Bradford White Corp Boiler BJVS User Manual

InstallationandOperationInstructions

Document1242

Installation and Operation

Instructions for

BRUTE M INI

Residential

Gas-Fired

Hydronic Boilers

Models BJVS, BJVT

Sizes 50-225

U.S. Patent No. 1,609,692

Canada Patent No. 383,318

Vent damper is optional in some provinces of Canada.

These instructions are to be stored in the packet

provided on the boiler.

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,

qualified in hot water boiler installation and maintenance. Improper installation and/or operation could

create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.

Improper installation and/or operation will void the warranty.

AVERTISSEMENT

WARNING

Assurez-vous de bien suivres les instructions

If the information in this manual is not

données dans cette notice pour réduire au

followed exactly, a fire or explosion may

minimum le risque d’incendie ou d’explosion ou

result causing property damage, personal

pour éviter tout dommage matériel, toute

injury or loss of life.

blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ni

Do not store or use gasoline or other

d’autres vapeurs ou liquides inflammables dans

flammable vapors and liquids in the vicinity

le voisinage de cet appareil ou de tout autre

of this or any other appliance.

appareil.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Immediately call your gas supplier from a

nearby phone. Follow the gas supplier's

instructions.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas vous

servir des téléphones dansle bâtiment où vous

vous trouvez.

• Appelez immédiatement votre fournisseur de

gaz depuis un voisin. Suivez les instructions

du fournisseur.

• If you cannot reach your gas supplier, call

the fire department.

• Si vous ne pouvez rejoindre le fournisseur de

gaz, appelez le sservice des incendies.

Installation and service must be performed by

a qualified installer, service agency, or gas

supplier.

L’installation et l’entretien doivent être assurés par

un installateur ou un service d’entretien qualifié ou

par le fournisseur de gaz.

238-49219-00A REV 4/11

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All boilers must be installed in accordance with

the local building and installation codes as per the

utility or authorities having jurisdiction. All local

codes take precedence over national codes.

In the absence of local codes, refer to the

SECTION 1.

General Information

1.1 Introduction

following national codes for installation:

This manual provides information necessary for

the installation, operation, and maintenance of Model

BJV copper tube hydronic boilers.

1. In the United States, the latest edition of "The

National Fuel and Gas Code", ANSI Z223.1.

Specifically, refer to Chapter 10, "Venting of

Equipment".

All application and installation procedures

should be reviewed completely before proceeding with

the installation. Consult the factory, or local factory

representative, with any problems or questions

regarding this equipment. Experience has shown that

most operating problems are caused by improper

installation.

2. In Canada, the latest edition of "The Installation

Codes for Gas Burning appliances and

Equipment", CSA B149.1.

Any changes to the boiler, gas controls, gas

orifices, wiring, draft diverter, or improper installation

may void the warranty. If change is required to any of

the above, consult the factory.

These boilers are available in two configurations;

the BJVT has a thermocouple/continuous burning pilot,

and the BJVS has an electronic intermittent ignition

device (I.I.D.). Look for the model designation on the

rating plate, which can be found on top of the boiler in

the right rear corner.

The automatic vent dampers are standard on all

U.S. and Canadian models. The side wall power

venters can be used on both BJVS and BJVT models.

Special instructions for their installation are included

in the vent damper and power venter package. Read

them carefully before installation.

1.4 Technical Assistance

Consult Bradford White or your local factory

representative with any questions or problems

involving the specifications, installation, and operation

of your equipment. An experienced technical support

staff is ready to assist you in assuring the proper

performance and application of products. For

technical support call the Bradford White Technical

Service Department.

1.2 Warranty

Model BJV boilers are covered by a limited

warranty. The owner should fill out the warranty

registration card and return it to .

1.5 Materials Installer Must Provide

1.5.1 Materials for All Installations

The following items are needed and are to be

supplied by the installer for all Brute Mini boiler

installations:

1. The correct size gas pipe to supply the gas to the

boiler (see Section 4.1 for correct gas pipe size).

2. A CSA listed manually operated gas valve to be

installed in the gas line outside of the boiler

jacket.

3. A suitable gas union joint or other removable

connector to connect the boiler to the gas line

outside of the boiler.

4. Plumbing items needed to provide a sediment

trap (drip leg) in the gas line between the manual

gas valve and the union to the boiler.

5. A 115 VAC power supply. A junction box is not

needed at the boiler, connections are made inside

of the boiler’s control panel (see Figure 8).

6. Vent pipe of the same or larger diameter as the

vent damper or draft diverter outlet (see Section

3.3 for venting instructions).

All warranty claims must be made to an

authorized representative or directly to the factory.

Claims must include the boiler serial number and

model (this information can be found on the

rating plate), installation date, and name of the

installer. Shipping costs are not included in the

warranty coverage.

Some accessory items are shipped in separate

packages. Verify receipt of all packages listed on the

packing slip. Inspect everything for damage

immediately upon delivery, and advise the carrier of

any shortages or damage. Any such claims should be

filed with the carrier. The carrier, not the shipper, is

responsible for shortages and damage to the shipment

whether visible or concealed.

The warranty does not cover damage caused by

improper assembly installation, operation or field

modification.

1.3 Codes and Standards

1.5.2 Materials for Most Installations

In addition to the items listed above, the

following items may be needed:

The BJV Hydronic Boiler (or Brute Mini) is

design certified by CSA (Canadian Standards

Association) as complying with the latest edition of

the “Standard for Gas Fired Low Pressure Steam and

Hot Water Boilers”, ANSI Z21.13 in the USA and

CAN1-4.9 in Canada.

1. Plumbing materials for the bypass piping, which

is required for:

a. Any system where the return water

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temperature may be less than 120°F, such

as in-floor radiant systems, snow melt

systems or other systems where a “cold

start” is expected frequently due to

12. Modification of Boiler for High Altitude:

Brute Mini Boilers are normally shipped from the

factory in the low altitude (sea level) operational

configuration. When requested, the boilers can be

configured and shipped for higher altitudes. For

field conversions to change altitude

thermostat setbacks, etc. See Figure 11.

b. Any system where the temperature rise

across the heat exchanger is above 30°F

(see Section 5 and Figure 7).

configurations, conversion parts are available

from. For more information or call the Customer

Service Department.

2. Combustion air grates for openings sized in

accordance with Section 3.1.

3. Field interlock wiring for any motorized

combustion air louvers to ensure the boiler does

not fire if motorized louvers do not open.

4. A suitable non-combustible base if installed on a

combustible floor (see Section 2.3.2)

1.5.3 Diagnostic Tools

1.6.2 Dimensions

See Figure 1 for a diagram showing the boiler’s

exterior dimensions and dimensions to critical

connections on the boiler.

The following materials are needed to verify

correct installation:

1. Gas manometer to verify gas pressure

2. Strap-on, digital or infrared thermometer to

check temperature rise across the heat exchanger.

3. Suggested: Draft gauge and combustion test

equipment.

SECTION 2.

Installation Instructions

2.1 Introduction

WARNING

Improper installation or maintenance can cause

nausea or asphyxiation from carbon monoxide in

flue gases which could result in severe injury, or

death.

1.6 Specifications

1.6.1 General Specifications

1. InstallationLocation:

Certified for use in Indoor Applications only

2. Minimum Clearance From Combustible

AVERTISSEMENT

Une installation ou un entretien in adéquat peut

causer la nausée ou l’asphyxie en raison du

monoxyde de carbone présent dans les gaz de

combustion et même entrainer des blessures

graves ou la mort.

Material:

See Table 1 in Section 2.3.1.

3. Supply Gas Type:

Certified for use with Natural Gas and LP Gas

4. Gas Pipe/Boiler Gas Valve Connection:

Nat

½" NPT

Install the Brute Mini boilers and vent dampers in

accordance with the procedures in this manual, local

codes and ordinances, and in accordance with the

latest edition of the appropriate national code (see

Section 1.3 “Codes and Standards”).

50-225

½" NPT

5. Inlet Gas Supply Pressure:

Minimum

Maximum

10.5" WC

13.0" WC

Natural Gas:

LP Gas:

5.5" WC

10.0" WC

All gas-fired products require correct installation

to assure safe operation. The requirements for boilers

include the following:

6. Water Pipe/Boiler Connection:

1¼" NPT

7. Water Flow Rate:

See Table in Section 5.2

1. Field assembly

2. Appropriate site location (clearances) and

flooring

8. Pressure Relief Valve:

30 PSI

3. Sufficient combustion and ventilation air

4. Properly sized gas meter and piping

5. Proper electrical wiring (if required)

6. Adequate water flow

9. Recommended system pressure:

12 PSI

10. Exhaust Vent Connection Size:

This manual provides the information needed to

meet these requirements. Review all application and

installation procedures completely before continuing

the installation.

NOTE: The Brute Mini boiler is approved for indoor

installation only.

4" Diameter

75-100 5" Diameter

125-160 6" Diameter

225

7" Diameter

11. Electrical Supply:

115 Volts AC

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Dimensions in inches cm

Dimensions

Water Gas

inches cm

Conn. Conn.

in.

1/2

Size*

100

125

160

225

13-3/8 34

16-7/8 43

20-3/8 52

25-5/8 65

27-3/4 71

28-3/4 73

31-1/2 80

23-5/8 60

24-1/8 61

23-5/8 60

23-1/4 59

21-3/4 55

22-3/4 58

23-3/4 63

26-1/2 67

27-1/2 70

1-1/4

1/2

*3/4**

* Values shown are for both BJVS and BJVT Models

**1/2 for propane

Figure 1. Dimensional Information.

2.2 Field Assembly

1. Brute Mini boilers have built-in draft diverter for

natural draft operation.

2. Find the vent damper box which is located in the

boiler package.

3. Install the vent damper directly to the top of the

draft diverter outlet with the damper operator

facing to the front of the boiler, and with the flow

direction arrow pointing upward. Use the vent

damper wire harness provided with the boiler to

connect the vent damper to the boiler. The

bracket end of the harness should be connected

to the vent damper actuator.

4. For Model BJVS only: Install the metal plug

provided with the vent damper onto the damper

plate hole. Disregard the metal plug in case of

standing (continuous) pilot boilers. For all

BJVT models, the damper plate hole should

never be blocked.

5. Do not modify the automatic vent damper

device. It is very important that no other vents

are closed. Provide at least six inches clearance

between the automatic vent damper and

combustible construction, and be sure to allow

access for servicing the damper.

Figure 2. Field Assembly Items.

6. Install the temperature/pressure gauge provided

in the parts box.

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Caution

Do not force motor operation when operator is

fastened to the damper by moving the damper

blade, turning the shaft or by turning the position

indicator.

6 15

Attention

Ne pas tourner le registre manuellement avec ou

sans courant électrique ou le moteur sera

endommagé.

Dimensions in inches cm.

*6" for models BJV160 to BJV225.

Figure 3. Closet and Alcove Installation (see Table 3).

