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Brute Deluxe (500-2000)
The Brute Deluxe 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 the
right side of the boiler. 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 boiler.
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.
10. Inspect the inside of the copper tubes for scale
buildup. Scale can build up on the inner surface of
the heat exchanger tubes, which can restrict water
flow. If the tubes show signs of scaling, clean the
internal surface. offers a tube cleaning kit, part
number R0010000.
11. Reassemble in the reverse order, and check
appliance operation after start-up.
NOTE: The Warranty does not cover damage caused
by lack of required maintenance, lack of water flow,
or improper operating practices.
SECTION 8.
Trouble Shooting
8.1 Resolving Lockouts
There are many causes of lockouts. The three most
common causes are: (1) inadequate gas supply, (2) poor
combustion, (3) ignitor failure.
1. Inadequate gas supply: Before proceeding, ensure
that the gas supply has not been shutoff or the LP tank
(LP boilers) is not empty. Then, restart the boiler and
observe the operational cycle. After a 15-second fan
pre-purge, the ignitor will heat up for 20 seconds, and
then the unit will light. If it does not, check the gas
supply pressure to the appliance, after resetting the
appliance and attempting another start-up. The gas
pressure to the appliance must be above 5" W.C.
(1.2kPa) throughout the entire start-up cycle. If it is
not, correct the supply problem (check gas valves or
supply piping). If the supply pressure is adequate,
consult the factory for assistance.
2. Poor combustion: Poor combustion should be
suspected if there is a strong flue gas odor. The
odor may result from an improper gas/air ratio
(high or low O
2
or CO
2
). Brute Deluxe appliances
operate best with 45% excess air (8% CO
2
on
natural gas, 9.2% CO
2
on LP). Check the CO
2
of
the appliance and adjust if necessary.
3. Ignitor failure: If the boiler goes through a normal
start cycle but combustion does not occur, ignitor
failure should be suspected. Check the ignitor by
unplugging the ignitor plug and measuring the
ignitor resistance. It should be 50-80 ohms at room
temperature. If the resistance is not 50-80 ohms,
replace the ignitor. If the resistance is correct, reset
the boiler and check for 120 VAC at the ignitor
plug during the start cycle. If there is no voltage,
replace the faulty ignitor wire harness or the
ignition control.
8.2 Delayed Ignition — Possible Causes
A defective burner can cause a delayed ignition. If
the gas supply pressure is proper and the gas valves are
functioning properly, then burners should be inspected.
There should be no distortion or perforations in the
burners outside of the active burner port area. Replace if
indicated.