hydronic Heating Using Local Lead-
Lag/Cascading Feature with Indirect
When using single or multiple Brute Elites in lead
lag configuration, the system sensor and TT terminals of
the Master boiler create heat demand. The TT terminals
on the slave boilers are ignored as the demand for those
heaters is given from the master control. The system
sensor is also used to control the modulation rate of the
lead lag system. (see Section 7 for wiring instructions).
Hot Water
When using the lead lag boiler system to provide
indirect domestic hot water heating, the DHW demand
should be supplied to the master boiler through the existing
DHW terminals. The lead lag system will change the
operating mode of the Master boiler only to supply water at
the DHW setpoint. The remaining boilers on the system
will continue to supply hydronic heating.
Let’s consider the following example:
Three Brute Elite boilers (let’s call them “Lead”,
“Slave1” and “Slave2”) tied together via Modbus 1
connection, with appropriate RMT Address (1, 2, 3).
System sensor input is used to indicate common
secondary loop temperature.
When the system is supplying both hydronic heat and
domestic hot water at the same time both the system pump
and DHW pump contacts are closed, so special attention
must be paid to allow for proper operation. During a DHW
call, the master boiler pump may need to be turned off in
applications serving both hydronic and domestic heating.
This will cause the DHW pump to provide flow through
the boiler and indirect tank (pump must be sized properly)
when there is a DHW call. To turn off the boiler pump in
this application the "boiler pump interrupt" jumper should
be installed. The terminal block location is terminal block 5
(TB5) contacts labeled "boiler pump interrupt" in the
control panel.
System setpoint = 150°F
HS (hysteresis) = 10°F (default)
BL (base load) = 50% (default)
Anti-short-cycle = 5 minutes
Run sequence is initiated when system temperature
falls to 140°F (setpoint less hysteresis value). Lead
boiler will start. All firing rates will depend on several
application characteristics, including flow rate, system
load, water volume, etc. Boilers will start at a rate of
35%. If the load is such that Lead’s rate increases to
50%, “Slave1” will go through its startup sequence and
begin firing at 35%. At this point, both boilers (Lead
and Slave1) will continue to respond simultaneously to
the load/system characteristics, by modulating up or
down together, in relation to the relative system setpoint
and load characteristics.
9.7 Warm Weather Shutdown
Warm weather shutdown overrides a hydronic call
for heat when the outdoor air temperature is greater than
the warm weather shutdown setpoint. Warm weather
shutdown is always active whenever there is an outdoor
sensor attached to the control. To avoid warm weather
shutdown the warm weather shutdown temperature
should be increased as necessary. The warm weather
shutdown setpoint can be adjusted in SETUP mode,
using the SD menu.
Scenario 1: If the system loop temperature rises
quickly, and moves above setpoint, then the
boilers will simultaneously drop their firing rate. If
when reaching the point where both boilers drop
toward their minimum firing rate (20%), then the
first slave will drop out. Slave1 will remain
9.8 Domestic Hot Water Demand (BNTV
unavailable until its ASC timer has expired (5
minutes). If the load were to increase such to drive
all active boilers to 50% firing rate or more, during
the ASC time, Slave2 will begin its startup se-
quence and begin to fire at 35%, etc.
only)
When using the Brute Elite for DHW heating a
call for heat must be supplied to the "DHW stat"
terminal located on terminal block 6 (TB6). The DHW
heating call can be from the supplied DHW sensor or
from an aquastat. If the DHW sensor is used the heater
operates to maintain the temperature at the DHW
sensor. This may allow the actual heater outlet water
temperature to exceed the DHW sensor setpoint. If an
aquastat is used to supply the DHW demand the heaters
Scenario 2: If the system loop temperature continues to
drop (load increases), then the two boilers will
increase firing rate together. At 50%, Slave2 will
begin its firing sequence and be added to the group.