2.3.2 Flooring

2.3.1 Clearances

The boiler shall be installed on a level floor of

noncombustible construction or on fire-resistant slabs

or arches. Noncombustible flooring is defined as

flooring material and surface finish not capable of

being ignited and burning and with no combustible

materials against the underside. Acceptable materials

are those consisting entirely of a combination of steel,

iron, brick, tile, concrete, slate, glass or plaster. Do

not install the heater directly on a combustible wood

or carpet floor without placing a noncombustible

platform between the floor and the heater.

The boiler must be placed to provide clearances

on all sides for maintenance and inspection. There

must also be minimum distances maintained from

Boiler Sizes

Clearances

Left side

Right side

Rear

50-125

160-225

Front

Flue

Top

The boiler can be installed on a combustible

floor if a noncombustible base assembly, available

from , is used. See the boiler rating plate or the Parts

List (Section 11) of this manual for the appropriate

base part number. Boilers must never be installed

directly on carpeting.

As an alternative to the noncombustible base

plate, in the United States, the National Fuel Gas Code

allows a heater to be placed on a combustible surface

when there is a platform under the heater made of

hollow masonry no less than 4 inches (102 millimeters

[mm]) thick, covered with sheet metal at least 24

gauge thick and extending beyond the full width and

depth of the heater by at least 12 inches (305mm) in

all directions. The masonry must be laid with ends

unsealed, and joints matched to provide free

circulation of air from side to side through the

masonry (see Figure 4). If the boiler is installed in a

carpeted alcove, the entire floor of the alcove must be

covered by a noncombustible platform.

Note: Clearances listed in Table 1 are manufacturer’s tested values.

These are given as minimum values. Where local and national codes

apply, and values are different than those listed in Table 1, use the

greater value to ensure safe operation.

Table 1. Minimum Boiler Clearances

From Combustible Surfaces.

Dégagements Minimaux à Assurer Entre Ics Parois de

L’appareil et leo Constructions Combustibles

combustible surfaces (see Table 1).

At least 15" (381mm) access must be available

in front of the boiler for burner removal. Consult local

codes for clearances to hot water pipes and

accessories.

If the boiler is to be installed in a garage, all

burners and burner ignition devices must have a

minimum 18" (457mm) clearance above the floor.

The Model BJV-50 through BJV-100 boilers can

be installed in a closet, as long as the minimum

clearances shown in Table 1 and Figure 3 are

observed. Special attention should be paid to

clearances between the front of the boiler and the

closet door when it is closed.

Consult the American National Standard Z21.13

for more information concerning closet installations.

In Canada, refer to the latest edition of CSA-B149.1.

Figure 4. Typical Combustible Floor Installation.

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Inside Air Supply: When combustion is

SECTION 3.

Venting

supplied from inside the building, each opening should

have a minimum free area of one square inch per 1,000

BTU/h (0.3kW) input of the total input rating of all

appliances in the enclosed area. These openings

should never be less than 100 square inches

(645 sq. cm).

3.1 Combustion Air Supply

The boiler location must provide sufficient

air supply for proper combustion, and ventilation

of the surrounding area as outlined in the latest

edition of ANSI standard Z223.1 or in Canada,

CSA-B149.1, and any local codes that may be

applicable.

Note: In Canada, follow Canadian Standard, CSA-

B149.1 or local codes.

Exhaust Fans or Vents: Any equipment which

exhausts air from the boiler room can deplete the

combustion air supply or reverse the natural draft

action of the venting system. This could cause flue

products to accumulate in the boiler room. Additional

air must be supplied to compensate for such exhaust.

The information in Table 2 is not applicable in

installations where exhaust fans or blowers of any

type are used. Such installations must be designed by

qualified engineers.

In general, these requirements specify that boiler

rooms which represent confined spaces should be

provided with two permanent air supply openings; one

within 12 inches (305mm) of the ceiling, the other

within 12 inches (305mm) of the floor (see Table 2).

Outside Air Area*

Inside Air Area*

Inside Air

Outside Air

Boiler Size

Sq. In.

sq cm

Sq. In. sq cm

Area in Sq. In.* (sq cm)

Area in Sq. In.*

If a blower or fan is used to supply air to the

boiler room, the installer should make sure it does not

create drafts which could cause nuisance shutdowns of

the pilot. If a blower is necessary to provide adequate

combustion air to the boiler, a suitable switch or

equivalent must be wired into the boiler control circuit

to prevent the boiler from firing unless the blower is

operating.

100

125

160

225

645

129

161

206

258

387

100

125

160

225

645

807

1032

1452

The boiler must be completely isolated and

protected from any source of corrosive chemical

fumes such as those emitted by trichlorethylene,

perchlorethylene, chlorine, etc.

*Area indicated is for one of two openings; one at floor level and

one at the ceiling, so the total net free area would be double the

figures indicated. For special conditions, refer to NFPA54 ANSI

Z223.1. In Canada refer to the National Standard CSA B149.1

which differs from this table.

NOTE: Check with louver manufacturers for Net Free Area of

louvers. Correct for screen resistance to the Net Free Area if a

screen is installed. Check all local codes applicable to

combustion air.

WARNING

Do not store any chemical, cleaners, or other

corrosive material near combustion air openings or

in the room. Avoid locating dryer vents in the vicinity

of combustion air openings. Failure to prevent

corrosive materials from mixing with combustion air

can result in reduced boiler life and unsafe boiler

operation.

Table 2. Minimum Recommended

Air Supply to Boiler Room.

Important: See gas piping selection chart, Table 3 for

gas line sizing. In all cases, pipe size is larger than inlet

connection on heater. Run pipe size shown in chart and

reduce at heater inlet.

AVERTISSEMENT

Outside Air Supply: When combustion air is

supplied directly through an outside wall, each opening

should have a minimum free area of one square inch per

4,000 BTU/h (1.2kW) input of the total input rating of

all appliances in the enclosed area.

N’entrepposeraucunproduitchimique,produit

nettoyant ou produit corrosif à proximité des

bouches d’air de combustion ou dans la pièce.

Éviter de placer des tuyaux de ventilation pour

sécheuse à proximité des bouches d’air de

combustion. Le fait de laisser des maitières

corrosives se mélanger à l’air de combustion risque

de réduire le cycle de vie de l’appareil de chauffage

et de compromettre son fonctionnement.

If air is provided through horizontal ducts,

each opening and duct must provide one square inch

of flow area for each 2000 BTU/h (0.6 kW). These

requirements are summarized in Table 2. Note that

the required size of openings shall be based on the

net free area of each opening. Where the free area

of louver or grille is known it shall be used in

calculating the effective free area. Where the free

area are not known, it shall be assumed that wood

louvers will have 25 percent free area, and metal

louvers and grilles will have 75 percent free area.

3.2 Exhaust Venting

Vent piping must be of the same or larger

diameter as the vent damper or draft diverter outlet.

The only correct procedure for vent pipe sizing is to

do so in accordance with Table 3 and the applicable

installation code as stated in the following warning.

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Do not weld or fasten the vent pipe to the boiler

draft diverter. The weight of the stack must not rest on

the boiler. The draft diverter and boiler top must be

easily removable for normal boiler service and

inspection.

WARNING

Vent pipe diameter must be as required by the

National fuel Gas Code Z223.1 or the Canadian

Installation Codes for Gas Appliances CSA-B149.1.

Undersize pipe can result in inadequate venting

and oversize pipe can result in vent condensation.

In either case the result can be release of

combustion products to the indoors. This can cause

serious injury or death by carbon monoxide

poisoningorasphyxiation.

Avoid horizontal runs of the vent pipe, and 90°

elbows, reductions and restrictions. Horizontal runs

should have at least a 1/4" rise per foot (20mm per

meter) in the direction of flow. A vent connector shall

be supported for the design and weight of the material

employed to maintain clearances and prevent physical

damage and separation of joints.

AVERTISSEMENT

Avoid terminating boiler vents near air

Le diamètre des tuyaux de ventilation doit répondre

aux exigences du National Fuel Gas Code Z223.1

ou du code canadien des installations des appareils

à gaz CSA B149.1. Des tuyaux trop petits rispquent

d’entraîner une ventilation inadéquate et des tuyaux

trop gros risquent de provoquer une condensation

dans les tuyaux. Dans un cas comme dans l’autre,

des produits de combustion risquent de s’échapper

dans le bâtiment et causer des blessures graves ou

l’asphyxie par le monoxyde de carbone.

conditioning or air supply fans. The fans can pick up

exhaust flue products from the boiler and return them

inside the building, creating a possible health hazard.

Do not located the vent terminal where flue products

could strike against building materials and cause

degradation.

Always use double-wall or insulated vent pipe

when used as a chimney (Type B or equivalent). In

cold weather, uninsulated outside vents can chill the

rising flue products, blocking the natural draft action

of the venting system. This can create a health hazard

by spilling flue products into the boiler room. Use

engineered venting tables acceptable to the authority

having jurisdiction to size the venting pipe or liner.

Avoid oversize vent piping or extremely long

runs of the pipe which may cause excessive cooling

and condensation.

BJVS/BJVT

Size

Vent Pipe Diameter

inch

100

125

160

Before connecting a vent connector to a

chimney, the chimney passageway shall be examined

to ascertain that it is clear and free of obstructions.

When inspection reveals that an existing chimney is

not safe for the intended application, it shall be rebuilt

to conform to nationally recognized standards (see

National Building Code or ANSI/NFPA 211), lined or

relined with a suitable liner, or replaced with a vent or

chimney suitable for the equipment to be attached.

225

Table 3. Exhaust Vent Connection Size.

3.3 Vent Pipe Sizing and General

Installation

All vent installations and boiler stacking must be

designed and installed in accordance with all local,

state or provincial codes and with:

3.4 Common Venting Systems

3.4.1 Venting Multiple Appliances

When common venting BJVS or BJVT natural

draft boilers with other appliances through one shared

duct called a “common vent”, special care must be

taken by the installer to ensure safe operation. In the

event that the common vent is blocked, it is possible,

especially for fan-assisted devices, to vent backwards

through non-operating appliances sharing the vent,

allowing combustion products to infiltrate occupied

spaces. If the appliances are allowed to operate in

this condition, serious injury or death may occur.

1. Chapter 7, “Venting of Equipment” of the

national Fuel Gas Code, ANSI 223.1 latest

edition, or the applicable provisions of the local

building codes.

2. In Canada, CSA-B149.1.

The draft diverter outlet is to be connected to an

unobstructed vent pipe of the same or larger diameter,

terminating outside the building. The vent pipe must

have a listed vent cap and extend at least two feet

above any object with a ten foot radius. All

connections should be made with rustproof sheet

metal screws.

IMPORTANT NOTE: Do not use sheet metal screws

at the snap lock joints of Type B gas vents.

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At the time of removal of an existing boiler, the

WARNING

following steps shall be followed with each appliance

remaining connected to the common venting system

placed in operation, while the other appliances

remaining connected to the common venting system

are not in operation.

