Installation and Operation Instructions Document 1281D Installation and Operation Instructions for Brute Elite 125 Wall-Mounted Modulating Boiler Model BLMH 125 MBTU/h Combination Boiler and Water Heater Model BLMC 125 MBTU/h FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler and heater installation and maintenance.
Bradford White Corp. TABLE OF CONTENTS SECTION 1. General Information SECTION 6. Water Connections 1.1 Introduction ......................................................... 2 6.1 Central Heat System Piping.............................. 15 1.2 Rating Plate......................................................... 2 6.2 Cold Water Make-Up......................................... 15 1.3 Model Nomenclature........................................... 2 6.3 Freeze Protection..........................
Page 1 The Brute Elite 125 SECTION 9. Modes of Operation SECTION 12. Trouble Shooting 9.1 Hydronic Heating Demand................................ 28 12.1 Sequence of Operation . ................................... 35 9.2 Hydronic Heating with Outdoor Reset............... 28 12.2 Short Cycling..................................................... 35 9.3 Hydronic Heating Using External Modulation Control............................................ 28 12.3 Error Codes.............................
Page 2 Bradford White Corp. SECTION 1. General Information 1.1 Introduction This manual provides information necessary for the installation, operation, and maintenance of Bradford White Corp. Brute Elite appliances. Read it carefully before installation. All application and installation procedures should be reviewed completely before proceeding with the installation. Consult the Bradford White Corp. factory, or local factory representative, with any problems or questions regarding this equipment.
Page 3 The Brute Elite 125 5. THE TOP START UP / SHUT DOWN PANEL THEN INSTRUCTION (DECAL) SLIDES IS ON THE BACK OF THE UPWARD TOP COVER AND OFF 4. TWO MORE SCREWS RATING PLATE 3. FOLD USER INTERFACE CENTER PANEL DOWNWARD 1. LOOSEN THESE TWO SCREWS 2. FOLD BOTTOM PANEL DOWNWARD Figure 1A.
Page 4 Bradford White Corp. 1.7 Appliance Overview SHOWN WITH SEVERAL PANELS COMPLETELY REMOVED Figure 1B. Location of Components. 1) PRV, 30 PSI 5) Exhaust terminal assy 2) PRV Pipe w/ washer 6) Air intake terminal assy 3) Wall attach bracket 7) Ball valve 4) Outdoor sensor 8) System sensor (not shown) 9) Flow restrictor (not shown) Figure 2. Contents of Shipping Package.
Page 5 The Brute Elite 125 1.8 Dimensions Cond. Outlet Hydronic Return DHW Inlet 2nd Return Gas Supply Hydronic Supply DHW Outlet 2nd Supply 3/4" PVC 3/4" copper 1/2" NPT 3/4" copper 1/2" NPT 3/4" NPT 1/2" NPT 3/4" copper Figure 3. Dimensional Drawing.
Page 6 Bradford White Corp. SECTION 2. Locating the Appliance 2.1 Locating the Appliance Brute Elite is for indoor, wall-mounted installations only. The appliance should be located to provide clearances on all sides for maintenance and inspection. It should not be located in an area where leakage of any connections will result in damage to the area adjacent to the appliance or to lower floors of the structure.
Page 7 The Brute Elite 125 Brute Elite Brute Elite BLMC/H125 Note: Brute Elite bracket and wall bracket are purposely offset. Figure 5. Mounting Detail. (Minimum) Zero clearance is allowed to combustible surfaces. However, the above minimum service clearances are strongly recommended. Closet installations require minimum air ventilation (see Section 3). Figure 4. Locating the Appliance. Figure 6. Wall Template (not to scale). Full-size template is included with the unit.
Page 8 Bradford White Corp. SECTION 3. Venting and Combustion Air Bradford White Brute Elite includes a standard CPVC vent/combustion air adapter. If field connections require use of PVC/CPVC vent materials, the installer must use proper adhesive to join CPVC and/or PVC pipe and fittings. 3.
