Brute BNTH1000 User manual

Installation and Operation Instructions Document 1266F
H2360900F
Installation and
Operation Instructions for
Modulating Boiler Water Heater
Model BNTH1000 Model BNTV1000
1,000 MBTU/h 1,000 MBTU/h
Model BNTH1200 Model BNTV1200
1,200 MBTU/h 1,200 MBTU/h
Brute®
WARNING
If the information in this manual is not
followed exactly, a re or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
ammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
nearby phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the re department.
Installation and service must be performed
by a qualied installer, service agency, or gas
supplier.
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualiedinhotwaterboilerandheaterinstallationandmaintenance.Improperinstallationand/oroperation
couldcreatecarbonmonoxidegasinuegaseswhichcouldcauseseriousinjury,propertydamage,or
death. Improper installation and/or operation will void the warranty.
AVERTISSEMENT
Assurez-vous de bien suivres 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.
Ne pas entreposer ni utiliser d’essence ni d’autres
vapeurs ou liquides inammables dans le
voisinage de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous
servir des téléphones dansle bâtiment où vous
vous trouvez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions du
fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés par
un installateur ou un service d’entretien qualié ou
par le fournisseur de gaz.

Table of Contents
SECTION 1 General Information
1.A Introduction....................................................... 5
1.B Warranty ........................................................... 5
1.C ModelIdentication........................................... 5
1.D Safety Notes ..................................................... 6
1.E Model Overview................................................ 8
1.F Dimensions....................................................... 8
1.G The Installation Kit ............................................ 9
SECTION 2 Locating the unit
2.A Locating the unit ............................................. 10
2.B Correct Vent Distance from Outside Wall or Roof
Termination ..................................................... 10
SECTION 3 Venting and Combustion Air
3.A General Venting.............................................. 11
3.B Combustion Air ............................................... 12
3.B.1 Combustion Air From Room ........................... 12
3.B.2 Ducted Combustion Air................................... 13
3.C Venting............................................................ 14
3.C.1 Common Venting ............................................ 14
3.C.2 Venting Requirements Unique to Canada ...... 14
3.D Locating the Vent and Combust Air Terminals 15
3.D.1 Side Wall Vent Terminal.................................. 15
3.D.2 Side Wall Combustion Air Terminal................. 17
3.D.3 Vertical Vent Terminal ..................................... 18
3.D.4 Vertical Combustion Air Terminal.................... 18
3.D.5 Installations in the
Commonwealth of Massachusetts.................. 18
3.E Common Vent Test ......................................... 18
3.F Outdoor Installation ........................................ 19
3.G Condensate Drain Trap .................................. 19
SECTION 4 Gas Supply and Piping
4.A Gas Supply and Piping ................................... 20
SECTION 5 Pump Requirements
5.A Boiler Flow and Head Requirements.............. 22
SECTION 6 Water Connections
6.A Boiler systems ................................................ 23
6.A.1 Boiler System Piping:
Hot Supply Connections ................................. 23
6.A.2 Boiler Cold Water Make-Up ............................ 23
6.A.3 Boiler Freeze Protection ................................. 24
6.A.4 Condensate Drain Trap .................................. 24
6.A.5 Boiler Suggested Piping Schematics.............. 24
6.B WATER Heater systems ................................. 29
6.B.1 Water Heater Quality ...................................... 29
6.B.2 Water Heater Piping Requirements ................ 29
6.B.3 Heater Cold Water Make-Up .......................... 30
6.B.4 Heater Freeze Protection ............................... 30
6.B.5 Heater Suggested Pumps .............................. 30
6.B.6 Condensate Drain Trap .................................. 30
6.B.7 Water Heater Suggested Piping Schematics . 31
SECTION 7 Electrical Connections
7.A Main Power..................................................... 33
7.B Pump Connections ......................................... 33
7.C Optional Variable Speed Pump Control.......... 35
7.D 24 VAC Transf w/ Integral Circuit Breaker ...... 35
7.E Signal Connections......................................... 35
7.F OptionalLowWaterCutO󰀨(LWCO).............. 35
7.G Other Optional Field Connections .................. 35
7.H Building Automation System Connections...... 36
7.I Lead Lag Connections & Wiring Diagram ...... 37
7.J Wiring Diagram............................................... 38
7.K Ladder Diagrams ............................................ 40
7.L About the Touch Screen Display .................... 42
SECTION 8 Using the touch screen
8.A Using the Touch Screen ................................. 44
8.B The Gauges.................................................... 46
8.C While Operating - Checking Lead Lag
Operating Information..................................... 46
8.D Checking the Lead Lag Leader ...................... 46
8.E Checking Individual Parameters..................... 47
8.F Checking Individual Details ............................ 48
8.G ConguringParametersonControllers .......... 48
8.H VericationProcessforSafetyParameters .... 49
B RADFORD W HITE