Operation of appliances with a blocked common

vent may lead to serious injury or death. Safety

devices must be implemented to prevent blocked

common vent operation. If safe operation of all

appliances connected to a common vent cannot be

assured, including prevention of spillage of flue

gasses into living spaces, common venting should

not be applied, and appliances should each be

vented separately.

1. Seal any unused openings in the common

venting system.

Sceller toutes les ouvertures non utilisées du

système d’évacuation.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is

no blockage or restriction, leakage, corrosion and

other deficiencies which could cause an unsafe

condition.

AVERTISSEMENT

Le fonctionnement des appareils avec un système

d’évacuation bloqué peut provoquer des blessures

graves, voire la mort. Des dispositifs de sécurité

doivent être installés pour éviter le blocage des

systèmes d’évacuation. Si le fonctionnement de

tous les appareils connectés à un système

Inspecter de façon visuelle le système

d’évacuation pour déterminer la grosseur et

l’inclinaison horizontale qui conviennent et

s’assurer que le système est exampt

d’obstruction, d’étranglement, de fuite, de

corrosion et autres défaillances qui pourraient

présenter des risques.

d’évacuation commun ne peut pas être assuré, y

compris la prévention de la dispersion des gaz

toxiques dans les espaces habités, on ne devrait

pas installer un système d’évacuation commun et

chaque appareil devrait être ventilé séparément.

3. Insofar as it is practical, close all building doors

and windows and all doors between the space in

which the appliances remaining connected to the

common venting system are located and other

spaces of the building. Turn on clothes dryers

and any appliance not connected to the common

venting system. Turn on any exhaust fans, such

as range hoods and bathroom exhausts, so they

will operate at maximum speed. Do not operate a

summer exhaust fan. Close fireplace dampers.

It is for this reason that, in addition to following

proper vent sizing, construction and safety

requirements from the National Fuel Gas Code, ANSI

Z223.1 or in Canada, from CSA B149.1 as well as all

applicable local codes, it is required that installers

provide some means to prevent operation with a

blocked common vent. It is suggested that a blocked

vent safety system be employed such that if the switch

from one appliance trips due to excessive stack spill or

backpressure indicating a blocked vent condition, that

all appliances attached to the vent be locked out and

prevented from operating. As an additional precaution,

it is recommended that a Carbon Monoxide (CO)

alarm be installed in all enclosed spaces containing

combustion appliances. If assistance is required in

determining how a blocked vent safety system should

be connected to a product, please call Applications

Engineering (see back cover for info).

Dans la mesure du possible, fermer toutes les

portes et les fenêtres du bâtiment et toutes les

portes entre l’espace où les appareils toujours

raccordés au système d’évacuation sont installés

et les autres espaces du bùtiment. Mettre en

marche les sécheuses, tous les appareils non

raccordés au systéme d’évacuation commun et

tous les ventilateurs d’extraction comme les

hottes de cuisinière et les ventilateurs des salles

de bain. S’assurer que ces ventilateurs

Refer to the installation and operating

instructions on all appliances to be common vented for

instructions, warnings, restrictions and safety

requirements. If safe operation of all appliances

connected to a common vent cannot be assured,

including prevention of spillage of flue gasses into

living spaces, common venting should not be applied,

and appliances should each be vented separately.

fonctionnent à la vitesse maximale. Ne pas faire

fonctionner les ventilateurs d’été. Fermer les

registres des cheminées.

4. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust

thermostat so appliance will operate

continuously.

3.4.2 Inspection of Commonly Vented

Appliances

Mettre l’appareil inspecté en marche. Suivre les

instructions d’allumage. Régler le thermostat de

façon que l’appareil fonctionne de façon

continue.

If the instrumentation of this boiler replaces an

older boiler in a common vent system with other

appliances, or if you remove additional appliances

from the common vent, all the appliances must be

checked for proper venting.

5. Test for spillage at the draft hood relief opening

after 5 minutes of main burner operation. Use the

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Page 10

flame of a match or candle, or smoke from a

SECTION 4.

cigarette, cigar or pipe.

Gas Connections

Faire fonctionner le brûleur principal pendant 5

min ensuite, déterminer si le coupe-tirage

déborde à l’ouverture de décharge. Utiliser la

flamme d’une allumette ou d’une chandelle ou la

fumée d’une cigarette, d’une cigare ou d’une

pipe.

4.1 Gas Supply and Piping

Review the following general instructions before

continuing the installation.

6. After it has been determined that each appliance

remaining connected to the common venting

system properly vents when tested as outlined

above, return doors, windows, exhaust fans,

fireplace dampers and any other gas burning

appliance to their previous conditions of use.

WARNING

The Brute Mini BJVS and BJVT boilers are designed

for use with either natural gas or LP gas. Check the

rating plate to be sure that the boiler is designed to

use the type of gas being supplied. DO NOT

ATTEMPT TO CONVERT THIS HEATER FOR

USE WITH ANY OTHER TYPE OF FUEL.

Une fois qu’il a été déterminé, selon la méthode

inidquée ci-dessus, que chaque appareil raccordé

au système d’évacuation est mis à l’air libre de

façon adéquate. Remettre les portes et les

fenêtres, les ventilateurs, les registres de

cheminées et les appareils au gaz à leur position

originale.

AVERTISSEMENT

Les appareils de chauffage à faibles sont conçus

pour être utillsés avec du gaz naturel ou du gaz de

pétrole liquéfié (GPL). Vérifiez l’information inscrite

sur la plaque signalétique du pour vous assurer que

l’appareil est conçu pour le type de gaz fourni. NE

PAS ESSAYER DE CONVERTIR CET APPAREIL

À UN AUTRE TYPE DE GAZ.\

7. Any improper operation of the common venting

system should be corrected so the installation

conforms with the National Fuel Gas Code,

ANSI Z223.1. When resizing any portion of the

common venting system, the common venting

system should be resized to approach the

minimum size as determined using the

1. Gas piping installation must be in accordance

with the latest edition of ANSI Z223.1 and all

local codes. In Canada, the installation must be

in accordance with CSA-B149.1 and all local

codes that apply.

appropriate tables in Appendix G in the National

Fuel Gas Code, ANSI Z223.1.

2. Check the gas supply to be sure that it is the

same as the gas indicated on the boiler’s plate.

Brute Mini BJVS and BJVT boilers, as shipped

from the factory, are certified to operate within

the altitude range indicated on the rating plate. If

a field conversion to a different altitude range

should be necessary, conversion parts are

available for changing the altitude range of the

heater. Contact factory for parts information.

Tout mauvais fonctionnement du système

d’évacuation commun devrait être corrigé de

façon que l’installation soit conforme au national

Fuel Gas Code, ANSI Z223.1 et (ou) aux codes

d}installation CSA-B149.1. Si la grosseur d’une

section du système d’évacuation doit être

modifiée, le système devrait être modifié pour

respecter les valeurs minimales des tableaux

pertinents de l’appendices F du National Fuel

Gas Code, ANSI Z2231.1 et (ou) des codes

d}installation CSA-B149.1.

Caution

Permanent damage to the gas valve will occur if the

following procedures are not followed.

Attention

Vous endommagerez la soupape de gaz si vous ne

respectez pas les procédures suivantes.

3. Use the figures in Table 4 to size the gas inlet

piping from the gas meter to the heater. Check all

local codes for compliance before installing the

heater.

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Page 11

Supply Pressure

Minimum

5.5 Inches WC 10.5 Inches WC

(1.3 kPa) (2.5 kPa)

10.0 Inches WC 13.0 Inches WC

(2.4 kPa) (3.1 kPa)

Maximum

Boiler Size

Distance

From Gas

Meter

100

125

160

225

Natural Gas

Pipe Size

0-50'

0-15m

50-100'

15-30m

100-200'

30-60m

LP Gas

1/2

3/4

1-1/4

Table 5. Gas Supply Pressure Requirements.

NOTE: The boiler and all other gas appliances

sharing the boiler gas supply line must be firing at

maximum capacity to properly measure the inlet

supply pressure. Low gas pressure could be an

indication of an undersize gas meter and/or

obstructed gas supply line.

1-1/4

*Note: These figures are for Natural Gas (.65 Sp. Gr.), and are

based on 1/2" water column pressure drop. Check supply

pressure with a manometer, and local code requirements for

variations. For LPG, reduce pipe diameter one size, but

maintain a 1/2" minimum diameter. A 'normal' number of Tees

and elbows have been taken into allowance.

8. The correct high fire burner manifold gas

pressure is stamped on the rating plate. The

regulator is pre-set at the factory, and normally

requires no further adjustment. For two-stage

units (BJVS 100-225) be sure unit is able to fire

at both high and low fire.

9. Before operating the boiler, the complete gas

supply system and all connections must be tested

for leaks using a leak detector solution. Do not

use an open flame.

Table 4. Natural Gas Pipe Size Requirements*

Gas Supply

Inlet

To Equipment

Inlet

Tee

Fitting

3 in.

(76mm) Min.

Nipple

Caution

Some leak test solutions (including soap and water)

may cause corrosion or stress cracking. Rinse the

piping with water after testing.

Cap

Figure 5. Typical design for a sediment trap/drip leg.

4. A sediment trap (drip leg) must be installed

ahead of the gas controls (see Figure 5). Fit the

trap with a threaded cap which can be removed

for cleaning.

5. Install a manual gas shutoff valve for service and

safety. Do not use a restrictive gas cock. Flexible

gas connectors, if used, must be CSA rated for

the total input rating of the boiler.

Attention

Certaines solultions d’essai d’étanchéité (y compris

l’eau et le savon) peuvent causer de la corrosion ou

de la fissuration. Rincez les tuyaux à l’eau apprès

l’essai d’étanchéité.

4.2 Special Precautions for LP Gas

LP Gas is heavier than air and can therefore

more readily collect or “pool” in enclosed areas if

provision for proper ventilation is not made. Be sure

to pay special attention to proper ventilation for LP

gas. Locate boilers a safe distance from LP gas

cylinders and filling equipment. In the United States,

consult the “National Fuel Gas Code” (NFPA 54 /

ANSI Z223.1, latest edition) or in Canada, the

Propane Installation Code (CSA-B149.1), any local

codes and fire protection authorities about specific

installation restrictions in your area.

6. Disconnect the boiler and its individual shutoff

valve from the gas supply system during pressure

testing of the system at pressures higher than 1/2

pounds per square inch (psi) (3.45 kilopascals

[kPa]). If the test pressure is equal to or less than

1/2 psi (3.45 kPa), close the manual shutoff

valve on the heater during the piping pressure

test.

7. If the gas supply pressure is less than required,

check for undersized pipe between the meter and

the boiler, a restrictive fitting, or an undersized

gas meter. Gas supply pressures to the heater are

listed in Table 5.

NOTE: The maximum inlet gas pressure must not

exceed the specified value. The minimum value

listed is for the purpose of input adjustment. Refer

to Table 5.