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firing rate is controlled by the DHW setpoint
The ignition process consists of a prepurge, trial for
temperature and the water temperature at the heat
exchanger outlet. Once the DHW call is supplied the
control starts the boiler and DHW pumps and begins the
ignition process. The ignition process consists of a
prepurge, trial for ignition, and run period. The prepurge
period starts on a call for heat once the fan RPM reaches
a preset level. The trial for ignition period follows once
the start-up RPM of the fan is reached. The trial for
ignition period lasts 4 seconds during which the direct
spark ignition system and gas valve are energized. At
the end of the trial for ignition period the flame signal is
compared with the preset flame threshold value. If the
flame signal is higher than the flame threshold the Brute
Elite enters "run". If the flame signal is below the
threshold the Brute Elite returns to prepurge and starts
the ignition process over. In "run" the Brute Elite
monitors the flame signal, call for heat, safeties, and
water temperatures modulating as needed between
100% and 20% of rate to satisfy the call for heat.
ignition, and run period. The prepurge period starts on a
call for heat once the fan RPM reaches a preset level. The
trial for ignition period follows once the start-up RPM of
the fan is reached. The trial for ignition period lasts 4
seconds during which the direct spark ignition system and
gas valve are energized. At the end of the trial for ignition
period the flame signal is compared with the preset flame
threshold value. If the flame signal is higher than the flame
threshold the Brute Elite enters "run". If the flame signal is
below the threshold the Brute Elite returns to prepurge and
starts the ignition process over. In "run" the Brute Elite
monitors the flame signal, call for heat, safeties, and water
temperatures. The heater setpoint is used to limit the
maximum water temperature leaving the boiler only. The
modulation rate is controlled by a 4-20mA (0-10Vdc using
converter) signal supplied by an external control. When
setting up a system using an external control care must be
taken to set the external control algorithms to prevent the
boiler from short cycling or "hunting " to prevent prema-
ture component failure.
9.9 Domestic Hot Water Heating Using
9.10 Domestic Hot Water Heating Using
External Modulation Control
Local Lead-Lag/Cascading Feature
When using multiple Brute Elites to supply
When using the Brute Elite for DHW heating with
external modulation control a call for heat must be supplied
to the "T-T or Interlock" terminal. By supplying a call to
the "T-T or interlock" terminal the operating temperature
setpoint defaults to the hydronic heating setpoint, so all of
the temperature adjustments must be made to the hydronic
setpoint. Once the call is supplied, the control starts the
boiler and system pumps and begins the ignition process.
Domestic hot water only the heaters should be setup as
stated in Section 8.12 “Lead/Lag Cascading,” and
Section 9.5 “Hydronic Heating Using Local Lead/Lag
Cascading Feature.” When the heaters are installed in
this fashion, all of the setpoints and adjustments are
done through the Lead Lag menus.
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13. Check gauge for correct water pressure and also
SECTION 10.
check water level in the system. If the height
indicated above the boiler insures that water is at
the highest point in the circulating loop, then the
system is ready for operation.
Operating Instructions
10.1 Filling the Boiler System
1. Ensure the system is fully connected. Close all
bleeding devices and open make-up water valve.
Allow system to fill slowly.
2. If make-up water pump is employed, adjust
pressure switch on pumping system to provide a
minimum of 12 psi (81.8 kPa) at the highest point
in the heating loop.
3. If a water pressure regulator is provided on the
make-up water line, adjust the pressure regulator
to provide at least 12 psi (81.8 kPa) at the highest
point in the heating loop.
4. Open bleeding devices on all radiation units at the
high points in the piping throughout the system,
unless automatic air bleeders are provided at such
points.
Note that there is an air bleed located on the left
side of Brute Elite, on top of the water manifold.
5. Cycle the boiler pump on and off 10 times, 10
seconds on and 10 seconds off to remove all air
from the heat exchanger. Then run system and
appliance pump for a minimum of 30 minutes with
the gas shut off.
14. Prime condensate trap with water (not required for
BNTH 600, 750, 850).
15. Refer to local codes and the make-up water valve
manufacturer’s instructions as to whether the
make-up water valve should be left open or closed.
16. After placing the unit in operation, the ignition
system safety shutoff device must be tested.
First, shut off the manual gas valve, and call the
unit for heat. Main gas terminals will be energized,
attempting to light, for four (4) seconds, and then
will de-energize. The unit will go into lockout
after the required number of trial for ignition
periods.
Second, turn the power off, press the manual reset
button on the boiler control, or the user display,
open the manual gas valve and allow the unit to
light. While the unit is operating, close the manual
gas valve and ensure that power to the main gas
valve has been cut.
17. Within three (3) days of start-up, recheck all air
bleeders and the expansion tank as described in
Steps 4 and 8 above.