SECTION 9 Setup and Conguration
9.A Review of Lead Lag Control System .............. 51
9.A.1 About Lead Lag Operation ............................. 51
9.A.2 Lead Lag Modulation Cycle ............................ 52
9.A.3 Boiler Lead Lag with Indirect
Domestic Hot Water........................................ 53
9.B Connection Terminals ..................................... 53
9.C SystemCongurations ................................... 54
9.D Installation Jobs.............................................. 62
9.E Setup for Domestic Hot Water on a
Lead Lag System............................................ 83
9.F Gateway Connections to a
Building Automation System........................... 87
9.G Installer Parameters ....................................... 88
9H Variable Speed Pump Control ........................ 95
SECTION 10 Initial startup Instructions
10.A Filling the Boiler System ................................. 96
10.B Initial Burner Operation................................... 97
10.C Shutting Down the Unit................................... 97
10.D Restarting the Unit.......................................... 97
SECTION 11 Maintenance
11.A System Maintenance ..................................... 98
11.B Maintenance Notes......................................... 98
11.B.1 Burner............................................................. 98
11.B.2 Modulating Gas Valve/ Venturi ....................... 98
11.B.3 Controllers ...................................................... 99
11.B.4 Ignitor Assembly ............................................. 99
11.B.5 Flame Sensor ................................................. 99
11.B.6 Transformer with Integral Circuit Breaker ....... 99
11.B.7 Blower............................................................. 99
11.B.8 Heat Exchanger Coils................................... 100
11.B.9 GasPressureSwitches(optional) ................ 100
11.B.10 Natural/Propane Gas Conversion................. 101
11.B.11 Condensate Trap .......................................... 101
11.B.12 Battery for Date and Time Back-Up ............. 101
SECTION 12 Troubleshooting
12.A Potential Setup and Synch Problems ........... 102
12.A.1 Controller Synchronization ........................... 102
12.A.2 Flap Valve Status Check ............................. 103
12.B About Lockouts, Holds, and Alerts............... 103
12.B.1 Responding to a Lockout, Hold, or Alert....... 103
12.B.2 Viewing the Lockout and Alert Histories ...... 104
12.C Troubleshooting Table .................................. 106
12.D Diagnostic Tests & Input/Output Indicators.. 115
12.E Lead Lag Follower Diagnostics ................... 116
12.F Statistics ....................................................... 116
12.G Analysis ....................................................... 116
12.H Control Snapshot.......................................... 116
12.I Operating Sequence..................................... 117
SECTION 13 Replacement Parts
13.A General Information..................................... 120
13.B Parts List...................................................... 120
13.C Parts Illustrations ......................................... 124
Brute®
BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h