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A full sized, 1¼" bypass with balancing valves is

strongly recommended for all systems, and required

when: 1) the boiler is installed without primary-

secondary piping in a multiple zone system; 2) when

the return water temperature can be expected to be

lower than 120°F (44°C); or 3) whenever the system

piping on the outlet side of the boiler may allow

reduced flow through the heat exchanger, causing

excessive temperature rise (see Section 5.2).

Note: Bradford White strongly recommends a

primary/secondary piping system for all installations,

especially sizes 125, 160 and 225. In this system, a

circulator is dedicated to pumping the boiler only. This

circulator should be sized for the boiler head loss and

flow rate.

SECTION 5.

Water Connections

5.1 Water Piping

Figure 6 shows ‘typical’ plumbing installations.

Be sure to provide unions and isolation valves at the

boiler inlet and outlet so it can be isolated for service.

Check local codes for specific plumbing requirements

before beginning the installation.

An ASME pressure relief valve is supplied on all

BJV boilers, and is pre-set at 30 PSI. The valve outlet

piping must discharge to a drain. Under no

circumstances should the relief valve piping be a

closed circuit.

A pressure reducing valve (automatic feed) must

be used to maintain system at constant proper pressure

(see Figure 6). Supply properly installed purge valves

to eliminate air from each circuit.

A drain valve is supplied with the boiler, and can

be found in the plastic bag shipped with each boiler.

This valve is to be installed on the lower right side of

the boiler, see Figure 1, and is used for draining the

unit. To drain the boiler completely, open the drain

valve and remove the two drain plugs located on

the lower left side of the boiler.

All precautions must be taken by the installer to

insure that a maximum temperature rise through the

boiler does not exceed 30°F (17°C). The temperature

rise on boilers installed in multi-zone systems using

zone valves must be taken when the zone of the

longest length and/or the zone of the highest head loss

is open.

A full size, 1¼" diameter by-pass with

balancing valve must be installed if a return water

temperature below 120°F (44°C) is expected under

operating conditions regardless of boiler size. This

may be expected in many systems, including in-

floor radiant and snow melt systems.

Be sure to include air vent devices located at the

highest point in the system to eliminate trapped air,

and an air elimination device near the outlet side of

the BJV boiler. Manual vent valves are recommended.

Hot water piping should be supported by suitable

hangers or floor stands, NOT by the boiler. Due to

expansion and contraction of copper pipe,

consideration should be given to the type of hangers

used. Rigid hangers could transmit noise through the

system caused by the piping sliding in the hangers. It

is recommended that padding be used when rigid

hangers are installed.

Adjusting the bypass:

Refer to figure 7. Provide a means of measuring

temperature on the inlet pipe to the boiler such as

using a strap on or infrared themometer. Starting with

both balancing valves fully open, start the boiler.

Adjust the balancing valve on the return to the system

slowly to provide 120°F (44°C) water at the inlet to

the boiler, leaving the bypass balancing valve fully

open. As the system warms up, this valve may need to

be adjusted open. In rare cases, this valve will have to

be kept fully open, and the bypass balancing valve

adjusted toward closed to prevent heated bypass water

from satisfying the call for heat when the system is up

to temperature.

Gas piping should also be supported by suitable

hangers or floor stands, not the boiler.

A properly sized expansion tank must be

included in the system. offers an aircharged

diaphragm-type expansion tank, with an automatic

feed valve, which includes a pressure regulator set at

12 psig. The part numbers are:

Less Than 20 Gallons in System A0066800

20 to 45 Gallons in System

A0066900

5.2 Alternate Auto-Bypass Operation

Use of the themostatic union, p/n 2400-030, can

provide automatic bypass operation in primary -

secondary piped systems (but cannot be used when

primary - secondary piping is not used). The

thermostatic union is installed on the outlet piping,

after the bypass assembly. It can be used in place of a

balancing valve. It opens fully at 140°F (see Figure 6).

Contact the factory for more information.

5.1.1 By-pass Piping

The following information and suggestions are

made on by-pass piping as it affects the temperature

rise at the boiler. A boiler temperature rise must be

taken on all BJV boiler installations. If the temperature

rise exceeds 30°F (17°C) at full rate, it is an indication

that the boiler is not receiving adequate water flow.

Check the pump for any obstruction, replace the pump

with a larger size where necessary, or install a system

by-pass as indicated in Figures 6 and 7.

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Page 13

Figure 6. Typical Plumbing Installations.

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Multi-Zone

BJV

Boiler

BJV

Boiler

Valve System

Single Circuit System

Multi-Zone

BJV

Boiler

Pump

System

Figure 6A. Typical Plumbing Installations.

Air Scoop

Pump

System

Loop

Feed

Water

Expansion

Tank

Figure 6B. Typical Plumbing Installations.

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Page 15

water temperature is 160°F (71°C), and the outlet

temperature is 180°F (82°C) at Normal Input Rate

from the rating plate. That means there is a 20° (11°C)

temperature rise through the boiler. According to

Table 1, that would indicate a flow rate of 8 GPM

(0.5L/S). Temperature rise must be measured with the

longest (highest head) zone calling for heat alone.

Other factors to be considered before selecting a

pump are pipe size, the number of fittings throughout

the system, smoothness of the interior surface of the

pipe, the quantity of water flowing through the pipe,

whether a glycol solution is being used, and the total

length of piping in the system. Table 7 provides

examle pump selection criteria using Type L copper

piping, one zone valve and up to eight elbows for

single zone systems. Consult the factory or a qualified

system designer if you have more fittings, different

size or type of pipe (especially in retrofit situations),

or some other unique system configuraiton not

illustrated in this manual.

System

From

System

Balancing

Valve

Balancing Valve

or optional

thermostatic union,

P/N 2400-030.

(Primary/Secondary

only)

(Return)

Out

(Supply)

Drip

Leg

Left Side View

1/2" Pipe

3/4" Pipe

1" Pipe

1-1/4" Pipe

A full size by-pass must be installed.

Size Pump

H.P.

Pump

H.P.

Pump

H.P.

Pump

H.P.

Figure 7. By-pass Piping.

1/25 1/12 1/25 1/12 1/6 1/25 1/12 1/6 1/25 1/12 1/6

50 50 99 390 680

5.3 Flow Requirements

35 160 300 460 640

All high recovery, low volume water boilers must

have adequate flow for efficient operation. Pump

selection is critical to this goal, and pumps should be

selected to provide for system design water

100

125

160

225

77 150 260 330 620

27 80 140 170 360 600

72 57 160 330 190 480

110

69 330

temperature rise. Table 6 details temperature rise and

water flow (GPM) for the Brute Mini boilers.

*Acirculatorand/orprimary/secondarypipingarerequired.Consult

factory.

1. Chart is based on 30°F (17°C) maximum temperature rise.

Damage from improper flow is not warranted.

2. Calculations are based on Type L copper tubing with one

Failure to insure proper water flow through the

heat exchanger of the boiler will void the warranty.

Flow can be verified by measuring the difference in

water temperatures between the boiler inlet and outlet.

For example: For a BJV-100 installation, the inlet

zone valve and eight elbows.

3. Typical circulating pumps: ¹/₂₅HP=Taco 007, B&G LR-20 or

SLC-25, Grundfos UP15-42F, or equivalent. ¹/₁₂HP=B&G LR-

12, Grundfos UP26-42F, or equivalent. ¹/₆HP=B&G series

HV, Grundfos UP43-75, or equivalent.

Table 7. Maximum Suggested Circuit Length in Feet.

15°F 8°C

20°F 11°C

Flow Rate

25°F 14°C

Size

Flow Rate

Headloss

Flow Rate

Headloss

gpm

l/s

gpm

l/s

gpm

l/s

100

125

160

225

5.3

10.7

13.3

0.3

0.5

0.7

0.8

1.1

1.5

0.3

0.6

1.3

2.2

2.5

0.1

0.2

0.4

0.7

0.8

1.5

12.8

0.3

0.4

0.5

0.6

0.8

1.1

0.2

0.3

0.7

1.3

1.8

3.1

0.1

0.2

0.4

0.5

0.9

3.2

4.8

6.4

10.2

14.4

0.2

0.3

0.4

0.5

0.6

0.9

0.1

0.2

0.5

0.8

1.2

1.9

0.1

0.2

0.4

0.6

gpm = Water Flow in gallons per minute. l/s = Water flow in liters per second.

ft = Pressure drop (headloss) through the boiler in feet of water. m = Pressure drop (headloss) through the boiler in meters of water.

Notes: 1. Shaded area is the recommended flow and temperature rise.

2. Temperature rise and associated flow rates are based on high fire operation at the Normal Input Rate from the rating plate.

Table 6. Temperature Rise °F °C.

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5.4 Chilled Water Systems

6.1 General Information

If the boiler is installed in conjunction with

refrigeration systems, it shall be installed so that the

chilled medium is piped in parallel with the heating

boiler with appropriate valves to prevent the chilled

medium from entering the heating boiler.

Wiring connections must be made exactly as

shown in the wiring diagram found on the inside of the

control box cover (see Figure 8). The boiler must

include a definite means of grounding. There is a

bonding lug, where a bond wire must be attached.

When boiler piping is connected to heating

coils, which are in close proximity to refrigerated air

circulation, there must be flow control valves or other

automatic methods to prevent gravity circulation of

the boiler water during the cooling cycle.

Pump Relay

Transformer BLK

Power

Supply

115V AC

60 Hz

GRN - Ground

BLK - Hot

WHT - Neutral

5.5 Oxygen Permeable Systems

The BJV boiler must not be direct connected to a

heating system utilizing oxygen permeable tubing.

Provide a water-to-water heat exchanger between

systems to prevent corrosion of ferrous metals such as

the boiler’s piping wet walls, etc. Air elimination

devices are not sufficient protection, and corrosion

damage is not covered under the limited warranty.

To Pump

115V AC

3/4 H.P.

Max

WHT - Neutral

BRN - Hot

On = Call

for heat

115V Field Wiring

115V Factory Wiring

BRN WHT

Figure 8. Field Wiring Connections.

5.6 Anti-Freeze

Non-toxic heating system anti-freeze may be

added to the hydronic system provided the

concentration does not exceed 50%, and the anti-

freeze contains an anti foamant. Follow the anti-freeze

manufacturer’s recommendations for yearly or

biannual replacement of system anti-freeze.

6.2 Main Power

Electrical wiring must be in accordance with the

latest edition of the National Electric Code (NEC),

ANSI/National Fire Protection Association (NFPA)

70, unless local code requirements indicate otherwise.

The heater comes factory-wired intended for

use with 115 Volt, 60 Hz AC field electrical supply.

Making electrical connections must be done by a

certified electrician only, as with all wiring. Be sure

that the power source to the heater is turned off or

disconnected before servicing.

SECTION 6.

Electrical

WARNING

ELECTRICALSHOCKHAZARD. Thisboiler

contains wiring that carries high voltage. Contact

with these wires may result in severe injury or

death.