Important Note: The installer is responsible for
identifying to the owner/operator the location of all
emergency shutoff devices.
WARNING
Failure to remove all air from the heat exchanger
could lead to property damage, severe injury or death.
WARNING
Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance
6. Open all strainers in the circulating system, check
flow switch operation (if equipped), and check for
debris. If debris is present, clean out to ensure
proper circulation.
and to replace any part of the control system and any
gas control that may have been
7. Recheck all air bleeders as described in Step 4.
8. Check liquid level in expansion tank. With the
system full of water and under normal operating
pressure, the level of water in the expansion tank
should not exceed ¼ of the total, with the balance
filled with air.
9. Start up boiler according to the procedure in this
manual. Operate the entire system, including the
pump, boiler, and radiation units for one (1) hour.
10. Recheck the water level in the expansion tank. If
the water level exceeds ¼ of the volume of the
expansion tank, open the tank drain, and drain to
that level.
under water.
10.2 Operating the Burner and Set Up
Initial setup must be checked before the unit is put
in operation. Problems such as failure to start, rough
ignition, strong exhaust odors, etc. can be due to
improper setup. Damage to the boiler resulting from
improper setup is not covered by the limited warranty.
10.2.1 Burner Operation
REQUIRED TOOLS: differential pressure gauge
capable of reading negative 0.01 inches W.C. (0.002kPa),
screw drivers, torx bits, combustion analyzer.
1. Using this manual, make sure the installation is
complete and in full compliance with the
instructions and all local codes.
11. Shut down the entire system and vent all radiation
units and high points in the system piping, as
described in Step 4.
12. Close make-up water valve and check strainer in
pressure reducing valve for sediment or debris
from the make-up water line. Reopen make-up
water valve.
2. Determine that the appliance and system are filled
with water and all air has been bled from both.
Open all valves.
3. Observe all warnings on the Operating Instructions
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label and turn on gas and electrical power to
in Table 16. If the CO2 is not within the range
shown, adjustments may be made. To adjust the
low fire CO2, locate the low fire adjuster screw
according to the appropriate figure. Slowly make
adjustments in 1/16 of a revolution increments
until the CO2 is within the range identified.
4. Repeat steps 2 and 3 to confirm that the CO2
ranges are within the required ranges. Adjust if
necessary.
appliance.
4. Brute Elite will enter the start sequence. Blower
and pump will energize for pre-purge, then the
ignition sequence starts. After all safety devices
are verified, the gas valve opens. If ignition
doesn’t occur, turn off the Brute Elite, check that
there is proper gas supply. Wait 5 minutes and
start the unit again.
5. Turn Brute Elite on.
5. Confirm that the differential pressure is still within
the appropriate range.
6. After placing the appliance in operation, the
Burner Safety Shutoff Device must be tested:
(a) Close gas shutoff valve with burner operating.
(b) Flame will go out and blower will continue to
run for the post purge cycle. One or three
additional attempts to light will follow
6. If any of the measurements cannot be adjusted
to the specified ranges or the CO levels are
above 150ppm when adjusted please consult the
factory for further information.
7. Remove the differential pressure gauge from the
air and gas pressure taps making sure to close all
ports after the gauge has been removed.
including pre-purge, ignitor on, valve/flame on
and post purge. Ignition will not occur as the
gas is off. The ignition control will lockout.
(c) Open gas shutoff valve. Reset the boiler
control by pressing the RESET button on the
control or on the display. Restart the
WARNING
Improper adjustment may lead to poor combustion
quality, increasing the amount of carbon monoxide
produced. Excessive carbon monoxide levels may
lead to personal injury or death.
appliance. The ignition sequence will start
again and the burner will start. The appliance
will return to its previous mode of operation.
DIFFERENTIAL
PRESSURE
GAS TYPE
HIGH FIRE, CO2
LOW FIRE, CO2
Caution
Should any odor of gas be detected, or if the gas
burner does not appear to be functioning in a normal
manner, CLOSE MAIN SHUTOFF VALVE. Do not
shut off switch. Contact your heating contractor, gas
company, or factory representative.
Natural
9.0 to 8.8%
0.5% lower than
high fire setting
-.005 to
-.015" wc
Propane
10.0 to 9.8%
Table 16. CO2 Range and Pressure Differential.