Page 4
B RADFORD W HITE

Page 5
Brute®
BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
SECTION 1 General Information
Pressure and
temperature
gauge
Touch Screen Display
(behindtheplasticcover
whichslidesdownward) Power switch
Rating Plate
1.A Introduction
1.B Warranty
1.C Model Identication
Bradford White Heating Systems’ Brute sare covered
by a limited warranty. The owner should complete
the warranty registration at:
www.BradfordWhite.com
All warranty claims must be made to an authorized
Bradford White representative. Claims must include
theserialnumberandmodel.(Thisinformation
canbefoundontheratingplate.)Theclaimmust
also include the installation date and name of the
installer. Shipping costs are not included in the
warranty coverage.
Some accessory items may be shipped in separate
packages. Verify receipt of all packages listed on
the packing slip. Inspect everything for damage
immediately upon delivery, and advise the carrier
of any shortages or damage. Any such claims
shouldbeledwiththecarrier.The carrier, not
the shipper, is responsible for shortages and
damage to the shipment whether visible or
concealed.
NOTE: Throughout the content of this manual,
the Brute will be referred to as a ‘unit’.
unit = Brute
Consult the rating plate on the outside of the unit.
The following information describes the model
number structure.
(1-3) Model Series Designation
B N T = Brute
(4) Usage
H = Hydronic
V = Volume Water
(5-8) Size
1 0 0 0 = 1,000,000 BTU/hr input
1 2 0 0 = 1,200,000 BTU/hr input
(9) Fuel
N = Natural Gas
P = LP Gas
(10) Options Code
J = CSD1 Version
X = Standard Unit
(11) Pump Options
N = Pump included
X = No pump
W = HLW w/ Pump
L = HLW w/out Pump
(12) Revision
1 = First version
PUMP OPTIONS
N - PUMP INCL.
X - NO PUMP
W - HLW w/PUMP
L - HLW w/out
PUMP
Model Nomenclature
SERIES
B N T
USAGE
H - HYDRONIC
V - VOLUME
WATER
SIZE
MBTU/h
1 0 0 0
1 2 0 0
FUEL
N - NATURAL
P - PROPANE
REVISION
1 - FIRST
1 2 3 4 5 6 7 8 9 10 11 12
1
B N T
This manual includes information which will help you
to install, operate, and maintain the Brute 100 and
1200 systems. Please read this manual completely
before proceeding with the installation. If you have
any questions regarding this equipment, please
consult the Bradford White factory, or a local factory
representative. Many operating problems are caused
by improper installation. The Brute is protected
against over pressurization. A pressure relief valve
is included with each unit. Some Brutes may require
thatthePRVbeinstalledpriortollingthesystem
OPTIONS CODE
X - U.S. STANDARD
J- CSD1
C - Canada STANDARD
D - Canada CSD-1

Page 6
B RADFORD W HITE
1.D Safety Notes
WARNING
Carbon Monoxide Hazard
Improper adjustment of the burners may lead to poor
combustion quality, increasing the amount of carbon
monoxide produced. Excessive carbon monoxide
levels may lead to personal injury or death.
WARNING
This unit must be installed in accordance with the
procedures detailed in this manual, or the manufacturers
warranty will be voided. The installation must conform
to the requirements of the local jurisdiction having
authority, and, in the United States, to the latest edition
of the National Fuel Gas Code, ANSI Z223.1/NFPA54.
In Canada, the installation must conform to the latest
edition of CSA B149.1 Natural Gas and Propane Gas
Installation Code, and/or local codes. Where required
by the authority having jurisdiction, the installation of
these units must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASMECSD-1.Anymodicationstotheboiler,its
gascontrols,orwiringmayvoidthewarranty.Ifeld
conditionsrequiremodications,consultthefactory
representativebeforeinitiatingsuchmodications.
WARNING
• Watertemperatureover125°F(52°C)cancause
severe burns instantly or death from scalds.
• Children, disabled and
elderly are at highest
risk of being scalded.
• See instruction manual
before setting temperature
at the unit.
• Feel water before bathing
or showering.
• If this unit is used
to produce water that could scald if too hot, such
as domestic hot water use, adjust the outlet control
(limit)orusetemperaturelimitingvalvestoobtaina
maximumwatertemperatureof125°F(52°C).
WARNING
The inlet gas pressure to the unit must not
exceed13”W.C.(3.2kPa).
WARNING
Fire or Explosion Hazard
Impropercongurationcancausefuelbuildupand
explosion. Improper user operation may result in
property loss, severe physical injury, or death.
Anychangestosafety-relatedconguration
parameters must only be done by experienced and/or
licensed burner/boiler operators and mechanics.
If any odor of gas is detected, or if the gas burner does
not appear to be functioning in a normal manner, close
themaingasshuto󰀨valve.Donotshuto󰀨thepower
switch. Contact your heating contractor, gas company,
or factory representative.
NOTE: This unit is protected against hydronic
over-pressurization. A pressure relief valve is included
with each unit.
WARNING
Indicates an imminently hazardous situation which, if not
avoided, can or will result in death or serious injury and can
or will result in catastrophic property damage.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
may result in moderate injury and/or property damage.
NOTE:
Indicates instructions that are important to that topic but not
related to personal injury or property damage.
Safety Notes are used thoughout this manual to bring attention to the presence of hazards with various risk
levelsandtoo󰀨erimportantinformationconceringthelifeofthisproduct.Thereare3basictypes.
WARNING
CANCER AND REPRODUCTIVE HARM.
WWW.P65WARNINGS.CA.GOV.
AS REQUIRED BY THE STATE OF
CALIFORNIA PROPOSITION 65.
1
2
3