To wire the Brute Mini boiler to a 115V / 60

Hertz (Hz) electrical source:

1. Remove the two screws attaching the front cover

of the control box.

2. There are four wires coiled in the area on the

right side of the control box, supplied with wire

nuts: 2 black wires twisted together, a white wire

and a brown wire (see Figure 8).

AVERTISSEMENT

POSSIBILITÉ DE CHOCS ÉLECTRIQUES. Ce

système de chauffage contient du filage de haut

voltage. Un contact avec ces fils peut résulter en

des blessures sérieuses ou la mort.

3. Follow the schematics in Figure 9. Remove the

wire nut from the two black wires, and connect

the hot lead from a 115V power supply to both

wires. Secure the three wires with the wire nut.

The white, neutral wire should be joined to the

other neutral lead coming from the 115V power

supply, and the neutral lead coming from the

pump. The brown wire attaches to the hot side of

the pump.

Caution

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation. Verify proper operation after

servicing.

Attention

Au moment de l’entretien des commandes, étiquetez

tous les fils avant de les débrancher. Des erreurs de

câblagepeuvententraînerunfonctionnement

inadéquatetdangereux.

NOTE: No external junction box is required.

4. Attach the leads from the wall thermostat to the

R and W terminals on the terminal strip, located

on the left side of the control box.

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Page 17

Figure 9a. Wiring Diagram, Spark Ignition System (BJVS 50 & 75).

5. When using a or field supplied power venter, the

proving switch must be connected in series with

thehi-limit.

110V

Hot

110V

Neutral

Space Heating

Pump

(Field Supplied)

Zone

Pump

Relay

6. Check the boiler wiring and pump for correct

voltage, frequency and phase. If the pump circuit

is other than 115V, be sure there is an

appropriate transformer or relay installed. The

pump relay is suitable for pumps of ¾ HP or

less.

115V

24V

7. For systems with multiple zone pumps or valves,

see Figure 10.

Fuse

A means of disconnecting the electrical supply

must be provided within sight of the boiler. The pump

and boiler must be wired as shown to insure that the

pump is running whenever the boiler is firing.

Thermostat

Field

Supplied

Zone

Pump

Relay

Boiler

Terminal

Boiler

Terminal

Zone

Pump

Relay

Boiler

Terminal

Optional

Aquastat

High

Limit

Zone

Pump

Relay

Vent

Damper

Receptacle

Ignition Control

MV/

Power

Venter

Receptacle

24V

MV GND GND

Jumper

24V PV

Roll-Out

Safety

Switch

Blocked

Vent

Safety

Switch

PV MV/ MV

Remote Flame Sensor

High Altitude (Optional)

Gas Valve

HW VR8304

Figure 9b. Schematic, Spark Ignition System

(BJVS 50 & 75).

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Figure 9c. Wiring Diagram, Standing Pilot System (BJVT).

Figure 9d. Schematic, Standing Pilot System (BJVT).

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Page 19

Figure 9e. Wiring Diagram, Spark Ignition, Two-Stage (BJVS 100-225).

110V

Hot

110V

Neutral

Space Heating

Pump

(Field Supplied)

Zone

Pump

Relay

115V

24V

Thermostat

Field

Supplied

Zone

Pump

Relay

Fuse

Boiler

Terminal

Boiler

Terminal

Zone

Pump

Relay

Boiler

Terminal

Optional

Aquastat

High

Limit

Zone

Pump

Relay

Vent

Damper

Receptacle

Ignition Control

Power

Venter

Receptacle

Jumper

Roll-Out

Safety

Switch

Blocked

Vent

Safety

Switch

MV/PV

GND

24V (GR)

24V

TH-W

SPARK

Pilot Burner With

Spark Electrode

Sensor

LO HI

Remote Flame Sensor

High Altitude

(Optional)

Two-Stage

Aquastat

Two-Stage

Gas Valve

HW VR8304

Figure 9f. Schematic, Two-Stage (BJVS 100-225).

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Wiring

with Taco

Zone Valves

Wiring with

Honeywell

Zone Valves

Wiring

with Multiple

Zone Pumps

For primary/secondary pumping: Connect

to "W" in lieu of "A." Boiler relay is used for

boiler pump and connection to "W" will

energize boiler pump when any zone is

calling for heat.

Figure 10. Multiple Zone Wiring.

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Page 21

6.3 Grounding

SECTION 7.

Operating Instructions

WARNING

The boiler must be electrically grounded in

7.1 Normal Operation

The Brute Mini BJVS and BJVT boilers are

capable of automatic operation based on a call for

heat at present temperatures. The boiler has an internal

safety system which allows operation in a variety of

conditions and prevents operation when certain

adverse conditions are encountered.

When the wall thermostat calls for heat and the

boiler is powered, an operating cycle is initiated. (On

continuous pilot ignition models (BJVT) the pilot must

also be lit). The pump relay turns on the pump, the

damper activator rotates the damper blade to the open

position and the indicator light comes on.

On spark ignition models (BJVS 50-75), if the

water temperature is below the limit setting, the

ignition module lights the pilot and checks the flame

existence. After the pilot is proven to be lit, the

ignition module opens the main gas valve and the

main burners ignite.

On 2-Stage spark ignition models (BJVS 100-

225), if the water temperature is below the limit

setting, the ignition module lights the pilot and checks

the flame existence. After the pilot is proven to be lit,

the ignition module opens the main gas valve and the

main burners ignite. The main gas valve is controlled

by the two-stage operating control (see Figure 11) and

will cycle between high, low and off as the load

demands.

accordance with the requirements of the authority

having jurisdiction or, in the absence of such

requirements, with the latest edition of the National

Electrical Code, ANSI/NFPA 70, in the U.S. and

with latest edition of CSA C22.1 Canadian Electrical

Code, Part 1, in Canada. Do not rely on the gas or

water piping to ground the metal parts of the boiler.

Plastic pipe or dielectric unions may isolate the

boiler electrically. Service and maintenance

personnel who work on or around the boiler may be

standing on wet floors and could be electrocuted by

an ungrounded boiler.

AVERTISSEMENT

La chaudière doit être mise à la terre selon les

exigences officielles locales ou, en l’absence de

toute instruction officelle, l’installation doit être

conforme au National Electrical Code, ANSI/NFPA

70, aux États-Unis et avec la dernière édition du

Code électrique canadien CSA C22.1, Partie 1, au

Canada. N’utilisez pas la tuyauterie de gaz ou

d’eau pour mettre à la terre les parties métalliques

de la chaudière. Les unions diélectriques ou avec

tuyau en plastique peuvent isoler la chaudière

électriquement. Les membres du personnel de

service et d’entretien qui travaillent sur et autour de

la chaudiére peuvent marcher dur des planchers

mouillés et pourraient se faire électrocuter par une

chaudière non mise à la terre.

BREAKS R-B

MAKES R-W

ON RISE

LEFT SWITCH

DIFFERENTIAL

TEMPERATURE

RISE

BREAKS R-W

MAKES R-B

ON FALL

6.4 Auxiliary Devices

6.4.1 Flow Switch

LOW

FIRE

If the system includes a flow switch, it should be

wired in series with the high-limit switch. The boiler

will not fire unless the pump is running and the flow

switch is closed.

Field installed safety devices and operating

controllers, such as a valve end switch, draft switches,

relays, timers, and outdoor temperature reset devices,

can be connected to the boiler through the wall

thermostat circuit. Do not exceed a draw of 30VA on

the transformer secondary.

INTERSTAGE

DIFFERENTIAL

BREAKS R-B

MAKES R-W

ON RISE

RIGHT SWITCH

DIFFERENTIAL

BOILER INLET

SETPOINT

(ADJUSTABLE,

FACTORY SET

AT 140°F)

BREAKS R-W

MAKES R-B

ON FALL

HIGH

FIRE

6.4.2 Heat Anticipator

DIFFERENCE BETWEEN THE TEMPERATURES AT WHICH THE

TWO SWITCHES MAKE R-W. FACTORY SET AT 10°F (6.6°C)

For single zone installations, the wall thermostat

heat anticipator should be set at 0.5 amperes. For

multi-zone installations, have a qualified electrical

technician make the necessary measurements to

properly set the thermostats.

TWO SPDT SWITCHES OPERATE IN SEQUENCE. EACH

SWITCH DIFFERENTIAL AT APPROXIMATELY 3°F (1.7°C)

Figure 11. L6008G Operation.

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On continuous pilot ignition models (BJVT), if

including the pump, boiler, and radiation units,

for one hour.

10. Recheck the water level in the expansion tank,

if necessary. If it exceeds ½ of the volume of

the tank, open the tank drain and reduce the water

level.

11. Shut down the entire system, and vent all

radiation units and high points in the system.

12. Closethewatermakeupvalveandcheckthestrainer

in the pressure reducing valve for sediment or

debris. Reopen the water makeup valve.

13. Verify system pressure with the boiler pressure

gauge before beginning regular operation.

14. Within 3 days of start-up, recheck and bleed all

air vents and the expansion tank using these

instructions.

15. In systems piped with cross-linked polyethylene

tubng (PEX) it is essential that all air is purged

from all zones in the system to prevent PEX

tubing failure.

the water temperature is below the limit setting, the

ignition module opens the main gas valve, and the

main burners ignite.

Operation will continue on all ignition systems

until either the wall setting thermostat is satisfied or

the high-limit thermostat opens. The burners and pilot

(on BJVS models) shut-off and the pump relay turns

off the pump. The damper activator rotates the damper

blade to the closed position and the indicator light

goes off.

When the room temperature falls below the wall

thermostat setting, the cycle repeats.

Note: When equipped with a pump delay option, the

pump runs for a short time after the burners turn off

and the damper closes.

7.2 Start-up

7.2.1 Filling the System

NOTE: It is strongly recommended that the system be

cleaned and flushed to remove scale, oil, paste, flux,

etc., before the system is filled.

7.2.2 BoilerStart-up

WARNING

It is crucial to the efficient operation of the

system that all air be removed from the circuit. For

this reason, an air scoop and vent should be located

close to the boiler outlet, and there should be a

minimum distance between cold water feed and

system purge valve.

1. When the system has been completely installed,

close all air vents and open the makeup water

valve. Allow the circuit to fill slowly.

For your safety, when starting the boiler, keep your

head and face well away from the burner area to

prevent any risk of personal injury.

AVERTISSEMENT

Pour votre sécurité personnelle lorsque vous mettez

l’appareil en marche, tenez votre tête et votre visage

loin du brûleur pour éviter tout risque de blessure.

2. Adjust the pressure to provide a minimum of 12

psi (82.7kPa) at the highest point in the circuit. If

a pressure regulator is also installed in the line,

adjust it to the same pressure.

WARNING

Vent pipes, and heater tops get hot! These

surfaces can cause serious burns. Do not touch

these surfaces while the heater is in operation.

3. Close all gate valves. Purge one circuit at a time

as follows:

AVERTISSEMENT

Open one circuit drain valve and let water

drain out for at least 5 minutes. Be certain

there are no air bubbles visible in the water

stream before closing the drain valve.