10.3 Shutting Down Brute Elite
10.2.2 Boiler Setup and Adjustment
1. Connect a manometer capable of reading 0.01"wc
to the gas valve locations shown in Figure 33. The
positive side of the manometer should be
1. Turn off the main electrical disconnect switch.
2. Close all manual gas valves.
3. If freezing is anticipated, drain Brute Elite and be
sure to also protect building piping from freezing.
All water must be removed from heat exchanger or
damage from freezing may occur.
connected to the location labeled “air pressure
tap.” The negative side of the manometer should
be connected to the location labeled "gas pressure
tap." This differential pressure should be slightly
negative (see Table 16).
This step to be performed by a qualified service person.
10.4 To Restart Brute Elite
2. Measure the CO2/O2 in the flue products at high
fire. The Brute Elite can be forced to high fire to
allow for easier setup. Refer to Section 8.1, Table
14 for instructions on how to access the forced rate
menu. The CO2 readings should be between the
values shown in Table 16. If the CO2 is not within the
range shown, adjustments may be made. To adjust
the high fire CO2, locate the high fire adjuster screw
according to the appropriate figure. Slowly make
adjustments in 1/16 of a revolution increments until
the CO2 is within the range identified.
3. Measure the CO2/O2 in the flue products at low
fire. Brute Elite can be forced to low fire to allow
for easier setup. Refer to Section 8.1, Table 14 for
instructions on how to access the forced rate menu.
CO2 readings should be between the values shown
If drained, follow Section 10.1 in this manual
for proper filling and purging.
1. Turn off the main electrical disconnect switch.
2. Close all manual gas valves.
3. WAIT FIVE (5) MINUTES.
4. Set the aquastat or thermostat to its lowest setting.
5. Open all manual gas valves.
6. Reset all safety switches (pressure switch, manual
reset high limit, etc.).
7. Set the temperature controller to the desired
temperature setting and switch on electrical power.
8. Burner will go through a prepurge period and
ignitor warm-up period, followed by ignition.
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80–285
399
500
600
750, 850
Figure 33B. Brute Elite Gas Valves (600, 750 and 850).
Figure 33A. Brute Elite Gas Valves (285, 399 and 500).
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qualified service technician should inspect the basic
items listed below every year:
SECTION 11.
Maintenance
a. Appliance control
b. Automatic gas valve
c. Pressure switches
d. Blower
f. Flow switch
g. Low water cutoff
h. Burner
WARNING
Disconnect all power to the appliance before
attempting any service to the appliance. Contact with
electricity can result in severe injury or death.
i. Heat exchanger
e. Pump
11.2.1 Burner
11.1 System Maintenance
Check the burner for debris. Remove the blower
arm assembly to access the burner. Remove the 4 bolts
connecting the blower to the arm (see Figure 34).
Remove the 5 bolts, which hold the burner arm in place.
Pull burner up and out. Clean burner, if necessary, by
blowing compressed air from the outside of the burner
into the center of the burner, and wipe the inside of the
burner clean with glass cleaner. A dirty burner may be
an indication of improper combustion or dirty
combustion air. Determine the cause, and correct. If
damaged, replace the burner gasket when replacing the
burner.
(yearly, unless otherwise noted)
1. Lubricate the system water-circulating pump, if
required, per the instructions on the pump.
2. If a strainer is employed in a pressure reducing
valve or the piping, clean it every six moBNTHs.
3. Inspect the venting system for obstruction or
leakage at least once a year. Periodically clean the
screens in the vent terminal and combustion air
terminal (when used).
4. Keep the appliance area clear and free from
combustible materials, gasoline, and other
flammable vapors and liquids.
NOTE: When installing the burner, make sure the
flange is aligned with the mating surface, as each is
keyed to control fit.
5. If the appliance is not going to be used for
extended periods in locations where freezing
normally occurs, it should be isolated from the
system and completely drained of all water.
6. Low water cutoffs, if installed, should be checked
every year. Float type low water cutoffs should be
flushed periodically.
7. Inspect and clean the condensate collection, float
switch and disposal system yearly.
8. When a means is provided to neutralize
condensate, ensure that the condensate is being
neutralized properly.