Page 7
Brute®
BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
WARNING
Electrical Shock Hazard
Electrical shock can cause severe injury, death or
property damage. Disconnect the power supply before
beginning installation or changing the wiring to prevent
electrical shock or damage to the equipment. It may be
necessarytoturno󰀨morethanonepowersupply
to disconnect.
All electrical wiring is to be done in accordance with
localcodes,orintheabsenceoflocalcodes,with:1)
The National Electrical Code ANSI/NFPA No. 70 - latest
Edition,or2)CSASTD.C22.1“CanadianElectricalCode
- Part 1.” This appliance must be electrically grounded in
accordance with these codes.
WARNING
The Repair Parts list designates parts that contain
refractoryceramicbers(RCF).RCFhasbeenclassied
as a possible human carcinogen. When exposed to
temperaturesabove180ºF,suchasduringdirectame
contact, RCF changes into crystalline silica, a known
carcinogen. When disturbed as a result of servicing or
repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
Do not remove or replace RCF parts or attempt any
service or repair work involving RCF without wearing
the following protective gear:
1. A National Institute for Occupational Safety and
Health(NIOSH)approvedrespirator.
2. Longsleeved,loosettingclothing.
3. Gloves.
4. Eye Protection.
NOTE: All installations must be made in accordance with
1)AmericanNationalStandardZ223.1/NFPA54-Latest
Edition“NationalFuelGasCode”or
2)CSAB149.1“NaturalGasandPropaneInstallation
Code” or in Canada reference the B149.1 latest
edition and with the requirement of the local utility or
other authorities having jurisdiction. Such applicable
requirements take precedence over the general
instructions contained herein. All electrical wiring is to
be done in accordance with the local codes, or in the
absenceoflocalcodes,with:1)TheNationalElectrical
Code ANSI/NFPA No. 70-latest Edition, or
2)CSASTD.C22.1“CanadianElectricalCode-Part
1”. This appliance must be electrically grounded in
accordance with these codes.
CAUTION
The supply voltage to this unit must not be
disengaged, except for service or isolation, or
unless otherwise instructed by procedures outlined
in this manual. To signal a call for heat, use the
correct terminals as instructed in the Electrical
Connections, Section 7

Page 8
B RADFORD W HITE
1.E Model Overview
Figure 1. Components
Pressure and
temperature
gauge
Blower 1
(underbezel)
Automatic
gas valves
Manual
gas valve
Blower 2
Touchscreen
Protective Cover
(slidesdownward)
Power switch Ducted air inlet
Rating Plate
(onoutsidepanel)
Electrical box
PRV and
owswitch
Outlet
temperature
sensors
Inlet
temperature
sensors
Condensate
trap
Leveling feet
Figure 2. Dimensions
1.F Dimensions