Les tuyaux d’aération et le dessus de l’appareil

deviennent chauds! Ils peuvent causer de graves

brûlures. Ne touchez pas à ces surfaces lorsque

l’appareil est en marche.

b. Repeat this procedure for each circuit.

4. Open all gate valves after all circuits have been

purged.

Caution

Do not use this boiler if any part has been under

water. Immediately call a qualified service

technician to inspect the heater and replace any

part of the control system and any gas control

which has been under water.

5. Run the system circulating pump for a minimum

of 30 minutes with the boiler shut off.

6. Open all strainers in the system, and check for

debris.

7. Recheck all air vents as described in Step 3 above.

8. Some expansion tanks require visual inspection

of liquid level. If necessary, inspect the liquid

level in the expansion tank. With the system

full of water, and under normal operating

pressure, to ensure proper water level in the

expansion tank.

Attention

N’utilisez pas cet appareil s’il a été plongé dans

l’eau, même partiellement. Faites inspecter

l’appareil par un technicien qualifié et remplacez

toute partie du systéme de contrôle et toute

commande qui ont été plongés dans l’eau.

9. Start up boiler according to the procedures

described in Section 7 and operate the system,

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Brut e M ini Hydronic Boile r

Page 23

NOTE: If your boiler is configured to operate on LP

Caution

gas and the LP tank runs out of fuel, turn off gas at

the boiler. After the tank is refilled, the boiler must

be relit following the instructions found on the boiler.

DO NOT attempt repairs on the gas control or

heater. Tampering is dangerous and voids all

warranties.

Should overheating occur or the gas supply fail to

shut off, do not turn off or disconnect the electrical

supply to the pump. Instead, shut off the gas supply

at a location external to the appliance.

Attention

En cas de surchauffe ou si l’admission de gaz ne

peut être coupée, ne pas couper ni débrancher

l’alimentation électrique de la pompe. Fermer plutôt

le robinet d’admission de gaz à l’extérieur de

l’appareil.

WARNING

If the information in these instructions are not

followed exactly, a fire or explosion may result

causing property damage, personal injury or death.

AVERTISSEMENT

Assurez-vous de bien suivre les instructions données

dans cette notice pour réduire au minimum le risque

d’incendie ou d’explosion ou pour éviter tout

dommage matériel, toute blessure ou la mort.

Caution

Do not attempt repairs on the gas controls or

appliance. Tampering is dangerous and voids all

warranties.

Attention

7.3.1 Lighting the Boiler

Ne tentez pas d’effectuer des réparations au

système de régulation du débit du gaz ou à

l’appareil. Toute modification non autorisée est

dangereuse et entraîne l’annulation de toutes les

garanties.

Lighting instructions are as follows:

1. Verify that the pump system is operating

properly:

a. Shut off the manual gas valve located

outside the boiler.

b. Raise the wall thermostat high enough to

call for heat.

Caution

Keep all objects off the top of the boiler. Blocking air

flow could damage the heater, and may void the

warranty.

The pump should come on immediately. If

it doesn't, test the electrical circuits.

2. Pilot Information:

Attention

a. The BJVS boilers do not require manual

lighting. The pilot is controlled by the

automatic ignition system.

Ne posez aucun objet sur le dessus de l’appareil. Il

pourrait empêcher la circulation de l’air, ce qui

risquerait d’endommager, l’appareil et d’annuler la

garantie.

b. The BJVT boilers do require manual pilot

lighting. For access to the pilot burner,

remove the louvered airbox cover by

loosening the two thumb screws.

7.3 Lighting and Shutdown Procedures

c. Different models of the BJV boiler utilize

various gas valves. Although the gas valves

may have different control knobs, they are

all similar in operation. The BJVS gas

valve has a two-position knob, ON and

OFF. The BJVT valve has a three-position

knob, ON, OFF and PILOT, some models

come with extra push-button (see Figure

12).

WARNING

Do not attempt to light the boiler with the burner

cover off. Doing so may cause severe bodily injury.

AVERTISSEMENT

Ne tentez pas d’allumer l’appareil sans que la soit en

place. Vous pourriez être victime de blessures

corporelles graves.

Before starting your boiler, be sure that all of the

functions and limits of the BJVS and BJVT boilers

have been set according to the previous section of this

manual (Section 7.2). Follow the instructions outlined

below. Read and follow all safety instructions first. A

more detailed set of lighting and shutdown

instructions are listed on the label located on the

boiler.

Figure 12. Gas Valves.

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3. BEFORE LIGHTING smell all around the

appliance area for gas. Be sure to smell next to

the floor because some gas is heavier than air

and will settle on the floor.

14. Turn gas control knob counterclockwise

to ON.

15. Replace control box cover.

16. Restore power to the boiler and adjust the

thermostat high enough to call for heat to verify

the boiler is operating properly.

a. WHAT TO DO IF YOU SMELL GAS

a.1 Do not try to light any appliance.

a.2 Do not touch any electric switch; do not use

any phone in your building.

a.3 Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

a.4 If you cannot reach your gas supplier, call

the fire department.

17. BJVS 100-225 ONLY - Adjust two-stage

operating control setting to maximum, verify

high fire operation. Reduce setting to just below

the return water temperature and verify low fire

operation.

18. BJVS 100-225 ONLY - Set two-stage operating

control to desired low fire set point. Generally

20°F below desired loop temp. i.e. for 180°F

loop, set two stage operating control at 160°F.

Adjust as necessary to maintain proper loop

temperature.

All Models:

4. Shut off electrical power to the boiler.

5. Turn the gas valve knob clockwise

to OFF.

Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, don't try to repair it,

call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

6. Wait five (5) minutes to clear out any gas. Then

smell for gas, including near the floor. If you

smell gas, STOP! Follow 7.3.1 (3.)a. If you don't

smell gas, go to the next step.

19. Set the thermostat to the desired temperature.

7.3.2 Shutdown

7.3.2.1 Main Burner Shutdown (BJVT only):

1. Lower the wall thermostat setting so that there is

no call for heat.

2. To turn off the main burners turn the gas valve

knob clockwise until it stops at pilot.

BJVS Models: (BJVT skip 7 )

7. Turn gas valveknobcounterclockwise

7.3.2.2 Complete Shutdown:

1. Lower the wall thermostat setting so that there is

no call for heat.

toON.

Restore power to the boiler, and set the thermostat

to the desired temperature. The pilot will

automatically ignite when there is a call for heat.

BJVT Models: (Continuous Pilot)

2. Turn off all electrical power to the boiler.

3. Turn the gas valve knob clockwise to “OFF”. Do

not force the knob.

(BJVS skip to step 16)

4. Shut off the external gas supply valve to the

boiler.

8. Remove louvered burner cover by loosening the

two thumb screws to access the pilot burner.

9. Remove the control box cover to fully access the

gas valve.

7.4 High Altitude Burner

Air Shutter Adjustment

10. Find pilot - follow metal tube from gas control.

The pilot is on the right hand side of the first

burner.

11. Turn knob on gas control counterclockwise

to PILOT.

DANGER

This procedure must be followed exactly and

must be performed by a qualified installer or

warranty may be voided.

12. Push in control knob or push-button all the way

and hold in. Immediately light the pilot with a

match using the match holder. Continue to hold

the control knob in for about one (1) minute after

the pilot is lit. Release knob and it will pop back

up. Pilot should remain lit. If it goes out, repeat

steps 2 through 8.

DANGER

Cette manière de procéder doit être faite

exactement et accomplie par un installateur qualifié

sous risque d’annulation de la garantie.

a. If the knob does not pop up when released,

stop and immediately call your service

technician or gas supplier.

b. If the pilot will not stay lit after several

tries, turn the gas control knob to OFF and

call your service technician or gas supplier.

13. Replace the louvered airbox cover and tighten

the two thumb screws securely.

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Page 25

SECTION 8.

DANGER

Readandunderstandthisentireprocedure

prior to proceeding. Improper adjustment of

high altitude shutters may result in a fire,

explosion, and/or high levels of toxic gases

which may cause property damage, personal

injury, or loss of life.

Maintenance

8.1 General Maintenance

WARNING

Improper installation or maintenance can cause

nausea or asphyxiation from carbon monoxide in

flue gases which could result in severe injury, or

death.

DANGER

Lisez la manière de procéder dans sa totalité et

comprenez-la bien avant de commencer. Un

ajustement inadéquat des volets en haute altitude

peut provoquer un incendie, une explosion, et/ou

des niveaux élevés de gaz toxiques qui pourraient

causer des dégâts matériels, des blessures

personnelles, voire la mort.

AVERTISSEMENT

Une installation ou un entretien inadéquat peut

causer la nausée ou l’asphyxie en raison du

monoxyde de carbone présent dans les gaz de

combustion et même entraîner des blessures

graves ou la mort.

WARNING

SERVICINGSAFETY

1. STOP! Read the safety information above.

2. Perform System Start-Up in accordance with

Section 7.2 of this manual.

Some of the servicing procedures for the Brute Mini

BJVS and BJVT boilers are hazardous because they

involve fuel gas, electricity, moving parts and

procedures which require testing or temporary

bypass of safety controls. For this reason, the

heater must be serviced only by a qualified

professionalservicetechnician.

3. Remove burner cover by loosening two (2)

thumbscrews.

4. Observe flame pattern on all burners. If the flame

on any burner is pulsing, unstable or lifting

continue with this procedure. Otherwise skip to

step 10.

IMPROPER SERVICE HAZARD

The Brute Mini BJVS and BJVT boilers incorporate

unique design features. Incorrect service of this

boiler can result in personal injury or damage to

property. To avoid such hazards, the heater must be

serviced only by a qualified professional service

technician.

5. On all burners exhibiting an abnormal flame,

loosen but do not remove the air shutter locking

screw using a 5/16 inch wrench (see Figure 12).

6. On each affected burner, slowly close the air

shutter until a normal flame is observed then re-

tighten its associated locking screw.

7. Turn the boiler off.

8. Perform System Start-Up in accordance with

Section 2A of this manual.

AVERTISSEMENT

PRÉCAUTIONS LORS DES RÉPARTATIONS ET

DE L’ENTRETIEN

9. Observe flame pattern on all burners. If the flame

on any burner is pulsing, unstable or lifting then

repeat steps 5 and 6 until all burners are

exhibiting a normal flame.

10. Re-install the burner cover and tighten it in

place.

Certaines procédures d’entretien et de réparation

des appareils de chauffage à faibles émissions

présentent des changers, car elles mettent en jeu

des gaz combustibles, des composants électriques,

des pièces mobiles et des procédures qui

nécessitent des mises à l’essai ou la dérivation

temporaire des commandes de sécurité. Pour cette

raison, l’appareil de chauffage doit être entretenu et

réparé uniquement par un technicien professionnel

qualifié

LOCKING SCREW

(5/16" HEAD)

AIR SHUTTER

BURNER

DANGERS D’UN ENTRETIEN INADÉQUAT

Les appareils de chauffage à faibles émissions

comportent des caractéristiques techniques

uniques. Une réparation ou un entretien inadéquat

peut entraîner des blessures corporelles ou des

dommages à la propriété. Pour cette raison,

l’appareil de chauffage doit être entretenu et réparé

uniquement par un technicien professionnel

qualifié.