9. Inspect flue passages, and clean with brushes/
vacuums, if necessary. Sooting in flue passages
indicates improper combustion. Determine the
cause and correct.
10. Inspect the vent system and air intake system, and
ensure that all joints are sealed properly. If joints
need to be resealed, completely remove existing
sealing material, and clean with alcohol. Apply
new sealing material, and reassemble.
11.2.2 Modulating Gas Valve / Venturi
The modulating gas valve consists of a valve body
that incorporates the ON/OFF gas flow control and a
negative pressure regulator. It provides the air/gas ratio
control in combination with the venturi to the unit. It is
designed to operate with gas supply pressure between 4
and 13 inches w.c.. To remove the gas valve and or
venturi, shut off the 120 Volt power supply to the
boiler. Turn off all manual gas valves connecting the
boiler to the main gas supply line. Remove the front
door of the boiler to gain access to the gas valve and
venturi. Disconnect the four (4) flange bolts connecting
the gas manifold pipe to the gas valve. Remove the
electrical connections to the gas valve. Remove the bolts
connecting the venturi flange to the blower. This allows
the entire gas valve/venturi assembly to be removed as
an assembly to facilitate inspection and cleaning.
After the valve has been removed, reassemble in
reverse order making sure to include all gaskets and O-
rings. Turn on the manual gas valves and check for gas
leaks. Turn on the 120 Volt power. Place the unit in
operation following the instructions in Section10. Once
the boiler is operating check for leaks again and confirm
all fasteners are tight.
11.2 Appliance Maintenance and
Component Description
Use only genuine Bradford White replacement
parts.
Check appliance setup according to Section 10.
11.2.3 Appliance Control
Caution
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and danger-
ous operation. Verify proper operation after servicing.
Brute Elite has an integrated control that
incorporates manual reset high limit control, operating
temperature control, modulating control, ignition
control, outdoor reset control, pump control and many
other features. If any of these features are thought to be
defective, please consult the factory for proper trouble
shooting practices prior to replacing the control. If
control replacement is required, turn off all power to the
Brute Elite gas and electric controls are engineered
for long life and dependable operation, but the safety of
equipment depends on their proper functioning. Only a
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Brut e Elit e
Page 47
appliance and shut off all manual gas valves to the
appliance. Remove the front door to the appliance and
the control panel plastic bezel. Remove all wire
connections from the control board. The control board
connections are keyed to only allow connection in the
proper location, but proper handling techniques should
be used to avoid damage to the wiring or connectors. To
remove the control push in on the two tabs on the left
side of the board to unlatch the clips from the control
panel. Rotate the control around the fastening points on
the right side of the control to remove the hooks from
the control panel. To replace the control repeat the steps
above in the reverse order making sure to connect all
wires in the proper location. Place the appliance in
operation following the steps outlined in Section 10.
11.2.4 Ignitor Assembly
ignitor assembly to the burner door. Remove and
replace the old ignitor assembly gasket. Reinstall a new
ignitor assembly in the reverse order if the old assembly
is determined defective. Replace gasket if necessary.
11.2.5 Flame Sensor
The flame sensor is a single rod system. To replace
the flame sensor electrode, shut off the 120 Volt power
supply to the boiler. Turn off all manual gas valves
connecting the boiler to the main gas supply line.
Remove the front door of the boiler to gain access to the
flame sensor electrode. Remove the flame sensor wire
from the electrode. Remove the two bolts fastening the
electrode to the burner doors. Remove and replace the
old flame sensor gasket. Reinstall a new flame sensor
electrode in the reverse order if the old electrode is
determined defective.
The ignitor assembly is a two rod system that
Caution
Igniters and sensors get hot and
can cause burns or injury.
consists of a ground rod and a sense rod. To remove the
ignitor assembly, shut off the 120 Volt power supply to
the appliance. Turn off all manual gas valves connecting
the appliance to the main gas supply line. Remove the
front door of the boiler to gain access to the ignitor
assembly. Remove the two wires connected to the
assembly. Then remove the two bolts connecting the
Figure 34. Burner Service.
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11.2.6 Transformer with Integral Circuit
Caution
Breaker
Black carbon soot buildup on a dirty heat exchanger
can be ignited by a random spark or flame. To
prevent this from happening, dampen the soot
deposits with a wet brush or fine water spray before
servicing the heat exchanger.
