Bradford-White Corp BWCV User Manual

Internet Version for Reference Only

Page 32

Copper Brute II

Page 33

ignitor out. Install in reverse order, always using a new 

ignitor gasket with the replacement ignitor.

Ignitor gets hot.

The ignition sensors ensure that the main flame 

is ignited, so that raw gas is not allowed to fill the 

combustion chamber. Copper Brute II models 500 and 

750 have one sensor. Models 1000 to 2000 have two 

sensors (one for each ignition control). The ignitors 

are the ignition sensors on the heater. There are no 

separate ignition sensors.

The Copper Brute II’s transformer is not capable 

of supplying control voltage for external devices such 

as zone valves, which must have their own separate 

power supply. Should a transformer need replacing, 

shut off the 120-volt power. Unplug the transformer 

wires, remove the mounting screws and remove the 

transformer. Replace transformer in the reverse order.

The combustion air blowers bring the 

combustion air for the heater from the upper chamber 

to the lower chamber. Mixing of the gas and air occurs 

in the burners. Models 500, 750 and 1000 each have 

one blower, and models 1250 to 2000 each have two 

blowers (one blower for stages 1 and 2, and one for 

stages 3 and 4). If a blower change is required, turn off 

the 120-volt power and gas supply to the unit. Remove 

the front panel. Disconnect the blower's wire harness. 

Remove the screws at the blower flange, and pull the 

blower out. Replace blower in reverse order, ensuring 

that all joints are made correctly. After replacement, 

ensure that the unit operates properly, by following the 

set-up procedure in this manual.

The heater uses a paddle-type flow switch to 

ensure that the unit has water flow before ignition is 

allowed.

Black carbon soot buildup on a dirty heat exchanger 
can be ignited by a random spark or flame, thereby 
creating a risk of fire or explosion.. To prevent this 
from happening, dampen the soot deposits with a 
wet brush or fine water spray before servicing the 
heat exchanger.

The heater has a pre-mixed burner system. These 

systems provide the burners with sufficient air for 

complete combustion, and black carbon sooting is 

seldom experienced. If sooting is suspected, view ports 

for inspection of the heat exchanger are provided on 

both sides of the heater. They are located below the 

headers, and are accessed by opening the small round 

cover that is attached by one screw. In the unlikely 

event that there is a buildup of black carbon soot 

or other debris on the heat exchanger, clean per the 

following:

1.      Disconnect the electrical supply to the unit.

2.      Turn off the gas supply by closing the manual gas 

valve on the heater.

3.      Disconnect and remove the wires, conduit and 

sensors from all components that are attached to 

the inlet/outlet header.

4.      Isolate the heat exchanger from the water supply.

5.      Disconnect the header flanges from the inlet and 

outlet.

6.      Allow the heat exchanger to drain. Remove the 

front cover(s) by removing the rubber access 

strip(s) and the retaining screws. Remove the 

venting and remove the top, by removing the 

screws that attach the top to the side panels. 

Remove the side panels. Remove the front lower 

panels sealing the combustion area. To remove 

the gas train, disconnect the unions located 

below the intermediate pan and the field installed 

union located outside the cabinet, and pull up, 

bringing the union end connectors through the 

grommets in the intermediate pan. To remove the 

intermediate pan, remove the slide out control 

assembly and blower(s) to reveal the screws. 

Remove the screws holding the intermediate pan, 

and lift up to remove it. The heat exchanger has 

integral metal sections attached, which connect 

to the frame of the heater. Locate and remove 

the screws along the front, rear and bottom of 

the integral metal sections, and remove the heat 

exchanger and metal sections by lifting up. On 

the larger appliances, a center heat exchanger 

support must be unbolted before it can be 

removed.

7.      Remove the heat exchanger from the unit. 

NOTE: The heat exchangers are heavy and may 

require two people to remove to avoid personal 

injury.

8.      Clean the heat exchanger: A light accumulation 

of soot or corrosion on the outside of the heat 

exchanger can be easily removed. Use a wire 

brush to remove loose soot and scale from the 

heat exchanger. Do not use water or compressed 

air for cleaning.

9.      NOTE: While the heat exchanger is out of the 

unit, inspect the firewall refractory insulation. 

Replace if necessary.