Page 9 The Brute Elite 125 shall also be supplied for ventilation, including air required for comfort and proper working conditions for personnel. 3.2 Venting (Exhaust) WARNING Failure to use the appropriate vent material, installation techniques, glues/sealants could lead to vent failure causing property damage, personal injury or death. WARNING All venting must be installed according to this manual and any other applicable local codes, including but not limited to, ANSI Z223.1/NFPA 54, CSA B149.
Page 10 IMPORTANT NOTE ABOUT COMMON VENTING: A single vent that is shared by multiple Brute Elite units MUST be engineered by a competent venting specialist, and involves the selection of draft inducing equipment, hardware and controls to properly balance flue gas pressures. Do not common vent Brute Elite units unless the vent system meets this requirement. Brute Elite units are never permitted to share a vent with Category I appliances. 3.3 Locating Vent & Combustion Air Terminals 3.3.
Page 11 The Brute Elite 125 U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) See note 6 12 inches (30 cm) See note 6 B= Clearance to window or door that may be opened Direct vent only: 12 inches (30cm); Other than Direct vent: 4 ft (1.
Page 12 Bradford White Corp. 3.3.5 Installations in the Commonwealth of Massachusetts In Massachusetts the following items are required if the side-wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches. From Massachusetts Rules and regulations 248 CMR 5.08 1.
The Brute Elite 125 fireplace dampers. 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance will operate continuously. 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. 6.
Page 14 Bradford White Corp. SECTION 4. Gas Supply and Piping Brute Elite NATURAL GAS REQUIRED 4.1 Gas Supply and Piping Gas piping should be supported by suitable hangers or floor stands, not the appliance. Review the following instructions before proceeding with the installation. 1. Verify that the appliance is fitted for the proper type of gas by checking the rating plate. Brute Elite will function properly without the use of high altitude modification at elevations up to 10,000 feet (3050 m). 2.
Page 15 The Brute Elite 125 SECTION 5. Pump Capacity PRV Included with Brute Elite 5.1 Brute Elite Heating System Pump Capacity A Pressure Relief Valve is included with each Brute Elite. The PRV must be installed prior to filling the system. Figure 11. Available Pump Head. Figure 12. DHW Connections with Anti-Scald Valve and Flow Restrictor. SECTION 6. Water Connections 6.1 Central Heat System Piping NOTE: This appliance must be installed in a closed pressure system with a minimum of 12 psi (82.
Page 16 Bradford White Corp. Figure 13. Hydronic Piping — High and low temp zones with indirect water heater (BLMH using internal 3-way). The boiler piping system of a hot water heating boiler connected to heating coils located in air handling appliances where they may be exposed to refrigerated air circulation, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
Page 17 The Brute Elite 125 6.5 Recognized Chemicals The following manufacturers offer glycols, inhibitors, and anti-foamants that are suitable for use in the Brute Elite. Please refer to the manufacturers instructions for proper selection and application. 1. Sentinel Performance Solutions Group 2. Hercules Chemical Company 3. Dow Chemical Company 6.6 Hot Water Piping 6.6.1 Domestic Hot Water Piping (BLMC) Connect domestic hot and cold water piping to the boiler at locations noted in Figure 13.
Page 18 Bradford White Corp. INLET TEMPERATURE °F 50°F GPM 60°F 70°F TEMP RISE °F 1.0 100 90 81 2.0 90 83 79 3.0 78 76 68 4.0 59 56 51 INLET TEMPERATURE °C 10°C LPM 16°C 21°C TEMP RISE °C 4 56 50 45 8 50 46 44 11 43 42 38 15 33 31 28 Caution Scalding Risk: Bradford White recommends the use of a thermostatic mixing valve at domestic hot water outlet (boiler location) to reduce potential for scalding.
Page 19 Installer to provide DHW (anti-scald) thermostatic mixing valve. The Brute Elite 125 Figure 16. Hydronic Piping — Multi boilers for large homes with long / multiple baseboard zones.
Bradford White Corp. Installer to provide DHW (anti-scald) thermostatic mixing valve. Page 20 Figure 17. Hydronic Piping — Multi boilers for large homes with long / multiple radiant zones.