Figure 13. Air Shutter Adjustment.

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1. Lubricate the water circulating pump per the

instructions on the pump.

strongly recommended that the basic items listed

below be inspected by a qualified service

technician every year.

2. If a strainer is employed in a pressure reducing

valve or the piping, clean it every six months.

3. At start-up, and periodically thereafter, the

burner flame should be observed. If the flame

has the appearance of ‘sooting’ tips, check for

debris near the orifices and call the service

technician.

a. Water temperature controls

b. Pilot safety system.

c. Automatic gas valves.

d. Flow sensing safety devices.

e. Vent dampers and power venters.

Venting system.

4. Inspect the venting system for obstruction,

leakage or corrosion at least once a year.

5. Do not store or use gasoline or other flammable

vapors, liquids or chemicals in the vicinity of

this or any other appliance.

NOTE: The Warranty does not cover damage caused

by lack of required maintenance, lack of water flow, or

improper operating practices.

12. Fouling on the external surfaces of the heat

exchanger is caused by incomplete combustion,

and is a sign of venting and/or combustion air

problems. The heat exchanger can be inspected

by using a flashlight and placing a mirror under

the burners. An alternate method is to remove the

venting and top panel to inspect the exchanger

from above. The vent system should be

inspected at the same time. If cleaning is

required:

Ne pas entreposer ni utiliser d’essence ni

d’autres vapeurs ou liquides inflammables à

proximité de cet appareil ou de tout autre

appareil.

6. Do not use this boiler if any part has been under

water. Immediately call a qualified service

technician to inspect the heater and replace any

part of the control system and any gas control

which has been under water.

N’utilisez pas cet appareil s’il a été plongé dans

l’eau, même partiellement. Faites inspecter

l’appareil par un technicien qualifié et remplac

ez toute partie du système de contrôle et toute

commande qui ont été plongés dans l’eau.

7. Be sure that all combustion air and ventilation

openings are unobstructed.

a. Shut off all power to the boiler.

b. Remove the draft hood, venting top, flue

collector, and heat exchanger baffles.

c. Remove the burners by lifting them off the

orifices and pulling them out of the boiler.

d. Use a hand-operated spray bottle filled with

water, and a wire brush to clean soot and

loose scale from the underside of the heat

exchanger. DO NOT USE COMPRESSED

AIR, HIGH PRESSURE WATER OR A

GARDEN HOSE.

8. Upon completion of the installation, inspect the

external surfaces of the heat exchanger for

fouling based on the following schedule:

24 hours 7 days 30 days 90 days

e. Clean any fallen debris from the bottom of

the unit.

Once every six months thereafter.

9. If the boiler is not going to be used for long

periods of time in locations where freezing

occurs, it should be completely drained of all

water. To accomplish this, there is a drain valve

on the right side of the boiler which can be

opened. This will drain the right side of the

boiler. There are two plugs located on the left

side of the heater which must be removed to

drain that side. Both sides must be drained.

10. The gas and electric controls on the boiler are

engineered for long life and dependable

operation, but the safety of the equipment

depends on their proper functioning. It is

Check to make sure the burner ports and

pilot assembly are free of debris before

returning the burners to their original

position.

g. Reassemble the boiler in reverse order,

making sure to replace the heat exchanger

baffles.

8.2 Boiler Components and Their

Operation

1. Gas Valve / Regulator - The gas valve controls

gas flow into the manifold. It provides flow only

when the temperature control requires heat and

only if all safety controls enable operation. It is

also a positive pressure regulator. It regulates the

gas pressure in the manifold to specifications

addressed earlier in this manual. This is

necessary for proper operation of the burner

system. BJVS 100-225 Only - Gas Valve /

Regulator has two output stages controlled by

two-stage temperature control.

Figure 14. 1) BJVS Pilot; 2) BJVH Pilot;

3) Main Burner Flame Pattern; 4) BJVT Pilot.

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Page 27

SECTION 9.

Caution

Two-stage Operating Control (BJV100-225 ONLY):

Factory setting is 140°F (60°C). This setting is

correct for most hydronic heating applications.

Adjustments to this setting must be made by an

authorized service technician.

Troubleshooting

9.1 General Boiler Troubleshooting

Table 8 lists some of the more common

problems, causes and solutions encountered when

running the boiler. Most problems occur when the

boiler is being started for the first time after

installation. Careful installation and maintenance will

help ensure years of trouble free use from your Brute

Mini boiler.

2. Two-stage Temperature Control - BJVS 100-

225 are equipped with a two-stage temperature

control which senses inlet water temperature. It

is used to control the firing rate of the main

burners, cycling the gas valve between low, high

and off.

3A. Ignition Control, BJVS - When the thermostat

calls for heat and all limits are satisfied a pilot

trial for ignition is initiated. If pilot is not

established a 5 minute minimum delay is

implemented prior to the next trial for ignition.

This cycle repeats until pilot is established or the

system is shut down manually.

WARNING

SERVICINGSAFETY

Some of the servicing procedures for the Brute Mini

BJVS and BJVT boilers are hazardous because they

involve fuel gas, electricity, moving parts and

procedures which require testing or temporary

bypass of safety controls. For this reason, the boiler

must be serviced only by a qualified professional

servicetechnician.

BJVS 100-225 only - Once pilot is established

the main valve is enabled and controlled by the

two-stage temperature control.

BJVS 50-75 only - Once pilot is established the

main valve will open until the limit circuit opens.

3B. BJVT Flame Control - The standing pilot BJVT

models rely on a flame sensor on the gas valve.

When the thermostat calls for heat and adequate

pilot flame is sensed, the gas valve will open.

The valve will remain open until the limit circuit

opens.

IMPROPER SERVICE HAZARD

The Brute Mini BJVS and BJVT boilers incorporate

unique design features. Incorrect service of this

heater can result in personal injury or damage to

property. To avoid such hazards, the boiler must be

serviced only by a qualified professional service

technician.

4. Pilot Assembly

AVERTISSEMENT

BJVS - The pilot assembly utilizes an electrode

that is used to generate spark to ignite the pilot

flame as well as sense flame presence.

BJVT - The BJVT pilot is lit manually and

senses pilot flame via a thermocouple which

generates a signal that allows the gas valve to

open.

PRÉCAUTIONS LORS DES RÉPARTATIONS ET

DE L’ENTRETIEN

Certaines procédures d’entretien et de réparation

des appareils de chauffage à faibles émissions

présentent des changers, car elles mettent en jeu

des gaz combustibles, des composants électriques,

des pièces mobiles et des procédures qui

nécessitent des mises à l’essai ou la dérivation

temporaire des commandes de sécurité. Pour cette

raison, l’appareil de chauffage doit être entretenu et

réparé uniquement par un technicien professionnel

qualifié

5. Hi-Limit Switch: Factory setting is 190°F

(88°C). This setting is correct for normal

operations, and should only be changed by an

authorized service technician. Under no

circumstances should the setting exceed 220°F

(104°C).

6. Blocked Vent Switch - BJVS and BJVT boilers

are equipped with a manual reset blocked vent

switch designed to shut the boiler down in the

event the vent is completely blocked. The switch

is located in the draft diverter opening on the rear

of the boiler.

7. Rollout Switch - BJVS and BJVT boilers are

equipped with a manual reset rollout switch

designed to shut the boiler down in the event a

flame rollout situation occurs causing excessive

temperatures. The switch is located on the burner

cover.

DANGERS D’UN ENTRETIEN INADÉQUAT

Les appareils de chauffage à faibles émissions

comportent des caractéristiques techniques

uniques. Une réparation ou un entretien inadéquat

peut entraîner des blessures corporelles ou des

dommages à la propriété. Pour cette raison,

l’appareil de chauffage doit être entretenu et réparé

uniquement par un technicien professionnel

qualifié.

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Page 28

9.2 Troubleshooting Guide

Symptom

Cause

Remedy

Pumpnot

operating

A. No power

A. Check circuit breakers and power source.

B. Pump defective

C.Incorrectly wired

B. Replace.

C.Recheck wiring diagrams.

Pilot outage

A. Inlet gas pressure too low

A. Consult gas utility company. Inlet gas pressure to boiler

should be 5.5" to 10.5" water column on natural gas. 0.0" to

13.0" on propane gas.

B. Inlet gas pressure too high causing

an unstable blowing pilot

B. Pressure should be regulated within limits shown above.

C.Weak or defective thermocouple

D.Damaged pilot or thermocouple

E. Dirty pilot

C.Replacethermocouple.

D.Replace.

E. Blow dust or lint out of pilot.

F. Clean or replace pilot orifice.

F. Plugged or undersized pilot orifice

Flame roll-out

on start-up

A. Blocked flue

A. Remove blockage.

B. Pilot out of position (delayed ignition)

C.Blocked heat exchanger or flue

D.Refractory tile out of place

E. Altered draft diverter

B. Correct pilot position.

C.Clean and correct as necessary.

D.Correct or replace tile as necessary.

E. Install factory-provided draft diverter.

Spillage at

draft hood

A. Cold chimney

A. Allow boiler to operate 5 minutes to create draft action.

B. Reinstall vent pipe to pitch up from boiler to chimney.

C.Remove blockage.

B. Vent pipe pitches down to chimney

C.Blocked chimney

D.Draft hood altered

D.Install factory-provided draft diverter.

E. Install U.L. listed vent cap.

E. Pre-fabricated chimney with incorrect cap

Flame has

A. Low primary air

A. Correct manifold pressure according to rating plate. Correct

orifice size if necessary (see parts list). Clean burner ports if

dirty. Verify correct fuel type.

lazy yellow tip

Not enough heat

A. Inadequate gas supply

A. Gas meter too small. Gas line from meter to boiler too small.

B. Gas pressure on boiler manifold (at normal firing rate)

should be adjusted to 4.0"W.C. natural gas, 9.0"W.C.

propane.

B. Low manifold gas pressure

C.Boiler size inadequate

D.BJVS 100-225 only - Boiler not going

to high fire.

C.Replace with boiler of higher input.

D.Check operation and setting of two-stage operating control.

Pumpnoisy

A. Air in volute

A. Bleed air from volute. Check pump alignment.

B. Replace worn parts.

B. Worn coupling or bearings

Boiler pounding

or knocking

A. Too low water flow through boiler

A. Check temperature rise between inlet and outlet boiler piping.

15°F to 25°F temperature rise is recommended. If temperature

rise is over 25°F, increase pipe size or pump capacity or

locate obstruction. Check for stuck closed zone valves.

Check for zone pumps not operating. Check for closed valve

in system.