Page 9
Brute®
BOILERS AND VOLUME WATER HEATERS, 1,000 & 1,200 MBTU/h
Figure 3. Dimensions overall
Dimensions (continued)
1.G The Installation Kit
The unit is shipped in a single crate with a boxed
installation kit that contains these components.
• Vent Pipe Adapter, 6” PVC to 6” Steel
• Vent Pipe, CPVC, 6” SCH 40 @ 6” dia.
• Cable Tie for Vent Pipe.
• Boxed Kit for tank and outdoor system sensor.
1. Remove all packing and tie-down materials.
2. Check that the outdoor/system sensor kit is included.
Customer Service and Product Support: 800.900.9276 • Fax [phone]
Headquarters: 20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax [phone]
9 Brigden Gate, Halton Hills, Ontario, Canada L7G 0A3 [phone] Fax: [phone]
www.Laars.com Litho in U.S.A. © Laars Heating Systems 1805 Document 1249H
Laars Heating Systems Company reserves the right to change specications, components, features, or to discontinue products without notice.
Dimensional Data
NeoTherm LC
1000 & 1200

Page 10
B RADFORD W HITE
SECTION 2 Locating the unit
2.A Locating the unit
This unit may be installed indoors or outdoors.
If installing in a location that may experience
freezing temperatures, precautions must be
taken to prevent water in the heat exchanger
and condensate inside and outside of the boiler
from freezing. Damage due to freezing water or
condensate is not covered by the warranty.
This unit 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unitortoloweroorsofthe
structure. When such a location is not available,
it is recommended that a suitable drain pan,
adequately drained, be installed under the unit.
Alwaysinstalltheunitonarm,levelsurface.
Theunitisdesign-certiedbyCSA-Internationalfor
installationoncombustibleooring;inbasements;
in closets, utility rooms or alcoves. These boilers
and water heaters must never be installed on
carpeting. The location should be chosen with regard
to the vent pipe lengths and external plumbing.
The unit shall be installed such that the gas ignition
system components are protected from water
(dripping,spraying,rain,etc.)duringoperation
andservice(circulatorreplacement,control
replacement,etc.).
When vented vertically, this unit must be located as
close as practical to the vertical section of the vent.
If the vent terminal and/or combustion air terminal
terminate through a wall, and there is potential for
snow accumulation in the local area, both terminals
should be installed at an appropriate level above
grade or the maximum expected snow line.
The dimensions and requirements that are shown
in Table 1 should be met when choosing the
locations for the appliance.
2.B Correct Vent Distance from
Outside Wall or Roof Termination
The forced draft combustion air blower in the
appliancehassu󰀩cientpowertoventproperly
when the guidelines in Table 2 are followed.
SUGGESTED SERVICE CLEARANCE
SURFACE INCHES CM
Front 24 60.9
Left Side 12 30.5
Right Side 18 45.7
Back 24 60.9
Top 24 60.9
REQUIRED CLEARANCE TO COMBUSTIBLES
SURFACE INCHES CM
Front 25.1
Left Side 00
Right Side 00
Back 00
Top 820.3
Vent 12.6
Table 1. Clearances
Combustion Intake and Vent must be the same size.
Installations in the U.S. require exhaust vent pipe that is PVC or
CPVC complying with ANSI/ASTM D1785 F441, polypropylene
complying with ULC-S636, or stainless steel complying with
UL1738. Installations in Canada require exhaust vent pipe that
iscertiedtoULCS636.
Intake(air)pipemustbePVCorCPVCthatcomplieswithANSI/
ASTM D1785 F441, ABS that complies with ANSI/ASTM D1527,
stainless steel, or galvanized material.
Closet and alcove installations do not allow the use of PVC
under any circumstances
To calculate max equivalent length, measure the linear feet of
the pipe, and add 5 feet (1.5 m) for each elbow used.
STANDARD MAX EQUIV.
VENT F T. M
6” 100 30
Unit
Table 2. Vent / Air Pipe Sizes
Note - When located on the same wall, the units
combustion air intake terminal must be installed a
minimum of 12” below the exhaust terminal. There
must also be a minimum horizontal distance from
intake to the exhaust terminal of 36.”
Fortheconcentricventterminalkit(optional),follow
the installation instructions included with the kit.
Table 3. Placeholder. for 5a 5b, and 5c on next page