Page 21 Installer to provide DHW (anti-scald) thermostatic mixing valve. The Brute Elite 125 Figure 18. Hydronic Piping — Heating zones piped with zone pumps.
Bradford White Corp. Installer to provide DHW (anti-scald) thermostatic mixing valve. Page 22 Figure 19. Hydronic Piping — Heating zones piped with zone valves.
Page 23 The Brute Elite 125 SECTION 7. Electrical Connections three-way valve if central heat) upon a call for heat. Once the call for heat is satisfied the pump will remain on for the defined pump overrun time. WARNING The appliance must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the latest edition of the National Electrical Code, ANSI/ NFPA 70, in the U.S. and with latest edition of CSA C22.
Page 24 b. c. d. e. 7.10 Bradford White Corp. If there are more boilers in the system connect a wire from Modbus port 1 terminal A of boiler 2 to Modbus port 1 terminal A of boiler 3. Repeat these steps until all Modbus port 1 terminal A connections are wired. Repeat the above steps for Modbus port 1 terminal B and C connections to complete the wiring. Connect the drain wire from the twisted pair wire to ground on one end of the wire only.
R R K BK 3 WAY ATER FLOW VALVE P O BK R Y P R 1 R BK BK 2 13 BL T-T OR INTERLOCK 3 GR 5 14 Y BR DOMESTIC EMP. SENSOR ANALOG INPUT + Y BR R BR GR 2 1 P BL O 3 1 4 2 BLINLET OUTLET TEMP. GR TEMP. SENSOR SENSOR R GR 2 1 6 3 Y 13 654 321 J4B 5 4 J1 3 1 4 2 J2 J8A GR SYSTEM SENSOR DOMESTIC EMP.
Page 26 Bradford White Corp. SECTION 8. Control Setup and Operation MENU ITEM The Brute Elite control is an integrated electronic control that replaces many of the individual components found on older appliances. The control acts as the ignition control, pump control, high limit and cascading/ lead lag control and is setup using the digital display on the appliance.
Page 27 The Brute Elite 125 8.2 Ignition Control- Sequence of Events 1. 2. 3. 4. 5. Call for heat Safety chain check Fan starts. Prepurge timer is started. Pre ignition time of 2 seconds to check the flame sensor operation and status. 6. Trial for ignition period, 4 seconds. The direct spark ignition switches to constant spark for three seconds, during which time the gas valve is open.
Page 28 Bradford White Corp. on when the water temperature reaches 115°F. Set the hysteresis values to match the boiler to the system operating characteristics. Setting this value correctly will help reduce the chance of short cycling. 8.8.5 Lead Lag Base Load Setting The lead lag system uses a base load setting that is set through the "setup" menu called "bL".
Page 29 The Brute Elite 125 water temperatures. The boiler setpoint is used to limit the maximum water temperature leaving the boiler only. The modulation rate is controlled by a 4-20mA (010Vdc using converter) signal supplied by an external control. When setting up a system using an external control care must be taken to set the external control algorithms to prevent the boiler from short cycling or "hunting " to prevent premature component failure. NOTE: A call for DHW will override external control. 9.
Page 30 SECTION 10. Set Up Instructions 10.1 Filling the Boiler System 1. 2. 3. 4. 5. 6. Ensure the system is fully connected. Close all bleeding devices and open make-up water valve. Allow system to fill slowly. Move manual lever on 3-way valve actuator to "open" position, allowing air to purge from boiler loop. Valve is normally in DHW position until there is a call for Central Heat via "T-T" contacts.
Page 31 The Brute Elite 125 4. 5. 6. Brute Elite will enter the start sequence. Blower and pump will energize for pre-purge, then the ignition sequence starts. After all safety devices are verified, the gas valve opens. If ignition doesn’t occur, turn off the Brute Elite, check that there is proper gas supply. Wait 5 minutes and start the unit again. Turn Brute Elite on.