Boiler condensing A. Low water temperature

A. Flue product moisture will condense at the start-up until the

boiler water temperature reaches the normal operating

conditions.

10. Pump cavitates

A. Defective fill valves or pressure regulator

B. Oversized expansion tank

A. Replace.

or low water

B. Replace.

pressure at boiler C.Expansion tank piped incorrectly

C.Repipe expansion tank to suction size of pump.

gauge or bubbles

in system at high

temperature

11. Pressure relief

valve opens

A. Water-logged expansion tank

A. Drain ²/3 of the water from the expansion tank.

12. Pilot is lit but main A. Gas valve not at "on" position (BJVT)

A. Turn knob to "on" position.

burners will not

come on

B. Boiler off on hi-limit control

C.Boiler incorrectly wired

B. Check for low water flow or hi-limit setting.

C.On single or multiple zone systems with zone valves, room

thermostat should be wired to R & W terminals. For multiple

zone systems with zone pumps, thermostats for extra zones

should be wired to R & A terminals.

D.Boiler off on blocked vent switch

E. Boiler off on flame roll-out switch

F. Broken wire in thermostat circuit

or defective thermostat

D.Remedy as in symptom #4. Reset the manual reset switch.

E. Remedy as in symptom #3. Reset the manual reset switch.

F. Checkcontinuitythroughthermostatcircuitwithwires

disconnected from R & W.

G.BJVS 100-225 Only - Two-stage operating G.Checkcontinuityandoperationthroughtwo-stage

controlnotfunctioningorloosecontact.

operatingcontrol.

13. Boiler short cycles A. Heat anticipator in room thermostat

set too low

A. Increase setting (0.8 - 1.0 is usually satisfactory).

B. Low water flow through boiler

B. Increase size of pump or increase piping size.

C.Hi-limit switch may be set too low

C.Increase setting to at least 20°F over outlet water temperature.

Table 8. Troubleshooting Guide.

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Brut e M ini Hydronic Boile r

Page 29

9.3 Troubleshooting Honeywell S8600 Intermittent Pilot System

Some boilers may be equipped with an ignition module that shuts off pilot gas if pilot fails to light.

To reset, interrupt power to heater

Start

Note: Before troubleshooting, familiarize yourself with the start-up and

checkout procedure.

Turn off gas supply.

Turnthermostat

(controller) to call for

heat.

Check line voltage power, low voltage transformer, hi- limit switch,

thermostat (controller) and wiring.

Power to module

(24V nominal).

YES

Pull ignition lead and check spark at module.

Spark okay?

ꢀ

Spark across igniter/

sensor gap.

YES

ꢀ

YES

ꢀ

• Check ignition cable ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or buckling. Take

protective action to shield cable and boot from excessive temperatures.

• Check that all manual gas valves are open, supply tubing and pressures

are good, and pilot burner orifice is not blocked.

• Check electrical connections between module and pilot operator on gas

Turn gas supply on.

Pilot burner lights?

control.

• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is

okay, replace gas valve; if not, replace module.

YES

ꢀ

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

Spark stops when pilot

is lit?

• Check electrical connections between flame rod and module.

• Check for cracked ceramic flame rod insulator.

• Check that pilot flame covers flame rod and is steady and blue.

• Adjust pilot flame.

YES

ꢀ

• If problem persists, replace module.

• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace

module.

Main burner lights?

• Check electrical connections between module and gas valve. If okay,

replace gas valve.

YES

ꢀ

• Check continuity of ignition cable and ground wire.

System runs until call

for heat ends?

Note: If ground is poor or erratic, shutdowns may occur occasionally even

though operation is normal at the time of checkout.

• Check that pilot flame covers flame rod and is steady and blue.

• If checks are okay, replace module.

YES

ꢀ

Call for heat ends.

System shuts off?

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature

controller and wiring; if not, replace gas valve.

YES

ꢀ

Repeat procedure until trouble-free operation is obtained.

Troubleshooting ends

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doesn't, replace the pilot thermocouple. The

second test requires the use of a Millivolt

Reading Adapter to test the thermocouple under

load. Once again, remove the pilot thermocouple

compression fitting from the gas valve. Replace

it with a Millivolt Reading Adapter, and screw

the thermocouple fitting into the end of the

adapter. Attach one lead from the millivoltmeter

to either side of the adapter and the other lead to

ground. Light the pilot and set the wall

thermostat high enough to call for heat. With the

boiler firing, take a millivolt reading. It should

be in the 15 millivolt range. If it isn't, replace the

pilot thermocouple.

9.4 Electrical Troubleshooting

1. Remove the control box cover on the front of the

boiler.

2. Verify that 115V is reaching the boiler by testing

across the black wire on the pump relay and the

white wire on the transformer.

3. Verify 24V transformer output by placing the

meter leads on the yellow and red wires. If 24V

is not evident, replace the transformer. Perform

the following series of tests with one meter lead

attached to the yellow wire on the transformer.

4. Place the second lead on the "W" connection on

the terminal board. Turn the wall thermostat high

enough to call for heat. If the meter fails to

defective.

Caution

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation. Verify proper operation after

servicing.

5. Make sure thermostat is set high enough to call

for heat. Place second lead on the "A"

connection on the terminal board. If voltage is

evident, skip to step 6. If no voltage, test the

circuit between the red wire on the transformer

and terminal 4 on the pump relay; from terminal

6 on the pump relay and the "A" connection on

the terminal board; and from the purple wire

terminal on the pump relay to the "W"

ATTENTION

Au moment de l’entretien des commandes, mettez

des étiquettes sur tous les fils avant de les

débrancher. Des erreurs de câblage peuvent

causer un fonctionnement inadéquat et dangereux.

Vérifier que tout fonctionne bien après votre

entretien.

connection on the terminal board. If no output is

found, the

connections or the pump relay could be defective.

6. Place the second lead on the orange wire

terminal on the hi-limit switch. If no voltage

across the switch, check for defective hi-limit,

open circuit due to excessive water temperature,

or a low temperature setting.

SECTION 10.

Glossary

7. Place the second lead on the orange wire

terminal on the blocked vent safety switch. If

voltage is present, the vent damper is open. If

voltage isn't present, connections or the vent

damper could be defective.

10.1 Glossary of Terms

Air Vent

Another device used to purge air from the circuit.

Should be located at the highest point in the circuit.

8. Verify the voltage across the blocked vent and

Branch

roll-out safety switches.

The section(s) of supply and return piping, including

the heat distribution units (see below), connected

directly to the trunk. Also referred to as a "zone."

9. On BJVT boilers, test for voltage at the "TH"

terminal on the gas valve. If none is found,

follow steps 1 through 8.

10. If it is determined that there is voltage to the gas

valve, the pilot is lit and the thermocouple is

properly positioned, and the thermostat is set

high enough to call for heat, the gas valve or the

pilot thermocouple may be defective

By-pass

A section of pipe (including an adjustable valve) that

diverts part of the water flow from the boiler outlet to

the inlet, adjusted to maintain minimum flow

requirement (GPM) or inlet water temperature.

11. There are two tests necessary to make sure the

problem is not in the pilot thermocouple. The

first test can be performed by unscrewing the

compression fitting on the gas valve, and placing

one millivoltmeter lead on the center post of the

tube and the other lead on the copper tubing. If

the meter shows a reading of approximately 30

millivolts, proceed to the second test. If it

Circuit

Entire water circulation piping, beginning and ending

at the boiler (Series Loop System).

Expansion Tank (Compression Tank)

Installed in the circuit to accommodate excess water

produced by heat expansion, and to maintain the

system pressure.

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Brut e M ini Hydronic Boile r

Page 31

Heat Distribution Units

SECTION 11.

Transfers heat from the water supplied by the boiler to

the area to be heated through the use of baseboard,

convector, radiator, finned tube. Also known as

"radiation."

Replacement Parts

11.1 Ordering Information

To order or purchase parts for the Brute Mini

BJVS or BJVT boiler, contact your nearest

Representative. If you need assistance in finding a

local dealer or distributor, contact the Technical

Service Department.

Isolation Valve

Used to isolate the boiler from the circuit. It minimizes

the amount of water drained from the system.

Primary-Secondary Piping

Two or more interconnecting circulating loops, each

with its own pump.

NOTE: To supply the correct part it is important that

you state the model number, serial number and type

of gas when applicable. This information is on the

rating plate on the heater.

Reverse-return Piping

Balanced, equal flow (first in, last out) piping. Utilized

with multiple boilers and/or radiation. Applied with

single system pumps, or primary-secondary pumps.

11.2 Parts List

The following pages contain a parts list and a

general exploded view to aid in parts identification.

Please refer to these pages when ordering parts for

your BJVS or BJVT boiler.

Side Wall Power Venter

This accessory allows the boiler exhaust to be routed

horizontally through an adjoining outside wall, rather

than gravity venting with a chimney or stack when local

codes allow.

System Purge Valve

A device used to purge air from the circuit. Should be

located as close as possible to the cold water feed,

but not immediately after the cold water feed.

Trunk

The section of piping which connects the boiler return

and supply with the branch(es). Also known as a

"main" or "header." Should be same size as boiler

inlet/outlet connections.

Vent Damper (optional in Canada)

Standard on BJV boilers. This energy-saving device

prevents heated air from exiting the open vent when

the boiler is not operating.

Zone Pump

Circulators installed in branch piping that divert hot

water coming from the boiler into various areas

(zones) of a building.

Zone Valve

Diverts hot water from the boiler into various areas

(zones) of a building.

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Page 33

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BRADFORD WHITE CORP .

Page 34

11.3Exploded View

Vent Damper Connection Harness

Vent Damper

Draft Diverter

Pressure

Relief Valve

A - Inlet Pipe

B - 4-1/2”x3/4” Pipe

C - Outlet Pipe

Gap Closure

1-1/4” Hold

1-1/8” Hold

1-1/4” Hold

1-7/8” Hold

‚

„

Top

‚

Heat Exchanger

Temperature/

Pressure Gauge

Immersion Well

Refractory, Front

Flue Collector

Aquastat

Bulb

Refractory,

Rear

Blocked

Vent

Safety

Switch

Cover,

Control

Box

½” Close

Nipple

(Model 50

and 100)

Terminal

Strip

Tile Cover

Transformer

Pump Relay

High

Limit

Base

Assembly

HX Access

Panel

Drain

Valve

Burner with Pilot Bracket

Pilot Assembly

Gas Manifold

Rear Panel

1/2" Coupling

(Model 50 and 100)

P0005200

Orifices

Pilot Gas Tube

Jacket, One Piece

Wraparound

Gas Valve

2-Stage Operating Control (100-225)

Burner Cover

Flame Roll-Out

Safety Switch

Figure 15. Parts Identification.

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Brut e M ini Hydronic Boile r

Page 35

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Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement.

Ambler, PA19002

Tech. Service (800) 334-3393

Service Parts (800) 538-2020

Warranty Service (800) 531-2111

www.BradfordWhite.com

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