Bradford-White Corp BWCV User Manual

Internet Version for Reference Only

Page 20

Copper Brute II

Page 21

Most of the time, the number of stages from the 

external control will match the number of stages on the 

heater.  However, in some instances, the controller will 

not have enough staging capability to work with all of 

the stages on a heater (for instance, using an 8-stage 

external control with four 4-stage Copper Brute II 

units.)  In these instances, it is very important to follow 

the instructions in this section.  Figure 9 shows how to 

combine stages on the heater for those instances when 

the external controller cannot control all the stages 

available on the heater.

Note:  The only time heater stages should be 

jumpered is when the heater has an external control, 

and the heater is used in Mode 6.  In all other modes, 

when the heater controls its stages, the terminals 

shown in Figure 9 must NOT be jumpered.

A call for heat can be initiated either 

automatically (“auto mode”) under thermostatic 

control by the heater temperature control, or by an 

external contact closure (“manual mode”).

In auto mode, the heater will fire its stages of 

input to maintain a target temperature programmed 

into the temperature control. The controller can be 

programmed per section 6.2.

In manual mode, an external control will control 

the heater stages, as long as the heater control is set to 

mode 6, and the auto/manual switch (located inside the 

control compartment) is set to manual.

The amber “Ready” light on the front panel 

indicates that the control system is energized. Upon a 

call for heat, the green “Heat” indicator on the front 

panel will light.

If the unit is pump-mounted, the pump will be 

energized. The pump terminals on the field-wiring 

terminals strip will energize a field pump that is 

properly interlocked with the heater. The green 

“Pump” indicator on the front panel will light.

Once the water flow switch makes, and if all of 

the safety interlocks are closed, the ignition module 

will energize the blower(s) for a 15-second pre-purge, 

followed by a 20-second period to allow the ignitor to 

heat.

Energizing the blower pressurizes the air box 

(which supplies air to the burners) and closes the 

normally-open contact(s) of the airflow pressure 

switch(es). This allows the ignition module to proceed 

with the ignition sequence.

The blocked flue pressure switch senses the 

pressure in the plenum. It will interrupt the airflow 

sensing circuit if this pressure exceeds a maximum 

value. If airflow is not proven, the ignition module  

will lockout.

The ignition module checks that the ignitor 

current has reached a minimum value and energizes 

the gas valve at the end of the ignitor heating period. 

The green “Stage 1” indicator on the front panel will 

light, indicating that the stage 1 gas valve is open. 

After a 4-second trial for ignition, the ignitor 

switches off, and unless a flame is detected by the 

flame sensor, the gas valve will close and the ignition 

module will either attempt ignition again (up to three 

times) or will lockout (if the optional lockout ignition 

module is used).

If flame is sensed, the burner will continue to 

fire as long as there is a call for heat. In Auto mode, 

additional stages are delayed by a minimum of 60 

seconds (less prepurge and ignitor warm-up time) and 

once energized, must fire for at least 30 seconds. The 

request for additional stages is indicated on the control 

display, and the energizing of additional burner stages 

is indicated by front panel lights.

If there is a subsequent loss of flame signal, the 

burner will attempt re-ignition up to three times (only 

once if optional lockout ignition module is used.)

When the call for heat is satisfied, the gas 

valve(s) closes and the blower(s) continues to run 

for 30 seconds. The pump will continue to run for a 

minimum of 20 seconds and up to a programmable 

maximum of 10 minutes.

If a call for heat is prevented from being satisfied 

either by a safety interlock or due to an ignition 

lockout, the red “Service” indicator on the front panel 

will light. To reset the standard ignition module, 

the reset button on the module must be pressed. 

Interrupting power to this module will not reset the 

lockout.

The Copper Brute II 1000 - 2000 models have 

two ignition modules that control different burners. If 

one module should fail for any reason, the remaining 

module can operate its burner(s) independently.

Important: The installer is responsible for identifying 

to the owner/operator the location of all emergency 

shutoff devices.

Do not use this appliance if any part has been 

under water. Immediately call a qualified service 

technician to inspect the appliance 

and to replace any part of the control system and 

any gas control that may have been 

under water.

The same temperature control is used on all 

versions of the Copper Brute II (in two-and four-stage 

configurations), providing maximum flexibility to meet 

the needs of any system. Before start-up, you must 

program the temperature control for the type of system