The appliance has a 24Vac transformer with
integral 4 amp circuit breaker installed for supplying the
control voltage required for the appliance only. The
transformer is sized for the appliance load only and
should not be used to supply power to additional field
devices. If additional loads are added or a short occurs
during installation the integral circuit breaker may trip.
If this happens make sure to reset the circuit breaker
prior to replacing the transformer.
1. Shut off the 120 Volt power supply to the boiler
2. Turn off all manual gas valves connecting the
boiler to the main gas supply line.
Depending upon the revision of the appliance the
transformer may be mounted to the back or underneath
the control panel. In either case, if the transformer must
be replaced turn off the 120Vac power to the appliance.
Remove the transformer wires from terminal blocks.
Remove the fasteners holding the transformer and
remove the transformer. Replace with a new transformer
in reverse order.
3. For NT 600 models only (all other sizes please
skip to step four). NT 600 models will require the
gas valve to be removed in order to remove the
burner door. To do this, remove the wire
connections from the gas valve. Remove the flange
bolts from the gas supply pipe connected to the gas
valve (1B). Remove the flange bolts connecting
the gas train to the venturi (1A). Remove the gas
train assembly keeping gaskets and o-rings.
If the transformer is replaced with parts other than
the OEM transformer, be sure to add circuit protection if
it is not integral to the new transformer.
4. Remove the four bolts connecting the blower
flange to the burner door arm.
5. Remove the nuts located on the outside diameter
of the burner door to the heat exchanger.
WARNING
Failure to include proper circuit protection may lead
to premature component failure, fire, injury or death.
6. Remove the burner door/burner assembly from the
heat exchanger.
11.2.7 Blower
7. Disconnect the condensate drain line.
The combustion air blower is a high-pressure
centrifugal blower with a variable speed motor. Speed
of the motor is determined by the control logic. 120
Volts remain on to the blower at all times. If a blower
change is required, turn off the 120 Volt power and gas
supply to the unit. Take the front panel off. Disconnect
the 120 Volt and control signal connections from the
blower. Disconnect the bolts connecting the venturi to
the blower housing. Disconnect the fan outlet bolts from
the burner door blower arm. If the fan is determined to
be defective replace the existing fan with a new one
reversing the steps above. Make sure to install all of the
required O-rings and gaskets between the blower arm
and the blower and blower face and venturi flange.
11.2.8 Heat Exchanger Coils
8. Attach a longer hose to drain and run to a bucket.
9. Clean the heat exchanger by brushing light
accumulations of soot and debris. Use a brush with
soft bristle (non metal) to avoid damaging the
surface of the heat exchanger tubes.
10. Once the tubes have been brushed clean rinse the
tubes and combustion chamber with a small
amount of water to rinse all of the debris out of the
bottom of the flue collector and into the longer
condensate trap line, which is being diverted into a
separate container.
NOTE: The Warranty does not cover damage caused
by lack of required maintenance, lack of water flow,
or improper operating practices.
Black carbon soot buildup on the external surfaces
of the heat exchanger is caused by one or more of the
following; incomplete combustion, combustion air
problems, venting problems and heater short cycling.
Soot buildup or other debris on the heat exchanger may
restrict the flue passages.
If black carbon soot buildup on the heat exchanger
is suspected, disconnect electrical supply to the unit,
and turn off the gas supply by closing the manual gas
valve on the unit. Access the heat exchanger through the
burner door at the front of the boiler, and inspect the
tubing using a flashlight. If there is a buildup of black
carbon soot or other debris on the heat exchanger, clean
per the following:
WARNING
Failure to rinse the debris from the heat exchanger
and temporary drain line may lead to clogged
condensate lines, traps and neutralizers. Condensate
pumps (if used) may also be damaged from the
debris left behind, possibly causing property damage.
11. Install all components removed in the reverse
order to place the appliance back in operation.
Make sure all gaskets are in place as components
are installed. Replace any damaged gaskets. Do
NOT reuse damaged gaskets.
12. Place the appliance in operation according to
Section 10 checking all gas connections for leaks.
Confirm all fasteners are tight.
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11.2.9 Gas Pressure Switches (optional)
SECTION 12.