Page 32 Bradford White Corp. Gas Supply Line Manifold Pressure Screw (under cap) O-Ring Propane Gas Orifice High-fire setting Note: H igh and Low Fire CO2 settings should be approximately equal. Figure 25. Adjustment Screws and Settings for CO2 MANIFOLD GAS TYPE CO2 (%) RANGE PRESSURE (inH20) Natural Propane 8.8 __ 9.8 9.8 __ 10.8 3.5 __ 4.5 3.5 __ 4.5 Table 13. CO2 Range and Pressure Settings.
Page 33 The Brute Elite 125 SECTION 11. Maintenance WARNING Disconnect all power to the appliance before attempting any service to the appliance. Contact with electricity can result in severe injury or death. 11.1 System Maintenance 1. 2. 3. 4. 5. 6. 7. 8. 9. (yearly, unless otherwise noted) If a strainer is employed in a pressure reducing valve or the piping, clean it every six months. Inspect the venting system for obstruction or leakage at least once a year.
Page 34 Bradford White Corp. 11.2.4 Flame Sensor The flame sensor is a single rod system. To replace the flame sensor electrode, shut off the 120 Volt power supply to the boiler. Turn off all manual gas valves connecting the boiler to the main gas supply line. Remove the front door of the boiler to gain access to the flame sensor electrode. Remove the flame sensor wire from the electrode. Remove the two bolts fastening the electrode to the burner doors. Remove and replace the old flame sensor gasket.
Page 35 The Brute Elite 125 not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer's instruction supplied with the kit. AVERTISSEMENT Ce conversion doit être installé par un organisme de service conformément aux instructions du fabricant et tous les codes et les exigences de l'autorité compétente.
Page 36 CODE# PROBLEM Bradford White Corp.
Page 37 The Brute Elite 125 CODE# PROBLEM PROBABLE CAUSE SOLUTION ALERT CODES was reached however the cycle count will not increment any higher than 999,999 cycles Replace controller or adjust the count using blue display 50 Maximum hours count was reached Control operates correctly, however the hours count will not increment any higher than 999,999 hours 248 CH outdoor temperature was invalid 251 CH ODR max
Page 38 Bradford White Corp. SECTION 13. Replacement Parts Use only genuine Bradford White replacement parts. 13.1 General Information To order or purchase parts for the Bradford White Brute Elite, contact your nearest Bradford White dealer or distributor. If they cannot supply you with what you need, contact Customer Service (see back cover for address, telephone and fax numbers). 13.
Page 39 The Brute Elite 125 ITEM DESCRIPTION BURNER COMPONENTS - see Figure 33 1 Burner, main 2 3 4 5 6 7 SIZE 125 ITEM DESCRIPTION PLUMBING COMPONENTS - see Figure 35 SIZE 125 R2069102 P1 Tank, expansion, rect, 10 liter Gasket, burner RS2108500 P2 Bracket weldment, expansion tank Tile, refractory, front, combustion chamber RT2109000 P3 Grommet, pipe, wire, multi size, rubber Ignitor, spark, w/gasket R2069300 P4 Pipe, gas Flame sensor, w/gasket R2069200 P5 O-ring, 20.
Page 40 Figure 28. Panel Assembly, Door Top. Bradford White Corp.
The Brute Elite 125 Figure 29. Panel Assembly, Door Middle.
Page 42 Figure 30. Panel Assembly, Door Bottom. Bradford White Corp.
The Brute Elite 125 Figure 31. Base Jacket Assembly.
Page 44 Figure 32. Heat Exchanger Cabinet, Fan. Bradford White Corp.
The Brute Elite 125 Figure 33. Heat Exchanger Burner Components.
Page 46 Figure 34. Pump Assembly Components. Bradford White Corp.
The Brute Elite 125 Figure 35. Plumbing Components.
Page 48 Bradford White Corp.
The Brute Elite 125 Page 49
H2364500A Dimensions and specifications subject to change without notice in accordance with our policy of continuous product improvement. Ambler, PA 19002 Tech. Service (800) 334-3393 Service Parts (800) 538-2020 Warranty Service (800) 531-2111 www.BradfordWhite.com Litho in U.S.A.