The high and low gas pressure switches are 24V
manual reset switches that act to cut power to the gas
valves if the gas pressure is too low or too high for
proper operation. The gas pressure switches used are
integrally vent limited, and do not require venting to
atmosphere. To remove a switch, remove the screw on
the plastic housing and pull the clear cover off.
Disconnect the two wires from the screw terminals.
Twist the switch off the pipe nipple. Reassemble in
reverse order. For natural gas, set the low gas pressure
switch to 3" w.c. For propane, set the low gas pressure
switch to 5" w.c. For natural and propane, set the high
gas pressure switch to 14".
Trouble Shooting
12.1 Sequence of Operation
Brute Elite is a cold start appliance that should
start only on a call for heat from a tank aquastat, room
thermostat, zone valve end switch or other space
temperature control device.
1. Upon a call for heat: (a) the internal pump and
system pump will start; (b) the blower will begin a
30 second pre-purge.
2. Following the prepurge cycle the direct spark
ignition will spark and will begin a 4 second trial
for ignition. The unit is allowed one or three
ignition retries.
3. The gas valve will then be energized and a reduced
rate ignition will occur. The unit will remain in a
reduced rate start-up period for several seconds.
4. After the reduced rate start time is over, the unit
will be in normal operation. Firing rate will
modulate based on the heating load via the
temperature controller settings and readings.
5. When the call for heat is complete, or the unit reaches
its setpoint temperature, the gas valve will close, and
the fan will continue to run for its 20 second post-
purge. If a pump delay time is used, the pump will
continue to run for the specified amount of time
(adjustable from 0.1 to 10 minutes).
11.2.10 Gas Conversion
Brute Elite units can be converted from natural to
propane gas or from propane to natural gas easily in the
field. Some units require the addition of a gas orifice
along with proper gas valve adjustment. Other units
require no additional parts, only proper gas valve
adjustment. Please contact the Bradford White factory
for specific information regarding the gas conversion of
an appliance. If a gas conversion is performed, the unit
must be identified with the appropriate gas labels and a
conversion sticker to allow technicians performing
maintenance in the future to properly identify the gas
type of the appliance.
SIZE (MBTU)
80
KIT NUMBER
CA006201
CA006202
CA006203
CA006204
CA006204
CA006205
CA006207
CA006207
CA006207
CA006207
CA006207
12.2 Short Cycling
Because Brute Elite is a modulating boiler, and its
input will decrease when there is a reduction in heating
load, short cycling is greatly reduced. If the heating load
drops below the minimum input of the boiler for an
extended period, the boiler will have a tendency to short
cycle. This can be a symptom of improper control
strategy or setpoints, or a load distribution problem.
Brute Elite has a built-in anti-short cycle (ASC) feature.
ASC is a timed setting that will delay the boiler start for
a specified time after one call for heat is completed.
ASC time may be adjusted as desired (see Section 8 for
more information).
105
150
199
210
285
399
500
600
750
850
12.3 Error Codes - See Table 18.
Table 17. Propane Gas Conversion Kits.
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CODE# PROBLEM
PROBABLE CAUSE
SOLUTION
COMMON LOCKOUT CODES
27 Internal error
Flame rod to ground
Faulty flame detector
Faulty transformer
Check wiring / probe grounded, dirty probe
Clean or replace flame detector
Check/correct supply line voltage; replace faulty
transformer
47 Flame rod to ground leakage
49 24VAC voltage low/high
52 Motor tachometer fault
Faulty fan / fan wiring
fan circuit
Check fan harness wiring for continuity; replace faulty
53 AC inputs phase reversed
61 Anti short cycle
Reverse 24V hot/neutral - use common ground
Change ASC timer setting
Call for heat will be held
until timer resets
62 Fan speed not proved
63 LCI off
Dirty / defective fan
Safety chain interrupt
Clean or replace fan; check wiring
Check flow switch, aux high limit, LWCO, gas
pressure switches, condensate level and correct
problem
69 Outlet high limit
High limit tripped
Determine cause: low/no flow, valves closed, settings
and correct
79 Outlet high limit
80 DHW high limit
81 Delta T inlet/outlet limit
82 Stack limit
Check pump, time delay, valves closed, etc. and
correct overtemp
High limit reached
High limit reached
Could be caused by high ambient temperature, or
high return water temperature
88 Outlet T-rise limit
90 Heat exchanger high limit
91 Inlet sensor fault
High limit reached
Diagnose / repair cause of high temperature
92 Outlet sensor fault
93 DHW sensor fault
95 Stack sensor fault
Faulty sensor or wiring
Check wiring / replace sensor; condition can be
caused by short
96 OAT temperature sensor fault
temperature sensor
Faulty outdoor air
is open or shorted
Check wiring and sensor for short; replace sensor
105 Flame detected
out of sequence
Flame exists at burner
when it should not be
Clean burner of soot or other debris that could
maintain flame
106 Flame lost in MFEP
107 Flame lost early in Run
108 Flame lost in Run
109 Ignition failed
Unstable flame during
lighting / flame proving
sequence
Check venting, gas supply pressure, burner, fan, etc.
Problem with ignitor, or
other ignition-related device
Check / replace ignitor, wiring; check for shorting
in ignitor cable
113 Flame circuit timeout
Flame not established
within expected time limit
Check all combustion components; purge gas;
check ignition source
122 Lightoff rate proving failed
123 Purge rate proving failed
128 Fan speed failed / prepurge
129 Fan speed failed / preignition
130 Fan speed failed / ignition
Fan did not reach
expected RPM
Check fan wiring; replace fan
131 Fan movement detected
during standby
Fan should not be moving
when not powered
Check for common venting problems or otherwise
forced air
132 Fan speed failed during run
Fan lost or gained speed
during run sequence away
from control spec
Fan overheating or otherwise failing; check cable;
replace fan
137 ILK failed to close
No power at interlock ILK
Check J5 pin 1 for power - if no power, confirm
safeties are closed
continued next page >
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CODE# PROBLEM
PROBABLE CAUSE
SOLUTION
ALERT CODES
49 Maximum cycle count
was reached
Control operates correctly,
however the cycle count will
not increment any higher
than 999,999 cycles
Replace controller or adjust the count using blue display
50 Maximum hours count
was reached
Control operates correctly,
however the hours count will
not increment any higher
than 999,999 hours
248 CH outdoor temperature
was invalid
251 CH ODR max outdoor temp-
erature setpoint was invalid
Confirm outdoor reset
settings. An invalid
adjustment has been
made
252 CH ODR min outdoor temp-
erature setpoint was invalid
253 CH ODR min water temp-
erature setpoint was invalid
Adjust setting to within appropriate range
254 CH ODR temperature range
was too small
Increase Outdoor air temp-
erature min and max values
to a difference greater than
22°F (12°C)
(min. 12°C / 22°F)
255 CH setpoint minus ODR
min water temperature was
too small (min. 12°C / 22°F)
Increase setpoint or
Increase Outdoor water
temperature min and max
values to a difference greater
than 22°F (12°C)
decrease min water temp.
565 Heat exchanger T-rise limit
was exceeded
Heat exchanger temperature Check for correct water flow
rise exceed
MISCELLANEOUS
Boiler will not stay lit
Indicates lack of flame signal, Check flame detector wiring; clean / replace flame
check fault code on display
detector
Boiler bangs, knocks, hisses
Insufficient water flow /
Check for proper flow, follow piping guidelines in
pump failure; improper piping manual; replace pump; improper glycol percentage
(see Section 4.3)
Flame pulsates, venting
noise or has difficulty lighting
Insufficient / improper
venting; dirty burner; air in
gas line; dirty heat exchanger
Ensure venting complies with Section 2
980 Display error
981 Display error
Communication error
between the control
and display.
Check wiring and connectors. Possible software
revision incompatibility.
Communication error
between the control
and display.
Check wiring and connectors. Possible software
revision incompatibility.
Table 18. Error Codes.
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Figure 35. Jacket Components.
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Figure 36A. Internal Components, Sizes 80–210.
Figure 36B. Internal Components, Sizes 285–600.
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Figure 36C. Internal Components, Sizes 750-850.
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Figure 37A. Gas Train Components, Sizes 80-500.
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Figure 37B. Gas Train Components, Sizes 600-850.
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Figure 38. Heat Exchanger Components.
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Figure 39. Electrical Components.
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Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement.
®
Ambler, PA 19002
Tech. Service (800) 334-3393
Service Parts (800) 538-2020
Warranty Service (800) 531-2111
Litho in U.S.A. © Bradford White 1102 Document 1243
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